Mariner 70 Service Manual
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Mariner 70 Service Manual

Mariner outboard motor service manual
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SERVICE
1987–1993 70 75 75 Marathon
75XD 75 Seapro 80 90
with Serial Numbers
UNITED STATES S/N 0A996142 thru 0D283221
BELGIUM
CANADA
Printed in U.S.A.
MANUAL
70 75 80 90 100 115
(3 Cylinder)
S/N 09502135 thru 09793576
S/N 0A722297 and Above
1995, Brunswick Corporation
MODELS
1988–1993 100 115 (4 Cylinder)
with Serial Numbers
UNITED STATES
BELGIUM
CANADA
S/N 0B209468 thru 0D283221
S/N 09523034 thru 09793576
S/N 0A731673 and Above
90-13645--2 1095

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  • Page 1 SERVICE MANUAL MODELS 70 75 80 90 100 115 1987–1993 70 75 75 Marathon 1988–1993 100 115 (4 Cylinder) 75XD 75 Seapro 80 90 (3 Cylinder) with Serial Numbers with Serial Numbers UNITED STATES S/N 0A996142 thru 0D283221 UNITED STATES...
  • Page 2 Notice Notice to Users of This Manual Throughout this publication, “Dangers”, “Warnings” This service manual has been written and published by the service department of Mercury Marine to aid and “Cautions” (outlined in a border and accompa- our dealers’ mechanics and company service person- nied by the International HAZARD Symbol ) are nel when servicing the products described herein.
  • Page 3 Cleanliness and Care of Service Manual Outline Outboard Motor General Information and Specifications Electrical and Ignition A marine power product is a combination of many ma- chined, honed, polished and lapped surfaces with tol- Ignition System erances that are measured in the ten thousands of an Battery, Charging System and inch.
  • Page 4 GENERAL INFORMATION AND SPECIFICATIONS...

  • Page 5: Table Of Contents

    Table Of Contents Page Page General Specification ..... . Following Complete Submersion ... . Cowl Removal .

  • Page 6: General Specification

    NOTE: Other specification (torques, etc.) are listed in the respective sections. Model 70 Model 75 Model 80 Model 90 Horsepower 70 (52.2 kw) 75 (55.9 kw) 80 (59.6 kw) 90 (67.1 kw) Idle RPM (in forward gear) 650 - 700 Full Throttle RPM Range...
  • Page 7 General Specification (continued) NOTE: Other specification (torques, etc.) are listed in the respective sections. Model 100 Model 115 Horsepower 100 (74.6 kw) 115 (85.8 kw) Idle RPM (in forward gear) 650 - 700 Full Throttle RPM Range 4750 - 5250 Piston Replacement 105 (1720.9cc) Cylinder Bore...

  • Page 8: Cowl Removal

    Filling Oil Injection System Cowl Removal Open starboard cowl (refer to cowl removal on this Pull outward on starboard side of front shield (a). page). Some earlier outboards will have a cowl brack- Remove spring (b) from latch and open cowls. et to hold cowl open as shown.

  • Page 9: Power Trim General Information

    Power Trim System Trim “In” Angle Adjustment GENERAL INFORMATION MODELS WITH POWER TRIM The power trim system is filled at the manufacturer WARNING and is ready for use. Operating some boats with outboard trimmed to the Trim outboard through entire trailering range several full “in”...

  • Page 10: Checking Trim System Fluid Level

    Checking Trim System Fluid Level Tilt Angle Adjustment IMPORTANT: This trim system is pressurized. MODELS WITHOUT POWER TRIM Remove fill screw (b) when outboard is trimmed to the full “up” position. Retighten fill screw WARNING securely. Operating some boats at minimum trim “In” at 1.

  • Page 11: Connecting Engine Wiring Harness And Routing Of Engine Battery Cables

    1. Plug remote control harness connector into en- Connecting Engine Wiring gine harness connector, then secure connector in Harness and Routing of place with retainer as shown. Engine Battery Cables 2. Wrap neoprene sheet around cable bundle and secure each end with a sta-strap. Secure to bracket with retainer.

  • Page 12: Ride-Guide Steering Cable And Pivot Points Lubrication

    Lubrication Points Lubricant Used or Description Fresh Water Frequency Salt Water Frequency Maintenance Ride-Guide Steering Cable Throttle-Shift Quicksilver Linkage Every 60 Days 60 D Every 30 Days 30 D 2-4-C Upper Shift Shaft w/Teflon w/Teflon Tilt Tube Swivel Pin Tilt Lock Lever Quicksilver Propeller Shaft Once in Season...

  • Page 13: Following Complete Submersion

    NOTE: 4 CYL. MODELS Following Complete Submersion Submerged engine treatment is divided into 3 distinct problem areas. The most critical is submersion in salt water; the second is submersion while running. Salt Water Submersion (Special Instructions) Due to the corrosive effect of salt water on internal en- gine components, complete disassembly is neces- sary before any attempt is made to start the engine.

  • Page 14: Out-Of-Season Outboard Storage

    10. Reinstall spark plugs, carburetors and fuel pump. 6. Drain and refill lower unit with Quicksilver Gear Lube, as explained in “Gear Housing Lubrication” 11. Attempt to start engine, using a fresh fuel source. (see “Table of Contents”). If engine starts, it should be run for at least one 7.

  • Page 15: How Weather Affects Engine Performance

    Out-of-Season Battery Storage Corporations internationally have settled on adoption of I.S.O. (International Standards Organization) 1. Remove battery as soon as possible and remove engine test standards, as set forth in I.S.O. 3046 all grease, sulfate and dirt from top surface. standardizing the computation of horsepower from data obtained on the dynamometer, correcting all 2.

  • Page 16: Conditions Affecting Operation

    (3.) If excessive, can make the boat veer left For boaters to realize optimum engine performance and right (bow steer). under changing weather conditions, it is essential that the engine have the proper propeller to allow it to op- 2. Boat Bottom: For maximum speed, a boat bot- erate at or near the top end of the recommended max- tom should be nearly a flat plane where it contacts imum RPM range at wide-open-throttle with a normal...

  • Page 17: Detonation: Causes And Prevention

    Detonation: Causes and Prevention Compression Check Detonation in a 2-cycle engine somewhat resembles 1. Remove spark plugs. the “pinging” heard in an automobile engine. It can be 2. Install compression gauge in spark plug hole. otherwise described as a tin-like “rattling” or “plinking” 3.
  • Page 18 ELECTRICAL AND IGNITION IGNITION SYSTEM...
  • Page 19 Table Of Contents Page Page Description ......2A-1 Ignition Components Removal and Installation .

  • Page 20: Description

    Description Test Procedures The outboard ignition system is alternator-driven with Direct Voltage Adapter (DVA) Tests distributor-less capacitor discharge. Major compo- nents of the ignition system are the flywheel, stator, WARNING trigger, switch box, ignition coils and spark plugs. DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do The stator assembly is mounted stationary below the not touch ignition components and/or metal test flywheel and has 2 capacitor charging coils.

  • Page 21: Test Sequence

    Test Sequence 3. If reading is still BELOW specification, proceed with Step 3-A. 1-A) Check primary input voltage to coils. (See 4. If reading is WITHIN specification, either the Test Chart). ignition switch, stop switch, or wiring is bad. 1. If voltage readings to coil(s) are BELOW specifi- 3-A) Check stator low speed and high speed input cation, proceed with Step 2-A.

  • Page 22: Ignition System Test Chart

    Ignition System Test Chart IMPORTANT: BEFORE attempting the ignition system checks, following, thoroughly read the preceding pages of these instructions to become familiar with the proper Automatic Distributorless Ignition (ADI) test sequence and procedures (particularly any “Safety Warnings” and “Cautions”). ALL tests are per- formed with lead wires connected –...

  • Page 23: Stator Test

    STATOR TEST WARNING NOTE: Stator can be tested without removing from When testing or servicing the ignition system, engine. high voltage is present, be extremely cautious! 1. Disconnect stator leads from switch box. DO NOT TOUCH OR DISCONNECT any ignition parts while engine is running, while key switch is 2.

  • Page 24: Ignition Coil Test

    Resistance Scale Reading IGNITION COIL TEST Test Leads (OHMS) (x__________) IMPORTANT: Ohmmeter tests can only detect cer- Between Brown Trigger Lead 7-10 700-1000 and Black Trigger Lead (R x 100) tain faults in the ignition coil. Replace ignition Between White Trigger Lead 7-10 coil, if ohmmeter readings (listed in chart, follow- 700-1000...

  • Page 25: Ignition Components Removal And Installation

    INSTALLATION Ignition Components Removal and Installation WARNING Engine could possibly start when turning flywheel Flywheel during installation; therefore, disconnect (and REMOVAL isolate) spark plug leads from spark plugs to prevent engine from starting. 1. Remove flywheel cover from engine. 1. Disconnect spark plug leads from spark plugs. WARNING 2.

  • Page 26: Stator

    Stator INSTALLATION 1. Install stator as shown. REMOVAL 1. Remove flywheel; refer to “Flywheel Removal.” 2. Remove screws. 51124 a - Screws; apply Loctite Grade “A” on threads (unless Patch 51123 Screw used) and torque to 60 lbs. in. (6.6 Nm) b - Stator a - Screws 2.

  • Page 27: Trigger

    Trigger INSTALLATION 1. Install trigger and connect link arm. REMOVAL 1. Remove flywheel and stator; refer to “Flywheel” and “Stator” removal, preceding. 2. Disconnect link arm and remove trigger. 19459 a - Trigger b - Link Arm 19459 2. Connect trigger leads to switch box; refer to wiring a - Link Arm diagrams in Section 2D.

  • Page 28: Ignition Coils (3 Cylinder Models)

    Ignition Coils (3 Cylinder Models) Ignition Coils (4 Cylinder Models) 1. Refer to wiring diagrams in Section 2D when con- 1. Refer to wiring diagrams in Section 2D when con- necting wires. necting wires. 19455 25931 a - Coils a - Coils b - Cover b - Cover c - Hex Nuts;...

  • Page 29: Switch Box

    Switch Box 1. Refer to wiring diagrams in Section 2D when con- necting wires. 19454 a - Switch Box b - Bushings c - J-Clip d - Bolt [Torque to 40 lb. in. (4.5 N·m)] e - Screw (Secure coil ground wires under screw) f - Coil Ground Wires (BLACK) 2A-10 ELECTRICAL AND IGNITION...
  • Page 30 ELECTRICAL AND IGNITION 11669 BATTERY, CHARGING SYSTEM, AND STARTING SYSTEM...
  • Page 31 Table of Contents Page Page Battery ........2B-1 3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram...

  • Page 32: Battery

    Battery Recommended Battery The 2-cycle Outboard type engine requires a 12 volt Precautions battery with a “Cold Cranking Amperage” rating for When charging batteries, an explosive gas mixture cranking and a “Reserve Capacity” rating. The mini- forms in each cell. A portion of this gas escapes thru mum should be a “Cold Cranking Amperage”...

  • Page 33: Specific Gravity Readings

    5. Avoid dropping electrolyte on boat or clothing, as Specific Gravity Readings it is extremely corrosive. Wash off immediately Use a hydrometer to measure specific gravity of elec- with baking soda solution. trolyte in each cell. Specific gravity of electrolyte varies not only with per- centage of acid in liquid but also with temperature.

  • Page 34: Charging A Discharged Battery

    1. Remove battery from its installation as soon as Charging a Discharged Battery possible and remove all grease, sulfate and dirt The following basic rules apply to any battery charg- from top surface by running water over top of bat- ing situation: tery.

  • Page 35: Optional Voltage Regulator Test

    Optional Voltage Battery Charging System Regulator Test (9 Ampere Alternator) 1. Check battery voltage at Description battery with engine running. The battery charging system components are the sta- 2. If battery voltage is above 14.5 volts, replace volt- tor, rectifier, and battery. Alternating current (gener- age regulator.

  • Page 36: Battery Charging System Troubleshooting

    2. Use an ohmmeter and perform the following test. Battery Charging System Troubleshooting IMPORTANT: If stator is mounted on engine, black stator lead (if provided) must be grounded to pow- A fault in the battery charging system usually will erhead when testing. cause the battery to become undercharged.

  • Page 37: Standard Stator (Alternator Coils)

    9. With engine running at the indicated RPM’s, the Standard Stator (Alternator Coils) ammeter should indicate the following approxi- 9 Amperes Output mate amperes: IMPORTANT: Rectifier must be functioning prop- AMPERES IDLE erly for accurate test results to be obtained. 1000 1.

  • Page 38: 16 Ampere Alternator System Test

    16 Ampere Alternator System Test Optional 24 Amp Alternator System Test (SMALL VOLTAGE REGULATOR/RECTIFIER) (LARGE FINNED VOLTAGE REGULATOR/RECTIFIER) 1. Check battery voltage at battery with engine run- 1. Check battery voltage at battery with engine ning. running. 2. If battery voltage is above 14.5 volts, replace volt- 2.

  • Page 39: Tachometer Terminal Block (Design 1)

    Tachometer Terminal Block (Design 1) DESCRIPTION ALT YEL Contains a diode which blocks high voltage AC GREY pulses (180 VAC) coming from the stator and allows TACH low voltage DC pulses (20-30 VDC) to pass through ALT YEL to be counted by the tachometer. This terminal block (with diode) is only used with large, finned type regu- lators.

  • Page 40: Cylinder 16 And 24 Ampere Battery

    3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW 50405 a - Stator e - To Remote Control Harness...

  • Page 41: Cylinder 16 Ampere Battery Charging

    3 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW 51000 a - Stator...
  • Page 42 4 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW 50406 a - Stator e - To Remote Control Harness...

  • Page 43: Cylinder 16 Ampere Battery Charging Wiring Diagram (With Small Voltage Regulator/Rectifier)

    4 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW 51001 a - Stator...

  • Page 44: Cylinder Battery Charging Diagram With Battery Isolator

    3 Cylinder Battery Charging Diagram with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW Move Red Lead From Start Solenoid to Position Shown Start...

  • Page 45: Cylinder Battery Charging Diagram With Battery Isolator (Small Voltage Regulator)

    3 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW Small (Sense)Lead Large Red...

  • Page 46: Cylinder Battery Charging Diagram With Battery Isolator

    4 Cylinder Battery Charging Diagram with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW Move Red Lead From Start Solenoid to Position Shown User Supplied Red Lead...

  • Page 47: Cylinder Battery Charging Diagram With Battery Isolator (Small Voltage Regulator)

    4 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion. BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW Small Red (Sense) Lead...

  • Page 48: Rectifier Test

    Rectifier Test WARNING Disconnect battery leads from battery before testing rectifier. NOTE: Rectifier can be tested without removing from engine. 1. Disconnect all wires from terminals on rectifier. 07300 2. Use an ohmmeter (R x 1000 scale) and perform the following test. Refer to illustration for rectifier a - Terminal d - Stator Terminals terminal identification.

  • Page 49: Starting System

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

  • Page 50: Starting Circuit Troubleshooting Flow Chart

    Battery Starter Solenoid Starter Starter Solenoid Fuse Holder (If Equipped) (20 Amp Fuse) Neutral Start Switch (Located in Control Housing) Ignition Switch Starter Circuit Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking.
  • Page 51 TEST 2 a - Disconnect BLACK ground wire(s) from Test Point 2. No voltage reading; proceed to TEST 3. b - Connect voltmeter between common engine ground and Test Point 2. c - Turn ignition key to “Start” position. TEST 3 12 Volt Reading* Check BLACK ground wire for a - Reconnect BLACK ground wire(s).

  • Page 52: Starter Motor

    Starter Motor Disassembly 1. Remove 2 thru bolts and commutator end cap, Removal taking care not to lose brush springs. CAUTION Disconnect battery leads from battery before removing starter. 1. Disconnect battery leads from battery. 2. Disconnect YELLOW cable. 11646 3.

  • Page 53: Starter Cleaning, Inspection And Testing

    Starter Cleaning, Inspection and 11. Check the armature for ground. See the following procedure (“Testing”). Testing Testing CLEANING AND INSPECTION ARMATURE TEST FOR SHORTS 1. Clean all starter motor parts. Check armature for short circuits by placing on 2. Check pinion teeth for chips, cracks or excessive growler and holding hack saw blade over armature wear.

  • Page 54: Checking Positive Brushes And Terminal

    CHECKING POSITIVE BRUSHES AND STARTER SOLENOID TEST TERMINAL 1. Disconnect all wires from solenoid. Set ohmmeter to (R x 1 scale). Connect meter leads 2. Use an ohmmeter (R x 1 scale) and connect meter between POSITIVE brushes. Meter must indicate full leads between solenoid terminals 1 and 2.

  • Page 55: Brush Replacement

    Brush Replacement 2. If removed, reinstall parts on armature shaft. Use a new locknut and tighten securely on end of STARTER REASSEMBLY shaft. 1. If brushes were removed, replace as follows: a. Install POSITIVE brushes (along with POS- ITIVE terminal) into commutator end cap. 11658 a - Locknut b - Spacer...
  • Page 56 Metric Scale 11648 = 76.2mm = 50.8mm a - Alignment Marks 1-3/4 = 44.5mm 1-11/16 = 42.9mm b - Alignment Marks = 19.1mm c - Bolts [Torque to 70 lb. in. (7.9 N·m)] = 12.7mm 90-13645--2 495 ELECTRICAL AND IGNITION 2B-25...

  • Page 57: Installation

    Installation 2. Install components as shown. 3. Connect battery leads to battery. 1. Install 2 rubber collars and 2 rubber bumpers. 11645 a - Rubber Collars b - Rubber Bumpers 19452 a - Starter b - Rubber Mount, oil tank c - Clamp, upper d - BLACK Cable e - Bolt and Lockwasher...
  • Page 58 ELECTRICAL AND IGNITION 22480 TIMING/SYNCHRONIZING/ADJUSTING...
  • Page 59 Table Of Contents Page Page Timing/Synchronizing/ Timing/Synchronizing/ Adjusting (3 Cylinder Models) ... 2C-1 Adjusting (4 Cylinder Models) ... 2C-6 Specifications .

  • Page 60: Timing/Synchronizing/Adjusting (3 Cylinder Models)

    Idle RPM (in “FORWARD” Gear) 650 - 700 Specifications Maximum Timing @ 5000 RPM 16_ B.T.D.C. (@ Cranking Speed) (18_ B.T.D.C.) 70, 75 and 80 Models Idle Timing 0_ - 4_ B.T.D.C. Serial Number and Above Spark Plug NGK BUHW-2 U.S.

  • Page 61: Carburetor Synchronization

    4. Reposition timing pointer if necessary, so that tim- ing pointer is aligned with 0.491 in. (12.47 mm) timing mark on flywheel. Retighten attaching screws. 20440 22480 a - Set Screw a - Timing Pointer b - Synchronizing Screws b - Timing Mark 9.

  • Page 62: Carburetor/Oil Pump Synchronization

    11. Holding throttle arm against throttle stop screw, TIMING ADJUSTMENTS adjust cam follower, so that a clearance of 0.005 in. - 0.020 in. (0.127 - 0.508 mm) exists between CAUTION roller of cam follower and throttle cam. Tighten set Engine is timed while cranking engine with starter screw securing cam follower.

  • Page 63: Maximum Timing

    MAXIMUM TIMING 2. Install remaining spark plugs and high tension spark plug leads. 1. Hold control arm so that maximum spark advance screw is against stop. 2. Crank engine with starter motor and adjust maxi- mum spark advance screw to align the specified BTDC timing mark on flywheel with timing pointer (due to the advance characteristic of this ignition system, this cranking speed adjustment will auto-...

  • Page 64: Throttle Cable Installation

    2. Shift into “Forward” gear and adjust carburetor Throttle Cable Installation low speed mixture screws properly (refer to “Car- 1. With end of throttle cable connected to throttle le- buretor” section). ver, hold throttle lever against idle stop. Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop.

  • Page 65: Timing/Synchronizing/Adjusting (4 Cylinder Models)

    Timing Pointer Alignment Timing/Synchronizing/ Adjusting (4 Cylinder Models) WARNING Specifications Engine could start when turning flywheel to check timing pointer alignment. Remove all spark plugs Models 100/115 from engine to prevent engine from starting. Full Throttle RPM Range 4750 - 5250 1.

  • Page 66: Carburetor Synchronization

    CARBURETOR SYNCHRONIZATION 1. Remove sound box cover. 2. Loosen cam follower adjustment screw. 3. Loosen 6 synchronizing screws. 4. Look into throats of carburetors and make sure all throttle shutters are completely closed. 5. Apply light down pressure on carburetor synchro- nizing shaft and tighten 6 synchronizing screws from top to bottom.

  • Page 67: Carburetor/Oil Pump Synchronization

    11. Hold throttle cam in full throttle position. If neces- CARBURETOR/OIL PUMP SYNCHRONIZATION sary adjust acceleration pump adjusting bolts po- IMPORTANT: Some engines may have an addi- sition so that a gap of 0.030 in. (0.762mm) exists tional stamped mark (d) which SHOULD NOT be between throttle cam and top of acceleration used.

  • Page 68: Maximum Timing

    1. Connect timing light to no. 1 (top) spark plug lead. MAXIMUM TIMING 2. Shift engine into neutral. 1. Hold control arm against maximum advance stop. Crank engine with starter motor and adjust maxi- 3. Holding throttle arm at idle position, crank engine mum advance screw to align 25 BTDC mark on with starter motor and adjust idle timing screw to flywheel with timing pointer (due to the advance...

  • Page 69: Carburetor Specifications

    Carburetor Specifications Carburetor number stamped at TOP of carburetor mounting flange NOTE: Early model engines may have identification stamped on face of air box mounting flange. Carb Number Location Model HP Main Jet* Bowl* Vent Jet WME-11, 20- 1 Top Carburetor Top Center Carburetor .054 None...

  • Page 70: Idle Adjustment

    Idle Adjustment Throttle Cable Installation 1. With engine in water, connect electrical harness 1. With end of throttle cable connected to throttle le- and fuel line to engine. Start engine and allow to ver, hold throttle lever against throttle stop. Adjust warm up.
  • Page 71 ELECTRICAL AND IGNITION WIRING DIAGRAMS...
  • Page 72 Table Of Contents Page Page Engine Wiring Diagram (3 Cylinder Power Trim System Wiring Diagram Models with Low Oil Warning Module) ..2D-1 (4 Cylinder Models using COMMANDER 2000 Side Mount Remote Control) ..2D-8 Engine Wiring Diagram (3 Cylinder Tachometer (with Adjustable Dial) and...

  • Page 73: Engine Wiring Diagram (3 Cylinder Models With Low Oil Warning Module)

    Engine Wiring Diagram (3 Cylinder Models With Low Oil Warning Module) BLK D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN VIO D VIOLET WHT D WHITE YEL D YELLOW 50388 a - Stator...

  • Page 74: Models Without Low Oil Warning Module) . 2D-2

    Engine Wiring Diagram (3 Cylinder Models Without Low Oil Warning Module) BLK D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN VIO D VIOLET WHT D WHITE YEL D YELLOW 23888 a - Stator...

  • Page 75: Engine Wiring Diagram (3 Cylinder Models With Small Voltage Regulator/Rectifier)

    Engine Wiring Diagram (3 Cylinder Models With Small Voltage Regulator/Rectifier) BLK D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN VIO D VIOLET WHT D WHITE YEL D YELLOW 51003 a - Stator...

  • Page 76: Engine Wiring Diagram (4 Cylinder Models)

    Engine Wiring Diagram (4 Cylinder Models) BLK D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN VIO D VIOLET WHT D WHITE YEL D YELLOW 50389 a - Stator k - Voltage Regulator/Rectifier b - Trigger...

  • Page 77: Engine Wiring Diagram (4 Cylinder Models With Small Voltage Regulator/Rectifier)

    Engine Wiring Diagram (4 Cylinder Models With Small Voltage Regulator/Rectifier) BLK D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN VIO D VIOLET WHT D WHITE YEL D YELLOW 51002 a - Stator...

  • Page 78: Power Trim System Wiring Diagram

    Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control) BLK D BLACK BLU D BLUE GRN D GREEN RED D RED WHT D WHITE 23886 a - Power Trim Pump Motor e - Red (+) Battery Cable b - Trim Solenoid “UP”...

  • Page 79: Power Trim System Wiring Diagram (3 Cylinder Models Using Commander Side Mount Remote Control)

    Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER Side Mount Remote Control) BLK D BLACK BLU D BLUE GRN D GREEN PUR D PURPLE RED D RED WHT D WHITE 23884 a - Power Trim Pump Motor e - Fuse Holder (20 Amp Fuse) b - Trim Solenoid “UP”...

  • Page 80: Power Trim System Wiring Diagram (4 Cylinder Models Using Commander 2000 Side Mount Remote Control)

    Power Trim System Wiring Diagram (4 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control) BLK D BLACK BLU D BLUE GRN D GREEN RED D RED WHT D WHITE 23885 a - Power Trim Pump Motor e - Red (+) Battery Cable b - Trim Solenoid “UP”...

  • Page 81: Tachometer (With Adjustable Dial) And Trim Indicator Gauge Wiring Diagram

    Tachometer (With Adjustable Dial) and Trim Indicator Gauge Wiring Diagram BLK D BLACK BRN D BROWN GRY D GRAY PUR D PURPLE TAN D TAN WHT D WHITE BATT SENDER a - Tachometer d - Tachometer/Accessories Harness Plug from Remote Control b - Position Dial to Point Toward “4”...

  • Page 82: Key/Choke Switch Continuity Test (Commander 2000 Side Mount Remote Control)

    Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount Remote Control) BLK D BLACK PUR D PURPLE RED D RED YEL D YELLOW 23894 “OFF” BLK/YEL – BLK “RUN” RED – PUR “START” RED – PUR – YEL/RED PUSH (CHOKE)* RED – YEL/BLK *Key switch must be positioned to “RUN”...

  • Page 83: 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 D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN WHT D WHITE YEL D YELLOW 23891 a - Ignition/Choke Switch...

  • Page 84: Commander 2000 Side Mount Remote Control (Electric Start With Warning Horn) Wiring Diagram

    COMMANDER 2000 Side Mount Remote Control (Electric Start With Warning Horn) Wiring Diagram BLK D BLACK BLU D BLUE BRN D BROWN GRY D GRAY GRN D GREEN PUR D PURPLE RED D RED TAN D TAN WHT D WHITE YEL D YELLOW 23892 a - Ignition/Choke Switch...

  • Page 85: 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 D BLACK BLU D BLUE BRN D BROWN GRN D GREEN GRY D GRAY PUR D PURPLE RED D RED TAN D TAN WHT D WHITE YEL D YELLOW LIT D LIGHT 24072...
  • Page 86 FUEL SYSTEM AND CARBURETION...
  • Page 87 Table Of Contents Page Page Fuel Pumps ......3A-1 Idle Speed Adjustment .

  • Page 88: Fuel Pumps

    If, after using a separate fuel supply, it is found that Fuel Pumps the anti-siphon valve is the cause of the problem, there are 2 solutions to the problem; either (1) remove General Information the anti-siphon valve or (2) replace it with a solenoid- FUEL PUMP DESCRIPTION/OPERATION operated fuel shutoff valve.

  • Page 89: Fuel Pump Components (Design 1)

    Troubleshooting Fuel Pump Fuel Pump Components (Design 1) (continued) NOTE: In fuel pump reassembly, remember that re- spective diaphragms go against the mating surfaces PROBLEM: LACK OF FUEL PUMP PRESSURE of the fuel pump body, and respective gaskets are be- Possible Cause Corrective Action tween the diaphragms and end caps.

  • Page 90: Fuel Pump Removal/Installation (Design 1)

    S Attach fuel lines (inlet and outlet). Fuel Pump Removal/Installation S Attach oil injection hose. (Design 1) S Attach pulse hose. S Remove 4 hoses from fuel pump. S Secure each hose connection with a sta-strap. S Remove 2 phillips-head screws -- lift off fuel pump. S Remove 2 hex-head bolts to disassemble fuel pump.

  • Page 91: Check Valve Reassembly

    Check Valve Reassembly 4. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap rod down ASSEMBLY (DESIGN I) into retainer until flush with top of retainer. 1. Insert retainer thru plastic disc and rubber check valve.
  • Page 92 2. Install check valves and retainers into fuel pump Step-by-Step Reassembly body. IMPORTANT: ALWAYS REPLACE GASKETS. STEP-BY-STEP FUEL PUMP REASSEMBLY After reassembling check valve in fuel pump body, using the following procedure will help insure proper reassembly: 1. Insert two 3 in. minimum length 1/4 bolts (not the fuel pump bolts) OR 1/4 dowels, through the opposite large holes (6mm bolt holes) in the chamber plate, as locating dowels, and turn plate...
  • Page 93 70-75-80-90 (3 cyl.) (Design 1) Previous body with rubber check valve retainers was colored black. 50289 a - Body (Opposite Side View) b - Natural Body (Off White) c - Rubber Valve d - Cover (Opposite Side View) e - Plastic Disc...
  • Page 94 100-115 (4 cyl.) (Design 1) Previous body with rubber check valve retainers was colored black. 50291 a - Body (Opposite Side View) b - Natural Body (Off White) c - Rubber Valve d - Cover (Opposite Side View) e - Plastic Disc f - Plastic Check Valve Retainer g - Two Oil Passage Holes h - Cast Aluminum Cover...
  • Page 95 REASSEMBLY SEQUENCE (DESIGN 1) CAUTION Observe position both Pulse Chamber DIAPHRAGM and GASKET. The two larger holes allow oil injection output to enter the gas flow. Failure to reinstall as shown WILL result in extensive damage to engine. 51119 a - Chamber Plate (Step 1) b - Boost Compression Spring &...
  • Page 96 70-75-80-90 (3 cyl.) (Design 2) 51549 a - Body (Opposite Side View) b - Rubber Valve c - Plastic Disc d - Cover (Opposite Side View) e - Plastic Check Valve Retainer f - Cast Aluminum Cover g - Three Tabs...
  • Page 97 100-115 (4 cyl.) (Design 2) 51548 a - Body (Opposite Side View) b - Rubber Valve c - Plastic Disc d - Cover (Opposite Side View) e - Plastic Check Valve Retainer f - Cast Aluminum Cover g - Body h - Three Tabs i - Three Tabs 3A-10...
  • Page 98 MODEL 100, 115 Installation of Design 2 Fuel Pump MODEL 70, 75, 80, 90 51519 a - Clear Tube [8 in. (203.2mm)] 51519 b - To Oil Pump Outlet c - Check Valve a - Clear Tube [5.5 in. (139.7mm)] b - To Oil Pump Outlet d - Hose [1.5 in.

  • Page 99: Carburetion

    PROBLEM: ENGINE FLOODS Carburetion Possible Cause Corrective Action Fuel System Troubleshooting Dirt or foreign particles Flush out inlet seat and are preventing inlet clean inlet needle. Troubles, that are caused by items 1-thru-5, listed be- needle from seating. low, may give the impression that a problem exists in Worn inlet needle.

  • Page 100: Checking For Restricted Fuel Flow

    PROBLEM 1: ENGINE IDLES ROUGH AND A crack in the fuel outlet Replace. STALLS tube (located in fuel tank.) PROBLEM 2: ENGINE RUNS UNEVEN OR Anti-Siphon valve Refer to “Checking for SURGES restricting fuel flow. Restricted Fuel Flow PROBLEM 3: ENGINE WILL NOT ACCELERATE Caused by Anti-Siphon Possible Cause Corrective Action...

  • Page 101: Fuel System (Carburetor)

    Fuel System (Carburetor) Specifications Float Setting – 7/16 in ("0.015 in.) Float Weight – 7 grams ("0.4 grams) Idle Adjustment Screw – 1-1/2 turns ("1/4) (Set Halfway Between Lean and Rich) IMPORTANT: DO NOT touch this adjustment. This is preset by the manufacturer, and is NOT for field service.
  • Page 102 Fuel System (Carburetor) (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Carburetor Body Gasket Retaining Ring Fuel Bowl Throttle Shaft (Upper/Bottom) Throttle Shaft (Center) Throttle Valve Float Float Shaft Inlet Needle Valve Plug Gasket Gasket Gasket Screw Screw Screw Cover Plate Main Jet...

  • Page 103: Fuel System (Linkage)

    Fuel System (Linkage) 4 Cylinder Carburetor/Linkage Arrangement 3 Cylinder Carburetor/Linkage Arrangement a - Screw (6) b - Washer (6) c - Carburetor Link d - Carburetor Link e - Oil Injection Pump Link Rod f - Roller g - Throttle Shaft a - Sta-Straps (4) h - Throttle Link b - Fuel Liners (2)

  • Page 104: Carburetor Adjustments

    3. If necessary, adjust float level by bending metal indicated, following: tab on float to which inlet needle is clipped. 70 H.P. --- 1-1/4 90 H.P. --- 1-1/2 11.1 mm (7/16 in.) 75 H.P.

  • Page 105: Specification Sheet - Wme Carburetors

    Specification Sheet - WME Carburetors Carburetor Number Stamped at TOP of carburetor mounting flange. NOTE: Early model engines may have identification stamped on face of air box mounting flange. Carburetor Number Location Model H.P. Main Jet* Bowl Vent Jet* WME-9 - 1 Top Carburetor .064 .094...

  • Page 106: Idle Speed Adjustment

    Bowl Vent 5000 ft. Model Number Size (inch) Jet (inch) Model (1524m) WME-7 .072 .094 70, 75, 80, 90 – Std. Ratio – 2.33:1 None Available WME-8, 17 .068 .094 100, 115 – Std. Ratio – 2.08:1 2.33:1 WME-9 .064 .094 WME-10 .072...

  • Page 107: Jet Orifice Size/Part Number Chart

    JET ORIFICE SIZE/PART NUMBER CHART CARBURETOR REMOVAL AND DISASSEMBLY NOTE: Thread size for jets is 10-32. Carburetor Removal - remove the six nuts (on carb studs), and lift off carburetor assembly. See Section JET ORIFICE SIZE/PART NUMBER CHART 4A, this manual, for step-by-step procedure. To Disassemble Orifice Orifice...

  • Page 108: Carburetor Disassembly

    S Remove fuel inlet needle. Carburetor Disassembly S Remove stem gasket. S Remove main jet plug and gasket. S Remove main jet. 51116 51116 a - Fuel Inlet Needle b - Stem Gasket a - Main Jet Plug and Gasket S Remove mixing chamber cover and gasket.

  • Page 109: Cleaning And Inspection

    S Install mixing chamber cover and gasket as CLEANING AND INSPECTION shown. 1. Carefully inspect carburetor body and fuel bowl S Install low speed mixture screw. for cracks, stripped threads, plugged or restricted passages and passage plugs that show signs of S Install bowl vent jet (back drag) (3-Cylinder Models leakage.

  • Page 110: Idle Air Screw

    S Install stem gasket. S Install float bowl. S Install fuel bowl gasket. 51119 a - Stem Gasket b - Fuel Bowl Gasket NOTE: If spring clip on inlet needle was removed, or 51116 if needle was replaced, be sure spring clip is a - Float Bowl reattached.

  • Page 111: Enrichener System

    Description for Four Cylinder Engines Enrichener System Enrichener valve receives fuel from a T-fitting be- Description for Three Cylinder tween #1 and #2 carburetors. Valve is electrically Engines opened when ignition key is turned to the “ON” posi- tion and pushed in (and held in). Fuel is dispensed to Fuel flows from top carburetor float bowl to fuel en- T-fittings on intake manifold of cylinders #2 and #4.

  • Page 112: Enrichener Valve Test

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

  • Page 113: Acceleration Pump Circuit Operation - Four Cylinder Engines

    Acceleration Pump Circuit Operation - FLOW RESTRICTOR - Helps equalize pressure with- in the accelerator pump circuit while allowing air or Four Cylinder Engines any vapor which has formed to pass through and be ACCELERATOR PUMP - Receives pressurized fuel vented at the carburetors.

  • Page 114: Acceleration Pump Fuel Flow Circuit For Four Cylinder Engines

    Acceleration Pump Fuel Flow Circuit for Four Cylinder Engines +5 .0 PSI CARB. +4 .5 PSI CARB. ACCELERATOR LARGE PUMP FUEL FILTER +4.0 PSI SMALL FUEL FILTER +5 .0 PSI CYL. #3 CARB. FUEL PUMP CHECK VALVES LOCATED IN CYLINDER BLOCK TRANSFER PORTS (UNSEAT AT 11–14 PSI –0 .5 PSI...

  • Page 115: Fuel Tank

    Fuel Tank Fuel Tank Components MAINTENANCE The inside of the fuel tank should be cleaned once each season. Dirt or water may have entered the fuel tank during refilling. Clean the tank by flushing with clean, lead-free gasoline or kerosene. If a fuel restriction problem is encountered, the fuel filter on end of outlet tube may be obstructed.

  • Page 116: Fuel Line And Primer Bulb Assembly

    Fuel Line and Primer Bulb Assembly a - Fuel Line Assembly b - Primer Bulb Assembly c - Check Valve, Inlet d - Fittng, Outlet e - Clamp, Primer Bulb to Check Valve (Large) f - Clamp, Fuel Line to Check Valve (Small) g - Connector, Fuel Tank (Outlet) h - Connector, Engine (Inlet) i - Clamp, Fuel Line to Connector...

  • Page 117: Maintenance

    Maintenance 2. To install fuel line clamps, grip hose clamp with pliers and push down on hook with screwdriver Periodically check fuel line and primer bulb for cracks, until hooks interlock. breaks, restrictions or chafing. Check all fuel line con- nections for tightness.
  • Page 118 OIL INJECTION SYSTEM...
  • Page 119 Table Of Contents Page Page Description ......3B-1 Models Equipped with Test Button (3 Cylinder Only) .

  • Page 120: Description

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

  • Page 121: Filling Oil Tank

    Filling Oil Tank Carburetor/Oil Pump Synchronization 1. Quicksilver 2-Cycle Outboard Oil is recom- mended for this oil injection system. In an emer- 1. While holding throttle arm at idle position, adjust gency, when Quicksilver 2-Cycle Outboard Oil is length of link rod so that stamped mark of oil pump not available, substitute a high quality 2-cycle oil body aligns with stamped mark of oil pump lever, that is intended for outboard use and meets BIA...

  • Page 122: Bleeding Air From Oil Injection System

    4 Cylinder: pump # 44345/44345--1/44345--2 = 28.6 2.6cc pump # 44345--3 = 33.3 NOTE: Pump output specifications are derived at 70 degrees room temperature. Cooler or warmer test temperature will result in LESS oil pump discharge. 22988 a - Outlet Hose...

  • Page 123: Low Oil Sensor Test

    With the ignition switch in the “Run” position, electrical Low Oil Sensor Test current is routed thru the warning horn and supplied to the powerhead temperature sensor, low oil sensor, NOTE: Low oil sensor is located in bottom of oil tank. and warning horn test button.

  • Page 124: Models Not Equipped With Test Button (3 And 4 Cylinder)

    Models Not Equipped With Test Button (3 and 4 Cylinder) DESCRIPTION Self-test of the warning system is performed by turning the ignition key to the “RUN” position. A steady beep is indicative of an overheat condition. An intermittent beep refers to a low oil condition. Both overheat and low oil conditions are monitored by a warning module mounted on the starboard side of the engine block.

  • Page 125: Warning Horn System Wiring Diagram

    WARNING HORN SYSTEM WIRING DIAGRAM a - Ignition Switch e - Terminal Block h - Magnetic Float b - Powerhead Temperature Sensor f - Warning Horn i - Warning Horn Test Button (Some c - Battery g - Low Oil Sensor Models) d - Wiring Harness Connectors 3B-6...

  • Page 126: Oil Injection System Troubleshooting Chart (Models With Warning Module)

    NOTE: There is a safety reserve of oil left in the reser- Oil Injection System voir after the low oil warning is sounded. There is Troubleshooting Chart enough oil for approximately 50 minutes of full throttle operation on four cylinder engines and approximately (Models with Warning Module) 1 hour of full throttle operation on three cylinder en- gines.
  • Page 127 POWERHEAD 20032 3-CYLINDER ENGINES...
  • Page 128 Page Page Throttle Lever And Linkage Wave Washer Cylinder Cover, Exhaust Divider Plate Removal - Models 70-75-80-90-100 ..4A-1 and Exhaust Cover ....

  • Page 129: Throttle Lever And Linkage Wave Washer

    - Wave Washer (Remove) q - Throttle Cam h - Swivel Bushings (2) r - Return Spring When servicing 3 cylinder model 70-75-80-90 and 4 i - Nylon Caps (2) s - Stud cylinder 100/115 HP outboards for any reason, remove...

  • Page 130: Crankshaft Assembly

    Crankshaft Assembly Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) 2 Cycle Outboard Oil (92-13249A24) 4A-2 POWERHEAD 90-13645--2 495...
  • Page 131 Crankshaft Assembly (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Crankshaft Upper Main Bearing O-Ring Seal Key-Flywheel Connecting Rod Connecting Rod Cap Piston Pin Needle Bearings Needle Bearing Locating Rings Piston Piston Rings - 2 Each Piston Pin Piston Pin Retainer Rings - 2 Each Rod Bearing Assembly Center Main Bearings - (32 Each Main)

  • Page 132: Powerhead Block And Cover Assemblies

    Powerhead Block and Cover Assemblies Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) Loctite Master Gasket (92-12564-1) Perfect Seal (92-34227-1) 4A-4 POWERHEAD 90-13645--2 495...
  • Page 133 Powerhead Block and Cover Assemblies (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Cylinder Block Exhaust Plate Cover Exhaust Divider Plate Exhaust Plate Gaskets Thermostat/Poppet Valve Cover Thermostat/Poppet Valve Cover Gasket Thermostat Poppet Valve Assembly Temperature Sensor Cylinder Cover Cylinder Cover Gasket Starter Hold-Down Brackets Gasket--Powerhead to Driveshaft Housing...

  • Page 134: Torque Specifications, Torque Sequences

    Torque Specifications, Torque Sequences Reed Block Assembly Connecting Rod Bolts Flywheel Nut 120 lb. ft. (162.7 Nm) 80 lb. in. (9.0 Nm) 30 lb. ft. (40.7 Nm) Check Alignment Turn bolt 90_ further after torque of 30 lb. ft. is reached IMPORTANT: See page 4A-32 (this Section) Intake Manifolds...
  • Page 135 Cylinder Block Cover 18 lb. ft. (24.4 Nm) Electrical Component Plate 13.5 lb. ft. (18.3 Nm) Loctite 271 Required. Exhaust Cover (and Divider Plate) 18 lb. ft. (24.4 Nm) We recommend that you read the sub-section on reassembly BEFORE proceeding. There are specifics relating to this engine which are NOT applicable to prior engines.
  • Page 136 TORQUE SPECIFICATIONS Application (Listed in Reassembly Sequence) Torque Rod Cap Bolts 1st Torque 15 lb. in. (1.7 Nm) 2nd Torque (after checking alignment) 30 lb. ft. (40.7 Nm) Recheck Alignment NOTE: See page 4A-32 Crankcase End Cap Bolts (Lower) 18 lb. ft. (24.4 Nm) Crankcase Cover 1st Torque Pattern (Large Bolts) 25 lb.

  • Page 137: Tools For Powerhead Repair

    Tools for Powerhead Repair Powerhead Component Removal Part No. Tool Description 91-52344 Flywheel Holder 1. Remove Front Cowl Bracket before removing air box cover, by removing 2 bolts, cable retainer, 91-24161 Protector Cap and fuel connector. Bushings normally remain in 91-73687A1 Flywheel Puller brackets.
  • Page 138 3. Remove 10mm bolt from lower oil tank support (starboard side of engine, base). 4. Remove 2 (8mm) Bolts from upper oil tank neck brace. 5. Remove Air Box by removing 6 nuts and pulling off of carburetor studs. 6. Disconnect Oil Lines - Remove Oil Reservoir. 1-unit Removal Of Carburetor Assembly.

  • Page 139: Flywheel Removal

    11. The intake manifolds may be removed as 1-unit. Flywheel Removal CAUTION DO NOT strike end of puller center bolt to remove flywheel, or damage may result to crankshaft or bearings. 1. Remove flywheel cover from powerhead. 2. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer.
  • Page 140 6. Remove Rear Cowl Mounting Bracket from pow- 8. Remove shift arm linkage at stud. erhead by removing 4 bolts. 7. Remove Ignition Components, from powerhead, including starter motor S Stator Plate and Trigger S Starter Motor S Electrical Components Mounting Plate S Plug Wires S Temperature Sensor S Solenoid...

  • Page 141: Powerhead Disassembly

    5. Remove thermostat housing and components. Powerhead Disassembly 1. Remove fuel pump by removing 2 screws. 2. Remove oil injection pump by removing 2 bolts. 3. Remove hoses to fuel pump and oil injection pump. 25907 a - Bolts b - Thermostat Cover c - Thermostat d - Poppet Valve 6.
  • Page 142 8. Remove 3 bolts from crankcase end cap (lower). 19314 13. Remove main roller bearing assemblies (2) from crankshaft as follows; S Remove retaining ring. S Remove race. 20020 a - Bolts S Remove main roller bearings. b - End Cap 9.
  • Page 143 IMPORTANT: On some engines, BOTH the piston 18. Use piston ring expander (91-24697) to remove rod and rod cap bolt holes are threaded. The rod piston rings. Always install new piston rings. cap and rod must be aligned and held tight togeth- NOTE: Cylinders must be honed in order for new rings er when threading in rod cap bolts.
  • Page 144 21. Remove piston pin needle bearings (29 per piston 23. Press crankshaft out of bearing, as shown. pin) and locating washers ( 2 per piston) as shown. IMPORTANT: We recommend that you use new needle bearings at reassembly for lasting repair. However, if needle bearings must be re-used, keep each set of bearings identified for reas- sembly on same connecting rod.

  • Page 145: Cleaning And Inspection

    Seal carrier is press-fitted into the spline end of crank- Cleaning and Inspection shaft. Cylinder Block and Crankcase Cover NOTE: Seal should be replaced as a routine proce- dure without regard to appearance, to prevent water IMPORTANT: Crankcase cover and cylinder block leakage into crankshaft/driveshaft splines.

  • Page 146: Honing Procedure

    S Measure cylinder bore inside diameter (with an in- CYLINDER BORE SIZE side micrometer) of each cylinder, as shown be- Piston Size Cylinder Block low. Check for tapered, out-of-round (“egg- Finish Hone shaped”) and oversize bore. Standard Diameter 3.375 in. (85.725mm) .015 Oversize 3.390 in.

  • Page 147: Check Valves

    Check Valves This kit is for use in three cylinder 71 cubic inch 70, 75, 80 and 90 horsepower models and four cylinder 105 DESIGN I (MODELS WITH CHECK VALVE ONLY) cubic inch 100 and 115 horsepower models. Located in crankcase cover under center main NOTE: Three cylinder and four cylinder outboards bearings.

  • Page 148: Design 3 (Models With Check Valve And Carrier)

    3. Push check valve out of carrier. If nylon ball within check valve is stuck or carrier is charred, replace check valve and/or carrier as required. IMPORTANT: SINGLE HOLE side of check valve MUST FACE CRANKCASE. a - Crankcase Cover b - Check Valve Assembly P/N 21-42657A1 c - Valve Restrictor P/N 22-814204 d - Install From Crankshaft Side...

  • Page 149: Piston And Piston Rings

    3. Clean mating surfaces of crankcase cover and CLEANING PISTON RING GROOVES intake manifold. Install new gaskets. IMPORTANT: The piston rings are half-keystone 4. Install intake manifold/reed block assemblies to rings – (tapered on the top side) - follow cleaning crankcase cover.

  • Page 150: Measuring Piston Skirt

    S Use a bristle brush and carbon remover solution to Crankshaft remove carbon from side surfaces. S Inspect crankshaft to drive shaft splines for wear. S A tool can be made for cleaning the inner diameter (Replace crankshaft, if necessary.) of the tapered ring grooves.

  • Page 151: Connecting Rods

    Connecting Rods Cylinder Cover, Exhaust Divider Plate and Exhaust Cover If necessary, clean connecting rod surfaces as fol- lows: S Thoroughly clean cylinder cover and gasket surfaces. S Attach end caps to connecting rods. Following these directions, tighten rod cap attaching bolts to S Inspect cylinder cover.

  • Page 152: Thermostat

    Thermostat Reed Blocks Wash thermostat with clean water. Using a thermo- NOTE: Do not disassemble reed block unless neces- stat tester, similar to the one shown, test thermostat sary. It may be necessary to apply heat to bolt (e) to as follows: soften Loctite before removal.

  • Page 153: Powerhead Reassembly And Installation

    There are 3 reed segments. Reed should lie flat. Powerhead Reassembly and There should be no preload (pressure between reed Installation and reed-block), but a slight preload is tolerable. The maximum allowable opening between reed and General Information reed-block is 0.020 (in.). This must be checked with a flat blade feeler gauge, as shown.

  • Page 154: Design 1 - Bottom Guided

    IMPORTANT: There are two types of piston/rod as- Top guided piston and rod assembly can be installed semblies available for the 3 cylinder powerheads: in a powerhead with bottom guided piston and rod Design 1 – Bottom guided (centered in bore assemblies.

  • Page 155: Assembling Rod To Piston

    Insert piston pin tool through piston in the direction CAUTION shown, pushing out sleeve. Any GREASE used for bearings INSIDE the Powerhead MUST BE gasoline soluble. Use only Quicksilver Needle Bearing Assembly Lubricant (92-42649A-1) or 2-4-C w/Teflon (92-825407A12). If other lubricants are used inside the Powerhead, damage to engine may occur.

  • Page 156: Piston Ring Installation

    Install new piston pin lockrings (each side of piston) Piston Ring Installation using Lockring Tool (91-77109A1). IMPORTANT: Piston ring side with letter or mark Make sure lockrings are properly seated in piston must be facing up. grooves. CAUTION Do not reuse piston pin lockrings. Use only new Piston Ring lockrings and make sure they are properly seated in piston grooves.

  • Page 157: Crankshaft Installation

    3. Align piston ring end gaps with ring locating pins Check rings by viewing through exhaust ports while as shown. Check locating pins making sure they depressing rings with a screwdriver. If no spring ten- are tight. sion is there (ring fails to “spring” back), the ring is probably broken and must be replaced, NOW, before installing the crankshaft.
  • Page 158 S Install 2 ring seals into slot between each center Grease crankshaft journal with Needle Bearing As- main bearing and position ring seal end gaps 180_ sembly Lubricant, to hold bearings in place. Position apart. bearings on journal, 32 each center main bearing. 20046 Attach bearing races with holes toward lower gear end of crankshaft.

  • Page 159: Installing Rods To Crankshaft

    Position Cylinder Block and Piston Rods, as shown. INSTALLING RODS TO CRANKSHAFT Note locating pins. Pull rod up to position shown. Grease rod, bearing area, with Needle Bearing Assembly Lubricant or 2-4-C w/Teflon - lay roller bearings out on clean sheet of paper and grease each bearing.

  • Page 160: Connecting Rod Cap Alignment

    S Replace lower crankshaft End Cap. IMPORTANT: On some engines, BOTH the piston rod and rod cap bolt holes are threaded. The rod 1. Coat mating surface with Perfect Seal. DO NOT cap and rod must be aligned and held tight coat O-ring seal.

  • Page 161: Reattach Crankcase Cover

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

  • Page 162: Cylinder Head Cover Torque Sequence

    NOTE: Keep clips positioned, as shown, during EXHAUST PLATE COVER TORQUE SEQUENCE torque sequence. All Cover Bolts: 18 lb. ft. (24.4 Nm) CYLINDER HEAD COVER TORQUE SEQUENCE All Cover Bolts: 18 lb. ft. (24.4 Nm) S Reinstall Oil Injection Pump Shaft and housing; check O-rings - replace as necessary.

  • Page 163: Powerhead To Driveshaft Housing

    Powerhead to Driveshaft Housing Clean holes (threads) and bolts thoroughly, with Loc- quic Primer T (92-59327-1). Dry, apply Loctite 271 to S Temporarily install flywheel with nut, as shown. bolts, and install. There are 8 bolts (3 each side, 2 backside).

  • Page 164: Reinstall Wiring Harness And Components As A Unit

    REINSTALL WIRING HARNESS AND ELECTRICAL COMPONENTS INSTALLED COMPONENTS, AS A UNIT S Reinstall Trigger Assembly and Stator Assembly. (Refer to Section 2 - this manual.) Apply Loctite stator screws torque 60 lb. in. (6.8 Nm). S Attach Electrical Component Mounting Plate. Apply Loctite 271 to bolts and torque to 13.5 lb.

  • Page 165: Flywheel Installation

    Flywheel Installation 5. Install Carburetor Gaskets. 6. Reinstall Carburetors as Single-Unit Assembly. 1. Reinstall Flywheel, washer and nut. Note manifold hose position and connection. 2. Torque Flywheel Nut to 120 lb. ft. (162.7 Nm). 20344 3. Reinstall Reed Block Housings, Intake Manifolds, and Flywheel Cover Bracket.

  • Page 166: Attach Rear Cowl Mounting Bracket

    9. Reinstall Flywheel Cover. Tighten 3 wing-nuts se- 14. Reinstall Air Box Cover and Gasket; tighten curely. screws securely. 10. Reinstall oil reservoir. Reconnect hoses and se- cure with sta-straps. See Section 3B for more de- tails, if necessary. See “Oil Reservoir” diagrams at beginning of this section.

  • Page 167: Attach Front Cowl Mounting Bracket

    ATTACH FRONT COWL MOUNTING BRACKET Install Mounting Bracket, as shown below. Grommets “c” and “g” normally are left in place in the bracket on Front cowl mounting bracket is installed in location disassembly. Bushing “d” inserts in grommet “c”. “a”. Position wiring and secure with cable retainer (“strap”...

  • Page 168: Lower Unit

    LOWER UNIT 791-H GEAR HOUSING...
  • Page 169 Table of Contents Page Page Notes ........5A-1 Bearing Carrier Reassembly .

  • Page 170: Notes

    Notes: 90-13645--2 1095 LOWER UNIT 5A-1...

  • Page 171: Drive Shaft And Water Pump Components

    Drive Shaft and Water Pump Components Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) Loctite 271 (Obtain Locally) 5A-2 LOWER UNIT 90-13645--2 1095...
  • Page 172 Drive Shaft and Water Pump Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Drive Shaft (Long) Drive Shaft (X-Long) Shim Bearing Race Tapered Bearing Washer Screw Washer Screw Washer Screw (Magnetic) Pinion Nut 94.9 Pinion Gear Shift Cam (Letters Face Up) Trim Tab Washer Trim Tab Bolt...
  • Page 173 Drive Shaft and Water Pump Components (Continued) Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) Loctite 271 (Obtain Locally) 5A-4 LOWER UNIT 90-13645--2 1095...
  • Page 174 Drive Shaft and Water Pump Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Impeller Drive Key Impeller Water Pump Assembly Water Tube Seal Water Pump Bolt Delete Delete Cover Screw Delete Wear Sleeve Seal Ring Bushing Screw Oil Seal (Lip Up) Shift Shaft Bushing O-Ring...

  • Page 175: Propeller Shaft Components

    Propeller Shaft Components 2-4-C With Teflon (92-825407A12) Loctite 271 (Obtain Locally) 5A-6 LOWER UNIT 90-13645--2 1095...
  • Page 176 Propeller Shaft Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Gear Case Shim Bearing Race Tapered Roller Bearing Roller Bearing Forward Gear Cam Follower Ball Bearing Slide Cross Pin Spring Clutch Clutch Cross Pin Retainer Spring Propeller Shaft Reverse Gear O-Ring Thrust Bearing...

  • Page 177: Special Tools

    Special Tools 6. Remove gear housing. Part No. Description 91-46086A1 Puller Jaws 91-85716 Puller Bolt 91-34569A1 Slide Hammer 91-36569 Mandrel* 91-37263 Mandrel* 91-37323 Driver Rod* 91-56775 Drive Shaft Holding Tool 91-37241 Universal Puller Plate 91-83165M Bearing Puller Assembly 91-31106 Mandrel 91-31108 Oil Seal Driver 91-37350...

  • Page 178: Draining And Inspecting Gear Housing Lubricant

    2. Place a block of wood, as shown, to prevent pro- peller from rotating and to protect hands during removal of nut. 3. Remove nut and pull components from shaft. 51552 a - Oil Level Screw b - Fill/Drain Screw c - Vent Screw 2.

  • Page 179: Water Pump (Design 1)

    7. Inspect impeller. Replace impeller if any of the Water Pump (Design 1) following conditions exist: 1. If water tube seal stayed on water tube (inside of – Impeller blade(s) are cracked, torn, or worn. drive shaft housing) when gear housing was removed, pull water tube seal from water tube.

  • Page 180: Water Pump (Design 2)

    DESIGN 1 model water pump, previous. IMPORTANT: Gear housing on 3 CYLINDER MODELS 70, 75, 80, 90 and 4 CYLINDER MODELS 100 and 115 have been modified to accept a new style plastic water pump base (P/N 19282A1). This new base does not require gaskets as it has a sili- cone impregnated seal on the top and bottom.

  • Page 181: Bearing Carrier And Propeller Shaft

    5. Lift reverse gear, thrust bearing and thrust wash- Bearing Carrier and Propeller Shaft er from bearing carrier. 1. Drain lubricant from gear housing; refer to “Drain- 6. Replace reverse gear if gear teeth or clutch teeth ing and Inspecting Gear Housing Lubricant.” on reverse gear are chipped or worn.
  • Page 182 9. If bearing is rusted or does not roll freely, replace 11. Remove spring. bearing. Remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. * From Bearing Removal and Installation Kit (91-31229A5). 51876 a - Spring 12.
  • Page 183 13. Remove components from propeller shaft. 16. Check bearing surfaces of propeller shaft for pit- ting or wear. If shaft is worn or pitted, replace shaft 14. Replace cam follower if worn or pitted. and corresponding bearing. 15. Replace sliding clutch if jaws are rounded or 17.

  • Page 184: Pinion Gear, Drive Shaft, And Forward Gear

    6. Replace bearing if it is rusted or does not roll free- Pinion Gear, Drive Shaft, and Forward ly; use a punch and hammer to remove bearing. Gear 1. Hold drive shaft using Drive Shaft Holding Tool (91-56775); remove (and discard) pinion nut. 2.

  • Page 185: Upper Drive Shaft Bearing

    8. Replace drive shaft if splines are worn or twisted. Upper Drive Shaft Bearing 9. If bearing surface is damaged, replace drive shaft 1. Replace upper drive shaft bearing and sleeve if and corresponding bearing. either are rust stained, or if bearing will not roll freely.

  • Page 186: Oil Sleeve

    IMPORTANT: Upper drive shaft bearing/sleeve IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Re- and oil sleeve do not have to be removed for lower fer to “Upper Drive Shaft Bearing,” preceding. drive shaft bearing race removal. Oil Sleeve Lower Drive Shaft Bearing Race 1.

  • Page 187: Shift Shaft

    4. Remove shift cam from housing. Shift Shaft 5. Replace shift cam if worn. 1. Remove shift shaft coupler nylon spacer. 51117 19221 a - Shift Cam a - Shift Shaft Coupler 6. Remove shift shaft bushing and clip from shift b - Spacer shaft.

  • Page 188: Forward Gear Bearing Race

    Forward Gear Bearing Race Reassembly IMPORTANT: Retain shim(s) for reassembly. Forward Gear Bearing Race 1. Remove race shim(s) using Slide 1. Place shim(s) (retained from disassembly) into Hammer (91-34569A1). housing. If shim(s) were lost, or a new gear hous- ing is being assembled, start with 0.010I (0.254mm) shim(s).

  • Page 189: Bearing Carrier Reassembly

    5. Assemble components as shown. 8. Apply Loctite 271 on bottom 1/2 of threads of bolts; install bolts and torque to 60 lb. in. (6.8 N·m). 19200 a - Shift Shaft c - Shift Shaft Bushing b - “E” Clip 6.
  • Page 190 4. Place smaller diameter seal on longer shoulder 8. Install O-ring. of Oil Seal Driver (91-31108) with seal lip away 9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate from shoulder. seal lips with 2-4-C w/Teflon (92-825407A12). Lu- 5. Protect lip on front side of bearing carrier using bricate outside diameter of bearing with a light Bearing Installation Tool (91-13945).

  • Page 191: Forward Gear Reassembly

    12. Install thrust bearing . Coat thrust bearing with Forward Gear Reassembly Quicksilver Gear Lubricant (92-13783A24). 1. Press bearing onto gear (press only on inner race of bearing). 51869 a - Mandrel (91-37350) b - Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon 19168 2.

  • Page 192: Propeller Shaft Reassembly

    Propeller Shaft Reassembly Drive Shaft Wear Sleeve Installation 1. Install components into propeller shaft in 1. Install new rubber ring. sequence shown. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. 19154 a - Spring c - 3 Metal Balls* b - Guide Block d - Cam Follower*...

  • Page 193: Lower Drive Shaft Bearing Race Installation

    4. Press sleeve onto drive shaft using Wear Sleeve Lower Drive Shaft Bearing Race Installation Tool (91-14310A1); continue pressing Installation until surface contacts surface. IMPORTANT: Lower drive shaft bearing cup can be installed with or without upper drive shaft bear- ing/sleeve and oil sleeve installed.

  • Page 194: Oil Sleeve Installation

    IMPORTANT: Oil sleeve must be installed prior to Oil Sleeve Installation upper drive bearing installation. 1. Install oil sleeve with tab positioned as shown. IMPORTANT: Upper drive shaft bearing/sleeve can be installed with or without lower drive shaft bearing cup installed. 3.

  • Page 195: Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, And Drive Shaft Installation

    - Drive Shaft Holding Tool (91-56775) f - Pinion Nut (New): Apply Loctite 271 to threads during final assembly (after pinion gear depth and forward gear backlash have been set), torque to 70 lb. ft. (95 N·m). Pinion Gear Depth and Forward Gear Backlash...
  • Page 196 6. Assembly Pinion Gear Locating Tool (91-12349A2) 10. Install the number “3” locating disc against bear- as shown; do not tighten collar retaining bolt at ing carrier shoulder in gear housing. this time. 11. Position access hole as shown. a - Arbor b - Gauging Block;...
  • Page 197 5. Install components as shown. DETERMINING FORWARD GEAR BACKLASH NOTE: Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to “Deter- mining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A1) on drive shaft;...

  • Page 198: Bearing Carrier And Propeller Shaft Installation

    7. Lightly turn drive shaft back-and-forth (no move- 3. Lubricate o-ring (c) and areas (d) with 2-4-C w/ ment should be noticed at propeller shaft). Teflon (92-825407A12). 8. Dial Indicator registers amount of backlash, which 4. Install bearing carrier and propeller shaft into must be between specification shown in chart.

  • Page 199: Water Pump Reassembly And Installation

    8. Place seal on shorter shoulder side of Oil Seal Water Pump Reassembly and Driver (91-13949) with seal lip toward shoulder. Installation 9. Apply Loctite 271 on O.D. of seal; press seal into 6. Place seal on longer shoulder side of Oil Seal water pump base until tool bottoms.
  • Page 200 12. Install components as shown. 15. Lubricate I.D. of cover with Quicksilver 2-4–C w/ Teflon (92-825407A12). 16. Rotate drive shaft clockwise and push cover down over impeller. 17. Install cover. 18. If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was re- moved, pull water tube seal from water tube.

  • Page 201: Gear Housing Pressure Test

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

  • Page 202: Propeller Installation

    7. Replace second lubricant “Vent” screw and gas- ket. CAUTION IMPORTANT: Do not lose more than one fluid Do not misinterpret propeller shaft movement ounce (30cc) of gear lubricant while reinstalling with propeller movement. If propeller and “FILL” screw. propeller shaft together move forward-and-aft, this is normal;...
  • Page 203 4. Install water tube seal; lube I.D. of seal with Quick- 8. Install components as shown in appropriate silver 2-4-C w/Teflon (92-825407A12). photo. 5. Apply a bead of RTV Sealer as shown. 19215 a - Water Tube Seal b - RTV Sealer 19883 CAUTION a - Nylon Spacer...
  • Page 204 NOTE: If, while performing Step 11, the drive shaft 16. Check shift operation as follows: splines will not align with the crankshaft splines, place a. Place shift lever in forward gear. Gear housing a propeller onto propeller shaft and turn it counter- should ratchet when propeller shaft is turned clockwise as the gear housing is being pushed to- clockwise and resistance should be felt when...
  • Page 205 LOWER UNIT MID-SECTION...
  • Page 206 Table of Contents Page Page Swivel Bracket Components ....5B-2 Drive Shaft Housing Components ..5B-8 Transom Bracket Components .
  • Page 207 Notes: 90-13645--2 495 LOWER UNIT 5B-1...

  • Page 208: Swivel Bracket Components

    Swivel Bracket Components Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) 5B-2 LOWER UNIT 90-13645--2 495...
  • Page 209 Swivel Bracket Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. N·m Swivel Bracket Oil Seal (LIPS FACE DOWN) Bushing O-Ring (UPPER) Spacer (UPPER) Grease Fitting Bushing Swivel Pin and Steering Arm Assembly Bolt Rubber Mount (UPPER) Washer Washer 108.4 Steering Link Assembly...

  • Page 210: Transom Bracket Components

    Transom Bracket Components 17 18 Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) Quicksilver Gear Lubricant (92-13783A24) Loctite 271 (Obtain Locally) 5B-4 LOWER UNIT 90-13645--2 495...
  • Page 211 Transom Bracket Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. N·m Transom Bracket (STARBOARD) Transom Bracket (PORT) Grease Fitting (PORT TRANSOM BRACKET) Tilt Tube Nut (1I-14); No Torque Requirement, Drive Nut Until Bottomed On Shoulder Of Tilt Tube O-Ring Wave Washer Nut (7/8I-14);...

  • Page 212: Exhaust Plate Components

    Exhaust Plate Components Quicksilver Lubrication/Sealant Application Points Loctite 271 (Obtain Locally) 5B-6 LOWER UNIT 90-13645--2 495...
  • Page 213 Exhaust Plate Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. N·m Exhaust Plate Dowel Pin Lower Cowl Seal Upper Mount Bolt – Upper Mount to Exhaust Plate 31.2 Bolt – Upper Mount Spacer – Upper Mount Bolt Washer –...

  • Page 214: Drive Shaft Housing Components

    Drive Shaft Housing Components Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) Loctite 35 (92-59328-1) 5B-8 LOWER UNIT 90-13645--2 495...
  • Page 215 Drive Shaft Housing Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. N·m Drive Shaft Housing Drive Shaft Housing Stud Dowel Pin Gear Housing Stud Washer 54.5 Plug – Power Trim Speedometer Pick Up Assembly 90 Degree Connector Straight Connector Lower Mount Lower Mount Bolt...

  • Page 216: Reference Views

    Reference Views 21046 a - Steering Arm 21054 b - Swivel Pin a - Push Rod End c - Thrust Washer (Aluminum side towards swivel bracket) b - Nut d - Spacer (Upper) c - Push Rod Yoke e - O-Ring d - Cotter Pin Swivel Pin/Steering Arm e - Clevis Pin...
  • Page 217 21048 a - Upper Mount 21050 b - Nut (2) [Torque to 80 lb. ft. (108.5 Nm)] a - Upper Shift Linkage c - Bolt (2) b - Steering Arm/Swivel Pin d - Rubber Space (2) c - Upper Mount Bolt e - Washer (2) d - Swivel Bracket f - Bolt (4) [Torque to 23 lb.
  • Page 218 LOWER UNIT SHOCK ABSORBER...
  • Page 219 Table Of Contents Page Page Engine Equipped with a Single Inspection and Repair ....5C-2 Shock Absorber ..... . 5C-1 Installation .
  • Page 220 Engines Equipped with a Single Shock Absorber Removal 1. Tilt engine to full “UP” position and engage tilt lock lever. WARNING Failure to support engine as shown could result in personal injury and/or damage to engine or boat. IMPORTANT: Support engine with tool as shown, to prevent engine from tipping over center into boat when retaining pin is removed.
  • Page 221 4. Support lower mount bracket and remove (6) Inspection and Repair bolts. 1. Inspect bushings and replace if worn. 17244 a - Bushings a - Bolts (3 Each Side) b - Lower Mount Bracket CAUTION 5. Remove shock absorber from lower mount bracket by driving out cross pin using a punch and The shock absorber is pressurized with gas.
  • Page 222 Installation 3. Reinstall shock absorber assembly between clamp brackets and secure shock assembly to 1. Remove anode plate. Lubricate retaining pin with clamp brackets with 6 bolts and lockwashers (3 Quicksilver 2-4-C w/Teflon. Place shock absorber each clamp bracket). Torque bolts to 30 lb. ft. into lower mount bracket, as shown, and install re- (40.7 N·m).
  • Page 223 POWER TRIM 17250 DESIGN I (SIDE FILL RESERVOIR)
  • Page 224 Table Of Contents Page Page Power Trim - General Information ..6A-1 Support Tool ..... . 6A-17 Description .

  • Page 225: Power Trim - General Information

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

  • Page 226: Tilting Outboard Manually

    Tilting Outboard Manually Trim “In” Angle Adjustment WARNING WARNING Before opening the manual release valve knob, Boat operation with outboard trimmed to the full insure all persons are clear of outboard as “In” trim angle [not using the trim angle outboard will drop to full “Down”...

  • Page 227: Striker Plate Replacement

    Striker Plate Replacement Trim Indicator Gauge Visually inspect striker plates and replace if worn ex- A Quicksilver Trim Indicator Gauge accessory kit is cessively. available for the power trim sender (if not previously installed). Fill, Check, and Purge - Power Trim System TO FILL: IMPORTANT: This trim system is pressurized.

  • Page 228: Bleeding Air From Power Trim System

    Bleeding Air From Power Trim System To determine if the Power Trim system contains air, position engine so two trim rods are slightly extended. Do not extend tilt ram. Push down on lower unit. If trim rods retract into trim cylinders more than 1/8I (3.2mm), it will be necessary to bleed air from the Power Trim system.

  • Page 229: Troubleshooting

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

  • Page 230: Hydraulic System Troubleshooting

    6. Disconnect trim pump motor wires, and remove Hydraulic System starboard transom bracket from engine. Refer to Troubleshooting “Removal” instructions in “Power Trim Assembly Removal and Installation,” following. IMPORTANT: Operate Power Trim system after Slowly remove fill screw to bleed pressure from each check to see if problem has been corrected.

  • Page 231: Wiring Diagram

    Wiring Diagram Trim Indicator Gauge and Trim Sender Wiring Diagrams Wiring Diagram – For boats equipped with Quicksilver Commander Series side mount remote control. 8 PIN HARNESS TRIM INDICATOR GAUGE ENGINE TRIM SENDER REMOTE CONTROL GROUND Rubber Sleeve Connect Wires Together with (Slide over Screw and Hex Nut;...

  • Page 232: Side Mount Remote Control Wiring Diagram

    Side Mount Remote Control Wiring Diagram BLK DBLACK BLU DBLUE BRN DBROWN GRY DGRAY GRN DGREEN PUR DPURPLE RED DRED TAN DTAN WHT DWHITE YEL DYELLOW 23891 a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Wiring Harness Connector f - Warning Horn...
  • Page 233 Commander Side Mount Remote Control Wiring Diagram...
  • Page 234 Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER Side Mount Remote Control) BLK DBLACK BLU DBLUE GRN DGREEN PUR DPURPLE RED DRED WHT DWHITE 23884 Power Trim System Wiring Diagram (3 Cylinder Models Using COMMANDER 2000 Side Mount Remote Control) BLK DBLACK BLU DBLUE GRN DGREEN...

  • Page 235: Electrical System Troubleshooting

    2. Make certain all connections are tight and corro- Electrical System sion free. Troubleshooting 3. Check that plug-in connectors are fully engaged. General Checks 4. Make certain battery is fully charged. Refer to the preceding wiring diagrams for connection Before troubleshooting the Power Trim electrical sys- points when troubleshooting the electrical system.

  • Page 236: Troubleshooting The "Down," "Up" And

    Troubleshooting the “Up” Circuit* (When “Trailer” Circuit Is OK) * Remote Control Equipped with Trailer Button Use an Ohmmeter (R x 1 scale) and check continuity of wire between Point 10 on “Up” solenoid and Point 7 on trim button. Continuity: No Continuity: Connect Voltmeter RED lead to Point...

  • Page 237: Troubleshooting The "Down," "Up" And

    Troubleshooting the “Down,” “Up” and “Trailer” Circuits* (All Circuits Inoperative) * Remote Control Equipped with Trailer Button continued from preceding page Battery Voltage Indicated: D Check BLACK ground wires at solenoids for poor connection or poor ground. D Check BLACK motor lead for poor ground at Point 12.

  • Page 238: Troubleshooting The "Down" Circuit (When "Up" Circuit Is Ok)

    Troubleshooting the “Down” Circuit (When “Up” Circuit Is OK) Remote Controls With or Without Trailer Buttons Connect Voltmeter RED lead to Point 1 and BLACK lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter RED lead to Point 9. Connect Voltmeter RED lead to Point 4 and BLACK lead to ground.

  • Page 239: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is Ok)

    Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) * Remote Control NOT Equipped with Trailer Button Connect Voltmeter RED lead to Point 10 and BLACK lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter RED lead to Point 3.

  • Page 240: Troubleshooting The "Down" And "Up" Circuits* (All Circuits Inoperative)

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

  • Page 241: Power Trim Assembly Removal And Installation

    Power Trim Assembly WARNING Removal and Installation Failure to support outboard as shown could result in personal injury and/or damage to outboard or Removal boat. 1. Remove clamps on transom bracket to free power trim wiring. 20290 a - Harness Retainer b - Clamp 20319 c - Sta-Strap(s)
  • Page 242 IMPORTANT: Outboards equipped with thru-the- tilt-tube steering - remove steering link arm from end of steering cable and cable retaining nut from tilt tube. 51346 a - Tilt Lock Lever 51354 b - Support Tool a - Retaining Nut c - Retaining Clips 5.

  • Page 243: Installation

    6. Remove 3 screws and washers and move Installation starboard transom bracket so that manual 1. Paint any exposed metal surfaces to prevent release valve will clear bracket when power trim corrosion. is removed. 2. Apply Loctite 271 to screws. Install trim system, starboard transom bracket, and tilt tube nut.

  • Page 244: Testing Power Trim System With Test Gauge Kit (91-52915A3)

    5. Position slot on end of swivel shaft in line with hole 9. Apply Quicksilver Liquid Neoprene (91-25511--2) in tilt ram end. Insert a punch into tilt ram hole to on all electrical connections. align cross hole in upper swivel shaft. Tap new cross pin in until flush.

  • Page 245: Up" Pressure Check

    “UP” Pressure Check 5. Install components. IMPORTANT: Insure battery is fully charged be- fore performing tests. 1. Tilt outboard to full “Up” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed pressure from reservoir. 3. Turn Manual Release Valve 3 to 4 turns (counter- clockwise) to bleed any remaining pressure.

  • Page 246: Down" Pressure Check

    11. Run trim “UP”. The minimum pressure should be CAUTION 1300 P.S.I. (91 kg/cm 12. Run trim “DOWN” to release pressure and re- Failure to install spare tilt pin (or hardened bolts move spare tilt pin or bolts and nuts. and nuts) in hole shown could result in transom bracket failure and possible injury.
  • Page 247 2. Install components. 3. Open valve (d) and close valve (e). 4. Install fill plug. 5. Close Manual Release Valve (clockwise). 6. Run trim “DOWN”. Minimum pressure should be 500 P.S.I. (35 kg/cm 7. Tilt outboard full “UP” and engage tilt lock lever. 8.

  • Page 248: Power Trim Components

    Power Trim Components Quicksilver Lubrication/Sealant Application Points Anti-Corrosion Grease (92-78376A6) Power Trim and Steering Fluid (92-90100A12) Liquid Neoprene (92-25711--2) Loctite 271 (Obtain Locally) TORQUE REF. NO. DESCRIPTION lb. in. lb. ft. Housing Allen Plug Manual Release Valve O-ring [.239I (6.07mm) I.D.] O-ring [.208I (5.28mm) I.D.] O-ring [.114I (2.90mm) I.D.] O-ring [.989I (25.12mm) I.D.]...
  • Page 249 Power Trim Components (Continued) TORQUE REF. NO. DESCRIPTION lb. in. lb. ft. Tilt Cylinder Assembly Cross Pin Retaining Pin O-ring [1.248I (31.70mm) I.D.] Trim Rod Assembly w/Check Valve, Port O-ring [.612I (15.54mm) I.D.] O-ring [1.475I (37.47mm) I.D.] Cap, Trim Cylinder Seal O-ring (2.864I I.D.) Washer...

  • Page 250: 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 251: 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 252: Tilt Ram Components

    Tilt Ram Components TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Housing, Tilt Ram O-ring (1.957I I.D.) O-ring (.307I I.D.) Rod End O-ring (.661I I.D.) Washer Piston O-ring (2.067I I.D.) O-ring (.854I I.D.) Scraper Washer Retaining Ring Check Valve Assembly Check Valve Assembly Roll Pin _ Contents of “Tilt Cylinder O-ring Kit”...

  • Page 253: Tilt Ram

    DISASSEMBLY Tilt Ram 1. Secure tilt ram (at its base) in a soft jawed vise. REMOVAL Using Spanner Wrench, loosen cap by turning 1. Remove Power Trim assembly from engine, refer cap in direction. to “Removal” instructions in “Power Trim Assem- Remove ram from vise, and pour fluid from ram.
  • Page 254 2. Clamp tilt rod in a soft jawed vise, as shown. 4. Slide cap off from rod. Remove o-ring. Heat rod with Torch Lamp (91-63209 or 91-74042). Using spanner wrench (91-74951), remove rod end by turning rod end in direction shown. Ç...

  • Page 255: Cleaning And Inspection

    7. Insert shaft into housing, as shown. 51342 Tap shaft into housing until shaft is positioned as shown. 51353 a - Shop Cloth b - Solid Work Bench (or Floor) c - Air Nozzle CLEANING AND INSPECTION Inspect O-rings, and replace if damaged. Clean components with parts cleaner and dry with compressed air.

  • Page 256: Reassembly

    REASSEMBLY 4. Install components, as shown. IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. 1. Apply Automatic Transmission Fluid (ATF) Type A (Dexron II) on O-rings during reassembly. NOTE: Refer to “Tilt Ram Components”...

  • Page 257: Installation

    Screw rod end into rod. Tighten rod end securely INSTALLATION using Spanner Wrench. 1. Lubricate alignment tool and shaft with Quicksil- ver Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) Type F, FA or Dexron II. 51369 a - Alignment Tool (91-11230) b - Shaft 2.

  • Page 258: Pump Replacement

    4. Install pin. Drive pin in until flush. Tighten manual release valve to full right (clockwise). Install Power Trim assembly on engine, refer to Operate trim motor in “Up” direction by connecting “Installation” instructions in “Power Trim Assem- trim motor wires to a 12-volt battery [BLUE wire to bly Removal and Installation,”...

  • Page 259: Motor And Electrical Tests/Repair

    2. Remove screws and clamp. Motor and Electrical Remove screws. Tests/Repair Lift motor from end cap, taking care not to drop Thermal Overload Switch Test armature. IMPORTANT: If trim pump has just been operated, do not run pump for approximately one minute be- fore testing thermal overload switch.

  • Page 260: Motor Disassembled

    MOTOR DISASSEMBLED 3. Connect a 12-volt power supply to terminals 3 and 4. Solenoid should click and meter should read Connect Ohmmeter (R x 1 scale) leads as shown. If zero (0) ohms (full continuity). switch is good, full continuity (zero ohms) will be indicated.

  • Page 261: Armature Tests

    2. Lift motor from end cap. Use care not to drop CHECKING AND CLEANING COMMUTATOR armature. 1. If commutator is worn, it may be turned on an ar- mature conditioner or a lathe. 2. Clean commutator with “OO” sandpaper. a - Commutator Field Tests IMPORTANT: Commutator end of armature must be installed in brushes when performing the fol-...

  • Page 262: Trim Sender (Optional Accessory) Test

    Trim Sender (Optional Accessory) Test Trim Indicator Gauge (Optional Accessory) Needle Adjustment Check trim sender BLACK lead for proper ground. Trim engine to full “Down” position. If trim indicator Trim engine to full “Down” position. needle is not at the bottom of the green arc on the Place ignition switch in “Off”...

  • Page 263: Square" Motor Components

    “Square” Motor Components Quicksilver Lubrication/Sealant Application Points Liquid Neoprene (92-25711--2) Bellows Adhesive (92-86166) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Thru Bolt Nylon Washer (If Equipped) O-ring Self-Tapping Screw Retainer, metal Nylon Isolator (If Equipped) Seal, rubber End Frame Cap, upper Square Ring, used when end frame cap has groove Gasket, used when end frame cap does not have groove Connector, metal...

  • Page 264: Reassembly

    Reassembly 3. Install a flat ring (if equipped) into groove in each end cap. IMPORTANT: Components must be dirt and lint NOTE: Verify rings are not twisted after installation. free. Slightest amount of debris in Power Trim system could cause system to malfunction. 1.
  • Page 265 4. Install armature into pump. 6. Spread brushes; position brushes as shown. Rotate armature to align hex shaft with pump. Install thrust washer (if equipped). 18464 a - Armature 18457 b - Pump a - Brushes 5. Install field and frame assembly onto pump as b - Thrust Washer shown.

  • Page 266: Brush Replacement

    8. Install O-ring [2.739I (69.57mm) I.D.]. It is recom- Brush Replacement (“Square” Motor) mended O-ring be installed even if pump did not 1. Brush replacement is recommended if brushes originally have O-ring. are pitted, chipped, or if distance (a) between the Insert pump and motor assembly into Power Trim brush pigtail and end of brush holder slot is 1/16I housing, with rocker arm positioned as shown.
  • Page 267 2. To replace brush card, remove plastic insulators. 3. Remove metal connectors by separating the slit in connectors using a side cutter, as shown. 18463 18466 a - Insulators a - Metal Connectors Install new brush card. Crimp metal connectors on connections. Use heat shrink tubing to insulate connections.
  • Page 268 POWER TRIM 51344 DESIGN II (AFT FILL RESERVOIR)
  • Page 269 Table Of Contents Page Page Power Trim System ..... . . 6B-1 Installation ......6B-16 Specifications .

  • Page 270: Power Trim System

    Power Trim System Specifications Test Readings Trim “UP” 1300 PSI (91 kg/cm Maximum Pressure Trim “DOWN” 500 PSI (35 kg/cm Minimum Pressure Special Tools Part No. Description 91-11230 Alignment Tool 91-44486A1 Trim Rod Removal Tool 91-44487A1 Trim Rod Guide Removal Tool 91-52915A3 Power Trim Test Gauge Kit 91-11243...

  • Page 271: Power Trim Components

    Power Trim Components NOTE : All O-rings - Lubricate with Power Trim and Steering Fluid. Loctite 271 (Obtain Locally) Liquid Neoprene (92-25711-1) Power Trim and Steering Fluid (92-90100A12) Anti-Corrosion Grease (92-19007A24) 6B-2 90-13645--2 1095 POWER TRIM...
  • Page 272 Power Trim Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Manifold Pipe Plug Tilt Cylinder Assembly Piston Rod (Bolt Type) Design 1 Piston Rod (Nut Type) Design 2 Guide Kit O-ring Repair Kit (811607A1) Check Valve Kit Guide Assembly Piston and Rod Assembly (Port) Piston and Rod Assembly (Starboard)

  • Page 273: Power Trim - General Information

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

  • Page 274: Tilting Outboard Manually

    Before the boat is trailered, the operator should check Trim “In” Angle Adjustment for clearance between the outboard skeg and pave- ment to prevent damage to skeg from striking pave- WARNING ment. Boat operation with outboard trimmed to the full If the outboard must be tilted for clearance between “In”...

  • Page 275: Striker Plate Replacement

    Striker Plate Replacement Trim Indicator Gauge Visually inspect striker plates (a) and replace if worn A Quicksilver Trim Indicator Gauge accessory kit is excessively. available for the power trim sender (if not previously installed). Fill, Check, and Purge - Power Trim System IMPORTANT: This trim system is pressurized.

  • Page 276: To Purge

    TO PURGE: Hydraulic System IMPORTANT: Fill plug and O-ring must be tight- Troubleshooting ened securely before purging system. IMPORTANT: Operate Power Trim System after IMPORTANT: Run Trim System in short “jogs” un- each check to see if problem is corrected. If prob- til pump is primed and trim system moves.
  • Page 277 Troubleshooting IMPORTANT: Determine if Electrical or Hydraulic problem exists. HYDRAULIC SYSTEM TROUBLESHOOTING IMPORTANT: Make one correction at a time. Check operation of trim system before proceeding to the next check. CONDITION OF TRIM SYSTEM PROBLEM A. Trim motor runs; trim system does not move up or down. 1, 2, 5, 10 B.

  • Page 278: Electrical System Troubleshooting

    ELECTRICAL SYSTEM TROUBLESHOOTING CONDITION OF TRIM SYSTEM PROBLEM A. Trim motor does not run when trim button is depressed. 1, 2, 4, 5, 6, 7 B. Trim system trims opposite of buttons. C. Cowl mounted trim buttons do not activate trim system. 2, 4, 5, 6 PROBLEM 1.

  • Page 279: Side Mount Remote Control Wiring Diagram (Test Points For Electrical Troubleshooting)

    Side Mount Remote Control Wiring Diagram (Test Points for Electrical Troubleshooting) 23891 6B-10 POWER TRIM 90-13645--2 495...

  • Page 280: Electrical System

    2. Make certain all conditions are tight and corrosion Electrical System free. Troubleshooting 3. Check that plug-in connectors are fully engaged. GENERAL CHECKS 4. Make certain battery is fully charged. Before troubleshooting the Power Trim electrical sys- Refer to the preceding four wiring diagrams for tem, check the following: connection points when troubleshooting the electrical systems (Connection points are specified by...

  • Page 281: Troubleshooting The "Up" Circuit (When "Down" Circuit Is Ok)

    Troubleshooting the “Up” Circuit (When “Down” Circuit is OK) Connect Voltmeter RED lead to Point 10 and BLACK lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter RED lead to Point 3. There is an open circuit in wires (BLUE- WHITE, PURPLE-WHITE, or PURPLE) between “Up”...

  • Page 282: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)

    Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative) Check in-line fuses (under cowl) to see if fuses are blown. Blown Fuse: Fuse Not Blown: Correct problem that caused fuse Connect Voltmeter RED lead to to blow. Point 3 and BLACK lead to ground. Battery voltage should be indicated.

  • Page 283: Power Trim Assembly Removal And Installation

    Power Trim Assembly WARNING Removal and Installation Failure to support outboard as shown could result in personal injury and/or damage to outboard or Removal boat. 1. Remove clamps on transom bracket to free power trim wiring. 51377 a - Clamps 2.
  • Page 284 5. Remove outboard transom mounting bolts, and CAUTION loosen tilt tube nut until nut is flush with end of tilt tube thread. Disconnect battery cables at battery before removing power trim wires from solenoids. 3. Disconnect power trim wires at solenoids (BLUE, GREEN, and BLACK).

  • Page 285: Installation

    IMPORTANT: Cross pin (a) should not be reused. Installation Replace with new cross pin. 1. Paint any exposed metal surfaces to prevent 7. Drive out cross pin, push out upper swivel pin, and corrosion. remove 3 screws and washers retaining trim sys- 2.
  • Page 286 5. Position slot on end of swivel shaft in line with hole WARNING in tilt ram end. Insert a punch into tilt ram hole to align cross hole in upper swivel shaft. Tap new Electrical wires passing through cowl openings cross pin in until flush.

  • Page 287: Up" Pressure Check

    “UP” Pressure Check 6. Disengage tilt lock lever. IMPORTANT: Insure battery is fully charged be- CAUTION fore performing tests. Failure to install spare tilt pin (or hardened bolts 1. Tilt outboard to full “Up” position and engage tilt and nuts) in hole shown could result in transom lock lever.

  • Page 288: Down" Pressure Check

    11. Run trim “UP”. The minimum pressure should be 2. Install components. 1300 P.S.I. (91 kg/cm 12. Run trim “DOWN” to release pressure and re- move spare tilt pin or bolts and nuts. 13. Tilt outboard full “UP” and engage tilt lock lever. 14.

  • Page 289: 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 290: Trim Rod End Cap Seal

    1. Inspect check valve and check valve screen for Trim Rod End Cap Seal debris; if debris cannot be removed, replace trim 1. Inspect trim cap end seal and replace if damaged rod assembly. Clean trim rod with parts cleaner or if seal does not keep trim rod clean.

  • Page 291: Tilt Ram

    Tilt Ram TILT RAM COMPONENTS REMOVAL - TILT ROD ASSEMBLY ONLY NOTE : Tilt Rod Assembly can be removed from cylinder without removing entire power trim system from outboard. Refer to page 6A-13 to remove upper swivel pin. CAUTION Insure Power Trim System Is Depressurized Prior To Tilt Rod Removal.

  • Page 292: Tilt Ram Removal - Power Trim System Removed From Outboard

    TILT RAM REMOVAL - POWER TRIM SYSTEM Disassembly REMOVED FROM OUTBOARD 1. Secure tilt ram in a soft jawed vise. Remove tilt rod and cap. CAUTION Insure Trim System Is Depressurized Prior To Tilt 91-74951 Ram Removal. 1. Remove cross pin. 51337 51364 51366...
  • Page 293 IMPORTANT: Note Design 1 and 2 previous. 4. Remove end cap from tilt rod. Design 1 tilt rod assembly replaces either tilt rod assembly Either design will fit as a (replace) cylinder assembly complete. Design 2 will NOT fit a cylinder originally using a Design 1 tilt rod assembly.

  • Page 294: Cleaning And Inspection

    7. Tap shaft into cylinder until shaft is positioned as CLEANING AND INSPECTION shown. 1. Inspect all internal parts for damage or wear. Clean and replace parts as necessary. 2. Inspect tilt rod for scratches. Replace scraper seal in rod end cap if tilt rod is scratched or worn. 3.

  • Page 295: Reassembly

    REASSEMBLY 4. Install end cap. IMPORTANT: Components must be clean for reas- sembly. Any debris in the system can cause the system to malfunction. NOTE : Refer to “Tilt Ram Components” for proper O-ring sizes. 51376 1. Apply Quicksilver Power Trim and Steering Fluid a - End Cap on O-rings prior to reassembly.

  • Page 296: Tilt Ram Assembly Installation

    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. 51369 a - Alignment Tool (91-11230) b - Shaft 2. Align tilt ram and housing using alignment tool. 51356 a - Pin (Drive against knurled end) 5.

  • Page 297: Motor And Pump Replacement

    MOTOR AND PUMP REPLACEMENT 3. Remove two screws to remove pump. IMPORTANT: The pump is not rebuildable. If pump is defective, replace as an assembly. NOTE : Power Trim System does not have to be re- moved from outboard to replace pump or motor. 1.

  • Page 298: Motor And Electrical Tests/Repair

    MOTOR DISASSEMBLY Motor and Electrical 1. Remove screws and clamp. Tests/Repair Trim Pump Motor Test WARNING Do not perform this test near flammable materials, as a spark may occur while making electrical connections. 1. Connect a 12 volt power supply to motor wires [positive (+) to blue wire and negative (-) to black wire].

  • Page 299: Armature Tests

    Armature Tests FIELD TESTS IMPORTANT: Commutator end of armature must TEST FOR SHORTS be installed in brushes when performing the fol- Check armature on a Growler per the Growler man- lowing tests. ufacturer’s instructions. Replace armature if a short is indicated.

  • Page 300: Motor Repair

    Motor Repair CLEANING AND INSPECTION Inspect O-rings and replace if necessary. Clean, in- REMOVAL spect, and test motor components. Refer to “Brush NOTE : Power Trim System does not have to be Replacement,” “Armature Test,” and “Field Tests” removed from outboard to repair/replace motor. for inspection and test procedures.

  • Page 301: Brush Replacement

    BRUSH REPLACEMENT 1. Brush replacement is required if brushes are pitted, chipped, or if distance (a) between the brush pigtail and end of brush holder slot is 1/16 in. or less. Check distance with armature installed. 18466 a - Metal Connectors 4.

  • Page 302: Reassembly

    Reassembly 3. Install screws and clamp. Tighten screws securely. IMPORTANT: Components must be clean. Any de- bris in power trim system can cause system to malfunction. 1. Install armature in motor housing. 51357 51349 a - Motor Housing b - Armature (Spread brushes to insert commutator) 51345 2.

  • Page 303: Reassembly - Motor And Pump

    51433 a - Motor b - O-ring c - Screw (2) - Torque screws to 70 lb. in. (7.9 N·m) 4. Complete reassembly of Power Trim System as outlined in “Installation” on page 6B-15 and 6B-16.

  • Page 304: Trim Indicator Gauge Needle Adjustment

    5. Tighten trim sender screws. 22908 a - Trim Sender b - Connect with screw and hex nut (coat with liquid neoprene). c - Rubber Sleeve (Slide over connection) Trim Indicator Gauge Needle Adjustment 1. Turn ignition key to “RUN” position. 2.
  • Page 305 POWER TRIM 51485 SINGLE RAM...
  • Page 306 Table Of Contents Page Page Special Tools ......6C-1 COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Quicksilver Lubricants and Service Aids .

  • Page 307: Special Tools

    Increases clearance over submerged objects. Special Tools In excess, can cause “porpoising” and/or ventilation. Part No. Description In excess, can cause insufficient water supply to wa- 91-63209 Torch Lamp ter pump resulting in serious water pump and/or pow- erhead overheating damage. 91-74951 Spanner Wrench 91-99750...

  • Page 308: Trailering Outboard

    Improves planing speed acceleration (by moving tilt Trim “In” Angle Adjustment bolt one hole closer to transom). WARNING Operating “Down” circuit will actuate the “down” relay (located under engine cowl) and close the electric Operating some boats with engine trimmed to the motor circuit (motor will run in opposite direction of the full “in”...
  • Page 309 Notes: 90-13645--2 495 POWER-TRIM 6C-3...

  • Page 310: Power Trim System Components

    Power Trim System Components Quicksilver Lubrication/Sealant NOTE: Lubricate all Application Points O-rings and seals with Power Trim and Steering Fluid (92-90100A12) Loctite 271 (Obtain Locally) Liquid Neoprene (92-25711--2) 6C-4 POWER-TRIM 90-13645--2 495...
  • Page 311 Power Trim System Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Tilt/Trim Cylinder Reservoir/Motor Housing Piston Rod Upper Pivot Shaft Cross Pin O-ring Seal-End Cap End Cap O-ring O-ring Piston Assembly O-ring O-ring Memory Piston Lower Pivot Shaft Cross Pin Screw 11.3...

  • Page 312: Troubleshooting

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

  • Page 313: Hydraulic System Troubleshooting

    Hydraulic System Troubleshooting Preliminary Checks Support outboard with tilt lock lever when servicing Operate Power Trim System after each check to power trim system. see if problem is corrected. If not, proceed with the next check. After debris or failed components have been found (during troubleshooting procedures) dis- 1.

  • Page 314: Leak Down Check - Pump And Manifold Assembly

    Leak Down Check - Pump and 2. The spool is considered stuck when the pin end is protruding out past the end of the sleeve. Manifold Assembly The 1993 and 1994 models listed with power trim date codes 13011 through 23288 ONLY may experience a very slow trim rate (one minute or more) with the out- board drifting back down as soon as the UP trim but- ton is released.

  • Page 315: Reassembly

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

  • Page 316: Power Trim Partial Leak Down At Maximum Trim

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

  • Page 317: Leak Down Check - Pilot Valve Assembly

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

  • Page 318: Power Trim Rocker Arm

    Power Trim Rocker Arm 2. Clearance between the side of the rocker arm and each pin is 0.001 to 0.010 in. (0.025 – 0.25mm). Power Trim Date Code 14182 and Below. Refer to 3. Torque bolt to 125 – 140 lb. in. (14.1 – 15.8 N·m). Service Bulletin No.

  • Page 319: Troubleshooting Flow Diagram

    Troubleshooting Flow Diagram Outboard falls to full down position with manual release valve closed. Example a: Outboard lowers more than one tilt bolt hole in eight hours. Example Outboard lowers during acceleration. Inspect Manual Release Valve. Result Result Manual release valve and/or O-ring damage.
  • Page 320 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed deceleration. Inspect Manual Release Valve. Result Result Manual release valve and O-rings Manual release valve and/or appear to be OK. Replace O-rings O-ring damage. and proceed.

  • Page 321: Electrical System Troubleshooting

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

  • Page 322: Power Trim System Wiring Diagram

    Power Trim System Wiring Diagram BLK D BLACK Negative (–) BLU D BLUE Trim Motor (UP) GRN D GREEN Trim Motor (DOWN) RED D RED Positive (+) BLU/WHT D BLUE/WHITE Wiring From Trim Switch to UP Relay Side Mount GRN/WHT D GREEN/WHITE Trim Switch to DOWN Relay Remote Control Harness...

  • Page 323: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is Ok)

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

  • Page 324: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)

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

  • Page 325: Power Trim System Removal

    6. Use suitable punch to remove lower cross pin. Power Trim System Removal Retain cross pin. Support outboard with tilt lock lever when servicing power trim system. 1. Disconnect power trim harness from outboard wir- ing harness. 2. Remove screw and clip securing wiring harness to clamp bracket.

  • Page 326: Power Trim System Disassembly

    8. Tilt power trim assembly (top first) out from clamp Power Trim System bracket and remove assembly. Disassembly Trim Rod Removal 1. Secure power trim assembly in soft jawed vise. 2. Open manual release valve three turns maxi- mum (counterclockwise) and position trim rod to full up position.

  • Page 327: Trim Rod Disassembly

    5. Remove memory piston from cylinder using lock- Trim Rod Disassembly ring pliers (Craftsman P/N 4735) or suitable tool. 1. Place trim rod assembly on clean work surface. 2. Remove screws securing plate to trim rod piston and O-ring. 3. Remove check ball components from trim rod piston.
  • Page 328 8. Remove rod wiper, inner O-ring and outer O-ring. 51147 51146 b - Spanner Wrench c - Trim Rod Piston CAUTION Do not remove check ball components (a) from trim rod piston. Removal and re-installation of 51145 check valve could result in improper operating pressure and possible power trim system a - Rod Wiper b - Inner O-ring...

  • Page 329: Trim "Motor" Removal

    Trim “Motor” Removal Trim “Motor” Disassembly 1. Secure power trim assembly in soft jawed vise. 1. Remove armature from motor frame. Note posi- tion of washers on armature. 2. Remove screws securing end cap to reservoir and remove end cap. 51486 a - Armature b - Motor Frame...

  • Page 330: Manifold Removal

    3. Remove four screws securing reservoir to manifold. Manifold Removal 1. Remove screws and manifold from cylinder. 51193 a - Screws (4) 51007 4. Remove reservoir from manifold. a - Trim Cylinder b - Manifold 5. Remove drive shaft from oil pump. c - Screw (2) 2.

  • Page 331: Cleaning And Inspection Of Trim Rod Components

    3. Remove O-rings from cylinder. Motor and Electrical Tests/Repair Trim Pump Motor Test WARNING Do not perform this test near flammables (or explosives), as a spark may occur when making connections. 1. Disconnect GREEN (motor) wire and BLUE (mo- tor) wire from trim system wiring harness. 2.

  • Page 332: Checking And Cleaning Commutator

    CHECKING AND CLEANING COMMUTATOR 1. Install check valve components into pump man- ifold. If commutator is worn it can be turned down on an ar- mature conditioner tool or on a lathe. IMPORTANT: Sleeve (d) is chamfered on I.D. on end opposite drilled cross hole.

  • Page 333: Trim Motor Reassembly

    2. Lubricate end cap bushing with Quicksilver 2-4-C Lubricant and install armature and motor frame into end cap. As brushes contact commutator, re- lease brush tension spring from ends of brush housings (returning springs to apply brush pres- sure to commutator). Install washer on each end of armature before installing armature into end cap (see inset).

  • Page 334: Reservoir Installation

    Reservoir Installation 5. Secure reservoir to manifold using four screws. Torque screws to 70 lb. in. (7.9 N·m). 1. Torque end cap screws to 13 lb in. (1.5 N·m). 51193 a - Screw 6. Install lubricated O-rings and “E” clip to manual re- lease valve.

  • Page 335: Trim Rod Reassembly

    Trim Rod Reassembly 4. Apply Loctite 271 (Obtain Locally) to threads of trim rod and install rod piston. Tighten piston se- 1. Install lubricated O-rings and rod wiper to end curely using spanner wrench (1/4 in. x 5/16 in. cap. long peg).

  • Page 336: Trim Rod Installation

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

  • Page 337: Purging Power Trim Unit

    Power Trim Unit Installation Purging Power Trim Unit 1. Apply 2-4-C w/Teflon (92-825407A12) to lower Manual release valve must be in full closed posi- pivot pin bore and pivot pin surface. tion during power trim purging and operation. 2. Position trim cylinder assembly (BOTTOM 1.
  • Page 338 4. Using a suitable punch, drive lower pivot pin into 6. Apply 2-4-C w/Teflon (92-825407A12) to surface clamp bracket and trim cylinder assembly until of upper pivot pin, pivot pin bore and trim ram pivot pin is flush with outside surface. bore.
  • Page 339 7. Using a suitable mallet, drive upper pivot pin into 8. Drive upper retaining pin in until seated. swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 51505 a - Retaining Pin 51515 9. Recheck fluid level. a - Pivot Pin 10.
  • Page 340 ENGINE ATTACHMENTS/ ENGINE INSTALLATION 50099...
  • Page 341 Table Of Contents Page Page Steering Cable and Steering Link Rod Steering Cable Installation ..7A-16 Installation ......7A-1 Maintenance Instructions .

  • Page 342: Steering Cable And Steering Link Rod Installation

    4. Install rubber bumper on inside of locking sleeve, Steering Cable and Steering then install locking sleeve over steering cable at- Link Rod Installation taching nut ) and secure with cotter pin . Spread ends of cotter pin. Be sure to install cotter pin so that it is located in-between attaching nut and CAUTION grease fitting , as shown.

  • Page 343: Ride-Guide Attachment - Dual Front Installation (92876A2)

    Cable Routing Types CAUTION Use “1” or “2”, following, to route steering cables: Steering link must be installed in rear hole in engine steering arm. Failure to install in rear hole 1. Parallel cable routing: Cables routed together may cause damage to steering system. down starboard side of boat.

  • Page 344: Parallel Routed Steering Cables And Attaching Kit Installation

    Parallel Routed Steering WARNING Cables and Attaching Kit Before using engine after installation of cables, check to see that boat will turn right when steering Installation wheel is turned right and that boat will turn left when wheel is turned left. Do this check at all tilt (Both Steering Cables Routed Together Down angles and thru full range of turn angles.
  • Page 345 NOTE: Torque steering cables attaching nuts and 2. Install steering cable mounting tube into mounting bracket with 2 adjustment nuts and tab lock wash- install locking sleeve after final tension adjustment. ers, as shown in Figure 3. Be sure that longer 5.

  • Page 346: Steering Eyes And Coupler Installation

    Steering Eyes and Coupler Installation 1. Position engines so that they are facing straight forward. (Distance between centers of threaded pivot bolt holes in engine steering arms must be equal to distance between propeller shaft centers.) 2. Lubricate inside of rubber sleeves (Figure 9) and slide onto coupler.

  • Page 347: Steering System Tension Adjustment (Parallel Routed Steering Cables)

    50061 a - Rubber Bushing b - Rubber Sleeve c - Jam Nut; Torque to 20 lbs. ft. (27.1 Nm) d - Coupler e - Steering Eye Figure 9. Coupler Assembled a - Jam Nut; Torque to 20 lbs. ft. (27.1 Nm) Steering System Tension Adjustment b - Engine Steering Arm (Parallel Routed Steering Cables)
  • Page 348 3. Secure each steering cable attaching nut to tubes by torquing steering cable attaching nuts (Fig- ure 13) to 35 lbs. ft. (47.5 Nm). 4. Install rubber bumpers on inside of locking sleeves, then install a locking sleeve over each steering cable attaching nut and secure with cot- ter pin.

  • Page 349: Opposite Side Routed Steering Cables And Attaching Kit Installation

    Figure 1. Tube Mounting Bracket Installed Opposite Side Routed Steering Cables and Attaching Kit Installation (ONE CABLE ROUTED DOWN STARBOARD SIDE OF BOAT AND ONE CABLE ROUTED DOWN PORT SIDE OF BOAT) IMPORTANT: Steering cable must be installed into tilt tube of “port” engine before engine is mounted.
  • Page 350 c. Insert ends of steering cables thru engine tilt tube and cable mounting tube (Figure 3). Thread steering cable attaching nuts hand-tight onto tubes. 50180 50101 a - Mark Made in Step 5a a - Flat Washer (2 Each Link Rod) Figure 5.

  • Page 351: Steering Eyes And Coupler Installation

    Steering Eyes and Coupler Installation 1. Position engines so that they are facing straight forward. (Distance between centers of threaded pivot bolt holes in engine steering arms must be equal to distance between propeller shaft centers.) 2. Lubricate inside of rubber sleeves (Figure 8) and slide onto coupler.

  • Page 352: Steering System Tension Adjustment

    a - Jam Nut; Torque to 20 lbs. ft. (27.1 Nm) 7. Torque pivot bolts to 20 lbs. ft. (27.1 Nm), then b - Engine Steering Arm thread self-locking nut onto bolts and torque nuts c - Coupler to 20 lbs. ft. (27.1 Nm). d - Steering Eye e - Rubber Sleeves WARNING...

  • Page 353: Trim Tab Installation

    50101 Figure 13. Attachment Kit Installation Complete 2. After steering system tension is adjusted correct- 51887 ly, torque adjustment nuts (Figure 11) to 35 lbs. ft. a - Steering Cable Mounting Tube (47.5 Nm) and bend a tab lockwasher against a b - Adjustment Nuts flat on each nut.

  • Page 354: Trim Tab Adjustment

    2. Check trim tab position as follows: WARNING a. Operate boat at normal cruise throttle setting Core of each steering cable (transom end) must and adjust trim to optimum setting. Turn steer- be fully retracted into cable housing before ing wheel to left and right, noting in which direc- lubricating cable.

  • Page 355: Ride Guide Steering Attachment Extension Couplers

    Ride Guide Steering Attachment Extension Couplers Outboard Center Required Coupler(s) Line Distance Between Steering Eyes (Shown Below) 22-1/2 in. thru 12 in. (30.5cm) Coupler 24-1/2 in. (57.2cm 51890 thru 62.2cm) a - Couplers Connected Together 23-1/2 in. thru 15 in. (38.1cm) Coupler b - Lockwashers 27-1/2 in.
  • Page 356 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 357: Steering Cable Installation

    a - Ride-Guide Yoke g - After Jam Nuts are Torqued to Specification, Bend Locking Tabs against Nuts. b - 0 in. to 1/2 in. (0mm to 12.8mm) (Center of Ride-Guide Yoke to Top of Transom) h - Cable Guide Tube c - Top of Transom i - Ride-Guide Cable Attaching Nut - Torque to 35 lbs.

  • Page 358: Ride-Guide Steering Cable/Attaching Kit Installation (92876A3)

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

  • Page 359: Mounting Bracket Installation

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

  • Page 360: Installing Steering Cables

    Temporarily adjust tube so that longer threaded end Torque steering cable attaching nuts only after final of tube extends out the same distance as the out- steering adjustments have been made. board tilt tube. Do not tighten adjustment nuts at this time.

  • Page 361: Coupler Installation

    Coupler Installation Lubricate ball joint in steering link rod with SAE 30W Motor Oil. Secure link rod to outboard steering arm, using special washer head bolt (10-14000) provided WARNING and nylon insert locknut as shown. Torque special Locknuts must be used with bolts to secure bolt to 20 Ib.

  • Page 362: Maintenance Instructions

    Loosen adjustment nuts and pull steering cable Install rubber bumpers (a) on inside of each locking mounting tube (by hand) away from end of steering sleeve (b). cable (to remove slack in steering system). Tighten adjustment nuts against mounting bracket and check system for slack (play).

  • Page 363: Remote Control Installation

    Normal Service –Every 50 hrs. of operation or 60 Remote Control Installation days (whichever comes first) Shift Cable Installation and *Severe Service –Every 25 hrs. of operation or 30 Adjustment to Engine days (whichever comes first) * Operation in a salt water area is considered “Severe Service.” IMPORTANT: Install control cables to remote con- trol and mount remote control BEFORE attaching 1.

  • Page 364: Throttle Cable Installation And Adjustment To Engine

    3. Adjust cable barrel to attain the same length be- Throttle Cable Installation and tween cable barrel and hole in end of cable guide Adjustment to Engine as exists between barrel retainer and shift actua- 1. Shift remote control into neutral. tor stud, with a slight preload toward reverse.

  • Page 365: Connecting Engine Wiring Harness And Routing Of Engine Cables

    Connecting Engine Wiring Harness 2. Wrap neoprene sheet around cable bundle and secure each end with a sta-strap. Secure to and Routing of Engine Cables bracket with retainer. WARNING Wiring passing through cowl must be protected from damage by using a neoprene sheet as shown.

  • Page 366: Installing Outboard Motor On Transom

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

  • Page 367: Remove Cowling From Engine

    Drilling Outboard Mounting Holes Lifting Engine IMPORTANT: Before drilling any mounting holes, WARNING carefully read “Determining Recommended Out- board Motor Mounting Height”, preceding. There Make sure that lifting eye is threaded into flywheel is a 3/4 in. (19mm) difference between outboard a minimum of 5 turns and that hoist has a mounting holes in transom bracket.
  • Page 368 2. Apply marine sealer to shanks of mounting bolts WARNING (not threads) and secure engine to transom with 4 bolts, flat washers and locknuts, as shown. Be Before operating, motor(s) MUST BE SECURED to sure that installation is water-tight. boat transom with four 1/2 diameter bolts and locknuts, as follows: 2 bolts must be installed thru upper mounting holes and 2 bolts thru lower mounting holes, as shown in step 5.
  • Page 369 OUTBOARD MOTOR INSTALLATION/ ATTACHMENTS TILLER HANDLE AND CO-PILOT...
  • Page 370 Table Of Contents Page Tiller Arm Components ....7B-2 Tiller Arm Reassembly ....7B-13 Tiller Handle/Shaft Bracket Installation .
  • Page 371 Notes: 90-13645--2 495 OUTBOARD MOTOR INSTALLATION/ATTACHMENTS 7B-1...

  • Page 372: Tiller Arm Components

    Tiller Arm Components Quicksilver Lubrication/Sealant Application Points 2-4-C W/Teflon (92-825407A12) Soapy Water Solution (Obtain Locally) Loctite 271 (Obtain Locally) 7B-2 OUTBOARD MOTOR INSTALLATION/ATTACHMENTS 90-13645--2 495...
  • Page 373 Tiller Arm Components (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Steering Arm Throttle Tube Housing Gasket Plate Screw Drive Tight Throttle Clamp Screw Throttle Handle Screw Drive Tight Stop Switch Harness Stop Switch Grip Clip Screw Conduit Guide Tube Barrel Set Screw...

  • Page 374: Tiller Arm Bracket Assembly

    Tiller Arm Bracket Assembly Quicksilver Lubrication/Sealant Application Points 2-4-C With Teflon (92-825407A12) Loctite 271 (Obtain Locally) 7B-4 OUTBOARD MOTOR INSTALLATION/ATTACHMENTS 90-13645--2 495...
  • Page 375 Tiller Arm Bracket Assembly (Continued) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Bracket Assembly Stud Spacer Tab Washer 47.4 Grommet Harness Assembly Key Switch Cover Screw Drive Tight Plug Stop Switch Assembly Lanyard Retainer Bolt 12.4 Tab Washer Bushing Shift Lever Washer...

  • Page 376: Co-Pilot Components

    Co-Pilot Components 2-4-C With Teflon (92-825407A12) TORQUE REF. NO. QUAN. DESCRIPTION lb. in. lb. ft. Pilot Rod Friction Assembly Bolt Wing Nut Steering Link Rod Bushing Washer Nut -- Tighten until it seats; do not exceed 120 lb. in. (13.6 Nm), then 13.6 back off 1/4 turn.

  • Page 377: Tiller Arm/Shift Lever Removal

    5. Remove access cover from underneath tiller Tiller Arm/Shift Lever handle bracket. Removal 1. Remove BATTERY CABLES from BATTERY. 2. Remove outboard cowling. 3. Remove nuts securing shift link rod and throttle cable to engine. Release latch and remove shift link rod and throttle cable from anchor bracket.
  • Page 378 7. Remove nuts securing key switch and trim switch 9. Remove electrical panel access cover. to tiller handle bracket. Disconnect switch harness from engine harness Remove clip securing lanyard stop switch and re- plug. move switch from bracket. Disconnect PURPLE bullet connector. 51626 a - Nuts b - Key Switch...
  • Page 379 10. Disconnect BLUE/WHITE and GREEN/WHITE 13. Remove bolt and nut (hidden) from tiller handle trim leads from trim solenoids. bracket. 51625 a - Bolt 51622 b - Nut (Hidden) a - BLUE/WHITE Lead 14. Remove tiller handle, 2 nylon bushings, stainless b - GREEN/WHITE Lead bushing and 2 flat washers from bracket.

  • Page 380: Tiller Handle Disassembly

    15. Bend tab washer away from bolt securing shift le- 17. Bend tabs on tab washers away from nuts secur- ver and remove bolt and lever from bracket. ing bracket to steering arm. Remove nuts, tab washers and bracket from steering arm. 51622 a - Tab Washer b - Bolt...
  • Page 381 2. Remove screw from twist grip. 5. Remove throttle cable anchor screws and remove cable guide. 51603 a - Screw 3. Cut sta-strap securing stop switch harness and remove screw from harness J-clip. 51602 a - Anchor Screws b - Throttle Cable Guide 6.
  • Page 382 7. Unscrew (counterclockwise) stainless conduit 9. Remove cover plate and gasket from tiller handle. from tiller handle. 10. Remove bolt from throttle friction assembly. 51604 51603 a - Cover Plate b - Gasket (below plate) a - Conduit c - Screws 8.

  • Page 383: Tiller Arm Reassembly

    12. Drive out drift pin and remove throttle gear from 3. Slide cover and friction device onto throttle arm. throttle arm. 51604 a - Throttle Arm b - Gear c - Throttle Friction Device 51602 d - Cover 4. Install throttle arm assembly into tiller arm. a - Gear b - Drift Pin 5.
  • Page 384 6. Install gasket and cover plate over gear 9. Retract throttle cable into gear assembly until assembly. DO NOT OVERTIGHTEN attaching approximately 17 in. (43 cm) extends from the til- screws. ler arm. 51604 51604 a - Cover Plate a - Cable [Extends 17 in. (43 cm)] b - Gasket (below cover) c - Screws 10.
  • Page 385 11. Slide brass barrel over throttle cable tube. Secure 13. Position throttle arm slot to face stop harness exit barrel to tube with allen screw approximately hole in tiller handle. Route stop switch harness 3.5 in. (89 mm) from stainless conduit. DO NOT through twist grip, into throttle arm, and out OVERTIGHTEN screw as tubing may be crushed through side of tiller handle.

  • Page 386: Tiller Handle/Shaft Bracket Installation

    17. Attach sta-strap to end of harness sleeve. Tiller Handle/Shaft Bracket Installation 1. Slide bracket over steering arm studs. Secure bracket to arm with retained nuts and NEW tab washers. Torque nuts to 35 lb. ft. (47.5 Nm). Bend locking tabs against flats of nuts. 51603 a - Sta-strap b - J-clip...
  • Page 387 3. Insert bushings and thrust washer into shift lever. 5. Install two nylon bushings into tiller handle. Install shift lever onto bracket. Install stainless bushing into bracket. Install tiller handle to bracket using bolt and two washers. 51620 51622 a - Bushings a - Nylon Bushings b - Thrust Washer b - Stainless Bushing...
  • Page 388 7. Reinstall plug. 9. Reinstall lanyard stop switch in bracket and se- cure with clip. 51626 51608 a - Nuts b - Key Switch a - Plug c - Lanyard Stop Switch 8. Route key switch and trim switch harness through d - Trim Switch tiller bracket.
  • Page 389 11. Secure access cover to tiller bracket with five 14. Reinstall electrical panel access cover and screws. DO NOT OVERTIGHTEN SCREWS. secure with screws. Torque screws to 30 lb. in. (3.4 Nm). 51626 a - Access Cover b - Screws 12.

  • Page 390: Shift Link Rod Installation And Adjustment To Engine

    Shift Link Rod Installation Throttle Cable Installation and Adjustment to Engine and Adjustment to Engine 1. Position shift lever handle into neutral detent. IMPORTANT: Turn throttle cable conduit clockwise until bottomed on tiller handle then 2. Manually shift outboard into neutral (propeller will back off one turn before reconnecting throttle rotate freely).

  • Page 391: Co-Pilot Installation

    5. Check preload on throttle cable by placing a thin 3. Loosen wing nut on friction device and insert pilot piece of paper between idle stop screw and idle rod thru friction device and into tilt tube. stop. Preload is correct when paper can be re- 4.

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