Mercury 75 Service Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Outboard Motor
  5. 75
  6. Service manual

Mercury 75 Service Manual

Hide thumbs Also See for 75:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
Table of Contents

Advertisement

Quick Links

Download this manual See also: Operation & Maintenance Manual, User Manual
SERVICE
Printed in U.S.A.
MANUAL
75 75 MARATHON 75 SEA PRO
90 100 115 125 65/80 JET
United States
Belgium
1997, Mercury Marine
MODELS
With Serial Numbers
. . .
0D283222 and Above
. . . . . . . .
09793577 and Above
90-830234R3 DECEMBER 1997

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 75 and is the answer not in the manual?

Questions and answers

Villy Solvang
March 13, 2025

Hei I have alarm going on my Optimax 75 I have mounted an smart craft and The alarm says: Pilot water pressure. Can it be the sensor that is wrong?? I have messured the water outlet to 4 liter pr min. at idle and 6,5liter pr min at 1800 - 2000 RPM. If I have to change the sensor, where is it located? Hope you can give me a good answer, and advise what I shoould do. Thank you.

0

Related Manuals for Mercury 75

Summary of Contents for Mercury 75

  • Page 1 SERVICE MANUAL MODELS 75 75 MARATHON 75 SEA PRO 90 100 115 125 65/80 JET With Serial Numbers United States . . . 0D283222 and Above Belgium ..09793577 and Above 1997, Mercury Marine 90-830234R3 DECEMBER 1997 Printed in U.S.A.
  • 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 dealers’ mechanics and company service per-...

  • Page 3: How To Use This Manual

    Whenever components are removed for service, How To Use This Manual they should be retained in order. At the time of instal- The manual is divided into SECTIONS (shown, right) lation, they should be installed in the same locations which represents major components and systems. and with the same mating surfaces as when re- moved.
  • Page 4 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 5 IMPORTANT INFORMATION 52485 SPECIFICATIONS...
  • Page 6 Table of Contents Page Master Specifications ..... 1A-1 1A-0 - IMPORTANT INFORMATION 90-830234R3 DECEMBER 1997...
  • Page 7 Master Specifications Model 65/80 Jet/75/90/100/115/125 HORSEPOWER Model 75 75 (55.9) (KW) Model 65 Jet/90 90 (67.1) Model 100 100 (74.6) Model 80 Jet/115 115 (85.8) Model 125 125 (93.2) OUTBOARD Model 65 Jet 315 lbs. (143kg) WEIGHT Model 75/90 305 lbs. (139kg) Model 80 Jet 357 lbs.
  • Page 8 - Commercial 75 Recoil Starter SYSTEM Manual Start - All Electric Models Emergency Starter Rope Electric Start - Model 65 Jet/75/90 Starter Draw (Under Load) 120 Amperes Starter Draw (No Load) 75 Amperes Electric Start - Model 80Jet/100/115/125 Starter Draw (Under Load)
  • Page 9 0.040 in. (1.0mm) Optional (Inductor Plug) BPZ8H-N-10 Idle RPM 25 RPM Wide Open Throttle (WOT) RPM – Model 75/80 Jet/100/115/125 4750 – 5250 – Model 65 Jet/90 5000 – 5500 Idle Mixture Screw Adjustment (Preset - Turns Out) Model 75Work/75...
  • Page 10 .054 – Carb #3 .054 WME-77 – Carb #1 .054 – Carb #2 .054 – Carb #3 .054 – Model 75 Work WME-30 – Carb #1 .050 – Carb #2 .052 _ Carb #3 .050 WME-47/48/76 – Carb #1 .054 –...
  • Page 11 Model 65/80 Jet/75/90/100/115/125 – Model 100 WME-32 – Carb #1 .046 – Carb #2 .048 – Carb #3 .052 – Carb #4 .052 WME-50 – Carb #1 .048 – Carb #2 .050 – Carb #3 .048 – Carb #4 .052 WME-50-3A –...
  • Page 12 Model 65/80 Jet/75/90/100/115/125 Model 125 WME-34 – Carb #1 .066 – Carb #2 .068 – Carb #3 .070 – Carb #4 .072 WME-52 – Carb #1 .070 – Carb #2 .080 – Carb #3 .078 – Carb #4 .082 WME-52-3A – Carb #3 .080...
  • Page 13 IMPORTANT INFORMATION GENERAL INFORMATION...

  • Page 14: Table Of Contents

    Table of Contents Page Table of Contents ......1C-0 Serial Number Location ..... . . 1C-1 Conditions Affecting Performance .

  • Page 15: Serial Number Location

    30% relative humidity at 77 F (25 C) tem- perature and a barometric pressure of 29.61 inches OGXXXXXX of mercury. 19XX XXXX Summer Conditions of high temperature, low baro- metric pressure and high humidity all combine to re- duce the engine power.

  • Page 16: Boat

    Boat WATER ABSORPTION It is imperative that all through hull fasteners be WEIGHT DISTRIBUTION coated with a quality marine sealer at time of installa- tion. Water intrusion into the transom core and/or in- 1. Proper positioning of the weight inside the boat ner hull will result in additional boat weight (reduced (persons and gear) has a significant effect on the boat performance), hull decay and eventual structur-...

  • Page 17: Following Complete Submersion

    Detonation usually can be prevented if: Fresh Water Submersion (Special Instructions) 1. The engine is correctly set up. 2. Diligent maintenance is applied to combat the 1. Recover engine as quickly as possible. detonation causes. 2. Remove cowling. 3. Flush exterior of outboard with fresh water to re- move mud, weeds, etc.

  • Page 18: Propeller Selection

    3. After initial propeller installation, the following Propeller Selection common conditions may require that the propel- For in-depth information on marine propellers and ler be changed to a lower pitch: boat performance - written by marine engineers - see a. Warmer weather and great humidity will your Authorized Dealer for the illustrated “What You cause an RPM loss.

  • Page 19: Power Trim System

    4. Increase steering torque or pull to the right (with 6. Place a block of wood between gear case and the normal right hand rotation propeller). propeller and torque propeller nut to 55 lb. ft. (75 5. In excess, lower the bow of some boats to a point N·m).

  • Page 20: Trim "In" Angle Adjustment

    Trim “In” Angle Adjustment Compression Check Some outboard boats, particularly some bass boats, 1. Remove spark plugs. are built with a greater than normal transom angle 2. Install compression gauge in spark plug hole. which will allow the outboard to be trimmed further “in”...

  • Page 21: Painting Procedures

    3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or 8. Use Ditzler Urethane DU9000 for Mercury Black, equivalent (Xylene or M.E.K.). DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray 4.

  • Page 22: Decal Application

    DECAL APPLICATION Decal Application 1. Mix ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solu- Decal Removal tion. NOTE: Leave protective masking, if present, on the 1. Mark decal location before removal to assure face of decal until final steps of decal installation.
  • Page 23 IMPORTANT INFORMATION OUTBOARD INSTALLATION...
  • Page 24 Table of Contents Page Determining Recommended Outboard Mounting Height ......1D-1 Notice to Installer and Owner .

  • Page 25: Notice To Installer And Owner

    U.S. COAST GUARD CAPACITY have been specifically designed and tested for your outboard. MAXIMUM HORSEPOWER MAXIMUM PERSON Mercury Marine Quicksilver accessories are avail- CAPACITY (POUNDS) able from Mercury Marine dealers. MAXIMUM WEIGHT Some accessories not manufactured or sold by Mer-...
  • Page 26 Determining Recommended WARNING Outboard Mounting Height Boat instability can occur at high speeds by installing engine at the wrong transom height. Contact the boat manufacturer for their recom- mendations for a specific engine installation. 26 in. (660m 25 in. (635m 24 in.

  • Page 27: Locate Center Line Of The Outboard

    NOTE: When drilling into a fiberglass boat, place Locating Center Line Of The masking tape directly onto boat where mounting Outboard holes will be drilled to help prevent fiberglass from chipping. Locate (and mark with pencil) the vertical centerline Use a 17/32 inch (13.5mm) diameter drill bit and drill (a) of boat transom.

  • Page 28: Lifting Outboard

    Lifting Outboard Installing Outboard To Boat Transom WARNING IMPORTANT: If boat is equipped with thru tilt tube Verify that the lifting ring is threaded into the fly- steering, steering cable end must be installed wheel a minimum of 5 turns and that hoist has a into tilt tube of outboard (port outboard only for maximum lift capacity over 500 lbs.

  • Page 29: Single Steering Cable And Steering Link Rod Installation

    Steering Link Rod Installation Single Steering Cable and Steering Link Rod IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened Installation using special washer head bolt (“a” – Part Num- ber 10-14000) and self locking nuts (“b”& “c”– NOTE: These instructions are for single cable–single Part Number 11-34863).

  • Page 30: Co-Pilot Installation (Tiller Handle Models)

    IMPORTANT: The co-pilot link rod (c) must be fas- Co-Pilot Installation (Tiller tened using self locking nylon insert locknuts Handle models) (“f”& “g”– Part Number 11-45592).These lock- nuts must never be replaced with common nuts WARNING (non locking) as they will work loose and vibrate off freeing the link rod to disengage.

  • Page 31: Remote Control Installation

    Remote Control Installation Shift and Throttle Cable Installation To The Outboard Refer to “Quicksilver Accessories Guide” to deter- mine correct length of remote control cables. Install the shift cable and throttle cable into the re- IMPORTANT: Remote control cables must be cor- mote control and mount the remote control following rect length.

  • Page 32: Throttle Cable Installation

    5. Place cable barrel into retainer and fasten the 3. Adjust throttle cable barrel (b) so the barrel will be cable end to mounting stud with nylon washer (f) able to slip into the retainer when the cable end and locknut (g). Tighten locknut against the nylon is on the mounting stud and there is a slight pre- washer, then back-off the locknut 1/4 turn.
  • Page 33 NOTE: The rubber grommet has to be lubricated to Connecting Remote Wiring ease installation. Harness To The Engine 1. Pull up the cowl seal (a) and remove the star- board side rubber grommet (b). 2. Take hold of the engine connector (c) and install the remote wiring harness plug (d).

  • Page 34: Battery Connections

    3. Push the connector and plug into the holder (e). Battery Connections CAUTION For dual outboard installations, the black (–) bat- tery cable of each engines starter motor ground circuit, MUST BE connected to each other by a common circuit (cable) capable of carrying the starting current of each engine’s starter motor.

  • Page 35: Filling The Oil Injection System

    Filling The Oil Injection System Bleeding Air From The Oil Injection System 1. Open the cowl cap (a). Turn the oil fill cap (b) to the left and remove. IMPORTANT: If air exists in either the oil pump in- let hose (a) or oil pump outlet hose (b), the air MUST BE bled from the hose(s) or engine dam- age may occur.

  • Page 36: Adjusting The Oil Injection Pump

    Adjusting The Oil Injection Pump Trim Tab Adjustment When carburetor linkage is at idle position, alignment Propeller steering torque will cause your boat to pull mark (a) on oil injection arm should be in-line with in one direction. This steering torque is a normal thing mark (b) on pump as shown.
  • Page 37 ELECTRICAL 53970 IGNITION...
  • Page 38 ......2A-26 75 Manual with 9 Ampere Stator 398-9873A20, Ignition Component Description ... .

  • Page 39: Special Tools

    4. Spark Gap Tester 91-63998A1 Special Tools 1. Flywheel Holder 91-52344 5. CDM Test Harness 84-825207A2 2. Flywheel Puller 91-73687A1 3. Volt/Ohm/DVA Meter 91-99750 90-830234R3 DECEMBER 1997 ELECTRICAL - 2A-1...

  • Page 40: Cylinder Electrical Components (Usa-0G127499/Bel-9836632 & Below)

    3 Cylinder Electrical Components (USA-0G127499/BEL-9836632 & BELOW) IMPORTANT: All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec- tive screw, bolt or nut is tightened. 25 26 Liquid Neoprene(92-25711--2) 2A-2 - ELECTRICAL 90-830234R3 DECEMBER 1997...
  • Page 41 3 Cylinder Electrical Components (USA-0G127499/BEL-9836632 & BELOW) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m IGNITION PLATE SWITCH BOX ASSEMBLY SCREW(10-16 x 7/16 IN.) Drive Tight SCREW(M5 x .8 x 30) STARTER SOLENOID GROMMET BUSHING NUT(8-32) SCREW WASHER WIRE(BLACK) LOCKWASHER(1/4 IN.) NUT(1/4-20)

  • Page 42: Electrical Components (Usa-0G127500 Thru 0G437999)(Bel-9836633 Thru 9926999)

    Electrical Components (USA-0G127500 thru 0G437999)(BEL-9836633 thru 9926999) Quicksilver Lubrication/Sealant Application Points Liquid Neoprene (92-25711--2) IMPORTANT: All eyelet electrical connections should be coated with LIQUID NEOPRENE after respective screw, bolt or nut is tightened 2A-4 - ELECTRICAL 90-830234R3 DECEMBER 1997...
  • Page 43 Electrical Components (USA-0G127500 thru 0G437999)(BEL-9836633 thru 9926999) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HARNESS SWITCH BOX SCREW (M5 x 12) SCREW (M5 x .8 x 30) VOLTAGE REGULATOR SCREW STARTER SOLENOID BUSHING NUT (8-32) SCREW WASHER WIRE (BLACK –...

  • Page 44: Cylinder Electrical Components (Usa-S/N-0G438000/Bel-9937000 & Up)

    3 Cylinder Electrical Components (USA-S/N-0G438000/BEL-9937000 & UP) IMPORTANT: All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec- tive screw, bolt or nut is tightened. Liquid Neoprene(92-25711--2) 2A-6 - ELECTRICAL 90-830234R3 DECEMBER 1997...
  • Page 45 3 Cylinder Electrical Components (USA-S/N-0G438000/BEL-9937000 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m IGNITION PLATE SCREW(M8 x 30) WASHER BUSHING GROMMET SCREW(M5 x 12) ELECTRIC CLAMP CABLE(10 IN.) SCREW(M5 x 12) WASHER HARNESS-Engine FUSE ELECTRIC HARNESS-Ignition BATTERY CABLE (POSITIVE) BOOT HI–TENSION CABLE...

  • Page 46: Cylinder Electrical Components (S/N-Usa-437999/Bel-9926999 & Below)

    4 Cylinder Electrical Components (S/N-USA-437999/BEL-9926999 & BELOW) Liquid Neoprene (92-25711--2) IMPORTANT: All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec- tive screw, bolt or nut is tightened. 2A-8 - ELECTRICAL 90-830234R3 DECEMBER 1997...
  • Page 47 4 Cylinder Electrical Components (S/N-USA-437999/BEL-9926999 & BELOW) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – PLUG–female wires IGNITION PLATE SWITCH BOX ASSEMBLY SCREW J-CLIP PRIMARY HARNESS ASSEMBLY SPARK PLUG (NGK #BP8H-N-10) SPARK PLUG (CAN/BEL-NGK#BPZ8H-N-10) HIGH TENSION CABLE (S/N–USA–0G301750/BEL–9885504 &...

  • Page 48: Cylinder Electrical Components (Usa-S/N-0G438000/Bel-9937000 & Up)

    4 Cylinder Electrical Components (USA-S/N-0G438000/BEL-9937000 & UP) IMPORTANT: All eyelet electrical connections should be coated with LIQUID NEOPRENE after respec- tive screw, bolt or nut is tightened. Liquid Neoprene (92-25711--2) 2A-10 - ELECTRICAL 90-830234R3 DECEMBER 1997...
  • Page 49 4 Cylinder Electrical Components (USA-S/N-0G438000/BEL-9937000 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m IGNITION PLATE SCREW (M8 x 30) WASHER BUSHING GROMMET SCREW (M5 x 12) WASHER CLAMP CABLE (10 IN.) HARNESS-Engine FUSE HARNESS-Ignition BATTERY CABLE (POSITIVE) BOOT CDM (S/N-USA-0G589999/BEL-9973099 &...

  • Page 50: Description

    Description Test Procedures The outboard ignition system is alternator-driven Direct Voltage Adapter (DVA) Tests with distributor-less capacitor discharge. Major com- ponents of the ignition system are the flywheel, sta- WARNING tor, trigger, switch box, ignition coils and spark plugs. The stator assembly is mounted stationary below the DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do flywheel and has 2 capacitor charging coils.

  • Page 51: Test Sequence

    TROUBLESHOOTING TIPS: 2-A) Check switch box “stop” circuit. (See Test 4 CYLINDER MODELS – Chart). 1. Intermittent, weak, or no spark output at two 1. If reading is BELOW specifications, proceed with spark plugs usually indicates a bad TRIGGER. Step 2-B. 2.

  • Page 52: Ignition System Dva Specifications Test Chart

    SWITCH BOX MUST BE GROUNDED (CASE TO ENGINE BLOCK) FOR ALL TESTS – IF NOT, SWITCH BOXES MAY BE DAMAGED. 3 Cylinder Stators 75 Manual with 9 Ampere Stator 398-9873A20, USA-0D283222 thru 0G227199 75/90 Electric with 16 Ampere Stator 398-9710A3, USA-0D283222 thru 0G280043 Belgium-09793577 thru 09879064...

  • Page 53: Cylinder Stators

    3 Cylinder Stators 75 Manual with 9 Ampere Stator 398-9873A21, USA-0D227200 and Above 75/90 Electric with 14 Ampere Stator 398-9873A24, USA-0G280044 thru 0G404505 Belgium-09879065 thru 09916672 Selector Voltage Voltage Voltage DVA Leads Test Test @ 300 @ 300 @ 1000...
  • Page 54 3 CYLINDER STATORS 75 MANUAL WITH 9 AMPERE STATOR CAUTION 398-9873A20 USA-0D283222 THRU 0G227199 Failure to comply with the following items may 75/90 ELECTRIC WITH 16 AMPERE STATOR result in damage to the ignition system.

  • Page 55: Adi Ignition Using A Red Stator With An Adapter Module

    * Connect test lead to BLACK stator lead if stator is TRIGGER TEST removed from engine. 1. Disconnect all trigger leads from switch box. 4 CYLINDER WITH 16 AMPERE STATOR 2. Use an Ohmmeter and perform the following 398-9710A33 tests. USA-0G301751 –...

  • Page 56: Red Stator With Adaptor And Ignition Coils

    RED Stator with Adaptor and Ignition Coils RED Stator DVA Test Selector RED DVA BLACK DVA Voltage Voltage Voltage Test Switch Lead Lead @ 300 RPM @ 1000 RPM @ 4000 RPM Position Coil (+) Coil (–) 130 Volts Coil Primary 400 VDC* 195 to 275 195 to 275...

  • Page 57: Theory Of Operation

    3 CYLINDER MODELS – 4 CYLINDER MODELS – Disconnect the BLUE adapter lead from the Disconnect the BLUE adapter lead from the switch box. switch box. Connect the DVA meter between the BLUE Connect the DVA meter between the BLUE adapter lead and ground.

  • Page 58: Capacitor Charging #1 Cdm

    Capacitor Charging #1 CDM AC voltage (260-320 volts). The AC voltage is then conducted to the CAPACITOR DISCHARGE MOD- The STATOR assembly is mounted to the block ULES (CDM), where it is rectified (DC) and stored in below the flywheel and has 3 CAPACITOR CHARG- a capacitor.

  • Page 59: Capacitor Charging #2 & #3 Cdm

    Capacitor Charging #2 & #3 CDM NOTE: #1 CDM stator voltage return path is through either CDM #2 or #3. The return path for CDM #2 and The flywheel rotates the permanent magnets past #3 is through CDM #1, if #1 stator wire is discon- the capacitor charging coils causing the coils to pro- nected the engine will die (the stator circuit is incom- duce AC voltage (260-320 volts).

  • Page 60: Cylinder Trigger Circuit

    #1 Cylinder Trigger Circuit ic switch (SCR) inside the capacitor discharge mod- ule (CDM). The switch discharges the capacitor volt- The TRIGGER assembly (also mounted under the age through the coil primary windings. The return flywheel) has one coil for each cylinder. These coils voltage pulse exits the CDM through the ground wire are mounted adjacent to the flywheel center hub.

  • Page 61: Ignition Coil Circuit

    Ignition Coil Circuit As the capacitor voltage flows through the primary windings of the ignition coil, a voltage is induced into the ignition coil secondary windings. This secondary voltage rises to the level required to jump the spark plug gap and return to ground. This secondary volt- age can, if necessary, reach approximately 40,000 volts.

  • Page 62: Stop Circuit

    Stop Circuit To stop the engine, the stop switch is closed allowing the capacitor charge current from the stator to drain directly to ground. NOTE: The CDM contains a zener diode (not shown for clarity). This diode prevents overcharging of the capacitor (and possible failure) if the SCR does not receive a trigger pulse.

  • Page 63: Rev Limiter Circuit

    Rev Limiter Circuit The rev limiter is activated through the PURPLE wire when the key switch is rotated to the “on” position. The rev limiter uses a trigger signal (BROWN WIRE) to determine engine speed or rpm. If the engine speed exceeds the specified rpm, the rev limiter will ground out the CDM capacitor charge.

  • Page 64: Red Stator With Cdm

    FLYWHEEL RED Stator with CDM Contains 6 magnets (12 pole) around circumference. Has one magnet on inner hub for trigger. Outer mag- Ignition Component Description nets are for battery charge coils and ignition charge coils. CAPACITOR DISCHARGE MODULE (CDM) Each module contains an ignition coil and amplifier circuitry which produces approximately 45,000 volts at the spark plugs.

  • Page 65: Cdm (P/N 827509)

    CDM (P/N 827509) Trouble Shooting Flowchart Chart 1 Step Action Value Tools Verify High Tension Leads, Spark – Step 2 Replace High Tension Plug and Spark Boots are in good Failed Com- lead pin condition. Inspect wires for chafing. ponent 84-813706A56 Visual Inspection Step 2...
  • Page 66 CDM Stop Diode Trouble Shooting 2 Cyl.: CDM #1 gets its charging ground path through CDM #2 CDM #2 gets its charging ground path through CDM #1 A shorted Stop Diode in either CDM would prevent the opposite one from sparking. 3 Cyl.: CDM #1 gets its charging ground path through CDM #2 or #3 CDM #2 and #3 get their charging ground path through CDM #1...
  • Page 67 CDM Trouble Shooting Flowchart Chart #2 (No Spark on any CDM) Step Action Value Tools With the key switch ON: NO continuity Step 2 Repair or DVA/Multimeter Verify continuity between BLK/YEL Replace Com- P/N 91-99750 harness wire and ground. ponent This Test Checks: Run Engine Verify Repair...
  • Page 68 CDM Trouble Shooting Flowchart Chart #3 (At least one CDM has spark) Step Action Value Tools Resistance Check ALL CDMs Refer to chart Step 3 Replace any DVA/Multimeter CDMs that P/N 91-99750 do not pass specifica- tions even if they fire Step 2 Test all CDMs at Cranking with 7/16 in.
  • Page 69 CAPACITOR DISCHARGE MODULE IMPORTANT: Spark plug wires are screwed into CDM. A B C D a - Ground b - Black/Yellow c - Trigger Connection d - Stator Connection A resistance check is required and can be performed on the CDM as follows: NOTE: This test can be performed using the test harness (P/N 84-825207A2).

  • Page 70: Direct Voltage Adaptor (Dva) Test

    Direct Voltage Adaptor (DVA) Test 5. Test Stator and Trigger voltage to CDM: a. Install test harness 84-825207A2 between CAUTION ignition harness and CDM. DVA checks can be made while cranking engine with starter motor. To prevent engine from start- ing while being cranked, all spark plugs must be removed.
  • Page 71 c. Test each CDM. Test each CDM. Stop Circuit Test Trigger Output Test 400 DVA Scale 2 DVA Scale @ Cranking Speed @ Cranking Speed Positive Meter Negative Positive Meter Negative Lead ( +) Meter Lead (–) Reading Lead (+) Meter Lead (–) Reading Connect to...

  • Page 72: Resistance Tests

    ENGINE RUNNING AT IDLE: Resistance Tests It is not necessary to perform this test if the voltage RED STATOR output was tested in the previous step CRANKING ENGINE. 1. Disconnect stator leads. NOTE: Resistance varies greatly with temperature. Red Stator Output Test 400 DVA Scale Measurements should be taken with an ambient tem- Positive Meter...

  • Page 73: Ignition (Key) Switch Test

    Ignition (Key) Switch Test 2. Disconnect spark plug leads from spark plugs. 3. While holding flywheel with Flywheel Holder 1. Disconnect remote control wiring harness and (91-52344), remove flywheel nut and washer. instrument panel connector. NOTE: Wiring diagram for control boxes is located in SECTION 2D.

  • Page 74: Stator Removal And Installation

    INSTALLATION Stator Removal and Installation WARNING Engine could possibly start when turning fly- REMOVAL wheel during installation; therefore, disconnect (and isolate) spark plug leads from spark plugs 1. Remove flywheel; refer to “Flywheel Removal.” to prevent engine from starting. 2. Remove screws. 1.
  • Page 75 4 Cylinder Models INSTALLATION Two styles of stators are currently being used on 1994 through 1996 model 75 - 125 outboards. These stators can be identified by a large rim or small rim on the underside of the stator where the stator harness exits the stator.
  • Page 76 Large Rim Stator 1. Install stator as shown. 53973 Loctite 222 (92-809818) a - Screws; apply Loctite 222 on threads (unless Patch Screw used) and torque to 60 lbs. in. (6.6 N·m) b - Stator c - Stator Harness d - Trigger Harness 2.

  • Page 77: Trigger Removal And Installation

    4 Cylinder Models 5. Disconnect trigger leads from switch box and re- move trigger. 3 Cylinder Models 53970 a - Sta-Strap b - Stator Harness 53972 c - Switch Box a - Sta-straps b - Bullet Connectors; Disconnect Trigger Leads 5.
  • Page 78 INSTALLATION 4 Cylinder Models 1. Install trigger and connect link arm. 19459 53970 a - Trigger b - Link Arm a - Sta-Strap b - Trigger Harness 2. Connect trigger leads to switch box; refer to wir- c - Switch Box ing diagrams in Section 2D.

  • Page 79: Ignition Coil Removal And Installation

    Refer to wiring diagrams in Section 2D when con- Ignition Coil Removal and necting wires. Installation 4 Cylinder Models Refer to wiring diagrams in Section 2D when con- necting wires. 3 Cylinder Models 53975 Liquid Neoprene (92-25711--2) 53974 a - Coils a - Coils b - Cover b - Cover...

  • Page 80: Switch Box Removal And Installation

    3 Cylinder Models w/CDM Ignition Switch Box Removal and Installation Refer to wiring diagrams in Section 2D when con- necting wires. 3 Cylinder Models 55418 53971 a - CDM b - Bolt – Torque to 60 lb. in. (6.8 N·m) a - Bolts [Torque to 40 lb.
  • Page 81 ELECTRICAL 11669 CHARGING AND STARTING SYSTEM...
  • Page 82 Table of Contents Page Page Specifications ....... . 2B-1 3 Cylinder 14 and 16 Ampere BLACK Stator Special Tools .

  • Page 83: Specifications

    - Commercial 75 Recoil Starter SYSTEM Manual Start - All Electric Models Emergency Starter Rope Electric Start - Model 65 Jet/75/90 Starter Draw (Under Load) 120 Amperes Starter Draw (No Load) 75 Amperes Electric Start - Model 80Jet/100/115/125 Starter Draw (Under Load)

  • Page 84: Special Tools

    Operating Engine Without Battery Special Tools If desired (or in an emergency), engines equipped 1. Volt/Ohm/DVA Meter 91-99750 with an alternator can be started and operated with- out a battery (either disconnected or removed) if “Warning”, below, is followed. WARNING Before operating engine with battery leads dis- connected from battery, disconnect stator leads (YELLOW) from rectifier.

  • Page 85: Electrolyte Level

    2. Never take hydrometer readings immediately af- Electrolyte Level ter water has been added. Water must be thor- Check electrolyte level in battery regularly. A battery oughly mixed with electrolyte by charging for at in use in hot weather should be checked more fre- least 15 minutes at a rate high enough to cause quently because of more rapid loss of water.

  • Page 86: Winter Storage Of Batteries

    Winter Storage of Batteries BLACK Stator Battery Charging System Troubleshooting Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, MODELS EQUIPPED WITH REGULATOR if the following instructions are not observed: (BLACK STATOR) 1. Remove battery from its installation as soon as possible and remove all grease, sulfate and dirt from top surface by running water over top of bat- tery.

  • Page 87: Ampere (Manual Start) Black Stator Output Test

    9 Ampere (Manual Start) BLACK BLACK Stator 14 and 16 Ampere Stator Output Test Alternator System Test The 9 ampere stator that comes with manual start 1. Check battery voltage at battery with engine run- models is NOT designed to produced its rated am- ning.

  • Page 88: Tachometer Terminal Block

    10. A reading of 16 amperes (or 12 amperes for 15 RED Stator Battery Charging System ampere stator) at 3500 RPM indicates the charg- Troubleshooting ing system is functioning properly. The battery is discharging due to the amperage draw on the MODELS EQUIPPED WITH REGULATOR (RED system is greater than the amperage output of STATOR)
  • Page 89 If visual inspection determines that battery connec- ALTERNATOR SYSTEMS TEST (RED STATOR) tions and wiring are OK, perform the following stator 9 Ampere Manual Stator and rectifier tests. IMPORTANT: Rectifier (optional accessory) must STATOR OHMS TEST be functioning properly for accurate test results (ALTERNATOR COILS ONLY) to be obtained.
  • Page 90 6. Remove RED sense lead wire (A) from starter so- lenoid terminal and connect to the positive (+) ter- minal of a 9 volt transistor battery. Ground the negative (–) terminal of the 9 volt battery to the engine. a - Red Sense Lead (Female Connector) 7.

  • Page 91: Cylinder 14 And 16 Ampere Black Stator Battery Charging Wiring Diagram

    3 Cylinder 14 and 16 Ampere BLACK Stator Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid cor- rosion. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE...

  • Page 92: Cylinder 14 And 16 Ampere Black Stator Battery Charging Wiring Diagram

    4 Cylinder 14 and 16 Ampere BLACK Stator Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid cor- rosion. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE...

  • Page 93: Cylinder Battery Charging Diagram (With Black Stator) With Battery Isolator

    3 Cylinder Battery Charging Diagram (with BLACK STATOR) with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid cor- rosion. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE...

  • Page 94: Cylinder Battery Charging Diagram (With Red Stator) With Battery Isolator

    3 Cylinder Battery Charging Diagram (with RED STATOR) with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid cor- rosion. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE...

  • Page 95: Cylinder Battery Charging Diagram (With Black Stator) With Battery Isolator

    4 Cylinder Battery Charging Diagram (with BLACK Stator) with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid cor- rosion. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE...

  • Page 96: Cylinder Battery Charging Diagram (With Red Stator) With Battery Isolator

    4 Cylinder Battery Charging Diagram (with RED Stator) with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid cor- rosion. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE...

  • Page 97: 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 illustration for rectifier terminal identification.

  • Page 98: Starting System

    Starting System CAUTION The starter motor may be damaged if operated continuously. DO NOT operate continuously for Starting System Components more than 30 seconds. Allow a 2 minute cooling The starting system consists of the following compo- period between starting attempts. nents: 1.

  • Page 99: Starting Circuit Troubleshooting Flow Chart

    BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE Starter Circuit YEL = YELLOW a - Battery e - Ignition Switch b - Starter Solenoid f - Fuse Holder (If Equipped) (20 Amp Fuse) c - Starter...
  • Page 100 TEST 2 a - Disconnect BLACK ground wire(s) from Test Point 2. No voltage reading; b - Connect voltmeter between common engine ground and Test Point 2. proceed to TEST 3. c - Turn ignition key to “Start” position. TEST 3 12 Volt Reading* Check BLACK ground wire for a - Reconnect BLACK ground wire(s).

  • Page 101: Starter Motor

    7. Remove 2 rubber collars and 2 rubber bumpers. Starter Motor Removal CAUTION Disconnect battery leads from battery before re- moving starter. 1. Disconnect battery leads from battery. 11645 2. Remove sta-strap. a - Rubber Collar 3. Disconnect YELLOW cable. b - Rubber Bumpers 4.

  • Page 102: Starter Cleaning, Inspection And Testing

    4. Remove components from armature. b. Clean the commutator slots after undercut- ting. c. Sand the commutator lightly with No. 00 sandpaper to remove burrs, then clean the commutator. d. Recheck the armature on a growler for shorts as specified in the following procedure (“Test- ing”).
  • Page 103 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 the ohmmeter on armature core or shaft and other ohmmeter on the NEGATIVE brush and the other lead on commutator.

  • Page 104: Brush Replacement

    STARTER SOLENOID TEST Brush Replacement 1. Disconnect all wires from solenoid. STARTER REASSEMBLY 2. Use an ohmmeter (R x 1 scale) and connect me- ter leads between solenoid terminals 1 and 2. 1. If brushes were removed, replace as follows: a.
  • Page 105 2. If removed, reinstall parts on armature shaft. Use 6. To prevent damage to brushes and springs when a new locknut and tighten securely on end of installing commutator end cap, it is recom- shaft. mended that a brush retaining tool be made as shown: 2”...
  • Page 106 INSTALLATION 1. Install 2 rubber collars and 2 rubber bumpers. 11661 11645 a - Rubber Collars a - Brush Retainer Tool b - Rubber Bumpers b - Bushing (DO NOT Over Lubricate) 2. Install components as shown. 9. Install armature into starter frame and align match marks.
  • Page 107 4. Reinstall electrical plate cover. Torque bolts to 30 lb. in. (3.4 N·m). 53958 a - Bolts [Torque to 30 lb. in. (3.4 N·m)] 90-830234R3 DECEMBER 1997 ELECTRICAL - 2B-25...
  • Page 108 ELECTRICAL 22480 TIMING/SYNCHRONIZING/ADJUSTING...
  • Page 109 Table of Contents Page Page Timing/Synchronizing/ Timing/Synchronizing/ Adjusting (3 Cylinder Models) ....2C-1 Adjusting (4 Cylinder Models) ....2C-5 Specifications .

  • Page 110: Timing/Synchronizing/Adjusting (3 Cylinder Models)

    2. Timing Light* 91-99379 Timing/Synchronizing/ Adjusting (3 Cylinder Models) Specifications 65 JET, 75 and 90 Models Full Throttle RPM Range Model 75 4750 - 5250 Model 65 JET/90 5000 - 5500 3. Spark Gap Tool 91-63998A1 Idle RPM (in “FORWARD” Gear)
  • Page 111 CARBURETOR SYNCHRONIZATION 1. Disconnect remote fuel line from engine. 2. Connect remote control electrical harness to en- gine wiring harness. 3. Remove throttle cable barrel from barrel retainer. 4. Remove sound air box cover to verify throttle shutters are closed. 5.
  • Page 112 TIMING ADJUSTMENTS MAXIMUM TIMING 1. Hold control arm so that maximum spark ad- CAUTION vance screw is against stop. Engine is timed while cranking engine with start- 2. Crank engine with starter motor and adjust maxi- er motor. To prevent engine from starting when mum spark advance screw to align the specified being cranked, all spark plugs must be removed, BTDC timing mark on flywheel with timing pointer...
  • Page 113 After service or replacement of carburetor, turn low speed mixture screw adjustment in (clockwise) until it seats lightly, then back off (each carburetor) to specifications (65JET/75/90 – 1 turn on #1 carb; 1 – 1-1/2 turns on #2 and #3 carbs). This will permit en- gine start-up.

  • Page 114: Throttle Cable Installation

    NOTE: On this type of engine, idle RPM is adjusted Timing/Synchronizing/ exclusively with ignition timing. Adjusting (4 Cylinder Models) Throttle Cable Installation 1. With end of throttle cable connected to throttle le- Specifications ver, hold throttle lever against idle stop. Adjust throttle cable barrel to slip into barrel retainer on Models 80 JET/100/115/125 cable anchor bracket with a very light preload of...
  • Page 115 8. Place roller of cam follower against throttle cam 10. Hold throttle arm against full throttle stop. Adjust and adjust idle stop screw to align raised mark of full throttle stop screw to allow throttle shutters to throttle cam with center of cam follower roller. open fully.
  • Page 116 CARBURETOR/OIL PUMP SYNCHRONIZATION IDLE TIMING ADJUSTMENT IMPORTANT: Some engines may have an addi- WARNING tional stamped mark (d) which SHOULD NOT be used. Before cranking engine, keep clear of propeller, as it may rotate. 1. While holding throttle arm at idle position, adjust length of link rod so that stamped mark of oil IMPORTANT: To accurately time engine at crank- pump body aligns with stamped mark of oil pump...
  • Page 117 MAXIMUM TIMING INITIAL STARTING ADJUSTMENTS 1. Hold control arm against maximum advance NOTE: For adjusting carburetor throttle linkage and synchronizing carburetors, see section “Timing/ stop. 1994/1995 Models – Crank engine with Synchronizing/Adjusting” of this manual. starter motor and adjust maximum advance screw to align 22 BTDC mark on flywheel with After service or replacement of carburetor, turn low timing pointer (due to the advance characteristics...

  • Page 118: Idle Adjustment

    Idle Adjustment 1. With engine in water, connect electrical harness and fuel line to engine. Start engine and allow to warm up. 2. Properly adjust carburetor low speed mixture screws. Refer to “Carburetor Adjustments” sec- tion 3A. 3. Holding throttle arm at idle position (throttle cable barrel removed from barrel retainer), adjust idle timing screw to attain an engine idle RPM of 650-700 RPM in “Forward”...
  • Page 119 ELECTRICAL WIRING DIAGRAMS...
  • Page 120 Side Mount Remote Control) ....2D-20 1996 75 Work Model Wiring Diagram Manual Start Tachometer (With Adjustable Dial) and (1-2-3 Firing Order) ......

  • Page 121: 1994/1995 65 Jet Wiring Diagram Electric (1-3-2 Firing Order)

    1994/1995 65 Jet Wiring Diagram Electric (1-3-2 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 53475 a - Stator j - Temperature Switch...

  • Page 122: 65 Jet Wiring Diagram Electric (1-2-3 Firing Order)

    1996 65 Jet Wiring Diagram Electric (1-2-3 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 55420 a - Stator j - Temperature Switch...

  • Page 123: 1994/1995 75/90 Wiring Diagram (1-3-2 Firing Order)

    1994/1995 75/90 Wiring Diagram (1-3-2 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...

  • Page 124: 75/90 Wiring Diagram (1-2-3 Firing Order)

    1996 75/90 Wiring Diagram (1-2-3 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...
  • Page 125 1994/1995 75 Work Model Wiring Diagram Manual Start (1-3-2 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE...

  • Page 126: 75 Work Model Wiring Diagram Manual Start (1-2-3 Firing Order)

    1996 75 Work Model Wiring Diagram Manual Start (1-2-3 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE...

  • Page 127: 1994/1995/1996 80 Jet/100/115/125 Wiring Diagram

    1994/1995/1996 80 Jet/100/115/125 Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 53474 a - Stator j - Enrichment Valve b - Trigger k - Voltage Regulator/Rectifier...

  • Page 128: 65 Jet Wiring Diagram (W/Cdm) (1-2-3 Firing Order)

    1997 65 Jet Wiring Diagram (w/CDM) (1-2-3 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW WHT/GRN BLK/YEL GRN/WHT...
  • Page 129 1997 75 Work Model Wiring Diagram (w/CDM) Manual Start (1-2-3 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE...

  • Page 130: 75/90 Wiring Diagram (W/Cdm) (1-2-3 Firing Order)

    1997 75/90 Wiring Diagram (w/CDM) (1-2-3 Firing Order) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...

  • Page 131: 80 Jet/100/115/125 Wiring Diagram (W/Cdm)

    1997 80 Jet/100/115/125 Wiring Diagram (w/CDM) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW a - Trigger m - Fuel Enrichment Solenoid b - Stator n - Temperature Switch...

  • Page 132: 1998 65 Jet Wiring Diagram

    1998 65 Jet Wiring Diagram 1 2 3 4 5 6 7 8 RED/PPL RED/PPL BLK W/YEL ENDS YEL/RED BLK/YEL YEL/BLK YEL/BLK WHT/GRN TAN/LT.BLU TAN/LT.BLU BLK/YEL GRN/WHT TAN/LT.BLU TAN/LT.BLU TAN/LT.BLU LT.BLU LT.BLU BLK/YEL GRN/WHT BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL a - Trigger b - Stator c - Engine Harness...

  • Page 133: 1998 75 Work Model Wiring Diagram

    1998 75 Work Model Wiring Diagram BLK/YEL WHT/GRN BLK/YEL TAN/LT.BLU TAN/LT.BLU GRN/WHT TAN/LT.BLU TAN/LT.BLU BLK/YEL GRN/WHT BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL DK.BLU BLK/YEL BLK/YEL BLK/YEL BLK/YEL a - Trigger b - Stator c - Electrical Plate d - Block e - Temperature Switch...

  • Page 134: 75 Electric Start Tiller Handle W/Power Trim Wiring Diagram

    1998 75 Electric Start Tiller Handle w/Power Trim Wiring Diagram YEL/RED YEL/BLK GRN/WHT LT.BLU/WHT TAN/LT.BLU TAN/LT.BLU BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL 1 2 3 4 5 6 7 8 308586 308586 1 2 3 4 5 6 7 8...

  • Page 135: 1998 75/90 Electric Start Wiring Diagram

    1998 75/90 Electric Start Wiring Diagram 1 2 3 4 5 6 7 8 RED/PPL RED/PPL BLK W/YEL ENDS YEL/RED BLK/YEL YEL/BLK YEL/BLK WHT/GRN TAN/LT.BLU TAN/LT.BLU BLK/YEL GRN/WHT TAN/LT.BLU TAN/LT.BLU TAN/LT.BLU LT.BLU LT.BLU BLK/YEL GRN/WHT BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL...

  • Page 136: 1998 75/90 Electric Start W/Power Trim Wiring Diagram

    1998 75/90 Electric Start w/Power Trim Wiring Diagram 30 8586 308586 1 2 3 4 5 6 7 8 RED/PPL RED/PPL BLK W/YEL ENDS YEL/RED BLK/YEL YEL/BLK YEL/BLK WHT/GRN TAN/LT.BLU TAN/LT.BLU BLK/YEL GRN/WHT TAN/LT.BLU TAN/LT.BLU TAN/LT.BLU LT.BLU LT.BLU BLK/YEL GRN/WHT...

  • Page 137: 1998 80 Jet/100/115/125 Wiring Diagram

    1998 80 Jet/100/115/125 Wiring Diagram 308586 308586 87a 1 2 3 4 5 6 7 8 RED/PPL RED/PPL BLK W/YEL ENDS YEL/RED BLK/YEL YEL/BLK YEL/BLK WHT/GRN TAN/LT.BLU TAN/LT.BLU BLK/YEL WHT/GRN TAN/LT.BLU TAN/ LT.BLU TAN/LT.BLU LT.BLU LT.BLU BLK/YEL GRN/WHT BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL...

  • Page 138: Power Trim System Wiring Diagram (3 Cylinder Models Using Commander 2000 Side Mount Remote Control)

    Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE 23886 RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...

  • Page 139: Power Trim System Wiring Diagram (3 Cylinder Models Using Commander Side Mount Remote Control)

    Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER Side Mount Remote Control) BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN 23884 PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW a - Power Trim Pump Motor...
  • Page 140 Power Trim System Wiring Diagram (4 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control) RED 8 BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN 23885 PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...

  • Page 141: Tachometer (With Adjustable Dial) And Trim Indicator Gauge Wiring Diagram

    Tachometer (With Adjustable Dial) and Trim Indicator Gauge Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE BATT YEL = YELLOW SENDER...

  • Page 142: Key/Choke Switch Continuity Test (Commander 2000 Side Mount Remote Control)

    Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount Remote Control) “OFF” BLK/YEL – BLK “RUN” RED – PUR “START” RED – PUR – YEL/RED PUSH (CHOKE)* RED – YEL/BLK BLK = BLACK *Key switch must be positioned to “RUN” or BLU = BLUE “START”...

  • Page 143: Warning Horn) Wiring Diagram

    COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE 23891 RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...

  • Page 144: 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 PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE 23892 YEL = YELLOW...
  • Page 145 COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 24072...
  • Page 146 FUEL SYSTEM 53992 FUEL PUMP...
  • Page 147 ........3A-1 65 Jet 75-90 (3 cyl.) ......

  • Page 148: Notes

    Notes: 90-830234R3 DECEMBER 1997 FUEL SYSTEM - 3A-1...

  • Page 149: Jet 75-90 (3 Cyl.)

    65 Jet 75-90 (3 cyl.) 51549 a - Body (Opposite Side View) b - Rubber Valve c - Plastic Disc d - Cover (Opposite Side View) e - Plastic Check Valve Retainer f - Cast Aluminum Cover g - Three Tabs...

  • Page 150: Jet-100-115-125 (4 Cyl.)

    80 Jet-100-115-125 (4 cyl.) 51548 a - Body (Opposite Side View) b - Rubber Valve c - Plastic Disc d - Cover (Opposite Side View) e - Plastic Check Valve Retainer f - Cast Aluminum Cover g - Body h - Three Tabs i - Three Tabs 90-830234R3 DECEMBER 1997 FUEL SYSTEM - 3A-3...

  • Page 151: Fuel Pump (65 Jet/75/90)

    Fuel Pump (65 Jet/75/90) A = TO OIL PUMP B = TO CRANKCASE C = TO CARBURETOR D = TO TOP CARBURETOR E = TO CENTER CARBURETOR F = TO BOTTOM CARBURETOR G = DESIGN I H = DESIGN II...
  • Page 152 O RING SCREW(M6 x 35) GROMMET ENRICHER VALVE (S/N-0G437999/BEL-9926999 & BELOW) ENRICHER VALVE (S/N-0G438000/BEL-9927000 & UP) TUBING(15 IN.) TUBING(8 IN.)(Use W/WME–29/30/31/41/46/47/48/49 Carbs) TUBING(11-1/2 IN.)(Use W/WME–59/60/61/62/ 75/76/77/78 Carbs) CLAMP – GASKET SET – POWERHEAD 90-830234R3 DECEMBER 1997 FUEL SYSTEM - 3A-5...
  • Page 153 Fuel Pump (65 Jet/75/90) A = TO OIL PUMP B = TO CRANKCASE C = TO CARBURETOR D = TO TOP CARBURETOR E = TO CENTER CARBURETOR F = TO BOTTOM CARBURETOR G = DESIGN I H = DESIGN II...
  • Page 154 Fuel Pump (65 Jet/75/90) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TUBING Drive Tight FUEL FILTER BRACKET NON OIL INJECTED SCREW DESIGN I Drive Tight WASHER TUBING(17 IN.) FUEL FILTER BRACKET SCREW(M6 x 14) NON OIL INJECTED...

  • Page 155: Fuel Pump (80 Jet/100/115/125)

    Fuel Pump (80 Jet/100/115/125) Perfect Seal (92-34227-1) A=TO LOWER TEE B=TO OIL PUMP C=TO UPPER TEE D=TO CRANKCASE 3A-8 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 156 Fuel Pump (80 Jet/100/115/125) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP ASSEMBLY DIAPHRAGM KIT CHECK VALVE GASKET–boost DIAPHRAGM GASKET–pulse SPRING CHECK VALVE RETAINER SPRING GASKET BASE PLATE ELBOW SCREW–fuel pump (M5 x 40) SCREW–pump to block (M6 x 50) TUBING (4 IN.) TUBING (8-1/2 IN.) TUBING (2 IN.)

  • Page 157: Theory Of Operation

    If, after using a separate fuel supply, it is found that Theory Of Operation the anti-siphon valve is the cause of the problem, The fuel pump is a crankcase-pressure-operated, di- there are 2 solutions to the problem; either (1) re- aphragm-type pump.

  • Page 158: Removal

    Troubleshooting Fuel Pump Fuel Pump – (continued) Cleaning/Inspection Clean fuel pump housing, check valves, pulse cham- PROBLEM: Lack of Fuel Pump Pressure ber, and pump base in solvent, and dry all but check Possible Cause Corrective Action valves with compressed air. Hole in pulse hose Replace pulse hose.

  • Page 159: Reassembly

    2. Install check valves and retainers into fuel pump Reassembly body. IMPORTANT: ALWAYS REPLACE GASKETS. After reassembling check valve in fuel pump body, using the following procedure will help insure proper reassembly: 1. Insert two 3 in. minimum length 1/4 bolts (not the fuel pump bolts) OR 1/4 dowels, through the op- posite large holes (6mm bolt holes) in the cham- ber plate, as locating dowels, and turn plate up-...

  • Page 160: Installation Of Fuel Pump

    MODEL 80 JET, 100, 115, 125 Installation of Fuel Pump MODEL 65 JET, 75, 90 53992 a - Fuel Pump b - Pulse Hose c - Inlet Hose d - Outlet Hose e - Elbow [Apply PERFECT SEAL (92-34227--1) to threads] f - Check Valve g - Bolts [Torque to 40 lb.
  • Page 161 FUEL SYSTEM CARBURETOR...
  • Page 162 ....... . 3B-3 Carburetor (WME–29/30/31/41/46/47/48/49) ..3B-4 Carburetor (WME–59/60/61/62/75/76/77/78/82/83) 3B-6 Carburetor–WME-32/32A/33/34/40/40A ..3B-10 Carburetor–WME-50/51/52/79/80/81 .

  • Page 163: Specifications

    Specifications Idle RPM (In Forward Gear) Wide Open Throttle (WOT) RPM Model 65 Jet/90 5000-5500 Model 75/80 Jet/100/115/125 4750-5250 CARBURETOR Float Height 9/16 in. (14.29 mm) WME Carburetor Chart NOTE: Carburetor Number Stamped on Side of Carburetor Body. Model Year...
  • Page 164 6/19/97 1995 40 -1A 0.066 in. 1-1/2 0.070 in. 1-1/2 0G143417 0.070 in. and above 0.074 in. 6/20/94 75 ELH 1994 41 -1 0.052 in. 0.052 in. 1-1/2 0.052 in. 1-1/2 75 ELPTO 1995 46 -1 0.052 in. 0.052 in.

  • Page 165: Special Tools

    81 -1 0.070 in. 1-1/2 0.080 in. 1-1/2 0.080 in. 1-1/2 0.082 in. 1-1/2 *Late 1996 running change: 75/90 S/N 0G428199 (4/15/96) 100-125 S/N 0G428125 (4/12/96) Special Tools P/N 91-36392 Carburetor Scale 73656 90-830234R3 DECEMBER 1997 FUEL SYSTEM - 3B-3...

  • Page 166: Carburetor (Wme-29/30/31/41/46/47/48/49)

    Carburetor (WME–29/30/31/41/46/47/48/49) Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) A – DO NOT touch this adjustment. This is preset by the manufacturer and is NOT for field service. Conventional carb cleaners will not affect the sealant securing this adjustment 3B-4 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 167 FUEL BOWL (UPPER)(WME-30/46/47/49) FUEL BOWL (UPPER)(WME-29/31/41/48) FUEL BOWL (CENTER/LOWER) SCREW–fuel bowl PLUG SEAL–drain plug MAIN FUEL JET (.050)(75) MAIN FUEL JET (.052)(75) MAIN FUEL JET (.054)(75) MAIN FUEL JET (.062)(90) MAIN FUEL JET (.064)(90) MAIN FUEL JET (.044)(Belgium) MAIN FUEL JET (.046)(Belgium)
  • Page 168 Carburetor (WME–59/60/61/62/75/76/77/78/82/83) Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) A – DO NOT touch this adjustment. This is preset by the manufacturer and is NOT for field service. Convention- al carb cleaners will not affect the sealant securing this adjustment...
  • Page 169 Carburetor (WME–59/60/61/62/75/76/77/78/82/83) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR (TOP) CARBURETOR (CENTER) 75 MANUAL-WME-76 CARBURETOR (BOTTOM) CARBURETOR (TOP) CARBURETOR (CENTER) 75 ELECTRIC-WME-75 CARBURETOR (BOTTOM) CARBURETOR (TOP) CARBURETOR (CENTER) 75 ELECTRIC-WME-77 CARBURETOR (BOTTOM) NON –OIL CARBURETOR (TOP)
  • Page 170 Carburetor (WME–59/60/61/62/75/76/77/78/82/83) Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) 3B-8 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 171 MAIN FUEL JET (.054)(CENTER/BOTTOM)(WME–59) MAIN FUEL JET (.054)(WME–60/61/76/77) MAIN FUEL JET (.062)(TOP)(WME–62) MAIN FUEL JET (.064)(CENTER/BOTTOM)(WME–62) MAIN FUEL JET (.044)(Belgium) MAIN FUEL JET (.052)(TOP)(WME–75) MAIN FUEL JET (.054)(CENTER/BOTTOM)(WME–75) MAIN FUEL JET (.062)(TOP)(WME–78) MAIN FUEL JET (.064)(CENTER/BOTTOM)(WME–78) 90-830234R3 DECEMBER 1997 FUEL SYSTEM - 3B-9...

  • Page 172: Carburetor-Wme-32/32A/33/34/40/40A

    Carburetor–WME-32/32A/33/34/40/40A IMPORTANT: DO NOT touch this adjustment. This is preset by the manufacturer, and is NOT for field service. Conventional carb. cleaners will not affect the sea- lant securing this adjustment. Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) 3B-10 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 173 Carburetor–WME-32/32A/33/34/40/40A TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR CARBURETOR 100 - WME-32/32A CARBURETOR CARBURETOR CARBURETOR CARBURETOR 115 - WME-33 CARBURETOR CARBURETOR CARBURETOR CARBURETOR 115 - WME-40/40A CARBURETOR CARBURETOR CARBURETOR CARBURETOR 125 - WME-34 CARBURETOR CARBURETOR GASKET–fuel bowl RETAINING RING FUEL BOWL FUEL BOWL (WME-40-TOP)

  • Page 174: Carburetor-Wme-50/51/52/79/80/81

    Carburetor–WME-50/51/52/79/80/81 IMPORTANT: DO NOT touch this adjustment. This is preset by the manufacturer, and is NOT for field service. Conventional carb. cleaners will not affect the sea- lant securing this adjustment. Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) 3B-12 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 175 Carburetor–WME-50/51/52/79/80/81 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR CARBURETOR 100 - WME-50 CARBURETOR CARBURETOR CARBURETOR CARBURETOR 115 - WME-51 CARBURETOR CARBURETOR CARBURETOR CARBURETOR 125 - WME-52 CARBURETOR CARBURETOR CARBURETOR CARBURETOR 100 - WME-79 CARBURETOR CARBURETOR CARBURETOR CARBURETOR 115 - WME-80 CARBURETOR...
  • Page 176 Carburetor–WME-50/51/52/79/80/81 IMPORTANT: DO NOT touch this adjustment. This is preset by the manufacturer, and is NOT for field service. Conventional carb. cleaners will not affect the sea- lant securing this adjustment. Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) 3B-14 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 177 Carburetor–WME-50/51/52/79/80/81 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW–throttle valve SCREW–cover plate SCREW–fuel bowl COVER PLATE MAIN FUEL JET (.048) (WME-50-1) MAIN FUEL JET (.050) (WME-50-2/3) MAIN FUEL JET (.052) (WME-50-4) MAIN FUEL JET (.062) (WME-51–1/2/3) MAIN FUEL JET (.070) (WME-52-1) MAIN FUEL JET (.080) (WME-52-2/3) MAIN FUEL JET (.082) (WME-52-4) MAIN FUEL JET (.048) (WME-79-1)

  • Page 178: Fuel System (Linkage)

    Fuel System (Linkage) 4 Cylinder Carburetor/Linkage Arrangement 3 Cylinder Carburetor/Linkage Arrangement 3 Cylinder Models 54138 a - Oil Injection Pump Link b - Throttle Link c - Gasket d - Fuel Enrichment Fitting 4 Cylinder Models 54137 a - Oil Injection Pump Link b - Throttle Link c - Gasket d - Fuel Enrichment Fitting...

  • Page 179: Adjustments

    3. Check for too lean mixture on acceleration. Adjustments 4. DO NOT adjust leaner than necessary to attain reasonably smooth idling. When in doubt, stay on Idle Mixture Screw Adjustment the slightly rich side of the adjustment. INITIAL STARTING ADJUSTMENT Idle Speed Adjustment Turn idle mixture screw in (clockwise) until it seats LIGHTLY--then back-off (each carburetor) the cor-...

  • Page 180: Main (High Speed) Jet Adjustment

    Main (High Speed) Jet Adjustment Jet Orifice Size Chart The carburetor has a fixed high speed jet. Extreme NOTE: 10-32 Thread Size changes in weather (temperature and humidity) and/ or elevation may result in a too lean or rich fuel mix- Jet Orifice Part ture at wide-open-throttle, which may require a...

  • Page 181: High Altitude Jet Chart

    High Altitude Jet Chart Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet (1524m) above sea level. Between 2000 feet (609.6m) and 5000 feet (1524m) the reduction of the main fuel jet(s) may result in improved performance and fuel economy. Above 5000 feet, however, it is recommended that main jet size be reduced as shown per 1000 feet (304.8m) in the following chart.

  • Page 182: Fuel System Troubleshooting

    Fuel System Troubleshooting General Information Problems that are thought to be caused by the fuel system may, in reality, be something completely dif- ferent. Items, that are shown below, could give the impression that there is a problem in the fuel system. 1.

  • Page 183: Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold

    Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold Possible Cause Corrective Action Improper starting procedure used. Review starting procedure as outlined in “Operation and Maintenance Manual”. Fuel tank empty or too low. Improperly mixed fuel. Check fuel in tank and replace or add whichever is Contaminants (water, dirt, etc.) in fuel.

  • Page 184: Problem: Engine Runs Too Lean

    Problem: Engine Runs Too Lean Possible Cause Corrective Action Carburetor is loose. Air leaks past mixing chamber Tighten bolts securely. Tighten cover or replace gas- cover. ket. Fuel level is too low. Reset float level. Clogged high speed jet. Inspect jet for varnish or debris and clean. Restricted fuel flow to carburetor.

  • Page 185: Inspection

    Inspection 3. Inspect idle mixture screw. Replace if bent or damaged. CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously af- fect performance. Use a petroleum based solvent for cleaning and blow out all passages with com- pressed air.

  • Page 186: Enrichener System

    Description for Four Cylinder Engines Enrichener System Enrichener valve receives fuel from a T-fitting be- tween #1 and #2 carburetors. Valve is electrically Description for Three Cylinder opened when ignition key is turned to the “ON” posi- Engines tion and pushed in (and held in). Fuel is dispensed to T-fittings on intake manifold of cylinders #2 and #4.
  • Page 187 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 battery voltage Squeeze primer bulb until bulb is firm. YELLOW/BLACK wire at terminal block Remove lower hose from fitting on on engine when key (or choke button) is enrichener valve.

  • Page 188: Acceleration Pump Circuit Operation - Four Cylinder Engines

    Acceleration Pump Circuit Operation FLOW RESTRICTOR - Helps equalize pressure within the accelerator pump circuit while allowing air - Four Cylinder Engines or any vapor which has formed to pass through and be vented at the carburetors. ACCELERATOR PUMP - Receives pressurized fuel from T-fitting in fuel line between #1 and #2 carbure- FUEL CONNECTOR - Spring loaded shut off valve tors.
  • Page 189 Acceleration Pump Fuel Flow Circuit for Four Cylinder Engines +5 .0 PSI CARB. +4 .5 PSI CARB. ACCELERATOR LARGE PUMP FUEL FILTER +4.0 PSI SMALL FUEL FILTER +5 .0 PSI CYL. #3 CARB. FUEL PUMP CHECK VALVES LOCATED IN CYLINDER BLOCK TRANSFER PORTS (UNSEAT AT 11–14 PSI) –0 .5 PSI...
  • Page 190 FUEL SYSTEM OIL INJECTION...
  • Page 191 Table of Contents Page Page Notes: ........3C-1 Oil Pump Test .

  • Page 192: Notes

    Notes: 90-830234R3 DECEMBER 1997 FUEL SYSTEM - 3C-1...

  • Page 193: Oil Injection Components

    Oil Injection Components (S/N–USA–0G301750/BEL–9885504 & BELOW) A = TO FUEL PUMP 3C-2 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 194 Oil Injection Components (S/N–USA–0G301750/BEL–9885504 & BELOW) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m OIL TANK ASSEMBLY COVER ASSEMBLY GASKET LATCH SPRING SCREW WASHER GROOVE PIN ROLL PIN (.093 x 1.250) VENT ASSEMBLY VALVE SCREW WASHER GROMMET BUSHING BOOT BASE SCREW...
  • Page 195 Oil Injection Components (S/N–USA–0G301751/BEL–9885505 & UP) A = TO FUEL PUMP 3C-4 - FUEL SYSTEM 90-830234R3 DECEMBER 1997...
  • Page 196 Oil Injection Components (S/N–USA-0G301751/BEL–9885505 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m OIL TANK CAP ASSEMBLY O RING DIPSTICK Push Nut VENT ASSEMBLY VALVE BRACKET BOOT SCREW (M6X20) GROMMET BUSHING WASHER SCREW (M8X35) 20.5 SWITCH ASSEMBLY SCREW Drive Tight WASHER...

  • Page 197: Description

    Description Hose Connections CAUTION Be careful not to get dirt or other contamination in tank, hoses or other components of the oil in- jection system. CAUTION Engines with oil injection must be run on a fuel/ oil ratio of 50:1 in the fuel tank, in addition to the oil supplied by the oil injection system, for the first 30 gallons of fuel.

  • Page 198: And 4 Cylinder Oil Flow Diagram

    3 and 4 Cylinder Oil Flow Diagram 54129 a - Oil Tank Vent h - Fuel Pump b - Oil Tank i - 2 psi (13.7kPa) Check Valve c - Low Oil/Overheat Warning Module j - Oil Pump Bleed Valve d - Fuel Enrichment Valve Fuel Fitting k - Oil Pump e - Accelerator Pump Fitting (4 Cylinder Models Only)

  • Page 199: Filling Oil Tank

    Filling Oil Tank 1. Quicksilver 2-Cycle Outboard Oil is recom- mended for this oil injection system. In an emer- gency, when Quicksilver 2-Cycle Outboard Oil is not available, substitute a high quality 2-cycle oil that is intended for outboard use and meets BIA rating TC-WII or TC-W3, shown on oil container.

  • Page 200: Bleeding Air From Oil Injection System

    Bleeding Air from Oil Oil Pump Test Injection System NOTE: A graduated container is required to perform this test. IMPORTANT: If air exists in either oil pump hose 1. Connect engine to remote fuel tank containing a (inlet or outlet), the air MUST BE bled from the 50:1 fuel/oil mixture (25:1 if during break-in peri- hose(s) before operating engine.

  • Page 201: Low Oil Sensor Test

    With the ignition switch in the “Run” position, electri- Low Oil Sensor Test cal current is routed thru the warning horn and sup- NOTE: Low oil sensor is located in bottom of oil tank. plied to the powerhead temperature sensor and low oil sensor.

  • Page 202: Oil Injection System Troubleshooting Chart

    NOTE: There is a safety reserve of oil left in the reser- Oil Injection System voir after the low oil warning is sounded. There is Troubleshooting Chart enough oil for approximately 50 minutes of full throttle operation on four cylinder engines and (Models with Warning Module) approximately 1 hour of full throttle operation on three cylinder engines.
  • Page 203 FUEL SYSTEM Emission Control 1998 1848 Information PART # 37–855211 11 This engine is certified to operate on regular 87 This engine conforms to 1998 Model Year octane unleaded fuel (R+M)/2 U.S. EPA regulations for marine SI engines. Idle Speed (in gear): 675 RPM Refer to Owners Manual for required maintenance.
  • Page 204 Table of Contents Page Exhaust Emissions Standards ....3D-1 What Are Emissions ..... . . 3D-1 Hydrocarbons –...

  • Page 205: Exhaust Emissions Standards

    is a harmless gas. But carbon often combines with Exhaust Emissions insufficient oxygen (one carbon atom with one oxy- Standards gen atom). This forms carbon monoxide, CO. Car- bon monoxide is the product of incomplete combus- Through the Environmental Protection Agency tion and is a dangerous, potentially lethal gas.

  • Page 206: Outboard Hydrocarbon Emissions Reductions

    As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temper- atures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combus- tion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as pos- sible.

  • Page 207: Stratified Vs Homogenized Charge

    STRATIFIED VS HOMOGENIZED CHARGE DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is: Homogenized Charge Stratified Charge A homogenized charge has the fuel/air particles A stratified charge engine only pulls air through the mixed evenly throughout the cylinder.

  • Page 208: Emissions Information

    EPA Emission Regulations: Emissions Information All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States En- Manufacturer’s Responsibility: vironmental Protection Agency as conforming to the requirements of the regulations for the control of air Beginning with 1998 model year engines, manufac- pollution from new outboard motors.
  • Page 209 - Recommended oil/fuel ratio for best engine performance and minimal emissions k - Month of production (Boxing month will punched) l - FEL: Represents (Mercury Marine) statement of the maxi- mum emissions output for the engine family m - Family example: W M9X M 112.8 2 1 0...

  • Page 210: Decal Location For 1998 Models

    Service Part No. Location on Engine Merc/Mar 85 C.I. 37-855211 10 37-855577 10 Block Exhaust Cover (75 – 90 H.P.) Merc/Mar 113 C.I. 37-855211 11 37-855577 11 Block Exhaust Cover (100 – 115 – 125 H.P.) 3D-6 - FUEL SYSTEM...
  • Page 211 POWERHEAD 20032...
  • Page 212 ......4-63 (65 Jet/75/90 Models) ......

  • Page 213: Specifications

    WEIGHT Model 75/90 305 lbs. (139kg) Model 80 Jet 357 lbs. (162kg) Model 100/115/125 348 lbs. (158kg) CYLINDER Model 65 Jet/75/90 BLOCK Type In-line 3 Cylinder, 2 Cycle, Loop Charged Displacement 84.6 cu. in. (1387cc) Model 80 Jet/100/115/125 Type In-Line 4 Cylinder, 2 Cycle, Loop Charged Displacement 112.8 cu.

  • Page 214: Tools For Powerhead Repair

    7. Lockring Installation Tool 91-77109A2/A3 Tools for Powerhead Repair 1. Flywheel Holder 91-52344 8. Powerhead Stand 91-812549 2. Protector Cap 91-24161 3. Flywheel Puller 91-73687A1 4. Lifting Eye 91-90455 General Information DISASSEMBLY AND REASSEMBLY If complete disassembly is not necessary, start at ap- propriate spot;...

  • Page 215: Notes

    Notes: 90-830234R3 DECEMBER 1997 POWERHEAD - 4-3...

  • Page 216: Crankshaft, Pistons And Connecting Rods (3 Cyl.)

    Crankshaft, Pistons and Connecting Rods (3 Cyl.) 2-4-C With Teflon (92-825407A12) 2 Cycle Outboard Oil (92-13249A24) 4-4 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 217 Crankshaft, Pistons and Connecting Rods (3 Cyl.) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CRANKSHAFT BALL BEARING(LOWER) WEAR SLEEVE O-RING RING ASSEMBLY DRIVER GEAR ROLLER BEARING ASSEMBLY(UPPER) OIL SEAL O-RING ROLLER BEARING ASSEMBLY PISTON ASSEMBLY (STANDARD) PISTON ASSEMBLY (.015 O.S.) PISTON ASSEMBLY (.030 O.S.) LOCK RING PISTON RING ASSEMBLY (STANDARD)

  • Page 218: Cylinder Block (3 Cyl.) (Usa-0G127499/Bel-9836632 & Below)

    Cylinder Block (3 cyl.) (USA-0G127499/BEL-9836632 & BELOW) Loctite 35 (92-59328-1) Loctite Master Gasket (92-12564-1) 4-6 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 219 Cylinder Block (3 cyl.) (USA-0G127499/BEL-9836632 & BELOW) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK ASSEMBLY SCREW ADJUSTING SCREW 33.9 CHECK VALVE (PRESS-IN) CARRIER ASSEMBLY CHECK VALVE DOWEL PIN (BEARING RACE) DOWEL PIN (DESIGN I) SCREW 33.9 STUD DESIGN II...
  • Page 220 Cylinder Block (3 cyl.) (USA-0G127499/BEL-9836632 & BELOW) Loctite 35 (92-59328-1) Loctite Master Gasket (92-12564-1) 4-8 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 221 Cylinder Block (3 cyl.) (USA-0G127499/BEL-9836632 & BELOW) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m COVER ASSEMBLY GASKET PIPE PLUG LIFTING EYE THERMOSTAT GASKET GASKET COVER SCREW–air vent hole SCREW (35 MM) 24.4 SCREW Drive Tight WASHER DIAPHRAGM SCREW Drive Tight WASHER...

  • Page 222: Cylinder Block (3 Cyl.) (Usa-0G127500/Bel-9836633 & Up)

    Cylinder Block (3 Cyl.) (USA-0G127500/BEL-9836633 & UP) Loctite 271 (92-809820) Liquid Neoprene(92-25711--2) Loctite Master Gasket(92-12564-1) 4-10 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 223 Cylinder Block (3 Cyl.) (USA-0G127500/BEL-9836633 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK ASSEMBLY SCREW(M10 x 80) 33.9 ADJUSTING SCREW(M6 x 55) CHECK VALVE(PRESS-IN) CARRIER ASSEMBLY CHECK VALVE DOWEL PIN(BEARING RACE) DOWEL PIN STUD(M10 x 136) WASHER COVER(BOTTOM) SCREW(M8 x 50)
  • Page 224 Cylinder Block (3 Cyl.) (USA-0G127500/BEL-9836633 & UP) Loctite 271 (92-809820) Liquid Neoprene(92-25711--2) Loctite Master Gasket(92-12564-1) 4-12 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 225 CYLINDER BLOCK (USA-S/N-0G127500/BEL-9836633 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m COVER ASSEMBLY GASKET PIPE PLUG LIFTING EYE NON OIL INJECTION WASHER THERMOSTAT (OIL INJECTION) GASKET GASKET COVER SCREW–air vent hole (Use where Applicable) SCREW (M8 x 35) 24.4 SCREW(10-16 x 3/4) Drive Tight...

  • Page 226: Induction Manifold And Reed Block (3 Cyl.)

    Induction Manifold and Reed Block (3 Cyl.) Perfect Seal(92-34227-1) 2-4-C With Teflon(92-825407A12) 4-14 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 227 Induction Manifold and Reed Block (3 Cyl.) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m EXHAUST COVER/PLATE KIT GASKET SCREW(M8 x 35) 24.4 ELBOW GASKET SHIFT RAIL TAB WASHER SCREW(M8 X 25) 24.4 SLIDE Drive Tight; But Joint Must Pivot Freely WASHER LOWER END CAP ASSEMBLY...

  • Page 228: Crankshaft, Pistons And Connecting Rods (4 Cyl.)

    Crankshaft, Pistons and Connecting Rods (4 Cyl.) 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) 4-16 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 229 Crankshaft, Pistons and Connecting Rods (4 Cyl.) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CRANKSHAFT ASSEMBLY BALL BEARING (LOWER) WEAR SLEEVE O-RING RING ASSEMBLY DRIVER GEAR ROLLER BEARING ASSEMBLY PISTON ASSEMBLY (STANDARD) PISTON ASSEMBLY (.015 O.S.) PISTON ASSEMBLY (.030 O.S.) LOCK RING PISTON RING ASSEMBLY (STANDARD) PISTON RING ASSEMBLY (.015 O.S.)

  • Page 230: Cylinder Block And Crankcase (80 Jet/100/115/125)

    Cylinder Block and Crankcase (80 Jet/100/115/125) Loctite 271 (92-809820) Loctite 35 (92-59328-1) Liquid Neoprene (92-25711--2) Loctite Master Gasket (92-12564-1) 4-18 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 231 Cylinder Block and Crankcase (80 Jet/100/115/125) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK USA-S/N-0G437999 /BEL-9926999 & BELOW CYLINDER BLOCK USA-S/N-0G438000 /BEL-9927000 & UP SCREW (M10 x 80) 33.9 DOWEL PIN (BEARING RACE) DOWEL PIN COVER (TOP) COVER (BOTTOM) SCREW (M8 x 50) 12.5...
  • Page 232 Cylinder Block and Crankcase (80 Jet/100/115/125) Loctite 271 (92-809820) Loctite 35 (92-59328-1) Liquid Neoprene (92-25711--2) Loctite Master Gasket (92-12564-1) 4-20 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 233 Cylinder Block and Crankcase (80 Jet/100/115/125) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TEMPERATURE SENDER (35-1/2 IN.)(RING TERMINAL) TEMPERATURE SENDER (22-1/2 IN.)(FEMALE TERMINAL) RETAINER SCREW Drive Tight WASHER POPPET VALVE DIAPHRAGM WASHER SCREW (10-16 x 3/4 IN.) Drive Tight SPRING THERMOSTAT...

  • Page 234: Induction Manifold And Reed Block (80 Jet/100/115/125)

    Induction Manifold and Reed Block (80 Jet/100/115/125) Loctite 35 (92-59328-1) Perfect Seal (92-34227-1) 2-4-C With Teflon (92-825407A12) 4-22 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 235 Induction Manifold and Reed Block (80 Jet/100/115/125) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m EXHAUST COVER PLATE KIT GASKET GASKET SCREW (M8 x 35) 24.4 ELBOW SHIFT RAIL TAB WASHER SCREW (M8 x 25) SLIDE WASHER Drive Tight; But Joint Must be Free to Pivot GASKET LOWER END CAP ASSEMBLY...

  • Page 236: Throttle Lever And Linkage (65 Jet/75/90 Models)

    Throttle Lever and Linkage (65 Jet/75/90 Models) 2-4-C With Teflon (92-825407A12) 4-24 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 237 Throttle Lever and Linkage (65 Jet/75/90 MODELS) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m THROTTLE LEVER SCREW DESIGN II SPRING ADJUSTING SCREW DESIGN I JAM NUT SPARK ADVANCE LEVER ADJUSTING SCREW (6 MM) JAM NUT NYLON CAP...

  • Page 238: Throttle Lever (Models 80Jet/100/115/125)

    Throttle Lever (Models 80Jet/100/115/125) 2-4-C With Teflon (92-825407A12) 4-26 - POWERHEAD 90-830234R3 DECEMBER 1997...
  • Page 239 Throttle Lever (Models 80 Jet/100/115/125) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m THROTTLE LEVER ADJUSTING SCREW JAM NUT DESIGN I NYLON CAP SCREW (M5 x 40) DESIGN II SPRING NYLON CAP SPARK ADVANCE LEVER ADJUSTING SCREW (M6 x 55) JAM NUT NYLON CAP Tighten Screw Se-...
  • Page 240 Cylinder Block Cover USA - 437999/BEL-9926999 & 18 lb. ft. (24.4 Nm) BELOW Electrical Component Plate 13.5 lb. ft. (18.3 Nm) Loctite 271 Required. Exhaust Cover (and Divider Plate) 18 lb. ft. (24.4 Nm) Loctite 271 (92-809820) USA -438000/BEL-9937000 & UP Electrical Component Plate 200 lb.

  • Page 241: Powerhead Removal

    Remove 2 bolts securing aft end of lower cowling. Powerhead Removal Remove top cowl. Disconnect bullet connectors in cowl mounted trim switch harness. 53953 a - Bolts Remove bolt securing forward portion of lower cowling. 53952 a - Cowl Mounted Trim Switch Remove tell-tale hose from exhaust cover.
  • Page 242 Remove shift arm linkage at stud. Remove 2 nuts securing GREEN and BLUE trim harness leads to solenoids. Remove bolt secur- ing BLACK trim harness lead. 19060 a - Shift Arm Linkage b - Stud Remove 4 bolts securing electrical plate cover and remove cover.
  • Page 243 Remove 8 powerhead to driveshaft housing Remove Air Box Cover by removing 6 screws. mounting nuts and washers (4 each side). 19070 a - Nuts and Washers (4 Each Side) 3 Cylinder Models 53977 Screw lift eye (91-90455) into flywheel at least 5 a - Air Box Cover full turns.
  • Page 244 Disconnect oil lines - remove oil reservoir. 3 Cylinder Models 53978 a - Bolt – Lower Oil Tank Support b - Bolt – Upper Oil Tank Support 54131 c - Bolts – Voltage Regulator d - Nuts (4) Bolts (2) a - Main Fuel Hose b - Fuel Enrichment Hose c - Oil Pump Linkage...
  • Page 245 4 Cylinder Models 54134 4 Cylinder Models 54135 a - Fuel Enrichment Fitting b - Accelerator Pump Fitting a - Intake Manifolds Remove intake manifolds. Remove intake manifolds as an assembly. 3 Cylinder Models 19330 3 Cylinder Models 54136 a - Intake Manifolds 90-830234R3 DECEMBER 1997 POWERHEAD - 4-33...

  • Page 246: Flywheel Removal

    Pry off each reed-block, as shown, using screw- Flywheel Removal driver. DO NOT strike end of puller center bolt to remove flywheel, or damage may result to crankshaft or bearings. Remove flywheel cover from powerhead. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer.

  • Page 247: Powerhead Disassembly

    Remove check valves. Powerhead Disassembly Remove fuel pump by removing 2 screws. Remove oil injection pump by removing 2 bolts. Remove hoses to fuel pump and oil injection pump. 52478 a - Check Valve (4 Cylinder Models Only) Accelerator check valves can be tested for prop- er performance as follows: 1.
  • Page 248 Remove thermostat housing and components. Remove 3 bolts from crankcase end cap (lower). 20020 a - End Cap Bolts Remove crankcase bolts, and cover. 25907 a - Bolts b - Thermostat Cover c - Thermostat d - Poppet Valve Remove cylinder block cover. 20032 Remove crankcase end cap (lower).
  • Page 249 Crankshaft may be removed as an assembly, or Remove piston assembly from crankshaft; reat- by component parts. tach caps to respective rods, as each is removed. CAPS MUST BE INSTALLED IN SAME DIREC- IMPORTANT: Rod caps MUST be reassembled on TION ON SAME ROD, or mating surfaces will not the same rod - in the same direction.
  • Page 250 Use piston ring expander (91-24697) to remove Support piston and tap out piston pin, using ser- piston rings. Always install new piston rings. vice tool 91-74607A2, as shown. NOTE: Cylinders must be honed in order for new rings to seat properly. 51086 51081 a - Piston Pin...
  • Page 251 NOTE: There is NO main bearing retaining ring or re- taining ring groove in the crankshaft on the following a - Oil Drive Gear outboards: 75/90/100/115/125 -- SERIAL NUMBER b - Key OC259434 and above. Seal carrier is press-fitted into the spline end of Press crankshaft out of bearing, as shown.

  • Page 252: Cleaning And Inspection

    Some models may be equipped with the following Cleaning and Inspection sleeve , which retains an O-ring seal . The sleeve is pushed over the crankshaft end until it bottoms- Cylinder Block and Crankcase Cover out on a crank flange, leaving space for the O-ring between the sleeve lip and the end of the crank- IMPORTANT: Crankcase cover and cylinder shaft.
  • Page 253 Measure cylinder bore inside diameter (with an CYLINDER BORE SIZE inside micrometer) of each cylinder, as shown Piston Size Cylinder Block Fin- below. Check for tapered, out-of-round (“egg- ish Hone shaped”) and oversize bore. Standard Diameter 3.501 in. (88.77mm) 0.015 Oversize 3.516 in.

  • Page 254: Check Valves

    Check Valves INSTALLATION Install check valve (if removed) inside of carrier REMOVAL (single hole of valve faces tapered end of carrier). Remove carburetors and intake manifold/reed Align carrier tab with slot in crankcase cover and block assemblies. insert check valve/carrier assembly into cover. Grasp carrier and remove carrier/check valve as- sembly from crankcase cover.
  • Page 255 Check tightness of piston ring locating pins. Lo- MEASURING PISTON SKIRT cating pins must be tight. Measure piston skirt at right angle (90_) to piston pin Thoroughly clean pistons. Carefully remove car- centerline, 0.50 in. (12.7mm) up from bottom edge of bon deposits, with a soft wire brush or carbon re- skirt.

  • Page 256: Crankshaft

    Crankshaft Connecting Rods Inspect crankshaft to drive shaft splines for wear. If necessary, clean connecting rod surfaces as (Replace crankshaft, if necessary.) follows: Check crankshaft for straightness. Total maxi- Attach end caps to connecting rods. Following mum runout for crankshaft is 0.006 (0.15mm). these directions, tighten rod cap attaching bolts Replace as necessary.

  • Page 257: Cylinder Cover, Exhaust Divider Plate And Exhaust Cover

    Cylinder Cover, Exhaust Divider Plate Thermostat and Exhaust Cover Wash thermostat with clean water. Using a thermo- stat tester, similar to the one shown, test thermostat Thoroughly clean cylinder cover and gasket sur- as follows: faces. Open thermostat valve, then insert a thread be- Inspect cylinder cover.

  • Page 258: Temperature Switch Test

    Temperature Switch Test Reed Blocks 190 F (88 C) NOTE: Do not disassemble reed block unless neces- sary. It may be necessary to apply heat to bolt to soft- The 190 F (88 C) temperature switch is located in en Loctite before removal.

  • Page 259: Powerhead Reassembly And Installation

    If the opening exceeds 0.020 in. (0.51mm), or if the Powerhead Reassembly and reed is chipped, cracked, or otherwise damaged, re- Installation place. General Information Before proceeding with powerhead reassembly, be sure that all parts to be reused have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspection”.

  • Page 260: End Cap

    End Cap Assembling Rod to Piston Clean thoroughly, including seal and O-ring seats; re- Place clean needle bearings on a clean sheet of move perfect seal residue and clean cap-to-head paper and lubricate with Quicksilver 2-4-C w/Teflon mating surfaces. (92-825407A12). NOTE: There are 29 needle bearings per piston.

  • Page 261: Piston Ring Installation

    Insert piston pin tool through piston in the direction WARNING shown, pushing out sleeve. Eye protection must be worn while installing pis- ton pin lockrings. Install new piston pin lockrings (each side of piston) using Lockring Tool (91-77109A2). Make sure lockrings are properly seated in piston grooves.
  • Page 262 Piston rings are TAPERED top side, and flat (rectan- 3. Align piston ring end gaps with ring locating pins gular) on the bottom side (half-keystone rings). as shown. Check locating pins making sure they are tight. 53988 a - Locating Pin b - Piston Rings a - Enlarged View of Piston Ring Grooves 4.

  • Page 263: Crankshaft Installation

    (ring fails to “spring” back), the ring is taining ring groove in the crankshaft on the following probably broken and must be replaced before instal- outboards: ling the crankshaft. 75/90/100/115/125 - Serial Number 0C 259434 and above 25949 51084 a - Lower Bearing...
  • Page 264 Install 2 ring seals into slot between each center Attach bearing races with holes toward lower gear main bearing and position ring seal end gaps end of crankshaft. Secure each main bearing race 180_ apart. with retaining ring. 20040 a - Main Bearing Race b - Retaining Ring c - Top Main Bearing To install top main bearing, lubricate needle bearing...
  • Page 265 Position Cylinder Block and Piston Rods, as shown. Place crankshaft into cylinder block; align and seat Note locating pins. top and center main bearings so that locating pins on block mate with holes in each bearing race. 20336 3 Cylinder Models 20038 3 Cylinder Models 4 Cylinder Models...

  • Page 266: Connecting Rod Cap Alignment

    INSTALLING RODS TO CRANKSHAFT Place Rod Cap carefully over cage and bearings, and while holding cap tight to rod, and rod tight to Pull rod up to position shown. journal, insert bolt and lightly tighten, observing Grease rod, bearing area, with 2-4-C w/Teflon - cap-to-rod alignment.

  • Page 267: Crankcase Cover To Block

    2. When connecting rods are attached, and bolts Crankcase Cover to Block drawn down finger tight, torque rod-cap bolts to LOCTITE MASTER GASKET SEALANT, 15 lb. in. (1.7 N·m). Recheck alignment. Retor- 92-12564-1 is used; it comes as a kit, which includes que 5/16 in.

  • Page 268: Cylinder Block Cover

    REATTACH CRANKCASE COVER Cylinder Block Cover After the application of the Loctite Master Gasket Align cover and gasket on block. Sealing Kit, place crankcase cover onto block, and align. Recheck that bolt holes and bolts are clean to as- sure accurate torque. Insert bolts - note 2 sizes and finger tighten.

  • Page 269: Exhaust Plate Cover And Exhaust Divider Plate

    Position clips, align cover holes and insert bolts - Exhaust Plate Cover and Exhaust finger tighten (located under bolts #2 and 10). Divider Plate Insert remaining cover bolts - finger tighten. Assemble in order shown. NOTE: Keep clips positioned, as shown, during a.
  • Page 270 EXHAUST PLATE COVER TORQUE SEQUENCE Reattach fuel/oil line hoses and secure with sta- straps. All Cover Bolts: 18 lb. ft. (24.4 Nm) 3 Cylinder Models 3 Cylinder Models 53992 a - Bolts [Torque to 40 lb. in. (4.5 N·m)] b - Bolts [Torque to 60 lb. in. (6.8 N·m)] 4 Cylinder Models Reinstall Oil Injection Pump Shaft and housing;...

  • Page 271: Intake Manifold And Reed Block Installation

    Reattach shift arm linkage on stud. Intake Manifold and Reed Block Installation Reinstall Reed Block Housings and Intake Manifolds. 3 Cylinder Models 19544 a - Shift Arm Linkage b - Stud 3 Cylinder Models 19574 a - Gasket b - Intake Manifold c - Reed Block Assembly d - Install Intake Manifold as One Unit INTAKE MANIFOLD - TORQUE SEQUENCE...

  • Page 272: Accelerator Pump Installation (4 Cylinder Models)

    Accelerator Pump Installation (4 Cylinder Models) Install accelerator pump check valves and hoses. 25914 4 Cylinder Models a - Intake Manifolds 25913 b - Reed Block Assemblies 4 Cylinder Models a - Accelerator Pump Hoses b - Check Valves Install accelerator pump with 2 bolts. Torque bolts to 130 lb.

  • Page 273: Cylinder Bleed Hose Routing

    3 Cylinder Bleed Hose Routing a - Pressed-In Check Valve b - Threaded Check Valve 90-830234R3 DECEMBER 1997 POWERHEAD - 4-61...

  • Page 274: Cylinder Bleed Hose Routing (1995 And Prior)

    4 Cylinder Bleed Hose Routing (1995 and Prior) 52478 a - Pressed-In Check Valve b - Threaded Check Valve 4-62 - POWERHEAD 90-830234R3 DECEMBER 1997...

  • Page 275: Cylinder Bleed Hose Routing (1996 And Newer)

    4 Cylinder Bleed Hose Routing (1996 and Newer) a - Pressed-In Check Valve b - Threaded Check Valve 90-830234R3 DECEMBER 1997 POWERHEAD - 4-63...

  • Page 276: Cylinder Fuel Enrichment/Accelerator Pump Hose Routing

    4 Cylinder Fuel Enrichment/Accelerator Pump Hose Routing 4-64 - POWERHEAD 90-830234R3 DECEMBER 1997...

  • Page 277: And Newer 3 Cylinder Harness Routing (Without Oil Reservoir Installed)

    1994 and Newer 3 Cylinder Harness Routing (without Oil Reservoir Installed) 54161 a - Stator Harness e - NEGATIVE (–) Battery Cable b - Trigger Harness f - Power Trim Harness c - Voltage Regulator Harness g - POSITIVE (+) Battery Cable d - Fuel Enrichment Harness h - Lower Cowl Trim Harness 90-830234R3 DECEMBER 1997...

  • Page 278: And Newer 3 Cylinder Harness Routing (With Oil Reservoir Installed)

    1994 and Newer 3 Cylinder Harness Routing (with Oil Reservoir Installed) 54162 a - Trigger Harness b - Voltage Regulator Harness c - NEGATIVE (–) Battery Cable d - Low Oil Warning Module Harness e - POSITIVE (+) Battery Cable f - Power Trim Harness g - Lower Cowl Power Trim Harness 4-66 - POWERHEAD...

  • Page 279: Cylinder Manual Start Harness Routing

    3 Cylinder Manual Start Harness Routing a - Stator Harness b - Trigger Harness c - RPM Limiter Harness d - Overheat Sensor Lead 90-830234R3 DECEMBER 1997 POWERHEAD - 4-67...
  • Page 280 1994 and Newer 4 Cylinder Harness Routing (without Oil Reservoir Installed) 54163 a - Stator Harness b - Trigger Harness c - Fuel Enrichment Harness d - Voltage Regulator Harness e - NEGATIVE (–) Battery Cable f - Power Trim Harness 4-68 - POWERHEAD 90-830234R3 DECEMBER 1997...

  • Page 281: And Newer 4 Cylinder Harness Routing

    1994 and Newer 4 Cylinder Harness Routing (with Oil Reservoir Installed) 54164 a - Stator Harness e - Voltage Regulator Harness b - Trigger Harness f - POSITIVE (+) Battery Cable c - Fuel Enrichment Harness g - Power Trim Harness d - NEGATIVE (–) Battery Cable h - Low Oil Warning Harness 90-830234R3 DECEMBER 1997...

  • Page 282: Ignition Plate Installation

    Ignition Plate Installation Install ignition plate. Apply Loctite 271 to bolt threads. Torque ignition plate bolts to 13.5 lb. ft. (18.5 Nm). 25922 4 Cylinder Models Loctite 271 (92-809820) 3 Cylinder Models a - Ignition Plate Loctite 271 (92-809820) b - RPM Limiter (outer) and Oil Warning Module (inner) c - Ignition Plate Bolts (4 Each) a - Bolts d - RPM Limiter/Oil Warning Module Bolts (2 Each)

  • Page 283: Trigger And Stator Installation

    Trigger and Stator Installation Install trigger and connect link arm. 53970 19459 4 Cylinder Models a - Trigger a - Sta-Strap b - Link Arm b - Trigger Harness c - Switch Box Connect trigger leads to switch box; refer to wir- ing diagrams in Section 2D.

  • Page 284: Stator Installation

    Large Rim Stator Two styles of stators are used on 1994 through 1996 model 75/90 outboards. These stators can be identified by a large rim or small rim on the un- derside of the stator where the stator harness ex- stator.
  • Page 285 Install stator as shown. 53973 4 Cylinder Models 53790 a - Screws; apply Loctite 271 on threads (unless Patch Screw is used) and torque to 60 lb. in. (6.8 Nm) a - Sta-Strap b - Stator b - Stator Harness c - Stator Harness c - Switch Box d - Trigger Harness...

  • Page 286: Temperature Sensor Installation

    Temperature Sensor Installation Carburetor Installation Install carburetor gaskets. Reinstall carburetors as a single unit assembly. Note manifold hose position and connection. 3 Cylinder Models 19094 a - Manifold Hose 3 Cylinder Models a - Temperature Sensor b - Retainer Screws 25914 4 Cylinder Models a - Base Gaskets...
  • Page 287 - Carburetors b - Top Carb Input Fuel Hose c - Input Hose to Fuel Enrichment Valve d - Input Hose to Accelerator Pump e - Fuel Enrichment Valve f - Accelerator Pump 90-830234R3 DECEMBER 1997 POWERHEAD - 4-75...

  • Page 288: Flywheel Installation

    Flywheel Installation Oil Reservoir Installation IMPORTANT: Inspect flywheel magnets for cling- Install oil tank assembly on powerhead. Torque ing debris prior to installing flywheel over stator. aft bottom oil tank bracket bolt to 15 lb. ft. (20.3 Failure to remove debris from magnets will result Nm).

  • Page 289: Air Box Installation

    Air Box Installation Install Gaskets - Air Box Plate to carburetor. Reinstall Air Box Plate. Torque bolts and nuts to 100 lb. in. (11.3 Nm). 3 Cylinder Models 53982 a - Oil Reservoir b - Flywheel Cover 3 Cylinder Models c - Bolt [Torque to 15 lb.

  • Page 290: Powerhead To Driveshaft Housing

    Reinstall Air Box Cover; tighten screws securely. Powerhead to Driveshaft Housing Install lifting eye (91-90455) onto flywheel. Thread on at least 5 full turns. After checking mating surfaces between power- head and driveshaft housing for condition and cleanliness, use hoist to lift powerhead, being careful not to damage powerhead to driveshaft housing gasket surface.

  • Page 291: Reinstall Bottom Cowl

    Reinstall Bottom Cowl Install 2 bolts securing aft end of lower cowling. Torque bolts to 65 lb. in. (7.3 N·m). Reconnect bullet connectors to cowl mounted trim switch. 53953 a - Bolts Install bolt securing forward portion of lower cowl. Torque bolt to 65 lb.
  • Page 292 MID-SECTION CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING...
  • Page 293 Exhaust Plate (80 Jet/100/115/125) ... . 5A-16 Transom Bracket (Manual Tilt Assist) Drive Shaft Housing (65 Jet/75/90) ... . . 5A-18 (65 Jet/75/90) .
  • Page 294 Notes: 90-830234R3 DECEMBER 1997 MID-SECTION - 5A-1...

  • Page 295: Swivel Bracket And Steering Arm (65 Jet/75/90)

    Swivel Bracket and Steering Arm (65 Jet/75/90) Loctite 271 (92-809820) 2-4-C With Teflon(92-825407A12) a - Torque nut to 120 lb. in. (13.6 N· m); then back off 1/4 turn. b - Torque nut to 20 lb. ft. (27.0 N· m).
  • Page 296 Swivel Bracket and Steering Arm (65 Jet/75/90) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SWIVEL BRACKET (BLACK) NON-POWER TRIM SWIVEL BRACKET (GRAY) SWIVEL BRACKET (BLACK) SWIVEL BRACKET (GRAY) MANUAL TILT ASSIST/POWER TRIM SWIVEL BRACKET (TRACKER-GRAPHITE GRAY)

  • Page 297: Transom Bracket(Non Power Trim & Power Trim) (65 Jet/75/90)

    Transom Bracket(Non Power Trim & Power Trim) (65 Jet/75/90) 21 22 Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-13783A24) 2-4-C With Teflon (92-825407A12) 5A-4 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 298 Transom Bracket (Non Power Trim & Power Trim) (65 Jet/75/90) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N· m (STARBOARD) TRANSOM BRACKET (PORT) TRANSOM BRACKET (PORT) GREASE FITTING NON POWER TRIM TILT PIN ASSEMBLY DECAL-tilt/lock TILT TUBE...

  • Page 299: Transom Bracket (Manual Tilt Assist) (65 Jet/75/90)

    Transom Bracket (Manual Tilt Assist) (65 Jet/75/90) Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-13783A24) 2-4-C With Teflon (92-825407A12) 5A-6 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 300 Transom Bracket (Manual Tilt Assist) (65 Jet/75/90) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N· m (STARBOARD) TRANSOM BRACKET (PORT) TRANSOM BRACKET (PORT) GREASE FITTING TILT PIN ASSEMBLY DECAL-tilt/lock TILT TUBE Tighten Nut until Bot- tomed on Shoulder...

  • Page 301: Swivel Bracket And Steering Arm (80 Jet/100/115/125)

    Swivel Bracket and Steering Arm (80 Jet/100/115/125) Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) a - Torque nut to 120 lb. in (13.6 N· m)., then back off 1/4 turn. b - Torque nut to 20 lb. ft. (27.0 N· m). 5A-8 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 302 Swivel Bracket and Steering Arm (80 Jet/100/115/125) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SWIVEL BRACKET (BLACK) SWIVEL BRACKET (GRAY) SWIVEL BRACKET (TRACKER-GRAPHITE GRAY) OIL SEAL (LOWER) BUSHING O-RING SPACER GREASE FITTING BUSHING SCREW 11.3 SWIVEL PIN/STEERING ARM (BLACK) SWIVEL PIN/STEERING ARM (GRAY) SWIVEL PIN/STEERING ARM (TRACKER-GRAPHITE GRAY) STEERING LINK ASSEMBLY...

  • Page 303: Transom Bracket (S/N-Usa-0G589999/Bel-9973099 & Below)

    Transom Bracket (S/N-USA-0G589999/BEL-9973099 & BELOW) 18 19 Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-13783A24) 2-4-C With Teflon (92-825407A12) 5A-10 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 304 Transom Bracket (S/N-USA-0G589999/BEL-9973099 & BELOW) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N· m (STARBOARD) TRANSOM BRACKET (PORT) TRANSOM BRACKET GREASE FITTING (PORT) TILT TUBE Tighten Nut until Bot- tom on Shoulder of Tilt Tube O-RING WAVE WASHER Drive Nut Until As- sembly is Drawn to- gether;...
  • Page 305 Transom Bracket (S/N-USA-0G590000/BEL-9973100 & UP) Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-13783A24) 2-4-C With Teflon (92-825407A12) 5A-12 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 306 Transom Bracket (S/N-USA-0G590000/BEL-9973100 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m TRANSOM BRACKET (STARBOARD) BLACK TRANSOM BRACKET (PORT) TRANSOM BRACKET (STARBOARD) GRAY TRANSOM BRACKET (PORT) GREASE FITTING (PORT) TILT TUBE Tighten Nut until Bot- tomed on Shoulder of Tilt Tube O-RING WAVE WASHER...

  • Page 307: Exhaust Plate (65 Jet/75/90)

    Exhaust Plate (65 Jet/75/90) Loctite 271 (92-809820) 5A-14 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 308 Exhaust Plate (65 Jet/75/90) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N· m EXHAUST PLATE ASSEMBLY DOWEL PIN SCREW (M8 x 35) 20.3 SCREW (M8 x 70) 20.3 (NON OIL INJECTION)(LL) MOUNT (OIL INJECTION)(JET 65) MOUNT SCREW (M8 x 50) 33.9...

  • Page 309: Exhaust Plate (80 Jet/100/115/125)

    Exhaust Plate (80 Jet/100/115/125) Loctite 271 (92-809820) 5A-16 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 310 Exhaust Plate (80 Jet/100/115/125) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N· m EXHAUST PLATE ASSEMBLY DOWEL PIN SCREW (M8 x 35) 20.3 SCREW (M8 x 70) 20.3 MOUNT SCREW 33.9 SCREW WASHER WASHER 74.6 GASKET EXHAUST TUBE SCREW 33.9 SEAL--exhaust tube...

  • Page 311: Drive Shaft Housing (65 Jet/75/90)

    Drive Shaft Housing (65 Jet/75/90) Loctite 35 (92-59328-1) 2-4-C With Teflon (92-825407A12) 5A-18 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 312 POWER TRIM SPRING YOKE JAM NUT CLEVIS PIN COTTER PIN MOUNT (ELO/ELHPTO/SCATTO/TYPHOON) MOUNT (ALL OTHER MODELS) BOLT (M12 x 1.75 x 154) COVER (BLACK) SCREW (12-24 x 5/8²) Drive Tight WASHER 67.8 GROUND WIRE ASSEMBLY SCREW (1/4-20 x 1/2) Drive Tight CLAMP SCREW (M8 x 1.25 x 25)

  • Page 313: Drive Shaft Housing (80 Jet/100/115/125)

    Drive Shaft Housing (80 Jet/100/115/125) Loctite 35 (92-59328-1) 5A-20 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 314 Drive Shaft Housing (80 Jet/100/115/125) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N· m DRIVE SHAFT HOUSING ASSEMBLY (JET) DRIVE SHAFT HOUSING ASSEMBLY (LONG) STUD (X-LONG) STUD DOWEL PIN (LONG) STUD (X-LONG) STUD WASHER 54.2 X-LONG SPACER--drive shaft housing SPACER--drive shaft housing DOWEL PIN (W/HOLE) DOWEL PIN...

  • Page 315: Reference Views

    Reference Views 21054 Non Power Trim Reverse Lock Hook (Shown From Above) a - Push Rod End b - Nut c - Push Rod Yoke d - Cotter Pin e - Clevis Pin f - Reverse Lock Hook Shaft Arm g - Reverse Lock Hook Shaft h - Return Spring i - Tilt Pin...
  • Page 316 Upper Mount 21048 a - Upper Mount 2-4-C With Teflon (92-825407A12) 21050 b - Nut (2) [Torque to 80 lb. ft. (108.5 N¡ m)] c - Bolt (2) a - Upper Shift Linkage d - Rubber Washer (2) b - Steering Arm/Swivel Pin e - Washer (2) c - Upper Mount Bolt f - Bolt (4) [Torque to 23.5 lb.
  • Page 317 MID-SECTION 51485 POWER TRIM (S/N-USA 0G360002/BEL-9934136 & BELOW)
  • Page 318 Table of Contents Page Page Special Tools ....... . 5B-1 Power Trim System Removal .

  • Page 319: Special Tools

    Special Tools 1. Torch Lamp 91-63209 2. Spanner Wrench 91-74951 3. Multi-Meter DVA Tester 91-99750 90-830234R3 DECEMBER 1997 MID-SECTION - 5B-1...

  • Page 320: Power Trim Components (Black Fill Plug) (S/N-Usa-0G360002/Bel-9934136 & Below)

    Power Trim Components (Black Fill Plug) (S/N-USA-0G360002/BEL-9934136 & BELOW) 29 30 Liquid Neoprene (92-25711--2) Power Trim and Steering Fluid (92-90100A12) NOTE: Lubricate all O-rings and seals with Power Trim and Steering Fluid. 5B-2 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 321 Power Trim Components (Black Fill Plug) (S/N-USA-0G360002/BEL-9934136 & BELOW) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – POWER TRIM PUMP SHOCK ROD ASSEMBLY CYLINDER END CAP CYLINDER SEAL KIT MEMORY PISTON KIT CYLINDER SCREW AND SEAL KIT 11.3 PUMP/MANIFOLD ROCKER ARM...

  • Page 322: Power Trim - General Information

    Operating “Up” circuit will actuate the “up” relay (lo- Power Trim - General cated under engine cowl) and close the electric motor Information circuit. The electric motor drives the pump, forcing fluid thru internal passageways into the “up” side of the trim cylinder.

  • Page 323: Tilting Outboard Up And Down Manually

    Make sure that water level is above gear housing ing trim adjustment bolt may be desired. Howev- water intake holes whenever engine is running. er, some boats with engine trimmed to the full “in” trim angle at planing speed will cause unde- While operating “up”...

  • Page 324: Troubleshooting

    Troubleshooting Determining if Problem is Electrical or Hydraulic When a problem is encountered with the Power Trim system, the first step is to determine whether the mal- function is in the “electrical system” or the “hydraulic system.” Refer to the following chart to determine which system is at fault.

  • Page 325: Hydraulic System Troubleshooting

    Hydraulic System Troubleshooting Date Code Location Support outboard with tilt lock lever when servicing Date codes are placed on power trim assemblies at power trim system. date of manufacture. These date codes are designed to quickly identify assemblies which may be affected After debris or failed components have been found by service bulletins pertaining to specific problems.

  • Page 326: Preliminary Checks

    Preliminary Checks 2. The spool is considered stuck when the pin end is protruding out past the end of the sleeve. Operate Power Trim System after each check to see if problem is corrected. If not, proceed with the next check.

  • Page 327: Reassembly

    3. A leak path is created between the UP side of the 6. Inspect for nicked, deteriorated, or misplaced cylinder and the reservoir when the spool sticks O-ring. holding the pilot valve open. a - Cylinder/Manifold Mating Surface b - O-ring c - Spool d - Return Spring e - Valve Seat...

  • Page 328: Power Trim Partial Leak Down At Maximum Trim

    Power Trim Partial Leak Down at 3. Remove all burrs and filings from the memory piston. Maximum Trim 4. Reassemble the trim/tilt ram assembly using new Power Trim Date Code 14182 and Below – Service O-rings and seals. Bulletin No. 94-13. Some units, when trimmed to the maximum 20 de- gree limit, will leak down approximately 5 degrees and then hold.

  • Page 329: Leak Down Check - Pilot Valve Assembly

    Leak Down Check - Pilot Valve Leaks Past Ball and Seat - Piston Assembly Assembly 1. Debris or chips between valve and seat (a), usu- Unit will trim to full or near full down position and then ally imbedded in rubber valve seat. will begin to trim up while trim switch is held in ‘‘DOWN”...

  • Page 330: Power Trim Rocker Arm

    Power Trim Rocker Arm 2. Clearance between the side of the rocker arm and each pin is 0.001 to 0.010 in. (0.025 – Power Trim Date Code 14182 and Below. Refer to 0.25mm). Service Bulletin No. 92-12. 3. Torque bolt to 125 – 140 lb. in. (14.1 – 15.8 N·m). Outboard in the trim position will not trim up or down OR pump motor will lock up (not turn) in either direc- tion.

  • Page 331: Troubleshooting Flow Diagram

    Troubleshooting Flow Diagram Outboard falls to full down position with manual release valve closed. Example a: Outboard lowers more than one tilt bolt hole in eight hours. Example b: Outboard lowers during acceleration. Inspect Manual Release Valve. Result Result Manual release valve and/or O- ring damage.

  • Page 332: Troubleshooting Flow Diagram

    Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed deceleration. Inspect Manual Release Valve. Result Result Manual release valve and O-rings ap- Manual release valve and/or pear to be OK. Replace O-rings and pro- O-ring damage.

  • Page 333: Electrical System Troubleshooting

    Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW...

  • Page 334: Power Trim System Wiring Diagram

    Power Trim System Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 51306 a - Cowl Trim Switch BLK D BLACK = Negative (–) b - To Ignition Switch BLU D BLUE = Trim Motor (UP)

  • Page 335: Troubleshooting The "Down" Circuit

    Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) *Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. No Voltage Indicated: Connect Voltmeter red lead to Point 4 and Battery Voltage Indicated: black lead to ground.

  • Page 336: Troubleshooting The "Down" And "Up" Circuits* (All Circuits Inoperative)

    Troubleshooting the “Down” and “Up” Circuits* (All Circuits Inoperative) *Remote Control NOT Equipped with Trailer Button Check in-line fuse (under cowl) to see if fuse is blown Blown Fuse: Fuse Not Blown: Correct problem that Connect Voltmeter red lead to Point 3 caused fuse to blow.

  • Page 337: Power Trim System Removal

    3. Remove tell-tale hose from exhaust cover. Power Trim System Removal IMPORTANT: With outboard in the full tilt UP position, support outboard with tilt lock lever when servicing trim system. 1. Remove top cowl. 2. Disconnect bullet connectors in cowl mounted trim switch harness.
  • Page 338 4. Remove 2 bolts securing aft end of lower cowling. 7. Remove 4 bolts securing electrical plate cover and remove cover. 53953 a - Bolts 5. Remove bolt securing forward portion of lower cowling. 53958 a - Bolts 8. Remove 2 bolts and J-clips securing trim motor harness to starboard clamp bracket.
  • Page 339 9. Turn manual release valve 3 turns COUNTER- 11. Remove 2 nuts securing GREEN and BLUE trim CLOCKWISE. harness leads to solenoids. Remove bolt secur- ing BLACK trim harness lead. 53969 a - Manual Release Valve 10. Manually raise outboard to the full UP position and engage tilt lock lever to support outboard while servicing power trim system.
  • Page 340 13. Push grommet up through engine tray and re- 15. If necessary, drive out upper pivot pin. This will move grommet from harness. Pull harness down shear cross pin. through engine tray. 53949 a - Upper Pivot Pin Inspect cross pin hole and pivot pin hole for damage. 16.
  • Page 341 17. Use suitable punch to drive out lower pivot pin. 19. Remove fill screw and drain unit. 53951 53945 a - Pivot Pin a - Fill Screw 18. Tilt power trim assembly (top first) out from clamp bracket and remove assembly. 20.

  • Page 342: Power Trim System Disassembly

    5. Remove memory piston from cylinder using lock- Power Trim System ring pliers (Craftsman P/N 4735) or suitable tool. Disassembly Trim Rod Removal 1. Secure power trim assembly in soft jawed vise. 2. Open manual release valve three turns maxi- mum (counterclockwise) and position trim rod to full up position.

  • Page 343: Trim Rod Disassembly

    8. Remove trim system from vise and empty fluid into appropriate container. Trim Rod Disassembly 1. Place trim rod assembly on clean work surface. 2. Remove screws securing plate to trim rod piston and O-ring. 3. Remove check ball components from trim rod piston.

  • Page 344: Trim Motor Removal

    8. Remove rod wiper, inner O-ring and outer O-ring. Trim Motor Removal 1. Secure power trim assembly in soft jawed vise. 2. Remove screws securing motor to reservoir and remove motor. 51147 53946 a - Screws (4) 51145 3. Remove motor from reservoir. a - Rod Wiper b - Inner O-ring c - Outer O-ring...

  • Page 345: Trim Motor Disassembly

    Trim Motor Disassembly 2. Remove “E” clip and O-rings from manual re- lease valve. 1. Remove armature from motor frame. Note posi- tion of washers on armature. 51196 a - “E” Clip b - O-rings c - Manual Release Valve 3.

  • Page 346: Manifold Removal

    4. Remove reservoir from manifold. 2. Remove check valve components from manifold. IMPORTANT: Sleeve (f) is chamfered on I.D. on end opposite drilled cross hole. Install spool (g) (with O-ring installed) from chamfered end of sleeve to avoid possibility of damaging O-ring on spool.

  • Page 347: Motor And Electrical Tests/Repair

    Cleaning and Inspection of Motor and Electrical Trim Rod Components Tests/Repair CAUTION Trim Pump Motor Test Do not remove check ball components from trim WARNING rod piston. Removal and re-installation of check valve could result in improper operating pres- Do not perform this test near flammables (or ex- sure and possible power trim system damage.

  • Page 348: Motor Disassembly

    Motor Disassembly Armature Tests 1. Remove screws and clamp. TEST FOR SHORTS Check armature on a Growler (follow Growler man- ufacturer’s test instructions). Indication of a short re- quires replacement of armature. TEST FOR GROUND Use an Ohmmeter (R x 1 scale). Place one lead on Ohmmeter on armature shaft and other lead on com- mutator, as shown.

  • Page 349: Motor Repair

    FIELD TESTS CLEANING AND INSPECTION IMPORTANT: Commutator end of armature must Inspect O-rings and replace as necessary. Carefully be installed in brushes when performing the fol- inspect harness for cuts or tears which will allow wa- lowing tests. ter to enter motor. Replace harness if cut or torn. Clean, inspect and test motor components.
  • Page 350 BRUSH REPLACEMENT 2. To replace brush card, remove metal connectors. 1. Brush replacement is required if brushes are pitted, chipped or if distance between the brush pigtail and end of brush holder slot is 1/16 in. (1.6mm) or less. Check distance with armature. 51351 a - Metal Connectors 3.

  • Page 351: Reassembly

    Reassembly Power Trim System Reassembly IMPORTANT: Components must be clean. Any debris in power trim system can cause system to malfunction. Manifold Installation 1. Install armature in motor housing. IMPORTANT: Install spring, check valve and O- ring into manifold. Position components in place using sleeve to seat in place.

  • Page 352: Reservoir Installation

    2. Install O-rings on cylinder and secure manifold Reservoir Installation assembly to cylinder using screws. Torque 1. Inspect O-ring on bottom of reservoir for cuts or screws to 100 lb. in. (11.3 N·m). abrasions. Replace as required. 28381 a - O-ring (2) 53960 a - O-ring 2.

  • Page 353: Motor Installation

    Motor Installation 5. Install lubricated O-rings and “E” clip to manual release valve. 1. Inspect O-ring on top of reservoir for cuts or abra- sions. Replace as required. Guide armature and motor frame into reservoir housing as shown. 51196 a - “E” Clip b - O-ring c - Manual Release Valve 6.

  • Page 354: Trim Rod Reassembly

    Trim Rod Reassembly 4. Apply Loctite 271 (92-809820) to threads of trim rod and install rod piston. Tighten piston securely 1. Install lubricated O-rings and rod wiper to end using spanner wrench (1/4 in. x 5/16 in. long peg). cap. 51145 a - Rod Wiper b - Inner O-ring...

  • Page 355: Trim Rod Installation

    Trim Rod Installation 4. Install trim rod into cylinder. 1. Place trim cylinder in soft jawed vise. 2. Fill trim cylinder three inches (76.2mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid or; (ATF) Type F, FA or Dexron II. 3.

  • Page 356: Purging Power Trim Unit

    Purging Power Trim Unit Power Trim Unit Installation Manual release valve must be in full closed position 1. Apply 2-4-C w/Teflon (92-825407A12) to lower during power trim purging and operation. pivot pin bore and pivot pin surface. 1. Secure power trim unit in soft jawed vise. 2.
  • Page 357 4. Using a suitable punch, drive lower pivot pin into 6. Apply 2-4-C w/Teflon (92-825407A12) to surface clamp bracket and trim cylinder assembly until of upper pivot pin, pivot pin bore and trim ram pivot pin is flush with outside surface. bore.
  • Page 358 7. Using a suitable mallet, drive upper pivot pin into 8. Drive upper retaining pin in until seated. swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 52941 a - Retaining Pin 9. Recheck fluid level. 53966 10.
  • Page 359 MID-SECTION 55331 POWER TRIM (S/N USA-0G360003/BEL-9934137 & UP)
  • Page 360 Table of Contents Page Page Special Tools ....... . 5C-1 Power Trim System Removal .

  • Page 361: 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 90-830234R3 DECEMBER 1997 MID-SECTION - 5C-1...

  • Page 362: Power Trim Components (Yellow Fill Plug)

    Power Trim Components (Yellow Fill Plug) (S/N-USA-0G360003/BEL.-9934137 & UP) Loctite 271 (92-809820) Liquid Neoprene (92-25711--2) 2-4-C With Teflon (92-825407A12) Power Trim and Steering Fluid (92-90100A12) NOTE: Lubricate all o-rings and seals with Power Trim and Steering Fluid. 5C-2 - MID-SECTION 90-830234R3 DECEMBER 1997...

  • Page 363: Description

    Power Trim Components (Yellow Fill Plug) (S/N-USA-0G360003/BEL.-9934137 & UP) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – POWER TRIM PUMP SHOCK ROD KIT O RING REBUILD KIT MEMORY PISTON ASSEMBLY CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG MANUAL RELEASE ASSEMBLY...
  • Page 364 Notes: 5C-4 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 365 Description The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and trim cylinder. The remote control (or trim panel) is equipped with a switch that is used for trimming the outboard “up” and “down”, and for tilting the outboard for shallow water operation (at slow speed) or for “trailering”.

  • Page 366: Power Trim Flow Diagrams - Trim Up Circuit

    Í Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) 2800 (75-125HP) Tilt Relief Pressure min. 250-400 (40-60HP) 540-990 (75-125HP) a - Piston Rod i - Up Circuit Suction Port...
  • Page 367 Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the pas- sages for the up circuit.

  • Page 368: Tilt Circuit

    Filtered Feed Oil Return Oil Í Í Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) Tilt Relief Pressure 2800 (75-125HP) 250-400 (40-60HP) min. 540-990 (75-125HP) a - Piston Rod...
  • Page 369 Tilt Up In the up mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt re- lief piston (s) to open the tilt pressure relief valve (r).

  • Page 370: Maximum Tilt

    Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) 2800 (75-125HP) Tilt Relief Pressure min. 250-400 (40-60HP) 540-990 (75-125HP) a - Piston Rod i - Up Circuit Suction Port...
  • Page 371 Maximum Tilt With the piston rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylin- der (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston’s “pin” opens the tilt relief valve (r).

  • Page 372: Down Circuit

    Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) 2800 (75-125HP) min. Tilt Relief Pressure 250-400 (40-60HP) 540-990 (75-125HP) a - Piston Rod i - Up Circuit Suction Port...
  • Page 373 Down Mode When the trim switch is activated in the down posi- tion, the electric motor (c) will rotate the pump (j) in the opposite direction. With the pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump (j).

  • Page 374: Shock Function Up

    Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) 2800 (75-125HP) Tilt Relief Pressure min. 250-400 (40-60HP) 540-990 (75-125HP) a - Piston Rod i - Up Circuit Suction Port...
  • Page 375 Shock Function Up Oil inside the down cavity is locked in a static position by the closed pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear the piston rod (a) will try to rap- idly extend from the cylinder (w), the pressure in- creases inside the trim cylinder down cavity and con-...

  • Page 376: Shock Function Return

    Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) 2800 (75-125HP) Tilt Relief Pressure min. 250-400 (40-60HP) 540-990 (75-125HP) a - Piston Rod i - Up Circuit Suction Port...
  • Page 377 Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure be- tween the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity.

  • Page 378: Manual Release

    Reservoir Oil Return Oil Filtered Oil Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60HP) 1220-1420 (75-125HP) Up Pressure 1625 (40-60HP) 2800 (75-125HP) Tilt Relief Pressure min. 250-400 (40-60HP) 540-990 (75-125HP) i - Up Circuit Suction Port q - Manifold...
  • Page 379 Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal pas- sages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allow- ing the engine to be raised or lowered.

  • Page 380: Adjustments

    Adjustments WARNING Excessive engine trim angle will result in insuffi- Trimming Characteristics cient water supply to water pump causing water pump and/or powerhead overheating damage. NOTE: Because varying hull designs react differently Make sure that water level is above gear housing in various degrees of rough water, it is recommended water intake holes whenever engine is running.

  • Page 381: Trailering Outboard

    Trailering Outboard Tilting Outboard Up and Down Manually WARNING WARNING Excessive engine trim angle will result in insuffi- cient water supply to water pump causing water Before loosening the manual release valve, make pump and/or powerhead overheating damage. sure all persons are clear of engine as engine will Make sure that water level is above gear housing drop to full “down”...

  • Page 382: Troubleshooting

    Preliminary Checks Troubleshooting IMPORTANT: Operate Power Trim system after Support outboard with tilt lock pin when servicing each check to see if problem has been corrected. power trim system. If problem has not been corrected proceed to IMPORTANT: After debris or failed components next check.

  • Page 383: 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 valve and Manual release Inspect manual release valve O-rings appear to be O.K. valve and O-ring Clean reinstall damaged manual release valve Trim will not hold...
  • Page 384 Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage Suction seat assembly appears O.K. - Clean and Debris and/or damage reinstall suction seat as- identified sembly Replace suction seat Trim will not hold assembly Trim system holds reverse thrust...
  • Page 385 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 Trim system...
  • Page 386 Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis- ton O-ring and cylinder bore Cylinder bore ap- Cylinder bore appears pears rough and/or smooth with no debris debris found in cylin- Replace memory pis- ton and shock piston Trim leaks down O-rings Trim system does leak...

  • Page 387: Troubleshooting The Power Trim Electrical System

    Troubleshooting the Power Trim Electrical System BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN BLU/WHT PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET GRN/WHT WHT = WHITE YEL = YELLOW BLU/WHT or PUR GRN/WHT or GRN –...
  • Page 388 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 inoperative, 1. Open wire between Wire Connection (1) and 1. Check for a open connection or cut wire. but the Cowl Switch “UP”...

  • Page 389: 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 - Trilobe Pin b - Upper Pivot Pin 55464 5.

  • Page 390: Power Trim Disassembly

    6. Use suitable punch to remove (Drive Up) lower Power Trim Disassembly pin. Retain dowel pin. IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual re- lease valve removal.

  • Page 391: Trim Motor Removal

    Trim Motor Removal Pump and Components Removal 1. Secure power trim assembly in a soft jaw vise. 1. Remove pressure operated plugs on pump. Re- move spring and check valve/poppet (both 2. Remove four (4) screws to remove motor/reser- sides). Use special tool CG 41-11 and special tool voir.

  • Page 392: Manifold Removal

    2. Remove three (3) screws to remove pump. Re- 2. Remove tilt relief components. move filter and filter seal under pump. Remove suction seat assembly. 51008 a - Spring b - Poppet c - Spool Housing d - Trim Limit Spool Shock Rod Removal a - Screws (3) b - Filter Seal...

  • Page 393: Shock Rod Disassembly

    3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove O-ring from shock rod piston. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
  • Page 394 10. Remove inner O-ring from shock rod piston. 51146 51199 a - Shock Piston b - O-ring 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13.

  • Page 395: Memory Piston Removal

    Memory Piston Removal 2. Remove O-ring from memory piston. 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or suitable tool. 51144 a - O-ring b - Memory Piston 51144 b.

  • Page 396: Cleaning/Inspection/Repair

    Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced.

  • Page 397: Reassembly

    Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1. 90-830234R3 DECEMBER 1997 MID-SECTION - 5C-37...

  • Page 398: O-Ring Sizes

    O-Ring Sizes 4, 22 12, 17, 18 15, 20 Cutaway View of O-Ring Width O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 5C-38 - MID-SECTION 90-830234R3 DECEMBER 1997...

  • Page 399: O-Ring Description And Sizes

    O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring (412585) Cyl. Cap, Inner12586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap8134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in.

  • Page 400: Power Trim Reassembly

    4. Clamp shock rod in soft jawed vise. Power Trim Reassembly 5. Position cylinder end cap onto rod as shown. IMPORTANT: Lubricate all O-rings with Quicksil- ver Power Trim Fluid (92-90100A12). If not avail- able, use automotive (ATF) automatic transmis- sion fluid.

  • Page 401: Shock Rod Installation

    9. Remove shock rod assembly from vise. 3. Fill cylinder three inches (76.2mm) from top of cylinder using Quicksilver Power Trim and Steer- 10. Install ball, seat, and spring (five sets) to shock ing Fluid. If not available, use automotive (ATF) rod piston.

  • Page 402: Trim Limit Assembly Installation

    NOTE: There are two different size springs used in this manifold. The heavy spring is used on 75 to 125 HP engines. The light spring is used on 40 to 60 HP engines.

  • Page 403: Oil Pump Installation

    3. Install the two (2) long screws and torque to 100 Oil Pump Installation lb. in. (11.3 N m). 1. Install spring, ball, lubricated O-ring and plastic seat to manifold. 2. Check to see that O-rings are placed on bottom of pump.

  • Page 404: Pressure Operated Assembly Installation

    Pressure Operated Assembly Reservoir/Motor Installation Installation 1. Install coupler into top of pump. Make sure reser- voir seal is in the reservoir groove and place res- IMPORTANT: Inspect poppet assembly for debris ervoir onto pump/manifold assembly. Install in the area shown. If debris is found on poppet re- ground strap under screw shown.

  • Page 405: Bleeding Power Trim Unit

    Bleeding Power Trim Unit Installation of Power Trim System 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until its even with the bottom 1. Lubricate lower pivot pin, mounting holes with of the fill hole. Reinstall plug. 2-4-C w/Teflon Marine Lubricant.
  • Page 406 4. Apply 2-4-C w/Teflon Marine Lubricant 6. Apply 2-4-C Marine Lubricant (92-90018A12) to (92-90018A12) to lower pivot pin. Using a suit- surface of upper pivot pin, pivot pin bore and trim able punch, drive lower pivot pin into clamp ram bore. bracket and trim cylinder assembly until pivot pin is flush with outside surface.
  • Page 407 Drive trilobe pin (a) into its hole until seated. 10. Route trim harness through clamp bracket and cowling. 55464 a - Trilobe Pin 55264 9. Install sacrificial aluminum anode to reservoir a - Trim Harness bracket placing ground strap between bracket and anode as shown.
  • Page 408 MID-SECTION SHOCK ABSORBER...
  • Page 409 Table of Contents Page Removal ........5D-1 Inspection and Repair .
  • Page 410 Removal 1. Tilt engine to full “UP” position and engage tilt lock lever. WARNING Failure to support engine as shown could result in personal injury and/or damage to engine or boat. IMPORTANT: Support engine with tool as shown, to prevent engine from tipping over center into boat when retaining pin is removed.
  • Page 411 4. Support lower mount bracket and remove (6) Inspection and Repair bolts. 1. Inspect bushings and replace if worn. 17244 a - Bushings a - Bolts (3 Each Side) b - Lower Mount Bracket CAUTION 5. Remove shock absorber from lower mount The shock absorber is pressurized with gas.
  • Page 412 3. Reinstall shock absorber assembly between Installation clamp brackets and secure shock assembly to 1. Remove anode plate. Lubricate retaining pin with clamp brackets with 6 bolts and lockwashers (3 Quicksilver 2-4-C w/Teflon. Place shock absorb- each clamp bracket). Torque bolts to 30 lb. ft. er into lower mount bracket, as shown, and install (40.7 N·m).
  • Page 413 MID-SECTION MANUAL TILT...
  • Page 414 Table of Contents Page Page Special Tools ....... . 5E-1 Shock Rod Disassembly .

  • Page 415: Special Tools

    Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 90-830234R3 DECEMBER 1997 MID-SECTION - 5E-1...

  • Page 416: Manual Tilt Assist Components

    Manual Tilt Assist Components Loctite 271 (92-809820) 5E-2 - MID-SECTION 90-830234R3 DECEMBER 1997...
  • Page 417 Manual Tilt Assist Components TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m – TRIM PUMP ASSEMBLY SHOCK ROD ASSEMBLY O RING REBUILD KIT-Cylinder MEMORY PISTON ASSEMBLY CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY CAM KIT VELOCITY VALVE KIT CHECK SYSTEM REPAIR KIT...

  • Page 418: Manual Trim Flow Diagrams - Up Circuit

    Manual Trim Flow Diagrams - Up Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...

  • Page 419: Tilt Up

    Tilt Up With the engine in the down position, the accumula- tor piston (d) will be at the top of the accumulator (c) with the gas at maximum pressure. To raise the en- gine, the camshaft lever (f) is rotated all the way down.

  • Page 420: Down Circuit

    Down Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...

  • Page 421: Tilt Down

    Tilt Down With the engine tilted up, the piston inside the accu- mulator piston (d) will be at the bottom of the accumu- lator (c) and the gas pressure is low. To lower the en- gine, the camshaft lever (f) is rotated down, the internal cam will cause the push rods to open the ac- cumulator check valve (e), both fast transfer valves (h &...

  • Page 422: Slow Tilt Down Under High Thrust

    Slow Tilt Down Under High Thrust a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...

  • Page 423: Slow Tilt Down Under High Thrust

    Slow Tilt Down Under High Thrust To tilt the engine down under high thrust conditions [where the propeller thrust forces the shock rod down, creating higher pressure below the memory piston (m)] the camshaft lever (f) is rotated slightly downward. The internal shaft connected to the lever will open the down slow transfer valve (i) allowing oil under pressure into the cavity around the shaft.

  • Page 424: Under Water Strike (Valves Open)

    Under Water Strike (Valves Open) a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...

  • Page 425: Under Water Strike With Valves Open

    Under Water Strike With Valves Open Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the interconnecting passage. The rapid fluid flow will increase the pressure below the surge valve (k), causing the valve to move, closing the oil return passage back into the accumulator (c).

  • Page 426: Shock Function (Valve Closed)

    Shock Function (Valve Closed) Accumulator Gas Pressure 400 PSI a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston...

  • Page 427: Shock Function With Valves Closed

    Shock Function With Valves Closed Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the closed up fast transfer valve (j), the closed down slow transfer valve (i) and closed down fast transfer valve (h).

  • Page 428: Shock Function Return

    Shock Function Return a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...

  • Page 429: Shock Function Return

    Shock Function Return After the drive clears the object, the shock return valve (o) will allow the oil to flow from between the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to it’s original running position.

  • Page 430: Hydraulic System Troubleshooting

    3. Check for discharged accumulator. 35 to 50 lb. ft. Hydraulic System (47-68 N·m) of pulling force must be attained Troubleshooting when tilting outboard from full “down” to full “up” position. If more than 50 lb. ft. (68 N·m) of force Refer to disassembly/reassembly instructions (fol- is required, replace accumulator.

  • Page 431: Manual Tilt System Removal

    3. Position piece of wood under transom bracket Manual Tilt System Removal instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper CAUTION dowel pin. Retain dowel pin. Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard.

  • Page 432: Manual Tilt System Disassembly

    6. Use suitable punch to drive out lower pivot pin. Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitro- gen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumu- lator only when shock rod is in full up position. 51144 a - Pivot Pin Accumulator Removal...

  • Page 433: Shock Rod Removal

    6. If plunger can be compressed into accumulator Shock Rod Removal by hand, accumulator is defective. Replace 1. Unscrew cylinder end cap assembly using span- accumulator. ner wrench [1/4 in. x 5/16 in. long pegs]. 51145 2. Remove shock rod assembly from cylinder. 51143 a - Plunger 7.

  • Page 434: Shock Rod Disassembly

    3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove O-ring. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
  • Page 435 CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).

  • Page 436: Valve Block Removal

    Valve Block Removal Memory Piston Removal 1. Remove two screws from the shock rod cylinder 1. Remove memory piston from cylinder using one to separate the valve block. of two methods: a. Using lock ring pliers (a) (Craftsman P/N 4735) or (Snap-on P/N SRP4). a a a 51146 a - Screw...

  • Page 437: Valve Block Disassembly

    2. Remove O-ring from memory piston. 3. Remove surge valve assembly. 51144 a - O-Ring b - Memory Piston a - Spool b - Spring c - O-ring Valve Block Disassembly d - Screw Plug 1. Remove check retainer plug and components. 4.

  • Page 438: Reassembly - O-Ring And Seal Placement

    Reassembly - O-Ring and Seal Placement Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5E-24 - MID-SECTION 90-830234R3 DECEMBER 1997...

  • Page 439: Actual O-Ring Sizes

    Actual O-Ring Sizes 4, 14 6 (2) 11 & 13 8 (2) Cutaway View of O-Ring Width O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 90-830234R3 DECEMBER 1997 MID-SECTION - 5E-25...

  • Page 440: O-Ring Description And Sizes

    O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring (412585) Cyl. Cap, Inner (412586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap (408134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in.

  • Page 441: Manual Tilt System Cleaning And Inspection

    Tighten screw securely. a - Spool b - Spring c - O-ring d - Screw Plug - Torque to 75 lb. in. (8.5 N m) 2-4-C With Teflon (92-825407A12) a - Spacer Retainer Clip b - Retainer Clip...

  • Page 442: Valve Block Installation

    - Shock Rod Cylinder 51142 a - Plunger (2) b - Steel Ball (2) c - Spring (2) d - O-ring (2) e - Screw Plug (2) Torque to 75 lb. in. (8.5 N m) 5E-28 - MID-SECTION 90-830234R3 DECEMBER 1997...

  • Page 443: Shock Rod Reassembly

    Shock Rod Reassembly 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 1. Install lubricated O-rings to end cap. 2. Install rod wiper. 51146 51145 a - Rod Wiper b - Inner O-ring CAUTION c - Outer O-ring When installing shock rod piston, spanner...

  • Page 444: Shock Rod Installation And Fluid Filling Procedure

    9. Install ball, seat, and spring (five sets) to shock Shock Rod Installation and Fluid rod piston. Filling Procedure 10. Secure components with plate. Torque screws to NOTE: There are two ways for the filling procedure. 35 lb. in. (4.0 N m). The first is the easiest and less time consuming.
  • Page 445 6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) and screw cylinder cap down. 7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap to 45 lb.

  • Page 446: Filling Procedure Option Two Instructions For Making Retaining Tool

    Filling Procedure Option Two Instructions for Making Retaining Tool 10 in. (25 cm) 1 in. 8 in. (20 cm) (25mm) 3 in. (76mm) 1 1/4 in. dia. 5 in. (30m) (125mm) 20 in. (508mm) 2 in. (50mm) 4 in. (100 mm) 8 in.

  • Page 447: Bleeding Manual Tilt System

    3. Bleed unit by pushing rod down slowly (18-20 se- Bleeding Manual Tilt System conds per stroke) until stopped at base. Wait until IMPORTANT: While bleeding tilt system, time all air bubbles exit accumulator base. must be allowed between each stroke to allow air bubbles to dissipate.
  • Page 448 7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), cycle unit 2-3 more times using short strokes. No remove tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise.

  • Page 449: Manual Tilt System Installation

    4. Using a suitable punch, drive lower pivot pin into Manual Tilt System clamp bracket and trim cylinder assembly until Installation pivot pin is flush with outside surface. 1. Apply 2-4-C w/Teflon Marine Lubricant to lower pivot pin hole and pivot pin surface. 2.

  • Page 450: Manual Release Valve Adjustment

    6. Apply 2-4-C w/Teflon Marine Lubricant 8. Drive upper dowel pin (a) into its hole until seated. (92-90018A12) to surface of upper pivot pin, pivot pin hole and shock rod hole. 51147 a - Dowel Pin 9. Check manual release cam adjustment. Cam 2-4-C With Teflon (92-825407A12) 51148 must open and close freely.
  • Page 451 LOWER UNIT 791-H GEAR HOUSING...
  • Page 452 Table of Contents Page Page Specifications ....... . 6A-1 Reassembly .

  • Page 453: Specifications

    Number of Teeth 30 Spiral/Bevel Pinion Gear Number of Teeth 13 Spiral/Bevel Pinion Height 0.025 in. (0.64mm) Pinion Gear Locating Tool MODEL 75/90 (91-12349A2) Flat #8 Disc #3 Forward Gear Backlash 0.012-0.019 in. (0.30-0.48mm) Backlash Indicator Tool (91-78473) Mark #4...

  • Page 454: Special Tools

    6. Wear Sleeve Installation Tool (91-14310A1) Special Tools 1. Pinion Gear Locating Tool (91-12349A2) 7. Bearing Preload Tool (91-14311A2) 55079 8. Mandrel (91-15755)* 2. Bearing Installation Tool (91-13945) 73815 9. Backlash Indicator Tool (91-19660--1) (4 cyl.) 3. Oil Seal Driver (91-13949) 19660-1 10.
  • Page 455 12. Treaded Rod (91-31229) and Nut (91-24156)* 19. Driver Shaft Holding Tool (91-56775) 13. Slide Hammer (91-34569A1) 20. Dial Indicator (91-58222A1) 14. Mandrel (91-36569)* 21. Backlash Indicator Tool (91-78473) (3 cyl.) 15. Universal Puller Plate (91-37241) 22. Puller Bolt (91-85716) 23.

  • Page 456: Gear Housing (Drive Shaft)

    Gear Housing (Drive Shaft) Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-19007A24) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) 6A-4 - LOWER UNIT 90-830234R3 DECEMBER 1997...
  • Page 457 Gear Housing (Drive Shaft) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING DOWEL PIN (FRONT) DRAIN SCREW SCREW (MAGNETIC) WASHER–Sealing DOWEL PIN (REAR) (USE W/GH W/O ANODES) TRIM TAB (USE W/GH WITH ANODES) TRIM TAB SCREW (7/16-14 x 1-1/4) 29.8 WASHER...

  • Page 458: Gear Housing (Propeller Shaft)

    Gear Housing (Propeller Shaft) Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-19007A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6A-6 - LOWER UNIT 90-830234R3 DECEMBER 1997...
  • Page 459 Gear Housing (Propeller Shaft) TORQUE REF. REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING SHIM ASSEMBLY TAPERED ROLLER BEARING ASSEMBLY FORWARD GEAR ROLLER BEARING CAM FOLLOWER ASSEMBLY BALL SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR BEARING CARRIER ASSEMBLY O-RING ROLLER BEARING...

  • Page 460: Gear Case Identification

    Gear Case Identification Removal CAUTION WARNING Identify gear case design to ensure correct To prevent accidental engine starting, remove components are being installed. Design I - “3 Jaw (and isolate) spark plug leads from spark plugs Reverse Clutch” (a) gear case identified with before removing gear housing.

  • Page 461: Water Pump

    Water Pump 1. If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was re- moved, pull water tube seal from water tube. 2. Replace water tube seal, if damaged. 3. Remove 4 bolts, washers, and isolators. 4.
  • Page 462 7. Inspect impeller. Replace impeller if any of the 11. Remove water pump base. following conditions exist: Impeller blade(s) are cracked, torn, or worn. Impeller is glazed or melted (caused by operation without sufficient water supply). Rubber portion of impeller is not bonded to impel- ler hub.

  • Page 463: Bearing Carrier And Propeller Shaft

    Bearing Carrier and Propeller Shaft 4. Lift reverse gear, thrust bearing and thrust wash- er from bearing carrier. 1. Remove fasteners. 5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage.
  • Page 464 8. If bearing is rusted or does not roll freely, replace 10. Remove spring. bearing. Remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. * From Bearing Removal and Installation Kit (91-31229A7) 51876 a - Spring 11.

  • Page 465: Pinion Gear, Drive Shaft, And Forward Gear

    50 Bigfoot (4-Stroke) 91-56775 b. Engine idle speed too high while shifting. 60 Bigfoot 91-817070 75/90/100/115/125 91-56775 c. Shifting from neutral to reverse (or forward) too slowly. 1. Hold drive shaft using Drive Shaft Holding Tool (91-56775); remove (and discard) pinion nut.
  • Page 466 6. Replace bearing if it is rusted or does not roll free- 8. Replace drive shaft if splines are worn or twisted. ly; use a punch and hammer to remove bearing. 9. If bearing surface is damaged, replace drive shaft and corresponding bearing.

  • Page 467: Upper Drive Shaft Bearing

    Upper Drive Shaft Bearing Oil Sleeve 1. Replace upper drive shaft bearing and sleeve if 1. Remove oil sleeve (if necessary) using Puller As- either are rust stained, or if bearing will not roll sembly (91-83165M) with suitable jaws. freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws.

  • Page 468: Lower Drive Shaft Bearing Race

    Lower Drive Shaft Bearing Race Shift Shaft IMPORTANT: Retain shim(s) for reassembly. 1. Remove shift shaft coupler and nylon spacer. 1. Remove race and shim(s) using bearing race tool (91-14308A1). 53925 a - Shift Shaft Coupler b - Spacer 2. Remove bolts. 53926 a - Bolts 19171...

  • Page 469: Forward Gear Bearing Race

    4. Remove shift cam from housing. Forward Gear Bearing Race 5. Replace shift cam if worn. IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1).

  • Page 470: Reassembly

    - Shift Shaft Bushing 6. Install shift cam (numbers toward top of gear housing); align hole in shift cam with hole. 60 Bigfoot 75/90/100/115/125 2-4-C With Teflon (92-825407A12) 19179 a - Shim(s) b - Race, Apply 2-4-C w/Teflon Lubricant on O.D.

  • Page 471: Bearing Carrier Reassembly

    50 Bigfoot (4-Stroke) 8. Apply Loctite 271 on bottom half of threads of bolts; install bolts and torque to 35 lb. in. (4.0 N·m). 850307 Loctite 271 (92-809820) 53926 a - Bolts [Torque to 35 lb. in. (4.0 N·m)] 51117 Bearing Carrier Reassembly a - Shift Cam (Numbers Down) b - Hole...
  • Page 472 4. Place smaller diameter seal on longer shoulder 8. Install O-ring. of Oil Seal Driver (91-31108) with seal lip away 9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate from shoulder. seal lips with 2-4-C w/Teflon. Lubricate outside 5. Protect lip on front side of bearing carrier using diameter of bearing and bearing carrier bore with Bearing Installation Tool (91-13945).

  • Page 473: Forward Gear Reassembly

    12. Install thrust bearing. Coat thrust bearing with Forward Gear Reassembly Quicksilver Gear Lubricant. 1. Press tapered bearing onto gear (press only on inner race of bearing). Quicksilver Gear Lubricant (92-19007A24) 51869 19168 a - Mandrel (91-37350) Quicksilver Gear Lubricant (92-19007A24) b - Bearing;...

  • Page 474: Propeller Shaft Reassembly

    6 Jaw Reverse Clutch Propeller Shaft Reassembly 1. Install components into propeller shaft in se- quence shown. 19154 a - Spring b - Guide Block c - 3 Metal Balls* 56784 d - Cam Follower* a - Stamped “6” b - Numbered end of Needle Bearing * Hold in Place With Quicksilver 2-4-C w/Teflon c - 6 Jaw Reverse Clutch 3.

  • Page 475: Drive Shaft Wear Sleeve Installation

    Drive Shaft Wear Sleeve Installation 4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); continue press- 1. Install new rubber ring. ing until surface contacts surface. 2. Apply a light coat of Loctite 271 on outside diame- ter of rubber ring.

  • Page 476: Lower Drive Shaft Bearing Race Installation

    Lower Drive Shaft Bearing Race Oil Sleeve Installation Installation 1. Install oil sleeve with tab positioned as shown. IMPORTANT: Lower drive shaft bearing cup can be installed with or without upper drive shaft bearing/sleeve and oil sleeve installed. 1. Lubricate O.D. of bearing race with Quicksilver 2-4-C w/Teflon.

  • Page 477: Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, And Drive Shaft Installation

    Model Drive Shaft Holding Tool 3. Install bearing/sleeve into housing. 50 Bigfoot (4-Stroke) 91-56775 60 Bigfoot 91-817070 75/90/100/115/125 91-56775 1. Install components in sequence shown. 53935 a - Bearing/Sleeve b - Tapered End c - Mandrel* (91-13781) d - Mandrel* (91-13780)

  • Page 478: Pinion Gear Depth And Forward Gear Backlash

    Pinion Gear Depth and Forward Gear 3. Measure distance between top of nut and bottom of bolt head. Backlash 4. Increase distance by 1 in. (25.4mm). DETERMINING PINION GEAR DEPTH 5. Rotate drive shaft 5 to 10 revolutions. This should properly seat upper drive shaft tapered roller NOTE: Read entire procedure before attempting any bearing.
  • Page 479 FLAT REVERSE GEAR TEETH) MODEL 50 Bigfoot (4-stroke) 13/30 60 Bigfoot/60 Sea- 13/30 pro/60 Marathon 75-thru-90 13/30 (3 Cylinder) 100/115/125 (4 Cylinder) 14/29 10. Install the number “3” locating disc against bear- ing carrier shoulder in gear housing. 11. Position access hole as shown.
  • Page 480 12. Determine pinion gear depth by inserting a feeler DETERMINING FORWARD GEAR BACKLASH gauge thru access hole in locating disc. NOTE: Read entire procedure before attempting any change in shim thickness. 13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64mm). 1.
  • Page 481 MAXIMUM 0.012 in. 0.019 in. 50 Bigfoot (4-Stroke) (0.30mm) (.48mm) 0.012 in. 0.019 in. 60 Bigfoot (0.30mm) (.48mm) 75-thru-90 0.012 in. 0.019 in. (3 Cylinder) (0.30mm) (.48mm) 100/115/125 0.015 in. 0.022 in. (4 Cylinder) (0.38mm) (0.55mm) 9. If backlash is less than the minimum specifica- tion, remove shim(s) from in front of forward gear bearing race to obtain correct backlash.

  • Page 482: Bearing Carrier And Propeller Shaft Installation

    Bearing Carrier and Propeller Shaft 4. Install bearing carrier and propeller shaft into housing with the word “TOP” located on flange to- Installation ward top of housing. 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in.

  • Page 483: Water Pump Reassembly And Installation

    Water Pump Reassembly and 3. Place seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. Installation 4. Apply Loctite 271 on O.D. of seal; press seal into 1. Place seal on longer shoulder side of Oil Seal water pump base until tool bottoms.
  • Page 484 7. Install components as shown. 9. Install gasket, drive key and impeller. 19220 a - Gasket b - Drive Key Loctite 271 (92-809820) 19217 c - Impeller a - Water Pump Base b - Bolts and Washers; Apply Loctite 271 on bottom 1/2 of 10.

  • Page 485: Gear Housing Pressure Test

    Gear Housing Pressure Test Filling Gear Housing With Lubricant 1. Remove vent plug and install pressure test gauge. NOTE: Gear housing lubricant capacity is 22.5 fl. oz. (665.2ml). WARNING If gear housing is installed on engine, to avoid ac- cidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller.

  • Page 486: Gearcase Installation

    7. Remove lubricant tube from “Fill” hole; install “Fill” screw and gasket. Torque “Fill” screw to 60 lb. in. (6.8 N·m). a - Shift Block Models 75/90/100/115/125 19879 a - Shift Block; Front of Block MUST Extend 1/8 in. (3.2mm) Past Front of Rail.
  • Page 487 2. Tilt engine to full “UP” position and engage tilt 8. Install components as shown in appropriate lock lever. photo. 3. Shift gear housing into neutral position. Propeller POWER TRIM MODELS shaft will rotate freely in either direction. 4. Install water tube seal; lube I.D. of seal with Quicksilver 2-4-C w/Teflon (92-825407A12).

  • Page 488: Trim Tab Adjustment

    10. Apply Loctite Grade 271 on threads of gear hous- IMPORTANT: If shift operation is not as de- ing retaining bolts. scribed, preceding, the gear housing must be re- moved and the cause corrected. NOTE: If, while performing Step 11, the drive shaft splines will not align with the crankshaft splines, place a propeller onto propeller shaft and turn it coun- Trim Tab Adjustment...
  • Page 489 LOWER UNIT JET DRIVE...
  • Page 490 Table of Contents Page Page 65 Jet Drive (3 cylinder) ..... . . 6B-2 Worn (Dull) Impeller ......6B-13 Jet Pump Assembly .
  • Page 491 Notes: 90-830234R3 DECEMBER 1997 LOWER UNIT - 6B-1...

  • Page 492: Jet Drive (3 Cylinder)

    65 Jet Drive (3 cylinder) 2-4-C With Teflon (92-825407A12) 6B-2 - LOWER UNIT 90-830234R3 DECEMBER 1997...

  • Page 493: Jet Pump Assembly

    Jet Pump Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m (BLACK) S/N-0G582704 & BELOW – JET PUMP ASSEMBLY (GRAY) – JET PUMP ASSEMBLY (S/N-0G582705 & UP) – JET PUMP ASSEMBLY (S/N-0G582704 & BELOW) HOUSING–pump (S/N-0G582705 & UP) HOUSING-pump HOSE–lube IMPELLER...

  • Page 494: Jet Drive (4 Cylinder)

    80 Jet Drive (4 cylinder) 2-4-C With Teflon (92-825407A12) 6B-4 - LOWER UNIT 90-830234R3 DECEMBER 1997...
  • Page 495 80 Jet Drive (4 cylinder) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m (BLACK) S/N-0G582704 & BELOW – JET PUMP – (GRAY) JET PUMP (S/N-0G582705 & UP - W/ALUMINUM IMPELLER) – JET PUMP (W/STAINLESS STEEL IMPELLER) – JET PUMP (S/N-0G582705 &...

  • Page 496: Jet Water Pump Components

    Jet Water Pump Components Loctite 271 (92-809820) Liquid Neoprene (92-25711--2) 2-4-C With Teflon (92-825407A12) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m REV LIMITER HARNESS–adaptor–rev Limiter HARNESS–adaptor SCREW (M6 x 50) GREASE KIT GASKET GASKET WATER PUMP ASSEMBLY FACE PLATE SCREW (M6 x 1 x 30) SEAL...

  • Page 497: Selecting A Boat That Is Best Suited For Jet Power

    Selecting A Boat That Is Engine Horsepower Best Suited For Jet Power Selection To obtain the best performance from the jet drive, the A boat operating at slow speed requires considerably boat should have the following features: more depth than one which is planing on the surface of the water.

  • Page 498: Transom Height Of The Boat

    SETTING OUTBOARD MOUNTING HEIGHT ON Transom Height of the Boat BOATS WITH “V” BOTTOM HULLS Outboards with jet drives will be mounted approxi- 1. Measure the width of the leading edge on the wa- mately 7 inches higher on the transom than propeller ter intake housing.

  • Page 499: Water Testing

    SETTING OUTBOARD MOUNTING HEIGHT ON When operating the boat, the outboard drive shaft BOATS WITH FLAT BOTTOM HULLS should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water 1. Place (center) the outboard on the boat transom intake.

  • Page 500: Shift Cable Installation

    4. Attach the brass barrel (c) to the bracket with bolt Water Testing and locknut. Tighten the bolt until it seats against the barrel, then back-off the bolt 1/4 turn. Hold Checking for Cavitation (Continued) bolt from turning, and tighten locknut on bolt. The barrel must be free to pivot.

  • Page 501: Lubricating The Drive Shaft Bearing

    Lubricating the Drive Shaft Impeller Removal and Bearing Installation Recommended Lubrication - Use 2-4-C w/Teflon. REMOVAL IMPORTANT: It is important that you do not use 1. Shift outboard to NEUTRAL (N) position. a general-all-purpose grease for this bearing. The lubricant we recommend is a water resistant 2.
  • Page 502 INSTALLATION 1. Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve (a) inside the im- peller (b) and install impeller, shear key (c), shims (d) nut retainer (e), and impeller nut (f). Turn the nut tight on the shaft to remove any play between the impeller and shaft.

  • Page 503: Steering Pull Adjustment

    Steering Pull Adjustment Worn (Dull) Impeller The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins (a) 1/16 in. (1.5mm) toward the starboard side of the outboard.

  • Page 504: Liner Replacement

    4. Stop the engine, turn off the water, and remove Jet Drive Removal the hose coupling. Reinstall the plug and gasket. 1. Shift outboard to NEUTRAL (N) position and dis- connect the shift linkage. 2. Remove spark plug leads to prevent engine from starting.

  • Page 505: Bearing Carrier Removal

    6. Remove 5 bolts securing pump drive to drive Bearing Carrier Removal shaft housing and remove pump. NOTE: Water pump assembly must be removed be- fore bearing carrier can be removed. 1. Remove 4 bolts (2 each side) securing water pump assembly and remove water pump.

  • Page 506: Bearing Carrier Disassembly

    2. Remove 4 bolts securing bearing carrier to jet 6. Clean all parts thoroughly and remove any burrs. drive. a - Snap Ring 54165 b - Bearing Carrier c - Ball Bearing a - Bolts d - Upper Seal Housing e - Thrust Ring Bearing Carrier Disassembly 1.

  • Page 507: Bearing Carrier Reassembly

    Installing Upper Seals Bearing Carrier Reassembly 1. Install spiral retaining ring (a) into the inner ring Installing Lower Seals groove of the upper seal housing. 2. Spread a film of grease around the inside bore of Install seals into bearing carrier as follows: the seal surface before pressing in the seals.

  • Page 508: Installing Drive Shaft Ball Bearings

    Installing Drive Shaft Ball Bearings Installing Drive Shaft 1. If removed, install the bearing thrust ring (a) into 1. Lubricate the seals and inside bore of the bearing the groove on the drive shaft. carrier (a). 2. Press new ball bearings (b) onto the drive shaft, 2.

  • Page 509: Installing Upper Seal Housing

    Installing Upper Seal Housing 4. Install the beveled snap ring (a), beveled side facing up into the ring groove. Make sure the 1. Grease the upper seals and inside bore of the snap ring is fully seated into groove. bearing carrier to ease entry of the seal housing. 2.

  • Page 510: Jet Drive Installation

    5. Apply Loctite 271 to retaining bolts and torque Jet Drive Installation bolts to 60 lb. in. (6.8 N·m). Reassembling Water Pump to Jet Drive NOTE: Replace cover if thickness of steel at dis- charge slots is 0.060 in. (1.524mm) or less, or if groove(s) (other than impeller sealing groove) in cov- er roof are more than 0.030 in.

  • Page 511: Installing Jet Drive To Drive Shaft Housing

    Installing Jet Drive to Drive Shaft 5. Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve (a) inside the im- Housing peller (b) and install impeller, shear key (c), shims (d) nut retainer (e), and impeller nut (f). Turn the 1.
  • Page 512 7. After setting the impeller height, tighten the im- NOTE: If the outboard is used in salt water, apply peller nut snug with a wrench. Secure impeller Quicksilver Anti-Corrosion Grease around the entire nut by bending tabs (a) against the flats on the im- mounting flange on the water intake housing and also to the threads on the six mounting bolts.
  • Page 513 ATTACHMENTS/ CONTROL LINKAGE 50099 THROTTLE/SHIFT LINKAGE...
  • Page 514 Table of Contents Page Page Steering Cable and Steering Link Ride-Guide Steering Cable/Attaching Kit Rod Installation ......7A-1 Installation (92876A3) .

  • Page 515: Steering Cable And Steering Link Rod Installation

    3. Insert steering cable end thru engine tilt tube and Steering Cable and Steering secure steering cable to tilt tube with steering Link Rod Installation cable attaching nut as shown. Torque nut to 35 lb. ft. (47.5 N·m). CAUTION 4. Install rubber bumper on inside of locking sleeve, then install locking sleeve over steering cable (at- Control cables must be the correct length when taching nut) and secure with cotter pin.

  • Page 516: Ride-Guide Attachment - Dual Front Installation (92876A2)

    Installation and Maintenance CAUTION IMPORTANT: The distance from each engine’s Steering link must be installed in rear hole in centerline to the side of transom opening must engine steering arm. Failure to install in rear hole be a minimum of 16 (40.6cm). may cause damage to steering system.

  • Page 517: Parallel Routed Steering Cables And Attaching Kit Installation

    Parallel Routed Steering WARNING Cables and Attaching Kit Before using engine after installation of cables, check to see that boat will turn right when steer- Installation ing wheel is turned right and that boat will turn left when wheel is turned left. Do this check at all (Both Steering Cables Routed Together Down Star- tilt angles and thru full range of turn angles.
  • Page 518 2. Install steering cable mounting tube into mount- NOTE: Torque steering cables attaching nuts and ing bracket with 2 adjustment nuts and tab lock install locking sleeve after final tension adjustment. washers, as shown in Figure 3. Be sure that long- 5.

  • Page 519: Steering Eyes And Coupler Installation

    2. Lubricate inside of rubber sleeves (Figure 9) and slide on to coupler. 3. Slide rubber bushings (Figure 9) onto steering eyes. 4. Thread steering eyes (Figures 9 and 10) into cou- pler and adjust steering eyes so that distance be- tween centers of pivot bolt holes in steering eyes is the same distance as between centers of threaded pivot holes in engine steering arms.

  • Page 520: Steering System Tension Adjustment (Parallel Routed Steering Cables)

    51520 a - Rubber Bushing b - Rubber Sleeve c - Jam Nut; Torque to 20 lbs. ft. (27.0 Nm) d - Coupler e - Steering Eye Figure 9. Coupler Assembled 51520 2-4-C With Teflon (92-825407A12) a - Jam Nut; Torque to 20 lbs. ft. (27.0 Nm) Steering System Tension Adjustment b - Engine Steering Arm (Parallel Routed Steering Cables)
  • Page 521 3. Secure each steering cable attaching nut to tubes by torquing steering cable attaching nuts (Figure 13) to 35 lbs. ft. (47.5 Nm). 4. Install rubber bumpers on inside of locking sleeves, then install a locking sleeve over each steering cable attaching nut and secure with cot- ter pin.

  • Page 522: Opposite Side Routed Steering Cables And Attaching Kit Installation

    3. Temporarily adjust tube so that longer, threaded Opposite Side Routed end of tube is aligned with outward edge of tran- Steering Cables and som bracket. DO NOT tighten adjustment nuts at this time. Attaching Kit Installation (ONE CABLE ROUTED DOWN STARBOARD SIDE OF BOAT AND ONE CABLE ROUTED DOWN PORT SIDE OF BOAT) IMPORTANT: Steering cable must be installed...
  • Page 523 c. Insert ends of steering cables thru engine tilt tube and cable mounting tube (Figure 3). Thread steering cable attaching nuts hand- tight onto tubes. 50180 50101 a - Mark Made in Step 5a a - Flat Washer (2 Each Link Rod) b - Nylon Insert Locknut - Torque Until it Seats [DO NOT Ex- Figure 5.

  • Page 524: Steering Eyes And Coupler Installation

    Steering Eyes and Coupler Installation 1. Position engines so that they are facing straight forward. (Distance between centers of threaded pivot bolt holes in engine steering arms must be equal to distance between propeller shaft cen- ters.) 2. Lubricate inside of rubber sleeves (Figure 8) and slide onto coupler.
  • Page 525 51520 2-4-C With Teflon (92-825407A12) a - Jam Nut; Torque to 20 lbs. ft. (27.0 Nm) 7. Torque pivot bolts to 20 lbs. ft. (27.0 Nm), then b - Engine Steering Arm thread self-locking nut onto bolts and torque nuts c - Coupler to 20 lbs.

  • Page 526: Steering System Tension Adjustment

    Steering System Tension Adjustment OPPOSITE SIDE ROUTED STEERING CABLES IMPORTANT: After this Ride-Guide Attachment Kit is installed, there must be proper tension in the steering system. Not enough tension will cause slack (play) in steering system. Too much tension will cause steering cables to bind. Per- form Step 1, following, to adjust for correct ten- sion.

  • Page 527: Trim Tab Installation

    Maintenance Instructions Trim Tab Installation Maintenance inspection is owner’s responsibility and IMPORTANT: With dual engine installation, exist- must be performed at intervals specified, following: ing trim tabs MUST BE replaced with new trim tabs (supplied with kit). Normal Service – Every 50 hrs. of operation or 60 days (whichever comes first) 1.

  • Page 528: Ride Guide Steering Attachment

    26-1/2 in. thru 30-1/2 in. 18 in. (45.7cm) Coupler transom bracket with 3/8 in. x 2-1/2 in. (9.5mm x (67.3cm thru 75.5cm) 63.5mm) bolt, flat washer and locknut, as 30 in. thru 34 in. (76.3cm 9 in. (22.9cm) Coupler and 12 in.
  • Page 529 2-4-C With Teflon (92-825407A12) Figure 1 a - Ride-Guide Cable b - Ride-Guide Yoke c - Pivot Block d - Pivot Spacer e - 15 in. (38.1cm) (Centerline of Attaching Kit Pivot to Center- line of Outboard) f - Pivot Attaching Locknut - Torque to 20 lbs. ft. (27.0 Nm) g - Outboard Steering Arm h - “Clevis Kit”...

  • Page 530: Maintenance Instructions

    a - Ride-Guide Yoke 4. Adjust 2 large jam nuts on cable tube of attaching b - 0 in. to 1/2 in. (0mm to 12.8mm) (Center of Ride-Guide kit, so that steering wheel is in normal straight- Yoke to Top of Transom) driving position with outboard in straight-running c - Top of Transom position.

  • Page 531: Ride-Guide Steering Cable/Attaching Kit Installation (92876A3)

    CAUTION CAUTION Core of steering cable must be fully retracted into With this kit installed, the upper (outboard) cable housing when lubricating cable. If cable is mounting bolts MUST BE installed so that hex lubricated while extended, hydraulic lock of head end of bolts is on the inside of boat tran- cable could occur.

  • Page 532: Mounting Bracket Installation

    Mounting Bracket Installation Steering Cable Mounting Tube Installation IMPORTANT: Spacers (d) must be installed be- tween engine and mounting bracket. IMPORTANT: Spacers (b) must be installed be- tween outboard swivel bracket and mounting 1. Install mounting bracket to engine with 2 spacers, bracket for steering cable mounting tube to pro- 2 locking retainers and 4 bolts.

  • Page 533: Installing Steering Cables

    51891 51891 a - Steering Cable Mounting Tube (End of Tube with Longer a - Steering Cable Ends Threads Toward Starboard Side of Boat) b - Outboard Tilt Tube b - Mounting Bracket c - Cable Mounting Tube c - Locking Tab Washers (2) d - Cable Attaching Nuts d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab Washer)

  • Page 534: Coupler Installation

    Coupler Installation Lubricate ball joint in steering link rod with 2-4-C w/ Teflon. Secure link rod to outboard steering arm, us- ing special washer head bolt (10-14000) provided WARNING and nylon insert locknut as shown. Torque special Locknuts must be used with bolts to secure bolt to 20 Ib.
  • Page 535 Loosen adjustment nuts and pull steering cable mounting tube (by hand) away from end of steering cable (to remove slack in steering system). Tighten adjustment nuts against mounting bracket and check system for slack (play). If steering system is too tight, readjust tube toward end of steering cable or, if too much slack (play) exists in system, readjust tube 51889...

  • Page 536: Maintenance Instructions

    Maintenance Instructions 5. Inspection and lubrication of steering head assembly (rotary or straight rack) should be Maintenance inspection is owner’s responsibility and performed once each year (by your Authorized must be performed at intervals specified, following: Dealer) or whenever steering mount and/or steering head are disassembled, or if steering Normal Service –...

  • Page 537: Required Side Mount Remote Control Or Ignition Key Switch Assembly

    Required Side Mount Connecting Remote Wiring Remote Control or Ignition Harness To The Engine Key Switch Assembly 1. Pull up the cowl seal (a) and remove the star- board side rubber grommet (b). 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.

  • Page 538: Shift And Throttle Cable Installation To The Outboard

    3. Push the connector and plug into the holder (e). Shift Cable Installation 1. Pull up the cowl seal and remove the port side rubber grommet (a). 2. Position the remote control and outboard into neutral. 3. Slide shift actuator (b) toward the rear of engine (reverse gear) until resistance is felt.

  • Page 539: Throttle Cable Installation

    6. Check shift cable adjustments as follows: 6. Lock the cable barrels in-place with cable latch (e). a. With remote control in forward the propshaft should lock solidly in gear. If it does not, ad- just the cable barrel closer to the cable end guide.

  • Page 540: Installing Outboard Motor On Transom

    a - This solid line is recommended to determine the outboard Installing Outboard Motor on mounting height dimension. Use transom mounting bolt holes that will position outboard nearest to the recom- Transom mended height. After engine break-in (if necessary), raise or lower outboard one position at a time to attain best per- formance.

  • Page 541: Drilling Outboard Mounting Holes

    Drilling Outboard Mounting Holes Lifting Engine IMPORTANT: Before drilling any mounting holes, WARNING carefully read “Determining Recommended Out- board Motor Mounting Height”, preceding. There Make sure that lifting eye is threaded into fly- is a 3/4 in. (19mm) difference between outboard wheel a minimum of 5 turns and that hoist has a mounting holes in transom bracket.
  • Page 542 2. Apply marine sealer to shanks of mounting bolts WARNING (not threads) and secure engine to transom with 4 bolts, flat washers and locknuts, as shown. Be Before operating, motor(s) MUST BE SECURED sure that installation is water-tight. to boat transom with four 1/2 diameter bolts and locknuts, as follows: 2 bolts must be installed thru upper mounting holes and 2 bolts thru lower mounting holes, as shown in step 5.
  • Page 543 ATTACHMENTS/ CONTROL LINKAGE TILLER HANDLE...
  • Page 544 Table of Contents Page Steering Handle Components ....7B-2 Co-Pilot ........7B-6 Tiller Arm/Shift Lever Removal .
  • Page 545 Notes: 90-830234R3 DECEMBER 1997 ATTACHMENTS/CONTROL LINKAGE - 7B-1...

  • Page 546: Steering Handle Components

    Steering Handle Components Soapy Water Solution (Obtain Locally) Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 7B-2 - ATTACHMENTS/CONTROL LINKAGE 90-830234R3 DECEMBER 1997...
  • Page 547 Steering Handle Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m STEERING ARM (BLACK) STEERING ARM (GRAY ) – GREASE FITTING BUSHING HOUSING PLATE GASKET SCREW (3/5 IN.) Drive Tight SCREW (1/2 IN.) Drive Tight CLAMP SCREW (M5 x 40) Hand Tighten THROTTLE HANDLE/STOP SWITCH KIT STOP SWITCH...
  • Page 548 Steering Handle Components Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 7B-4 - ATTACHMENTS/CONTROL LINKAGE 90-830234R3 DECEMBER 1997...
  • Page 549 Steering Handle Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m BRACKET ASSEMBLY (BLACK) BRACKET ASSEMBLY (GRAY) SCREW (3/8-24 x 1-1/4 IN.) STUD (5/16 x 2-1/2) SPACER WASHER 54.2 GROMMET HARNESS ASSEMBLY (22 IN.) HARNESS ASSEMBLY (33 IN.) PLUG (ELECTRIC) KEY SWITCH ( KEYS LISTED UNDER KEY CHART ) Drive Tight...

  • Page 550: Co-Pilot

    Co-Pilot TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – CO-PILOT REPLACEMENT ROD LENGTH PILOT ROD is 12-5/8 IN. – CO-PILOT REPLACEMENT ROD LENGTH PILOT ROD is 14-5/8 IN. NUT ASSEMBLY SCREW KNOB–PRONG BUSHING WASHER Tighten Until Nut Seats;...

  • Page 551: Tiller Arm/Shift Lever Removal

    5. Remove access cover from underneath tiller Tiller Arm/Shift Lever handle bracket. Removal 1. Remove battery cables from battery. 2. Remove outboard cowling. 3. Remove nuts securing shift link rod and throttle cable to engine. Release latch and remove shift link rod and throttle cable from anchor bracket.
  • Page 552 7. Remove nuts securing key switch and trim switch 9. Remove electrical panel access cover. to tiller handle bracket. Disconnect switch harness from engine harness Remove clip securing lanyard stop switch and re- plug. move switch from bracket. Disconnect PURPLE bullet connector. 51626 a - Nuts b - Key Switch...
  • Page 553 10. Disconnect BLUE/WHITE and GREEN/WHITE 13. Remove bolt and nut (hidden) from tiller handle trim leads from trim solenoids. bracket. 51625 a - Bolt b - Nut (Hidden) 51622 14. Remove tiller handle, 2 nylon bushings, stainless a - BLUE/WHITE Lead bushing and 2 flat washers from bracket.

  • Page 554: Tiller Handle Disassembly

    15. Bend tab washer away from bolt securing shift 17. Bend tabs on tab washers away from nuts secur- lever and remove bolt and lever from bracket. ing bracket to steering arm. Remove nuts, tab washers and bracket from steering arm. 51622 a - Tab Washer b - Bolt...
  • Page 555 2. Remove screw from twist grip. 5. Remove throttle cable anchor screws and re- move cable guide. 51603 a - Screw 3. Cut sta-strap securing stop switch harness and remove screw from harness J-clip. 51602 a - Anchor Screws b - Throttle Cable Guide 6.
  • Page 556 7. Unscrew (counterclockwise) stainless conduit 9. Remove cover plate and gasket from tiller from tiller handle. handle. 10. Remove bolt from throttle friction assembly. 51603 51604 a - Conduit a - Cover Plate b - Gasket (below plate) 8. Pull throttle cable from tiller handle. c - Screws d - Throttle Friction Assembly e - Bolt...

  • Page 557: Tiller Arm Reassembly

    12. Drive out drift pin and remove throttle gear from 3. Slide cover and friction device onto throttle arm. throttle arm. 2-4-C With Teflon (92-825407A12) 51604 a - Throttle Arm b - Gear 51602 c - Throttle Friction Device a - Gear d - Cover b - Drift Pin 4.
  • Page 558 6. Install gasket and cover plate over gear assem- 9. Retract throttle cable into gear assembly until bly. DO NOT OVERTIGHTEN attaching screws. approximately 17 in. (43 cm) extends from the til- ler arm. 51604 51604 a - Cover Plate b - Gasket (below cover) a - Cable [Extends 17 in.
  • Page 559 11. Slide brass barrel over throttle cable tube. Se- 13. Position throttle arm slot to face stop harness exit cure barrel to tube with allen screw approximate- hole in tiller handle. Route stop switch harness ly 3.5 in. (89mm) from stainless conduit. DO NOT through twist grip, into throttle arm, and out OVERTIGHTEN screw as tubing may be crushed through side of tiller handle.

  • Page 560: Tiller Handle/Shaft Bracket Installation

    17. Attach sta-strap to end of harness sleeve. Tiller Handle/Shaft Bracket Installation 1. Slide bracket over steering arm studs. Secure bracket to arm with retained nuts and NEW tab washers. Torque nuts to 40 lb. ft. (54.0 Nm). Bend locking tabs against flats of nuts. 51603 a - Sta-strap b - J-clip...
  • Page 561 3. Insert bushings and thrust washer into shift lever. 5. Install two nylon bushings into tiller handle. Install shift lever onto bracket. Install stainless bushing into bracket. Install tiller handle to bracket using bolt and two washers. 51622 51620 a - Nylon Bushings b - Stainless Bushing a - Bushings c - Bolt...
  • Page 562 7. Reinstall plug. 9. Reinstall lanyard stop switch in bracket and se- cure with clip. 51626 51608 a - Nuts a - Plug b - Key Switch c - Lanyard Stop Switch 8. Route key switch and trim switch harness d - Trim Switch through tiller bracket.
  • Page 563 11. Secure access cover to tiller bracket with five 14. Reinstall electrical panel access cover and screws. DO NOT OVERTIGHTEN SCREWS. secure with screws. Torque screws to 30 lb. in. (3.4 Nm). 51626 a - Access Cover b - Screws 12.

  • Page 564: Shift Link Rod Installation And Adjustment To Engine

    6. Check shift link rod adjustment as follows: Shift Link Rod Installation a. Place engine shift lever in “F” (Forward) posi- and Adjustment to Engine tion. Propeller should not rotate in a COUN- 1. Position shift lever handle into neutral detent. TERCLOCKWISE direction.

  • Page 565: Throttle Cable Installation And Adjustment To Engine

    5. Check preload on throttle cable by placing a thin Throttle Cable Installation piece of paper between idle stop screw and idle and Adjustment to Engine stop. Preload is correct when paper can be re- moved without tearing, but has some drag on it. IMPORTANT: Turn throttle cable conduit clock- Readjust cable barrel, if necessary.
  • Page 566 4. Lubricate both ends of link rod with Quicksilver 2-4-C w/Teflon. 5. Secure link rod between steering handle assem- bly and pilot rod end as shown. 6. Adjust wing nut on friction device to provide de- sired steering control. IMPORTANT: Tighten wing nut to increase fric- tion;...

  • Page 567: Manual Starter

    MANUAL STARTER 51605...
  • Page 568 Table of Contents Page Notes: ........8A-1 Starter Assembly (Manual) .

  • Page 569: Notes

    Notes: 90-830234R3 DECEMBER 1997 MANUAL STARTER - 8A-1...

  • Page 570: Starter Assembly (Manual)

    Starter Assembly (Manual) 2 Cycle Outboard Oil (92-826666A24) 2-4-C With Teflon (92-825407A12) 8A-2 - MANUAL STARTER 90-830234R3 DECEMBER 1997...
  • Page 571 Starter Assembly (Manual) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HANDLE ASSEMBLY REST SEAL SCREW (M6 x 50) WASHER SPACER BUSHING GROMMET NUT (S/N- & BELOW) 10.2 NUT (S/N & UP) WASHER (S/N- & BELOW) WASHER BRACKET BRACKET SCREW WASHER...

  • Page 572: Rewind Starter Disassembly

    5. Remove cam and spring. Rewind Starter Disassembly WARNING When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Untie knot in starter rope and release starter rope to allow rewind spring to unwind. 2.

  • Page 573: Cleaning And Inspection

    2. Install starter sheave to housing and secure in Cleaning and Inspection place with screw. Torque to 135 lb. in. (15.3 N·m). 1. Clean components in solvent and dry with com- pressed air. 2. Inspect rewind spring for kinks, burrs, corrosion of breakage.

  • Page 574: Adjusting Rewind Spring Tension

    4. Install cam retainer. 4. Pull starter rope thru bracket, handle, and rope retainer. Secure rope retainer with knot in rope. 51605 a - Screws (2) b - Cam Retainer Adjusting Rewind Spring Tension 51606 a - Retaining Clip 1. Rotate sheave counterclockwise until it stops b - Screw (coil is bound).

This manual is also suitable for:

75 marathon75 sea pro11512565/80 jet90 ... Show all

Table of Contents

Save PDF