Mariner Mercury 135 JET Service Manual
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Mariner Mercury 135 JET Service Manual

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Table of Contents

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SERVICE
MANUAL
MODELS
105/140 JET 135 150 175
200 225
1992 Through 2000
105/140 Jet
135 150
150 XR6 150 Magnum III 150 EFI
175 175 EFI 200 200 EFI
With Serial Numbers
0D082000 Through 0G960499
1992 Through 2000
150/200/225 Pro Max
150/200/225 Super Magnum
With Serial Numbers
0D082000 Through 0T105314
2002, Mercury Marine
90-824052R3 JUNE 2002
Printed in U.S.A.

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Summary of Contents for Mariner Mercury 135 JET

  • Page 1 SERVICE MANUAL MODELS 105/140 JET 135 150 175 200 225 1992 Through 2000 105/140 Jet 135 150 150 XR6 150 Magnum III 150 EFI 175 175 EFI 200 200 EFI With Serial Numbers 0D082000 Through 0G960499 1992 Through 2000 150/200/225 Pro Max 150/200/225 Super Magnum With Serial Numbers 0D082000 Through 0T105314...
  • Page 2 Notice who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must Throughout this publication, “Dangers”, “Warnings” completely satisfy himself that neither his nor the and “Cautions” (accompanied by the International products safety will be endangered by the service HAZARD Symbol ) are used to alert the mechanic procedure selected.

  • Page 3: Page Numbering

    Cleanliness and Care of In addition, personnel should not work on or under an outboard which is suspended. Outboards should be Outboard Motor attached to work stands, or lowered to ground as soon as possible. A marine power product is a combination of many We reserve the right to make changes to this manual machined, honed, polished and lapped surfaces with without prior notification.
  • Page 4 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

    IMPORTANT INFORMATION SPECIFICATIONS...
  • Page 6 Table of Contents Page Master Specifications ..... 1A-1 1A-0 - IMPORTANT INFORMATION 90-824052R3 JUNE 2002...
  • Page 7 Master Specifications Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 HORSEPOWER Model 135 135 (100.6) (KW) Model 105 Jet/150/150XRI 150 (111.8) Model XR6/MAGIII 150 (111.8) Model 175/175XRI 175(130.5) Model 140 Jet/200/200XRI 200(149.1) Model Pro Max/Super Magnum 150 150 (111.8) Model Pro Max/Super Magnum 200 200(149.1) Model Pro Max/Super Magnum 225 225(167.9)
  • Page 8 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 COMPRESSION All Models – Using a fully charged 110 – 135 psi battery, throttle shutters wide open (753.3 – 924.5 kPa) and cylinder block warm Variance between cylinders should not exceed 15 psi (102.7 kPa) REEDS Model 105 Jet/135/150 Model XR6/MAGIII/175/200...
  • Page 9 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 FUEL Fuel Gasoline w/Oil Injection SYSTEM Recommended Gasoline Model 105/140 Jet/135/150 Model XR6/MAGIII/175/200 Model 150XRI/175XRI/200XRI Unleaded 87 Octane Minimum Model Pro Max/Super Magnum 150/200/225 Unleaded 92 Octane Minimum Recommended Oil All Models Quicksilver TC-W3 2 Cycle Outboard Oil Only Gasoline/Oil Ratio 50:1 (25:1 Break-In)
  • Page 10 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 Idle RPM – Model 105/140 Jet 135/150/175/200 – Model Pro Max/Super Magnum 150/200/225 – Model XR6/MAGIII Wide Open Throttle (WOT) RPM – Model 105/140 Jet 5000 – 5600 135/150/175/200 5000 – 5500 – Model XR6/MAGIII 5000 –...
  • Page 11 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 WMV Carburetor Jets – Model 135 (WMV 1/1A) – Main Jet .072 – Idle Air Jet Cyl. 1,2,3,4,6 – .036; Cyl. 5 – .040 – Vent Jet .086 – Model 105 Jet/150 (WMV 2/2A) –...
  • Page 12 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 Idle Speed/Pickup Timing – 105 JET/135/150 Carb Models 2 – 9 ATDC – XR6/MAG III/175 Carb – 140 Jet/200 Carb – All Pro Max/Super Magnum – 150XRI/175 XRI Models – 200 XRI Model 0 – 9 ATDC Maximum BTDC –...
  • Page 13 Model 105/140Jet/135/150/XR6/MAGIII/175/200/150XRI/175XRI/200XRI PRO MAX/SUPER MAGNUM 150/200/225 Recommended Oil (All Models) Quicksilver TC-W3 INJECTION Hi-Perf. Pro Max/Super Magnum Quicksilver TC-W3 Oil Tank Capacity 3 gal. (11.4Liter) Approx. Time – Model 105 Jet/135/150 8.7 hrs. Approx. – Model 140 Jet/XR6/MAGIII/175/200 6.6 hrs. Approx. –...
  • Page 14 IMPORTANT INFORMATION MAINTENANCE...

  • Page 15: Table Of Contents

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

  • Page 16: Specifications

    Specifications Inspection and Maintenance Schedule Gear Case Lubricant Capacity Before Each Use Gear Case Ratio Capacity 1. Check that lanyard stop switch stops the engine. 1.78:1 21 fl. oz. (625ml) 2. Visually inspect the fuel system for deterioration 1.87:1 24-1/4 fl oz. (717ml) or leaks.

  • Page 17: Lubrication Points

    14. Check tightness of bolts, nuts, and other fasten- Lubrication Points ers. Item Descrip- Type of Fresh Salt Water 15. Replace water pump impeller (more often if over- tion Lubricant Water Frequency heating occurs or reduced water pressure is Frequency ∗...
  • Page 18 RIDE-GUIDE STEERING CABLE AND PIVOT POINTS LUBRICATION WARNING Core of steering cable (transom end) must be fully retracted into cable housing before lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur. With core of Ride-Guide Steering cable (transom end) fully retracted, lubricate transom end of steering cable thru grease fitting and exposed portion of cable 1 - Throttle/Shift Linkage Pivot Point Lubrication...

  • Page 19: Checking Power Trim Fluid

    Checking Power Trim Fluid The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trailing range several times to remove any air from the system. The trim system is pressurized and is not externally vented.

  • Page 20: Gear Case Lubrication

    Gear Case Lubrication 4. Inspect gear lubricant for metal particles (lubri- cant will have a “metal flake” appearance). Pres- ence of a small amount of fine metal particles (re- sembling powder) on the fill screw bar magnet Gear Case Lubricant Capacity indicates normal gear wear.

  • Page 21: Propeller Replacement

    Propeller Replacement Installation WARNING Removal When installing or removing propeller, verify re- mote control is in NEUTRAL position and that key WARNING switch is “OFF.” Place a block of wood between the anti-ventilation plate and propeller to prevent Disconnect high tension leads from spark plugs accidental engine starting and to protect hands and remove spark plugs from engine before re- from propeller blades while removing propeller...

  • Page 22: Corrosion Control Anode

    4. Place rear thrust hub on propeller shaft. Corrosion Control Anode 5. Place locking tab washer on propeller shaft, then The gear case has two corrosion control anodes. thread propeller nut on shaft. Another anode is installed on the bottom of the tran- som bracket assembly.

  • Page 23: Flushing Engine

    Flushing Engine 3. With the outboard in the normal operating position (vertical), partially open water tap (IT IS NOT NECESSARY to use full water pressure) and adjust water flow so that there is a significant Flushing Cooling System with water loss around the rubber cups. Engine NOT Running (Using Cowl 4.

  • Page 24: Storage

    Storage GEAR CASE Drain and refill the gear case lubricant. PROTECTING EXTERNAL OUTBOARD COMPONENTS POSITIONING OUTBOARD FOR STORAGE 1. Lubricate all outboard components listed in the Store outboard in an upright (vertical) position to al- Inspection and Maintenance Schedule. low water to drain out of outboard. 2.
  • Page 25 IMPORTANT INFORMATION GENERAL INFORMATION...
  • Page 26 Table of Contents Page Serial Number Location ....1C-1 Conditions Affecting Performance ..1C-1 Weather .

  • Page 27: Serial Number Location

    Serial Number Location Corporations internationally have settled on adop- tion of I.S.O. (International Standards Organization) The engine serial number is located on the lower engine test standards, as set forth in I.S.O. 3046 starboard side of the engine block. A serial number standardizing the computation of horsepower from is also located on the starboard side of the swivel data obtained on the dynamometer, correcting all val-...

  • Page 28: Boat

    Boat water inlet holes in the gear housing and cause the engine to overheat. WEIGHT DISTRIBUTION TRIMMING OUTBOARD “OUT” (“UP”) 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the WARNING boat’s performance, for example: Excessive trim “out”...

  • Page 29: Engine

    WATER ABSORPTION (4.) Spark plugs (heat range too hot – incor- rect reach – cross-firing). It is imperative that all through hull fasteners be coated with a quality marine sealer at time of (5.) Inadequate engine cooling (deteriorated installation. Water intrusion into the transom core cooling system).

  • Page 30: Following Complete Submersion

    Following Complete 8. Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug Submersion opening. Again rotate flywheel to distribute oil in cylinders. 9. Remove and clean carburetors and fuel pump Salt Water Submersion (Special assembly.

  • Page 31: Propeller Selection

    Propeller Selection Painting Procedures For best all around performance from your outboard/boat combination, select a propeller that Cleaning & Painting Aluminum allows the engine to operate in the upper half of the Propellers & Gear Housings recommended full throttle RPM range with the boat normally loaded (refer to Specifications).

  • Page 32: Decal Application

    3. Sand blistered area with 3M 180 grit sandpaper Decal Application or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. Decal Removal 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 1.
  • Page 33 DECAL APPLICATION 1. Mix ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps it’s shape during installation.
  • Page 34 IMPORTANT INFORMATION OUTBOARD MOTOR INSTALLATION...
  • Page 35 Table of Contents Page Page Notice to Installer and Owner ....1D-1 Shift and Throttle Cable Installation to Boat Horsepower Capacity ....1D-1 the Outboard .

  • Page 36: Notice To Installer And Owner

    Notice to Installer and Owner Outboard Remote Control This manual as well as safety labels posted on the The remote control connected to the outboard must outboard use the following safety alerts to draw your be equipped with a start-in-gear protection device. attention to special safety instructions that should be This prevents the engine from starting when the out- followed.

  • Page 37: Determining Recommended Outboard Mounting Height

    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 38: Locating Centerline Of Boat Transom

    Locating Centerline of Boat IMPORTANT: If using “Transom Drilling Fixture” (part number 91-98234A2), use drill guide holes Transom marked “A” when drilling outboard mounting holes. Locate (and mark with pencil) vertical centerline (a) of boat transom. a - Centerline of Transom NOTE: Dimensions “A”...

  • Page 39: Lifting Outboard

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

  • Page 40: Single Steering Cable And Steering Link Rod Installation

    Single Steering Cable and Steering Link Rod Installation 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 41: Routing Location For Wiring And Hoses Thru Clamp In Bottom Cowl

    Routing Location for Wiring Remote Control Installation and Hoses thru Clamp in Refer to “Quicksilver Accessories Guide” to deter- mine correct length of remote control cables. Bottom Cowl IMPORTANT: Remote control cables must be cor- IMPORTANT: Sufficient slack must exist in en- rect length.

  • Page 42: Required Side Mount Remote Control Or Ignition Key Switch Assembly

    Required Side Mount Shift and Throttle Cable Remote Control or Ignition Installation to the Outboard Key Switch Assembly Shift Cable Installation Boats Equipped with Side Mount 1. Install the shift cable to the remote control. Refer Remote Control to installation instructions included with the remote control.

  • Page 43: Throttle Cable Installation

    3. Position remote control into NEUTRAL detent. Throttle Cable Installation 4. Manually shift outboard into NEUTRAL position. NOTE: Attach Shift cable to engine prior to attaching throttle cable. 5. Slide the shift cable retainer (d) forward until re- sistance is felt, then slide cable anchor toward 1.

  • Page 44: Remote Wiring Connections

    Remote Wiring Connections Battery Connections 1. Connect the remote wiring harness from the CAUTION remote control or key switch assembly into the engine wiring harness connector. For dual outboard installations, the negative (–) battery cable of each engines starter motor 2.

  • Page 45: Fuel Connections

    Fuel Connections Set Up Instructions for Oil Injection System Connecting Fuel Hose to Engine CAUTION EFI MODELS 1. Connect fuel hose (a) to fitting inside of bottom Be careful not to get dirt or other contamination cowl as shown. Secure with hose clamp (b). in tanks, hoses or other components of the oil in- jection system during installation.

  • Page 46: Installing Oil Hoses To Engine

    Installing Oil Hoses To Engine Filling the Oil Injection System 1. Remove (and discard) the shipping cap from 1. Fill remote oil tank with the recommended oil hose fitting (a). listed in the Operation and Maintenance Manual. Tighten fill cap. 2.

  • Page 47: Bleeding Air From Oil Injection Pump And Oil Injection Outlet Hose

    Bleeding Air from Oil Injection Pump Propeller Selection and Oil Injection Outlet Hose Refer to “Quicksilver Accessory Guide” for a com- plete list of available propellers. BLEEDING AIR FROM OIL INJECTION PUMP For best all around performance from your outboard/ With engine not running, place a shop towel below boat combination, select a propeller that allows the the oil injection pump.

  • Page 48: Power Trim System

    Power Trim System Consider the following lists carefully. Trimming In or Down Can: 1. Lower the bow. General Information 2. Result in quicker planing off, especially with a The power trim system is filled at the manufacturer heavy load or a stern heavy boat. and is ready for use.

  • Page 49: Trim "In" Angle Adjustment

    Trim “In” Angle Adjustment Checking Trim System Fluid Level Some outboard boats, particularly some bass boats, 1. Tilt outboard to the full up position and engage are built with a greater than normal transom angle the tilt support lever. which will allow the outboard to be trimmed further 2.
  • Page 50 ELECTRICAL IGNITION SYSTEM...
  • Page 51 Table of Contents Page Page Ignition Specifications ..... 2A-1 Idle Stabilizer Modules ....2A-20 40 Ampere Stator .

  • Page 52: Ignition Specifications

    Ignition Specifications Trigger Ignition System Test Resistance Scale Leads to Ohms Reading Type Capacitor Discharge Between BROWN Spark Plug Type NGK BU8H Trigger Lead (without (Except 225 ProMax and YELLOW Sleeve) and 225 Super Magnum) 1100-1400 R x 100 WHITE Trigger Lead Spark Plug Type NGK BUZHW (with YELLOW...

  • Page 53: Special Tools

    Special Tools Volt/Ohm Multi-Meter 91-62562 DMT 2000 Digital Tachometer Multimeter 91-854009A1 55218 NOTE: Volt/Ohm Multi-Meter 91-62562 can be used to test ignition system voltages if used in conjunction Spark Gap Tester 91-63998A1 with DVA ADAPTOR 91-89045. DVA Adapter 91-89045 55218 Cylinder Timing Decal 91-853883-1 Decal can be used to help troubleshoot ignition NOTE: There are 2 versions of the DVA adapter –...
  • Page 54 Test Harness 91-14443A1 Flywheel Holder 91-52344 91–52344 Heat Lamp 91-63209 54964 Timing Light 91-99379 Crank Shaft Protector Cap 91-24161 Flywheel Puller 91-849154T1 55117 90-824052R3 JUNE 2002 ELECTRICAL - 2A-3...

  • Page 55: Flywheel/Starter Motor

    Flywheel/Starter Motor Loctite 271 (92-809820) Liquid Neoprene (92-25711--2) 2A-4 - ELECTRICAL 90-824052R3 JUNE 2002...
  • Page 56 Flywheel/Starter Motor TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FLYWHEEL COVER ASSEMBLY MARKER SCREW WASHER PLUG PLUG WASHER FLYWHEEL STATOR SCREW WASHER TRIGGER PLATE ASSEMBLY STARTER MOTOR COLLAR RUBBER STOP SCREW WIRE ASSEMBLY (BLACK) WIRE ASSEMBLY (BLACK) LOCKWASHER 90-824052R3 JUNE 2002 ELECTRICAL - 2A-5...

  • Page 57: Ignition Coil/Voltage Regulator

    Ignition Coil/Voltage Regulator Dielectric Grease (92-823506--1) Liquid Neoprene (92-25711--2) Loctite 680 (92-809833) NOTE: Apply Liquid Neoprene to all eyelet wiring terminal connections. 2A-6 - ELECTRICAL 90-824052R3 JUNE 2002...
  • Page 58 Ignition Coil/Voltage Regulator TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m MOUNTING PLATE STUD SPACER LOCKWASHER CABLE VOLTAGE REGULATOR PLUG HARNESS ASSEMBLY (#2,4 & 6) HARNESS ASSEMBLY (#1,3 & 5) STA-STRAP COVER–ignition coil SCREW–ignition coil cover WASHER NUT–cover screw/ground wire Drive Tight GROUND WIRE SCREW–grounding wire...

  • Page 59: Wiring Harness/Starter Solenoid

    Wiring Harness/Starter Solenoid 23 22 Loctite 271 (92-809820) Liquid Neoprene (92-25711--2) NOTE: Apply Liquid Neoprene to all eyelet wiring terminal connections. 2A-8 - ELECTRICAL 90-824052R3 JUNE 2002...
  • Page 60 Wiring Harness/Starter Solenoid TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m ENGINE HARNESS FUSE STA-STRAP TERMINAL BLOCK SCREW WASHER J CLAMP IGNITION PLATE SWITCH BOX SCREW (2-1/2 ) BUSHING CABLE ASSEMBLY (150/175) CABLE ASSEMBLY (3 - WHITE/BLACK)(150/175) CABLE ASSEMBLY (6 - RED/WHITE) WIRE SCREW CABLE ASSEMBLY (BLACK)

  • Page 61: Theory Of Operation

    Theory of Operation Flywheel Shift Interrupt Switch Stator #2 Coil Idle Stabilizer Trigger #1 Coil #4 Coil Diode Inner Switch Box #3 Coil #6 Coil Ignition Key Switch Mercury (Tilt) Switch #5 Coil Outer Switch Box Description The trigger assembly (also mounted under the fly- wheel) has 3 coils.

  • Page 62: Ignition Test Procedures

    Ignition Test Procedures Checking for Loss of Spark The use of an inductive timing light while cranking or WARNING running the engine will show whether there is spark present or not. The timing light will not show the When testing or servicing the V-6 outboard strength of the spark.

  • Page 63: Troubleshooting Tips

    NOTE: If using a heat device to warm electrical Troubleshooting Tips components, maximum temperature electrical 1. Intermittent, weak or no spark output at 2 spark components can be heated to without damage is plugs (one plug from each bank of three cylin- 311 F (155 C ).

  • Page 64: Ignition Troubleshooting

    Ignition Troubleshooting 1-C. If Steps 1-A and 1-B check OK, replace spark plugs. If problem still is evident after replacing spark plugs, Multimeter/DVA Tester 91-99750A1 proceed with Step 1-D. 1-D. If Steps 1-A, 1-B and 1-C check OK, check WARNING ignition timing.

  • Page 65: Stator Low Speed Test

    2-B. Check ignition switch/wiring, as follows: STATOR HIGH SPEED TEST WARNING DVA RED DVA BLK 400 RPM 1000 3000 DANGER--HIGH VOLTAGE SHOCK/FIRE HAZ- GROUND 25 - 50 120 - 160 230 - 320 ARD. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark 1.

  • Page 66: Bias Circuit Test

    STATOR HIGH SPEED TEST BIAS CIRCUIT TEST DVA RED DVA BLK 400 RPM 1000 3000 DVA RED DVA BLK 400 RPM 1000 3000 RED/WHT GROUND 25 - 50 120 - 160 230 - 320 GROUND WHT/BLK 1 - 6 3 - 15 10 - 30 1.

  • Page 67: Ignition System Test Chart

    Ignition System Test Chart IMPORTANT: BEFORE attempting the ignition BOXES MUST BE GROUNDED (CASE TO system checks, below, thoroughly read the ENGINE BLOCK) FOR ALL TESTS--IF NOT, preceding pages of these instructions to become SWITCH BOXES MAY BE DAMAGED. familiar with the proper test sequence and procedures (particularly any “Warnings”...

  • Page 68: Trigger Assembly Test

    TRIGGER ASSEMBLY TEST 3. Use an ohmmeter and perform the following tests: 1. Remove 2 screws and lift outer switch box from inner switch box. Refer to switch box(es) removal NOTE: Copper wire is an excellent conductor, but it will have a noticeable difference in resistance from and installation, following.

  • Page 69: Ignition (Key) Switch Test

    IGNITION (KEY) SWITCH TEST 3. If meter readings are other than specified in the preceding tests, verify that switch and not wiring 1. Disconnect remote control wiring harness and in- is faulty. If wiring checks OK, replace switch. strument panel connector. NOTE: Wiring diagram for control boxes is located in CONTINUITY SHOULD BE INDICATED AT THE SECTION 2D.

  • Page 70: Ignition Switch (Bullet Connections)

    IGNITION SWITCH (BULLET CONNECTIONS) TESTS FOR PROPER FUNCTION OF LOW SPEED/ HIGH SPEED SPARK ADVANCE MODULE IMPORTANT: Due to the sensitivity characteris- tics of individual modules and tachometer vari- ances, the engine RPM at which the module will advance/retard the ignition timing may vary slightly from specification.

  • Page 71: Low Speed/High Speed Spark Advance Module Removal

    LOW SPEED/HIGH SPEED SPARK ADVANCE TEST FOR PROPER FUNCTION OF IDLE MODULE REMOVAL STABILIZER 1. Disconnect spark advance module harness IMPORTANT: Due to the sensitivity characteris- leads from switch box. tics of individual modules and tachometer vari- ances, the engine RPM at which the module will 2.

  • Page 72: Test For Proper Function Of Idle Stabilizer Shift System

    The purpose of this system is to help prevent the IDLE STABILIZER MODULE REMOVAL outboard from stalling when shifting into gear while 1. Disconnect stabilizer module harness leads from using a high pitch propeller. switch box. IMPORTANT: On models OTHER THAN XR6 and 2.

  • Page 73: Ignition Components Removal And Installation

    Ignition Components Removal and flywheel removal, as excessive heat may seize flywheel to crankshaft. Installation FLYWHEEL REMOVAL AND INSTALLATION Flywheel Removal 1. Remove 3 wing nuts and lift flywheel cover off engine. 2. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer. 51839 a - Flywheel b - Flywheel Puller (91-849154T1)

  • Page 74: Stator Assembly Removal And Installation

    STATOR ASSEMBLY REMOVAL AND Stator Assembly Installation INSTALLATION 1. Clean stator attaching screw threads with Loctite Stator Assembly Removal Primer T (92-59327--1 ) and apply Loctite 271 (obtain locally). Install stator assembly in position 1. Remove flywheel, as outlined in “Flywheel on upper end cap and secure with attaching Removal and Installation,”...

  • Page 75: Trigger Plate Assembly Removal And Installation

    TRIGGER PLATE ASSEMBLY REMOVAL AND Trigger Plate Assembly Installation INSTALLATION 1. If link rod swivel was disassembled or removed, Trigger Plate Assembly Removal reassemble to trigger as shown. 1. Remove flywheel, as outlined in “Flywheel Removal and Installation,” preceding. 2. Remove 4 screws which secure stator assembly to upper end cap.

  • Page 76: Ignition Coil Removal And Installation 2A-25

    2. Place trigger plate assembly in upper end cap. 6. Secure wires with sta-strap and “J” clamp. Fasten link rod swivel to spark advance lever with locknut. 51840 a - Spark Advance Lever a - ‘‘J” Clamp b - Locknut b - Sta-Strap c - Trigger Harness c - Trigger Wiring Harness (Routes as Shown-Wires with...

  • Page 77: Switch Box(Es) Removal And Installation

    Ignition Coil Installation SWITCH BOX(ES) REMOVAL AND INSTALLATION 1. Place coil in coil cover and install to engine with 4 screws and nuts. Switch Box(es) Removal 1. Remove 2 screws and lift switch boxes from engine. (Retain round metal spacers.) 51843 a - Ground Wire [Between (–) Coil Terminal and Engine Ground]...

  • Page 78: Spark Plug Wire Routing (Production Outboards)

    SPARK PLUG WIRE ROUTING (PRODUCTION CAUTION OUTBOARDS) Switch boxes must be grounded to engine before To avoid the possibility of cross-firing occurring cranking engine, or switch boxes will be between spark plug high tension leads, it is damaged. recommended that wiring be routed as shown: 51844 a - Switch Box Mounting Screws (2) b - Round Metal Spacer (2)

  • Page 79: Spark Plug Wire Routing (High Performance Outboards)

    SPARK PLUG WIRE ROUTING (HIGH PERFORMANCE OUTBOARDS) 2A-28 - ELECTRICAL 90-824052R3 JUNE 2002...
  • Page 80 ELECTRICAL 51797 BATTERY CHARGING SYSTEM AND STARTING SYSTEM...
  • Page 81 Table of Contents Page Page Specifications ......2B-1 Installation of Voltage Regulator/ Special Tools ......2B-1 Rectifier .

  • Page 82: Specifications

    Specifications Special Tools DMT 2000 Digital Tachometer Multimeter Starter Draw (No Load) 40 Amperes 91-854009A1 Starter Draw (Under 175 Amperes Load) Battery Rating 630 Marine Cranking Amperes (MCA) 490 Cold Cranking Am- peres (CCA) Alternator Output (@ 38-42 Amperes Net @ each regulator –...

  • Page 83: Battery

    Battery 2. Never take hydrometer readings immediately after water has been added. Water must be thoroughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause Precautions vigorous gassing. 3. If hydrometer has built-in thermometer, draw WARNING liquid in several times to ensure correct If battery acid comes in contact with skin or eyes,...

  • Page 84: Specific Gravity Cell Comparison Test

    A fully charged battery will have a specific gravity Charging a Discharged reading of approximately 1.270 at an electrolyte Battery temperature of 80 F (27 C). If electrolyte temperature is above or below 80 F, additions or The following basic rules apply to any battery charg- subtractions must be made in order to obtain a ing situation: hydrometer reading corrected to 80 F standard.

  • Page 85: Winter Storage Of Batteries

    Winter Storage of Batteries Battery Charging System Description Battery companies are not responsible for battery damage either in winter storage or in dealer stock if The battery charging system components are the the following instructions are not observed: flywheel permanent magnets, stator, voltage...

  • Page 86: Battery Charging System Troubleshooting

    Battery Charging System 40 Ampere Alternator System Troubleshooting 40 AMP STATOR TEST (ALTERNATOR COILS ONLY) NOTE: Stator can be tested without removing from General Troubleshooting engine. A fault in the battery charging system will usually 1. Disconnect 2 short YELLOW and 2 long YEL- cause the battery to become UNDERCHARGED.

  • Page 87: Determining Cause Of Problem

    IMPORTANT: Check that all connections are tight PROBLEM: NO OUTPUT prior to starting tests. Ensure that the battery IMPORTANT: Regulators MUST have a good posts and terminals are clean and making good ground. Verify a clean contact surface exists contact. Verify with test equipment that wiring between regulator case,...

  • Page 88: Voltage Regulator Test

    VOLTAGE REGULATOR TEST Voltage Regulator Resistance Scale Test (Ohms) IMPORTANT: Make sure meter is “zeroed” by Using Digital Meter shorting meter leads together after changing Test Leads To- selector knob to appropriate setting. The meter reading must read “0” Ohms. Diode Check: Con- 0.4 –...

  • Page 89: Installation Of Voltage Regulator/Rectifier

    Pro Max/Super Magnum Models – INSTALLATION OF VOLTAGE REGULATOR/ RECTIFIER 1. Position regulators over attaching studs (production models). 2. Connect YELLOW, RED and GRAY (as required) leads to their respective bullet connectors. 3. Position spacers over attaching studs (production models). NOTE: Pro Max/Super Magnum regulators are secured to powerhead with bolts and lock nuts.

  • Page 90: Incorporating A Battery Isolator With

    INCORPORATING A BATTERY ISOLATOR WITH 2. Using BATTERY ISOLATOR HARNESS KIT V-6 40 AMP CHARGING SYSTEM 84-815366A3, charging system can be wired to provide either 20 amps to auxiliary battery and 20 A battery isolator will allow the charging system to amps to cranking battery or 40 amps to isolator.

  • Page 91: System Wired For 40 Ampere Output To Isolator

    System Wired for 40 Ampere Output IMPORTANT: After electrical connections are made, coat all terminal connections using to Isolator Quicksilver Liquid Neoprene (92-25711) to avoid corrosion. a - Starter Solenoid h - Plug (from kit) b - RED Lead to Starter Solenoid i - Lower Regulator c - Battery Isolator j - Upper Regulator...

  • Page 92: Starter System

    Starter System CAUTION The starter motor may be damaged if operated STARTER SYSTEM COMPONENTS continuously. DO NOT operate continuously for 1. Battery more than 30 seconds. Allow a 2 minute cooling period between starting attempts. 2. Starter Solenoid 3. Neutral Start Switch TROUBLESHOOTING THE STARTER CIRCUIT 4.

  • Page 93: Starter Circuit Troubleshooting Flow Chart

    Starter Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect YELLOW (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (Rx1 scale) and connect meter leads between NEGATIVE (-) battery post and common pow- erhead ground.

  • Page 94: Starter Removal And Installation

    TEST 7 a. Connect voltmeter between common engine and Test Point 1. b. Turn ignition key to “Start” position. 12 Volt Reading* No voltage reading: Defective starter solenoid Should hear solenoid click: proceed to TEST 8 TEST 8 a. Reconnect BLACK cable (with YELLOW sleeve) to starter solenoid Test Point 1.

  • Page 95: Installation

    INSTALLATION a. Remove hex nut and washers from POSI- TIVE (+) terminal and remove POSITIVE 1. Slide rubber collars on starter. brushes and terminal as an assembly. 2. If the removed starter was equipped with a b. Remove 2 bolts securing NEGATIVE (–) spacer replace spacer on upper collar.

  • Page 96: Starter Cleaning, Inspection And Testing

    Then remove parts from shaft. 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 (“Testing”). 8. Open-circuited armatures often can be repaired. The most likely place for an open circuit is at the a b c d commutator bars, as a result of long cranking...
  • Page 97 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 x1 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 98: Starter Reassembly

    STARTER REASSEMBLY b. Install NEGATIVE brushes (along with brush holder). 1. If brushes were removed, replace as follows: a. Install POSITIVE brushes (along with POSI- TIVE terminal) into commutator end cap. 11656 a - POSITIVE (+)Brushes b - NEGATIVE (-) Brushes c - Brush Holder d - Bolts (Fasten NEGATIVE Brushes and Holder) 2.
  • Page 99 5. Position armature into starter frame. 8. Place springs and brushes into brush holder and hold in place with brush retainer tool. 6. To prevent damage to brushes and springs when installing commutator end cap, it is recom- mended that a brush retaining tool be made as shown: 11661 a - Brush Retainer Tool...

  • Page 100: Starter Solenoid Test

    STARTER SOLENOID TEST 1. Disconnect all wires from solenoid. 2. Use an ohmmeter (R x1 scale) and connect meter leads between solenoid terminals 1 and 2. 3. Connect a 12-volt power supply between sole- noid terminals 3 and 4. Solenoid should click and meter should read 0 ohms (full continuity).
  • Page 101 ELECTRICAL TIMING, SYNCHRONIZING & ADJUSTING...
  • Page 102 Table of Contents Page Page Timing/Synchronizing/Adjusting ... . 2C-1 Adjustments ......2C-7 Specifications .

  • Page 103: Timing/Synchronizing/Adjusting

    Timing/Synchronizing/ Model 140 JET/200 Full Throttle RPM Range 5000-5600 Adjusting Idle RPM (in Forward Gear) 625-725 Maximum Timing: Specifications *(Models with Spark Advance Module) @ Cranking Speed 21 BTDC CARBURETED MODELS @ Wide Open Throttle 25 BTDC Models 105 JET/135/150 Maximum Timing: *(Models with Idle Full Throttle RPM Range...

  • Page 104: Electronic Fuel Injection Models

    ELECTRONIC FUEL INJECTION MODELS Model 200/225 PRO MAX/SUPER MAGNUM Full Throttle RPM Range 6200-6500 Models 150 XRI Idle RPM (in Forward Gear) 600-700 Full Throttle RPM Range 5000-5600 Maximum Timing: Idle RPM (in Forward Gear) 625-725 @ Cranking Speed 25 BTDC 1992 –...

  • Page 105: Adjustments

    Adjustments 5. Remove dial indicator from cylinder. CARBURETOR SYNCHRONIZATION Carburetor Models Loosen 3 carburetor synchronization screws (a) TIMING POINTER ADJUSTMENT to allow shutter plates to close completely. Position throttle lever so that idle stop screw is WARNING against idle stop and move roller arm until roller Engine could start when turning flywheel to lightly touches throttle cam (b).

  • Page 106: Carburetor/Oil Pump Synchronization

    Move throttle lever to wide-open-throttle (W.O.T.) CARBURETOR/OIL PUMP SYNCHRONIZATION position and adjust full throttle stop screw (a) to When carburetor linkage is at idle position, allow full throttle shutter opening at W.O.T. Verify alignment mark (a) on oil injection arm should be that throttle shutters do not act as a throttle stop.

  • Page 107: Timing Adjustments

    TIMING ADJUSTMENTS MAXIMUM TIMING ADJUSTMENT CAUTION CAUTION Engine may be timed while cranking engine with Models equipped with Idle Stabilizer Shift Kit starter motor. To prevent engine from starting Accessory (P/N 87-814281A1), excluding when being cranked, all spark plugs must be re- Mercury XR6, Mariner Magnum llI and 175 require moved.

  • Page 108: Primary Pickup Timing Adjustment

    PRIMARY PICKUP TIMING ADJUSTMENT IDLE SPEED ADJUSTMENT With engine in neutral, hold throttle arm so that With engine in water, connect fuel line to engine. idle stop screw (a) is against idle stop. Crank en- Start engine and allow to warm up. gine with starter motor and adjust throttle primary Place outboard in gear and monitor engine RPM.

  • Page 109: Adjustments

    Idle Stabilizer Shift System 4. Reposition timing pointer (1) (if necessary) so that timing pointer is aligned with .462 in. mark (2) on timing decal. Retighten pointer attaching screws (3). 50707 a - Inner Switch Box b - To Outer Switch Box c - Diode d - Shift Interrupt Switch Adjustments...

  • Page 110: Throttle Cam Adjustment

    ADJUSTMENTS THROTTLE CAM ADJUSTMENT 1. Loosen cam follower screw (1) allowing cam CAUTION follower to move freely. Engine is initially timed while cranking engine 2. Allow roller (2) to rest on throttle cam (3). Adjust with starter motor. To prevent engine from idle stop screw (4) on throttle arm (5) to align starting when being cranked, all spark plugs mark (6) on throttle cam (3) with center of roller...

  • Page 111: Static Idle Timing Adjustment (Cranking Engine With Starter)

    STATIC IDLE TIMING ADJUSTMENT 1. Connect timing light to No 1 spark plug lead (TOP (CRANKING ENGINE WITH STARTER) STARBOARD BANK). Disconnect WHITE/BLACK lead (1) from idle WARNING stabilizer box at bullet connector (2). Disconnect ECU harness for ignition timing procedure. While cranking engine, keep clear of propeller, as it may rotate.

  • Page 112: Static Maximum Timing Adjustment (Cranking Engine With Starter)

    STATIC MAXIMUM TIMING ADJUSTMENT 3. Reconnect WHITE/BLACK lead from idle (CRANKING ENGINE WITH STARTER) stabilizer box. Reconnect harness. Disconnect timing light and install spark plugs IMPORTANT: Do not use this procedure for 225 and fuel line. Pro Max/Super Magnum models. NOTE: WHITE/BLACK lead and ECM harness remain disconnected...

  • Page 113: Throttle Position Sensor (Tps) Adjustment

    THROTTLE POSITION SENSOR (TPS) 5. Loosen screws (1) securing TPS to manifold. ADJUSTMENT 1. Disconnect TPS from EFI harness (1). 6. Rotate TPS fully clockwise (holding throttle shaft in closed position). On models with ECM P/N 14623A15 and above, voltmeter should read .200 - .300.

  • Page 114: Idle Timing (Engine Running)

    12. Reconnect TAN/BLACK engine head tempera- 5. Reconnect WHITE/BLACK lead of idle stabilizer ture sensor leads located on port cylinder head. (1) at bullet connector (2). IDLE ADJUSTMENT 1. With outboard in water, start and allow to warm 51785 a - Head Temperature Sensor Leads 2.

  • Page 115: Throttle Valve/Oil Pump Synchronization

    THROTTLE VALVE/OIL PUMP THROTTLE CABLE INSTALLATION SYNCHRONIZATION 1. With end of throttle cable connected to throttle 1. While holding throttle arm against idle stop, lever, hold throttle lever (1) against idle stop (2). adjust length of link rod (1) so that stamped mark Adjust throttle cable barrel to slip into barrel (2) of oil pump lever aligns with stamped mark (3) recess of control cable anchor bracket, with a...

  • Page 116: Detonation Control (200 Model)

    DETONATION CONTROL (200 MODEL) With outboard running in “FORWARD” gear, advance throttle to 3500 RPM and check that spark timing has electronically advanced timing to 26 BTDC. This indicates knock control circuit is functioning. MAXIMUM TIMING ADJUSTMENT (ENGINE RUNNING) 1. Disconnect WHITE/BLUE lead (1) from detona- tion sensor (2).
  • Page 117 ELECTRICAL WIRING...
  • Page 118 Table of Contents Page Page Wiring Diagram 135/150 ....2D-1 Commander 2000 Side Mount Remote Wiring Diagram XR6/MAG III/175 ... 2D-2 Control (Power Trim/Tilt Electric Start with Wiring Diagram 200...

  • Page 119: Wiring Diagram 135/150

    Wiring Diagram 135/150 BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - 40 Ampere Stator 14- Terminal Block 2 - Starter 15- Water Temperature Switch...

  • Page 120: Wiring Diagram Xr6/Mag Iii/175

    Wiring Diagram XR6/MAG III/175 BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - 40 Ampere Stator 17- Coil # 1 2 - Starter 18- Coil # 3...

  • Page 121: Wiring Diagram 200

    Wiring Diagram 200 BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - 40 Ampere Stator 14- Terminal Block 2 - Starter 15- Water Temperature Switch...

  • Page 122: Wiring Diagram 200 Carb Serial # 0D077248 Thru Serial # 0D122746

    Wiring Diagram 200 Carb Serial # 0D077248 thru Serial # 0D122746 54963 1 - 40 Ampere Stator 13- Water Temperature Switch 2 - Starter 14- Outer Switch Box 3 - Warning Module 15- #5 Coil 4 - Oil Cap 16- #3 Coil 5 - Motion Sensor 17- #1 Coil 6 - Fuel Enrichment Valve...

  • Page 123: Wiring Diagram 150/175 Efi

    Wiring Diagram 150/175 EFI BLK = BLACK RED = RED BLU = BLUE TAN = TAN BRN = BROWN VIO = VIOLET GRY = GRAY WHT = WHITE GRN = GREEN YEL = YELLOW PUR = PURPLE 14 15 54352 1 - Water Temperature Switch 17- 20 Ampere Fuse (To Trim Solenoid) 2 - Warning Module...

  • Page 124: Wiring Diagram 200 Efi

    Wiring Diagram 200 EFI 16 17 BLK = BLACK BLU = BLUE 54353 BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - Detonation Sensor 18- Voltage Regulator 2 - Detonation Module...

  • Page 125: Wiring Diagram 200 Pro Max/Super Magnum (Early Model With Detonation Module)

    Wiring Diagram 200 Pro Max/Super Magnum (Early Models with Detonation Module) TAN/BLU 16 17 BLK = BLACK BLU = BLUE BRN = BROWN 54353 GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - Detonation Sensor...

  • Page 126: Wiring Diagram 150/200/225 Pro Max/Super Magnum

    Wiring Diagram 150/200/225 Pro Max/Super Magnum BLK = BLACK RED = RED BLU = BLUE TAN = TAN BRN = BROWN VIO = VIOLET GRY = GRAY WHT = WHITE GRN = GREEN YEL = YELLOW PUR = PURPLE TAN/BLU 14 15 54352 1 - Water Temperature Switch...

  • Page 127: Wiring Diagram105/140 Jet

    Wiring Diagram105/140 Jet BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - Stator 13- Starter Solenoid 2 - Trigger 14- Voltage Regulator 3 - Starter...
  • Page 128 Power Trim Wiring Diagram with Solenoids 52203 a - Start Solenoid f - Trim Sender b - Tach. Connector g - Bottom Cowl Switch c - Key Switch Assembly h - Pump and Motor d - Trim Switch i - UP Solenoid e - 20 Ampere Fuse j - DOWN Solenoid 2D-10 - ELECTRICAL...

  • Page 129: Power Trim Wiring Diagram With Relays

    Power Trim Wiring Diagram with Relays a - Tach. Connector h - Trim Pump and Motor b - Key Switch Assembly i - DOWN Solenoid c - Trim Switch j - UP Solenoid d - Trim Sender k - Bottom Cowl Switch e - Start Solenoid l - 20 Ampere Fuse f - To Battery...

  • Page 130: Instrument Wiring Connections

    Instrument Wiring Connections IMPORTANT: installations where gauge options will not be used, tape back and isolate any unused wiring harness leads. Figure 1 Without Light Switch mercv6carb_1 To 12V Figure 2 · · With Light Switch · mercv6carb_2 51819 Wire Color Where To = BLACK Ground...

  • Page 131: Commander 3000 Classic Panel Remote Control

    Commander 3000 Classic Panel Remote Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark <...

  • Page 132: Commander 3000 Panel Remote Control

    Commander 3000 Panel Remote Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark PURPLE...
  • Page 133 Notes: 90-824052R3 JUNE 2002 ELECTRICAL - 2D-15...
  • Page 134 Commander 3000/3000 Classic Components Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 2D-16 - ELECTRICAL 90-824052R3 JUNE 2002...
  • Page 135 Commander 3000/3000 Classic Components TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HOUSING-Control (Panel Mount) HOUSING-Control (Console Mount) BOLT-Locking (Special) 12.5 17.0 SPRING ROLLER BUSHING SWITCH ASSY-Neutral Start (2 Ring Terminals) SWITCH ASSY-Neutral Start (No Terminals) GROMMET BALL-Steel RING-Retaining GEAR-Shift SPRING SHAFT-Throttle Only...

  • Page 136: Commander Side Mount Remote Control (Power Trim/Tilt Electric Start With Warning Horn) Wiring Diagram

    Commander Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow...

  • Page 137: Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start With 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 ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow...

  • Page 138: Oil Level Gauge Wiring Diagram

    Oil Level Gauge Wiring Diagram a - To 12 Volt Source k - Oil Clip Connector b - PURPLE Wire (Connect to Trim Indicator Gauge “I” [or l - Adaptor Housing POSITIVE (+) 12 Volt Source that is Turned “ON” and m - Screw (10-16 x 1/4 in.) “OFF”...

  • Page 139: Visual Warning Wiring Diagram

    Visual Warning Wiring Diagram 1 - Bezel 7 - Screw (Self Tapping) [5/8 in. (15.7mm) Long 2 - Lamp (GE #257) 8 - Screw [1/4 in. (6.3mm) Long 3 - Socket Assembly 9 - Harness, 20 ft. (6m) Long 4 - Connect to Trim Indicator Gauge Terminal “I” or POSITIVE 10- Spring (+) 12 Volt Source that is turned “ON”...

  • Page 140: Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)

    Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BATT GND BLK=BLACK BLU=BLUE SENDER BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW PORT INSTALLATION 52205 a - Ignition/Choke Switch f - Trim Indicator Gauge b - Lanyard Stop Switch g - Temperature Gauge c - Lead not used on Outboard Installations h - Remote Control d - Retainer...
  • Page 141 IMPORTANT: On installations where gauge op- tions will not be used, tape back and isolate un- used wiring harness leads. BATT GND SENDER STARBOARD INSTALLATION 52206 k - Lanyard Switch (Isolation) Diode n - Connect Wires together with Screw and Nut (4 Places); l - Y Harness Apply Liquid Neoprene to Connections and slide Rubber m - Power Trim Harness Connector...
  • Page 142 Instrument/Lanyard Stop Switch Wiring Diagram BLK=BLACK BLU=BLUE BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW 52204 a - Ignition/Choke Switch b - Lanyard Stop Switch c - Lead Not Used on Outboard Installations d - Retainer e - Tachometer f - Trim Indicator Gauge (Optional) g - Temperature Gauge h - Remote Control i - Power Trim Harness Connector...

  • Page 143: Qsi Gauge Wiring Diagrams

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

  • Page 144: Oil Level Gauge Wiring

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

  • Page 145: Engine Synchronizer Wiring Diagram

    Engine Synchronizer Wiring Diagram Wiring Diagram – Gauge needle to point toward slow running engine LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting. GRY=GRAY WHT=WHITE BLK=BLACK PUR=PURPLE 51107 SEND a - Tachometer Starboard Engine b - Synchronizer Gauge c - Tachometer Port Engine d - Synchronizer Module...

  • Page 146: Multi-Function Gauge

    Multi-Function Guage Dip Switch Setting/Testing NOTE: The multi-function gauge “Dip Switch” must be set on the back of gauge prior to operation. Turn the ignition switch to the “OFF” position before setting dip switch. The guage will reset to selected settings when the ignition is turned “On”.

  • Page 147: Panel Mount Remote Control Wiring Installation

    Panel Mount Remote Control Wiring Installation BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan Liquid Neoprene (92-25711--2) WHT = White YEL = Yellow LIT = Light DRK = Dark...

  • Page 148: Side Mount Remote Control Wiring Installation

    Side Mount Remote Control Wiring Installation BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple Liquid Neoprene (92-25711--2) RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...

  • Page 149: Fuel Systems

    FUEL SYSTEMS FUEL PUMP...
  • Page 150 Table of Contents Page Specifications ......3A-1 Fuel Pump Pressure @ W.O.T... 3A-1 Fuel Pump Pressure @ Idle .

  • Page 151: Specifications

    Specifications Fuel Pump Pressure @ W.O.T. Maximum – 10 psi (69 kPa) Normal – 8-10 psi (55 - 69 kPa) Minimum – 3 psi (21 kPa) Fuel Pump Pressure @ Idle Normal – 2-3 psi (14 - 21 kPa) Minimum – 1 psi (7 kPa) NOTE: Electric fuel pump pressure, if used in conjunction with engine mechanical fuel pump, must be limited to no more than 4 psi (27 kPa).

  • Page 152: Fuel Pump

    Fuel Pump Perfect Seal (92-34227-1) 3A-2 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 153 Fuel Pump TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP ASSEMBLY DIAPHRAGM KIT CHECK VALVE– plastic RETAINER GASKET–boost SPRING DIAPHRAGM GASKET–pulse SPRING GASKET–base BASE–fuel pump PLATE–fuel pump ELBOW FUEL LINE (6 IN.) ELBOW STA STRAP SCREW–fuel pump to crankcase SCREW–fuel pump 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3A-3...

  • Page 154: General Information

    Fuel Pump CHECKING FOR RESTRICTED FUEL FLOW CAUSED BY ANTI-SIPHON VALVES While anti-siphon valves may be helpful from a safety General Information stand-point, they clog with debris, they may be too small, or they may have too heavy a spring. FUEL PUMP DESCRIPTION/OPERATION Summarizing, the pressure drop across these valves The fuel pump is a crankcase-pressure-operated,...

  • Page 155: Testing Fuel Pump

    Testing Fuel Pump Problem: Air Bubbles in Fuel Line Low fuel in tank. Fill tank with fuel. Loose fuel line connection. Check and tighten all connectors. Fuel pump fitting loose. Tighten fitting. A hole or cut in fuel line. Check condition of all fuel lines and replace Fuel Pump anchor screw(s) loose.

  • Page 156: Vacuum Test Troubleshooting

    2. Disconnect pulse hose. 3. Remove two mounting screws. 4. Remove fuel pump from engine. Clear Hose T-fitting Vacuum Gauge (obtain locally) Vacuum Test Troubleshooting This test is normally performed at an idle speed. As engine rpm increases, there will be a slight increase in vacuum.

  • Page 157: Cleaning/Inspection

    Cleaning/Inspection 2. Install check valves and retainers into fuel pump body. 1. Clean fuel pump housing, check valves, pulse chamber and pump base in solvent and dry all but check valves with compressed air. 2. Inspect each check valve for splits, chips and for proper sealing against pump housing.
  • Page 158 4. Reinstall rod into retainer cap and, use a small 6. Assemble remainder of components as shown hammer or hammer and punch to tap rod down and install retaining screws thru to align. into retainer until flush with top of retainer. 23601-3 a - Rod b - Retainer Cap...
  • Page 159 FUEL SYSTEMS 54350 CARBURETORS...
  • Page 160 Table of Contents Page Page Notes: ........3B-1 WMV Carburetor Fuel Circuit Description .

  • Page 161: Notes

    Notes: 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3B-1...

  • Page 162: Wmh 1,2,3,4,5,6,7,8,9,10,11 Carburetor Assembly

    WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Assembly 16 17 3B-2 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 163 WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR LIMITER CAP IDLE NEEDLE/SPRING GASKET JET – progression air JET – bowl vent JET – idle air bleed EMULSION TUBE SPRING – valve return THROTTLE LEVER SPACER WASHER GASKET –...

  • Page 164: Wmh 1,2,3,4,5,6,7,8,9,10,11 Carburetor Specifications

    WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Specifications Carburetor Year Engine Venturi Main Jet Progres- Idle Air Jet Back Draft sion Jet Vent Jet WMH 1 1990 1.312 .062 .044 .040 .084 1A–2A–3A WMH 2 1990 1.312 .064 .044 .044 .080 1A–2A–3A WMH 3 1990 1.312 .066...
  • Page 165 WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Front View CYLINDERS 1,3,5 CYLINDERS 2,4,6 51861 a - Idle Air Jet b - Back Draft Vent Jet c - Progression Jet d - Main Jet 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3B-5...

  • Page 166: Wmh 12,13,14,15,16,27 Carburetor Assembly

    WMH 12,13,14,15,16,27 Carburetor Assembly 3B-6 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 167 WMH 12,13,14,15,16,27 Carburetor Assembly TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR LIMITER CAP IDLE NEEDLE/SPRING GASKET JET – progression air JET – bowl vent JET – idle air bleed EMULSION TUBE PLUG SPRING – valve return THROTTLE LEVER SPACER WASHER GASKET –...

  • Page 168: Wmh 12,13,14,15,16,27 Carburetor Specifications

    WMH 12,13,14,15,16,27 Carburetor Specifications Carburetor Year Engine Venturi Main Jet Progres- Idle Air Jet Back Draft sion Jet Vent Jet WMH 12 1992 1.312 .064 .048 .052 .090 1A–2A–3A WMH 13 1992 1.312 .064 .048 .050 .096 1–2–3 WMH 14 1992 XR-6 1.000...
  • Page 169 WMH 12,13,14,15,16,27 Carburetor Front View CYLINDERS 2,4,6 CYLINDERS 1,3,5 51863 a - Idle Air Jet b - Back Draft Vent Jet c - Progression Jet d - Main Jet 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3B-9...

  • Page 170: Wmh 21,22,23,25,26,28 Carburetor Assembly

    WMH 21,22,23,25,26,28 Carburetor Assembly 3B-10 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 171 WMH 21,22,23,25,26,28 Carburetor Assembly TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR LIMITER CAP IDLE NEEDLE/SPRING GASKET JET – progression air JET – bowl vent JET – idle air bleed EMULSION TUBE PLUG and GASKET SPRING – valve return THROTTLE LEVER SPACER WASHER...

  • Page 172: Wmh 21,22,23,25,26,28 Carburetor Specifications

    WMH 21,22,23,25,26,28 Carburetor Specifications Carburetor Year Engine Venturi Main Jet Progres- Idle Air Jet Back Draft sion Jet Vent Jet WMH 21 1993 1.312 1,2 = .066 .050 .046 .096 3,4,5,6=.064 1A–2–3 WMH 22 1993 1.312 .064 .040 .050 .098 1–2–3 WMH 23 1993...
  • Page 173 WMH 21,22,23,25,26,28 Carburetor Front View CYLINDERS 2,4,6 CYLINDERS 1,3,5 51863 a - Idle Air Jet b - Back Draft Vent Jet c - Progression Jet d - Main Jet 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3B-13...

  • Page 174: Wmh 30,31,32,33,34,39 Carburetor Assembly

    WMH 30,31,32,33,34,39 Carburetor Assembly 16 17 52154 3B-14 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 175 WMH 30,31,32,33,34,39 Carburetor Assembly TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR LIMITER CAP IDLE NEEDLE/SPRING GASKET JET – progression air JET – bowl vent JET – idle air bleed EMULSION TUBE, PLUG and GASKET SPRING – valve return THROTTLE LEVER SPACER WASHER...

  • Page 176: Wmh 30,31,32,33,34,39 Carburetor Specifications

    WMH 30,31,32,33,34,39 Carburetor Specifications Carburetor Year Engine Venturi Main Jet Progres- Idle Air Jet Back Draft sion Jet Vent Jet WMH 30 1994-5 1.312 .066 .050 .054 .084 1–2–3 WMH 31 1994-5 105 JET 1.312 .062 .050 .052 .086 1–2–3 WMH 32 1994-5 XR-6...
  • Page 177 WMH 30,31,32,33,34,39 Carburetor Front View CYLINDERS 2,4,6 CYLINDERS 1,3,5 51863 a - Idle Air Jet b - Back Draft Vent Jet c - Progression Jet d - Main Jet 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3B-17...

  • Page 178: Wmv 1/1A, 2/2A, 3/3A, 4/4A, 5/5A

    WMV 1/1A, 2/2A, 3/3A, 4/4A, 5/5A 3B-18 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 179 WMV 1/1A, 2/2A, 3/3A, 4/4A, 5/5A TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TOP CARBURETOR CENTER CARBURETOR 135 - WMV-1 BOTTOM CARBURETOR TOP CARBURETOR CENTER CARBURETOR 150 - WMMV-2 BOTTOM CARBURETOR TOP CARBURETOR CENTER CARBURETOR XR6/MAGNUM III BOTTOM CARBURETOR WMV-3 TOP CARBURETOR CENTER CARBURETOR...
  • Page 180 WMV 1/1A, 2/2A, 3/3A, 4/4A, 5/5A 3B-20 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 181 WMV 1/1A, 2/2A, 3/3A, 4/4A, 5/5A TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m JET–bowl vent (.086)(135/150/175) JET–bowl vent (.082)(XR6/Magnum III) JET–bowl vent (.096)(200) JET–idle air vent (.036)(135) JET–idle air vent (.034)(150) STARBOARD JET–idle air vent (.044)(XR6/Magnum III) JET–idle air vent (.030)(175) JET–idle air vent (.052-Top)(200) JET–idle air vent (.028-Center/Bottom)(200) LIMITER CAP...

  • Page 182: Wmv 1,2,3,4,5 Carburetor Specifications

    WMV 1,2,3,4,5 Carburetor Specifications Carburetor Year Engine Venturi Main Jet Idle Air Jet Back Draft Vent Jet WMV 1/1A 1996-1998 1.312 .072 1,2,3,4,6=.036 .086 5=.040 1–2–3 WMV 2/2A 1996-1998 105 JET 1.312 .074 1,2,3,4,6=.034 .086 5=.038 1–2–3 WMV 3/3A 1996-1998 XR-6 1.312 .074...

  • Page 183: Fuel System - Troubleshooting

    Fuel System - 1. Propeller 2. Spark plugs Troubleshooting 3. Ignition timing 4. Ignition spark voltage General Information 5. Cylinder compression Problems, that are thought to be caused by the fuel system, may be, in reality, something completely 6. Reed valves different.
  • Page 184 Possible Cause Corrective Action Low fuel pump pressure. Refer to Section 3A. An anti-siphon valve. Refer to Section 3A. A needle and seat (in carburetor) that is either stuck Refer to ‘‘Carburetor Adjustments” in this section. open or closed. (A needle and seat, that is stuck open, will cause a flooding condition.

  • Page 185: Reed Valve Leak Test

    Reed Valve Leak Test 3. Remove and plug bleed hoses (one at a time) from crankcase cover and connect fuel pressure gauge as shown. TOOLS NEEDED FOR TEST-- 4. With engine at idle, a reading of 3 to 6 psi must a) Fuel Pressure Gauge (0 to 15 psi) be attained.

  • Page 186: Thermal Air Valve Circuit Description

    Thermal Air Valve Circuit Description WMH Carburetor Fuel Circuit Description Idle Circuit Description IMPORTANT: If welch plugs and air trim screws must be removed for carburetor cleaning, count number of turns air screw is turned in until seated, then remove. Apply Loctite 271 and set air screws to the same position (approx.

  • Page 187: Off-Ldle Circuit Description

    b. Idle Air Bleed Jets (1 per carb.) - The idle air Back Draft Circuit Description bleed jet meters air and is located next to the Side View back drag vent jet. If a jet with a smaller orifice is installed the fuel/air ratio becomes richer. If a jet with a larger orifice is installed, fuel/air ratio becomes leaner.

  • Page 188: Carburetor Placement

    Carburetor Placement JET LOCATION FOR EACH CYLINDER Example: 135 Model 12-1 Cylinder Cylinder Middle 12-2 Cylinder Cylinder Bottom 12-3 Cylinder Cylinder 51863 Carburetor jets and adjustment screw installed in the 51863 starboard side of the carburetor supply fuel to the port cylinder, jets and adjustment screw installed in the port side supply fuel to the starboard cylinder.

  • Page 189: Wmv Carburetor Fuel Circuit Description

    WMV Carburetor Fuel Circuit Idle Circuit Description Top View – Float Bowl Circuit a - Idle Discharge Ports b - Off-Idle Discharge Ports c - Idle Fuel Transfer Passage d - Idle Mixture Screw e - Main Discharge Vent Tube f - Idle Pickup Tube g - Idle Air Passage h - Thermal Air Valve Air Inlet...

  • Page 190: Cold Start Circuit

    As the engine rotates, the piston moves away from idle mixture is richened. A failure in the thermal air the crankcase. This movement creates a low pres- valve (closed) will cause the idle circuit to be rich. To sure area behind the throttle plate. Atmospheric test the thermal air valve, plug the inlet fitting (located pressure pushes air through the carburetor throat on the valve).

  • Page 191: Main Circuit

    Main Circuit Back Draft Circuit Fuel Fuel NOTE: Fuel Flow Not Shown For Clarity a - Back Draft Port a - From Open Thermal Air Valve b - Back Draft Jet b - Air Flow c - Air Flow c - Venturi d - Main Discharge Tube d - Main Discharge Air Inlet Tube e - Fuel Bowl...

  • Page 192: Carburetor Placement And Jet Location For Each Cylinder (Wmv Carburetors)

    Carburetor Placement and Jet Location for Each Cylinder (WMV Carburetors) Cylinder Cylinder MIDDLE Cylinder Cylinder BOTTOM Cylinder Cylinder 54349 A – Backdraft jet affects both cylinders. 3B-32 - FUEL SYSTEMS 90-824052R3 JUNE 2002...

  • Page 193: High Altitude Recommendations

    High Altitude Recommendations High Performance Models – NOTE: Refer to “Jet Charts” for jet sizes and part numbers. Model High Altitude Gear Ratio Change IMPORTANT: When operating outboard above 150 Pro Max/Super 135/150 - 2:1 Complete 5000 ft. (1524m), it is recommended outboard Magnum with 1.78:1 Gearcase or Torque- gear ratio be reduced as shown in chart below:...

  • Page 194: 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 195: Enrichener System Description

    Enrichener System Description Fuel is gravity fed to the valve from the float bowl of the top carburetor via a hose. When the key (or choke button) is pushed in (and held in) current is sent to the valve causing it to open, which allows fuel to pass thru.

  • Page 196: Enrichener Valve Test

    ENRICHENER VALVE TEST Push key (or choke button) in. Valve should click No Click Click Check for battery voltage to yellow/black Squeeze primer bulb until bulb is firm. wire at terminal block on engine when key Remove hose from fitting on bottom of (or choke button) is pushed in enrichener valve.

  • Page 197: Removing Carburetor(S) From Engine

    Removing Carburetor(s) 5. Remove fuel hose, fuel enrichener valve hose and thermal valve hose from carburetors. from Engine NOTE: Removal,disassembly and reassembly of WMH and WMV carburetors are very similar. 1. Remove top cowling. IMPORTANT: Place an identifying mark on each carburetor before removal as each carburetor must be reinstalled in same location from which removed.
  • Page 198 1. Remove off-idle tube access plugs and off-idle 3. Remove off-idle air jets from carburetor. tubes from carburetor. 51861 a - Off-Idle Jets (2) 51859 a - Access Plug (2) 4. Remove idle air jet and back draft vent jet (if b - Gaskets (2) equipped) from carburetor.

  • Page 199: Fuel Bowl Removal And Disassembly

    5. Remove emulsion tube from carburetor. 2. Remove screw securing float assembly in place. 51863 a - Screw b - Float Pin c - Float 51862 3. Remove needle and seat from fuel bowl. a - Emulsion Tube Fuel Bowl Removal and Disassembly 1.

  • Page 200: Throttle Shaft Component Removal

    THROTTLE SHAFT COMPONENT REMOVAL Carburetor Cleaning and Inspection 1. Bend tab washer away from nut. Remove nut, tab 1. Place carburetor body, fuel bowl and metal parts washer, spacer, throttle lever and spring from in carburetor cleaning solution for a short period throttle shaft.

  • Page 201: Fuel Bowl Reassembly

    2. Install spring, throttle lever, spacer, tab washer 3. Install float with float pin to fuel bowl. Secure in and nut. Bend tab washer against flats of nuts. place with retained screw. 3. Install throttle link and screw. 51863 a - Screw b - Float Pin c - Float 51863...

  • Page 202: Carburetor Jet Installation

    5. Install emulsion tube to carburetor. Carburetor Jet Installation 1. Install idle air jet and back draft vent jet (if equipped) to carburetor body. 51861 a - Idle Air Jet 51862 b - Back Draft Jet a - Emulsion Tube 2.

  • Page 203: Installing Carburetor(S) To Engine

    3. Install high speed fuel jet access plugs with Installing Carburetor(s) to Engine gaskets and main (high speed) fuel jet to 1. Place new carburetor gaskets onto carburetor carburetor body. mounting studs on intake manifold. 51859 51844 a - Access Plugs (2) a - Fuel Hose b - Gaskets (2) c - Main Fuel Jets (2)

  • Page 204: Fuel Line And Primer Bulb Assembly

    4. Attach throttle linkage and oil pump link rod to Fuel Line and Primer Bulb carburetors as shown. Assembly 51860 50165 a - Throttle Linkage b - Oil Pump Link Rod 1 - Fitting (Fuel Line) 2 - Clamp 3 - Fuel Line 5.

  • Page 205: Fuel Line Clamp Removal And Installation

    FUEL LINE CLAMP REMOVAL AND 2. To install fuel line clamps, grip hose clamp with INSTALLATION pliers and push down on hook with screwdriver until hooks interlock. 1. To remove fuel line clamps, grip clamp with pliers and bend overlapping hook backward. 51115 51115 90-824052R3 JUNE 2002...
  • Page 206 FUEL SYSTEMS FUEL INJECTION SN 0G303045 AND BELOW...
  • Page 207 Table of Contents Page Page Specifications ......3C-1 Engine Head Temperature Sensor Removal 3C-40 Special Tools .

  • Page 208: Specifications

    Specifications Electronic Fuel Injection Idle RPM – All Models Wide Open Throttle RPM – Model 150XRI/175XRI 5000 – 5600 – Model 200XRI 5000 – 5800 – Pro Max/Super Magnum 150/200/225 6200 – 6500 Float Adjustment (Vapor Separator) – Float Level Preset @ Factory Fuel Injectors –All Models (Quantity)

  • Page 209: Electronic Control Module (Ecm) Assembly

    Electronic Control Module (ECM) ASSEMBLY Dielectric Grease (92-823506--1) Liquid Neoprene (92-25711--2) 3C-2 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 210 Electronic Control Module (ECM) Assembly TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m ECM ASSEMBLY SPACER CLIP MOUNT – cowl mounting bracket WASHER CABLE ASSEMBLY GROMMET BUSHING SCREW LOCKWASHER WASHER WATER SENSOR MODULE ASSEMBLY WIRE ASSEMBLY (BLACK) SCREW WASHER WIRING HARNESS –...

  • Page 211: Fuel Management System

    Fuel Management System 3C-4 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 212 Fuel Management System TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL MANAGEMENT ASSEMBLY THROTTLE BODY COVER RETAINING KIT ROLLER – cam FUEL INJECTOR FILTER – injector HARNESS KIT FUEL FILTER KIT (DESIGN 1) FUEL FILTER KIT (DESIGN 2) FUEL FILTER KIT (DESIGN 3) FUEL FILTER SCREW –...
  • Page 213 Fuel Management System 3C-6 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 214 Fuel Management System TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m LINK LEVER KIT STOP SCREW KIT FUEL RAIL FUEL PIPE JOINT KIT SCREW KIT – Fuel Rail LINK (DESIGN 1) LINK (DESIGN 2) SCHRADER VALVE KIT 90-824052R3 JUNE 2002 FUEL SYSTEMS - 3C-7...

  • Page 215: Fuel Pump And Fuel Filter

    Fuel Pump and Fuel Filter 3C-8 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 216 Fuel Pump and Fuel Filter TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP ASSEMBLY DIAPHRAGM KIT CHECK VALVE – rubber GASKET – boost DIAPHRAGM GASKET – pulse SPRING CHECK VALVE RETAINER SPRING GASKET – base BASE – fuel pump PLATE –...

  • Page 217: Outboard Powerhead View

    Outboard Powerhead View Engine starboard view of EFI components. Engine port view of EFI components. 51793 a - Electronic Control Module (ECM) 51784 b - ECM Harness a - Electric Fuel Pump c - Engine Harness b - Fuel Pressure Regulator d - Throttle Position Sensor Harness c - Vapor Separator e - Water Separating Filter...

  • Page 218: Efi System Tests

    EFI System Tests CAUTION EFI Electrical System and ECM Check Wipe up fuel spills immediately. Fuel Gauge Connection/Pressure Test CAUTION Vapor Separator Fuel Delivery Test Depressurize fuel system prior to opening line Vapor Separator Float Test connections removing fuel system Water Separating Filter Flow Test components.

  • Page 219: Preliminary Steps

    Preliminary Steps Results: IMPORTANT: The presence of a good spark will not necessarily indicate condi- tion of timing. Ignition timing may be off Ignition Spark Check far enough to prevent the engine from Purpose: This test determines if the ignition system starting, but still allow a good spark to be is delivering usable spark to the spark plugs.

  • Page 220: Fresh Quality Fuel

    Fresh Quality Fuel Low Battery Voltage Using a remote fuel tank containing a major brand of premium unleaded gasoline, test run the outboard to eliminate any problems related to restricted fuel supply (clogged lines, malfunctioning anti-siphon valve, etc.) and/or marginal gasoline. Low battery voltage can cause EFI system to deliver fuel in an inconsistent manner.

  • Page 221: Fuel Flow Diagram

    Fuel Flow Diagram a - To Upper Manifold Fitting b - Bleed Shut Off Valve c - Bleed Line Filter d - Bleed System Circuit of Engine e - To Upper Manifold Lower Fitting f - Bleed Line Inlet g - Fresh Fuel Inlet h - Needle/Float Device i - Oil Supply Inlet j - Water Separating Filter...

  • Page 222: Fuel Flow Components

    Fuel Flow Components (from ELECTRIC FUEL PUMP (O) Fuel Flow Diagram) The electric fuel pump is continually providing fuel in excess of engine demands. The excess fuel A description of each component (on diagrams) circulates through the fuel rail back to the vapor will aid in the diagnosis of EFI problems.

  • Page 223: Efi Electrical Diagram

    EFI Electrical Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark 1 - Detonation Sensor* 11- Throttle Position Sensor...

  • Page 224: Efi Electrical Components

    EFI Electrical Components (from ENGINE HEAD TEMPERATURE SENSOR Electrical Component Diagram) The Engine Head Temperature Sensor provides the ECM signals related to engine temperature to deter- mine level of fuel enrichment during engine warm up. ELECTRONIC CONTROL MODULE (ECM) The ECM is receiving information at all engine tem- The ECM is continually monitoring various engine peratures but stops fuel enrichment at an engine conditions (engine temperature, engine detonation...
  • Page 225 DETONATION CONTROL SYSTEM FUNCTION Fuel Injectors - A four wire harness connects the fuel injectors to the ECM. The red wire is at 12 volts 1. Combustion noise (or vibration) excites the and connects to all injectors. The blue, yellow and piezoelectric circuit located inside the detonation white wires each go to a pair of injectors and are sensor, which transmits a voltage to the control...

  • Page 226: Efi Fuel Management (Low Pressure Fuel Route)

    EFI Fuel Management (Low Pressure Fuel Route) Perform all preliminary checks Install fuel pressure gauge (P/N 91-16850A2) on to manifold pressure port. Place ignition switch in “OFF” position 30 sec- onds before testing. Place ignition switch in “ON” position and note pressure within 30 seconds (36 to 39 psi;...

  • Page 227: Efi Fuel Management (High Pressure Fuel Route)

    EFI Fuel Management (High Pressure Fuel Route) Perform low pressure checks (3C-19) before performing checks on high pressure route. Install fuel pressure gauge (P/N 91-16850A2) on to manifold pressure port. Place ignition switch in “OFF” position 30 sec- onds before testing. Place ignition switch in “ON”...

  • Page 228: Fuel Rail Electrical/Fuel Determination

    Fuel Rail Electrical/Fuel Determination Perform all preliminary checks page 3C-12. Adequate fuel pressure (36 to 39 psi; 248 to 269 kPa) follow Low/High Fuel Route Flow Charts. Place outboard in water or on flush attach- ment (P/N 44357A2) run engine speed be- tween 2000 and 2500 RPM.

  • Page 229: Efi System Test Procedures

    EFI System Test Procedures STEP 2: Prime engine using fuel primer bulb. Fuel Gauge Connection/Pressure Test IMPORTANT: When checking fuel pressure while engine is running, fuel pressure may fluctuate. Fuel pressure fluctuation (i.e. 36 to 39 psi “213 to 290 kPa”) is common, as the regulated pressure is a differential between fuel rail and manifold vacuum.

  • Page 230: Vapor Separator Fuel Delivery Test

    Vapor Separator Fuel Delivery Test STEP 4: Look for fuel flow from hose. Purpose: Verifying there is adequate fuel flow to the electric fuel pump (through full RPM range) will determine components in low pressure fuel system are functioning correctly. Procedure: STEP 1: Remove hose from intake port of electric fuel pump and put discon- nected end of hose in clean container.

  • Page 231: Water Separating Filter Flow Test

    STEP 3: Turn ignition key switch to “START” Water Separating Filter Flow Test position and operate starter motor for 15 Purpose: This test will indicate if water separating to 20 seconds. filter is clogged. Procedure: STEP 1: Remove fuel inlet hose to START water separating filter.

  • Page 232: Pulse Fuel Pump Delivery Test

    STEP 4: Look for fuel flow from hose. Pulse Fuel Pump Delivery Test Purpose: This test will indicate pulse fuel pump is capable of supplying the low pressure fuel route with adequate fuel supply. Procedure: STEP 1: Remove inlet hose to pulse fuel pump and put end into clean container.

  • Page 233: Final Filter Check And De-Pressurizing Efi System Procedures

    Results: Fuel flows freely from pulse pump inlet STEP 2: Remove filter cap. hose. Remove, disassemble, and inspect pulse fuel pump (Section 3A). IMPORTANT: All fragments of failed pump must be located before re-assembly. No or low fuel flow from pulse pump inlet hose. Check for restrictions, holes, or loose connections from fuel supply.

  • Page 234: Pressure Regulator Test

    Pressure Regulator Test STEP 3: Remove fuel pressure regulator, but do not disconnect any hoses from regulator. Purpose: This test will determine if a weak, plugged STEP 4: Put discharge end of regulator in clean or open pressure regulator is causing container.

  • Page 235: Electric Fuel Pump Test

    Electric Fuel Pump Test CAUTION Purpose: This test will determine if electric fuel pump Do not close-off fuel hose completely in step 4, or is capable of producing adequate fuel “pres- damage could result to hose or pump. sure” needed for normal engine operation, 36 STEP 4: Partially close off fuel hose to pressure to 39 psi (248 to 269 kPa).
  • Page 236 Procedure B: Negative Test Terminal CAUTION When checking voltage at pump, DO NOT pry boot covers off terminals with a metal object, as each terminal is at 12 volts when engine is off. Serious damage to electric fuel pump and/or ECM box can result.

  • Page 237: Voltage Test Chart

    STEP 3: Perform voltage tests “all (1-6) engine modes” below. VOLTAGE TEST CHART Engine Mode BLACK Meter Lead to Approximate Voltage If Approximate Voltage Engine Ground; RED Reading is not obtained, this in- Meter Lead to: dicates: 1. All models (+) terminal of fuel pump 12 –...

  • Page 238: Injector Electrical Harness Test

    Injector Electrical Harness Test Results: If readings are 1.1 .2 both injector circuits are complete. Perform Injector Fuel Delivery Purpose: This test will determine if electrical or fuel Test. delivery problem exists during the fuel If readings are 2.2 .2 one injector does not have delivery process by checking for open circuits a complete circuit.

  • Page 239: Injector Operation Test

    Results: If RPM increase occurs while injecting fuel into disabled cylinder, clogged injector filter or defective injector may be the problem. Perform Induction Manifold Disassembly (page 3C-38) for inspection. NOTE: Injector fuel delivery can be tested with manifold cover removed. See Injector Operation Test (manifold cover removed) below.

  • Page 240: Induction Manifold Leak Check

    Procedure B: STEP 1: Connect EFI tester. Steps Induction Manifold Leak Check outlined in electrical system and ECM (Manifold Cover Removed) check. Purpose: Lack of good fuel pressure may be caused STEP 2: Connect remote starter Quicksilver by an internal leak in the fuel induction man- (91-52024A1) to negative terminal of ifold and not caused by a weak pump.

  • Page 241: Air Temperature Sensor Test

    STEP 3: Connect a jumper wire between the STEP 6: Look for leak points on induction man- metal case of ECM and a good engine ifold while depressing remote starter ground. switch. WARNING If a serious leak is present in the induction man- ifold, fuel may spray out of bad seal.

  • Page 242: Engine Head Temperature Sensor Test

    NOTE: Temperature/resistance reading may differ NOTE: Temperature/resistance reading may differ slightly from graph curve. slightly from graph curve. SENSOR RESISTANCE VS. AIR TEMPERATURE Results: Resistance does not change inversely with temperature change. Replace defective Air Results: Resistance does not change inversely with Temperature Sensor.

  • Page 243: Detonation Sensor Check

    Detonation Sensor Check Detonation Control Module Check IMPORTANT: When testing detonation control Purpose: This check will determine if control module system keep all test leads away from high is correctly signaling ECM when signals are tension leads (i.e. spark plug lead, electrical received from sensor.

  • Page 244: Throttle Position Sensor Test

    Throttle Position Sensor Test Map Sensor Test Purpose: This test eliminates possibilities of Purpose: This test eliminates possibilities of improper fuel delivery related to the throttle improper fuel delivery caused by the map position indicator. Refer to EFI electrical sensor. Refer to EFI electrical system and system and ECM test.
  • Page 245 Condition Possible Source Action Poor Acceleration – Idles Ok, Top – Timing Not Advancing. Check for stuck trigger. Speed Ok. (Continued) Engine Surges Between 4000 – Intermittant Switch Box Failure. Refer to Section 2A Electrical and And 5000 RPM Ignition for tests. –...
  • Page 246 Condition Possible Source Action Engine Idles Rough (May Lean – Improper EFI Set Up. Refer to Section 2A Electrical and Sneeze) – Acceleration Ok; Full Ignition for proper EFI set up pro- Throttle Ok. cedures. – MAP Sensor Failure. Refer to Electronic Fuel Injection Tester Manual 91-11001A2.

  • Page 247: Efi Induction Manifold Removal

    Engine Head Temperature 1. Disconnect ECM at harness connector. Sensor Removal 1. Remove screw and retaining plate. 51793 a - Connector 2. Remove screws (b) and ground wires (c). 3. Remove water sensing module (d). 4. Remove nuts (e) and screw (f). 51785 a - Screw b - Retaining Plate...

  • Page 248: Water Separating Filter Assembly Removal

    5. Carefully raise ECM (g) from studs. Disconnect Throttle Position Sensor MAP sensor hose (b) at manifold fitting (i) and re- Temperature Sensor Fuel Injector move ECM. Harness Disconnections 1. Disconnect throttle position sensor at 3 pin con- nector and remove ECM harness bracket. 51793 Water Separating Filter Assembly Removal...

  • Page 249: Oil Reservoir Removal

    3. Disconnect fuel injector harness at 4 pin Final Filter Assembly Removal connector. CAUTION De-pressurize EFI system prior to fuel filter removal. Refer to page 3C-26. 1. Remove screw from final filter housing assembly. 51787 a - Fuel Injector Harness b - 4 Pin Connector 51785 a - Screw...

  • Page 250: Electric Fuel Pump Removal

    Electric Fuel Pump Removal Vapor Separator Removal 1. Remove 4 screws from cover plate. 1. Disconnect fuel rail re-circulation hose at manifold fitting. 2. Remove rubber boots from electric fuel pump cap. 2. Disconnect fuel pressure regulator vacuum hose. 3. Disconnect bleed hose and vapor separator vacuum hose.

  • Page 251: Vapor Separator Disassembly

    Vapor Separator Disassembly 3. Remove screws and regulator fitting from regulator. Then remove O-ring from regulator. PRESSURE REGULATOR REMOVAL AND DISASSEMBLY 1. Remove screws, plate and grommet. Then remove regulator assembly. 51794 a - Screws b - Regulator Fitting c - Regulator d - O-ring 51792 VAPOR SEPARATOR FLOAT REMOVAL...
  • Page 252 2. Remove pivot pin. 4. Remove O-ring from housing. 51791 a - O-Ring b - Housing 51794 a - Pivot Pin 3. Remove float (a) and needle (b) and if necessary, remove needle from float. Do not change angle of brass tab that the needle is attached to. 51795 a - Float b - Needle...

  • Page 253: Vapor Separator Float Installation

    Vapor Separator Component Vapor Separator Float Installation Reassembly 1. If removed, install needle on float and install float assembly. 1. Assemble components as shown. 51795 a - Float b - Needle 2. Install new O-ring in housing. a - Screw b - Lock Washer c - Plate and Grommet d - Pressure Regulator...

  • Page 254: Manifold Removal

    3. Install cover using screws. 4. Remove12 screws securing manifold cover to manifold. 5. Remove manifold cover. 51794 a - Cover 51795 b - Screws a - Ground Wires b - Screws (12) c - Manifold Cover Manifold Removal 1. Disconnect throttle link rod from throttle cam. 6.

  • Page 255: Efi Induction Manifold Disassembly

    EFI Induction Manifold Air Temperature Sensor Removal Disassembly 1. Remove screws and sensor. 1. Remove manifold cover seal from manifold. 51790 a - Screws b - Sensor 2. Remove O-ring from sensor. 51785 a - Manifold Cover Seal b - Manifold 51791 a - O-Ring b - Sensor...

  • Page 256: Throttle Position Sensor Removal

    Throttle Position Sensor Removal Fuel Rail Removal IMPORTANT: Sensor position will need to be set 1. Remove manifold vacuum hoses. after induction manifold assembly has been 2. Remove engine bleed hose. installed. 3. Remove screws securing manifold fitting to 1. Remove throttle position sensor screws. manifold.

  • Page 257: Fuel Rail Disassembly

    5. Remove 4 screws securing fuel rail to manifold. Fuel Rail Disassembly 1. Remove tube support from fuel rail. 2. Remove plugs from fuel rail. 3. Remove tubes from tube support. 4. Remove O-rings from plugs, tube support and tubes. 51795 a - Tube Support b - Fuel Rail...

  • Page 258: Fuel Injector Removal And Disassembly

    Fuel Injector Removal and 4. Place injector on clean work surface. Remove seals, O-ring and injector filter. Disassembly 1. Lift wire clamp from slot. 2. Disconnect connector from injector. 51789 a - Injector 51792 b - Seals c - O-Ring a - Clamp d - Filter b - Slot...

  • Page 259: Injector Harness Removal

    Injector Harness Removal Throttle Linkage Removed 1. Remove protective casing from injector wiring harness. Note position of wires for reassembly. 51786 a - Throttle Cam b - Bushings c - Nut; Tighten until snug against cam, then back off 1/4 turn 51795 a - Casing b - Harness...

  • Page 260: Efi System Cleaning And Inspection

    EFI System Cleaning and 6. Look for loose, missing or damaged mounting hardware such as stripped threads on screws. Inspection 7. Look at sensors for signs of wear or damage such as cracks, chips, etc. Cleaning 8. Look at filter housing for cracks, holes or other 1.

  • Page 261: Induction Manifold Assembly

    Induction Manifold 4. Install protective casing over positioned injector wiring harness and insert into manifold. Assembly Injector Harness Installation 1. Carefully route injector harness into manifold. 2. Install O-ring into groove on injector harness insert. Install harness insert into manifold port. 51795 a - Casing b - Harness...

  • Page 262: Fuel Injector Assembly And Installation

    Fuel Injector Assembly and 3. Install wire clamp into slot on injector connector. Installation 4. Connect to injector. 1. Install inspected seals, O-ring and injector filter to injector. 51792 a - Clamp b - Slot c - Connector d - Injector 51789 Fuel Rail Assembly a - Seals...

  • Page 263: Fuel Rail Installation

    Fuel Rail Installation 3. Install O-rings to manifold fitting. Install fitting to manifold. 1. With fuel rail guides in place, install fuel rail to manifold. 51791 a - O-Rings b - Fitting 4. Install screws securing manifold fitting to manifold. 5.

  • Page 264: Throttle Position Sensor Installation

    Throttle Position Sensor Installation Air Temperature Sensor Installation IMPORTANT: Throttle position sensor must be 1. Install O-ring to air temperature sensor. adjusted following reassembly (see Section 2C - Timing, Synchronizing, Adjustment). 1. Install sleeve to throttle position sensor. 2. Install sensor into manifold. Sleeve must guide sensor to throttle shaft.

  • Page 265: Efi Induction Manifold Installation

    3. Carefully install manifold cover seal to manifold. EFI Induction Manifold Installation 1. Install new gasket on induction manifold as shown. Removing dotted line sections after manifold installation. 51785 a - Cover Seal 51784 b - Manifold a - Gasket b - Induction Manifold 4.
  • Page 266 4. Secure induction manifold assembly to engine IMPORTANT: Before connecting oil pump control with screws. Torque screws to 90 Ib. in. (10.0 rod verify pump quadrant is rotated to the N·m) using torque sequence shown below. clockwise of center. NOTE: Remove M8 x 1.25 x 38mm long bolts used 5.

  • Page 267: Vapor Separator Installation

    Vapor Separator Installation Electric Fuel Pump Installation 1. With vapor separator held in place install screws 1. Install electric fuel pump with rubber blanket. securing vapor separator to engine block. Torque 2. Connect fuel pump inlet hose. Secure with screws to 45 lb. in. (5.0 N·m). sta-strap.

  • Page 268: Final Filter Assembly Installation

    5. Install rubber boots on electric fuel pump cap. Final Filter Assembly Installation 6. Install cover plate using four (4) screws. Tighten 1. Install fuel rail inlet hose and cap to manifold securely. fitting. 2. Install O-ring to filter and cap as shown. 3.

  • Page 269: Oil Reservoir Installation

    Oil Reservoir Installation Throttle Position Sensor and Temperature Sensor Fuel Injector 1. Install oil reservoir to engine. Connect hose to Harness Connections fitting and secure with hose clamp. 2. Install studs, nuts, and mounting bracket. Secure 1. Connect fuel injector harness at 4 pin connector. reservoir using screws.

  • Page 270: Water Separating Filter Assembly Installation

    3. Install ECM harness bracket and connect throttle Water Separating Filter Assembly position sensor at 3 pin connector. Installation 1. Install spacer block to engine block. 2. Install filter base secure with screws. Tighten screws securely. 3. Connect fuel inlet hose and fuel inlet hose to fittings.

  • Page 271: Engine Head Temperature Sensor Installation

    2. Secure ECM to manifold using nuts and screw. Engine Head Temperature Sensor Tighten securely. Installation 3. Water sensing module and ground wires, tighten IMPORTANT: Engine Head Temperature Sensor securely in place using screws. must make clean contact with cylinder head for circuit to function properly.
  • Page 272 FUEL SYSTEMS 55173 FUEL INJECTION SN 0G303046 AND ABOVE...
  • Page 273 Table of Contents Page Page Specifications ......3D-1 Throttle Position Sensor Test ... 3D-39 Special Tools .

  • Page 274: Specifications

    Specifications Electronic Fuel Injection Idle RPM – All Models Wide Open Throttle RPM – Model 150XRI/175XRI 5000 – 5600 – Model 200XRI 5000 – 5800 – Pro Max/Super Magnum 150/200/225 6200 – 6500 Float Adjustment (Vapor Separator) – Float Level Preset @ Factory Fuel Injectors –All Models (Quantity)
  • Page 275 Remote Starter Switch 91-52024A1 Injector Test Harness 91-833169A1 – For Mercury/Mariner 150 thru 250 HP with Electronic Fuel Injection – For Hi-Performance 150 thru 300 HP PRO MAX/SUPER MAGNUM models only Can be used to verify that the ECM is supplying operating voltage to the injectors.

  • Page 276: Detonation Controller/Air Temperature Sensor/Throttle Position Sensor

    Detonation Controller/Air Temperature Sensor/Throttle Position Sensor TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m DETONATION CONTROLLER ASSEMBLY SCREW WASHER PLATE CABLE ASSEMBLY SCREW BUSHING OIL INJECTION WARNING MODULE INDICATOR–throttle position SCREW LOCKWASHER WASHER SLEEVE PLATE AIR TEMPERATURE SENSOR ASSEMBLY O-RING SCREW Drive Tight...

  • Page 277: Electronic Control Module (Ecm) Assembly

    Electronic Control Module (ECM) Assembly Dielectric Grease (92-823506--1) Liquid Neoprene (92-25711--2) 3D-4 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 278 Electronic Control Module (ECM) Assembly TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m E.C.M. ASSEMBLY (150) E.C.M. ASSEMBLY (175) E.C.M. ASSEMBLY (200) SPACER CLIP MOUNT–cowl mounting bracket WASHER CABLE ASSEMBLY GROMMET BUSHING SCREW (1/4-20 x 1) LOCKWASHER WASHER WATER SENSOR MODULE ASSEMBLY WIRE ASSEMBLY (BLACK) SCREW (3/16-32 x 1/2) WASHER...

  • Page 279: Fuel Management System

    Fuel Management System 3D-6 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 280 Fuel Management System TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – FUEL MANAGEMENT ASSEMBLY COVER HARNESS KIT SEAL O RING/SEAL KIT FUEL RAIL FUEL INJECTOR FILTER RETAINING KIT THROTTLE BODY JOINT KIT LINK LINK LEVER KIT STOP SCREW KIT SCREW KIT ELBOW KIT SCHRADER VALVE KIT...
  • Page 281 Fuel Management System A = LARGE SCREW (5 MM) (TORGUE TO 30 LB. IN. (3.4 N.M) B = SMALL SCREW (4 MM) (TORQUE TO 20 LB. IN. (2.3 N.M) 3D-8 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 282 Fuel Management System TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – FUEL MANAGEMENT ASSEMBLY VAPOR SEPARATOR BODY KIT O RING MOUNTING SCREW KIT COLLAR GROMMET WASHER WASHER LOCKWASHER SCREW DRAIN SCREW KIT CHECK VALVE FLOAT KIT FLOAT VALVE KIT SCREW KIT COVER KIT ELBOW KIT...

  • Page 283: Fuel Pump

    Fuel Pump Perfect Seal (92-34227-1) 3D-10 - FUEL SYSTEMS 90-824052R3 JUNE 2002...
  • Page 284 Fuel Pump TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP ASSEMBLY DIAPHRAGM KIT CHECK VALVE–rubber CHECK VALVE RETAINER GASKET–boost SPRING DIAPHRAGM GASKET–pulse SPRING GASKET–base BASE–fuel pump PLATE–fuel pump ELBOW TUBING (6 IN.) FUEL LINE (10-1/2 IN.) STA STRAP SCREW–fuel pump to crankcase SCREW–fuel pump CONNECTOR...

  • Page 285: Outboard Powerhead View

    Outboard Powerhead View Engine starboard view of EFI components. Engine port view of EFI components. 55175 a - Electronic Control Module (ECM) b - ECM Harness c - Engine Harness 55174 d - Throttle Position Sensor e - Water Separating Filter a - Electric Fuel Pump b - Fuel Pressure Regulator c - Vapor Separator...

  • Page 286: Efi System Tests

    EFI System Tests DANGER EFI Electrical System and ECM Check Perform the tests in this section in a well ventilated area to avoid being overcome by fuel Fuel Gauge Connection/Pressure Test vapors or poisonous exhaust gases. Vapor Separator Fuel Delivery Test WARNING Vapor Separator Float Test Water Separating Filter Flow Test...

  • Page 287: Preliminary Checks

    Preliminary Checks A steady, blue spark should be present at each spark plug wire. If a good spark is present, problem may not be ignition related. If good spark is not present, Ignition Spark Check problem may be ignition related. Trouble shoot Purpose: This test determines if the ignition system ignition system or make sure engine timing is set is delivering usable spark to the spark plugs.
  • Page 288 Fresh Quality Fuel Low Battery Voltage Using a remote fuel tank containing a major brand of premium unleaded gasoline, test run the outboard to eliminate any problems related to restricted fuel supply (clogged lines, malfunctioning anti-siphon valve, etc.) and/or marginal gasoline. Low battery voltage can cause EFI system to deliver fuel in an inconsistent manner.

  • Page 289: Fuel Flow Diagram

    Fuel Flow Diagram 53646 a - Fuel Injectors (6) o - Vapor Separator b - Fuel Rail p - Vapor Separator to Manifold Vent Hose c - Fuel Rail Pressure Port q - Vapor Separator Float d - Fuel Pressure Regulator Manifold Hose r - Electric Fuel Pump e - Fuel Pressure Regulator s - Manifold...

  • Page 290: Fuel Flow Component Description

    Fuel Flow Component Bleed System Description On carbureted engines, excess fuel which collects in the crankcase is channeled into the transfer ports to be burned. Pulse Fuel Pump On EFI engines, excess crankcase fuel is directed through a filter (to eliminate contaminates) and The pulse fuel pump operates through alternating emptied into the vapor separator.
  • Page 291 Induction Manifold Fuel Pressure Regulator The induction manifold is a common plenum The fuel pressure regulator is located on top of the chamber for accurate pressure measurement. It vapor separator and is continuously regulating fuel contains 4 throttle shutters on 2 throttle shafts. The pressure produced by the electric fuel pump.
  • Page 292 Wiring Diagram 150 EFI/175 EFI/150 Pro Max/Super Magnum BLK = BLACK RED = RED BLU = BLUE TAN = TAN BRN = BROWN VIO = VIOLET GRY = GRAY WHT = WHITE GRN = GREEN YEL = YELLOW PUR = PURPLE 14 15 54352 1 - Water Temperature Switch...
  • Page 293 Wiring Diagram 200 EFI/200 & 225 Pro Max/Super Magnum 54353 BLK = BLACK 16 17 BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN VIO = VIOLET WHT = WHITE YEL = YELLOW 1 - Detonation Sensor 17- Engine Harness Connector...

  • Page 294: Efi Electrical Components (From Electrical Component Diagram)

    EFI Electrical Components (from ENGINE HEAD TEMPERATURE SENSOR Electrical Component Diagram) The Engine Head Temperature Sensor provides the ECM signals related to engine temperature to determine level of fuel enrichment during engine ELECTRONIC CONTROL MODULE (ECM) warm up. The ECM is receiving information at all The ECM is continually monitoring various engine engine temperatures but stops fuel enrichment at an conditions (engine temperature, engine detonation...
  • Page 295 DETONATION CONTROL SYSTEM FUNCTION Fuel Injectors - A four wire harness connects the fuel injectors to the ECM. The red wire is at 12 volts 1. Combustion noise (or vibration) excites the and connects to all injectors. The blue, yellow and piezoelectric circuit located inside the detonation white wires each go to a pair of injectors and are sensor, which transmits a voltage to the control...

  • Page 296: Efi Fuel Management (Low Pressure Fuel Route)

    EFI Fuel Management (Low Pressure Fuel Route) Perform all preliminary checks 3D-13. Install fuel pressure gauge (P/N 91-16850A2) on to manifold pressure port. Place ignition switch in “OFF” position 30 sec- onds before testing. Place ignition switch in “ON” position and note pressure within 30 seconds (34 to 36 psi;...

  • Page 297: Efi Fuel Management (High Pressure Fuel Route)

    EFI Fuel Management (High Pressure Fuel Route) Perform low pressure checks (page 3D-23) be- fore performing checks on high pressure route. Install fuel pressure gauge (P/N 91-16850A2) on to manifold pressure port. Place ignition switch in “OFF” position 30 sec- onds before testing.

  • Page 298: Fuel Rail Electrical/Fuel Determination

    Fuel Rail Electrical/Fuel Determination Perform all preliminary checks page 3D-14. Adequate fuel pressure (34 to 36 psi; 234 to 248 kPa) follow Low/High Fuel Route Flow Charts. Place outboard in water or on flush attach- ment (P/N 44357A2) run engine speed be- tween 2000 and 2500 RPM.

  • Page 299: Efi System Test Procedures

    EFI System Test Procedures 2. Prime engine using fuel primer bulb. Fuel Gauge Connection/Pressure Test IMPORTANT: When checking fuel pressure while engine is running, fuel pressure may fluctuate. Fuel pressure fluctuation (i.e. 34 to 36 psi “234 to 248 kPa”) is common, as the regulated pressure is a differential between fuel rail and manifold vacuum.

  • Page 300: Vapor Separator Fuel Delivery Test

    Vapor Separator Fuel Delivery Test 3. Turn ignition key switch to “START” and operate starter motor for 10 to 20 seconds. Purpose: Verifying there is adequate fuel flow to the electric fuel pump (through full RPM range) will determine components in low pressure fuel system are functioning correctly.

  • Page 301: Vapor Separator Float Test

    Vapor Separator Float Test Water Separating Filter Flow Test Purpose: This test will indicate if float is stuck in the Purpose: This test will indicate if water separating up position. filter is clogged. NOTE: If float is stuck down, vapor separator will 1.

  • Page 302: Pulse Fuel Pump Delivery Test

    Pulse Fuel Pump Delivery Test Results: Fuel flows freely from pulse pump inlet hose. Remove, disassemble, and inspect Purpose: This test will indicate pulse fuel pump is pulse fuel pump (section 3A). capable of supplying the low pressure fuel IMPORTANT: All fragments of failed pump must route with adequate fuel supply.
  • Page 303 2. Remove drain plug from vapor separator and 6. Rotate inlet filter counterclockwise and pull allow fuel to drain into suitable container. downward to remove filter from fuel pump. 55205 55177 a - Inlet Filter 3. Remove 3 bolts securing vapor separator assembly to manifold.

  • Page 304: Pressure Regulator Test

    Pressure Regulator Test 6. Check for fuel flow out of regulator. Purpose: This test will determine if a weak, plugged or open pressure regulator is causing inadequate fuel pressure in the system. 1. Connect pressure gauge to EFI test port. Results: If steady stream of fuel exits regulator into container and pressure is below 34 psi (234 kPa), replace pressure regulator.

  • Page 305: Electric Fuel Pump Voltage Test

    Electric Fuel Pump Voltage Test 2. Set volt meter to read battery voltage and con- nect BLACK test lead to ground, POSITIVE test lead to NEGATIVE (–) post of fuel pump. CAUTION Negative Test Terminal When checking voltage at pump, DO NOT pry boot covers off terminals with a metal object, as OHMS each terminal is at 12 volts when engine is off.

  • Page 306: Voltage Test Chart

    3. Perform voltage tests “all (1-4) engine modes” below. VOLTAGE TEST CHART Engine Mode BLACK Meter Lead to Approximate Voltage If Approximate Voltage Engine Ground; RED Reading is not obtained, this in- Meter Lead to: dicates: 1. All models (+) terminal of fuel pump 12 –...

  • Page 307: Injector Electrical Harness Test

    Injector Electrical Harness Test ECM Injector Driver Test Purpose: This test will determine if electrical or fuel To verify that the ECM is operating the injector pairs, delivery problem exists during the fuel connect test harness between manifold connector delivery process by checking for open circuits and engine harness.

  • Page 308: Injector Operation Test

    NOTE: Switch box panel and lube alert control box 1. Remove induction manifold cover using may have to be shifted to the side to allow bleed fitting procedures outlined under “lnduction Manifold connection. Ground boxes to engine as required. Removal.” 2.

  • Page 309: Induction Manifold Leak Check

    Results A: If fuel spray is not present in all injectors Induction Manifold Leak Check or spray pattern is extremely weak, check (Manifold Cover Removed) wiring harness to injector connectors, or injector filters for plugging. Purpose: Lack of good fuel pressure may be caused by an internal leak in the fuel induction man- If spray patterns are available in most of the injectors, ifold and not caused by a weak pump.

  • Page 310: Air Temperature Sensor Test

    3. Connect a jumper wire between the metal case Results: If no leaks are present, replace cover and of ECM and a good engine ground. gasket using normal length screws. If fuel leak is present between sealing surfaces, WARNING rebuild system using new O-rings. If a serious leak is present in the induction man- ifold, fuel may spray out of bad seal.

  • Page 311: Detonation Control System Test (200 Models Only)

    3. Place sensor in ice water while monitoring meter Timing advancement does not occur (19 to 25 reading. Use graph (below) for reference. BTDC). System functioning properly detonation may be occurring. See Detonation Sensor/Module NOTE: Temperature/resistance reading may differ Checks (following). slightly from graph curve.

  • Page 312: Detonation Control Module Check

    Detonation Control Module Check Throttle Position Sensor Test Purpose: This check will determine if control module Purpose: This test eliminates possibilities of is correctly signaling ECM when signals are improper fuel delivery related to the throttle received from sensor. position indicator. Refer to EFI electrical system and ECM test.

  • Page 313: Map Sensor Test

    IMPORTANT: TAN/BLK head temperature leads Map Sensor Test must be disconnected from port cylinder head Purpose: This test eliminates possibilities of before adjusting TPS. improper fuel delivery caused by the map Disconnect TAN/BLACK engine head tempera- sensor. Refer to Electronic Fuel Injection ture sensor leads located on port cylinder head.

  • Page 314: Problem Diagnosis

    Problem Diagnosis Condition Possible Source Action Engine Down On Power Or RPM – Failed Switch Box Refer to Section 2A Electrical and Ignition Tests. – Failed Stator Refer to Section 2A Electrical and Ignition Tests. – Failed Coil Refer to Section 2A Electrical and Ignition Tests.
  • Page 315 Condition Possible Source Action Engine Surges Between 4000 – Intermittant Switch Box Failure. Refer to Section 2A Electrical and And 5000 RPM Ignition for tests. – Final Filter Clogging. Perform Final Filter Check (page 3D-29). – T.P.S. – Improper Adjustment. Refer to Section 2A Electrical and Ignition for T.P.S.
  • Page 316 Condition Possible Source Action Engine Idles Rough (May Lean – Low Speed Winding Failure. Refer to Section 2A Electrical and Sneeze) – Acceleration Ok; Full Ignition Tests. Throttle Ok. (continued) – Broken Reed. Perform Injector Fuel Delivery Test (page 3D-34). Engine Runs but Slowly Drops –...

  • Page 317: Efi Induction Manifold Removal

    Engine Head Temperature 1. Disconnect ECM at harness connector. Sensor Removal 1. Remove screw and retaining plate. 2. Disconnect wires and remove sensor. 55173 a - Connector a. Remove screws (b) and ground wires (c). b. Remove water sensing module (d). c.

  • Page 318: Water Separating Filter Assembly Removal

    2. Carefully raise ECM from studs. Disconnect MAP Water Separating Filter Assembly sensor hose at manifold fitting and remove ECM. Removal NOTE: To inspect or replace water separator, it is not necessary to remove inlet and outlet fuel lines or to unbolt bracket from manifold.

  • Page 319: Water Separating Filter Assembly Installation

    Water Separating Filter Assembly Throttle Position Sensor and Installation Temperature Sensor Fuel Injector Harness Disconnections IMPORTANT: Apply a light coat of outboard oil to the rectangular sealing ring on the water 1. Disconnect throttle position sensor at 3 pin separator before installation. connector and remove ECM harness bracket.

  • Page 320: Oil Reservoir Removal

    3. Disconnect fuel injector harness at 4 pin Fuel Pressure Regulator Removal connector. 1. Disconnect boat battery from engine harness. 2. De-pressurize EFI fuel system by wrapping a clean cloth around pressure port valve and inserting tip of screwdriver into valve, depressing valve core.

  • Page 321: Fuel Pressure Regulator Disassembly

    Fuel Pressure Regulator Vapor Separator Removal Disassembly 1. Disconnect boat battery from engine harness. 1. Inspect O-rings for cuts and abraisions. Replace 2. De-pressurize EFI fuel system by wrapping a as required. clean cloth around pressure port valve and in- serting tip of screwdriver into valve, depressing 2.

  • Page 322: Vapor Separator Disassembly

    6. Remove drain screw from separator and drain Vapor Separator Disassembly fuel into suitable container. Remove 9 screws securing cover to vapor separator 7. Remove fuel inlet hose to vapor separator. and remove separator tank. 55177 55209 a - Fuel Inlet Hose a - Screws (3 screws are hidden on back side) 8.
  • Page 323 ELECTRIC FUEL PUMP REMOVAL VAPOR SEPARATOR FLOAT REMOVAL NOTE: There are no individually replaceable parts NOTE: Inspect float for fuel absorbtion or within the electric pump. If brushes or armature fails, deterioration. DO NOT attempt to bend float arm to entire pump must be replaced.

  • Page 324: Vapor Separator Reassembly

    Vapor Separator Reassembly ELECTRIC FUEL PUMP INSTALLATION 1. Slide fuel pump into separator cover. VAPOR SEPARATOR FLOAT INSTALLATION NOTE: Fuel pump electrical studs are different 1. Attach float needle to float arm. diameters. Pump will install properly into cover only one way.
  • Page 325 3. Install rubber pad on bottom of pump. INSTALLING SEPARATOR COVER ASSEMBLY ONTO SEPARATOR TANK NOTE: Rubber pad is molded to fit flush on bottom of pump on one side only. 1. Inspect separator tank sealing O-ring for cuts or abraisions.

  • Page 326: Installing Vapor Separator Assembly To Induction Manifold

    Installing Vapor Separator Assembly 3. Secure adaptor plate to manifold with 2 screws. Torque screws to 45 lb. in. (5.0 N·m). to Induction Manifold 1. Inspect O-rings on ends of separator fuel tubes for cuts or abraisions. Replace O-rings as required.

  • Page 327: Manifold Removal

    NOTE: For ease of reassembly, reinstall oil reservoir Manifold Removal on engine BEFORE installing vapor separator. 1. Disconnect throttle link rod from throttle cam. 7. Secure separator to manifold with 3 bolts and 2. Disconnect oil injection link rod from injector arm. washers.

  • Page 328: Efi Induction Manifold Disassembly

    6. Disconnect bleed line hoses from manifold Air Temperature Sensor Removal fittings. 1. Remove screws and sensor. 7. Remove manifold assembly and place on clean work surface. 51790 a - Screws 51795 b - Sensor a - Bleed Hoses 2. Remove O-ring from sensor. EFI Induction Manifold Disassembly 1.

  • Page 329: Throttle Position Sensor Removal

    Throttle Position Sensor Removal Fuel Rail Removal IMPORTANT: Sensor position will need to be set 1. Remove manifold vacuum hoses. after induction manifold assembly has been 2. Remove engine bleed hose. installed. 3. Remove screws securing manifold fitting to 1. Remove throttle position sensor screws. manifold.

  • Page 330: Fuel Rail Disassembly

    5. Remove 4 screws securing fuel rail to manifold. Fuel Rail Disassembly 1. Remove tube support from fuel rail. 2. Remove plugs from fuel rail. 3. Remove tubes from tube support. 4. Remove O-rings from plugs, tube support and tubes. 51795 a - Tube Support b - Fuel Rail...

  • Page 331: Fuel Injector Removal And Disassembly

    Fuel Injector Removal and 4. Place injector on clean work surface. Remove seals, O-ring and injector filter. Disassembly 1. Lift wire clamp from slot. 2. Disconnect connector from injector. 51789 a - Injector 51792 b - Seals c - O-Ring a - Clamp d - Filter b - Slot...

  • Page 332: Injector Harness Removal

    Injector Harness Removal Throttle Linkage Removal 1. Remove protective casing from injector wiring harness. Note position of wires for reassembly. 51786 a - Throttle Cam b - Bushings c - Nut; Tighten until snug against cam, then back off 1/4 turn 51795 a - Casing b - Harness...

  • Page 333: Efi System Cleaning And Inspection

    EFI System Cleaning and 6. Look for loose, missing or damaged mounting hardware such as stripped threads on screws. Inspection 7. Look at sensors for signs of wear or damage such as cracks, chips, etc. Cleaning 8. Look at filter housing for cracks, holes or other 1.

  • Page 334: Induction Manifold Assembly

    Induction Manifold 4. Install protective casing over positioned injector wiring harness and insert into manifold. Assembly Injector Harness Installation 1. Carefully route injector harness into manifold. 2. Install O-ring into groove on injector harness insert. Install harness insert into manifold port. 51795 a - Casing b - Harness...

  • Page 335: Fuel Injector Assembly And Installation

    Fuel Injector Assembly and 3. Install wire clamp into slot on injector connector. Installation 4. Connect to injector. 1. Install inspected seals, O-ring and injector filter to injector. 51792 a - Clamp b - Slot c - Connector d - Injector 51789 Fuel Rail Assembly a - Seals...

  • Page 336: Fuel Rail Installation

    Fuel Rail Installation 3. Install O-rings to manifold fitting. Install fitting to manifold. 1. With fuel rail guides in place, install fuel rail to manifold. 51791 a - O-Rings b - Fitting 4. Install screws securing manifold fitting to manifold. Torque screws to 45 lb. in. (5.0 N·m). 5.

  • Page 337: Throttle Position Sensor Installation

    Throttle Position Sensor Installation Air Temperature Sensor Installation IMPORTANT: Throttle position sensor must be 1. Install O-ring to air temperature sensor. adjusted following reassembly (see Section 2C - Timing, Synchronizing, Adjustment). 1. Install sleeve to throttle position sensor. 2. Install sensor into manifold. Sleeve must guide sensor to throttle shaft.

  • Page 338: Efi Induction Manifold Installation

    3. Carefully install manifold cover seal to manifold. EFI Induction Manifold Installation 1. Install new gasket on induction manifold as shown. Removing dotted line sections after manifold installation. 51785 a - Cover Seal b - Manifold 51784 a - Gasket 4.

  • Page 339: Oil Reservoir Installation

    3. Secure induction manifold assembly to engine IMPORTANT: Before connecting oil pump control with screws. Torque screws to 90 Ib. in. (10.0 rod verify pump quadrant is rotated to the N·m) using torque sequence shown below. clockwise of center. NOTE: Remove M8 x 1.25 x 38mm long bolts used 4.

  • Page 340: Vapor Separator Installation

    Vapor Separator Installation IMPORTANT: If fuel outlet hose from electric fuel pump or fuel return hose from manifold to 1. Secure adaptor plate to manifold with 2 screws. pressure regulator was disconnected, stainless Torque screws to 45 lb. in. (5.0 N·m). steel hose clamps MUST BE USED to secure connections.

  • Page 341: Throttle Position Sensor, Air Temperature Sensor And Fuel Injector Harness Connections

    6. Connect fuel inlet hose to vapor separator. Throttle Position Sensor, Air Secure hose with sta-strap. Temperature Sensor and Fuel 7. Connect oil inlet hose to vapor separator. Secure Injector Harness Connections hose with sta-strap. 1. Connect fuel injector harness at 4 pin connector. 8.

  • Page 342: Ecm Installation

    3. Connect throttle position sensor at 3 pin 2. Secure ECM to manifold using nuts and screw. connector. Torque nuts and screw to 45 lb. in. (5.0 N·m). 3. Secure water sensing module and ground wires with screws. Torque screws to 25 lb. in. (3.0 N·m). 51787 a - Throttle Position Sensor 55173...

  • Page 343: Engine Head Temperature Sensor Installation

    Engine Head Temperature Sensor Installation IMPORTANT: Engine Head Temperature Sensor must make clean contact with cylinder head for circuit to function properly. 1. Connect wires and install sensor. 2. Install retaining plate and screw. Torque screw to 200 lb. in. (22.5 N·m). 55196 a - Wires b - Sensor...
  • Page 344 FUEL SYSTEMS OIL INJECTION...
  • Page 345 Table of Contents Page Operation of the Oil Injection System ..3E-1 Oil Injection Components ....3E-2 Oil Injection Flow System .

  • Page 346: Operation Of The Oil Injection System

    FINAL CHECKS BEFORE OPERATION OF CAUTION ENGINE Be careful not to get dirt or other contamination Make sure fill cap gaskets are in place and caps in tanks, hoses or other components of the oil are tight on engine oil reservoir and remote oil injection system during installation.

  • Page 347: Oil Injection Components

    Oil Injection Components 11 OIL INJECTION PUMP (See Page 3 for Location) Injection pump is driven off the crankshaft. See illustration on page 3. 1 REMOTE OIL TANK The oil injection pump is a variable metering pump. At idle the pump will meter the oil at Holds 3 gallons (11.5 liters) of oil.

  • Page 348: Oil Injection Flow System

    Oil Injection Flow System TAN/BLUE 1 - Remote Oil Tank 14- To 12 Volt Supply 2 - Oil Pick Up Tube 15- To Switch Box 3 - Air Pressure 16- Oil Hose to Pump 4 - Oil Line (Blue Stripe) 17- Oil Inlet 5 - Open 18- Fuel/Oil Mixture...

  • Page 349: Pump Drive Assembly

    Pump Drive Assembly a - Oil Pump b - Retaining Bolts (2) c - O-ring d - Magnet e - Coupler f - Driven Gear g - Oil Pump (Installed) NOTE: If magnet should fall out of the coupler, using a directional compass, locate end of magnet that attracts the North Arrow of the compass.

  • Page 350: Set Up Instructions For Oil Injection System

    NOTE: An oil hose extension kit (41729A3) is avail- Set Up Instructions for Oil Injection able for the remote oil tank. System CAUTION Be careful not to get dirt or other contamination in tanks, hoses or other components of the oil injection system during installation.
  • Page 351 INSTALLING OIL HOSES TO ENGINE FILLING THE OIL INJECTION SYSTEM 1. Remove shipping cap from hose fitting (a). Use Quicksilver NMMA Certified TC-W3 or TC-WII 2-Cycle Outboard Oil. 2. Connect oil hose (“b” with blue stripe) to fitting as Quicksilver Certified TC-W3 Outboard Oil is shown.
  • Page 352 CAUTION Be certain that all reservoir and remote oil tank caps are installed tightly. An air leak, on the remote oil tank cap, will prevent oil from moving from the remote oil tank to the oil reservoir. A leak at the engine reservoir will cause oil spillage. a - Bleed Screw b - Outlet Hose 50047...

  • Page 353: Oil Injection Pump

    OPERATION OF THE OIL INJECTION SYSTEM Oil Injection Pump 1. Make sure fill cap gaskets or O-rings are in place and caps are tight on engine reservoir tank and Oil Pump Removal remote oil tank. 1. Disconnect and plug inlet hose to oil pump. 2.

  • Page 354: Worm Bushing

    Worm Bushing 1. Inspect bushing O-rings for cuts and abrasions. Replace O-rings if necessary. Worm Bushing Removal 1. Grasp bushing and remove from oil pump. NOTE: If seal is defective, seal and bushing are replaced as an assembly. 51782 a - O-rings 2.

  • Page 355: Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft

    Installing Drive Gear (for Oil Injection INSTALLATION OF NEW DRIVE GEAR Pump) Onto Crankshaft NOTE: If drive gear must be replaced, it is recom- mended that the oil pump be inspected for operating IMPORTANT: Oil pump drive gear retaining smoothness; plastic bearing, bronze bushing and oil screws ARE STAKED after installation.

  • Page 356: Oil Injection System Troubleshooting Chart

    Installation--Insert MOTION SENSOR into pocket Oil Injection System Trouble behind oil pump. Secure sensor with screw. Torque Shooting Chart screw to 30 Ib. in. (3.5 N·m). Connect WHITE and BLUE/WHITE leads to respective leads of WARN- TROUBLE SHOOTING THE OIL INJECTION ING MODULE.
  • Page 357 Problem: Oil Level in Engine Oil Reservoir Tank is Low but NOT Low in Remote Oil Tank Possible Cause Corrective Action Fill cap is leaking air on the remote tank. Verify o-rings or gaskets are in place and caps are tight.
  • Page 358 Problem: Oil Level in Engine Oil Reservoir Tank is Low but NOT Low in Remote Oil Tank Possible Cause Corrective Action Fill cap is leaking air on the remote tank. Verify O-rings or gaskets are in place and caps are tight.
  • Page 359 Problem: Warning Horn sounds when Engine is Running and Oil Level in Engine Reservoir is Full (continued) Drive system of the oil injection pump Check drive system as follows: 1. Use a 50:1 gas and oil mixture and start engine. Verify engine has proper cooling water.

  • Page 360: Oil Pump Volume (Flow) Test

    Oil Pump Volume (Flow) Test Oil Warning Module NOTE: The following specifications are determined REMOVAL with the outboard running off a remote fuel supply with pre-mix fuel. The oil pump output hose (clear) 1. Disconnect PURPLE and TAN leads from termi- must be disconnected from the input fuel line TEE nal block above ignition plate on starboard side fitting and directed into a graduated container.
  • Page 361 4. Remove three bolts securing oil reservoir to INSTALLATION powerhead and remove reservoir. 1. Apply Loctite 222 (FT2962-2) to threads of 3 attaching bolts and secure oil reservoir to powerhead. Torque bolts to 25 Ib. in. (3.0 N·m). 2. Install input oil hose to top of oil reservoir and secure with sta-strap.

  • Page 362: Emission Control Information

    FUEL SYSTEMS Emission Control 2000 2507 Information PART # 37–804669-00 This engine conforms to 2000 Model Year Idle Speed (in gear): 650 RPM U.S. EPA regulations for marine SI engines. Refer to Owners Manual Timing: Idle – 0 – 9 ATDC for required maintenance WOT –...
  • Page 363 Table of Contents Page Exhaust Emissions Standards ... . . 3F-1 What Are Emissions ....3F-1 Hydrocarbons - HC .

  • Page 364: Exhaust Emissions Standards

    Exhaust Emissions is a harmless gas. But carbon often combines with in- sufficient oxygen (one carbon atom with one oxygen Standards atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion Through the Environmental Protection Agency and is a dangerous, potentially lethal gas.

  • Page 365: Outboard Hydrocarbon Emissions Reductions

    As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases HC and CO, as well as lowering fuel economy.

  • Page 366: 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 367: Emissions Information

    Emissions Information EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Manufacturer’s Responsibility: Environmental Protection Agency as conforming to the requirements of the regulations for the control of Beginning with 1998 model year engines, manufac- air pollution from new outboard motors.

  • Page 368: Service Replacement Certification Label

    Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine out- boards have a visible and legible emission certification label. If this label is missing or damaged, contact Mercury Marine Service for replacement if appropriate. Removal Remove all remaining pieces of the damaged or illegible label.

  • Page 369: Decal Location For 1998 Models

    Decal Location for 1998 Models: Model Production Part No. Service Part No. Location on Engine Merc/Mar 2.0 L V6 Carb 37-855211 12 37-855577 12 Air Cover (135 – 150 H.P.) Merc/Mar 2.5 L 1998 37-855211 13 37-855577 13 Vapor Separator (EFI) V6 EFI/Carb Air Cover (Carb) (150 –...
  • Page 370 POWERHEAD 51804...
  • Page 371 Table of Contents Page Page Powerhead Specifications ....Piston and Connecting Rod Reassembly 4-37 Special Tools ......Piston and Piston Ring Combinations .

  • Page 372: Powerhead Specifications

    Powerhead Specifications IMPORTANT: Using a micrometer, measure di- mension “B” at location shown. Dimension “B” Block should be .008 in. or less than dimension “A”. Type ..... 60 V, 2 Cycle Displacement 135 and 150...

  • Page 373: Special Tools

    Special Tools Powerhead Stand 91-30591A1 Lifting Eye 91-90455 Piston Ring Expander 91-24697 Flywheel Holder 91-52344 91–52344 Lockring Removal Tool 91-52952A1 54964 Protector Cap 91-24161 Piston Pin Tool 91-74607A1 Flywheel Puller 91-849154T1 4A-2 - POWERHEAD 90-824052R3 JUNE 2002...

  • Page 374: Powerhead Repair Stand

    Driver Head 91-55919 Piston Ring Compressor for 2 Litre (122 cu. in.) 91-65494 Universal Puller Plate 91-37241 Piston Ring Compressor for 2.5 Litre (153 cu. in.) 91-818773 Snap Ring Pliers 91-24283 Compression Tester 91-29287 Lockring Installation Tool 91-91-77109A1 54965 Powerhead Repair Stand A powerhead repair stand may be purchased from: Bob Kerr’s Marine Tool Co.

  • Page 375: Cylinder Block And End Caps

    Cylinder Block and End Caps Loctite 271 (92-809820) Loctite Master Gasket (92-12564-1) 2 Cycle Outboard Oil (92-13249A24) Loctite 222 (FT2962-2) Loctite 680 (92-809833) 2-4-C With Teflon (92-825407A12) 4A-4 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 376 Cylinder Block and End Caps TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK (135/150) CYLINDER BLOCK (XR6/MAG. IlI ) CYLINDER BLOCK (175) CYLINDER BLOCK (200) STUD–powerhead (1-3/4 IN.) STUD–powerhead (5-1/2 IN.) STUD–powerhead (6-3/4 IN.) DOWEL PIN–locating DOWEL PIN (BEARING RACE) GASKET–sealing COVER–starter motor (UPPER) SCREW (1-1/2 IN.) (HEX FLANGE)

  • Page 377: Exhaust Manifold And Exhaust Plate

    Exhaust Manifold and Exhaust Plate Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Loctite 222 (FT2962-2) Loctite 262 (Obtain Locally) A = TO BLOCK 4A-6 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 378 Exhaust Manifold and Exhaust Plate TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GASKET DIVIDER PLATE (S/N-0G437999 & BELOW) DIVIDER PLATE (S/N-0G438000 & UP) SEAL J-CLAMP SCREW 16.5 22.5 FITTING FITTING (90 ) HOSE (23-1/2 IN.) STA-STRAP COVER–relief valve SCREW (1-1/4 IN.) 12.5 17.0...

  • Page 379: Reed Block And Cylinder Head

    Reed Block and Cylinder Head Dielectric Grease (92-823506--1) Loctite PST Pipe Sealant (92-809822) 2 Cycle Outboard Oil (92-13249A24) A = TO TELL-TALE HOSE B = TO ADAPTOR PLATE 4A-8 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 380 Reed Block and Cylinder Head TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER HEAD 135/150 GASKET CYLINDER HEAD XR6/ Magnum III GASKET CYLINDER HEAD GASKET SCREW (2 IN.) 30 lb. ft. (40.5 N·m); Then Turn Additional DOWEL PIN GASKET COVER THERMOSTAT...

  • Page 381: Crankshaft, Pistons And Connecting Rods

    Crankshaft, Pistons and Connecting Rods Loctite 271 (92-809820) 2 Cycle Outboard Oil (92-13249A24) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) 4A-10 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 382 Crankshaft, Pistons and Connecting Rods TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CRANKSHAFT ASSEMBLY BALL BEARING (LOWER) RETAINING RING DRIVE GEAR SCREW CARRIER ASSEMBLY SEAL RING–sealing - crankshaft ROLLER BEARING–crankshaft PISTON (STARBOARD-STANDARD) PISTON (STARBOARD-.015 O.S.) PISTON (STARBOARD-.030 OS.) PISTON (PORT-STANDARD) PISTON (PORT-.015 O.S.) 135/150...

  • Page 383: Torque Sequence

    Torque Sequence CYLINDER HEAD BOLTS Add light oil to threads and bolt face: 30 lb. ft. (40.5 N·m) then turn an additional 90 . CRANKCASE COVER BOLTS (AND TORQUE SEQUENCE) Add light oil to threads and bolt face: 8 Bolts (3/8 in. - 16 in.) 38 lb.

  • Page 384: General Information

    General Information 1996 Standard Models – NOTE: Throughout this section, STANDARD MODELS will refer to 135/150/175/200 carbureted outboards. HIGH PERFORMANCE MODELS will refer to PRO MAX and SUPER MAGNUM 150/200/225 outboards. Powerhead “Disassembly” “Reassembly” instructions are printed in a sequence that should be followed to assure best results when removing or replacing powerhead components.
  • Page 385 8. 1994 - 1995 Standard Models – Remove BLUE, 1994 - 1995 High Performance Models – GREEN and BLACK trim harness leads from trim solenoids. Remove trim harness from J-clip on exhaust cover. 55007 a - Blue Trim Lead 51809 b - Green Trim Lead c - Black Trim Lead (Hidden –...
  • Page 386 11. Remove locknut that secures shift cable latch 13. Remove four bolts which secure bottom cowl assembly and remove latch, flat washer, nylon halves together and remove bottom cowling. wear plate, spring and shift cable from control 1994-1995 Standard Models – cable anchor bracket.
  • Page 387 1996 Standard Models – All High Performance Models – 52354 a - Bolts 55005 a - Bottom Pan (The bottom pan does not have to be removed to remove the powerhead) b - Skirt c - Bolts, Washers, Nuts (8 each) 14.

  • Page 388: Removing Engine Components

    15. All High Performance Models – Remove water 17. Remove plastic cap from center of flywheel and hose from fitting on exhaust adaptor plate and install LIFTING EYE (91-90455) into flywheel at pull hose through bottom pan. least five full turns. Using a hoist, lift powerhead assembly from driveshaft housing.

  • Page 389: Powerhead Disassembly

    Powerhead Disassembly 4. Remove exhaust manifold cover and seal. 1. Place powerhead in repair stand or on a bench. 2. Remove thermostat covers, thermostats and gaskets. 51852 a - Thermostat Cover 51852 b - Thermostat a - Exhaust Manifold Cover c - Gasket b - Seal c - Gasket...
  • Page 390 6. Inspect reeds as outlined in “Cleaning and LOWER END CAP Inspection”. 51849 a - Crankcase Attaching End Cap Bolts 1. Remove bolts which secure crankcase cover to cylinder block. 51850 2. Pry crankcase cover off cylinder block using pry 7.
  • Page 391 CRANKCASE COVER REMOVED 3. Use a 5/16 in. 12 point socket to remove connecting rod bolts, then remove rod cap, roller bearings and bearing cage from connecting rod. 51848 1. Use Powerhead Stand (91-30591A1) for rotating crankshaft to desired position for removal of connecting rods.
  • Page 392 7. Use Piston Ring Expander (91-24697) to remove 9. Using tool (91-52952A1), remove piston pin piston rings. Always install new piston rings. lockrings from both ends of piston pin. Never re-use piston pin lockrings. 51083 51081 a - Lockring IMPORTANT: Warming the piston dome using a 8.
  • Page 393 NOTE: If roller bearing is damaged, replace upper IMPORTANT: We recommend that you use new needle bearings at reassembly for lasting repair. end cap and roller bearings as an assembly. However, if needle bearings must be re-used, keep each set of bearings identified for reassembly on same connecting rod.
  • Page 394 17. Remove retaining ring as shown. 19. Remove lower ball bearing from crankshaft as follows: a. Remove retaining ring using a pair of snap ring pliers. 51850 a - Retaining Ring 18. Remove bearing race halves and roller bearings from crankshaft. IMPORTANT: Keep same bearing races and roller 51854 bearings together.

  • Page 395: Water Pressure Relief Valve Components

    Water Pressure Relief Valve Components If necessary, remove water pressure relief valve components as shown. 50803 Torque Specifications 150 lb. in. (17.0 N·m) b - 25 lb. in. (3.0 N·m) 1 - Cover 2 - Bolt 3 - Gasket 4 - Relief Valve Plate 5 - Diaphragm 6 - Water Deflector 7 - Washer...

  • Page 396: Cleaning And Inspection

    Cleaning and Inspection Special Service Information Grooves in Cylinder Block Caused By Cylinder Block and Crankcase Cover Crankshaft Sealing Rings Grooves in cylinder block caused by crankshaft IMPORTANT: Crankcase cover and cylinder sealing rings are not a problem, except if installing a block are a matched, line-bored assembly and never should be mismatched by using a different new crank- shaft and the new sealing rings on...
  • Page 397 d. Localize stroking in the smallest diameter 135 and 150 (carbureted) Models until drill speed is constant throughout length Models Cylinder Block of bore. Expand stones, as necessary, to Finish Hone compensate for stock removal and stone wear. Stroke at a rate of 30 complete cycles 135 and 150 with a Stan- 3.125 in.

  • Page 398: Pistons And Piston Rings

    Pistons and Piston Rings 2. A tool can be made for cleaning the inner diameter of the tapered ring grooves. The tool IMPORTANT: If engine was submerged while can be made from a broken tapered piston ring engine running, piston and/or with the side taper removed to enable the inside connecting rod may be bent.

  • Page 399: Measuring Piston Roundness

    MEASURING PISTON ROUNDNESS Standard 175, XR6, Magnum III, 150 EFI, 200 EFI Models and High Performance Pro Max/Super Piston has a barrel profile shape and is not a true Magnum 150, 200, 225 Models - 153 cu. in. diameter. (2508 cc) Standard 135 and 150 (carbureted) Models - 1.

  • Page 400: Crankshaft

    Crankshaft Crankshaft (and End Cap) Bearings 1. Inspect crankshaft to drive shaft splines for wear. 1. After cleaning crankshaft, grasp outer race of (Replace crankshaft, if necessary.) crankshaft ball bearing (installed on lower end of crankshaft) and attempt to work race back-and- 2.

  • Page 401: Reed Block Assembly

    Reed Block Assembly 3. Check that bleed system check valves are pressed tight into reed housing. IMPORTANT: DO NOT remove reeds from reed 4. Inspect passages in reed block housing to be blocks, unless replacement is necessary. DO sure that they are not obstructed. NOT turn used reeds over for re-use.
  • Page 402 4. Water Marks: When bearing surfaces are sub- the engine will emit a “whirr” and/or “chirp” sound jected to water contamination, a bearing surface when it is accelerated rapidly from idle speed to “etching” occurs. This etching resembles the size approximately 1500 RPM, then quickly returned of the bearing.
  • Page 403 IMPORTANT: Clean connecting rod just enough c. Fill thermostat tester with water to cover to clean up bearing surfaces. DO NOT continue thermostat. to clean after marks are removed from bearing d. Plug tester into electrical outlet. surfaces. e. Observe temperature at which thermostat begins to open.

  • Page 404: Powerhead Reassembly And Installation

    Powerhead Reassembly and 1. If removed, press lower crankshaft ball bearing onto crankshaft as shown. Be sure bearing is Installation pressed firmly against counterweight. General Before proceeding with powerhead reassembly, be sure that all parts to be re-used have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspection,”...
  • Page 405 3. If removed, spread new crankshaft sealing rings 5. Lubricate center main crankshaft roller bearings just enough to slide over crankshaft journal. and races with light oil. 51854 a - Install so LARGER of the 3 holes is toward DRIVE SHAFT 51854 end of crankshaft a - Crankshaft Sealing Rings...
  • Page 406 8. Secure center main bearing races together with retaining rings. Make sure retaining ring bridges the separating lines of the bearing race. 51849 a - O-ring 10. Install oil seal into upper end cap as follows: a. Apply a thin bead of Loctite 271 (obtain locally) to outer diameter of upper end cap oil seal.

  • Page 407: Crankshaft Installation

    Crankshaft Installation 5. Gently push crankshaft down into position mak- ing sure that the dowel pins are lined up with the holes in center main bearings and crankshaft SPECIAL INFORMATION seal rings are in place. Installing A New Crankshaft Assembly Into Cylin- der Block Check the crankshaft sealing ring mating surfaces in the cylinder block and crankcase cover for wear...

  • Page 408: Piston And Connecting Rod Reassembly

    Piston and Connecting Rod 4. Insert piston pin tool (91-74607A1) and push sleeve out of piston. Keep piston pin tool in Reassembly piston. 1. Place needle bearings on a clean piece of paper and lubricate with Quicksilver 2-4-C w/Teflon Marine Lubricant (92-825407A12). NOTE: There are 29 needle bearings per piston.
  • Page 409 7. Make sure lockrings are properly seated in piston grooves. 51086 a - Lockring Installation Tool 51086 a - Lockring Installation Tool (91-77109A1) b - Lockring 4A-38 - POWERHEAD 90-824052R3 JUNE 2002...

  • Page 410: Piston And Piston Ring Combinations

    Piston and Piston Ring Combinations 122 CU. IN. (1999cc) MODELS All 122 cu in. (1999cc) models have one keystone (tapered) ring on top and one rectangular ring on bottom. Piston with one keystone (tapered) ring on top and one rectangular ring on bottom .093 in.

  • Page 411: Piston Installation (Standard And High Performance Models)

    Piston Installation (Standard and 5. Lubricate piston, rings and cylinder wall with 2-Cycle Outboard Oil. High Performance Models) 1. Before installing new piston rings, check gap between ring ends by placing each ring in its respective cylinder, then pushing ring about 1/2 in.
  • Page 412 9. Coat cylinder bore with 2-cycle oil. Match piston 12. Tighten connecting rod bolts (using a 5/16 in. - 12 assembly with cylinder it was removed from, and point socket). First torque to 15 lb. in. (1.5 N·m) position piston as described below. Push piston then 30 lb.

  • Page 413: Crankcase Cover Installation (Standard And High Performance Models)

    14. Verify that no piston rings were broken during installation by pressing in on each piston ring thru exhaust port using a screwdriver. If no spring tension exists (ring fails to return to position), it’s likely ring is broken and must be replaced. a - Loctite Master Gasket (92-12564-1) 4.

  • Page 414: Assembly Of Reed Blocks To Intake Manifold (Standard And High Performance Models)

    Assembly of Reed Blocks to Intake 5. Torque exhaust divider plate bolts in following sequence. Torque bolts to 16.5 lb. ft. (22.5 N·m). Manifold (Standard and High Add Loctite 271 to threads. Performance Models) 50806 a - Torque to 25 lb. in. (3.0 N·m) 50806 b - Torque to 105 lb.

  • Page 415: Cylinder Head Installation (Standard And High Performance Models)

    NOTE: During normal engine operating tempera- CYLINDER HEAD INSTALLATION (STANDARD AND HIGH PERFORMANCE MODELS) ture, the sender electrical circuit is open and will close if temperature reaches 240 F 8 F (116.0 C 1. Install each cylinder head to engine block with 13.3 C) thus activating the overheat alarm.

  • Page 416: Bleed Line Routing (Carbureted Models)

    Bleed Line Routing STARBOARD SIDE VIEW (Carbureted Models) FRONT VIEW 50801 Bleed Line Routing (Fuel 50801 Injected Models) PORT SIDE VIEW FRONT VIEW 50802 50935 a - To Vapor Separator Thru Bleed Shut-Off Valve (0G303045 and Below) – Direct to Vapor Separator (0G303046 and Above) b - To Bottom of EFI Manifold if Equipped NOTE: Filter removed S/N 0G654636 and above.

  • Page 417: Port Side View

    PORT SIDE VIEW Reinstalling Engine Components Reinstall the following engine components: Section 2 Starter Motor Ignition Switch Boxes Ignition Coil Starter Solenoid Voltage regulator/rectifier Flywheel Stator Assembly Trigger Assembly Low speed/high speed spark advance module Idle Stabilizer Section 3 Air Silencer Carburetors and Linkage Fuel Pump 50934...

  • Page 418: Notes

    Notes: 90-824052R3 JUNE 2002 POWERHEAD - 4A-47...

  • Page 419: Throttle Lever And Shift Shaft

    Throttle Lever and Shift Shaft Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 4A-48 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 420 Throttle Lever and Shift Shaft TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SPARK ADVANCE LEVER SCREW SCREW (1-1/4 IN.) WASHER LINK ROD BALL JOINT PIVOT SPRING BUSHING THROTTLE CONTROL LEVER SCREW (1-3/4 IN.) BUSHING SCREW (2-1/8 IN.) NUT (1/4-20) LATCH SCREW SPRING...
  • Page 421 Throttle Lever and Shift Shaft Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 4A-50 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 422 Throttle Lever and Shift Shaft TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m ANCHOR BRACKET LATCH SCREW WEAR PLATE LATCH WASHER SCREW 13.5 18.0 GUIDE BLOCK SPRING LINK ROD ASSEMBLY SHIFT SHAFT ASSEMBLY (LONG) SHIFT SHAFT ASSEMBLY (X-LONG) USE WITH REF #46 SHIFT SHAFT LEVER–UPPER WITH TAB ( SEE BUBBLE A) BUSHING...

  • Page 423: Powerhead Installation On Driveshaft Housing

    Powerhead Installation on 6. Install 10 flat washers,and10 locknuts which secure powerhead exhaust extension Driveshaft Housing plate/driveshaft housing. Torque locknuts in 3 progressive steps until secured. 1. Install Lifting Eye (91-90455) into flywheel. 7. Disconnect hoist from Lifting Eye and remove WARNING Lifting Eye from flywheel.
  • Page 424 10. All High Performance Models – Install water hose through bottom pan and secure hose to fitting. 51851 a - Hose b - Fittings – Fittings must be turned to allow clearance for 51846 bottom pan a - Bolts All High Performance Models – 11.
  • Page 425 1996 Standard Models – 12. Reconnect input fuel line. 52354 a - Bolts 51803 a - Sta-Strap b - Fuel Line 13. 1994 - 1995 Standard Models – Connect BLUE, GREEN and BLACK trim harness leads to trim solenoids. Install trim harness to J-clip on exhaust cover.
  • Page 426 14. 1996/1997 Standard Models – Reconnect trim 15. Reconnect remote control harness to powerhead relay harnesses. harness connector and wires as shown. 51851 a - Control Harness 54938 b - Powerhead Harness c - Trim 12 Volt Power Supply (RED) a - UP Trim Relay d - Trim Up Lead (BLUE/WHITE) b - DOWN Trim Relay...
  • Page 427 NOTE: Diagram shown without bleed shut-off valve 19. Install shift cable assembly as shown Refer to “Cable Adjustment” Section 7. SN. 0G303046 and Above. 51853 a - Lock Nut b - Shift Cable Latch c - Flat Washer (Hidden) 50345 d - Nylon Wear Plate a - Vapor Separator e - Spring (Hidden)

  • Page 428: Break-Ln Procedure

    Break-ln Procedure GASOLINE/OIL MIXING RATIO CHART GAS/OIL 1 GAL- 3 GAL- 6 GAL- RATIO LON GAS LONS LONS Break-in Fuel Mixture (3.8 LI- GAS (11.5 GAS (23 TERS) LITERS) LITERS) Use a 50:1 (2%) gasoline/oil mixture in the first tank of fuel.
  • Page 429 POWERHEAD 51804 COOLING...
  • Page 430 Table of Contents Page Specifications ......4B-1 Thermostat ......4B-1 Water Pressure .

  • Page 431: Specifications

    Specifications Thermostat 2. Water Pressure Gauge 91-79250A2 ... 143 F (61.7 C) Water Pressure Idle 1.0 – 3.0 PSI (6.8 – 20.5 kPa) Poppet Valve Opening 4 – 9 PSI (27.4 –...
  • Page 432 Temperature Sensor EFI Models – Sensor (in port cylinder head) provides NOTE: The Digital Diagnostic Terminal (DDT) can be the ECM signals related to engine temperature to de- used to monitor temperature readings from both air and head temperature sensors. termine the level of fuel enrichment during engine warm up.

  • Page 433: Water Flow

    Water Flow Description Water that passes through the poppet valve enters water passages in the adaptor plates. Water passes Cooling water enters the cooling system through the through the adaptor plates into the driveshaft lower unit water inlets. The pump assembly forces housing.
  • Page 434 Notes: 4B-4 - POWERHEAD 90-824052R3 JUNE 2002...
  • Page 435 2.5 Litre V-6 Water Flow Diagram 2000 Models 58063 Cylinder Head Cover – Removed from head for illustration, normally part of head casting. Thermostat (2) 143 F (61.7 C) – If stuck closed, engine will over heat at low speed. If stuck open, engine will not warm up at idle speed.
  • Page 436 90-824052R3 JUNE 2002 4B-6 - POWERHEAD...

  • Page 437: Troubleshooting

    NOTE: BE SURE that water in thermostat tester is Troubleshooting allowed to cool sufficiently [below 110 F (43.3 C)] before testing the other thermostat. Thermostat Test 1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and corrosion damage that could cause leakage. Replace parts as necessary.

  • Page 438: Water Pressure Check

    Water Pressure Check Water pressure may be checked by attaching a test pressure gauge to the top of the engine block. A water pressure line (GRAY colored) is provided that exits at the front of the lower cowl. A dash style gauge may be connected to this line to register water pressure.

  • Page 439: Water Pump Cleaning And Inspection

    Water Pump Cleaning and Inspection 1. Inspect the water tube coupling for wear or dam- age. If necessary replace.. Water Tube Coupling 2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller blades. Re- place the impeller if this condition is found.

  • Page 440: Problem Diagnosis

    Problem Diagnosis Condition Recommended Range Possible Cause Pressure below specification @ 1.0 – 3.0 PSI (6.8 – 20.5 kPa) Poppet valve spring defective idle (weak, broken, missing) Defective poppet valve seal Thermostat stuck open Severe internal leak Low output water pump Inlet restriction Pressure above 5 psi (34.2kPa) 1.0 –...
  • Page 441 MID-SECTION CLAMP/SWIVEL BRACKET AND DRIVESHAFT HOUSING...
  • Page 442 Table of Contents Page Notes: ........5A-1 Swivel Bracket and Steering Arm .

  • Page 443: Notes

    Notes: 90-824052R3 JUNE 2002 MID-SECTION - 5A-1...

  • Page 444: Swivel Bracket And Steering Arm

    Swivel Bracket and Steering Arm Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 5A-2 - MID-SECTION 90-824052R3 JUNE 2002...
  • Page 445 Swivel Bracket and Steering Arm TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SWIVEL BRACKET ASSEMBLY OIL SEAL (LOWER) BUSHING SPACER O-RING GREASE FITTING BUSHING THRUST WASHER SCREW MOUNT (135/150/175LONG)(JET) MOUNT (ALL OTHER MODELS) WASHER WASHER 68.0 STEERING LINK ASSEMBLY SCREW 27.0 WASHER...

  • Page 446: Transom Brackets (S/N-0G590000

    Transom Brackets (S/N-0G589999 & BELOW) 2-4-C With Teflon (92-825407A12) 5A-4 - MID-SECTION 90-824052R3 JUNE 2002...
  • Page 447 Transom Brackets (S/N-0G589999 & BELOW) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TRANSOM BRACKET (STARBOARD) TRANSOM BRACKET (PORT) GREASE FITTING (PORT) JAM NUT TILT TUBE NUT (1 -14) O-RING WAVE WASHER NUT (7/8-14) BOLT WASHER TILT LOCK LEVER ASSEMBLY WAVE WASHER BUSHING KNOB...
  • Page 448 Transom Brackets (S/N-0G590000 & UP) 2-4-C With Teflon (92-825407A12) 5A-6 - MID-SECTION 90-824052R3 JUNE 2002...
  • Page 449 Transom Brackets (S/N-0G590000 & UP) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TRANSOM BRACKET (BLACK) STARBOARD TRANSOM BRACKET (GRAY) TRANSOM BRACKET (BLACK) PORT TRANSOM BRACKET (GRAY) GREASE FITTING (PORT) TILT TUBE NUT (1 IN.-14) 61.0 O-RING WAVE WASHER NUT (7/8-14) 61.0 BOLT...

  • Page 450: Drive Shaft Housing And Exhaust Tube

    Drive Shaft Housing and Exhaust Tube Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) 2-4-C With Teflon (92-825407A12) 5A-8 - MID-SECTION 90-824052R3 JUNE 2002...
  • Page 451 Drive Shaft Housing and Exhaust Tube TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m DRIVE SHAFT HOUSING STUD SCREW GROUND WIRE LOWER MOUNT (135/150/175 LONG)(JET) WASHER GROUND WIRE SCREW WASHER 68.0 CLAMP SCREW (1-1/4 ) 17.5 COVER SCREW (5/8 ) 17.5 WASHER 74.5...

  • Page 452: Drive Shaft Housing And Dyna-Float Suspension

    Drive Shaft Housing and SHIFT LINKAGE ASSEMBLY Dyna-Float Suspension Refer to “Powerhead Removal” Section to Remove Powerhead. Refer to “Lower Unit Removal” in This Section to Remove Lower Unit. Removal and Disassembly 1. Remove shift shaft from driveshaft housing by pulling straight up on shaft.
  • Page 453 5. Lift driveshaft housing plate off housing. 8. Pull exhaust tube out of drive shaft housing. 51850 51850 a - Drive Shaft Housing Plate a - Exhaust Tube b - Drive Shaft Housing b - Drive Shaft Housing 6. Remove water tube from driveshaft housing 9.

  • Page 454: Reassembly And Installation

    12. Remove lower mount nuts. 3. Push exhaust tube boots onto tabs on each side of exhaust tube. 4. Position exhaust tube in drive shaft housing and push down on tube until boots rest in grooves on inside of housing. 5.
  • Page 455 7. Apply a small amount of 2-4-C w/Teflon Marine 14. Insert a mounting bolt thru the short end of each Lubricant onto water tube seal. lower mount. 8. Install water tube seal into driveshaft housing 15. Position a mount on each lower side of driveshaft plate with plastic end of seal facing up and install housing.
  • Page 456 22. Install lower mount retainers and secure each 24. Install exhaust extension plate on driveshaft retainer with 2 bolts. (Secure ground strap with housing with shift shaft assembly. Secure exten- the nearest retainer bolt.) Torque bolts to 160 sion plate to drive shaft housing with 5 bolts. Ib.
  • Page 457 MID-SECTION POWER TRIM SQUARE MOTOR AND ROUND MOTOR DESIGN...
  • Page 458 Table of Contents Page Page Power Trim Specifications ....5B-1 Installation ......5B-16 Special Tools .

  • Page 459: Power Trim Specifications

    Power Trim Specifications 5. Adaptor Fitting 91-82278A2 and 91-82278A3 NOTE: Maximum acceptable amount of leak down in 24 hours is 1 in. (25.4 mm) Test Reading Trim “UP” 1300 PSI (91kg/cm Maximum Pressure 54458 Trim “DOWN” 500 PSI (35kg/cm Minimum Pressure 6.

  • Page 460: Power Trim Components

    Power Trim Components Loctite 271 (92-809820) Anti-Corrosion Grease (92-78376A6) GM Silicone Sealer (92-91600-1) Power Trim & Steering Fluid (92-90100A12) 5B-2 - MID-SECTION 90-824052R3 JUNE 2002...
  • Page 461 Power Trim Components TORQUE REF. QTY. DESCRIPTION lb-in lb-ft – POWER TRIM ASSEMBLY–Complete MANIFOLD ASSEMBLY PIPE PLUG TILT CYLINDER ASSEMBLY PISTON ROD GUIDE KIT REPAIR KIT CHECK VALVE KIT GUIDE ASSEMBLY PISTON/ROD ASSEMBLY (PORT) PISTON/ROD ASSEMBLY (STBD.) TRIM FILTER ASSEMBLY VALVE ASSEMBLY E RING O RING KIT...

  • Page 462: Power Trim Motor

    Power Trim Motor TORQUE REF. QTY. DESCRIPTION lb.in. lb.ft. N·m – POWER TRIM MOTOR BRUSH AND SEAL KIT ARMATURE KIT END FRAME (Complete) 5B-4 - MID-SECTION 90-824052R3 JUNE 2002...

  • Page 463: Power Trim - General Information

    Power Trim - General The “Up” circuit actuates the up solenoid (under outboard cowl) and closes the motor circuit. The Information electric motor drives the pump, forcing fluid thru passageways into the up side of the trim cylinders. The trim cylinders position the outboard at the Description desired trim angle in the 20 degree maximum trim range.

  • Page 464: Tilting Outboard Manually

    Tilting Outboard Manually IMPORTANT: Some boat/motor combinations not using the trim angle adjustment pin (a) and trimmed to the full “In” trim angle position may WARNING not exhibit any undesirable and/or unsafe handling and/or steering characteristics at Before opening the manual release valve knob, planing speed.

  • Page 465: Anode Plate

    NOTE: Automatic Transmission Fluid (ATF) Type F, Anode Plate FA, Dexron II or Dexron III may be used. Anode plate is a self-sacrificing alloy plate that is consumed gradually by corrosion while providing protection to the midsection and power trim from galvanic corrosion.

  • Page 466: Troubleshooting

    IMPORTANT: Run Trim System in short “jogs” Troubleshooting until pump is primed and trim system moves. If IMPORTANT: Determine if Electrical or Hydraulic trim motor is run without priming pump, drive- problem exists. shaft failure could result. IMPORTANT: Acceptable power trim leak down Cycle outboard through entire trim/tilt range 4 times.
  • Page 467 ELECTRICAL SYSTEM TROUBLESHOOTING If the motor will not run in the UP direction, it could be CONDITION OF TRIM SYSTEM PROBLEM either the UP relay is not making contact to 12 volts A. Trim motor does not run when 1, 2, 4, 5, OR the DOWN relay is not making contact to ground.

  • Page 468: Power Trim System With Relays And 2 Wire Trim Motor

    Power Trim System with Relays and 2 Wire Trim Motor 53794 UP Relay DOWN Relay BLK = Black BLU = Blue GRN = Green RED = Red WHT = White 5B-10 - MID-SECTION 90-824052R3 JUNE 2002...

  • Page 469: Electrical System Troubleshooting

    Electrical System 3. Check that plug-in connectors are fully engaged. 4. Make certain battery is fully charged. Troubleshooting Refer to the preceding wiring diagrams for connection points when troubleshooting electrical systems (Connection points are specified General Checks by number.) Before troubleshooting the Power Trim electrical system, check the following: 1.

  • Page 470: Troubleshooting The "Up" Circuit

    Troubleshooting the “Up” Circuit Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. No Voltage Indicated: Battery Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 7 and black lead to ground. Point 9.

  • Page 471: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)

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

  • Page 472: Power Trim Assembly Removal And Installation

    Power Trim Assembly Removal and Installation Removal 1. Remove clamps on transom bracket to free power trim wiring. 2. Raise outboard to full “Up” position and engage tilt lock lever. 51346 a - Tilt Lock Lever b - Support Tool c - Retaining Clips IMPORTANT: Support outboard as shown above to prevent engine from tipping when power trim...
  • Page 473 IMPORTANT: Outboards equipped with thru-the- 6. Remove 3 screws and washers and move star- tilt-tube steering - remove steering link arm from board transom bracket. end of steering cable and cable retaining nut from tilt tube. 51375 51339 51375 a - Transom Mount Bolts (2) b - Tilt Tube Nut (flush with end of thread) 51354 c - Screws (3)

  • Page 474: Installation

    7. Drive out cross pin, push out upper swivel pin, and remove 3 screws and washers retaining trim system. Remove system from outboard. 51375 51339 a - Cross Pin b - Upper Swivel Pin a - Screw (6) Torque to 40 lb. ft. (54.0 N·m) c - Port Transom Bracket Screws and Washers (3).

  • Page 475: Testing Power Trim System With Test Gauge Kit (91-52915A6)

    NOTE: The 2 power leads going to the trim motor should be encapsulated with conduit tubing. If tubing has not been previously installed, order 32-828547-353 and cut to appropriate length. 56921 56922 a - Conduit Tubing 7. Apply marine sealer to shanks of mount bolts and WARNING install transom mount bolts.
  • Page 476 NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suitable contain- er under trim assembly to collect any leakage. NOTE: Assemble test adaptor by using O-ring instal- lation tool to position small O-ring onto adaptor 1st, then install medium O-ring and lastly large O-ring.

  • Page 477: Down" Pressure Check

    6. Reinstall fill plug. 15. Reinstall Manual Release Valve and secure valve with circlip. 7. Disengage tilt lock lever. 16. Retighten “Fill” plug. CAUTION NOTE: If pressure is less than 1300 PSI (91 kg/cm troubleshoot system per instructions on page 5B-11. Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could result in transom bracket failure and possible injury.
  • Page 478 4. Install test adaptor 91-822778A3 into manual release valve hole. 54458 a - Test Adaptor (91-822778A3) 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 a - Brass Fitting b - Test Gauge Assembly c - Tilt Pin (Position in Hole Shown) d - Hose e - Hose (Not Used) f - OPEN Valve...

  • Page 479: Hydraulic Repair

    Hydraulic Repair 5. Install trim rod removal tool and pull trim rod from cylinder. TRIM ROD REMOVAL AND REPAIR NOTE: Power Trim does not have to be removed from outboard to remove trim rods. 1. Tilt outboard to full “UP” position and engage tilt lock lever.

  • Page 480: Trim Rod End Cap Seal

    Trim Rod End Cap Seal 1. Apply Quicksilver Power Trim and Steering Fluid on all O-rings and seals before installation. 1. Inspect trim cap end seal and replace if damaged 2. Install trim rods and caps. Use installation tool or if seal does not keep trim rod clean. (91-44487A1) or spanner wrench (91-74951) to tighten caps securely.

  • Page 481: Disassembly

    TILT RAM REMOVAL - POWER TRIM 91-74951 SYSTEM REMOVED FROM OUTBOARD CAUTION Insure trim system is depressurized prior to tilt ram removal. 1. Remove cross pin. 51337 2. Remove lower swivel pin. 51364 a - Cap (Turn Counterclockwise to Remove) b - Spanner Wrench (91-74951) c - Tilt Rod - Pull to Remove 2.
  • Page 482 IMPORTANT: Note Design 1 and 2 on page 5B-22. IMPORTANT: Remove plug from same side as Design 1 tilt rod assembly replaces either tilt rod holes in shaft. assembly. Either design will fit as a (replace) cyl- inder assembly complete. Design 2 will NOT fit a cylinder originally using a Design 1 tilt rod assembly.

  • Page 483: Scraper Seal Replacement

    7. Tap shaft into cylinder until shaft is positioned as Scraper Seal Replacement shown. 1. Remove components from end cap. 51365 a - Cap WARNING b - O-ring (2) c - Scraper Seal d - Washer Memory Piston Cup may be expelled at a high e - Retaining Ring velocity when air pressure is applied.
  • Page 484 3. Assemble end cap. 5. Install components on rod. 4. Install end cap. 51363 51340 a - Piston b - O-ring c - Check Valve Assembly (7) d - Washer e - Bolt or Locknut. (Tighten securely) 51376 a - End Cap 6.

  • Page 485: Motor And Electrical Tests/Repair

    TILT RAM ASSEMBLY INSTALLATION 4. Drive pin in until flush. 1. Lubricate alignment tool (91-11230) and shaft. Use Quicksilver Power Trim and Steering Fluid. 51356 a - Pin (Drive Against Knurled End) 51369 a - Alignment Tool (91-11230) Motor and Electrical b - Shaft Tests/Repair 2.

  • Page 486: Motor Disassembly

    1. Connect a 12 volt power supply to motor wires; 2. Remove frame and armature from end cap. Use one motor lead to POSITIVE (+) battery terminal care not to drop armature. and the other motor lead to the NEGATIVE (–) battery terminal.

  • Page 487: Motor Repair

    2. Clean commutator with “OO” sandpaper. FIELD TESTS IMPORTANT: Commutator end of armature must be installed in brushes when performing the following tests. Ohmmeter Resistance Scale Reading* Leads Between (Ohms) (x____________) BLUE and BLACK (Rx1) Motor Wires 53775 BLACK Motor Wire, and Frame No Continuity (Rx1)
  • Page 488 CLEANING AND INSPECTION Inspect O-rings and replace if necessary. Carefully inspect power cord for cuts or tears which will allow water to enter motor. Replace cord if cut or torn. Clean, inspect, and test motor components. Refer to “Brush Replacement”, “Armature Test”, and “Field Tests” for inspection and test procedures. 53779 a - Frame b - Armature...
  • Page 489 8. Secure brush card to end cap with 2 screws and 2. Inspect bushing for wear. If bushing appears to lockwashers. be excessively worn – grooves, scratches, etc. – install END FRAME ASSEMBLY (COMPLETE) 9. Inspect O-ring for cuts and abraisions. Replace 828715A1.

  • Page 490: Reassembly

    3. If trim motor is overheated, a thermoswitch lo- 1. Install armature into end cap/brush card cated under brush card will open. Normally, this assembly. switch will reset itself within 1 minute. 53781 a - Thermoswitch 53779 Reassembly IMPORTANT: Components must be clean. Any debris in power trim system can cause system to malfunction.

  • Page 491: Reassembly - Motor And Pump

    2. Install O-rings in end cap. 6. Secure frame assembly to end cap with 2 screws. 53784 53776 a - Vise Grip Pliers b - Armature Shaft c - O-ring d - End Cap e - Harness Retainer 53783 f - Retainer Hole g - O-ring a - O-rings h - Frame Assembly...

  • Page 492: Priming Power Trim System

    NOTE: Verify motor and drive shaft are aligned. IMPORTANT: Install pump with location flat facing towards starboard transom bracket. 53782 51433 a - Pump (Flat Towards Starboard Transom Bracket) b - Flat - Faces Starboard Transom Bracket) c - O-rings (4) d - Drive Shaft (Install in Center Hole in Pump) 2.

  • Page 493: Trim Sender Test

    Trim Sender Test 5. Tighten trim sender screws. 1. Check trim sender BLACK lead for proper ground. 2. Trim outboard to full “DOWN” position. 3. Place ignition switch to “ON” position. 4. Disconnect BRN/WHT trim sender wire from trim sender harness. 5.

  • Page 494: Trim Indicator Wiring Diagrams

    Trim Indicator Wiring Diagrams Wiring Diagram - For boats equipped with Quicksilver Commander Series side mount remote control. Wiring Diagram - For boats equipped with Quicksilver Ignition/Choke and Main Harness Assembly. 22908 a - Trim Indicator b - Remote Control c - Trim Sender d - Engine Ground e - To Engine...

  • Page 495: Lower Unit

    LOWER UNIT E-Z SHIFT GEAR HOUSING (STANDARD ROTATION)
  • Page 496 Table of Contents Page Page Gear Housing Specifications Clutch Actuator Rod ....6A-34 (Standard Rotation) ..... 6A-1 Cleaning/Inspection .

  • Page 497: Pinion Depth

    Gear Housing Specifications FORWARD GEAR BACKLASH (Standard Rotation) Gear Case & Backlash Dial Indicator Ratio Inches (mm) Pointer on Line Mark PINION DEPTH Production .018-.027 Gear Case Pinion Depth 1.87:1 (.46-.69) 91-78473 1.87:1 (15/28 teeth) 0.025 in. (0.635mm) CLE/Torque .021-.026 and 2.00:1 With Tool 91-12349A2 Master/Sport...
  • Page 498 Shift Shaft Bushing Tool 91-31107 Bearing Removal and Installation Kit 91-31229A5. This kit contains the following tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plate 91-29310; Mandrel 91-38628; and Driver Rod 91-37323. 73658 Gear Housing Cover Nut Tool 91-61069 73605 70615 Bearing Carrier Removal Tool 91-46086A1 and...
  • Page 499 Pilot 91-36571 Cross Pin Tool 91-86642 Driveshaft Holding Tool 91-34377A1 74187 Puller Rod 91-31229 and Nut 91-24156 Puller Plate 91-29310 55079 Oil Seal Driver 91-31108 74190 Mandrel 91-38628 73651 Forward Gear Bearing Tool 91-86943 74193 Driver Rod 91–37323 74184 Universal Puller Plate 91-37241 73652 90-824052R3 JUNE 2002 LOWER UNIT - 6A-3...
  • Page 500 Bearing Driver Cup 91-87120 Backlash Indicator Rod 91-78473 Dial Indicator 91-58222A1 Pinion Locating Gear Tool 91-12349A2 or 91-74776 73429 Bearing Retainer Tool 91-43506 55079 73600 Backlash Indicator Rod 91-19660 6A-4 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 501 Bearing Preload Tool 91-14311A1 Seal Driver 91-816294 Slotted Cross Pin Tool 91-86642-1 a - Adaptor (N.S.S.) b - Bearing (N.S.S.) Threaded Cross Pin Tool 91-86642-2 c - Washer (N.S.S.) d - Spring (24-14111) e - Bolt (10-12580) f - Nut (11-13953) g - Set Screw (10-12575) h - Sleeve (23-13946) Mandrel 91-92788...
  • Page 502 Gear Housing (Drive Shaft) (Standard Rotation) (S/N-0G437999 & BELOW) 1647– 9147–C1 Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6A-6 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 503 Gear Housing (Driveshaft) (Standard Rotation) (S/N-0G437999 & BELOW) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CONNECTOR ASSEMBLY TUBING CONNECTOR DOWEL PIN STUD (3-1/8 IN.) (LONG) STUD (3-11/16 IN.) (X-LONG) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/8 IN.) FILLER BLOCK ROLLER BEARING ANODE...

  • Page 504: (S/N-0G437999 & Below)

    Gear Housing (Prop Shaft) (Standard Rotation) (S/N-0G437999 & BELOW) 1647– 9147–C1 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6A-8 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 505 Gear Housing (Prop Shaft) (Standard Rotation) (S/N-0G437999 & BELOW) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CAM FOLLOWER SHIFT CAM ROD ASSEMBLY SPRING WASHER GEAR SET (XR6/MAG. III/175/200)(1.87:1 – 15/28) GEAR SET (135/150)(2.0:1 – 14/28) GEAR SET (HIGH ALTITUDE)(2.3:1) NEEDLE BEARING SHIM (.002–3–5–10) TAPERED ROLLER BEARING...

  • Page 506: Gear Housing (Drive Shaft) (Cle) (Standard Rotation) (Pro Max/Super Magnum Models)

    Gear Housing (Drive Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models) Note Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Perfect Seal (92-34227-1) GM Silicone Sealer (92-91600-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) 6A-10 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 507 Gear Housing (Driveshaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING COVER O-RING SCREW ROLLER BEARING DOWEL PIN STUD (3-1/8 IN.) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/4 IN.) SLEEVE PLUG FILLER BLOCK PINION GEAR...

  • Page 508: Gear Housing (Prop Shaft) (Cle) (Standard Rotation) (Pro Max/Super Magnum Models)

    Gear Housing (Prop Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models) 80 81 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6A-12 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 509 Gear Housing (Prop Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CAM FOLLOWER SHIFT CAM ROD ASSEMBLY SPRING WASHER SHIM TAPERED ROLLER BEARING GEAR SET ROLLER BEARING CLUTCH DETENT PIN CROSS PIN SPRING PROPELLER SHAFT...

  • Page 510: Gear Housing (Drive Shaft) (Standard Rotation) (Torque Master)(Pro Max/Super Magnum Models)

    Gear Housing (Driveshaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models) Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6A-14 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 511 Gear Housing (Driveshaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CONNECTOR ASSEMBLY TUBING CONNECTOR DOWEL PIN STUD (3-1/8 IN.) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/8 IN.) FILLER BLOCK ROLLER BEARING ANODE...

  • Page 512: Gear Housing (Prop Shaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models)

    Gear Housing (Prop Shaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models) Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6A-16 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 513 Gear Housing (Prop Shaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CAM FOLLOWER SHIFT CAM ROD ASSEMBLY SPRING WASHER SHIM (.002–3–5–10) TAPERED ROLLER BEARING GEAR SET ROLLER BEARING CLUTCH CROSS PIN DETENT PIN...

  • Page 514: Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster)

    Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster) Note Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6A-18 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 515 Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (WITH TORQUE TAB) BASIC GEAR HOUSING (WITHOUT TORQUE TAB) COVER O RING SCREW DOWEL PIN ROLLER BEARING FILLER BLOCK PLUG STUD (5/16 x 3-3/8 IN.) STUD (5/16 x 3-1/4 IN.) STUD (7/16 x 2-11/16 IN.)(SHORT/LONG) STUD (7/16 x 3-1/8 IN.)
  • Page 516 Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster) Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6A-20 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 517 Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (WITH TORQUE TAB) BASIC GEAR HOUSING (WITHOUT TORQUE TAB) WATER PUMP BASE ASSEMBLY GASKET O RING OIL SEAL OIL SEAL GASKET (LOWER) GASKET (UPPER) FACE PLATE WATER PUMP BODY ASSEMBLY INSERT...

  • Page 518: Gear Housing (Prop Shaft) (Standard Rotation) (Sportmaster)

    Gear Housing (Prop Shaft) (Standard Rotation) (Sportmaster) Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6A-22 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 519 Gear Housing (Prop Shaft) (Standard Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (WITH TORQUE TAB) BASIC GEAR HOUSING (WITHOUT TORQUE TAB) CAM FOLLOWER SHIFT CAM SPRING WASHER SHIM SET TAPERED ROLLER BEARING FORWARD GEAR SET (Includes Pinion) ROLLER BEARING RATCHET DETENT PIN...

  • Page 520: General Service Recommendations

    General Service When inspecting tapered bearings, determine condition of rollers and inner bearing race by Recommendations inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or There may be more than one way to “disassemble” discoloration from overheating. Always replace or “reassemble”...

  • Page 521: Removal, Disassembly, Cleaning And Inspection - Standard Rotation

    Removal, Disassembly, 5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position. Remove Cleaning and Inspection - plastic cap at rear edge of drive shaft housing, then unthread bolt that secures trim tab and re- Standard Rotation move trim tab from gear housing.

  • Page 522: Draining And Inspecting Gear Housing Lubricant

    8. Remove locknut from the front gear housing 2. Position a clean drain pan under gear housing mounting stud. and remove “Fill” and “Vent” screws from gear housing. 9. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before opposite side is loosened sufficiently, or driveshaft housing could be damaged.) 10.

  • Page 523: Water Pump

    Water Pump 3. Remove (and retain) 3 nuts, one bolt and all washers which secure water pump cover to gear housing. CLEANING AND INSPECTION 1. Clean all water pump parts with solvent and dry with compressed air. 2. Inspect water pump cover and base for cracks and distortion (from overheating).

  • Page 524: Bearing Carrier And Propeller Shaft Removal

    a. Drive water pump insert out of water pump 10. Using 2 pry bars, positioned and padded as cover with a punch and hammer. shown, lift water pump base up and off drive shaft. 51874 51874 a - Pads b. Drill two 3/16 (4.8mm) diameter holes thru the top of water pump cover (but not thru 11.
  • Page 525 IMPORTANT: Prior to removal of shift shaft from CAUTION gear housing, recheck that gear housing is in NEUTRAL position. Once bearing carrier is removed from gear housing, extreme care MUST BE taken not to 3. Bend cover nut lock tab out of cover nut recess. apply any side force on propeller shaft.

  • Page 526: Shift Shaft

    7. With gear housing in NEUTRAL, pull shift shaft a. Push propeller shaft back into place against out of gear housing. If necessary, use a pliers to the forward gear. Visually inspect location of pull shift shaft out of gear housing. If pliers are shift cam by looking down shift shaft hole used to pull shift shaft out, wrap a strip of soft (illuminated with a flashlight).

  • Page 527: Disassembly- Bearing Carrier

    CLEANING/INSPECTION - BEARING CARRIER Use a suitable mandrel and press gear out of bearing. IMPORTANT: It is recommended that all seals and O-rings be replaced (as a normal repair proce- dure) to assure effective repair. 1. Clean bearing carrier assembly with solvent and dry with compressed air.

  • Page 528: Propeller Shaft

    4. If inspection of propeller shaft needle bearing 4. Inspect propeller shaft splines for wear and/or determines that replacement of bearing is corrosion damage. required, use Universal Bearing Removal and 5. Check propeller shaft for straightness. Use either Installation Tool (91-31229A1) to press bearing method, following: and seals out of bearing carrier.
  • Page 529 c. Engine idle speed too high (while shifting). 4. Detent pins are free and can be removed from sliding clutch at this time. 51864 51865 a - Detent Pins a - Clutch “Jaws” b - Cross Pin c - Sliding Clutch 7.

  • Page 530: Disassembly (Std. Gear Cases)

    6. Pull sliding clutch off propeller shaft. 6. If disassembly is performed on clutch actuator rod, spring length must be 1.535 to 1.560 7. Pull cam follower and clutch actuator rod out of 1-17/32 to 1-9/16 (38.9mm to 39.7mm). propeller shaft. DO NOT force cam follower up-or-down or side-to-side when pulling from propeller shaft.

  • Page 531: Pinion Gear And Drive Shaft

    DISASSEMBLY (HI-PERFORMANCE GEAR 2. Place Driveshaft Holding Tool (91-34377A1) over CASES) drive shaft splines. IMPORTANT: Keep a record of shim amounts and 3. Use a socket and flex handle to hold pinion nut. location during disassembly of clutch actuator (Pad area of gear housing where flex handle will rod to aid in reassembly.
  • Page 532 9. If necessary, carefully use a slide hammer a. Position driveshaft in a vise; DO NOT tighten (91-34569A1) to remove lubrication sleeve (if vise jaws against shaft. equipped) from gear housing. b. Strike shaft with a lead hammer; take care not to drop shaft.

  • Page 533: Forward Gear

    13. Remove 18 loose needles from outer race of 3. Inspect driveshaft needle bearing surface (area driveshaft needle bearing. just above pinion gear splines) for pitting, grooves, scoring, uneven wear and/or discolor- 14. If inspection of driveshaft needle bearing surface ation from overheating.

  • Page 534: Gear Housing

    b. Place forward gear, bearing and puller plate CLEANING AND INSPECTION on a press and press gear out of bearing with CAUTION a suitable mandrel. DO NOT spin bearings dry with compressed air, as this could cause bearing to score. 1.

  • Page 535: Reassembly And Installation Standard Rotation

    Reassembly and Installation Bearing Carrier Standard Rotation REASSEMBLY Driveshaft Needle Bearing 1. Place reverse gear on a press with gear teeth facing down. REASSEMBLY/INSTALLATION IMPORTANT: The reverse gear thrust washer has a tapered outside diameter so that one side is CAUTION larger than the other.
  • Page 536 8. Use Mandrel 91-15755 and press needle bearing 12. Place second seal on short shoulder side of seal into bearing carrier. driver with lip of seal toward shoulder. Press seal into bearing carrier until seal driver bottoms against bearing carrier. 51872 a - Mandrel (91-15755) 51872...

  • Page 537: Forward Gear

    16. Place O-ring over bearing carrier and position it 6. Place one forward gear needle bearing on longer between bearing carrier and thrust washer. shoulder side of Forward Gear Bearing Tool (91-86943) with numbered side of bearing 17. Lubricate oil seals and O-ring with Quicksilver toward shoulder.

  • Page 538: Driveshaft And Pinion Gear

    5. Place propeller shaft into hole in center of bearing 2. Thread a used pinion nut onto end of drive shaft. driver cup. Leave approximately 1/16 (2mm) of nut threads exposed. Drive shaft threads MUST NOT extend 6. Install bearing carrier assembly over propeller beyond nut or thread damage could result while shaft and lower it into gear housing.
  • Page 539 5. Position lubrication sleeve (if equipped) in drive- 7. Position pinion gear in gear housing below drive- shaft bore. shaft bore with teeth of pinion gear meshed with teeth of forward gear. 8. Insert drive shaft into drive shaft bore while holding pinion gear.
  • Page 540 11. Install bearing race and bearing retainer. 13. Place Driveshaft Holding Tool (91-34377A1) over crankshaft end of driveshaft. Torque pinion nut to 75 lb. ft. (101.5 N·m) on standard gear cases. Torque pinion nut on CLE, Torque Master and Sportmaster to 85 lb. ft. (115 N 51880 a - Driveshaft Holding Tool (91-34377A1) b - Torque Wrench;...
  • Page 541 NOTE: Bearing Preload Tool (91-44307A1) may also 5. Measure distance (a) and increase that distance be used. Follow instructions provided with tool for by 1 (25.4mm) by turning bottom nut away from proper installation. top nut. 1 in. (25.4mm) a - Adaptor b - Bearing c - Washer d - Spring...
  • Page 542 10. If clearance is correct, leave Bearing Preload 3. Attach Bearing Carrier Removal Tool Tool on drive shaft and proceed to “Determining (91-46086A1) and Puller Bolt (91-85716) onto Forward Gear Backlash,” following. gear housing. 11. If clearance is not correct, add (or subtract) shims 4.

  • Page 543: Play (Sport Master)

    8. Lightly turn driveshaft back-and-forth (no move- 5. Secure pipe against carrier with propeller nut and ment should be noticed at propeller shaft). tab washer. 9. Backlash specifications: Gear Case & Backlash Dial Indicator Ratio Inches (mm) Pointer on Line Mark Production .018-.027 1.87:1...
  • Page 544 3. Place Driveshaft Holding Tool (91-34377A1) over 6. Install the upper drive shaft bearing cup and crankshaft end of drive shaft. Use a socket and install and torque the upper bearing retainer to breaker bar to hold pinion nut and remove the 100 lb.

  • Page 545: Clutch Actuator Rod

    NOTE: If forward gear backlash has not yet been 8. Move driveshaft up and down to determine end play. Total up and down movement should be determined, do not use a new pinion nut until final 0.00 to 0.001 (0.025mm). There should be no assembly.

  • Page 546: Reassembly/Shimming (High-Performance Gear Cases)

    REASSEMBLY/SHIMMING 5. If measurements ( X and Y ) taken in Step 4 are (HIGH-PERFORMANCE GEAR CASES CLE, not equal to within 1/64 , remove retaining pin TORQUE MASTER, & SPORT MASTER.) and re-shim compression spring, to obtain the measurement needed. If shims are required, 1.
  • Page 547 NOTE: Pro Max and Super Magnum models use a 2. On PRODUCTION MODEL GEAR CASES, position sliding clutch onto propeller shaft with slotted cross pin 91-86642-1 and Cross Pin Handle GROOVED RINGS (ON SLIDING CLUTCH) 91-86642-2 to assemble clutch onto propshaft. Turn handle COUNTERCLOCKWISE to install cross pin.
  • Page 548 (3.) Position spring in groove so that straight 10. With shift cam positioned as shown, insert end of spring is against the side of groove propeller shaft thru forward gear until shaft and not over-lapping the first spring. bottoms out. 51864 a - The Line of “Sight”...

  • Page 549: Water Pump

    12. Apply a light coat of Quicksilver 2-4-C w/Teflon bolted to a driveshaft housing to avoid possible Marine Lubricant to threads of shift shaft bushing. damage to the gear case. (Thread bushing into position, but do not tighten 20. Start cover nut a few turns by hand, then using down at this time.) Cover Nut Tool (91-61069) and torque wrench, torque cover nut to 210 Ib.
  • Page 550 b. Just before installing each seal apply Loctite 4. Install a new water pump base gasket and install 271 on outside diameter of oil seal. water pump base. c. With a suitable mandrel, press the smaller diameter oil seal into pump base with lip of oil seal toward impeller side of base.

  • Page 551: Gear Lubricant Filling Instructions

    15. Install centrifugal slinger over drive shaft and CAUTION down against pump cover. A visual inspection of impeller drive key MUST BE made to determine that drive key is on flat of driveshaft after impeller is installed. If key has moved off flat of driveshaft, repeat Steps 6 and 7.

  • Page 552: Installing Gear Housing To Drive Shaft Housing

    Installing Gear Housing to Drive 8. Move gear housing up toward driveshaft housing, while aligning shift shaft splines and Shaft Housing water tube with water tube guide (in water pump cover). WARNING 9. Place flat washers onto studs (located on either Disconnect high tension leads from spark plugs side of driveshaft housing).

  • Page 553: Propeller Installation

    Propeller Installation 8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller nut. (If tab washer tabs do not align with slots, continue to WARNING tighten propeller nut to obtain alignment. DO When installing or removing propeller, because NOT loosen nut to align tabs.) of the engine’s ease in starting, be sure that the...
  • Page 555 LOWER UNIT COUNTER ROTATING (LEFT HAND) GEAR CASE...
  • Page 556 Table of Contents Page Page Gear Housing Specifications Reassembly and Installation of Counter (Counter Rotation) ..... . 6B-1 Rotation Gear Housing .
  • Page 557 Gear Housing Specifications Gear Housing Cover Nut Tool 91-61069 (Counter Rotation) PINION DEPTH Gear Case Pinion Depth All Ratios 0.025 in. (0.635mm) With Tool 91-12349A2 using Disc #2 and Flat #7 73605 REVERSE GEAR BACKLASH Bearing Carrier Removal Tool 91-46086A1 and Gear Case Reverse Gear Puller Bolt 91-85716...
  • Page 558 Pilot 91-36571 Universal Puller Plate 91-37241 74187 Puller Rod 91-31229 and Nut 91-24156 73652 Cross Pin Tool 91-86642 Puller Plate 91-29310 Driveshaft Holding Tool 91-34377A1 74190 Mandrel 91-38628 55079 Oil Seal Driver 91-31108 74193 Driver Rod 91-37323 73651 Forward Gear Bearing Tool 91-86943 74184 6B-2 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 559 Bearing Driver Cup 91-87120 Backlash Indicator Rod 91-78473 Dial Indicator 91-58222A1 Pinion Locating Gear Tool 91-12349A2 or 91-74776 73429 Bearing Retainer Tool 91-43506 73600 Mandrel 91-92788 55079 90-824052R3 JUNE 2002 LOWER UNIT - 6B-3...
  • Page 560 Dial Indicator Holder 91-89897 Propeller Shaft 44-93003 and Load Washer(a) 12-37429 51876 Bearing Cup Driver 91-34379 Bearing Preload Tool 91-14311A1 73659 Bearing Installation Tool 91-18601 a - Adaptor (N.S.S.) b - Bearing (N.S.S.) c - Washer (N.S.S.) d - Spring (24-14111) Reverse Gear Installation Kit 91-18605A1 includes e - Bolt (10-12580) Pilot 91-18603;...
  • Page 561 Retainer 91-18604 Threaded Cross Pin Tool 91-86642-2 Shaft 91-18605 Mandrel 91-15755 Screw 10-18602 73815 Mandrel 91-31106 Seal Driver 91-816294 Slotted Cross Pin Tool 91-86642-1 Propeller Shaft Bearing Installer 91-816292 90-824052R3 JUNE 2002 LOWER UNIT - 6B-5...
  • Page 562 Gear Housing (Driveshaft) (Counter Rotation) (S/N-0G437999 & BELOW) 1647– 9147–C1 Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6B-6 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 563 Gear Housing (Driveshaft) (Counter Rotation) (S/N-0G437999 & BELOW) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BLACK)(BASIC) GEAR HOUSING (GRAY)(BASIC) CONNECTOR ASSEMBLY TUBING CONNECTOR DOWEL PIN STUD (3-11/16 IN.) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/8 IN.) FILLER BLOCK ROLLER BEARING ANODE...

  • Page 564: Gear Housing (Prop Shaft)(Counter Rotation) (S/N-0G437999 & Below)

    Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G437999 & BELOW) 1647– 9147–C1 Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) Anti-Corrosion Grease (92-78376A6) Super Duty Gear Lubricant (92-13783A24) 6B-8 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 565 Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G437999 & BELOW) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BASIC–BLACK) GEAR HOUSING (BASIC–GRAY) CAM FOLLOWER SHIFT CAM SPRING WASHER BEARING CUP BALL BEARING REVERSE GEAR (PART OF 43-18572A1 or 43-18475A1) ROLLER BEARING CLUTCH DETENT PIN...
  • Page 566 Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G437999 & BELOW) 1647– 9147–C1 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6B-10 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 567 Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G437999 & BELOW) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BASIC–BLACK) GEAR HOUSING (BASIC–GRAY) ROLLER BEARING THRUST RING O RING BEARING ADAPTOR ROLLER BEARING THRUST WASHER THRUST BEARING PROPELLER SHAFT BEARING CARRIER ASSEMBLY ROLLER BEARING OIL SEAL (INSIDE)

  • Page 568: Gear Housing (Driveshaft)(Counter Rotation) (Sportmaster)

    Gear Housing (Driveshaft) (Counter Rotation) (Sportmaster) Note Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Super Duty Gear Lubricant (92-13783A24) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6B-12 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 569 Gear Housing (Driveshaft)(Counter Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BASIC) COVER O RING SCREW Drive Tight DOWEL PIN ROLLER BEARING FILLER BLOCK PLUG (See Note Below) STUD (5/16 x 3-3/8 IN.) STUD (5/16 x 3-1/4 IN.) STUD (7/16 x 2-11/16 IN.)(SHORT/LONG) STUD (7/16 x 3-1/8 IN.) LONG...
  • Page 570 Gear Housing (Driveshaft) (Counter Rotation) (Sportmaster) Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Super Duty Gear Lubricant (92-13783A24) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6B-14 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 571 Gear Housing (Driveshaft) (Counter Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BASIC) WATER PUMP BASE ASSEMBLY GASKET O RING OIL SEAL OIL SEAL GASKET (LOWER) GASKET (UPPER) FACE PLATE WATER PUMP BODY ASSEMBLY INSERT SEAL SLEEVE IMPELLER...

  • Page 572: Gear Housing (Prop Shaft)(Counter Rotation) (Sportmaster)

    Gear Housing (Prop Shaft) (Counter Rotation) (Sportmaster) 78 79 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6B-16 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 573 Gear Housing (Prop Shaft) (Counter Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BASIC) CAM FOLLOWER SHIFT CAM SPRING WASHER BEARING CUP BALL BEARING REVERSE GEAR (Part of 43-15845A2)(1.87:1 GEAR RATIO) REVERSE GEAR (2:1 GEAR RATIO) ROLLER BEARING RATCHET DETENT PIN...
  • Page 574 Gear Housing (Prop Shaft) (Counter Rotation) (Sportmaster) 78 79 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6B-18 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 575 Gear Housing (Prop Shaft) (Counter Rotation) (Sportmaster) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BASIC) ROLLER BEARING THRUST RING O RING BEARING ADAPTOR ROLLER BEARING THRUST BEARING PROPELLER SHAFT BEARING CARRIER ROLLER BEARING OIL SEAL SNAP RING MAGNETIC DRAIN SCREW SEALING WASHER TAB WASHER...

  • Page 576: General Service Recommendations

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

  • Page 577: Removal, Disassembly, Cleaning And Inspection Of Counter Rotation (Left Hand) Gear Housing

    Removal, Disassembly, 4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller locknut, Cleaning and Inspection of tab washer, thrust hub (rear), propeller and thrust hub (forward) from propeller shaft. Counter Rotation (Left Hand) Gear Housing REMOVAL WARNING Disconnect high tension leads from spark plugs...

  • Page 578: Draining And Inspecting Gear Housing Lubricant

    7. Remove 2 locknuts from bottom middle of anti- DRAINING AND INSPECTING GEAR HOUSING cavitation plate. LUBRICANT 1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical position, as shown. 2. Position a clean drain pan under gear housing and remove “Fill”...

  • Page 579: Water Pump

    Water Pump 3. Remove (and retain) 3 nuts, one bolt and all washers which secure water pump cover to gear housing. CLEANING AND INSPECTION 1. Clean all water pump parts with solvent and dry with compressed air. 2. Inspect water pump cover and base for cracks and distortion (from overheating).

  • Page 580: Bearing Carrier And Propeller Shaft Removal

    a. Drive water pump insert out of water pump 10. Using 2 pry bars, positioned and padded as cover with a punch and hammer. shown, lift water pump base up and off driveshaft. 51874 a - Pads 11. Remove (and discard) O-ring from O-ring groove on water pump base.
  • Page 581 3. Bend cover nut lock tab out of cover nut recess. CAUTION Once bearing carrier is removed from gear hous- ing, extreme care MUST BE taken not to apply any side force on propeller shaft. Side force on propeller shaft may break the neck of the clutch actuator rod.
  • Page 582 NOTE: Sliding clutch, forward gear assembly, bear- 7. With gear housing in neutral, pull shift shaft out of gear housing. If necessary, use a pliers to pull ing adaptor, thrust washer and thrust bearings will be shift shaft out of gear housing. If pliers are used removed from gearcase with propeller shaft.

  • Page 583: Shift Shaft

    Shift Shaft DISASSEMBLY- BEARING CARRIER 1. Remove thrust bearing and thrust washer (not CLEANING AND INSPECTION used in Sport Master gear case) from bearing carrier. 1. Clean shift shaft and bushing with solvent and dry with compressed air. 2. Check shift shaft splines on both ends for wear and/or corrosion damage.

  • Page 584: Propeller Shaft

    NOTE: Do not remove bearing carrier needle bearing Balance Wheels unless replacement is needed. Place propeller shaft on balance wheels, as shown. 4. Use bearing removal and replacement tool Rotate propeller shaft and observe propeller end of (91-31229A5) or equivalent to press bearings out shaft for “wobble.”...
  • Page 585 NOTE: Sport Master gear cases use a threaded 3. Remove the second cross pin retainer spring from sliding clutch in the same way as in Step 2. cross pin. Use Cross Pin Tool 91-86642-2 to remove cross pin. Turn tool CLOCKWISE to remove CAUTION threaded cross pin.

  • Page 586: Clutch Actuator Rod

    9. Once cam follower and clutch actuator rod are 1. Clean clutch actuator rod in solvent and dry with removed from propeller shaft, lift rod out of cam compressed air. follower. 2. Insert Cross Pin Tool (91-86642) between com- pression springs in elongated slot in clutch rod. 3.

  • Page 587: Forward Gear And Bearing Adapter

    2. After locating pin is removed, compression 5. Remove thrust bearing and spacer shim. Inspect springs and shim(s) are free to fall out of clutch thrust bearing for pits, rust, or discoloration actuator rod. (blueing) due to lack of lubricant. 51864 a - Locating Pin b - Shim Washer(s)

  • Page 588: Pinion Gear And Driveshaft

    6. Remove thrust washer and O-ring. The thrust 8. The forward gear bearing should be carefully washer acts as a bearing surface for the thrust inspected for smoothness of movement, pits, bearing and it should be inspected for pits, rust, rust, or signs of discoloration (blueing) due to lack scoring or discoloration due to lack of lubricant.
  • Page 589 3. Use a socket and flex handle to hold pinion nut. 9. If necessary, carefully use a slide hammer (Pad area of gear housing, where flex handle will (91-34569A1) to remove lubrication sleeve (if make contact, to prevent damage to gear equipped) from gear housing.
  • Page 590 a. Position driveshaft in a vise; DO NOT tighten 14. If inspection of driveshaft needle bearing surface vise jaws against shaft. determines that replacement of needle bearing is required, loose needle bearings b. Strike shaft with a lead hammer; take care not previously removed must be reinstalled in to drop shaft.

  • Page 591: Reverse Gear

    3. Inspect driveshaft needle bearing surface (area b. Place reverse gear, bearing and puller plate just above pinion gear splines) for pitting, on a press and press gear out of bearing grooves, scoring, uneven wear and/or discolor- using a suitable mandrel. ation from overheating.

  • Page 592: Gear Housing

    IMPORTANT: Removing reverse gear assembly 3. Install and seat needle bearing with the following from gearcase with slide hammer may damage tools: Puller Rod* (91-31229), Nut* (91-24156), reverse gear needle bearing. Pilot* (91-36571), Plate* (91-29310), and Mandrel* (91-92788). Pull bearing up into bore until it bottoms on gear housing shoulder.

  • Page 593: Bearing Carrier, Forward Gear And Bearing Adaptor

    Bearing Carrier, Forward Gear and 3. With seal lip facing towards bearing, press inner seal (a) using long end of mandrel (b) (91-31108) Bearing Adaptor into bearing carrier (c) until mandrel shoulder (d) bottoms out on bearing carrier. REASSEMBLY NOTE: Sport Master gear cases use Driver 1.

  • Page 594: Reverse Gear And Bearing Cup Adaptor Reassembly

    REVERSE GEAR AND BEARING CUP 3. With reverse gear teeth facing down, use a suit- ADAPTOR REASSEMBLY able mandrel which contacts the INNER RACE DIAMETER of the reverse gear ball bearing, to 1. With reverse gear teeth facing down, use press bearing and adapter onto reverse gear until mandrel (91-86943) to press propeller shaft the bearing seats against gear shoulder.

  • Page 595: Driveshaft And Pinion Gear

    securely. Continue to apply pressure against 3. Place bearing over driveshaft. driver rod until reverse gear/bearing cup adaptor Sport Master only - Both bearings can be JUST SEATS gearcase. installed on the driveshaft in one operation. Place OVER-SEAT the adaptor as the reverse gear the smaller bottom bearing over the driveshaft bearing will be damaged.
  • Page 596 5. Position lubrication sleeve (if equipped) in drive- 10. Place shim(s) (retained from disassembly) into shaft bore. gear housing. If shim(s) were lost or are not reusable (damaged), start with approximately 0.010 (0.254mm). 11. Install bearing race and bearing retainer. 51870 a - Lubrication Sleeve b - Tab (MUST align with slot)

  • Page 597: Pinion Gear Depth

    NOTE: Bearing Preload Tool (91-44307A1 ) may 13. Place Driveshaft Holding Tool (91-34377A1) over crankshaft end of driveshaft. Torque pinion nut to also be used. Follow instructions provided with tool 75 Ib. ft. (101.5 N·m). For Sportmaster gear- for proper installation. cases, torque pinion nut to 85 lb.

  • Page 598: Setting/Checking Driveshaft End Play (Sport Master Only)

    5. Measure distance (a) and increase that distance 8. Determine pinion gear depth by inserting a feeler by 1 (25.4mm) by turning bottom nut away from gauge thru access slot in pinion gear shimming top nut. tool. 9. Clearance between shimming tool and pinion gear should be 0.025 (0.64mm).
  • Page 599 3. Place Driveshaft Holding Tool (91-34377A1) over 6. Install the upper driveshaft bearing cup and crankshaft end of driveshaft. Use a socket and install and torque the upper bearing retainer to breaker bar to hold pinion nut and remove the 100 lb.

  • Page 600: Reverse Gear

    8. Move driveshaft up and down to determine end 14. Apply #271 Loctite to a NEW pinion nut and install play. Total up and down movement should be the pinion gear, washer and nut using procedures 0.00 to 0.001 (0.025mm). There should be no detailed earlier in this section.

  • Page 601: Forward Gear

    8. Lightly turn driveshaft back-and-forth (no move- Forward Gear ment should occur at propeller shaft). DETERMINING FORWARD GEAR BACKLASH 9. Dial Indicator registers amount of backlash, which should be 0.030 to 0.050 (0.76mm to NOTE: Propeller Shaft 44-93003 is for used for 1.27mm).
  • Page 602 3. Position shim against shoulder in gear case. 7. Tighten nut to 45 lb. in. (5.0 N·m). This will seat the forward gear against the forward thrust bearing and tends to hold the propeller shaft from moving when measuring backlash. NOTE: Bearing Preload Tool (91-44307A1) should still be installed from having previously been used to determine pinion gear depth and reverse gear...

  • Page 603: Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier

    11. Gently rock driveshaft back and forth to deter- Sport Master Gear Cases - Install thrust bearing mine forward gear backlash. (no thrust washer) into bearing carrier with the smooth surface (back) of the bearing against the ENGINE GEAR BACK- BACK- bearing carrier.
  • Page 604 2. Install propeller shaft into bearing carrier. 3. Install thrust bearing and thrust washer onto propeller shaft. Sport Master Gear Cases - Install thrust bearing onto propeller shaft with the bearing rollers against the flange of the prop shaft. 51882 a - Propeller Shaft b - Bearing Carrier CAUTION...
  • Page 605 4. Install forward gear bearing adaptor into bearing 6. Install thrust bearing onto thrust washer. carrier. Tap gently around circumference of adaptor to seat adaptor into bearing carrier. 51886 a - Thrust Bearing b - Thrust Washer 51885 a - Forward Gear Bearing Adaptor b - Bearing Carrier 5.

  • Page 606: Clutch Actuator Rod

    7. Position shim against shoulder in gear case. 2. Place a small amount of Quicksilver 2-4-C w/Teflon Marine Lubricant on retaining pin. Position pin in cross-hole in end of clutch actuator rod with flat side of pin toward shim washer. 51864 Clutch Actuator Rod Sub-Assembly Sequence a - Retaining Pin...

  • Page 607: Shift Shaft Bushing

    5. Measure distance (A and B) from each end of Shift Shaft Bushing elongated slot to the near side of cross pin tool. The measurements taken must be equal within REASSEMBLY 1/64 (0.4mm). 1. Position shift shaft bushing on a press with 6.
  • Page 608 NOTE: Sport Master models use a slotted cross pin 2. Attach cam follower to clutch actuator rod and slide assembly into propeller shaft. Align cross 91-86642-1 and Cross Pin Handle 91-86642-2 to pin slot in actuator rod with cross pin slot in clutch/ assemble clutch onto propshaft.
  • Page 609 7. Install cross pin retaining springs onto sliding 10. Place shift cam into cam pocket of cam follower clutch as follows: with numbered side of cam facing up. IMPORTANT: DO NOT over-stretch retaining springs when installing them onto sliding clutch. a.
  • Page 610 IMPORTANT: Prior to installation of shift shaft, 17. Place tab washer against bearing carrier. verify that the round retaining ring and “E” ring (if equipped) are in position and secure. 51885 a - Tab Washer IMPORTANT: Ensure that the “V” shaped tab on cover nut tab washer locates in the “V”...

  • Page 611: Water Pump

    21. Bend remaining tabs of tab washer toward front 2. Install O-ring into O-ring groove of water pump of gear housing. base. Lubricate O-ring and oil seals with 2-4-C w/Teflon Marine Lubricant (92-90018A12). 22. Use Shift Shaft Bushing Tool (91-31107) and torque shift shaft bushing to 50 Ib.
  • Page 612 4. Install a new water pump base gasket and install IMPORTANT: When completing gear housing water pump base. repair that requires removal of water pump impeller, it is recommended that the impeller be replaced. If it is necessary to reuse the impeller, DO NOT install in reverse to original rotation or premature impeller failure will occur.

  • Page 613: Gear Lubricant Filling Instructions

    15. Install centrifugal slinger over driveshaft and Installing Gear Housing to Driveshaft down against pump cover. Housing WARNING Disconnect high tension leads from spark plugs and remove spark plugs from engine before installing gear housing onto driveshaft housing. 1. Tilt engine to full up position and engage the tilt lock lever.

  • Page 614: Propeller Installation

    8. Move gear housing up toward driveshaft housing Propeller Installation while aligning shift shaft splines and water tube with water tube guide (in water pump cover). WARNING 9. Place flat washers onto studs (located on either When installing or removing propeller, because side of driveshaft housing).
  • Page 615 7. After propeller nut is recessed into tab washer, tighten nut securely [minimum of 55 Ib. ft. (74.5 N·m) torque]. 8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller nut. (If tab washer tabs do not align with slots, continue to tighten propeller nut to obtain alignment.
  • Page 616 LOWER UNIT MERCURY XR6/MARINER MAGNUM III GEAR HOUSING...
  • Page 617 Table of Contents Page Page Gear Housing Specifications (1.78:1 Ratio) 6C-1 Reassembly and Installation ....6C-20 Special Tools ......6C-1 Driveshaft Needle Bearing .

  • Page 618: Gear Housing Specifications (1.78:1 Ratio)

    Gear Housing Specifications Bearing Preload Tool 91-14311A1 (1.78:1 Ratio) Ratio Pinion Forward Reverse Depth Gear Gear Backlash Backlash 1.78:1 0.025 in. 0.016 in. to 0.030 in. to (14/25 (0.635mm) 0.019 in. 0.050 in. teeth) With Tool (0.41mm (0.762mm 91-12349A 2 Using 0.48mm) 1.27mm) Disc #1...
  • Page 619 Bearing Removal and Installation Kit 91-31229A5. Driver Rod 91-37323 This kit contains the following tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plate 91-29310; Mandrel 91-38628; and Driver Rod 91-37323. 74184 Mandrel 91-31106 70615 Shift Shaft Bushing Tool 91-31107 Mandrel 91-38628 73658 74193...
  • Page 620 Driveshaft Holding Tool 91-34377A1 Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716 55079 73599 Slide Hammer Puller 91-34569A1 Dial Indicator 91-58222A1 73655 Universal Puller Plate 91-37241 73429 Cover Nut Tool 91-73688 73652 Bearing Retainer Tool 91-43506 51866 Dial Indicator Holder 91-89897 73600 90-824052R3 JUNE 2002 LOWER UNIT - 6C-3...
  • Page 621 Gear Housing (Driveshaft) - XR6/Magnum III - 1.78:1 Ratio Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) 6C-4 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 622 Gear Housing (Driveshaft) - XR6/Magnum III - 1.78:1 Ratio TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CONNECTOR ASSEMBLY LUBRICATION SLEEVE (OLD DESIGN) DOWEL PIN STUD (3-1/8 ) STUD (2-1/16 ) STUD (3-3/8 ) STUD (3-1/8 ) ROLLER BEARING SCREW - grease filler SCREW - drain (MAGNETIC)

  • Page 623: Gear Housing (Prop Shaft) - Xr6/Magnum Iii - 1.78:1 Ratio

    Gear Housing (Prop Shaft) - XR6/Magnum III - 1.78:1 Ratio Loctite 271 (92-809820) RTV Silicone Sealer (92-91601-1) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6C-6 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 624 Gear Housing (Prop Shaft) - XR6/Magnum III - 1.78:1 Ratio TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING (BLACK)(BASIC) GEAR HOUSING (GRAY)(BASIC) SHIFT CAM CAM FOLLOWER SPRING SHIM TAPERED ROLLER BEARING FORWARD GEAR ROLLER BEARING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR...

  • Page 625: General Service Recommendations

    General Service When inspecting tapered bearings, determine condi- tion of rollers and inner bearing race by inspecting Recommendations bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from There may be more than one way to “disassemble” overheating.

  • Page 626: Removal, Disassembly, Cleaning And Inspection

    Removal, Disassembly, 5. Remove plastic cap at rear edge of driveshaft housing. Using a 12-point socket, un-thread bolt Cleaning and Inspection that secures anodic plate gear housing and remove tab. (It is not necessary to remove bolt at this time.) REMOVING GEAR HOUSING FROM DRIVESHAFT HOUSING 6.

  • Page 627: Draining Lubricant From Gear Housing

    NOTE: Gear lubricant drained from a recently run 11. Pull gear housing from driveshaft housing. gear case will be a light chocolate brown in color due to agitation/aeration. Oil which is stabilized will be a clear yellow brown in color. 51873 a - Front Mounting Locknut b - Side Mounting Locknut (One Each Side)

  • Page 628: Water Pump

    NOTE: Try Step “a” first. If insert cannot be removed Water Pump with Step “a”, use Step “b”. REMOVAL AND DISASSEMBLY a. Drive water pump insert out of water pump cover with a punch and hammer, as shown. IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal repair proce- dure) to assure effective repair.

  • Page 629: Cleaning And Inspection

    9. Remove water pump face plate and both gaskets Bearing Carrier and Propeller Shaft (one above and below face plate) from water Removal pump base. 1. Bend cover nut lock tab out of cover nut recess. 10. Remove the flush plug from gear housing, if so equipped.

  • Page 630: Bearing Carrier Cleaning And Inspection

    4. Use Long Puller Jaws (91-46086A1) and Puller BEARING CARRIER DISASSEMBLY Bolt (91-85716), as shown, to remove bearing 1. Remove and discard O-ring from between carrier. (Use propeller thrust hub to maintain bearing carrier and thrust washer. outward pressure on puller jaws). 2.

  • Page 631: Propeller Shaft Cleaning And Inspection

    NOTE: Reverse gear must be removed from bearing Balance Wheels carrier before propeller shaft needle bearing can be Place propeller shaft on balance wheels. Rotate removed. propeller shaft, observe propeller end of shaft for “wobble” and replace shaft if any “wobble” is observed.

  • Page 632: Propeller Shaft Disassembly

    6. Check the reverse gear shift “dogs”. Rounded 4. Push against cam follower. Use a punch or awl to shift “dogs” indicate improper shift cable push cross pin out of sliding clutch. adjustment, improper shift habits of operator(s), 5. Release pressure against cam follower. shifting from NEUTRAL to REVERSE gear too 6.

  • Page 633: Cleaning And Inspection

    CLEANING AND INSPECTION CAUTION 1. Clean driveshaft, tapered bearing and race, and DO NOT strike gear housing hard with the mallet pinion gear with solvent. Dry with compressed or allow gear housing to fall. air. DO NOT allow driveshaft bearing to spin while drying.

  • Page 634: Forward Gear And Bearings

    Forward Gear and Bearings REMOVAL AND DISASSEMBLY NOTE: Forward gear can only be removed from gear housing after driveshaft and pinion gear have been removed. 1. Reach into gear housing and lift out forward gear. IMPORTANT: DO NOT remove tapered bearing or needle bearing from forward gear, unless replacement of bearings is required.

  • Page 635: Shift Shaft, Bushing And Cam

    Shift Shaft, Bushing and Cam SHIFT SHAFT AND BUSHING DISASSEMBLY 1. Remove (and discard) O-ring from shift shaft SHIFT SHAFT REMOVAL bushing. NOTE: The propeller shaft, driveshaft and forward 2. Remove (and discard) oil seal by prying out or gear assembly must be removed before removal of driving it out with a punch and hammer.

  • Page 636: Driveshaft Needle Bearing

    Driveshaft Needle Bearing 3. Using suitable mandrel, PILOT (91-36571), and DRIVER ROD (91-37323), remove race from NOTE: Two different sized driveshaft needle gear housing. bearings may be found in XR6 and MAGNUM III gearcases. Externally, these gearcases may be identified as follows: 51882 a - Suitable Mandrel 50737...

  • Page 637: Removal Of Driveshaft Needle Bearing - Late Model

    REMOVAL OF DRIVESHAFT NEEDLE BEARING Reassembly and Installation - LATE MODEL 1. If inspection of driveshaft needle bearing surface Driveshaft Needle Bearing (refer to “CLEANING and INSPECTION,” following) determines that replacement of needle bearing is required, remove bearing from gear INSTALLATION - EARLY MODEL housing, following.

  • Page 638: Driveshaft Needle Bearing

    6. Use a mallet to drive needle bearing downward 1. Apply a thin coat of Quicksilver 2-4-C w/Teflon until it is approximately 1/16 (1 .6mm) above Marine Lubricant to driveshaft needle bearing bottom end of driveshaft cavity. Remove driver bore in gear housing. rod, mandrel and pilot washer.

  • Page 639: Lower Shift Shaft And Bushing

    Lower Shift Shaft and Bushing 13. Finish tightening shift shaft bushing with Shift Shaft Bushing Tool (91-31107). REASSEMBLY AND INSTALLATION 14. Torque Bushing to 50 Ib. ft. (67.5 N·m). 1. Position shift shaft bushing on a press with threaded side down. 2.

  • Page 640: Bearing Carrier

    5. Place one seal on longer shoulder side of Oil Seal 8. Assemble bearing carrier, as follows: Driver (91-31108) with lip of seal away from a. Install O-ring onto groove on bearing carrier. shoulder. Press seal into bearing carrier until seal IMPORTANT: The reverse gear thrust washer has driver bottoms against bearing carrier.
  • Page 641 5. Apply Quicksilver Super Duty Gear Lubricant to 9. Position tapered bearing race squarely over bore in center of forward gear. bearing bore in front portion of gear housing. 10. Place Bearing Driver Cup (91-31106) over tapered bearing race. NOTE: A used propeller shaft is recommended for use in Step 11.

  • Page 642: Driveshaft And Pinion Gear

    Driveshaft and Pinion Gear 6. Install 18 needles into race of driveshaft needle bearing, using Quicksilver 2-4-C w/Teflon Marine Lubricant to retain needles. REASSEMBLY/INSTALLATION 1. Apply Quicksilver Super Duty Gear Lubricant on l.D. of driveshaft tapered bearing. 2. Thread a used pinion nut onto end of driveshaft. Leave approximately 1/16 (2mm) of nut threads exposed.

  • Page 643: Determining Pinion Gear Depth

    11. Place shim(s) (retained from disassembly) into Determining Pinion Gear Depth gear housing. If shim(s) were lost, or are not NOTE: Read entire procedure before attempting any reusable (damaged), start with approximately change in shim thickness. 0.010 (0.254mm). IMPORTANT: Forward gear assembly must be 12.

  • Page 644: Propeller Shaft

    5. Measure distance (a) and increase that distance 10. If clearance is correct, leave Bearing Preload by 1 (25.4mm) by turning bottom nut away from Tool on driveshaft and proceed to “Determining top nut. Forward Gear Backlash,” following. 11. If clearance is not correct, add (or subtract) shims at location shown to raise (or lower) pinion gear.

  • Page 645: Determining Forward Gear Backlash

    4. Lubricate 3 metal balls with Quicksilver 2-4-C Determining Forward Gear Backlash w/Teflon Marine Lubricant; insert balls into NOTE: Read entire procedure before attempting any propeller shaft. change in shim thickness. 5. Place a small amount of 2-4-C w/Teflon into end 1.
  • Page 646 NOTE: By adding or subtracting 0.001 (0.025mm) 14. Start cover nut a few turns by hand, then, using shim, the backlash will change approximately 0.001 Cover Nut Tool (91-73688) and torque wrench, (0.025mm). torque cover nut to 210 Ib. ft. (285.0 N·m). 15.

  • Page 647: Water Pump

    Water Pump 5. Install a new water pump base gasket and install water pump base. REASSEMBLY/INSTALLATION 1. Install divider block; use RTV Sealer to seal seams between divider block and gear housing. 2. Install oil seals into water pump base, as follows: a.

  • Page 648: Filling Gear Housing With Lubricant

    13. Position assembled water pump cover over CAUTION driveshaft and lower over water pump studs. Rotate driveshaft in a clockwise direction (viewed A visual inspection of impeller drive key MUST from top), while pushing down on pump cover to BE made to determine that drive key is on flat of ease impeller entry into cover.
  • Page 649 9. Place flat washers onto studs (located on either CAUTION side of driveshaft housing). Start nut on these studs and tighten finger-tight. DO NOT allow lubricant on top of driveshaft. Excess lubricant, that is trapped in clearance 10. Start bolt at rear of gear housing inside anodic space, will not allow driveshaft to fully engage plate recess.

  • Page 650: Propeller Installation

    Propeller Installation 7. Bend 3 of the tabs of tab washer down in grooves of propeller hub to secure propeller nut. (If tab washer tabs do not align with slots, continue to WARNING tighten propeller nut to obtain alignment. DO When installing or removing the propeller on all NOT loosen nut to align tabs.) models, because of the motor’s ease in starting,...
  • Page 651 LOWER UNIT E-Z SHIFT GEAR HOUSING (NON-RATCHETING) (STANDARD ROTATION) STARTING S/N 0G438000...
  • Page 652 Table of Contents Page Page Gear Housing Specifications Reassembly and Installation (Standard Rotation) ..... 6D-1 Standard Rotation ..... 6D-23 Special Tools .

  • Page 653: Gear Housing Specifications (Standard Rotation)

    Gear Housing Specifications Gear Housing Cover Nut Tool 91-61069 (Standard Rotation) Ratio Pinion Forward Reverse Depth Gear Gear Backlash Backlash 1.87:1 0.025 in. 0.018 in. to 0.030 in. to (15/28 (0.635mm) 0.027 in. 0.050 in. teeth) With Tool (0.460mm (0.762mm 91-12349A2 using Disc 0.686mm)
  • Page 654 Pilot 91-36571 Universal Puller Plate 91-37241 74187 Puller Rod 91-31229 and Nut 91-24156 73652 Cross Pin Tool 91-86642 Puller Plate 91-29310 Driveshaft Holding Tool 91-34377A1 74190 Mandrel 91-38628 55079 Oil Seal Driver 91-31108 74193 Driver Rod 91-37323 73651 Forward Gear Bearing Tool 91-86943 74184 6D-2 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 655 Bearing Driver Cup 91-31106 Backlash Indicator Rod 91-78473 Dial Indicator 91-58222A1 Pinion Locating Gear Tool 91-12349A2 or 91-74776 73429 Bearing Retainer Tool 91-43506 55079 73600 90-824052R3 JUNE 2002 LOWER UNIT - 6D-3...
  • Page 656 Bearing Preload Tool 91-14311A1 Mandrel 91-92788 Dial Indicator Holder 91-89897 Mandrel 91-15755 a - Adaptor (N.S.S.) b - Bearing (N.S.S.) c - Washer (N.S.S.) d - Spring (24-14111) e - Bolt (10-12580) f - Nut (11-13953) g - Set Screw (10-12575) h - Sleeve (23-13946) 73815 6D-4 - LOWER UNIT...
  • Page 657 Notes: 90-824052R3 JUNE 2002 LOWER UNIT - 6D-5...

  • Page 658: (S/N-0G438000

    Gear Housing (Driveshaft) (Standard Rotation) (S/N-0G438000 & UP) 1647– 9147–C2 Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 6D-6 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 659 Gear Housing (Driveshaft) (Standard Rotation) (S/N-0G438000 & UP) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CONNECTOR ASSEMBLY DOWEL PIN STUD (3-1/8 IN.) (LONG) STUD (3-11/16 IN.) (X-LONG) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/8 IN.) FILLER BLOCK ROLLER BEARING ANODE...

  • Page 660: (S/N-0G438000

    Gear Housing (Prop Shaft) (Standard Rotation) (S/N-0G438000 & UP) Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6D-8 - LOWER UNIT 90-824052R3 JUNE 2002...
  • Page 661 Gear Housing (Prop Shaft) (Standard Rotation) (S/N-0G438000 & UP) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CAM FOLLOWER SHIFT CAM GEAR SET (XR6/MAG. III/175/200)(1.87:1 – 15/28) GEAR SET (135/150)(2.0:1 – 14/28) SHIM (.006-7-9-10-20) TAPERED ROLLER BEARING NEEDLE BEARING CLUTCH CROSS PIN...

  • Page 662: General Service Recommendations

    General Service When inspecting tapered bearings, determine condition of rollers and inner bearing race by Recommendations inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or There may be more than one way to “disassemble” discoloration from overheating. Always replace or “reassemble”...

  • Page 663: Removal, Disassembly, Cleaning And Inspection - Standard Rotation

    Removal, Disassembly, 5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position. Remove Cleaning and Inspection – plastic cap at rear edge of driveshaft housing, then unthread bolt that secures trim tab and Standard Rotation remove trim tab from gear housing.

  • Page 664: Draining And Inspecting Gear Housing Lubricant

    8. Remove locknut from the front gear housing 2. Position a clean drain pan under gear housing mounting stud. and remove “Fill” and “Vent” screws from gear housing. 9. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before opposite side is loosened sufficiently, or driveshaft housing could be damaged.) 10.

  • Page 665: Water Pump

    Water Pump 3. Remove (and retain) 3 nuts, one bolt and all washers which secure water pump cover to gear housing. CLEANING AND INSPECTION 1. Clean all water pump parts with solvent and dry with compressed air. 2. Inspect water pump cover and base for cracks and distortion (from overheating).

  • Page 666: Bearing Carrier And Propeller Shaft Removal

    a. Drive water pump insert out of water pump 10. Using 2 pry bars, positioned and padded as cover with a punch and hammer. shown, lift water pump base up and off driveshaft. 51874 a - Pads 51874 b. Drill two 3/16 (4.8mm) diameter holes thru 11.
  • Page 667 3. Bend cover nut lock tab out of cover nut recess. 5. After cover nut has been removed, remove lock tab washer from gear housing. CAUTION Once bearing carrier is removed from gear housing, extreme care MUST BE taken not to apply any side force on propeller shaft.

  • Page 668: Shift Shaft

    7. With gear housing in NEUTRAL, pull shift shaft in shift cam is visible, reinstall shift shaft and out of gear housing. If necessary, use a pliers to rotate shift shaft to neutral position. Remove pull shift shaft out of gear housing. If pliers are shift shaft, then remove propeller shaft as used to pull shift shaft out, wrap a strip of soft instructed in Step 8, immediately preceding.

  • Page 669: Disassembly- Bearing Carrier

    2. Bearing carrier propeller shaft needle bearing Use a suitable mandrel and press gear out of condition is determined by propeller shaft bearing. bearing surface condition. (See “Propeller Shaft Inspection.”) 3. Inspect reverse gear to pinion gear wear pattern (should be even and smooth). If not, replace reverse gear and pinion gear.

  • Page 670: Propeller Shaft

    4. If inspection of propeller shaft needle bearing 4. Inspect propeller shaft splines for wear and/or determines that replacement of bearing is corrosion damage. required, use Universal Bearing Removal and 5. Check propeller shaft for straightness. Use either Installation Tool (91-31229A1) to press bearing method, following: and seals out of bearing carrier.
  • Page 671 c. Engine idle speed too high (while shifting). CAUTION Detent pin is free and can fall out of sliding clutch. Care MUST BE taken not to lose pin. 3. Detent pin is free and can be removed from sliding clutch at this time. 51865 a - Clutch “Jaws”...

  • Page 672: Clutch Actuator Rod

    5. Pull sliding clutch off propeller shaft. 2. Place Driveshaft Holding Tool (91-34377A1) over driveshaft splines. 6. Pull cam follower and clutch actuator rod out of propeller shaft. DO NOT force cam follower 3. Use a socket and flex handle to hold pinion nut. up-or-down or side-to-side when pulling from (Pad area of gear housing where flex handle propeller shaft.

  • Page 673: Cleaning And Inspection

    b. Strike shaft with a lead hammer; take care not IMPORTANT: Discard driveshaft needle bearing to drop shaft. after removal. (Bearing cannot be reused.) 51866 10. Remove 18 loose needles from outer race of driveshaft needle bearing. 11. If inspection of driveshaft needle bearing surface determines that replacement of needle bearing is required, loose...

  • Page 674: Forward Gear

    5. Inspect tapered bearing race for pitting, grooves, c. Use Slide Hammer (91-34569A1) to remove scoring, uneven wear and discoloration from forward gear tapered bearing race. overheating. Replace tapered bearing and race as a set, if any of the preceding conditions are found.

  • Page 675: Gear Housing

    4. Inspect tapered bearing race for pitting, grooves, Reassembly and Installation scoring, uneven wear and discoloration (from Standard Rotation overheating). Replace tapered bearing (on forward gear) and race if any of these conditions Driveshaft Needle Bearing are found. (Always replace tapered bearing and race as a set.) REASSEMBLY/INSTALLATION 5.

  • Page 676: Bearing Carrier

    Bearing Carrier 8. Use Mandrel 91-15755 and press needle bearing into bearing carrier. REASSEMBLY 1. Place reverse gear on a press with gear teeth facing down. IMPORTANT: The reverse gear thrust washer has a tapered outside diameter so that one side is larger than the other.

  • Page 677: Forward Gear

    Forward Gear REASSEMBLY 1. Place forward gear on a press with gear teeth down. 2. Apply a light coat of Quicksilver Super Duty Gear Lubricant onto the inside diameter of forward gear tapered bearing. 3. Position forward gear tapered bearing over gear. 4.

  • Page 678: Forward Gear Bearing Race

    6. Place one forward gear needle bearing on longer 5. Place propeller shaft into hole in center of bearing shoulder side of Forward Gear Bearing Tool driver cup. (91-86943) with numbered side of bearing 6. Install bearing carrier assembly over propeller toward shoulder.

  • Page 679: Driveshaft And Pinion Gear

    Driveshaft and Pinion Gear 7. Place a small amount of Loctite 271 onto threads of pinion gear nut and install flat washer and nut on driveshaft with flat side of nut away from pinion REASSEMBLY/INSTALLATION gear. Hand tighten pinion nut. 1.

  • Page 680: Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash

    8. Place shim(s) (retained from disassembly) into IMPORTANT: Wipe any excess Loctite from gear housing. If shim(s) were lost or are not pinion nut and pinion gear. reusable (damaged), start with approximately 0.010 (0.254mm). Pinion Gear Depth/Forward Gear 9. Install bearing race and bearing retainer. Backlash/Reverse Gear Backlash DETERMINING PINION GEAR DEPTH NOTE: Read entire procedure before attempting any...

  • Page 681: Determining Forward Gear Backlash

    4. With tool installed over driveshaft, tighten both 8. Determine pinion gear depth by inserting a feeler set screws securely, making certain to align gauge thru access slot in pinion gear shimming sleeve holes to allow set screws to pass thru. tool.
  • Page 682 3. Attach Bearing Carrier Removal Tool 8. Lightly turn driveshaft back-and-forth (91-46086A1) and Puller Bolt (91-85716) onto movement should be noticed at propeller shaft). gear housing. 9. Dial indicator registers amount of backlash which 4. Torque puller bolt against propeller shaft to 45 Ib. must be 0.018 to 0.027 (0.46mm to 0.69mm) in.

  • Page 683: Clutch Actuator Rod

    REVERSE GEAR Clutch Actuator Rod Determining Reverse Gear Backlash REASSEMBLY Although reverse gear backlash is not adjustable, it 1. Place a small amount of Quicksilver 2-4-C may be checked as follows: w/Teflon Lubricant on actuator rod and install 1. Propeller shaft and bearing carrier must be com- cam follower.

  • Page 684: Propeller Shaft

    Propeller Shaft 3. Insert cross pin thru sliding clutch, propeller shaft and actuator rod, forcing cross pin tool out. REASSEMBLY/INSTALLATION 1. Insert clutch actuator rod assembly into end of propeller shaft. Align cross pin slot in actuator rod with cross pin slot in propeller shaft. 51864 51864 a - Cross Pin...
  • Page 685 9. Place shift cam into cam pocket of cam follower 12. Apply a light coat of Quicksilver 2-4-C w/Teflon with numbered side of cam facing up. Marine Lubricant to threads of shift shaft bushing. (Thread bushing into position, but do not tighten down at this time.) 51864 a - Cam Pocket...

  • Page 686: Water Pump

    19. Start cover nut a few turns by hand, then using 2. Install O-ring into O-ring groove of water pump Cover Nut Tool (91-61069) and torque wrench, base. Lubricate O-ring and oil seals with 2-4-C torque cover nut to 210 Ib. ft. (284.5 N·m). w/Teflon Marine Lubricant (92-90018A12).
  • Page 687 4. Install a new water pump base gasket and install IMPORTANT: When completing gear housing water pump base. repair, that requires removal of water pump impeller, it is recommended that the impeller be replaced. If it is necessary, however, to reuse the impeller, DO NOT install in reverse to original rotation, or premature impeller failure will occur.

  • Page 688: Gear Lubricant Filling Instructions

    15. Install centrifugal slinger over driveshaft and Installing Gear Housing to Driveshaft down against pump cover. Housing WARNING Disconnect high tension leads from spark plugs and remove spark plugs from engine before installing gear housing onto driveshaft housing. 1. Tilt engine to full up position and engage the tilt lock lever.

  • Page 689: Propeller Installation

    8. Move gear housing up toward driveshaft hous- Propeller Installation ing, while aligning shift shaft splines and water tube with water tube guide (in water pump cover). WARNING 9. Place flat washers onto studs (located on either When installing or removing propeller, because side of driveshaft housing).
  • Page 690 8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller nut. (If tab washer tabs do not align with slots, continue to tighten propeller nut to obtain alignment. DO NOT loosen nut to align tabs.) CAUTION DO NOT misinterpret propeller shaft movement with propeller movement.
  • Page 691 LOWER UNIT E-Z SHIFT COUNTER ROTATING GEAR HOUSING (NON-RATCHETING) (LEFT HAND ROTATION) STARTING S/N 0G438000...
  • Page 692 Table of Contents Page Page Gear Housing Specifications Reassembly and Installation of Counter (Counter Rotation) ..... . 6E-1 Rotation Gear Housing .
  • Page 693 Gear Housing Specifications Gear Housing Cover Nut Tool 91-61069 (Counter Rotation) Ratio Pinion Forward Reverse Depth Gear Gear Backlash Backlash 1.87:1 0.025 in. 0.018 in. to 0.030 in. to (15/28 (0.635mm) 0.027 in. 0.050 in. teeth) With Tool (0.460mm (0.762mm 91-12349A2 using 0.686mm)
  • Page 694 Pilot 91-36571 Universal Puller Plate 91-37241 74187 Puller Rod 91-31229 and Nut 91-24156 73652 Driveshaft Holding Tool 91-34377A1 Puller Plate 91-29310 55079 74190 Oil Seal Driver 91-31108 Mandrel 91-38628 73651 74193 Forward Gear Bearing Tool 91-86943 Driver Rod 91-37323 74184 90-824052R3 JUNE 2002 6E-2 - LOWER UNIT...
  • Page 695 Pinion Locating Gear Tool 91-12349A2 or 91-74776 Bearing Retainer Tool 91-43506 73600 Mandrel 91-92788 55079 Backlash Indicator Rod 91-78473 Dial Indicator Holder 91-89897 Dial Indicator 91-58222A1 Forward Gear Installation Tool 91-815850 73429 72486 90-824052R3 JUNE 2002 LOWER UNIT - 6E-3...
  • Page 696 Bearing Preload Tool 91-14311A1 Retainer 91-18604 Shaft 91-18605 Screw 10-18602 a - Adaptor (N.S.S.) b - Bearing (N.S.S.) c - Washer (N.S.S.) d - Spring (24-14111) e - Bolt (10-12580) f - Nut (11-13953) g - Set Screw (10-12575) h - Sleeve (23-13946) Mandrel 91-15755 Propeller Shaft 44-93003 and Load Washer (a) 12-37429...
  • Page 697 Notes: 90-824052R3 JUNE 2002 LOWER UNIT - 6E-5...
  • Page 698 Gear Housing (Driveshaft) (Counter Rotation) (S/N-0G438000 & UP) 1647– 9147–C2 Loctite 271 (92-809820) Perfect Seal (92-34227-1) Loctite 680 (92-809833) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) 90-824052R3 JUNE 2002 6E-6 - LOWER UNIT...
  • Page 699 Gear Housing (Driveshaft) (Counter Rotation) (S/N-0G438000 & UP) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CONNECTOR ASSEMBLY DOWEL PIN STUD (3-11/16 ) STUD (2-1/16 ) STUD (3-3/8 ) STUD (3-1/8 ) FILLER BLOCK ROLLER BEARING ANODE SCREW PINION GEAR (Part of 43-828703A1 or 43-828701A1) WASHER...

  • Page 700: Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & Up)

    Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & UP) Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 90-824052R3 JUNE 2002 6E-8 - LOWER UNIT...
  • Page 701 Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & UP) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING CAM FOLLOWER SHIFT CAM SHIM BEARING ADAPTOR ASSEMBLY ROLLER BEARING THRUST WASHER THRUST BEARING REVERSE GEAR (135/150) REVERSE GEAR (175/200) ROLLER BEARING SPRING SLIDING CLUTCH...
  • Page 702 Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & UP) Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 90-824052R3 JUNE 2002 6E-10 - LOWER UNIT...
  • Page 703 Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & UP) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GEAR HOUSING ROLLER BEARING THRUST WASHER BEARING ADAPTOR ASSEMBLY ROLLER BEARING THRUST WASHER THRUST BEARING THRUST RACE KEEPER O RING BEARING CARRIER ASSEMBLY ROLLER BEARING OIL SEAL (INSIDE) OIL SEAL (OUTSIDE)

  • Page 704: General Service Recommendations

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

  • Page 705: Removal, Disassembly, Cleaning And Inspection Of Counter Rotation (Left Hand) Gear Housing

    Removal, Disassembly, 4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller locknut, Cleaning and Inspection of tab washer, thrust hub (rear), propeller and thrust hub (forward) from propeller shaft. Counter Rotation (Left Hand) Gear Housing REMOVAL WARNING Disconnect high tension leads from spark plugs...

  • Page 706: Draining And Inspecting Gear Housing Lubricant

    7. Remove 2 locknuts from bottom middle of anti- DRAINING AND INSPECTING GEAR HOUSING cavitation plate. LUBRICANT 1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical position, as shown. 2. Position a clean drain pan under gear housing and remove “Fill”...

  • Page 707: Water Pump

    Water Pump 3. Remove (and retain) 3 nuts, one bolt and all washers which secure water pump cover to gear housing. CLEANING AND INSPECTION 1. Clean all water pump parts with solvent and dry with compressed air. 2. Inspect water pump cover and base for cracks and distortion (from overheating).

  • Page 708: Bearing Carrier And Propeller Shaft

    a. Drive water pump insert out of water pump 10. Using 2 pry bars, positioned and padded as cover with a punch and hammer. shown, lift water pump base up and off driveshaft. 51874 a - Pads 11. Remove (and discard) O-ring from O-ring groove on water pump base.
  • Page 709 3. Bend cover nut lock tab out of cover nut recess. CAUTION Once bearing carrier is removed from gear housing, extreme care MUST BE taken not to apply any side force on propeller shaft. Side force on propeller shaft may break the neck of the clutch actuator rod.
  • Page 710 NOTE: Sliding clutch, forward gear assembly, bear- 7. With gear housing in neutral, pull shift shaft out of gear housing. If necessary, use a pliers to pull ing adaptor, thrust washer and thrust bearings will be shift shaft out of gear housing. If pliers are used removed from gearcase with propeller shaft.

  • Page 711: Shift Shaft

    Shift Shaft DISASSEMBLY- BEARING CARRIER 1. Remove thrust bearing and thrust washer from CLEANING AND INSPECTION bearing carrier. 1. Clean shift shaft and bushing with solvent and dry with compressed air. 2. Check shift shaft splines on both ends for wear and/or corrosion damage.

  • Page 712: Propeller Shaft

    4. Use bearing removal and replacement tool Balance Wheels (91-31229A5) or equivalent to press bearings out Place propeller shaft on balance wheels, as shown. of bearing carrier. Rotate propeller shaft and observe propeller end of shaft for “wobble.” Replace shaft if any “wobble” is observed.
  • Page 713 b. Improper shift habits of operator(s) (shift from CAUTION neutral to reverse gear or forward gear too slowly). Detent pin is free and can fall out of sliding clutch. Care MUST BE taken not to lose pin. c. Engine idle speed too high (while shifting). 3.

  • Page 714: Clutch Actuator Rod

    10. Remove forward gear and bearing adaptor Forward Gear and Bearing Adapter assembly. DISASSEMBLY/CLEANING/INSPECTION 11. Remove 2 thrust races and 2 keepers from prop shaft. 1. Remove forward gear from bearing adapter. 2. Inspect forward gear clutch teeth for signs of wear.

  • Page 715: Pinion Gear And Driveshaft

    6. Remove thrust washer and O-ring. The thrust 8. The forward gear bearing should be carefully washer acts as a bearing surface for the thrust inspected for smoothness of movement, pits, bearing and it should be inspected for pits, rust, rust, or signs of discoloration (blueing) due to lack scoring or discoloration due to lack of lubricant.
  • Page 716 2. Place Driveshaft Holding Tool (91-34377A1) over b. Strike shaft with a lead hammer; take care not driveshaft splines. to drop shaft. 3. Use a socket and flex handle to hold pinion nut. (Pad area of gear housing, where flex handle will make contact, to prevent damage to gear housing.) 4.

  • Page 717: Cleaning And Inspection

    11. If inspection of driveshaft needle bearing surface 3. Inspect driveshaft needle bearing surface (area determines that replacement of needle bearing is just above pinion gear splines) for pitting, required, loose needle bearings grooves, scoring, uneven wear and/or discolor- previously removed must be reinstalled in ation from overheating.

  • Page 718: Cleaning And Inspection

    2. Remove thrust bearing and thrust washer from CLEANING AND INSPECTION reverse gear bearing cup. CAUTION DO NOT spin bearings dry with compressed air, as this could cause bearing to score. 1. Clean reverse gear and bearing with solvent and dry with compressed air.

  • Page 719: Gear Housing

    5. If reverse gear needle bearing is found to be 1. Apply a thin coat of Quicksilver 2-4-C w/Teflon damaged, place reverse gear in a press and use Lubricant to driveshaft needle bearing bore in mandrel 91-63569 to press bearing out of gear. gear housing.

  • Page 720: Bearing Carrier, Forward Gear And Bearing Adaptor

    Bearing Carrier, Forward Gear and 3. With seal lip facing towards bearing, press inner seal (a) using long end of mandrel (b) (91-31108) Bearing Adaptor into bearing carrier (c) until mandrel shoulder (d) bottoms out on bearing carrier. REASSEMBLY 1. Using suitable mandrel, press forward gear bearing into bearing adaptor until bearing is flush with lip of adaptor.

  • Page 721: Reverse Gear And Bearing Cup Adaptor Reassembly

    REVERSE GEAR AND BEARING CUP IMPORTANT: The appearance of the forward and ADAPTOR REASSEMBLY reverse gear is almost identical. There are two ways to distinguish between the reverse and 1. With reverse gear teeth facing down, use forward gears. The reverse gear has a shorter mandrel (91-86943) to press propeller shaft hub and it has a smaller inner diameter needle needle bearing (NUMBERS/LETTERS UP) into...
  • Page 722 4. Position the reverse gear (without the thrust race Example 1 (if backlash is too high) or thrust bearing) into the gear housing and into the adaptor. Backlash checks: .045 in. (1.14 mm) (subtract) middle .025 in. (0.64 mm) specification: You get: .020 in.

  • Page 723: Driveshaft And Pinion Gear

    6. After reverse bearing adaptor is seated, remove Driveshaft and Pinion Gear screw, retainer, driver tool, pilot ring and reverse gear. Apply Quicksilver Super Duty Gear REASSEMBLY/INSTALLATION Lubricant to thrust bearing and install thrust race 1. Apply a light coat of Quicksilver Super Duty Gear and bearing onto bearing adaptor.

  • Page 724: Pinion Gear Depth

    8. Place shim(s) (retained from disassembly) into Pinion Gear Depth gear housing. If shim(s) were lost or are not reusable (damaged), start with approximately DETERMINING PINION GEAR DEPTH 0.010 (0.254mm). NOTE: Read entire procedure before attempting any 9. Install bearing race and bearing retainer. change in shim thickness.
  • Page 725 5. Measure distance (a) and increase that distance 8. Determine pinion gear depth by inserting a feeler by 1 (25.4mm) by turning bottom nut away from gauge thru access slot in pinion gear shimming top nut. tool. 9. Clearance between shimming tool and pinion gear should be 0.025 (0.64mm).

  • Page 726: Reverse Gear

    Reverse Gear 9. Dial Indicator registers amount of backlash, which should be 0.030 to 0.050 (0.76mm to 1.27mm). DETERMINING REVERSE GEAR BACKLASH NOTE: Reverse gear backlash is adjustable using shims; it can be checked as follows: 1. Install Driver Tool (91-18605) into reverse gear assembly.
  • Page 727 2. Assemble BEARING CARRIER, BEARING 6. Install a 5 x 2 (127mm x 50.8mm) long piece of ADAPTOR, THRUST WASHER, THRUST PVC pipe (obtain locally) over propeller shaft and BEARING, and FORWARD GEAR onto propeller secure it against the bearing carrier with a flat shaft.
  • Page 728 NOTE: By adding or subtracting 0.002 (0.051 mm) 10. Position dial indicator pointer on line marked “1” on BACKLASH INDICATOR TOOL, if gear ratio shim, the backlash will change approximately 0.002 is 1.87:1 (15 teeth on pinion gear), or on line (0.051 mm).

  • Page 729: Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier

    Propeller Shaft/Forward Gear 3. Slide clutch actuator assembly into propeller shaft. Align cross pin slot in actuator rod with Bearing Adapter/Bearing Carrier cross pin slot in clutch/propeller shaft. REASSEMBLY 1. Position sliding clutch onto propeller shaft. “GROOVED RINGS” are for manufacturing purposes only and may be positioned towards either gear.
  • Page 730 6. Install cross pin retaining spring onto sliding 11. Apply a light coat of 2-4-C w/Teflon to the threads clutch as follows: of the shift shaft bushing. IMPORTANT: DO NOT over-stretch retaining 12. Insert shift shaft down shift shaft hole in gear spring when installing onto sliding clutch.
  • Page 731 14. Apply Quicksilver Super Duty Gear Lubricant to 16. Install tool with adaptor assembly over propeller to thrust bearing and install thrust bearing and shaft and into gear housing. Applying downward thrust race onto forward gear bearing adaptor. pressure to bearing adaptor, remove installation tool from assembly.
  • Page 732 18. Apply Quicksilver Super Duty Gear Lubricant to 20. Pull up slightly on the propeller shaft to gain small thrust bearing and install bearing on thrust access to the groove on the shaft for the keepers. race. Install the 2 keepers into the groove and lower the propeller shaft.
  • Page 733 22. Apply Quicksilver Super Duty Gear Lubricant to 24. Apply Quicksilver 2-4-C w/Teflon Marine the second thrust bearing and install it on top of Lubricant to bearing carrier O-ring. Install O-ring the second thrust collar. onto bearing adaptor. 55113 55112 a - O-ring a - Thrust Bearing b - Thrust Collar...
  • Page 734 28. Verify bearing carrier keyway is aligned with gear 34. Use Shift Shaft Bushing Tool (91-31107) and housing keyway and install bearing carrier key. torque shift shaft bushing to 50 Ib. ft. (67.5 N·m). 29. Place tab washer against bearing carrier. 51885 a - Tab Washer 51882...

  • Page 735: Water Pump

    Water Pump 4. Install a new water pump base gasket and install water pump base. REASSEMBLY/INSTALLATION 1. Install oil seals into water pump base, as follows: a. Place water pump base on a press. b. Just before installing each seal apply Loctite 271 on outside diameter of oil seal.
  • Page 736 NOTE: If 2 holes were drilled in top of water pump CAUTION cover to aid in removal of insert, fill holes with RTV Sealer or equivalent. Allow to cure 24 hours prior to A visual inspection of impeller drive key MUST operating engine.

  • Page 737: Gear Lubricant Filling Instructions

    Gear Lubricant Filling Instructions 5. Insert trim tab bolt into hole in rear of gear hous- ing to driveshaft housing machined surface. 1. Remove any gasket material from “Fill” and 6. Shift gear housing into forward gear and place “Vent” screws and gear housing. guide block anchor pin into forward gear position.

  • Page 738: Propeller Installation

    IMPORTANT: If shifting operation is not as 3. Place propeller on propeller shaft and slide it up described, preceding, the gear housing must be against thrust hub. removed and the cause corrected. 14. Install washers and nuts onto studs (located on bottom center of anti-cavitation plate).
  • Page 739 9. After first use, retighten propeller nut and again secure with tab washer (Steps 7 and 8, preced- ing). Propeller should be checked periodically for tightness, particularly if a stainless steel propeller is used. 51916 a - Continuity Washer (If Equipped) b - Rear Thrust Hub c - Tab Washer d - Propeller Nut...
  • Page 740 JET OUTBOARDS...
  • Page 741 Table of Contents Page 105/140 Jet ......6F-2 Jet Components ......6F-4 Selecting a Boat that is best suited for Jet Power...
  • Page 742 Notes: 90-824052R3 JUNE 2002 JET OUTBOARDS - 6F-1...
  • Page 743 Jet Pump Assembly 18 19 2-4-C With Teflon (92-825407A12) 6F-2 - JET OUTBOARDS 90-824052R3 JUNE 2002...
  • Page 744 Jet Pump Assembly TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – JET PUMP (BLACK) S/N-0G605661 & BELOW – JET PUMP (GRAY) – JET PUMP (S/N-0G605662 & UP - W/ALUMINUM IMPELLER) – JET PUMP (JET 105 - W/STAINLESS STEEL IMPELLER) –...

  • Page 745: Jet Components

    Jet Components 2-4-C With Teflon (92-825407A12) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (.190-32 x 1.62) WASHER BUSHING PLATE REV LIMITER HARNESS–Adaptor-rev limiter GREASE KIT WATER PUMP BASE GASKET OIL SEAL OIL SEAL GASKET–lower GASKET–upper FACE PLATE WATER PUMP BODY ASSEMBLY INSERT SEAL–rubber...

  • Page 746: 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 747: Transom Height Of The Boat

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

  • Page 748: Water Testing

    SETTING OUTBOARD MOUNTING HEIGHT ON When operating the boat, the outboard driveshaft 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 749: Shift Cable Installation Jet 105 And

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

  • Page 750: Lubricating The Driveshaft Bearing

    Lubricating the Driveshaft Impeller Removal and Bearing Installation Recommended Lubrication - Use Quicksilver REMOVAL 2-4-C w/Teflon, or Lubriplate 630-AA Grease. 1. Shift outboard to NEUTRAL (N) position. IMPORTANT: It is important that you do not use a general-all-purpose grease for this bearing. 2.
  • Page 751 INSTALLATION 3. After setting the impeller height, tighten the impeller nut snug with a wrench. Secure impeller 1. Grease the driveshaft, shear key, and impeller nut by bending tabs (a) against the flats on the bore. Place the plastic sleeve (a) inside the impeller nut.

  • Page 752: 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 753: Liner Replacement

    4. Stop the engine, turn off the water, and remove Jet Drive Removal and the hose coupling. Reinstall the plug and gasket. Installation Jet 105 and 140 REMOVAL 1. Remove 3 locknuts and one bolt securing jet drive to driveshaft housing and remove jet drive. INSTALLATION 1.
  • Page 754 Jet 105 and 140 Jet 105 and 140 REMOVAL REMOVAL 1. Remove water pump assembly as shown. 1. Remove water pump assembly. INSTALLATION 2. Remove 4 bolts securing bearing carrier to jet drive, and remove bearing carrier. IMPORTANT: If impeller being installed has been previously used and vanes have taken a “set,”...

  • Page 755: Bearing Carrier Disassembly

    Bearing Carrier Disassembly Bearing Carrier Reassembly 1. Remove the large beveled snap ring (a) from the Installing Seals bearing carrier. 2. Heat the bearing carrier (b) with a torch only until Install seals into bearing carrier as follows: you can barely touch it. 1.

  • Page 756: Installing Upper Seals

    Installing Upper Seals Installing Driveshaft Bearing(s) 1. Install spiral retaining ring (a) into the inner ring DOUBLE BEARING SYSTEM groove of the upper seal housing. 1. If removed, install the bearing thrust ring (a) into 2. Spread a film of grease around the inside bore of the groove on the driveshaft.

  • Page 757: Installing Driveshaft

    Installing Driveshaft 1. Lubricate the seals and inside bore of the bearing carrier (a). 2. Place the driveshaft (“b” impeller end facing up) into a vise. 3. Heat the bearing carrier (a) until it feels warm to the touch. 4. Place the bearing carrier (a) onto the driveshaft. Square up the inner bore with the ball bearings and push the bearing carrier down until it bottoms out against the bearing.

  • Page 758: Installing Upper Seal Housing

    Installing Upper Seal Housing 3. Install the upper seal housing (b) being careful not to damage the O-ring seals as they pass the DOUBLE BEARING SYSTEM snap ring groove. Only finger pressure should be necessary to push in the housing. 1.
  • Page 759 ATTACHMENTS/CONTROL LINKAGE...
  • Page 760 Table of Contents Page Page Installing Production Outboards ... . . Steering Arm Extension Bracket Installing High Performance Outboards - Installation ..... . . 7-23 Pro Max/Super Magnum Models .

  • Page 761: Installing Production Outboards

    Installing Production WARNING Outboards Boat instability can occur at high speeds by installing engine at the wrong transom height. Contact the boat manufacturer for their recom- Determining Recommended mendations for a specific engine installation. Outboard Mounting Height 26 in. (660m 25 in.

  • Page 762: Installing High Performance Outboards - Pro Max/Super Magnum Models

    Installing High Performance IMPORTANT: The optimum height for each application will need to be determined by Outboards - Pro Max/Super individual boat testing. Some generalities may apply when increasing the transom height: Magnum Models More top speed Outboard mounting height is measured in a vertical Greater boat stability line from the top of the transom clamping bracket to the bottom of the boat.

  • Page 763: Installing Outboard On Transom

    INSTALLING OUTBOARD ON TRANSOM IMPORTANT: If using “Transom Drilling Fixture” (part number 91-98234A2), use drill guide holes Locate (and mark with pencil) vertical centerline (a) marked “A” when drilling outboard mounting of boat transom. holes. a - Centerline of Transom NOTE: Dimensions “A”...

  • Page 764: Lifting Outboard

    8. Dual Outboard Installations: Align vertical Apply “COUNTER ROTATION” decal (supplied with centerline of template with each outboards’ left hand rotation outboard) onto bottom cowl (rear) selected centerline on boat transom. Refer to of right hand rotation outboard. Match decal caution, preceding.
  • Page 765 SECURING OUTBOARD TO BOAT TRANSOM WARNING IMPORTANT: If boat is equipped with thru tilt tube Before operating, outboard(s) MUST steering, steering cable end must be installed SECURED to boat transom with four 1/2 in. into tilt tube of outboard (port outboard only for diameter bolts and lock-nuts, as follows: 2 bolts dual outboard installations) before securing must be installed thru upper mounting holes and...

  • Page 766: Rideguide Steering Cable/Attaching Kit Installation (92876A1)

    RideGuide Steering Cable/ 1. Lubricate seal (a) inside of outboard tilt tube and entire cable end (b) with Quicksilver 2-4-C Attaching Kit Installation w/Teflon. (92876A1) 2. Insert steering cable end thru outboard tilt tube and secure steering cable to tilt tube with steering cable attaching nut (c), as shown.

  • Page 767: Maintenance Instructions

    STEERING LINK ROD INSTALLATION Maintenance Instructions IMPORTANT: The steering link rod that connects Maintenance inspection is owner’s responsibility and the steering cable to the engine must be fastened must be performed at intervals specified, following: using special washer head bolt (“a” - Part Num- Normal Service - Every 50 hrs.

  • Page 768: Rideguide Steering Cable/Attaching Kit Installation (92876A3)

    RideGuide Steering Cable/ Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard to transom with 4 bolts, Attaching Kit Installation flat washers and locknuts, as shown. Be sure that installation is water-tight. (92876A3) Install upper bolts so that hex head end of bolts is on the inside of boat transom.

  • Page 769: Steering Cable Mounting Tube Installation

    Steering Cable Mounting Tube Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 locking tab Installation washers. Verify longer threaded end of tube is toward starboard side of boat. IMPORTANT: Spacers (b) must be installed between outboard swivel bracket and mounting Temporarily adjust tube so that longer threaded end bracket for steering cable mounting tube to...

  • Page 770: Coupler Installation

    Insert steering cable ends (a) thru outboard tilt tube Coupler Installation (b) and cable mounting tube (c). Thread steering cable attaching nuts (d) on to tubes hand tight. WARNING NOTE: Torque steering cable attaching nuts only Locknuts must be used with bolts to secure after final steering adjustments have been made.

  • Page 771: Steering System Tension Adjustment

    Lubricate ball joint in steering link rod with SAE 30W Loosen adjustment nuts and pull steering cable Motor Oil. Secure link rod to outboard steering arm, mounting tube (by hand) away from end of steering using special washer head bolt (10-14000) provided cable (to remove slack in steering system).

  • Page 772: Maintenance Instructions

    Tighten steering cable attaching nuts of each 3. With core of RideGuide Steering Cable (transom steering cable to a torque of 35 Ib. ft. (47.5 N·m). end) fully retracted, lubricate transom end of steering cables thru grease fittings (a) with 2-4-C w/Teflon (92-825407A2).

  • Page 773: Rideguide Steering Cable/Attaching Kit Installation (92876A6)

    RideGuide Steering Cable/ CAUTION Attaching Kit Installation With this kit installed, the upper (outboard) mounting bolts MUST BE installed so that hex (92876A6) head end of bolts is on the inside of boat transom, as illustrated. Failure to install upper Dual Cable - Dual Outboard mounting bolts, as shown in illustration, could result in interference between steering cable nut...

  • Page 774: Steering Cable Installation Starboard Outboard

    2. Make sure that both gear racks or rotary steering WARNING heads are installed so that both steering cables are routed together and will push-and-pull Locking retainer corner tabs, MUST BE bent up together. and against flats on each bolt that secures mounting bracket for steering cable mounting tube to outboard swivel bracket, to prevent bolts from turning out.

  • Page 775: Steering Cable Installation - Port Outboard

    Place a mark (a) on steering cable mounting tube (b) Insert steering cable end (b) thru tilt tube (c) of port 5/8 in. (16mm) from end of mounting tube. Slide outboard and thread steering cable attaching nut (d) plastic spacer (c), O-ring (d) and cap (e) over steering onto tilt tube hand tight.

  • Page 776: Steering Link Rod Installation

    STEERING LINK ROD INSTALLATION Both special washer head bolt and nylon insert locknuts MUST BE tightened as specified. WARNING Steering link rods MUST BE secured between outboard steering arm and steering cable end, using special washer head bolt (10-14000) and two nylon insert locknuts (11-34863), as shown.

  • Page 777: Steering Arm Extension Bracket Installation

    STEERING ARM EXTENSION BRACKET STEERING COUPLER ASSEMBLY AND INSTALLATION INSTALLATION Secure a steering arm extension bracket to each Position outboards so that they are facing straight outboard’s steering arm. forward. (Distance between threaded hole centers of steering arm extensions MUST BE equal to distance between propeller shaft centerlines.) Lubricate inside of rubber sleeves with 2-4-C w/Teflon and slide sleeves on steering coupler.
  • Page 778 Lubricate ball joint in steering eyes, with SAE 30W Torque special washer head bolts to 20 Ib. ft. (27.0 Motor Oil. N·m), then torque locknuts to 20 Ib. ft. (27.0 N·m). Assemble steering coupler between outboard steer- WARNING ing arm extension brackets, using special washer head bolts (10-14000) provided and nylon insert Both steering eyes MUST BE threaded into locknuts as shown.

  • Page 779: Steering System Tension Adjustment (Parallel Routed Steering Cables)

    STEERING SYSTEM TENSION ADJUSTMENT Tighten steering cable attaching nuts of each (PARALLEL ROUTED STEERING CABLES) steering cable to a torque of 35 Ib. ft. (47.5 N·m). IMPORTANT: For proper operation of this dual cable - dual outboard steering installation, there MUST BE proper tension in the steering system.

  • Page 780: Opposite Side Routed Steering Cables And Attaching Kit Installation

    Opposite Side Routed Steering WARNING Cables and Attaching Kit Installation Locking retainer corner tabs MUST BE bent up (One Cable Routed down Starboard Side of Boat and against flats on each bolt that secures and One Cable Routed down Port Side of Boat) mounting bracket for steering cable mounting tube, to prevent bolts from turning out.

  • Page 781: Steering Cable Installation - Port Outboard

    Place a mark (a) on steering cable mounting tube (b) STEERING CABLE INSTALLATION - 5/8 in (16mm) from end of mounting tube. Slide PORT OUTBOARD plastic spacer (c), O-ring (d) and cap (e) over steering IMPORTANT: Lubricate inside of port outboard’s cable.

  • Page 782: Steering Link Rod Installation

    STEERING LINK ROD INSTALLATION Lubricate ball joints in steering link rods with SAE 30W Motor Oil. Secure link rods to outboard steering WARNING arms, using special washer head bolts (10-14000) provided and nylon insert locknuts as shown. Torque Steering link rods MUST BE secured between special bolts to 20 lb.

  • Page 783: Steering Arm Extension Bracket Installation

    STEERING ARM EXTENSION BRACKET Thread steering eyes equally into coupler, so that INSTALLATION distance between hole centers of steering eye ball joints is equal to distance between threaded hole Secure a steering arm extension bracket to each centers of steering arm extensions. Exposed threads outboard’s steering arm.
  • Page 784 Lubricate ball joint in steering eyes with SAE 30W Torque special washer head bolts to 20 Ib. ft. (27.0 Motor Oil. N·m), then torque locknuts to 20 Ib. ft. (27.0 N·m). Assemble steering coupler between outboard WARNING steering arm extension brackets, using special washer head bolts (10-14000) provided and nylon Both steering eyes MUST BE threaded into insert locknuts, as shown.

  • Page 785: Steering System Tension Adjustment (Parallel Routed Steering Cables)

    STEERING SYSTEM TENSION ADJUSTMENT After steering system tension is adjusted correctly, (PARALLEL ROUTED STEERING CABLES) tighten adjustment nuts against mounting bracket to a torque of 35 Ib. ft. (47.5 N·m) and bend a tab lock IMPORTANT: For proper operation of this dual washer against a flat on each nut.

  • Page 786: Trim Tab Adjustment

    Trim Tab Adjustment RideGuide Steering Attachment Extension Couplers DUAL OUTBOARD - COUNTER ROTATION Listed below are typical couplers available. Refer to INSTALLATION the current Quicksilver Accessory Guide for specific 1. Shift outboard into neutral and make sure ignition coupler lengths and part numbers. key is at “OFF”...

  • Page 787: Maintenance Instructions

    1. Carefully check steering system components for WARNING wear. Replace worn parts. When 2 couplers are connected together with 2. Check steering system fasteners to be sure that coupler link rod, a lock washer must be used on they are torqued to correct specifications. each side of coupler link rod, and link rod must NOTE: RideGuide Steering Cables are lubricated at be torqued to 20 Ib.

  • Page 788: Transom Mounted Rideguide Attaching Kit Installation (73770A1)

    Transom Mounted RideGuide Attaching Kit Installation (73770A1) Attaching Kit Installation 1. Lubricate both holes in pivot block (Figure 1) with Quicksilver 2-4-C w/Teflon. 2. Place pivot block on pivot spacer and secure to transom bracket with 3/8 in. x 2-1/2 in. (9.5mm x 63.5mm) bolt, flat washer and locknut, as shown in Figure 1.

  • Page 789: Steering Cable Installation

    4. Install one cable tube jam nut onto steering cable centerline and draw a vertical line on tube. Place tab washer over RideGuide yoke, transom. (Figure 1) then insert cable tube thru tab washer and yoke. b. Position attaching kit on transom so that Install second cable tube jam nut onto cable tube transom bracket is centered on the 15 in.

  • Page 790: Maintenance Instructions

    Maintenance Instructions Installation Instructions Lubrication and maintenance inspection is owner’s 1. Install clevis to steering cable as shown. responsibility and must be performed at intervals 2. Lubricate 3/8 in. x 1-3/8 in. (9.5 mm x 34.9 mm) specified, following: bolt (area without threads) with 2-4-C w/Teflon, Normal Service - Every 50 hrs.

  • Page 791: Remote Control Installation

    Maintenance Instructions Required Side Mount Remote Control or Ignition Lubrication and maintenance inspection is owner’s responsibility and must be performed at intervals Key Switch Assembly specified, following: Normal Service - Every 50 hrs. of operation or 60 Boats Equipped with Side Mount days (whichever comes first) Remote Control *Severe Service - Every 25 hrs.

  • Page 792: Routing Location For Wiring And Hoses Thru Clamp In Bottom Cowl

    Routing Location for Wiring 1996 Models and Newer Production Outboards and Hoses thru Clamp in Bottom Cowl IMPORTANT: Sufficient slack must exist in wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.

  • Page 793: Remote Control Installation

    High Performance Outboards - Pro Max/Super Magnum Models 1. Route wiring harness, battery cables, oil hoses and control cables through rubber boots in bottom cowl at locations shown. a d c a - Remote Control Wiring Harness b - Engine Wiring Harness c - RED Trim 12 Volt Power Supply a - Bottom Cowl d - BLUE/WHITE Trim UP Lead...

  • Page 794: Throttle Cable Adjustment And Installation To The Engine

    b. Move the remote control handle into reverse 7. Place shift cable end guide (f) on anchor pin and and advance the handle to the full speed adjust cable barrel (g) so that the barrel slips position. Slowly return the handle back to the freely into the plastic barrel retainer.

  • Page 795: Battery Connections

    3. Attach throttle cable end to throttle lever anchor Battery Connections pin and secure with latch (b). CAUTION 4. With end of throttle cable connected to throttle lever, hold idle screw (c) against the stop. Adjust For dual outboard installations, the negative (–) throttle cable barrel to slip into barrel receptacle battery cable of each engines starter motor with a very light pre-load of the idle screw against...

  • Page 796: Fuel Connections

    Fuel Connections 2. Refer to page 7-32 for proper routing of fuel hose thru clamp in bottom cowl. WARNING Avoid serious injury or death from a gasoline fire or explosion. All fuel lines must meet U.S. Coast Guard approval for class “A” fuel lines. FUEL LINE Minimum fuel line inside diameter (I.D.) is 5/16 in.

  • Page 797: Auxiliary Fuel Pump

    AUXILIARY FUEL PUMP PORTABLE FUEL TANK Select a suitable location in boat within engine fuel WARNING line length limitations and secure tank in place. Avoid serious injury or death from a gasoline fire or explosion. If an auxiliary electrical fuel pump PERMANENT FUEL TANK is used to feed the mechanical pump on the These should be installed in accordance with...

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