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IMPORTANT INFORMATION

1. 1 a NNUS lt J up T SS 0712 E 4 gj E um 22062 Carburetor Model Shown Others Similar a Throttle Cable End Guide b Carburetor Throttle Lever 3 Disconnect Remote Control Shift Cable 22267 a Remote Control Shift Cable b Plastic Shift Lever C Clevis Pin And Cotter Pin d Locknut And Washer Page 1C 38 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING IMPORTANT When pushing or pulling on drive unit shift cable in the following steps apply just enough pressure so that V notch moves then ease up slightly Use a fine tip marking device to mark threaded tube to obtain an accurate measurement 22058 Roller Type Switch CD wx Nd _ Plunger Type Switch 4 Check for excessive play in drive unit shift system as follows a Pushin on drive unit shift cable b Place a mark on shift cable threaded tube against cable end guide 50499 a Drive Unit Shaft Cable b Threaded Tube Lightly pull on drive unit shift cable end guide and place another mark on threaded tube 90 818177 3 APRIL 2001 Page 1C 39 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 d Measure distance between both marks Distance should be 9 16 in 14 mm or less 50497 a 9 16 in 14 mm Or Less If play is 9 16 in 14 mm or less No further attention to drive unit is needed Proceed with adjustments If play is more than 9 16 in 14 mm Drive uni
2. 1 31 Modes 1 23 MerCathode Controller 1C 32 Pump Motor Runs Down But Not Shift System Troubleshooting 1C 33 UP In Both The Manual And Auto Troubleshooting Shift Problems 1C 34 MDUBS 16 23 Checking for Excessive Play 1C 36 Pump Motor Will Run Down But Isolating Excessive Play 1C 40 Not UP In Auto Mode 1C 24 Checking Remote Control Shift Pump Motor Will Run UP But Not Cable Output 1C 42 DOWN In Auto Mode 1C 24 Checking Cutout Switch Timing Trim DOWN IN Switch Inoperative Models With Roller Type Switch 1C 43 In Manual Trim Control 1C 24 Checking Cutout Switch Timing Trim UP OUT Switch Inoperative Models With Plunger Type Switch 1C 45 In Manual Trim Control 1C 25 Checking Operation 1C 47 Trailer Switch In Manual Trim Control Inoperative 1C 25 Boat Is On Plane Well Before Drive Unit Begins To Trim Out 1C 25 Boat Is Not On Plane Before Drive Unit Begins To Trim Out 1C 25 Page 1C 2 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Troubleshooting This section is a guide for performance and product troubleshooting Referrals to specific sections of this manual are made where special tests or repair procedures are to be performed Because of the relationship between Power P
3. 1 32 in 4 8 0 8 mm tighten the screws on the cutout switch After tightening screws recheck the plunger pin position Page 1C 46 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Checking Operation 1 Reconnect throttle cable 2 Place boat in water and start engine Check the following a Shift into forward and reverse gear verify clutch engages before engine begins to accelerate b Accelerate engine in forward and reverse gear to ensure engine does not shut down c Check that shift cutout switch roller is centered in notch of shift cutout lever with drive unit in forward and reverse gear d Shift from IN gear position to neutral ensure drive unit is in neutral before remote control shift lever comes to neutral detent position 90 818177 3 APRIL 2001 Page 1C 47 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 THIS PAGE IS INTENTIONALLY BLANK Page 1C 48 90 818177 3 APRIL 2001 L002 11 ZZ1818 06 69 21 a e N INDEX SCALE PASTE TO HEAVY STOCK PAPER OR CARDBOARD CUTOUT SWITCH ADJUSTMENT TOOL 1 8 in Dia 1 16 in 3mm 1 6mm POINTER SIDE VIEW BEND AS SHOWN C TOP VIEW 1 2 tmm 5 1 16 in 1 6mm Dia STIFF WIRE vl IVANVIN 39IAB3S SNILOOHSATENOYL INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 THIS PAGE IS INTENTIONALLY BLANK
4. Check for battery voltage at terminal 8 while trimming OUT UP and at terminal 6 Open circuit in trim control wiring while trimming OUT UP If no voltage is harness indicated check trim control for a loose or corroded connection or a damaged power supply lead in harness nd circuit breaker in pump motor Replace commutator end plate assembly Page 1C 12 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Power Trim Pump Motor Will Not Run In The OUT UP Or IN DOWN Direction BOTH SOLENOIDS CLICK Cause Special Instructions Check for battery voltage at terminals 5 Faulty solenoids or loose or corroded while trimming OUT UP If no voltage is connections indicated check connections 2 3 4 and 5 and or replace solenoids Pump motor brushes stuck corroded or Clean or replace as required worn Out Armature commutator dirty Clean or replace armature as required Test for shorted open or grounded condition and replace if needed Check for open or grounded condition Field and frame faulty Replace field and frame assembly if needed Water or oil in motor Replace motor assembly Pump gears frozen Replace pump valve body and gear assembly Power trim pump harness or trim control Disconnect BLU WHI lead from solenoid harness shorted between OUT UP and terminal 8 If pump motor will now run in IN DOWN circuit pump trying to run in the OUT UP direction a short in the OUT UP and IN DOWN
5. Page 1C 50 90 818177 3 APRIL 2001
6. 3C or 3D Check gear housing backlash and pinion Incorrect gear shimming gear height Refer to SECTION 3B 3C or 3D Worn or damaged gears and or bearings caused by impact overheating or improper shimming Disassemble inspect and replace Refer to SECTION 3B 3C or 3D Page 1C 4 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Drive Shaft Housing Noise Cause Special Instructions Determine cause for interference loose Engin ee inner engine mounts transom too thin etc and pipe correct as necessary Propeller with untrue or out of balance Repair or replace as required blades i Abnormal sterndrive operation Instruct operator on proper operating technique U joint cross and bearing assembly e ys dcus retaining rings improperly installed or of usec a aie seated in U joint bearing cap grooves incorrect size Refer to SECTION 3A Excessive side to side play in U joint Replace cross and bearing assembly cross and bearing assemblies sure proper cross and bearing U joint bearing caps contacting U joint assemblies are used If interference is bellows retention sleeve severe replace cross and bearing assembly and or sleeve assembly Replace assemblies Signs of scoring U joint cross and bearings rough galling or roughness are the result of lack of lubricant Refer to SECTION 3A O rings missing or flattened out on U
7. Quicksilver isolator Paint on drive heavily worn exposing Prime and repaint and or install additional more metal anode s Sacrificial anode s painted Remove paint or replace anode s Leave drive down install additional anode below waterline or transom mount a MerCathode Only power trim cylinders are corroded Provide good ground to drive All parts must be grounded Corrosion in area of exhaust outlets Remove deposits with marine or auto wax Exhaust deposits can cause corrosion Corrosion occurring after unit removed Wash exterior and flush interior with fresh from saltwater water Corrosion and or salt build up between Exclude moisture from between mating mating parts parts with Quicksilver 2 4 C with Teflon Stainless Steel parts corroding Tightly wrapped fishing line or foreign material excludes oxygen causing corrosion Clean parts remove foreign material Iron particles such as from a wire brush ensure continuity cause rusting Propeller pitting can occur if electrical continuity is lost Sacrificial anode s not grounded to drive Drive tilted so far that anode s are out of the water 90 818177 3 APRIL 2001 Page 1C 27 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Corrosion On Underwater Parts With MerCathode Or Impressed Current Protection DRIVE CORRODING Cause Special Instructions P gor Sone Wag een nee Clean and or tighten connection Repair electrode BRN l
8. check leads 28 and 34 for a loose or corroded connection or damage Check for voltage at terminal 22 while Faulty mode switch trimming DOWN If no voltage exists switch is faulty Open circuit in wiring harness Page 1C 24 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Trim UP OUT Switch Inoperative In Manual Trim Control TRIM DOWN IN SWITCH FUNCTIONS AUTO MODE FUNCTIONS PROPERLY Cause Special Instructions Instructions Trim 20 amp fuse 43 blown if equipped EET r cause for blown fuse and correct before replacing fuse Check voltage at terminal 44 If no voltage is indicated check lead 45 for a poor Open in power supply lead to trim and HH WIR connection or damage Faulty trim UP OUT switch applies only to trim controls where it is necessary to actuate trim UP switch in order for trailer switch to function Check for voltage at terminal 40 while actuating trim UP OUT switch Replace switch if no voltage is indicated Trailer Switch In Manual Trim Control Inoperative TRIM UP OUT SWITCH FUNCTIONS Cause Special Instructions Check for voltage at terminal 41 and 42 while actuating trailer switch If voltage exists at terminal 42 but not at terminal 41 a faulty switch is indicated If no voltage exists at terminal 42 check power supply lead for an opening Opening in wiring Check lead 39 for damage or a loosened i or corroded connection Boat Is On Plane
9. IN DOWN circuit leaking manual Replace adaptor or attempt to internally repair by replacing the pilot check valves or seals Install Trim Pump Rebuild Kit 90 818177 3 APRIL 2001 Page 1C 17 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Oil Foams Out Of Pump Fill Vent Screw Cause Special Instructions Contaminated oil Flush system with clean oil refill pump and bleed trim system Check for cause of low oil level and Oil level low correct Add oil to pump and bleed system Sterndrive Unit Cannot Be Lowered From UP Position Or Lowers With Jerky Movements Cause Special Instructions Air in trim system Check for cause of entry Fill and bleed trim system Low oil level Add oil Test If shuttle 1 is stuck replace pump adaptor Refer to SECTION 5 If valve stuck to repair by replacing the following items e IN DOWN pressure relief valve 1 Trim cylinder s binding Check for cause of binding Repair or replace as necessary Gimbal housing to trim pump hydraulic Replace hose 8 hose pinched Hoses reversed on one trim cylinder only Reconnect hoses correctly Drive unit binding in gimbal ring Check for cause of binding and replace Down pressure relief valve 6 has dirt Replace with a new valve kit particles under check ball Sterndrive Unit Will Not Stay In Full UP Position For Extended Periods Cause Special Instructions External leakage Check for cause and correct Add oil to
10. Not Stay In Full UP Position For Extended Periods sse es c ers Sterndrive Will Not Stay In The Trimmed OUT UP Position When Underway Sterndrive Unit Trails OUT UP On Deceleration Or When Shifting Into Reverse Oil Foams Out Of Pump Fill Vent Screw Trim Motor Runs But Does Not Pump Oil Trim Pump Runs Slowly In Both Directions xxu hades ERRORS Trim Pump Runs Slowly With A Laboring Page 1C 1 4 INDEX BR TROUBLESHOOTING Table of Contents continued SERVICE MANUAL NUMBER 14 1C 26 Power Trim Hydraulic Schematic 1C 26 Auto Trim Il Electrical System 1C 21 Auto Trim 11 System Wiring Diagram Corrosion Protection Pump Motor Will Not Run UP Or DOWN In Either Manual Or Auto Corrosion On Underwater Parts Without MerCathode Or Impressed Current DOG on 1 21 Protection xao oic dae xed ake 1C 27 Pump Motor Will Not Stop Running Corrosion On Underwater Parts Down In Auto Mode 1C 22 With MerCathode Or Impressed Pump Motor Will Not Run Up Or Current Protection 1C 28 Down In Auto Mode 1C 22 Corrosion On Underwater Parts Trim System Completely Inoperative With MerCathode Or Impressed In Manual Mode 1C 23 Current Protection 1C 30 Pump Motor Will Run UP But Not Testing Procedure for Corrosion Down In Both Manual And Auto Protection
11. boat manufacturer Boat is underpowered Check horsepower to weight ratio Contact the boat manufacturer Page 1C 8 90 818177 3 APRIL 2001 Boat is bow heavy INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Check for a hook in the boat bottom by Permanent hook in boat bottom some placing a straight edge at least 6 ft 2 m boats are built with a slight hook for long under the bottom edge of the correct boat performance transom If a hook is found contact the boat manufacturer Water test boat Boat will perform normally until hook develops at high speed then loss of rpm and speed will occur Contact boat manufacturer Power hook or weak boat bottom Poor Boat Performance And Or Poor Maneuverability Bow Too High Improper drive unit trim angle Properly adjust drive unit trim angle Redistribute boat load to bow If stern overweight is caused by permanently installed fuel tank s contact the boat manufacturer Propeller pitch too high Water test the boat using a lower pitch propeller Check for a rocker in the boat bottom by Permanent rocker in boat bottom some placing a straight edge at least 6 ft 2 m boats are built with a slight rocker for long under bottom edge of the transom If correct boat performance a rocker is found contact the boat manufacturer Water test boat Boat will perform normally until hook develops at high speed then loss of rpm and speed will occur Contact boa
12. direction harness exists Repair or replace harness simultaneously as needed Power Trim Pump Motor Runs In The OUT UP Direction But Not In The IN DOWN Direction IN DOWN SOLENOID DOES NOT CLICK Causes Special Instructions Instructions Loose or n solenoid connections XL connections 6 and 7 and clean and or tighten as required Open IN DOWN circuit in trim control or Check for battery voltage at terminal 6 pump wiring harness while trimming OUT UP If no voltage is indicated check for a loose or corroded OUT UP circuit connection damaged OUT UP circuit lead or a faulty OUT UP trim switch Repair or replace as required Solenoid faulty Replace solenoid 90 818177 3 APRIL 2001 Page 1C 13 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Power Trim Pump Motor Runs In The OUT UP Direction But Not In The IN DOWN Direction IN DOWN SOLENOID CLICKS Cause Special Instructions Instructions Loose or dirty solenoid connections _ A connections 4 and 5 Clean and or tighten as necessary Check for battery voltage at terminal 5 Faulty solenoid while trimming IN DOWN If no voltage is indicated replace solenoid Faulty IN DOWN field winding Replace field and frame assembly Power Trim Pump Motor Runs In The IN DOWN Direction But Not In The OUT UP Direction Both Trim And Trailer Switches Inoperative OUT UP SOLENOID DOES NOT CLICK Causes Special Instru
13. joint shaft causing shaft to rattle against ID of pinga Reer 16 9 EO gimbal bearing 90 818177 3 APRIL 2001 Page 1C 5 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Drive Shaft Housing Noise Continued Cause Special Instructions Remove U joint coupling end yoke and insert into gimbal bearing and engine Worn U joint shaft splines and or engine coupling Rotate shaft back and forth If coupler splines play is excessive replace U joint coupling end yoke and or engine coupler as necessary Adjust alignment Ensure that alignment tool moves in and out of coupler freely After proper alignment has been obtained Engine alignment incorrect or engine check for a crooked coupler by rotating coupler crooked engine coupler 1 2 turn and rechecking alignment If proper alignment is no longer observed coupler is crooked and must be replaced Refer to SECTION 2 Replace gimbal bearing Refer to SECTION 4 IMPORTANT Gimbal bearing and carrier Gimbal bearing rough MUST BE replaced as an assembly be cause they are a matched set Failure to do this may result in a loose bearing fit in carrier Reinstall bearing assembly using a new tolerance ring if carrier is loose in gimbal Loose gimbal bearing housing If bearing is loose in carrier bearing assembly must be replaced Refer to SECTION 4 Gimbal bearing not fully seated in gimbal Drive bearing assembly into place housing Excessive clear
14. INDEX SERVICE MANUAL NUMBER 14 TROUBLESHOOTING IMPORTANT INFORMATION Section 1C Troubleshooting Table of Contents Troubleshoobthg sco eb mb ERR Sterndrive Unit Troubleshooting Sterndrive Unit Will Not Slide Into Bell Housing Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Moves Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Does Not Move Drive Unit Shifts Hard Drive Unit In Gear Will Not Shift Out Of Gear Housing Noise Drive Shaft Housing Noise Drive Shaft Housing Noise Continued Drive Shaft Housing Noise Continued Performance Troubleshooting Low WOT Engine Rpm High WOT Engine Rpm Propeller Ventilating Cavitating Poor Boat Performance And Or Poor Maneuverability Bow Too Low Poor Boat Performance And Or Poor Maneuverability Bow Too High Power Steering Hard Steering Helm And Cable Hard Steering Engine Running Power Steering System Power Steering System External Fluid Leaks auc tae esce rgo RR Compact Hydraulic Steering Important Information Helm Becomes Jammed During Filling System Difficult To Fill Steering Hard To Turn Helm Unit Bumpy Requires Too Many lt Power Trim Electrical System Power Trim Pump Motor Will Not Run In The OUT UP Or IN DOWN Direction iu eR s Power Trim Pump Motor Wil
15. Not Pump Oil Cause Special Instructions Broken coupler between the pump and the Replace the coupler motor Plugged pick up screens Replace pick up screens Trim Pump Runs Slowly In Both Directions Check the condition of the oil It may be Remove the reservoir and clean out the contaminated and thick like honey contaminated oil Trim Pump Runs Slowly With A Laboring Sound Cause Special Instructions Replace the pump assembly in the adaptor or replace the electric motor assembly A possible tight adaptor pump gear or water or oil in the motor 90 818177 3 APRIL 2001 Page 1C 19 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Power Trim Hydraulic Schematic 1 Shuttle Pump Adaptor UP OUT Pressure Relief Valve Thermal Relief Valve Trim Cylinder IN DOWN Pressure Relief Valve UP OUT Hose INDOWN Hose Poppet Valves OOANOORWND Page 1C 20 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Auto Trim Il Electrical System NOTE Refer to Auto Trim Il System Wiring Diagram Pump Motor Will Not Run UP Or DOWN In Either Manual Or Auto Mode SOLENOIDS CLICK Causes Special Instructions Instructions n M positive battery cable connection Check cable 14 loose or corroded 110 amp fuse blown or loose or corroded Check for voltage at terminal 5 solenoid connection Pump motor brushes stuck corroded or Clean or replace wor
16. Well Before Drive Unit Begins To Trim Out Control module adjustment incorrect Adjust Refer to SECTION 5 Faulty control module Replace control module Boat Is Not On Plane Before Drive Unit Begins To Trim Out Faulty trailer switch Cause Special Instructions Control module adjustment incorrect Adjust Refer to SECTION 5 Faulty control module Replace control module 90 818177 3 APRIL 2001 Page 1C 25 INDEX TROUBLESHOOTING Auto Trim Ill System Wiring Diagram BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark BLU WHT Corrosion Protection NOTE Refer to MerCathode Controller Wiring Diagram Page 1C 26 SERVICE MANUAL NUMBER 14 22178 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Corrosion On Underwater Parts Without MerCathode Or Impressed Current Protection Cause Special Instructions Sacrificial anode s consumed Replace anode s when 5096 consumed Stainless steel propeller installed Add MerCathode impressed current protection or additional sacrificial anodes Remove anode s clean contact surface reinstall and check continuity Loss of continuity between underwater Provide good ground connections parts amp ground Shore power causing overload of anode s Disconnect shore power or install and or MerCathode
17. ackage components engine and sterndrive it will be necessary in some cases to simultaneously refer to the appropriate Engine Service Manual for further troubleshooting information Effective troubleshooting is best enhanced by e Personal product knowledge and experience of the trained mechanic technician e Allowing adequate time for testing and analysis e Utilizing these charts as a guide a starting point Sterndrive Unit Troubleshooting Sterndrive Unit Will Not Slide Into Bell Housing Causes Special Instructions Instructions U joint n splines not aligned with Rotate propeller engine coupler splines COUNTERCLOCKWISE to align splines Engine not aligned Check engine alignment Check engine alignment to determine if Gimbal bearing not properly installed gimbal bearing is cocked or improperly installed in gimbal housing Damaged U joint shaft splines and or Inspect and replace if necessary engine coupler splines Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Moves NOTE For additional information on troubleshooting refer to SECTION 2A and see Troubleshooting Shift Problems Drive Unit Does Not Shift Into Gear Remote Control Shift Handle Does Not Move NOTE For additional information on troubleshooting refer to SECTION 2A and see Troubleshooting Shift Problems Control box not properly assembled Properly reassemble control box Broken or damaged l
18. ance between gimbal ring and gimbal housing This could cause misalignment between bell housing and gimbal housing and also may allow gimbal ring to vibrate up and down Check and adjust clearance Refer to SECTION 4 Check for uneven mount height or loose Improperly installed or failed rear engine soft mounts Make sure there is mounts This will affect engine alignment clearance between flywheel housing and but usually is not detectable with engine fiber washer If no clearance exists alignment tool mounts have probably sagged Install mounts correctly or replace as necessary Page 1C 6 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Drive Shaft Housing Noise Continued Cause Special Instructions Boat transom too thin Thickness 2 in b1 mm minimum 2 1 4 in 57 mm Add thickness to transom maximum Boat transom thickness uneven This could affect engine to transom assembly alignment and is usually not detectable with Repair boat as necessary alignment tool Variation 1 8 in 3 mm maximum Bell housing contacting gimbal ring This Check for soft or split trim cylinder would cause knocking in the fully trimmed bushings and loose or worn hinge IN position only bushings Refer to SECTION 5B Measure the distance between the engine flywheel housing and the inner transom plate on both sides If distances are uneven the problem may be due to uneven st
19. boat is equipped with A REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS this shift assist assembly should NOT be used The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly 23159 a Shift Lever b Throttle Lever 90 818177 3 APRIL 2001 Page 1C 33 INDEX TROUBLESHOOTING Troubleshooting Shift Problems NOTE The following information is provided to assist an installer in troubleshooting if hard shifting or chucking racheting is encountered when shifting into forward gear Page 1C 34 1 SERVICE MANUAL NUMBER 14 When installing the control box in the side panel of the boat make sure that the cables have enough clearance to operate This is necessary because the cables move up and down when the shift handle is moved If the control box is mounted too far back toward any fiberglass structure the cables will be interfered with This will cause very hard shifting NOTE The control box housing can be rotated in 30 increments to improve cable routing 2 oon N Proper Cable Bend Improper Cable Bend Make sure that when the shift cable from the control box is led through the side gunnel of the hull it does not have any extremely sharp bends in it as this will cause the stiff shifting Before installing the shift cable into the control box extend the stainless rod eye end of the cable and grease it with 2 4 C Marine Lubrican
20. ck for voltage at terminal 24 and 25 with switch in AUTO mode If voltage exists at terminal 25 but not 24 switch is faulty Fauly contro module Faulty mode switch Page 1C 22 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Trim System Completely Inoperative In Manual Mode AUTO MODE FUNCTIONS PROPERLY Cause Special Instructions Check for voltage at terminal 26 with Faulty mode switch mode switch in MANUAL mode If no voltage is indicated replace switch Open circuit in wiring harness Check leads 27 and 33 for loose or corroded connections or damage Pump Motor Will Run UP But Not DOWN In Both Manual And Auto Modes DOWN SOLENOID DOES NOT CLICK Loose or dirty solenoid connections Check connections 4 7 and 12 Check for voltage at terminal 12 while trimming Down in MANUAL mode If no voltage is indicated repeat test at terminal Faulty mode switch or open in DOWN 22 and 23 If voltage exists at terminal 23 circuit but not at 22 switch is faulty If voltage is present at terminal 22 check leads 3 and 48 and connector 47 for an open condition Faulty DOWN solenoid Replace solenoid DOWN SOLENOID CLICKS Loose or dirty solenoid connections Check connections 10 and 11 Check for voltage at terminal 11 while Faulty solenoid trimming Down in MANUAL mode If no voltage is indicated replace solenoid Pump Motor Runs DOWN But Not UP In Both The Manual And Auto Mode
21. ctions Instructions Loose or dirty solenoid connections NENNEN _ SEM N connections 8 and 9 Clean and or tighten as necessary Check for battery voltage at terminal 8 while trimming OUT UP If no voltage is indicated check for a loose or corroded Open OUT UP circuit trim control or OUT UP circuit connection blown fuse if pump wiring harness trim control is equipped damaged OUT UP circuit lead or a faulty OUT UP trim switch Repair or replace as necessary Faulty solenoid Replace solenoid Power Trim Pump Motor Runs In The IN DOWN Direction But Not In The OUT UP Direction Both Trim And Trailer Switches Inoperative OUT UP SOLENOID CLICKS Cause Special Instructions Loose or dirty solenoid connections Check connections 2 and 3 Clean and or tighten as necessary Check for battery voltage at terminal 3 Faulty solenoid while trimming OUT UP If no voltage is indicated replace solenoid Faulty OUT UP field winding Replace solenoid Page 1C 14 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Trim Control OUT UP Trim Switch Inoperative TRAILER SWITCH OPERATES Cause Special Instructions Trim limit switch lead bullet connectors Clean and or tighten connections 14 15 loose or corroded 16 and 17 as necessary Disconnect trim limit switch leads from trim harness Connect a continuity meter between leads 16 and 17 Continuity Faulty trim limit switch or leads
22. ead or anode ORN lead wiring 9 and MerCathode controller Disconnect reference electrode lead BRN from the controller terminal Connect the lead to positive 4 terminal of a digital multi meter set on 0 2000 millivolt scale Connect negative meter Faulty MerCathode reference electrode lead to negative battery terminal Note meter reading then repeat the test with a test silver silver chloride reference electrode held behind the drive The same reading should be obtained in both cases If not replace the reference electrode With anode and reference electrode leads connected to controller connect a jumper wire between and negative terminals on controller Connect positive lead of volt meter set on 0 20 scale to A terminal on controller Connect the negative meter lead to the negative Faulty MerCathode controller controller terminal Reading should be as follows e Freshwater Areas 11 5 volts minimum e Seawater Areas 3 55 volts minimum If the reading is low replace the controller MerCathode system overpowered by large quantity of stainless steel below the waterline Loss of continuity between sterndrive Ensure continuity check continuity wires components and ground and washers Sacrificial anodes consumed painted or Replace anodes inoperative MerCathode reference electrode or anode Remove paint or replace anode or painted MerCath
23. er silver chloride reference electrode and digital volt ohm meter READINGS Below 850 millivolts Dele Refer to Drive Corroding Between 850 1100 Drive is protected millivolts Above 1100 millivolts Mis Refer to Drive Corroding Below 750 millivolts Brive Refer to Drive Corroding Between 750 1050 Drive is protected millivolts Above 1050 millivolts Refer to Drive Corroding e Paint blistering usually on sharp edges CORROSION SYMPTOMS e Loosely adhering white corrosion products on exposed aluminum surfaces do not confuse these with tenaciously clinging calcium carbonate deposits e Aluminum pitting 90 818177 3 APRIL 2001 Page 1C 31 INDEX B TROUBLESHOOTING SERVICE MANUAL NUMBER 14 MerCathode Controller BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 73596 a Controller b 20 Amp Fuse Electrode Page 1C 32 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Shift System Troubleshooting NOTE Some models may be equipped with a shift assist assembly The only difference with these models is that the remote control shift cable attaching hardware is slightly longer Shift cable adjustment is the same as all other versions 50308 a Shift Assist Assembly b Remote Control Shift Cable If the
24. fer to SECTION Air in system and correct source of leak Refer to SECTION 6A If the above 4 steps do not solve the Test power steering system Refer to problem test the power steering system SECTION 6A Power Steering System External Fluid Leaks Cause Special Instructions Instructions Paanga Papasan tng a Gag Remove fluid to bring to proper level reservoir too full Locate source of air or water and correct Pump reservoir leaking at fill cap air or Air may enter because of low reservoir water in fluid fluid level or internal pump leak Test pump Refer to SECTION 6A Bad power steering pump seals and Repair pump Refer to SECTION 6A O rings Cracked or porous metal parts Replace part s Page 1C 10 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Compact Hydraulic Steering Important Information Whenever a troubleshooting solution calls for removal from vessel and or dismantling of steering system components such work must be carried out by a qualified marine mechanic The following is offered as a guide only and neither Mercury MerCruiser nor the helm manufacturer are responsible for any consequences resulting from incorrect repairs Most faults occur when the installation instructions are not followed and usually show up immediately upon filling the system The most common faults encountered and their likely cause and solution are pr
25. ge this movement 50497 a Special Tool b 1 8 in 3 mm If switch closes too early less than 1 8 in Roller must be bent away from its seat If switch closes too late more than 1 8 in Roller must be bent toward its seat 50499 a Lever b Roller Special Tool Page 1C 44 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING 4 Once cutout switch is timed properly reconnect wires at terminal block and coat terminals with Liquid Neoprene 50499 a BLACK Wires b WHITE GREEN Wires Checking Cutout Switch Timing Models With Plunger Type Switch 1 While holding the retainer nuts on the back of the shift plate loosen the two phillips head screws on the shift cutoff switch and slowly move the switch either forward or aft 75225 a Switch Plunger Pin b Activating Lever Assembly c 1 32 in 0 8 mm Adjustment d Two Screws 90 818177 3 APRIL 2001 Page 1C 45 INDEX B TROUBLESHOOTING SERVICE MANUAL NUMBER 14 2 Adjust switch to locate plunger pin to 1 32 in 0 8 mm between plunger pin and activating lever assembly 75679 3 Slowly move activating lever assembly off until cutout switch opens or closes Circuit should open or close when the activating lever assembly is moved 3 16 1 32 in 4 8 0 8 mm 75225 a Cutout Switch b Movement of Activating Lever Assembly 4 After adjustments are made and are within 3 16
26. inkage in control box Repair linkage Controls improperly adjusted cable end Adjust shift cables guide hitting brass barrel 90 818177 3 2001 1 3 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Drive Unit Shifts Hard NOTE For additional information on troubleshooting refer to SECTION 2A and see Troubleshooting Shift Problems Special Instructions Shift cables improperly adjusted Adjust shift cables Damaged remote control or drive unit shift Replace cable s and adjust cable Shift cable too short sharp bends or too long loops and long bends Corroded shift cables Replace adjust and check for water leakage Internal wear in remote control box Repair as needed Shift cable attaching nuts too tight end Properly install nuts cannot pivot Shift cable pivot ends are corroded or not Clean and lubricate lubricated Drive Unit In Gear Will Not Shift Out Of Gear NOTE For additional information on troubleshooting refer to SECTION 2A and see Troubleshooting Shift Problems Gear Housing Noise Select and install proper length cable Cause Special Instructions clean and inspect and Metal particles in drive unit lubricant replace necessary components Refer to SECTION 3B 3C or 3D Propeller incorrectly installed Inspect mounting hardware Install propeller correctly Inspect and replace if necessary Refer to Propeller shaft bent SECTION 3B
27. it stops to ensure full clutch engagement b Place a mark on shift cable threaded tube against edge of end guide N e 22266 a Drive Unit Shift Cable b Propeller Shaft Rotate c Threaded Tube Mark Here c While maintaining pressure on propeller shaft in a counterclockwise direction to keep clutch locked with gear lightly pull out on drive unit shift cable end guide and place another mark on threaded tube d Measure distance between both marks Distance should be 9 16 in 14 mm or less 22266 a 9 16 in 14 mm Or Less b Propeller Shaft Maintain Pressure If play is 9 16 in 14 mm or less No further attention to drive unit is needed Proceed with adjustments If play is more than 9 16 in 14 mm Drive unit must be removed to further isolate excessive play 90 818177 3 APRIL 2001 Page 1C 37 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 BOAT IN WATER ENGINE RUNNING At least two people will be needed for the following procedure one person to check the adjustment and one person to stay at the control station of the boat Ensure boat is secured to dock and precautions have been taken to avoid damage to boat prior to placing drive unit into gear 1 Start engine and let it warm up to normal operating temperature Refer to operating procedures in Operation and Maintenance Manual 2 Disconnect throttle cable E 3 lt
28. itch Faulty mode switch 90 818177 3 APRIL 2001 Page 1C 21 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Pump Motor Will Not Stop Running Down In Auto Mode TRIM UP OUT SWITCH AND TRAILER SWITCH INOPERATIVE IN MANUAL MODE NOTE An internal timer in the control module stops the pump motor 50 seconds after this problem condition occurs Loose or dirty solenoid connection Check connections 7 and 8 Check for voltage at terminal 8 while trimming UP in MANUAL mode If voltage exists an open condition in solenoid is indicated and solenoid must be replaced If no voltage is indicated refer to steps 3 through 6 following Loose or corroded trim limit switch lead Chack connections 32 and 36 connections Disconnect trim limit switch leads 32 and 36 and connect a continuity meter Faulty trim limit switch between leads Continuity should exist with drive unit in DOWN position If not readjust or replace switch as necessary Open circuit in wiring harness Check leads 30 35 46 and 2 for loose or corroded connections or damage Faulty control module Pump Motor Will Not Run Up Or Down In Auto Mode Faulty solenoid MANUAL MODE FUNCTIONS PROPERLY Cause Special Instructions Instructions Control module 20 amp fuse blown NN cause for blown fuse and correct before replacing fuse Open in control module battery cables or Check cables 16 and 18 and lead 20 wiring harness Che
29. itch Improper propeller pitch propeller Dirty or damaged boat bottom Clean and or resurface boat bottom Drive installation too low on transom Contact boat manufacturer for installation specifications Check for a hook in the boat bottom by Permanent hook in boat bottom some placing a straight edge at least 6 ft 2 m boats are built with a slight hook for long under the bottom edge of the correct boat performance transom If a hook is found contact the boat manufacturer Water test boat Boat will perform normally until hook develops at high speed then loss of rom and speed will occur Contact boat manufacturer Power hook or weak boat bottom High WOT Engine Rpm Propeller ventilating Determine cause for ventilation Water test boat using a higher pitch Improper propeller pitch propeller Propeller hub slipping Replace hub or replace propeller Drive installation too high on transom Contact boat manufacturer for installation specifications Engine coupler hub spun Replace coupler Propeller Ventilating Cavitating Drive unit trimmed too high Trim drive unit IN DOWN Incorrect propeller Install correct propeller Poor Boat Performance And Or Poor Maneuverability Bow Too Low Special Instructions Improper drive unit trim angle Properly adjust drive unit trim angle Redistribute boat load to stern If bow overweight is caused by permanently installed fuel tank s contact the
30. l Not Run In The OUT UP Or IN DOWN Direction Power Pump Motor Runs In The OUT UP Direction But Not In The IN DOWN Direction Power Trim Pump Motor Runs In The OUT UP Direction But Not In The IN DOWN Direction 90 818177 3 APRIL 2001 1C 3 1 3 1 3 ooooo o ooo oo MAK RO OQ 1C 10 1C 10 1 11 1 11 1 11 1 11 1C 11 10412 1 12 1 13 1 13 1 14 Power Trim Pump Motor Runs In The IN DOWN Direction But Not In The OUT UP Direction Both Trim And Trailer Switches Inoperative Power Trim Pump Motor Runs In The IN DOWN Direction But Not In The OUT UP Direction Both Trim And Trailer Switches InoperallVO Trim Control OUT UP Trim Switch Inoperative Trim Control Trailer Switch Inoperative Trim System Functions While Unattended Power Trim System Wiring Diagram Power Trim Hydraulic System Drive Unit Cannot Be Trimmed OUT UP Or Trims Slowly Or With Jerky Movements Drive Unit Will Not Stay In Trimmed OUT UP Position Sterndrive Unit Trails OUT UP On Deceleration Or When Shifting Into Reverse Oil Foams Out Of Pump Fill Vent Screw Sterndrive Unit Cannot Be Lowered From UP Position Or Lowers With Jerky Movements Sterndrive Unit Will
31. n be routed under the starboard rear engine mount and turned toward the transom c Then route the cable behind the power steering valve and loop over to the shift plate on the engine Connect it to the anchor points on the shift plate Following this routing will prevent the engine coupler from damaging the cable 4 Cylinder Inline Model V6 and V8 Models 90 818177 3 APRIL 2001 Page 1C 35 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Checking for Excessive Play Checking for excessive play in the drive unit shift system can be done with the boat in the water or on land Refer to the appropriate procedure BOAT OUT OF WATER ENGINE OFF 1 Disconnect remote control shift cable 22267 a Remote Control Shift Cable b Plastic Shift Lever c Clevis Pin and Cotter Pin d Locknut and Washer IMPORTANT When pushing or pulling on drive unit shift cable in the following steps apply just enough pressure so that V notch starts moving Then ease up slightly Use a fine tip marking device to mark threaded tube to obtain an accurate measurement 22058 Roller Type Switch a V notch E NC TH SI 75225 Plunger Type Switch a V notch 2 Check for excessive play in drive unit shift system Page 1C 36 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING a Place drive unit into gear by pushing in on drive unit shift cable while rotating propeller shaft counterclockwise until
32. n out Armature commutator dirty Clean or Cleanorreplae Armature faulty LLLI and replace if bad Field and frame faulty Test and replace if bad Pump gears frozen Replace pump Disconnect blue white lead 2 from Trim harness shorted between UP and solenoid terminal If pump motor will now DOWN circuit run in the DOWN direction a short in the harness is indicated SOLENOIDS DO NOT CLICK Causes Special Instructions Instructions negative battery cable loose EN cable 13 for damage or a loose or corroded or damaged corroded connection Mode switch wiring harness connector is Secure connection 47 loose at pump Connect a jumper wire between terminals Faulty thermal circuit breaker in pump 1 and 7 If pump now operates circuit motor breaker is faulty and field and frame assembly must be replaced With ignition switch in RUN position and mode switch in MANUAL mode check for Open circuit in mode switch wiring voltage at terminal 8 while trimming UP harness and terminal 12 while rimming DOWN If no voltage is indicated refer to items 5 and 6 immediately following Check for voltage at terminal 25 with ignition switch in RUN position If no voltage is indicated check power lead for a poor connection Check for voltage at terminal 24 with mode switch in AUTO mode and terminal 26 with switch in the MANUAL mode Replace switch if no voltage is indicated No power to mode sw
33. ode reference electrode Too much cathode such as stainless steel Page 1C 28 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING DRIVE CORRODING CONTINUED Cause Special Instructions Connect positive lead of volt meter set on 0 20 volt scale to positive terminal on the controller and negative volt meter lead to negative terminal Meter should indicate battery voltage Check for blown fuse if equipped on a standard MerCathode system Clean the connection No power to MerCathode controller or repair wiring as required Check the fuse in the hot lead Check battery MerCathode system not functioning Check for loose connections at controller and battery Check the grounding wire between the drive and the controller 90 818177 3 APRIL 2001 Page 1C 29 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Corrosion On Underwater Parts With MerCathode Or Impressed Current Protection DRIVE OVER PROTECTED Cause Special Instructions Disconnect reference electrode lead BRN from R terminal on controller Connect the lead to the positive terminal of a digital multimeter set on 0 2000 millivolt scale Connect the negative meter lead to the negative battery terminal Note the meter reading then repeat the test with a test silver silver chloride reference electrode held behind the drive The same reading should be obtained in both cases If n
34. on for repair of applicable components 90 818177 3 APRIL 2001 Page 1C 41 INDEX B TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Checking Remote Control Shift Cable Output IMPORTANT Remote control must provide a shift cable travel at the shift plate end of 2 7 8 in 73 mm to 3 1 8 in 80 mm with a 15 20 Ib 6 8 9 kg load applied to the cable end guide Models With Shift Assist This measurement can be taken by installing the remote control shift cable and using the shift assist assembly provided to place the proper load on the shift cable drive unit shift cable should not be installed Models Without Shift Assist This measurement can be taken by lightly pushing and pulling on the remote guide to place the proper load 15 20 Ib 6 8 9Kg on the shift cable 1 Place remote control into gear Right Hand Rotation Drive Unit Forward gear wide open throttle position Left Hand Rotation Drive Unit Reverse gear wide open throttle position Place a mark on threaded tube against edge of cable end guide 2 Place remote control into the opposite gear Measure the distance between the edge of the shift cable end guide and the mark line in step 1 Total shift cable output must not be less than 2 7 8 in 73 mm or more than 3 1 8 80 mm If output is incorrect remote control and or shift cable must be replaced 50368 With Shift Assist Assembly a Shift Assist Assembly b Remote Control Shift Cable Ret
35. ot replace the reference electrode Check controller output If the hull potential indicates overprotection remove the reference electrode lead from the controller If the controller is off no impressed current called for the voltage between the negative BLK and the anode should be less than 1 volt Measure amperage with the reference electrode disconnected the amperage between the negative on the controller and the anode terminal should be less than 1 milli amp Replace the controller if needed Disconnect electrical components one at a time and observe the multimeter reading until you eliminate the high reading Correct the source of the stray current Faulty MerCathode reference electrode Faulty MerCathode controller Stray current corrosion electrical current leaves a metal conductor and creates a path through the water Poor connection between the MerCathode reference electrode lead BRN and the R terminal on the controller Clean and or tighten the connection Repair wiring as needed Check the fuse in the hot lead Check the battery MerCathode system not functioning Check for loose connections at controller and battery Check the grounding wire between the sterndrive and the controller Page 1C 30 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Testing Procedure for Corrosion Protection 1 Unplug shore power if equipped 2 Measure hull potential with silv
36. ovided in the following Sometimes when returning the steering wheel from a locked position a slight resistance may be felt and a clicking noise may be heard This should not be mistaken as a fault as itis a completely normal situation caused by the releasing of the lockspool in the system Avoid serious injury or death due to FIRE or EXPLOSION Be sure that engine com partment is well ventilated and that no gasoline vapors are present to prevent the possibility of a FIRE or EXPLOSION Helm Becomes Jammed During Filling Causes Special Instructions certain that hoses were not kinked or pinched during installation If so the hose must be removed and replaced Blockage in the line between the helm s and the cylinder s System Difficult To Fill Special instructions Steering Hard To Turn Cause Special Instructions To test disconnect clevis from steering lever and turn the steering wheel If it now Steering cylinder pivot bushings are too turns easy correct cause of mechanical tight or trunion is bent causing binding Please note that excessively mechanical binding loose connections to steering cylinder or steering lever can also cause mechanical binding Restrictions in hoses Find restrictions and correct Air in Air in hydraulic fluid fluid See See filling and purging instructions and See filling and purging instructions instructions hydraulic fluid has been used
37. pump and bleed trim system Test Refer to SECTION 5A Replace and 2 or attempt to repair by replacing Pump OUT UP circuit leaking internally _ the following e Thermal relief valve 4 Poppet valve seals 9 Trim cylinder s leaking internally and pump DOWN circuit leaking internally Rebuild cylinders 5 Repair or replace both must be faulty to cause this adaptor 2 as required problem Page 1C 18 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Sterndrive Will Not Stay In The Trimmed OUT UP Position When Underway Cause Special Instructions Air in trim system Check for cause of entry Fill and bleed system Leaky poppet valve Install repair kit for poppet valve 1 Sterndrive Unit Trails OUT UP On Deceleration Or When Shifting Into Reverse UNIT THUMPS WHEN SHIFTING Cause Special Instructions Trim cylinders s leaking internally oaa mag may ITER SECTIONS RU 9r Test Refer to SECTION 5A Replace adaptor or attempt to repair by replacing Trim pump IN DOWN circuit leaking the following internally e Pilot check valves or seals 9 e Install trim pump rebuild kit Oil Foams Out Of Pump Fill Vent Screw Case Special Instructions Instructions Contaminated oil S K e ai system with clean oil refill pump and bleed trim system Check for cause of low oil level and Oil level low correct Add oil to pump and bleed system Trim Motor Runs But Does
38. racted c Place a Mark On Tube Against Edge Of Cable End Guide d Remote Control Shift Cable Extended e Measurement Taken from Mark To Edge Of Cable End Guide 2 7 8 in 73 mm To 3 1 8 in 80 mm Page 1C 42 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING 50499 Without Shift Assist Assembly a Shift Cable end Guide b Remote Control Shift Cable Lightly Pull On End Guide c Place A Mark On Tube Against Edge Of Cable End Guide d Remote Control Shift Cable Lightly Push In On End Guide e Measurement Taken From Mark To Edge Of Cable End Guide 2 7 8 in 73 mm to 3 1 8 in 80 mm Checking Cutout Switch Timing Models With Roller Type Switch 1 Disconnect Cutout Switch WHITE GREEN wire from terminal block or bullet conector 2 Connect ohmmeter positive lead to cutout switch WHITE GREEN wire and ohmmeter negative lead to cutout switch black wire at terminal block 3 Set Ohmmeter on Rx1 scale 50497 a Terminal Block b Cutout Switch WHITE GREEN Wire Cutout Switch BLACK Wire 90 818177 3 APRIL 2001 Page 1C 43 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 NOTE Refer to the end of this section for the pattern and dimensions needed to fabricate a similar tool Slowly move cutout switch roller off of its seat Circuit should close full continuity reading when roller is moved 1 8 in 3 mm Use the 1 8 in rod on the end of special tool to gau
39. rim Hydraulic System NOTE Refer to Power Trim Hydraulic Schematic Drive Unit Cannot Be Trimmed OUT UP Or Trims Slowly Or With Jerky Movements Check for cause of low oil level correct Add oil and bleed trim system Air in trim system Check for cause of entry and correct Add oil to pump and bleed air from system O rings damaged on Manual Release Valve if equipped or valve not completely Replace valve and or close completely closed Test If shuttle 1 is stuck replace pump adaptor Refer to SECTION 54 If pressure is low replace adaptor or attempt Insufficient pump pressure or pump to repair by replacing the following shuttle valve stuck components e OUT UP Pressure Relief Valve e Thermal Relief Valve Hoses reversed on one cylinder only Connect hoses 7 and 8 correctly Check for cause of binding bent piston Trim cylinder s binding rod scored cylinder Repair or replace as necessary Gimbal housing to trim pump hydraulic Replace hose 7 hose pinched Up pressure relief valve has dirt particles Replace with a new valve kit under check ball Drive Unit Will Not Stay In Trimmed OUT UP Position Cause Special Instructions Air in trim system Check for cause of entry Fill and bleed system Sterndrive Unit Trails OUT UP On Deceleration Or When Shifting Into Reverse UNIT THUMPS WHEN SHIFTING Cause Special Instructions Test according to appropriate service Trim pump
40. ringer height or a cocked transom assembly Adjust the stringer height or relocate the transom cutout as required This condition can sometimes be detected Weak boat transom or boat bottom that by having someone apply force to the top flexes under power and causes engine of the drive unit while watching the inner misalignment this condition will usually transom plate If movement can be cause engine coupler failure observed the transom is weak and must be repaired Rear engine mount attaching hardware Reinstall hardware correctly improperly installed or missing Engine mounting holes drilled off center in Make sure the holes are equally spaced inner transom plate engine supports or fore and aft and are equal distance from engine flywheel housing the centerline Contact your service center and arrange to have a technical service representative check the unit using a special gauge Stringer height uneven or transom assembly installed cocked on boat transom This will affect engine alignment but is usually not detectable with alignment tool Misalignment between bell housing gimbal housing and engine coupler 90 818177 3 APRIL 2001 Page 1C 7 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Performance Troubleshooting Low WOT Engine Rpm Improper drive unit trim angle Properly adjust drive unit trim angle Damaged propeller propeller Repair or replace or replace a test boat using a lower p
41. s UP SOLENOID CLICKS Cause Special Instructions Loose or dirty solenoid connections Check connections 5 and 6 Check for voltage at terminal 6 while Faulty solenoid trimming UP If no voltage is indicated replace solenoid Faulty UP field winding Replace field and frame 90 818177 3 APRIL 2001 Page 1C 23 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Pump Motor Will Run DOWN But Not UP In Auto Mode MANUAL MODE FUNCTIONS PROPERLY Cause Special Instructions Instructions Open circuit in control module sense EE a a lead 17 for loose or corroded lead connections or damage Faulty control module Pump Motor Will Run UP But Not DOWN In Auto Mode MANUAL MODE FUNCTIONS PROPERLY Cause Special Instructions Check for voltage at terminal 21 and 22 while turning ignition switch to RUN position in AUTO mode If voltage exists at 21 but not at 22 switch is faulty Open circuit in wiring Check lead 19 for a loose or corroded connection or damage Faulty control module Trim DOWN IN Switch Inoperative In Manual Trim Control Faulty mode switch TRIM UP OUT SWITCH AND TRAILER SWITCH FUNCTION AUTO MODE FUNCTIONS PROPERLY Cause Special Instructions ILL Check for voltage at terminal 38 while E reum switch in manual trim trimming DOWN in MANUAL mode If no voltage is indicated switch is faulty Check for voltage at terminal 23 while trimming DOWN If no voltage is present
42. should be indicated with drive unit in full IN DOWN position If not check for damaged leads or poor connections If this is not the cause replace limit switch Check for a loose or corroded OUT UP circuit connection damaged OUT UP circuit lead or faulty OUT UP trim switch Repair or replace as necessary Open trim control OUT UP circuit Trim Control Trailer Switch Inoperative TRIM OUT UP SWITCH FUNCTIONS Cause Special Instructions Check for a faulty trailer switch loose or Open trim control trailer circuit corroded connections or damaged trailer circuit lead Trim System Functions While Unattended Faulty trim or trailer switch Replace switch Shorted trim pump harness or trim control Repair or replace as required harness 90 818177 3 APRIL 2001 Page 1C 15 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Power Trim System Wiring Diagram w E BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK v c 2 m lt How nom og won on lt trad on wy on d NOTE Numbered callouts refer to Power Trim Electrical System Troubleshooting Chart a 20 Amp Fuse b Ground Bolt Floor Mount c UP Solenoid d 110 Amp Fuse e DOWN Solenoid f Trim Trailer Switch g Neutral Switch to Instrument Wiring Harness h Trim Limit Switch Page 1C 16 90 818177 3 APRIL 2001 INDEX B SERVICE MANUAL NUMBER 14 TROUBLESHOOTING Power T
43. t manufacturer Boat is stern heavy Power hook or weak boat bottom Power Steering If Power Package is equipped with Power Steering first determine if problem is caused by the Power Steering System or the Ride Guide portion of the Steering System 1 Remove clevis pin which attaches steering cable to power steering unit piston rod end clevis Remove clevis pin which secures piston rod end clevis to sterndrive steering lever 2 Turn steering wheel through entire steering range If steering difficulty is encountered it is located in the Ride Guide Steering System If steering wheel turns with ease problem is located in Power Steering System Hard Steering Helm And Cable Damaged steering cable Replace cable Refer to SECTION 2 Steering cable too short sharp bends or Select and install proper length cable too long loops and long bends Refer to SECTION 2A Steering cable corroded or not lubricated Lubricate or Lubricate or replace the cable the cable Over lubed cable eee cable RideGuide rack or rotary head not Disassemble and lubricate lubricated 90 818177 3 APRIL 2001 Page 1C 9 INDEX BR TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Hard Steering Engine Running Power Steering System Cause Special Instructions Low power steering pump fluid level Check fluid level Refer to SECTION 6A Loose power steering pump drive belt belt tension Refer to SECTION to remove air Re
44. t must removed to further isolate excessive play Isolating Excessive Play NOTE Refer to the end of this section for templates and patterns needed to fabricate similar tools 1 To determine shift shaft rotational end play use a tool such as the one shown to measure degrees of play in the shift shaft with clutch locked and held in gear NOTE Tool pattern on p 1C 45 a While maintaining pressure on propeller shaft to keep clutch locked with gear lightly turn shift shaft coupler counterclockwise Make note of pointer location 50498 a Pointer Installed on Shift Shaft b Scale 1 Increments c Nut Hand Tight Only Page 1C 40 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 b Rotate shift shaft coupler clockwise while simultaneously turning propeller shaft counterclockwise until clutch locks into gear Make note of pointer location on scale TROUBLESHOOTING 50498 a Shift Shaft Coupler b Pointer c Scale c While maintaining pressure on propeller shaft to keep clutch locked with gear lightly turn shift shaft coupler counterclockwise Make note of pointer location 50498 a Shift Shaft Coupler b Pointer c Scale d Determine total degrees of movement If 12 or less problem is with the drive unit shift cable upper shift shaft assembly and lever assembly If more then 12 problem is with gear case shift spool assembly Whichever the case refer to appropriate secti
45. t with Teflon Move it back and forth to allow even distribution of the grease 22005 Do not strap or clamp the control cables to any other cables or rigid structure within 3 ft 914 mm of the control box Be sure the cable is not permanently kinked Make sure there is proper clearance for cable movement when the control box is installed in the side panel The cables must have room to move up and down when the control handle is shifted into either forward or reverse Ensure that the engine was not set down on the intermediate shift cable during installation as this will crush the inner cable tubing and cause improper and or stiff shifting 90 818177 3 APRIL 2001 INDEX BR SERVICE MANUAL NUMBER 14 TROUBLESHOOTING 8 DO NOT fasten the shift cable with straps or clamps to any other cable within 5 ft 1524 mm of the shift plate 9 DO NOT fasten the shift cable to the transom with any type of plastic clips or fasteners within 5 ft 1524 mm of the shift plate 10 DO NOT over tighten the throttle or shift cable attaching nuts at the engine end Barrel and cable end must be free to rotate on the mounting stud 11 Check the intermediate shift cable routing from the transom assembly to the shift plate as follows a The cable should come through the transom above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing b The cable should the
46. to fill Drain system and fill with approved steering system hydraulic fluid Helm Unit Bumpy Requires Too Many Turns Dirt in inlet check of helm pump Replace helm unit 90 818177 3 APRIL 2001 Page 1C 11 INDEX B TROUBLESHOOTING SERVICE MANUAL NUMBER 14 Power Trim Electrical System NOTE Refer to Power Trim System Wiring Diagram Power Trim Pump Motor Will Not Run In The OUT UP Or IN DOWN Direction SOLENOIDS DO NOT CLICK Special Instructions Bad electrical connection at the 110 amp fuse or at the battery or the harness came Check all electrical connection points unplugged from the pump Determine cause for the blown fuse and correct before replacing fuse NOTE If fuse blows while trimming OUT UP or raising drive unit problem may be due to 20 amp fuse blown grounded trim limit switch leads To check for grounded condition disconnect trim limit switch leads at bullet connector 14 15 16 and 17 If drive unit can now be raised using Trailer switch trim limit switch or leads are grounded Power trim pump battery cables or wiring Clean and or tighten connections 1 2 4 harness connections corroded or loose 10 11 12 and 18 as necessary Trim control wiring harness connector Clean and secure connection 13 as loose or corroded necessary Check for voltage at terminal 4 If no voltage indicated determine cause of blown fuse 110 amp fuse blown does not apply to intermittent problem

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