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Cleanliness and Care of Outboard Motor Service Manual Outline

1. b a NA e f 2 N j k e f IC m n Reservoir Oil g g Filtered Feed Oil t Return Oil as Oil Under Pressure x Impact Relief Pressure 22 880 1110 40 60 A c 1220 1420 75 125 Up Pressure 1625 40 60 Tilt Relief i 250 400 40 60 q 540 990 75 125 a Piston Rod m Shuttle Valve b End Cap n Up Pressure Operated Valve c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 12 MID SECTION o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief Valve s Tilt Relief Piston t Memory Piston u Shock Piston v Impact Relief Valve w Cylinder 90 817643R1 DECEMBER 1996 PAS Down Mode When the trim switch is activated in the down posi tion the electric motor c will rotate the pump j in the opposite direction With the pump gears rotating backwards the flow of oil is reversed Oil is drawn through the filter g through the down circuit suction port k and into the oil pump j The pump forces pressurized oil into the down p
2. nn MANUAL RELEASE b lt S i 7 2 Y e Z 525 880 PSI zit N h t e i e f Reservoir Oil m g L Return Oil uH Filtered Oil o p Impact Relief Pressure 22 880 1110 40 60 1220 1420 75 125 Up im 1625 40 60 2800 75 125 a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 18 MID SECTION 5 ressure 250 400 40 60 540 990 75 oA e lt ctH7QTO53 Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder 90 817643R1 DECEMBER 1996 Manual Tilt To manually tilt the outboard engine the owner will need to back out the manual release valve p 3 4 turns With the valve backed out the internal pas sages inside the manifold are connected together These passages connect both the cylinder down and up cavities together along with the reservoir allowing the engine to be raised or lowered Piston rod a mov
3. Shim s d Disassembled Propeller b Race Apply 2 4 Cw Tefl Shaft on Lubricant on O D e Assembled Bearing c Mandrel 91 31106 Carrier Shift Shaft 1 Apply Loctite 271 on O D of new seal 2 Press seal into shift shaft bushing until seal is seated against shoulder 3 Install new O ring 4 Apply 2 4 C with Teflon on O ring and I D of seal Jer b d 53930 a Seal b Bushing c Surface d O ring 90 817643R1 DECEMBER 1996 5 Assemble components as shown a Shift Shaft b Clip c Shift Shaft Bushing 6 Install shiftcam numbers toward top of gear hous ing align hole in shift cam with hole 7 QUE 51117 a Shift Cam Numbers UP b Hole 7 Install shift shaft assembly insert splines into shift cam 53932 a Shift Shaft Assembly b Splines 90 817643R1 DECEMBER 1996 8 Apply Loctite 271 on bottom half of threads of bolts install bolts and torque to 60 Ib in 6 5 N m a Bolts Torque to 60 Ib in 6 5 N m Bearing Carrier Reassembly 1 Lubricate O D of bearingand bearing carrier bore with Quicksilver 2 4 C w Teflon 2 Protectlip on forward side of bearing carrier using bearing installation tool 91 13945 3 Press propeller shaft needle bearing number side toward mandrel into carrier until bearing bottoms out
4. Wiring Diagram O a 3 BLK BLACK d d BLU BLUE BRN BROWN GRY GREY GRN GREEN ae PUR PURPLE gmr RED RED e e Stator Trigger Switch Box Ignition Coil Cylinder No 1 Ignition Coil Cylinder No 2 Ignition Coil Cylinder No 3 Starter Motor Starter Solenoid Regulator Fuse Holder 20 Amp Fuse Battery Engine Wiring Harness Connector Enrichment Valve Temperature Switch Low Oil Warning Module Low Sensor s RPM Limiter S i Stop Button UN Q Lanyard Stop Switch P i Key Switch 4 Neutral Start Switch n Warning Horn Tiller Handle Wiring Harness Connector o gt co YEL RED YEL RED BLK mm PUR lt ho 20 4 ELECTRICAL and IGNITION 90 817643R1 DECEMBER 1996 p i Model 55 Manual Start Wiring Diagram Stator Trigger Switch Box Ignition Coil Cylinder No 1 Ignition Coil Cylinder No 2 Ignition Coil Cylinder No 3 Temperature Switch Overheat Warning Module Warning Horn Stop Button Lanyard Stop Switch a s p Q s BLK e BLACK BLU e BLUE BRN BROWN GRY GREY GRN GREEN PUR PURPLE RED e RED TAN WHT WHITE YEL YELLOW LIT
5. supi Pump Drive System Variable Ratio Oil PUMP TER Oil Pump to Powerhead Assembly Variable Ratio Oil Pump Set Up Instructions for Oil Injection System Carburetor Oil Pump Synchronization Variable Ratio Oil Pump Filling Oil Injection System with Bleeding Air From Oil Injection Bleeding Air From Oil Pump Inlet Hose Bleeding Air From Oil Pump Outlet Hose Page 3D 1 3D 1 3D 2 3D 3 3D 3 3D 4 3D 5 3D 6 3D 6 3D 7 3D 9 3D 8 3D 8 3D 9 3D 9 3D 9 Page Outboard Operation 3D 10 Check Operation of the Oil Injection System Engine Running 3D 10 Required Side Mount Remote Control or Ignition Key Switch Assembly 3D 10 Oil Injection System Troubleshooting Chart 3D 11 Troubleshooting the Oil Injection System 3D 11 Installing Drive Gear For Oil Injection Pump On Crankshaft 30 12 Oil Warning Module 3D 12 Removal Installation 3D 12 Engine Mounted Oil Reservoir 3D 13 Removal 3D 13 Installation 3D 14 90 817643R1 DECEMBER 1996 Operation of the Injection System The oil injection system delivers a oil mi
6. Page 2 1 2 1 2B 1 Page Starting System 2B 12 Starting System Components 2B 12 Description 2B 12 Troubleshooting the Starting Circuit 2B 12 Starter Motor 2B 15 Removal 25 saus ape enews 2B 15 Disassembly 2B 15 Cleaning and Inspection 2B 16 s eee ee ede be ed eed ax 2B 16 Armature Test for Shorts 2B 16 Armature Test For Ground 2B 17 Checking Positive Brushes and Terminals 2B 17 Testing Negative Brushes For Ground 2B 17 Starter Solenoid 2B 18 Brush 2B 18 Reassembly 2B 18 Installation uu ee eR CREER 2B 20 90 817643R1 DECEMBER 1996 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 bat tery if ventilation is poor This explosive gas may remain in or around battery for several hours after it has been charged Sparks or flames can ignite this gas and cause an internal explosion which may shatter the battery The following precautions should be observed to prevent an explosion 1 DONOT
7. 6 20 LOWER UNIT 2 f 2 Check to see if the shift cable will slide through the drilled hole necessary use a file to remove any extra metal from the hole 3 Install the shift cable to the jet drive Use the exist ing mounting hardware supplied with the outboard Adjust shift cable after kit is installed Shift Cable Bolt Locknut Flat Washer op 90 817643R1 DECEMBER 1996 4 Lubricate the shift cable Slide the cable boot onto 8 Drill the shift cable retainer mounting hole as fol the cable lows a Remove air box cover off the carburetors Re install after installation b Lay a straight ruler above the corner radius and across the flat side of the cable opening in the D bottom cowl locate the center of hole by measuring 1 1 4 in I 5 31 mm from the opening d Drill a 9 32 in hole through bottom cowl a Cable Boot b Lubricant Slide the shift cable through the drilled hole Position the cable boot 1 2 in 12 mm out of the drilled hole 7 Fasten shift cable to the starter motor mount with J clip a Straight Ruler 9 Rotate the shift cable retainer so that the set screw is facing up and the slot is facing out 10 Slide shift cable into retainer until brass tube ex tends out 2 1 4 in 56 mm Sec
8. Tiller Handle Adaptor Kit JET 45 Tiller Arm Shift Lever Removal Tiller Handle Disassembly Tiller Arm Reassembly Tiller Arm Shift Lever Installation Shift Link Rod Installation and Adjustment to Engine ee Eee eta Throttle Cable Installation and Adjustment Co Pilot Installation Wiring Harness Connection Page 7B 1 7B 2 EY 90 817643R1 DECEMBER 1996 Notes 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 1 Steering Handle Kit 6 2 4 C With Teflon 92 825407A12 Bs 2 4 C Soapy Water Solution Obtain Locally 7B 2 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 Steering Handle Kit DESCRIPTION Ib in Ib ft N m STEERING ARM BUSHING HOUSING PLATE GASKET SCREW 1 2 IN Drive Tight SCREW 3 5 IN Drive Tight CLAMP SCREW 4 5 WING NUT THROTTLE HANDLE STOP SWITCH KIT STOP SWITCH SCREW Drive Tight GRIP J CLAMP J CLAMP THROTTLE CABLE KIT CONDUIT GUIDE TUBE BARREL SET SCREW Drive Tight CABLE GUIDE ANCHOR SET SCREW Drive Tight SCREW CAP WASHER WASHER SPACER THROTTLE TUBE NN
9. 5D 4 Determining if Problem is Electrical or Hydraulic 5D 4 Hydraulic System Troubleshooting 5D 5 Preliminary Checks 5D 5 Leak Down Check Pump and Manifold Assembly 5D 5 Leak Down Check Pilot Valve E 50 6 Leak Down Check Manual Release Valve 5D 6 Leaks Past Ball and Seat Piston 222222 45 5 66 5D 6 Troubleshooting Flow Diagram 5D 7 Troubleshooting Flow Diagram 5D 8 Electrical System Troubleshooting 5D 9 Commander 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5D 9 Power Trim System Wiring Diagram 5D10 Troubleshooting the Down Circuit When Up Circuit is OK 5D 11 Troubleshooting the Up Circuit When Down Circuit Is OK 5D 12 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5D 13 Page Power Trim System Removal 5D 14 Power Trim System Disassembly 5D 15 Trim Rod Removal 5D 15 Trim Rod Disassembly 5D 16 Trim Motor Removal 5D 18 Trim Motor Disassembly 5D 18 Reservoir Assembly Removal 5D 18 Manifold Removal 5D 19 Cleaning
10. Reservoir Plug Fill Hole Manual Release Valve Using a 12 volt power supply connect the positive lead to blue trim motor wire and negative lead to green trim motor wire and drive shock rod to the up position Repeat for three times Connect the positive lead to the green trim mo tor wire and the negative lead to the blue trim motor wire and drive the shock rod to the down position Recheck fluid level add fluid if required and re peat cycle until fluid level stays even with the bot tom of the fill hole 90 817643R1 DECEMBER 1996 Installation of Power Trim System 1 Lubricate lower pivot pin mounting holes with 2 4 C Marine Lubricant Start lower pivot pin into pivot pin bore and posi tion lower dowel pin Retained in its respective hole 51148 a Lower Pivot Pin b Lower Dowel Pin 3 Position trim cylinder assembly Bottom First be tween clamp brackets a Trim Cylinder Assembly MID SECTION 5E 43 4 Apply 2 4 C Marine Lubricant 92 90018A12 to lower pivot pin Using a suitable punch drive low er pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside sur face 51147 a Lower Pivot Pin 5 Using a suitable punch drive lower dowel pin into its hole until seated a Lower Dowel Pin 5E 44 MID SECTION 6 Apply 2 4 C Marine Lubricant 92 90018 12 to surface of upper pivot p
11. j O NUT 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 3 Steering Handle Kit Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 7B 4 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 Steering Handle Kit TORQUE ary DESCRIPTION bf Nm BRACKET STUD TAB WASHER NUT STOP HARNESS CABLE PLUG GROMMET COVER SCREW Drive Tight HORN PLUG STOP SWITCH LANYARD RETAINER CABLE STUD NUT WASHER SHIFT LEVER SCREW TAB WASHER BUSHING WASHER BELLEVILLE WASHER PLASTIC NI O On N A NINI 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 5 Steering Handle Kit Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 7B 6 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 Steering Handle Kit QTY DESCRIPTION Ib in Ib ft N m 25 1 WASHER SHIFT ROD ROD END BUSHING WASHER COTTER PIN DETENT ASSEMBLY STUD KNOB CO PILOT LEVER CO PILOT DRIVER WASHER BRAKE DISC ARM TOP ARM BOTTOM HARNESS ASSEMBLY KEY SWITCH NUT TRIM SWITCH NUT SWITCH ASSEMBLY SCREW Drive Tight CLAMP SCREW Drive Tight Pol PO
12. 7A 2 Securing Outboard to Boat Transom Electric Start Models 7 5 Steering Cable Installation 7A 5 Dual Outboard 7A 5 Cable Installation to Tilt Tube Cable Routed on Starboard Side of Boat 7 6 Cable Installation to Tilt Tube Cable Routed on Port Side of Boat 7A 7 Tilt Tube Reversal 7 7 Installing Steering Link Rod 7A 7 Models with One Piece steering Arm 74 8 Models with One Piece steering Arm Bracket 7 8 Maintenance Instructions 7 9 Dual Steering Installation 7A 9 Steering Coupler Assembly 7A 9 Installation 0 0 0 0 cece eee ees 7A 10 Models With Forged Two Hole Steering Arm and One Piece Top Cowl 7A 10 Models With Two Hole Two Piece Steering Arm Bracket and One Piece Top Cowl 7A 11 Ride Guide Steering Attachment Extension Couplers 7 12 Trim Tab Adjustment 7 12 Dual Outboard 7A 12 Maintenance Instructions 7 12 Transom Mounted Ride Guide Attaching Kit Installation 7 13 Attaching Kit Installation 7 13 Clevis Attaching Kit Installation 7A 14 Installation Instructio
13. 6C 13 Bearing Carrier Disassembly 6C 14 Bearing Carrier Reassembly 6C 14 Installing Lower Seals 6C 14 Installing Upper Seals 6C 15 Installing Drive Shaft Ball Bearing 6C 15 Installing Drive Shaft 6C 15 Installing Upper Seal Housing 6C 16 Installing Jet Drive to Drive Shaft Housing 6C 17 Reassembling Water Pump to Jet Drive 6C 17 Installing Jet Drive to Drive Shaft Housing 6C 18 Jet Drive Tiller Handle Adaptor Klt 6C 20 Installation Instructions 6C 20 Shift Cable Adjustement 6C 23 90 817643R1 DECEMBER 1996 Notes 90 817643R1 DECEMBER 1996 LOWER UNIT 6C 1 JET PUMP ASSEMBLY 95 D 2 4 With Teflon 92 825407A12 90 817643R1 DECEMBER 1996 6C 2 LOWER UNIT JET PUMP ASSEMBLY DESCRIPTION Ib in Ib ft N m JET PUMP ASSEMBLY HOUSING Pump HOSE lube IMPELLER HOUSING Intake LINER DRIVESHAFT SLEEVE NUT Drive Tight KEY SHIM TAB WASHER SCREW 1 4 20 x 875 SCREW 1 4 20 x 875 SCREW 1 4 20 x 625 SCREW 312 18 x 1 25 BRACKET NUT PIN Dowel SCREW M10 x 60 SCREW M10 x 90 SCREW M10 x 70 SCREW 375 16 x 75 WASHER N O N PO Pr NN QO O 90 817643R1 DE
14. Page Key Choke Switch Continuity Test COMMANDER 2000 Side Mount Remote Control Wiring Diagram 2D 9 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 2D 10 COMMANDER Side Mount Remote Control Power Tilt Electric Start with Warning Horn Wiring Diagram 2D 11 COMMANDER 2000 Side Mount Remote Control Electric Start with Warning Horn Wiring Diagram 2D 12 90 817643R1 DECEMBER 1996 p i Model 45 Jet Electric Start Wiring Diagram BLK BLACK BLU e BLUE BRN BROWN GRY GREY GRN GREEN PUR PURPLE RED e RED WHT WHITE YEL YELLOW LIT LIGHT O GQ N Stator Trigger Switch Box Voltage Regulator Rectifier Starter Starter Solenoid Battery Engine Harness RPM Limiter 10 Warning Module 11 Temperature Switch 12 Enrichment Valve 13 20 Ampere Fuse 14 Low Oil Sensor 15 To Power Trim Motor 16 Ignition Coil 3 Cylinder 17 Ignition Coil 2 Cylinder 18 Ignition Coil 1 Cylinder 90 817643R1 DECEMBER 1996 BRN C 3 BRN m BLK BLK YEL WHT BRN PUR acp WHT BLK C 3 WHT BLK BRN m gt PUR WHT
15. st 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 7 Tiller Handle Adaptor Kit JET 45 5 OS 9 Zi 10 wu ORT Loctite 271 92 809820 A Drive tight and then back off 1 4 turn B Tighten until snug and then tighten an additional 1 8 turn TORQUE QTY DESCRIPTION Ib in Ib ft TILLER HANDLE ADAPTOR KIT SHIFT CABLE TAB WASHER SHIFT LEVER STUD SHIFT KNOB CABLE BOOT J CLIP SCREW 1 4 20 x 7 8 WASHER BUSHING NUT CABLE SEAL SCREW 1 4 28 x 1 3 4 LOCKWASHER RETAINER SET SCREW WASHER WASHER WASHER WASHER NUT Ke CO N MD oO WS 7B 8 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 PAS Tiller Arm Shift Lever Removal 1 Remove battery cables from battery 51084 2 Remove outboard cowling 3 Remove nut securing throttle cable to engine ZA go s O LN M S E PAPS a LZ Sy Se E A 51092 Throttle Cable Throttle Lever Washer Locknut ao oo 90 817643R1 DECEMBER 1996 4 Release latch and remove throttle cable with grommet from bottom cowl 51093 a Rubber Grommet b Throttle Cable 5 Remove cotter key from shift rod 54256 Tiller Handle Shift Rod
16. J 50447 a Retaining Tool b Tilt System c Container d Cam Lever e Accumulator Opening 90 817643R1 DECEMBER 1996 3 Bleed unit by pushing rod down slowly 18 20 se conds per stroke until stopped at base Wait until all air bubbles exit accumulator base 4 During up stroke pull up on rod slowly 3 in 76mm from base 5 Wait until all air bubbles exit accumulator base 6 Slowly cycle unit 5 8 times round trip per cycle using short strokes 3 in 76mm from base allow ing bubbles to disappear during each stroke MID SECTION 56 33 2 7 Allow unit stand five minutes then proceed to 11 With cam lever remaining open facing down re cycle unit 2 3 more times using short strokes No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise Torque accumulator to 35 Ib ft 47 at this time 8 With oil level well above accumulator port slowly pull rod to full up position 9 Install accumulator making sure air bubbles do not enter system 10 Tighten accumulator snugly at this time 5G 34 MID SECTION 90 817643R1 DECEMBER 1996 anual Tilt System 4 Using suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until Installation pivot pin is flush with outside surface 1 Apply 2 4 C Marine Lubricant to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into p
17. D PUR ELECTRICAL and IGNITION 2D 1 Model 50 60 Electric Start Wiring Diagram RECTIFIER MODELS rE 53 x e O OoOo oo Stator Trigger Switch Box Ignition Coil Cylinder No 1 Ignition Coil Cylinder No 2 Ignition Coil Cylinder No 3 Starter Motor Starter Solenoid Rectifier Fuse Holder 20 Amp Fuse Battery Wiring Harness Connector Enrichment Valve Temperature Switch Low Oil Warning Module Low Oil Sensor d GRNIRED lt s SZ t DE Wiz 2 Se Wet BLK e BLACK BLU e BLUE BRN BROWN GRY GREY GRN GREEN PUR PURPLE RED e RED TAN WHT WHITE YEL YELLOW LIT LIGHT YEL BLK RED PUR 2D 2 ELECTRICAL and IGNITION 90 817643R1 DECEMBER 1996 A Model 50 60 Electric Start Wiring Diagram REGULATOR MODELS Stator Trigger Switch Box Ignition Coil Cylinder No 1 Ignition Coil Cylinder No 2 Ignition Coil Cylinder No 3 Starter Motor Starter Solenoid Regulator Fuse Holder 20 Amp Fuse Battery Wiring Harness Connector Enrichment Valve Temperature Switch Low Oil Warning Module Low Oil Sensor 5 e GREY PUR PURPLE ED PUR RED WHITE YELLOW LIGHT 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2D 3 Model 50 60 Electric Start Tiller Handle
18. Pump motor operates Outboard will not return complete Pump motor does not operate ly to down position or returns part way with jerky motion Outboard thumps when shifted Refer to Hydraulic System Refer to Electrical System Outboard trails out when backing off throttle at high speed Outboard will not hold a trimmed position or will not remain tilted for any extended period Outboard will not hold trim position when in reverse 90 817643R1 DECEMBER 1996 Troubleshooting Troubleshooting MID SECTION 5 11 Hydraulic System Troubleshooting Support outboard with tilt lock lever when servicing power trim system IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reas sembly IMPORTANT Power trim system is pressurized Outboard must be in the full UP position trim rod fully extended prior to fill drain plug or man ual release valve removal Refer to instructions following if disassembly is re quired when servicing Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been correct
19. 2 1 GASKET boost 1 GASKET pulse 1 PLATE 2 FITTING 2 SCREW fuel pump 2 SCREW fuel pump to crankcase 1 BASE wem HOSE 1 1 2 5 1 2 9 1 2 9 1 2 o co a lt 2 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3B 5 AWARNING FIRE AND EXPLOSION HAZARD Observe fire preven tion rules particularly NO SMOKING Before servicing any part of the fuel system disconnect electrical sys tem at the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Materials used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be per formed in a well ventilated area FUEL LEAKAGE FROM ANY PART OF THE FUEL SYS TEM CAN BE A FIRE AND EXPLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH Careful periodic inspection of the entire fuel system is mandatory particularly after engine storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines primer bulbs fittings swelling and must be inspected for corrosion Any sign of leakage or deterioration necessitates re placement before further engine operation Fuel Pumps General Information FUEL PUMP DESCRIPTION OPERATION The fuel pump is a crankcase pressure operated dia phragm type pump Crankcase pulsating pressure is transferred by way of a passage hole from the crankc
20. Outboard trails out when backing Refer to Hydraulic System off throttle at high speed Troubleshooting Outboard will not hold a trimmed position or will not remain tilted for any extended period Outboard will not hold trim position Refer to Electrical System when in reverse Troubleshooting 90 817643R1 DECEMBER 1996 MID SECTION 5B 11 Hydraulic System Troubleshooting Support outboard with tilt lock lever when servicing power trim system IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reas sembly IMPORTANT Power trim system is pressurized Outboard must be in the full UP position cylin der fully extended prior to fill screw or manual re lease valve removal Refer to instructions following if disassembly is re quired Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been corrected If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and f
21. Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground Depress the Up trim button Battery Voltage Indicated No Voltage Indicated UP Relay is defective Replace and retest Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 7 and 8 No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 5D 12 MID SECTION 90 817643R1 DECEMBER 1996 Troubleshooting the Down Up Circuits All Circuits Check in line fuse under cowl to Inoperative see if fuse is blown Remote Control NOT Equipped with Trailer Button 90 817643R1 Blown Fuse Correct problem that caused fuse to blow e Replace fuse No Voltage Indicated Check battery leads for poor connections or open circuits Check battery charge No Voltage Indicated Check that voltage is being supplied to control by performing the following checks e DO NOT start engine Turn ignition switch to Run po sition e Check for voltage at any instru ment using a Voltmeter No Voltage Indicated Red wire is open between Point 3 and red terminal on back of
22. Down Pressure Regulating Valve Down Pressure Operated Valve Filter 2 shown for clarity Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap pb 09 x 5E 16 MID SECTION Tilt Relief 250 400 40 60 q 540 990 75 125 Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder lt 90 817643R1 DECEMBER 1996 PAS Shock Function Return After the engine clears the under water object the weight of the engine will increase the oil pressure be tween the memory piston t and shock piston u to the level required to open the shock return valve h inside the shock piston allowing the oil to bleed back through the shock piston into the down cavity If re quired additional oil will enter the down cavity through the manifold reverse suction valve 0 This will return the engine back against the memory piston t and into the original running position 90 817643R1 DECEMBER 1996 MID SECTION 17 cM
23. a Using lock ring pliers Craftsman P N 4735 or suitable tool LOCK RING PLIERS CY 4 b Blowing compressed air into manual release valve hole using adaptor P N 91 822778A3 Memory piston cup may be expelled at a high velocity when air pressure is applied Failure to place cylinder as shown below could result in personal injury 51144 NOTE Point cylinder opening down and away Use a shop rag or towel to avoid damage to the memory piston a Adaptor Air Hose b Memory Piston Exit c Shop Rag 90 817643R1 DECEMBER 1996 2 Remove o ring from memory piston a O Ring b Memory Piston 51144 MID SECTION 5E 33 Cleaning Inspection Repair IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction Clean shock rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Use O Ring Kit 25 827668A1 Lubricate all o rings with Quicksilver Power Trim Fluid 92 90100A1 2 If not available use automotive ATF automatic transmission fluid Trim Motor Electrical Tests 1 Connect a 12 volt supply to motor leads If motor fails to run replace pump motor IMPORTANT Trim Motor is not serviceable If mo tor fails to run replace motor assembly 5E 34 MID SECTION EY 90 817643R1 DECEMBER 1996 PAS i Reassembly O Ring and Seal Placeme
24. 11 Install VENT plug and washer c 12 Clean magnet on FILL plug and install FILL plug and washer b SALT WATER CORROSION GEAR HOUSING BEARING CARRIER and COVER NUT Salt water corrosion buildup can be sufficientto split a gear housing and destroy an entire lower unit To protect against such damage therefore it is recommended that the gear housing bearing carrier be lubricated on a regular basis as follows Service first at the 20 hour inspection then on an annual basis Remove the entire bearing carrier to adequately clean corrosive deposits and dried up lubricant from both ends of the bearing carrier as well as the gear housing Apply a liberal amount of 2 4 C w Teflon Marine Lubricant to the 2 ends of the bearing carrier then reassemble and torque to specifications Refer to gear housing disassem bly and reassembly Section 6A 90 817643R1 DECEMBER 1996 c n Periodic Inspection Conduct a periodic systematic inspection to uncover and correct a failure before it can cause inconvenience or me chanical damage Inspection interval is based on average operating conditions in recreation service Under severe conditions the inspection interval should be shortened In spection includes 1 Clean entire unit thoroughly including all accessible powerhead parts 2 Checkentire unit for loose damaged or missing parts Tighten or replace as required Lubricate gear housing Lubricate other points as indicated
25. 2 2 2 SI 9 a Trilobe Pin 25464 b Upper Pivot Pin WS a Tilt Lock Pin 5 Remove the sacrificial anode 2 Disconnect the power trim wire harness and re move clamp a Sacrificial Anode 55264 a Power Trim Wire Harness Clamp b Harness MID SECTION 5E 27 90 817643R1 DECEMBER 1996 6 Use suitable punch to remove Drive Up lower Power Trim Disassembly pin Retain dowel pin IMPORTANT Power trim system is pressurized Trim rod must be in the full UP position fully ex tended prior to fill drain plug or manual release valve removal 1 Remove reservoir cap 2 Remove manual release valve assembly to drain oil a Dowel Pin 7 Use suitable punch to drive out lower pivot pin a Reservoir Cap b Manual Release Valve a Lower Pivot Pin 5E 28 MID SECTION 90 817643R1 DECEMBER 1996 Trim Motor Removal 1 2 Secure power trim assembly in a soft jaw vise Remove four 4 screws to remove motor reser voir Remove reservoir seal and coupler a D eEg Screw 4 b Reservoir c Reservoir Seal d Coupler e Manifold Assembly 90 817643R1 DECEMBER 1996 Pump and Components Removal 1 Remove pressure operated plugs on pump Re move spring and check valve poppet both
26. 250 400 40 60 540 990 75 125 q lt Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder 90 817643R1 DECEMBER 1996 ar Tilt Up In the up mode as the piston rod a extends from the cylinder w the memory piston t clears or un covers the pressure relief passage Oil from the up cavity will enter this passage and if required causes the tilt relief piston s to open the tilt pressure relief valve r This valve lowers the amount of pressure available to lift the outboard motor With the engine in forward gear and at high engine rpm the oil pressure available will not be able to overcome the propeller thrust limiting the trim range to below the pressure re lief orifice When the engine rpm s fall or if engine is not in forward gear the oil pressure is available to ex tend the piston rod a up into the tilt range 90 817643R1 DECEMBER 1996 MID SECTION 5E 9 p i e MAXIMUM TILT a lt b u V _ h WY 1 ff x i k e
27. 38 Spacer 2 39 Anode 40 Washer 2 41 Screw 2 42 Manual Release Valve ao 43 O ring 44 E clip 51498 NOTE Lubricate all O rings and seals with Quicksilver Lubricants Torque Specifications and Service Aids 100 Ib in 11 1 N m Loctite 271 92 32609 1 9 13 lb ft 1 5 70 Ib in 7 7 Liquid Neoprene 92 25711 1 D 35 lb in 4 0 Power Trim and Steering Fluid 92 90100A12 90 817643R1 DECEMBER 1996 MID SECTION 5D 3 Troubleshooting Determining if Problem is Electrical or Hydraulic When a problem is encountered with the Power Trim system the first step is to determine whether the mal function is in the electrical system or the hydraulic system Refer to the following chart to determine which system is at fault Problem Chart Outboard will not trim up or down Determine if Power Trim Outboard trims up will not trim pump motor operates when down appropriate trim circuit is activated Outboard trims down will not trim up Outboard will not return com pletely to down position or re Pump Pump motor does nor operate turns part way with jerky mo tion Outboard thumps when shifted Refer to Hydraulic System Refer to Electrical System Troubleshooting Troubleshooting Outboard trails out when back ing off throttle at high speed
28. 5C 3 Torque Specifications 5C 3 Quicksilver Lubricant Sealant Application POIUIS iras aa Exe RR Re od 5C 3 Power Trim Flow Diagrams Design Il 5C 4 Design lll ep m 5C 5 Design pester purane RENE 56 6 Pr 56 7 Design ll 5 8 Design 5 9 Design 5C 10 Troubleshooting 5C 11 Determining if Problem is Electrical or 56 11 Trouble Chart 5C 11 Hydraulic System Troubleshooting 5C 12 Preliminary Checks 5C 12 Leak Down Check Pump and Manifold Assembly 5C 12 Leak Down Check Pilot Valve Assembly 5C 13 Leak Down Check Manual Release UI todas 5C 13 Leakage Past Ball and Seat Piston aaa 5C 13 Troubleshooting Flow Diagram 5C 14 Troubleshooting Flow Diagram 5C 15 Electrical System Troubleshooting 5C 16 cM Page COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5C 16 Power Trim System Wiring Diagram 5C 17 Troubleshooting the Down Circuit When Circuit is 5C 18 Troubleshooting the Up Circuit When Down Circuit Is OK 5C 19 Troubleshooting the Down and Up
29. 7 21042 a Bearing Installation Tool 91 13945 b Mandrel 91 37263 c Suitable Driver Rod LOWER UNIT 6B 19 4 Place smaller diameter seal on longer shoulder of Oil Seal Driver 91 31108 with seal lip away from shoulder Protect lip on front side of bearing carrier using Bearing Installation Tool 91 13945 Apply Loctite 271 on O D of seal Press seal into carrier until tool bottoms 21040 a Seal b Oil Seal Driver 91 31108 c Bearing Installation Tool 91 13945 6 Place larger diameter seal on shorter shoulder of Oil Seal Driver 91 31108 with seal lip toward shoulder 7 Protect lip on front side of bearing carrier using Bearing Installation Tool 91 13945 Apply Loctite 271 on O D of new seal Press seal into carrier until tool bottoms 21041 a Seal b Oil Seal Driver 91 31108 c Bearing Installation Tool 91 13945 6B 20 LOWER UNIT 10 Install O ring Lubricate O ring with 2 4 C w Teflon Lubricate seal lips with 2 4 C w Teflon 92 825407A12 Lu bricate outside diameter of bearing and bearing carrier bore with a light coating of 2 4 C w Teflon Press bearing into carrier until tool bottoms 19163 a O ring b Bearing Numbered Side Toward Tool c Bearing Installation Tool 91 13945 11 Install thrust washer Coat thrust washer with Quicksilver Gear
30. Design 2 SHOCK FUNCTION VALVES CLOSED 90 817643R1 DECEMBER 1996 Q Manual Tilt Flow Diagrams Design 3 TILT UP GAS PRESSURE 300 700 P S I 51661 90 817643R1 DECEMBER 1996 MID SECTION 5F 13 Design 3 TILT DOWN p OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 5F 14 MID SECTION 90 817643R1 DECEMBER 1996 EY Design 3 SLOW TILT DOWN UNDER HIGH THRUST OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 90 817643R1 DECEMBER 1996 MID SECTION 5F 15 EY Design 3 UNDER WATER STRIKE VALVES OPEN 90 817643R1 DECEMBER 1996 Q Design 3 SHOCK FUNCTION VALVES CLOSED 90 817643R1 DECEMBER 1996 Hydraulic System Troubleshooting Refer to disassembly reassembly instructions fol lowing if disassembly is required when servicing IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball components and castings must be cleaned using engine cleaner and com pressed air or replaced prior to reassembly Support outboard with tilt lock lever when servicing manual tilt system 1 Check manual release cam adjustment Cam must open and close freely Adjust cam link rod as necessary 51143 a Link Rod b Manual Release Lever c Accumulator 5F 18 MID SECTION Cn 2 Checkfor ext
31. Do not remove check ball components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age 51199 Inspect check valve for debris clean debris form check valve if found If debris cannot be cleaned from check valve replace trim rod piston as an assembly Clean trim rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Inspect trim rod If scraper located in cap has failed to keep rod clean replace scraper Lubricate all O rings using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron ll 5D 20 MID SECTION Motor and Electrical Tests Repair Trim Pump Motor Test Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect green motor wire and blue motor wire from trim system wiring harness 2 Connect a 12 volt power supply to motor wires positive to blue negative to green results in mo tor up direction Positive to green negative to blue results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Armature Tests TEST FOR SHORTS Check armature on a Growler follow Growler man ufacturer s test instructions Indication of a short re quires replacement of armature TEST
32. Hydrometer measures percentage of sulfuric acid in bat tery electrolyte in terms of specific gravity As a battery drops from a charged to a discharged condition acid leaves the solution and chemically combines with the plates causing a decrease in specific gravity of electrolyte An indication of concentration of electrolyte is obtained with a hydrometer When using a hydrometer observe the following points 1 Hydrometer must be clean inside and out to insure an accurate reading 2 Nevertake hydrometer readings immediately after wa ter has been added Water must be thoroughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing 3 If hydrometer has built in thermometer draw liquid in several times to ensure correct temperature before taking reading 4 Holdhydrometer vertically and draw in just enough liq uid from battery cell so that float 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 Dis regard 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 ELECTRICAL and IGNITION 2B 1 Specific gravity of electrolyte varies not only with percent age of acid in liquid but also with temperature As tempera ture drops electrolyte con
33. Lower Cowl Bushing Shift Handle Washer Cotter Key OUTBOARD INSTALLATION ATTACHMENTS 7B 9 cM 6 Remove cover 8 Remove plug from tiller handle bracket a Cover b Screw 4 7 Disconnect stop switch wire at bullet connector and Screw securing ground wire 51608 a Plug 51608 CE a Stop Switch Wire Bullet Connector 51608 Bolt b Nut Hidden 7B 10 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 2 L 10 Removetiller handle 2 nylon bushings stainless steel Tiller Handle Disassembly spacer and 2 flat washers from bracket 1 Using a flat tip screwdriver carefully pry push rubber grip off tiller handle a Tiller Handle b Nylon bushing 2 a Grip c Stainless Steel Spacer b Tiller Handle d Washer 2 e Bolt 2 Remove screw from twist grip 11 Bend tab washer away form bolt securing shift lever and remove bolt and lever from bracket 51603 a Screw 51606 a Tab Washer b Bolt c Shift Lever d Bracket 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 11 3 Cut sta strap securing stop switch harness and re 5 Remove throttle cable anchor screws and remove move screw from harness J clip cable guide 51603 a Sta Strap a Anchor Screws b Screw b Throttle Cable Guide 4 Remove stop switch and twist grip from tiller handle 6 Rem
34. SEC 6B 18 Bearing Carrier Reassembly 6B 19 Forward Gear Reassembly 6B 21 cM Page Propeller Shaft Reassembly 6B 22 Drive Shaft Wear Sleeve Installation 6B 22 Lower Drive Shaft Bearing Race Installation 6B 23 Oil Sleeve Installation 6B 24 Upper Drive Shaft Bearing Installation 6B 24 Forward Gear Lower Drive Shaft Bearing Pinion Gear and Drive Shaft Installation 6B 25 Pinion Gear Depth and Forward Gear Backlash 6 25 Determining Pinion Gear Depth 6B 25 Determining Forward Gear Backlash 6B 27 Bearing Carrier and Propeller Shaft Installation 6B 28 Water Pump Reassembly and Installation 6B 29 Gear Housing Pressure Test 6B 31 Filling Gear Housing With Lubricant 6B 31 Propeller Installation 6B 32 Gearcase Installation 6B 33 Trim Tab Adjustment 6B 34 90 817643R1 DECEMBER 1996 Notes 90 817643R1 DECEMBER 1996 LOWER UNIT 6B 1 2 Gear Hsg Drive Shaft 60 Seapro Marathon Big Foot asl C 95 Sa 31 Loctite 271 92 809820 Super Duty Gear Lubricant 92 13783A24 5 H 92 D Loctite 7649 Primer 92 809824 2 4 With Teflon 92 825407A12 6B 2 LOWER UNIT 90 81764
35. b End Cap 90 817643R1 DECEMBER 1996 POWERHEAD 4 33 x L Intake Reed Block Manifold Installa 3 Install reed block manifold and intake manifold with gasket to cylinder block tion 1 Place engine on repair stand or on bench NOTE Powerhead repair stand p n 91 25821A1 can be used Can only be installed one way PE 51225 4 Install bolts and torque to 18 Ib ft 24 5 N m in se quence shown below PE 51227 2 Install check valve holders 51085 51227 Check Valve Holders 4 34 POWERHEAD 90 817643R1 DECEMBER 1996 Thermostat Cover Installation 1 Install thermostat components into cylinder block Torque bolts to 18 Ib ft 24 5 50 60 Models 55 Model Install Remaining Engine Components Component Assembly Section Starter Motor 2B Ignition Switch Box 2A Ignition Coil 2A Starter Solenoid 2B Voltage Regulator Rectifier 2B Flywheel 2A Stator Assembly 2A Trigger Assembly 2A Air Silencer 3A Carburetor and Linkage 3A Fuel Pump 3B Fuel Enrichment Valve 3C Shift Cable Latch Assembly 7A Control Cable Anchor Bracket 7A Warning Module 3D Oil Pump 3D Note All ignition and electrical components can be moved and installed as an assembly 90 817643R1 DECEMBER 1996 Powerhead Installation 1 Install lifting eye p n 91 90455 into flywheel a mini mum of 5 turns Install powerhead to driveshaft hous ing Slide shift slide on
36. c i Special Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 LOCK RING PLIERS OD gt I 3 Expanding Rod P N CG 41 11 ml 4 Collet P N CG 41 14 x Ex 90 817643R1 DECEMBER 1996 MID SECTION 5E 1 POWER TRIM COMPONENTS B 7 Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all o rings be replaced when servicing tilt system 5E 2 MID SECTION 90 817643R1 DECEMBER 1996 POWER TRIM COMPONENTS TORQUE a DESCRIPTION Ib in Ib ft N m POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O RING REBUILD KIT O RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG Drive Tight MANUAL RELEASE ASSEMBLY Drive Tight MANIFOLD KIT SCREW KIT MOTOR DRIVE SHAFT FILTER KIT P O CHECK ASSEMBLY KIT CABLE O RING KIT COMPLETE TRIM GROOVE PIN ANCHOR PIN PIN BRACKET HARNESS Trim SCREW M6 x 25 RELAY BRACKET GROMMET BUSHING A Torque cylinder cap to 45 Ib ft 61 N m B Torque screws to 80 Ib in 9 0 N m C Torque screws to 70 Ib in 7 9 N m D Torque plugs to 120 Ib in 13 5 E Torque screws to 100 Ib in
37. f o g p h 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7A 11 Ride Guide Steering Attachment Extension Couplers Required Coupler s Between Steering Eyes Shown Below 9 in 229mm Coupler p n 814951 1 12 in 305mm Coupler p n 814951 2 15 in 381mm Coupler p n 814951 3 18 in 457mm Coupler p n 814951 4 Outboard Center Line Distance 18 in thru 22 1 2 in 457mm thru 572mm 22 1 2 in thru 24 1 2 in 572mm thru 622mm 23 1 2 in thru 27 1 2 in 597mm thru 699mm 26 1 2 in thru 30 1 2 in 673mm thru 755mm 18 in 457mm Coupler P N 814951 4 15 381mm Coupler P N 814951 3 12 in 305mm Coupler P N 814951 2 9 in 229mm Coupler P N 814951 1 Trim Tab Adjustment DUAL OUTBOARD 1 Check trim tab position as follows IMPORTANT Initial trim tab setting for both outboards should be straight to rear of outboard so that tabs are aligned with gear housing centerline Refer to If nec essary adjust trim tab as follows a Operate boat at normal cruise throttle setting and adjust trim to optimum setting b If boat pulls to the right starboard trailing edge of trim tab must be moved to the right when viewing outboard from behind If boat pulls to the left port trailing edge of trim tab must be moved to the left 7A 12 OUTBOARD INSTALLATION ATTACHMENTS a Shift outboard into neutral and make sure
38. 1 It is recommended that all O rings exposed dur ing disassembly be replaced 2 Clean components filter and check valve seats using engine cleaner and compressed air Do not use cloth rags Inspect all machined surfaces for burrs or scoring to assure O ring longevity 4 Inspect shock rod If wiper located in cap has failed to keep rod clean replace wiper Manual Tilt System Reassembly IMPORTANT Components must be dirt and lint free Slightest amount of debris in tilt system could cause system to malfunction Apply Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron II on all O rings during reassembly NOTE Refer to Manual Tilt System Components for proper O ring sizes Valve Block Reassembly IMPORTANT Cam shaft O ring must be lubri cated using Special Lubricant 101 prior to instal lation 1 Install lubricated O ring to cam shaft 2 Install cam shaft in valve block 3 Secure cam shaft in place using insulator retain er plate and screw Tighten screw securely 5F 28 MID SECTION om 51142 Screw Retainer Plate Insulator Cam Shaft O ring Installpush rod ball flat spring and screw in valve block Torque screw to 27 in 3 0 N m 51145 Screw Flat Spring Ball Push Rod 90 817643R1 DECEMBER 1996 6 Install spool spring lubricated O ring and screw plug Surge valve assembly into v
39. 23 Oil Sleeve Installation 1 Install oil sleeve with tab positioned as shown m 9 a Oil Sleeve b Tab Upper Drive Shaft Bearing Installation 1 Lubricate 1 0 of bearing holder and O D of bearing with 2 4 C w Teflon 2 Press bearing into sleeve Bearing Sleeve Tapered End Bearing Numbered Side Toward Mandrel Mandrel From Bearing Installation Tool 91 14309A1 O mM 6B 24 LOWER UNIT IMPORTANT Oil sleeve must be installed prior to upper drive bearing installation IMPORTANT Upper drive shaft bearing sleeve can be installed with or without lower drive shaft bearing cup installed 3 Install bearing sleeve into housing f 53935 Bearing Sleeve Tapered End Mandrel Mandrel Threaded Rod 91 31229 Nut 11 24156 From Bearing Installation Tool 91 14309A1 From Bearing Removal and Installation Kit 91 31229A5 00009 90 817643R1 DECEMBER 1996 Forward Gear Lower Drive Shaft Bearing Pinion Gear and Drive Shaft Installation 1 Install components in sequence shown a Forward Gear Bearing Work Quicksilver gear lube into bearing rollers b Lower Drive Shaft Tapered Roller Bearing Work Quicksilver gear lube into bearing rollers Pinion Gear Drive Shaft Drive Shaft H
40. 4 Press into water pump base until tool bottoms 51263 Quicksilver Gear Lubricant 6A 22 LOWER UNIT 90 817643R1 DECEMBER 1996 ax i 7 removed previously re install seal and plate b O E 8 Install gasket a and face plate b 51268 51293 IMPORTANT If the old impeller is re used install in the original clockwise direction of rotation 9 Install drive key a and impeller b 90 817643R1 DECEMBER 1996 10 Lubricate of cover with Quicksilver Needle Bearing Assembly Lubricant P N 92 42649 1 Install gasket a with bead b towards cover 51290 11 Rotate driveshaft clockwise and push cover down Se cure cover a Cover b Isolators Design 1 Note 2 isolators for forward screws are different from remaining 4 isolators c Washers 6 d Bolts 6 Apply Loctite on threads and torque to 60 Ib in 6 8 N m NOTE Torque cover screws as shown 51271 LOWER UNIT 6A 23 12 If water tube seal a stayed on water tube inside of driveshaft pull seal from water tube 13 Lubricate 1 0 of water tube seal a with Quicksilver 2 4 C Marine Lubricant P N 92 90018A12 and in stall a Water Tube Seal Gear Housing Pressure Test 1 Remove vent plug and install pressure test gauge Tighten securely 2 Pressurize housing to 10 12 p s i and observe gauge for 5 minutes 6A 24 LOWER UN
41. 51148 a Lower Dowel Pin a Trim Cylinder Assembly 90 817643R1 DECEMBER 1996 MID SECTION 5C 37 6 Apply Special Lubricant 101 92 13872A1 to sur face of upper pivot pin pivot pin bore and trim ram bore 08 51148 Pivot Pin Pivot Pin Bore Trim Ram Bore N oon Using a suitable mallet drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flushed with swivel bracket a Pivot Pin b Swivel Bracket c Trim Ram 5C 38 MID SECTION i 8 Drive upper dowel pin a into its hole until seated 9 Recheck fluid level 10 Power trim may now be operated to lower out board to desired position Trim system is self bleeding 51147 11 Re connect spark plug leads to spark plugs 12 Re install top cowl 13 Connect battery leads to battery terminals 90 8i7643R1 DECEMBER 1996 c MID SECTION POWER TRIM DESIGN 3 Table of Contents Page Special Tools 5D 1 Power Trim General Information 5D 1 Description 5D 1 Trimming Characteristics 5D 1 Trimming Outboard Up Out 5D 1 Trimming Outboard Down In 5D 1 Trailering Outboard 5D 2 Tilting Outboard Up and Down Manually 5D 2 Trim In Angle Adjustment 5D 2 Power Trim System Components 5D 3 Troubleshooting
42. 5F 2 Manual Tilt Flow Diagrams Design 1 5F 3 Manual Tilt Flow Diagrams Design 2 5F 8 Manual Tilt Flow Diagrams Design 3 5F 13 Hydraulic System Troubleshooting 5F 18 Troubleshooting Flow Chart 5F 19 Manual Tilt System Removal 5F 21 Manual Tilt System Disassembly 5F 22 Accumulator Removal 5F 22 Shock Rod Removal 5F 23 Shock Rod Disassembly 5F 24 Valve Block 5F 26 Valve Block Disassembly 5F 27 Manual Tilt System Cleaning and Inspection 5 28 Manual Tilt System Reassembly 5F 28 Valve Block Reassembly 5F 28 Valve Block Installation 5F 30 Shock Rod Reassembly 5F 30 Shock Rod Installation 5F 32 Instructions for Making Retaining Tool 5F 33 Bleeding Manual Tilt System 5F 34 Manual Tilt System Installation 5F 35 90 817643R1 DECEMBER 1996 2 Manual Tilt System Components Design One and Two 2 Torque Specification Accumulator 3 Shock Rod 4 Valve Block 351b ft 47 N m 5 Dowel Pin 6 Pivot Pin 9 10016 in 11 5 N m 7 Rod Wiper 8 O ring 671 in 1 0 en 35 b in 4 0 10 O ring 1 864 in 1 0 11 O ring 614 in LD 2700 in 3 0 12 Shock R
43. 90 817643R1 DECEMBER 1996 POWERHEAD 4 19 8 Remove piston pin PE 51086 a Piston Pin b Piston Pin Tool 91 74607A2 9 Remove piston pin needle bearings 29 per piston pin and locating washers 2 per piston as shown PE 51088 a Locating Washers ACAUTION Bearing removal will cause bearing damage and will require replacement 10 Inspect crankshaft bearing Remove bearing a and retaining ring b only if necessary PE 51084 4 20 POWERHEAD c 11 Press crankshaft bearing as shown PE 51081 a Oil Drive Gear b Key PE 51084 90 817643R1 DECEMBER 1996 Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT Crankcase cover and cylinder block are matched line bored assembly should not be mis matched by using a different crankcase cover or cylin der block e Inspect cylinder block and crankcase cover for cracks or fractures e Check gasket surfaces for nicks deep grooves cracks and distortions that could cause compression leakages e Check that all water passages in cylinder block are not obstructed Check locating pins in cylinder block that they are tight e Check crankcase cover fuel bleed passages that they are not obstructed Verify that check valves in crank case cover are not damaged e Thoroughly clean cylinder block and crankcase cover Verify that all sealant and old gaskets are removed from matching surfaces Clean all car
44. Engine Mounted Oil 3 Disconnect oil hose and low oil sensor wires BLUE at bullet connectors Remove oil reservoir Reservoir Removal 1 Disconnect battery cables a Oil Tank Wires BLUE b Oil Hose 4 Remove oil level sensor from oil reservoir ACAUTION Oil level sensor is FRAGILE Handle with care 51204 a Screw b Oil Level Sensor a Starter Bracket b Bolts 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3D 13 Installation 3 Install starter oil tank bracket 1 Install oil level sensor and secure in place 51204 a Oil Level Sensor b Screw Tighten Securely 2 Connectsensoroillevel wires BLUE at bullet connec a Starter Oil Tank Bracket tors Re connect oil hose and secure in place with stay Paes strap Install reservoir to outboard 4 Re connect battery cables Oil Level Sensor Wires Oil Hose 30 14 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 cM POWERHEAD Table of Contents Specifications Special Tools Quicksilver Lubricants and Service Aids Cylinder Block and Crankcase Induction Manifold and Reed Block Crankshaft Pistons and Connecting Rods Throttle Lever and Linkage Powerhead Torque Sequence General Information ELPTO Po
45. LIGHT 90 817643R1 DECEMBER 1996 BLK YEL 51126 ELECTRICAL and IGNITION 2D 5 55 60 Manual Start with RED Stator Wiring Diagram a Stator b Terminal Block c Adaptor d Ground e Switch Box f RPM Limiter g Audio Horn h Insulate Unused Red Lead and Secure with Sta Strap BLK BLU BRN GRY GRN ORN PNK PUR RED TAN WHT YEL LT DRK 2D 6 ELECTRICAL and IGNITION Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark BLK YEL o 90 817643R1 54488 DECEMBER 1996 Q 50 60 Electric Start with RED Stator Wiring Diagram a 16 Amp Red Stator b Switch Box c Stator Adaptor d Ground Connection e Voltage Regulator f Insulate Unused Red Lead WHT GRN ac WHT GRN WHT BLK tts WHT BLK b acm BLK YEL a cite cc BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LT Light DRK Dark 54982 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2D 7 Model 50 60 Power Trim Wiring Diagram Power Trim Power Trim Relay Engine Starter Motor Solenoid Rectifier Cowl Mounted Trim Switch Red Battery Cable Fuse Holder 20 Amp Fuse Engine Wiring Harness Connector Remote
46. Plate 6A 8 LOWER UNIT 1 Bearing Carrier and Propeller Shaft 1 Drain lubricant refer to Draining and Inspecting Gear Lubricant 2 Remove bolts a 51117 3 With propeller shaft horizontal pull carrier to break seal with gear housing Remove bearing carrier pro peller shaft components Do not leave cam follower in end of propeller shaft Remove propeller shaft from bearing carrier using bearing puller Bearing Carrier Puller Jaws 91 46086A1 Puller Bolt 91 85716 Thrust Hub Propeller Shaft 90 817643R1 DECEMBER 1996 p 4 Replace reverse gear if gear teeth or clutch teeth on 7 verse gear are chipped or worn If reverse gear must be replaced pinion and sliding clutch should also be in spected for damage 5 lfreverse gear bearing is rusted or does not roll freely replace bearing Remove bearing and reverse gear using bearing puller 91 27780 51205 6 Remove ball bearing a from reverse gear b using Universal Puller Plate c and mandrel d Ball Bearing Reverse Gear Universal Puller Plate 91 37241 Driver Head 91 37312 90 817643R1 DECEMBER 1996 If bearing is rusted or does roll freely replace bearing Remove bearing and oil seals Discard oil seals Driver Rod 91 37323 Driver Head 91 37312 Propeller Shaft Needle Bearing Oil Seals 2 Remove seals
47. Screws 4 4 Remove reservoir from manifold 5 Remove drive shaft from oil pump 51007 O rings 3 Oil Pump Screw Spring Check Ball Remove screws and manifold from cylinder N Drive Shaft b Oil Pump 51007 a Trim Cylinder b Manifold c Screw 90 817643R1 DECEMBER 1996 MID SECTION 5C 27 IMPORTANT Removal of O ring e from manifold will result in damage to O ring O ring MUST be replaced after removal 3 Remove check valve components from manifold Manifold Spring Check Valve Check Valve Seat O ring Spring Sleeve Spool 56 28 MID SECTION 4 Remove O rings from cylinder 51008 a O rings Cleaning and Inspection of Trim Rod Components IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction A CAUTION Do not remove check valve components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age 51199 Inspect check valve for debris clean debris form check valve if found If debris cannot be cleaned from check valve replace trim rod piston as an assembly Clean trim rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Inspect trim
48. gine Throttle Cable Installation 1 With end of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place IMPORTANT Excessive preload on throttle cable will cause difficulty when shifting from forward to neutral Re adjust throttle cable barrel if necessary 2 Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Pre load is correct when paper can be removed without tearing but has some drag on it Re adjust throttle cable barrel if necessary 90 817643R1 DECEMBER 1996 cM ELECTRICAL AND IGNITION WIRING DIAGRAMS Table of Contents Model 45 Jet Electric Start Wiring Diagram Model 50 60 Electric Start Wiring Diagram Rectifier Models Model 50 60 Electric Start Wiring Diagram Regulator Models Model 50 60 Electric Start Tiller Handle Wiring Diagram Model 55 Manual Start Wiring Diagram Model 50 60 Power Trim Wiring Diagram Model 50 60 Manual Start with RED Stator Wiring Diagram Model 50 60 Electric Start with RED Stator Wiring Diagram
49. use in the same locations whenever possible Where the fasteners are not satisfactory for re use care should be taken to select a replacement that matches the original GENERAL INFORMATION and SPECIFICATIONS 1 Table of Contents Propeller Information How To Use This Manual Page Numbering Master Specifications crees rece eese mte es Specifications Special Tools Cowl Removal Filling Oil Injection System Propeller Selection Propeller Installation Trim In Angle Adjustment Propeller Information Chart 50 55 models 60 models Propeller Information Chart 60 Big foot 60 SeaPro Marathon 50 60 Models Stainless Steel Race Propellers Available from Mercury Performance PIOGUCIS oss AIEA EEPE General Information Power Trim System Models with Power Trim General Information Checking Trim System Fluid Level Trimming Models with Power Trim Trimming Outboard Out Up Trimming Ou
50. 1 Inspect balls and seats in piston assembly for de A leak path is created between the UP side of the cyl bris or damage Repair or replace balls seats inder and the reservoir The trim system will leak down until the trim port in cylinder is covered 51143 51960 a Ball and Seat Check All For Debris or Damage a Valve and Seat b Pilot Valve O ring c O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a O ring 5D 6 MID SECTION 90 817643R1 DECEMBER 1996 lt 1 Troubleshooting Flow Diagram Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt bolt hole in eight hours Example b Outboard lowers during acceler ation Inspect Manual Release Valve Result Result Manual release valve and or O ring damage Manual release valve and O rings appear to be OK Replace O rings rings Replace defective valve and O Result O rings appear to be OK Cylin der bore and memory piston are OK Replace O rings and pro ceed Inspect O rings on Pilot Relief Valve located in manifold assem bly Results Results O ring failure O rings appear to be OK Re place O rings Inspect Memory Piston Replace O rings O ring Results Results All components appear to be OK O ring
51. 11 N m F Torque shock piston to 90 Ib ft 122 N m By nm NI NI N N 90 817643R1 DECEMBER 1996 MID SECTION 5E 3 Theory Of Operation The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or trim panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Adjustments Trimming Characteristics NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion trim tab in neutral straight fore and aft position you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor In slightly before resuming high speed operation Rapid reduction in power will
52. 91 14308A1 19222 a Oil Sleeve b Puller Assembly 91 83165M a Race b Shim s c Bearing Race Tool 91 14308A1 6B 16 LOWER UNIT 90 817643R1 DECEMBER 1996 Shift Shaft 1 Remove shift shaft coupler and nylon spacer 53925 a Shift Shaft Coupler b Spacer 2 Remove bolts 53926 a Bolts Note Gearcase should be in FORWARD for easiest removal of shift shaft 3 Remove shift shaft bushing and shift shaft a Bushing b Shift Shaft 90 817643R1 DECEMBER 1996 4 Remove shift cam from housing 5 Replace shift cam if worn LLM 51117 a Shift Cam Note If shift shaft splines are rough shift shaft seal lips wil be cut during removal installation 6 Remove shift shaft bushing and clip from shift shaft 7 Replace shift shaft if splines are worn or shaft is twisted 8 Remove and discard O ring P c a Bushing d Splines b Clip e O ring c Shift Shaft 9 Remove and discard seal 53929 a Seal LOWER UNIT 6B 17 Forward Gear Bearing Race IMPORTANT Retain shim s for reassembly If shims are damaged replace with new shims of equal thickness 1 Remove and using Slide Hammer 91 34569A1 shim s 27653 Race Slid
53. Crank engine thru at least 4 compression strokes to obtain highest possible reading 5 Check and record compression of each cylinder Variation of more than 15 psi 103 5 kPa between cylinders indicates that lower compression cylinder is in some way defective such as worn or sticking piston rings and or scored piston and cylinder 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 discolored or scorched paint visually inspect cylinders for scoring or other damage as outlined in Section 4 Powerhead Water Pressure Check NOTE To perform these checks a Water Pressure Gauge Kit P N 91 79250A2 is recommended 1 Water pressure at idle in neutral is 1 3 psi 7 21 kPa 2 Water pressure should increase then drop to 4 6 psi 21 35 kPa prior to 2500 RPM due to poppet valve opening 3 At2500 RPM water pressure should not exceed 12 psi 83 kPa Readings above 12 psi at 2500 RPM may in dicate a stuck poppet valve 4 Static test boat stationary operate in forward gear with a cut down smaller diameter propeller at 5000 RPM or above is 7 12 psi 48 83 kPa ACAUTION A MODIFIED PROPELLER OR LOW PITCH PROPEL LER IS REQUIRED TO PERFORM THE A
54. Down Circuit When Up Circuit is OK Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 2 Point 3 and positive battery ter Depress Down trim button minal Check for loose or corroded con nections Check wires for open circuit Battery Voltage Indicated No Voltage Indicated e Pump motor wiring is defective Relay Switch is defective Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 5C 18 MID SECTION 90 8i7643R1 DECEMBER 1996 Troubleshooting the Up Circuit When Down Circuit Is OK Connect Voltmeter red lead to Point 8 and black lead to ground Depress the Up trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 7 and black le
55. Impact Relief Pressure 22 880 1110 40 60 1220 1420 75 125 Tilt oed q 250 400 40 60 540 990 75 125 e lt ctH7QTO53 Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder 90 817643R1 DECEMBER 1996 Trim Up When the trim switch is activated in the up position the electric motor c begins to rotate the pump gears j the oil pump draws a small amount of oil through the filter g and through the up circuit suction port i The oil pump gear j rotation forces oil into the pas sages for the up circuit Oil under pressure will slide the shuttle valve m against the down circuit pres sure operated valve f The shuttle valve will me chanically open the down pressure operated valve allowing oil from the down cavity of the trim cylinder to flow into the oil pump This returning oil from the down cavity will supply most of the oil required for the up circuit Oil in the up circuit is blocked from returning into the reservoir by the ball inside the down circuit suction port k The pressure of the oil will force the up circuit pressure operated valve n to open allow ing the oil to enter the passages inside the manifold q leading to the trim cylinder w up cavity Oil is blocked from all other pass
56. J LOWER UNIT 6A 3 19660 1 91 19660 1 Backlash Indicator Tool 7005 re 91 81 r QUSS NA 51043 51043 91 817005 Bearing Installer Forward Gear Needle Bearing 51043 91 817011 Needle Bearing Installer Bearing Carrier pn 51043 bi 51043 91 817006 Seal Installer Water Pump Base 51270 Plate 51043 Nut Stud Sleeve 91 817057A 1 Update Kit Converts 91 14311A 1 Bear ing Preload Kit Tool to a 91 14311A 2 51043 91 817008A2 Pinion Gear Locating Tool 6A 4 LOWER UNIT 90 817643R1 DECEMBER 1996 51043 91 817058A 1 Bearing Driver Assy Lower Drive Shaft Bearing e 51043 91 817070 Drive Shaft Holding Tool 90 817643R1 DECEMBER 1996 Draining and Inspecting Gear Lubricant A WARNING If gear housing is installed on outboard disconnect and isolate spark plug leads from spark plugs before working near the propeller 1 With gear housing in normal running position place a clean pan under housing and remove two vent plugs and one fill drain plug with gaskets APAPARA 50558 a Vent Plug b Fill Drain Plug 2 Inspect gear lubricant for metal particles lubricant will have a metal flake appearance Presence of fine metal particles resembling powder on the drain plug magnet indicates normal wear Metal chips on the magnet indicate the need for gear housing disassem
57. MID SECTION 90 817643R1 DECEMBER 1996 c Design 1 TRIM DOWN O RESERVOIR AND FEED OIL OIL UNDER PRESSURE RETURN OIL 22000 Sees r 51637 90 817643R1 DECEMBER 1996 MID SECTION 5B 5 EY Design 1 HYDRAULIC TILT Ls RESERVOIR AND FEED OIL 5 OIL UNDER PRESSURE 5B 6 MID SECTION 90 817643R1 DECEMBER 1996 Q Design 1 MAXIMUM TRIM _ BLOW OFF 1 RESERVOIR AND FEED OIL OIL UNDER PRESSURE RETURN OIL 51640 90 817643R1 DECEMBER 1996 MID SECTION 5B 7 Design 1 SHOCK FUNCTION UP 1 RESERVOIR AND FEED OIL OIL UNDER PRESSURE 51641 5B 8 MID SECTION 90 817643R1 DECEMBER 1996 c Design 1 SHOCK FUNCTION RETURN 1 RESERVOIR AND FEED OIL 2554 OIL UNDER PRESSURE 51642 90 817643R1 DECEMBER 1996 MID SECTION 5B 9 3 Design 1 MANUAL TILT Troubleshooting Determine if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys tem is at fault Trouble Chart Outboard will not trim up or down Determine if Power Trim pump Outboard trims up will not trim motor operates when appro down priate trim circuit is activated Outboard trims down will not trim up Outboard will not return complete ump motor operates ly to down position or returns part way with jerky motion Pump motor does not operate Outboard thumps when shifted
58. NOTE Raising or lowering the outboard by one mounting hole will change outboard height by approximately 3 4 in 19mm 90 817643R1 DECEMBER 1996 Locate Centerline of Boat Transom Locate and mark with a pencil vertical centerline a of boat transom as shown NOTE Dimension A amp B and C amp D are Equal Length Lifting Outboard Electric Start Models AWARNING Make sure that lifting eye is threaded into flywheel a minimum of 5 turns and that hoist has a minimum lift capacity of at least 500 Ibs 227 kg BEFORE lifting outboard Remove cowling from outboard and plastic cap from center of flywheel Thread lifting eye a into flywheel hub a mini mum of 5 turns Replace plastic cap after installation Connect hoist minimum lift capacity of 500 Ibs 227 kg to lifting eye or rings of lift harness and lift outboard onto boat transom 50565A a Lifting Ring P N 91 75132 b Hoist OUTBOARD INSTALLATION ATTACHMENTS 7A 1 Lifting Outboard Manual Start Models Remove cowling from outboard Use lifting eye on out board and lift outboard on boat transom 51456 Drilling Outboard Mounting Holes Electric Start Models IMPORTANT Before drilling any mounting holes care fully read Determining Recommended Outboard Mo tor Mounting Height preceding There is a 3 4 in 19mm difference between outboard mounting holes in transom bracket AWARNING DO NOT un
59. Outboard will not hold a trimmed position or will not re main tilted for any extended period Outboard will not hold trim po sition when in reverse 5D 4 MID SECTION 90 817643R1 DECEMBER 1996 c Hydraulic System Troubleshooting Support outboard with tilt lock lever when servicing power trim system After debris or failed components have been found during troubleshooting procedures dis assemble unit completely and replace all O rings Check ball valve components and castings must be cleaned using engine cleaner and com pressed air or replaced prior to reassembly Power trim system is pressurized Outboard must be in the full UP position cylinder fully ex tended prior to fill screw or manual release valve removal Refer to instructions following if disassembly is re quired Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks Operate Power Trim System after each check to see if problem is corrected If not proceed with the next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Fill and Purge the Power Trim System 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls to trim in position indicat
60. Relay Switch DOWN d Engine Starter Motor Solenoid e Cowl Trim Switch f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness 90 817643R1 DECEMBER 1996 BLKe Black BLU e Blue GRN Green RED Red WHT White 50285 MID SECTION 5B 17 Troubleshooting the Down Circuit When Up Circuit is OK Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 2 Point 3 and positive battery ter Depress Down trim button minal Check for loose or corroded con nections Check wires for open Battery Voltage Indicated No Voltage Indicated Pump motor wiring is defective Relay Switch is defective Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Poi
61. Retaining Plate 14 Screw 5 o 13 Ib 15 O ring 1 600 in 1 0 Rod Piston 16 O ring 1 600 in I D Memory Piston P ey PIRON Quicksilver Lubricants and Service 18 Trim Rod Cylinder N 19 Screw 2 Aids 20 O ring 208 in I D 2 21 Filter B A Loctite Grade 271 22 O ring 301 in I D 23 Valve Seat B 4 i i ig 2 4 Marine Lubricant 92 90018A12 25 Ball 26 Spring Guide 27 Spring 28 Dowel Pin 2 29 Reservoir 30 Fill Screw 31 O ring 583 in I D 32 Screw 4 33 Washer 4 34 O ring 2 364 I D 35 Screw 36 Drive Shaft 37 Pump 38 O ring 176 1 0 2 39 Dowel Pin 40 Manifold 41 O ring 114 I D 42 O ring 208 in I D 43 O ring 239 in I D 44 Relief Valve 45 E Clip 46 Wire Harness 47 Cap 48 Washer 49 Grommet 50 Screw 4 51 Screw 52 Reservoir Cap 53 O ring 2 364 I D 54 Disk Foam Pad 55 Nut 2 56 End Cap 57 Washer 030 in Thick 2 58 Washer Thrust 59 Armature 60 Washer 010 in Thick 61 Housing 62 O ring 63 End Frame 64 O ring 489 I D 65 Screw 2 in 26153 90 817643R1 DECEMBER 1996 MID SECTION 5B 3 Power Trim Flow Diagrams Design 1 EB TRIM UP C 1 RESERVOIR AND FEED OIL 52 OIL UNDER PRESSURE RETURN OIL um 309529 2222232 5 ee 4 ae 55555 2222 s MEUS q 51638 5B 4
62. The voltage regulator senses battery voltage and allows the correct amount of di rect current to charge the battery Models Equipped With Rectifier a Stator b Rectifier c Battery Models Equipped With Regulator Rectifier a Stator b Regulator Rectifier c Battery The charging system may be damaged by 1 reversed bat tery cables 2 running the engine with battery cables dis connected and stator leads connected to rectifier and 3 and open circuit such as a broken wire or loose connec tion ELECTRICAL and IGNITION 2B 3 Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged Check battery electro lyte level and charge battery See Electrolyte Level and Charging a Discharged Battery If battery will NOT accept a satisfactory charge replace battery If battery accepts a satisfactory charge determine the cause of the charging system problem as follows 1 Check for correct battery polarity red cable to positive battery terminal If polarity was incorrect check for damaged rectifier See Rectifier Test Check for loose or corroded battery connections 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
63. Use suitable tool to remove DRIVE DOWN up per dowel pin Retain pin N S 51144 a Dowel Pin 4 Use suitable punch to drive out upper pivot pin 51144 Pivot Pin 90 817643R1 DECEMBER 1996 5 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a Dowel Pin 6 Use suitable punch to drive out lower pivot pin a Pivot Pin MID SECTION 5C 21 cM 7 Tilt power trim assembly top first out from clamp Power Trim System bracket and remove assembly Disassembly Trim Rod Removal A CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three or four turns counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using trim cylinder spanner wrench 1 4 in x 5 16 in long pegs 51194 a Manual Release Valve b Manifold c Reverse Thrust Valve Do Not Remove or Adjust 5C 22 MID SECTION 90 8i7643R1 DECEMBER 1996 x L 4 Remove trim rod assembly from cylinder 6 Remove O ring from memory piston 51196 O ring Memory Piston oo 7 Remove trim system from vise and empty fluid 51196 into appropriate container 5 Remove memory piston from cylinder using l
64. Will help planing off particularly with a heavy load Usually improves ride in choppy water In excess can cause boat to veer to the left or right bow steer Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt pin one hole closer to transom Operating Down circuit will actuate the down sole noid located under engine cowl and close the elec tric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the down side of the tilt ram The tilt ram will move the engine downward to the desired angle MID SECTION 5C 1 Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running While operating up circuit tilt ram will continue to tilt outboard to full up position for trailering Tilting Outboard Up and Down Manually Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns counterclockwi
65. b Flat Washer 4 Req d c Locknut 4 Steering Cable Installation Refer to Quicksilver Accessories Guide to determine cor rect length of steering cable and remote control cables IMPORTANT Steering cable and remote control cables must be the correct length Cables which are too short or too long will result in unwanted cable stress Install steering mount and steering wheel in accor dance with installation instructions that accompany each Dual Outboard IMPORTANT The distance from each outboard s cent erline to the side of transom opening or gunnel MUST BE a minimum of 16 in 406mm With a dual steering system installation a minimum out board centerline distance of 21 in 533mm must be at tained to assure interference free movement OUTBOARD INSTALLATION ATTACHMENTS 7A 5 Ride Guide steering cable can be routed on either side of boat If steering cable is routed on starboard side of boat cable attaches to port outboard If steering cable is routed on port side of boat cable attaches to starboard outboard Cable Installation to Tilt Tube Cable Routed on Starboard Side of Boat 51130 Single Cable Dual Single Cable Single Outboard Outboard IMPORTANT Before installing steering cable tilt tube lubricate entire cable end with Quicksilver 2 4 C Ma rine Lubricant NOTE Ride Guide Steering cable is lubricated at the fac tory and requires no additional lubrication at initial installa t
66. bly and component inspection 3 Note color of gear lubricant White or cream color indi cates presence of water Gear lubricant drained from a gearcase recently in operation will have a yellowish color due to lubricant agitation aeration This is normal and should not be confused with the presence of water 4 Presence of water indicates the need for disassembly and inspection of oil seals o rings gaskets and com ponents for damage LOWER UNIT 6A 5 Propeller Removal AWARNING If gear housing is not removed from outboard before attempting to remove or install the propeller remove and isolate spark plug leads from spark plugs to pre vent outboard from starting 1 Bend tabs of tab washer a away from nut b 51119 2 Use a block of wood a to prevent propeller from rotat ing Remove nut and pull components from shaft 6A 6 LOWER UNIT a Gear Housing Removal AWARNING To prevent accidental engine starting remove and isolate spark plug leads from spark plugs before re moving gear housing 1 Remove and isolate spark plug leads from spark plugs Shift into forward gear Tilt engine to full Up position Remove four bolts and washers a two from each side Remove trim tab b Remove locknut and washer c in trim tab recess Remove gear housing 90 817643R1 DECEMBER 1996 a Gear Housing Disassembly Water Pump 1 If water tube seal a stayed on water tube
67. cause a sudden change of steering torque and may cause additional momentary boat instability e Will lift bow of boat generally increasing top speed e Transfers steering torque harder to left on instal lations below 23 in transom height e Increases clearance over submerged objects e In excess can cause porpoising and or ventila tion e excess can cause insufficient water supply to water pump resulting in serious water pump and or powerhead overheating damage 5E 4 MID SECTION Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up relay lo cated under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid through internal passageways into the up side of the trim cylinder The trim cylinder trim rod will position the engine at the desired trim angle within the 20 maximum trim range The power trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine RPM increases
68. relative humidity at 77 F 25 C temperature and a barometric pressure of 29 61 inches of mercury 1 20 GENERAL INFORMATION and SPECIFICATIONS 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 will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and in turn this density is dependent upon the temperature of the air its barometric pressure and water vapor or humidity content Accompanying this weather inspired loss of power is a second but more subtle loss At rigging time in early spring the engine was equipped with a propeller that allowed the engine to turn within its recommended RPM range at full throttle With the coming of the summer weather and the consequent drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less than its recommended RPM Due to the horsepower RPM characte
69. the products safety will be endangered by the service pro cedure selected Allinformation 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 vi olent and damaging short circuits or severe electrical shocks When performing any work where electrical termi nals could possibly be grounded or touched by the me chanic the battery cables should be disconnected at the battery Any time the intake or exhaust openings are exposed dur ing service they should be covered to protect against acci dental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started It is important to note during any maintenance procedure replacement fasteners must have the same measure ments and strength as those removed Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength American bolts use radial lines for this purpose while most American nuts do not have strength markings Mismatched or incorrect fasteners can result in damage or malfunction or possibly personal inju ry Therefore fasteners removed should be saved for re
70. will not ex perience any undesirable and or unsafe steering conditions during planing speed Thus not using trim adjustment bolt may be desired However some boats with engine trimmed to the full in trim angle at planing speed will cause undesir able and or unsafe steering conditions If these steering conditions are experienced under no circumstances should the engine be operated without the trim adjustment bolt and without the bolt adjusted in the proper holes to prevent un safe handling characteristics Water test the boat not using the trim adjustment bolt If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment bolt in proper hole to prevent unsafe han dling characteristics 52029 a Trim Adjustment Bolt 90 817643R1 DECEMBER 1996 Power Trim System Components Tilt Trim Cylinder Reservoir Motor Housing Piston Rod Upper Pivot Shaft Cross Pin O ring End Cap Seal End Cap O ring O ring Piston Assembly O ring O ring Memory Piston 15 Lower Pivot Shaft 16 Cross Pin 17 Screw 2 18 Pump Assembly 19 Pilot Valve Assembly 20 O ring 21 Driveshaft 22 Washer 4 23 Screw 4 24 Fill Screw 25 O ring 26 Motor Frame 27 Thrust Washer 2 28 Armature 29 Ring 30 Seal 31 Screw 2 32 Screw 4 33 Relay 34 Wiring Harness 35 Relay Mount 2 36 Rubber Mount 2 37 Screw 2
71. 100 Ib in 11 N m 2 Secure power trim unit in soft jawed vise Trim Motor Reassembly 1 Place brush tension springs on outer ends of brush housings to release tension on brushes N oom Brush Tension Spring 2 Brush Housing 2 Brush 2 Lubricate end cap bushing with Quicksilver 2 4 C Lubricant and install armature and motor frame into end cap As brushes contact commutator re lease brush tension spring from ends of brush housings returning springs to apply brush pres sure to commutator Install washer on each end of armature before installing armature into end cap see inset 5D 22 MID SECTION wo Cap Bushing Lubricate with Quicksilver 2 4 C Lubricant Brush 2 Commutator Brush Tension Spring 2 Guide armature and motor frame into reservoir housing as shown 51485 End Cap Motor Housing Armature and Motor Frame Washer One Each End of Armature 90 817643R1 DECEMBER 1996 Reservoir Installation 1 Torque end cap screws to 13 Ib ft 1 5 End Cap O ring Screws 4 Place drive shaft into oil pump Install lubricated O ring to base of reservoir OM OTD Carefully guide with motor down onto drive shaft a Drive Shaft b O ring 90 817643R1 DECEMBER 1996 5 Secure reservoir to manifold using four screws Torque screws to 70 Ib in 7 7 N m a
72. 13 NOTE When drilling thru transom be sure that holes are drilled perpendicular to transom 6 With attaching kit positioned as outlined preceding use 3 holes in transom bracket as a guide and drill three 11 32 in 8 7mm holes thru transom 7 Use amarine type sealer on three 5 16 in x 3 1 4 in bolts Secure attaching kit to transom using transom backing plate 3 bolts with sealer and 3 locknuts in stalled as shown in Figure 2 Torque locknuts to 10 Ib ft 13 5 N m W Hee W 51140 a Ride Guide Yoke b to 1 2 in 12 7 mm Center of Ride Guide Yoke to Top of Transom Top of Transom Transom Bracket Cable Tube Jam Nuts Torque to 35 Ib ft 47 5 N m Tab Washer After Jam Nuts are Torqued to Specification Bend Locking Tabs Against Nuts Cable Guide Tube Ride Guide Cable Attaching Nut Torque to 35 Ib ft 47 5 N m Clevis Kit Clevis Attaching Locknut Torque to 20 Ib ft 27 1 N m Figure 3 Installing Attaching Kit Ss 7A 14 OUTBOARD INSTALLATION ATTACHMENTS Q Clevis Attaching Kit Installation NOTE This kit is used to attach Ride Guide cable to out board steering arm ONLY when Transom Mounted Ride Guide Attaching Kit is being used If Ride Guide cable is installed thru outboard tilt tube then Steering Link Rod must be used Installation Instructions CAUTION Models with two hole two piece ste
73. 16 to 18 24 30 48 85632A40 12 10 1 2 3 Alum 2000 2600 17 22 28 48 42740A10 11 1 4 10 3 Alum 2100 2600 17 20 26 48 73132A40 12 1 4 9 3 Steel 2400 18 14 22 48 97868A5 12 1 4 9 3 Alum 2400 18 14 22 48 87818A10 12 1 2 8 3 Alum 2800 19 1 18 48 42738A10 1 8 GENERAL INFORMATION and SPECIFICATIONS 90 817643R1 DECEMBER 1996 Propeller Information Chart 60 BIG FOOT 60 SEAPRO MARATHON MODELS Wide Open Throttle RPM 5000 5500 Recommended Transom Height Short Shaft 16 1 2 in 41 9 cm Long Shaft 21 in 53 3 cm Extra Long Shaft 23 1 2 in 59 7cm Right Hand Rotation 4 1 4 in Gear Case Torpedo Gear Reduction 2 3 1 Thrust Hub 13191A1 Approx Approx Speed No of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wot Lbs Length MPH Part Number 12 3 4 26 5 Steel Up to 800 Up to 15 48 55 48 815748A40 13 1 2 26 3 Steel Up to 800 Up to 15 48 54 48 16996A40 12 3 4 24 5 Steel Up to 1000 Up to 15 46 52 48 815746A40 13 1 2 24 3 Steel Up to 1000 Up to 15 46 52 48 16994A40 12 1 2 23 3 Alum 700 1100 Up to 15 45 51 48 77350A40 12 3 4 22 5 Steel 700 1100 Up to 15 43 49 48 815744A40 13 1 2 22 3 Steel 700 1100 Up to 16 43 49 48 16992A40 12 3 4 21 3 Alum 800 1200 13 to 16 40 47 48 77348A40 12 3 4 20 5 Steel 800 1200 13 to 16 38 45 48 816612A40 13 1 2 20 3 Steel 800 1200 13 to 16 3
74. 16 in long pegs 51199 a O ring b Shock Piston 4 Clamp shock rod in soft jawed vise 51146 5 Position cylinder end cap onto rod as shown Shock Rod Piston b Spanner Wrench 9 Remove shock rod assembly from vise 10 Install lubricated O ring to shock rod piston 11 Install ball seat and spring five sets to shock rod piston 12 Secure components with plate Torque screws to 35 Ib in 4 0 51146 A CAUTION When installing shock rod piston spanner wrench must have1 4 in x 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite 271 to threads on shock rod d 7 Install shock rod piston Cee Screw 3 Plate O ring Ball 5 Seat 5 Spring 5 51147 90 817643R1 DECEMBER 1996 MID SECTION 5F 31 cM Shock Rod Installation 6 Refill cylinder to top 1 Place cylinder manifold assembly into soft jawed A CAUTION vise M End cap must not make contact with shock rod 2 Fill cylinder to top using Quicksilver Power Trim piston when tightening Shock rod piston must and Steering Fluid or ATF Type F FA of Dexron be positioned in cylinder deep enough to avoid ll contact 3 Place cam shaft lever in the open position lever 7 Tighten end cap securely using spanner wrench facing down 1 4 in x 5 16 in 6 4mm x 8mm long pegs 4 Install lubricated O ring to memory piston and in stall piston into cylinder three inche
75. 36 Clamp 2 37 Washer 2 38 Nut 2 39 Connector 40 Tube 41 Fitting 42 Washer 4 43 Bolt 4 44 Lock Nut 45 Washer 46 Stud 47 Mount 2 OANDAARWN Torque Specification No Torque Requirement Drive Unit Until Tight But Joint Must Be Free to Pivot 80 Ib in 9 0 Lubrication Sealant Application 220 lb in 25 0 N m Points 40 Ib ft 54 0 N m S 50 Ib hi BN H AD 2 4 w TeflonMarine Lubricant 92 9001 8A1 2 ft 67 5 N m 28 Ib ft 38 0 N m H O gt Loctite 35 92 59328 1 5A 4 MID SECTION 90 817643R1 DECEMBER 1996 Disassembly Remove shock system assembly refer to Section 5C from non power trim models Remove power trim assembly refer to Section 5B from power trim models Servicing components such as steering arm driveshaft housing exhaust assembly swivel bracket assembly etc generally require powerhead and or gear housing remov al Refer to appropriate section in service manual Compo nents such as transom bracket lower mount bracket tilt tube and lower engine mounts can be serviced without powerhead gear housing removal however outboard must be supported shown before servicing components not requiring powerhead gear housing removal AWARNING Failure to support outboard as shown could result in personal injury and or damage to outboard or boat Typical Outboard Shown a Hoist b Rope c Lifting Eye P N 91
76. 5 Pull impeller straight off the shaft If the impeller is tight use ahammer and block of wood to rotate the impeller clockwise the shaft until the keyway is directly above the flat on the shaft This will free the jammed key and allow removal Tabs Nut oo 6 Remove 5 bolts securing jet drive to drive shaft housing and remove pump a Bolts 4 b Bolt 1 90 817643R1 DECEMBER 1996 Bearing Carrier Removal NOTE Water pump assembly must be removed be fore bearing carrier can be removed 1 Remove 4 bolts securing water pump assembly and remove water pump b gt 4 2 m 54258 Bolts 4 Seal Housing Key Impeller Gasket Plate LOWER UNIT 6C 13 2 f 2 Remove 4 bolts securing bearing carrier to jet Bearing Carrier Reassembly drive a Bolts Bearing Carrier Disassembly 1 Remove the large beveled snap ring a from the bearing carrier 2 Heat the bearing carrier b with a torch only until you can barely touch it 3 Hold the drive shaft vertical and bump the impeller end of the drive shaft against a wooden block caus ing the bearing carrier to slide down off the bearing 4 Remove snap ring e press the ball bearing c off the drive shaft Leave the bearing thrust ring f lo cated in the drive shaft groove unless damaged 5 Remove the seals and spiral retaining rings from the bearing carrier and the upp
77. 6 5225 5000 5500 1 1 8 1 4 1 1 2 1 4 7 16 in 11 2mm 048 in 060 in 062 in 090 in None 090 in Quicksilver TC W II or TC W 3 0 gts 2 8L 7 hrs 14 5 fl oz 0 43L 1 2 hr 10 0cc 3cc 2 6 ATDC 24 BTDC 18 BTDC 22 BTDC 16 BTDC GENERAL INFORMATION and SPECIFICATIONS 1 3 Powerhead Specifications Block nien det 3 Cylinder 2 Cycle Displacement 50 55 60 Horsepower 51 8 cu in 849 cc Cylinder Bore Dia Standard 2 955 in 75 057 mm Dia 015 in Oversize 2 970 in 75 438 mm Dia 030 in Oversize 2 985 in 75 819 mm Out of Round Max 0 003 in 0 076 mm Taper Max 0 003 in 0 076 mm Piston Dia Standard 2 950 in 74 93 mm Dia 015 in Oversize 2 965 in 75 31 mm Dia 030 in Oversize 2 980 in 75 69 mm IMPORTANT Measure piston skirt at right angle 90 to piston pin center line 0 50 in 12 7mm up from bot tom edge of skirt p MM C oL 0 50 in 12 7mm PISTON PISTON SKIRT CYLINDER BORE SIZE DIAMETER FINISH HONE Standard 2 950 in 2 955 in Piston 74 93 mm 75 057mm 0 015 in 2 965 in 2 970 in 0 381 mm 75 31 mm 75 438 mm Oversize 0 030 in 2 980 in 2 985 in 0 752 mm 75 69 mm 75 819 mm Oversize 1 4 GENERAL INFORMATION and SPECIFICATIONS Reed Block R
78. 90455 Refer to parts views on pages 1 2 and 3 and disassemble mid section components as required 90 817643R1 DECEMBER 1996 Reassembly Tilt Lock Lever Transom Bracket Apply Quicksilver 2 4 C Marine Lubricant to tilt lock lever shank spacer and bushing prior to reassembly 51079 Spring Tilt Lock Lever Bushing Spring Lever Roll Pin Install roll pin to tilt lock lever assembly using appropriate punch ACAUTION When reinstalling outboard tilt tube longer threaded end of tilt tube must extend approximately 3 4 in 19mm toward steering cable nut side of boat MID SECTION 5A 5 Lubricate outboard tilt tube using Quicksilver 2 4 C Marine Install and secure yoke and washer using snap ring Lubricant and install into swivel bracket Secure transom brackets into place using fiber washers and lock nuts 51078 a Tilt Tube b Fiber Washer c Lock Nuts Apply Quicksilver 2 4 C Marine Lubricant to steering arm 5 i shaft and install c Snap Ring Install lower mounting bracket to transom brackets 51079 a Steering Arm b Washer a Lower Mounting Bracket b Bolt 5A 6 MID SECTION 90 817643R1 DECEMBER 1996 Drive Shaft Housing Secure transom bracket assembly to transom Install drive shaft housing to transom bracket assembly Secure using bolts and components as shown 51097 Transom Bracket Assembly Drive Shaft Housing Assembly
79. BLOCK Displacement 217 0 lbs 98 4kg 213 0 lbs 96 6kg 213 0 lbs 96 6kg Two Stoke Cycle Loop Charged 51 8 cu in 849cc STROKE Length 2 520 in 64 008mm CYLINDER Diameter Std BORE Taper Out of Round Maximum Bore Type PISTON Piston Type Standard 0 015 in 0 381mm Oversize 0 030 in 0 762 Oversize Reed Stand Open Max Reed Stop Max Reed Thickness 45 Jet 50 60 55 50 55 60 Gear Ratio Gearcase Capacity Forward Gear No of Teeth Pinion Gear No of Teeth Pinion Height Forward Gear Backlash Water Pressure Idle o WOT 60 SeaPro Marathon 60 Bigfoot Gear Ratio Gearcase Capacity Forward Gear No of Teeth Type Pinion Gear No of Teeth Type Pinion Height Forward Gear Backlash Water Pressure RPM FUEL Fuel SYSTEM Recommended Gasoline Recommended Oil Gasoline Oil Ratio Fuel Pressure Idle o WOT 1 2 GENERAL INFORMATION and SPECIFICATIONS 2 955 in 75 057mm 0 003 in 0 076mm Cast Iron Aluminum 2 950 in 74 93 mm 2 965 in 75 31 mm 2 980 in 75 69 mm 0 020 in 0 50mm Not Adjustable 0 008 in 0 203mm 0 010 in 0 254mm 1 64 1 11 5 fl oz 340ml 23 14 0 025 in 0 64mm 0 013 in 0 019 in 0 33mm 0 48mm 1 3 PSI 7 12 PSI 2 3 1 22 5 fl oz 655ml 30 13 0 025 in 0 64mm 0 012 in to 0 019 in 0 30mm to 0 48mm 10 to 15 PSI 69 to 103 kPa 5250 RPM Pre Mixed Gasoline and Oil Unleaded 87 Octane Minimum
80. Bolts 28 Ib in 32 N m Lock Nuts 50 Ib ft 69 N m Washer Rubber Mount Washer Secure lower mount assembly to drive shaft housing Se cure drive shaft housing to yoke 51097 Lower Mount Bolt Washer Rubber Washer Lock Nut 50 Ib ft 68 N m 90 817643R1 DECEMBER 1996 Install clamp a Clamp b Bolts 220 lb in 24 N m Install shift linkage assembly and new gasket to drive shaft housing a Shift Linkage Assembly b Gasket Install powerhead and gearcase assemblies referring to appropriate sections of service manual Powerhead Section 4A Lower Unit Section 6A MID SECTION 5A 7 c MID SECTION POWER TRIM DESIGN 1 Table of Contents Page Power Trim General Information 5B 1 Description 5B 1 Trimming Characteristics 5B 1 Trimming Outboard Up Out 5B 1 Trimming OUtboard Down In 5B 1 Trailering Outboard 5B 2 Tilting Outboard Up and Down Manually 5B 2 Trim In Angle Adjustment 5B 2 Power Trim System Components 5B 3 Torque Specifications 5B 3 Quicksilver Lubricants and Service Aids 5B 3 Power Trim Flow Diagrams Design 1 5B 4 Determine if Problem is Electrical or Flydra lie a y bra us
81. CHECK Inspect check valves by looking through hole If light can be seen the nylon ball is bad probably melted REPLACE valve If you see no light insert fine wire into check valve hole to see if there is slight movement of nylon ball If ball moves valve is O K Replace valve if ball does not move Install check valve into check valve holder as shown Air Air PE 51080 a Check Valve b Holder Piston and Piston Rings IMPORTANT If engine was submerged while engine was running piston pin and connecting rod may be bent If piston pin is bent piston must be replaced Pis ton pins are not sold separately because of matched fit into piston If piston pin is bent connecting rod must be checked for straightness refer to ing Rods for checking straightness e Inspect piston for scoring and excessive piston skirt wear e Check tightness of piston ring locating pins Locating pins must be tight Thoroughly clean pistons Carefully remove carbon de posits with a soft wire brush or carbon remover solu tion DO NOT burr or round off machined edges e Inspect piston grooves for wear and carbon accumula tion If necessary scrape carbon from piston ring grooves being careful not to scratch sides of grooves Refer to procedure for cleaning piston ring grooves 90 817643R1 DECEMBER 1996 CLEANING PISTON RING GROOVES IMPORTANT The piston rings are half keystone rings tapered on the
82. Circuits All Circuits Inoperative 5C 20 Power Trim System Removal 5C 21 Power Trim System Disassembly 5C 22 Trim Rod 5C 22 Trim Rod Disassembly 5C 23 Trim Motor Removal 5C 25 Trim Motor Disassembly 5C 25 Reservoir Assembly Removal 5C 26 Oil Pump Manifold Removal 5C 27 Cleaning and Inspection of Trim Rod Components 5C 28 Motor and Electrical Tests Repair 5C 29 Trim Pump Motor Test 5C 29 Thermal Overload Switch Test 5C 29 Motor Assembled 5C 29 Motor Disassembled 5C 29 Armature Tests 5C 30 Test for Shorts 5C 30 Test for Ground 5C 30 Checking and Cleaning Commutator 5C 30 Power Trim System Re assembly 5C 30 Manifold Oil Pump Installation 5C 30 Trim Motor Re assembly 5C 31 Reservoir Installation 5C 33 Trim Rod Re assembly 5C 34 Trim Rod Installation 5C 35 Bleeding Power Trim Unit 5C 36 Power Trim Unit Installation 5C 37 90 8i7643R1 DECEMBER 1996 p Power Trim General Information Description The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The
83. Clip b Retainer Clip c Screw d Shaft Seal e O ring f Back up Seal g Cam 90 817643R1 DECEMBER 1996 VALVE BODY CHECK REASSEMBLY 1 Install lubricated O ring plunger steel ball and conical spring to valve block 51145 Conical Spring Steel Ball Plunger O ring om VELOCITY VALVE REASSEMBLY 1 Install spool spring lubricated O ring and screw plug surge valve assembly into valve block 2 Torque screw plug to 75 10 in 8 5 N m b gt Spool b Spring c O ring d Screw Plug Torque to 75 Ib in 8 5 N m MID SECTION 5G 27 CHECK RETAINER REASSEMBLY Valve Block Installation 1 Install plunger spring large ball spring small 1 Install lubricated O rings and dowel pins and plug into valve block 51148 a O rings 2 b Dowel Pins 2 51142 2 Install valve block to shock rod cylinder Insert screws to shock rod cylinder and torque to 100 Ib Plunger in 11 Spring Large Ball Spring Small Plug om VALVE PLUG REASSEMBLY 1 Install plunger steel ball spring lubricated O ring and screw plug Torque screw plugs to 75 Ib in 8 5 N m 51146 a Valve Block b Screws 2 Torque to 100 Ib in 11 c Shock Rod Cylinder 2 01 b Oo o c aa e Plungers 2 Steel Balls 2 Springs 2 O ring
84. Control Wiring Harness Connector BLK BLACK BLU BLUE BRN BROWN GRY GREY GRN GREEN PUR PURPLE RED RED L TAN WHT WHITE YEL YELLOW LIT LIGHT BLU oc Ie BLU GRN GRN 2D 8 ELECTRICAL and IGNITION RED RED PUR BLU WHT GRN WHT 51125 90 817643R1 DECEMBER 1996 Q Key Choke Switch Continuity Test COMMANDER 2000 Side Mount Remote Control 23894 OFF BLK YEL BLK RUN RED PUR START RED PUR YEL RED PUSH CHOKE RED YEL BLK Key switch must be positioned to RUN or START and key pushed in to actuate choke for this continuity test 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2D 9 EY COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram a Ignition Choke Switch b Emergency Stop Switch Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch BLK 4 TAN BLU 3 TAN BLU C GRY B PUR 2 BLK D PUR A YEL BLK 6 BLK YEL 1 YEL RED 7 BRN WHT E RED 8 BLK BLACK BLU e BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED e RED TAN TAN WHT WHITE YEL YELLOW 23891 2D 10 ELECTRICAL and IGNITIO
85. FOR GROUND Use an Ohmmeter R x 1 scale Place one lead on Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced 90 817643R1 DECEMBER 1996 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper N GI xA E SLY Power Trim System Reassembly Manifold Installation IMPORTANT Install spring check valve and O ring into manifold Position components in place using sleeve to seat in place It is recommended that O ring and valve seat be replaced when in stalling Screw and Seal Kit 811226A1 in manifold 50999 a Spring b O ring c Sleeve d Valve Seat 90 817643R1 DECEMBER 1996 1 Install check valve components into manifold O ring 0 114 1 0 Spool O ring 0 301 1 0 3 each Sleeve Spring Valve Seat Valve Spring IMPORTANT Sleeve d is chamfered 1 0 end opposite drilled cross hole Install spool e with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool m O o 09 2 Install O rings on cylinder and secure manifold assembly to cylinder using screws Torque screws to 100 Ib in 11 0 N m 51486 a O rings 2 MID SECTION 5D 21 b 3 Screws
86. Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve 90 817643R1 DECEMBER 1996 m Water Strike With Valves Open Should the drive unit strike a submerged object while in forward motion the shock rod a will extend from the tilt cylinder Fluid will attempt to exit the cylinder through the interconnecting passage The rapid fluid flow will increase the pressure below the surge valve K causing the valve to move closing the oil return passage back into the accumulator c Oil inside the up cavity is locked in a static position by the closed up fast transfer valve j the closed down slow transfer valve i and down fast transfer valve h As the shock rod extends outward the pressure inside the up cav ity will reach sufficient pressure to open the shock valve p which opens at 880 1110 psi Oil will flow into the cavity created as the shock rod amp shock piston a amp n moves away from the memory piston m 90 817643R1 DECEMBER 1996 MID SECTION 5G 11 a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 12 MID SECTION Shock Function Valve Closed Accumulator Gas Pressure 400 PSI i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shoc
87. For ward Gear Backlash following 15 If clearance is incorrect add or subtract shims from above bearing race to lower or raise pinion gear When reinstalling pinion nut apply Loctite 271 on threads of nut a Feeler Gauge b Gauging Block c Pinion Gear d Bearing Race 90 817643R1 DECEMBER 1996 DETERMINING FORWARD GEAR BACKLASH NOTE Read entire procedure before attempting any change in shim thickness 1 Obtain correct pinion gear depth refer to Deter mining Pinion Gear Depth preceding 2 Install Bearing Preload Tool 91 14311A1 on drive shaft refer to Determining Pinion Gear Depth preceding 3 Install components as shown a Propeller Shaft b Bearing Carrier Assembled c Puller Jaws 91 46086A1 d Puller Bolt 91 85716 Torque to 45 Ibs in 5 0 N m Refer to Bearing Carrier and Propeller Shaft Installation fol lowing 4 Rotate drive shaft 5 to 10 revolutions This should properly seat forward gear tapered roller bearing 90 817643R1 DECEMBER 1996 5 Install components as shown e f afm Se n a Hd E U Ke
88. IMPORTANT Some boat motor combinations that doe not use the trim adjustment pin a and are trimmed to the full in trim angle will not ex perience any undesirable and or unsafe steering conditions during planing speed Thus not using trim adjustment pin may be desired However some boats with engine trimmed to the full in trim angle at planing speeds will cause undesir able and or unsafe steering conditions If these steering conditions are experienced under no circumstances should the engine be operated without the trim adjustment pin and without the pin adjusted in the proper holes to prevent unsafe handling characteristics Water test the boat not using the trim adjustment pin If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment pin in proper hole to prevent unsafe han dling characteristics 90 817643R1 DECEMBER 1996 PAN Power Trim System NOTE It is recommended that ALL O rings be re placed when servicing tilt system Components 1 Trim Rod 25 2 Dowel Pin Upper Torque Specifications 3 Upper Pivot Pin 4 Rod Wiper 35 Ib in 4 0 N m 5 O ring 671 in 1 0 Oylinder Cap 9 100 lb in 11 2 N m O ring 1 864 in I D O ring 614 in 1 0 70 b in 7 9 N m Trim Rod Piston 10 Ball 5 90 Ib in 10 2 2 8 N m 1 5 N m O gt 11 Spring Seat 5 12 Spring 5 25 lb in 13
89. It may be necessary to lightly tap bearing carrier onto the bearing using a rubber hammer NOTE Only a light pressing force is needed to press on the bearing carrier It may be necessary to lightly tap the bearing carrier onto the bearing using a rubber hammer a Bearing Carrier b Drive Shaft LOWER UNIT 6C 15 O oO O v Grease the upper seals and inside bore of the bearing carrier to ease entry of the seal housing Install the thrust washer d against the ball bear ing Snap Ring Upper Seal Housing Spacer Thrust Washer Bolts Torque to 70 Ib in 7 9 N m 6C 16 LOWER UNIT Install spacer and the upper seal housing b being careful not to damage the O ring seals as they pass the snap ring groove Only finger pres sure should be necessary to push in the housing Install the beveled snap ring a beveled side fac ing up into the ring groove Make sure the snap ring is fully seated into groove Bearing Carrier Installation 1 Install the bearing carrier into the jet drive Secure carrier in drive with 4 bolts Torque bolts to 70 Ib in 7 9 N m Fill carrier with grease using the grease gun sup plied with the jet drive If using a hand lever gun pump very slowly so as to not build up internal grease pressure and damage the seals or housing 90 817643R1 DECEMBER 1996 G Installing Jet Drive to Drive Shaft Housing Reassemb
90. Long End of Clutch with 3 Teeth Towards Propshaft Shoulder c Guide Block d Cam Follower Hold in Place with Quicksilver 2 4 C Marine Lubricant 6A 14 LOWER UNIT 2 Install cross pin a Cross Pin b Cam Follower c Apply Pressure in This Direction 3 Install spring NOTE Spring windings must lay flat with no overlapping in clutch groove after installation 51265 a Spring 90 817643R1 DECEMBER 1996 c Forward Gear Bearing Race 1 Place shim s retained from disassembly into housing If shim s were lost or damaged or a new gearcase is being assembled start with a 010 in 254mm shim 2 Drive bearing race into housing Use alead hammer to avoid damage to propshaft Ed Bam 55 554 51265 Shim s b Race Apply Quicksilver Needle Bearing Assembly Lubricant on O D c Driver Cup 91 817009 d Propeller Shaft e Assembled Bearing Carrier Bearing Carrier 1 Lubricate O D of needle bearing a with Quicksilver Needle Bearing Assembly Lubricant 2 Install needle bearing Installation Note Push against numbered end of bearing a Needle Bearing b Installer 91 817011 90 817643R1 DECEMBER 1996 3 Install small diameter oil seal a Seal lip faces away from shoulder on Installer Tool Press seal in until In staller Tool bottoms n x 91 81 7007 oo 51206 H gt Loctite Grade A
91. Lubricant 101 Anti Corrosion Grease or 2 4 C w Teflon Marine Lubricant to propeller shaft and reinstall propeller Refer to Propeller Installation see Table of Contents 90 817643R1 DECEMBER 1996 10 If the water pickup is clogged the speedometer will be inoperative Clean the pickup with a piece of wire or blow out with compressed air Before blowing out with air disconnect the tubing from the speedometer 11 To prevent freeze damage drain the speedometer system of water completely before storage Remove tubing from speedometer fitting and blow thru the tubing to remove water 12 Store battery as outlined in Out of Season Battery Storage following 13 For out of season storage information on Autoblend units refer to Section 8 in this service manual IMPORTANT When storing outboard for the winter be sure that all water drain holes in gear housing are open and free so that all water will drain out If a speedome ter is installed in the boat disconnect the pickup tube andallow itto drain Reconnect the tube after draining Trapped water may freeze and expand thus cracking gear housing and or water pump housing Check and refill gear housing with Quicksilver Gear Lube before storage to protect against possible water leakage into gear housing which is caused by loose lubricant vent plug or loose grease fill plug Inspect gaskets under lubricant vent and fill plugs replacing any damaged gaskets before reinstalling
92. Lubricant 92 13783A24 19167 a Thrust Washer 90 817643R1 DECEMBER 1996 12 Install thrust bearing Coat thrust bearing with Quicksilver Gear Lubricant 92 13783A24 a 19168 a Thrust Bearing 13 Apply gear lubricant to bearing surface of reverse gear and install reverse gear 19202 a Reverse Gear b Bearing Surface 90 817643R1 DECEMBER 1996 Forward Gear Reassembly 1 Press bearing onto gear press only on inner race of bearing w Mandrel 91 37350 Bearing Lubricate 1 0 with Quicksilver 2 4 C w Teflon N Apply 2 4 Cw Teflon to bore in center of gear and to O D of bearing 3 Press bearing into gear until bearing bottoms out NOTE Do not apply pressing force AFTER bearing bottoms out as bearing damage could result QOL OO 28062 a Mandrel b Bearing Numbered Side Toward Mandrel LOWER UNIT 6B 21 Propeller Shaft Reassembly 1 Install components into propeller shaft in sequence shown 222 Spring b Guide Block Hold in Place With Quicksilver 2 4 C w Teflon c 3 Metal Balls d Cam Follower 2 Install cross pin 51800 a Apply Pressure in This Direction b Cross Pin Install spring DO NOT overlap springs 51876 a Spring 6B 22 LOWER UNIT oo cM Drive Shaft Wear Sleeve Installation 1 Install new rub
93. 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 is 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 insula tion 5 Checkin line fuse in red wire see diagram 90 817643R1 DECEMBER 1996 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 out in the chart are numbered in diagram below RED SLEEVE NEUTRAL START SWITCH LOCATED IN CONTROL HOUSING IF ENGINE IS EQUIPPED WITH REMOTE CONTROL 51208 Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING Disconnect black starter motor cable from starter solenoid test point 1 BEFORE making tests 1 thru 7 to prevent unexpected engine cranking TEST 1 Use an ohmmeter R x 1 scale and connect meter leads be tween negative battery post and common powerhead ground No continuity indicated there is an open circuit in the black neg Continuity Indicated ative battery cable betwee
94. O G N P P 00 0000 N IO NOOB O O Q OON O O ON O I O 1 Shock Rod Cylinder Accumulator Shock Rod Valve Block Dowel Pin Pivot Pin Rod Wiper O ring 671 in 1 0 Cylinder Cap O ring 1 864 in 1 0 O ring 614 in 1 0 Shock Rod Piston Ball 5 Spring Seat 5 Spring 5 Retaining Plate Screw 3 O ring 1 600 1 0 Shock Piston O ring 1 600 in 1 0 Memory Piston Memory Piston Screw 2 O Ring 208 in 1 0 2 Plug Spring Large Spring Small Ball Plunger Screw Plug 2 Spring 2 O ring 2 Ball 2 Push Rod 2 Dowel Pin Spool Spring O ring 301 in I D Screw Plug O ring 301 in 1 0 Cam Shaft Insulator Retainer Plate Screw O ring 2 114 in 1 0 Push Rod Ball Flat Spring Screw Torque Specification 35 Ib ft 47 9 9 10000 in 11 5 351b in 4 0 27 b in 3 0 7506 in 8 5 M 0 0 DESIGN 3 0 d X Quicksilver Lubricant Sealant Application Points Lubricate ALL O rings using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron Il Loctite Grade A 271 Loctite Pipe Sealant with Teflon 592 S
95. O D of Seal a Small Diameter Seal b Installer Tool 91 817007 4 Install large diameter seal on Installer Tool Seal lip faces towards shoulder on Installer Tool Press in until Installer tool bottoms Loctite Grade A O D of Seal a Large Diameter Seal b Installer Tool 91 817007 LOWER UNIT 6A 15 Installation Note If service tools are not available the fol lowing reference dimensions apply for installing bearing and seals to proper depths 82 in 20mm 51275 a Bearing 44 in 11mm 04 in 1mm a Oil Seal Install with Lip Down b Oil Seal Install with Lip Up 5 Lubricate O ring with Special Lubricant 101 Install O ring a 51263 6A 16 LOWER UNIT Reverse Gear Lubricate 1 0 of bearing a with Quicksilver Needle 1 cM Bearing Assembly Lubricant Use Installer Tool and press onto gear until bearing bottoms Bearing Installer Tool 91 817007 u y mee ___ __ 51205 Install reverse gear and bearing assembly a Lubri cate O D of bearing with Quicksilver Needle Bearing Assembly Lubricant before installation l LLL 2 9492 2777 lm ZZ N ZZZ 51264 Reverse Gear and Bearing Assembly b Installer Tool 91 817007 c Bearing Carrier 90 817643R1 DECEMBER 1996 e Forward Gear Press new propshaft bearing into gear Lubricate O D o
96. O K Clean and reinstall tilt relief valving Trim system does not leak down Test ing complete Trim system leaks down Remove PO check valve assembly inspect O rings and seals for damage PO check valve appears O K Clean and reinstall PO check valve assembly Trim system does not leak down Test ing complete Trim system leaks down continued on next page MID SECTION 5E 23 Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis ton O ring and cylinder bore Cylinder bore appears Cylinder bore appears rough and or debris smooth with no debris found in cylinder Replace memory pis ton and shock piston Trim leaks down O rings Trim system does not leak down Test ing complete Replace trim system 5E 24 MID SECTION 90 817643R1 DECEMBER 1996 p L Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch Remote Control Panel Mounted Mounted Fuse e BLU WHT or PUR gt gt T GRN WHT or GRN gt gt RED ne eee T Fuse Holder Battery Solenoid GRN WHT BLU WHT LT GRN WH LT GRN WHT lt LT BLU WH LT BLU WHT Up Relay Cowl Switch Trim Pump Motor 90 817643R1 DECEMBER 1996 MID SECTION 5E 25 Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections Trim S
97. Position barrel to face towards tiller handle 51602 a Slot b Exit Hole c Harness d Twist Grip e Stop Switch 14 Secure twist grip to throttle arm with attaching screw 51607 Brass Barrel Tube Allen Screw Tiller Handle 2 Install throttle cable guide onto throttle cable Secure guide to cable with anchor and two screws Guide hole should face up 51603 a Screw 51602 a Cable Guide b Screws 2 c Hole Faces Up 7B 16 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 15 Sta strap harness to throttle arm Tiller Arm Shift Lever Installation ACAUTION 1 Install shift lever with detent assembly to bracket Allow enough slack in harness rotate throttle grip in both directions before securing harness to handle as sembly with J clip 16 Attach harness to tiller arm with J clip allowing enough slack in harness for full throttle rotation 17 Attach sta strap to end of harness sleeve e 51607 Bolt Tab Washer Washer Wave Washer 2 Shift Lever Bushing Detent Assembly N Install tiller handle with bushings to bracket Secure in 51609 place with washers and bolt with nut Tighten bolt al a Sta strap lowing tiller handle movement Torque nut to 40 Ib ft Sdn 54 N m 18 Install rubber twist grip by aligning ridges on plastic twist grip with grooves inside of rubber grip NOTE Applying
98. Pump Components Torque Specifications Lubrication Sealant Application Points Propeller Shaft Components Torque Specifications Lubrication Sealant Application Points Special Tools Quicksilver Lubricants and Service Aids New Tools Required for 50 60 Gear Housing Draining and Inspecting Gear Lubricant Propeller Removal Gear Housing Removal Gear Housing Disassembly Water Pump Bearing Carrier and Propeller Shaft Propeller Shaft Disassembly Pinion Gear Driveshaft and Forward Gear Upper Driveshaft Bearing Lower Driveshaft Bearing Forward Gear Bearing Race Shift Shalt ERE e RET ER Page 6A 1 6 1 Page Gear Housing Re assembly 6A 13 Shift Shaft 6A 13 Propeller Shaft 6A 14 Forward Gear Bearing Race 64 15 Bearing 6A 15 Reverse 6A 16 Forward 6A 17 Lower Driveshaft Bearing Installation 6A 17 Upper Driveshaft Bearing Installation 6A 18 Forward Gear
99. Quicksilver TC W Il or TC W3 2 Cycle Outboard Oil 50 1 25 1 Break In 3 1 2 PSI 6 PSI 90 817643R1 DECEMBER 1996 Model 45 Jet 50 55 Marathon Seapro 60 60 Marathon Seapro 60 Bigfoot STARTING SYSTEM IGNITION SYSTEM CHARGING SYSTEM OIL INJECTION C A R B U R E T R T N G Manual Start All Models Electric Start Optional All Models Starter Draw Under Load Battery Rating Type Spark Plug Type Spark Plug Gap Alternator Output Electric Models Manual Models Not Regulated Idle RPM Wide Open Throttle WOT RPM Idle Mixture Screw Adjustment Preset Turns Out Model 50 All Other Models Float Adjustment Float Level Main Jet Model 50 WME 43 Model 55 60 Seapro Marathon WME 44 Model 45 Jet 60 WME 45 Vent Jet Model 50 WME 43 Model 55 60 Seapro Marathon WME 44 Model 45 Jet 60 WME 45 Recommended Oil Oil Tank Capacity Approx Time Reserve Capacity Approx Time Output 1500 RPM for 10 Minutes with Pump Full Open Idle Maximum BTDC Cranking Speed Model 50 60 Model 55 60 Seapro Marathon 5000 RPM Model 50 60 Model 55 60 Seapro Marathon 90 817643R1 DECEMBER 1996 Recoil Starter 125 Amperes Min Reserve Cap Rating of 100 Min and CCA of 350 Amperes Capacitor Discharge NGK BP8H N 10 0 040 in 1 0mm 16 Amperes 3000 RPM 14 Amperes 300 RPM 9 Amperes 3000 RPM
100. Replace Incorrect float setting Reset float PROBLEM ENGINE RUNS TOO LEAN Possible Cause Corrective Action Carburetor is loose Air Tighten bolts securely leaks past mixing Tighten cover or re chamber cover place gasket Fuel level too low Restricted fuel flow to Check fuel lines and fil carburetor ter s for restricted flow Incorrect high speed jet Refer to main jet chart and replace with prop er jet Idle mixture set too lean Adjust to run richer Air leakage into fuel sys Check fuel line connec tem tions hose clamps fuel pump and fuel outlet tube located in fuel tank for loose fit tings Anti Siphon valve re Referto Checking for re stricting fuel flow stricted fuel flow caused by Anti Siphon valves PROBLEM ENGINE RUNS TOO RICH Possible Cause Corrective Action Reset float to correct level Fuel level too high Carburetor floods See preceding Engine Floods Idle nozzle air Blow out with com holes plugged pressed air Check air inlet and carburetor for obstruc tions Restricted air flow Main Fuel Jet loose Retighten Jet 90 817643R1 DECEMBER 1996 Reset float level Clogged high speed jet Check and clean PROBLEM 1 ENGINE IDLES ROUGH AND STALLS PROBLEM 2 ENGINE RUNS UNEVEN OR SURGES PROBLEM 3 ENGINE WILL NOT ACCELERATE Possible Cause Corrective Action Fuel tank air vent closed Check Air vent must be or restricted open
101. Replace this Vent plug and gasket c Install Fill plug and gasket a 50558 a Fill Plug b Vent Plug Vent Plug Torque screws to 35 80 in 3 8 8 8 90 817643R1 DECEMBER 1996 Gear Housing Installation AWARNING Disconnect and isolate spark plug leads before in stalling gear housing onto driveshaft housing 1 Position shift block a in forward gear position 51190 Shift Block Tilt engine to full Up position Engage tilt lock lever Shift gear housing into neutral Propeller shaft will ro tate freely in either direction 4 Install water tube seal a spacer b and shift shaft coupler c 2 4 C Marine Lubricant I D of seal coupler splines LOWER UNIT 6A 25 ACAUTION Do not lubricate top of driveshaft Excess lubricant will not allow driveshaft to fully engage crankshaft Tight ening the gear housing fasteners if excess lubricant is on top of driveshaft will load the driveshaft crank shaft and may damage either or both powerhead and gear housing Wipe the top of driveshaft free of lubri cant 5 Lightly apply Quicksilver 2 4 C Marine Lubricant onto the driveshaft splines 6 Shift gear housing into forward gear Gear housing will not engage when propeller shaft is turned clockwise 7 Position driveshaft into driveshaft housing Move gear housing towards driveshaft housing while aligni
102. STARTER SHEAVE SPRING CAM RETAINING RING STARTER ROPE SPRING CAM SCREW BUSHING 1 2 2 4 8 8 4 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 2 2 2 1 1 1 1 1 1 RETAINING RING 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7C 3 Rewind Starter Disassembly AWARNING When disassembling and reassembling rewind start er SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing 1 Remove retaining clip and attaching screw which se cures shift interlock cable to starter housing 2 Remove bolts 4 securing rewind starter to engine 51606 a Retaining Clip b Screw c Bolts 4 3 Slowly pull the starter rope out from the handle rest approximately 2 feet 60 cm and tie an overhand knot between the rewind housing and the handle rest 4 Remove retainer from rope handle and untie the rope handle knot 5 Remove the rewind starter a Overhand Knot b Retainer 7C 4 OUTBOARD INSTALLATION ATTACHMENTS 6 Remove cam retainer a Screws 3 b Cam Retainer 7 Remove cam lever cam lever spring and interlock le a Cam Lever b Cam Lever Spring Interlock Lever 90 817643R1 DECEMBER 1996 2 i 8 Remove starter sheave 51605 a Starter Sheave b Screw 9 Spring is replaced as a spring cover assembly 51607 a Spring Cover Assembly 90 817643R1 D
103. Shaft Seal Cam 51142 a Transfer Valve Plug Assembly 2 b Check Retainer Plug or Screw Assembly 90 817643R1 DECEMBER 1996 MID SECTION 56 23 cM REASSEMBLY O RING AND SEAL PLACEMENT NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all O rings be replaced when servicing tilt system 5G 24 MID SECTION 90 817643R1 DECEMBER 1996 a O ring Sizes full E 4 14 Cutaway View of O Ring O RINGS SHOWN ARE ACTUAL SIZE 90 817643R1 DECEMBER 1996 MID SECTION 5G 25 O ring Description and Sizes O Ring Description O RingO D O Ring Width 2 OwCapimer ost 17 04 mm 0 949 2410 mm 0139n 353 _ 3 O Ca fen 4734 2004 6030 mm 007m 78 4 Shock Piston 1 6 in 40 64 mm 2 02 in 53 086 mm 0 21 in 5 334 mm 5 Piston Bot 0 676 in 17 17 1 816 in 20 726 mm 0 07 in 1 78 mm 0 208 in 5 283 mm 0 348 in 8 839 mm 0 07 in 1 78 mm 0 114 in 2 90 mm 0 07 in 1 78 mm 8 2 0 489 in 12 42 mm 0 629 in 15 97 mm 0 07 in 1 78 mm 9 Accumulator 2 114 in 53 69 mm 2 254 57 25 mm 0 07 in 1 78 mm 10 CamShaft 0 301 7 645 mm 0 441 in 11 20 mm 0 07 in 1 78 mm 14 Back
104. Special Lubricant 101 to gearteeth and inside of gear cover a Bolt Torque to 40 Ib in 4 5 N m 7B 14 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 x L 6 Installgasketand cover plate over gear assembly DO 9 Retractthrottle cable into gear assembly until approxi NOT OVERTIGHTEN attaching screws mately 17 in 43 cm extends from the tiller arm 51604 2 i 51604 a Cover Plate a Cable Extends 17 in 43 cm b Gasket Below Cover c Screws 10 Slide stainless steel conduit over throttle cable and thread into tiller arm until lightly seated Rotate conduit 7 Rotate throttle arm so that twist grip attaching screw COUNTERCLOCKWISE ONE FULL TURN from a hole faces DOWN and gear drift pin faces UP 8 Insert throttle cable CURVED END FACING UP into tiller handle gear assembly while rotating tiller arm COUNTERCLOCKWISE lightly seated position a Stainless Steel Conduit 51604 a Gear Drift Pin FACES UP 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7 15 ax L 11 Slide brass barrel over throttle cable tube Secure bar 13 Position throttle arm slot to face stop harness exit hole rel to tube with allen screw approximately 3 5 in 89 intillerhandle Route stop switch harnessthrough twist mm from stainless conduit DO NOT OVERTIGHTEN grip into throttle arm and out through side of tiller han screw as tubing may be crushed binding throttle cable dle
105. Steering Cable transom end fully retracted lubricate transom end of steering cables thru grease fittings with 2 4 C w Teflon Marine Lubricant Lubricate exposed portion of cable ends with 2 4 C w Teflon Marine Lubricant 4 Lubricate pivot points of steering link rods and ball joints of link rods steering coupler with Quicksilver 2 4 C w Teflon Lubricant 5 Inspection and lubrication of steering head assembly rotary or straight rack should be performed once each year by your Authorized Dealer or whenever steering mount and or steering head are disas sembled or if steering effort has increased Lubricate with 2 4 C w Teflon Marine Lubricant 90 817643R1 DECEMBER 1996 ransom Mounted Ride Guide Attaching Kit Installation Attaching Kit Installation 1 I TAT Lubricate both holes in pivot block Figure 1 with Quicksilver 2 4 C w Teflon Marine Lubricant Place pivot block on pivot spacer and secure to tran som bracket with 3 8 in x 2 1 2 in bolt flat washer and locknut as shown in Figure 1 Torque locknut to 20 Ib ft 27 N m TIT MM 51140 d 51140 Ride Guide Cable Ride Guide Yoke Pivot Block Pivot Spacer 15in Centerline of Attaching Kit Pivot to Centerline of Outboard Pivot Attaching Locknut Torque to 20 Ib ft 27 1 N m Outbo
106. Test Sequence 1 A Check primary input voltage to coils See Test Chart 1 If voltage readings to coil s are BELOW specification proceed with Step 2 A 2 If voltage readings to coil s are WITHIN specifica tions proceed with Step 1 B 1 B Check coils for spark Connect Spark Gap Tester 91 63998A1 between coil high voltage tower and spark plug 1 No spark or weak spark COIL is bad 2 Spark is OK proceed with Step 1 C 1 C If Step 1 A and 1 B check OK replace spark plugs If problem exists after replacing spark plugs proceed with Step 1 D 1 D If Steps 1 A 1 B and 1 C check OK check igni tion timing 1 If ignition timing does not check to specification or a sudden or unexplained timing change occurs check trigger advance linkage for loose and or broken parts and check trigger magnet ring on flywheel hub for looseness and or a shift in position 2 If ignition checks to specification and engine does not run or runs poorly trouble exists with fuel system or engine mechanical 2 A Check switch box stop circuit See Test Chart 1 Ifreading is BELOW specifications proceed with Step 2 B 2 If reading is ABOVE specifications the Trigger or Switch Box is bad test trigger as outlined in this ser vice manual section if trigger checks OK replace switch box and repeat check 3 Ifreading is WITHIN specifications proceed with Step 3 A 2A 2 ELECTRICAL and IGNITION Q 2 B Chec
107. Torque to 90 Ib ft 122 N m b Spanner Wrench 90 817643R1 DECEMBER 1996 c 9 Remove shock rod assembly from vise 10 Install ball seat and spring five sets to shock rod piston 11 Secure components with plate Torque screws to 35 Ib in 4 0 Nm b 51147 Screws 3 Torque to 35 Ib in 4 0 N m Plate Springs 5 Seats 5 Balls 5 90 817643R1 DECEMBER 1996 Shock Rod Installation 1 Place trim cylinder in soft jawed vice 2 Install lubricated O ring to memory piston and place into cylinder Push memory piston all the way to bottom a Memory Piston b O ring 3 Fillcylinderthree inches 76 2mm from top of cyl inder using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF auto matic transmission fluid 4 Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage Fill re maining cylinder to just below the cylinder threads a Oil Blow Off Ball Passage A CAUTION End cap must not make contact with shock rod piston when tightening Shock rod piston must be positioned in cylinder deep enough to avoid contact 5 Tighten end cap securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten end cap then torque to 45 Ib ft 61 0 N m MID SECTION 5E 39 Trim Limit Assembly Installation 1 Lubricate a
108. Up Ring 301 in 7 645 mm 0 441 11 20 0 07 in 1 78 mm Surge Valve 1 Memory Piston 6 in 40 64 mm 2 02 in 53 086 mm 0 21 in 5 334 mm bed ma ma 5G 26 MID SECTION 90 817643R1 DECEMBER 1996 anual Tilt System Cleaning and Inspection 1 It is recommended that all O rings exposed dur ing disassembly be replaced 2 Clean components filter and check valve seats using engine cleaner and compressed air Do not use cloth rags Inspect all machined surfaces for burrs or scoring to assure O ring longevity 4 Inspect shock rod If wiper located in cap has failed to keep rod clean replace wiper Manual Tilt System Reassembly IMPORTANT Components must be dirt and lint free Slightest amount of debris in tilt system could cause system to malfunction Apply Quicksilver Power Trim and Steering Fluid to all O rings during reassembly If not available use auto motive ATF automatic transmission fluid CAM SHAFT REASSEMBLY IMPORTANT Cam shaft O ring must be lubri cated using 2 4 C with Teflon 92 825407 12 Install lubricated O ring and back up seal to cam Install shaft seal in valve block with lips facing out Install cam shaft assembly in valve block ON Secure cam shaft in place using insulator retain er plate and screw Tighten screw securely a Spacer Retainer
109. Volts Mini 275 to 320 260 to 320 Sw Box Termi mum nal Blue Sw Box 400 VDC Blue Sw Box Ground 190 Volts Mini 275 to 320 260 to 320 Terminal Terminal mum Blue White Sw 400 VDC Blue White Sw Ground 190 Volts Mini 275 to 320 260 to 320 Box Terminal Box Terminal mum NOTE The stator for manual start engines have a BLUE WHITE and a BLACK wire which provide power for the over heat horn and overspeed limiter module Electric Start Engines Red Stator Resistance Test all wires disconnected Positive Meter Lead Connect to White Green Green White stator lead stator lead Connect to Yel Connect to Yel low stator lead low stator lead 0 165 0 181 Manual Start Engines Red Stator Resistance Test all wires disconnected R x 1 Ohms Positive Meter Negative Scale Lead Meter Lead Connect to Connect to White Green stator lead Connect to Connect to 130 145 Blue White Black Connect to Yel Connect to Yel low stator lead low stator lead R x 1 Ohms Negative Scale Meter Lead Connect to 660 710 Green White stator lead 660 710 0 17 0 19 2A 6 ELECTRICAL and IGNITION NOTE Resistance varies greatly with temperature Mea surements should be made within an ambient range of 65 to 85 degrees F Troubleshooting Procedures If the DVA reading is HIGH particularly 1000 RPM the ADAPTER MODULE is defective If the DVA reading is LOW the stator adapter
110. above 2000 RPM the thrust created by the propeller if deep enough in the water will cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering conditions Each boat should be tested for handling charac teristics after any adjustment is made to the tilt angle tilt pin relocation e Will help planing off particularly with a heavy load e Usually improves ride in choppy water e n excess can cause boat to veer to the left or right bow steer e Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt pin one hole closer to transom Operating Down circuit will actuate the down relay located under engine cowl and close the electric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump thus forcing automatic transmission fluid through in ternal passageways into the down side of the trim cylinder The trim rod will move the engine downward to the desired angle 90 817643R1 DECEMBER 1996 c i Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engi
111. all the way and free from restrictions A pinched cut or re Check all fuel lines and stricted fuel line also replace needed loose fuel line connec Check and tighten all tion fuel line connections A dirty or restricted fuel Check replace or clean filter all fuel filters Restricted filter in fuel Clean by rinsing in clean tank lead free gasoline or kerosene Improperly mixed fuel Check fuel and replace contaminants water if necessary dirt etc in fuel An inlet needle in carbu Remove and replace retor that is either with new inlet needle stuck open or closed A needle that is stuck open will cause a flooding condition A needle that is stuck closed will prevent fuel from entering car buretor Incorrect idle mixture ad Re adjust justment Damaged fuel pump dia Replace phragm Carburetor is loose Tighten bolts securely Chamber cover leaking Tighten or replace gas air ket Off idle holes plugged Blow out with com pressed air Main nozzle or idle Blow out with com nozzle air bleed holes pressed air plugged Improper main jet or re Clean or replace with stricted jet proper jet refer to Main Jet Chart Inspect reeds as outlined A crack in the fuel pick Replace up outlet tube located in fuel tank FUEL SYSTEMS 3A 9 Damaged reed s PROBLEM 1 ENGINE IDLES ROUGH AND STALLS PROBLEM 2 ENGINE RUNS ENEVEN OR SURGES PROBLEM 3 ENGINE WILL NOT
112. allow air bubbles to exit inlet hose Torque bleed screw to 25 Ib in 3 0 N m This procedure also allows oil pump to fill with oil BLEEDING AIR FROM OIL PUMP OUTLET HOSE 1 Purge air from outlet hose by running engine on 50 1 gasoline oil mixture in fuel tank at idle speed until no air bubbles are present in outlet hose Fixed Ratio Oil Pump a Bleed Screw b Inlet Hose c Outlet Hose 90 817643R1 DECEMBER 1996 Outboard Operation 1 Check oil level in oil tank 2 A50 gasoline oil mixture must be used during break in or after extended storage 3 Check warning horn operation Turning the key from the off to on position engine not running will momentarily trigger the warning horn This alerts you the warning system is functional If the warning horn does not sound or stays on when the key is in the on position refer to oil injection system troubleshooting chart following to correct the problem The oil injection warning sound is an intermittent beep beep etc The overheat warning sound is con tinuous Check Operation of the Oil Injection System Engine Running 1 Operate engine following the break in procedure out lined in the Operation and Maintenance Manual If warning horn should sound and intermittent beep beep during operation a problem may be occur ring in the oil injection system Refer to troubleshoot
113. and spark plug lead using Quicksilver Insulating Compound 90 817643R1 DECEMBER 1996 Switch Box 1 Referto wiring diagrams in Section 2D when connect ing wires 51123 White Black Purple a b C d White e f 9 Grommet ELECTRICAL and IGNITION 2A 11 ELECTRICAL BATTERY CHARGING SYSTEM and STARTING SYSTEM Table of Contents stc u akayta HEA lt Recommended Operating Engine Without Battery Specific Gravity Readings Specific Gravity Cell Comparison Test Electrolyte Level Charging A Discharged Battery Winter Storage of Batteries Battery Charging System 2 Battery Charging System Troubleshooting Stator Ohms Test Alternator Coils Only Alternator System Test Unregulated Systems Regulated Systems 9 Ampere Battery Charging Wiring Diagram Rectifier Models 9 Ampere Battery Charging Wiring Diagram Regulator Models 9 Ampere Battery Charging Diagram with Battery Isolator Rectifier Models 15 16 Ampere Battery Charging Diagram with Battery Isolator Rectifier
114. anual Tilt System Removal A CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard Service or installation of the tilt system may re sult in loss of pressure in the shock cylinder If the outboard is not in the full down position such loss of pressure will cause the engine to fall to the full down position with a potential for damaging engine or causing personal injury To avoid such injury support outboard in the up position using tilt lock lever Manual tilt system is pressurized Accumulator must be removed when shock rod is in the full up position prior to servicing otherwise oil spray back may occur 1 Support outboard in the up position using tilt lock lever 2 Remove link rod 51143 a Link Rod b Accumulator 90 817643R1 DECEMBER 1996 3 Position piece of wood under transom bracket instead of tilt lock for access of removing pin Use suitable punch to remove DRIVE DOWN upper dowel pin Retain dowel pin a Dowel Pin b Wood 4 Position tilt lock and remove piece of wood Use suitable punch to drive out upper pivot pin 51144 a Pivot Pin b Tilt Lock 5 Use punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a Dowel Pin MID SECTION 5G 17 6 Use suitable punch to drive out lower pivot pin 51144 a Pivot Pin 7 Tilt shock absorber assembly TOP FIRST out from
115. armature on a growler for shorts See Testing following 9 Open circuited armatures often can be saved where and open circuit is obvious and repairable The most likely place for an open circuit is at the commutator bars Long cranking periods overheat the starter motor so that solder in the connections melts The poor con nections cause arcing and burning of the commutator bars 10 Repair bars that are not too badly burned by re sold ering the leads in bars using rosin flux solder and turning down the commutator in a lathe to remove burned material then undercut the mica 11 Clean out the copper or brush dust from slots between the commutator bars 12 Check the armature for shorts and ground See Test ing Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated If saw blade vibrates armature is shorted Re check after cleaning between commutator bars If saw blade still vibrates replace armature 11669 90 817643R1 DECEMBER 1996 ARMATURE TEST FOR GROUND 1 Setohmmeter to R x 1 scale Place one lead of ohm meter on armature core or shaft and other lead on commutator as shown 2 If meter indicates continuity armature is grounded must be replaced lt gprs 5 11675 CHECKING POSITIVE BRUSHES AND TERMINALS 1 Con
116. as possi ble out of powerhead Most water can be eliminated by placing engine in a horizontal position with spark plug holes down and rotating flywheel Pour alcohol into carburetor throat alcohol will absorb water Again rotate flywheel Turn engine over and pour alcohol into spark plug openings and again rotate flywheel Turn engine over place spark plug openings down and pour engine oil into throats of carburetors while rotating flywheel to distribute oil throughout crankcase 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 Remove and clean carburetors and fuel pump assem bly Reinstall spark plugs carburetors and fuel pump 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 If engine fails to start determine cause fuel electrical or mechanical Engine should be run within 2 hours after recovery of outboard from water as serious inter nal damage may occur If unable to start engine in this period disassemble engine and clean all parts and apply oil as soon as possible 90 817643R1 DECEMBER 1996 c n Out of Season Outboard Storage A WARNING As a safety precaution when boat is in storage remove positive battery cable This will eliminate possibility of accidental starting of engine and resul t
117. best accuracy will be obtained by running with or against any wind Side winds require driving in a con stant turn to keep the boat moving straight ahead If winds are 10 MPH 16 km hr or greater itis suggested that all acceleration runs be made downwind 4 The top speed WOT wide open throttle test should be done with the boat normally loaded to duplicate actual running conditions Operate boat in gear at WOT and check RPM Engine RPM must be within the recommended full throttle RPM range listed in the Operation and Maintenance Manual NOTE When performing an acceleration test it is recommended that a stop watch be used to improve testing accuracy A wrist watch with a second hand may also be substituted 90 817643R1 DECEMBER 1996 BOAT TEST CHART Example Propeller Acceleration Propeller Break Loose Wind during Run 101 x 5450 15 5700 1014 x is wide open throttle 5 Anacceleration test can also be performed if desired Startthe test with boat motionless in the water and out board in neutral A stop watch should be started as the throttle is quickly pushed to WOT wide open throttle Stop the watch as the speedometer needle sweeps past 20 MPH 32 km hr Several runs should be made to assure a good average 6 Prop break loose sudden higher RPM if not exces sive in some cases can be beneficial during accelera tion If undesirable break loose occurs it can be de creased by tr
118. closed position during power trim bleeding and operation 1 Secure power trim unit in soft jawed vise 2 Remove fill screw Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF F FA or Dexron II up to threads of reservoir Install cap m II 50241 3 Using 12 volt power supply connect positive lead to green wire negative lead to blue wire and drive trim rod to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Recheck fluid level add fluid if required and repeat cycle until fluid level remains at lower portion of threads 90 8i7643R1 DECEMBER 1996 Power Trim Unit Installation 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until 1 Apply Special Lubricant 101 92 13872A1 to pivot pin is flush with outside surface lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivot pin bore and posi tion lower dowel pin RETAINED in its respective hole T 51147 a Lower Pivot Pin 5 Using a suitable punch drive lower dowel pin into its hole until seated 51148 Lower Pivot Pin Lower Dowel Pin 3 Position trim cylinder assembly BOTTOM i FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket oo
119. excess oil with clean dry cloth Cyl inders should not be cleaned with kerosene or gaso line Clean remainder of cylinder block e Hone all cylinder walls just enough to de glaze POWERHEAD 4 21 e Measure cylinder bore inside diameter with an inside micrometer of each cylinder as shown below Check for tapered out of round egg shaped and oversize bore TOP CENTER BOTTOM e f a cylinder bore is tapered out of round or worn more than 003 in 0 08 mm from standard Cylin der Block Finish Hone diameter refer to chart it will be necessary to rebore that cylinder s to designated oversize bore and install oversize piston s and pis ton rings during reassembly NOTE The weight of an oversize piston is approximately the same as a standard size piston therefore it is not nec essary to rebore all cylinders in a block just because one cylinder requires reboring IMPORTANT Ports must be deburred after honing e After honing and thoroughly cleaning cylinder bores apply 2 cycle outboard oil to cylinder walls to prevent rusting Check Valves NOTE Check valves can be replaced by removing intake manifold when powerhead is attached to driveshaft hous ing The check valves are a 3 16 in 4 76 mm diameter brass casing containing a nylon ball valve These can be dam aged by hot combustion blow by into crankcase ie back fire or a hole in top of piston etc 4 22 POWERHEAD 2 1 TO
120. fluid Grease threads on accumulator and open ing with 2 4 C with Teflon Start accumulator in threads and open cam lever Down Position Torque accumulator to 35 Ib ft 47 N m 51143 a Accumulator b Cam Lever Down Position NOTE If filling procedure is done correctly it should be hard to turn cylinder rod assembly by hand 90 817643R1 DECEMBER 1996 MID SECTION 5G 31 Filling Procedure Option Two Instructions for Making Retaining Tool LLLLLLU 3 16 in x 3 in 5 x 7 5 cm Steel Plate 3 8 in x 13 in 10mm x 33cm Threaded Rod f Ain x 1 4 in min 10cm x 6 4mm minimum Channel Iron 2 holes 7 16 in dia 11 mm 5in 1 1 4 in dia 125mm gt 30m 20 in 508mm 4in 100 mm 2 in 50mm m 3 8 in dia 2 holes 152mm 203mm 5G 32 MID SECTION 90 817643R1 DECEMBER 1996 eeding Manual Tilt System IMPORTANT While bleeding tilt system time must be allowed between each stroke to allow air bubbles to dissipate 1 With shock rod in the full up position and manifold cam lever open facing down secure tilt system to retaining tool and container A No 10 can or 3 Ib coffee can could be used 2 Fill container to near full level using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid IMPORTANT Fluid level must remain above accu mulator opening during bleeding process
121. fuse to blow e Replace fuse No Voltage Indicated Check battery leads for poor connections or open circuits Check battery charge No Voltage Indicated Check that voltage is being supplied to control by performing the following checks DO NOT start engine Turn ignition switch to Run po sition e Check for voltage at any instru ment using a Voltmeter No Voltage Indicated Red wire is open between Point 3 and red terminal on back of the ig nition switch Check for loose or corroded con nections Check for open in wire 5B 20 MID SECTION Check in line fuse under cowl to see if fuse is blown No Voltage Indicated Connect red Voltmeter lead to Point 5 and black lead to ground Fuse Not Blown Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated Battery Voltage Indicated Connect Voltmeter red lead to Point 8 and black lead to ground Depress Up trim button and check for battery voltage Battery Voltage Indicated Check black ground wires for poor connection or poor ground Pump motor is faulty Refer to Motor and Electrical Tests Rep air following Battery Voltage Indicated Trim switch is faulty or there is an open circuit in wires green white blue white between trim buttons and trim pump e Check trim switch e Check all trim harness connec tors for loose or corrode
122. good full continuity zero ohms will be indi cated 51193 If full continuity is not indicated clean switch contact surfaces using an ignition point file Recheck switch if full continuity is not indicated re place end frame MID SECTION 5C 29 Armature Tests TEST FOR SHORTS Check armature on a Growler follow Growler man ufacturer s test instructions Indication of a short re quires replacement of armature TEST FOR GROUND Use an Ohmmeter R x 1 scale Place one lead on Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced A Y 152 51195 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper A lt MESS 5C 30 MID SECTION Power Trim System Reassembly Manifold Oil Pump Installation IMPORTANT Install spring check valve and O ring into manifold Position components in place using sleeve to seat in place 50999 1 Install check valve components into manifold 8 0 O d O lt o 90 c O 51008 Manifold Spring Check Valve Check Valve Seat O ring Spring Sleeve Spool m Q0 09 90 8i7643R1 DECEMBER 1996 2 1 2 Install
123. if not removed with bearing and O ring a 51263 LOWER UNIT 6A 9 Propeller Shaft Disassembly 1 Remove spring a Push out cross pin 51265 a Cam Follower 51265 b Guide Block a Spring b Cam Follower c Apply Pressure as Shown d Punch e Cross Pin 2 Replace cam follower if worn or pitted on either end 3 Replace sliding clutch if jaws are rounded or chipped Rounded jaws indicate the following c Spring d Sliding Clutch e Jaws 4 Check bearing surfaces of propeller shaft If shaft is worn pitted replace shaft and corresponding bearing Replace propeller shaft if a Splines are twisted or worn b Oil seal surface b is grooved in excess of 0 005 in 0 12 c Shaft has a noticeable wobble or is bent more than 0 006 in 152 mm Check with a dial indica tor and V blocks a Vee Blocks a Improper shift cable adjustment b Bearing Surfaces c Check with Dial Indicator Here b Engine idle speed too high while shifting c Shifting too slowly 6A 10 LOWER UNIT 90 817643R1 DECEMBER 1996 Pinion Gear Driveshaft and Forward Gear 1 CT e Hold driveshaft using Driveshaft Holding Tool a 91 817070 remove and discard pinion nut b Remove driveshaft c pinion gear d and forward gear f Replace pinion gear d if chipped or worn Replace bearing e if rusted or da
124. impeller to make sure SA the water intake housing is centered and not rub bing against the liner Torque mounting bolts to 100 14 c Ib in 11 2 N m d NOTE If the outboard is used in salt water apply lt e Quicksilver Anti Corrosion Grease around the entire TTF f mounting flange on the water intake housing and also a Plastic Sleeve to the threads on the six mounting bolts b Impeller c Shear Key d Shims e Nut Retainer f Impeller Nut 2 Temporarily reinstall the water intake housing in or der to check for impeller clearance The clearance between the impeller and liner should be 0 030 in 0 8 mm Shim washers can be transferred to ei ther side of the impeller to raise or lower the impel ler to the correct clearance setting The water in take housing can be shifted side ways a small amount in order to center the liner MNT SS woe T 6C 10 LOWER UNIT 90 817643R1 DECEMBER 1996 p 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 a 1 16 in 1 5mm toward the starboard side of the outboard a Exhaust Fins Impeller Clearance Adjustment 1 a The impeller should be adjusted so there is approx imately 0 03 in 0 8mm clearance between the impeller edge and liner Operating the jet drive in wat
125. module or switch box may be defective Refer to the particular engine model procedure following to isolate the prob lem e Disconnect the BLUE adapter lead from the switch box e Connect the DVA meter between the BLUE adapter lead and ground e Crank the engine manual or electric e Ifthe DVA is normal 190 to 260 volts the switch box is defective e If the DVA reading is still low either the stator or the adapter is defective e Disconnect the GREEN WHITE and WHITE GREEN stator leads from the adapter e Measure the resistance between the GREEN WHITE and WHITE GREEN stator leads e Ifthe resistance is normal 660 to 710 ohms the adapter is defective e lf the resistance is incorrect the stator is defec tive 90 817643R1 DECEMBER 1996 Q Ignition Key Switch Test 1 Disconnect remote control wiring harness and instru ment panel connector NOTE Wiring diagram for control boxes is located in SEC TION 2D 2 Setohmmeter R x 1 scale for the following tests COMMANDER 2000 KEY SWITCH COMMANDER KEY SWITCH PUR BLK YELIM MELK RED B S YEL RED ELIBLK CONTINUITY SHOULD BE INDICATED KEY AT THE FOLLOWING POINTS POSITION BLK BLK YEL RED YEL RED PUR YEL BL Key switch must be positioned to RUN or START and key pushed in to actuate choke for this continuity test BLKeBLACK PUR PURPLE REDeRED YELeYELLOW 3 meter readings are other than specified in
126. of cam lever with pointer of rewind housing Interlock Cable Retaining Pin Adjustment Screw Raised Mark of Cam Lever Pointer of Rewind Housing oO Tighten cable adjustment screw and check adjustment after 4 or 5 shift cycles OUTBOARD INSTALLATION ATTACHMENTS 7C 7
127. piston t holding the outboard motor in position 90 817643R1 DECEMBER 1996 MID SECTION 5E 13 cM SHOCK FUNCTION UP Reservoir Oil BM Return Oil w aM Oil Under Pressure Impact Relief Pressure 22 Up Pressure 1625 40 60 2800 75 125 min Piston Rod b End Cap Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 14 MID SECTION 880 1110 40 60 1220 1420 75 125 Tilt Relief Pressure 250 400 40 60 q 540 990 75 125 lt Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Cylinder 90 817643R1 DECEMBER 1996 Shock Function Up Oil inside the down cavity is locked in a static position by the closed pressure operated valve f the manual release valve p and the manifold reverse
128. position NOTE Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges in gear case before at tempting to move tab DO NOT strike trim tab with a hard object to make adjustments b If boat pulls to the left adjust trailing edge of trim tab to the left If boat pulls to the right adjust trail ing edge of trim tab to the right 3 Tighten trim tab retaining bolt and washer to 22 Ib ft 80 0 N m 90 817643R1 DECEMBER 1996 LOWER UNIT JET DRIVE 6 Table of Contents Page je E 6 1 Jet Pump Assembly 6C 2 Jet Components 6C 4 Selecting A Boat Best Suited For Jet Power 6C 5 Engine Horsepower Selection 6C 5 Transom Height ofthe Boat 6C 6 Locate Center line Of The Outboard 6C 6 Outboard Mounting Height 6C 6 Water Testing 6C 7 Checking for Cavitation 6C 7 Shift Cable Installation 6C 8 Lubricating The Drive Shaft Bearing 6C 9 Impeller Removal and Installation 6C 9 Steering Pull Adjustment 6C 11 Impeller Clearance Adjustment 6C 11 Page Worn Dull Impeller 6C 11 Flushing The Cooling System 6C 12 Liner Replacement 6C 12 Jet Drive Removal 6C 12 Bearing Carrier Removal
129. previously Lubricate starter motor shaft with light film of SAE 10W motor oil Do not over lubricate 6 Service spark plugs Inspect spark plug leads and electrical leads for damage or deterioration as ex plained in Section 2 Electrical and Ignition 7 Inspect fuel lines for damage or deterioration and ser vice fuel filters as indicated in Section 3 Fuel System and Carburetion 8 Remove propeller and inspect Trim nicks and burrs with a file being careful not to remove more metal than absolutely necessary Inspect for cracks damage or bent condition If condition is doubtful refer to autho rized Quicksilver Propeller Repair Station facilities Before reinstalling propeller coat propeller shaft with Quicksilver Special Lubricant 101 Anti Corrosion Grease or 2 4 C w Teflon Marine Lubricant 9 Inspect the outboard surface finish for damage or corrosion Thoroughly clean damaged or corroded areas and apply matching paint Quicksilver Spray Paints 10 Checktrimtab and galvanic corrosion sacrificial anode for damage or for deterioration from salt water operation 11 Check remote controls and steering Be sure that all connections and fittings are in good condition properly secured and correctly adjusted 90 817643R1 DECEMBER 1996 Flushing Outboard Cooling System A WARNING When flushing be certain that area in vicinity of pro peller is clear and that no person is standing nearby to avoid possible inj
130. rail while lowering powerhead on splines of drive shaft PE 51081 POWERHEAD 4 35 2 Install Powerhead bolts Torque to 28 Ib ft 38 0 SS is V D a QN JZ 2 A 0 a W 51088 3 Install cover Torque bolts to 80 Ib in 9 0 N m V 8 rs PE 51083 4 36 POWERHEAD 4 Reattach ground wire to powerhead Connect wires from trim relay switch Connect tel tale hose Design 1 Module s Ground Lead Tel Tale Hose oom Reconnect wires and oil hose Secure in place with sta strap PE 51088 a Oil Tank Wires b Power Trim Wires c Oil Hose Connect to Tank 90 817643R1 DECEMBER 1996 Cn 6 Install oil tank 9 Install bolt and rubber grommet 7 Install battery cables and starter bracket 6 ae 2 pa O dem MIL ES R HS E Pe CUN m lt LEE ON a P PE 51082 PE 51080 a Bolt Positive Cable b Fuel Connector Ground Cable c Rubber Grommet 10 Install control cables Refer to cable adjustment in Sec Install electrical box cover Note bottom edge of cover tion 7A fits into groove of plate a b C Bracket 8 PE 51088 a Shift Cable b Throttle Cable PE 51089 90 817643R1 DECEMBER 1996 POWERHEAD 4 37 11 Reconnect trim sw
131. re Reservoir L o m n 9 Filtered Feed Oil is Return Oil Oil Under Pressure Impact Relief Pressure 22 h 880 1110 40 60 DR 1220 1420 75 125 once m d Up Pressure 5 1625 40 60 EE Tilt Relief Pressur 2800 75 125 250 400 40 60 min a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 10 MID SECTION 540 990 75 125 q m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief Valve S Tilt Relief Piston t Memory Piston u Shock Piston v Impact Relief Valve w Cylinder 90 817643R1 DECEMBER 1996 PAS Maximum Tilt With the piston rod at maximum travel and due to no rod movement the pressure inside of the trim cylinder w will increase to the pressure required to move the tilt relief piston s The tilt relief piston s pin opens the tilt relief valve r Up pressure flows into the trim relief passage and returns back into the reservoir 90 817643R1 DECEMBER 1996 MID SECTION 5E 11 cM DOWN CIRCUIT
132. remote control or trim panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Trimming Characteristics NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion trim tab in neutral straight fore and aft posi tion you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor In slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty Will lift bow of boat generally increasing top speed Transfers steering torque harder to left on installa tions below 23 in transom height Increases clearance over submerged objects In excess Can cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow e
133. screw and clip securing wiring harness to clamp bracket 3 Remove trim gauge sender if equipped Use suitable tool to remove upper headed cross pin Retain pin Straight pin is hard to remove see item 5 51144 a Cross Pin 7 Use suitable punch to drive out lower pivot pin a Cross Pin Design 1 Straight b Cross Pin Design 2 Headed 5 Drive out upper pivot pin This will shear cross pin a Pivot Pin 50515 a Upper Pivot Pin 5D 14 MID SECTION 90 817643R1 DECEMBER 1996 8 Tilt power trim assembly top first out from clamp Power Trim System bracket and remove assembly Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three turns maxi mum counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 9 Remove fill screw and drain unit a Manual Release Valve b Manifold c Spanner Wrench P N 91 74951 4 Remove trim rod assembly from cylinder a Fill Screw 10 Remove O ring from fill cap 51196 90 817643R1 DECEMBER 1996 MID SECTION 5D 15 5 Remove memory piston from cylinder using lock ring pliers Craftsman P N 4735 or suitable tool 51193 51196 a O ring b Memory Piston 7 Remove trim system from vise and empty fluid into appropriate container 5D
134. sides Use special tool CG 41 11 and special tool CG 41 14 with 5 16 end to remove spool a Plug 2 b Spring 2 c Check Valve Poppet 2 d Seat 2 e Spool IMPORTANT Inspect poppet assembly for debris in the area shown If debris is found on poppet re place poppet a Debris Under Valve Tip b Rubber Seat MID SECTION 5E 29 cM 2 Remove three 3 screws to remove pump Re 2 Remove tilt relief components move filter and filter seal under pump Remove suction seat assembly 8 a b d 51008 Spring Poppet Spool Housing Trim Limit Spool om a Screws 3 Shock Rod Removal b Filter Seal c Filter 1 d Suction Seat Assembly Unscrew end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs Manifold Removal 1 Remove two 2 screws to remove manifold from cylinder 51146 a Screw 2 5E 30 MID SECTION 90 817643R1 DECEMBER 1996 Q Shock Rod Disassembly NOTE The only serviceable items on the shock rod assembly are the O rings and wiper ring If shock rod requires any other repair replace shock rod assem bly e C b b a a End Cap b O ring c Wiper Ring 1 Place shock rod assembly on clean work surface 2 Remove three 3 screws and remove plate from shock rod piston 51143 a Screw 3 b Plate c Shock
135. suction valve o If the outboard strikes an underwater object while in forward gear the piston rod a will try to rapid ly extend from the cylinder w the pressure in creases inside the trim cylinder down cavity and con necting passages When the pressure increases to the level required the impact relief valves v located inside the shock piston u will open and allow the fluid to pass through the shock piston As the fluid passes through the piston the piston rod a will ex tend from the trim cylinder The memory piston t is held in position by vacuum created by the oil in the up cavity being locked in a static position Therefore oil passing through the shock piston is trapped be tween the memory piston t and shock piston u 90 817643R1 DECEMBER 1996 MID SECTION 5E 15 p 1 SHOCK FUNCTION RETURN Reservoir Return V EN Oil Under Pressure amp O Impact Relief Pressure 22 aR 9 880 1110 40 60 F 1220 1420 75 125 Up 1625 40 60 2800 75 125 mm Piston Rod End Cap Electric Motor Reservoir Oil
136. surfaces gt Clean piston pin end of connecting rod using same method as above Use 320 grit carborundum cloth in stead of crocus cloth gt Thoroughly wash connecting rods to remove abrasive grit Recheck bearing surfaces of connecting rods Re place any connecting rod that cannot be properly pol ished Lubricate bearing surfaces of connecting rods which will be reused with 2 cycle engine oil to prevent rust 51083 4 24 POWERHEAD PAS Thermostat Wash thermostat with clean water Using a thermostat tes ter similar to the one shown test thermostat as follows gt Open thermostat valve then insert a thread between valve and thermostat body Allow valve to close against thread gt Suspend thermostat from thread and thermometer in side tester so thatneither touches the container Bottom of thermometer must be even with bottom of thermostat to obtain correct thermostat opening gt Fill thermostat tester with water to cover thermostat M Plug tester into electrical outlet 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 tempera ture reaches 5 3 C 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 o
137. tab washer Propeller should be checked periodically for tightness particularly if a stainless steel propeller is used 51871 a Tab Washer b Locknut c Grooves 90 817643R1 DECEMBER 1996 p Gearcase Installation Disconnect and isolate spark plug leads from spark plugs before installing gear housing onto drive shaft housing Failure to follow this warning could result in accidental engine starting and possible injury 1 Position shift block in forward gear position as shown 19879 a Shift Block Front of Block MUST Extend 1 8 3 2mm Past Front of Rail b Rail 2 Tilt engine to full up position and engage tilt lock lever 3 Shift gear housing into neutral position Propeller shaft will rotate freely in either direction 4 Install water tube seal lube 1 0 of seal with Quick silver 2 4 C w Teflon 92 825407A12 5 Apply a bead of RTV Sealer as shown a Water Tube Seal b RTV Sealer 90 817643R1 DECEMBER 1996 A CAUTION Do not use lubricant on top of drive shaft Excess lubricant that is trapped in clearance space will not allow drive shaft to fully engage with crankshaft Subsequently tightening the gear housing fasteners while lubricant is on top of drive shaft will load the drive shaft crankshaft and damage either or both the power head and gear housing Top of drive shaft is to be wiped free of lubricant 6 Apply a light coat of Quicksilver 2 4 C w Teflon onto dr
138. that battery connections and wiring are OK perform the following stator and rectifier tests 2B 4 ELECTRICAL and IGNITION cM NOTE Stator can be tested without removing from engine Stator Ohms Test Alternator Coils Only 1 Disconnectboth yellow stator leads from voltage reg ulator rectifier or terminal block 2 Use an ohmmeter and perform the following test IMPORTANT If stator is mounted on engine black sta tor lead if provided must be grounded to powerhead when testing 3 Replace stator if readings are outside ranges shown NOTE When servicing a unit listed Serial Number and Below it is recommended that the flywheel be removed and the stator part number verified to determine proper testing applications 55 60 MARATHON SEAPRO 398 9873A 5 or 398 9873A21 printed on the stator LIGHTING COIL STATOR 7 AMPERE 96 WATTS Test Leads Resistance OHMS Scale Reading Between Yellow 12 23 12 23 Stator Leads R x 1 Between Either Yellow Stator Lead and Engine Ground Between Blue White and Black 100 140 Stator Leads No Continuity No Continuity R x 1000 DC Resistance of these windings generally is less than 1 5 OHMS If a reading resembling a short is obtained this would be accept able If stator is removed from engine connect test lead to black stator lead if provided 45 JET 50 60 ELECTRIC 398 9710A22 398 9710A23 or 398 9710A34 p
139. the ig nition switch Check for loose or corroded con nections e Check for open circuit in wire DECEMBER 1996 No Voltage Indicated Connect red Voltmeter lead to Point 5 and black lead to ground Fuse Not Blown Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated Battery Voltage Indicated Connect Voltmeter red lead to Point 8 and black lead to ground Depress Up trim button and check for battery voltage Battery Voltage Indicated Check black ground wires for poor connection or poor ground Pump motor is faulty Refer to Motor and Electrical Tests Rep air following Battery Voltage Indicated Trim switch is faulty or there is an open circuit in wires green white blue white between trim buttons and trim pump e Check trim switch e Check all trim harness connec tors for loose or corroded con nections Check for pinched or severed wires Battery Voltage Indicated There is an open circuit in wire be tween Point 5 and Red terminal on the back of the ignition switch MID SECTION 5D 13 x f Power Trim System Removal Inspect cross pin hole and pivot pin hole for damage 6 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin Support outboard with tilt lock lever when servicing power trim system 1 Disconnect power trim harness from outboard wiring harness 2 Remove
140. top side follow cleaning and in spection carefully Chromed ring is installed on top Enlarged View of Piston Ring Grooves CAUTION Care must be taken not to scratch the side surfaces of ring groove Scratching the side surfaces of the ring groove will cause damage to the ring groove Use a bristle brush and carbon remover solution to re move carbon from side surfaces A tool can be made for cleaning the inner diameter of the tapered ring grooves The tool can be made from a broken tapered piston ring with the side taper removed to enable inside edge of the ring to reach the inside di ameter of the groove Carefully scrape the carbon from inner diameter of ring grooves Care must be taken not to damage the grooves by scratching the surfaces of the grooves MEASURING PISTON SKIRT Measure piston skirt at right angle 90 to piston pin cent erline 0 50 in 12 7 mm up from bottom edge of skirt 90 817643R1 DECEMBER 1996 PISTON PISTON SKIRT CYL BORE SIZE DIAMETER FINISH HONE Standard Piston 015 2 965 in Oversize 75 31 mm 2 950 in 74 93 mm 2 955 in 75 057 mm 2 970 in 75 438 mm 2 985 in 75 819 mm 030 2 980 in Oversize 75 69 mm Crankshaft Inspect crankshaft to drive shaft splines for wear Re place crankshaft if necessary Check crankshaft for straightness Replace as neces sary Inspect crankshaft oil seal surfaces Sealing surfaces must not be gr
141. 00 6 8 1000 12 90 817643R1 DECEMBER 1996 14 16 18 2000 22 24 26 28 3000 32 34 36 Gross Weight Lbs LOWER UNIT 6C 5 Transom height of the boat Outboards with jet drives will be mounted approxi mately 7 inches higher on the transom than propeller driven outboards This requires outboards that have a 15 in shaft length to be installed on boats having a 22 in transom height and outboards that have a 20 in shaft length to be installed on boats having a 27 in transom height If the boat transom is of insufficient height and the out board cannot be installed to the recommended height contact the boat manufacturer for recommended pro cedure to build up the boat transom Locate Center line Of The Outboard Locate and mark with pencil the vertical centerline a of boat transom D a Centerline of Transom Outboard Mounting Height The initial outboard mounting height setting will work good for most applications however because of differ ent boat hulls designs the setting should be re checked by test running the boat Refer to Water Test ing e Installing the outboard too high on the transom will allow the water intake to suck in air and cause vitation cavitation will cause the engine to over speed in spurts and reduce thrust This condition should be avoided by proper height setting e Installing the outboard too low on the transom will allow excessive drag 6C 6 L
142. 00 for Mercury Black DU34334 for Mariner Grey and DU35466 for Force Charcoal and DU33414M for Sea Ray White Catalyze all three colors with Ditzler DU5 catalyst mixed 1 1 ratio Reduce with solvents per Ditzler label ACAUTION Be sure to comply with instructions on the label for ventilation and respirators Using aspray gun apply one half to one mil even film thickness Let dry flash off for five minutes and apply another even coat of one half to one mil film thickness This urethane paint will dry to the touch in a mat ter of hours but will remain sensitive to scratches and abrasions for a few days 9 The type of spray gun used will determine the proper reduction ratio of the paint IMPORTANT Do not paint sacrificial zinc trim tab or zinc anode 10 Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing GENERAL INFORMATION and SPECIFICATIONS 1 23 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 removing old decal 3 Clean decal contact area with a 1 1 mixture of iso propyl alcohol and water 4 Thoroughly dry decal contact area and check for a completely cleaned surface Instructions for Wet Application NOTE Thefollowing decal installation instructi
143. 02A40 10 88 11 3 Alum 1200 1900 16 to 18 24 30 48 85632A40 12 10 1 2 3 Alum 1400 2100 16 22 28 48 42740A10 11 1 4 10 3 Alum 1500 2300 17 20 26 48 73132A40 12 1 4 9 3 Steel 1800 18 14 22 48 97868A5 12 1 4 9 3 Alum 1800 18 14 22 48 87818A10 12 1 2 8 3 Alum 2100 18 1 18 48 42738A10 60 MODELS Wide Open Throttle RPM 5000 5500 Recommended Transom Height Short Shaft 16 1 2 in 41 9 cm Long Shaft 20 in 53 3 cm Right Hand Rotation Gear Reduction 1 64 1 Thrust Hub 73345A 1 Approx Approx Speed No of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wot Lbs Length MPH Part Number 10 19 3 Alum Up to 800 Up to 14 48 55 48 73146A40 10 17 3 Alum Up to 1000 Up to 15 44 51 48 73144A40 10 16 3 Steel 700 1100 Up to 15 41 48 48 91818A5 10 16 3 Alum 700 1100 Up to 15 41 48 48 73142A40 10 13 15 3 Steel 800 1200 13 to 15 38 45 48 76232A5 10 13 15 3 Alum 800 1200 13 to 15 38 45 48 73140A40 10 38 14 3 Alum 900 1500 14 to 16 35 41 48 816706A40 10 1 4 14 3 Steel 900 1500 14 to 16 35 41 48 76230A5 10 38 13 3 Steel 1200 1800 15 to 17 32 38 48 76228A5 10 1 2 13 3 Alum 1200 1800 15 to 17 32 38 48 816704A40 10 63 12 3 Steel 1500 2100 16 to 18 28 34 48 79792A5 10 3 4 12 3 Alum 1500 2100 16 to 18 28 34 48 816702A40 10 88 11 3 Alum 1800 2400
144. 1 5 hours of full throttle operation 2 If there is more than approximately 14 5 fl oz 435 ml of oil remaining in tank then the problem may be a faulty low oil warning sensor or a faulty warning mod ule Refer to troubleshooting chart following 90 817643R1 DECEMBER 1996 Installing Drive Gear For Oil Injection Pump Onto Crankshaft 1 Refer to Section 4A Powerhead for proper disassem bly of components Inspect gear teeth for damage Replace gear if any of these problems exist Excessive Wear Cracks in hub or rear Do Not mistake plastic flow lines for cracks Distorted Teeth 51084 a Oil Drive Gear b Key 3 Refer to Section 4 POWERHEAD for proper reassembly of components FUEL SYSTEMS 3D 11 Oil Warning Module Removal Installation 1 Disconnect battery cables 51084 2 Disconnect warning module PURPLE TAN and both BLUE leads at bullet connectors Remove warning module from lower cowl 51204 Warning Module Warning Module Leads Screws Ground Wire 30 12 FUEL SYSTEMS x 14 Connect PURPLE and both BLUE leads at respective bullet connectors Secure warning module BLACK lead to switch box mounting bolt and install warning module Tighten bolts securely We 51204 Warning Module Warning Module Leads Screws Ground Wire BLACK Re connect battery cables 51084 90 817643R1 DECEMBER 1996
145. 1145 a Rod Wiper b Inner O ring C Outer O ring 2 Secure trim rod in soft jawed vise as shown 3 Slide end cap onto trim rod a Trim Rod Piston b Spanner Wrench 5 Install lubricated O ring to trim rod piston 6 Install check ball components into its respective bore 7 Secure components in place using plate and screws Torque screws securely 51146 a End Cap 51147 a Screw b Plate c O ring d Ball e Seat Spring f Spring 90 817643R1 DECEMBER 1996 MID SECTION 5B 35 Trim Rod Installation 4 Install trim rod into cylinder 1 Place trim cylinder in soft jawed vise 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron ll 3 Install lubricated O ring to memory piston and place into cylinder Push piston down to level of oil 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs 51144 a O ring b Memory Piston IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 51145 6 Tighten manual release valve snuggly following end cap installation 5B 36 MID SECTION 90 817643R1 DECEMBER 1996 PAS Bleeding Power Trim Unit IMPORTANT Manual release valve must be in the closed position during power trim bleeding and operation 1 Secure power trim unit in soft jawed vise 2 Remo
146. 16 MID SECTION c Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod pis ton a Screw 3 b Plate c O ring d Piston A CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston 90 817643R1 DECEMBER 1996 fn 4 Place trim rod into soft jawed vise and apply heat to shock piston using torch lamp a P N 91 63209 5 Loosentrim rod piston using spanner wrench 1 4 in x 5 16 in long pegs 6 Allow trim rod piston to cool Remove from trim rod 51146 51146 b Spanner Wrench c Trim Rod Piston 90 817643R1 DECEMBER 1996 A CAUTION Do not remove check ball components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age If check valve is defective replace trim rod piston 7 Remove inner O ring from piston 51199 a Check Ball Components b O ring c Piston 8 Remove rod wiper inner O ring and outer O ring 51147 a 51145 Rod Wiper b Inner O Ring c Outer O Ring MID SECTION 5D 17 c t Trim Motor Removal Trim Motor Disassembly 1 Secure power trim assembly in soft jawed vise 1 Remove armature from motor frame Note posi i hers
147. 2 E 0 5 Qn um FI AES Con 9 i lt 5 Y Oo 51117 a Threaded Rod Obtain Locally b Washers c Nuts d Dial Indicator Adaptor Kit 91 83155 e Dial Indicator 91 58222A1 f Backlash Indicator Tool 6 Position Dial Indicator on appropriate line from chart marked on Backlash Indicator Tool ALIGN POINTER OF DIAL INDICATOR WITH MARK LOWER UNIT 6B 27 60 Big Foot 60 SeaPro Marathon Backlash Indicator Tool 91 78473 75 thru 90 3 Cylinder Backlash Indicator Tool 91 78473 100 115 125 4 Cylinder Backlash Indicator Tool 91 19660 7 Lightly turn drive shaft back and forth no move ment should be noticed at propeller shaft 8 Dial Indicator registers amount of backlash which must be between specification shown in chart DIAL INDICATOR MODEL MINIMUM 60 Big Foot 0 012 in 0 019 in 60 SeaPro Marathon 0 30mm 48mm READING MAXIMUM 30mm 75 thru 90 0 012 in 0 019 in 3 Cylinder 0 30mm 48mm 100 115 125 0 015 in 0 022 in 4 Cylinder 0 38mm 0 55mm 9 If backlash is less than the minimum specification remove shim s from in front of forward gear bear ing race to obtain correct backlash When reinstal ling pinion nut apply Loctite 271 on threads of nut 10 If backlash is more than the maximum specifica add shim s in front of forward gear bearing race to obtain correct backlash When reinstal
148. 24 MID SECTION 90 817643R1 DECEMBER 1996 Trim Motor Removal 4 Remove motor and harness from reservoir 1 Secure power trim assembly in soft jawed vise 2 Remove cap washer and grommet from reser voir assembly 51196 Trim Motor Disassembly 51195 1 Remove end cap from motor housing Note posi Cap tion of washers on armature Washer Grommet Remove screws securing reservoir cap to reser voir End Cap Motor Housing Wave Washer 2 Washer a Screws 51193 90 817643R1 DECEMBER 1996 MID SECTION 5B 25 2 Remove O ring from end frame 3 Place scribe mark on motor housing and end frame as reassembly reference as shown 51194 a O ring b Scribe Mark 4 Remove end frame and armature from housing 51194 End Frame Washer Armature Fiber Guard Brush Wires Housing oo 5B 26 MID SECTION Reservoir Assembly Removal A CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Remove manual release valve from manifold DO NOT remove or adjust reverse thrust valve 51194 a Manual Release Valve b Manifold c Reverse Thrust Valve 2 Remove clip and O rings from manual release valve a E Clip b O rings c Manual Release Valve 90 817643R1 DECEMBER 19
149. 25 6 Assemble Pinion Gear Locating Tool 91 12349A2 as shown do not tighten collar retaining bolt at this time a Arbor b Gauging Block Install With Numbers Away From Split Collar c Bolt Gauging Block Retaining d Split Collar e Bolt Collar Retaining f Snap Ring 7 Insert tool into forward gear assembly position gauging block under pinion gear as shown 22067 a Gauging Block 8 Remove tool taking care not to change gauging block position and tighten collar retaining bolt 9 Insert tool into forward gear assembly position proper numbered flat from chart of gauging block under pinion gear PINION GEAR TEETH FLAT MODEL REVERSE GEAR TEETH NO 60 Big Foot 60 SeaPro Marathon 13 30 GEAR RATIO USE 75 thru 90 8 Oylinder 13 30 100 115 125 4 Oylinder 14 29 2 6B 26 LOWER UNIT 10 Install the number 3 locating disc against bearing carrier shoulder in gear housing 11 Position access hole as shown 24643 a Locating Disc b Access Hole 12 Determine pinion gear depth by inserting a feeler gauge thru access hole in locating disc 13 The correct clearance between gauging block and pinion gear is 0 025 0 64mm 14 If clearance is correct leave Bearing Preload Tool on drive shaft and proceed to Determining
150. 3 Hold throttle arm at idle position crank engine with starter motor and adjust idle timing screw a to align 2 degrees ATDC timing mark of flywheel with timing pointer Tighten locknut b NOTE Timing will be 2 6 ATDC after adjusting idle RPM 2 ATDC 0 0 0 1 20442 m Hf Z 07 7 LY A SNI Nae x ES HI 4 AS Y 51045 ELECTRICAL and IGNITION 2C 3 MAXIMUM TIMING 1 Hold control arm a so that maximum spark advance screw b is against stop Crank engine with starter mo tor and adjust maximum spark advance screw to align the specified BTDC timing mark on flywheel with timing pointer Tighten locknut c b 51045 NOTE Alltiming adjustments made to engine under crank ing speed conditions shouldbe verified with engine running and adjustments made if necessary This is due to advance characteristics of individual ignition systems Idle Adjustment 1 With engine is water connect electrical harness and fuel line to engine Start engine and allow to warm up Properly adjust carburetor low speed mixture screws Initial setting is 1 1 4 turns off seat 2C 4 ELECTRICAL and IGNITION 3 x f Hold throttle arm at idle position throttle cable barrel removed from barrel retainer Adjust idle timing screw a to attain an engine idle RPM of 650 750 RPM in FORWARD gear Tighten locknut b and turn off en
151. 3R1 DECEMBER 1996 P Gear Hsg Drive Shaft 60 Seapro Marathon Big Foot DESCRIPTION Ib in Ib ft N m GEAR HOUSING LONG GEAR HOUSING ASSEMBLY DOWEL PIN FRONT OILER TUBE DRAIN SCREW 60 SCREW MAGNETIC 60 WASHER Sealing DOWEL PIN REAR TRIM TAB SCREW 22 WASHER CARRIER ANODE NUT 60 SCREW PINION GEAR NUT 70 SHIFT CAM TAPERED ROLLER BEARING 90 817643R1 DECEMBER 1996 LOWER UNIT 6B 3 o oci A OIN 1 1 2 1 3 1 1 1 1 1 2 1 1 1 1 1 1 EY Gear Hsg Drive Shaft 60 SeaPro Marathon Big Foot m ix C gt Es 31 7 Loctite 271 92 809820 Super Duty Gear Lubricant 92 13783A24 Loctite 7649 Primer 92 809824 2 4 C With Teflon 92 825407A12 6B 4 LOWER UNIT 90 817643R1 DECEMBER 1996 P Gear Hsg Drive Shaft 60 Seapro Marathon Big Foot DESCRIPTION Ib in Ib ft N m GEAR HOUSING GEAR HOUSING ASSEMBLY SHIM ASSEMBLY DRIVE SHAFT ASSEMBLY WEAR SLEEVE ASSEMBLY COVER ASSEMBLY GASKET GASKET OIL SEAL LOWER OIL SEAL UPPER GASKET WATER PUMP ASSEMBLY FACE PLATE SCREW M6 x 1 x 30 60 7 0 COUPLING KEY IMPELLER SCREW 60 7 0 SHIFT SHAFT ASSEMBLY E RING BUSHING ASSEMBLY O RING OIL SEAL SCREW M6 x 1 35 4 0 N mo L
152. 51046 a Metal Tab b Inlet Needle MAIN HIGH SPEED JET ADJUSTMENT The carburetor has a fixed high speed jet Extreme changes in weather temperature and humidity and or ele vation may result in a too lean or rich fuel mixture at wide open throttle which may require a change in the high speed jet A smaller size main jet will lean the fuel mixture and a larger size jet will enrich the fuel mixture High Speed Jet Bowl Drain Plug Bowl Vent Jet Idle Mixture Screw FUEL SYSTEMS 11 WME Carburetor Specifications Carburetor Number Stamped at TOP of carburetor mounting flange Carburetor Number Bowl Vent Jet 052 092 m WME 26 WME 27 o WME 45 REJETTING CARBURETORS FOR HIGH ALTITUDE Standard Jets listed are for operation of engine from 0 ft 2500 ft OPERATION 0 762 M of elevation The carburetor jet installed at the manufacturer is for en gine operation at sea level through an elevation of 2500 JET ORIFICE SIZE PART NUMBER CHART feet 762m above sea level If the engine is to be operated NOTE Thread size for jets is 10 32 at an altitude higher than 2500 feet above sea level it will be necessary to rejet remove the carburetor jets and in JETORIFICE SIZE PART NUMBER CHART stall jets with a different orifice size the carburetors Each JET ORIFICE SIZE PART NUMBER CHART time the engine is to be operated at a diff
153. 5G 2 MID SECTION 90 817643R1 DECEMBER 1996 MANUAL TILT COMPONENTS TORQUE QTY DESCRIPTION Ib in Ib ft MANUAL TRIM ASSEMBLY MANUAL TRIM BEACHING ASSEMBLY SHOCK ROD ASSEMBLY SHOCK ROD ASSEMBLY BEACHING MEMORY PISTON ASSEMBLY O RING REBUILD KIT Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY CAM KIT VELOCITY VALVE KIT CHECK SYSTEM REPAIR KIT O RING KIT PIN GROOVE PIN A Torque cylinder cap to 45 Ib ft 61 B Torque Accumulator to 35 Ib ft 47 N m C Torque Velocity Valve to 75 Ib in 8 5 N m D Torque Transfer Valve Plug to 75 Ib in 8 5 N m E Torque Screw to 100 Ib in 11 N m F Torque Shock Piston to 90 Ib ft 122 N m 2 3 4 5 6 7 8 9 o N N a 90 817643R1 DECEMBER 1996 MID SECTION 5G 3 cM MANUAL TRIM FLOW DIAGRAMS a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 4 MID SECTION Up Circuit i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve 90 817643R1 DECEMBER 1996 ilt Up With the engine in the down position the accumulator piston d will b
154. 6 Remove O ring from memory piston O ring Memory Piston oo 7 Remove trim system from vise and empty fluid 51196 into appropriate container 5 Remove memory piston from cylinder using lock ring pliers shown or suitable tool Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod pis ton a Screw b Plate c O ring A CAUTION 51193 When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston 90 817643R1 DECEMBER 1996 MID SECTION 5B 23 c 4 Place trim rod into soft jawed vise and apply heat to shock piston using torch lamp P N 91 63209 CAUTION Do not remove check ball components from trim rod piston Removal and reinstallation of check valve could result in improper operating pressure 6 Allowtrim rod piston to cool remove from trim rod and possible power trim system damage If check valve is defective replace trim rod piston 5 Loosentrim rod piston using spanner wrench 1 4 in x 5 16 in long pegs 7 Remove inner O ring from piston 51199 a Check Ball Components b O ring c Piston 8 Remove rod wiper inner O ring and outer O ring 114 51145 a Trim Rod Piston b Spanner Wrench a Rod Wiper b Inner O ring c Outer O ring 5B
155. 78 mm 20 TrimLimitSpool 0 114 in 2 895 mm 0 254 in 6 451 mm 07 in 1 78 mm 21 2 0 208 in 5 283 mm 0 348 in 8 839 mm 22 Memory Piston 1 6 in 40 64 mm 2 02 in 53 086 mm 0 21 in 5 334 ojojo 315 1 oj 90 817643R1 DECEMBER 1996 MID SECTION 5E 37 Power Trim Reassembly IMPORTANT Lubricate all o rings with Quicksil ver Power Trim Fluid 92 90100A12 If not avail able use automotive ATF automatic transmis sion fluid Shock Rod Reassembly 1 Install lubricated o rings to end cap 2 Install rod wiper 51145 a Rod Wiper b Inner O ring c Outer O ring 3 Install lubricated o rings to shock piston 51199 a Shock Piston b O ring c O ring 5E 38 MID SECTION cM Position cylinder end cap onto rod as shown 4 Clamp shock rod in soft jawed vise 51146 A CAUTION When installing shock rod piston spanner wrench must have1 4 in 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod Install shock rod piston 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in long pegs If a torquing type spanner tool is used to tighten shock piston then torque to 90 Ib ft 122 N m 51146 a Shock Rod Piston
156. 8 45 48 16990A40 13 19 3 Alum 1000 1500 14 to 17 35 42 48 77346A40 13 18 3 Steel 1000 1500 14 to 17 33 40 48 16988A 5 13 1 4 17 3 Alum 1300 1800 15 to 18 31 38 48 77344A40 13 1 8 16 3 Steel 1300 1800 15 to 18 29 36 48 16986A 5 13 3 4 15 3 Alum 1600 2200 16 to 19 26 33 48 77342A40 13 3 8 14 3 Steel 1600 2200 16 to 19 23 31 48 17314A 5 14 13 3 Alum 2000 2600 17 20 28 48 77340A40 14 12 3 Steel 2000 2600 17 17 26 48 17312A 5 14 11 3 Alum 2400 18 1 22 48 77338A40 14 10 3 Steel 2800 19 1 20 48 17310A 5 50 60 MODELS Stainless Steel Race Propellers Available from Mercury Performance Products No of Propeller Diameter Pitch Blades Rotation Part Number 11 18 3 RH 48 66106 11 20 3 RH 48 66108 11 22 3 RH 48 66110 GENERAL INFORMATION Propeller Drive Hub 43676 Diffuser Rings Alum Propellers 32201 90 817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS 1 9 Power Trim System Models with Power Trim GENERAL INFORMATION NOTE 50 60 models are not equipped with Trim System Design I See chart below 40 4cyl X X X 50 60 X X The power trim system is filled at the manufacturer and is ready for use Trim outboard through entire trailering range several times to remove any air from the system The trim system is pressurized andis not externally vented The outboard can be raised or lo
157. 817643R1 DECEMBER 1996 Specifications Fuel Pump Pressure W O T 4 7 PSI 28 43 kPa 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3B 1 Fuel Pump 50 60 19 Dz Perfect Seal 92 34227 1 A To Carburetor B To Crankcase C To Oil Pump 90 817643R1 DECEMBER 1996 3B 2 FUEL SYSTEMS Fuel Pump 50 60 DESCRIPTION Ib in Ib ft N m FUEL PUMP ASSEMBLY DIAPHRAGM KIT RUBBER CHECK VALVE CHECK VALVE RETAINER SPRING CAP SPRING CAP DIAPHRAGM GASKET GASKET boost GASKET pulse PLATE FITTING SCREW fuel pump SCREW fuel pump to crankcase BASE HOSE FUEL FILTER FUEL LINE STA STRAP HOSE 1 1 4 1 1 4 14 1 4 TEE CHECK VALVE FUEL CONNECTOR SCREW HOSE 4 1 4 SOLENOID VALVE HOSE 1 3 4 3 1 4 11 1 2 TEE FITTING HOSE 16 CLAMP SCREW k 2 2 2 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 gt amp 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3B 3 Fuel Pump 55 60 Seapro Marathon 19 Perfect Seal 92 34227 1 A To Carburetor B To Crankcase 90 817643R1 DECEMBER 1996 3B 4 FUEL SYSTEMS Fuel Pump 55 60 Seapro Marathon TORQUE QTY DESCRIPTION FUEL PUMP ASSEMBLY DIAPHRAGM KIT RUBBER CHECK VALVE SNG T T GP
158. 96 3 Remove four screws securing reservoir to man Oil Pump Removal ifold IMPORTANT The oil pump is not rebuildable If oil pump is defective replace as an assembly 1 Remove screw oil pump and O rings from man ifold a Screw 4 Remove reservoir from manifold 5 Remove drive shaft from oil pump a O ring b Oil Pump c Screw Manifold Removal 1 While holding trim cylinder to manifold remove screws a Drive Shaft b Oil Pump 51007 a Trim Cylinder b Manifold c Screw 90 817643R1 DECEMBER 1996 MID SECTION 5B 27 2 Slowly remove manifold from cylinder Note posi tion of above trim check ball assembly and re move 54744 a Above Trim Check Ball Components 5B 28 MID SECTION cM 3 Remove O rings from cylinder 4 Remove filter a O rings b Filter Cleaning and Inspection of Trim Rod Components IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction A CAUTION Do not remove check valve components from trim rod piston Removal and reinstallation of check valve could result in improper operating pressure and possible power trim system dam age 51199 a Check Ball Components 90 817643R1 DECEMBER 1996 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace trim
159. 98 9873A 5 printed on the stator USA S N 0G277479 and BELOW BELGIUM S N Not Available at Time of Printing 45 JET 50 60 ELECTRIC 398 9710A22 398 9710A23 or 398 9710A34 printed on the stator USA S N 0G277605 and BELOW BELGIUM S N Not Available at Time of Printing NOTE When servicing a unit listed Serial Number and Below it is recommended that the flywheel be removed and the stator part number verified to determine proper testing applications Test Leads Resistance Scale Reading OHMS x Between Blue Stator Lead and Red Stator Lead 3600 4200 90 140 3 6 4 2 1000 Low Speed Between Red Stator Lead and Engine Ground Hi Speed 90 140 stator is mounted on engine black stator lead must be grounded to powerhead when testing Connect test lead to black stator lead if stator is removed from engine 55 60 MARATHON SEAPRO 398 9873A21 printed on the stator USA S N 0G277480 and ABOVE BELGIUM S N Not Available at Time of Printing 45 JET 50 60 ELECTRIC 398 9873A24 printed on the stator USA S N 0G277606 and ABOVE BELGIUM S N Not Available at Time of Printing Test Leads Resistance Scale Reading OHMS x Between Blue Stator Lead and 1100 1600 1 1 1 6 Red Stator Lead R x 1000 Low Speed Between Red Stator Lead and 30 35 30 35 Engine Ground R x 1 Hi Speed stator is mounted on engine black stator lead must be gr
160. ACCELERATE Possible Cause Corrective Action A crack in the fuel outlet Replace tube located in fuel tank Anti Siphon valve re Refer to Checking for stricting fuel flow Restricted Fuel Flow Caused by Anti Si phon Valves follow ing PROBLEM FUEL BLOW BACK OUT OF CAR BURETOR Possible Cause Corrective Action Replace Reeds Chipped Broken reed block Reeds PROBLEM ROUGH IDLE If related to reed block indicates excessive preload in reeds Replace Reeds PROBLEM CAN T REDUCE ENGINE RPM TO SLOW IDLE Replace Reeds Multiple chipped reeds 3A 10 FUEL SYSTEMS CHECKING FOR RESTRICTED FUEL FLOW CAUSED BY ANTI SIPHON VALVES While anti siphon valves are helpful from a safety stand point they clog they may be too small or they may have too heavy aspring The pressure drop across these valves can create operational problems and or powerhead dam age by restricting fuel Some symptoms of restricted lean fuel flow are 1 Loss of fuel pump pressure 2 Loss of power 3 High speed surging 4 Preignition detonation piston dome erosion 5 Outboard cuts out or hesitates upon acceleration 6 Outboard runs rough 7 Outboard quits and cannot be restarted 8 Outboard will not start 9 Vapor lock Any type of anti siphon device must be located between the outboard fuel inlet and fuel tank outlet A method of checking if such a device or bad fuel is a problem source is to o
161. ATTACHMENTS 7A 17 Route remote control harness or key switch harness d along side oil tank e and out of bottom cowl thru opening f in battery cable grommet N D dd ZO 9 c AA gt BSP Qs m WE gt A n lt f 50566 ACAUTION Remote control wiring harness and key switch wiring harness must be routed between control cable rubber grommet and engine harness connector so that har ness will not interfere with engine throttle and shift op eration 7A 18 OUTBOARD INSTALLATION ATTACHMENTS PAS L Power Trim Wiring Connections Models So Equipped Make bullet connector wiring connection between remote control wiring harness key switch wiring harness and en gine wiring IMPORTANT Tape back and isolate any unused wiring harness leads a Lead From Trim Solenoid Down Solenoid b Lead From Trim Solenoid Up Solenoid Battery Connections ACAUTION Failure to observe correct polarity when connecting battery cables to battery will result in damage to the charging system 1 Connect battery cables from engine to battery Con nect red battery cable to positive battery terminal and black battery cable to negative battery terminal 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS TILLER HANDLE and CO PILOT B Table of Contents Garces eames Steering Handle Kit
162. BOVE STATIC TEST STATIC TEST REQUIRES THE BOAT BE STA TIONARY IN THE WATER SECURED TO A DOCK OR TRAILER AND RUN IN FORWARD GEAR DO NOT USE A FLUSHING DEVICE FOR THIS TEST 1 22 GENERAL INFORMATION and SPECIFICATIONS a Compression Gauge P N 91 29287 Serial Number Location The engine serial number is located on the starboard side of the swivel bracket as on all Mariner Mercury models and also on the cylinder head a 90 817643R1 DECEMBER 1996 Painting Procedures Cleaning amp Painting Aluminum Propellers amp Gear Housings AWARNING Avoid serious injury from flying debris Avoid se rious injury from airborne particles Use eye and breathing protection with proper ventilation PROPELLERS 1 Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch Brite disc or belts 2 Feather edges of all broken paint edges Try not to sand through the primer 3 Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent Xylene or M E K 4 f bare metal has been exposed use Quicksil ver s Light Gray Primer 5 Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat 6 Apply the finish coat using Quicksilver s EDP Propeller Black GEAR HOUSINGS The following procedures should be used in refinish ing gear housings This procedure will provide the most durable paint system available in the fie
163. Blocks b Bearing Surfaces c Measure with Dial Indicator at This Point LOWER UNIT 6B 13 Pinion Gear Drive Shaft and Forward Gear 1 O O Hold drive shaft using Drive Shaft Holding Tool 91 56775 remove and discard pinion nut Remove drive shaft pinion gear bearing and for ward gear Replace pinion gear if it is chipped or worn Replace bearing and race if either are rusted or damaged or if bearing does not roll freely To re move race refer to Lower Drive Shaft Bearing Race following Replace forward gear if gear teeth or clutch teeth are chipped or worn Set g 19175 Drive Shaft Holding Tool 91 817070 Pinion Nut Drive Shaft Pinion Gear Bearing Forward Gear 6B 14 LOWER UNIT 6 cM Replace bearing if it is rusted or does not roll free ly use a punch and hammer to remove bearing a 19203 a Bearing 7 Replace forward gear bearing and race if either are rusted or damaged or if bearing does not roll freely Remove bearing from gear using Universal Puller Plate 91 37241 and man drel To remove race refer to Forward Gear Bear ing Race following a Forward Gear Bearing b Universal Puller Plate 91 37241 c Mandrel 90 817643R1 DECEMBER 1996 8 Replace drive shaft if splines a
164. C WII The use of an inferior 2 Cycle outboard oil can reduce engine durability Damage from use of inferior oil may not be covered under the limited war ranty GENERAL INFORMATION and SPECIFICATIONS 1 5 Propeller Selection 1 Selecta propeller that will allow the engine to operate at or near the top of the recommended full throttle RPM range listed in Specifications preceding with a nor mal 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 determin ing 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 possi ble engine damage 3 For better acceleration such as is needed in water skiing changing to a different pitch to increase the engine speed to 500 RPM above the recommended range is advised Continuous operation above the rec ommended maximum RPM however is not permissi ble 4 Afterinitial propeller installation the following common conditions may require that the propeller be changed to a lower pitch a Warmer weather and great humidity will cause an RPM loss b Operating in a higher elevation causes an RPM loss c Operating with a damaged propeller or a dirty boat bo
165. CEMBER 1996 17 Install the throttle cable as follows a Rotate the throttle grip to the IDLE position b loosen the set screw a in the cable barrel c Position the throttle cable barrel b so the bar rel will be able to slip into the retainer when the cable end is on the mounting stud and there is a slight pre load against the throttle stop d Apply asmall amount of Loctite to threads on set screw and tighten until snug then add an additional 1 8 turn a Set Screw b Cable Barrel 18 Place the cable barrel into retainer 19 Fasten the cable end to mounting stud with nylon washer a and locknut b Tighten locknut against the nylon washer then back off the locknut 1 4 turn 20 Secure the retainer in place with cable latch c a Nylon Washer b Locknut Tighten Locknut Against The Nylon Washer Then Back Off The Locknut 1 4 turn c Cable Latch 90 817643R1 DECEMBER 1996 Shift Cable Adjustment AWARNING The shift cable must be adjusted to lock the re verse gate against unexpected engagement caused by water pressure hitting the gate while operating the boat in forward Activation of the re verse gate will cause sudden unexpected stopping of the boat Sudden stopping may cause occu pants to be thrown within the boat or even out of the boat This action may result in serious injury or death 1 Place shift lever into full forward position 2 Adjust the brass barrel c on the sh
166. CEMBER 1996 LOWER UNIT 6C 3 EY JET COMPONENTS Loctite 271 92 809820 H 250 Liquid Neoprene 92 25711 2 2 4 C With Teflon 92 825407A12 QTY DESCRIPTION Ib in Ib ft N m 1 REV LIMITER HARNESS Adaptor Rev Limiter BRACKET SCREW M6 x 16 70 8 0 SCREW M5 x 25 70 8 0 GREASE KIT IMPELLER KEY WATER PUMP GASKET UPPER SEAL FACE PLATE SCREW 60 7 0 OI A OIN A po N 6C 4 LOWER UNIT 90 817643R1 DECEMBER 1996 Selecting A Boat That Is Best Suited For Jet Power Too obtain the best performance from the jet drive the boat should have the following features 1 The boat should be as light as possible 2 The boat should have hull and transom that is de signed for use with a jet drive 3 The boat should be at least 13 feet in length Engine Horsepower Selection A boat operating at slow speed requires considerably more depth than one which is planing on the surface of the water It is important therefore to use sufficient horsepower and not to overload your boat beyond its ability to plane See the following table Engine Horsepower Selection The following table is based on experience obtained with sled type boats using outboard jets The gross weights shown in cludes the outboard boat people and all the gear carried For given horsepower loading beyond these weights will give less than good performance 5
167. Cleanliness and Care of Outboard Motor A marine power product is a combination of many ma chined honed polished and lapped surfaces with toler ances that are measured in the ten thousands of an inch mm When any product component is serviced care and cleanliness are important Throughout this manual it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the re pair procedure This is considered 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 Before raising or removing and outboard engine from a boat the following precautions should be adhered to 1 Check that flywheel is secured to end of crankshaft with a locknut and lifting eye is threaded into flywheel a mini mum of 5 turns 2 Connect a hoist of suitable strength to the lifting eye In addition personnel should not work on or under an out board 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 with out prior notification Refer to dealer service bulletins for other pertinent informa tion concerning the products described in this manual cM Service Manual Outline Section 2 Electr
168. DECEMBER 1996 10 Remove cover a J PE 51083 Am Qo Qom PE 51088 POWERHEAD 4 15 12 Install lifting eye p n 91 90455 into flywheel a mini Powerhead Disassembly mum of five turns Lift powerhead from drive shaft housing allowing shift linkage to slide off shift rail guide Removing Engine Components Remove the following engine components Component Assembly Starter Motor Ignition Switch Box Ignition Coil Starter Solenoid Voltage Regulator Rectifier Flywheel Stator Assembly Trigger Assembly Air Attenuator Carburetor and Linkage Fuel Pump Fuel Enrichment valve Shift Cable Latch Assembly Control Cable Anchor Bracket Warning Module Oil Pump NOTE all ignition and electrical components can be re moved and installed as an assembly 1 Place powerhead in repair stand or on bench NOTE Powerhead stand p n 91 25821A1 can be used PE 51081 PE 51227a 4 16 POWERHEAD 90 817643R1 DECEMBER 1996 2 i 2 Remove thermostat components 4 Remove check valves and holders Bolts Thermostat Cover Thermostat Gasket Thermostat Poppet Valve Spring o0oo0oo0n Remove intake manifold and reed block manifold PE 51227c Check Valve Holders 5 Place engine on work bench and remove end cap bolts PE 51085 a Bolts PE 51227a a Bolts 14 90 817643R1 DECEMBER 1996 POWERHEAD 4 17 cM 1 Remove roller bearing assem
169. ECEMBER 1996 Cleaning and Inspection 1 Clean components in solvent and dry with compressed air 2 Inspect rewind spring for kinks burrs corrosion of breakage 3 Inspect starter sheave rope guide and starter housing for nicks grooves cracks wear or distortion especial ly area of rope travel 4 Inspect bushing starter drive pawl and spring for wear or damage Inspect starter rope for wear Replace components as necessary Rewind Starter Reassembly AWARNING When reassembling rewind starter SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing 1 Install spring cover assembly into sheave 51607 a Spring Cover Assembly OUTBOARD INSTALLATION ATTACHMENTS 7 5 2 Install starter sheave to housing and secure in place with screw Torque to 135 Ib in 15 3 N m 51605 a Starter Sheave b Screw 3 Install interlock lever position cam spring into recess of starter housing and reinstall cam lever a Cam Lever b Cam Lever Spring c Interlock Lever 7C 6 OUTBOARD INSTALLATION ATTACHMENTS cM 4 Reinstall cam retainer and secure with screws 3 M RIO N E SAIS MD S ASK 28374 Adjusting Rewind Spring Tension a Screws 3 b Cam Retainer 1 Rotate sheave counterclockwise until it stops coil is bound Then back off one full turn plus what is needed to align rope end with hole in housing Never back off sheave less th
170. IDLE TIMING 2 6 IDLE RPM IN FORWARD GEAR 650 750 RPM MAXIMUM TIMING 5000RPM 50 60 22 BTDC 55 16 BTDC Cranking Speed 50 60 24 BTDC 55 18 BTDC SPARK PLUG TYPE NGK BP8H N 10 50 55 60 NGK BPZ8H N 10 FIRING ORDER 50 55 60 Models Serial No D000750 to 0181999 came standard with NGK BU8H spark plugs BP8H N 10 can be used in these models Z 58222A1 3 Turn flywheel clockwise until No 1 TOP piston is at top dead center TDC Set dial indicator to 0 zero Description 4 Turn flywheel counterclockwise until dial indicator Part Number Description needle reads 550 in 14 0 mm BTDC then turn fly 91 58222A1 Dial Indicator Gauge Kit wheel clockwise until needle reads 459 in 11 7 mm BTDC exactly Q4 5 Flywheel cover timing pointer a should align exactly 21735879 tiring Light with 459 14 0 mm timing mark b on flywheel If not 91 63998A1 Spark Gap Tool loosen two 2 timing pointer attaching screws c and adjust pointer After adjusting pointer torque attaching screws to 20 Ib in 2 26 N m Timing Pointer Adjustment p su sa 51128 51046 Suppressor Resistor Spark Plug Special Tools 91 59339 Service Tachometer May be obtained locally IMPORTANT Models equipped with adjustable timing pointer or 459 mark on flywheel require the following procedure before timing engine A WARNING Remove all spark p
171. ION 90 817643R1 DECEMBER 1996 cM FUEL SYSTEMS CARBURETION Table of Contents Page Specifications 3A 1 Special Tools 3A 1 Attenuator 3A 2 WME Carburetor Specifications 3A 4 Reed Valve Specifications 3A 4 aaa 5 Carburetor 3A 6 Carburetion 3A 8 Fuel System Troubleshooting 3A 8 Troubleshooting Charts 3A 8 Carburetor Adjustments 11 Initial Starting 3A 11 idle Speed Adjustment 3A 11 Idle Mixture Screw Adjustment 3A 11 Carburetor Float Adjustment 3A 11 Main High Speed Jet Adjustment 3A 11 WME Carburetor Specifications 12 Rejetting Carburetors For High Altitude Operation 12 Jet Size Part Number Chart 12 Carburetor Removal 3A 13 Carburetor Disassembly 3A 13 Cleaning and Inspection 3A 15 Carburetor Reassembly 3A 15 Carburetor Installation 3A 17 90 817643R1 DECEMBER 1996 Specifications Special Tools in Forward Gear 91 36392 Carburetor Scale Flo
172. IT 2 L 3 Rotate driveshaft prop shaft and move shift rod while housing is pressurized to check for leaks 4 If pressure drop is noted immerse housing in water 5 Re pressurize to 10 12 p s i and check for air bubbles 6 Replace leaking seals as necessary Retest housing NOTE It should hold 10 12 p s i for 5 minutes 7 Remove tester from housing and install vent plug Gear Housing Installation Filling Gear Housing with Lubricant NOTE Gear housing lubricant capacity is approximately 11 5 fl oz 340 ml A WARNING If gear housing is installed on outboard disconnect and isolate spark plug leads from spark plugs before working near the propeller ACAUTION Do not use automotive grease in the gear housing Use only Quicksilver Gear Lube 1 Remove any gasket material from Fill and Vent plugs and gear housing Install new gaskets on Fill and Vent plugs IMPORTANT Never add lubricant without removing Vent plugs Gear housing cannot be filled because of trapped air Fill gear housing when driveshaft is in a vertical position 2 Remove Fill plug and gasket a 90 817643R1 DECEMBER 1996 3 Insert lubricant tube Fill hole then remove Vent plugs and gaskets b and c Fill until excess lubricant flows out of Vent hole b Replace this Vent plug and gasket and continue to fill until lubricant flows from second Vent hole c
173. Installation 1 Place seal on longer shoulder side of Oil Seal Driver 91 13949 with seal lip away from shoulder 2 Apply Loctite 271 on O D of seal press seal into water pump base until tool bottoms TEFLON COATED LIP FLAT BROWNISH BLACK COLOR LIP FACES TOWARD POWER HEAD SPRING FACES TOWARD POWER HEAD Xe a Seal b Oil Seal Driver 91 13949 51553 90 817643R1 DECEMBER 1996 3 Place seal on shorter shoulder side of Oil Seal Driver 91 13949 with seal lip toward shoulder 4 Apply Loctite 271 on O D of seal press seal into water pump base until tool bottoms Lubricate lip of each seal with Quicksilver 2 4 C w Teflon 92 825407A12 LIP FACES TOWARD GEAR CASE GLOSS BLACK SPRING FACES TOWARD GEAR CASE a Seal b Oil Seal Driver 91 13949 6 Install gasket 51553 a Gasket LOWER UNIT 6B 29 7 Install components as shown a Water Pump Base b Bolts and Washers Apply Loctite 271 on bottom 1 2 ofThreads and Torque to 60 Ib in 6 5 N m 8 Install gasket and plate 19219 Gasket b Plate IMPORTANT If the old impeller will be re used impeller must be installed in original clockwise direction of rotation 6B 30 LOWER UNIT 9 Inst
174. Installation The shift cable must be adjusted to lock the re verse gate against unexpected engagement caused by water pressure hitting the gate while operating the boat in forward Activation of the re verse gate will cause sudden unexpected stopping of the boat Sudden stopping may cause occu pants to be thrown within the boat or even out of the boat This action may result in serious injury or death 1 Attach shift cable a to the shift cam b with flat washer and locknut as shown Tighten locknut against the flat washer then back off the locknut 1 4 turn 2 Place remote control handle into full forward posi tion 3 Adjust the brass barrel c on the shift cable so that roller d is at the full end of travel bottom in the shift cam when the remote control is in full forward 6C 8 LOWER UNIT C 4 Attach the brass barrel c to the bracket with bolt and locknut Tighten the bolt until it seats against the barrel then back off the bolt 1 4 turn Hold bolt from turning and tighten locknut on bolt The barrel must be free to pivot Shift Cable Shift Cam Barrel Roller 2009 Recheck the shift cable adjustment in forward shift position The correct shift adjustment will position the cam far enough on the roller in order to lock the the reverse gate into forward position You should not be able to forcibly push up the reverse gate to ward neutral Pull on the reverse gate by hand to verify thi
175. MID SECTION Down Circuit i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve 90 817643R1 DECEMBER 1996 I own With the engine tilted up the piston inside the accu mulator piston d will be at the bottom ofthe accumu lator c and the gas pressure is low To lower the en gine the camshaft lever f is rotated down the internal cam will cause the push rods to open the ac cumulator check valve e both fast transfer valves h amp j and the down slow transfer valve i The operator will have to press down on the engine cowl to over come the pressure inside cylinder Fluid will flow out of the bottom of the cylinder past both the down fast transfer valve h and down slow transfer valve i Fluid will flow past the up fast transfer valve j surge valve k and through the interconnecting passage into the top of the cylinder 1 Due to the shock rod a the tilt cylinder cavities differ in volume the extra fluid from the up cavity forced into the accumulator c will cause the internal accumulator piston d to com press the gas With the engine in the correct position the camshaft lever is rotated up and the push rods al low the check valves e h i amp j to close 90 817643R1 DECEMBER 1996 MID SECTION 5G 7 a Shock Rod b End Cap c Accumulator d Accumulator Pist
176. MS x Between Brown Trigger Lead 11 14 and White Black Trigger Lead 1100 1400 R x 100 Test Leads Between White Trigger Lead 11 14 and White Black Trigger Lead 1100 1400 R x 100 Between Violet Trigger Lead 11 14 and White Black Trigger Lead 1100 1400 R x 100 NOTE Above readings are for a cold engine room tem perature Resistance will increase slightly if engine is warm 3 If meter readings are not as specified replace trigger 90 817643R1 DECEMBER 1996 ADI Ignition using a RED Stator with an Adapter Module Red stators require an adapter module that is con nected between the stator and switch box Without the adapter module the voltage supplied by the stator would exceed the voltage capability of the switch box ELECTRICAL and IGNITION 2A 5 RED Stator with Adaptor and Ignition Coils RED Stator DVA Test Test Selector RED DVA Switch Posi Lead tion Coil Primary 400 VDC Coil Termi nal BLACK DVA Coil Termi NOTE If using a meter with a built in DVA place selector switch in the DVA 400 VDC position NOTE Red stators require an adapter module that is connected between the stator and switch box With out the adapter module the voltage supplied by the stator would exceed the voltage capability of the switch box Voltage 300 Voltage Voltage RPM 1000 RPM 4000 RPM 130 Volts Mini 195 to 275 195 to 275 mum Stop Circuit 400 VDC Black Yellow Ground 190
177. Manual Release Valve Result Result Manual release valve and or O ring damage Manual release valve and O rings appear to be OK Replace O rings rings Inspect Memory Piston O ring Replace defective valve and O Result Result O ring appear to be OK Cylinder O ring memory piston or cylinder bore and memory piston are OK bore defective Replace O rings and proceed Inspect Oil Pump O rings located Replace defective O rings or below oil pump components Result Result O ring failure located below oil O rings appear to be OK Re pump place O rings Replace O rings Replace oil pump 5C 14 MID SECTION 90 8i7643R1 DECEMBER 1996 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Inspect Manual Release Valve Result Manual release valve and or O ring damage Result Inspect Manifold Reverse Thrust Valve Result Debris found in manifold reverse thrust valve components Clean manifold reverse thrust valve without removing compo nents using engine or cleaner and compressed air or replace 90 817643R1 DECEMBER 1996 Result Manual release valve and O rings appear to be OK Replace O rings and proceed Replace defective valve and O Inspect Trim Rod Piston Check rings Valve Result Clean check valve components No debris or defective components Debris found in check
178. N 5E 41 Pressure Operated Assembly Installation IMPORTANT Inspect poppet assembly for debris in the area shown If debris is found on poppet place poppet Debris Under Valve Tip Rubber Seat 1 Lubricate o rings 2 Install spool seat with O ring check valve pop pet spring and plug with O ring into pump Re peat for other side Torque plugs to 120 Ib in 13 5 N m a Plugs 2 Torque to 120 Ib in 13 5 N m b Springs 2 c Check Valve Poppet 2 d Seats 2 Spool 5E 42 MID SECTION Reservoir Motor Installation 3 Install coupler into top of pump Make sure reser voir seal is in the reservoir groove and place res ervoir onto pump manifold assembly Install ground strap under screw shown Torque screws to 80 Ib in 9 EE B wu S17 C 0 Screw 4 Torque to 80 Ib in 9 N m Reservoir Reservoir Seal Coupler Manifold Assembly Ground Strap 0 4 Fill reservoir to bottom of fill hole using Quicksil ver Power Trim Fluid 92 901000A12 If not available use automotive ATF automatic trans mission fluid 90 817643R1 DECEMBER 1996 Bleeding Power Trim Unit 1 2 Secure power trim unit in soft jawed vise Add power trim fluid until even with the bottom of the fill hole Reinstall plug Close the manual release valve Turn full clock wise
179. N 90 817643R1 DECEMBER 1996 Q COMMANDER Side Mount Remote Control Power Tilt Electric Start with Warning Horn Wiring Diagram Ignition Choke Switch m Emergency Stop Switch 31 Neutral Start Switch Tachometer Accessories Harness Wiring Harness Connector Warning Horn Trim Tilt Switch Wire Retainer wien w Mn ro Q O 0M i Control Handle j Trim Harness Bushing k Trim Harness Connector Lead to Trim Indicator Gauge BLK e BLACK BLU BLUE BRN BROWN GRY GREY GRN GREEN PUR e PURPLE RED e RED WHT WHITE YEL YELLOW LIT LIGHT 90 817643R1 DECEMBER 1996 24072 ELECTRICAL and IGNITION 2D 11 COMMANDER 2000 Side Mount Remote Control Elec tric Start with Warning Horn Wiring Diagram BLK 4 TAN BLU 3 TAN BLU GRY IB YEL BLK 6 PUR 2 BLK D PUR A YEL RED 7 BLK YEL 1 RED 8 TANT Ste gt 5 2 A o x io 3 TIME a Ignition Choke Switch b Emergency Stop Switch z Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn ov BLK BLACK BLU BLUE BRN BROWN GRY GREY GRN e GREEN PUR e PURPLE RED e RED TAN TAN WHT e WHITE YEL YELLOW LIT LIGHT 2D 12 ELECTRICAL and IGNIT
180. NE PIECE STEERING ARM Starboard Cable Entry Into Tilt Tube 50056 51103 Port Cable Entry Into Tilt Tube Eo Ez 51103 a Flat Washer 2 Nylon Insert Locknut Torque until it seats DO NOT Exceed 120 Ib in 13 5 or Torque Then back off 1 4 Turn Special Washer Head Bolt Torque to 20 Ib ft 27 N m Spacer Nylon Insert Locknut Torque to 20 Ib ft 27 N m Steering Link Rod o 7 8 OUTBOARD INSTALLATION ATTACHMENTS MODELS WITH TWO PIECE STEERING ARM BRACKET Starboard Cable Eniry Into Tilt Tube Two Piece Steering Bracket Mount Steering Link Rod in Back Hole Flat Washer 2 Nylon Insert Locknut Torque until it seats DO NOT Exceed 120 Ib in 14 N m or Torque Then back off 1 4 Turn Special Washer Head Bolt Torque to 20 Ib ft 27 N m Spacer Nylon Insert Locknut Torque to 20 Ib ft 27 N m Steering Link Rod A WARNING 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 right and left at all tilt angles to assure inter ference free movement 90 817643R1 DECEMBER 1996 aintenance Instructions Maintenance is the owner s responsibility and must be per formed at intervals specified Normal Service Every 50 hours of operati
181. NGER HIGH VOLTAGE SHOCK HAZARD Do not touch ignition components and or metal test probes while engine is running and or being cranked STAY CLEAR OF SPARK PLUG LEADS To assure personal safety each individual spark plug lead should be grounded to engine CAUTION To protect against meter and or component damage observe the following precautions 400 VDC test position or higher MUST BE used for all tests INSURE the Positive lead terminal of DVA is con nected to the Positive receptacle of meter DO NOT CHANGE meter selector switch position while engine is running and or being cranked Switch box MUST BE GROUNDED during tests Running or cranking engine with switch box un grounded may damage switch box using a meter with a built in DVA the DVA 400 VDC test position should be used NOTE Test leads are not supplied with the DVA Use test leads supplied with meter Test procedures and specifications are provided for check ing primary ignition voltage while the engine is running and or being cranked TROUBLESHOOTING TIPS 1 Intermittent weak or no spark output at two spark plugs usually indicates a bad TRIGGER 2 Intermittent weak or no spark output at all three spark plugs usually indicates a bad STATOR or SWITCH BOX 3 Intermittent weak or no spark at any one spark plug usually indicates a bad SPARK PLUG COIL or SWITCH BOX ELECTRICAL and IGNITION 2A 1
182. O rings cylinder and secure manifold 4 Install check valve components and O rings to assembly to cylinder using screws Torque manifold Secure oil pump to manifold using bolt screws to 100 Ib in 11 3 Torque bolt to 90 Ib in 10 2 N m O rings 3 Oil Pump Screw Spring Check Ball O o Trim Motor Reassembly 1 Apply Quicksilver Marine Lubricant 2 4 C to ar mature shaft and insert into end frame 51007 a O ring b Screws 100 Ib in 11 3 N m 3 Secure power trim unit in soft jawed vise SEND af aA Sym SG AA y 51195 a Armature Shaft b Washer c End Frame 90 817643R1 DECEMBER 1996 MID SECTION 5C 31 2 Guide armature and end frame into housing as shown LL s ITU d 51196 3 Align scribe mark on housing to mark on end frame 4 Install lubricated O ring to end frame 51194 a O ring b Scribe Mark 5 Install washers to armature shaft as shown 5C 32 MID SECTION 6 Install end cap to housing Torque nuts to 25 lb in 2 8 N m End Cap Motor Housing Wave Washer Washer IMPORTANT When installing motor wires black orange must rest in cavity of cylinder allowing motor to seat properly 51194 Manifold b Cavity 90 8i7643R1 DECEMBER 1996 Reservoir Installation 1 Connect trim motor wires to ha
183. OWER UNIT u 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 on the transom up from the V bottom the same length as the width of the water intake housing b MM 2 Place center the outboard on the boat transom so that di transom brackets are resting on top of the transom Temporally fasten the outboard to the transom using two C clamps 3 Position the outboard in a vertical position Line up a straight edge c along the bottom of the boat with the horizontal line made in Step 1 and measure the distance between the horizontal line and top front edge of the water intake housing d M 5 Raise The outboard up on the transom the dis tance measured in Step 4 Use a straight edge and recheck the mounting height The top edge of the water intake housing should be lined up with the horizontal line made in Step 1 6 Fasten outboard to the transom at this height 90 817643R1 DECEMBER 1996 SETTING OUTBOARD MOUNTING HEIGHT BOATS WITH FLAT BOTTOM HULLS 1 Place center the outboard on the boat transom so that the transom brackets are resting on top of the transom Temporally fasten the outboard to the transom using two C clamps 2 Position the outboard in a vertical position 3 Place a straight edge a along the bottom of the boat as shown and measure the distance between the bot
184. Pinion Gear Upper Driveshaft Bearing Race Retainer and Driveshaft Installation 6A 18 Pinion Gear Location and Forward Gear Backlash 6A 19 Determining Pinion Gear Location 6A 19 Determining Forward Gear Backlash 6A 20 Bearing Carrier and Propeller Shaft Installation 6A 21 Water Pump Re assembly and Installation 6A 22 Gear Housing Pressure Test 6A 24 Gear Housing Installation 6A 24 Filling Gear Housing with Lubricant 6A 24 Gear Housing Installation 6A 25 Propeller Installation 6A 26 Trim Tab Adjustment and Replacement 6A 27 90 817643R1 DECEMBER 1996 Q Drive Shaft and Water Pump Components Gear Housing Drain Screw Screw Washer Dowel Pin Hollow Dowel Pin Solid Pipe Plug Roller Bearing Pinion Gear 10 Nut 11 Shift Shaft 12 Retaining Ring 13 Bushing 14 O ring 15 Oil Seal 16 Drive Shaft 17 Shim Set 18 Tapered Roller Bearing 19 Nut 20 Water Pump Base 21 O ring 22 Oil Seal 23 Oil Sea 24 Face Plate 25 Impeller 26 Key 27 Water Pump 28 Gasket Lower 29 Gasket Upper 30 Seal 31 Screw 32 Washer 33 Insulator Design 1 34 Insulator Design 1 35 Shift Cam 36 Spacer 37 Coupler 38 Plate 39 Seal Torque Specificatio
185. ROLLER BEARING 90 817643R1 DECEMBER 1996 POWERHEAD 4 9 E Throttle Lever and Linkage 2 4 C With Teflon 92 825407A12 4 10 POWERHEAD 90 817643R1 DECEMBER 1996 Throttle Lever and Linkage un DESCRIPTION Ib in Ib ft N m THROTTLE LEVER ADJUSTING SCREW JAM NUT PIN ADJUSTING SCREW WASHER NUT Drive Tight then Back Off 1 2 Turn a BUSHING JAM NUT CAP SWIVEL BUSHING SPRING WASHER SPARK ADVANCE LEVER SPARK ADVANCE ROD SWIVEL BASE SWIVEL BALL SCREW Drive Tight THROTTLE ROD STUD SPRING THROTTLE CAM WASHER NUT Drive Tight then Back Off 1 2 Turn Op N 90 817643R1 DECEMBER 1996 POWERHEAD 4 11 Powerhead Torque Sequence INTAKE MANIFOLD TORQUE SEQUENCE Install bolts and torque to 18 Ib ft 24 5 N m 5 11 12 1 2 9 10 3 4 13 14 8 7 PE 51085 CRANKCASE COVER AND LOWER END CAP COV ER TORQUE SEQUENCE Torque bolts to 18 Ib ft 24 5 N m 5 13 51085 51086 4 12 POWERHEAD 90 817643R1 DECEMBER 1996 lt e General Information Powerhead Disassembly and Reassembly instructions are printedin a sequence that should be followed to assure best results when removing or replacing powerhead com ponents If complete disassembly is not necessary start reassembly at point disassembly was stopped R
186. Retaining Ring Roll Pin 10 Steering Arm 11 Bracket 12 Locking Plate 13 Bolt 2 14 Steering Link 15 Bolt 16 Spacer 17 Lock Nut 18 Washer 2 19 Washer 2 OONOAARWN Lubrication Sealant Application Points 2 4 w Teflon Marine Lubricant 92 9001 8A12 90 817643R1 DECEMBER 1996 Torque Specifications 201b ft 27 0 9 40 lb ft 54 0 Torque until it seats then back off 1 4 turn MID SECTION 5A 1 Mid Section Components Transom Bracket Components 55 Model Transom Bracket Grease Fitting Pin Transom Bracket Lock Lever Spring Bushing Spring Lever Roll Pin Washer 2 Bracket Anode Bolt 2 Washer 2 Bolt 5 30mm 1 35mm 17 Lockwasher 2 18 Lock Nut 2 19 Pin 20 Tilt Tube 21 Lock Nut 2 22 Bolt 4 23 Washer 4 24 Nut 4 25 Bolt 2 26 Washer 2 27 Thumb Screw 2 28 Rubber Grip 29 Tilt Lever 30 Bushing 31 Washer 32 Washer 33 Bolt 34 Link 35 Bolt 4 36 Washer 8 37 Bracket 2 38 Shim 4 39 Nut 4 ak O Q Q N per ere mk nk Ld l4 Q N Lubrication Sealant Application Torque Specifications Points 601b in 7 0 Nm 2 4 C Marine w Teflon Lubricant 92 90018 12 25 Ib ft 84 0 N m Loctite 271 92 823089 1 Special Lubricant 101 92 13872A1 5A 2 MID SECTION 90 817643R1 DECEMBER 1996 Mid Se
187. Rod Piston 90 817643R1 DECEMBER 1996 3 Remove check ball components from shock rod piston 4 Remove o ring from shock rod piston 2 51147 Spring 5 Seat 5 Ball 5 O ring MID SECTION 31 A CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to shock piston 5 Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 6 Loosen shock rod piston using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs 7 Allow shock rod piston to cool Remove from shock rod 51146 Spanner Wrench Shock Rod Piston 5 8 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 9 Clean shock and components with compressed air 5E 32 MID SECTION a i 10 Remove inner o ring from shock rod piston 51199 a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock If wiper located in cap has failed to keep rod clean replace wiper 13 Place end cap on clean work surface 14 Remove rod wiper inner o ring and outer o ring 51145 a Rod Wiper b Inner O ring c Outer O ring 90 817643R1 DECEMBER 1996 c Memory Piston Removal 1 Remove memory piston from cylinder using one of two methods
188. Rod Wiper O ring 671 in 1 0 Cylinder Cap O ring 1 864 in I D O ring 614 I D Trim Rod Piston Ball 5 Seat Spring 5 Spring 5 Retainer Plate Screw 3 O ring 1 600 in 1 0 2 Memory Piston Trim Rod Cylinder Screw 2 O ring 208 1 0 2 O ring 114 1 0 Spool O ring 301 in 1 0 Sleeve Spring Valve Seat Valve Spring 2 Ball Dowel Pin 2 Manifold O ring 114 in 1 0 O ring 208 I D O ring 239 I D Relief Valve E Clip Dowel Pin O ring 176 in 1 0 Bolt Drive Shaft O ring 2 364 I D Reservoir Bolt 4 Washer 4 O ring 538 I D Fill Screw Wire Harness Cap Washer Grommet Screw 4 Screw Reservoir Cap O ring 2 634 in I D Nut 2 Disk Foam Pad End Cap Washer 2 030 in Thick Thrust Washer Armature Washer 010 in Thick Housing End Frame O ring 489 I D Bolt 2 Trim Pump 90 817643R1 DECEMBER 1996 NOTE It is recommended that ALL O rings be re placed when servicing tilt system 51005 Torque Specifications 35 lb in 4 0 9 100 bb in 11 3 N m Q 70 b in 7 9 N m 90 lb in 10 2 N m 25 bb in 2 8 131b in 1 5 p c Quicksilver Lubricant Sealant Application Points Loctite Grade A 271
189. Screws 4 6 Install lubricated O rings and E clip to manual release valve E Clip O ring Manual Release Valve N oon Insert manual release valve into manifold and tighten snuggly Back release valve out 3 turns maximum allowing trim rod installation a Manual Release Valve b Manifold MID SECTION 5D 23 Trim Rod Reassembly 1 Install lubricated O rings and rod wiper to end ay e 51145 Rod Wiper Inner O ring Outer O ring Secure trim rod in soft jawed vise as shown N Slide end cap onto trim rod 51146 a End Cap 50 24 MID SECTION O 2 4 Apply Loctite Grade A 271 to threads of trim rod and install rod piston Tighten piston securely us ing spanner wrench 1 4 in x 5 16 in long peg Trim Rod Piston Spanner Wrench Install lubricated O ring to trim rod piston Install check ball components into its respective bore Secure components in place using plate and screws Torque screws to 35 Ib in 4 0 N m 51147 Screw 3 Plate O ring Ball 5 Seat Spring 5 Spring 5 90 817643R1 DECEMBER 1996 L Trim Rod Installation 4 Install trim rod into cylinder 1 Place trim cylinder in soft jawed vise 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron ll 3 Install lu
190. Special Lubricant 101 MID SECTION 5C 3 Power Trim Flow Diagrams Design Il TRIM e OIL UNDER PRESSURE RETURN OIL DEZ 4 ae 24 V T 51644 5C 4 MID SECTION 90 8i7643R1 DECEMBER 1996 Design Il TRIM DOWN RESERVOIR AND FEED OIL OIL UNDER PRESSURE 90 817643R1 DECEMBER 1996 MID SECTION 5C 5 Design Il EB HYDRAULIC TILT EJ RESERVOIR AND FEED OIL 21 OIL UNDER PRESSURE RETURN OIL 5C 6 MID SECTION 90 8i7643R1 DECEMBER 1996 Design Il MAXIMUM TRIM BLOW OFF C RESERVOIR AND FEED OIL p OIL UNDER PRESSURE B RETURN OIL 5555 x SE ETT SEELEY C yu 90 817643R1 DECEMBER 1996 MID SECTION 5C 7 EY Design Il SHOCK FUNCTION UP J RESERVOIR AND FEED OIL OIL UNDER PRESSURE RETURN OIL 5C 8 MID SECTION 90 8i7643R1 DECEMBER 1996 G Design ll ES SHOCK FUNCTION RETURN 90 817643R1 DECEMBER 1996 MID SECTION 5C 9 Design Il MANUAL TILT EY 90 8i7643R1 DECEMBER 1996 Troubleshooting Determining if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys tem is at fault Trouble Chart Outboard will not trim up or down Determine if Power Trim pump Outboard trims up will not trim motor operates when appro down E dd priate trim circuit is activated Outboard trims down will not trim up
191. Steering Arm 7B 22 OUTBOARD INSTALLATION ATTACHMENTS 2 Install tiller handle to studs with shift rod positioned thru cowl opening as shown 54256 a Tiller Handle b Shift Rod c Cowl d Bushing e Shift Handle f Washer g Cotter Key 3 Secure tiller handle assembly in place A a Tiller Handle Assembly b Tab Washer bend tabs against flats of locknuts c Locknuts Torque to 26 Ib ft 35 N m 90 817643R1 DECEMBER 1996 u 4 Install rubber grommet to throttle cable and install into bottom cowl Note a light lubricant on grommet will aid in installation over shift rod i 51093 Rubber Grommet Throttle Cable Shift Rod Adjust shift link rod and throttle cable Shift Link Rod Installation and Adjustment and Throttle Cable In stallation and Adjustment as required Wiring Harness Connection 1 Remove battery cables from battery 51084 90 817643R1 DECEMBER 1996 2 Route wiring harness thru rubber grommet Note light oil on rubber grommet will aid in wiring harness instal lation 51095 a Wiring Harness b Rubber Grommet 3 Connect handle wiring harness at engine harness con nector 51091 a Engine Harness Connector b Handle Harness Connector OUTBOARD INSTALLATION ATTACHMENTS 7B 23 4 Reconnect battery cables 7B 24 OUTBOARD INSTALLATION ATTACHMENTS 51084 Adjust co pilo
192. TBOARD INSTALLATION ATTACHMENTS N gt 0 a i Position remote control handle into neutral detent Manually shift outboard into neutral propeller will ro tate freely Route shift cable a thru control cable grommet b Adjust cable barrel c to attain the same length be tween cable barrel and hole in end of cable as exists between barrel receptacle d and shift actuator stud e keep a slight preload toward reverse Place end of shift cable on actuator stud e then place plastic washer f on stud and secure with locknut g 50564C 6 Check shift cable adjustment as follows a Shift remote control into forward gear Now check prop shaft the shaft should not be able to turn counterclockwise If it does adjust cable bar rel closer to cable end guide Shift remote control into neutral The prop shaft now should turn freely without drag If not adjust cable barrel away from cable end guide Repeat steps a and b Shift remote control into reverse as the prop shaft is rotated by hand The prop shaft should not be able to turn clockwise If it does adjust cable barrel away from cable end guide Repeat steps a thru c Shift remote control into neutral The prop shaft should turn freely without drag If not adjust cable barrel closer to cable end guide Repeat steps a thru d 90 817643R1 DECEMBER 1996 rottle Cable Installation and Adjustment to Engine Shift remote control into neutral Ro
193. TOP 55 60 SeaPro Marathon CARBURETOR CENTER CARBURETOR BOTTOM WME 44 CARBURETOR TOP 60 WME 45 CARBURETOR CENTER BEACHING PONTOON BIG FOOT CARBURETOR BOTTOM FORMULA MAGNUM SCREW throttle adjustment UPPER BOTTOM THROTTLE SHAFT UPPER THROTTLE SHAFT CENTER 50 60 THROTTLE SHAFT BOTTOM THROTTLE SHAFT UPPER BOTTOM THROTTLE SHAFT CENTER WME 44 SPRING throttle return VENT JET 090 50 60 IDLE NEEDLE SPRING idle needle GASKET cover plate COVER PLATE SCREW cover plate GASKET flange LEVER oil pump WME43 45 Bottom SCREW oil pump lever WME43 45 Bottom SCREW throttle valve THROTTLE VALVE RETAINING RING FLOAT SHAFT GASKET nozzle well GASKET fuel bowl INLET NEEDLE VALVE FLOAT SCREW fuel bowl FUEL BOWL UPPER FUEL BOWL CENTER BOTTOM PLUG KIT SEAL bowl drain MAIN FUEL JET 048 50 MAIN JET 060 55 60 SeaPro Marathon Pontoon MAIN FUEL JET 062 60 1 3 3 3 3 3 3 6 3 1 1 6 3 3 3 3 3 3 3 4 j N 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3A 7 Carburetion Fuel System Troubleshooting Troubles that are caused by items 1 thru 5 listed below may give the impression that a problem exists in the fuel system 1 Spark plugs Ignition spark voltage Cylinder compression Reed valves gt Ig
194. Teflon 92 825407A12 4 2 POWERHEAD 90 817643R1 DECEMBER 1996 Cylinder Block and Crankcase QTY DESCRIPTION Ib in Ib ft N m CYLINDER BLOCK SCREW SCREW CHECK VALVE HOSE 16 CHECK VALVE PRESS IN CARRIER ASSEMBLY CHECK VALVE ADJUSTING SCREW JAM NUT CAP DOWEL PIN LOCATING DOWEL PIN BEARING RACE COVER SCREW GASKET STUD PIPE PLUG SCREW SCREW 25MM Qty of 3 on 55 SCREW 55 Drive Tight POPPET VALVE DIAPHRAGM WASHER SCREW 50 60 Drive Tight SPRING SPRING 60 Pontoon Big Foot THERMOSTAT 120 GASKET cnm 8 6 1 1 1 2 2 1 1 1 1 3 1 2 1 2 4 6 4 1 1 90 817643R1 DECEMBER 1996 POWERHEAD 4 3 Cylinder Block and Crankcase Loctite 271 92 809820 Loctite PST Pipe Sealant 92 809822 12 Loctite Master Gasket 92 12564 2 2 4 C With Teflon 92 825407A12 4 4 POWERHEAD 90 817643R1 DECEMBER 1996 Cylinder Block and Crankcase S SENDER FITTING 50 60 COVER O RING SCREW LIFTING EYE SCREW 55MM Drive Tight 90 817643R1 DECEMBER 1996 POWERHEAD 4 5 Induction Manifold and Reed Block 2 Cycle Outboard Oil 92 13249A24 Perfect Seal 92 34227 1 4 6 POWERHEAD 90 817643R1 DECEMBER 1996 Induction Manifold and Reed Block QTY DESCRIPTION Ib in Ib ft N m GASKET LOWER END CAP ASSEMBL
195. Vent screw gas ket IMPORTANT Do not lose more than one fluid ounce 30cc of gear lubricant while reinstalling FILL screw 8 Remove lubricant tube from Fill hole install Fill screw and gasket Propeller Installation If gear housing is not removed from drive shaft housing before attempting to remove or install the propeller remove and isolate spark plug leads from spark plugs to prevent engine from starting accidentally 1 Apply a liberal coat of one of the following Quicksil ver products on propeller shaft splines Special Lubricant 101 P N 92 13872A1 2 4 C w Teflon 92 825407A12 Anti Corrosion Grease 92 19007A24 6B 32 LOWER UNIT cM 2 Install components as shown 51801 a Thrust Hub Flat Surface Toward Propeller b Propeller 3 Install tab washer and locknut 4 Thread locknut onto propeller shaft until locknut is recessed into tab washer Torque locknut to 55 Ibs ft 75 N m Bend 3 tabs of tab washer down into grooves to secure locknut If tab washer tabs do not align with slots continue to tighten locknut to obtain align ment pm A CAUTION Do not misinterpret propeller shaft movement with propeller movement If propeller and propeller shaft together move forward and aft this is normal however propeller should not move forward and aft on propeller shaft 7 Afterfirst use retighten propeller nut and again se cure with
196. Vz CH T aj cS a TEN Eh t 51092 Shift Link Rod End Actuator Bolt Washer Locknut Tighten until snug then back off 1 4 turn Check shift link rod adjustment as follows KR a Place shift lever in F forward position Propeller should rotate in a CLOCKWISE direction If pro peller does not rotate CLOCKWISE length of link rod must be reduced and step a repeated b Place shift lever in N neutral position Propeller should rotate freely without drag If not length of link rod must be increased and steps a and b must be increased c While rotating propeller place shift lever in R re verse position If propeller can rotate in either di rection length of link rod must be increased and steps a thru c repeated d Place engine shift lever in N neutral position Propeller should turn freely in both directions If not length of link rod must be decreased and steps thru d must be repeated OUTBOARD INSTALLATION ATTACHMENTS 7B 19 Throttle Cable Installation and Adjustment 1 Rotate throttle twist grip fully clockwise to stop IDLE position 2 Back out set screw from throttle cable barrel until two or three threads are exposed IKES 29502520920 51077 Set Screw b Throttle Cable Barrel 3 Place end of throttle cable guide over p
197. Y OIL SEAL OIL SEAL O RING SCREW BRACKET ASSEMBLY STUD WASHER WASHER WING NUT Hand Tight SCREW 220 18 5 25 0 INDUCTION MANIFOLD ELBOW Qty of 2 on 55 GASKET SCREW REED BLOCK ASSEMBLY GASKET REED SET 0 008 THICK REED SET 0 010 THICK TAB WASHER RETAINER SCREW SHIFT RAIL TAB WASHER SCREW SLIDE NYLINER NUT Drive Tight WASHER NUT Drive Tight l O OF 90 817643R1 DECEMBER 1996 POWERHEAD 4 7 Crankshaft Pistons and Connecting Rods 2 Cycle Outboard Oil 92 13249A24 2 4 C With Teflon 92 825407A12 4 8 POWERHEAD 90 817643R1 DECEMBER 1996 Crankshaft Pistons and Connecting Rods DESCRIPTION Ib in Ib ft N m CRANKSHAFT ASSEMBLY BALL BEARING RETAINING RING KEY DRIVER GEAR ROLLER BEARING ASSEMBLY TOP OIL SEAL ROLLER BEARING ASSEMBLY CENTER PISTON ASSEMBLY STANDARD PISTON ASSEMBLY 015 O S PISTON ASSEMBLY 030 O S LOCK RING PISTON RING STANDARD PISTON RING 015 O S PISTON RING 030 O S CONNECTING ROD ASSEMBLY WASHER NEEDLE BEARING SCREW 1st Torque 15 Ib in 1 5 N m 2nd Torque 1 4 Bolt 120 Ib in 13 5 N m an addi tional 1 4 turn 5 16 Bolt 27 Ib ft 36 5 ow NI S gt O NI O c N 4
198. a soapy water solution to rubber grip will ease installation 51603 a Ridges b Grooves Under Handle Tiller Handle Bushings 2 Stainless Steel Bushing Washers 2 Bolt om 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 17 3 Reinstall plug LT a Plug 4 Connect stop switch wire at bullet connector and se cure ground wire to handle with screw a Stop Switch Wire Bullet Connector 7B 18 OUTBOARD INSTALLATION ATTACHMENTS 51608 51608 5 Install Cover a b 6 o G O 51608 Cover Screw 4 Install cotter key and components to shift rod 54256 Tiller Handle Shift Rod Lower Cowl Bushing Shift Handle Washer Cotter Key 90 817643R1 DECEMBER 1996 cM 7 Install throttle cable with grommet 51093 a Rubber Grommet b Throttle Cable 8 Proceedto Shift Link Rod Installation and Adjustment to Engine and Throttle Cable Installation and Adjust ment 90 817643R1 DECEMBER 1996 Shift Link Rod Installation and Adjustment to Engine Position shift handle to neutral 2 Manually shift outboard shift actuator lever to neutral Propeller turns freely in both directions 3 Adjust shift link rod end to slip over shift actuator bolt with slight preload toward reverse Install washer and locknut Q Un a z i
199. accumulator base 4 During up stroke pull up on rod slowly 3 in 76mm from base 5 Wait until all air bubbles exit accumulator base 6 Slowly cycle unit 5 8 times round trip per cycle using short strokes 3 in 76mm from base allow ing bubbles to disappear during each stroke 90 817643R1 DECEMBER 1996 i 7 Allow unit to stand five minutes then proceed to 11 With cam lever remaining open facing down re cycle unit 2 3 more times using short strokes No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise Torque accumulator to 35 Ib ft 47 at this time N m 8 With oil level well above accumulator port slowly pull rod to full up position 9 Install accumulator making sure air bubbles do not enter system Manual Tilt System Installation 1 Apply Special Lubricant 101 to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivot pin hole and posi tion lower dowel pin retained in its hole 51148 a Lower Pivot Pin b Lower Dowel Pin 90 817643R1 DECEMBER 1996 MID SECTION 5F 35 3 Reinstall manual tilt system Reconnect release valve link rod 51144 a Manual Tilt System 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a Lower Pivot Pin 5 Using a punch drive lower dowel pin
200. ad to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 7 and 8 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 6 Point 3 and positive battery ter Depress Up trim button minal Check for loose or corroded con nections Check wires for open circuit Battery Voltage Indicated No Voltage Indicated Pump motor wiring is defective Relay Switch is defective Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 90 817643R1 DECEMBER 1996 MID SECTION 5C 19 Blown Fuse Correct problem that caused fuse to blow Replace fuse No Voltage Indicated Check battery leads for poor connections or open circuits Check battery charge No Voltage Indicated Check that voltage is being supplied to control by performing the following checks DO NOT start engine Turn ignition switch to Run po sition e Check for voltage at any instru ment using a Voltmeter No Voltage Indicated Red wire is open between Point 3 and red terminal on back of the ig nition switch Check for loose or corroded con nections C
201. ages by the closed manual tilt valve p Oil under pressure will enter the trim cyl inder below the memory piston t With an increasing amount of oil entering the cylinder the memory piston contacts the shock piston u and forces the piston rod a up and out raising the outboard motor Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and en ters the manifold passages The oil is drawn back into the pump j through the open down pressure oper ated valve f and enters the pump as supply for the up circuit 90 817643R1 DECEMBER 1996 MID SECTION 5E 7 a Up Pressure 1625 40 60 2800 75 125 min Ld a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port j Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 8 MID SECTION cM TILT CIRCUIT Reservoir Oil Filtered Feed Oil Return Oil Oil Under Pressure FTA anl s r p Impact Relief Pressure 22 880 1110 40 60 1220 1420 75 125 Tilt Relief P SN
202. ak ing care not to lose cam follower or 3 metal balls in end of propeller shaft 4 Remove propeller shaft from bearing carrier a Seals 13 Remove gasket MEN 51116 Bearing Carrier Puller Jaws 91 46086A1 Puller Bolt 91 85716 Thrust Hub Propeller Shaft a Gasket pm 90 817643R1 DECEMBER 1996 LOWER UNIT 6B 11 cM 5 Liftreverse gear thrust bearing and thrust washer bearing is rusted or does not roll freely replace from bearing carrier bearing Remove bearing and oil seals using 6 Replace reverse gear if gear teeth or clutch teeth Mandrel 91 36569 and Driver Rod 91 37323 Discard oil seals on reverse gear are chipped or worn If reverse gear must be replaced pinion gear and sliding clutch should be inspected for damage From Bearing Removal and Installation Kit 91 31229A5 7 Replace thrust bearing and thrust washer if rusted or damaged 51264 a Bearing 19202 b Mandrel 91 26569 c Driver Rod 91 37323 a Reverse Gear b Thrust Bearing 10 Remove if not removed with bearing in Step 9 c Thrust Washer propeller shaft seals and bearing carrier O ring 8 If bearing is rusted or does not roll freely replace bearing R
203. ake electrical connections as shown Bundle and secure stator adaptor harnesses and connections with sta straps as shown ELECTRICAL and IGNITION 2A 9 Q 3 Disconnecttrigger leads a from switch box b and re move trigger 4 ME 5 54981 Sw Electrical Plate Grommet Blue Lead of Stator Adaptor Stator Harness 51123 Black Ground Lead of Stator Adaptor Stator Adaptor INSTALLATION Sta Straps 1 Install trigger a and connect link arm b Trigger REMOVAL 1 Remove flywheel and stator refer to Flywheel and Stator removal preceding 2 Disconnect link arm a and remove trigger b 19459 19459 2 10 ELECTRICAL and IGNITION 90 817643R1 DECEMBER 1996 ax L 2 Connect trigger leads to switch box b refer to wir ing diagrams in Section 2D NS n 110 qL b 51123 3 Install stator refer to Stator Installation preceding 4 Install flywheel refer to Flywheel Installation preced ing Ignition Coils 1 Refer to wiring diagrams in Section 2D when connect ing wires _ 51124 Coils Cover Hex Nuts coat with Quicksilver Liquid Neoprene d Bolts torque to 20 Ib in 2 5 N m e Coil Tower Boots form a water tight seal between coil tower
204. all gasket drive key and impeller a Gasket b Drive Key c Impeller 10 Lubricate 1 0 of cover with Quicksilver 2 4 w Teflon 92 825407A12 11 Rotate drive shaft clockwise and push cover down over impeller 12 Install cover 13 If water tube seal stayed on water tube inside of drive shaft housing when gear housing was re moved pull water tube seal from water tube 14 Lubricate 1 0 of water tube seal with Quicksilver 2 4 C w Teflon 92 825407A12 and install as shown THe 19212 Cover Seal c Bolts 4 Apply Loctite 271 on Threads and Torque to 60 Ib in 6 5 N m NOTE It is recommended that the gearcase be pres sure tested for leaks after reassembly and BEFORE gear lube is added Gearcase should hold 10 to 12 psi for 5 minutes 90 817643R1 DECEMBER 1996 Gear Housing Pressure Test 1 Remove vent plug and install pressure test gauge 2 Pressurized housing to 10 to 12 psi and observe gauge for 5 minutes 3 Rotate drive shaft prop shaft and move shift shaft while housing is pressurized to check for leaks 4 lf pressure drop is noted immerse housing in wa ter 5 Re pressurize to 10 to 12 psi and check for air bubbles 6 Replace leaking seals as necessary Retest hous ing NOTE Gearcase should hold 10 to 12 psi for 5 min utes 7 Remove tester from housing and
205. alve block 7 Torque screw plug to 75 Ib in 8 5 a Q N b C d e 4S 51142 f a Spool 1 b Spring c O ring d Screw Plug 8 Install push rod ball spring lubricated O rings and screw plug transfer valve components in valve block 9 Install plunger ball spring small spring large in valve block Slow Trim Valve Assembly 10 Apply Loctite Pipe Sealant with Teflon 592 to threads of pipe plug design one and two style valve block 1 Install pipe plug or plug into valve block Tighten pipe plug if equipped securely nado 90 817643R1 DECEMBER 1996 51142 Plunger Ball Spring Small Spring Large O ring Plug Design 3 2 Torque screw plug to 75 Ib in 8 5 Push Rod 2 Ball 2 Spring 2 O ring 2 screw Plug 2 MID SECTION 5F 29 Valve Block Installation 1 Install lubricated O rings 51148 a O rings 2 2 Install valve block to shock rod cylinder Torque screws to 100 Ib in 11 5 N m 51146 a Screw 2 b Valve Block Shock Rod Cylinder 5F 30 MID SECTION EY 3 Install lubricated O ring 51145 Shock Rod Reassembly 1 Install lubricated O rings 2 Install rod wiper a Rod Wiper b Inner O ring c Outer O ring 90 817643R1 DECEMBER 1996 G 3 Install lubricated O ring 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5
206. ame screw at terminal block Check that other BLACK wire at terminal block is properly grounded Repair connections s as necessary then push key or choke but ton in If enrichener valve DOES NOT click replace valve Click Squeeze primer bulb until bulb is firm Remove lower hose from fit ting on enrichener valve Place a container under valve then push key or choke button Check for fuel flow from fitting No Voltage Indicated Check for open in YELLOW BLACK wire between key switch or choke button and terminal block Fuel Flow from Fitting Valve is O K Check hoses and fittings from valve to carburetors for leaks or obstructions No Fuel Flow from Fitting Remove upper hose from fitting on enrichener valve If fuel flows from hose replace valve If not check hose and carburetor fittings for leaks or obstructions 3C 2 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 FUEL SYSTEMS OIL INJECTION Table of Contents Operation of the Injection System Oil Injection System Oil Injection Flow System Fixed Ratio Oil s Pump Drive Assembly Fixed Ratio Oil ers Pump Drive System Fixed Ratio Oil Pump Oil Pump to Powerhead Assembly Fixed Ratio Oil Pump Oil Injection Flow System Variable Ratio Oil PUMP ARR ER Een eed Pump Drive Assembly Variable Ratio Oil Pump
207. an one full turn 2 Route starter rope thru rope guide in housing Tie a overhand knot in rope approximately 12 in 305 mm from end of rope a Rotate Counterclockwise and Back Off at Laest One Full Turn b Tie Off Starter Rope 12 Inches 305 mm from End with Overhand Knot 90 817643R1 DECEMBER 1996 NOTE Check operation of rewind and rewind tension be fore outboard installation 3 Place rewind starter on engine 4 Pull starter rope thru bracket handle and starter rope retainer Secure starter rope to starter rope retainer with knot a Starter Rope b Bracket c Handle d Starter Rope Retainer 5 Secure rewind starter to engine bolts 4 torque to 90 Ib in 10 N m Secure interlock lock cable with retaining clip and screw AE BO Retaining Clip Screw Bolts 4 Torque to 90 Ib in 10 N m Bracket 90 817643R1 DECEMBER 1996 Starter Interlock Cable Adjustment IMPORTANT Lubricate core wire of interlock cable with light oil prior to making adjustments 1 While rotating the propeller shaft place the gear shift lever into REVERSE 2 Return the gear shift lever to NEUTRAL without going past neutral detent 3 Place end of interlock cable over pin of cam lever and secure with retaining pin 4 Secure interlock cable to starter housing using adjust ing screw Do not tighted screw at this time 5 Adjustinterlock cable to align raised mark
208. and Inspection of Trim Rod Components 5D 20 Motor and Electrical Tests Repair 5D 20 Trim Pump Motor Test 5D 20 Armature Tests 5D 20 Test for Shorts 5D 20 Test for Ground 5D 20 Checking and Cleaning Commutator 5D 21 Power Trim System Reassembly 5D 21 Manifold Installation 5D 21 Trim Motor Reassembly 5D 22 Reservoir Installation 5D 23 Trim Rod Reassembly 5D 24 Trim Rod Installation 5D 25 Purging Power Trim Unit 5D 26 Power Trim Unit Installation 5D 26 90 817643R1 DECEMBER 1996 x f Special Tools Description Torch Lamp 91 63209 Spanner Wrench 91 74951 Multi Meter DVA Tester 91 99750 Quicksilver Lubricants and Service Aids Description Power Trim and Steering Fluid 91 9010012 Loctite 271 91 32609 1 Liquid Neoprene 91 25711 1 Anti Corrosion Grease 91 78376A6 Power Trim General Information Description The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or trim panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be tri
209. and make sure they are properly seated in piston grooves PE 51086 a Lockring Installation Tool 91 77109A1 b Lockring 2 5 51086 NOTE Shaft of Lockring Installation 91 77109A1 must be modified shortened to 1 050 in 26 7 mm 1 050 in 26 7 mm 4 28 POWERHEAD PAS Piston Ring Installation IMPORTANT Piston ring side with letter or mark must be facing up Piston Ring Piston rings are TAPERED top side and flat rectangular on the bottom side half keystone rings Note that top ring is chromed and bottom ring is steel Enlarged View of Piston Ring Grooves ACAUTION Care must be taken not to scratch the side surfaces of ring groove Scratching this area will damage the ring groove 90 817643R1 DECEMBER 1996 1 Install piston ring in appropriate groove on piston using Piston Ring Expander Tool Spread rings just enough to slip over piston Top Groove Chromed Ring Bottom Groove Steel Ring 2 Check piston rings to be sure they fit freely in groove Lubricate rings and cylinder wall with 2 cycle oil PE 51081 a Piston Ring Expander b Piston Rings 3 Align piston ring end gaps with ring locating pins as shown Check locating pins making sure they are tight PE 51082 a Locating Pin b Piston Rings 90 817643R1 DECEMBER 1996 4 Remove connecting rod cap from connecting rod be ing installed 5 Install each piston with UP
210. angle trim ad justment pin relocation 1 Will help planing off particularly with a heavy load 2 Usually improves ride in choppy water 3 In excess can cause boat to veer to the left or right bow steer 4 Transfers steering torque harder to right or less to the left on single outboard installations 5 Improves planing speed acceleration GENERAL INFORMATION and SPECIFICATIONS 1 11 Trim Tab Adjustment 1 Check trim tab position as follows a Operate boat at the speed at which it would nor mally be operated b 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 2 If necessary adjust trim tab as follows a Shift outboard control into neutral and turn ignition key to Off position b Loosen bolt c and trim tab b If boat pulls to the left adjust trailing edge of trim tab to the left If boat pulls to the right adjusttrailing edge of trim tab to the right d Tighten trim tab bolt securely e Operate boat per Check trim tab position as follows to check trim tab setting If necessary readjust trim tab 50553 a Anti Ventilation Plate b Adjustable Trim Tab c Bolt 1 12 GENERAL INFORMATION and SPECIFICATIONS Boat Performance TEST INSTRUCTIONS AWARNING A tight grip on the steering wheel tiller handle is always a
211. ant overheating and damage to engine from lack of water In preparing an outboard for out of season storage 2 pre cautions must be considered 1 The engine must be pro tected from physical damage and 2 the engine must be protected from rust corrosion and dirt 1 Remove cowling from engine 2 Place outboard in water or install Quicksilver Flushing Attachment over water intake by following instructions outlined in Flushing Cooling System see Table of Contents 3 Start engine and allow to warm up Disconnect fuel line When engine starts to stall quickly spray Quicksil ver Storage Seal into each carburetor throat Continue to spray until engine dies from lack of fuel 4 Remove spark plugs and inject a 5 second spray of Quicksilver Storage Seal around the inside of each cyl inder Manually turn engine over several times to dis tribute Storage Seal throughout cylinders Reinstall spark plugs 5 f engine fuel filter appears to be contaminated re move and replace Refer to Section 3 Fuel System and Carburetion 6 Drain and refill lower unit with Quicksilver Gear Lube as explained in Gear Housing Lubrication see Table of Contents 7 Clean outboard thoroughly including all accessible powerhead parts and spray with Corrosion and Rust Preventive 8 Refer to lubrication chart in this section see Table of Contents and lubricate all lubrication points 9 Removepropeller Apply Quicksilver Special
212. ard 51509 a Mounting Bolts 4 b Flat Washers 4 c Locknuts 4 d Transom Clamp Retainers With Mounting Hardware e Shims Transom Clamp Retainers If Required a Tighten Transom Clamp Handels b Part Number 812433 C1 Fasten outboard to boat transom following installation A or c Part Number 812432 C1 B shown below d Transom Clamp Retainers Opitional Installation A Installation A Use for permanent installation Fastening outboard for permanent installation Drill four 1 2 in 12 5mm holes and fasten outboard to boat transom 51489 Bolts 4 Flat Washers 4 Locknuts 4 Marine Sealer a Tighten Transom Clamp Handles b Mounting Bolts Supplied with Outboard 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7A 3 Installation B Retainers installed Fastening outboard for easy removal and installation Mark hole location 51394 51393 Drill four 3 8 in 9 5mm holes and fasten transom clamp retainers to transom Add shims if necessary to allow for a small amount of clearance between transom clamps and retainers 51395 Bolts 4 Flat Washers 4 Locknuts 4 Marine Sealer Transom Clamp Retainers 2 Shims 4 Transom Clamp 7 4 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 utboard installed 51462 a Tighten transom clamp handles Retighten every 1 2 ho
213. ard Steering Arm or Steering Arm Bracket Clevis Kit Ride Guide Cable Attaching Locknut Torque to 10 Ib ft 13 5 N m Bolt 3 8 in x 2 1 2 in Flat Washer Transom Bracket Figure 1 Installing Attaching Kit 90 817643R1 DECEMBER 1996 Place Ride Guide yoke on pivot block and secure with 7 16 in x 1 3 4 in bolt and locknut as shown in Figures 1 and 2 Torque locknut to 10 Ib ft 13 5 N m then back off 1 4 turn Install one cable tube jam nut onto steering cable tube Place tab washer over Ride Guide yoke then insert cable tube thru tab washer and yoke Install second cable tube jam nut onto cable tube but do not tighten at this time Figure 3 Position transom attaching kit on transom as follows a Determine centerline of outboard then measure 15 38 1cm over from this centerline and draw a vertical line on transom Figure 1 b Position attaching kit on transom so that transom bracket is centered on the 15 in line Figure 1 at a height where the center of Ride Guide yoke is even with or not more than 1 2 in 12 8mm above top edge of transom Figure 3 Transom Backing Plate Bolt 5 16 in x 3 1 4 in Locknut Torque to 10 Ib ft Ride Guide Yoke Attaching Locknut Torque to 10 Ib ft Then Back Off 1 4 Turn 2 3 8 in Maximum Transom Thickness Bolt 7 16 in x 1 3 4 in Ride Guide Yoke igure 2 Installing Attaching Kit OUTBOARD INSTALLATION ATTACHMENTS 7A
214. ase to the fuel pump When the piston travels upward a vacuum is created in the crankcase This vacuum pulls in the fuel pump diaphragm the inlet check valve in fuel pump is opened and and fuel is drawn into fuel pump Downward motion of the piston forces out the fuel pump di aphragm closes the inlet check valve to keep fuel from re turning to fuel tank and opens the outlet check valve forc ing fuel to the carburetors 3B 6 FUEL SYSTEMS e CHECKING FOR RESTRICTED FUEL FLOW CAUSED BY ANTI SIPHON VALVES While anti siphon valves are helpful from a safety stand point they clog they may be too small or they may have too heavy a spring The pressure drop occures these valves can create operational problems and or powerhead damage by restricting flow of fuel Some symptoms of re stricted lean fuel flow are 1 Loss of fuel pump pressure 2 Loss of power 3 High speed surging 4 Preignition detonation piston dome erosion 5 Outboard hesitates upon acceleration 6 Outboard runs rough 7 Outboard quits and cannot be restarted 8 Outboard will not start 9 Vapor lock Any type of anti siphon device must be located between the outboard fuel inlet and fuel tank outlet A method of checking if such a device or bad fuel is a problem source is to operate the outboard with a separate fuel supply which is known to be good If it is found that the anti siphon valve is the cause of the problem either 1 replace
215. assages oil will slide the shuttle valve m into the up circuit pressure oper ated valve n The shuttle valve will mechanically open the up circuit pressure operated valve and allow oil from the up cavity of the trim cylinder w to return into the oil pump This returning oil from the up cavity will supply the oil required for the down circuit The oil is blocked from returning into the reservoir by the ball inside the up circuit suction port i Oil under pres sure opens the down pressure operated valve f and enters the down passages inside of the manifold q The manifold passage connects into the trim cylinder passage leading to the top of the cylinder The cavity inside the cylinder above the shock piston u is the down cavity As the down cavity fills with oil the piston rod a retracts into the cylinder lowering the out board motor Oil from the up cavity exits in the cylinder and is drawn back into the pump through the open up pressure operated valve n When the piston rod reaches full travel the oil pressure inside the down circuit will rise until the down pressure relief valve e opens bypassing oil back into the reservoir When the trim button is released and the oil pump stops supplying pressure both of the pressure operated valves f amp n will close and if open the down pres sure regulating valve e will close The closed valves will lock the fluid on either side of the shock piston u amp memory
216. assembly Actual O ring Sizes O ring Description and Sizes Page Manual Tilt System Cleaning and Inspection 5G 27 Manual Tilt System Reassembly 5G 27 Cam Shaft Reassembly 5G 27 Valve Body Check Reassembly 5G 27 Velocity Valve Reassembly 5G 27 Check Retainer Reassembly 5G 28 Valve Plug Reassembly 5G 28 Valve Block Installation 5G 28 Shock Rod Reassembly 5G 29 Shock Rod Installation and Fluid Filling Procedure 5G 30 Instructions for Making Retaining Tool 5G 32 Bleeding Manual Tilt System 5G 33 Manual Tilt System Installation 5G 35 Manual Release Valve Adjustment 5G 36 90 817643R1 DECEMBER 1996 om Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 LOCK RING PLIERS 90 817643R1 DECEMBER 1996 MID SECTION 5G 1 MANUAL TILT COMPONENTS B 7 Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all O rings be replaced when servicing tilt system
217. at Level 9 16 in 14 3mm Fuel Pump Pressure W O T 4 7 PSI 28 43 kPa 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3A 1 Attenuator Plate 3A 2 FUEL SYSTEMS Q 7 Ni Qu S Q E 4 Y 222 90 817643R1 DECEMBER 1996 Attenuator Plate DESCRIPTION Ib in Ib ft N m SOUND ATTENUATOR SCREW Drive Tight CAP PLUG SEAL SOUND ATTENUATOR PLATE SCREW ARM ROLLER SCREW Drive Tight WASHER TUBING 4 1 4 IN STA STRAP GASKET THROTTLE LINK 1 2 3 4 5 6 7 8 rm oln oo gt Co h 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3A 3 WME Carburetor Specifications Carburetor Number Stamped at TOP of Carburetor Mounting Flange Carburetor Number Model Bowl Vent Jet Top Carburetor Center Carburetor Bottom Carburetor Top Carburetor Center Carburetor Bottom Carburetor Top Carburetor Center Carburetor Bottom Carburetor REED VALVE SPECIFICATIONS Reed Valve Opening Maximum 020 in 0 5 mm 3A 4 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 Notes 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3A 5 Carburetor Loctite 271 92 809820 Loctite 7649 Primer 92 809824 3A 6 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 Carburetor QTY DESCRIPTION in Ib ft N m CARBURETOR TOP CARBURETOR CENTER 50 WME 43 CARBURETOR BOTTOM CARBURETOR
218. ave not been properly cleaned or which are questionable can severely damage an other wise perfectly good powerhead within a few minutes of op eration All new powerhead gaskets must be installed dur ing assembly During reassembly lubricate parts with Quicksilver 2 Cycle Outboard Oil whenever 2 cycle oil is specified and Quicksilver 2 4 C Marine Lubricant whenever grease is specified Atorque wrench is essential for correct reassembly of pow erhead Do not attempt to reassemble powerhead without using a torque wrench End Cap 1 Clean thoroughly including seal and O ring seats re move Perfect Seal residue and clean cap to head mat ing surface 2 Using suitable mandrel press oil seals into cap until fully seated NOTE Lip of smaller seal faces away from powerhead Lip of larger seal faces towards powerhead 3 Lubricate oil seal lips with 2 cycle oil 4 Lubricate O ring seal with 2 cycle oil and install in groove 5 Apply Perfect Seal to flange of end cap Lip of Larger Seal Lip on Bottom of Smaller Seal PE 51088 a 2 Cycle Oil b Perfect Seal 4 26 POWERHEAD c CAUTION Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline soluble Use only Quicksilver Needle Bearing Assembly Lubricant DO NOT use 2 4 C Marine Lubricant or other lubricants inside the powerhead or damage may occur Assembling Rod to Piston ACAUTION Never intermix new needle bearings with used ne
219. b Lone D a a End Cap b O rings 2 c Wiper Ring 1 Place shock rod assembly on clean work surface 2 Remove three 3 screws and remove plate from shock rod piston 51143 a Screw 3 b Plate c Shock Rod Piston 5G 20 MID SECTION 3 Remove check ball components from shock piston 4 Remove O ring 2 51147 Springs 5 Seats 5 Balls 5 O ring 90 817643R1 DECEMBER 1996 x CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to shock piston 5 Place shock rod in soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 Loosen shock rod piston using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs Allow shock rod piston to cool Remove from shock rod 51146 a Spanner Wrench b Shock Rod Piston 8 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly Clean shock and components with compressed air 90 817643R1 DECEMBER 1996 10 Remove inner O ring 51199 a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock If wiper located in cap has failed to keep rod clean replace wiper 13 Place end cap on clean work surface 14 Remove rod wiper inner O ring and outer O
220. b ft 136 N m 6 Install flywheel cover 2A 8 ELECTRICAL and IGNITION BLACK and RED Stator cM REMOVAL 1 Remove flywheel refer to Flywheel Removal 2 Remove screws a a Stator Leads to Switch Box 2 b Yellow Leads to Rectifier 2 c Ground Lead 1 90 817643R1 DECEMBER 1996 BLACK STATOR INSTALLATION 1 Install stator as shown a Screws apply Loctite 271 on Threads unless Patch Screw used and torque to 60 Ibs 7 0 b Stator 2 Connect stator leads refer to wiring diagrams in Sec tion 2D a Stator Leads to Switch Box 2 b Yellow Leads to Rectifier 2 c Ground Lead 1 90 817643R1 DECEMBER 1996 51124 RED STATOR INSTALLATION IMPORTANT The stator must be oriented as shown to obtain correct system voltage 1 Position red stator so appropriate arrow decal points aft Secure stator with four 4 attaching screws re tained from disassembly Apply Loctite 222 to threads and torque to 60 Ib in 7 0 FORWARD 54067 Orient Appropriate Arrow of Decal Aft Apply Loctite 222 obtain locally To Screws 4 and Torque to 60 in 7 0 N m Stator Harness Route stator harness thru top of electrical plate grommet as shown Secure to powerhead with sta strap Position stator adaptor in cavity of electrical plate with blue lead toward top of engine Refer to electrical diagram and m
221. ber ring 2 Apply a light coat of Loctite 271 on outside diameter of rubber ring a 19152 a Ring Insert sleeve into holder Component of Wear Sleeve Installation Tool 91 14310A1 19169 a Sleeve b Holder 90 817643R1 DECEMBER 1996 4 Press sleeve onto drive shaft using Wear Sleeve Installation Tool 91 14310A1 continue pressing until surface contacts surface _ b 19166 a Drive Shaft b Wear Sleeve Installation Tool c Surface d Surface 5 Remove excess Loctite from assembled shaft 90 817643R1 DECEMBER 1996 Lower Drive Shaft Bearing Race Installation IMPORTANT Lower drive shaft bearing cup can be installed with or without upper drive shaft bear ing sleeve and oil sleeve installed 1 Lubricate O D of bearing race with Quicksilver 2 4 w Teflon 2 Install shim s and bearing race into housing NOTE Verify shim s are not cocked when drawing up race III a Shim s Retained From Disassembly If Shim s Were Lost or a New Gear Housing is Being Assembled Start With 0 025 0 635mm Shim s Bearing Race Mandrel Mandrel Threaded Rod 91 31229 Nut 11 24156 From Bearing Installation Tool 91 14309A1 From Bearing Removal and Installation Kit 91 31229A5 LOWER UNIT 6
222. blies from crankshaft 6 Remove crankcase cover bolts Crankshaft Disassembly PE 51085 Bolts 14 Lower End Cap a b 7 Remove crankcase cover from cylinder block 8 Remove end cap PE 51085 Roller Bearing Race Roller Bearing Retaining Ring Remove 2 bolts from each rod cap Keep components with respective connecting rod IMPORTANT DO NOT reuse connecting rod bolts PE 51087 Crankcase Cover Removed 9 Remove crankshaft assembly PE 51080 a Bolts use 5 16 in 12 point socket or 1 4 12 point socket PE 51085 Crankshaft Assembly Removed 4 18 POWERHEAD 90 817643R1 DECEMBER 1996 3 Remove connecting rod piston assembly from crank 6 Remove piston rings Always install new piston rings shaft re attach caps to respective rod as each is re moved CAPS MUST BE INSTALLED IN SAME DI RECTION ON SAME ROD or mating surface will not seat properly 4 Remove main bearing sealing rings PE 51081 a Piston Ring Expander p n 91 24697 b Piston Rings NOTE Cylinders must be honed for rings to seat properly ACAUTION Safety glasses should be worn when removing or in PE 51083 stalling locking rings 7 Remove piston pin lock rings using awl Always install 5 Scribe with awl identification number cylinder 1 2 new lock rings and 3 on inside of piston and connecting rod in order to reassemble piston to same connecting rod PE 51081
223. boat performance written by marine engineers see your Au thorized Dealer for the illustrated What You Should Know About Quicksilver Propellers and Boat Performance In formation Part No 90 86144 How To Use This Manual The manualis divided into SECTIONS shown right which represents major components and systems Some SECTIONS are further divided into PARTS Each PART has atitle page A Table of Contents for the particu lar PART is printed on the back of the title page SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately follows the cover of this book Section Section Heading General Information and Specifications Electrical amp Ignition Fuel Systems Powerhead Mid Section Lower Unit Outboard Installation Attachments OI gt Q N Page Numbering Two number groups appear at the bottom of each page The example below is self explanatory EXAMPLE 90 817643R2 DECEMBER 1996 Revision No 2 Month of Printing Year of Printing 90 817643R1 DECEMBER 1996 Section Description Section Number Part of Section Letter Page Number LOWER UNIT 6A 7 GENERAL INFORMATION and SPECIFICATIONS 1 1 Master Specifications Model 45 Jet 50 55 Marathon Seapro 60 60 Marathon Seapro 60 Bigfoot HORSEPOWER Model 50 KW Model 55 Model 60 Model 45 Jet OUTBOARD Electric Start ELPTO WEIGHT ELO Manual Start ML CYLINDER Type
224. bon deposits from exhaust ports Inspect spark plug holes for stripped or damaged threads 90 817643R1 DECEMBER 1996 ACAUTION If crankcase cover and cylinder block is to be sub merged in a very strong cleaning solution it will be necessary to remove the crankcase cover cylinder block bleed system from cover cylinder block to pre vent damage to hoses and check valves CYLINDER BORE SIZE PISTON SIZE CYL BLOCK FINISH HONE Standard Diameter 2 955 in 75 057 mm 2 970 in 75 438 mm 2 985 in 75 819 mm 015 Oversize 030 Oversize e Inspect cylinder bores for scoring a transfer of alumi num from piston to cylinder wall Cylinder wall scor ing usually can be cleaned up by honing or rebor ing ACAUTION When reboring cylinder block remove hone frequent ly and check condition of cylinder walls DO NOT hone any more than absolutely necessary as hone can re move cylinder wall material rapidly HONING PROCEDURE Follow hone manufacture s recommendations for use of hone cleaning and lubrication during honing IMPORTANT After honing bores should be thorough ly cleaned with hot water and detergent Scrub well with stiff bristle brush and rinse with hot water If any abrasive material is allowed to remain in the cylinder bore it will cause a rapid wear of new piston rings and cylinder bore After cleaning bores should be swabbed several times with 2 cycle engine oil and a clean cloth Wipe
225. bricated O ring to memory piston and place into cylinder Push piston down to level of oil Memory piston must not contact end cap during trim rod end cap installation 51196 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs 51144 a O ring b Memory Piston 51145 a Spanner Wrench P N 91 74951 6 Tighten manual release valve snuggly following end cap installation 90 817643R1 DECEMBER 1996 MID SECTION 5D 25 c Purging Power Trim Unit Power Trim Unit Installation Manual release valve must be in full closed posi 1 Apply Special Lubricant 101 92 13872A1 to tion during power trim purging and operation lower pivot pin bore and pivot pin surface 1 Secure power trim unit in soft jawed vise 2 Start lower pivot pin into pivot pin bore and posi 2 Remove fill cap a Add Quicksilver Power Trim Gross PIM RE TANE DINIS FS paella and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF F FA or Dexron II up to threads of reservoir Install cap N NN 2 0 c3 W Au 48 a a 51148 Lower Pivot Pin Lower Dowel Pin 3 Position trim cylinder assembly BOTTOM FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket 3 Using a 12 volt power supply connect positive lead to green wire negative lead to blue wire and drive trim r
226. brication at initial installa lion 90 817643R1 DECEMBER 1996 1 Lubricate inside of outboard tilt tube a and steering cable end b with Quicksilver 2 4 C w Teflon Marine Lubricant 2 nsertsteering cable end thru outboard tilt tube and se cure with steering cable attaching nut c Torque to 35 Ib ft 41 N m 3 Make pencil mark a on tilt tube 1 4 in 6 4mm from starboard end of tube Slide spacer b O ring c and cap d over steering cable end AS jani Y 6 4mm 4 Thread cap d onto tilt tube up to mark a Installing Steering Link Rod AWARNING Steering link rod MUST BE secured between outboard steering arm bracket and steering cable end using a special washer head bolt spacer and nylon locknuts as shown Both special washer head bolt and locknuts MUST BE tightened as specified OUTBOARD INSTALLATION ATTACHMENTS 7A 7 Lubricate hole in end of cable with Quicksilver 2 4 C w Te flon Marine Lubricant Assemble steering link rod to steer ing cable end using 2 flat washers and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 13 5 N m of torque then back off 1 4 turn Lubricate ball joint in steering link rod with SAE 30W motor oil Secure link rod to outboard steering arm inner hole us ing special washer head bolt and nylon insert locknut as shown Torque bolt to 20 Ib ft 27 N m then torque nut to 20 Ib ft 27 N m MODELS WITH O
227. by carefully running fingernails up and down edge of rod cap If not aligned a ridge can be seen or felt at the separating line Correct any misalignment Front View Front View Correct Incorrect Side View Side View Side View Correct Incorrect Incorrect PE 51224 2 When connecting rods are attached and bolts drawn down finger tight torque rod cap bolts to 15 Ib in 1 7 N m Recheck alignment Re torque 1 4 in bolts to 120 Ib in 13 5 N m and then turn additional 1 4 turn or 5 16 in bolts to 27 Ib ft 36 5 N m Recheck alignment 4 32 POWERHEAD c Crankcase Cover to Block 1 Install upper seal to crankshaft PE 51243 a Oil Seal Lubricate Inside with 2 cycle oil 2 Apply LOCTITE MASTER GASKET SEALANT to clean block surface Instructions in kit must be followed exactly IMPORTANT Extend sealer to edge on each center main journal to prevent blow by between cylinders m a PE 51087 Sealant Bead Pattern Indicated by Bold Line Above 90 817643R1 DECEMBER 1996 2 f 3 Install end cap assembly lubricate seals with 2 cycle 5 Insert clean bolts note 2 sizes and finger tighten 22 6 Torque bolts to 18 Ib ft 24 5 N m following sequence shown below PE 51088 3 13 PE 51085 NOTE Inspect all hoses on reinstallation Replace if nec PE 51084
228. checking the ignition system without a Multi Meter DVA Tester 91 99750 or a voltmeter capable of measuring 400 volts DC or higher and Direct Voltage Adaptor 91 89045 as the switch box and ignition coils cannot be thoroughly checked with conventional test equipment All other components can be tested with an ohmmeter Be fore troubleshooting the ignition system check the follow ing 1 Make sure that electrical harness and ignition switch are not the source of the problem 2 Check that plug in connectors are fully engaged and terminals are free of corrosion 3 Make sure that wire connections are tight and free of corrosion 4 Checkallelectrical components that are grounded di rectly to engine and all ground wires to see that they are grounded to engine 5 Checkfor disconnected wires and short and open cir cuits STATOR TEST NOTE Stator can be tested without removing from engine 1 Disconnect stator leads from switch box 2 Use ohmmeter and perform the following tests IMPORTANT If stator is mounted on engine black sta tor lead must be grounded to powerhead when testing Connect test lead to black stator lead if stator is re moved from engine NOTE Readings are for a cold engine room temperature Resistance will increase slightly if engine is warm 3 If meter readings are other than specified replace sta tor assembly 2A 4 ELECTRICAL and IGNITION 55 60 MARATHON SEAPRO 3
229. cing fluid thru internal passageways into the up side of the trim cylinder The trim cylinder trim ram will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine RPM increases above 2000 RPM the thrust created by the propeller if deep enough in the water will cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering conditions Each boat should be tested for handling charac teristics after any adjustment is made to the tilt angle tilt bolt relocation Will help planing off particularly with a heavy load Usually improves ride in choppy water In excess can cause boat to veer to the left or right bow steer Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt bolt one hole closer to transom MID SECTION 5D 1 Operating Down circuit will actuate the down relay located under engine cowl and close the electric motor circuit motor will run in o
230. clamp bracket and remove assembly 51144 a Manual Tilt System 5G 18 MID SECTION Manual Tilt System Disassembly NOTE Accumulator contains a high pressure nitro gen charge and is NOT SERVICEABLE Replace if necessary This tilt system is pressurized Remove accumu lator only when shock rod is in full up position Accumulator Removal Place manual tilt system in soft jawed vise Position shock rod to full up position Open cam shaft valve Down Position Te ue Loosen surge valve enough to drip wait until drip ping stops 5 When fluid stops dripping loosen and remove ac cumulator a Accumulator 51143 b Cam Lever c Velocity Plug 90 817643R1 DECEMBER 1996 i plunger can be compressed into accumulator by hand accumulator is defective Replace accu mulator 51143 a Plunger 7 Once accumulator is removed remove O ring conical spring steel ball and plunger 51145 a Conical Spring b Steel Ball c Plunger d O ring 90 817643R1 DECEMBER 1996 Shock Rod Removal 1 Unscrew cylinder end cap assembly using span ner wrench 1 4 in x 5 16 in long pegs 51145 2 Remove shock rod assembly from cylinder MID SECTION 5G 19 Shock Rod Disassembly NOTE The only serviceable items on the shock rod assembly are the O rings and wiper ring If shock rod requires any other repair replace shock rod assem bly f
231. cowl and close the elec tric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump thus forcing automatic fluid thru internal pas sageways into the down side of the tilt ram The tilt ram will move the engine downward to the desired angle MID SECTION 5B 1 Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running While operating up circuit tilt ram will continue to tilt outboard to full up position for trailering Tilting Outboard Up and Down Manually Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns counterclockwise lt 50146 Manual Release Valve 5B 2 MID SECTION c Trim In Angle Adjustment Operating some boats with engine trimmed to the full in trim angle not using trim adjustment pin a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after en gine installation and after any trim adjustments
232. ction Components Transom Bracket Components 50 60 Models Transom Bracket Grease Fitting Pin Transom Bracket Tilt Lock Lever Spring Bushing Spring Lever 10 Roll Pin 11 Washer 2 12 Bracket 13 Anode Plate 14 Bolt 2 15 Washer 2 16 Bolt 5 30mm 1 85mm 17 Lockwasher 2 18 Lock Nut 2 19 Pin 20 Tilt Tube 21 Lock Nut 2 22 Spacer 23 O ring 24 Cap 25 Clamp 26 Washer 27 Screw 28 Bolt 4 29 Washer 4 30 Nut 4 Non Power Trim 31 Link 32 Tilt Lever 33 Bushing 34 Washer 35 Wave Washer 36 Knob 37 Bolt 38 Nut 39 Bolt Lubrication Sealant Application Torque Specifications Poin oints 60 lb in 7 0 N m 2 4 C w Teflon Marine Lubricant 92 9001 8A12 25 lb ft 34 0 N m 90 817643R1 DECEMBER 1996 MID SECTION 5A 3 Mid Section Components Drive Shaft Housing Components Drive shaft Housing Seal Bolt 4 Exhaust Tube Gasket Pin Exhaust Plate Bolt Lock Nut 2 10 Washer 2 11 Washer 2 12 Bolt 4 13 Mount 14 Bolt 2 15 Pin 4 16 Bushing 17 Coupling 18 Spacer 19 Lock Nut 20 Washer 21 Wave Washer 22 Shift Link 23 Bushing 24 Shift Shaft 25 Seal 26 Clamp 27 Bolt 2 28 Water Tube 29 Seal 30 Bolt 2 31 Ground Strap 32 Bolt 4 33 Cover 2 34 Screw 4 35 Nut 4
233. d Components 5B 28 Motor and Electrical Tests Repair 5B 29 Trim Pump Motor Test 5B 29 Thermal Overload Switch Test 5B 29 Motor Assembled 5B 29 Motor Disassembled 5B 29 Armature Tests 5 30 Test for Shorts 5B 30 Test Tor Ground 5B 30 Checking and Cleaning Commutator 5B 30 Power Trim System Reassembly 5B 30 Manifold Installation 5B 30 Oil Pump Installation 5B 31 Trim Motor Reassembly 5B 32 Reservoir Installation 5B 33 Trim Rod Re assembly 5B 35 Trim Rod Installation 5B 36 Bleeding Power Trim Unit 5B 37 Power Trim Unit Installation 5B 37 90 817643R1 DECEMBER 1996 p Power Trim General Information Description The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or trim panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Trimming Characteristics NOTE Because varying hull designs react differently in var
234. d be installed when rebuilding a fuel pump 3B 10 FUEL SYSTEMS NOTE In fuel pump reassembly remember that respec tive diaphragms go against the mating surfaces of the fuel pump body and respective gaskets are between the dia phragms and end caps Gaskets should always be re placed on fuel pump during reassembly Fuel Pump Body Reverse Angle View 1 Ao 50569 90 817643R1 DECEMBER 1996 Q Fuel Tank Fuel Tank Components Maintenance The inside of the fuel tank should be cleaned once each season Dirt or water may have entered the fuel tank during refilling Clean the tank by flushing with clean lead free gasoline or kerosene If a fuel restriction problem is encountered the fuel filter on end of outlet tube may be obstructed Remove cover and inspect filter for varnish dirt or deposits Clean filter by rins ing in clean lead free gasoline or kerosene Fuel Tank Filter Pick Up Tube Cover Gasket FUEL TANK ASSEMBLY PLASTIC 6 6 GAL FILLER CAP GASKET filler cap PICK UP BODY ASSEMBLY ADAPTOR WINDOW ASSEMBLY GASKET pick up body FUEL GAUGE ASSEMBLY SCREW gauge HOSE FILTER SCREW pick up body WASHER pick up body screw G er a MH aaa anni 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3B 11 Fuel Line and Primer Bulb Assembly FUEL LINE ASSEMBLY PRIMER BULB ASSEMBLY CHECK VALVE inlet FITTING outlet CLAMP primer bulb to check
235. d con nections Check for pinched or severed wires Battery Voltage Indicated There is an open circuit in wire be tween Point 5 and Red terminal on the back of the ignition switch 90 817643R1 DECEMBER 1996 Q Power Trim System Removal Support outboard with tilt lock lever when servicing power trim system 1 Disconnect power trim harness from outboard wiring harness 2 Remove screw and clip securing wiring harness to clamp bracket 3 Use suitable tool to remove DRIVE DOWN up per dowel pin Retain dowel pin 51144 a Dowel Pin 4 Use suitable punch to drive out upper pivot pin a Pivot Pin 90 817643R1 DECEMBER 1996 5 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a Dowel Pin 6 Use suitable punch to drive out lower pivot pin a Pivot Pin MID SECTION 5B 21 EY 7 Tilt power trim assembly top first out from clamp 9 Remove O ring from fill cap bracket and remove assembly Power Trim System Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three or four turns counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 51194 a Manual Release Valve 5B 22 MID SECTION 90 817643R1 DECEMBER 1996 c 4 Remove trim rod assembly from cylinder
236. d more frequently because of more rapid loss of water If electrolyte level is found to be low then distilled water should be added to each cell until liquid level rises approximately 3 16 4 8mm over plate DO NOT OVERFILL because this will cause loss of elec trolyte and result in poor performance short life and exces sive corrosion CAUTION During service only distilled water should be added to the battery not electrolyte 2B 2 ELECTRICAL and IGNITION Charging Discharged Battery The following basic rules apply to any battery charging situ ation 1 battery may be charged at any rate in amperes as long as spilling of electrolyte from violent gassing does not occur and as long as electrolyte temperature does not exceed 125 F 52 C If spewing of electro lyte occurs or if electrolyte temperature exceeds 125 F charging rate in amperes must be reduced or tem porarily halted to avoid damage to the battery 2 Battery is fully charged when over a 2 hour period at a low charging rate in amperes all cells are gassing freely not spewing liquid electrolyte and no change in specific gravity occurs Full charge specific gravity is 1 260 1 275 corrected for electrolyte temperature with electrolyte level at 3 16 4 8mm over plate For most satisfactory charging lower charging rates in am peres are recommended 3 If after prolonged charging specific gravity of at least 1 230 on a
237. d on the stator USA S N 0G277479 and BELOW BELGIUM S N Not Available at Time of Printing 45 JET 50 60 ELECTRIC 398 9710A22 398 9710A23 or 398 9710A34 printed on the stator USA S N 0G277605 and BELOW BELGIUM S N Not Available at Time of Printing NOTE When servicing a unit prior to the listed serial number and below it is recommended that the flywheel be removed and the stator part number verified to determine proper testing applications ADI Test Test Selector Sw DVA Leads Voltage 1 Voltage Seq Position Red Black 9300 1000 RPM 1000 4000 RPM 1 Coil Primary 400 VDC Coil Coil 150 250 180 280 Terminal Terminal 2 A Switch Box 400VDC Black Yellow 3 Ground 200 360 200 360 Stop Circuit Sw Box Terminal Stator 400VDC Blue Sw Box Ground 200 300 200 330 Low Speed Terminal Red Sw Box Ter Ground 20 90 130 300 minal Switch Box 20 VDC Ground 1 White Black Sw 10 10 30 Bias 40 VDC Box Terminal 1 1 Using meter only REVERSE LEAD POLARITY connect leads as specified If using a meter with built in DVA place selector switch in the DVA 400 VDC position 55 60 MARATHON SEAPRO 398 9873A21 printed on the stator USA S N 0G277480 and ABOVE BELGIUM S N Not Available at Time of Printing 45 JET 50 60 ELECTRIC 398 9873A24 printed on the stator USA S N 0G277606 and ABOVE BELGIUM S N Not Available at Time of Printing ADI Test Test Selector Sw DVA Leads Voltage Voltage Volta
238. der any circumstances allow upper out board mounting bolts to be closer than 1 in 25 4mm from top of boat transom Upper mounting bolts must never be installed thru shims 7A 2 OUTBOARD INSTALLATION ATTACHMENTS IMPORTANT If using Transom Drill Fixture 91 98234A2 use drill guide holes marked A when drilling outboard mounting holes 1 Secure tape Outboard Mounting Template located in center of Installation Manual to outside of boat tran som 2 Align Top of Boat Transom Line of template with top edge of real boat transom not shim s 3 Align vertical centerline of template with centerline of transom 4 Use a 17 32 in 13 5mm diameter drill bit and drill 4 mounting holes perpendicular to and thru transom at marked hole centers on template Fastening Outboard on Boat Transom Manual Start Models AWARNING Outboard must be fastened to boat transom with tran som clamp handles and transom clamp retainers or mounting bolts as shown in installation A or B should the outboard strike an underwater object or be steered into a sharp turn Failure to tighten transom clamp handles along with installing transom clamp retainers or mounting bolts could result in outboard ejecting suddenly off boat transom causing serious injury or death boat damage or loss of outboard 90 817643R1 DECEMBER 1996 utboard Mounting Hardware Installation B Use for easy removal and installation of outbo
239. dicator Tool 91 19660 1 Backlash Indicator Update Kit 91 24273 Mandrel 91 27780 Puller 91 37241 Universal Puller Plate 91 37312 Driver Head 91 37323 Driver Rod 91 43506 Bearing Retaining Tool 91 46068A1 Puller Jaws 91 58222A1 Dial Indicator Dial Indicator Adaptor Kit Puller Bolt Forward Gear Bearing Installer Water Pump Base Seal Installer Bearing Carrier Seal Installer Pinion Gear Location Tool Forward Gear Bearing Race Driver Cup 91 817011 Needle Bearing Installer 91 817058A1 Lower Driveshaft Bearing Driver Assembly Driveshaft Holding Tool 91 83155 91 87516 91 817005 91 817006 91 817007 91 817008 91 817009 91 817070 Tools included in Bearing Removal and Installation Kit 91 31229A5 Quicksilver Lubricants and Service Aids Fanno Deser 92 34227 1 Perfect Seal 92 42649A1 Needle Bearing Assembly Lubricant 92 13872A1 Special Lubricant 101 92 19007A12 Gear Lubricant 92 32609 Loctite A 271 92 90018 12 2 4 C Marine Lubricant 90 817643R1 DECEMBER 1996 New Tools Required for 50 60 Gear Housing Description Bushing 3 4 in 19mm I D Bushing 7 8 in 22mm I D Set Screw Nut Bolt Spring Washer Bearing Adaptor Plate Nut Stud 91 14311A 2 Bearing Preload Tool NOTE Bearing Preload Tool 91 14311A 1 may be up dated to a 91 14311A 2 tool by ordering Update Kit 91 817057A 1 a b 9 f g h j k
240. dvisable and is required when accelerating decelerating or when trimming the boat On models with Power Trim upon reaching cruising speed the outboard should be trimmed to obtain a balanced steering condition While trimming steering loads will vary and will pull in one direction until a balanced condition has been attained If the outboard is trimmed past the balanced steering condition the steering wheel tiller handle then will have a tendency to pull in the opposite direction Excessive trimming past the balanced steering position will result in increased steering loads and in most boat applications a decrease in performance ACAUTION When trimming boat with dual outboards both out boards should be at approximately the same tilt angle and be tilted out up simultaneously to prevent boat from veering side to side until desired boat attitude is achieved Outboards can then be trimmed individually to precisely adjust boat trim angle and pitch 1 With boat in water trim the outboard s trim button in remote control handle so that the decal on the side of cowl is horizontal This is a typical average setting that should give reasonable acceleration and top speed 2 Goforashort familiarization ride at various throttle and trim settings BEFORE starting testing NOTE Instruments should be read with eye directly in front to eliminate any error in reading the instruments 3 When making either top speed or acceleration runs
241. e shaft splines DO NOT APPLY GREASE TO THE TOP OF THE DRIVE SHAFT AS THE GREASE WILL PREVENT THE DRIVE SHAFT FROM FUL LY ENGAGING THE CRANKSHAFT AND DAM AGE TO THE POWERHEAD AND OR GEAR CASE WILL RESULT Carefully slide jet drive into drive shaft housing while aligning drive shaft splines with crankshaft and the water tube with the water pump cover seal Secure jet drive to drive shaft housing with 4 bolts Torque bolts to 25 Ib ft 84 0 N m 54165 Bolts Torque to 25 Ib ft 33 9 N m 4 Secure aft end of jet drive to drive shaft housing with bolt and washer Torque bolt to 22 5 Ib ft 30 5 Nem w O oooon Grease the drive shaft shear key and impeller bore Place the plastic sleeve a inside the impel ler b and install impeller shear key c shims d nut retainer e and impeller nut f Turn the nut tight on the shaft to remove any play between the impeller and shaft If the tabs on the retainer do not line up with the flats on the nut remove the nut and turn the retainer over and re tighten the nut again Bolt and Washer Torque to 22 5 N m amp d amp e amp amp f Plastic Sleeve Impeller Shear Key Shims Nut Retainer Impeller Nut Temporarily reinstall the water intake housing in or der to check for impeller clearance The clearance between the impeller and liner should be 0 030 in 0 8 mm Shim washers can be transferred to ei th
242. e Hammer b 91 34569A1 Trim Tab Adjustment and Replacement IMPORTANT The trim tab is now painted and does NOT aid in protecting the drive shaft housing and gear housing from galvanic corrosion corrosion and pitting of metal surfaces Side anodes now provide protection Do not paint or place protec tive coating on the side anodes or corrosion protection function will be lost 1 Replace trim tab if damaged Mark location of old trim tab on anti ventilation plate before removal install new trim tab in same location 2 The trim tab provides a means to offset balance some of the steering load that is caused by propel ler torque at higher operating speeds If at higher speeds the boat turns more easily to the left loos en bolt move the trim tab trailing edge to the left when viewed from behind retighten bolt Turn trim tab trailing edge to the right if the boat turns more easily to the right 53931 Trim Tab Anti Ventilation Plate c Retaining Bolt and Washer Torque Bolt to 22 lbs ft 29 8 N m 6B 18 LOWER UNIT Reassembly Forward Gear Bearing Race 1 Place shim s retained from disassembly into housing If shim s were lost or a new gear hous ing is being assembled start with 0 010 0 254mm shim s 2 Assemble components as shown drive race into housing by striking propeller shaft end with lead hammer e
243. e OK bore defective Replace O rings and proceed Inspect Oil Pump O rings located Replace defective O rings or below oil pump components Result Result O ring failure located below oil O rings appear to be OK Re pump place O rings Replace O rings Replace oil pump 5B 14 MID SECTION 90 817643R1 DECEMBER 1996 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Result Manual release valve and or O ring damage Inspect Manual Release Valve Replace defective valve and O Result No debris or defective components found Inspect Manifold Reverse Thrust Valve Result Manual release valve and O rings appear to be OK Replace O rings and proceed Inspect Trim Rod Piston Check Valve Result Debris found in check valve com ponents Clean check valve components using engine cleaner and com pressed air or replace A CAUTION Result DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FACTORY FOR PRECISE REVERSE THRUST PRESSURE AND DOES NOT RE QUIRE ADJUSTMENT REVERSE THRUST VALVE COMPONENTS CAN ONLY BE CLEANED USING ENGINE CLEANER AND COM PRESSED AIR THROUGH MAN IFOLD PORTS WHILE VALVE COMPONENTS REMAIN IN MAN IFOLD Debris found in manifold reverse thrust valve components Clean manifold reverse thrust valve without removing compo nents usin
244. e at the top of the accumulator c with the gas at maximum pressure To raise the engine the camshaft lever f is rotated all the way down The internal shaft connected to the camshaft lever will move the push rods opening the accumulator check valve e both fast transfer valves h amp j and the down slow transfer valve i As the operator lifts the engine oil under pressure inside the accumulator will flow around both the slow transfer valve i and the down circuit fast transfer valve h Oil flows into the bottom of the tilt cylinder forcing the memory piston m into the shock piston n and then forcing the shock rod a up and out Oil above the shock piston exits the cylinder I through an interconnecting pas sage along side of the cylinder and returns into the manifold g Inside the manifold the oil flows past the groove in the surge valve k through the transfer valve j and mixes with the oil flowing from the accu mulator into the up cavity With the engine in the cor rect position the camshaft lever f is rotated up and the push rods allow the check valves e h i amp j to close The closed check valves prevent the oil from traveling between cavities and locks the engine into position 90 817643R1 DECEMBER 1996 MID SECTION 5G 5 a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 6
245. earing Puller 91 27780 6A 12 LOWER UNIT cM Shift Shaft 1 Remove shift shaft coupler a and spacer b 51271 2 Remove shift shaft bushing a and shift shaft b Pro tect shift shaft to prevent spline damage 51205 3 Remove shift shaft cam a replace if worn 51117 90 817643R1 DECEMBER 1996 Q 4 Remove shift shaft bushing a and clip b from shift shaft c Replace shift shaft if splines are twisted or damaged on either end of shaft Remove and discard O ring d if damaged 5 Remove and discard seal a if damaged N 51265 Gear Housing Reassembly Shift Shaft 1 Apply Perfect Seal on O D of new seal a Install with seal lip up as shown 2 Press seal into shift shaft bushing b until seal bot toms Use a suitable tool c Apply Quicksilver Needle Bearing Assembly Lubricant on O ring and I D of seal 90 817643R1 DECEMBER 1996 KR lt S 5 Assemble components Shift Shaft E Clip Bushing O ring 51264 Install shift cam a numbers toward top of gear hous ing align hole in shift cam with hole b 7 TS 51117 LOWER UNIT 6A 13 5 Install shift shaft assembly a insert splines into shift cam 51268 Propeller Shaft 1 Install components 51265 A D 2 4 C Quicksilver Marine Lubricant a Spring b Clutch Align Hole with Slot in Propshaft
246. ecal 3 Using a spray bottle flood the entire adhesive side of the decal with the pre mixed wetting solu tion 4 Floodarea where the decal will be positioned with wetting solution 5 Position pre wetted decal on wetted surface and slide into position 6 Starting at the center of the decal lightly squeegee outthe air bubbles and wetting solution with overlapping strokes to the outer edge of the decal Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface Wipe decal surface with soft paper towel or cloth Wait 10 15 minutes Starting at one corner carefully and slowly pull the masking off the decal surface at a 180 angle NOTE To remove any remaining bubbles pierce the decal atone end of the bubble with stick pin and press out the en trapped air or wetting solution with your thumb moving to ward the puncture 90 817643R1 DECEMBER 1996 cM ELECTRICAL and IGNITION OSA 51123 IGNITION SYSTEM Table of Contents Description Test Procedures Direct Voltage Adapter DVA Tests Test Sequence Ignition System Test Chart Stator lest usse lt lt E ERE urnas Ignition Coil Trigger ADI Ignition using a RED Stator with an Adapter M
247. eck that boat will turn right when steer ing wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right atall tiltangles to assure inter ference free movement 6 Lubricate outboard end of Ride Guide steering cable thru grease fitting next to cable attaching nut with Quicksilver 2 4 C w Teflon Marine Lubricant NOTE Ride Guide steering cable is lubricated at the facto ry and requires no additional lubrication at initial installa tion 7 Lubricate all steering system pivot points and ex posed portion of steering cable core with Quicksilver 2 4 C w Teflon Marine Lubricant Lubricate at intervals specified preceding 8 Carefully check steering system components for wear atintervals specified preceding Replace worn parts 9 Check steering system fasteners at intervals speci fied preceding to be sure that they are torqued to cor rect specifications Figures 1 2 and 3 Maintenance Instructions Lubrication and maintenance inspection is owner s re sponsibility and must be performed at intervals as specified following Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in salt water is considered Severe Service 1 Carefully check steering components for wear Re place as necessary 2 Check steering syste
248. ectifier Connect red ammeter lead to rectifier terminal and black ammeter lead to red rectifier wire Run engine at 3000 RPM Meter should read 7 9 amperes if not replace stator 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2B 5 10 A reading of 18 amperes 16 amp system or 9 am peres 9 amp system at 3000 RPM indicates the charging system is functioning properly and the battery being discharging current due to the amperage draw on the system is greater than the amperage output of the engine charging system 11 If ammeter reads less than required amperes 3000 RPM test the stator refer to Stator Ohm Test Alterna tor Coils Only If stator tests OK replace voltage reg ulator 51000 Voltage Regulator Rectifier Red Lead 2 Yellow Lead 2 Grey Lead Qo oo 2B 6 ELECTRICAL and IGNITION 90 817643R1 DECEMBER 1996 9 Ampere Battery Charging Wiring Diagram RECTIFIER MODELS BLK BLU Blue GRY Gray RED e Red YEL Yellow Stator Alternator Assembly Rectifier 20 Ampere Fuse Remote Control Harness Starter Solenoid GRAY Wire to Tachometer To Battery Positive Terminal O Q G 0 m 90 817643R1 DECEMBER 1996 RED SLEEVE 51249 IMPORTANT After electrical connections are made coat all terminal connections using Quicksilver Liquid Neoprene 92 25711 to avoid corrosion ELECTRICAL and IGNITION 2B 7 9 Ampere Bat
249. ed If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Bleed ing Power Trim Unit 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls down to trim position indicates debris or defective com ponents in trim valve assembly Clean or replace components as required 5 Check manual release valve for broken stem and one O ring remaining in the release valve pas sage Separate the manifold assembly from the cylinder to dislodge broken stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system 5C 12 MID SECTION cM Leak Down Check Pump Man ifold Assembly NOTE Scribe d pump housing halves before disas sembly Check pump for problems as follows 1 Debris or chips between valve and seat a Usu ally imbedded in rubber valve seat Nicked or deteriorated O ring b Nicked deteriorated or misplaced O ring be tween manifold and trim cylinder Refer to ifold Removal for O ring location 4 After reassembly insert drive shaft and check pump rotation resistance to turning housing halves can shift turn during reassembly A
250. edle bearings It is required to replace needle bearings as a set Never intermix needle bearings from one con necting rod with those of another connecting rod 1 Place clean needle bearings on a clean sheet of paper and lubricate with Quicksilver Needle Bearing Lubri cant Service Tip PE 51228 If the tip of an awl can be inserted between needle bear ings one or more needles are missing and must be re placed 90 817643R1 DECEMBER 1996 2 Install needle bearings a Needle Bearings 29 b Sleeve from Piston Pin Tool 91 74607A2 3 Place locating rings on connecting rod carefully place piston over end of rod Refer to scribed identification number for matching rod to piston and direction of as sembly which side of rod is UP PE 51083 a Scribed Identification Number b Locating Washer 90 817643R1 DECEMBER 1996 4 Push sleeve from piston using piston pin tool PE 51080 a Sleeve b Piston Pin Tool 91 74607A2 5 Place piston pin over tool and tap into position driving tool out other side PE 51086 a Piston Pin b Piston Pin Tool AWARNING Eye protection must be worn while installing piston pin lockrings POWERHEAD 4 27 6 Install new piston pin lockrings each side of piston us ing Lockring Tool p n 91 77109 1 7 Make sure lockrings are properly seated in piston grooves ACAUTION Do not re use piston pin lockrings Use only new lock rings
251. eed Stop Opening Max 0 020 in 0 50 mm Crankshaft Runout Max 0 003 in 0 08 mm Taper Max 0 003 in 0 08 mm Firing Order 1 3 2 Special Tools Part Number Lock Ring Installation 91 77109A1 Tool Powerhead Stand 91 25821A1 Torque Wrench 150 91 66274 Ib in Compression Tester 91 29287 be Obtained Locally Torque Wrench 0 200 91 32610 Ib ft 90 817643R1 DECEMBER 1996 ax t Cowl Removal 50553 50554 90 817643R1 DECEMBER 1996 Filling Oil Injection System Remove fill cap a from the oil tank and fill tank with oil Re tighten the fill cap 50552 Use Quicksilver NMMA Certified TC W3 or TC WII 2 Cycle Outboard Oil Quicksilver Certified TC W3 Outboard Oil is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or va rying grades of gasoline Quicksilver Certified TC WII Outboard Oil is an industry leading oil that provides superior outboard lubrication and resistance to carbon buildup when used with good grades of gasoline Periodically consult with your dealer to get the latest gaso line and oil recommendations If Quicksilver 2 Cycle Out board Oil is not available substitute a 2 Cycle outboard manufacturers oil that is NMMA Certified TC W3 or TC WII or another brand of 2 Cycle outboard oil that is NUMA Certified TC W3 or T
252. eering bracket middle hole using clevis kit P N 70599A4 4 Adjust 2 large jam nuts on cable tube of attaching kit so that steering wheel is in normal straight driving po sition with outboard in straight driving position Torque each jam nut to 35 Ib ft 47 5 N m then bend a side of tab washer against flat of each jam below 5 Torque Ride Guide cable attaching nut which secures cable to guide tube to 35 Ib ft 47 5 below In stall locking sleeve over cable attaching nut and se cure with cotter pin Spread ends of cotter pin NO ECT wt WI 51140 Ride Guide Cable Ride Guide Yoke Pivot Block Pivot Spacer 15 Centerline of Attaching Kit Pivot to Centerline of Engine Pivot Attaching Locknut Torque to 20 Ib ft 27 N m Engine Steering Arm Clevis Kit Ride Guide Cable Attaching Locknut Torque to 10 Ib ft 13 5 N m Bolt 3 8 x 2 1 2 Flat Washer Transom Bracket Cable Tube Jam Nut Torque to 35 Ib ft 47 5 N m Tab Washers Bend Over Flat of Jam Nuts Cable Attaching Nut O253237 7751 0 Q O TM 90 817643R1 DECEMBER 1996 NOTE Some Ride Guide steering cables may not be equipped with locking sleeve and cotter pin If cable being installed does not have these parts disregard instructions to install them A WARNING After installation is completed and before operating outboard ch
253. efer to Table of Contents preceding If major powerhead repairs are to be performed remove powerhead from drive shaft housing as an assembly Re move external engine components referring to appropriate section of service manual ELPTO MODEL 1 Remove battery cables PE 51084 90 817643R1 DECEMBER 1996 2 Disconnect control trim harness and fuel line as bs PE 51082 3 Disconnect trim switch and trim relay wires PE 51089 Blue White Green White Red Black Trim Switch POWERHEAD 4 13 4 Remove control cables 6 Remove electrical box cover PE 51088 a Shift Cable b Throttle Cable 5 Remove bolt and rubber grommet PE 51089 7 Remove battery cables and starter bracket m A FLA 4 ro fi gt 9 INCE a Bolt b Fuel Connector c Rubber Grommet PE 51080 a Positive Cable b Ground Cable c Bracket 4 14 POWERHEAD 90 817643R1 DECEMBER 1996 2 1 Disconnect wires and remove oil tank 8 51088 Oil Tank Wires Blue Power Trim Wires Blue White and Green White Oil Hose From Tank Remove ground wire to powerhead Disconnect wires from trim relay module s Disconnect tel tale hose Design 2 a c Trim Relay Module s Ground Lead Tel Tale Hose 90 817643R1
254. eg of throttle le ver and secure with locknut and washer Throttle Cable Guide Throttle Lever Washer Locknut Tighten until snug then back off 1 4 turn ACAUTION DO NOT exceed 1 4 turn on set screw after it has bottomed out oo 7B 20 OUTBOARD INSTALLATION ATTACHMENTS p i 4 Holding throttle lever against idle stop adjust throttle cable to slip into upper hole of barrel receptacle with a very light preload of throttle lever against idle stop Ap ply small amount of Loctite 271 to threads of set screw Tighten until snug then an additional 1 8 turn Throttle Lever Idle Stop Barrel Receptacle Secure barrel in place with barrel retainer TUE P 51091 Barrel Retainer w 6 Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Pre load is correct when paper can be removed without tearing and still have drag on it Readjust cable barrel if necessary 7 Install Cowl 90 817643R1 DECEMBER 1996 Co Pilot Installation NOTE To instal Co Pilot kit tiller handle must be removed and battery cables disconnected 1 Install brake disk on swivel bracket Position bottom up lever brake disk and top up lever onto swivel bracket Note location of pin on steering arm in rela tion to top and bottom levers as shown 51094 51093 a Swivel Bracket b Brake Disk c Bott
255. eller Nut Flo Torg Drive Hub Propellers ed Forward Thrust Hub Replaceable Drive Sleeve Rear Thrust Hub Propeller Nut Retainer Propeller Nut 1 90 817643R1 DECEMBER 1996 3 Tighten propeller nut to 55 Ib ft 75 N m Bend tabs against nut a Propeller Nut Torque To 55 Ib ft 75 N n b Bend Tabs Against Nut ACAUTION Do not misinterpret propeller shaft movement for pro peller movement propeller and propeller shaft howev er may move fore and aft However the propeller itself should not move fore and aft on the propeller shaft 4 Re check propeller nut for tightness after first use Check for tightness periodically especially if a stain less propeller is used 5 Install and adjust trim tab as follows Trim Tab Adjustment and Replacement IMPORTANT The trim tab is made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion corrosion and pit ting of metal surfaces Do not paint or place protective coating on the trim tab or trim tab corrosion protec tion function will be lost 1 Replace trim tab if 5096 or more consumed Mark lo cation of old trim tab on anti ventilation plate before re moval install new trim tab in same location 90 817643R1 DECEMBER 1996 2 The trim tab will offset balance some of the steering load that is caused by propeller torq
256. ement will continue until the manual release valve p is closed locking the fluid inside of the cylin der and manifold 90 817643R1 DECEMBER 1996 MID SECTION 5E 19 Troubleshooting Support outboard with tilt lock pin when servicing power trim system IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re as sembly IMPORTANT Power trim system is pressurized Outboard must be in the full UP position trim rod fully extended prior to fill drain plug or manu al release valve removal Refer to instructions following if disassembly is re quired when servicing Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been corrected If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Bleed ing Power Trim Unit 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted po
257. emove bearing using Slide Hammer 91 34569A1 Aa 51263 a O ring a Bearing 6B 12 LOWER UNIT 90 817643R1 DECEMBER 1996 11 Remove spring 51876 a Spring 12 Apply constant pressure to cam follower to pre vent cam follower assembly from ejecting from propeller shaft while pushing cross pin out of clutch dog a Cross Pin b Cam Follower 13 Remove components from propeller shaft 90 817643R1 DECEMBER 1996 c b 51800 Set a pu u 14 Replace cam follower if worn or pitted 15 Replace sliding clutch if jaws are rounded or chipped Rounded jaws indicate one or more of the following a Improper shift cable adjustment b Engine idle speed too high while shifting c Shifting from neutral to reverse or forward too slowly f f 51265 e a Cam Follower b 3 Metal Balls c Guide Block d Spring e Sliding Clutch f Jaws 16 Check bearing surfaces of propeller shaft for pit ting or wear If shaft is worn or pitted replace shaft and corresponding bearing 17 Replace propeller shaft if any of the following exist a Splines are twisted or worn b Oil seal surface is grooved c Shaft has a noticeable wobble or is bent more than 0 009 in 0 228mm Prop shaft trueness should be measured with a dial indicator with prop shaft on V blocks 51877 a V
258. empting any change in shim thickness 1 Obtain correct pinion gear location refer to Determin ing Pinion Gear Location preceding 2 Install Bearing Preload Tool on driveshaft refer to De termining Pinion Gear Location preceding Install components Torque to 45 Ib in 5 N m aw 51119 a Propeller Shaft b Bearing Carrier Assembled Puller Jaws 91 46086A1 d Puller Bolt 91 58716 Torque to 45 Ib in 5 1 N m Refer to Bearing Carrier and Propeller Shaft Installation following 5 Rotate driveshaft 10 revolutions to properly seat for ward gear tapered roller bearing 6 Re torque puller bolt to 45 Ib in 5 1 N m 90 817643R1 DECEMBER 1996 cM Install components T 10 11 12 Threaded Rod Washers Nuts Dial Indicator Adaptor Kit 91 83155 Dial Indicator 91 58222A1 Backlash Indicator Tool 91 19660 1 Position Dial Indicator on line 3 on Backlash Indicator Tool Turn driveshaft back and forth check for no rotation at the propeller shaft Dial Indicator registers amount of backlash which must be between 013 in and 019 48mm If backlash is less than the minimum reading remove shim s from in front of the forward gear bearing race If backlash is more than the maximum reading add shim s in front of the forward gear bearing race By adding or subt
259. ently start the engine and run it at idle speed only Check for a steady stream of water flowing out of the water pump indicator hole Continue flushing the outboard for 3 to 5 minutes adjust water pres sure if needed Stop the engine turn off the water and remove the hose coupling Reinstall the plug and gasket a Plug and Gasket b Hose Coupling Liner Replacement 1 Mark the liner mounting bolts for reassembly into the same holes Remove the bolts 6C 12 LOWER UNIT 2 Cu Remove the liner If the liner is tight tap on the inner edge of the liner with a long drift punch through the intake grate 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 it in It may be necessary to tap or press the liner into the water intake housing to locate the liner for installa tion of the remaining bolts Torque bolts to 100 Ibs in 11 2 N m Grind off the ends of any bolts that may extend be yond the inner liner surface Jet Drive Removal Shift outboard to NEUTRAL N position and dis connect the shift linkage Remove spark plug leads to prevent engine from starting Remove the water intake housing that is fastened with six screws 90 817643R1 DECEMBER 1996 Q 4 Straighten the bent tabs a on the impeller nut re tainer and remove the impeller nut b
260. er voir assembly 51195 Cap Washer Grommet Remove screws securing reservoir cap to voir a Screws 4 51193 90 817643R1 DECEMBER 1996 4 Remove moior harness from reservoir 51196 Trim Motor Disassembly 1 Remove end cap from motor housing Note posi tion of washers on armature End Cap Motor Housing Wave Washer 2 Washer MID SECTION 5 25 2 Remove O ring from end frame 3 Place scribe mark on motor housing and end frame as re assembly reference as shown 51194 a O ring b Scribe Mark 4 Remove end frame and armature from housing 51194 End Frame Washer Armature Fiber Guard Liner Housing oo 5C 26 MID SECTION cM Reservoir Assembly Removal A CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Remove manual release valve form manifold DO NOT remove or adjust reverse thrust valve 51194 a Manual Release Valve b Manifold 2 Remove E clip and O rings from manual release valve a E Clip b O rings c Manual Release Valve 90 8i7643R1 DECEMBER 1996 3 Remove four screws securing reservoir to man Oil Pump Manifold Removal ifold 1 Remove screw oil pump O rings and check valve components from manifold 51193 a
261. er seal housing d 6 Clean all parts thoroughly and remove any burrs Snap Ring Bearing Carrier Ball Bearing Upper Seal Housing Snap Ring Thrust Ring 66 14 LOWER UNIT Installing Lower Seals Install seals into bearing carrier as follows Install O ring seals a into the top seats of the three passage holes Install spiral retaining ring b into the inner ring groove Spread a film of grease around the inside bore of the seal surface before pressing in the seals Press in the garter spring seal c against the inner retaining ring as shown Fill the garter spring cavity in the seal with grease Install spiral retaining ring d into the outer ring groove Align the notched ends of the retaining ring to straddle the small vent hole drilled in the ring groove Press in the outer seal e against the retaining ring as shown Grease all the seal lips IMPORTANT The notched ends of the retaining ring must straddle this vent hole O rings Retaining Ring Spring Seal Retaining Ring Outer Seal 90 817643R1 DECEMBER 1996 1 Installing Upper Seals 1 Install spiral retaining ring into the inner ring groove of the upper seal housing Spread a film of grease around the inside bore of the seal surface before pressing in the seals Press in the garter spring seal b against the inner r
262. er sealing bead groove in cover roof are more than 0 030 0 762mm deep Lift impeller drive key and gasket from drive shaft 9 a Impeller b Drive Key c Gasket 6B 10 LOWER UNIT 7 Inspect impeller Replace impeller if any of the following conditions exist Impeller blade s are cracked torn or worn Impeller is glazed or melted caused by opera tion without sufficient water supply Rubber portion of impeller is not bonded to impeller hub 8 Remove plate and gasket 9 Replace plate if groove s other than impeller sealing bead groove in plate are more than 0 030 0 762mm deep a b A gt DA 19219 a Plate b Gasket c Impeller Sealing Groove 10 Remove bolts and washers Q f Wx a Bolts and Washers 6 each 90 817643R1 DECEMBER 1996 11 Remove water pump base Bearing Carrier and Propeller Shaft 1 Drain lubricant from gear housing refer to Drain ing and Inspecting Gear Housing Lubricant 2 Remove bolts and washers or self locking nuts if applicable 19226 a Water Pump Base 12 Remove and discard seals 51117 a Bolt and Washers or Locknuts i lt 3 With propeller shaft horizontal pull carrierto break X seal with gear housing Remove bearing carrier propeller shaft components as an assembly t
263. er side of the impeller to raise or lower the impel ler to the correct clearance setting The water in take housing can be shifted side ways a small amount in order to center the liner 6C 18 LOWER UNIT 90 817643R1 DECEMBER 1996 7 After setting the impeller height tighten the impel NOTE If the outboard is used in salt water apply ler nut snug with a wrench Secure impeller nut by Quicksilver Anti Corrosion Grease around the entire bending tabs a against the flats on the impeller mounting flange on the water intake housing and also nut to the threads on the six mounting bolts a Tabs 8 Reinstall the water intake housing with six bolts 2 Wet sure 9 Refer to SHIFT CABLE INSTALLATION page 8 Me wale NOUSIN IS Aa and reinstall shift cable to jet drive bing against the liner Torque mounting bolts to 100 Ibs in 11 5 N m 90 817643R1 DECEMBER 1996 LOWER UNIT 6C 19 Jet Drive Tiller Handle Adaptor Kit Installation Instructions NOTE This kit must be used in conjunction with the recommended Quicksilver tiller handle kit 1 Drill hole in bottom cowl for cable routing as fol lows a Locate the center lines for the hole following the dimensions given in the illustration below Use a center punch to mark center of hole b Drilla 1 4 in pilot hole and then a 9 16 in hole angling up into the bottom cowl Side View Front View
264. er tube with water tube seal and crank shaft splines with drive shaft splines 13 Install 4 bolts and washers two each side 14 Install locknut and washer 15 Torque bolts and locknut or nuts only if applicable to 40 Ibs ft 54 6B 34 LOWER UNIT ee 53922 a Bolts and Washers 4 b Locknut and Washer 16 Check shift operation as follows a Place shift lever in forward gear Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller shaft is turned counterclockwise b Place shift lever in neutral Propeller shaft should rotate freely in either direction c While rotating propeller shaft place shift lever in reverse gear Resistance should be felt when propeller shaft is rotated in either direction IMPORTANT If shift operation is not as described preceding the gear housing must be removed and the cause corrected Trim Tab Adjustment 1 Check trim tab position as follows a Operate boat at the speed at which it normally would be operated b If the boat pulls to the right STARBOARD the trailing edge of trim tab must be moved to the right If the boat pulls to the left PORT the trailing edge of trim tab must be moved to the left 2 If necessary adjust trim tab as follows a Shift engine control into NEUTRAL and turn igni tion key to OFF
265. erent elevation Jet Orifice Part Orifice Part from the previous time refer to the Carburetor Jet Charts Size Number Size Number following and rejet the carburetors for elevation engine will inch inch be operated at HIGH ALTITUDE JET CHART Engine Operation Elevation High Speed Jet Size Above Sea Level 19266040 1395 7831 1399 5315 3 1395 6487 1395 7394 i 1399 4217 1399 5317 1399 4216 1395 6246 1399 4215 1395 6028 1395 6029 1395 6359 1395 6030 1399 5225 j 1395 6207 1399 5213 1399 3794 1399 3796 1395 8423 1395 6680 i 1399 6249 1395 6201 1395 7335 1399 3518 1399 3517 1395 5815 1395 6202 1395 6247 1395 5733 2500 5000 002 smaller than standard jet 750 1500m 5000 7500 004 smaller than standard jet 1500 2250m 7500 and Up 006 smaller than standard jet 2250m and Up 3A 12 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 2 i Carburetor Removal Carburetor Disassembly e Remove four screws and lift off attenuator e Remove fuel bowl e Remove six screws and remove carburetors Disconnect linkages and fuel and primer lines a Fuel Bowl e Remove float pin and remove float e Remove fuel bowl gasket a Attenuator Screw 4 b Carburetor Screw 6 a Float Pin b Float c Gasket 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3A 13 Remove fuel inlet needle e Remove main jet plug and gasket e Remove stem gasket e Remove main j
266. ering arm require outer connection hole to be used when connecting clevis to steering arm Clevis Steering Cable Bolt 3 8 in x 1 3 8 in Clevis to Steering Cable Locknut Torque to 10 Ib ft 13 5 N m Bolt 3 8 in x 1 1 4 in Torque to 20 Ib ft 27 0 N m Thin Washer 1 16 in 1 6mm Thick Spacer Thick Washer 1 8 in 3 2mm Thick Outboard Steering Arm use Inner Hole on Models with One Piece Steering Arm or Outer Hole on Models with Two Hole Two Piece Steering Arm j Clevis to Outboard Locknut Torque to 20 Ib ft 27 0 N m 1 Lubricate shank of bolt c with 2 4 C w Teflon Marine Lubricant then secure clevis to steering cable with this bolt and locknut Torque locknut d to 10 Ib ft 13 5 N m 2 Lubricate spacer supplied with kit with 2 4 C w Teflon Marine Lubricant 3 Attach clevis to steering arm using thin washer spacer thick washer positioned between clevis and steering arm and locknut as shown Torque bolt e to 20 Ib ft 27 0 N m then torque locknut j to 20 Ib ft 27 0 N m 90 817643R1 DECEMBER 1996 teering Cable Installation 1 Lubricate steering cable end with Quicksilver 2 4 C w Teflon Marine Lubricant 2 Install steering cable thru steering cable tube and se cure to cable tube with cable attaching nut See be low Do not tighten cable attaching nut at this time 3 Attach ride guide cable to outboard st
267. ernal leaks in the manual tilt system Replace defective part s if leak is found IMPORTANT If cut or damaged O rings are found inspect machined surfaces for scoring burrs or debris 3 Checkfor discharged accumulator 35 to 50 Ib ft 47 68 of pulling force must be attained when tilting outboard from full down to full up position If more than 50 Ib ft 68 N m of force is required replace accumulator 50431 a Weight Scale b Valve Lever open position 90 817643R1 DECEMBER 1996 Q Troubleshooting Flow Chart Outboard falls to full down position with manual re lease valve lever in LOCK RUN up position Ex ample a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceleration A CAUTION Tilt ram must be in full up position and accu mulator removed before manual tilt system disassembly Inspect memory piston O ring Results Results O ring defect O ring appears to be o k cylinder bore and memory piston Replace O rings and proceed Inspect Transfer Valve Results Results No debris or defective components found Debris or defective components found in transfer valve Replace valve block Clean components using engine cleaner and compressed air or replace as necessary Replace defective O ring 90 817643R1 DECEMBER 1996 MID SECTION 5F 19 EY Troubleshooting Flow Chart Continued Outb
268. ers that contain sand and gravel can cause wear to the impeller blades and the clearance will start to exceed 0 03 in 0 8mm As the blades wear shims a located in the stack outside of the impeller can be transferred behind the impeller This will move the impeller further down into the ta pered liner to reduce the clearance Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation Shims 90 817643R1 DECEMBER 1996 Worn Dull Impeller Do Not sharpen or alter the top side lifting angle Enlarged leading View edge Sharpen to 1 32 in 8mm radius by removing material from bottom side only The intake of gravel through the pump can round off and wear the leading edges on the impeller Some conditions you may experience from a worn impeller are 1 a noticeable performance loss especially on acceleration 2 difficultly getting the boat on plane or 3 an increase in engine RPM at wide open throttle Check the impeller blades occasionally for damage Use a flat file to resharpen the leading edges as shown LOWER UNIT 6C 11 Flushing The Cooling System Use Quicksilver accessory hose coupling Part Number 24789A1 1 Remove plug and gasket a and thread in hose coupling b Attach a water hose to the hose coupling Turn on the water g
269. es debris or defective compo nents in trim valve assembly Clean or replace components as required 5 Check manual release valve for broken stem and one O ring remaining in the release valve pas sage Separate the manifold assembly from the cylinder to dislodge broken stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system 90 817643R1 DECEMBER 1996 Leak Down Check Pump and Manifold Assembly NOTE Scribe pump housing and manifold before disassembly 1 Debris or chips between valve and seat a usu ally imbedded in rubber valve seat Nicked or deteriorated O ring b Nicked deteriorated or misplaced O ring c 4 After reassembly insert driveshaft and check pump rotor resistance to turning housing halves can shift turn during reassembly Align scribe marks carefully MID SECTION 5D 5 2 1 Leak Down Check Pilot Valve Leaks Past Ball and Seat Piston Assembly Assembly 1 Debris or chips between valve and seat a usu Unit will trim to full or near full down position and then ally imbedded in rubber valve seat will begin to trim up while trim switch is held in 2 Pilot valve installed from non chamfered end of DOWN mode spool results in nicked or damaged O ring b If trim switch is released outboard can be pushed by 3 Nicked or deteriorated O ring c hand down to the point where trim UP started
270. et 51116 a Fuel Inlet Needle a Main Jet Plug and Gasket b Stem Gasket b Main Jet e Remove mixing chamber cover and gasket NOTE It is not necessary to disassemble carburetor be yond this point for cleaning Examine throttle shaft for wear ku a and inspect for damaged throttle shutter plate Remove bowl vent jet If removal of throttle shaft and or throttle shutter plate is necessary remove 2 screws which secure throttle shutter plate to throttle shaft Remove retaining clip from end of throttle shaft then pull shaft out of carburetor 51116 a Mixing Chamber Cover and Gasket 51117 b Idle Mixture Screw c Bowl Vent Jet a Throttle Shaft b Screw 2 c Throttle Shaft Spring 3A 14 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 c Cleaning and Inspection 1 Carefully inspect carburetor body and fuel bowl for cracks stripped threads plugged or restricted pas sages and passage plugs that show signs of leakage 2 Thoroughly clean all carburetor parts with a mild clean ing solution that will not damage rubber or plastic to remove dirt and varnish that may have accumulated 3 After washing parts blow parts dry with compressed air Be sure to blow air thru all passages orifices and nozzles 4 Check float hinge in the float pin area for wear and check float for leaks Replace parts as necessary 5 Examine inlet needle for wear If worn replace with new inlet needle Carbureto
271. etaining ring as shown Fill the garter spring cavity in the seal with grease Install spiral retaining ring c into the outer ring groove Align the notched ends of the retaining ring to_straddle the small vent hole drilled the ring groove Press in the outer seal against the retaining ring as shown Grease all the seal lips Grease the two O ring seals e and install then into the outer ring grooves IMPORTANT The notched ends of the retaining ring must straddle this vent hole Retaining Ring Spring Seal Retaining Ring Outer Seal O rings 90 817643R1 DECEMBER 1996 Installing Drive Shaft Ball Bearing 1 If removed install the bearing thrust ring a into the groove on the drive shaft Install collar onto the drive shaft Press the new ball bearing c 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 d into drive shaft groove below the bearing Installing Drive Shaft 1 Lubricate the seals and inside bore of the bearing carrier a Place 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 and push the bearing carrier down until it bottoms out against the bearing
272. f bearing with Quicksilver Needle Bearing Assembly Lubri cant before installation Press until Installer Tool bottoms Installation Note Push against numbered end of bearing 91 817005 51291 a Installer Tool 91 817005 1 Press tapered roller bearing a onto gear Lubricate I D of bearing with Quicksilver Needle Bearing As sembly Lubricant before installation Use Installer b Press until bearing bottoms on gear a Bearing Lubricate 1 0 Before Assembly b Installer Tool 91 817007 90 817643R1 DECEMBER 1996 Lower Driveshaft Bearing Installation 1 Lubricate O D of bearing race with Quicksilver Needle Bearing Assembly Lubricant 2 Install bearing a into housing Press until Installer Tool bottoms Installation Note Push against numbered end of bearing 7 05 179 0mm 7 07 in V 179 5mm Ref Bear ing Depth 51260 a Needle Bearing Lubricate O D Before Assembly b Bearing Installer Tool 91 817058A1 LOWER UNIT 6 17 Upper Driveshaft Bearing Installation 1 Press upper driveshaft bearing a onto driveshaft Lu bricate of bearing with Quicksilver Needle Bearing Assembly Lubricant before pressing in place WOON gt 51268 Upper Driveshaft Bearing Lubricate 1 0 Before Assembly 6A 18 LOWER UNIT Forward Gear Pinion Gear Upper Driveshaft Bearing Race Retainer and Driveshaft Installat
273. f cylinder allowing 4 o 13 b ft GS Nim motor to seat properly i ft 1 Manifold b Cavity 51195 Reservoir Installation a End Cap b O ring 1 Connect trim motor wires to harness c Foam Pad 2 Insert motor into reservoir Motor must be seated 5 Install grommet washer and screw cap to cylin properly prior to end cap installation der end cap Tighten screw securely a Grommet b Washer c Screw Cap 90 817643R1 DECEMBER 1996 MID SECTION 5B 33 Place drive shaft into oil pump Install lubricated O ring to base of reservoir Carefully guide reservoir with motor down onto drive shaft a Drive Shaft b O ring 9 Secure reservoir to manifold using four screws Torque screws to 70 Ib in 7 9 N m 51193 a Screw 5B 34 MID SECTION C 10 Install lubricated O rings and E clip to manual release valve a E Clip b O ring c Manual Release Valve 11 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 or 4 turns allowing trim rod installation a Manual Release Valve b Manifold C Reverse Thrust Valve 90 817643R1 DECEMBER 1996 L Trim Rod Reassembly 4 Apply Loctite Grade A 271 to threads of trim rod and install trim rod piston Tighten piston securely 1 Install lubricated O rings and rod wiper to end using spanner wrench 1 4 in x 5 16 in long peg cap e 5
274. g Driven Gear Q N 3D 4 FUEL SYSTEMS 51203 TORQUE SPECIFICATIONS 60 Ib in 7 0 N m 90 817643R1 DECEMBER 1996 Oil Injection Flow System Variable Ratio Oil Pump lt lt Lo 52049 MS Fill Cap Vent Warning Module Fuel Filter Carburetors Fuel Pump 2 psi Check Valve Oil Pump Fuel Line Connector Low Oil Sensor Oil Level Sight Gauge ATT Ta 09 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3D 5 Pump Drive Assembly Variable Ratio Oil Pump 52046 Oil Outlet Oil Pump Oil Inlet Bleed Screw om 1 KASSANS EI 52044 Oil Pump Apply 2 4 C w Teflon to Shaft Driven Gear Bushings O Rings oag go 3D 6 FUEL SYSTEMS c Pump Drive System Variable Ratio Oil Pump KC Le LS SSS N E ES 52044 O Rings Driven Gear Drive Gear Crankshaft Oil Pump om 90 817643R1 DECEMBER 1996 PAS CE Oil Pump to Powerhead Assembly Variable Ratio Oil Pump 2 4 C With Teflon 92 825407A12 TORQUE SPECIFICATIONS 60 b in 7 0 Bolt Oil Pump O Rings Bushing Bearing Bushing Driven Gear 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3D 7 Set Up Instructions for Oil Injection System ACAUTION During break in engine must be run on a 25 1 gasoli ne oil ratio 50 1 mixed oil fue
275. g engine cleaner and compressed air or replace 90 817643R1 DECEMBER 1996 Result No debris found in manifold re verse thrust valve Replace Manifold as a Unit MID SECTION 5 15 EY Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram BLK 4 TAN BLU 3 TAN BLU GRY YEL BLK 6 PUR A YEL RED 7 YEL RED BLK e Black BLU e Blue BRN e Brown GRY Gray i GRN e Green Ye LM 74 5 PUR Purple AN RED Red p TAN Tan d WHT White YEL e Yellow Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector 23891 Wiring Harness Connector Warning Horn Trim Tilt Switch PUR p gt G 5B 16 MID SECTION 90 817643R1 DECEMBER 1996 PANS Power Trim System Wiring Diagram AN g ES L 2 v o 9 gi bi x 7 x rt HN XY amp T Ho Sb VN a S e 7 4 DX d 5 GRNIWHT GRNIWHT 1 Of BLUWHT O 12 4 GRNIWHT BLUIWHT RED PUR a To Power Trim Pump Motor b Relay Switch UP c
276. ge 6 Repair of fuel pump is limited to the replacement of those bad parts found during inspection 90 817643R1 DECEMBER 1996 Q Fuel Pump Reassembly Check Valve Assembly 1 Insert retainer a thru plastic disc b and rubber check valve c b 23601 23601 2 Install check valves and retainers into fuel pump body 23610 Fuel Pump Assembly 1 Assemble remaining components as shown in Fuel Pump Exploded View 2 Install bolts a and torque to 40 Ib in 4 5 N m 51267 23601 3 With retainer installed in pump body break retainer rod a from retainer b by bending sideways 4 Reinstall rod a into retainer cap b and use a small hammer or hammer and punch to tap rod down into re tainer until flush with top of retainer 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3B 9 Fuel Pump Exploded View IMPORTANT Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly Rubber Disc 2 Plastic Check Valve Disk 2 Retainer 2 Spring Cap Diaphragm Boost Gasket Spring Cap Chamber Plate Diaphragm Pulse Gasket Fuel Pump Base Gasket Bolt 40mm 2 Bolt 50mm 2 Pipe Plug Fitting 90 A gt ak mi LE GQ N Al N Torque Specifications 40 Ib in 4 5 NOTE Gaskets items 8 and 13 were not used on early production units however they shoul
277. ge Seq Position Red Black 300 RPM 1000 RPM 4000 RPM 1 Coil Primary 400 VDC Coil Coil 145 175 210 250 200 240 Terminal Terminal 2 A Switch Box 400VDC Black Yellow 3 Ground 215 265 280 340 260 320 Stop Circuit Sw Box Termi nal 3 A 400VDC Blue Sw Box Ground 215 265 280 340 260 320 4 Low Speed Terminal 3 A Stator 400VDC Red Sw Box Ground 10 15 45 55 205 255 4 High Speed Terminal Switch Box 20 VDC Ground 1 White Black Sw 2 10 10 30 10 30 Bias 40 VDC Box Terminal 1 1 Using meter only REVERSE LEAD POLARITY connect leads as specified If using a meter with built in DVA place selector switch in the DVA 400 VDC position 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2A 3 AWARNING When testing or servicing the ignition system high voltage is present be extremely cautious DO NOT TOUCH OR DISCONNECT any ignition parts while en gine is running while key switch is on or while battery cables are connected ACAUTION Failure to comply with the following items may result in damage to the ignition system 1 DO reverse battery cable connections The battery negative cable is ground 2 DO NOT spark battery terminals with battery cable connections to check polarity 3 DO NOT disconnect battery cables while engine is running 4 DO NOT crank engine when switch box is not grounded to engine A process of elimination must be used when
278. ges and fuel and primer lines e Install sound attenuator a Fuel Bowl b Screw 4 Torque 18 Ib in 2 1 N m a Attenuator Brackets 2 b Carburetor Screw 6 Torque 100 Ib in 11 5 N m c Attenuator Screw 4 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3A 17 FUEL SYSTEMS FUEL PUMP Table of Contents Page Specifications 3B 1 Fuel Pump 50 60 3B 2 Fuel Pump 55 60 Seapro Marathon 3B 4 Fuel Pumps 3B 6 General Information 3B 6 Fuel Pump Description Operation 3B 6 Checking for Restricted Fuel Flow Caused by Anti siphon Valves 3B 6 Testlhg 3B 6 Troubleshooting Fuel Pump 3B 7 Fuel Pump Removal 3B 8 Fuel Pump Disassembly 3B 8 Cleaning and Inspection 3B 8 Fuel Pump Reassembly 3B 9 Check Valve Assembly 3B 9 Fuel Pump Assembly 3B 9 Fuel Pump Exploded View 3B 10 Torque Specification 3B 10 Fuel Tank idee assaka wasipiqa 3B 11 Maintenance 3B 11 Fuel Tank Components 3B 11 Fuel Line and Primer Bulb Assembly 3B 12 Maintenance 3B 13 90
279. h 90 817643R1 DECEMBER 1996 MID SECTION 5D 9 Power Trim System Wiring Diagram BLK Black Negative BLU Blue Trim Motor UP GRN Green Trim Motor DOWN RED Red Positive Wiring From Side Mount Remote Control Harness BLU WHT Blue White Trim Switch to UP Relay GRN WHT Green White Trim Switch to DOWN Relay peto emm l Power Trim I Motor x Engine Harness BLU WHT GRN WHT RED StartSolenoid S To Battery Trim Relays 51507 5D 10 MID SECTION 90 817643R1 DECEMBER 1996 PAS Troubleshooting the Down Circuit When Up Circuit is OK Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Battery Voltage Indicated No Voltage Indicated Down Relay is Defective Replace and retest Connect Voltmeter red lead to Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 90 817643R1 DECEMBER 1996 MID SECTION 5D 11 Troubleshooting the Up Circuit When Down Circuit Is OK
280. h 90 817643R1 DECEMBER 1996 4 Hold throttle arm at idle position Adjust cam follower so that a clearance of 005 in 040 in 0 13 mm 1 02 mm exists between roller e of cam follower and throttle cam f Tighten screw a securing cam follow er 51069 5 Hold throttle arm a against full throttle stop screw b Adjust full throttle stop screw to allow throttle shutters to open fully while providing approximately 015 in 38 mm freeplay in throttle linkage to prevent carburetor throttle shutters from acting as throttle stops at wide open throttle Tighten locknut c on stop screw b Z w CAO A 51045 6 Reinstall sound box cover 90 817643R1 DECEMBER 1996 Timing Adjustments ACAUTION Engine may be timed while cranking engine with start er motor To prevent engine from starting when being cranked all spark plugs must be removed 1 Insert Spark Gap Tool 91 63998A1 into each spark plug boot and attach alligator clips to good engine ground Disconnect remote fuel line from engine Connect remote control electric harness to engine wir ing harness 4 Remove throttle cable barrel from barrel retainer IDLE TIMING ADJUSTMENT 1 Connect timing light to No 1 TOP spark plug lead A WARNING While cranking engine keep clear of propeller as it may rotate 2 Shift engine to neutral IMPORTANT To time engine at cranking speed a fully charged battery must be used
281. heck for open in wire 5C 20 MID SECTION Check in line fuse under cowl to see if fuse is blown No Voltage Indicated Connect red Voltmeter lead to Point 5 and black lead to ground Troubleshooting the Down and Up Circuits All Circuits Inoperative Fuse Not Blown Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated Battery Voltage Indicated Connect Voltmeter red lead to Point 8 and black lead to ground Depress Up trim button and check for battery voltage Battery Voltage Indicated i Check black ground wires for poor connection or poor ground e Pump motor is faulty Refer to Motor and Electrical Tests Rep air following Battery Voltage Indicated Trim switch is faulty or there is an open circuit in wires green white blue white between trim buttons and trim pump e Check trim switch e Check all trim harness connec tors for loose or corroded con nections Check for pinched or severed wires Battery Voltage Indicated There is an open circuit in wire be tween Point 5 and Red terminal on the back of the ignition switch 90 8i7643R1 DECEMBER 1996 Power Trim System Removal Support outboard with tilt lock lever when servicing power trim system 1 Disconnect power trim harness form outboard wiring harness 2 Remove screw and clip securing wiring harness to clamp bracket 3
282. i Corro sion Grease Quicksilver 2 4 w Te flon Marine Lubricant Check and fill after first 10 days then every 30 days Drain and re fill after 1st 25 hours then after every 100 hours or once a year before storing Quicksilver Gear Lube Quicksilver 2 4 C w Te flon Marine Lubricant Once in Season Every Every flon 60 Days 30 Days Marine Lubricant Every Every 60 Days 30 Days Once in Every Season 60 Days Starter Motor SAE 30W Once in Every Pinion Gear Motor Oil Season 60 Days After first 20 Hours then once in season Check and fill after first 10 days then every 30 days Drain and re fill after 1st 25 hours then after every 100 hours or once a year before storing Once in Season Refer to lubrication instructions outlined in Salt Water Corrosion Gear Housing Bearing Carrier and Cover Nut of this section see Table of Contents Refer to Gear Housing Lubrication of this section see Table of Contents A Refer to Gear Housing Removal and Installation Section 5 1 14 GENERAL INFORMATION and SPECIFICATIONS 2 Upper Shift Shaft Lubrication 90 817643R1 DECEMBER 1996 3 Swivel Pin Grease Fittings RIDE GUIDE STEERING CABLE and PIVOT POINTS LUBRICATION AWARNING Core of steering cable transom end must be fully retracted into cable housing before lubricating cable If cable is lubricated while extended hydraulic l
283. ical amp Ignition Part A Ignition System Part B Battery Charging System amp Starting System Part C Timing Synchronizing amp Adjusting Part D Wiring Diagrams Section 3 Fuel Systems Part A Carburetion Part B Fuel Pump Part C Fuel Enrichment Part D Oil Injection Section 4 Powerhead Section 5 Section 6 Section 7 Mid Section Part A Clamp Swivel Brackets and Driveshaft Housing Part B Power Trim Design 1 Part C Power Trim Design II Part D Power Trim Design III Part E Power Trim Design IV Part F Manual Tilt Design l Il III Part G Manual Tilt Design IV Lower Unit Part A Standard Gear Housing Part B 60 Big Foot 60 SeaPro amp Marathon Gear Housing Part C Jet Drive Outboard Installation Attachments Part A Ride Guide Steering Throttle Shift Cables amp Electrical Connections Part B Tiller Handle and Co Pilot Part C Rewind Starter 90 817643R1 DECEMBER 1996 otice Throughout this publication Dangers Warnings and Cautions accompanied by the International HAZARD Symbol A are used to alert the mechanic to special in structions concerning 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 instruc tions when performing
284. icant VENT Plug Washer Lubricant Fill Plug Washer Lubricant VENT Plug Washer KR Inspect gear lubricant for metal particles lubricant will have a metal flake appearance Presence of fine metal particles resembling powder on the FILL plug bar magnet indicates normal wear The presence of metal chips on the drain plug bar magnet indicates the need for gear housing disassembly and components inspection 1 16 GENERAL INFORMATION and SPECIFICATIONS 5 Note color of gear lubricant White or cream color indi cates presence of water in lubricant Gear lubricant which has been drained from a gear housing recently in operation will have a yellowish color due to lubricant agitation aeration This is normal and should not be confused with the presence of water 6 Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals seal sur faces O rings water pump gaskets as well as gear housing components for damage IMPORTANT Never add lubricant to gear housing without first removing VENT plugs as trapped air will prevent housing from being filled Fill gear housing only when outboard is in operating position 7 With outboard in operating position insert lubricant tube into fill hole 8 Fill gear housing until excess lubricant flows from for ward VENT hole 9 Install VENT plug and washer a 10 Continue to fill gear housing until lubricant flows from VENT hole
285. identification facing fly wheel end Pistons MUST be installed in this direction ACAUTION Pistons must be installed very carefully into cylinders Piston rings can not be inspected thru exhaust ports 6 Bottom end of cylinder bore has taper which permits the insertion of the piston into block without using a pis ton ring compressor Place piston carefully into cylin der PE 51087 POWERHEAD 4 29 c Crankshaft Installation CAUTION 1 If lower bearing and gear were removed from crank Any grease used for bearings INSIDE the powerhead MUST BE gasoline soluble Use only Quicksilver Needle Bearing Assembly Lubricant DO NOT use 2 4 C Marine Lubricant or other lubricants inside pow 2 Install main bearing retaining ring after pressing main erhead or damage to engine may occur bearing tight against oil gear shaft slide gear in place note keyway and key in gear to crankshaft assembly Install gear to crankshaft us ing an arbor press and suitable mandrel 4 Grease crankshaft journal with Quicksilver Needle Bearing Assembly Lubricant to hold bearing in place Position needle bearings on journal There are 28 bearings per each center main dcn PE 51081 a Lower Bearing a Crankshaft Journal b Gear MA x c Retaining Ring b Bearings 28 IMPORTANT Snap ring groove faces up towards fly ACAUTION wheel Safety glasses should be worn when removing or in 5 Attach main bearing races with holes towa
286. ift cable so that roller d is at the full end of travel bottom in the shift cam when the shift lever is in forward 3 Attach the brass barrel c to the bracket with bolt and locknut Tighten the bolt until it seats against the barrel then back off the bolt 1 4 turn Hold bolt from turning and tighten locknut on bolt The barrel must be free to pivot Shift Cable Shift Cam Barrel Roller AA Recheck the shift cable adjustment forward shift position The correct shift adjustment will position the cam far enough on the roller in order to lock the the reverse gate into forward position You should not be able to forcibly push up the reverse gate to ward neutral Pull on the reverse gate by hand to verify this IMPORTANT The forward locking of the reverse gate must be met If not readjust the shift cable LOWER UNIT 6C 23 GUTBOARD INSTALLATION ATTACHMENTS RIDE GUIDE STEERING THROTTLE SHIFT CABLES amp ELECTRICAL CONNECTIONS 7 Table of Contents Page Installing Outboard Motor on Transom 7 1 Determining Recommended Outboard Mounting Height 7 1 Locate Centerline of Boat Transom 7 1 Lifting Outboard Electric Start Models 7 1 Lifting Outboard Manual Start Models 7 2 Drilling Outboard Mounting Holes Electric Start Models 7A 2 Fastening Outboard on Boat Transom Manual Start Models
287. ignition key is at OFF position 2 If necessary adjust trim tab as follows b Remove plastic cap from rear of drive shaft hous ing and loosen bolt and trim tab IMPORTANT Trim tabs MUST BE set in the same posi tion on both outboards c If boat pulls to the right adjust trailing edges of both trim tabs to the right If boat pulls to the left adjust trailing edges of both trim tabs to the left d Tighten both trim tab bolts securely and replace plastic caps e Operate boat following trim tab adjustment Read just trim tab if necessary Maintenance Instructions Maintenance inspection is owner s responsibility and must be performed at intervals specified following Normal Service Every 50 hrs of operation or 60 days whichever comes first Severe Service Every 25 hrs of operation or 30 days whichever comes first Operation in a salt water area is considered Sever Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifications NOTE Ride Guide Steering Cables are lubricated at the factory and require no additional lubrication at initial instal lation AWARNING Core of each steering cable transom end must be ful ly retracted into cable housing before lubricating cable If cable is lubricated while extended hydraulic lock of cable could occur 3 With core of Ride Guide
288. ill ing Procedure NOTE There are two ways for the filling procedure The first is the easiest and less time consuming Filling Procedure Option One 1 2 Place trim cylinder in soft jawed vice With manifold cam lever closed Up Position fill cylinder and manifold to top with Quicksilver Pow er trim and steering fluid or ATF automatic transmission fluid Let bubbles disperse Install lubricated O ring to memory piston Using lock ring pliers Craftsman P N 4735 or Snap on P N SRP4 set memory piston in top of cylinder then open cam lever Down Position and push memory piston down just below cylinder treads Close cam lever Up Position 51144 Fill top of cylinder again with fluid to top and install shock rod assembly on top memory piston Open cam lever Down Position and push shock rod assembly down to 1 8 below cylinder threads Close cam lever Up Position 90 817643R1 DECEMBER 1996 top of shock rod assembly with fluid to top of cylinder Open cam lever Down Position and screw cylinder cap down 7 Tighten end cap securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten end cap then torque the end cap to 45 Ib ft 61 0 N m Close cam lever up Position 51145 8 Open and close cam lever watching for bubbles coming from accumulator check ball hole When bubbles stop fill accumulator opening to top with
289. ill if necessary Refer to Fill and Purge the Power Trim System 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls to trim in position indicates debris or defective compo nents in trim valve assembly Clean or replace components as required 5 Check manual release valve for broken stem and one O ring remaining in the release valve pas sage Separate the manifold assembly from the cylinder to dislodge broken stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system 5B 12 MID SECTION c Leak Down Check Pump and Manifold Assembly NOTE Scribe d pump housing halves before disas sembly 1 Debris or chips between valve and seat a Usu ally imbedded in rubber valve seat Nicked or deteriorated O ring b Nicked deteriorated or misplaced O ring be tween manifold and trim cylinder Refer to ifold Removal for O ring location 51735 4 After reassembly insert driveshaft and check pump rotation resistance to turning housing halves can shift turn during reassembly Align scribe marks d carefully 90 817643R1 DECEMBER 1996 PAS Leak Down Check Pilot Valve Assembly 1 Debris or chips between check ball and seat a usually imbedded in rubber valve seat 2 Nicked or deteriorated O ring b A
290. im system is self b Swivel Bracket purging c Trim Ram 11 Reconnect power trim leads to relays under igni tion cover 12 Reinstall spark plug leads to spark plugs 13 Reinstall cowls 14 Connect battery leads to battery terminals 5D 28 MID SECTION 90 817643R1 DECEMBER 1996 MID 5 lO N Table of Contents Page Special Tools 5E 1 Theory Of Operation 5E 4 Adjustm nisS iis veu Rieke ee EE 5E 4 Trimming Characteristics 5E 4 Trimming Outboard Up Out 5E 4 Trimming Outboard Down In 5E 4 Trailering Outboard 5E 5 Tilting Outboard Up and Down Manually 5 5 THN asss Aaa ka 5E 7 TiIUUDS ase 9 Maximum Tilt 5E 11 Down Mode 5E 13 Shock Function Up 5E 15 Shock Function Return 5E 17 Manual Tilt 5E 19 Troubleshooting 5E 20 Preliminary Checks 5 20 Hydraulic System Troubleshooting Flow 5E 21 Hydraulic System Troubleshooting Flow Chart 5E 22 Hydraulic System Troubleshooting F
291. imming the outboard further under If it remains excessive with all similar propellers the out Air Diameter Time Water and RPN in Seconds During During Condition Temperature Comments Pitch Acceleration Turns It is suggested that all applicable data be recorded on a chart such as that illustrated above and retained for future reference After several propellers of different pitch and or design have been tried select one that best serves the gener al purpose of the boat The selected propeller should enable the engine to operate within its recommended full throttle RPM range without excessive propeller break loose during acceleration or turns A second propeller that would make both a suitable spare or a special purpose alternate might also be desirable board must be lowered 90 817643R1 DECEMBER 1996 NOTE A higher pitch often gives best top speed but the next lower pitch gives adequate top speed with much better acceleration GENERAL INFORMATION and SPECIFICATIONS 1 13 Lubrication Points T Type of Fresh Water Salt Water NT esee reme Throttle Shift Linkage Pivot Points Upper 2 Shift Shaft Ride Guide Steering Cable Tilt Tube Steering Link Rod Pivot Points Propeller Shaft Gear Housing Bearing Carrier 1 0 Housing Engine Crankshaft Splines to Drive Shaft Splines Quicksilver 2 4 C w Te SAE 30W Motor Oil Quicksilver Ant
292. in pivot pin bore and trim ram bore 51148 a Pivot Pin b Pivot Pin Bore c Trim Ram Bore 7 Using a suitable mallet drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket a Pivot Pin b Swivel Bracket c Trim Ram 90 817643R1 DECEMBER 1996 10 Route trim harness through clamp bracket and cowling L 8 Drive trilobe pin a into its hole until seated NI US eas i D D D 55464 a Trilobe Pin 55264 a Trim Harness 11 Secure trim harness with clamp as shown Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode as shown 9 Sacrificial Anode b Ground Strap c Bracket a Clamp MID SECTION 5E 45 90 817643R1 DECEMBER 1996 MID SECTION MANUAL TILT SYSTEM DESIGN Il III Table of Contents Page Manual Tilt System Components Design One and TWO 2 as i kepti 1 Quicksilver Lubricant Sealant Application Points 5F 1 Torque Specification 5F 1 Manual Tilt System Components Design jin rcp 5F 2 Quicksilver Lubricant Sealant Application PONS RA kiasa 5F 2 Torque Specification
293. in until seated 51148 a Lower Dowel Pin 5F 36 MID SECTION 6 Apply N Lubricant 2 4 w Teflon Marine 92 9001 8A12 to surface of upper pivot pin pivot pin hole and shock rod hole 51148 Pivot Pin Pivot Pin Bore Shock Rod Bore Using a mallet drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket Pivot Pin Swivel Bracket Shock Rod Drive upper dowel pin a into its hole until seated a Dowel Pin 9 Check manual release cam adjustment Cam must open and close freely Adjust link rod as nec essary 90 817643R1 DECEMBER 1996 MID SECTION MANUAL TILT SYSTEM d DESIGN 4 Table of Contents Special Tools ee week eme Til Dp LE CRUS bua latas Tilt DOWN Lugu asas eem mpm peregi Slow Tilt Down Under High Thrust Under Water Strike with Valves Open Shock Function with Valves Closed Shock Function Return Hydraulic System Troubleshooting Manual Tilt System Removal Manual Tilt System Disassembly Accumulator Shock Rod Removal Shock Rod Disassembly Valve Block Removal Memory Piston Removal Valve Block Dis
294. ing fol lowing FUEL SYSTEMS 3D 9 Required Side Mount Remote Control or Ignition Key Switch Assembly Boats Equipped with a Side Mount Remote Control A Quicksilver Commander Series Side Mount Remote Control equipped with a warning horn must be used with this outboard This warning horn is necessary for both the oil injection warning system and the engine overheat warn ing system Boats Equipped with Panel or Console Mount Remote Controls A Quicksilver Ignition Key Choke Assembly equipped with a warning horn is necessary for both the oil injection warn ing system and the engine overheat warning system Oil Injection System Troubleshooting Chart Troubleshooting the Oil Injection System If a problem occurs with the oil injection system and the warning horn sounds in a intermittent manner stop engine and check if problem is caused by 1 low oil Level or 2 a faulty warning sensor of module Troubleshooting Chart Problem Warning Horn Does Not Sound When Ignition Key is Turned to ON Position Possible Cause Corrective Action Horn malfunction or open tan blue wire between horn and Disconnect tan blue warning module lead engine over engine Faulty Warning Module Using incorrect side mount remote control or ignition choke assembly heat sensor located in cylinder head Use a jumper wire to ground tan blue warning module lead to engine ground Warning horn should sound If not check tan blue w
295. inside of dri veshaft housing when gear housing was removed then pull seal from water tube Replace water tube seal a if damaged 2 Remove 6 bolts b washers c and isolators d De sign 1 Remove cover e NOTE Isolators d from forward 2 screws are different from the other isolators Retain these for proper re assem bly Design 1 IMPORTANT The circular groove formed by the impel ler sealing bead should be disregarded when inspect ing cover and plate as the depth of the groove will not affect water pump output 3 Replace cover if thickness of steel at the discharge slots is 060 1 524mm or less or if groove s other than impeller sealing groove in cover roof are more than 030 in 762mm deep 4 Lift impeller a drive key b and gasket c Replace impeller if Impeller blades are cracked torn or worn Impeller is glazed or melted caused by insufficient water supply Rubber portion of impeller is not bonded to impeller hub 90 817643R1 DECEMBER 1996 51207 5 Remove plate a and gasket b 6 Replace plate if groove s other than impeller sealing groove in plate are more than 030 in 762mm deep 51206 7 Remove water pump base a by lifting gently as shown LOWER UNIT 6A 7 8 Remove and discard seals a if damaged 51205 9 Remove seal and plate if damaged or worn o IC 1 51268 a Seal b
296. install vent plug 90 817643R1 DECEMBER 1996 Filling Gear Housing With Lubricant NOTE Gear housing lubricant capacity is 22 5 fl oz 665 2ml If gear housing is installed on engine to avoid accidental starting disconnect and isolate spark plug leads from spark plugs before working near the propeller A CAUTION Do not use automotive grease in the gear housing Use only Quicksilver Gear Lube or Quicksilver Super Duty Lower Unit Lubricant 1 Remove any gasket material from Fill and Vent screws and gear housing 2 Install new gaskets on Fill and Vent screws IMPORTANT Never apply lubricant to gear hous ing without first removing Vent screws or gear housing cannot be filled because of trapped air Fill gear housing only when housing is in a vertical position 3 Remove lubricant Fill screw and gasket from gear housing 4 Insert lubricant tube into Fill hole then remove Vent screws and gaskets 5 Fill gear housing with lubricant until excess starts to flow out of one first Vent screw hole LOWER UNIT 6B 31 6 Replace this lubricant Vent screw and gasket only and continue filling until excess starts to flow out of second lubricant Vent screw hole 4 P4 e 53922 Vent Screw Fill Drain Screw Oil Level Vent Screw oon Replace second lubricant
297. ion 7A 6 OUTBOARD INSTALLATION ATTACHMENTS 1 Lubricate inside of outboard tilt tube and steering cable end b with Quicksilver 2 4 C Marine Lubricant 2 Insert steering cable end thru outboard tilt tube and se cure with steering cable attaching nut c Torque to 35 Ib ft 41 50564B 3 Make pencil mark a on tilt tube 1 4 in 6 4mm from port end of tube Slide spacer b O ring c and cap d over steering cable end 50180 50180 90 817643R1 DECEMBER 1996 able Installation to Tilt Tube Cable Routed on Port Side of Boat TILT TUBE REVERSAL ACAUTION Outboard tilt tube MUST BE removed and re installed in the opposite direction When re assembled longer threaded end of tilt tube extends out port side of out board approximately 3 4 in 19mm Failure to reposi tion outboard tilt tube as described could interfere with steering system operation Remove outboard tilt tube and re install in the opposite di rection turn end for end When re assembled longer threaded end a of tilt tube extends out port side of out board approximately 3 4 in 19mm Refer to Section 5A Midsection 51130 Single Cable Dual Single Cable Single Outboard Outboard IMPORTANT Before installing steering cable tilt tube lubricate entire cable end with Quicksilver 2 4 C w Te flon Marine Lubricant NOTE Ride Guide Steering cable is lubricated at the fac tory and requires no additional lu
298. ion NOTE If shim s were lost or are not reusable damaged start with approximately 015 in 0 361mm Install components in sequence shown Xe 1 i Z LL S SSS p 51263 a Forward Gear Bearing Apply Quicksilver Gear Lube to Bearing Rollers Before Installation b Pinion Gear c Upper Driveshaft Bearing Race and Shim s d Upper Driveshaft Bearing Retainer Torque to 75 Ib ft 101 7 N m Use Tool 91 43506 e Driveshaft f Driveshaft Holding Tool 91 817070 g Pinion Nut New See Note at Pinion Gear Depth Following Recess in Nut is Installed Toward Pinion Gear See Inset 90 817643R1 DECEMBER 1996 PAS hn Pinion Gear Location and Forward Gear Backlash DETERMINING PINION GEAR LOCATION NOTE Head entire procedure before attempting any change in shim thickness IMPORTANT Forward gear assembly must be in stalled in gear housing when checking pinion gear depth to obtain accurate shim measurements 1 Clean the gear housing bearing carrier shoulder and diameter 2 Position gear housing upright driveshaft vertical In stall Bearing Preload Tool in sequence shown 3 4 in 19mm 1 0 51270 Plate Adaptor Bearing surfaces clean and free of nicks Thrust Bearing Oiled and able to move freely Thrust Washer Clean and free of nicks and bends Spring Nut Threaded all the way onto bolt Bolt Held snug agai
299. ion plate and the propeller 5 Thread propeller nut on propeller shaft tighten secure ly with wrench minimum of 55 Ib ft 74 5 N m of torque and bend on tab washer to secure propeller nut 6 After first use bend the tab straight retighten propeller nut minimum of 55 Ib ft 74 5 N m of torque and again bend tab washer to secure nut Check propeller periodically for tightness 51119 c Tab Washer Propeller Nut Installing and Removing Propeller Trim In Angle Adjustment AWARNING Operating some boats with outboard trimmed to the full in trim angle not using trim adjustment bolt a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after outboard installation and after any trim adjustments IMPORTANT Some boat outboard combinations that do not use the trim adjustment pin a and are trimmed to the full in trim angle will not experience any unde sirable and or unsafe steering conditions during plan ing speed Thus not using trim adjustment pin may be desired However some boats with outboard trimmed to the full in trim angle at planing speeds will cause undesirable and or unsafe steering conditions If these steering conditions are experienced under no circumstances should the outboard be operated with out the trim adjustment pin and without the pin ad justed in the proper holes to prevent u
300. ious degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion trim tab in neutral straight fore and aft posi tion you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor in slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty Will lift bow of boat generally increasing top speed Transfers steering torque harder to left on installa tions below 23 transom height Increases clearance over submerged objects In excess Can cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating damage Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage 90 817643R1 DECEMBER 1996 Make sure that water level is above gear housing water intake holes whenever engine is running Operating up circuit will actuate the up solenoid located under engine cowl and close the elec
301. iring between engine and warning horn for open circuit Check horn Check if all warning module leads are connected See info above Problem Warning Horn Stays On When Ignition Key is Turned to ON Position Engine Cold Possible Cause Corrective Action Faulty Engine overheat sensor If warning horn sounds a continuous beep the engine overheat sensor may be faulty Disconnect tan blue over heat sensor lead at bullet connection Turn ignition key to position If horn stops sounding the engine overheat sensor is faulty Faulty Warning Module Check connections replace module Problem Warning Horn Sounds Intermittent Beep When Engine is Running and Oil Tank is Full Possible Cause Corrective Action Defective low oil sensor located in bottom of oil tank Disconnect both low oil sensor leads blue at bullet con nections Connect an ohmmeter between sensor leads There should be no continuity through sensor If continuity exists sensor is faulty If all of the checks are positive the Warning Module is faulty Replace Module and re test 30 10 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 ax L 1 Check oil level in oil tank If oil level is approximately 14 5 fl oz 435 ml or less the problem is low oil level Add oil to oil tank NOTE There is a safety reserve of oil left in the oil tank af ter the low oil warning is sounded that allows enough oil for approximately
302. itch i a ex tay 9 bt d PE 51089 a Blue White b Green White c Red Black d Trim Switch 12 Connect control trim harness and fuel line aT te s U PE 51082 PE 51084 4 38 POWERHEAD p Test Run Procedure ACAUTION When engine is started IMMEDIATELY check that wa ter pump is operating Operation of water pump is indi cated by water discharging from tell tale 1 While test running outboard check powerhead as sembly for leaks and or unusual noises Make any re pairs BEFORE placing outboard in service Important Information Proper break in assures that all moving parts wear in evenly to ensure a longer engine life and optimum perform ance Operate your new outboard motor at varied throttle settings not to exceed 1 2 throttle 2500 3500 RPM during the first hour or the first five gallons of break in fuel Refer to Fuel Mixture and Gasoline Oil Recommendations Break In Fuel Mixture located in your operation and Main tenance Manual During the second hour operation or the second 5 gallons 20 Litres of break in fuel operate the Outboard at varied throttle settings not to exceed 4500 RPM DO NOT OPERATE YOUR NEW OUTBOARD MOTOR AT FULL THROTTLE UNTIL THE SECOND HOUR OF BREAK IN IS COMPLETED This includes full throttle ac celeration pulling waterskiers or wide open throttle run ning After the first two hou
303. itive brushes into commutator end cap 2B 18 ELECTRICAL and IGNITION 11660 a Positive Terminal b Long Brush Lead c Push Lead Into Slot d Insulating Washer e Flat Washer f Lock Washer g Nut 2 Install components 11656 Positive Brushes Negative Brushes Brush Holder Bolts Fasten Negative Brushes and Holder Reassembly 1 Lubricate helix threads and drive end cap bushing with SAE 10W oil 2 Install components onto armature shaft 90 817643R1 DECEMBER 1996 4 Construct a brush retainer tool as shown 77 11658 Washer 90 Helix Threads B Armature Shaft 1 11 16 a b c d Drive End Cap e Drive Assembly f Spring g Spacer 3 Install locknut a 1 2 3 4 1 3 4 Brush Retainer Tool Layout Full Size Y 18 Gauge Sheet Metal 4 METRIC SCALE 3 76 2mm 2 50 8mm 1 3 4 44 5mm 1 11 16 42 9 3 4 19 1 1 2 12 7mm Brush Retainer Tool Side View Full Size 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2B 19 5 Place springs and brushes into brush holder and hold in place with brush retainer tool 6 Lubricate bushing with one drop of SAE 10W oil DO NOT over lubricate on Brush Retainer Tool Bushing Position armature into starter frame so that commuta tor end of armature is at end of starter frame where pe
304. ive shaft splines 7 Applya light coat of Quicksilver 2 4 C w Teflon on gear case shift shaft splines and upper shift shaft splines Do not use lubricant on ends of shift shafts 8 Install components as shown in appropriate photo a Nylon Spacer b Shift Shaft Coupler Used on Models Equipped with Power Trim LOWER UNIT 6B 33 53925 Nylon Spacer b Shift Shaft Coupler Used on Models NOT Equipped with Power Trim c Flat MUST BE Positioned Toward Front of Gear Housing Shift gear housing into forward gear position In forward gear the gear housing will ratchet when propeller shaft is turned clockwise and resistance will be felt when propeller shaft is rotated counter clockwise 10 Apply Loctite Grade 271 on threads of gear hous ing retaining bolts NOTE If while performing Step 11 the drive shaft splines will not align with the crankshaft splines place a propeller onto propeller shaft and turn it counter clockwise as the gear housing is being pushed toward drive shaft housing NOTE During installation of gear housing it may be necessary to move the shift block located under cowl slightly to align upper shift shaft splines with shift shaft coupler splines 11 Position gear housing so that the driveshaft is pro truding into drive shaft housing 12 Move gear housing up toward drive shaft housing while aligning upper shift shaft splines with shift shaft coupler splines wat
305. ivot pin hole and posi tion lower dowel pin retained in its hole 51147 a Lower Pivot Pin 51148 5 Using a punch drive lower dowel pin in until seated a Lower Pivot Pin b Lower Dowel Pin m 3 Reinstall manual tilt system bottom first Recon N nect release valve link rod N a 51148 a Lower Dowel Pin 51144 a Manual Tilt System 90 817643R1 DECEMBER 1996 MID SECTION 5G 35 6 Apply 2 4 C Marine Lubricant 92 90018A12 to surface of upper pivot pin pivot pin hole and shock rod hole 51148 a Pivot Pin b Pivot Pin Bore c Shock Rod Bore 7 Using a mallet drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket Pivot Pin Swivel Bracket c Shock Rod 5G 36 MID SECTION 2 f 8 Drive upper dowel pin a into its hole until seated a Dowel Pin 9 Check manual release cam adjustment Cam must open and close freely Adjust link rod as nec essary Manual Release Valve Adjustment 1 With outboard in full up position place tilt lock le ver forward 2 Lift cam lever with link rod to full up position 51143 a Tilt Lock Lever b Cam Lever c Link Rod 3 Link rod end must snap onto ball of tilt lock lever without moving tilt lock lever or cam lever 90 817643R1 DECEMBER 1996 ax L LOWER UNIT STANDARD GEAR HOUSING Table of Contents Drive Shaft and Water
306. k Piston o Shock Return Valve p Impact Relief Valve 90 817643R1 DECEMBER 1996 ay Function With Valves Closed Should the drive unit strike a submerged object while in forward motion the shock rod a will extend from the cylinder I Oil inside the up cavity is locked in static position by the closed up fast transfer valve j the closed down slow transfer valve i and closed down fast transfer valve h Fluid will attempt to exit the cylinder through the interconnecting passage back into the accumulator c The closed up fast transfer valve j will prevent the fluid return As the shock rod extends outward the pressure inside the up cavity will reach sufficient pressure to open the shock valve p which opens at 880 1110 psi Oil will flow into the cavity created as the shock rod amp shock piston a amp n moves away from the memory piston m 90 817643R1 DECEMBER 1996 MID SECTION 56 13 a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 14 MID SECTION c Shock Function Return i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve 90 817643R1 DECEMBER 1996 ock Function Return After the drive clears the object the shock return valve will allow the
307. k ignition switch wiring as follows CAUTION To prevent engine from starting remove spark plug leads from ALL spark plugs and ground leads to en gine 1 Disconnect ignition switch and stop switch leads from switch box and isolate the leads 2 Repeat check in Step 2 A a If reading is still BELOW specification proceed with Step 3 A b Ifreading is WITHIN specification either the igni tion switch stop switch or wiring is bad 3 A Check stator low speed and high speed input to switch box see Test Chart 1 If either the low speed or high speed reading to switch box is BELOW specification Stator or Switch Box is bad test stator as outlined in this service manual sec tion if stator checks to specification replace switch box and repeat check 2 If both the low speed and high speed reading are WITHIN specification replace switch box and repeat test 90 817643R1 DECEMBER 1996 1 Ignition System Test Chart IMPORTANT BEFORE attempting the ignition system checks following thoroughly read the preceding pages of these instructions to become familiar with the proper Automatic Distributorless Ignition ADI test sequence and pro cedures particularly any Safety Warnings and Cautions ALL tests are performed with lead wires connected terminals exposed SWITCH BOX MUST BE GROUNDED CASE TO ENGINE BLOCK FOR ALL TESTS IF NOT SWITCH BOXES MAY BE DAMAGED 55 60 MARATHON SEAPRO 398 9873A 5 printe
308. l ratio in fuel tank plus 50 1 ratio from oil pump for the first 15 gallons of fuel Refer to engine break in procedure in the Operation and Maintenance Manual ACAUTION If using an electric fuel pump fuel pressure must not exceed 4 psi 27 4 kPa If necessary install a pressure regulator between electrical fuel pump and engine Set at 4 psi maximum Carburetor Oil Pump Synchronization Variable Ratio Oil Pump While holding throttle arm at idle position adjust length of link rod so that stamped mark of oil pump body aligns with stamped mark of oil pump lever and lever is in closed posi tion a Mark on Body b Mark on Lever c Link Rod 3D 8 FUEL SYSTEMS c Filling Oil Injection System with Oil Quicksilver 2 Cycle Outboard Oil is recommended for this oil injection system In an emergency whin Quicksilver oil is not available substitute a high quality 2 cycle outboard oil that meets BIA ratings TC W and TC WII shown on oil container BIA ratings TC W and TC WII are the Boating Industry Association s designation for approved 2 Cycle water cooled outboard oils 90 817643R1 DECEMBER 1996 c Bleeding Air From Oil Injection System ACAUTION If air exists in either oil pump hose inlet or outlet the air MUST BE bled from hose s or engine damage may occur BLEEDING AIR FROM OIL PUMP INLET HOSE With engine not running place a shop towel below oil pump Loosen bleed screw three to four turns and
309. l to the full down position with a potential for damaging engine or causing personal injury To avoid such injury support outboard in the up position using tilt lock lever Manual tilt system is pressurized Accumulator must be removed when shock rod is in the full up position prior to servicing otherwise oil spray back may occur 1 Support outboard in the up position using tilt lock lever 2 Remove link rod 51143 a Link Rod b Accumulator 90 817643R1 DECEMBER 1996 3 Use suitable punch to remove DRIVE DOWN upper dowel pin Retain dowel pin a Dowel Pin 4 Use suitable punch to drive out upper pivot pin 51144 a Pivot Pin 5 Use punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a Dowel Pin MID SECTION 5F 21 6 Use suitable punch to drive out lower pivot pin 51144 a Pivot Pin 7 Tilt shock absorber assembly TOP FIRST out from clamp bracket and remove assembly 51144 a Manual Tilt System 5F 22 MID SECTION Manual Tilt System Disassembly NOTE Accumulator contains a high pressure nitro gen charge and is NOT SERVICEABLE Replace if necessary This tilt system is pressurized Remove accumu lator only when shock rod is in full up position Accumulator Removal 1 Place manual tilt system in soft jawed vise 2 Position shock rod to full up position 3 Remove accumulator 51143 a Shock Rod b Accumulato
310. ld 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 rec ommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet The minimum package quantity of each material shown following is sufficient to 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 90 817643R1 DECEMBER 1996 3 Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only Feather edge all broken paint edges 4 Clean gear housing thoroughly with DX 330 wax and grease remover 5 Spot repair surfaces where bare metal is ex posed with DX 503 alodine treatment IMPORTANT Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering 6 Mix epoxy chromate primer DP 40 with equal catalyst DP 401 per manufacturers instructions allowing proper induction period for permeation of the epoxy primer and catalyst 7 Allow a minimum of one hour drying time and no more than one week before top coating assem blies 8 Use Ditzler Urethane DU90
311. leak path is created between the UP side of the cyl inder and the reservoir The trim system will leak DOWN until the trim port in cylinder is covered a Check Ball and Seat b O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a O ring 90 817643R1 DECEMBER 1996 Leakage Past Ball and Seat Piston Assembly Unit will trim to full or near full DOWN position and then will begin to trim UP while trim switch is held in DOWN mode If trim switch is released outboard can be pushed by hand DOWN to the point where trim UP started 1 Inspect balls and seats in piston assembly for de bris or damage Repair or replace balls seats a Ball and Seat Check for Debris or Damage MID SECTION 5B 13 Troubleshooting Flow Diagram Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceler ation Inspect Manual Release Valve Result Result Manual release valve and or O ring damage Manual release valve and O rings appear to be OK Replace O rings rings Inspect Memory Piston O ring Replace defective valve and O Result Result O rings appear to be OK Cylinder O ring memory piston or cylinder bore and memory piston ar
312. lign scribe marks d carefully 90 8i7643R1 DECEMBER 1996 2 1 Leak Down Check Pilot Valve As Leakage Past Ball and Seat Piston sembly Assembly 1 Debris or chips between valve and seat a usu Unit will trim to full or near full DOWN position and ally imbedded in rubber valve seat then will begin to trim UP while trim switch is held in 2 Pilot valve installed from non chamfered end of THOS spool results in nicked or damaged O ring b If trim switch is released outboard can be pushed by hand DOWN to the point where trim UP started 1 Inspect balls and seats in piston assembly for de bris or damage Repair or replace balls seats 3 Nicked or deteriorated O ring c A leak path is created between the UP side of the cyl inder and the reservoir The trim system will leak DOWN until the trim port in cylinder is covered a Valve and Seat b Pilot Valve O ring c O ring a Ball and Seat Check for Debris or Damage Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a O ring 90 817643R1 DECEMBER 1996 MID SECTION 5C 13 Troubleshooting Flow Diagram Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceler ation Inspect
313. ling pinion nut apply Loctite 271 on threads of nut By adding or subtracting 0 001 0 025mm shim the back lash will change approximately 0 001 025mm Bearing Carrier and Propeller Shaft Installation 1 Insert propeller shaft assembly into bearing carrier 2 Before installing bearing carrier assembly into gear housing obtain locally a 6 152 4mm long by 1 1 4 1 1 2 31 7 38 1mm diameter piece of PVC pipe c Install the PVC pipe over the prop shaft a and secure the pipe against the bearing carrier assembly b with the propeller nut d and tab washer e This will allow the reverse gear to apply pressure to the reverse gear thrust bearing to preventthe thrust bearing from being in advertently dislodged as the bearing carrier assembly is installed in the gear housing e 21043 6B 28 LOWER UNIT 3 Lubricate o ring and mating surfaces with 2 4 C w Teflon 92 825407A12 4 Install bearing carrier and propeller shaft into housing with the word TOP located on flange to ward top of housing SI Apply 2 4 C w Teflon O ring TOP Install components as shown 19147 a Washers b Bolts Apply Loctite 271 on Threads and Torque to 25 Ib ft 34 0 N m NOTE If nuts are used in place of bolts torque nuts to 25 Ib ft 34 0 N m 90 817643R1 DECEMBER 1996 Water Pump Reassembly and
314. ling Water Pump to Jet Drive NOTE Replace cover if thickness of steel at discharge slots is 0 060 in 1 524mm or less or if groove s oth er than impeller sealing groove in cover roof are more than 0 030 in 0 762mm deep NOTE Replace impeller if a Impeller blades are cracked torn or worn b Impeller is glazed or melted caused by insuffi cient water supply c Rubber portion of impeller is not bonded to im peller hub 1 Install base plate pump cover gasket NEO PRENE STRIP FACES UP and impeller key IMPORTANT If impeller being installed has been previously used and vanes have taken a set DO NOT INSTALL THE IMPELLER WITH THE VANES REVERSED FROM THEIR PREVIOUS SET AS VANE BREAKAGE WILL OCCUR SHORTLY AFTER UNIT IS RETURNED TO SERVICE 2 Install impeller NOTE Apply a light coat of 2 4 C w Teflon to inside of pump cover to ease installation of cover over impeller 3 Install pump cover Rotate drive shaft CLOCK WISE while pressing cover down over impeller 90 817643R1 DECEMBER 1996 4 Apply Loctite 271 to retaining bolts 4 and torque to 60 Ib in 6 8 N m prs 0 54258 2 4 C With Teflon 92 825407 12 Bolts 4 Apply Loctite 271 Torque to 60 Ib in 7 0 N m Seal Cover Key Impeller Gasket Plate LOWER UNIT 6C 17 Installing Jet Drive to Drive Shaft Housing 1 a Apply a light coat of 2 4 C w Teflon to the driv
315. ll O rings Install spring poppet spool housing and trim limit spool into manifold NOTE There are two different size springs used in this manifold The heavy spring is used on 75 to 125 HP engines The light spring is used on 40 to 60 HP engines 51008 a Spring b Poppet c Spool Housing d Trim Limit Spool Manual Release Valve Installation 1 Install E clip if removed and lubricate O rings to manual release valve 2 Install manual release valve assembly into man ifold a Manifold b Manual Release Valve c E Clip 5E 40 MID SECTION cM 1 Install dowel pin and two 2 lubricated O rings into trim cylinder Manifold Installation a O Rings 2 Dowel Pin 2 Align the trim cylinder pump reservoir sembly together a Trim Cylinder Assembly b Reservoir Manifold Assembly 90 817643R1 DECEMBER 1996 3 Install the two 2 long screws and torque to 100 Ib 11 N m 51146 Screws 2 Torque to 100 Ib in 11 90 817643R1 DECEMBER 1996 Oil Pump Installation 1 Install spring ball lubricated O ring and plastic seat to manifold 2 Check to see that O rings are placed on bottom of pump 3 Install filter and filter seal under pump Install pump onto manifold Torque screws to 70 Ib in 7 7 N m a Screws 3 Torque to 70 Ib in 7 7 N m b Suction Seat Assembly MID SECTIO
316. ll cells cannot be reached battery is not in optimum condition and will not provide optimum per formance however it may continue to provide addi tional service if it has performed satisfactorily in the past 4 To check battery voltage while cranking engine with electric starter motor place red lead of tester on positive battery terminal and black lead of tester on negative battery terminal If the voltage drops be low 9 1 2 volts while cranking the battery is weak and should be recharged or replaced 90 817643R1 DECEMBER 1996 Winter Storage of Batteries Battery companies are not responsible for battery damage either in winter storage or in dealer stock if the following instructions are not observed 1 Remove battery from its installation as soon as possi ble and remove all grease sulfate and dirt from top sur face by running water over top of battery Be sure how ever that vent caps are tight beforehand and blow off all excess water thoroughly with compressed air Check water level making sure that plates are cov ered 2 When adding distilled water to battery be extremely careful notto fill more than 3 16 4 8mm over plate in side battery Battery solution or electrolyte expands from heat caused by charging Overfilling battery will cause electrolyte to overflow if filled beyond 3 16 over plate 3 Grease terminal bolts well with Quicksilver 2 4 C Ma rine Lubricant and store batter
317. ll check ball components into manifold 54744 3 Hold check ball components in place using screwdriver as shown Connect manifold to trim cylinder 54748 90 817643R1 DECEMBER 1996 4 Secure manifold to cylinder using screws torque to 100 Ib in 11 2 N m 54746 a Trim Cylinder b Manifold Screw Oil Pump Installation 1 Secure power trim unit in soft jawed vise 2 Install lubricated O rings to manifold Install oil pump to manifold and secure using screw torque to 90 Ib in 10 2 54747 a O ring b Oil Pump c Screw MID SECTION 5B 31 Trim Motor Reassembly 1 Apply Quicksilver Marine Lubricant 2 4 C to ar mature shaft and insert into end frame NE ti LJ Z mmm VALLI CCS 51195 Armature Shaft Washer End Frame N oom Guide armature and end frame into housing as shown fy AR 51196 5B 32 MID SECTION u 3 Align scribe mark on housing with mark on end frame 4 Installlubricated O ring to end frame 51194 a O ring b Scribe Mark 5 Install washers to armature shaft as shown 6 Install end cap to housing Torque nuts to 25 Ib in 2 8 N m End Cap Motor Housing Wave Washer Washer om 90 817643R1 DECEMBER 1996 u IMPORTANT Wheninstalling motor wires black 3 Installend cap O ring and foam pad to cylinder orange must rest in cavity o
318. low Chart 5E 23 Hydraulic System Troubleshooting Flow Chart 5E 24 Troubleshooting the Power Trim Electrical System Wiring Diagram 5 25 Troubleshooting the Power Trim Electrical System 5E 26 Page Power Trim System Removal 5E 27 Power Trim Disassembly 5E 28 Trim Motor Removal 5E 29 Pump and Components Removal 5E 29 Manifold Removal 5E 30 Shock Rod Removal 5E 30 Shock Rod Disassembly 5E 31 Memory Piston Removal 5E 33 Cleaning Inspection Repair 5E 34 Trim Motor Electrical Tests 5E 34 Reassembly 5E 35 O Ring and Seal Placement 5E 35 O ring SIZES 5E 36 O ring Description and Sizes 5E 37 Power Trim Reassembly 5E 38 Shock Rod Reassembly 5E 38 Shock Rod Installation 5E 39 Trim Limit Assembly Installation 5E 40 Manual Release Valve Installation 5E 40 Manifold Installation 5E 40 Oil Pump Installation 5E 41 Pressure Operated Assembly Installation 5E 42 Reservoir Motor Installation 5E 42 Bleeding Power Trim Unit 5E 43 Installation of Power Trim System 5E 43 90 817643R1 DECEMBER 1996
319. ls with Power Trim NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to ex periment with trim positions to determine whether trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim position trim tab in neutral straight fore and aft position you can expect the following results 90 817643R1 DECEMBER 1996 TRIMMING OUTBOARD OUT UP CHARACTER ISTICS A WARNING Excessive trim out also may reduce the stability of some high speed hulls To correct instability at high speed reduce the power GRADUALLY and trim the outboard in slightly before resuming high speed op eration Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability 1 Will lift bow of boat generally increasing top speed 2 Transfers steering torque harder to left on standard or slightly elevated transom installation single out board 3 Increases clearance over submerged objects In excess can cause porpoising and or ventilation If trimmed out beyond the water pickup reduced water supply can cause serious overheating TRIMMING OUTBOARD IN DOWN CHARACTERISTICS AWARNING Excessive speed at minimum trim in may cause un desirable and or unsafe steering conditions Each boat should be tested for handling characteristics af ter any adjustment is made to the trim
320. lugs from engine to prevent engine from starting 1 Remove three 3 spark plugs 51046 2 Install dial indicator into No 1 TOP cylinder 6 Remove dial indicator from No 1 TOP cylinder 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2C 1 Carburetor Synchronization MODELS WITH ONE PIECE THROTTLE LINK ROD a Remove four 4 attaching screws from sound box cover and remove cover Loosen screw a of cam follower Loosen two 2 synchronizing screws b located on throttle levers of top and bottom carburetors Look into throats of carburetors and verify all throttle shutters are completely closed Tighten synchronizing screws MODELS WITH 4 ADJUSTABLE LENGTH THROTTLE LINK ROD a Remove four 4 attaching screws from sound box cover and remove cover b Loosen screw a of cam follower c Loosen four 4 synchronizing screws b located on link rod 2C 2 ELECTRICAL and IGNITION c d Look into throats of carburetors and verify all throttle shutters are completely closed Tighten four 4 synchronizing screws b 51045 BOTH ONE PIECE AND ADJUSTABLE LINK ROD 1 Recheck throttle shutters and make any necessary ad justments Hold throttle arm c so that idle stop screw d is against stop Place roller e of cam follower against throttle cam f and adjust idle stop screw d to align raised mark g of throttle cam with center of cam follower roller Tight en locknut
321. m fasteners to be sure that they are torqued to correct specifications 3 Lubricate clevis points with a drop of light oil Inspection and lubrication of steering system should be performed once each year or whenever steering components are disassembled steering effort has in creased or steering seems loose OUTBOARD INSTALLATION ATTACHMENTS 7 15 Remote Control Installation IMPORTANT Connect control cables to remote control and mount remote control BEFORE attaching control cables to engine Install throttle and shift cables to remote control and mount remote control as outlined in the installation instructions which accompany the remote control NOTE It will necessary to lift control cable rubber grom met out of opening in bottom cowl so that control cables can be routed thru grommet and into bottom cowl 5 L 50566 a Control Cable Rubber Grommet b Shift Cable Opening c Throttle Cable Opening Shift Cable Installation and Adjustment to Engine NOTE Attach shift cable to engine first Shift cable is the first cable to move when remote control handle is vanced from neutral position toward in gear position If remote control has a neutral lock release secure the lease in the depressed position using a piece of tape Now the true neutral detent can be found NOTE Move remote control handle back and forth You will feel three detent positions center detent is neutral 7A 16 OU
322. maged or does not roll freely To remove refer to Lower Driveshaft Bear ing following Replace forward gear f if gear teeth are chipped or worn 3 PP Ls f 2 t eS J 5 LN I i CV 2 t SASS gt gt gt 51263 6 Replace bearing if rusted or does not roll freely after cleaning in solvent Remove as shown 90 817643R1 DECEMBER 1996 Replace forward gear tapered roller bearing a and race if either bearing or race are rusted or damaged or if bearing does not roll freely after cleaning in sol vent Remove bearing from gear using Universal Pull er Plate b 91 37241 and Mandrel c To remove race refer to Forward Gear Bearing Race following Upper Driveshaft Bearing Replace bearing a and race if either bearing or race are rusted or damaged or if bearing does not roll freely after cleaning in solvent To Remove 51271 LOWER UNIT 6A 11 Lower Driveshaft Bearing 1 Remove lower driveshaft bearing using tool 91 81 7058A1 with bushing installed Sa d GEN ae 51260 a Bearin b Removal Tool 91 817058A1 Bushing Forward Gear Bearing Race IMPORTANT Retain shim s for re assembly 1 Remove race a and shim s b using bearing puller c 91 27780 a Race b Shim s B
323. mmed up or down while engine is under power or when engine is not running Trimming Characteristics When trimming outboard from a mid trim position trim tab in neutral straight fore and aft position you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor In slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty 90 817643R1 DECEMBER 1996 Will lift bow of boat usually increasing top speed Transfers steering torque harder to port left on in stallations below 23 in transom height Increases clearance over submerged objects In excess can cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating damage Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up relay lo cated under engine cowl and close the electric motor circuit The electric motor drives the pump for
324. n 90 817643R1 DECEMBER 1996 LOWER UNIT 6B 5 Gear Hsg Prop Shaft 60 Seapro Marathon Big Foot par i B A E x NM Loctite 271 92 809820 Super Duty Gear Lubricant 92 13783A24 Anti Corrosion Grease 92 78376A6 2 4 C With Teflon 92 825407A12 6B 6 LOWER UNIT 90 817643R1 DECEMBER 1996 P Gear Hsg Prop Shaft 60 Seapro Marathon Big Foot DESCRIPTION Ib in Ib ft N m GEAR HOUSING GEAR HOUSING ASSEMBLY TAPERED ROLLER BEARING ASSEMBLY FORWARD GEAR ROLLER BEARING CAM FOLLOWER ASSEMBLY BALL SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR BEARING CARRIER ASSEMBLY O RING ROLLER BEARING OIL SEAL INNER OIL SEAL OUTER ROLLER BEARING THRUST WASHER THRUST BEARING STUD WASHER NUT 260 21 5 29 5 SHIM ASSEMBLY THRUST HUB ASSEMBLY PROPELLER NUT ASSEMBLY 55 74 5 TAB WASHER 90 817643R1 DECEMBER 1996 LOWER UNIT 6B 7 1 1 1 1 3 1 1 1 1 1 1 1 NN PO N Special Tools 91 46086A1 91 85716 91 34569A1 91 36569 91 15755 91 37323 91 56775 91 37241 91 83165M 91 31106 91 31108 91 37350 91 31229 11 24156 91 78473 91 58222A1 91 83155 91 12349A2 91 14308A1 91 14309A1 91 14310A1 91 14311A2 91 13945 91 13949 91 19660 1 Puller Jaws Puller Bolt Slide Hammer Mandrel Mandrel Driver Rod Drive Shaft Holding Tool Unive
325. n the negative battery post and Proceed to TEST 2 on next page the powerhead e Check cable for loose or corroded connections e Check cable for open 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2B 13 TEST 2 a Disconnect black ground wire s from Test Point 2 b Connect voltmeter between common engine ground and Test Point 2 No voltage reading c Turn ignition key to Start position proceed to TEST 3 TEST 3 a Reconnect black ground wire s b Connect voltmeter between common engine ground and Test Point 3 c Turn ignition key to Start position i Battery Voltage 12 Volt Reading Check black ground wire for poor connection or open circuit Reconnect ground wire to starter solenoid proceed to TEST 7 No voltage reading proceed to TEST 4 No voltage reading proceed to TEST 5 No voltage reading proceed to TEST 6 No voltage reading check red wire between battery positive terminal and Test Point 6 No voltage reading De fective starter solenoid No voltage reading check black cable for poor connection or open circuit 2B 14 ELECTRICAL and IGNITION 12 Volt Reading Defective starter solenoid TEST 4 a Connect voltmeter between common engine ground and Test Point 4 b Turn ignition key to Start position 12 Volt Reading Neutral start switch is open or yellow red wire is open between Test Points 4 and 3 TEST 5 Con
326. ne is running While operating up circuit the cylinder rod will con tinue to tilt the outboard to a full up position for trail ering 90 817643R1 DECEMBER 1996 Tilting Outboard Up and Down Manually Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns counterclockwise a Manual Release Valve MID SECTION 5E 5 p 1 POWER TRIM FLOW DIAGRAMS TRIM UP CIRCUIT Reservoir Oil Filtered Feed Oil Return Oil Oil Under Pressure Up Pressure 1625 40 60 2800 75 125 min Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter 2 shown for clarity Shock Return Valve Up Circuit Suction Port Oil Pump Down Circuit Suction Port Oil Fill Cap pb 09 5E 6 MID SECTION
327. necessary Some discoloration of the grease is normal during the break in period on a new set of seals 90 817643R1 DECEMBER 1996 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 a on the impeller nut re tainer and remove the impeller nut b 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 a Tab b Nut LOWER UNIT 6C 9 INSTALLATION 3 After setting the impeller height tighten the impel ler nut snug with a wrench Secure impeller nut by bending tabs a against the flats on the impeller nut 1 Grease the drive shaft shear key and impeller bore Place the plastic sleeve a inside the impel ler b and install impeller shear key c shims d nut retainer e and impeller nut f Turn the nut tight on the shaft to remove any play between the impeller and shaft If the tabs on the retainer do not line up with the flats on the nut remove the nut and turn the retainer over and re tighten the nut again a Tabs Reinstall the water intake housing with six bolts b Check clearance around the
328. nect ohmmeter R x 1 scale leads between posi tive brushes 2 Ohmmeter must indicate full continuity zero resis tance If resistance is indicated check lead to positive terminal solder connection If connection cannot be re paired brushes must be replaced Refer to Brush Re placement L L ae x LJ on x 11673 a Positive Brushes 90 817643R1 DECEMBER 1996 TESTING NEGATIVE BRUSHES FOR GROUND Set ohmmeter to R x 1 scale Place one lead of ohmmeter on the negative brush and the other lead on the end cap bare metal If the meter indicates NO continuity replace the negative brush Repeat this procedure on the other negative brush mmn Orc 11674 a Negative Brushes b End Cap ELECTRICAL and IGNITION 2B 17 STARTER SOLENOID TEST Test starter solenoid as follows 1 Disconnect all leads from solenoid terminals 2 Useanohmmeter set to R x 1 scale and connect be tween solenoid terminals 1 and 2 3 Connect 12 supply between solenoid terminals 3 and 4 Solenoid should click and meter should read zero ohms 4 f meter does not read zero ohms full continuity re place solenoid c 2 0 0 TS a 12 Volt Supply b Ohmmeter Leads Brush Replacement IMPORTANT Replace brushes that are pitted or worn to less than 1 4 6 4mm in length 1 Install pos
329. nect voltmeter between common engine ground and Test Point 5 12 Volt Reading Defective ignition switch TEST 6 Connect voltmeter between common engine ground and Test Point 6 12 Volt Reading Check fuse in red wire between test points 5 and 6 Check for open red wire between test points 5 and 6 TEST 7 a Connect voltmeter between common engine ground and Test Point 1 b Turn ignition key to Start position 12 Volt Reading Should hear solenoid click proceed to TEST 8 TEST 8 a Reconnect black starter motor cable to starter solenoid Test Point 1 b Connect voltmeter between common engine ground and Test Point 7 c Turn ignition key to Start position 12 Volt Reading Check black ground cable at starter for loose or corroded connection or open circuit If cable is O K check starter motor 90 817643R1 DECEMBER 1996 2 Starter Motor Disassembly 1 Remove 2 thru bolts and commutator end cap taking care not to lose brush springs Removal ACAUTION Disconnect battery leads from battery before remov ing starter 1 Disconnect battery leads from battery Disconnect black cable Remove bolts and remove starter clamp 11646 Thru Bolts Commutator End Cap Brush Springs Remove starter Suc c N Remove black cable Pull armature from starter frame N Remove locknut Black Cable a Armature Bolts 2 b Locknut a b c Starter Clam
330. nfused with the presence of water If water is suspected to be present in gearcase a pressure check of gearcase should be made with no lubri cant in gearcase Gearcase should hold 10 to 12 psi of pressure for 5 minutes without leaking down Pouring a portion of the gear lubricant into a glass jar and allowing the lubricant to settle will allow any water in the lube to separate and settle to the bot tom of the jar Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals seal surfaces O rings water pump gaskets as well as gear housing components for damage If gearcase is rebuilt gearcase should be pressure checked before filling with lubricant LOWER UNIT 6B 9 Water Pump 1 If water tube seal stayed on water tube inside of drive shaft housing when gear housing was removed pull water tube seal from water tube m Replace water tube seal if damaged Remove 4 bolts washers and isolators 4 Remove cover a b mm THe 8 19212 a Water Tube Seal b Bolts 4 each IMPORTANT The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover Step 5 and plate Step 9 as the depth of the groove will not affect water pump output c Cover 5 Replace cover if thickness of steel at the discharge slots is 0 060 or less or if groove s other than impell
331. ng shift shaft coupler water tube seal and driveshaft splines NOTE If the driveshaft splines will not align with the crank shaft splines install a propeller and turn the propeller shaft counterclockwise while pushing gear housing onto drive shaft housing It may also be necessary to move the shift block on the powerhead to align the shift shaft splines for proper re assembly 8 Install 4 bolts and washers a two each side Apply Loctite A 271 on threads of bolts prior to installation 9 Install locknut and washer b 10 Torque bolts and locknut to 40 Ib ft 54 N m 6A 26 LOWER UNIT a Gear housing should not engage when propeller shaft is turned clockwise when in forward gear 11 Check shift operation b Propeller shaft will rotate freely in either direction when gearcase is in neutral c Propeller shaft will not rotate in either direction when gearcase is in reverse IMPORTANT If shift operation is not as described re move the gear housing and correct the shift operation Propeller Installation A WARNING Disconnect and isolate spark plug leads when working near the propeller to prevent the outboard from start ing 1 Apply a thin coat of lubricant to propeller shaft splines with Quicksilver 2 4 C Marine Lubricant 2 Install components as shown Flo Torq Drive Hub Propellers a Forward Thrust Hub b Propeller Nut Retainer c Prop
332. nition timing 3A 8 FUEL SYSTEMS c PROBLEM 1 ENGINE TURNS OVER BUT WILL NOT START OR STARTS HARD WHEN COLD Troubleshooting Charts Possible Cause Corrective Action Check procedure as out lined in Operation and Maintenance Manual Improper starting proce dure Check fuel in fuel tank and replace or add Fuel tank empty improp erly mixed fuel con taminants water dirt etc in ih Fuel tank air vent closed Air vent must be open or restricted and free from contami nants A pinched or restricted Check and replace as fuel line needed Dirty or restricted fuel fil Check replace or clean ter Enrichener Valve not op Check enrichener sys erating tem Refer to Enri chener System following An inlet needle in carbu Remove clean or re retor that is stuck place open or closed A needle stuck open will cause a flooding con dition A needle stuck closed will prevent fuel from entering car buretor Anti Siphon valve re stricting fuel flow Refer to Checking for Restricted Fuel Flow caused by Anti Siphon Valves following See Checking for Restricted Fuel Flow caused by Anti Siphon Valves page 3A 13 90 817643R1 DECEMBER 1996 PROBLEM ENGINE FLOODS Possible Cause Corrective Action Dirt or foreign particles Flush out inlet seat and are preventing inlet clean inlet needle needle from seating Worn inlet needle Replace Punctured float
333. ns 7 14 Steering Cable Installation 7A 15 Maintenance Instructions 7 15 Remote Control Installation 7A 16 Shift Cable Installation and Adjustment to Engine 7A 16 Throttle Cable Installation and Adjustment to Engine eee Shad pakasqa 7 17 Connecting Remote Control Wiring Harness to Engine Wiring Harness Electric Start Models 7A 17 Power Trim Wiring Connections Models Equipped 7 18 Battery Connections 7 18 90 817643R1 DECEMBER 1996 Q Installing Outboard Motor on Transom Determining Recommended Outboard Mounting Height It is recommended for best all around boating perform ance the outboard should be mounted with the anti venti lation plate parallel to and at the same level as the boat bot tom On boats with a 20 in 508mm transom height this will re quire that the outboard be mounted approximately 1 in 25 4mm high on the transom as the outboard has a 21 in 533mm shaft length If with the outboard mounted so that the anti ventilation plate is level with the bottom of the boat excessive propel ler slippage cavitation is experienced it is recommended that the outboard be lowered one position on the transom to increase propeller BITE at a slight loss at top end speed and increase spray
334. ns 60 Ib in 6 8 20 Ib in 2 2 N m 75 Ib ft 101 7 N m 22 Ib ft 29 8 N m 50 Ib ft 67 8 N m 35 80 Ib in 3 8 8 8 N m 000 0 Lubrication Sealant Application Points gt 2 4 C Marine Lubricant P N 92 9001 8A12 KA No H BD Super Duty Marine Gear Lubricant P N 92 13135A12 H c O Special Lubricant 101 P N 92 13872A1 9 H Loctite Grade A P N 92 32609 1 51113 90 817643R1 DECEMBER 1996 LOWER UNIT 6A 1 Propeller Shaft Components 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Trim Tab 60 61 62 63 64 Shim Set Tapered Roller Bearing Forward Gear Roller Bearing Cam Follower Guide Spring Clutch Cross Pin Spring Propeller Shaft Reverse Gear Ball Bearing Bearing Carrier O ring Roller Bearing Oil Seal Oil Seal Screw Screw Washer Thrust Hub Propeller Nut Tab Washer 6A 2 LOWER UNIT EY 51114 Torque Specifications 55 lb ft 75 9 27516 in 31 0 150 lb in 17 0 22 lb ft 30 0 N m Lubrication Sealant Application Points B D D Loctite Grade A P N 92 32609 1 B E D 2 4 C Marine Lubricant P N 92 90018A12 gt Needle Bearing Assembly Lubricant P N 92 42649A 1 Special Lubricant 101 P N 92 13872 1 90 817643R1 DECEMBER 1996 Q Special Tools 91 14311 2 Bearing Preload Tool 91 817057A1 Backlash In
335. nsafe handling characteristics 90 817643R1 DECEMBER 1996 Water test the boat not using the trim adjustment pin If un desirable and or unsafe steering conditions are experi enced boat runs with nose down install trim adjustment pin in proper hole to prevent unsafe handling characteris tics GENERAL INFORMATION and SPECIFICATIONS 1 7 Propeller Information Chart 50 55 MODELS Wide Open Throttle RPM 5000 5500 Recommended Transom Height Short Shaft 16 1 2 in 41 9 cm Long Shaft 21 in 53 3 cm Right Hand Rotation Gear Reduction 1 64 1 Thrust Hub 73345A 1 Approx Approx Speed No of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wot Lbs Length MPH Part Number 10 19 3 Alum Up to 700 Up to 14 48 55 48 73146A40 10 17 3 Alum Up to 800 Up to 15 44 51 48 73144A40 10 16 3 Steel 700 900 Up to 15 41 48 48 91818A5 10 16 3 Alum 700 900 Up to 15 41 48 48 73142A40 10 13 15 3 Steel 800 1100 13 to 15 38 45 48 76232A5 10 13 15 3 Alum 800 1100 13 to 15 38 45 48 73140A40 10 38 14 3 Alum 900 1300 14 to 16 35 41 48 816706A40 10 1 4 14 3 Steel 900 1300 14 to 16 35 41 48 76230A5 10 38 13 3 Steel 1000 1500 14 to 17 32 38 48 76228A5 10 1 2 13 3 Alum 1000 1500 14 to 17 32 38 48 816704A40 10 63 12 3 Steel 1100 1700 15 to 17 28 34 48 79792A5 10 3 4 12 3 Alum 1100 1700 15 to 17 28 34 48 8167
336. nst spring Sleeve Holes in sleeve must align with set screws Set Screw 2 Tighten against drive shaft bolt should not slide on driveshaft 90 817643R1 DECEMBER 1996 3 Measure distance a Increase distance a by 1 in 25 4mm Rotate driveshaft 10 revolutions This properly seats upper driveshaft tapered roller bearing 19884 6 Insert Pinion Location Tool a Position access hole b as shown Insert feeler gauge between gauging sur face c and pinion gear d a 2 EL _ jJ 9 WLS 51265 f Pinion Location Tool 91 817008A2 Access Hole Gauging Surface Pinion Gear LOWER UNIT 6 19 7 The correct clearance between the gauging surface b and the pinion gear is 025 in 0 64mm 8 To obtain 025 in 0 64mm add or subtract shims be low the upper bearing race b to lower or raise the pin ion gear 9 After final adjustment to pinion height and forward gear backlash has been established apply Loctite 271 to threads and torque new pinion nut to 50 Ib ft 67 N m 1 1 SEGRE IE LL LLL Z j 2227 E 51263 Bearing Race Shim s Pinion Nut Recessed Side d Toward Pinion Recessed Side Toward Pinion 6A 20 LOWER UNIT DETERMINING FORWARD GEAR BACKLASH NOTE Read entire procedure before att
337. nt O Rings and Seals are part of O Ring Kit 25 809880A1 90 817643R1 DECEMBER 1996 MID SECTION 5E 35 O ring Sizes 2 ex 5 12 17 18 15 20 9 19 O Mes ne O RINGS SHOWN ARE ACTUAL SIZE 5E 36 MID SECTION 90 817643R1 DECEMBER 1996 O ring Description and Sizes O Ring Description O Ring Width 3 Wen O ETT 2 Ovi Cap Inner 0 671 in 17 04 mm 0 949 in 2410 mm 0139n 8 5 mm 3 Oca 185 47 34 2004 6030 mm 007m 178 4 Shock Piston 161 6064 mm 2 027 63086 mm 021m 6384 S Piston Bor foeren 1717 mm sem 20 726 mm 007m 78mm _6 ReservoirPug 0 549 in 1394 mm 0755 n 19 17 mm 7 Morsa SS 0 489 12 42 0 629 in 15 97 mm 0 07 in 1 78 mm 07 in 1 78 mm 07 in 1 78 mm 07 in 1 78 mm 10 2 P O Check Seat 0 364 in 9 25 mm 0 504 in 12 80 mm 11 2 0 145 in 3 683 mm 0 285 in 7 239 6 712 ense 02011 07 mm 1037916 526 713 1 39 1 78 1 78 1 78 1 78 2 90 mm 0 254 in 6 451 mm 0 07 in 4 47 mm 0 316 in 8 026 mm 07 in 6 07 mm 0 379 in 9 626 mm 07 6 07 0 379 9 626 07 i 0 76 n 7 0 239 in 18 Spot p 0 301 in 7 645 mm 0 441 in 11 20 mm 07 in 1
338. nt 5 5B 18 MID SECTION 90 817643R1 DECEMBER 1996 Troubleshooting the Up Circuit When Down Circuit Is OK Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground Depress the Up trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 7 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 7 and 8 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 6 Point 3 and positive battery ter Depress Up trim button minal Check for loose or corroded con nections Check wires for open circuit Battery Voltage Indicated No Voltage Indicated e Pump motor wiring is defective Relay Switch is defective Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 90 817643R1 DECEMBER 1996 MID SECTION 5B 19 x L Troubleshooting the Down and Up Circuits All Circuits Inoperative Remote Control Not Equipped with Trailer Button Blown Fuse Correct problem that caused
339. nutto 20 Ib ft 27 N m Spray Quicksilver Corrosion Guard on exposed threads of steering eyes and position rubber bushings and rubber sleeves to cover exposed threads of steering eyes A WARNING After installation is complete and before operating outboard s check that boat will turn right when steer ing wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right atall tiltangles to assure inter ference free movement Adjust trim tabs of both outboards as outlined in Trim Tab Adjustment following OUTBOARD INSTALLATION ATTACHMENTS 7A 9 ax i Installation IMPORTANT Lubricate all moving parts with Quicksil ver 2 4 C w Teflon Marine Lubricant MODELS WITH FORGED TWO HOLE STEERING IMPORTANT All 50 60 models with one piece top cowl ARM AND ONE PIECE TOP COWL require a minimum centerline distance of 21 in 533mm during dual outboard installation to assure interference free movement Steering Cable Routed on Starboard Side of Boat Con nected to Port Outboard Steering Cable Routed on Port Side of Boat Connected to Starboard Outboard Lock Nut P N 11 34863 Torque to 20 Ib ft 27 N m Steering Eye Rubber Sleeve Rubber Bushing Jam Nut Torque to 20 Ib ft 27 1 Steering Bracket Dual Steering Coupler Special Washer Head Bolt 3 8 x 1 5 8 P N 10 90041 Lock Nut P N 11 34863 Torque Until i
340. oard will not hold tilted position in reverse and or trails out during high speed deceleration with manual release valve lever in the lock run up position A CAUTION Tilt ram must be in full up position and accumu lator removed before manual tilt system disas sembly Inspect shock rod piston check valve s Results Results Debris or defective components found in check No debris or defective components found in check valve s valve s Clean check valve s components using engine clean Inspect transfer valve s er and compressed air or replace Results Results No debris or defective components found in Debris or defective components found in transfer valve s transfer valve s Inspect valve block Clean transfer valve s components using engine cleaner and compressed air or re place Results Results Debris found in valve block passages Clean valve block using engine cleaner and compressed air 5F 20 MID SECTION 90 817643R1 DECEMBER 1996 No debris found in valve block passages Replace defective valve block Manual Tilt System Removal A CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard Service or installation of the tilt system may re sultin loss of pressure in the shock cylinder If the outboard is not in the full down position such loss of pressure will cause the engine to fal
341. ock ring pliers Craftsman P N 4735 or suitable tool Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check valve components from trim rod piston a Screw 3 b Plate c O ring d Piston A CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston 51193 90 817643R1 DECEMBER 1996 MID SECTION 5C 23 p i 4 Place trim rod into soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 CAUTION Do not remove check ball components from trim rod piston Removal and re installation of check valve could result in improper operating pressure 6 Allow trim rod piston to cool remove from trim rod and possible power trim system damage If check valve is defective replace trim rod piston 5 Loosen trim rod piston using trim spanner span ner wrench 1 4 in x 5 16 in long pegs 7 Remove inner O ring from piston 51199 Check Ball Components O ring Piston Remove rod wiper inner O ring and outer O ring 51146 a Trim Rod Piston b Spanner Wrench 51145 a Rod Wiper b Inner O ring c Outer O ring 5C 24 MID SECTION 90 8i7643R1 DECEMBER 1996 Trim Motor Removal 1 Secure power trim assembly in soft jawed vise 2 Remove cap washer and grommet from res
342. ock of cable could occur With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with Quick silver 2 4 C Marine Lubricant Lubricate all pivot points with SAE 30W engine oil 4 Ride Guide Steering Grease Fitting 5 Tilt Tube Grease Fitting 6 Steering Link Rod Pivot Point Lubrication 90 817643R1 DECEMBER 1996 7 Propeller Shaft Lubrication a 51118 8 Rotate Starter Motor Pinion Gear To Expose Shaft and Lubricate Gear Housing Lubrication GENERAL INFORMATION and SPECIFICATIONS 1 15 GEAR HOUSING LUBRICATION NOTE Refer to Specifications for gear housing lubricant capacity AWARNING If gear housing is installed on outboard to avoid acci dental starting disconnect and isolate spark plug leads from spark plugs before working near the pro peller ACAUTION Do not use automotive grease in the gear housing Use only Quicksilver Gear Lube or Quicksilver Super Duty Lower Unit Lubricant 1 Tilt outboard so that lubricant in gear housing will drain toward front of housing out fill hole and into clean con tainer IMPORTANT Inspect FILL and VENT plug washers for damage Use new washer as needed 2 Remove lubricant fill plug and washer Note amount of metal particles on magnetic fill plug 3 Remove VENT plugs and washers a and c and allow all lubricant to drain Lubr
343. od Piston 13 Ball 5 75lb in 8 5 14 Spring Seat 5 15 Spring 5 16 ES Plate Bottom of Valve Block Cylinder 17 Screw 3 18 O ring 1 600 I D Shock Piston 19 O ring 1 600 I D Memory Piston 20 Memory Piston 21 Screw 2 GO 22 O Ring 208 in I D 2 23 Pipe Plug 2 d 25 Spring Small Check m 24 Spring Large 26 Ball Ball 27 Plunger DESIGN 2 28 Screw Plug 2 4 29 Spring 2 30 O ring 2 31 Ball 2 32 Push Rod 2 33 Dowel Pin 34 Spool 35 Spring 36 O ring 301 I D 37 Screw Plug 38 O ring 301 I D 39 Cam Shaft 40 Insulator 41 Retainer Plate 42 Screw 43 O ring 2 114 in 1 0 44 Push Rod 45 Ball 46 Flat Spring 47 Screw Design One Only 48 O ring 49 Filter 50 Valve Seat 51 O ring 364 I D 52 Ball 53 Spring Guide 54 Spring 55 Hole in Cyliner Quicksilver Lubricant Sealant Application Points DESIGN 1 DESIGN 2 t 600 e AA N Lubricate ALL O rings using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron ll Loctite 271 Loctite Pipe Sealant with Teflon 592 Special Lubricant 101 NOTE It is recommended that ALL O rings be re placed when servicing tilt system 90 817643R1 DECEMBER 1996 MID SECTION 5F 1 cM Manual Tilt System Components Design Three
344. od to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Recheck fluid level add fluid as required and repeat cycle until fluid level remains at lower portion of threads a Trim Cylinder Assembly 5D 26 MID SECTION 90 817643R1 DECEMBER 1996 u 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a Lower Cross Pin 5 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51148 a Lower Dowel Pin 90 817643R1 DECEMBER 1996 6 Apply Special Lubricant 92 13872A1 to surface of upper pivot pin pivot pin bore and trim ram bore NOTE Install trim ram with cross hole located as shown If trim ram is installed reversed the trim send er if installed will not operate 51515 Cross Hole Transom Side Engine Side Pivot Pin Pivot Pin Bore Trim Ram Bore Install Trim Ram As Shown om MID SECTION 50 27 7 Using suitable mallet drive upper pivot pin into 8 Drive upper retaining pin a in until seated swivel bracket and through trim ram until pivot pin is flush with swivel bracket 51505 9 Recheck fluid level 10 Power trim may now be operated to lower out a Pivot Pin board to desired position Tr
345. odule RED Stator with Adaptor and Ignition Coils RED Stator DVA Test Electric Start Engines Manual Start Engines Troubleshooting Procedures Ignition Key Switch Test Page 2A 1 Page Ignition Components Removal and Installation 2A 7 Flywheel 2A 7 Removal 2A 7 Installation 2A 8 BLACK and RED Stator 2A 8 Removal sqa coat beled q E ER 2A 8 BLACK Stator Installation 2A 9 RED Stator Installation 2A 9 e E eere ees 2A 10 Removal 2A 10 Installation 2A 10 Ignition 2A 11 Switch BOX 2A 11 90 817643R1 DECEMBER 1996 Description The outboard ignition system is alternator driven with dis tributor less capacitor discharge Major components of the ignition system are the flywheel stator trigger switch box ignition coils and spark plugs The stator assembly is mounted stationary below the fly wheel and has 2 capacitor charging coils The flywheel is fitted with permanent magnets inside the outer rim As the flywheel rotates the permanent magnets pa
346. oil to flow from between the shock piston n and memory piston m onto the down cavity as the drive returns to its original running position 90 817643R1 DECEMBER 1996 MID SECTION 56 15 Hydraulic System Troubleshooting Refer to disassembly reassembly instructions fol lowing if disassembly is required when servicing IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball components and castings must be cleaned using engine cleaner and com pressed air or replaced prior to reassembly Support outboard with tilt lock lever when servicing manual tilt system 1 Check manual release cam adjustment Cam must open and close freely Adjust cam link rod as necessary a Link Rod b Manual Release Lever c Accumulator 2 Check for external leaks in the manual tilt system Replace defective part s if leak is found IMPORTANT If cut or damaged O rings are found inspect machined surfaces for scoring burrs or debris 5G 16 MID SECTION 3 Check for discharged accumulator 35 to 50 Ib ft 47 68 N m of pulling force must be attained when tilting outboard from full down to full up position If more than 50 Ib ft 68 N m of force is required replace accumulator 50431 a Weight Scale b Valve Lever open position 90 817643R1 DECEMBER 1996
347. olding Tool 91 817070 Pinion Nut New Apply Loctite 271 to threads during final assembly after pinion gear depth and forward gear backlash have been set torque to 70 Ib ft 95 N m o an Pinion Gear Depth and Forward Gear Backlash DETERMINING PINION GEAR DEPTH NOTE Read entire procedure before attempting any change in shim thickness IMPORTANT Forward gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained 1 Clean the gear housing bearing carrier shoulder and diameter 90 817643R1 DECEMBER 1996 2 With gear housing positioned up right drive shaft vertical install Bearing Preload Tool 91 14311A1 over drive shaft in sequence shown a Adaptor Bearing surfaces clean and free of nicks b Thrust Bearing Oiled and able to move freely c Thrust Washer Clean and free of nicks and bends d Spring e Nut Threaded all the way onto bolt f Bolt Held snug against spring g Sleeve Holes in sleeve must align with set screws h Set Screw 2 Tightened against drive shaft bolt should not slide on drive shaft 3 Measure distance between top of nut and bottom of bolt head Increase distance by 1 25 4mm Rotate drive shaft 5 to 10 revolutions This should properly seat upper drive shaft tapered roller bear ing 19884 a 1 25 4mm b Nut c Bolt Head LOWER UNIT 6B
348. om Up Lever d Top Up Lever e Pin Steering Arm 2 Double nut co pilot stud and apply Loctite No 35 P N 92 59328 1 to swivel bracket end of stud and install until flush with bottom of swivel bracket Stake stud in place as shown Drive dowel pin c from bottom of swivel bracket until flush with bottom of bracket DS lt gt 51094 d b c Stake Marks Dowel Pin Driven thru Bottom of Swivel Bracket 90 817643R1 DECEMBER 1996 3 a b c 4 a 5 Install brake disk and brake Brake Disk 3 Brake Pin Holds brake in place Lubricate driver with Never Seize Lubricant or Special Lubricant 101 P N 92 13872A1 Install driver into handle and adjust until driver flat is flush with handle Handle Driver Flush to slightly recessed Install components to stud Align hex of driver with hex in brake Handle Driver Plastic Washer OUTBOARD INSTALLATION ATTACHMENTS 7B 21 6 Holding components in place lever facing forward in stall lock nut and torque to 75 Ib in 8 N m Secure knob to lever with bolt e v Locknut 75 10 in 8 N m Knob c Bolt 45 Ib in 5 N m on Tiller Handle Installation 1 Apply Loctite No 35 P N 92 59328 1 to threads steering arm end of tiller handle studs Install with stud installer Tighten securely 9 IN 51092 a Studs b
349. ometer Battery Isolation 51250 Black Blue Gray Red Yellow YEL C 7D YEL RED SLEEVE 2B 10 ELECTRICAL and IGNITION 90 817643R1 DECEMBER 1996 PAS Rectifier Test AWARNING Disconnect battery leads from battery before testing rectifier NOTE Rectifier can be tested without removing from en gine 1 Disconnect all wires from terminals on rectifier 2 Useanohmmeter R x 1000 scale and perform the fol lowing test Refer to drawing for rectifier terminal iden tification NOTE Due to differences in the manufacture of ohm me ters the internal battery polarity may vary from manufac turer to manufacturer As a result the test readings may be f 07300 a direct reversal of those listed If so reverse meter leads and reperform test a Terminal b Terminal C Terminal d Stator Terminals e Positive Terminal f Ground Rectifier Test continued Connect red meter lead to ground black lead alternately to terminals a and c Continuity Indicated No Continuity Indicated Connect black meter lead to ground red lead Connect black meter lead to ground red lead alternately to terminals a and c alternately to terminals a and c No Continuity Indicated Continuity Indicated Connect black meter lead to terminal b red Replace Rectifier lead alternately to terminals a and c No Continuity Indicated Continuity Indicated Replace Rectifie
350. on e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 8 MID SECTION c Slow Tilt Down Under High Thrust i Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston o Shock Return Valve p Impact Relief Valve 90 817643R1 DECEMBER 1996 ow Tilt Down Under High Thrust To tilt the engine down under high thrust conditions where the propeller thrust forces the shock rod down creating higher pressure below the memory piston m the camshaft lever f is rotated slightly down ward The internal shaft connected to the lever will open the down slow transfer valve i allowing oil un der pressure into the cavity around the shaft The higher oil pressure will open the up fast transfer valve j allowing oil from the bottom of the cylinder to flow above the shock piston n while lowering the engine Additional oil will flow into the accumulator c as the internal pressure forces the accumulator check valve e to open Oil flowing into the accumulator moves the accumulator piston d and compresses the gas 90 817643R1 DECEMBER 1996 MID SECTION 5G 9 a Shock Rod b End Cap c Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 10 MID SECTION Under Water Strike Valves Open i Down Slow Transfer Valve j Up
351. on armature 2 Remove screws securing end cap to reservoir tion of washers on armature and remove end cap a Armature b Motor Frame c Washer 1 each end of armature Reservoir Assembly Removal 1 Remove manual release valve from manifold 51486 a Screws 4 3 Remove motor from reservoir a Manual Release Valve b Manifold 2 Remove clip and O rings from manual release valve 51484 51196 a E Clip b O rings c Manual Release Valve 5D 18 MID SECTION 90 817643R1 DECEMBER 1996 3 Remove four screws securing reservoir to man ifold a Screws 4 4 Remove reservoir from manifold 5 Remove drive shaft from oil pump a Reservoir b Drive Shaft c Oil Pump 90 817643R1 DECEMBER 1996 Manifold Removal 1 Remove screws and manifold from cylinder 51007 a Trim Cylinder b Manifold c Screw 2 2 Remove check valve components from manifold IMPORTANT Sleeve d is chamfered 1 0 end opposite drilled cross hole Install spool b with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool O ring 0 114 1 0 Spool O ring 0 301 1 0 3 each Sleeve Spring Valve Seat Valve Spring m O oO 09 MID SECTION 5D 19 3 Remove O rings from cylinder 51008 a O rings 2 Cleaning and Inspection of Trim Rod Components A CAUTION
352. on or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in salt water is considered Severe Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifications NOTE Ride Guide Steering cable is lubricated at the fac tory and requires no additional lubrication at initial installa tion AWARNING Core of steering cable transom end must be fully re tracted into cable housing before lubricating cable If cable is lubricated while extended hydraulic lock of cable could occur 3 With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with 2 4 C Marine Lubricant Lubricate all pivot points with SAE 30W engine oil Dual Steering Installation Steering Coupler Assembly Position outboards so that they are pointing straight ahead Distance between threaded hole centers of steering arm brackets MUST BE equal to distance between propeller shaft centerlines Lubricate inside of rubber sleeves with 2 4 C w Teflon Ma rine Lubricant and slide sleeves on steering coupler Work rubber bushings onto threaded ends of steering eyes Thread jam nut on starboard steering eye Thread steering eyes equally into coupler so that distance bet
353. ons are pro vided for a Wet installation All decals should be applied Wet TOOLS REQUIRED 1 Plastic Squeegee 2 Stick Pin 3 Dish Washing Liquid Detergent without am Joy and Drift are known to be com patible 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 position de cal Read entire installation instructions on this technique before proceeding 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 application surface Clean entire application surface with mild dish wash ing liquid and water Rinse surface thoroughly with clean water 1 24 GENERAL INFORMATION and SPECIFICATIONS e DECAL APPLICATION 1 Mix 1 2 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 sur face and remove the paper backing from adhe sive side of d
354. ools General Type Two Stroke Cycle 91 52344 Displacement 51 8 cu in 849 cc s Cylinder Bore 91 90455 Diameter Standard 2 955 in 75 057 mm u Diameter 015 Oversize 2 970 in 75 438 mm 91 77109A1 Diameter 030 Oversize 2 985 in 75 819 mm 3192010 Out of Round Max 0 003 in 0 08 mm 91 66274 Taper Max 91 25821A1 Piston Diameter Standard 2 950 in 74 93 mm Diameter 015 Oversize 2 965 in 75 31 mm May be obtained locally Flywheel Holder Protector Cap Flywheel Puller Lifting Eye Piston Ring Expander Piston Pin Tool Lockring Installation Tool Torque Wrench 0 200 Ib ft 0 27 Torque Wrench 0 150 Ib ft 0 20 N m Powerhead Stand Diameter 030 Oversize 2 980 in 75 69 mm Quicksilver Lubricants and Piston Ring Service Aids End Gap 0 010 in 0 018 in 254 mm 457 mm Crankshaft Runout Max 0 002 in 0 05 mm 92 32609 1 92 12564 1 92 42649A1 92 13249A24 92 59327 1 92 90018A12 92 34277 1 May be obtained locally 90 817643R1 DECEMBER 1996 Deep Loctite 271 Grade A Master Gasket Sealant Needle Bearing Assembly Lubricant 2 Cycle Outboard Oil Loctite Primer T 2 4 C Marine Lubricant Perfect Seal Loctite 272 POWERHEAD 4 1 Cylinder Block and Crankcase Loctite 271 92 809820 Loctite PST Pipe Sealant 92 809822 12 D Loctite Master Gasket 92 12564 2 2 4 C With
355. oost diaphragm gasket Check seal between mat distorted or out of place ing surfaces where rib divides pulse cham ber and gasket must align with rib check for dis torted gasket Align or re place gasket if necessary IMPORTANT Align diaphragm aligning tabs with fuel pump aligning tabs during reassembly 90 817643R1 DECEMBER 1996 FUEL SYSTEMS 3B 7 Fuel Pump Removal 1 Remove oil tank from outboard Refer to Section 8A Oil Injection System 2 Remove fuel inlet hose a outlet hose b and pulse hose d 3 Remove two bolts f securing fuel pump to power head 51267 Inlet Fuel Hose Outlet Fuel Hose Oil Injection hose From Oil Tank Pulse Hose From Crankcase Sta Strap 6 Bolts 2 KR Remove gasket from backside and replace gasket as necessary check gasket in port area 51267 a Gasket b Port Area 3B 8 FUEL SYSTEMS Q Fuel Pump Disassembly 1 Remove bolts a and chamber plate b 51267 2 Disassemble fuel pump as shown in Fuel Pump Ex ploded View Cleaning and Inspection 1 Clean fuel pump housing chamber plate and pump base then dry with compressed air Look at spring for signs of bad coils or other damage Check pump body chamber plate and pump base for cracks or rough gasket surfaces Check hoses for looseness or signs of leakage Look at check valve discs for cracks tears or other dama
356. ooved pitted or scratched Replace as necessary Check all crankshaft bearing surfaces for rust water marks chatter marks uneven wear and or overheat ing Refer to Connecting Rods If necessary clean crankshaft surfaces with crocus cloth as shown PE 51089 POWERHEAD 4 23 gt Thoroughly clean with solvent and dry crankshaft and crankshaft ball bearings Recheck surfaces of crank shaft Replace crankshaftif surfaces cannot be proper ly cleaned up If crankshaft will be reused lubricate surfaces of crankshaft with light oil to prevent rust DO NOT lubricate crankshaft ball bearings atthis time WARNING DO NOT spin dry crankshaft ball bearing with com pressed air Connecting Rods If necessary clean connecting rod surfaces as follows gt Attach end caps to connecting rods Following these di rections tighten rod cap attaching bolts to specifica tions Recheck alignment ACAUTION Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of connecting rod DO NOT use any other type of abrasive cloth gt Cleancrankshaftend of connecting rod by using crocus cloth placed in a slotted 3 8 in 9 5 mm diameter shaft as shown Insertshaftin a drill press and operate press at full speed while keeping connecting rod at a 90 angle to slotted shaft IMPORTANT Clean connecting rod just enough to clean bearing surfaces DO NOT continue to clean af ter marks are removed from bearing
357. or Cylinder Bore Defective Replace Manifold and Pump Assembly Replace O ring or Components 90 817643R1 DECEMBER 1996 MID SECTION 5D 7 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Inspect Manual Release Valve Results Results Manual release valve and or O ring damage Manual release valve and O rings appear to be OK Replace O rings and proceed Replace defective valve and O Inspect Trim Rod Piston Check rings Valve Results Results No debris or defective components Debris found in check valve com found ponents Inspect Manifold Reverse Thrust Clean check valve components Valve using engine cleaner and com pressed air or replace Replace Pump and Manifold Assembly 5D 8 MID SECTION 90 817643R1 DECEMBER 1996 lt 1 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram GRY 5 TAN BLU 3 TAN BLU GRY PUR 2 BLK D PUR A BLK e Black BLU e Blue BRN Brown GRY e Gray var A GRN e Green PUR Purple NS RED e Red TAN e Tan WHT e White YELe Yellow 2ZZZZZZZZ A Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector 23891 Wiring Harness Connector Warning Horn Trim Tilt Switc
358. ot pin pivot pin bore and trim ram bore a Pivot Pin b Pivot Pin Bore c Trim Ram Bore 5B 38 MID SECTION 7 Using suitable mallet drive upper pivot into swivel bracket and through trim ram until pivot pin is flushed with swivel bracket a Pivot Pin b Swivel Bracket c Trim Ram 8 Drive upper dowel pin RETAINED into its re spective hole until seated gt 9 Remove trim fluid fill screw Fluid level should be to bottom of threads Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF FA or Dexron II to trim system if necessary 51147 a Dowel Pin 10 Reinstall fill screw 11 Power trim may now be operated to lower out board to desired position Trim system is self bleeding 12 Reconnect spark plug leads to spark plugs 13 Reinstall top cowl 14 Connect battery leads to battery terminals 90 817643R1 DECEMBER 1996 cM MID SECTION POWER TRIM DESIGN Il Table of Contents Page Power Trim General Information 5C 1 Description 5C 1 Trimming Characteristics 5C 1 Trimming Outboard Up Out 5C 1 Trimming Outboard Down In 5C 1 Trailering Outboard 5C 2 Tilting Outboard Up and Down Manually 5C 2 Trim In Angle Adjustment 5C 2 Power Trim System Components
359. ounded to powerhead when testing Connect test lead to black stator lead if stator is removed from engine 90 817643R1 DECEMBER 1996 IGNITION COIL TEST IMPORTANT Ohmmeter tests can only detect certain faults in the ignition coil Replace ignition coil if ohm meter readings listed in chart following are not as specified If coil tests OK and coil is still suspected of being faulty use Multi Meter DVA Tester 91 99750 or a voltmeter capable of measuring 400 volts DC or higher and Direct Voltage Adaptor 91 89045 to thor oughly check coil 1 Disconnect wires from coil terminals 2 Pull spark plug lead out of coil tower 3 Use an ohmmeter and perform the following tests Resistance Scale Reading OHMS x 02 04 02 04 Terminals Rx 1 Between Coil Tower T 8 11 Coil Terminal 800 1100 R x 100 The primary DC resistance of these coils generally is less than one 1 OHM If a reading resembling a short is obtained this would be acceptable Test Leads Between and Coil Copper wire is an excellent conductor but it will have a noticeable difference in resistance from cold to hot temperatures Reasonable variations from these readings are acceptable 4 If meter readings not as specified replace ignition Coil TRIGGER TEST 1 Disconnect all trigger leads from switch box 2 Usean Ohmmeter and perform the following tests Resistance Scale Reading OH
360. ove allen screw from brass barrel and remove barrel 51603 51602 a Allen Screw b Brass Barrel 7B 12 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 7 Unscrew counterclockwise stainless conduit from til 9 Remove cover plate and gasket from tiller handle ler handle 10 Remove bolt from throttle friction assembly 51604 a Cover Plate b Gasket below plate c Screws a Conduit d Throttle Friction Assembly e Bolt 8 Pull throttl ble f tiller handle 11 Remove throttle arm gear assembly and friction de vice from tiller handle Slide gear cover and friction de vice off of the throttle arm 51604 a Throttle Arm b Gear Assembly c Friction Device d Gear Cover a Throttle Cable 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7B 13 12 Drive outdrift pin and remove throttle gear from throttle 3 Slide cover and friction device onto throttle arm arm C2 QUT REST 51604 51602 Throttle Arm a Gear Gear u b Drift Pin Throttle Friction Device Cover Install throttle arm assembly into tiller arm m BR Tiller Arm Reassembly Torque friction device attaching bolt to 40 Ib in 4 5 N m 1 Reinstall throttle gear on throttle arm and secure gear to arm with new drift pin 51602 a Gear b Drift Pin 51604 2 Applyalightcoatof
361. p d Black Cable 6 Remove 2 rubber collars and 2 rubber bumpers a Rubber Collars b Rubber Bumpers 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2B 15 4 Remove components from armature Spacer Spring Drive Assembly Drive End Cap Armature Shaft Washer OQA0 0M Cleaning and Inspection 1 Clean all motor parts Check pinion teeth for chips cracks or excessive wear Replace the drive clutch spring and or collar if tension is not adequate or if wear is excessive 4 Check that the brush holder is not damaged or is not holding the brushes against the commutator 5 Replace brushes that are pitted or worn to less than 1 4 6 4mm in length Refer to Brush Replacement following 6 Replace a damaged or excessively worn bushing in the end cap 7 Check the armature conductor commutator bar junc tion for a firm connection A poor connection usually results in a burned commutator bar 8 Re surface and undercut a rough commutator as fol lows ACAUTION Do not turn down the commutator excessively a Re surface the commutator and undercut the in sulation between the commutator bars 1 32 0 8mm to the full width of the insulation make sure that the undercut is flat 2B 16 ELECTRICAL and IGNITION b Clean the commutator slots after undercutting c De burr the commutator lightly with No 00 sand paper then clean the commutator d Check the
362. pecial Lubricant 101 NOTE It is recommended that ALL O rings be re placed when servicing tilt system 5F 2 MID SECTION 90 817643R1 DECEMBER 1996 Q Manual Tilt Flow Diagrams Design 1 TILT UP RETURN OIL GAS PRESSURE 300 700 P S I 51651 90 817643R1 DECEMBER 1996 MID SECTION 5F 3 Design 1 TILT DOWN 234 OIL UNDER PRESSURE E RETURN OIL GAS PRESSURE 300 700 P S I 5F 4 MID SECTION 90 817643R1 DECEMBER 1996 Q Design 1 SLOW TILT DOWN UNDER HIGH THRUST 7 OIL UNDER PRESSURE L RETURN OIL GAS PRESSURE 300 700 P S I 9229992992 51653 90 817643R1 DECEMBER 1996 MID SECTION 5F 5 EY Design 1 UNDER WATER STRIKE VALVES OPEN 5F 6 MID SECTION 90 817643R1 DECEMBER 1996 Q Design 1 SHOCK FUNCTION VALVES CLOSED OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 90 817643R1 DECEMBER 1996 MID SECTION 5F 7 EY Manual Tilt Flow Diagrams Design 2 TILT UP OIL UNDER PRESSURE E RETURN OIL GAS PRESSURE 300 700 P S I 5F 8 MID SECTION 90 817643R1 DECEMBER 1996 Design 2 TILT DOWN OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 51657 90 817643R1 DECEMBER 1996 MID SECTION 5F 9 Design 2 SLOW TILT DOWN UNDER HIGH THRUST 90 817643R1 DECEMBER 1996 Design 2 UNDER WATER STRIKE VALVES OPEN 90 817643R1 DECEMBER 1996
363. pen PE 51087 90 817643R1 DECEMBER 1996 Reed Blocks If the opening exceeds 020 in 0 5 mm or if the reed is chipped cracked or otherwise damaged replace NOTE Do not disassemble reed block unless necessary PE 51089 a Reed Block ACAUTION b Reed 3 Sets c Retaining Washer Replace locking tab Washer DO NOT REUSE d Tab Washer e Bolt With Loctite Grade A If reed block was disassembled reassemble by locating reeds pins with retaining washer b Use new IMPORTANT Do not flop reverse the reed petels for tab washer Insert bolt d and to AS E in 6 5 additional use replace reed when necessary N m then if necessary continue the torque to align flat on Reed should lie flat There should be no pre load pressure hex head to locking tab e DO NOT exceed 100 Ib in between reed and reed block although a slight pre load 11 5 N m of torque Bend up lock tab to secure bolt posi is tolerable tion The maximum allowable opening between reed and reed block is 0 020 in 0 5mm This must be checked with a flat blade feeler gauge as shown Us 90 817643R1 DECEMBER 1996 POWERHEAD 4 25 Powerhead Reassembly and Installation General Information Before proceeding with powerhead reassembly be sure that all parts to be reused have been carefully cleaned and thoroughly inspected as outlined in Cleaning and Inspec tion Parts which h
364. perate the outboard with a separate fuel supply which is know to be good If it is found that the anti siphon valve is the cause of the problem either 1 replace the anti siphon valve or 2 re place it with a solenoid operated fuel shutoff valve 90 817643R1 DECEMBER 1996 PAN Carburetor Adjustments INITIAL STARTING ADJUSTMENT Turn idle mixture screw in clockwise until it seats LIGHT LY then back off each carburetor 1 1 4 turns IDLE SEED ADJUSTMENT 1 Adjust engine idle RPM as outlined in Section 2C Timing Synchronizing Adjusting IDLE MIXTURE SCREW ADJUSTMENT 1 Start engine and allow to warm up Throttle back en gine to idle for about one minute 2 With engine running at idle speed in Forward gear turn idle mixture screw IN clockwise until engine starts to bog down and misfire Back out 1 4 turn or more 50555 a Idle Mixture Screw on each carburetor 3 Check for too lean mixture on acceleration 4 DO adjust leaner than necessary to attain rea sonably smooth idling When in doubt stay on the slightly rich side of the adjustment 90 817643R1 DECEMBER 1996 CARBURETOR FLOAT ADJUSTMENT 1 Remove carburetor as outlined in Carburetor Remov al following 2 Remove fuel bowl and gasket and check float level us ing a carburetor scale 3 Ifnecessary adjust float level by bending metal tab on float to which inlet needle is clipped 9 16 14 3mm
365. plugs Out of Season Battery Storage 1 Remove battery as soon as possible and remove all grease sulfate and dirt from top surface 2 Cover PLATES with distilled water but not over 3 16 in bmm above perforated baffles Cover terminal bolts well with grease Store battery in a COOL DRY place in a dry carton or box 5 Remove battery from storage every 60 days Check water level and place on charge for 5 to 6 hours at 6 amperes DO NOT fast charge CAUTION A discharged battery can be damaged by freezing GENERAL INFORMATION and SPECIFICATIONS 1 19 How Weather Affects Engine Performance Rated HP Horsepower Loss Due to Atmosphere Conditions Secondary Loss Due to Propeller Becom ing Too Large for Summer 77 77 Horsepower HORSEPOWER RPM Drop Due to Weather ENGINE RPM Rated RPM It is a known fact that weather conditions exert a profound effect on power output of internal combustion engines Therefore established horsepower ratings refer to the power that the engine will produce at its rated RPM under a specific combination of weather conditions Corporations internationally have settled on adoption of I S O International Standards Organization engine test standards as set forth in 1 5 0 3046 standardizing the computation of horsepower from data obtained on the dy namometer correcting all values to the power that the en gine will produce at sea level at 30
366. pposite direction of the circuit The electric motor will drive the pump forcing fluid thru internal passageways into the down side of the tilt ram The tilt ram will move the engine down to the desired angle Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running While operating up circuit the ram will continue to tilt outboard to full up position for trailering Tilting Outboard Up and Down Manually Before opening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is opened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 turns maximum counterclockwise a Manual Release Valve 5D 2 MID SECTION t Trim In Angle Adjustment Operating some boats with engine trimmed to the full in trim angle notusing trim adjustment bolt a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after en gine installation and after any trim adjustments IMPORTANT Some boat motor combinations that do not use the trim adjustment bolt a and are trimmed to the full in trim angle
367. protect hands during re moval of nut m 3 Remove nut and pull components from shaft a Block of Wood Draining and Inspecting Gear Housing Lubricant If gear housing is installed on engine to avoid accidental starting disconnect and isolate spark plug leads from spark plugs before working near the propeller 1 With gear housing in normal running position place a clean pan under housing and remove the two vent screws and one fill drain screw with gaskets 90 817643R1 DECEMBER 1996 J N EN 53922 Oil Level Screw Fill Drain Screw Vent Screw Inspect gear lubricant for metal particles lubricant will have a metal flake appearance Presence of fine metal particles resembling powder on the drain plug bar magnet indicates normal wear The presence of metal chips on the drain plug bar mag net indicates the need for gear housing disassem bly and component inspection Note color of gear lubricant White or cream color MAY indicate presence of water in lubricant Gear lubricant which has been drained from a gear case recently in operation will have a yellowish color due to lubricant agitation aeration Gear lube which is mixed with assembly lubricant Special Lube 101 or 2 4 C w Teflon will also be creamy white in color This is normal and should not be co
368. q 5B 11 Trouble Chart 5B 11 Hydraulic System Troubleshooting 5B 12 Preliminary Checks 5B 12 Leak Down Check Pump and Manifold Assembly 5B 12 Leak Down Check Pilot Valve Assembly 5B 13 Leak Down Check Manual Release PP 5B 13 Leakage Past Ball and Seat Piston Assembly 5B 13 Troubleshooting Flow Diagram 5B 14 Troubleshooting Flow Diagram 5B 15 Electrical System Troubleshooting 5B 16 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5B 16 Power Trim System Wiring Diagram 5B 17 Troubleshooting the Down Circuit When Up Circuit is OK 5B 18 Troubleshooting the Up Circuit When Down Circuit Is OK 5B 19 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5B 20 Page Power Trim System Removal 5B 21 Power Trim System Disassembly 5B 22 Trim Rod 5B 22 Trim Rod Disassembly 5B 23 Trim Motor Removal 5B 25 Trim Motor Disassembly 5B 25 Reservoir Assembly Removal 5B 26 Oil Pump Removal 5B 27 Manifold Removal 5B 27 Cleaning and Inspection of Trim Ro
369. r 90 817643R1 DECEMBER 1996 a L 4 If plunger can be compressed into accumulator Shock Rod Removal by hand accumulator is defective Replace accu mulator 1 Remove cylinder end cap assembly using span ner wrench 1 4 in x 5 16 in long pegs 51145 51143 a Plunger 5 Remove O ring 51143 51145 90 817643R1 DECEMBER 1996 MID SECTION 5F 23 3 Remove memory piston from cylinder using lock ring pliers Craftsman P N 4735 or suitable tool Shock Rod Disassembly 1 Place shock rod assembly on clean work surface 2 Remove plate and O ring 3 Remove check ball components from shock rod piston a Screw 3 b Plate c O ring d Shock Rod Piston A CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to shock piston 51144 51144 a O ring b Memory Piston 5 Remove tilt system from vise and empty fluid into appropriate container 5F 24 MID SECTION 90 817643R1 DECEMBER 1996 Q 4 Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 5 Loosen shock rod piston using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs 6 Allow shock rod piston to cool Remove from shock rod 51146 51146 a Shock Rod Piston b Spanner Wrench 90 817643R1 DECEMBER 1996 A CAUTION Do not remove check ball components from shock rod piston Remo
370. r manent magnets are recessed 1 25 4mm Align marks a as shown Install commutator end cap onto starter frame align marks b as shown and remove brush retainer tool Install thru bolts c and torque to 70 165 8 11648 2B 20 ELECTRICAL and IGNITION Installation 1 Install 2 rubber collars and 2 rubber bumpers Rubber Collars Rubber Bumpers Install components as shown N Connect battery leads to battery __ EHE j J 51209 Starter Clamp Bolts 2 Black Cable from Battery Black Cable from Solenoid O o oO o 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION TIMING SYNCHRONIZING ADJUSTING Table of Contents Timing Synchronizing Adjusting Specifications Special Tools Timing Pointer Adjustment Carburetor Synchronization Models With One Piece Throttle Link ROG Models With Adjustable Length Throttle Link Rod Both One Piece and Adjustable Link ROQ Timing Idle Timing Adjustment Maximum Timing Idle Adjustment Throttle Cable Installation 90 817643R1 DECEMBER 1996 Timing Synchronizing Adjusting Specifications FULL THROTTLE RPM 5000 5500 RPM
371. r 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 terminal b Replace Rectifier black lead alternately to terminals a and Continuity Indicated No Continuity Indicated Replace Rectifier Connect red meter lead to terminal b black lead alternately to terminals a and c No Continuity Indicated Replace Rectifier 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2B 11 Continuity Indicated Replace Rectifier No Continuity Indicated Rectifier tests O K Continuity Indicated Rectifier Tests O K Starting System Starting System Components The starting system consists of the following components 1 Battery 2 Starter Solenoid 3 Neutral Start Switch 4 Starter Motor 5 Ignition Switch Description The function of the starting system is to crank the engine The battery supplies electrical energy to crank the starter motor When the ignition switch is turned to Start position the starter solenoid is activated and completes the starting circuit between the battery and starter 2B 12 ELECTRICAL and IGNITION The neutral start switch opens the start circuit when the shift control lever is not in neutral This prevents accidental starting when engine is in gear ACAUTION The starter motor may be damaged if operated contin uously DO
372. r Reassembly e f removed install throttle shaft throttle shutter plate 2 screws use Loctite Grade A and throttle shaft spring as shown Install retaining clip on other end of shaft 51117 a Throttle Shaft b Screws 2 Torque 6 Ib in 0 7 N m c Throttle Shaft Spring 90 817643R1 DECEMBER 1996 e Spring tension on stud 51259 c Spring d Stud e Install mixing chamber cover and gasket as shown e Install idle mixture screw Install bowl vent jet 51116 Mixing Chamber Cover and Gasket Idle Mixture Screw Bowl Vent Jet Screw 2 Torque 18 Ib in 2 1 N m FUEL SYSTEMS 15 e Install main jet e Attach Spring Clip on Inlet Needle to metal float tab and e Install main jet plug and gasket a Main Jet Torque 14 Ib in 1 6 N m b Main Jet Plug and Gasket Torque 22 Ib in 2 5 N m 51115 Install stem gasket a Spring Clip e Install fuel bowl gasket b Float Tab e Install float into carburetor with float pin e Adjust float following Carburetor Float Adjustment Page 3A 13 a Stem Gasket b Fuel Bowl Gasket NOTE If Spring Clip on Inlet Needle was removed or if needle was replaced be sure spring clip is reattached a Float b Float Pin 3A 16 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 fh e Install float bowl Carburetor Installation e Install carburetors attenuator plate connect linka
373. racting 001 in 0 025mm shim the backlash will change 00125 in 0 032mm NOTE When final measurement has been made apply Loctite 271 to threads of pinion nut Torque to 50 Ib ft 67 8 N m 90 817643R1 DECEMBER 1996 Bearing Carrier and Propeller Shaft Installation Insert propeller shaft assembly into bearing carrier Lubricate O ring a and areas b with Quicksilver Special Lubricant 101 P N 92 13872 1 Install bearing carrier and propeller shaft assembly into gear housing Use care not to displace cam follow er C ACAUTION Use care not to damage O ring a during installation of bearing carrier assembly Install bolts a Apply Loctite 271 to threads and torque to 150 Ib in 17 N m 51117 LOWER UNIT 6A 21 Water Pump Re assembly and Installation 1 Place seal a on longer shoulder side b of tool 2 Press into water pump base until tool bottoms a Seal Install with spring visible when installed b Seal Install with spring visible when installed If installation tool is not available press seals in as shown to depths indicated 5 Install O ring a Lubricate O ring and gear housing bore with Quicksilver Special Lubricant 101 6 Install water pump base b into gearcase c 51270 Quicksilver Gear Lubricant Seal Install with spring visible when installed Seal Installation Tool 91 817006 a b 3 Place seal a on shorter side b of tool c
374. rds lower stalling ring seals gear end of crankshaft Secure each main bearing race with retaining ring Lubricate top main bearing Install ring seals 2 to crankshaft with 2 cycle engine oil and install to crankshaft as shown PE 51083 a Main Bearing Race b Retaining Ring Groove Faces Flywheel Top Main Bearing One Piece PE 51083 a Ring Seal b Slot On Crankshaft 4 30 POWERHEAD 90 817643R1 DECEMBER 1996 cM 6 Position cylinder block and piston rods as shown In sert locating pins a PE 51088 Flywheel End Lower End 7 Placecrankshaft into cylinder block align and seat top and center main bearings so that locating pins on block align with larger holes in each bearing race PE 51080 90 817643R1 DECEMBER 1996 Installing Rods to Crankshaft 1 Oil rod and bearing cage with 2 cycle oil 2 Pullrod into place and install bearing cages as shown PE 51080 NOTE Clean rod bolt rod cap bolt holes of oil and debris before reassembly IMPORTANT The rod cap and rod must be aligned and held together when threading oiled bolt Check that mating surfaces are tight together after bolt enters threads in piston rod 3 Place rod cap over bearing cages While holding cap to rod insert slightly oiled bolts and lightly tighten while observing cap to rod alignment PE 51089 POWERHEAD 4 31 Connecting Rod Cap Alignment 1 Check each connecting rod for correct alignment
375. re worn or twisted 9 If bearing surface is damaged replace drive shaft and corresponding bearing IMPORTANT Do not tighten vise against drive shaft 10 If wear sleeve is deeply grooved allowing water to enter gear case remove and discard sleeve us ing Universal Puller Plate 91 37241 and mallet PS Fg a b a 19710 a Splines b Bearing Surface c Wear Sleeve d Universal Puller Plate 91 37241 e Mallet 11 Remove and discard rubber ring a Et Cow 19152 a Rubber Ring 90 817643R1 DECEMBER 1996 Upper Drive Shaft Bearing 1 Replace upper drive shaft bearing and sleeve if ei ther are rust stained or if bearing will not roll freely Remove bearing and then sleeve using Puller As sembly 91 83165M with suitable jaws 19177 a Upper Drive Shaft Bearing b Sleeve c Puller Assembly 91 83165M LOWER UNIT 6B 15 cM IMPORTANT Upper drive shaft bearing sleeve IMPORTANT Upper drive shaft bearing sleeve must be removed prior to oil sleeve removal Refer andoil sleeve do not have to be removed for lower to Upper Drive Shaft Bearing preceding drive shaft bearing race removal Cil Sleeve Lower Drive Shaft Bearing Race 1 Remove oil sleeve if necessary using Puller As IMPORTANT Retain shim s for reassembly sembly 91 83165M with suitable jaws 1 Remove race and shim s using bearing race tool
376. rench Apply Loctite Grade A 271 to threads of trim rod Trim Rod Installation andinstall rod piston Tighten piston securely us ing trim cylinder spanner wrench 1 4 in x 5 16 in 1 Place trim cylinder in soft jawed vise long peg 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron Il 3 Install lubricated O ring to memory piston and place into cylinder Push piston down to level of oil Install lubricated O ring to trim rod piston Install check valve components into their respec tive seats Secure components in place using plate and screws Torque screws to 35 in 4 0 N m a O ring b Memory Piston IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 51147 Screw 3 Plate O ring Ball 5 Seat Spring 5 Spring 5 90 817643R1 DECEMBER 1996 MID SECTION 5C 35 4 Install trim rod into cylinder 51196 IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 5 Tighten end cap assembly to cylinder securely using trim cylinder spanner wrench 1 4 in x 5 16 in long pegs 51145 6 Tighten manual release valve snuggly following end cap installation 5C 36 MID SECTION Q Bleeding Power Trim Unit IMPORTANT Manual release valve must be in the
377. rhead overheating damage 90 817643R1 DECEMBER 1996 Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up solenoid located under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the up side of the trim ram The trim cylinder trim ram will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine speed increases above 2000 RPM the thrust created by the propeller if deep enough in the water should cause the trim system to automatically lower the en gine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering conditions Each boat should be tested for handling charac teristics after any adjustment is made to the tilt angle tilt pin relocation
378. rim switch 3 Wire is open between fuse holder and solenoid 4 Wire is open between fuse holder and trim switch 1 One of the Trim Pump Motor wires is open between the motor and the Relays 2 Faulty trim pump motor 1 The Trim or Cowl switch is shorted 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection 2 Check for an open connection 3 Check for an open connection 4 Replace 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection 2 Check for an open connection 3 Check for an open connection 4 Replace 1 Replace fuse Locate the cause of the blown fuse Check electrical wiring for a shorted circuit 2 Replace 3 Check for an open connection or cut wire 4 Check for a loose or corroded connec tion 1 Check wire connections 4 for loose or corroded condition 2 If voltage is present at connections 4 when the appropriate trim button is pressed then motor is faulty Replace motor 1 Replace 90 817643R1 DECEMBER 1996 3 Remove the trilobe pin 4 Drive out the upper pivot pin Power Trim System Removal 1 Tilt outboard to the full up position and support with tilt lock pin 7 x 94 2 u Sy 2 71 lt lt x j9
379. ring 51147 51145 a Rod Wiper b Inner O ring c Outer O ring MID SECTION 5G 21 Valve Block Removal 1 Remove two screws from the shock rod cylinder to separate the valve block 51146 Screws 2 Valve Block Shock Rod Cylinder 2 Remove O rings and dowel pins 51148 a O ring 2 b Dowel Pin 2 5G 22 MID SECTION c 1 Remove memory piston from cylinder using one of two methods Memory Piston Removal a Usinglock ring pliers Craftsman P N 4735 or Snap on P N SRP4 LOCK RING PLIERS A b Blowing compressed air into center O ring hole Memory piston cup may be expelled at a high velocity when air pressure is applied Failure to place cylinder as shown below could result in personal injury 51144 NOTE Point cylinder opening down and away Use a shop rag or towel to avoid damage to the memory piston Fluid will blow out also a Adaptor Air Hose b Memory Piston Exit c Shop Rag 90 817643R1 DECEMBER 1996 O ring from memory piston 3 Remove surge valve assembly 51144 a O Ring b Memory Piston a Spool b Spring O ring Valve Block Disassembly d Screw Plug 1 Remove check retainer plug and components 2 Remove hydraulic oil transfer valve plugs and 4 Remove screw and remove cam assembly components e N a Spacer Retainer Clip b Retainer Clip c Screw d
380. rinted on the stator USA S N 0G277605 and BELOW BELGIUM S N Not Available at Time of Printing 9 AMPERE STATOR Test Leads Resistance Scale Reading OHMS x Between Yellow 6 1 1 6 1 1 Stator Leads R x 1 Between Either Yellow Stator No Continuity No Continuity Lead and Engine R x 1000 Ground 90 817643R1 DECEMBER 1996 c 16 AMPERE STATOR REGULATED SYSTEMS Test Leads Resistance Scale Reading 1 Check battery voltage at battery with engine running OHMS x 2 f battery voltage is above 14 5 volts replace voltage Belween Yellow 17 19 17 19 regulator rectifier Check condition of battery as over Stator Leads R x 1 charging may have damaged battery Between Either 3 If battery voltage is below 14 5 volts charge battery Yellow Stator No Continuity No Continuity refer to Charging a Discharged Battery If battery can Lead and Engine R x 1000 NOT be satisfactorily charged replace battery 4 If battery accepts a satisfactory charge check battery DC Resistance of these windings generally is less than 1 5 OHMS voltage while cranking engine refer to Charging a If a reading resembling a short is obtained this would be accept Discharged Battery If cranking voltage is not accept able able replace battery If stator is removed from engine connect test lead to black stator 5 If cranking voltage is acceptable disconnect larger di al pee ameter RED harness wire from starter
381. ristics 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 recom mended RPM For boaters to realize optimum engine performance under changing weather conditions it is essential that the engine have the proper propeller to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation This of course enhances overall reliability and durability of the engine 90 817643R1 DECEMBER 1996 PANS Conditions Affecting Operation 1 Proper positioning of the weight inside the boat per sons 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 boa
382. rness 2 Insert motor into reservoir Motor must be seated properly prior to end cap installation Install end cap O ring and foam pad to cylinder 4 Torque screws 13 Ib in 1 5 N m 51195 a End Cap b O ring Foam Pad 90 817643R1 DECEMBER 1996 5 b c Install grommet washer and screw to der end cap Tighten screw securely Screw Cap Washer Grommet Place drive shaft into oil pump Install lubricated O ring to base of reservoir Carefully guide cylinder motor down onto drive shaft a Drive Shaft b O ring MID SECTION 5C 33 9 Secure reservoir to manifold using four screws Torque screws to 70 Ib in 7 7 N m a Screw 10 Install E clip lubricated O rings and to manual release valve a E Clip b O ring Manual Release Valve 11 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 or 4 turns allowing trim rod installation a Manual Release Valve b Manifold 5C 34 MID SECTION cM 1 Install lubricated O rings and rod wiper to end R Trim Rod Reassembly e 51145 a Rod Wiper b Inner O ring C Outer O ring 2 Secure trim rod in soft jawed vise as shown 3 Slide end cap onto trim rod 51146 a End Cap 90 8i7643R1 DECEMBER 1996 x o O oO O Trim Rod Piston Spanner W
383. rod If scraper located in cap has failed to keep rod clean replace scraper Lubricate all O rings using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron Il 90 8i7643R1 DECEMBER 1996 Motor and Electrical Tests Repair Trim Pump Motor Test Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect orange motor wire and black mo tor wire from relay switch wiring harness 2 Connect a 12 volt power supply to motor wires positive to orange negative to black results in motor up direction Positive to black negative to orange results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Thermal Overload Switch Test IMPORTANT If thermal overload switch has been activated pump motor cannot be tested for a minimum of one minute After this period switch should close reset itself and pump motor may be operated Perform the following check s only if switch does not reset itself MOTOR ASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated If full continuity is not indicated disassemble motor and recheck switch per instructions following 90 817643R1 DECEMBER 1996 a Motor Wire Black b Motor Wire Orange MOTOR DISASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is
384. rod piston as an assembly Clean trim rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Inspect trim rod If scraper located in cap has failed to keep rod clean replace scraper Lubricate all O rings using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron ll Motor and Electrical Tests Repair Trim Pump Motor Test Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect orange motor wire and black mo tor wire from relay switch wiring harness 2 Connect a 12 volt power supply to motor wires positive to orange negative to black results in motor up direction Positive to black negative to orange results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Thermal Overload Switch Test IMPORTANT If thermal overload switch has been activated pump motor cannot be tested for a minimum of one minute After this period switch should close reset itself and pump motor may be operated Perform the following check s only if switch does not reset itself 90 817643R1 DECEMBER 1996 MOTOR ASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated If full continuity is not indicated disassemble motor and recheck switch per instr
385. rs of running approximately 10 gal lons 40 Liters of fuel full throttle operation may be at tained but not sustained for the remaining break in fuel approximately 5 gallons For the next five hours of operation full throttle operation may again be attained but itis strongly not recommended for sustained use Not more than 5 minutes of continuous wide open throttle ACAUTION SEVERE DAMAGE to your engine can result by not complying with the preceding break in procedures 90 817643R1 DECEMBER 1996 MID SECTION CLAMP SWIVEL BRACKETS and DRIVE SHAFT HOUSING Table of Contents Page Mid Section Components 1 Swivel Bracket Components 1 Mid Section Components 5A 2 Transom Bracket Components 55 Model 5A 2 Mid Section Components 5A 3 Transom Bracket Components 50 60 Models 4 rer er RE R E deere ri Rn eps 5A 3 Mid Section Components 5A 4 Drive Shaft Housing Components 5A 4 5 Reassembly 5 Tilt Lock Lever Transom Bracket 5A 5 Drive Shaft Housing 5A 7 90 817643R1 DECEMBER 1996 Mid Section Components Swivel Bracket Components Swivel Bracket Bushing 2 Oil Seal Bushing Grease Fitting Washer 2 Yoke
386. rsal Puller Plate Bearing Puller Assembly Oil Seal Driver Mandrel Threaded Nut Backlash Indicator Tool 3 Cyl Dial Indicator Dial Indicator Adaptor Kit Pinion Gear Locating Tool Bearing Race Tool Bearing Installation Tool Wear Sleeve Installation Tool Bearing Preload Tool Bearing Installation Tool Oil Seal Driver Backlash Indicator Tool 4 From Bearing Removal and Installation Kit 91 31229A7 Removal To prevent accidental engine starting remove and isolate spark plug leads from spark plugs before removing gear housing 1 Remove and isolate spark plug leads from spark plugs Shift engine into forward gear Tilt engine to full Up position Remove 4 bolts or locknuts on 1995 Models and washers two each side 5 Remove locknut and washer 6B 8 LOWER UNIT 6 Remove gear housing A b __ Ne Ej 53992 Bolts or Locknuts Washers b Locknut and Washer Propeller Removal If gear housing is not removed from drive shaft housing before attempting to remove or install the propeller remove and isolate spark plug leads from spark plugs to prevent engine from starting accidentally 1 Bend tabs of tab washer away from hub 51871 a Tab Washer b Hub 90 817643R1 DECEMBER 1996 Place a block of wood as shown to prevent pro peller from rotating and to
387. s IMPORTANT The forward locking of the reverse gate must be met If not readjust the shift cable 90 817643R1 DECEMBER 1996 G Lubricating The Drive Shaft Bearing Recommended Lubrication Use 2 4 C w Teflon IMPORTANT It is important that you do not use a general all purpose grease for this bearing The lubricant we recommend is a water resistant grease of the proper consistency for this applica tion If you use a substitute grease be sure that it is water resistant and of the same consistency Frequency of lubrication We recommend lubricat ing the drive shaft bearing after each day s use and af ter every 10 hours of operation After every 30 hours of operation pump in extra grease to purge out any moisture a Vent Hose b Grease Gun c Grease Exiting Vent Hose Lubricating Procedure Pull vent hose a off the grease fitting Pump in grease through the grease fit ting using the grease gun b provided until excess grease starts to exit the vent hose c Reconnect the vent hose a onto the grease fitting af ter greasing After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give you an indication of condi tions inside the bearing housing A gradual increase in moisture content indicates seal wear If the grease be gins to turn dark dirty gray the drive shaft bearing and seals should be inspected and replaced if
388. s 2 Screw Plugs 2 Torque to 75 Ib in 8 5 N m O 5G 28 MID SECTION 90 817643R1 DECEMBER 1996 Rod Reassembly 1 Install lubricated O rings to end cap 2 Install rod wiper E b Y 51145 a Rod Wiper b Inner O ring c Outer O ring 3 Install lubricated O rings to shock piston 51199 a Shock Piston b O ring c O ring 90 817643R1 DECEMBER 1996 4 Clamp shock rod in soft jawed vise 5 Position cylinder end cap onto rod as shown 51146 A CAUTION When installing shock rod piston spanner wrench must have1 4 in x 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod Install shock rod piston 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten shock piston then torque to 90 Ib ft 122 N m 51146 a Spanner Wrench b Shock Rod Piston Torque to 90 Ib ft 122 N m MID SECTION 56 29 9 Install ball seat and spring five sets to shock rod piston 10 Secure components with plate Torque screws to 35 3 9 11 Remove shock rod assembly from vise om b 51147 Screw 3 Torque to 35 Ib in 3 9 N m Plate Spring 5 Seat 5 Ball 5 5G 30 MID SECTION lt 1 Shock Rod Installation and Fluid F
389. s 76mm from top 51145 51144 a O ring b Memory Piston 5 Refill cylinder to top and install shock rod assem bly into cylinder 51143 5F 32 MID SECTION 90 817643R1 DECEMBER 1996 Instructions for Making Retaining Tool LLLLLLU 3 16 in x 3 in 5 x 7 5 cm Steel Plate 3 8 in x 13 in 10mm x 33cm Threaded Rod 4 in x 1 4 in min 10cm x 6 4mm minimum Channel Iron 2 holes 7 16 in dia 11 mm 5 in 1 1 4 in dia 125mm 3 30m 20 in 508mm 6 in 8 3 8 dia 2 holes 152mm 203mm 90 817643R1 DECEMBER 1996 MID SECTION 5F 33 Bleeding Manual Tilt System IMPORTANT While bleeding tilt system time must be allowed between each stroke to allow air bubbles to dissipate 1 With shock rod in the full up position and manifold cam lever open facing down secure tilt system to retaining tool and container A No 10 can or 3 lb coffee can can be used 2 Fill container to near full level using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron Il IMPORTANT Fluid level must remain above accu mulator opening during bleeding process T 50447 Retaining Tool Tilt System Container Cam Lever Accumulator Opening 5F 34 MID SECTION 3 Bleed unit by pushing rod down slowly 18 20 se conds per stroke until stopped at base Wait until all air bubbles exit
390. se Af 50146 a Manual Release Valve 5C 2 MID SECTION c Trim In Angle Adjustment Operating some boats with engine trimmed to the full in trim angle not using trim adjustment pin a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after en gine installation and after any trim adjustments IMPORTANT Some boat motor combinations that do not use the trim adjustment pin a and are trimmed to the full in trim angle will not experi ence any undesirable and or unsafe steering con ditions during planing speed Thus not using trim adjustment pin may be desired However some boats with engine trimmed to the full in trim angle at planing speed will cause undesir able and or unsafe steering conditions If these steering conditions are experienced under no circumstances should the engine be operated without the trim adjustment pin and without the pin adjusted in the proper holes to prevent unsafe handling characteristics Water test the boat not using the trim adjustment pin If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment pin a in proper hole to prevent unsafe handling characteristics 90 8i7643R1 DECEMBER 1996 cM Power Trim System Components Trim Rod Dowel Pin Pivot Pin
391. sition falls down to trim position indicates debris or defective com ponents in trim assembly Clean or replace com ponents as required 5E 20 MID SECTION EY 90 817643R1 DECEMBER 1996 c Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND OR TRAILS OUT DURING HIGH SPEED DECELERATION Manual release valve nspect manual release valve and O ring damaged O rings appear to be Clean and reinstall manual release valve Replace manual re Trim will not hold lease valve and O reverse thrust Trim system holds reverse thrust Test ing complete rings Trim system holds Remove and inspect pis reverse thrust Test ton rod assembly for de Shock piston appears O K ing complete bris and or shock ball Clean and reinstall piston hang up rod assembly Debris and or shock ball hang up identi Trim will not hold reverse thrust Trim system holds reverse thrust Test Replace piston ing complete rod assembly Remove PO check valve assembly inspect O rings and seals for damage Trim system holds reverse thrust Test ing complete Debris and or dam PO check valve appears age identified O K Clean and reinstall PO check valve assembly Replace PO check valve assembly Trim system holds reverse thrust Test ing complete Trim will not hold Trim system holds reverse thrust reverse thrust Test ing comple
392. smoke near batteries being charged or which have been charged very recently 2 DONOT break live circuits at terminals of batteries be cause a spark usually occurs at the point where a live circuit is broken Always be careful when connecting or disconnecting cable clamps on chargers Poor con nections are acommon cause of electrical arcs which cause explosions 3 DO NOT reverse polarity of battery cables on battery terminals CAUTION If battery acid comes into contact with skin or eyes wash skin immediately with a mild soap Flush eyes with water immediately and see a doctor Recommended Battery The 2 cycle Outboard type engine requires a 12 volt bat tery with a Cold Cranking Amperage rating for cranking and a Reserve Capacity rating The minimum should be a Cold Cranking Amperage of 350 amperes and a Re serve Capacity of 100 minutes for engines outlined in this manual Operating Engine Without Battery If desired or in an emergency engines equipped with an alternator can be started and operated without a battery either disconnected or removed if Warning below is fol lowed A WARNING Before operating engine with battery leads discon nected from battery disconnect stator leads yellow from rectifier Insulate tape stator lead ring terminals 90 817643R1 DECEMBER 1996 Specific Gravity Readings Use a hydrometer a to measure specific gravity of electro lyte in each cell 22532
393. solenoid termi 45 JET 50 60 ELECTRIC 398 9873A24 printed on nal the stator 6 Remove smaller diameter RED wire sense lead from USA S N 0G277606 and ABOVE E starter solenoid terminal and connectto the positive BELGIUM S N Not Available at Time of Printing terminal of a 9 volt transistor battery Ground the nega tive terminal of the 9 volt battery to the engine 15 AMPERE STATOR 7 Connect RED ammeter lead to larger diameter Test Leads Resistance Scale Reading RED harness wire and BLACK ammeter lead to OHMS x positive terminal on starter solenoid Between Yellow 20 25 20 25 8 Secure starter wires away from flywheel Stator Leads R x 1 5 Between Either With engine running at the indicated RPM s the am Yellow Stator No Continuity No Continuity Lead and Engine R x 1000 i Ground DC Resistance of these windings generally is less than 1 5 OHMS If a reading resembling a short is obtained this would be accept able If stator is removed from engine connect test lead to black stator lead if provided Alternator System Test UNREGULATED SYSTEMS IMPORTANT Rectifier must be functioning properly for accurate test results to be obtained 1 If engine is equipped with a voltage regulator discon nect voltage regulator leads at rectifier re install hex nut on rectifier terminal that has yellow stator lead Remove red wire from terminal of r
394. ss the capaci tor charging coils This causes the capacitor charging coils to produce AC voltage The AC voltage then is conducted to the switch box where it is rectified and stored in a capaci tor The trigger assembly also mounted under the flywheel has 3 coils The flywheel has a second set of permanent magnets located around the center hub As the flywheel rotates the second set of magnets pass the trigger coils This causes the trigger coils to produce an AC voltage that is conducted to an electric Silicon Controlled Rectifier SCR in the switch box The switch discharges the capacitor voltage into the igni tion coil at the correct time and firing order sequence Capacitor voltage is conducted to the primary side of the ignition coil The ignition coil multiplies this voltage high enough to jump the gap at the spark plug The preceding sequence occurs once per engine revolu tion for each cylinder Spark timing is changed advanced retarded by rotating the trigger assembly which changes each trigger coil posi tion in relation to the permanent magnets on the flywheel center hub IMPORTANT If the engine misfires runs rough or does not start the ignition system should be checked using a Multi Meter DVA Tester 91 99750 or a voltmeter capable of measuring 400 volts DC or higher and Di rect Voltage Adaptor 91 89045 90 817643R1 DECEMBER 1996 Test Procedures Direct Voltage Adapter DVA Tests A WARNING DA
395. t BEEP BEEP tone If the oil in the reservoir drops to less than 14 5 fl oz 435 ml the low oil sensor in the reservoir will signal the warn ing module to activate the warning horn If the powerhead temperature should exceed 300 F 65 C the overheat temperature sensor in the water jacket cover will signal the warning module to activate the warning horn FUEL SYSTEMS 3D 1 Oil Injection Flow System Fixed Ratio Oil Pump Fill Cap Fuel Filter BLU gt 16 OP J 3 Oil F Fuel Pump Level Sight Gauge BLU BLU Fuel Line Connector m GA e al a Oil Pump D J 51202 3D 2 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 Pump Drive Assembly Fixed Ratio Oil Pump 51203 Bleed Screw Oil Outlet Oil Pump Oil Inlet om a L u u N wA av 574554157 51203 Apply 2 4 w Teflon to Shaft Driven Gear Bushings O Rings 90 817643R1 DECEMBER 1996 Pump Drive System Fixed Ratio Oil Pump N V Z T LUSS S 1 E Z 51203 O Rings Driven Gear Drive Gear Crankshaft Oil Pump om FUEL SYSTEMS 3D 3 Oil Pump to Powerhead Assembly Fixed Ratio Oil Pump 2 4 C With Teflon 92 825407A12 Bolt Oil Pump O Rings Bushing Bearing Bushin
396. t Seats Do Not Exceed 120 Torque to 20 Ib ft 27 1 N m Ib in 14 N m of Torque Then Back Off 1 4 Turn h Special Washer P N 12 71970 Steering Link Connecting Hole Coupler Assembly Connecting Hole Steering Link Washer Ride Guide Cable 53 w 7A 10 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 LS WITH TWO HOLE TWO PIECE STEERING IMPORTANT Lubricate all moving parts with Quicksil ARM BRACKET AND ONE PIECE TOP COWL ver 2 4 C w Teflon Marine Lubricant IMPORTANT All 50 60 models with one piece top cowl require a minimum centerline distance of 21 in 533mm during dual outboard installation to assure interference free movement 51011 Steering Cable Routed on Starboard Side of Boat Con nected to Port Outboard Steering Cable Routed on Port Side of Boat Connected to Starboard Outboard Ride Guide Cable Dual Steering Coupler Steering Bracket Lock Nut P N 11 34863 Torque Until it Seats Do Not Exceed 120 Special Washer Head Bolt 3 8 x 1 5 8 P N 10 90041 Ib in 13 5 N m of Torque Then Back Off 1 4 Turn Torque to 20 Ib ft 27 N m Special Washer P N 12 71970 a Steering Link Connecting Hole j Lock Nut P N 11 34863 Torque to 20 Ib ft 27 N m b Coupler Assembly Connecting Hole k Steering Eye c Steering Arm I Rubber Sleeve d Steering Link m Rubber Bushing e Washer n Jam Nut Torque to 20 Ib ft 27 1
397. t tension by moving handle to port loos en or starboard tighten Locknut on co pilot stud may have to be adjusted to attain desired tension on tiller arm 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS REWIND STARTER Table of Contents Page NOTES 7 1 Rewind Starter Components 7C 2 Rewind Starter Disassembly 7C 4 Cleaning and Inspection 7C 4 Rewind Starter Reassembly 7C 5 Adjusting Rewind Spring Tension 7C 6 Starter Interlock Cable Adjustment 7C 7 90 817643R1 DECEMBER 1996 Notes 90 817643R1 DECEMBER 1996 OUTBOARD INSTALLATION ATTACHMENTS 7C 1 Starter Assembly MANUAL 55 2 Cycle Outboard Oil 92 13249A24 5 2 4 With Teflon 92 825407A12 7C 2 OUTBOARD INSTALLATION ATTACHMENTS 90 817643R1 DECEMBER 1996 Starter Assembly MANUAL 55 DESCRIPTION Ib in Ib ft N m HANDLE ASSEMBLY REST SEAL SCREW SPACER BUSHING GROMMET WASHER NUT INTERLOCK CABLE SCREW Drive Tight WASHER COTTER PIN SCREW Drive Tight COTTER PIN WASHER RECOIL STARTER STARTER HOUSING SPRING INTERLOCK LEVER CAM RETAINER SCREW WASHER SPRING SPRING
398. t veer left and right bow steer 2 Boat Bottom For maximum speed a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore and aft direction a Hook Exists when bottom is concave in fore and aft direction when viewed from the side When boat is planing hook causes more lift on bottom near transom and allows bow to drop thus greatly increasing wetted surface and reducing boat speed Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage b Rocker The reverse of hook and much less com mon Rocker exists if bottom is convex in fore and aft direction when viewed from the side and boat has strong tendency to porpoise c Surface Roughness Moss barnacles etc on boat or corrosion of outboard s gear housing in crease skin friction and cause speed loss Clean surfaces when necessary 3 Gear Housing If unitis leftin the water marine vege tation may accumulate over a period of time in certain types of water This growth must be removed from unit before operation as it may clog the water inlet holes in the gear housing and cause the engine to overheat Detonation Causes and Prevention Detonation in a 2 cycle engine somewhat resembles the pinging heard in an automobile engine It can be other wise described as a tin link rattling or pinging sound 90 817643R1 DECEMBER 1996 De
399. tboard In Down Trim Tab Adjustment Boat Performance Test Instructions 1 9 Page Lubrication Points 1 14 Ride Guide Steering Cable and Pivot Point Lubrication 1 15 Gear Housing Lubrication 1 16 Salt Water Corrosion Gear Housing Bearing Carrier and Cover Nut 1 16 Periodic Inspection 1 17 Flushing Outboard Cooling System 1 17 Following Complete Submersion 1 18 Salt Water Submersion Special 1 18 Submerged While Running Special Instructions 1 18 Submerged Engine Fresh Water Plus Special Instructions 1 18 Out of Season Outboard Storage 1 19 Out of Season Battery Storage 1 19 How Weather Affects Engine Performance 1 20 Conditions Affecting Operation 1 21 Detonation Causes and Prevention 1 21 Compression Check 1 21 Water Pressure Check 1 22 Serial Number Location 1 22 Painting Procedures 1 23 Decal Application 1 24 90 817643R1 DECEMBER 1996 T n Propeller Information For in depth information on marine propellers and
400. te continued on next page 90 817643R1 DECEMBER 1996 MID SECTION 5E 21 cM Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as sembly and inspect for debris and or damage Suction seat assembly ap pears O K Clean and rein stall suction seat assembly Replace suction seat assembly Trim will not hold reverse thrust Trim system holds reverse thrust Test ing complete Debris and or damage identified Trim system holds reverse thrust Test ing complete 5E 22 MID SECTION 90 817643R1 DECEMBER 1996 c Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED Manual release valve and O ring damaged Replace manual re lease valve and O rings Trim system does not leak down Testing complete Debris and or dam age identified Replace tilt relief valving Trim system does not leak down Test ing complete Debris and or dam age identified Replace PO check valve assembly Trim system does not leak down Test ing complete 90 817643R1 DECEMBER 1996 Inspect manual release valve Trim system leaks down Remove tilt relief valving and inspect O rings and seals for debris and or CI Manual release valve and O rings appear to be O K Clean and reinstall manual release valve Trim system does not leak down Test ing complete Tilt relief valving and O rings appear to be
401. tery Charging Wiring Diagram IMPORTANT After electrical connections are mat coat all terminal connections using Quicksilver Liqu Neoprene 92 25711 to avoid corrosion REGULATOR MODELS BLK e Black BLU Blue GRY Gray RED e Red YEL Yellow Mo gt gt a gt gt RED SLEEVE Stator Alternator Assembly Regulator 20 Amp Fuse Remote Control Harness Starter Solenoid Gray Wire to Tachometer To Battery Positive Terminal 51249 2 8 ELECTRICAL and IGNITION 90 817643R1 DECEMBER 1996 1 9 Ampere Battery Charging Diagram IMPORTANT After electrical connections are made coat all terminal connections using Quicksilver Liquid with Battery Isolator Neoprene 92 25711 to avoid corrosion RECTIFIER MODELS Black Blue Gray Red Yellow lt e Stator Alternator Assembly Rectifier 20 Amp Fuse Starter Solenoid Gray Wire to Tachometer Battery Isolation _ p G G 51251 90 817643R1 DECEMBER 1996 ELECTRICAL and IGNITION 2B 9 i 15 16 Ampere Battery Charging IMPORTANT After electrical connections are made coatall terminal connections using Quicksilver Liquid Diagram with Battery Isolator Neoprene 92 25711 to avoid corrosion lt e Stator Alternator Assembly Voltage Regulator 20 Amp Fuse E Starter Solenoid Gray Wire to Tach
402. the anti siphon valve or 2 re place it with a solenoid operated fuel shutoff valve Testing Install clear fuel hose s between fuel pump and carbure tor s Run engine and inspect hose s for air bubbles If air bubbles are found see Air Bubbles in Fuel Line If air bubbles are NOT found see Lack of Fuel Pump Pres sure 90 817643R1 DECEMBER 1996 Q Troubleshooting Fuel Pump PROBLEM LACK of FUEL PUMP PRESSURE PROBLEM AIR BUBBLES IN FUEL LINE Possible Cause Corrective Action Possible Cause Corrective Action An anti siphon valve Read Checking for Restricted Fuel Flow Low fuel in fuel tank Fill tank Caused by Anti Siphon Loose fuel line connection Check and tighten Valves preceding connections Air in fuel line Air Bubbles in Fuel Line preceding Fuel pump fitting loose Tighten fitting A hole or cut in fuel line Check condition of fuel A dirty or clogged fuel filter Clean or replace filter lines and replace any The fuel pickup in fuel tank Clean or replace pickup found bad clogged or dirty Fuel pump anchor Tighten all screws Worn out fuel pump Rebuild pump screw s loose diaphragm Fuel pump gasket s Rebuild fuel pump Defective hole or crack Rebuild pump worn out check valve s in fuel pump unlikely Broken check valve Rebuild pump retainer Pulse hole plugged Remove pump and clean out hole Hole in pulse hose Replace pulse hose Loose pulse hose Tighten connection B
403. the pre ceding test verify that switch and not wiring is faulty If wiring checks OK replace switch 90 817643R1 DECEMBER 1996 Ignition Components Removal and Installation Flywheel REMOVAL 1 Remove flywheel cover from engine A WARNING Engine could possibly start when turning flywheel during removal and installation therefore disconnect and isolate spark plug leads from spark plugs to pre vent engine from starting 2 Disconnect spark plug leads from spark plugs 3 While holding flywheel with Flywheel Holder a 91 52344 remove flywheel nut and washer 4 Install Crankshaft Protector Cap 91 24161 on the end of crankshaft then install Flywheel Puller a 91 73687A1 into flywheel b 5 Remove flywheel NOTE Neither heat or hammer should be used on flywheel to aid in removal as damage to flywheel or electrical com ponents under flywheel may result ELECTRICAL and IGNITION 2A 7 INSTALLATION AWARNING Engine could possibly start when turning flywheel during installation therefore disconnect and isolate spark plug leads from spark plugs to prevent engine from starting 1 Disconnect spark plug leads from spark plugs 2 Place flywheel key a into slot in crankshaft 51123 3 Align slot in flywheel center bore with flywheel key and install flywheel onto crankshaft Install washer and locknut Hold flywheel with Flywheel Holder a 91 52344 torque locknut to 100 I
404. the service plus Common Sense operation are major accident prevention measures ADANGER DANGER Immediate hazards which WILL result in se vere personal injury or death AWARNING WARNING Hazards or unsafe practices which COULD result in severe personal injury or death ACAUTION Hazards or unsafe practices which could result in mi nor 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 servic ing the products described herein It is assumed that these personnel are familiar with the servicing procedures of these products or like or similar products manufactured and marketed by Mercury Marine that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers 90 817643R1 DECEMBER 1996 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 eval uation Therefore anyone who uses a service procedure and or tool which is not recommended by the manufactur er first must completely satisfy himself that neither his nor
405. tom of the boat and top front edge of the wa ter intake housing b s Straight Edge Top Edge of Water Intake Housing 4 Raise The outboard up the transom the dis tance measured in Step 3 Use a straight edge and recheck the mounting height The top edge of the water intake housing should be in line with the bot tom of the boat as shown When operating the boat the outboard drive shaft should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water intake Tilting the outboard out beyond a vertical posi tion reduces the scoop angle and can cause impeller slippage and cavitation If the angle of the boat tran som does not allow the drive shaft to be positioned ver tical a Wedge kit should be installed behind the tran som brackets to increase the tilt in angle NOTE Slight cavitation in sharp turns and rough water is acceptable but excessive cavitation is harmful to the outboard and should be avoided Test run the boat If cavitation occurs air enters the pump causing loss of thrust engine over speeds errat ically the first thing to try is lowering the outboard height 1 4 in This can be accomplished by elongating the drilled mounting holes in the boat transom by 1 4 in If cavitation still exists after lowering the outboard 1 4 in it maybe helpful to seek advice from the boat manufacturer A number of other options are available to further re duce ca
406. tonation generally is thought of as spontaneous ignition but it is best described as a noisy explosion in an unburned portion of the fuel air charge after the spark plug has fired Detonation creates severe untimely shock waves in the engine and these shock waves often find or create a weak ness The dome of a piston piston rings or piston ring lands piston pin and roller bearings While there are many causes for detonation in a 2 cycle engine emphasis is placed on those causes which are most common in marine 2 cycle application A few which are not commonly understood are 1 Over advanced ignition timing 2 Use of low octane gasoline 3 Propeller pitch too high engine RPM below rec ommended maximum range Lean fuel mixture at or near wide open throttle Spark plugs heat range too hot incorrect reach cross firing 6 Inadequate engine cooling deteriorated cooling system 7 Combustion chamber piston deposits result in higher compression ratio Detonation usually can be prevented provided that 1 the engine is correctly set up and 2 diligent maintenance is applied to combat the detonation causes listed preceding uf ra P Tinh E I il 51115 Damaged Piston Resulting from Detonation Compression Check 1 Remove spark plugs 2 Install compression gauge in spark plug hole 3 Hold throttle plates at W O T GENERAL INFORMATION and SPECIFICATIONS 1 21 4
407. tracts 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 electrolyte A fully charged battery will have a specific gravity reading of approximately 1 270 at an electrolyte temperature of 80 27 If electrolyte temperature is above or below 80 F additions or subtractions must be made in order to obtain a hydrometer reading corrected to 80 F standard For ev ery 10 F 3 3 C above 80 F add 4 specific gravity points 004 to hydrometer reading Example A hydrometer reading of 1 260 at 110 43 C would be 1 272 corrected to 80 F indicating a fully charged battery For every 10 below 80 F subtract 4 points 004 from the reading Example A hydrometer reading of 1 272 at 0 F 18 C would be 1 240 corrected to 80 F indicating a par tially 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 re sults as follows If specific gravity readings show a differ ence between highest and lowest cell of 050 50 points or more battery is defective and should be replaced Electrolyte Level Check electrolyte level in battery regularly A battery in use in hot weather should be checke
408. tric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the up side of the trim cylinder The trim cylinder trim ram will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine RPM increases above 2000 RPM the thrust created by the propeller if deep enough in the water will cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering conditions Each boat should be tested for handling charac teristics after any adjustment is made to the tilt angle tilt pin relocation Will help planing off particularly with a heavy load Usually improves ride in choppy water In excess can cause boat to veer to the left or right bow steer Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt pin one hole closer to transom Operating Down circuit will actuate the down sole noid located under engine
409. ttom or gear housing will cause an RPM loss d Operation with an increased load additional pas sengers equipment pulling skiers etc 1 6 GENERAL INFORMATION and SPECIFICATIONS Propeller Installation cM A WARNING To avoid accidental starting which could result in per sonal injury remove spark plug leads from spark plugs before working near propeller Place a block of wood between the anti ventilation plate and propeller to protect hands from propeller blades while tighten ing propeller nut CAUTION If the propeller moves forward and aft on the propeller shaft is loose retighten the propeller nut Operation with a loose propeller could cause damage to the thrust hub and gear housing during acceleration de celeration or when shifting gears IMPORTANT To assure that the propeller remains se cure on the shaft during the season periodically check propeller shaft nut for tightness 1 Toaidin future removal of the propeller liberally coat the propeller shaft spline with one of the following Quicksilver lubricants Anti Corrosion Grease 2 4 C Marine Lubricant Special Lubricant 101 2 Place forward thrust hub on propeller shaft a Thrust Hub b Propeller Shaft 90 817643R1 DECEMBER 1996 fn 3 While aligning splines place Quicksilver propeller and tab washer on propeller shaft in this order 4 Toprevent propeller from rotating place a flat block of wood between the anti ventilat
410. uctions following a Motor Wire Black b Motor Wire Orange MOTOR DISASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated 51193 If full continuity is not indicated clean switch contact surfaces using an ignition point file Recheck switch if full continuity is not indicated re place end frame MID SECTION 5B 29 Armature Tests TEST FOR SHORTS Check armature on a Growler follow Growler man ufacturer s test instructions Indication of a short re quires replacement of armature TEST FOR GROUND Use an Ohmmeter R x 1 scale Place one lead of Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced E _ _ Ns 2 55 i s 51195 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper X EM SS tms WAI k 5B 30 MID SECTION Power Trim System Reassembly Manifold Installation IMPORTANT Filter must be installed in trim cylin der with ridge of filter housing facing out 50447 1 Install lubricated O rings and filter with housing ridge facing out to trim cylinder a O ring b Filter 90 817643R1 DECEMBER 1996 p 2 Insta
411. ue at higher speeds If at higher speeds the boat turns more easily to the left loosen bolt move the trim tab trailing edge to the left when viewed from behind re tighten bolt Turn trim tab trailing edge to the right if the boat turns more easily to the right 50553 a Trim Tab b Anti Ventilation Plate c Retaining Bolt and Washer Torque Bolt to 22 Ibs ft 29 8 N m LOWER UNIT 6A 27 LOWER UNIT 20 Pas 60 BIG FOOT 60 SEAPRO MARATHON GEAR HOUSING 4 1 4 inch Torpedo 2 3 1 Gear Ratio Table of Contents Page MR 6 1 Gear Housing Drive Shaft 6B 2 Gear Housing Propeller Shaft 6B 6 Special Tools 6B 8 Removal 6 8 Propeller Removal 6B 8 Draining and Inspecting Gear Housing Lubriea nt gta vd sos ep REA Er Rer 6B 9 Water Pump 6B 10 Bearing Carrier and Propeller Shaft 6B 11 Pinion Gear Drive Shaft and Forward 6 14 Upper Drive Shaft Bearing 6B 15 Oil Sleeve 6B 16 Lower Drive Shaft Bearing Race 6B 16 Shift Shaft u eie Rm 6B 17 Forward Gear Bearing Race 6B 18 Trim Tab Adjustment and Replacement 6B 18 Reassembly 6B 18 Forward Gear Bearing Race 6B 18 Shift Shall
412. ur Securing Outboard to Boat Transom Electric Start Models IMPORTANT If boat is equipped with thru tilt tube steering steering cable end must be installed into tilt tube of outboard before securing outboard to tran som Refer to Steering Cable and Steering Link Rod Installation following Refer to Determining Recommended Outboard Motor Mounting Height and position outboard on boat transom aligning mounting holes in transom bracket ACAUTION Marine sealer must be used on shanks of mounting bolts to make a water tight installation IMPORTANT In order to avoid transom damage DO NOT use an impact driver when tightening transom mounting bolts Apply marine sealer to shanks of mounting bolts not threads secure outboard to transom with 4 bolts flat wash ers and locknuts as shown Be sure that installation is wa ter tight AWARNING Before operating outboards s MUST BE SECURED to boat transom with four 1 2 in diameter bolts and lock nuts as follows 2 bolts must be installed thru upper mounting holes and 2 bolts thru lower mounting holes 90 817643R1 DECEMBER 1996 Installation must be water tight and outboard should be checked for tightness on the transom during opera tion Failure to bolt outboard to transom using 4 bolts and locknuts as shown may result in damage to boat and or loss of outboard and possible injury to occu pants of boat 50181 a Mounting Bolt 4 in Long 4
413. ure the retainer at this position by tightening the set screw until it is snug then add an additional 1 8 turn 11 Install the Allen head screw and tighten securely a Position Cable Boot 1 2 in 12 mm out of Drilled Hole b J Clip Cable Retainer Set Screw Lock Washer Allen Head Screw Tighten Securely O O on 90 817643R1 DECEMBER 1996 LOWER UNIT 6C 21 12 Fasten the shift cable retainer to the bottom cowl with the mounting hardware shown Tighten lock nut then back off the locknut 1 4 turn IMPORTANT Do not over tighten Shift cable re tainer must be free to pivot a 7 8 in OD White Nylon Washer b 1 00 in OD Flat Washer c Bottom Cowl d 5 8 in OD Black Nylon Washer e 21 32 in OD Flat WAsher f Locknut Tighten Then Back Off The Locknut 1 4 turn 6C 22 LOWER UNIT 13 Attach the shift cable to the outer flange hole IMPORTANT Do not over tighten Shift Cable must be free to pivot bo 1 2 in OD Flat Washer Shift Cable Nylon Bearing Locknut Tighten Then Back Off The Locknut 1 4 turn O oO om 14 Lubricate the new cable seal 15 Slip the cable seal onto the throttle cable 16 Place the cable seal along with the throttle cable into the cowl opening Spread the seal over the shift cable a Cable Seal b Lubricant 90 817643R1 DE
414. ury It is recommended to remove propeller as a precautionary measure 1 Install Quicksilver Flushing Attachment 73971 2 or equivalent tool on the gear housing from the FRONT side positioning the rubber cups over the water intake openings a Water Hose 1 2 in 13mm I D or Larger b Flushing Attachment 7397142 Typical Gear Housing 2 Connect hose 1 2 in 13mm I D or larger between flushing attachment and water tap IMPORTANT To prevent water pump damage do not start or run engine unless cooling water is flowing 3 With the outboard in normal operating position verti cal partially open water tap IT MAY NOT BE NECES SARY to use full water pressure and adjust water flow so that there is a significant water loss around the rub ber cups GENERAL INFORMATION and SPECIFICATIONS 1 17 4 Start engine and idle in neutral Then increase engine speed not to exceed 2500 RPM 5 Flush or service engine as required Be sure adequate cooling water is provided a Water must be discharged thru tell tale outlet IMPORTANT Prevent engine overheating If water flow is insufficient stop engine and determine cause be fore continuing b Flush until discharged water is clear In saltwater areas run outboard 3 to 5 minutes c Stop engine before turning off water 6 Stop engine turn water off and remove flushing attach ment from gear housing IMPORTANT While and after flushing keep o
415. utboard in upright position until all water has drained from drive shaft housing to prevent water from entering the powerhead via drive shaft housing and exhaust ports Following Complete Submersion Submerged engine treatment is divided into 3 distinct problem areas The most critical is submersion in salt water the second is submersion while running SALT WATER SUBMERSION SPECIAL INSTRUCTIONS Due to the corrosive effect of salt water on internal engine components complete disassembly is necessary before any attempt is made to start the engine SUBMERGED WHILE RUNNING SPECIAL INSTRUCTIONS When an engine is submerged while running the possibil ity of internal engine damage is greatly increased If after engine is recovered and with spark plugs removed engine fails to rotate freely when turning flywheel the possibility of internal damage bent connecting rod and or bent crank shaft exists If this is the case the powerhead must be disassembled 1 18 GENERAL INFORMATION and SPECIFICATIONS i SUBMERGED ENGINE FRESH WATER PLUS SPECIAL INSTRUCTIONS 1 2 3 10 11 12 Recover engine as quickly as possible Remove cowling Flush exterior of outboard with fresh water to remove mud weeds etc DO NOT attempt to start engine if sand has entered powerhead as powerhead will be severely damaged Disassemble powerhead if neces sary to clean components Remove spark plugs and get as much water
416. ute throttle cable a thru control cable grommet b Install throttle cable end a onto stud c of throttle le ver Place nylon washer d over stud and install lock nut e Tighten locknut against throttle cable end to snug cable end against throttle lever then back locknut off 1 4 turn 4 Holding engine throttle lever f against idle stop ad just throttle cable barrel g to slip into upper hole of barrel receptacle with a very light preload of throttle le ver against idle stop N Oy V D y sel Sa Zee y 505640 Lock barrels place with barrel retainer h Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Pre load is correct when paper can be removed without tearing but has some drag on it Re adjust cable bar rel if necessary r z 13 a um amic h 51026 90 817643R1 DECEMBER 1996 Connecting Remote Control Wiring Harness to Engine Wiring Harness Electric Start Models Route remote control harness or key switch harness along side of boat to engine fastening harness to boat Be sure that harness does not rub get pinched or come in contact with bilge water Plug remote control harness or key switch harness con nector a into engine harness connector b and push con nection securely into retainer c 50565B OUTBOARD INSTALLATION
417. val and reinstallation of check valve could result in improper operating pressure and possible manual tilt system dam age 7 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 8 Clean shock and components with compressed air 9 Remove inner O ring 51199 a O ring b Shock Piston 10 Remove cylinder end cap assembly from shock rod 11 Inspect shock If wiper located in cap has failed to keep rod clean replace wiper MID SECTION 5F 25 cM Remove valve block from shock rod cylinder 12 Place end cap on clean work surface Valve Block Removal 13 Remove rod wiper inner O ring and outer O ring 1 51147 51146 a Screws 2 b Valve Block c Shock Rod Cylinder 2 Remove O rings 51145 a Rod Wiper b Inner O ring c Outer O ring 5F 26 MID SECTION 90 817643R1 DECEMBER 1996 Q Valve Block Disassembly 1 Remove slow trim valve assembly 2 Remove hydraulic oil transfer valve components 51143 a Transfer Valves 2 b Slow trim Valve Assembly Plug or Screw Plug 3 Remove surge valve assembly 51145 a Surge Valve 90 817643R1 DECEMBER 1996 4 Remove reservoir assembly a Screw b Flat Spring c Ball 5 Remove cam assembly a Screw b Cam Assembly 51142 51145 MID SECTION 5F 27 Manual Tilt System Cleaning and Inspection
418. valve LARGE CLAMP fuel line to check valve SMALL CONNECTOR fuel tank OUTLET CONNECTOR engine INLET CLAMP fuel line to connector BAYONET BODY ASS Y FUEL TANK END STEM bayonet body O RING bayonet body stem SPRING bayonet body stem WASHER CUPPED body spring 3B 12 FUEL SYSTEMS 90 817643R1 DECEMBER 1996 Maintenance Periodically check fuel line and primer bulb for cracks breaks restrictions or chafing Check all fuel line connec tions for tightness All fuel line connections must be clamped securely Primer bulb assembly has 2 check valves Fuel inlet to ward tank and a fuel outlet toward engine The fuel inlet valve allows fuel to fill primer bulb but closes to prevent fuel from returning to tank when bulb is squeezed The fuel outlet valve opens when primer bulb is squeezed to allow fuel flow to carburetor but closes as bulb is released to prevent fuel from returning to primer bulb FUEL LINE CLAMP REMOVAL AND INSTALLATION 1 remove fuel line clamps grip clamp with pliers and bend over lapping hook backward Removing Fuel Line Clamps 51115 90 817643R1 DECEMBER 1996 2 To install fuel line clamps grip hose clamp with pliers and push down on hook with screwdriver until hooks in terlock Installing Fuel Line Clamps 51115 FUEL SYSTEMS 3B 13 FUEL SYSTEMS ENRICHMENT Table of Contents Enrichener System Enrichener Val
419. valve com found ponents using engine cleaner and com pressed air or replace Result No debris found in manifold re verse thrust valve Replace Manifold as a Unit MID SECTION 5C 15 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram BLK 4 TAN BLU 3 TAN BLU C GRY B PUR 2 BLK Di PUR YEL BLK 6 BLK YEL 11 RED 7 9 YEL RED 7 G a 8 xN BLK Black X 2 BLU Blue N BRN Brown GRY Gray N GRN Green NS PUR e Purple Red by E TAN Tan le WHT e White YELe Yellow Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector 23891 Wiring Harness Connector Warning Horn Trim Tilt Switch p gt G 5C 16 MID SECTION 90 8i7643R1 DECEMBER 1996 96704 ALOWSY LNNOW 395 m aas Cu qau 1 Ada1l1vg 1HA n18 OL a Y ON o Coes m dION310S H31HVIS posse HOLOW rll H3MOd LHM N18 k co a POWER TRIM MODULE Power Trim System Wiring Diagram 56 2 S 3 9 m m O x e o v25zarc a MID SECTION 56 17 90 817643R1 DECEMBER 1996 PAS Troubleshooting the
420. ve Test 90 817643R1 DECEMBER 1996 Enrichener System The enrichener system provides the engine with extra fuel charge for ease of starting cold engine The system con sists of an electrically operated enrichener valve which is connected by a hose to the intake manifold Fuel is gravity fed to the valve from the float bowl of the top carburetor via a hose When the ignition key is turned to the on position and pushed in and held in current is sent to the valve causing it to open which allows fuel to pass thru The fuel passes thru a hose and is supplied to the engine via fitting located in the intake manifold of the middle carbu retor When the key or choke button is released the valve will return to the closed position The valve can be operated manually by pressing and holding button located at bottom of valve Connect to Fitting on Oil Pump Base Connect to Fitting on bowl of TOP carburetor Enrichener Valve Manual Operation Button 90 817643R1 DECEMBER 1996 51223 FUEL SYSTEMS 3C 1 IMPORTANT Use of enrichener if engine is warm could result in engine flooding ENRICHENER VALVE TEST Push key or choke button in Valve should click No Click Check for battery voltage to YELLOW BLACK wire at terminal block on engine when key or choke button is pushed in Battery Voltage Indicated Check for loose or corroded connection between YELLOW BLACK wire and black wire under s
421. ve fill screw Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF Type F FA or Dexron II up to threads of reservoir 50241 3 Using a 12 volt power supply connect positive lead to green wire negative lead to blue wire and drive trim rod to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Recheck fluid level add fluid if required and repeat cycle until fluid level remains at lower portion of threads 4 Install fill plug 90 817643R1 DECEMBER 1996 Power Trim Unit Installation 1 Apply Special Lubricant 101 92 13872A1 to lower pivot pin hole and pivot pin surface Start lower pivot pin into pivot pin bore and posi tion lower dowel pin RETAINED in its respective hole 51148 Lower Pivot Pin Lower Dowel Pin Position trim cylinder assembly BOTTOM FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket a Trim Cylinder Assembly MID SECTION 5B 37 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a Lower Pivot Pin 5 Using a suitable punch drive lower dowel pin into its respective bore until seated a Lower Dowel Pin 6 Apply 2 4 C Marine Lubricant 92 90018A12 to surface of upper piv
422. vitation 1 Water intake fin kit a Available from the Special ty Mfg Co for jet models 30 thru 140 The purpose of these fins is to ram more water into the intake and shield the forward sides of the intake from the entrance of air This kit will help reduce cavitation when running with the wind in a chop 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 imperfections in the hull ahead of the water intake may require this setting to change in order to prevent cavitation at running speeds 90 817643R1 DECEMBER 1996 a Intake Fin Kit Water Intake Fin Kit Part No 1186 for jet models 45 thru 140 and Part No 1185 for jet model 30 is available from Specialty Mfg Co 2035 Edison Ave San Leandro CA 94577 Continued on next page LOWER UNIT 6C 7 Water testing Checking for Cavitation Continued 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 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 re duce spray b Rough Water Plate Shift Cable
423. ween hole centers of steering eye ball joints is equal to distance between threaded hole centers of steering arms brackets Exposed threads of steering eyes MUST BE of equal length and threads MUST NOT extend out from cou more than 2 3 4 in 70mm 90 817643R1 DECEMBER 1996 Coupler Rubber Sleeve Steering Eye Rubber Bushing Jam Nut AWARNING Both steering eyes must be threaded into coupler 3 4 in 19mm minimum Thread length of steering eye is 3 1 2 in 89mm so exposed thread must not extend out of coupler more than 2 3 4 in 70mm Failure to adhere to this requirement could result in steering sys tem failure Assemble steering coupler between outboard steering arms brackets as shown on the following pages IMPORTANT With assembled steering coupler in stalled and before tightening special washer head bolts locknuts check outboard alignment Distance between hole centers of steering eye ball joints MUST BE equal to distance between propeller shaft center lines for proper steering If adjustment is necessary temporarily remove special washer head bolt locknut from one steering eye and turn eye in or out to correct alignment A WARNING Both steering eyes MUST BE threaded into coupler 3 4 in 19mm minimum and jam nut must be tightened against coupler to prevent coupler from turning Torque jam nut to 20 Ib ft 27 N m Tighten jam nut against coupler Torque jam
424. wered manually by loos ening the manual release valve 2 to 3 turns counterclock wise The trim out angle of this outboard is not adjustable The trim system has an internal valve which will automatically stop the outward trim travel at 20 when engine RPM is ap proximately 2000 RPM or higher outboard also has to be in water and in gear The outboard can be operated beyond the 20 trim limit for operating outboard in shallow water if engine RPM is kept below approximately 2000 RPM 1 10 GENERAL INFORMATION and SPECIFICATIONS Trim System Design II 50158 50146 52029 52028 a Fill Screw System is Pressurized DO NOT Open Unless Outboard is Tilted to Full Up Position b Manual Tilt Release Valve Location 90 817643R1 DECEMBER 1996 CHECKING TRIM SYSTEM FLUID LEVEL IMPORTANT This trim system is pressurized Remove fill screw when outboard is trimmed to the full up po sition Retighten fill screw securely 1 Trimoutboardto full up position Engage tilt lock lever a Trim system fluid can only be checked when out board is in this position 50157 2 Remove fill screw and check fluid level Fluid level should be to bottom of threads in fill hole b 3 If necessary add Quicksilver Power Trim amp Steering Fluid or Automatic Transmission Fluid ATF Type F FA or Dexron II fluid to trim system 4 Reinstall fill screw Trimming Mode
425. werhead Disassembly Removing Engine Components Crankshaft Disassembly Cleaning and Inspection Cylinder Block and Crankcase Cover Honing Procedure Check Valves Piston and Piston Rings Cleaning Piston Ring Grooves Measuring Piston Skirt Crankshaft Connecting Rods Thermostat Reed Blocks Page Powerhead Reassembly and Installation 4 26 General Information 4 26 eb Ue nr ers bd date adds 4 26 Assembling Rod to Piston 4 26 Piston Ring Installation 4 28 Crankshaft Installation 4 30 Installing Rods to Crankshaft 4 31 Connecting Rod Cap Alignment 4 32 Crankcase Cover to Block 4 32 Intake Reed Block Manifold Installation 4 34 Thermostat Cover Installation 4 35 Install Remaining Engine Components 4 35 Powerhead Installation 4 35 Test Run Procedure 4 38 Important Information 4 38 90 817643R1 DECEMBER 1996 2 L Specifications Special T
426. witch UP is inopera tive but the Cowl Switch UP does operate Cowl Switch UP is inopera tive but the Trim Switch UP does operate Trim Switch UP and Cowl Switch UP are both inopera tive Trim Switch DOWN is inop erative but the Cowl Switch DOWN does operate Cowl Switch DOWN is inop erative but the Trim Switch DOWN does operate Trim Switch DOWN and Cowl Switch DOWN are both inoperative Trim Switch UP and DOWN are both inoperative but the Cowl Switch does op erate Trim Switch and Cowl Switch are both inoperative Trim system operates motor runs without pressing the switches 5E 26 MID SECTION 1 Open wire between Wire Connection 1 and Trim Switch 2 Faulty Trim Switch 1 Open wire between Wire Connection 2 and Solenoid 2 Faulty Cowl Switch 1 Open wire between Wire Connection 1 and the Up Relay 2 Open BLK wire between ground and UP Relay 3 Open RED wire between Solenoid and Up Relay 4 Faulty Up Relay 1 Open wire between Wire Connection 3 and Trim Switch 2 Faulty Trim Switch 1 Open wire between Wire Connection 2 and Solenoid 2 Faulty Cowl Switch 1 Open wire between Wire Connection 3 and the Up Relay 2 Open BLK wire between ground and Down Relay 3 Open RED wire between Solenoid and Down Relay 4 Faulty Down Relay 1 20 AMP Fuse blown 2 Faulty t
427. xture thru a con stant ratio oil pump The engine mounted oil reservoir holds 3 qts 2 8 Liters which will provide 10 5 hours of running time at wide open throttle A low oil warning horn will be activated when 14 5 fl oz 435 ml of oil remains in the reservoir This will provide ap proximately 1 5 hours of wide open throttle running before oil is depleted The crankshaft driven oil pump injects oil into the fuel be fore the fuel pump Oil Injection System 1 Oil Reservoir The oil reservoir gravity feeds oil to the oil pump The reservoir contains a low oil sensor which activates a warning horn when 14 5 fl oz 435 ml of oil remains in the reservoir 90 817643R1 DECEMBER 1996 2 Oil Injection Pump The crankshaft driven oil pump is a constant ratio oil pump which provides an oil fuel mixture 3 Check Valve Vent Provides air to oil reservoir for proper venting and also prevents oil leaks when outboard is tilted forward 4 2 PSI Check Valve This valve prevents gasoline from being forced into oil line 5 Low Oil Sensor When oil level in reservoir drops to approximately 14 5 fl oz 435 ml the sensor will signal warning module to activate warning horn 6 Warning Module When ignition key is initially turned on the warning module will briefly provide a self test of its engine over heat warning system a brief continuous BEEP tone followed by a self test of its low oil warning system a brief intermitten
428. y in COOL DRY place Remove battery from storage every 30 45 days check water level add water if necessary and puton charge for 5 or 6 hours at 6 amperes DO NOT FAST CHARGE 4 If specific gravity drops below 1 240 check battery for reason and then recharge When gravity reaches 1 260 discontinue charging To check specific gravity use a hydrometer which can be purchased locally 5 Repeat preceding charging procedure every 30 45 days as long as battery is in storage When ready to place battery back in service remove excess grease from terminals a small amount is desirable on termi nals at all times recharge again as necessary and re install battery A WARNING Hydrogen and oxygen gases are produced during nor mal 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 Battery Charging System Description The battery charging system components are the stator rectifier or voltage regulator rectifier and the battery Alter nating current is generated in the stator alternator coils and flows to the rectifier The rectifier changes the alternating current to direct current for charging the battery 90 817643R1 DECEMBER 1996 Some models are equipped with either a voltage regulator or a voltage regulator rectifier

Cleanliness and Care of Outboard Motor Service Manual Outline

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