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Mercury 30 Service Manual

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Download this manual See also: Operation & Maintenance Manual, User Manual
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
C - Oil Injection
Section 4 - Powerhead
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim
C - Manual Tilt
Section 6 - Lower Unit
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
90-826148R2 MARCH 1997
Important
Information
Electrical
Fuel System
Powerhead
Mid-Section
Lower Unit
Attachments/
Control Linkage
Manual Starter
iii
1
2
3
4
5
6
7
8

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Questions and answers

Wilfried Harald Czekansky
April 14, 2025

Batteriet är OK. Startmotorn slår inte till.Motorn har varit lagrad i garaget i c:a 2 år.

0
1 comments:
Mr. Anderson
April 15, 2025

The starter motor on a Mercury engine with part number 30 may not engage after being stored for about 2 years due to several possible reasons:

1. Weak or dead battery – The battery may have lost charge or degraded during storage.
2. Loose or corroded battery connections – Corrosion or loose terminals can prevent proper current flow.
3. Blown fuse – A blown 20 Amp fuse in the starting circuit can stop the motor from engaging.
4. Ignition key switch failure – The switch may not be functioning properly.
5. Outboard not in neutral – The motor must be in neutral to start.
6. Wiring issues – Loose, corroded, or damaged wiring can interrupt the circuit.
7. Starter motor or solenoid failure – Internal failure from corrosion or wear can prevent engagement.

These issues are common after long-term storage without proper maintenance.

This answer is automatically generated

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Summary of Contents for Mercury 30

  • Page 1 Service Manual Outline Important Section 1 - Important Information Information A - Specifications B - Maintenance C - General Information D - Outboard Installation Electrical Section 2 - Electrical A - Ignition B - Charging & Starting System C - Timing, Synchronizing & Adjusting Fuel System D - Wiring Diagrams Section 3 - Fuel System...
  • Page 2 This service manual has been written and published the same locations whenever possible. Where the by the Service Department of Mercury Marine to aid fasteners are not satisfactory for re-use, care should our dealer’s mechanics and company service per-...
  • Page 3 In addition, personnel should not work on or under an Cleanliness and Care of outboard which is suspended. Outboards should be Outboard Motor attached to work stands, or lowered to ground as soon as possible. A marine power product is a combination of many We reserve the right to make changes to this manual machined, honed, polished and lapped surfaces with without prior notification.

  • Page 4: Important Information

    IMPORTANT INFORMATION SPECIFICATIONS...
  • Page 5 Table of Contents Page General Specifications ..... . . 1A-1 General Specifications ..... . . 1A-2 General Specifications .

  • Page 6: General Specifications

    Cylinder Finish Hone (I.D.) 2.993 in. (76 mm) CRANKSHAFT Top Main Bearing Journal 1.375 in. (34.93 mm) Center Main Bearing Journal 1.216 in. (30.89 mm) Bottom Ball Bearing Journal 1.385 in. (35.17 mm) Connecting Rod Journal 1.181 in. (29.99 mm) Runout 0.003 in.
  • Page 7 2-Cycle Outboard Oil Oil Tank Capacity/Approx. Time 50.5 fl. oz. (1.5 liters) 4.7 Hours @ 5250 RPM Reserve Capacity/Approx. Time 30 Minutes @ 5250 Output (cc/min.) w/Pump @ Full Open 8.5 cc/10 Minutes @ 900 RPM STARTING Manual Start Recoil...
  • Page 8 Idle RPM 700 - 800 RPM SPECIFICATIONS (In Forward Gear) Full Throttle RPM Range - - Model 30/ 40 Sea Pro/Marathon 4500 - 5500 RPM - - Model 40 5000 - 5500 RPM Idle Mixture Screw Adjustment (Preset - Turns Out) 1-1/2 ±1/4 (All Models Except 40 MLL)
  • Page 9 IMPORTANT INFORMATION MAINTENANCE...

  • Page 10: Table Of Contents

    Table of Contents Page Specifications ......1B-1 Gear Case Lubricant Capacity ..1B-1 Special Tools .

  • Page 11: Specifications

    Specifications Gear Case Lubricant Capacity Gear Case Ratio Capacity 2.00:1 14.9 fl. oz. (440 mL) Special Tools P/N 44357A2 Flushing Kit. Quicksilver Lubricant/Sealant Description Part Number Gear Lubricant-Premium 92-19007A24 Blend Anti-Corrosion Grease 92-78376A6 2-4-C Marine Lubricant 92-825407A12 w/Teflon SAE 30W Motor Oil Obtain Locally 90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-1...

  • Page 12: Inspection And Maintenance Schedule

    Inspection and Maintenance Every 100 Hours of Use or Once Yearly, Whichever Occurs First Schedule 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. Before Each Use 2. Inspect and clean spark plugs. 1. Check that lanyard stop switch stops the engine. 3.

  • Page 13: Lubrication Points

    Lubrication Points ITEM TYPE OF FRESH WATER SALT WATER DESCRIPTION LUBRICANT FREQUENCY FREQUENCY Throttle/Shift linkage Pivot Points Quicksilver 2-4-C Quicksilver 2-4-C Upper Shift Shaft Marine Lubricant Marine Lubricant Swivel Pin 100 Hours of Use or 100 Hours of Use or Ride Guide Steering Once in Season Cable...
  • Page 14 Electric and Remote Control Models 52662 2 - Upper Shift Shaft Lubrication Tiller Handle Models 3 - Swivel Pin Grease Fittings 4 - Ride Guide Steering Grease Fitting 5 - Tilt Tube/Co-Pilot Grease Fitting WARNING 6 - Steering Link Rod Pivot Point Lubrication Core of steering cable (transom end) must be ful- ly retracted into cable housing before lubricating cable.

  • Page 15: Checking Power Trim Fluid

    Checking Power Trim Fluid 1. Tilt outboard to the full up position and engage the tilt support pin. 52661 8 - Starter Motor Pinion Gear Lubrication a - Tilt Support Pin 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole.

  • Page 16: Gear Case Lubrication

    Gear Case Lubrication When adding or changing gear case lubricant, visual- ly check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored ap- pearance.

  • Page 17: Propeller Replacement

    NOTE: Refer to “ Specifications,”for gear housing 5. Pull propeller straight off shaft. If propeller is lubricant capacity. seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. With outboard in operating position, insert lubri- cant tube into fill hole.

  • Page 18: Corrosion Control Anode

    Corrosion Control Anode While aligning splines, place Quicksilver propel- ler and tab washer on propeller shaft. The trim tab on the gear case is a corrosion control To prevent propeller from rotating, place a flat anode and Models which have the longer type of block of wood between the anti-ventilation plate transom brackets will have a second anode installed.

  • Page 19: Fuel Tank

    Fuel Tank To remove fuel line clamps, grip clamp with pliers and bend over, lapping hook backward. 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.

  • Page 20: Flushing The Cooling System

    Flushing The Cooling 5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing System the outboard for 3 to 5 minutes, carefully monitor- ing water supply at all times. WARNING To avoid possible injury when flushing, remove the propeller.

  • Page 21: Protecting External Outboard Components

    Gear Case 1. Portable Fuel Tank - Pour the required amount of Quicksilver Gasoline Stabilizer (follow instruc- 1. Drain and refill the gear case lubricant (refer to tions on container) into fuel tank. Tip fuel tank maintenance procedure). back and forth to mix stabilizer with the fuel. 2.
  • Page 22 IMPORTANT INFORMATION GENERAL INFORMATION...
  • Page 23 Propeller Selection ..... . 1C-4 Propeller Information Chart - 30 HP ..1C-6 Propeller Information Chart - 40 HP .

  • Page 24: Serial Number Location

    30% relative humidity at 77°F (25°C) tem- perature and a barometric pressure of 29.61 inches OGXXXXXX of mercury.

  • Page 25: Boat

    Boat TRIM TRIMMING OUTBOARD “OUT” (“UP”) WEIGHT DISTRIBUTION Proper positioning of the weight inside the boat WARNING (persons and gear) has a significant effect on the Excessive trim “out” also may reduce the stabil- boat’ s performance, for example: ity of some high speed hulls. To correct instabili- Shifting weight to the rear (stern) ty at high speed, reduce the power GRADUALLY and trim the outboard “in”...

  • Page 26: Cavitation

    CAVITATION Detonation usually can be prevented if: Cavitation is caused by water vapor bubbles forming 1. The engine is correctly set up. either from a sharp edge or angle on the gear case 2. Diligent maintenance is applied to combat the or from an irregularity in the propeller blade itself.

  • Page 27: Submerged Engine (Fresh Water) (Plus Special Instructions)

    Propeller Selection Submerged Engine (Fresh Water) (Plus Special Instructions) For in-depth information on marine propellers and boat performance - written by marine engineers - see 1. Recover engine as quickly as possible. your Authorized Dealer for the illustrated “ What You 2.
  • Page 28 After initial propeller installation, the following common conditions may require that the propel- ler be changed to a lower pitch: Warmer weather and great humidity will cause an RPM loss. Operating in a higher elevation causes an RPM loss. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss.

  • Page 29: Propeller Information Chart - 30 Hp

    Propeller Information Chart - 30 HP Wide Open Throttle RPM: 4500-5500 Recommended Transom Height: 15” , 20” , 22-1/2” Right Hand Rotation Standard Gear Reduction: 2:1 Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part Blades Boat Weight...

  • Page 30: Propeller Information Chart - 40 Hp

    Up To 15’ 38-45 48-73146A40 10” 17” Alum. Up To 1000 Up To 15’ 33-40 48-73144A40 10” 16” Steel 700-1200 13 - 16’ 30-36 48-91818A5 10” 16” Alum. 700-1200 13 - 16’ 30-36 48-73142A40 10-1/8” 15” Steel 900-1500 14 - 16’ 28-34 48-76232A5 10-1/8”...
  • Page 31 IMPORTANT INFORMATION OUTBOARD MOTOR INSTALLATION...
  • Page 32 Table of Contents Page Notice to Installer and Owner ... . 1D-1 Boat Horsepower Capacity ....1D-1 Outboard Remote Control .

  • Page 33: Notice To Installer And Owner

    Boat Horsepower Capacity Mercury Marine Quicksilver accessories are avail- able from Mercury Marine dealers. Some accessories not manufactured or sold by Mer- U.S. COAST GUARD CAPACITY cury Marine are not designed to be safely used with MAXIMUM HORSEPOWER XXX your outboard or outboard operating system.

  • Page 34: Selecting Steering Cables And Remote Control Cables

    Selecting Steering Cables Lifting Outboard and Remote Control Cables WARNING Refer to “ Quicksilver Accessories Guide” to deter- Verify that the lifting ring is threaded into the fly- mine correct length of steering cables and remote wheel a minimum of 5 turns and that hoist has a control cables.

  • Page 35: Installing Outboard To Boat Transom

    Installing Outboard to Boat Use a 17/32 inch (13.5mm) diameter drill bit and drill two mounting holes for the upper set of mounting Transom bolts and two holes for the lower set of mounting bolts. NOTE: using “ Transom Drilling Fixture”...

  • Page 36: Thumb Screws

    Measure the transom height of your boat. The boat WARNING bottom should be aligned or be within 1 in. (25mm) below the anti-ventilation plate of the outboard. Before operation, the outboard must be correctly installed with four mounting bolts shown. Failure to correctly fasten outboard could result in out- board ejecting off boat transom causing serious injury, death, or property damage.

  • Page 37: Fastening Outboard To The Boat Transom 1D-5

    Single Steering Cable and FASTENING OUTBOARD TO THE BOAT TRANSOM Steering Link Rod Type 1 Bracket Installation Drill two 1/2 in. (12.5mm) holes thru a lower set of mounting holes and fasten outboard to boat transom NOTE: These instructions are for single cable-single with two 1/2 in.

  • Page 38: Steering Link Rod Installation

    3. Place a mark on the tilt tube, 1/4 in. (6.4mm) from 1. Assemble steering link rod to steering cable with end of tilt tube. Install plastic spacer, o-ring and two flat washers and nylon insert locknut cap onto steering cable as shown. (11-34863).

  • Page 39: Required Side Mount Remote Control Or Ignition Key Switch Assembly

    Required Side Mount Remote Control or Ignition Key Switch Assembly Boats Equipped with Side Mount Remote Control A Quicksilver Commander 2000 series Side Mount Remote Control equipped with a warning horn must be used with this outboard. This warning horn is nec- essary for the engine warning system.

  • Page 40: Shift And Throttle Cable Installation To The Outboard

    Shift and Throttle Cable 3. Push-in on the cable end until resistance is felt. Adjust the cable barrel to attain the measured Installation To The Outboard distance “ a”taken in Step 2. 4. Place cable barrel into the bottom hole in the bar- Install cables into the remote control following the rel holder.

  • Page 41: Throttle Cable Installation

    Throttle Cable Installation 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to acti- 1. Position remote control into neutral. vate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse. 2.

  • Page 42: Battery Connections

    Battery Connections Set Up Instructions For Oil Injection System CAUTION For dual outboard installations, the BLACK (- -) CAUTION battery cable of each engines starter motor Oil injected engines additionally, must be run on ground circuit, MUST BE connected to each oth- a 50:1 gasoline/oil mixture in the fuel tank for the er by a common circuit (cable) capable of carry- first 10 gallons of fuel.

  • Page 43: Bleeding Air From The Oil Injection System

    Bleeding Air From The Oil Injection Adjusting The Oil Injection Pump System When carburetor linkage is at idle position, alignment mark on oil injection arm should be in-line with mark IMPORTANT: If air exists in either the oil pump in- on pump as shown.

  • Page 44: Tilt Pin Adjustment

    Tilt Pin Adjustment 4. Install thrust washer, propeller, propeller nut re- tainer, and propeller nut onto the shaft. WARNING DO NOT operate boat without the tilt pin in- stalled. Failure to install tilt pin could result in outboard kicking up when operated in reverse causing serious injury, death, or property dam- age.

  • Page 45: Trim Tab Adjustment

    PLACING TILT PIN IN UPPER HOLES CAN: MODELS WITHOUT POWER TRIM 1. Lift the bow out of the water. Operate your boat at normal cruising speed trimmed to desired position by installing the “ tilt pin”in the de- 2. Generally increase top speed. sired tilt pin hole.
  • Page 46 ELECTRICAL IGNITION...
  • Page 47 Principle of Operation with Timing Protection Module (TPM) ... 2A-12 Mercury/Mariner 30/40 (2 cyl.) ADI Ignition System (With Electronic Spark Advance) ..2A-13 Principle Of Operation,...

  • Page 48: Specifications

    Specifications IGNITION Type Capacitor Discharge SYSTEM Spark Plug Type (NGK) BP8H-N-10 Spark Plug Gap 0.040 in. (1.0mm) Optional Plug (NGK) BPZ8H-N-10* Spark Plug Gap 0.040 in. (1.0mm) Firing Order TIMING Models With (S/N-0G589999 & Below) Idle 3 BTDC (Not SPECIFICATIONS Adjustable) Maximum BTDC @ 2500-5500 RPM (Not Adjust- 25 BTDC...

  • Page 49: Stator/Trigger (Electric Models)

    STATOR/TRIGGER (ELECTRIC MODELS) Loctite 222 (92-809818) 2A-2 - ELECTRICAL 90-826148R2 MARCH 1997...
  • Page 50 PLUG–Starter Handle GROMMET–Oil Tank PLUG–Primer Hole NUT (M6 x 1) WASHER SPACER WING NUT WASHER WASHER (Neoprene) COVER–Flywheel SCREW (M5 x 30) STATOR O RING (S/N-USA-0G589999/BEL-9973099 & BELOW) TRIGGER ASSEMBLY TRIGGER ASSEMBLY (S/N-USA-0G590000/BEL-9973100 & ABOVE) 90-826148R2 MARCH 1997 ELECTRICAL - 2A-3...

  • Page 51: Starter Motor Components

    Starter Motor Components Liquid Neoprene (92-25711--2) 2A-4 - ELECTRICAL 90-826148R2 MARCH 1997...
  • Page 52 Starter Motor Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m STARTER MOTOR THRU BOLT DRIVE KIT DRIVE ASSEMBLY DRIVE CAP ARMATURE COMMUTATOR CAP BRUSH & SPRING KIT BRUSH HOLDER SCREW LOCKWASHER NUT (1/4-20) BATTERY CABLE (5/16) (POSITIVE) SCREW (M8 x 45) 16.5 22.3...

  • Page 53: Electrical Components (S/N-0G380074/ Bel-Manual-9928507/Bel-Elec 9928480 & Below)

    ELECTRICAL COMPONENTS (S/N-0G380074/ BEL-MANUAL-9928507/BEL-ELEC-9928480 & Below) 20 21 Liquid Neoprene (92-25711--2) Loctite “222” Small Screw Threadlocker (92-809818) Note: Apply Liquid Neoprene to all ring eyelet wiring terminals. 2A-6 - ELECTRICAL 90-826148R2 MARCH 1997...
  • Page 54 ELECTRIC GROMMET SCREW (M6 x 25) NUT (8–32) CABLE (RED) ELECTRIC BATTERY CABLE (NEGATIVE) INSULATOR RETAINER STATOR (MANUAL) SCREW (M5 x 30) O RING TRIGGER HARNESS ASSEMBLY PLATE–Electrical BUSHING–Flanged GROMMET WASHER SCREW (M6 x 25) 11.3 SCREW (M6 x 14)
  • Page 55 ELECTRICAL (S/N-USA-0G380075 Thru 0G589999/ BEL-MANUAL-9928508/BEL-ELEC-9928481 THRU 9973099) NOTE: APPLY LIQUID NEOPRENE TO ALL RING END WIRING TERMINALS. 2A-8 - ELECTRICAL 90-826148R2 MARCH 1997...
  • Page 56 ELECTRICAL (S/N-USA-0G380075 THRU 0G589999/ BEL-MANUAL-9928508/BEL-ELEC-9928481 THRU 9973099) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (M5 x 30) MANUAL STATOR O RING TRIGGER SOLENOID ASSEMBLY BUSHING GROMMET NUT (8-32) SCREW (M6 x 25) ELECTRIC NUT (1/4-20) LOCKWASHER...
  • Page 57 ELECTRICAL COMPONENTS (S/N-USA-0G590000/ BEL-9973100 & Above) NOTE: APPLY LIQUID NEOPRENE TO ALL RING END WIRING TERMINALS. 2A-10 - ELECTRICAL 90-826148R2 MARCH 1997...
  • Page 58 ELECTRICAL COMPONENTS (S/N-USA-0G590000/BEL-9973100 & ABOVE) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (M5 x 30) STATOR MANUAL PLUG TRIGGER CABLE TIE (4 IN.) SOLENOID ASSEMBLY BUSHING GROMMET NUT (8-32) SCREW (M6 x 25) ELECTRIC NUT (1/4-20)

  • Page 59: Theory Of Operation

    Theory of Operation Ignition Component Description The ignition system is alternator-driven with distri- butor-less capacitor discharge. Major components of the ignition system are the flywheel, stator, trigger, timing protection module (TPM), capacitor discharge Principle of Operation with Timing modules (CDM) and spark plugs. Protection Module (TPM) The stator assembly is mounted stationary below the Under normal circumstances, the TPM controls:...
  • Page 60 Mercury/Mariner 30/40 (2 cyl.) ADI IGNITION SYSTEM (With Electronic Spark Advance) GRN/WHT BLK/YEL BLK/YEL Wires to Voltage Regulator WHT/BLK Power Acceleration Cylinder Supply Detector Control Timing Control Counter TAN/BLU Warning Speed Cylinder Circuit Limiter Control a - Battery Charging Coils (8)

  • Page 61: Timing Protection Module (Tpm)

    Principle Of Operation, CDM without Trigger Coil Timing Protection Module (TPM) One Piece assembly, containing two trigger coils-one for each cylinder located under flywheel. Is charged The ignition system is alternator-driven with distribu- by single magnet on flywheel hub. Trigger pulses are tor-less capacitor discharge.

  • Page 62: Theory Of Operation

    CAPACITOR CHARGING #1 CDM Theory of Operation The STATOR assembly is mounted to the block This outboard ignition system is alternator–driv- below the flywheel and has 3 CAPACITOR en (distributor–less) capacitor discharge sys- CHARGING COILS wound in series. The FLY- tem.

  • Page 63: Capacitor Charging #2 Cdm

    CAPACITOR CHARGING #2 CDM The flywheel rotates the permanent magnets past the capacitor charging coils–causing the coils to produce AC voltage (260–320 volts). The opposite voltage pulse is then conducted to the CAPACITOR DISCHARGE MODULES (CDM), where it is rectified (DC) and stored in a capacitor.

  • Page 64: Cylinder Trigger Circuit

    #1 Cylinder Trigger Circuit A positive voltage pulse (N–S) will activate the electronic switch (SCR) inside the capacitor dis- The TRIGGER assembly (also mounted under charge module (CDM). The switch discharges the flywheel) has one coil for each cylinder. the capacitor voltage through the coil primary These coils are mounted adjacent to the fly- windings.

  • Page 65: Ignition Coil Circuit

    Ignition Coil Circuit As the capacitor voltage flows through the pri- mary windings of the ignition coil, a voltage is in- duced into the ignition coil secondary windings. This secondary voltage rises to the level re- quired to jump the spark plug gap and return to ground.

  • Page 66: Stop Circuit

    Stop Circuit To stop the engine, the stop switch is closed al- lowing the capacitor charge current from the sta- tor to drain directly to ground. NOTE: The CDM contains a zener diode (not shown for clarity). This diode prevents overcharging of the capaci- tor (and possible failure) if the SCR does not re- ceive a trigger pulse.
  • Page 67 To bypass a CDM with a failed stator voltage NOTE 1: This test will work on 3 & 4 cylinder return path, install the DVA adaptor harness (to engines, however the number of CDM’s allow easy access to the wire connectors) and (cylinders) that function correctly will vary.

  • Page 68: Ignition Test Procedures

    – DO NOT CHANGE meter selector switch posi- Ignition Test Procedures tion while engine is running and/or being “cranked”. Direct Voltage Adapter (DVA) Test – ALL COMPONENTS MUST BE GROUNDED for Stator during tests. Running or “cranking” engine with TPM or CDM ungrounded may damage WARNING components.

  • Page 69: Ignition Diagnostic Procedures

    Ignition Diagnostic IMPORTANT: If outboard appears to have an igni- Procedures tion system failure, it is recommended that be- TROUBLESHOOTING TIP: With engine running, fore beginning in-depth troubleshooting: use inductive timing light to check spark advance of a. Check ground leads on Timing Protection each cylinder as throttle is opened and closed.

  • Page 70: Testing Ignition Components

    TRIGGER (S/N-0G589999 & BELOW) Testing Ignition Components A resistance check can be made on trigger coil be- tween WHITE/BLACK and WHITE leads. Ohmmeter Resistance Tests should indicate between 1100 - 1300 ohms. TIMING PROTECTION MODULE Normally, if timing advances and retards with corre- sponding changes in RPM, most likely the TPM is functioning correctly.

  • Page 71: Capacitor Discharge Module P/N822779 . 2A-24

    CAPACITOR DISCHARGE MODULE P/N822779 A resistance check can be made of the CDM as fol- lows: a - Test Harness P/N 91-825270A1 b - Capacitor Discharge Module P/N 822779 CAPACITOR DISCHARGE MODULE RESISTANCE CHECK-ANALOG METER Connect Positive (+) Connect Negative (–) Ohms Reading Meter Lead To:...
  • Page 72 Capacitor Discharge Module (P/N 827509) Ohms Test IMPORTANT: a - Spark Plug Wire Spark Plug Wires Are Screwed into CDM. b - Part Number: 827509 Date Code:0415 (Julian Date and Year: 5=1995) c - Pins are Labeled: A:Black - Ground B:Black/Yellow - Stop Circuit C:White - Trigger D:Green - Stator...
  • Page 73 CAPACITOR DISCHARGE MODULE RESISTANCE CHECK - DIGITAL METER Connect Positive (+) Connect Negative (–) Ohms Results: Meter Lead To: Meter Lead To: Scale Ground Pin (A)/ or Black White (C)/ or White Test Ω or 2K 1.125-1.375 KΩ Test Harness Lead Harness Lead Green (D)/ or Green Test Ground Pin (A)/ or Black...

  • Page 74: Ignition Components Removal

    5. Install Crankshaft Protector Cap (91-24161) on Ignition Components the end of crankshaft, then install Flywheel Puller Removal (91-73687A1) into flywheel. 6. Remove flywheel. NOTE: Neither heat or hammer should be used on Flywheel flywheel to aid in removal as damage to flywheel or 1.
  • Page 75 ELECTRICAL CHARGING & STARTING SYSTEM...
  • Page 76 Page Table of Contents Checking Positive Brushes and Terminals 2B-15 Page Testing Negative Brushes For Ground ..2B-15 Specifications ....... 2B-1 Brush Replacement .

  • Page 77: Specifications

    Specifications STARTING Manual Start Recoil SYSTEM Electric Start 12 Volt Starter Draw (Under Load) 95 Amperes (No Load) 20 Amperes CHARGING Alternator Output Single Phase (12 Pole) SYSTEM – Electric Start 14 Amperes @ 5000 RPM – Manual Start 9 Amperes @ 3000 RPM Special Tools Recommended Battery 1.

  • Page 78: Specific Gravity Readings

    4. Hold hydrometer vertically and draw in just Specific Gravity Readings enough liquid from battery cell so that float is free- Use a hydrometer (a) to measure specific gravity of floating. Hold hydrometer at eye level so that float electrolyte in each cell. is vertical and free of outer tube, then take read- ing at surface of liquid.

  • Page 79: Electrolyte Level

    DRY place. Remove battery from storage every ing situation: 30-45 days, check water level (add water if nec- essary), and put on charge for 5 or 6 hours at 6 1. Any battery may be charged at any rate (in am- amperes.

  • Page 80: Battery Charging System (14 Or 18 Ampere Alternator)

    Battery Charging System Battery Charging System (14 or 18 Ampere Alternator) Troubleshooting A fault in the battery charging system usually will Description cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See The battery charging system components are the “Electrolyte Level”, and “Charging a Discharged stator, voltage regulator and battery.

  • Page 81: Stator Ohms Test-Alternator Coils Only

    Stator Ohms Test-Alternator Coils 16 AMPERE STATOR (S/N-0G590000 & ABOVE) Only Test Leads Resistance Scale Reading (Ohms) (x−−−−) NOTE: Stator can be tested without removing from engine. Between YEL- .16 – .19* .16 – .19* LOW Leads (R x 1) 1.

  • Page 82: Alternator System Test

    Alternator System Test 5. If cranking voltage is acceptable, disconnect larger diameter RED harness wire from starter solenoid terminal. 9 AMPERE STATOR 6. Remove smaller diameter RED wire (sense lead) IMPORTANT: Rectifier (optional accessory) must from starter solenoid terminal and connect to the be functioning properly for accurate test results positive (+) terminal of a 9 volt transistor battery.
  • Page 83 10. A reading of 14 amperes at 5000 RPM indicates the charging system is functioning properly. The battery being discharged is due to the amperage draw on the system being greater than the am- perage output of the engine charging system. 11.

  • Page 84: Rectifier Test

    Rectifier Test WARNING Disconnect battery leads from battery before testing rectifier. NOTE: Rectifier can be tested without removing from engine. 1. Disconnect all wires from terminals on rectifier. 2. Use an ohmmeter (R x 1000 scale) and perform the following test. Refer to drawing for rectifier terminal identification.

  • Page 85: Voltage Regulator/Rectifier Test Models With (S/N-0G590000 & Above)

    VOLTAGE REGULATOR/RECTIFIER SCR TEST: TEST - Models with (S/N-0G590000 & 1. Set Ohm meter to R X 1k scale. Above) 2. Connect Red (+) meter lead to regulator case. NOTE: Voltage regulator/rectifier specifications are 3. Connect Black (–) meter lead to one YELLOW given for informational purposes only, use the ap- regulator Lead.

  • Page 86: Starting System

    - 12-Volt Supply The starter motor may be damaged if operated continuously. DO NOT operate continuously for more than 30 seconds. Allow a 2 minute cooling Troubleshooting the Starting Circuit period between starting attempts Before beginning the starting circuit troubleshooting...
  • Page 87 The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to trouble- shooting 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. (S/N-0G589999 &...
  • Page 88 * Battery Voltage 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. 12 Volt Reading* TEST 3 a.

  • Page 89: Starter Motor

    Disassembly Starter Motor 1. Remove two (2) thru bolts and commutator end Removal cap, taking care not to lose brush springs. CAUTION Disconnect battery leads from battery before re- moving starter. 1. Disconnect battery leads from battery. 2. Disconnect BLACK cable (w/YELLOW sleeve). 3.

  • Page 90: Cleaning And Inspection

    4. Remove components from armature. b. Clean the commutator slots after undercut- ting. c. De-burr the commutator lightly with No. 00 sandpaper, then clean the commutator. d. Check the armature on a growler for shorts. See “TESTING”, following. 9. Open-circuited armatures often can be saved where and open circuit is obvious and repairable.

  • Page 91: Armature Test For Ground

    ARMATURE TEST FOR GROUND TESTING NEGATIVE BRUSHES FOR GROUND 1. Set ohmmeter to (R x 1 scale). Place one lead of Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core (or shaft) and other ohmmeter on the negative brush and the other lead lead on commutator, as shown.
  • Page 92 Brush Replacement Reassembly IMPORTANT: Replace brushes that are pitted or 1. Lubricate helix threads and drive end cap bush- worn to less than 1/4 in. (6.4mm) in length ing with SAE 10W oil. 1. Install positive brushes into commutator end cap. 2.
  • Page 93 4. Construct a brush retainer tool as shown. 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. 11661 a - Brush Retainer Tool b - Bushing 7.
  • Page 94 Installation 1. Secure starter to block with three (3) bolts. Torque bolts to 16.6 lb. ft. (22.5 N·m). Secure NEGATIVE battery lead to block with bottom bolt. 2. Connect battery lead (BLACK w/YELLOW sleeve) to starter. Torque attaching nut to 60 lb. in.
  • Page 95 ELECTRICAL TIMING, SYNCHRONIZING & ADJUSTING...
  • Page 96 Table of Contents Page Specifications ....... 2C-1 Special Tools ....... 2C-1 Tiller Handle Model (S/N-0G589999 &...
  • Page 97 Specifications Idle RPM (In Forward Gear) 700-800 RPM Full Throttle RPM Range - - Model 30, 40 Sea Pro, 40 Marathon 4500-5500 RPM - - Model 40 5000-5500 RPM Spark Plug Type (NGK) BP8H-N-10 SPECIFICATIONS 0.040 in. (1.0mm) Optional Plug (NGK)** BPZ8H-N-10* 0.040 in.

  • Page 98: Tiller Handle Model (S/N-0G589999 & Below)

    Tiller Handle Model 5. Tighten throttle cable jam nuts. (S/N-0G589999 & Below) 1. With engine off and gear shift in neutral position, loosen cam follower screw. 2. Back off idle speed screw until the throttle shutter positioner does not touch the taper of idle speed screw.

  • Page 99: Timing Adjustments

    16. Re-adjust idle speed screw in “ FORWARD”gear to specification. Timing Adjustments NOTE: No timing adjustments are required for the 30/40 model outboard with (S/N-0G589999 & Be- low). a - Carburetor b - Mixture Screw 90-826148R2 MARCH 1997 ELECTRICAL - 2C-3...

  • Page 100: Tiller Handle Model With Mechanical Spark Advance (S/N-0G590000 & Above)

    Tiller Handle Model with 6. Tighten throttle cable jam nuts. Mechanical Spark Advance (S/N-0G590000 & Above) 1. Check all electrical connections to ensure they are tight and secure (including battery connec- tions on electric start models). 2. With engine off and gear shift in neutral position, loosen cam follower screw.

  • Page 101: Timing And Maximum Spark Advance Adjustments - Mechanical Spark Advance Models

    8. With throttle at idle position, turn idle speed screw WARNING clockwise “ IN”until a gap of 0.005 in. - 0.040 in. (0.13 mm - 1.02 mm) is achieved between throttle Keep clear of propeller while cranking and run- cam and cam follower. This will open the throttle ning the outboard motor.

  • Page 102: Adjusting Maximum Spark Advance

    ADJUSTING MAXIMUM SPARK ADVANCE 21. Adjust carburetor for best performance, after clearing the engine. With engine running at idle IMPORTANT: Setting the idle timing is required speed in “ FORWARD”gear, turn mixture screw before adjusting the maximum spark advance. “ IN” (clockwise) until engine starts to loose 16.

  • Page 103: Throttle Cable Installation

    Throttle Cable Installation 3. Push-in on the cable end until resistance is felt. Adjust the cable barrel (b) to attain the measured 1. Position remote control into neutral. distance “ a”taken in Step 2. 4. Place cable barrel into the bottom hole in the bar- rel holder.

  • Page 104: Oil Pump Adjustment

    Oil Pump Adjustment 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to acti- While holding throttle arm at idle position, adjust vate the throttle linkage. Make sure to rotate length of link rod so the stamped mark of oil pump the propeller shaft while shifting into reverse.
  • Page 105 ELECTRICAL WIRING DIAGRAMS...
  • Page 106 30/40 Electric Start / Tiller Handle Ignition Diagram (S/N 0G380074 & Below) ..2D-3 30/40 Electric Start / Tiller Handle Ignition Diagram (S/N 0G380075 Thru S/N 0G589999) 2D-4 30/40 Electric Start Ignition Diagram (S/N 0G380074 & Below) .

  • Page 107: 30/40 Manual Start Ignition Diagram (S/N 0G380074 & Below)

    30/40 Manual Start Ignition Diagram (S/N 0G380074 & Below) 52618 BLK = Black 1 - Engine Temperature Sensor BLU = Blue 2 - Timing and Protection Module (TPM) BRN = Brown 3 - Trigger GRY = Gray 4 - Stator...

  • Page 108: 30/40 Manual Start Ignition Diagram (S/N 0G380075 Thru S/N 0G589999)

    30/40 Manual Start Ignition Diagram (S/N 0G380075 Thru S/N 0G589999) GRN/WHT WHITE BLK/YEL BLACK BLACK BLK/YEL WHT/BLK GRN/WHT GRN/WHT WHT/BLK BLK/YEL BLACK BLACK YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW GRN/WHT GRN/WHT BLACK WHT/GRN WHT/GRN GRN/WHT WHT/BLK GRN/WHT WHITE WHT/BLK WHT/BLK...

  • Page 109: 30/40 Electric Start / Tiller Handle Ignition Diagram (S/N 0G380074 & Below)

    30/40 Electric Start / Tiller Handle Ignition Diagram (S/N 0G380074 & Below) 1 - Engine Temperature Sensor 2 - Timing and Protection Module (TPM) 3 - Trigger 4 - Stator 5 - Starter 6 - Starter Relay 7 - 12VDC Battery...

  • Page 110: 30/40 Electric Start / Tiller Handle Ignition

    30/40 Electric Start / Tiller Handle Ignition Diagram (S/N 0G380075 Thru S/N 0G589999) GRN/WHT WHITE BLK/YEL BLACK BLACK BLK/YEL WHT/BLK GRN/WHT GRN/WHT WHT/BLK BLK/YEL BLACK BLACK YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW GRN/WHT GRN/WHT BLACK WHT/GRN WHT/GRN GRN/WHT WHT/BLK GRN/WHT...

  • Page 111: 30/40 Electric Start Ignition Diagram (S/N 0G380074 & Below)

    30/40 Electric Start Ignition Diagram (S/N 0G380074 & Below) 52905 1 - Engine Temperature Sensor 2 - Timing and Protection Module (TPM) 3 - Trigger 4 - Stator 5 - Starter BLK = Black 6 - Starter Relay BLU = Blue...

  • Page 112: 30/40 Electric Start Ignition Diagram (S/N 0G380075 Thru S/N 0G589999)

    30/40 Electric Start Ignition Diagram (S/N 0G380075 Thru S/N 0G589999) GRN/WHT WHITE BLK/YEL BLACK BLACK BLK/YEL WHT/BLK GRN/WHT GRN/WHT WHT/BLK BLK/YEL BLACK BLACK YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW GRN/WHT GRN/WHT BLACK WHT/GRN WHT/GRN GRN/WHT WHT/BLK GRN/WHT WHITE WHT/BLK WHT/BLK...

  • Page 113: 30/40 Manual Start / Tiller Handle Ignition Diagram (S/N-0G590000 & Above)

    30/40 Manual Start / Tiller Handle Ignition Diagram (S/N-0G590000 & Above) BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan...

  • Page 114: Electric Start Tiller Handle Ignition Diagram

    30 Electric Start Tiller Handle Ignition Diagram (S/N-0G590000 & Above) BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan...

  • Page 115: 30/40 Electric Start Ignition Diagram (S/N-0G590000 & Above)

    30/40 Electric Start Ignition Diagram (S/N-0G590000 & Above) BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White...

  • Page 116: 30/40 Electric Start / Power Trim Ignition Diagram (S/N-0G590000 & Above)

    30/40 Electric Start / Power Trim Ignition Diagram (S/N-0G590000 & Above) BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan...

  • Page 117: 14 Ampere Stator Charging Diagram

    14 Ampere Stator Charging Diagram BLK = Black GRY = Gray RED = Red YEL = Yellow RED SLEEVE a - Stator/Alternator Assembly b - Voltage Regulator c - 20 Amp Fuse d - Starter Solenoid e - Gray Wire to Tachometer 90-826148R2 MARCH 1997 ELECTRICAL - 2D-11...

  • Page 118: 14 Ampere Stator Charging Diagram With Battery Isolator

    14 Ampere Stator Charging Diagram With Battery Isolator BLK = Black GRY = Gray RED = Red YEL = Yellow 51930 Stator/Alternator Assembly Gray Wire to Tachometer Voltage Regulator Battery Isolation 20 Amp Fuse To Engine Harness Starter Solenoid 2D-12 - ELECTRICAL 90-826148R2 MARCH 1997...

  • Page 119: Commander 2000 Side Mount Remote Control (Electric Start With Warning Horn) Wiring Diagram

    Commander 2000 Side Mount Remote Control (Electric Start With Warning Horn) 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...

  • Page 120: Commander 3000 Panel Mount Control

    Commander 3000 Panel Mount Control RED = Red YEL = Yellow Neutral Interlock Switch 2D-14 - ELECTRICAL 90-826148R2 MARCH 1997...

  • Page 121: Commander 2000 Key Switch Test

    Commander 2000 Key Switch Test Disconnect remote control wiring harness and instrument panel connector. Set ohmmeter on R x 1 scale for the following tests: BLK = Black PUR = Purple RED = Red YEL = Yellow CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: POSITION BLK/YEL YEL/RED...

  • Page 122: Instrument Wiring Connections

    Instrument Wiring Connections Without Light Switch NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK TO THE HAR- NESS. Speedometer Tachometer Temperature/Oil Warning Panel Volt Meter TAN/WHT TAN/BLK 51820 a - Tachometer Receptacle-From Control Box or Ignition/ Wire Where To Choke Switch...

  • Page 123: Instrument/Lanyard Stop Switch Wiring Diagram 2D-17

    Instrument/Lanyard Stop IMPORTANT: On installations where gauge options will not be used, tape back any unused Switch Wiring Diagram wiring harness leads. BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red...

  • Page 124: Engine Synchronizer Wiring Diagram-Commander Gauges

    Engine Synchronizer Wiring Diagram-Commander Gauges Wiring Diagram -- Gauge needle to point toward slow running engine. TACHOMETER TACHOMETER STARBOARD ENGINE PORT ENGINE SYNCHRONIZER GAUGE BATT BATT SENDER SENDER STARBOARD PORT SYNCHRONIZER Wiring Diagram -- Gauge needle to point toward fast running engine. TACHOMETER TACHOMETER STARBOARD ENGINE...

  • Page 125: Notes

    Notes: 90-826148R2 MARCH 1997 ELECTRICAL - 2D-19...

  • Page 126: Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)

    Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK = Black BLU = Blue BRN = Brown BATT GRY = Gray GRN = Green SENDER ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...
  • Page 127 IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused wiring harness leads. BATT SENDER STARBOARD INSTALLATION 52654 k - Lanyard/Diode n - Connect Wires Together with Screw and Hex Nut (4 Places);Apply Quicksilver Liquid Neoprene to Connections l - “...

  • Page 128: Qsi Gauge Wiring Diagrams

    QSI Gauge Wiring Diagrams Water Temperature Gauge WIRING DIAGRAM A Tachometer Wiring Diagram Use this wiring diagram when using a separate light switch for instrument lighting. Tachometer dial on back side of case must be set to position number 4. +12 Volt Position Light Bulb to the Light Switch...

  • Page 129: Engine Synchronizer Wiring Diagram

    Route TAN lead on starboard side of engine to engi- LIGHT BULB POSITION B ne/remote control harness. Connect as shown. Use this position when instrument lighting is wired di- IMPORTANT: Tape back and isolate any unused rectly to the ignition key switch. (Instrument lights are wiring harness leads.

  • Page 130: Cleaning Gauges

    Wiring Diagram - - Gauge needle to point toward fast running engine Tachometer Tachometer Synchronizer Starboard Engine Port Engine Gauge Synchronizer 52565 CLEANING GAUGES Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with a soft cloth moistened with water.
  • Page 131 FUEL SYSTEM FUEL PUMP...
  • Page 132 Table of Contents Page Specifications ....... 3A-1 Fuel Pump (Manual) .

  • Page 133: Specifications

    Specifications Fuel Pump Pressure: @ 5000 RPM 4.0 - 7.0 PSI @ 750 RPM 2.5 - 4.0 PSI Electric fuel pump pressure, if used, must be lim- ited to no more than 6.0 PSI. 90-826148R2 MARCH 1997 FUEL SYSTEM - 3A-1...

  • Page 134: Fuel Pump (Manual)

    FUEL PUMP (MANUAL) Perfect Seal (92-34227-1) A = TO CARBURETOR B = TO INTAKE MANIFOLD C = TO CRANKCASE 3A-2 - FUEL SYSTEM 90-826148R2 MARCH 1997...
  • Page 135 FUEL PUMP (MANUAL) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m FUEL PUMP ASSEMBLY DIAPHRAGM KIT RUBBER CHECK VALVE CHECK VALVE RETAINER SPRING SPRING GASKET--Boost GASKET DIAPHRAGM GASKET--Pulse BASE PLATE SCREW--pump to crankcase (M6 x 1 x 50) SCREW--pump FITTING PRIMER BULB...

  • Page 136: Fuel Pump (Electric)

    FUEL PUMP (ELECTRIC) 22 23 Perfect Seal (92-34227-1) A = TO OIL PUMP B = TO MANIFOLD C = TO CRANKCASE D = TO TEE 3A-4 - FUEL SYSTEM 90-826148R2 MARCH 1997...
  • Page 137 FUEL PUMP (ELECTRIC) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m FUEL PUMP ASSEMBLY DIAPHRAGM KIT RUBBER CHECK VALVE CHECK VALVE RETAINER SPRING SPRING GASKET--Boost GASKET DIAPHRAGM GASKET--Pulse BASE PLATE SCREW--pump to crankcase (M6 x 1 x 50) SCREW--pump (M5 x .8 x 40) FITTING CLAMP...

  • Page 138: Theory Of Operation

    Theory of Operation Checking For Restricted Fuel Flow Caused By Anti-siphon Valves The fuel pump is a crankcase-pressure-operated, di- aphragm-type pump. Crankcase pulsating pressure While anti-siphon valves are helpful from a safety is transferred by way of a passage (hole) from the stand-point, they clog, they may be too small, or they crankcase to the fuel pump.

  • Page 139: Testing

    Testing PROBLEM: LACK OF FUEL PUMP PRESSURE Possible Cause Corrective Action Install clear fuel hose(s) between fuel pump and car- buretor(s). Run engine, and inspect hose(s) for air Anti-siphon valve. Refer to “ Checking for bubbles. If air bubbles are found, see “ Air Bubbles in Restricted Fuel Flow Fuel Line”.

  • Page 140: Reassembly

    Reassembly 3. With retainer installed in pump body, break re- tainer rod (a) from retainer (b) by bending side- ways. Check Valve Assembly 1. Insert retainer (a) thru plastic disc (b) and rubber check valve (c). 23601 a - Retainer Rod b - Retainer 23601 4.
  • Page 141 FUEL SYSTEM CARBURETOR...
  • Page 142 Table of Contents Page Specifications ......3B-1 WME Carburetor Specifications ..3B-1 Jet Orifice Size Chart .

  • Page 143: Specifications

    Specifications Idle RPM 700 - 800 RPM (In Forward Gear) Wide Open Throttle (W.O.T.) RPM - Model 30/40 Marathon/40 Seapro 4500 - 5500 RPM - Model 40 5000 - 5500 RPM Idle Mixture Screw Adjustment (Preset-Turns Out) 1-1/2 Float Level 9/16 in.

  • Page 144: Jet Orifice Size Chart

    Jet Orifice Size Chart Special Tools NOTE: Thread size for jets is 10-32. P/N 91-36392 Carburetor Scale Jet Orifice Part Size-inches Number 0.040 19266040 0.042 1399-5315 0.044 1395-7394 0.046 1399-5317 0.048 1395-6246 73656 0.050 1395-6028 0.052 1395-6359 0.054 1399-5225 0.056 1399-5213 0.058 1395-7831...

  • Page 145: Notes

    Notes: 90-826148R2 MARCH 1997 FUEL SYSTEM - 3B-3...

  • Page 146: Carburetor

    CARBURETOR Loctite 271 (92-809820) 3B-4 - FUEL SYSTEM 90-826148R2 MARCH 1997...
  • Page 147 N·m CARBURETOR (MANUAL – 40) (WME 66) CARBURETOR (ELECTRIC – 40) (WME 67) CARBURETOR (MANUAL – 30) (WME 63) CARBURETOR (ELECTRIC/ELECTRIC HANDLE – 30) (WME 64) CARBURETOR (ELECTRIC HANDLE – 30)(WME 65) RETAINING RING LEVER–Oil (ELECTRIC) SCREW–Lever Retainer...

  • Page 148: Fuel System Fuel Flow

    Fuel System Fuel Flow MANUAL START MODELS NOTE: The manual starting primer bulb is designed WARNING to provide a rich fuel mixture to the engine during cold start conditions. When the primer bulb is pressed in, All safety precautions should be adhered to fuel is forced from the primer bulb into the intake when testing the primer bulb system.

  • Page 149: Electric Start Models

    Fuel System Fuel Flow ELECTRIC START MODELS 90-826148R2 MARCH 1997 FUEL SYSTEM - 3B-7...

  • Page 150: Electric Start Tiller Handle Models

    Fuel System Fuel Flow ELECTRIC START TILLER HANDLE MODELS 3B-8 - FUEL SYSTEM 90-826148R2 MARCH 1997...

  • Page 151: Carburetor Adjustments

    Carburetor Float Adjustment Carburetor Adjustments Remove carburetor as outlined in “Carburetor Removal,” following. Initial Starting Adjustment Remove fuel bowl and gasket and check float lev- Turn idle mixture screw adjustment “in” (clockwise) el using a carburetor scale. until it seats lightly then, back off 1-1/2 turns. Idle Speed Adjustment 9/16 in.

  • Page 152: Main (High Speed) Jet Adjustment

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

  • Page 153: Rejetting Carburetors For High Altitude Operation

    Rejetting Carburetors For High Alti- tude Operation The carburetor jet installed at the manufacturer is for engine operation at sea level through an elevation of 2500 feet (762m) above sea level. If the engine is to be operated at an altitude higher than 2500 feet above sea level, it will be necessary to rejet (remove the carburetor jets and install jets with a different ori- fice size) the carburetors.

  • Page 154: Fuel System Troubleshooting

    Fuel System Propeller Troubleshooting Spark Plugs Ignition Timing General Information Ignition Spark Voltage Problems that are thought to be caused by the fuel Cylinder Compression system may, in reality, be something completely dif- Reed Valves ferent. Items, that are shown in the list on the right, could give the impression that there is a problem in Typical symptoms and solutions in troubleshooting a the fuel system...
  • Page 155 Possible Cause Corrective Action Improperly mixed fuel. Contaminants(water, dirt, Check fuel in tank and replace if necessary. etc.) in fuel. Fuel tank air vent closed or restricted. Check air vent on tank. Vent must be open all-the- way and free from any contaminants. A pinched, cut or restricted fuel line.
  • Page 156 Problem: Engine Floods Possible Cause Corrective Action Dirt or debris are preventing inlet needle from seat- Flush out inlet seat and clean inlet needle. ing. Worn inlet needle. Replace Punctured float Replace. Incorrect float setting Reset float. Problem: Engine Runs Too Rich Possible Cause Corrective Action Fuel level too high.

  • Page 157: Enrichener System Electric Start Models

    The enrichener system is pressurized by squeezing Enrichener System the fuel line primer bulb or by the fuel pump when the (Electric Start Models) engine is being cranked. When the ignition key is turned to the “on” position and pushed in (and held The enrichener system provides the engine with ex- in), current is sent to the valve causing it to open, tra fuel charge for ease of starting cold engine.

  • Page 158: Enrichener Valve Test

    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 Click Check for battery voltage to YELLOW/BLACK wire at Squeeze primer bulb until bulb is firm. Remove lower hose terminal block on engine when key (or choke button) is from fitting on enrichener valve.
  • Page 159 FUEL SYSTEM OIL INJECTION...
  • Page 160 Table of Contents Page Specifications ......3C-1 Oil Injection Components ....3C-2 Oil Injection Components .

  • Page 161: Specifications

    TC-W III 2- Cycle Outboard Oil Oil Tank Capacity/Approx. Time 50.5 fl. oz. (1.5 Liters) Oil Injection 4.7 Hours @ 5250 RPM Reserve Capacity/Approx. Time 30 Minutes @ 5250 Output w/Pump @ Full Open 8.5cc/10 Minutes @ 900 RPM 90-826148R2 MARCH 1997...

  • Page 162: Oil Injection Components

    Oil Injection Components 2-4-C With Teflon (92-825407A12) 3C-2 - OIL INJECTION SYSTEM 90-826148R2 MARCH 1997...

  • Page 163: Oil Injection Components

    Oil Injection Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m BUSHING-Flanged GROMMET OIL TANK ASSEMBLY CAP ASSEMBLY GASKET RETAINER NUT-Push VENT ASSEMBLY VALVE STA-STRAP CLAMP TUBING (4-3/4 IN.) ELBOW TUBING (1-1/4 IN.) GROMMET SPACER SWITCH SCREW (.164-18 x .375) WASHER TUBING (10”...

  • Page 164: Theory Of Operation

    The crankshaft driven oil pump is a variable ratio (200cc) of oil remains in the reservoir. This will pro- oil pump which provides an oil/fuel mixture of vide approximately 30 minutes of wide open throttle 100:1 @ idle and 60:1 @ WOT. running before oil is depleted.

  • Page 165: Oil Injection Flow System(Variable Ratio Oil Pump) S/N-0G589999 & Below

    Oil Injection Flow System (Variable Ratio Oil Pump) S/N-0G589999 & Below 52881 a - Fuel Pump f - Vent b - Fuel Filter g - Fill Cap c - Check Valve (2 PSI) h - Oil Level Sight Gauge d - Carburetor i - Fuel Line Connector e - Oil Pump 90-826148R2 MARCH 1997...

  • Page 166: Oil Injection Flow System (Variable Ratio Oil Pump) S/N-0G590000 & Above

    Oil Injection Flow System (Variable Ratio Oil Pump) S/N-0G590000 & Above a - Fuel Pump f - Vent b - Fuel Filter g - Fill Cap 52881 c - Check Valve (2 PSI) h - Oil Level Sight Gauge d - Carburetor i - Fuel Line Connector e - Oil Pump 3C-6 - OIL INJECTION SYSTEM...

  • Page 167: Pump Drive Assembly (Variable Ratio Oil Pump)

    Pump Drive Assembly (Variable Ratio Oil Pump) 52044 a - Oil Pump b - O-Ring (2) c - Driven Gear d - Drive Gear e - Crankshaft 52897 a - Oil Inlet Adjustments b - Bleed Screw c - Oil Outlet d - Oil Pump Carburetor/Oil Pump Synchroniza- tion...

  • Page 168: Troubleshooting

    Troubleshooting Oil Pump Volume (Flow) Test WARNING Bleeding Air From Oil Injection The input fuel line TEE fitting from which the oil System line was removed MUST BE CAPPED OFF to pre- vent fuel leakage while the engine is running. CAUTION NOTE: The following specifications are determined with the outboard running off a remote fuel supply...
  • Page 169 POWERHEAD...
  • Page 170 Thermostat Cover Installation ... . 4-30 30/40 Bleed Hose Routing ....4-31 Powerhead Installation .

  • Page 171: Specifications

    Specifications Type 2 Cyl. Loop Charged BLOCK Displacement 39.3 cu. in. (644.4cc) REED VALVE OPENING Opening (Max. Allowable) 0.020 in. (0.50mm) STROKE Length 2.796 in. (71.0mm) Dia. Standard 2.993 in. (76.0mm) CYLINDER BORE Taper/Out of Round Max 0.003 in. (0.08mm) PISTON Dia.

  • Page 172: Special Tools

    Special Tools 9. Universal Puller Plate 91-37241 1. Lifting Eye 91-90455 2. Flywheel Holder 91-52344 10. Snap Ring Pliers 91-24283 73790 3. Flywheel Puller 91-73687A1 11. Piston Lock Ring Installer 91-77109A1 4. Powerhead Stand 91-827001A1 12. Torque Wrench (0-200 lb. ft.) 91-32610* 13.

  • Page 173: Notes

    Notes: 90-826148R2 MARCH 1997 POWERHEAD - 4-3...

  • Page 174: Cylinder Block Components

    Cylinder Block Components 43 44 Loctite “ RCA/680”Retaining Compound Loctite Pipe Sealant with Teflon (592) (92-809833) 2 Cycle Outboard Oil (92-13249A24) Loctite “ 518”Master Gasket (92-12564-2) Perfect Seal (92-34227-1) 2-4-C With Teflon (92-825407A12) 4-4 - POWERHEAD 90-826148R2 MARCH 1997...
  • Page 175 Cylinder Block Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m CYLINDER BLOCK PIPE PLUG (1/8 Hex Head-Brass) ROLL PIN (Used on models prior to 1998) SCREW (M8 x 80 Hex flange head) 16.5 22.4 CARRIER ASSEMBLY CHECK VALVE CHECK VALVE FITTING (BARBED-ELECTRIC)

  • Page 176: Induction Manifold

    INDUCTION MANIFOLD Loctite 680 (92-809833) A = TO BASE OF OIL PUMP 4-6 - POWERHEAD 90-826148R2 MARCH 1997...
  • Page 177 STUD (M6 x 1 x 44) STUD (M6 x 1 x 55)(STUD ATTACHING) SCREW (M6 x 40)(SCREW ATTACHING) TUBING (12 1/2 IN.) SCREW (M8 x 30) (S/N-OG380075/ 16.5 22.4 BEL-9905361 & UP) SCREW (M8 x 1.25 x 25 Hex flange head) 16.5...

  • Page 178: Crankshaft/Piston/Flywheel

    CRANKSHAFT/PISTON/FLYWHEEL 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) 4-8 - POWERHEAD 90-826148R2 MARCH 1997...
  • Page 179 CRANKSHAFT/PISTON/FLYWHEEL TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m NUT (M16 x 1.5) WASHER FLYWHEEL (ELECTRIC) S/N-USA-0G590000/BEL-9973100 & ABOVE FLYWHEEL (MANUAL) FLYWHEEL(ELECTRIC)S/N-US-0G589999/BEL-9973099 & BELOW FLYWHEEL (MANUAL) CRANKSHAFT ASSEMBLY GEAR ASSEMBLY (DRIVER) BALL BEARING RETAINING RING ROLLER BEARING ASSEMBLY OIL SEAL BEARING ASSEMBLY--Center main ROLLER...

  • Page 180: Torque Sequence

    Torque Sequence Powerhead Removal 1. Disconnect battery leads from battery (if applica- ble). Intake Manifold Bolts 2. Remove spark plug leads from spark plugs. Torque bolts to 16.5 lb. ft. (22.4 N· m). 3. Disconnect remote control harness from engine (if applicable) - or lanyard and stop button/horn wiring on manual models.
  • Page 181 11. Thread lifting eye at least 5 turns into flywheel. WARNING DO NOT leave powerhead suspended from hoist. Powerhead should be installed on a suitable stand or lowered to floor upon removal from drive shaft housing to avoid personal injury or damage to product.

  • Page 182: Crankshaft Disassembly

    Crankshaft Disassembly NOTE: Refer to appropriate sections in service manual for removal of individual fuel and electrical 1. Remove center main bearing. sub-assemblies from powerhead. Component/Assembly Section Starter Motor Ignition Switch Box Ignition Coil Starter Solenoid Voltage Regulator/Rectifier Flywheel Stator Assembly Trigger Assembly Air Silencer Carburetor and Linkage...

  • Page 183: Crankshaft Inspection

    Crankshaft Inspection CAUTION · Inspect crankshaft to drive shaft splines for wear. Removal of lower crankshaft bearing will dam- (Replace crankshaft, if necessary.) age bearing and will require replacement. · Check crankshaft for straightness [(0.003 in. 4. Inspect lower bearing for roughness and exces- (0.076mm) maximum].

  • Page 184: Piston And Connecting Rod Disassembly

    Piston and Connecting Rod CAUTION Disassembly Safety glasses should be worn when removing or installing lock rings. 1. Remove piston rings. Always install new piston 3. Remove piston pin lock rings using awl. Always rings. install new lock rings. 52680 a - Piston Ring Expander (P/N 91-24697) 52679 4.

  • Page 185: Connecting Rods

    Connecting Rods 5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping. Spalling will 1. Check connecting rods for alignment by placing be most evident on the thrust portion of the rods on a surface plate. If light can be seen under connecting rod in line with the “...

  • Page 186: Cleaning And Inspection

    Cleaning and Inspection 7. Uneven Wear: Uneven wear could be caused by a bent connecting rod. Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are matched, line-bored assembly should not be mismatched by using a different crank- case cover or cylinder block.

  • Page 187: Cylinder Bores

    0.015 in. (0.381mm) oversize Stroke at a rate of 30 complete cycles per or re-sleeve and install oversize piston(s) and minute to produce best cross-hatch pattern.

  • Page 188: Pistons And Piston Rings

    IMPORTANT: Ports must be deburred after hon- CLEANING PISTON RING GROOVES ing. Keystone (tapered) ring grooves NOTE: The weight of an oversize piston is approxi- CAUTION mately the same as a standard size piston; therefore, it is not necessary to re-bore all cylinders in a block Care must be taken not to scratch the side sur- just because one cylinder requires re-boring.

  • Page 189: Check Valve

    Check Valve Thermostat NOTE: Check valve can be replaced by removing in- Wash thermostat with clean water. Using a thermo- take manifold when powerhead is attached to drive- stat tester, similar to the one shown, test thermostat shaft housing. as follows: The check valve is a 3/16 in.

  • Page 190: Reed Blocks

    - Reed (2 Sets) c - Retaining Washer (40 HP Only) d - Tab Washer e - Bolt f - Reed Stop (30 HP Only) IMPORTANT: Do not “flop”(reverse) the reed pet- als for additional use - replace reed when neces- sary.

  • Page 191: Powerhead Reassembly And Installation

    Powerhead Reassembly and REASSEMBLY S/N 0G380074 & BELOW If reed block was disassembled, reassemble by lo- Installation cating reeds on pins with retaining washer. Using new tab washer, insert bolt and torque to 60 lb. in. General Information (6.8 N· m); then, if necessary, continue the torque to align flat on hex-head to locking tab (e).

  • Page 192: Assembling Rod To Piston

    Assembling Rod to Piston 3. Place locating rings on connecting rod, carefully place piston over end of rod. Refer to scribed identification number for matching rod to piston CAUTION and direction of assembly (which side of rod is DO NOT intermix new needle bearings with used “...

  • Page 193: Piston Ring Installation

    6. Install new piston pin lock rings (each side of pis- NOTE: Shaft of Lock ring Installation Tool ton) using Lockring Tool (91-77109A1). 91-77109A1 must be modified (shortened) to 1.050 in. (26.7 mm). 7. Make sure lockrings are properly seated in piston grooves.
  • Page 194 1. Install piston ring in appropriate groove on piston 4. Remove connecting rod cap from connecting rod using Piston Ring Expander Tool. Spread rings being installed. just enough to slip over piston. 5. Install each piston with “ UP”identification facing 2.

  • Page 195: Crankshaft Installation

    Crankshaft Installation CAUTION 1. If lower bearing and gear were removed from Safety glasses should be worn when removing or crankshaft, slide gear in place (note keyway and installing ring seal. key in gear to crankshaft assembly). Install bear- 3. Install ring seal to crankshaft. ing to crankshaft using an arbor press and suit- able mandrel.

  • Page 196: Installing Rods To Crankshaft

    Installing Rods to Crankshaft IMPORTANT: Snap ring groove faces up towards flywheel. 1. Oil rod and bearing cage with 2-cycle oil. 5. Attach main bearing races with holes towards 2. Pull rod into place and install bearing cages as lower gear end of crankshaft. Secure each main shown.

  • Page 197: Connecting Rod Cap Alignment

    Connecting Rod Cap Alignment Crankcase Cover to Block 1. Check each connecting rod for correct alignment 1. Install upper seal on crankshaft and seat seal by carefully running fingernails up and down against bearing w/lips facing bearing. edge of rod cap. If not aligned, a ridge can be seen or felt at the separating line.
  • Page 198 3. Install end cap assembly (lubricate seals with 5. Insert clean bolts and finger tighten. 2-cycle engine oil) to block. Apply Perfect Seal to IMPORTANT: Torque crank case cover bolts flange of end cap (a). FIRST before torquing end cap cover bolts. 6.

  • Page 199: Intake/Reed Block Manifold Installation

    Intake/Reed Block Manifold 3. Install reed block manifold and intake manifold with gasket to cylinder block. Installation S/N 0G380074 & Below 1. Place engine on repair stand or on bench. NOTE: Powerhead repair stand 91-827001A1 can be used. 2. Install check valve/holder. S/N 0G380075 &...

  • Page 200: Thermostat Cover Installation

    Torque bolts to 16.5 lb. ft. (22.4 N· m). ELECTRIC MODELS 1994 THRU 1997 ALL MODELS 1998 AND ABOVE 52653 MANUAL MODELS 1994 THRU 1997 52890 52652 a - Plug - Apply Loctite Pipe Sealant with Teflon (592) to Threads 4-30 - POWERHEAD 90-826148R2 MARCH 1997...

  • Page 201: 30/40 Bleed Hose Routing

    30/40 Bleed Hose Routing 52882 a - Check Valves IMPORTANT: If engine smokes excessively at idle and/or runs rough (chugs) at off-idle when acceler- ating, inspect check valves in bleed hoses for proper functioning. Check valves should flow in one direction only.

  • Page 202: Powerhead Installation

    Powerhead Installation 1. Thread lifting eye at least 5 turns into flywheel. The following components/assemblies can be installed prior to installation of powerhead on drive- shaft housing: Component/Assembly Section Starter Motor Capacitor Discharge Module Starter Solenoid Voltage Regulator/Rectifier Flywheel Stator Assembly Trigger Assembly Air Silencer Carburetor and Linkage...

  • Page 203: Test Run Procedure

    Break-in Procedure 6. Install upper drive shaft housing cover and se- cure cover with bolt, nut and flat washer. CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. MODELS WITH OIL INJECTION Engine Break-in Fuel Mixture Use a 50:1 (2%) gasoline/oil mixture in the first tank of fuel.
  • Page 204 MID-SECTION CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING...
  • Page 205 Table of Contents Page Notes: ........5A-1 Clamp Bracket Components .

  • Page 206: Notes

    Notes: 90-826148R2 MARCH 1997 MID-SECTION - 5A-1...

  • Page 207: Clamp Bracket Components

    Clamp Bracket Components Loctite “ 271”Adhesive Sealant (92-809819) 2-4-C With Teflon (92-825407A12) 5A-2 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 208: Clamp Bracket Components

    Clamp Bracket Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m CLAMP BRACKET (BLACK) PORT SHORT CLAMP BRACKET (GRAY) 1 lower mounting hole CLAMP BRACKET (BLACK) PORT LONG CLAMP BRACKET (GRAY) 3 lower mounting holes CLAMP BRACKET (BLACK) STBD.

  • Page 209: Swivel Tube Components

    Swivel Tube Components Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 5A-4 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 210: Swivel Tube Components

    Swivel Tube Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SWIVEL TUBE HEAD (BLACK) SWIVEL TUBE HEAD (GRAY) HANDLE -Carrying (BLACK) HANDLE -Carrying (GRAY) TAB WASHER SCREW (M10 x 45 Hex head cap) 43.4 NUT (.375-24) LEVER-Co-pilot WASHER ROD (THREADED)

  • Page 211: Swivel Bracket Components

    Swivel Bracket Components Loctite “ 242”Removable Threadlocker (92-809821) 2-4-C With Teflon (92-825407A12) Tighten nut until it seats and then back off 1/4 turn. Tighten nut to 32 lb. ft. (43.4 N· m) and then back off 1/4 turn. 5A-6 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 212: Swivel Bracket Components

    Swivel Bracket Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m LINK ROD SCREW (1-1/2 IN.) 27.1 WASHER WASHER NUT (.375-24) PUCK-Co-pilot (NON HANDLE MODELS) SWIVEL BRACKET ASSEMBLY (BLACK) SWIVEL BRACKET ASSEMBLY (GRAY) BUSHING (UPPER) GREASE FITTING BUSHING (LOWER) SEAL GREASE FITTING...

  • Page 213: Drive Shaft Housing Components

    Drive Shaft Housing Components 41 42 Loctite “ RCA/680”Retaining Compound (92-809833) 5A-8 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 214: Drive Shaft Housing Components

    Drive Shaft Housing Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SCREW (M8 x 1.25 x 55) 16.5 22.4 GROMMET-Water Tube CLAMP-Water Tube SEAL-Water Tube WATER TUBE (SHORT) WATER TUBE (LONG) EXHAUST TUBE SCREW (M8 x 1.25 x 45) 16.5 22.4 GASKET-Drive Shaft Housing...

  • Page 215: Driveshaft Housing Components

    Driveshaft Housing Components 44 45 41 42 Loctite “ RCA/680”Retaining Compound (92-809833) Torque the rear TOP and then the BOTTOM lower mount bolt/nut first; then torque the FRONT bolt/nut. After torquing the front bolt/nut, retorque the rear top and bottom bolt/nut. 5A-10 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 216: Driveshaft Housing Components

    Driveshaft Housing Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SEAL-Exhaust Bucket EXHAUST BUCKET BUMPER-Trim Cover SEAL-Exhaust Tube SEAL-Idle Relief SCREW (M10 x 110) 39.3 DRIVESHAFT HOUSING (SHORT-BLACK) DRIVESHAFT HOUSING (SHORT-GRAY) DRIVESHAFT HOUSING (LONG-BLACK) DRIVESHAFT HOUSING (LONG-GRAY) STUD (M10 x 1.5 x 50) (SHORT/LONG) STUD (M10 x 1.5 x 114) (X-LONG) SCREW (M8 x 1.25 x 120)

  • Page 217: Drive Shaft Housing Disassembly/Reassembly

    Drive Shaft Housing WARNING Disassembly/Reassembly Failure to support outboard as shown could re- sult in personal injury and/or damage to out- Servicing components such as steering arm, drive board or boat. shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal.
  • Page 218 MID SECTION POWER TRIM...
  • Page 219 Disassembly ......5B-30 Shock Rod Removal ....

  • Page 220: Special Tools

    Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Expanding Rod P/N CG 41-11 4. Collet P/N CG 41-14 90-826148R2 MARCH 1997 MID-SECTION - 5B-1...

  • Page 221: Power Trim Components

    POWER TRIM COMPONENTS Liquid Neoprene (92-25711--2) Power Trim and Steering Fluid (92-90100A12) 5B-2 - MID-SECTION 90-826148R2 MARCH 1997...
  • Page 222 POWER TRIM TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m POWER TRIM ASSEMBLY (S/N-USA-0G124404/BEL-9948794 & BELOW) POWER TRIM ASSEMBLY (S/N-USA-0G124405/BEL-9948795 & ABOVE) – O RING KIT SHOCK ROD ASSY. (S/N-USA-0G124404/BEL-9948794 & BELOW) SHOCK ROD ASSY. (S/N-USA-0G124405/BEL-9948795 & ABOVE) PILOT CHECK ASSEMBLY 13.6 TILT RELIEF VALVE ASSEMBLY...

  • Page 223: Power Trim Mounting

    POWER TRIM MOUNTING 5B-4 - MID-SECTION 90-826148R2 MARCH 1997...
  • Page 224 POWER TRIM MOUNTING TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m PIN–anchor (14MM) BUSHING BUSHING WASHER SCREW (M10 x 40) WASHER SCREW (10-16 x .38) DRIVE TIGHT C WASHER CLIP 90-826148R2 MARCH 1997 MID-SECTION - 5B-5...

  • Page 225: Theory Of Operation

    Theory Of Operation WARNING The Power Trim system consists of an electric motor, Excessive engine trim angle will result in insuffi- pressurized fluid reservoir, pump and trim cylinder. cient water supply to water pump causing water pump and/or powerhead overheating damage. The remote control (or trim panel) is equipped with a Make sure that water level is above gear housing switch that is used for trimming the outboard “up”...

  • Page 226: Trailering Outboard

    Trailering Outboard Trim “In” Angle Adjustment WARNING WARNING Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to cient water supply to water pump causing water the full “in” trim angle at planing speed will cause pump and/or powerhead overheating damage.

  • Page 227: Power Trim Flow Diagrams

    POWER TRIM FLOW DIAGRAMS TRIM UP Reservoir and Feed Oil Oil Under Pressure Return Oil Up Pressure 2530 psi (min) a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve...
  • Page 228 TRIM UP When the trim switch is activated in the up position, the electric motor (a) begins to rotate the pump gears (n), the oil pump draws a small amount of oil through the filter, up circuit pick–up and past the feed valve check ball (o).

  • Page 229: Tilt Up

    TILT UP Reservoir and Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 500–600 psi a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...
  • Page 230 TILT UP In the up mode, as the trim rod (b) extends from the cylinder, the memory piston (e) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and open the tilt pressure re- lief valve (k).

  • Page 231: Maximum Tilt

    MAXIMUM TILT Reservoir and Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 500–600 psi a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...
  • Page 232 MAXIMUM TILT With the cylinder at maximum travel, and due to no ram movement, the pressure inside of the trim cylin- der will increase to the pressure required to move the tilt relief actuator (i). The tilt relief actuator’s ”pin” opens the tilt relief valve (k).
  • Page 233 TRIM DOWN Reservoir and Feed Oil Oil Under Pressure Return Oil Down Relief 500–800 psi a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...

  • Page 234: Down Mode

    DOWN MODE When the trim switch is activated in the down posi- tion, the electric motor (a) will rotate the pump (n) in the opposite direction. With the pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter, past the feed check ball (m), into the down circuit oil pick–up and finally into the oil pump.

  • Page 235: Shock Function Up

    SHOCK FUNCTION UP Reservoir and Feed Oil Oil Under Pressure Return Oil 1550–1850 psi a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...
  • Page 236 SHOCK FUNCTION UP Oil inside the down cavity is locked in a static position by the closed pressure operated valve (h), the manu- al release valve (j) and the tilt relief valve (k). If the outboard strikes an underwater object while in for- ward gear the trim ram (b) will try to rapidly extend from the cylinder , the pressure increases inside the trim cylinder down cavity and connecting passages.

  • Page 237: Shock Function

    SHOCK FUNCTION RETURN Reservoir and Feed Oil Oil Under Pressure Return Oil a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston r - Check Ball...
  • Page 238 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 (e) and shock piston (d) to the level required to open the shock return valve (v), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity.

  • Page 239: Manual Tilt

    MANUAL TILT Reservoir and Feed Oil Return Oil q r w a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston r - Check Ball...
  • Page 240 MANUAL TILT To manually tilt the outboard engine, the owner will need to back out the manual tilt valve (j). With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities to- gether, along with the reservoir (t), allowing the en- gine to be raised or lowered.

  • Page 241: Troubleshooting

    Follow preliminary checks before proceeding to trou- Troubleshooting bleshooting flow diagrams (following). Support outboard with tilt lock pin when servicing power trim system. Preliminary Checks IMPORTANT: After debris or failed components have been found (during troubleshooting proce- IMPORTANT: Operate Power Trim system after dure) it is recommended that unit be disas- each check to see if problem has been corrected.

  • Page 242: Hydraulic System Troubleshooting Flow Chart

    Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION Manual release Manual release valve and Inspect manual release valve valve and O-ring O-rings appear to be O.K. damaged Clean and reinstall manu- al release valve Trim will not hold Replace manual release...

  • Page 243: Hydraulic System Troubleshooting Flow Chart

    Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage Suction seat assembly Debris and/or damage appears O.K. - Clean and identified reinstall suction seat as- sembly Replace suction seat Trim will not hold assembly Trim system holds reverse thrust...

  • Page 244: Hydraulic System Troubleshooting Flow Chart

    Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED Manual release Inspect manual release valve Manual release valve and O- valve and O-ring rings appear to be O.K. - Clean damaged and reinstall manual release valve Replace manual re- Trim...

  • Page 245: Hydraulic System Troubleshooting Flow Chart

    Hydraulic System Troubleshooting Flow Chart continued Inspect memory piston O-ring cylinder bore Cylinder bore appears Cylinder bore appears rough and/or debris smooth with no debris found in cylinder Replace memory pis- Trim leaks down ton and shock piston O-rings Trim system does leak down: Testing complete...

  • Page 246: Troubleshooting The Power Trim Electrical System

    Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch (Remote Control (Panel Mounted) Mounted) BLU/WHT Fuse Holder GRN/WHT BLU/WHT or PUR GRN/WHT or GRN Remote Control Fuse Holder RED/PUR – RED/PUR Battery Starter Bolt GRN/WHT Solenoid BLU/WHT Down Relay LT.

  • Page 247: Troubleshooting The Power Trim Electrical System

    Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inopera- 1. Open wire between Wire Connection (1) 1. Check for a open connection or cut tive, but the Cowl Switch “UP”...

  • Page 248: Power Trim System Removal

    3. Remove the trilobe pin. Power Trim System Removal 4. Drive out the upper pivot pin. 1. Tilt outboard to the full up position and support with tilt lock pin. a - Tilt Lock Pin 2. Disconnect the power trim wire harness and re- move clamps.

  • Page 249: Disassembly

    1. Remove reservoir cap. 2. Remove manual release valve assembly. a - Reservoir Cap b - Manual Release Valve 3. Drain power trim fluid as shown. 5B-30 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 250: Shock Rod Disassembly

    4. Secure power trim assembly in a soft jaw vise. Shock Rod Disassembly 5. Unscrew end cap assembly from cylinder using NOTE: The only serviceable items on the shock rod spanner wrench 91-74951. assembly are the o-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
  • Page 251 3. Remove check ball components from shock rod CAUTION piston. When removing shock piston, spanner wrench 4. Remove o-ring from shock rod piston. 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).

  • Page 252: Memory Piston Removal

    10. Remove inner o-ring from shock rod piston. Memory Piston Removal 15. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or suitable tool. 51199 a - Shock Piston b - O-ring 11.

  • Page 253: Trim Motor Removal

    16. Remove o-ring from memory piston. Trim Motor Removal 1. Secure power trim assembly in soft jawed vise. 2. Remove screws securing trim motor to manifold. 3. Remove motor assembly. a - O-ring a - Trim Motor b - Screw (4) 5B-34 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 254: Oil Pump Removal

    Oil Pump Removal Tilt Relief Valve Removal NOTE: The following procedures requires the use of 1. Remove oil filter and pump from manifold. a Snap-On blind hole removal tool #CG-4111 with IMPORTANT: DO NOT disassemble the oil pump. 5/16” attachment #41-12. Or a removal tool can be The pump is not serviceable.

  • Page 255: Suction Seat Removal

    1. Unscrew plug from manifold and remove spring Suction Seat Removal and poppet assembly. 1. Unscrew plug from manifold and remove ball. NOTE: Do not lose shim that may be lodged in the 2. Use a pin punch and knock the filter and suction plug.

  • Page 256: Cleaning/Inspection/Repair

    3. Use the (.060 wire) removal tool (see previous Cleaning/Inspection/Repair page) and push out the spool and one seat. IMPORTANT: Components must be dirt and lint 4. From opposite side, use a punch and push out free. Slightest amount of debris in Power Trim the remaining seat.

  • Page 257: Reassembly

    Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-827668A1 5B-38 - MID-SECTION 90-826148R2 MARCH 1997...

  • Page 258: O-Ring And Seal Placement

    O-Ring and Seal Placement O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Actuator Pin 0.07 in. (1.78 mm) 0.21 in. (5.33 mm) 0.07 in. (1.78 mm) Tilt Relief Cartridge 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm) Tilt Relief Cartridge 0.301 in.

  • Page 259: Power Trim Reassembly

    Suction Seat Reassembly Power Trim Reassembly 1. Lubricate O-rings with power trim fluid. IMPORTANT: Lubricate all O-rings with Quicksil- ver Power Trim Fluid (92-90100A12). If not avail- 2. Install filter and suction seat using a 9/32” or 7 able, use automotive (ATF) automatic transmis- mm socket on OUTSIDE diameter of suction sion fluid.

  • Page 260: Pilot Check Valve Reassembly

    Pilot Check Valve Reassembly Oil Pump Reassembly 1. Lubricate o-rings with power trim fluid. 1. Install the down relief ball and spring into man- ifold. 2. Install one of the seats into manifold. Push the seat into place using a 9/32” or 7 mm socket on 2.

  • Page 261: Trim Motor Reassembly

    Trim Motor Reassembly Shock Rod Reassembly 1. Align coupler between oil pump and motor. 1. Install lubricated o-rings to end cap. 2. Install trim motor and secure with four (4) screws. 2. Install rod wiper. Torque screws to 80 lb. in. (9.0 N·m). 51145 a - Rod Wiper b - Inner O-ring...
  • Page 262 4. Clamp shock rod in soft jawed vise. 9. Remove shock rod assembly from vise. 5. Position cylinder end cap onto rod as shown. 10. Install ball, seat, and spring (five sets) to shock rod piston. 51147 51146 CAUTION a - Spring (5) When installing shock rod piston, spanner b - Seat (5) c - Ball (5)

  • Page 263: Shock Rod Installation

    Shock Rod Installation Manual Release Valve Installation 1. Place trim cylinder in soft jawed vice. 1. Install “E” clip (if removed) and lubricate O-Rings with power trim fluid. 2. Install lubricated o-ring to memory piston and place into cylinder. Push memory piston all the 2.

  • Page 264: Power Trim System Installation

    4. Install sacrificial anode to clamp brackets. Fasten Power Trim System ground strap between anode and clamp bracket. Installation Torque bolts to 60 lb. in. (6.8 N m). 1. Lubricate lower pivot pin, mounting holes and bushings with 2-4-C Marine Lubricant. 2.
  • Page 265 7. Secure upper pivot pin with trilobe pin. Press tri- 11. Secure wire harness with clamps as shown. lobe pin in until its fully seated. a - Trilobe Pin 8. Re-connect trim wire harness leads (see wiring diagram Section 2D for proper connections). 9.
  • Page 266 MID-SECTION GAS ASSIST MANUAL TILT...
  • Page 267 Table of Contents Page Notes: ....... . 5C-1 Clamp Bracket (Gas Assist Trim) .

  • Page 268: Notes

    Notes: 90-826148R2 MARCH 1997 MID-SECTION - 5C-1...

  • Page 269: Clamp Bracket (Gas Assist Trim)

    CLAMP BRACKET (GAS ASSIST TRIM) Loctite “ 271”Adhesive Sealant (92-809819) 2-4-C w/Teflon (92-825407A12) 5C-2 - MID-SECTION 90-826148R2 MARCH 1997...
  • Page 270 CLAMP BRACKET (GAS ASSIST TRIM) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m CLAMP BRACKET (BLACK) PORT CLAMP BRACKET (GRAY) CLAMP BRACKET (BLACK) STARBOARD CLAMP BRACKET (GRAY) THUMB SCREW ASSEMBLY HANDLE RIVET MANUAL WASHER SCREW (Hex shoulder) ANODE WASHER SCREW (M6 x 25)

  • Page 271: Hydraulic Assist Adjustments

    Hydraulic Assist Manual Trim System Adjustments Removal 1. Tilt outboard to the full up position and support WARNING with tilt stop pin. This hydraulic assist system’ s contents are un- der pressure. Do not puncture disassemble or apply heat or flame. IMPORTANT: If debris or leaking is found, unit must be replaced This hydraulic assist system is NOT SERVICEABLE.

  • Page 272: Manual Trim System Installation

    Manual Trim System 4. Disconnect link rod from cam lever. 5. Remove tilt lock pin. Remove nuts and washers Installation securing the lower pivot pin. Remove anode bolt to remove ground strap. Remove lower anchor 1. Apply 2-4-C Marine Lubricant (92-90018A12) to pin.
  • Page 273 3. Apply 2-4-C Marine Lubricant (92-90018A12) to surface of upper pivot pin, pivot hole and shock rod hole. 4. Position trim into position and drive pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket. Drive trilobe pin into its hole until seated.
  • Page 274 LOWER UNIT...
  • Page 275 Trim Tab Adjustment and Replacement ..6-29 Propeller Installation ....6-30 6-0 - LOWER UNIT 90-826148R2 MARCH 1997...

  • Page 276: Specifications

    Specifications Gear Ratio 2.00:1 Gearcase Capacity 14.9 fl. oz. (440 mL) Lubricant Type Quicksilver Gear Lube Premium Blend Forward Gear Number Of Teeth Type Spiral/Bevel Pinion Gear Number Of Teeth Type Spiral/Bevel Pinion Height No Adjustment Forward Gear Backlash No Adjustment Reverse Gear Backlash No Adjustment Water Pressure...

  • Page 277: General Service Recommendations

    General Service Roller bearing condition is determined by inspecting the surface of the shaft that the roller bearing sup- Recommendations ports. Check shaft surface for pitting scoring, groov- ing, imbedded particles, uneven wear and/or discol- There may be more than one way to “ disassemble” oration from overheating.

  • Page 278: Special Tools

    Special Tools 4. Bearing Puller Tool 91-27780 1. Bearing 31-85560 54978 2. Driver 91-13779 5. Mandrel 91-36571 6. Universal Puller Plate 91-37241 3. Bearing Puller & Installation Tool 91-31229A7 a. Nut 11-24156 b. Washer (2) 12-34961 7. Driver Head 91-37312 c.
  • Page 279 9. Driver Rod 91-37323 12. Driver 91-817007 13. Mandrel 91-825198 14. Pilot 91-825199 10. Drive Shaft Holding Tool 91-825196 15. Spring Hook 91-825200A1 11. Mandrel 91-825197 16. Driver 91-826872 17. Leakage Tester FT8950 6-4 - LOWER UNIT 90-826148R2 MARCH 1997...

  • Page 280: Notes

    Notes: 90-826148R2 MARCH 1997 LOWER UNIT - 6-5...

  • Page 281: Gear Housing Components (Drive Shaft)

    Gear Housing Components (Drive Shaft) Loctite “ 271”Adhesive Sealant (92-809819) Loctite 405 (Obtain Locally) Super Duty Gear Lubricant (92-13783A24) 2-4-C With Teflon (92-825407A12) 6-6 - LOWER UNIT 90-826148R2 MARCH 1997...
  • Page 282 Gear Housing Components (Drive Shaft) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m GEAR HOUSING (SHORT-BLACK) GEAR HOUSING (LONG-BLACK) GEAR HOUSING (X-LONG-BLACK) GEAR HOUSING (SHORT-GRAY) GEAR HOUSING (LONG-GRAY) GEAR HOUSING (X-LONG-GRAY) GEAR HOUSING (BASIC-BLACK) GEAR HOUSING (BASIC-GRAY) SEAL/PLATE KIT PLATE (Part Of Ref #2) SCREW (.375-16 x .25)

  • Page 283: Gear Housing Components (Propeller Shaft)

    Gear Housing Components (Propeller Shaft) Loctite “ 271”Adhesive Sealant (92-809819) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6-8 - LOWER UNIT 90-826148R2 MARCH 1997...
  • Page 284 Gear Housing Components (Propeller Shaft) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m GEAR HOUSING (SHORT-BLACK) GEAR HOUSING (LONG-BLACK) GEAR HOUSING (X-LONG-BLACK) GEAR HOUSING (SHORT-GRAY) GEAR HOUSING (LONG-GRAY) GEAR HOUSING (X-LONG-GRAY) GEAR HOUSING (BASIC-BLACK) GEAR HOUSING (BASIC-GRAY) DOWEL PIN GASKET Water Tube TUBE...

  • Page 285: Draining And Inspecting Gear Lubricant

    Draining and Inspecting Propeller Removal Gear Lubricant WARNING WARNING If gear housing is not removed from outboard, before attempting to remove or install the propel- If gear housing is installed on outboard, discon- ler, remove (and isolate) spark plug leads from nect (and isolate) spark plug leads from spark spark plugs to prevent outboard from starting.

  • Page 286: Gear Housing Removal

    Gear Housing Removal 4. Make a scribe line showing alignment of trim tab to gear case and remove trim tab bolt and wash- WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs before removing gear housing. 1.
  • Page 287 6. Remove 4 bolts securing gear case to drive shaft 8. Remove cover, washer (above impeller), impel- housing. ler, key and washer (below impeller). 9. Remove cover gasket, base plate and base gas- ket. 52836 a - Bolt (4) NOTE: If water tube seal remained in drive shaft housing, remove seal from housing and reinstall on water pump cover.
  • Page 288 10. Remove and/or replace exhaust deflector plate if NOTE: When removing propeller shaft assembly, damaged. cam follower may dislodge. Retrieve follower from gear housing 13. Remove propeller shaft assembly. 52832 52864 a - Exhaust Deflector Plate a - Propeller Shaft 11.
  • Page 289 16. Remove FORWARD gear. 18. Insert pinion bearing race PULLER (91-825200A1) through gear case and position inside of pinion bearing race. Insert DRIVER (91-13779) into puller through drive shaft cavity and drive out race. 52870 a - Forward Gear 52844 a - Puller (91-825200A1) 17.

  • Page 290: Water Pump Seals

    Water Pump Seals 3. With lip of ribbed neoprene O.D. seal facing to- wards small shoulder of Mandrel (91-825197), NOTE: All gaskets, seals and o-rings should be re- press seal into carrier until mandrel bottoms on placed as a normal repair procedure during gear carrier.

  • Page 291: Inspection

    Inspection Pinion Gear Bearing 1. Inspect bearing for rust, roughness or discolor- ation from lack of lubricant. Upper Drive Shaft Bearing 2. If bearing is damaged, bearing and race must be 1. Inspect bearing for rust, roughness or discolor- replaced as an assembly. ation from lack of lubricant.
  • Page 292 c. Shifting too slowly. 4. Use a suitable mandrel to press needle bearing out of forward gear. 52874 3. Inspect propeller shaft forward gear bearing sur- face to determine condition of forward gear needle bearing. If bearing surface is discolored 52873 (from lack of lubricant), pitted or worn, propeller a.

  • Page 293: Shift Shaft

    Shift Shaft 6. Inspect forward gear tapered bearing and race for rust, roughness or excessive wear (loose- 1. Inspect shift cam for wear or galling. Replace ness). cam if necessary. 7. If bearing is in serviceable condition, DO NOT re- 2.

  • Page 294: Propeller Shaft Disassembly

    Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disas- semble shaft. a - Prop Shaft b - Retaining Spring c - Clutch Dog d - Cross Pin 52877 e - Cam Follower Spring f - Cam Follower Propeller Shaft and Carrier 2.

  • Page 295: Reverse Gear

    Reverse Gear 4. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing 1. Inspect reverse gear teeth for rust, chipping ex- bearing. cessive wear (teeth are sharped edged) or bro- ken teeth. 2. Inspect reverse gear clutch jaws for wear. Rounded jaws indicate the following: a.

  • Page 296: Bearing Carrier

    Bearing Carrier 4. Apply a light coat of Special Lubricant 101 (92-13872A1) to O.D. of bearing. NEEDLE BEARING Install bearing using Mandrel 91-817011. 1. The condition of the carrier needle bearing can 6. Press bearing into carrier until mandrel bottoms be determined by inspecting its running surface on carrier.

  • Page 297: Gear Housing Reassembly

    Gear Housing Reassembly 9. Apply Loctite 271 to O.D. of large diameter seal. 10. With seal lip FACING TOWARDS SMALL IMPORTANT: The 30/40 gear case assembly does SHOULDER of Mandrel 91-817007, press seal not have have any shims for the gear assemblies.

  • Page 298: Pinion Bearing Race

    Pinion Bearing Race 5. Position shift shaft so ramp faces towards propel- ler shaft. 1. Apply Super Duty Gear Lubricant (92-13783A24) to O.D. of race. 2. Position race in gear housing (NUMBERS UP - TAPERED SIDE FACING DOWN). 3. Draw race up into housing until seated. 52841 a - O-rings b - Carrier...

  • Page 299: Forward Gear

    Forward Gear Pinion Gear/Drive Shaft Assembly 1. Apply Super Duty Gear Lubricant to O.D. of race. 1. Clean pinion nut and pinion nut threads of drive Install forward gear bearing race into housing us- shaft with Loctite Primer T (92-59327-1). ing Mandrel 91-36571 and propeller shaft.

  • Page 300: Propeller Shaft

    Propeller Shaft 6. Install cam follower. 1. Slide clutch (SHORT SHOULDER FACES FOR- WARD GEAR) over propeller shaft aligning cross pin hole with slot in propeller shaft. 2. Insert cam follower spring into propeller shaft. 3. Using a 3/16 in. Allen wrench or similar device, compress the follower spring enough to insert the cross pin partially through clutch.

  • Page 301: Water Pump

    Water Pump 4. Install impeller and nylon washer. 1. Install water pump seal carrier. 2. Install exhaust deflector plate, if removed. 52832 a - Seal Carrier b - Exhaust Deflector 52869 3. Install base gasket, base plate, pump cover gas- a - Impeller ket (NEOPRENE STRIP FACES UP), nylon b - Nylon Washer...

  • Page 302: Gear Housing Pressure Test

    Gear Housing Pressure Test Gear Housing Installation Remove vent plug and install pressure test gauge. Filling Gear Housing with Lubricant Tighten securely. NOTE: Gear housing lubricant capacity is approxi- mately 14.9 fl. oz. (440 ml). WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller.

  • Page 303: Installing Gear Housing To Drive Shaft Housing

    Installing Gear Housing to Drive 6. Install 4 bolts and washers, (two each side). Torque bolts to 40 lb. ft. (54.2 M· m). Shaft Housing WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto drive shaft housing. 1.

  • Page 304: Trim Tab Adjustment And Replacement

    Trim Tab Adjustment and 8. Install locknut and washer. Torque nut to 40 lb. ft. (54.2 N· m). 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 (cor- rosion and pitting of metal surfaces).

  • Page 305: Propeller Installation

    However, the pro- peller itself should not move fore-and-aft on the propeller shaft. 3. Re-check propeller nut for tightness after first use. Check for tightness periodically, especially if a stainless propeller is used. 6-30 - LOWER UNIT 90-826148R2 MARCH 1997...
  • Page 306 ATTACHMENTS/CONTROL LINKAGE THROTTLE/SHIFT LINKAGE...
  • Page 307 Table of Contents Page Notes: ....... . 7A-1 Throttle Linkage Components (S/N-0G589999 &...

  • Page 308: Notes

    Notes: 90-826148R2 MARCH 1997 ATTACHMENTS/CONTROL LINKAGE - 7A-1...

  • Page 309: Throttle Linkage Components (S/N-0G589999 & Below)

    Throttle Linkage Components (S/N-0G589999 & Below) Loctite 680 (Obtain Locally) Loctite “ 222”Small Screw Threadlocker (92-809818) Loctite “ 242”Removable Threadlocker (92-809821) 2-4-C With Teflon (92-825407A12) 7A-2 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997...
  • Page 310 Throttle Linkage (S/N-0G589999 & Below) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m BUMPER-Throttle Stop WASHER BUMPER-Throttle Stop LEVER-Throttle Control BALL-Threaded BUSHING KIT INSERT SCREW (M10 x 45) 16.7 22.6 NUT (M6) Drive Tight - But Joint Must Move Freely WASHER RETAINER...
  • Page 311 THROTTLE LINKAGE (S/N-0G590000 & Above) Loctite 222 (92-809818) Loctite 242 (92-809821) 2-4-C With Teflon (92-825407A12) 7A-4 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997...

  • Page 312: Throttle Linkage (S/N-0G590000 & Above)

    THROTTLE LINKAGE (S/N-0G590000 & ABOVE) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m BUMPER--Throttle Stop WASHER BUMPER--Throttle Stop LEVER--Throttle Control BALL--Threaded BUSHING KIT INSERT SCREW (M10 x 45) 16.7 22.6 Drive Tight -- NUT (M6) But Joint Must Move Freely WASHER RETAINER...

  • Page 313: Bottom Cowl/Shift Components

    Bottom Cowl/Shift Components Loctite “ 222”Small Screw Threadlocker (92-809818) 2-4-C With Teflon (92-825407A12) 7A-6 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997...

  • Page 314: Bottom Cowl/Shift Components

    SPRING-Backing PLATE SCREW (M5 x 14) STRAP-Horizontal Shift Shaft SCREW (M6 x 1 x 16) 11.3 CLAMP-Horizontal Shift Shaft SCREW (M6 x 1 x 30) 11.3 SWITCH SCREW (M3 x .5 x 20) Drive Tight PLATE-Switch CAP-Intermediate Lever SCREW (M6 x 16) 11.3...

  • Page 315: Bottom Cowl/Shift Components

    Bottom Cowl/Shift Components Loctite “ 222”Small Screw Threadlocker (92-809818) 2-4-C With Teflon (92-825407A12) 7A-8 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997...

  • Page 316: Bottom Cowl/Shift Components

    Bottom Cowl/Shift Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m PLUG-Stop Switch RETAINER STOP SWITCH LANYARD STOP SWITCH GROMMET SWITCH (ELECTRIC HANDLE) SEAL-Throttle Cable SEAL-Throttle Cable BOTTOM COWL (BLACK) BOTTOM COWL (GRAY) PLUG-Shift Lever SHIFT HANDLE GROMMET GROMMET (SPLIT - POWER TRIM) PLUG-Warning Alarm (ELECTRIC)
  • Page 317 ATTACHMENTS/CONTROL LINKAGE TILLER HANDLE...
  • Page 318 Table of Contents Page Notes: ....... . 7B-1 Tiller Handle Components .

  • Page 319: Notes

    Notes: 90-826148R2 MARCH 1997 ATTACHMENTS/CONTROL LINKAGE - 7B-1...

  • Page 320: Tiller Handle Components

    Tiller Handle Components 2-4-C With Teflon (92-825407A12) 7B-2 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997...

  • Page 321: Tiller Handle

    Tiller Handle TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m COVER KIT PULLEY CASE (Part of Ref #1) SCREW (10-16 x 1/2”Self Tap) CABLE--Throttle CABLE--Throttle SLEEVE--Insulation SCREW (M8 x 1.25 Hex flange head) 16.5 22.4 COVER--Side (BLACK) COVER--Side (GRAY) BUSHING ARM--Steering Handle (BLACK)

  • Page 322: Adjustments Tiller Handle Model (S/N-0G589999 & Below)

    Adjustments 5. Tighten throttle cable jam nuts. Tiller Handle Model (S/N-0G589999 & Below) 1. With engine off and gear shift in neutral position, loosen cam follower screw. 2. Back off idle speed screw until the throttle shutter positioner does not touch the taper of idle speed screw.

  • Page 323: Adjustments Tiller Handle Model With Mechanical Spark Advance (S/N-0G590000 & Above)

    Adjustments 5. Tighten throttle cable jam nuts. Tiller Handle Model with Mechanical Spark Advance (S/N-0G590000 & Above) 1. With engine off and gear shift in neutral position, loosen cam follower screw. 2. Back off idle speed screw until the throttle shutter positioner does not touch the taper of idle speed screw.
  • Page 324 MANUAL STARTER...
  • Page 325 Table of Contents Page Notes: ....... . Manual Start Components .

  • Page 326: Notes

    Notes: 90-826148R2 MARCH 1997 MANUAL STARTER - 8-1...

  • Page 327: Manual Start Components

    Manual Start Components 2-4-C With Teflon (92-825407A12) 8-2 - MANUAL STARTER 90-826148R2 MARCH 1997...

  • Page 328: Manual Start Components

    Manual Start Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SEAL-Handle rest NUT (M6 x 1) WASHER SPACER-Handle rest REST-Starter Handle HANDLE-Starter RETAINER WING NUT 10.2 WASHER GROMMET BUSHING GROMMET WASHER RECOIL STARTER (S/N-USA-0G239163/BEL-9864479 & BELOW) RECOIL STARTER (S/N-USA-0G239164/BEL-9864480 &...

  • Page 329: Rewind Starter Disassembly

    Rewind Starter Disassembly Remove cam retainer. WARNING When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. Untie knot in starter rope and release starter rope to allow rewind spring to unwind. Remove retaining clip and attaching screw which secures shift interlock cable to starter housing.

  • Page 330: Cleaning And Inspection

    Cleaning and Inspection Remove starter sheave. Clean components in solvent and dry with com- pressed air. Inspect rewind spring for kinks, burrs, corrosion of breakage. Inspect starter sheave, rope guide and starter housing for nicks, grooves, cracks, wear or dis- tortion, especially area of rope travel.
  • Page 331 Install starter sheave to housing and secure in 4. Position cam lever spring into recess of starter place with screw. Torque to 135 lb. in. (15.3 N· m). housing and re-install cam lever. 51605 a - Starter Sheave b - Screw 28375 a - Cam Lever Install interlock lever.

  • Page 332: Adjusting Rewind Spring Tension

    Adjusting Rewind Spring Starter Interlock Cable Tension Adjustment Rotate sheave counterclockwise until it stops IMPORTANT: Lubricate core wire of interlock (coil is bound). Then back off one full turn, plus cable with light oil prior to making adjustments. what is needed to align rope end with hole in 1.

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