Page 1 115/135/150/175 OptiMax Direct Fuel Injection Starting Model Year 2000 Starting Serial Number OG960500...
Page 2 Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers.
Page 3: Page Numbering
It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings.
Page 4: Service Manual Outline
Service Manual Outline General Information & Specifications Section 1 - General Information & Specifications A - Specifications B - Maintenance Ignition System C - General Information D - Outboard Installation Section 2 - Electrical A - Ignition Fuel System B - Charging & Starting System C - Timing, Synchronizing &...
Page 5: Master Specifications
SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Master Specifications ......1A-1 Master Specifications Model 135/150 DFI HORSEPOWER Model 135...
Page 6 SPECIFICATIONS Model 135/150 DFI Power Trim (Total Tilt Range) SECTION Power Trim (Tilt Range) Steering Pivot Range Tilt Pin Adjustment Positions Allowable Transom Thickness 2-3/8 in. (6.03 cm) GEAR Gear Ratio HOUSING Standard Ratio – 135 2.00:1 12/24 Teeth Standard Ratio – 150 1.87:1 15/28 Teeth Optional High Altitude Ratio –...
Page 7 SPECIFICATIONS Master Specifications Model 135/150 DFI FUEL Fuel Gasoline w/Oil Injection SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum Recommended Oil Quicksilver TC-W3 Premium Plus 2 Cycle Outboard Oil Gasoline/Oil Ratio – @ Idle 300 – 400:1 – @ WOT 60:1 Fuel Pressure Crankcase Pump –...
Page 8: Table Of Contents
MAINTENANCE IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Specifications ....... . 1B-1 Fuel System .
Page 9: Quicksilver Lubricant/Sealant
MAINTENANCE Special Tools 1. Grease Gun 91-37299A1 2. Flushing Attachment 44357A2 Quicksilver Lubricant/Sealant 1. Gear Lubricant - Premium Blend 92-19007A24 Page 1B-2 90-855347R1 JANUARY 1999...
Page 10 MAINTENANCE 2. Anti-Corrosion Grease 92-78376A6 3. 2-4-C Marine Lubricant with Teflon 92-825407A12 4. SAE 30W Motor Oil (Obtain Locally) 5. Quicksilver Power Trim and Steering Fluid 91-90100A12) 90-855347R1 JANUARY 1999 Page 1B-3...
Page 11: Inspection And Maintenance Schedule
MAINTENANCE Inspection and Maintenance Schedule Before Each Use 1. Check that lanyard stop switch stops the engine. 2. Visually inspect the fuel system for deterioration or leaks. 3. Check outboard for tightness on transom. 4. Check steering system for binding or loose components. 5.
Page 12: Flushing Engine
MAINTENANCE Flushing Engine Flushing Cooling System – Using Cowl Flush Plug Flush the internal water passages of the outboard with fresh water after each use in salt, polluted or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.
Page 13: Replacing Fuel Filter
MAINTENANCE IMPORTANT: While and after flushing, keep outboard in upright position until all water has drained from drive shaft housing to prevent water from entering the pow- erhead via drive shaft housing and exhaust ports. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions.
Page 14: Corrosion Control Anode
MAINTENANCE Corrosion Control Anode The gear case has two corrosion control anodes (a). Another anode (b) is installed on the bottom of the transom bracket assembly. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
Page 15: Battery Inspection
MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3.
Page 16: Compressor Air Intake Filter
MAINTENANCE Compressor Air intake Filter The filter should be changed every 100 hours of operation, or once a season. Never run the engine without the air filter. Removal 1. Remove flywheel cover from the engine. Snap out the retainer (a) and remove filter (b).
Page 17 MAINTENANCE Lubricate Point 2 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 2. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
Page 18: Checking Power Trim Fluid
MAINTENANCE 6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b). WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant.
Page 19: Gear Case Lubrication
MAINTENANCE Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer.Water in the lubricant may result in premature bearing failure or, in freezing temperatures, will turn to ice and damage the gear case.
Page 20: Storage Preparation
MAINTENANCE CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE NOTE: Some models may have the vent and fill/drain plugs on the opposite side. 1. Place outboard in a vertical operating position. 2. Remove vent plug (a). 3. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent hole (c).
Page 21 MAINTENANCE 3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine at 2000 rpm for 25 minutes to allow treated fuel to fill the fuel system. PROTECTING INTERNAL ENGINE COMPONENTS NOTE: Make sure the fuel system has been prepared for storage. 1.
Page 22 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents Serial Number Location ..... . . 1C-1 Model 135/150 DFI Powerhead Front View .
Page 23: Conditions Affecting Performance
30% relative humidity at 77 F (25 C) temperature and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce engine power.
Page 24 GENERAL INFORMATION To obtain optimum engine performance under changing weather conditions, the engine MUST be propped to allow it to operate at or near the top end of the recommended maxi- mum RPM range at wide-open-throttle with a normal boat load. This will allow the engine to develop full power while operating in an RPM range that dis- courages damaging detonation.
Page 25 GENERAL INFORMATION Trim TRIMMING OUTBOARD “OUT” (“UP”) WARNING Excessive trim “out” also may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power GRADUALLY and trim the out- board “in” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.) 1.
Page 26 GENERAL INFORMATION TRIMMING OUTBOARD “IN” (“DOWN”) CHARACTERISTICS WARNING Excessive speed at minimum trim “in” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the angle (trim adjustment bolt relocation.) 1.
Page 27: Engine Compression
GENERAL INFORMATION Engine DETONATION Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired.
Page 28: Following Complete Submersion
GENERAL INFORMATION Following Complete Submersion Salt Water Submersion Due to the corrosive effect of salt water on internal engine components, complete disas- sembly is necessary before any attempt is made to start the engine. Submerged While Running When an engine is submerged while running, the possibility of internal engine damage is greatly increased.
Page 29 GENERAL INFORMATION 8. Drain water from the oil injection system as follows: a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard side of engine. b. Drain any water from hose and reconnect. c. If water was present in hose, check for water in the remote oil tank. Drain tank if water is present.
Page 30: Model 135/150 Dfi Powerhead Front View
GENERAL INFORMATION Model 135/150 DFI Powerhead Front View 57314 High Pressure Electric Fuel Pump (Inside Vapor Separator) Vapor Separator Vapor Separator Drain Plug Air Temperature Sensor Fuel Hose Outlet from Low Pressure Electric Fuel Pump Fuel Return Hose from Fuel Cooler Electric Fuel Pump Harness Connection Electric Oil Pump (Hidden) Digital Diagnostic Terminal Harness Connection...
Page 31 GENERAL INFORMATION Model 135/150 DFI Powerhead Starboard View 57317 Fuel Pressure Test Valve 14 - Starter Solenoid Air Compressor Oil Return Line 15 - Oil Pump Fuse Crank Position Sensor 16 - Harness Fuse (20 Ampere) Throttle Plate/Air Plenum Assembly 17 - ECM Fuse (20 Ampere) Digital Diagnostic Terminal Connector...
Page 32: Model 135/150 Dfi Powerhead Port View
GENERAL INFORMATION Model 135/150 DFI Powerhead Port View 57312 High Pressure Electric Fuel Pump 17 - Excess Fuel Return to Fuel Cooler Fuel Out (90 psi) 18 - Air Pressure Test Port Crank Position Sensor 19 - 40 psi Check Valve Fuel Return from Fuel Cooler 20 - Fuel Cooler...
Page 33: Model 135/150 Dfi Powerhead Top View
GENERAL INFORMATION Model 135/150 DFI Powerhead Top View 57313 Air Compressor Inlet Nozzle 12 - MAP Sensor Hose Water Outlet (Tell-Tale) Hose 13 - Oil Return Hose from Air Compressor Thermostat Outlet Hose to Adaptor Plate 14 - Starter Motor Fuel (90 PSI) to Fuel Rails 15 - Oil Hose from Oil Pump to Air Compressor...
Page 34: Model 135/150 Dfi Powerhead Aft View
GENERAL INFORMATION Model 135/150 DFI Powerhead Aft View 57315 Air Compressor Restrictor/Air Inlet 15 - #5 Ignition Coil Water Out (tell-tale) from Air Compressor 16 - #3 Ignition Coil Air Compressor Oil Inlet from Oil Pump 17 - #1 Ignition Coil Air Compressor 18 - Water Inlet to Air Compressor...
Page 35: Painting Procedures
7. Allow a minimum of one hour drying time and no more than one week before top coat- ing assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio.
Page 36: Decal Application
GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensi- tive to scratches and abrasions for a few days.
Page 37 GENERAL INFORMATION DECAL APPLICATION 1. Mix ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation.
Page 38 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents Installation Specifications ..... . 1D-1 Dual Outboard .
Page 39: Installing Outboard To Boat Transom
OUTBOARD MOTOR INSTALLATION Installing Outboard to Boat Transom Determining Recommended Outboard Mounting Height 26 in. (660mm) 25 in. (635mm) 24 in. (609mm) 23 in. Outboard (584mm) Mounting Height (See 22 in. NOTE Below) (560mm) 21 in. (533mm) 20 in. (508mm) 19 in.
Page 40: Installing Outboard
OUTBOARD MOTOR INSTALLATION Installing Outboard Drilling Outboard Mounting Holes 1. Attach (tape) engine mounting template (located with the installation manual) to boat transom. IMPORTANT: If using “Transom Drilling Fixture” (part number 91-98234A2), use drill guide holes marked “A” when drilling outboard mounting holes. Centerline of Transom Transom Drilling Fixture (91-98234A2) 2.
Page 41: Securing Outboard To Boat Transom
OUTBOARD MOTOR INSTALLATION Securing Outboard To Boat Transom 1. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding and Install outboard to the nearest recommended mounting height. 2. Fasten outboard with provided mounting hardware shown. 1/2 In. Diameter Bolts (4) Flat Washers (4) Locknuts (4) Marine Sealer - Apply to Shanks of Bolts, Not Threads...
Page 42: Steering Link Rod
OUTBOARD MOTOR INSTALLATION 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 N·m). Steering Link Rod 1. Install steering link rod per illustration. Special Bolt (10-90041) Torque to 20 lb-ft (27 N·m) Nylon Insert Locknut (11-34863) Torque to 20 lb-ft (27 N·m) Flat Washer (2) Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn...
Page 43: Electrical, Hoses And Control Cables
OUTBOARD MOTOR INSTALLATION Electrical, Hoses and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch as- sembly must be wired with a warning horn. This warning horn is used with the en- gine warning system. Installation Note Open the front clamp assembly.
Page 44: Warning Gauge Harness
OUTBOARD MOTOR INSTALLATION Warning Gauge Harness Connect the harness extension to gauge and engine. 2 3 4 5 TAN/BLACK TAN/WHITE PINK/LT. BLUE to PINK/LT. BLUE ORANGE Connect PURPLE to 12 Volt Source or Adjacent Gauge Sta-Straps – Fasten Wiring to Prevent Catching on Cowl 90-855347R1 JANUARY 1999 Page 1D-7...
Page 45: Battery Cables
OUTBOARD MOTOR INSTALLATION Battery Cables Single Outboard (–) RED Sleeve (Positive) BLACK Sleeve (Negative) Starting Battery Dual Outboard Connect a common ground cable (wire size same as engine battery cables) between NEGATIVE (–) terminals on starting batteries. (–) (–) Common Ground Cable Page 1D-8 90-855347R1 JANUARY 1999...
Page 46: Shift Cable
OUTBOARD MOTOR INSTALLATION Shift Cable Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gear cases can be identified by a “L”...
Page 47: Installation
OUTBOARD MOTOR INSTALLATION Installation IMPORTANT: Step 1 must be followed for proper adjustment of the shift cable. 1. Locate the center point of the slack or lost motion that exists in the shift cable as fol- lows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position.
Page 48 OUTBOARD MOTOR INSTALLATION 2. Position remote control and outboard into neutral. 3. Slide the shift cable retainer forward until resistance is felt, then slide cable anchor toward rear until resistance is felt. Center the anchor pin between resistance points. Shift Cable Retainer Anchor Pin 4.
Page 49: Throttle Cable
OUTBOARD MOTOR INSTALLATION d. Return remote control handle to neutral. The propeller should turn freely without drag. If not, adjust barrel closer to cable end guide. Repeat steps a thru d. Throttle Cable INSTALLATION 1. Position remote control into neutral. 2.
Page 50: Front Clamp Reassembly
OUTBOARD MOTOR INSTALLATION b. Return remote control to neutral. Place a thin piece of paper between idle adjust- ment screw and idle stop. Adjustment is correct when the paper can be removed without tearing, but has some drag on it. Readjust cable barrel if necessary. IMPORTANT: The idle stop screw must be touching the stop.
Page 51: Filling Fuel System
OUTBOARD MOTOR INSTALLATION 2. Fasten clamp together with two screws. Screws Filling Fuel System NOTE: For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should to be filled as follows: Squeeze the fuel line primer bulb until it feels firm.
Page 52: Priming The Oil Injection Pump
OUTBOARD MOTOR INSTALLATION 2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap. Engine Oil Tank Fill Cap Priming the Oil Injection Pump Before starting engine for the first time, prime the oil injection pump. Priming will re- move any air that may be in the pump, oil supply hose, or internal passages.
Page 53: Purging Air From The Engine Oil Tank
OUTBOARD MOTOR INSTALLATION NOTE: It may take a few minutes for the pump to complete the priming process. Purging Air From the Engine Oil Tank 1. Loosen the fill cap on the engine oil tank. 2. Start the engine. Run the engine until the all the air has been vented out of the tank and oil starts to flow out of the tank.
Page 54: Trim Tab Adjustment
OUTBOARD MOTOR INSTALLATION Trim Tab Adjustment Propeller steering torque may cause your boat to pull in one direction. This steering torque results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque and can be adjusted within limits to reduce any unequal steering effort.
Page 55 IGNITION ELECTRICAL Section 2A – Ignition Table of Contents Specifications ....... . 2A-1 Disconnecting Harness Connectors from Special Tools...
Page 56: Special Tools
IGNITION Special Tools 1. Digital Diagnostic Terminal (DDT) 91-823686A2 2. Software Cartridge 91-822608--5 3. DDT Reference Manual 90-825159-3 4. Adaptor Harness 84-822560A5 Page 2A-2 90-855347R1 JANUARY 1999...
Page 57 IGNITION 5. Multi-Meter/DVA Tester (91-99750A1) 6. Inductive Timing Light 91-99379 7. Spark Gap Tester 91-850439T 55117 90-855347R1 JANUARY 1999 Page 2A-3...
Page 58: Electrical Components
IGNITION Electrical Components Dielectric Grease (92-823506--1) Liquid Neoprene (92-25711--2) NOTE: COAT ALL EYELET WIRING TERMINALS WITH #25 GACO N700 (LIQUID NEOPRENE 92-25711-2) NOTE: COAT ALL MULTI-PIN ELECTRICAL CONNECTIONS (EXCEPT POWER TRIM RELAY CONNECTORS) WITH #6 DC-4 (DIELECTRIC GREASE 92-823506--1) Page 2A-4 90-855347R1 JANUARY 1999...
Page 59 IGNITION Electrical Components TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft ELECTRICAL MOUNTING PLATE IGNITION COIL HI-TENSION CABLE SPARK PLUG (HEAVY DUTY) SPACER SCREW (1/4-20 x 3-1/4 IN.) MAP SENSOR SCREW (M6 x 14) TUBING (31 IN.) SCREW (.312-18 x 1-1/4 IN.) 19.6 26.5 WASHER...
Page 60: Theory Of Operation
IGNITION Theory of Operation When the ignition key is turned to the RUN position, battery voltage is applied to the main relay through the PURPLE wire. When the Electronic Control Module (ECM) receives a signal from the Crank Position Sensor, the main relay ground circuit is completed through the ECM.
Page 61: Flywheel
IGNITION Flywheel 24 teeth under the flywheel ring gear provide engine rpm and crankshaft position informa- tion to the ECM through the crank position sensor. Ignition Coils Inductive type ignition coils are used on the DFI engines. Ignition Coil Ohm Test Connect meter leads between primary terminal (GRN/Striped) 0.38 - 0.78 W and ground (Black) terminal pin.
Page 62: Temperature Sensor
IGNITION Temperature Sensor Two (2) temperature sensors are used to provide cylinder head temperature information to the ECM. One sensor is mounted in the starboard cylinder head and one in the air com- pressor cylinder head. The ECM uses this information to increase injector pulse width for cold starts and to retard timing in the event of an over-heat condition.
Page 63: Manifold Absolute Pressure (Map) Sensor
IGNITION Manifold Absolute Pressure (MAP) Sensor The MAP sensor is mounted between the cylinder heads. A vacuum hose connects the map sensor to the intake manifold. The ECM regulates fuel flow, in part, based on man- ifold absolute pressure. Drawing a vacuum on the MAP sensor hose will create a lean fuel condition.
Page 64: Troubleshooting Without Digital Diagnostic Terminal
IGNITION Troubleshooting Without Digital Diagnostic Terminal Troubleshooting without the DDT is limited to checking resistance on some of the sen- sors. Typical failures usually do not involve the ECM. Connectors, set-up, and mechanical wear are most likely at fault. Verify spark plug wires are securely installed (pushed in) into the coil tower. The engine may not run or may not run above idle with the wrong spark plugs installed.
Page 65: Troubleshooting With The Digital Diagnostic Terminal
Adapter Harness (84-822560A5) The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines. Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car- tridge.
Page 66: Notes
IGNITION Notes: Page 2A-12 90-855347R1 JANUARY 1999...
Page 67: Ddt Functions
PASS IGN 6 PASS PASS Select Auto Test: MARINE DIAGNOSTICS 1 - STATIC TEST Engine Not Running During Test 1 - Mariner/Mercury INJECTOR ACTIVE HIST 2 - MerCruiser INJ 1 PASS PASS 2 - RUNNING TEST Engine Running During Test...
Page 68: Dfi Troubleshooting Guide
IGNITION DFI Troubleshooting Guide Symptom Cause Action 1. Engine cranks but won’t 1.0 Lanyard stop switch in wrong Reset lanyard stop switch. start position. 1.1 Weak battery or bad starter Replace/charge battery. motor, battery voltage drops Inspect condition of starter motor. below 8 volts while cranking Check condition of battery termi- (ECM cuts out below 8 volts)
Page 69 IGNITION DFI Troubleshooting Guide (continued) Symptom Cause Action 1. Engine cranks but will not 1.9 ECM not functioning Injection System: start (continued) Listen for injector “ticking” when cranking or connect spare injector to each respective harness. Tick- ing should start after 2 cranking revolutions.
Page 70 IGNITION DFI Troubleshooting Guide (continued) Symptom Cause Action 3. Engine idle is rough 3.1 Low air pressure in rail (less See 1.2 than 79 2 psi while running) 3.2 Fouled spark plug Replace spark plug: –If carbon bridges electrode gap or if it is completely black.
Page 71: Ignition Components Removal And Installation
IGNITION DFI Troubleshooting Guide (continued) Symptom Cause Action 7. Speed Reduction (RPM 7.1 Low battery voltage Check battery and/or alternator. reduced or limited to 3000) ECM requires 8 volts minimum Check electrical connections. Fuel Pump requires 9 volts 7.2 Overheat condition (engine Check water pump impeller/cooling and/or air compressor) system.
Page 72: Electronic Control Module (Ecm)
IGNITION b. Push rear of the cover down onto the rear pin and air intake tube for the air com- pressor. c. Connect vent hose onto fitting. d. Position hoses into holder. Front Flange Air Intake Tube Fitting Holder Electronic Control Module (ECM) REMOVAL 1.
Page 73: Ignition Module (Coil)
IGNITION Ignition Module (Coil) REMOVAL 1. Disconnect coil harness and spark plug lead. 2. Loosen the electrical mounting plate to gain access to the rear locknuts. 3. Remove module attaching bolts. 56141 Bolts (6) –Torque to 80 lb-in (9 Nm). Ignition Coils (6) Spacer –...
Page 74: Crank Position Sensor
IGNITION Crank Position Sensor REMOVAL 1. Disconnect harness. 2. Remove bolt securing sensor to bracket. 56069 Shim (0.010 or 0.020 in.) (0.254 mm 0.508 mm) Crank Position Sensor Washer Bolt – Torque to 50 lb-in (5.5 Nm) INSTALLATION 1. Fasten sensor to bracket with bolt. 2.
Page 75 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B – Charging & Starting System Table of Contents Specifications ....... . 2B-1 Disassembly and Test .
Page 76: Battery Cable Size
= Standard (original) Cable Length and wire gage size. Replacement Parts WARNING Electrical, ignition and fuel system components on your Mercury/Mariner out- board are designed and manufactured to comply with U. S. Coast Guard Rules and Regulations to minimize risks of fire and explosions. Use of replacement...
Page 77: Special Tools
CHARGING & STARTING SYSTEM Special Tools 1. Volt/Ohm Meter 91-99750A1or DMT 2000 Digital Tachometer Multimeter 91-854009A1 Volt/Ohm Meter 91-99750A1 DMT 2000 Digital Tachometer Multimeter 91-854009A1 2. Ammeter (60 Ampere minimum) (Obtain locally) 3. Flywheel Holder 91-52344 54964 4. Protector Cap 91-24161 5.
Page 78: Charging A Discharged Battery
CHARGING & STARTING SYSTEM 1. DO NOT smoke near batteries being charged or which have been charged very recently. 2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at the point where a live circuit is broken. Always be careful when connecting or dis- connecting cable clamps on chargers.
Page 79: Flywheel Removal And Installation
CHARGING & STARTING SYSTEM 2. When adding distilled water to battery, be extremely careful not to fill more than 3/16 in. (4.8 mm) above perforated baffles inside battery. Battery solution or electrolyte ex- pands from heat caused by charging. Overfilling battery will cause electrolyte to over- flow (if filled beyond 3/16 above baffles).
Page 80: Installation
CHARGING & STARTING SYSTEM 5. Hold flywheel tool with wrench while tightening bolt down on protector cap. Tighten bolt until flywheel comes free. 57413 Flywheel Puller (91-73687A2) NOTE: Neither heat or hammer should be used on flywheel to aid in removal as damage to flywheel or electrical components under flywheel may result.
Page 81 CHARGING & STARTING SYSTEM Notes: 90-855347R1 JANUARY 1999 Page 2B-7...
Page 82: Flywheel/Alternator
CHARGING & STARTING SYSTEM Flywheel/Alternator Page 2B-8 90-855347R1 JANUARY 1999...
Page 83 CHARGING & STARTING SYSTEM Flywheel/Alternator TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft ALTERNATOR SCREW (M10 x 100) SCREW (M10 x120) WASHER MOUNT BRACKET WASHER BRACKET SCREW (M10 x 55) CABLE BRACKET SCREW (5/16-18 x 1 IN.) 15.5 SPRING BELT TENSIONER STUD (M10 x 85) BUSHING WASHER...
Page 84: System Components
CHARGING & STARTING SYSTEM System Components The battery charging system consists of the alternator, battery, ignition switch, starter solenoid and the wiring which connects these components. 51708 Alternator Battery 20 Ampere Fuse Starter Solenoid Precautions The following precautions must be observed when working on the alternator system. Fail- ure to observe these precautions may result in serious damage to the alternator system.
Page 85: Alternator Description
CHARGING & STARTING SYSTEM Alternator Description The alternator employs a rotor, which is supported in 2 end frames by ball bearings, and is driven at 2.5 times engine speed. The rotor contains a field winding enclosed between 2 multiple-finger pole pieces. The ends of the field winding are connected to 2 brushes which make continuous sliding contact with the slip rings.
Page 86: Alternator Assembly
CHARGING & STARTING SYSTEM Alternator Assembly 51683 Pulley Nut Pulley Spacer Frame and Rotor Assembly Brush Holder Brush Cover Regulator Rectifier (Diode Assembly) Insulator End Cover Page 2B-12 90-855347R1 JANUARY 1999...
Page 87: Alternator System Circuitry Test
CHARGING & STARTING SYSTEM Alternator System Circuitry Test Using a 0-20 volt DC voltmeter, perform the following tests: Output Circuit 1. Connect POSITIVE (+) voltmeter lead to alternator terminal B (output terminal). Con- nect NEGATIVE (–) lead to case ground on alternator. 2.
Page 88: Voltage Output
CHARGING & STARTING SYSTEM Voltage Output 1. Using a 0-20 volt DC voltmeter, connect POSITIVE (+) lead of voltmeter to TERMINAL B of alternator and NEGATIVE (–) lead of voltmeter to engine ground. 2. Start engine and allow to warm up. Increase engine RPM from idle to 2000. Normal voltage output should be 13.5 –...
Page 89: Current Output
CHARGING & STARTING SYSTEM Current Output 1. With engine shut off, install ammeter (capable of reading 60+ amperes) in series be- tween TERMINAL B on alternator and POSITIVE (+) terminal of battery. 2. Start engine and allow to warm up. Advance RPM to 2000. 3.
Page 90: Disassembly And Test
CHARGING & STARTING SYSTEM Disassembly and Test 1. Remove 3 screws and nut securing end cover and remove insulator and cover. 2. Remove 5 screws securing regulator and brush assembly. 51680 51683 Cover Screws Insulator Regulator Brush Assembly Screws NOTE: Proper regulator operation can be determined by VOLTAGE OUTPUT and CUR- RENT OUTPUT, previous.
Page 91 CHARGING & STARTING SYSTEM NOTE: To test rectifier assembly, touch POSITIVE (+) lead from ohmmeter to POSITIVE stud and NEGATIVE (–) lead from ohmmeter to each diode terminal. The ohmmeter should indicate continuity. 51679 Positive Stud Positive Ohm Lead Negative Ohm Lead Reverse leads –...
Page 92: Rotor Test
CHARGING & STARTING SYSTEM IMPORTANT: The regulator, rectifier and brush assembly are the only components individually replaceable on this alternator. If the rotor or stator is defective, the en- tire rotor, stator and housing must be replaced as an assembly. IMPORTANT: Clean anti-corrosion paint from electrical connections prior to reas- sembly.
Page 93: Stator Test
CHARGING & STARTING SYSTEM Stator Test 1. With rectifier removed, use an ohmmeter to check for a short circuit between each stator lead and the stator frame. If CONTINUITY exists, stator is defective. 51682 Stator Leads Frame 2. Inspect stator for open circuit. Using an ohmmeter, check for an open circuit between each of the stator leads.
Page 94: Reassembly
CHARGING & STARTING SYSTEM Reassembly 1. Position rectifier assembly over stator leads. 2. Form stator leads in a clockwise loop and secure leads to rectifier with 4 screws. Torque screws to 17 lb-in (1.9 Nm). 51684 51683 Rectifier Assembly Stator Leads Stator Leads Screws [Torque to 17 lb-in (1.9 Nm)] 3.
Page 95: Pulley
CHARGING & STARTING SYSTEM 5. Install end cover. Secure cover with 3 screws. Torque screws to 23 lb-in. (2.5 Nm). Install terminal insulator. Torque nut to 36 lb-in (4 Nm). 51683 Cover Screw [Torque to 23 lb-in (2.5 Nm)] Terminal Insulator Nut [Torque to 36 lb-in.
Page 96: Installation
CHARGING & STARTING SYSTEM Installation 1. Secure alternator to engine block with attaching bolts. Torque top bolt to 40 lb-ft (54 Nm). Torque bottom bolt to 35 lb-ft (47.5 Nm). 2. Install alternator belt in V-groove of flywheel and alternator pulley. 3.
Page 97: Starter System
CHARGING & STARTING SYSTEM Starter System Starter Motor Amperes Draw STARTER MOTOR NO LOAD NORMAL PART NO. AMP. DRAW AMP. DRAW 50-833153-1 30 AMPS 165 AMPS Starter System Components 1. Battery 2. Starter Solenoid 3. Neutral Start Switch 4. Starter Motor 5.
Page 98: Starter Motor
CHARGING & STARTING SYSTEM Starter Motor 2 Cycle Outboard Oil (92-826666A24) TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft STARTER MOTOR DRIVE CAP THRU BOLT DRIVE KIT PINION ARMATURE BRUSH/SPRING KIT BRUSH HOLDER COMMUTATOR CAP SCREW Drive Tight LOCKWASHER NUT (1/4-20) LOCKWASHER NUT (1/4-20) SCREW (5/16-18 x 1-3/4)
Page 99: Troubleshooting The Starter Circuit
CHARGING & STARTING SYSTEM Troubleshooting the Starter Circuit Before beginning the troubleshooting flow chart, verify the following conditions: 1. Confirm that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4.
Page 100: Starter Circuit Troubleshooting Flow Chart
CHARGING & STARTING SYSTEM Starter Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect yellow (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1–thru–7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (Rx1 scale) and connect meter leads between NEGATIVE (–) battery post and common power- head ground.
Page 101: Starter Removal And Installation
CHARGING & STARTING SYSTEM TEST 7 a. Connect voltmeter between common engine and Test Point1. b. Turn ignition key to “Start” position. 12 Volt Reading* No voltage reading: Defective starter solenoid Should hear solenoid click: proceed to TEST 8 TEST 8 a.
Page 102: Installation
CHARGING & STARTING SYSTEM Installation 1. Secure starter to engine with 3 bolts. Use Left top bolt to attach BLACK NEGATIVE (–) battery cable. Torque top attaching bolts to 23 lb-ft (31 Nm). Torque bottom attaching bolt to 21 lb-ft (28.5 Nm).
Page 103 CHARGING & STARTING SYSTEM 4. Brush replacement is recommended if brushes are pitted, chipped or worn to less than 0.25 in. (6.4 mm). If necessary, remove brushes as follows: a. Remove hex nut and washers from POSITIVE (+) terminal and remove POSITIVE brushes and terminal as an assembly.
Page 104: Starter Cleaning, Inspection And Testing
CHARGING & STARTING SYSTEM Starter Cleaning, Inspection and Testing Cleaning and Inspection 1. Clean all starter motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar if tension is not adequate or if wear is excessive.
Page 105 CHARGING & STARTING SYSTEM Armature Test for Ground 1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core or shaft and other lead on commutator. 2. If meter indicates continuity, armature is grounded and must be replaced. 51711 Checking Positive Brushes and Terminal Set ohmmeter to (R x 1 scale).
Page 106: Starter Reassembly
CHARGING & STARTING SYSTEM Starter Reassembly 1. If brushes were removed, replace as follows: a. Install POSITIVE brushes (along with POSITIVE terminal) into commutator end cap. 51713 52131 End Cap POSITIVE Brushes POSITIVE Terminal Insulating Block Insulating Washer Hex Nut POSITIVE (+) Terminal Long Brush Lead Push Lead into Slot...
Page 107 CHARGING & STARTING SYSTEM 2. If removed, reinstall parts on armature shaft. Use a new locknut and tighten securely on end of shaft. 11658 Locknut Spacer Spring Drive Assembly Drive End Cap Armature Shaft Washer 3. Lubricate helix threads on armature shaft with a drop of SAE 10W oil. 4.
Page 108: Starter Solenoid Test
CHARGING & STARTING SYSTEM 8. Place springs and brushes into brush holder and hold in place with brush retainer tool. 9. Install commutator end cap onto starter frame. Align marks on frame with alignment marks on end caps. Remove brush retainer tool. Install through bolts and torque to 70 lb-in (8 Nm).
Page 109: Commander 2000 Key Switch Test
CHARGING & STARTING SYSTEM Commander 2000 Key Switch Test 1. Disconnect remote control wiring harness and instrument panel connector. 2. Set ohmmeter on R x 1 scale for the following tests. 3. If meter readings are other than specified in the following tests, verify that switch and not wiring is faulty.
Page 110 TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL Section 2C – Timing, Synchronizing & Adjusting Table of Contents Specifications ....... . 2C-1 Throttle Plate Screw .
Page 111: Special Tools
TIMING, SYNCHRONIZING & ADJUSTING Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 2. Digital Diagnostic Tool (DDT) 91-823686A2 3. Software Cartridge 91-822608--4 Page 2C-2 90-855347R1 JANUARY 1999...
Page 112 TIMING, SYNCHRONIZING & ADJUSTING 4. DDT Reference Manual 90-825159-2 5. ECM Harness 84-822560--5 6. Extension Cable [10 ft. (3.05m)] 84-5003A1 90-855347R1 JANUARY 1999 Page 2C-3...
Page 113: Crank Position Sensor
TIMING, SYNCHRONIZING & ADJUSTING Crank Position Sensor NOTE: Crank Position Sensor is normally not adjustable, but shims are available if sensor is found to be to close to flywheel. 1. Remove flywheel cover. 2. Using a feeler gauge, measure the air gap between the crank position sensor and a tooth on the flywheel.
Page 114: Throttle Cam Adjustment
TIMING, SYNCHRONIZING & ADJUSTING Throttle Cam Adjustment NOTE: Low pressure electric fuel pump is removed for viewing purpose. 1. Loosen roller arm screw allowing roller to move freely. 2. Allow roller to rest on throttle cam. Adjust idle stop screw on throttle arm to align cam roller in the pocket of the throttle cam.
Page 115: Idle Speed
TIMING, SYNCHRONIZING & ADJUSTING 4. Check for free play (roller lifts from cam) between roller and cam at full throttle to pre- vent linkage from binding. Readjust full throttle stop screw, if necessary 56062 Throttle Arm Throttle Shaft Arm Stop 0.020 in.
Page 116 WIRING DIAGRAMS ELECTRICAL Section 2D – Wiring Diagrams Table of Contents Power Trim Wiring Diagram ....2D-2 Oil Level Gauge Wiring ....2D-12 Instrument Wiring Connections .
Page 117: Power Trim Wiring Diagram
WIRING DIAGRAMS Power Trim Wiring Diagram Tach. Connector Trim Pump and Motor Key Switch Assembly DOWN Solenoid Trim Switch UP Solenoid Trim Sender Bottom Cowl Switch Start Solenoid 20 Ampere Fuse To Battery Engine Harness To Alternator Remote Control Harness Page 2D-2 90-855347R1 JANUARY 1999...
Page 118: Instrument Wiring Connections
WIRING DIAGRAMS Instrument Wiring Connections Wire Color Where To Speedometer Tachometer BLACK GROUND TAN/WHT = TAN/WHITE OIL LIGHT Temperature/Oil TAN/BLK = TAN/BLACK TEMPERATURE LIGHT Volt Meter Warning Panel TEMPERATURE GAUGE PURPLE IGNITION 12 VOLT GRAY TACHOMETER BRN/WHT = BROWN/WHITE TRIM GAUGE TAN/BLU = TAN/BLUE VISUAL WARNING KIT (OPT.)
Page 119: Commander 3000 Classic Panel Remote Control 2D-4
WIRING DIAGRAMS Commander 3000 Classic Panel Remote Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...
Page 120: Commander 3000 Panel Remote Control
WIRING DIAGRAMS Commander 3000 Panel Remote Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...
Page 121: Instrument/Lanyard Stop Switch Wiring Diagram
WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram BLK=BLACK BLU=BLUE BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW 52204 Ignition/Choke Switch Lanyard Stop Switch Lead Not Used on Outboard Installations Retainer Tachometer Trim Indicator Gauge (Optional) Temperature Gauge Remote Control Power Trim Harness Connector Connect Wires Together w/Screw and Nut (2 Places);...
Page 122: Oil Level Gauge Wiring Diagram
WIRING DIAGRAMS Oil Level Gauge Wiring Diagram To 12 Volt Source PURPLE Wire (Connect to Trim Indicator Gauge “I” [or POSITIVE (+) 12 Volt Source that is Turned “ON” and “OFF” with Ignition Switch]) Oil Level Gauge BLACK Wire (Connects to NEGATIVE Ground) To Ground BLACK Wire (From Gauge to Oil Clip Connector) LIGHT BLUE Sender Lead to Gauge...
Page 123: Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK=BLACK BATT GND BLU=BLUE BRN=BROWN GRN=GREEN SENDER GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW 52205 PORT INSTALLATION Ignition/Choke Switch Lanyard Stop Switch Lead not used on Outboard Installations Retainer Tachometer Trim Indicator Gauge Temperature Gauge Remote Control Page 2D-8...
Page 124 WIRING DIAGRAMS IMPORTANT: On installations where gauge options will not be used, tape back and isolate unused wiring harness leads. BATT GND SENDER STARBOARD INSTALLATION 52206 Synchronizer Gauge Synchronizer Module Lanyard Switch (Isolation) Diode Y Harness Power Trim Harness Connector Connect Wires together with Screw and Nut (4 Places);...
Page 125: Qsi Gauge Wiring Diagrams
WIRING DIAGRAMS QSI Gauge Wiring Diagrams Tachometer Wiring Diagram Tachometer dial on back side of case must be set to position number 4. WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. 51106 Connect to +12 Volt +12 Volt Light Switch Wire Position Light Bulb to the Switched Position...
Page 126: Water Temperature Gauge
WIRING DIAGRAMS Water Temperature Gauge WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. SEND Connect to + 12 Volt +12 Volt Light Switch Wire Position Light Bulb to the Switched Position Connect to NEGATIVE (–) Ground Connect to TAN Lead located at the Tachometer Receptacle on Commander Side Mount Remote Control or TAN Lead coming from Accessory Ignition/ Choke Assembly.
Page 127: Oil Level Gauge Wiring
WIRING DIAGRAMS Route TAN lead on starboard side of engine to engine/remote control harness. Connect as shown. IMPORTANT: Tape back and isolate any unused wiring harness leads. 28086 Lead from Temperature Sender Engine/Remote Control Harness Oil Level Gauge Wiring LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting.
Page 128 WIRING DIAGRAMS LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch. (In- strument lights are on when ignition key switch is turned on.) 51112 Position Light Bulb to the Unswitched Position Sender SENDER WIRING 51108...
Page 129: Engine Synchronizer Wiring Diagram
WIRING DIAGRAMS Engine Synchronizer Wiring Diagram LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting. SEND 51105 +12 Volt Light Switch Wire Position Light Bulb to the Unswitched Position LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch.
Page 130: Maintenance
WIRING DIAGRAMS Wiring Diagram – Gauge needle to point toward slow running engine GRY=GRAY WHT=WHITE BLK=BLACK PUR=PURPLE 51107 Tachometer Starboard Engine Synchronizer Gauge Tachometer Port Engine Synchronizer Module Wiring Diagram – Gauge needle to point toward fast running engine GRY=GRAY WHT=WHITE BLK=BLACK PUR=PURPLE...
Page 131: Multi-Function Gauge
WIRING DIAGRAMS Multi-Function Gauge Dip Switch Setting/Testing NOTE: The multi-function gauge “Dip Switch” must be set on the back of gauge prior to operation. Turn the ignition switch to the “OFF” position before setting dip switch. The gauge will reset to selected settings when the ignition is turned “On”. IMPORTANT: Test the gauge and related wiring BEFORE making final “Dip Switch”...
Page 132: Outboard Multi-Function Gauge Setting
WIRING DIAGRAMS Outboard Multi-Function Gauge Setting Model Dip Switch Setting Test Display (All) Open 275 hp (3.4 Litre) Outboards (single engine) Open 135-250 hp Outboards (single engine) Open “Note” On Dual Engine/Single Fuel Tank Applications: Position Dip Switch 4 “Open” Open * Dip Switch (4) in “Open Position”...
Page 133: Warning System Signals
WIRING DIAGRAMS Warning System Signals NOTE: The warning system signals which includes audible and visual indicator involving the horn and lights will identify the potential problems listed in the chart Problem Horn Check Low Oil Over Water In Engine Speed Engine Light Heat...
Page 134: Warning System Operation
WIRING DIAGRAMS Problem Horn Check Low Oil Over Water In Engine Speed Engine Light Heat Fuel Reduction Acti- Light Light Light vated (approx. 3000 RPM) Over Heat Cyl. Head/ Continu- Compressor ous Beep Throttle Sensor Failure Continu- RPM reduces to ous Inter- 3000 if 1 sensor mittant...
Page 135 WIRING DIAGRAMS ENGINE OVERHEAT The system is activated when the engine temperature is too hot. The TEMP light (a) will come on and the warning horn begins sounding. The warning sys- tem will automatically limit the engine speed to 3000 RPM. After the engine has cooled, shift the outboard into neutral to reset the overheat circuit.
Page 136 WIRING DIAGRAMS ENGINE OVER-SPEED PROTECTION SYSTEM The system is activated when the engine speed exceeds the maximum allowable RPM. Anytime the engine over-speed system is activated, the warning horn (a) begins to sound continuously. The system will automatically reduce the engine speed to within the allow- able limit.
Page 137: Panel Mount Remote Control Wiring Installation 2D-22
WIRING DIAGRAMS Panel Mount Remote Control Wiring Installation BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...
Page 138 1998 Model 135/150 DFI Wiring Diagram Fuel Injector #1 Fuel Injector #2 Fuel Injector #3 Direct Injector #1 Direct Injector #2 A B C Direct Injector #3 Direct Injector #4 Direct Injector #5 Direct Injector #6 10 - Oil Pump 11 - MAP Sensor 12 -...
Page 139 1999 Model 135/150 DFI Wiring Diagram Fuel Injector #1 Fuel Injector #2 Fuel Injector #3 Direct Injector #1 Direct Injector #2 A B C Direct Injector #3 Direct Injector #4 Direct Injector #5 Direct Injector #6 10 - Oil Pump 11 - MAP Sensor 12 -...
Page 140 FUEL PUMP FUEL SYSTEM Section 3A – Pulse Crankcase Driven Fuel Pump Table of Contents Specifications ....... . 3A-1 Checking for Restricted Fuel Flow Caused by Fuel Pump Pressure @ W.O.T.
Page 141: Fuel Pump
FUEL PUMP Fuel Pump Loctite PST Pipe Sealant (92-809822) A = TO VAPOR SEPARATOR FUEL INLET FITTING B = REFER TO SERVICE BULLETIN 98- -8 Page 3A-2 90-855347R1 JANUARY 1999...
Page 142 FUEL PUMP Fuel Pump TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft FUEL PUMP ASSEMBLY DIAPHRAGM KIT DIAPHRAGM RUBBER CHECK VALVE RETAINER SPRING SPRING DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump (M5 x 40) SCREW–pump to crankcase (M6 x 50) BASE ELBOW (45 Degrees) FITTING...
Page 143 FUEL PUMP CHECKING for RESTRICTED FUEL FLOW CAUSED by ANTI-SIPHON VALVES While anti-siphon valves may be helpful from a safety stand-point, they clog with debris, they may be too small, or they may have too heavy a spring. Summarizing, the pressure drop across these valves can, and often does, create operational problems and/or pow- er-head damage by restricting fuel to the fuel pump and VST.
Page 144 FUEL PUMP Testing Fuel Pump Install clear fuel hose(s) between fuel pump and VST. Run engine, and inspect fuel pass- ing thru hose(s) for air bubbles. If air bubbles are found, see “Air Bubbles in Fuel Line,” below. If air bubbles are NOT found, see “Lack of Fuel Pump Pressure,” below. Problem: Air Bubbles in Fuel Line Low fuel in tank.
Page 145 FUEL PUMP Fuel Pump Removal/Disassembly IMPORTANT: Fuel pump diaphragm and gaskets should not be re-used once fuel pump is disassembled. NOTE: External low pressure electric fuel pump and vapor separator has been removed from illustration to provide improved visual clarity for location of mechanical fuel pump. 1.
Page 146 FUEL PUMP Cleaning/Inspection 1. Clean fuel pump housing, check valves, pulse chamber and pump base in solvent and dry all but check valves with compressed air. 2. Inspect each check valve for splits, chips and for proper sealing against pump hous- ing.
Page 147 FUEL PUMP 3. With retainer installed in pump body, break retainer rod from retainer by bending side- ways. 23601 Retainer Cap 4. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap rod down into retainer until flush with top of retainer. 23601 Retainer Cap Page 3A-8...
Page 148 FUEL PUMP 5. Place boost spring into pump body and place cap onto boost spring. 50161 Boost Spring Pump Body 6. Assemble remainder of components as shown and install retaining screws thru to align. 7. Install pump onto engine. Torque to 55 Ib-in (6 Nm). 8.
Page 149 DIRECT FUEL INJECTION FUEL SYSTEM Section 3B – Direct Fuel Injection Table of Contents Specifications ....... . 3B-2 Air Temperature Sensor Removal .
Page 150: Specifications
DIRECT FUEL INJECTION Specifications Fuel System Specifications Fuel Pressure 2 psi (613.5 13.8 kPa) Air Pressure 2 psi (544.0 13.8 kPa) Fuel/Air Differential 10 psi (68.5 kPa) High Pressure Electric Fuel Pump Amperage 6-9 Amps Draw Low Pressure Electric Fuel Pump Amperage 1-2 Amps Draw Low Pressure Electric Fuel Pump Output...
Page 151: Special Tools
DIRECT FUEL INJECTION Special Tools 1. Single Fuel/Air Pressure Gauge 160 psi – 91-16850A2 NOTE: To convert 100 psi gauge 91-16850A1 to 160 psi gauge, order upgrade 91-16850--1. 91-16850A2 57416 Schrader Valve (22-84906) – part of Schrader Valve Fuel Pressure Kit (849021A4) 2.
Page 152 DIRECT FUEL INJECTION 6. Seal/Teflon Ring Installation Tool – 91-851980 56015 7. Seal/Teflon Ring Sizing Tool – 91-851980-1 56014 8. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 9. Clamp Tool Kit 91-803146A2 57316 Clamp Tool 91-803146T Page 3B-4 90-855347R1 JANUARY 1999...
Page 153: Notes
DIRECT FUEL INJECTION Notes: 90-855347R1 JANUARY 1999 Page 3B-5...
Page 154: Air Handler
DIRECT FUEL INJECTION Air Handler Loctite Superbonder 454 GEL A = OIL LINE TO COMPRESSOR B = TO FITTING IN FLYWHEEL COVER C = PRESS INTO TUBING Page 3B-6 90-855347R1 JANUARY 1999...
Page 155 DIRECT FUEL INJECTION Air Handler TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft COVER ASSEMBLY GROMMET AIR FILTER COVER RIVET RETAINER GROMMET GROMMET (150) GROMMET (135) AIR HANDLER ASSEMBLY (See Breakdown on Air Handler Components) SHIM (.020 THICK) SHIM (.010 THICK) DECAL-Caution-Start in Gear BRACKET SLEEVE...
Page 156: Air Handler Components
DIRECT FUEL INJECTION Air Handler Components A = OIL LINE TO COMPRESSOR Page 3B-8 90-855347R1 JANUARY 1999...
Page 157 DIRECT FUEL INJECTION Air Handler Components TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft – AIR HANDLER ADAPTOR PLATE KIT GASKET GASKET REED BLOCK SCREW (1/4-20 x .88) 11.5 OIL PUMP GASKET BRACKET FITTING FITTING ELBOW FITTING (STRAIGHT) BUSHING GROMMET SCREW WASHER AIR PLENUM KIT ELBOW...
Page 158: Vapor Separator Components
DIRECT FUEL INJECTION Vapor Separator Components Page 3B-10 90-855347R1 JANUARY 1999...
Page 159 DIRECT FUEL INJECTION Vapor Separator Components TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft COVER KIT FITTING - Straight ELBOW SEAL FITTING KIT-Pump Outlet O RING SCREW GASKET FLOAT KIT FLOAT PIN NEEDLE VALVE SCREW FUEL PUMP KIT SLEEVE BOWL KIT SEAL PLUG KIT ELBOW...
Page 160: Fuel Rails/Air Compressor Hose Routing
DIRECT FUEL INJECTION Fuel Rails/Air Compressor Hose Routing Mineral Oil (Purchase Locally) A = TO TELL TALE B = TO STARBOARD FUEL RAIL C = TO FUEL COOLER D = TO TOP OF AIR HANDLER E = QTY. OF ONE (1) ON EACH SIDE OF COMPRESSOR FLANGE G = TO VAPOR SEPARATOR Page 3B-12 90-855347R1 JANUARY 1999...
Page 161 DIRECT FUEL INJECTION Fuel Rails/Air Compressor Hose Routing TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft AIR COMPRESSOR (See breakdown on Air Compressor Components) SCREW (M6 x 12) 11.5 PULLEY SCREW HOSE INSULATOR SLEEVE (16 IN.) FUEL RAIL (STARBOARD) INJECTOR CLAMP HOSE (16 IN.) STUD WASHER...
Page 162: Fuel Rails
DIRECT FUEL INJECTION Fuel Rails Page 3B-14 90-855347R1 JANUARY 1999...
Page 163 DIRECT FUEL INJECTION Fuel Rails TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft SCHRADER VALVE KIT (air and fuel) FITTING (air inlet) FITTING (fuel inlet) CLAMP (fitting retainer) SCREW M5X8 RAIL (starboard) w/out injectors SCREW M5X16 COVER (tracker valve) SPRING (tracker valve) DIAPHRAGM (tracker valve) O-RING (tracker cover) FITTING (air/fuel) starboard...
Page 164: Air Compressor Components
DIRECT FUEL INJECTION Air Compressor Components Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç 21 22 Dielectric Grease (92-823506--1) Loctite PST Pipe Sealant (92-809822) 2 Cycle Outboard Oil (92-826666A24) Page 3B-16 90-855347R1 JANUARY 1999...
Page 165 DIRECT FUEL INJECTION Air Compressor Components TORQUE REF. REF. DESCRIPTION lb-in lb-ft AIR COMPRESSOR END CAP RETAINING RING SCREW (M6 x 20) 11.5 O RING O RING CONNECTING ROD PISTON ASSEMBLY LOCK RING REED PLATE ASSEMBLY O RING O RING SEAL COMPRESSOR HEAD FITTING-Straight...
Page 166: Dfi Operation
DIRECT FUEL INJECTION DFI Operation Air Induction Through Crankcase Combustion air enters the cowl through holes located in the top aft end of the cowl. The cowl liner directs this air to the bottom of the powerhead. This limits the exposure of salt air to the components inside the engine cowl.
Page 167: Oil
DIRECT FUEL INJECTION rail until an injector opens. A fuel pressure regulator controls pressure in the fuel rails, and allows excess fuel to return into the vapor separator. The fuel regulator not only regulates fuel pressure but also regulates it at approximately 10 p.s.i. higher than whatever the air rail pressure is.
Page 168: Testing Electric Fuel Pump Pressure Output
DIRECT FUEL INJECTION Compressor Notes: To aid in starting when the air rail pressure is low and before the compressor has time to build pressure, the direct injector is held open by the ECM. This allows the compression from inside the cylinders to pressurize the air rail faster (1 or 2 strokes, or 60 of crankshaft rotation).
Page 169: High Pressure Electric Fuel Pump
DIRECT FUEL INJECTION High Pressure Electric Fuel Pump 1. Install Pressure Gauge Assembly 91-852087A1/A2 to starboard fuel rail pressure test valve. NOTE: After 15 seconds of cranking engine with starter motor, fuel pressure gauge should indicate 89 2 psi (613.5 13.8 kPa).
Page 170: Fuel Management Assembly Removal
DIRECT FUEL INJECTION Fuel Management Assembly Removal CAUTION Fuel system must be bled off prior to removal of fuel system components. NOTE: Use Fuel/Air Pressure Gauge 91-16850--1 or 91-852087A1/A2 to de-pressurize air hose first and then fuel hose. 1. De-pressurize fuel system. Starboard Fuel Rail Fuel Pressure Port 2.
Page 171 DIRECT FUEL INJECTION 4. Remove sta-strap securing air temperature sensor harness to fuel hose. 5. Remove vapor separator vent hose to air plenum. NOTE: Upper fuel hose goes to fuel cooler. Lower fuel hose goes to electric pump beside fuel/water separator. 6.
Page 172 DIRECT FUEL INJECTION 9. Disconnect throttle cam link rod and the Throttle Position Sensor link rod. 10. Disconnect MAP Sensor hose and compressor oil return hose from air management assembly. 56068 57317 Throttle Link Rod Throttle Position Sensor Link Rod MAP Sensor Hose Oil Return Hose 11.
Page 173: Reed Block Assembly Removal
DIRECT FUEL INJECTION Reed Block Assembly Removal 1. Remove 2 screws securing air plenum to reed plate assembly. 2. Remove 3 bolts securing oil pump adaptor plate to air plenum assembly. 56144 Screws (2 each) Bolts (3 each) Reed Block Assembly Installation 1.
Page 174: Air Temperature Sensor Installation
DIRECT FUEL INJECTION Air Temperature Sensor Installation Secure sensor in air plenum with 3 screws. Drive screws tight. Throttle Plate Assembly Removal NOTE: The throttle plate assembly is calibrated and preset for proper running character- istics and emissions at the factory. Other than complete assembly removal from the air plenum, no further disassembly should be made.
Page 175 DIRECT FUEL INJECTION 3. Fuel pump may be removed from cover by wiggling slightly while pulling outward. IMPORTANT: DO NOT twist pump during removal as wire harness may be dam- aged. 4. Disconnect harness from pump to separate pump from cover. Inspect filter screen for debris.
Page 176: Vapor Separator Reassembly
DIRECT FUEL INJECTION Vapor Separator Reassembly 1. Reinstall phenolic sealing plate onto vapor separator cover. 2. Secure float, needle and pivot pin assembly to separator cover with screw. Torque screw to 10 lb. in. (1.0 Nm) 3. Apply 2-4-C w/Teflon to lips of seal in separator cover. 4.
Page 177: Air Plenum Installation
DIRECT FUEL INJECTION Air Plenum Installation Secure plenum to crankcase with 12 bolts. Torque bolts to 100 lb. in. (11.5 Nm). in se- quence shown 56144 Air Plenum Bolts [Torque to 100 lb. in. (11.5 Nm)] Low Pressure Electric Fuel Pump Installation NOTE: If pump does not have a sleeve or grommet, refer to Service Bulletin 98-8.
Page 178 DIRECT FUEL INJECTION 2. Secure bracket assembly to vapor separator with 4 screws. Torque screws to 100 lb. in. (11.5 Nm). Screws – Torque to 100 lb. in. (11.5 Nm) Sta-strap securing pump to bracket Ground lead – attach to air plenum IMPORTANT: Only use tool 91-803146T (or Snap-On equivalent YA3080) to crimp full circle clamps.
Page 179: Vapor Separator Installation
DIRECT FUEL INJECTION 4. Connect fuel hose from top of low pressure fuel pump to 90 elbow on back side of vapor separator. Secure hose with 15.3 mm full circle clamp (54-856880) using crimp- ing tool 91-803146T. (Back view of vapor separator shown below) 57293 Secure Fuel Hose with 15.3 mm Full Circle Clamp (54-856880) Vapor Separator Installation...
Page 180 DIRECT FUEL INJECTION 4. Connect water separator sensor lead to water separator. 57317 Sensor Lead 5. Connect electric fuel pump harness. 6. Connect vapor separator vent hose to air plenum. 7. Secure air temperature sensor leads to fuel hose with sta-strap. 56157 Electric Fuel Pump Harness Connector Sta-Strap...
Page 181: Fuel Rail Removal
DIRECT FUEL INJECTION Fuel Rail Removal CAUTION Fuel system must be bled off prior to removal of fuel system components. NOTE: Use Fuel/Air Pressure Gauge 91-16850--1 or 91-852087A1/A2 to de-pressurize air hose first and then fuel hose. 1. De-pressurize fuel system. 2.
Page 182: Fuel Rail Disassembly
DIRECT FUEL INJECTION NOTE: It is recommended that direct injectors remain in the cylinder head (if they are not to be replaced) while removing the fuel rail. The direct injectors have a teflon seal which may expand if the injector is removed from the head. This expansion may cause rein- stallation difficulty or require the replacement of the seal.
Page 183 DIRECT FUEL INJECTION FUEL INJECTOR REMOVAL 1. Remove 2 screws securing injector. NOTE: Use a cotter pin extractor tool in pry holes to remove injectors. 2. Gently pry up on injector to loosen O-ring adhesion and remove injector. 56125 57418 Screws Pry Holes 3.
Page 184 DIRECT FUEL INJECTION FUEL INJECTOR INSTALLATION NOTE: Apply anti-seize grease (obtain locally) or 2-4-C w/Teflon to fuel injector attaching screw threads. 1. Insert fuel injector into fuel rail with connector pins facing (inwards) towards center of engine. NOTE: Turn injector back-and-forth slightly to seat injector O-rings in fuel rail while secur- ing injector with retainer and 2 screws.
Page 185: Fuel Pressure Regulator
DIRECT FUEL INJECTION Fuel Pressure Regulator Regulator Closed Regulator Open Ç Ç Ç Ç Ç Ç Ç Ç Top Cover Air Rail Expansion Plug Air Passage (from Air Compressor) O-ring 10 - Fuel Return Passage (to Vapor Separator) Spring Retainer 11 - Fuel Inlet Passage (from Electric Fuel Pump) Spring...
Page 186 DIRECT FUEL INJECTION FUEL REGULATOR REMOVAL 1. Remove 4 screws securing regulator and remove regulator. 2. Inspect regulator diaphragm for cuts or tears. 3. Inspect regulator housing O-ring for cuts and abrasions. Replace components as re- quired. 56127 56126 Screws Fuel Regulator Diaphragm Spring...
Page 187: Air Pressure Regulator
DIRECT FUEL INJECTION Air Pressure Regulator Regulator Closed Regulator Open Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Top Cover Air Rail Expansion Plug Air Passage (from Air Compressor) Spring Retainer Excess Air Passage (to Exhaust Adaptor) Vent 10 - Fuel Inlet Passage (from Electric Fuel Pump)
Page 188 DIRECT FUEL INJECTION AIR REGULATOR REMOVAL 1. Remove 4 screws securing regulator and remove regulator. 2. Inspect regulator diaphragm for cuts or tears. Replace as required. 56130 56129 Screws Air Regulator Diaphragm Spring AIR REGULATOR INSTALLATION NOTE: Apply a light coat of 2-4-C w/Teflon to diaphragm surface to aid in the retention of diaphragm on fuel rail during reassembly.
Page 189: Tracker Valve
DIRECT FUEL INJECTION Tracker Valve Engine Off (No Pressure) Engine at Operating Pressures Top Cover Air Rail Spring Retainer (not shown) Air Passage (from Air Compressor) Spring Fuel Inlet Passage (from Electric Fuel Pump) O-ring Diaphragm Assembly Diaphragm (at rest) Seat The tracker is located on the starboard fuel/air rail assembly.
Page 190 DIRECT FUEL INJECTION TRACKER VALVE REMOVAL 1. Remove 4 screws securing tracker valve and remove tracker assembly. 2. Inspect tracker diaphragm for cuts and tears. 3. Inspect tracker cover O-ring for cuts and abrasions. Replace components as re- quired. 56135 56136 Screws Diaphragm...
Page 191: Fuel Rail Cleaning
DIRECT FUEL INJECTION Fuel Rail Cleaning After all fuel injectors, air regulator, tracker valve, fuel regulator, inlet hoses and outlet hoses have been removed, the fuel rails may be flushed out with a suitable parts cleaning solvent. Use compressed air to remove any remaining solvent. 56140 Top Fuel Rail Connections Bottom Fuel Rail Connections...
Page 192 DIRECT FUEL INJECTION 5. If teflon seal requires replacement, use teflon ring installation tool 91-851980 to slide new seal onto injector. Following installation of teflon ring, the teflon ring sizing tool (91-851980-1) can be used to compress the teflon seal to aid in the installation of the injector into the cylinder head.
Page 193: Fuel Rail And Direct Injector Installation
DIRECT FUEL INJECTION NOTE: If cylinder head is going to be replaced, remove cup washers from each direct in- jector port by prying out with a flat tip screwdriver. Reinstall washers with retainers into new cylinder head. Washers provide tension between direct injectors, cylinder head and fuel rails.
Page 194: Air Compressor
DIRECT FUEL INJECTION Air Compressor Air compressor is a single cylinder, water cooled and lubricated by the outboard oil pump. Air Compressor Specifications Air Compressor Type Reciprocating Piston (1 to 1 ratio with engine RPM) Compressor Output @ Idle – 80 psi @ W.O.T.
Page 195 DIRECT FUEL INJECTION COMPRESSOR REMOVAL 1. Disconnect battery cables from battery terminals. 2. Remove top cowling. IMPORTANT: Prior to removing flywheel cover, remove vent hose from fitting on flywheel cover. 3. Remove flywheel cover. 4. Use 3/8 inch (9.5 mm) drive on belt tensioner arm to relieve belt tension. Remove belt. 56142 Belt Tensioner 3/8 in.
Page 196 DIRECT FUEL INJECTION 6. Disconnect water outlet hose (tell-tale). 56149 Air Pressure Outlet Hose Water outlet Hose (tell-tale) 7. Disconnect air compressor oil inlet hose. 8. Disconnect water inlet hose. 9. Disconnect excess oil return hose. 56147 Air Compressor Oil Inlet Hose Water Inlet Hose Excess Oil Return Hose 10.
Page 197: Air Compressor Disassembly/Reassembly
DIRECT FUEL INJECTION Air Compressor Disassembly/Reassembly NOTE: If cylinder bore is scored, air compressor must be replaced as an assembly. NOTE: The piston and rings are not sold separately. They must be replaced as an assem- bly. The connecting rod and bearings are not sold separately. They must be replaced as an assembly.
Page 198: Air Compressor Flow Diagram
DIRECT FUEL INJECTION Air Compressor Flow Diagram Î Î Î Î Î Î Î Î 56150 Air Inlet Tracker Valve Air Filter Fuel Inlet Compressor Air Inlet w/Inlet Restrictor Fuel Regulator [89 2 psi (613.5 13.8 kPa)] Air Compressor Air Regulator [79 2 psi (544.0 13.8 kPa)] Compressor Air Outlet...
Page 199: Air Compressor Pressure Test
DIRECT FUEL INJECTION Air Compressor Pressure Test Install Pressure Gauge Assembly 91-852087A1/A2 to fuel rail pressure test valves. Star- board rail has fuel pressure test valve. Port fuel rail has air pressure test valve. NOTE: After 15 seconds of cranking engine with starter motor, air pressure gauge should indicate 79 2 psi (544.0 13.8 kPa) and fuel pressure gauge should indicate 89 2 psi (613.5 13.8 kPa).
Page 200 DIRECT FUEL INJECTION FUEL PRESSURE AND AIR PRESSURE TROUBLESHOOTING CHART PROBLEM CORRECTIVE ACTION Fuel Pressure and Air Pressure are Both Low 1. Inspect air compressor air intake (air filter in fly- wheel cover) for blockage. 2. Remove air compressor cylinder head and in- spect for scuffing of cylinder wall.
Page 201 OIL INJECTION FUEL SYSTEM Section 3C – Oil Injection Table of Contents Oil System Operation ......3C-1 Priming the Oil Pump .
Page 202: Oil System
OIL INJECTION Oil System Remote Oil Tank Engine Oil Reservoir Oil Supply Hose to the Oil Pump Oil Pump Oil Supply Hoses to the Cylinders (6) Oil Supply Hose to the Air Compressor Air Compressor Check Valve Oil Return Hose from the Air Compressor Page 3C-2 90-855347R1 JANUARY 1999...
Page 203: Oil Hose Check Valve Installation On 1998 Model 135/150 Dfi Outboards Sn 0G886266 And Below
OIL INJECTION Oil Hose Check Valve Installation on 1998 Model 135/150 DFI Outboards SN 0G886266 and Below To prevent possible momentary oil starvation in the oil pump delivery hoses, it is recom- mended that check valve kit 21-858945A2 be installed as follows: NOTE: Refer to Service Bulletin 98-23.
Page 204 OIL INJECTION 4. Remove 3 bolts securing oil reservoir and lay reservoir off to one side. Bolts Oil Reservoir 5. Remove throttle link arm and bolt securing throttle arm. Remove throttle arm. – Throttle Link Arm Bolt Throttle Arm Page 3C-4 90-855347R1 JANUARY 1999...
Page 205 OIL INJECTION 6. Remove alternator/air compressor belt. 7. Remove aft alternator bolt and pivot alternator forward. Alternator/Air Compressor Belt Belt Tensioner (rotate counterclockwise) Aft Alternator Bolt Alternator (rotate forward) NOTE: It is recommended that a razor knife be used to make a small slit in the oil hoses to aid in removal.
Page 206 OIL INJECTION NOTE: All check valve/hose assemblies for cylinders 2, 4, 6 are brass colored and have 1.250 (31.75 mm) long hoses attached to check valve. IMPORTANT: Due to the close proximity of the #2 cylinder oil hose to the flywheel, it will be necessary to trim the length of the #2 oil hose to provide adequate clear- ance between the oil hose and the flywheel when the check valve assembly is installed.
Page 207 OIL INJECTION 11. Reinstall throttle control arm. Connect throttle link to throttle cam. Torque bolt to 20 lb. ft. (27 Nm). 12. Reinstall oil reservoir. Torque bolts to 170 lb. in. (19 Nm). 13. Reinstall alternator. Torque bolt to 40 lb. ft. (54 Nm). 57409 Torque Bolt to 20 lb.
Page 208 OIL INJECTION 18. Install new check valve/hose assemblies on cylinders #1, #3 and #5. Secure all hose connections with sta-straps. 57411 #1 Cylinder Check Valve/Hose Assembly #3 Cylinder Check Valve/Hose Assembly #5 Cylinder Check Valve/Hose Assembly 19. Reinstall starter motor. Torque bolts to 17.5 lb ft. (23.5 Nm). 20.
Page 209: Oil Injection Hose Installation
OIL INJECTION Oil Injection Hose Installation Install the correct inside diameter and length of hose between oil pump and fittings on the engine (see chart below). Cylinders #1, #3, #5 only have a BLUE stripe/band. Fasten hoses on both ends with sta-straps. Cyl #1 Cyl #2 Cyl #3...
Page 210: Oil Pump Removal And Installation
OIL INJECTION Oil Pump Removal and Installation REMOVAL 1. Disconnect the wiring harness from the pump. 2. Disconnect the oil hoses. 3. Remove three bolts and remove pump. Oil Pump Gasket Bracket Bushing (3) Rubber Grommet (3) – Insert into Hole Washer (3) Bolt (3) –...
Page 211 OIL INJECTION Engine Oil Reservoir Removal and Installation REMOVAL 1. Disconnect the oil hoses. Plug the hoses to prevent spillage. 2. Disconnect the LIGHT BLUE wire leads. 3. Remove three bolts securing oil tank and fuel cooler to powerhead and remove tank. Oil Reservoir Fuel Cooler (Design 1) Bolt (1) –...
Page 212: Priming The Oil Pump
OIL INJECTION Priming the Oil Pump Priming the oil pump (filling pump and hoses) is required on new or rebuild engines and any time maintenance is performed on the oiling system. There are three methods for priming the oil pump: METHOD 1 –...
Page 213: Priming Procedure - Method 1
OIL INJECTION Priming Procedure – Method 1 METHOD 1 – SHIFT SWITCH ACTIVATION PRIME PROCEDURE Before starting engine for the first time, prime the oil pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. Oil Injection Pump Oil Supply Hose CAUTION...
Page 214: Remote Oil Hose Connections
OIL INJECTION Remote Oil Hose Connections CONNECTING OIL HOSE WITH BLUE STRIPE 1. Remove shipping cap from fitting and connect oil hose (a). Fasten hose with sta-strap. Oil Hose with Blue Stripe CONNECTING OIL HOSE WITHOUT BLUE STRIPE 1. Remove shipping cap from fitting and connect hose (a). Fasten hose with sta-strap. Oil Hose Without Blue Stripe Filling the Oil Tanks 1.
Page 215: Purging Air From The Engine Oil Reservoir And Remote Oil Hose
OIL INJECTION Purging Air From the Engine Oil Reservoir and Remote Oil Hose NOTE: Before starting engine, make sure the oil pump has been primed. 1. Start the engine. Run the engine until all the air has been vented out of the reservoir and oil starts to flow out of the reservoir.
Page 216: Oil System Troubleshooting
OIL INJECTION Oil System Troubleshooting Low Oil Warning System is Activated Problem Problem Problem Problem Oil leaks out of Low oil level in en- Oil level is not low Low oil level in engine exhaust gine oil reservoir and in either tank oil reservoir but not low or #6 cylinder also remote oil tank...
Page 217 EMISSIONS FUEL SYSTEM Section 3D – Emissions Table of Contents Exhaust Emissions Standards ....3D-1 Emissions Information ......3D-4 What Are Emissions? .
Page 218: Oxides Of Nitrogen - Nox
EMISSIONS Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high.
Page 219: Stratified Vs Homogenized Charge
EMISSIONS Stratified vs Homogenized Charge DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This mixing occurs inside the carburetor venturi, reed blocks and crankcase.
Page 220: Stratified Charge
EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Sur- rounding this bubble is air supplied by the transfer system.
Page 221: Dealer Responsibility
EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards.
Page 222: Decal Location
Valve Clearance (Four Stroke engines only) Engine Horsepower rating Month of production (Boxing month will punched) FEL: Represents (Mercury Marine) statement of the maximum emissions out- put for the engine family Family example W M9X M. 02.5 2 2 0...
Page 223: Replacement Of Certification Label
EMISSIONS Replacement of Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label. If this label is mis- sing or damaged, replacement labels can be obtained from Mercury Marine.
Page 224 POWERHEAD POWERHEAD Section 4A Table of Contents Powerhead Specifications ..... 4A-1 Crankshaft (and End Cap) Bearings ..4A-31 Special Tools .
Page 225 POWERHEAD PISTON 3.4925 in. .0005 in. DIAMETER (88.7095 mm .0127 mm) Using a micrometer, measure dimension Dimension “A” at location shown. Dimension “A” “A” at Right should be 3.4925 in. .0005 for a STAN- Angle (90 ) DARD size piston (new) Dimension “A” to Piston will be 0.001 - 0.0015 less if coating is 0.700...
Page 226 POWERHEAD 7. Universal Puller Plate 91-37241 8. Snap Ring Pliers 91-24283 9. Lockring Installation Tool 91-77109A1 10. Piston Ring Compressor for 2.5 Litre (153 cu. in.) 91-818773 11. Compression Tester 91-29287 Powerhead Repair Stand A powerhead repair stand may be purchased from: Bob Kerr’s Marine Tool Co.
Page 227 POWERHEAD Cylinder Block and End Caps Loctite PST Pipe Sealant (92-809822) Loctite “514” Master Gasket (92-12564-2) 2 Cycle Outboard Oil (92-13249A24) PORT OIL FITTING ORIENTATION TOP OF BLOCK 2 o’clock HEAD CRANK Loctite “RCA/680” Retaining Compound BOTTOM OF BLOCK (92-809833) 2-4-C w/Teflon (92-825407A12) A = TO AIR HANDLER B = TO ON BOARD OIL TANK...
Page 228 POWERHEAD Cylinder Block and End Caps TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft CYLINDER BLOCK STUD–powerhead (1-3/4 IN.) STUD–powerhead (5-1/2 IN.) STUD–powerhead (6-3/4 IN.) DOWEL PIN–locating DOWEL PIN (BEARING RACE) GASKET–sealing PIPE PLUG (1/2-14) Drive Tight CHECK VALVE CHECK VALVE TUBING (19 IN.) STA STRAP FITTING (STRAIGHT)(STARBOARD - TOP/BOTTOM)
Page 229 POWERHEAD Exhaust Manifold and Exhaust Plate 18 13 19 20 44 45 Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Loctite 222 (92-809818) Permabond 105 Cyanacrylate Adhesive (Purchase Locally) 2-4-C With Teflon (92-825407A12) A = TO FUEL COOLER WATER IN B = TO FUEL COOLER WATER OUT FITTING C = TO LOWER PORT FUEL RAIL SIDE FITTING D = TO AIR COMPRESSOR LOWER WATER INLET FITTING...
Page 230 POWERHEAD Exhaust Manifold and Exhaust Plate TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft GASKET DIVIDER PLATE SEAL SCREW (5/16-18 x 1-1/2 IN.) SCREW (5/16-18 x 1 IN.) STRAINER HOSE (4-1/2 IN.) ELBOW HOSE (21-1/2 IN.) STA-STRAP COVER–relief valve SCREW (5/16-18 x 1-1/4 IN.) 12.5 SCREW (10-16 x 3/4 IN.) WASHER...
Page 231 POWERHEAD Cylinder Head Water Fitting Orientation Looking Down at Top of Block Back of Engine Dielectric Grease (92-823506--1) Loctite PST Pipe Sealant (92-809822) 2 Cycle Outboard Oil (92-13249A24) A = TO STRAIGHT FITTING ON BACK OF EXHAUST PLATE Page 4A-8 90-855347R1 JANUARY 1999...
Page 232 POWERHEAD Cylinder Head TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft CYLINDER HEAD (PORT) CYLINDER HEAD (STARBOARD) GASKET 30 lb-ft BOLT (2 IN.) (40.7 N·m) then tighten additional 90 DOWEL PIN GASKET COVER THERMOSTAT (143 degrees) SCREW (M6 x 25) 16.5 22.5 ELBOW (STARBOARD) ELBOW (PORT)
Page 233 POWERHEAD Crankshaft, Pistons and Connecting Rods 2 Cycle Outboard Oil (92-13249A24) 2-4-C w/Teflon (92-825407A12) Page 4A-10 90-855347R1 JANUARY 1999...
Page 234 POWERHEAD Crankshaft, Pistons and Connecting Rods TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft CRANKSHAFT ASSEMBLY BALL BEARING (LOWER) RETAINING RING CARRIER ASSEMBLY SEAL RING–sealing ROLLER BEARING RACE PISTON (STARBOARD) PISTON (PORT) PISTON RING LOCK RING CONNECTING ROD ASSEMBLY 1st Torque: 15 lb-in 2nd Torque: 30 lb-ft SCREW Turn Screw addition-...
Page 235 POWERHEAD EXHAUST DIVIDER PLATE BOLTS 200 lb. in. (22.5 N·m) Apply Loctite 271 to threads 56167 CYLINDER HEAD BOLTS Add light oil to threads and bolt face: 30 lb. ft. (41 N·m) then turn an additional 90 . 56168 Page 4A-12 90-855347R1 JANUARY 1999...
Page 236: General Information
POWERHEAD AIR PLENUM/REED BLOCK ASSEMBLY PLATE BOLTS 100 lb. in. (11.3 N·m) 56160 General Information Powerhead “Disassembly” and “Reassembly” instructions are printed in a sequence that should be followed to assure best results when removing or replacing powerhead compo- nents. If complete disassembly is not necessary, start reassembly at point disassembly was stopped.
Page 237 POWERHEAD 5. Disconnect remote oil tank hose connector. 6. Disconnect remote control harness from powerhead harness connector and wires as shown. BLU/WHT BLU/WHT GRN/WHT GRN/WHT BRN/WHT Power Trim Connections 7. Remove sta-strap which secures tell-tale hose to fitting on lower cowl and remove hose from fitting.
Page 238 POWERHEAD 9. Remove BLUE and GREEN trim harness leads from trim solenoids. Trim Solenoids 10. Slide outboard shift lever into neutral position. 11. Remove throttle cable. 12. Remove locknut that secures shift cable latch assembly and remove latch, flat wash- er, nylon wear plate, spring and shift cable from control cable anchor bracket.
Page 239 POWERHEAD 15. Remove fuel cooler inlet and outlet water hoses from fittings on exhaust adaptor plate and poppet valve cover. Remove excess air hose (from port fuel rail) from fitting on exhaust adaptor plate. 16. Remove thermostat cover hose from exhaust adaptor plate. 56158 56159 Fuel Cooler Outlet Water Hose...
Page 240: Powerhead Disassembly
POWERHEAD REMOVING ENGINE COMPONENTS Remove the following engine components: Section 2 Starter Motor Starter Motor *Electronic Control Module *Ignition Coil *Starter Solenoid Alternator Flywheel Section 3 Direct Fuel Injection Fuel Pump On-Board Oil Tank Oil Pump Section 7 Shift Cable Latch Assembly Control Cable Anchor Bracket *All ignition and electrical components should remain attached to electrical plate.
Page 241 POWERHEAD 4. Remove exhaust manifold cover and seal. 5. Referring to Section 3B, remove air plenum/reed block/adaptor plate assembly from cylinder block. 56166 Exhaust Manifold Cover Seal Gasket Reed Block/Adaptor Plate Assembly 6. Inspect reeds as outlined in “Cleaning and Inspection”. 56169 7.
Page 242 POWERHEAD UPPER END CAP 51854 Crankcase Attaching End Cap Bolts LOWER END CAP 51849 Crankcase Attaching End Cap Bolts 1. Remove bolts which secure crankcase cover to cylinder block. 2. Pry crankcase cover off cylinder block using pry bars in locations shown. 51845 Pry Points Crankcase Cover...
Page 243 POWERHEAD CRANKCASE COVER REMOVED 51848 1. Use Powerhead Stand (91-30591A1) for rotating crankshaft to desired position for re- moval of connecting rods. 2. Using an awl or electric pencil, scribe the cylinder identification number on each con- necting rod as shown. Reassemble connecting rods in same cylinder. Ä...
Page 244 POWERHEAD CAUTION Each connecting rod and end cap are a matched machined set and must never be mismatched. 6. Inspect pistons as outlined in “Cleaning and Inspection,” following. 7. Use Piston Ring Expander (91-24697) to remove piston rings. Always install new pis- ton rings.
Page 245 POWERHEAD 10. Support piston and tap out piston pin using service tool (91-76159A1) as shown. 11. Remove piston pin needle bearings (29 per piston) and locating washers (2 per pis- ton) as shown. IMPORTANT: We recommend that you use new needle bearings at reassembly for lasting repair.
Page 246 POWERHEAD 16. Remove crankshaft and place in powerhead stand as shown. IMPORTANT: DO NOT remove crankshaft sealing rings from crankshaft, unless re- placement of a sealing ring(s) is necessary. Usually, crankshaft sealing rings do not require replacement, unless broken. CAUTION Safety glasses should be worn when removing or installing crankshaft sealing rings.
Page 247 POWERHEAD Inspect crankshaft ball bearing as outlined in “Cleaning and Inspection,” following. IMPORTANT: DO NOT remove crankshaft ball bearing, unless replacement is re- quired. 19. Remove lower ball bearing from crankshaft as follows: a. Remove retaining ring using a pair of snap ring pliers. 51854 Crankshaft Ball Bearing Pliers...
Page 248 POWERHEAD Water Pressure Relief Valve Components 1. If necessary, remove water pressure relief valve components as shown. 50803 Cover Bolt Gasket Relief Valve Plate Diaphragm Water Deflector Washer Screw Spring 10 - Poppet Valve 11 - Grommet 12 - Carrier 13 - Washer Torque Specifications...
Page 249: Cylinder Block And Crankcase Cover
POWERHEAD Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored as- sembly and never should be mismatched by using a different crankcase cover or cylinder block. CAUTION If crankcase cover or cylinder block is to be submerged in a very strong cleaning solution, it will be necessary to remove the crankcase cover/cylinder block bleed system from crankcase cover/cylinder block to prevent damage to hoses and check valves.
Page 250 POWERHEAD Cylinder Bores 1. Inspect cylinder bores for scoring, scuffing or a transfer of aluminum from piston to cylinder wall. Scoring or scuffing, if NOT TOO SEVERE, can normally be removed by honing. If a transfer of aluminum has occurred, an acidic solution such as “TIDY BOWL CLEANER”...
Page 251 POWERHEAD 3. Measure cylinder bore diameter (with a snap gauge micrometer) of each cylinder, as shown below. Check for tapered, out-of-round (egg-shaped) and oversize bore. 51846 135/150 Models Models Cylinder Block Finish Hone Standard Piston Bore 3.501 in. (88.93mm) .015 in. (0.381mm) Oversize Piston Bore 3.516 in.
Page 252 POWERHEAD CLEANING PISTON RING GROOVES Keystone (tapered) ring grooves CAUTION Care must be taken not to scratch the side surfaces of the ring groove. Scratching the side surface of the ring groove will damage the ring groove. 1. Use a bristle brush and carbon remover solution to remove carbon from side surfaces. 2.
Page 253 POWERHEAD MEASURING PISTON ROUNDNESS Piston has a barrel profile shape and is not a true diameter. Standard 135/150 Models - 153 cu. in. (2508 cc) 1. Using a micrometer, measure dimension “A” at location shown. Dimension “A” should be as indicated in chart following. Piston Dimension “A”...
Page 254 POWERHEAD 5. If necessary, clean crankshaft surfaces with crocus cloth. 51847 Crankshaft Journals Crocus Cloth Work Cloth “Back-and-Forth” WARNING DO NOT spin-dry crankshaft ball bearing with compressed air. 6. Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearing. Re- check surfaces of crankshaft.
Page 255 POWERHEAD 4. Thoroughly inspect center main roller bearings. Replace bearings if they are rusted, fractured, worn, galled or badly discolored. Center Main Roller Bearing 5. Clean (with solvent) and dry crankshaft roller bearing that is installed in upper end cap. Lubricate bearing with light oil.
Page 256: Connecting Rods
POWERHEAD End Bearing Bleed System 1. Check rubber bleed hoses. Replace any hose that is cracked, cut or deteriorating. 2. Check operation of lower end cap check valve. If valve is working properly, air can be drawn thru check valve “one way” only. If air can pass thru a check valve both ways, valve is not working properly and must be replaced.
Page 257 POWERHEAD 6. Chatter Marks: Chatter marks are the result of a combination of low speed - low load - cold water temperature operation, aggravated by inadequate lubrication and/or im- proper fuel. Under these conditions, the crankshaft journal is hammered by the con- necting rod.
Page 258 POWERHEAD IMPORTANT: Clean connecting rod just enough to clean up bearing surfaces. DO NOT continue to clean after marks are removed from bearing surfaces. 51083 c. Clean PISTON PIN END of connecting rod, using same method as in Step “b”, preceding, but using 320 grit carborundum cloth instead of crocus cloth.
Page 259: Powerhead Reassembly And Installation
POWERHEAD NOTE: BE SURE that water in thermostat tester is allowed to cool sufficiently [below 130 F (56 C)] before testing the other thermostat. 51087 Powerhead Reassembly and Installation General Before proceeding with powerhead reassembly, be sure that all parts to be re-used have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspec- tion,”...
Page 260 POWERHEAD 2. Reinstall retaining ring using a suitable pair of Snap Ring Pliers. 51854 51852 Crankshaft Crankshaft Ball Bearing Suitable Mandrel Press Retaining Ring 90-855347R1 JANUARY 1999 Page 4A-37...
Page 261 POWERHEAD 3. If removed, spread new crankshaft sealing rings just enough to slide over crankshaft journal. 4. Use Piston Ring Expander (91-24697) and install crankshaft sealing rings into groove. 51849 51854 Crankshaft Sealing Rings 5. Lubricate center main crankshaft roller bearings and races with light oil. 51854 2 Cycle Outboard Oil (92-826666A24) Install so LARGER of the 3 holes is toward DRIVE SHAFT end of crankshaft...
Page 262 POWERHEAD 6. Place center main crankshaft roller bearings on upper and lower main bearing jour- nals as shown. 7. Install center main bearing races as shown. 8. Secure center main bearing races together with retaining rings. Make sure retaining ring bridges the separating lines of the bearing race. FLYWHEEL END 51850 DRIVE SHAFT END...
Page 263: Crankshaft Installation
POWERHEAD 10. Install oil seal into upper end cap as follows: a. Apply a thin bead of Loctite 271 to outer diameter of upper end cap oil seal. b. Use a suitable mandrel, press oil seal into upper end cap (lip facing down) until bottomed out on lip of end cap.
Page 264 POWERHEAD Install crankshaft as follows: 1. Lubricate crankshaft sealing rings with light oil. 2. Check cylinder block to be sure that dowel pins are in place. 51848 Dowel Pins 3. Position all crankshaft seal ring gaps straight up. 4. Align hole in each center main bearing race with dowel pin. 5.
Page 265 POWERHEAD Piston and Connecting Rod Reassembly 1. Place needle bearings on a clean piece of paper and lubricate with Quicksilver 2-4-C w/Teflon Marine Lubricant. NOTE: There are 29 needle bearings per piston. 2. Place sleeve which is part of piston pin tool (91-74607A1) into connecting rod and in- stall needle bearings around sleeve as shown.
Page 266 POWERHEAD 6. Install new piston pin lockrings (one each end of piston pin) with Lockring Installation Tool (91-77109A1). 7. Make sure lockrings are properly seated in piston grooves. 51086 51086 Lockring Installation Tool (91-77109A1) Lockring Piston and Piston Ring Combinations 153 CU.
Page 267 POWERHEAD Piston Installation 1. Before installing new piston rings, check gap between ring ends by placing each ring in its respective cylinder, then pushing ring about 1/2 in. (12.7 mm) into cylinder using piston to assure proper position. 2. Check end gap of each new piston ring with a feeler gauge. End gap must be within 0.010 in.
Page 268 POWERHEAD 8. Remove screws and connecting rod cap from piston rod assembly being installed. IMPORTANT: Piston must be correctly installed and positioned as shown. Pistons marked with the word “UP” and with the letter “P” or “S” on top of piston. Pistons with the letter “P”...
Page 269 POWERHEAD 13. Rotate crankshaft several times (using powerhead stand) to assure free operation (no binds and catching). Connecting Rod Cap Alignment Check each connecting rod cap for correct alignment. If not aligned, a ridge can be seen or felt at the separating line as shown below. Correct any misalignment. End View End View Side View...
Page 270 POWERHEAD 3. Apply a thin, even coat of Loctite Master Gasket #203 on mating surfaces of crank- case cover and cylinder block. 4. Place crankcase cover in position on cylinder block. Turn the 8 center main bolts in a LITTLE at a time, (following torque sequence) compressing crankshaft seal rings until crankshaft cover has been drawn down to cylinder block.
Page 271 POWERHEAD Assembly of Reed Blocks to Intake Manifold Torque to 105 lb. in. (12 N·m) Assembly of Exhaust Divider Plate to Block 1. Place exhaust divider seal into slot in block. 2. Install exhaust divider plate with gasket. 3. Clean bolt threads with Loctite 7649 Primer (92-809824). 4.
Page 272 POWERHEAD 6. If removed, install water pressure relief valve components as shown. Torque bolts to specifications. 50803 Cover Bolt - 150 lb. in. (17 N·m) Gasket Relief Valve Plate Diaphragm Water Deflector Washer Screw - 25 lb. in. (3 N·m) Spring 10 - Poppet Valve...
Page 273 POWERHEAD CYLINDER HEAD INSTALLATION 1. Install each cylinder head to engine block with thermostat pocket “UP”. Apply light oil to cylinder head bolt threads and torque bolts to 30 Ib. ft. (41 N·m) then turn an addi- tional 90 . 2.
Page 274 POWERHEAD 4. Thermostat and temperature sensor installed. 56164 56163 Thermostat (143 F 61.7 C) Overheat Temperature Sensor NOTE: When installing thermostat hoses, secure starboard to port thermostat hose (a) with sta-straps (b) to prevent hose from being cut by alternator/air compressor belt. Reinstalling Engine Components Reinstall the following engine components: Section 2...
Page 275 POWERHEAD Throttle Lever and Shift Shaft 2-4-C w/Teflon (92-825407A12) A – Tighten and back off 1/2 turn Page 4A-52 90-855347R1 JANUARY 1999...
Page 276 POWERHEAD Throttle Lever and Shift Shaft TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft THROTTLE CONTROL LEVER SCREW (.375-16 x 1-3/4 IN.) BUSHING WASHER WASHER SCREW (2-1/8 IN.) NUT (1/4-20) INSERT WASHER BUSHING SCREW (M6 x 40) SWIVEL BUSHING THREADED BALL Drive Tight LINK ROLLER...
Page 277 POWERHEAD Powerhead Installation on Driveshaft Housing 1. Install Lifting Eye (91-90455) into flywheel. WARNING BE SURE that Lifting Eye is threaded into flywheel as far as possible BEFORE lift- ing powerhead. 2. Using a hoist, lift powerhead high enough to allow removal of powerhead from repair stand.
Page 278 POWERHEAD 10. Install thermostat cover hose to exhaust adaptor plate. 56158 56159 Fuel Cooler Outlet Water Hose Fuel Cooler Inlet Water Hose Air Hose Thermostat Cover Hose 11. Install 4 bolts securing bottom cowl halves and install bottom cowling. 52352 55970 55932 Bolt...
Page 279 POWERHEAD 12. Reconnect input fuel line. 13. Reconnect BLUE and GREEN trim harness leads to trim solenoids. Hose Clamp Fuel Line Trim Solenoids 14. Reconnect remote control harness to powerhead harness connector and wires as shown. BLU/WHT BLU/WHT GRN/WHT GRN/WHT BRN/WHT Power Trim Connections Page 4A-56...
Page 280 POWERHEAD 15. Reconnect warning gauge harness. 2 3 4 5 TAN/BLACK TAN/WHITE PINK/LT. BLUE to PINK/LT. BLUE ORANGE Sta-Straps Connect PURPLE to 12 Volt Source or Adjacent Gauge IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to re- lieve stress and prevent hoses from being kinked or pinched.
Page 281 POWERHEAD 2. Fasten clamp together with two screws. 3. Slide outboard shift lever into neutral position. 4. Install shift cable and secure with spring, nylon wear plate, flat washer, latch and lock nut. Install throttle cable and secure with latch. Shift Cable Throttle Cable Refer to Section 2 of this Service Manual “Timing/ Synchronizing/Adjusting”...
Page 282 COOLING POWERHEAD Section 4B - Cooling Table of Contents Specifications ....... . 4B-1 1998/1999 Water Flow Diagram .
Page 283: Water Pressure
COOLING Special Tools 1. Volt/Ohm Meter 91-99750A1 2. Water Pressure Gauge 91-79250A2 56725 Page 4B-2 90-855347R1 JANUARY 1999...
Page 284: Temperature Sensor
COOLING Temperature Sensor Resistance (kW) Temperature Sensor Two temperature sensors are used to provide cylinder head temperature information to the ECM. A sensor is mounted in starboard cylinder head and one in the air compressor cylinder head. The ECM uses this information to increase injector pulse width for cold starts and to retard timing in the event of an over-heat condition.
Page 285 COOLING Water flow exiting the cylinder block is controlled by the thermostats (1 in each cylinder head) and the poppet valve (located at the bottom starboard side of powerhead). At low RPM (below 1500 RPM), the thermostats control water flow depending upon engine tem- perature.
Page 286: 1998/1999 Water Flow Diagram
1998/1999 Water Flow Diagram Cylinder Block and Adaptor Plate Lower Unit and Water Pump Drive Shaft Housing 1 - Air Compressor 2 - Cylinder Head Cover – Removed from head for illustra- tion, normally part of head casting 3 - Thermostats (2) 143 F (61.6 C) – If stuck closed, engine will overheat at idle.
Page 287: 1999 1/2 Water Flow Diagram
1999 1/2 Water Flow Diagram Cylinder Block and Adaptor Plate Drive Shaft Housing Lower Unit and Water Pump 1 - Air Compressor 2 - Cylinder Head Cover – Removed from head for illustra- 57339 tion, normally part of head casting 3 - Thermostats (2) 143 F (61.6 C) –...
Page 288: Thermostat Test
COOLING Troubleshooting Thermostat Test 1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and corrosion damage that could cause leakage. Replace parts as necessary. 2. Remove and discard gasket from each thermostat. 3. Wash thermostats with clean water. 4.
Page 289: Water Pressure Check
COOLING Water Pressure Check Using Water Pressure Gauge 91-79250A2, cut compressor water inlet hose and install tee fitting (provided) as shown. NOTE: This is also the same location for installing the water pressure hose for a dash mounted water pressure gauge. 56141 Loctite Pipe Sealant w/Teflon-592 52582...
Page 290: Water Pump Cleaning And Inspection
COOLING Water Pump Cleaning and Inspection 1. Inspect the water tube coupling for wear or damage. If necessary replace. Water Tube Coupling 2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller blades. Replace the impeller if this condition is found. 3.
Page 291: Problem Diagnosis
COOLING Problem Diagnosis Condition Recommended Range Possible Cause Pressure below specification @ 1.0 – 3.0 PSI (6.8 – 20.5 kPa) Poppet valve spring defective idle (weak, broken, missing) Defective poppet valve seal Thermostat stuck open Severe internal leak Low output water pump Inlet restriction Strainer screen for air compres- sor water supply is restricted...
Page 292 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A – Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Swivel Bracket and Steering Arm ... . 5A-2 Removal and Disassembly .
Page 293: Swivel Bracket And Steering Arm
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket and Steering Arm Loctite “271” Adhesive Sealant (92-809819) 2-4-C w/Teflon (92-825407A12) Page 5A-2 90-855347R1 JANUARY 1999...
Page 294 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket and Steering Arm TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft SWIVEL BRACKET ASSEMBLY (BLACK) OIL SEAL (LOWER) BUSHING SPACER O-RING GREASE FITTING BUSHING THRUST WASHER SCREW (7/16-20 x 7-1/2 IN.) MOUNT WASHER WASHER STEERING LINK ASSEMBLY SCREW (3/8-24 x 1-1/4 IN.)
Page 295: Transom Brackets
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Brackets 2-4-C w/Teflon (92-825407A12) Page 5A-4 90-855347R1 JANUARY 1999...
Page 296 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Brackets TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft TRANSOM BRACKET (STARBOARD)(BLACK) TRANSOM BRACKET (PORT) (BLACK) GREASE FITTING (PORT) TILT TUBE NUT (1 IN.-14) O-RING WAVE WASHER NUT (7/8-14) BOLT WASHER TILT LOCK LEVER ASSEMBLY SPRING BUSHING SPRING...
Page 297: Drive Shaft Housing And Exhaust Tube
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing and Exhaust Tube Loctite 271 (92-809820) Soap (Purchase Locally) P80 Rubber Lubricant (Purchase Locally) Permabond 105 Cyanacrylate Adhesive (Purchase Locally) 2-4-C w/Teflon (92-825407A12) Loctite Superbonder 454 Gel (Purchase Locally) Loctite “RCA/680” Retaining Compound (92-809833) Page 5A-6 90-855347R1 JANUARY 1999...
Page 298 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing and Exhaust Tube TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft DRIVE SHAFT HOUSING (LONG)(BLACK) DRIVE SHAFT HOUSING (X-LONG)(BLACK) STUD SCREW (1/2-20 x 6 IN.) GROUND WIRE LOWER MOUNT WASHER GROUND WIRE SCREW (1/4-20 x 3/8 IN.) WASHER CLAMP...
Page 299: Drive Shaft Housing And Dyna-Float Suspension
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing and Dyna-Float Suspension Refer to “Powerhead Removal” section to remove powerhead. Refer to “Lower Unit Removal” in this section to remove lower unit. Removal and Disassembly 1. Remove shift shaft from driveshaft housing by pulling straight up on shaft. 2.
Page 300 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING SHIFT LINKAGE ASSEMBLY Shift Shaft Assembly Bushing Lock Nut Washer (2) Bushing (Hidden) Spring Guide Block 1. Remove upper mount nuts and flat washers. Upper Mount Nuts 2. Lift driveshaft housing plate off housing. 51850 Drive Shaft Housing Plate Drive Shaft Housing...
Page 301 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 3. Remove water tube from driveshaft housing plate. 4. Exhaust diffuser is secured to housing plate with 6 bolts. Remove bolts, then remove diffuser. 5. Pull exhaust tube out of drive shaft housing. 51850 51857 Water Tube Exhaust Diffuser...
Page 302: Reassembly And Installation
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 9. Remove lower mount nuts. 51855 Lower Mount Nuts Lower Mount 10. Remove driveshaft housing from swivel bracket by pulling alternately from top to bot- tom on housing. 11. Remove upper and lower mounts by lifting them out of driveshaft housing. Reassembly and Installation 1.
Page 303 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 3. Push exhaust tube boots onto tabs on each side of exhaust tube. 4. Position exhaust tube in drive shaft housing and push down on tube until boots rest in grooves on inside of housing. 5.
Page 304 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 9. Position drive shaft housing plate on top of housing. 10. Apply a thin coat of Perfect Seal onto metal portion of upper dyna-float mounts. 11. Position mounts on drive shaft housing plate. 12. Install a rubber washer onto each upper mount, followed by a metal washer. 51857 Water Tube Seal (Plastic End) Dyna-Float Mounts...
Page 305 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 22. Install lower mount retainers and secure each retainer with 2 bolts. (Secure ground strap with the nearest retainer bolt.) Torque bolts to 160 Ib. in. (18.0 Nm). 51855 51855 Lower Mount Nut [Torque to 50 lb. ft. (68.0 Nm)] Rubber Cap Ground Strap (only one side) Lower Mount Retainer...
Page 306 POWER TRIM MID-SECTION Section 5B – Power Trim Table of Contents Power Trim Specifications ..... 5B-1 Installation ....... 5B-21 Special Tools .
Page 307: Special Tools
POWER TRIM Special Tools 1. Alignment Tool 91-11230 17238 2. Trim Rod Removal Tool 91-44486A1 51337 3. Trim Rod Guide Removal Tool 91-44487A1 51337 4. Power Trim Test Gauge Kit 91-52915A6 73835 Page 5B-2 90-855347R1 JANUARY 1999...
Page 308 POWER TRIM 5. Adaptor Fitting 91-82278A2 and 91-82278A3 54458 6. Spanner Wrench 91-74951 51337 7. Multi-Meter DVA Tester 91-99750A1 or DMT 2000 Digital Tachometer Multi-meter 91-854009A1 Multi-Meter DVA Tester 91-99750A1 DMT 2000 Digital Tachometer Multi-meter 91-854009A1 90-855347R1 JANUARY 1999 Page 5B-3...
Page 309: Power Trim Components
POWER TRIM Power Trim Components Loctite 271 (92-809820) Anti-Corrosion Grease (92-78376A6) GM Silicone Sealer (92-91600-1) Power Trim & Steering Fluid (92-90100A12) Page 5B-4 90-855347R1 JANUARY 1999...
Page 310 POWER TRIM Power Trim Components TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft – POWER TRIM ASSEMBLY–Complete MANIFOLD ASSEMBLY PIPE PLUG TILT CYLINDER ASSEMBLY PISTON ROD GUIDE KIT REPAIR KIT CHECK VALVE KIT GUIDE ASSEMBLY PISTON/ROD ASSEMBLY (PORT) PISTON/ROD ASSEMBLY (STBD.) TRIM FILTER ASSEMBLY VALVE ASSEMBLY E RING...
Page 311: Power Trim Motor
POWER TRIM Power Trim Motor TORQUE REF. REF. QTY. DESCRIPTION lb.in. lb.ft. N·m – POWER TRIM MOTOR BRUSH AND SEAL KIT ARMATURE KIT END FRAME (Complete) Page 5B-6 90-855347R1 JANUARY 1999...
Page 312: Power Trim - General Information
POWER TRIM Power Trim - General Information Description The Power Trim System consists of an electric motor, pressurized fluid reservoir, pump, tilt cylinder, and two trim rams. The remote control (or trim panel) has switches that trim the outboard “Up” or “Down” and tilt the engine for “Trailering”.
Page 313: Trailering Outboard
POWER TRIM TRIMMING OUTBOARD “DOWN” (IN): WARNING Excessive speed at minimum trim “In” may result in undesirable and/or unsafe steering conditions. Test for handling characteristics after any adjustment is made to the trim angle (and tilt pin location). Aids planing, particularly with heavy loads. Improves ride in choppy water conditions.
Page 314: Trim "In" Angle Adjustment
POWER TRIM Trim “In” Angle Adjustment WARNING Boat operation with outboard trimmed to the full “In” trim angle [not using the trim angle adjustment bolt] at planing speed may result in undesirable and/or un- safe steering conditions. A water test for handling/steering conditions is re- quired after any trim angle adjustments.
Page 315: Anode Plate
POWER TRIM Anode Plate Anode plate is a self-sacrificing alloy plate that is consumed gradually by corrosion while providing protection to the midsection and power trim from galvanic corrosion. Replace anode plate when it is 50% consumed. 27932 Anode Plate IMPORTANT: Do not paint or place protective coating on anode plate, or corrosion protection function will be lost.
Page 316 POWER TRIM TO FILL: IMPORTANT: This trim system is pressurized. Remove “Fill” plug only when out- board is tilted to the full “Up” position or the trim/tilt rams are fully extended. Re- tighten “Fill” plug before tilting outboard down or retracting tilt/trim rams. Remove “Fill”...
Page 317: Troubleshooting
POWER TRIM Troubleshooting IMPORTANT: Determine if Electrical or Hydraulic problem exists. IMPORTANT: Acceptable power trim leak down should not exceed 1 in. (25.4 mm) (when measured at the tilt ram) in a 24 hour period. HYDRAULIC SYSTEM TROUBLESHOOTING IMPORTANT: Make one correction at a time. Check operation of trim system before proceeding to the next check.
Page 318 POWER TRIM 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, 8 B. Trim system trims opposite of buttons. C. Cowl mounted trim buttons do not activate trim system. 2, 4, 5, 6, 7 PROBLEM 1.
Page 319: Power Trim System With Relays And 2 Wire Trim Motor
POWER TRIM Power Trim System with Relays and 2 Wire Trim Motor 53794 UP Relay DOWN Relay BLK = Black BLU = Blue GRN = Green RED = Red WHT = White Page 5B-14 90-855347R1 JANUARY 1999...
Page 320: Electrical System Troubleshooting
POWER TRIM Electrical System Troubleshooting General Checks Before troubleshooting the Power Trim electrical system, check the following: 1. Check for disconnected wires. 2. Make certain all connections are tight and corrosion free. 3. Check that plug-in connectors are fully engaged. 4.
Page 321: Troubleshooting The "Up" Circuit
POWER TRIM Troubleshooting the “Up” Circuit Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. No Voltage Indicated: Battery Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 7 and black lead to ground. Point 9.
Page 322: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)
POWER TRIM Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative) Check in-line fuse (under cowl) to see if fuse is blown. Fuse Not Blown: Blown Fuse: Connect Voltmeter red lead to Correct problem that caused Point 3 and black lead to fuse to blow.
Page 323: Power Trim Assembly Removal And Installation
POWER TRIM Power Trim Assembly Removal and Installation Removal 1. Remove clamps on transom bracket to free power trim wiring. 2. Raise outboard to full “Up” position and engage tilt lock lever. 51377 50605 Clamps Tilt Lock Lever WARNING Failure to support outboard as shown could result in personal injury and/or dam- age to outboard or boat.
Page 324 POWER TRIM SUPPORT TOOL 3/8 in. diameter metal rod (a used shift shaft works well) 14” 2” 1/4” Drill holes for retaining clips METRIC CONVERSION 14 in. = 35.56 cm 2 in. = 50.8 mm 3/8 in. = 9.5 mm 1/4 in.
Page 325 POWER TRIM 5. Remove outboard transom mounting bolts, and loosen tilt tube nut until nut is flush with end of tilt tube thread. 6. Remove 3 screws and washers and move starboard transom bracket. 51375 51375 Transom Mount Bolts (2) Tilt Tube Nut (flush with end of thread) Screws (3) Washers (3)
Page 326: Installation
POWER TRIM Installation 1. Paint any exposed metal surfaces to prevent corrosion. 2. Apply Loctite 271 to screws. Install trim system, starboard transom bracket, and tilt tube nut. 3. Use a 12 volt power source to extend tilt ram up to align upper swivel shaft hole and end of ram.
Page 327 POWER TRIM 6. Connect trim motor wires to solenoids. Refer to Wiring Diagrams in this manual. Route trim wires as specified in this manual. NOTE: The 2 power leads going to the trim motor should be encapsulated with conduit tubing. If tubing has not been previously installed, order 32-828547-353 and cut to ap- propriate length.
Page 328: Testing Power Trim System With Test Gauge Kit (91-52915A6)
POWER TRIM WARNING Electrical wires passing through cowl openings must be protected from chafing or being cut. Follow the recommended procedures outlined in Section 1D of this Manual. Failure to protect wires as described could result in electrical system fail- ure and/or injury to occupants of boat.
Page 329 POWER TRIM 4. Install test adaptor 91-822778A2 into manual release valve hole. 54458 Test Adaptor (91-822778A2) 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 Brass Fitting Test Gauge Assembly Tilt Pin (Position in Hole Shown) Hose Hose (Not Used) 6.
Page 330 POWER TRIM CAUTION Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could result in transom bracket failure and possible injury. 8. Move outboard “IN” until hole in swivel bracket “ear” aligns with the 3rd tilt hole in tran- som bracket.
Page 331: Down" Pressure Check
POWER TRIM “DOWN” Pressure Check IMPORTANT: Insure battery is fully charged before 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. Remove circlip securing manual release valve and unscrew release valve from trim assembly.
Page 332 POWER TRIM 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 Brass Fitting Test Gauge Assembly Tilt Pin (Position in Hole Shown) Hose Hose (Not Used) OPEN Valve CLOSE Valve 6. Reinstall fill plug. 7. Disengage tilt lock lever. 8.
Page 333: Hydraulic Repair
POWER TRIM Hydraulic Repair 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. 2. Slowly remove “Fill” plug to bleed reservoir pressure. 3.
Page 334: Trim Rod End Cap Seal
POWER TRIM CLEANING AND INSPECTION - TRIM RODS AND CAPS CAUTION Do not remove check valve (a). Check valve is preset to operate at a specific pres- sure. Removal and installation of check valve could result in improper operating pressure and possible system damage. NOTE: Check valve is in port side trim rod only.
Page 335: Tilt Ram
POWER TRIM 2. Install trim rods and caps. Use installation tool (91-44487A1) or spanner wrench (91-74951) to tighten caps securely. 51353 Trim Rods Cylinder End Caps Rod End Rollers (lubricate with Quicksilver Anti-Corrosion Grease or Special Lubricant 101) Tilt Ram REMOVAL - TILT ROD ASSEMBLY ONLY NOTE: Tilt Rod Assembly can be removed from cylinder without removing entire power trim system from outboard.
Page 336: Disassembly
POWER TRIM TILT RAM REMOVAL - POWER TRIM SYSTEM REMOVED FROM OUTBOARD CAUTION Insure trim system is depressurized prior to tilt ram removal. 1. Remove cross pin. 2. Remove lower swivel pin. 51355 51366 Cross Pin (Remove as shown) Lower Swivel Pin (Remove as shown) Disassembly 1.
Page 337 POWER TRIM 2. Clamp tilt rod in a soft jawed vise. Remove bolt or nut as applicable to disassemble rod assembly. Remove O-ring. 51378 51340 Bolt (Design 1) or Stud/Nut (Design 2) O-Ring IMPORTANT: Note Design 1 and 2 on page 5B-31. Design 1 tilt rod assembly re- places either tilt rod assembly.
Page 338 POWER TRIM 4. Remove end cap from tilt rod. 5. Remove allen plug. IMPORTANT: Remove plug from same side as holes in shaft. DO NOT REMOVE 51361 51376 End Cap Allen Plug Hole In Shaft 6. Lubricate shaft with Quicksilver Power Trim and Steering Fluid. Insert shaft into cylinder.
Page 339: Scraper Seal Replacement
POWER TRIM 8. Place cylinder as shown. Hold down on cylinder and inject air into shaft opening. 51353 Shop Cloth Solid Surface Air Nozzle 9. Remove shaft after Memory Piston Cup has been expelled. Replace allen plug re- moved in Step 5 and tighten securely. CLEANING AND INSPECTION 1.
Page 340 POWER TRIM REASSEMBLY IMPORTANT: Components must be clean for reassembly. Any debris in the system can cause the system to malfunction. NOTE: Refer to “Tilt Ram Components” for proper O-ring sizes. 1. Apply Quicksilver Power Trim and Steering Fluid on O-rings prior to reassembly. 2.
Page 341 POWER TRIM 5. Install components on rod. 51363 51340 Piston O-ring Check Valve Assembly (7) Washer Bolt or Locknut. (Tighten securely) 6. Clamp cylinder in a soft jawed vise and install tilt rod assembly. Use spanner wrench and tighten end cap securely. 91-74951 51337 51341...
Page 342 POWER TRIM TILT RAM ASSEMBLY INSTALLATION 1. Lubricate alignment tool (91-11230) and shaft. Use Quicksilver Power Trim and Steer- ing Fluid. 51369 Alignment Tool (91-11230) Shaft 2. Align tilt ram and housing using alignment tool. 3. Install shaft. 51348 51352 Alignment Tool (91-11230) Shaft Groove...
Page 343: Motor And Electrical Tests/Repair
POWER TRIM Motor and Electrical 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; one motor lead to POSITIVE (+) bat- tery terminal and the other motor lead to the NEGATIVE (–) battery terminal.
Page 344: Armature Tests
POWER TRIM 2. Remove frame and armature from end cap. Use care not to drop armature. 53779 Frame Armature End Cap Armature Tests TEST FOR SHORTS Check armature on a Growler per the Growler manufacturer’s instructions. Replace ar- mature if a short is indicated. TEST FOR GROUND 1.
Page 345: Motor Repair
POWER TRIM CHECKING AND CLEANING COMMUTATOR 1. If commutator is worn it may be turned on an armature conditioner or a lathe. 2. Clean commutator with “OO” sandpaper. 53775 Commutator FIELD TESTS IMPORTANT: Commutator end of armature must be installed in brushes when per- forming the following tests.
Page 346 POWER TRIM CLEANING AND INSPECTION Inspect O-rings and replace if necessary. Carefully inspect power cord for cuts or tears which will allow water to enter motor. Replace cord if cut or torn. Clean, inspect, and test motor components. Refer to “Brush Replacement”, “Armature Test”, and “Field Tests”...
Page 347 POWER TRIM 2. To replace brush card, disconnect spade terminal. 3. Cut crimped brush lead. 4. Remove 2 screws securing brush card to end cap. Spade Terminal Crimped Brush Lead Screws 5. Install new brush card (BRUSH and SEAL KIT 828714A1). 6.
Page 348 POWER TRIM END CAP INSPECTION 1. Inspect seal and O-ring for cuts and abrasions. If replacement is required, install BRUSH and SEAL KIT 828714A1. 2. Inspect bushing for wear. If bushing appears to be excessively worn – grooves, scratches, etc. – install END FRAME ASSEMBLY (COMPLETE) 828715A1. 53783 53785 Seal (Apply 2-4-C w/Teflon to seal lips)
Page 349: Reassembly
POWER TRIM Reassembly IMPORTANT: Components must be clean. Any debris in power trim system can cause system to malfunction. 1. Install armature into end cap/brush card assembly. 53779 53784 Armature Shim End Cap Assembly Armature (Spread brushes to install armature into end cap) 2.
Page 350 POWER TRIM IMPORTANT: Attach Vise Grip pliers to armature shaft before installing frame as- sembly. The Vise Grip pliers will prevent the armature from being drawn out of the brush card assembly by the frame magnets while installing the frame assembly. 3.
Page 351: Reassembly - Motor And Pump
POWER TRIM Reassembly - Motor and Pump NOTE: Drive shaft is a loose part and may fall out of position. 1. Install pump onto power trim manifold. Insure O-rings are in proper locations. Secure with two (2) screws. Torque screws to 80 lb. in. (9 N·m). IMPORTANT: Install pump with location flat facing towards starboard transom bracket.
Page 352: Priming Power Trim System
POWER TRIM NOTE: Verify motor and drive shaft are aligned. 53777 53782 Motor O-ring Screw (2) Tighten securely. 4. Complete reassembly of Power Trim System as outlined in “Installation” on page 5B-21. Priming Power Trim System 1. Fill system with Quicksilver Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) Type F,FA, Dexron II or Dexron III.
Page 353: Trim Indicator Gauge Needle Adjustment
POWER TRIM Trim Indicator Gauge Needle Adjustment 1. Turn ignition key to “RUN” position. 2. Tilt outboard to full “IN” position. Needle of trim indicator gauge should be in full “IN” position. 3. If not, tilt outboard to full “OUT” position to gain access to trim sender and engage tilt lock lever.
Page 354: Trim Indicator Wiring Diagrams
POWER TRIM Trim Indicator Wiring Diagrams Wiring Diagram - For boats equipped with Quicksilver Commander Series side mount remote control. Wiring Diagram - For boats equipped with Quicksilver Ignition/Choke and Main Harness Assembly. 22908 Trim Indicator Remote Control Trim Sender Engine Ground To Engine Ignition Switch...
Page 355 RIGHT HAND NON-RATCHETING LOWER UNIT Section 6A – Right Hand Non-Ratcheting Table of Contents Gear Housing Specifications (Standard Rotation) 6A-1 Forward Gear ......6A-25 Special Tools .
Page 356 RIGHT HAND NON-RATCHETING Special Tools 1. Shift Shaft Bushing Tool 91-31107 2. Gear Housing Cover Nut Tool 91-61069 3. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716 4. Slide Hammer Puller 91-34569A1 5. Bearing Removal and Installation Kit 91-31229A5. This kit contains the following tools: Pilot 91-36571;...
Page 357 RIGHT HAND NON-RATCHETING 8. Puller Plate 91-29310 9. Mandrel 91-38628 10. Driver Rod 91-37323 11. Universal Puller Plate 91-37241 12. Cross Pin Tool 91-86642 13. Driveshaft Holding Tool 91-34377A1or 91-90094 14. Oil Seal Driver 91-31108 15. Forward Gear Bearing Tool 91-86943 16.
Page 358 RIGHT HAND NON-RATCHETING 18. Backlash Indicator Rod 91-78473 19. Dial Indicator 91-58222A1 20. Bearing Retainer Tool 91-43506 21. Bearing Preload Tool 91-14311A1 Adaptor (N.S.S.) Bearing (N.S.S.) Washer (N.S.S.) Spring (24-14111) Bolt (10-12580) Nut (11-13953) Set Screw (10-12575) Sleeve (23-13946) 22. Mandrel 91-92788 23.
Page 359 RIGHT HAND NON-RATCHETING Notes: 90-855347R1 JANUARY 1999 Page 6A-5...
Page 360 RIGHT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Standard Rotation) 4.75 IN./120.65MM TORPEDO DIA. Loctite 271 (92-809820) Perfect Seal (92-34227-1) Soap (Purchase Locally) Loctite 680 (92-809833) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) Page 6A-6 90-855347R1 JANUARY 1999...
Page 361 RIGHT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Standard Rotation) TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BLACK)(BASIC) CONNECTOR ASSEMBLY DOWEL PIN STUD (3-1/8 IN.) (LONG) STUD (3-11/16 IN.) (X-LONG) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/8 IN.) FILLER BLOCK ROLLER BEARING ANODE SCREW (M6 x 40)
Page 362 RIGHT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Standard Rotation) 4.75 IN./120.65MM TORPEDO DIA. Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) Page 6A-8 90-855347R1 JANUARY 1999...
Page 363 RIGHT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Standard Rotation) TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BLACK)(BASIC) CAM FOLLOWER SHIFT CAM FORWARD GEAR (1.87:1 – 15/28)(150) FORWARD GEAR (2:1 – 14/28)(135) SHIM SET TAPERED ROLLER BEARING NEEDLE BEARING CLUTCH CROSS PIN DETENT PIN SPRING...
Page 364 RIGHT HAND NON-RATCHETING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more compo- nents.
Page 365 RIGHT HAND NON-RATCHETING To prevent corrosion damage after reassembly, apply Quicksilver 2-4-C w/Teflon Marine Lubricant to external surfaces of bearing carrier and cover nut threads prior to installation. Removal, Disassembly, Cleaning and Inspection – Standard Rotation Removal WARNING Disconnect high tension leads from spark plugs and remove spark plugs from engine before removing gear housing from driveshaft housing.
Page 366 RIGHT HAND NON-RATCHETING 7. Remove 2 locknuts from bottom middle of anti-cavitation plate. 51866 Bolt (Secures Trim Tab) Bolt (Inside Trim Tab Cavity) Locknuts and Washers 8. Remove locknut from the front gear housing mounting stud. 9. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo- site side is loosened sufficiently, or driveshaft housing could be damaged.) 10.
Page 367: Water Pump
RIGHT HAND NON-RATCHETING NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later models. 2. Position a clean drain pan under gear housing and remove “Fill” and “Vent” screws from gear housing. 51871 “Fill” Screw “Vent”...
Page 368 RIGHT HAND NON-RATCHETING IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal repair procedure) to assure effective repair. REMOVAL AND DISASSEMBLY 1. Slide rubber centrifugal slinger up and off driveshaft. 2. Remove water tube guide and seal from water pump cover. (Retain guide for reas- sembly and discard seal.) 3.
Page 369 RIGHT HAND NON-RATCHETING b. Drill two 3/16 in. (4.8mm) diameter holes thru the top of water pump cover (but not thru insert). Drive insert out of cover with a punch and hammer. 51873 Drill Two Holes at These Locations 7. Remove impeller from driveshaft. (It may be necessary to use a punch and hammer to drive impeller upward on driveshaft.
Page 370 RIGHT HAND NON-RATCHETING Bearing Carrier and Propeller Shaft Removal CAUTION Gear housing MUST BE in NEUTRAL position, and shift shaft MUST BE removed from gear housing before propeller shaft can be removed from gear housing. 1. Place gear housing in a suitable holding fixture with propeller shaft in a horizontal posi- tion.
Page 371 RIGHT HAND NON-RATCHETING 6. Use long Puller Jaws (91-46086A1) and Puller Bolt (91-85716) to remove bearing car- rier. (Use propeller thrust hub to maintain outward pressure on puller jaws.) NOTE: When bearing carrier is removed from gear housing, the bearing carrier alignment key will come out with it.
Page 372 RIGHT HAND NON-RATCHETING NOTE: If Step 8-b was used to remove propeller shaft, the shift cam can be retrieved after removal of forward gear. Shift Shaft CLEANING AND INSPECTION 1. Clean shift shaft and bushing with solvent and dry with compressed air. 2.
Page 373 RIGHT HAND NON-RATCHETING c. If reverse gear bearing remains attached to reverse gear, install Universal Puller Plate (91-37241) and position puller plate, gear and bearing on a press with gear side down. Use a suitable mandrel and press gear out of bearing. 51874 Universal Puller Plate Mandrel...
Page 374 RIGHT HAND NON-RATCHETING Propeller Shaft INSPECTION 1. Clean propeller shaft assembly with solvent and dry with compressed air. 2. Inspect bearing carrier oil seal surfaces for grooves. Run fingernail across seal sur- face to check for groove. Replace shaft if groove is found. 3.
Page 375 RIGHT HAND NON-RATCHETING 6. Inspect sliding clutch. Check reverse gear and forward gear clutch jaws. Rounded jaws indicate one or more of the following: a. Improper shift cable adjustment. b. Improper shift habits of operator(s) (shift from NEUTRAL to REVERSE gear too slowly).
Page 376 RIGHT HAND NON-RATCHETING 4. Push cross pin out of sliding clutch and propeller shaft with Cross Pin Tool (91-86642). 5. Pull sliding clutch off propeller shaft. 6. Pull cam follower and clutch actuator rod out of propeller shaft. DO NOT force cam follower up-or-down or side-to-side when pulling from propeller shaft.
Page 377 RIGHT HAND NON-RATCHETING 5. Remove gear housing from vise and re-position it as shown. Be sure to use soft jaw vise covers and clamp as close as possible to water pump studs. 6. Place a block of wood on gear housing mating surface. Use a mallet and carefully tap gear housing away from driveshaft.
Page 378 RIGHT HAND NON-RATCHETING NOTE: FORWARD gear must be removed first BEFORE removing driveshaft needle bearing. IMPORTANT: Discard driveshaft needle bearing after removal. (Bearing cannot be reused.) 51869 Mandrel (91-37263) Pilot* (91-36571) Driver Rod* (91-37323) *From Bearing Removal and Installation Kit (91-31229A5) CLEANING AND INSPECTION 1.
Page 379 RIGHT HAND NON-RATCHETING Forward Gear REMOVAL AND DISASSEMBLY NOTE: Forward gear can only be removed from gear housing after driveshaft and pinion gear have been removed. 1. Reach into gear housing and lift out forward gear. IMPORTANT: DO NOT remove tapered bearing or needle bearings from forward gear, unless replacement of bearings is required.
Page 380: Gear Housing
RIGHT HAND NON-RATCHETING CLEANING AND INSPECTION CAUTION DO NOT spin bearings dry with compressed air, as this could cause bearing to score. 1. Clean forward gear and bearings with solvent and dry with compressed air. 2. Inspect gear teeth for pitting, grooves, scoring, uneven wear and for discoloration (from overheating).
Page 381 RIGHT HAND NON-RATCHETING 3. Install and seat needle bearing with the following tools: Puller Rod* (91-31229), Nut* (11-24156), Pilot* (91-36571), Plate* (91-29310), and Mandrel (models with pre- loaded driveshaft use 91-38628*; models with standard driveshaft use 91-92788). Pull bearing up into bore until it bottoms on gear housing shoulder. (DO NOT use ex- cessive force.) *From Bearing Removal and Installation Kit (91-31229A5) 51869...
Page 382 RIGHT HAND NON-RATCHETING 5. Press ball bearing onto gear with a suitable mandrel until firmly seated. (Be sure to press only on inner race of bearing and that bearing is firm against gear.) 6. Apply a light coat of Quicksilver Super Duty Gear Lubricant onto outside diameter of propeller shaft needle bearing.
Page 383 RIGHT HAND NON-RATCHETING 11. Place second seal on short shoulder side of seal driver with lip of seal toward shoulder. Press seal into bearing carrier until seal driver bottoms against bearing carrier. 51872 Oil Seal (Lip of Seal Up) Oil Seal Driver Seated 12.
Page 384 RIGHT HAND NON-RATCHETING Forward Gear REASSEMBLY 1. Place forward gear on a press with gear teeth down. 2. Apply a light coat of Quicksilver Super Duty Gear Lubricant onto the inside diameter of forward gear tapered bearing. 3. Position forward gear tapered bearing over gear. 4.
Page 385: Forward Gear Bearing Race
RIGHT HAND NON-RATCHETING Forward Gear Bearing Race INSTALLATION 1. Place shim(s) (retained from disassembly) into gear housing. If shim(s) were lost or a new gear housing is being used, start with approximately 0.010 in. (0.254 mm). 2. Apply a light coat of Quicksilver Super Duty Gear Lubricant to forward gear bearing race bore in gear housing.
Page 386 RIGHT HAND NON-RATCHETING Driveshaft and Pinion Gear REASSEMBLY/INSTALLATION 1. Apply a light coat of Quicksilver Super Duty Gear Lubricant on l.D. of driveshaft ta- pered bearing. 2. Thread a used pinion nut onto end of driveshaft. Leave approximately 1/16 in. (2 mm) of nut threads exposed.
Page 387 RIGHT HAND NON-RATCHETING 9. Install bearing race and bearing retainer. 51867 51880 Driveshaft (rotate to engage splines with pinion gear) Forward Gear Assembly Pinion Gear Washer (located above pinion nut) Pinion Nut (apply Loctite 271 on threads and install with flat side away from pinion gear) Shim(s) Bearing Race...
Page 388 RIGHT HAND NON-RATCHETING Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash DETERMINING PINION GEAR DEPTH NOTE: Read entire procedure before attempting any change in shim thickness. IMPORTANT: Forward gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained. 1.
Page 389 RIGHT HAND NON-RATCHETING 5. Measure distance (a) and increase that distance by 1 in. (25.4 mm) by turning bottom nut away from top nut. 1 in. (25.4 mm) 51870 Distance Adaptor Ledge 6. Turn driveshaft clockwise 2 or more turns to seat driveshaft bearings. 7.
Page 390 RIGHT HAND NON-RATCHETING NOTE: Bearing Preload Tool (91-14311A1) should remain installed on driveshaft after setting pinion gear depth as it is required to properly check forward gear and reverse gear backlash. DETERMINING FORWARD GEAR BACKLASH IMPORTANT: Bearing carrier must be assembled to provide a pilot for propeller shaft.
Page 391 RIGHT HAND NON-RATCHETING 7. Position dial indicator pointer on line marked “1” on Backlash Indicator Tool, if gear ratio is 1.87:1 (15 teeth on pinion gear), or on line marked “2” on Backlash Indicator Tool, if gear ratio is 2:1 (14 teeth on pinion gear) or on line marked “4” if gear ratio is 2.3:1 (13 teeth on pinion gear).
Page 392 RIGHT HAND NON-RATCHETING 5. Secure pipe against carrier with propeller nut and tab washer. 51866 Pipe [6 in. x 1.5 in. (152.5 mm x 38.0 mm)] Propeller Nut Tab Washer 6. Torque propeller nut to 45 lb. in. (5 Nm). 7.
Page 393 RIGHT HAND NON-RATCHETING Propeller Shaft REASSEMBLY/INSTALLATION 1. Insert clutch actuator rod assembly into end of propeller shaft. Align cross pin slot in actuator rod with cross pin slot in propeller shaft. 2. On PRODUCTION MODEL GEAR CASES, position sliding clutch onto propeller shaft with GROOVED RINGS (ON SLIDING CLUTCH) TOWARD PROPELLER END OF PROPELLER SHAFT.
Page 394 RIGHT HAND NON-RATCHETING 5. Install cross pin retaining spring onto sliding clutch as follows: IMPORTANT: DO NOT over-stretch retaining spring when installing onto sliding clutch. 6. Spirally wrap spring into groove on sliding clutch. 7. Place gear housing in a soft jaw vise with the driveshaft in a vertical position. 8.
Page 395 RIGHT HAND NON-RATCHETING CAUTION Until bearing carrier is installed into gear housing, extreme care MUST BE taken not to apply any side force on propeller shaft. Side force on propeller shaft may break the neck of the clutch actuator rod. 11.
Page 396 RIGHT HAND NON-RATCHETING 19. Start cover nut a few turns by hand, then using Cover Nut Tool (91-61069) and torque wrench, torque cover nut to 210 Ib. ft. (285 Nm). 51871 O-ring Cover Nut Tool Torque Wrench 20. Bend one lock tab of tab washer into cover nut (only one will align). 21.
Page 397 RIGHT HAND NON-RATCHETING 3. Install divider block if removed. Use RTV Sealer to seal seams between divider block and gear housing. 4. Install a new water pump base gasket and install water pump base. 51866 51870 Divider Block Water Pump Base Gasket Hole (MUST be positioned as shown) 5.
Page 398 RIGHT HAND NON-RATCHETING 7. Slide impeller down driveshaft to impeller drive key. Align drive key with keyway in the center hub of impeller, and slide impeller over drive key. 8. If removed, install new water pump insert into pump cover as follows: a.
Page 399 RIGHT HAND NON-RATCHETING Gear Lubricant Filling Instructions 1. Remove any gasket material from “Fill” and “Vent” screws and gear housing. 2. Install new gaskets on Fill and Vent screws. IMPORTANT: Never apply lubricant to gear housing without first removing Vent screw, or gear housing cannot be filled because of trapped air.
Page 400: Propeller Installation
RIGHT HAND NON-RATCHETING NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward driveshaft housing. 8. Move gear housing up toward driveshaft housing, while aligning shift shaft splines and water tube with water tube guide (in water pump cover).
Page 401 RIGHT HAND NON-RATCHETING 2. Place forward thrust hub over propeller shaft with shoulder side toward propeller. 3. Place propeller on propeller shaft and slide it up against thrust hub. 51866 Forward Thrust Hub Propeller Shaft 4. Place continuity washer (if equipped) onto shoulder of rear thrust hub. 5.
Page 402 LEFT HAND NON-RATCHETING LOWER UNIT Section 6B – Left Hand Non-Ratcheting Table of Contents Gear Housing Specifications (Counter Rotation) 6B-1 Reassembly and Installation of Counter Rotation Special Tools ....... . 6B-2 Gear Housing .
Page 403 LEFT HAND NON-RATCHETING Special Tools 1. Shift Shaft Bushing Tool 91-31107T 2. Gear Housing Cover Nut Tool 91-61069 3. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716 4. Slide Hammer Puller 91-34569A1 5. Bearing Removal and Installation Kit 91-31229A5. This kit contains the following tools: Pilot 91-36571;...
Page 404 LEFT HAND NON-RATCHETING 8. Puller Plate 91-29310 9. Mandrel 91-38628 10. Driver Rod 91-37323 11. Universal Puller Plate 91-37241 12. Driveshaft Holding Tool 91-34377A1 or91-90094 13. Oil Seal Driver 91-31108 14. Forward Gear Bearing Tool 91-86943 15. Pinion Locating Gear Tool 91-12349A2 or 91-74776 16.
Page 405 LEFT HAND NON-RATCHETING 18. Bearing Retainer Tool 91-43506 19. Mandrel 91-92788 20. Mandrel 91-15755 21. Dial Indicator Holder 91-89897 22. Bearing Preload Tool 91-14311A1 Adaptor (N.S.S.) Bearing (N.S.S.) Washer (N.S.S.) Spring (24-14111) Bolt (10-12580) Nut (11-13953) Set Screw (10-12575) Sleeve (23-13946) 23.
Page 406 LEFT HAND NON-RATCHETING 25. Reverse Gear Installation Kit 91-18605A1 includes Pilot 91-18603; Retainer 91-18604; Shaft 91-18605 and Screw 10-18602 Pilot 91-18603 Shaft 91-18605 Retainer 91-18604 Screw 10-18602 90-855347R1 JANUARY 1999 Page 6B-5...
Page 407 LEFT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Counter Rotation) 4.75 IN./120.65 MM TORPEDO DIA. Loctite 271 (92-809820) Perfect Seal (92-34227-1) Soap (Purchase Locally) Loctite 680 (92-809833) 2-4-C With Teflon (92-825407A12) GM Silicone Sealer (92-91600-1) Page 6B-6 90-855347R1 JANUARY 1999...
Page 408 LEFT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Counter Rotation) TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BLACK)(BASIC) CONNECTOR ASSEMBLY DOWEL PIN STUD (3-11/16 IN.) STUD (2-1/16 IN.) STUD (3-3/8 IN.) STUD (3-1/8 IN.) FILLER BLOCK ROLLER BEARING ANODE SCREW PINION GEAR (1.87:1 - 15 TEETH)(150)(Part of 43-828701A1) PINION GEAR (2:1 - 14 TEETH)-(135)(Also part of 43-828703A1) WASHER...
Page 409 LEFT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Counter Rotation) 4.75 IN./120.65 MM TORPEDO DIA. Anti-Corrosion Grease (92-78376A6) Loctite 271 (92-809820) Quicksilver Gear Lubricant (92-19007A24) 2-4-C With Teflon (92-825407A12) Page 6B-8 90-855347R1 JANUARY 1999...
Page 410 LEFT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Counter Rotation) TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BLACK)(BASIC) CAM FOLLOWER SHIFT CAM SHIM SET BEARING ADAPTOR ASSEMBLY ROLLER BEARING THRUST WASHER THRUST BEARING REVERSE GEAR (1.87:1 – 15/28)(150) REVERSE GEAR (2:1 – 14/28)-(135) ROLLER BEARING SPRING SLIDING CLUTCH...
Page 411 LEFT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Counter Rotation) 4.75 IN./120.65 MM TORPEDO DIA. Anti-Corrosion Grease (92-78376A6) Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) Quicksilver Gear Lubricant (92-19007A24) Page 6B-10 90-855347R1 JANUARY 1999...
Page 412 LEFT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Counter Rotation) TORQUE REF. REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BLACK)(BASIC) ROLLER BEARING THRUST WASHER BEARING ADAPTOR ASSEMBLY ROLLER BEARING THRUST WASHER THRUST BEARING THRUST RACE KEEPER O RING BEARING CARRIER ASSEMBLY ROLLER BEARING OIL SEAL (INSIDE) OIL SEAL (OUTSIDE) TAB WASHER...
Page 413 LEFT HAND NON-RATCHETING BEARINGS Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes thru the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication.
Page 414 LEFT HAND NON-RATCHETING 4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propel- ler shaft. 51916 51912 Thrust Hub (Forward) Propeller Shaft Continuity Washer (If Equipped) Rear Thrust Hub Tab Washer...
Page 415 LEFT HAND NON-RATCHETING 8. Remove locknut from the front gear housing mounting stud. 9. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo- site side is loosened sufficiently, or driveshaft housing could be damaged.) 51873 Front Mounting Locknut Side Mounting Locknut (One Each Side) 10.
Page 416 LEFT HAND NON-RATCHETING Water Pump CLEANING AND INSPECTION 1. Clean all water pump parts with solvent and dry with compressed air. 2. Inspect water pump cover and base for cracks and distortion (from overheating). 3. Inspect face plate and water pump insert for grooves and/or rough surfaces. IMPORTANT: When completing gear housing repairs, that require removal of water pump impeller, it is recommended that the impeller be replaced.
Page 417 LEFT HAND NON-RATCHETING NOTE: Try Step “a” first. If insert cannot be removed with Step “a,” use Step “b.” a. Drive water pump insert out of water pump cover with a punch and hammer. b. Drill two 3/16 in. (4.8 mm) diameter holes thru the top of water pump cover (but not thru insert).
Page 418: Bearing Carrier And Propeller Shaft
LEFT HAND NON-RATCHETING Bearing Carrier and Propeller Shaft REMOVAL CAUTION Gear housing MUST BE in neutral position, and shift shaft MUST BE removed from gear housing before propeller shaft can be removed from gear housing. 1. Place gear housing in a suitable holding fixture or vise with propeller shaft in a horizon- tal position.
Page 419 LEFT HAND NON-RATCHETING CAUTION Once bearing carrier is removed from gear housing, extreme care MUST BE taken not to apply any side force on propeller shaft. Side force on propeller shaft may break the neck of the clutch actuator rod. 6.
Page 420 LEFT HAND NON-RATCHETING CAUTION Propeller shaft, cam follower and shift cam, in most cases, will come out of gear housing by simply pulling outward on propeller shaft. DO NOT FORCE shaft side- ways or ATTEMPT TO PULL with a slide hammer or any mechanical puller. 8.
Page 421 LEFT HAND NON-RATCHETING DISASSEMBLY 1. Remove (and discard) shift shaft bushing oil seal by prying it out or driving it out with a punch and hammer. CLEANING/INSPECTION - BEARING CARRIER IMPORTANT: It is recommended that all seals and O-rings be replaced (as a normal repair procedure) to assure effective repair.
Page 422 LEFT HAND NON-RATCHETING 4. Use bearing removal and replacement tool (91-31229A5) or equivalent to press bear- ings out of bearing carrier. 51885 Needle Bearing Push Rod Mandrel Propeller Shaft INSPECTION 1. Clean propeller shaft assembly with solvent and dry with compressed air. 2.
Page 423 LEFT HAND NON-RATCHETING “Vee” Blocks and Dial Indicator Position propeller shaft roller bearing surfaces on vee blocks. Mount a dial indicator at front edge of propeller splines. Rotate propeller shaft. Dial indicator movement of more than 0.006 in. (0.152 mm) (or noticeable wobble) is reason for replacement. DISASSEMBLY 1.
Page 424 LEFT HAND NON-RATCHETING 5. Pull sliding clutch off propeller shaft. 6. Inspect sliding clutch. Check reverse gear clutch “jaws” and forward gear clutch “jaws.” Rounded “jaws” indicate one or more of the following: a. Improper shift cable adjustment. b. Improper shift habits of operator(s) (shift from neutral to reverse gear or forward gear too slowly).
Page 425 LEFT HAND NON-RATCHETING Clutch Actuator Rod CLEANING AND INSPECTION 1. Clean clutch actuator rod in solvent and dry with compressed air. 2. Inspect actuator components for wear or damage. Replace components as required. Forward Gear and Bearing Adapter DISASSEMBLY/CLEANING/INSPECTION 1. Remove forward gear from bearing adapter. 2.
Page 426 LEFT HAND NON-RATCHETING 6. Remove thrust washer and O-ring. The thrust washer acts as a bearing surface for the thrust bearing and it should be inspected for pits, rust, scoring or discoloration due to lack of lubricant. O-ring should be inspected for cuts or abrasions and replaced if necessary.
Page 427 LEFT HAND NON-RATCHETING Pinion Gear and Driveshaft REMOVAL 1. Remove bearing retainer using Bearing Retainer Tool (91-43506). 51865 Bearing Retainer Bearing Retainer Tool (91-43506) 2. Place Driveshaft Holding Tool (91-34377A1) over driveshaft splines. 3. Use a socket and flex handle to hold pinion nut. (Pad area of gear housing, where flex handle will make contact, to prevent damage to gear housing.) 4.
Page 428 LEFT HAND NON-RATCHETING 8. After driveshaft is removed from gear case, remove and retain shim(s) that were lo- cated under upper tapered driveshaft bearing. 9. If inspection determines that replacement of driveshaft tapered bearing is required, remove bearing from driveshaft as follows: a.
Page 429 LEFT HAND NON-RATCHETING CLEANING AND INSPECTION 1. Clean driveshaft, tapered bearing and race, and pinion gear with solvent. Dry with compressed air. DO NOT allow driveshaft bearing to spin while drying. 2. Inspect pinion gear for pitting, grooves, scoring, uneven wear and/or discoloration from overheating.
Page 430 LEFT HAND NON-RATCHETING 2. Remove thrust bearing and thrust washer from reverse gear bearing cup. 3. Remove reverse gear bearing adaptor. Remove, measure and make note of the shim thickness and discard (DO NOT reuse) the shims. 50882 50780 Thrust Bearing Thrust Washer Reverse Gear Bearing Adaptor Bolt (91-31229)
Page 431 LEFT HAND NON-RATCHETING 3. Check clutch jaws on reverse gear for damage. Replace reverse gear if damage is found. 23351 Reverse Gear Teeth Clutch Jaws NOTE: The needle bearings in the reverse gear should not be removed unless damage has been found. Inspect to ensure that all of the needles are present and in position. Needles that have been dislodged may be snapped back into place as long as no damage has occurred to the bearing cage.
Page 432 LEFT HAND NON-RATCHETING Reassembly and Installation of Counter Rotation Gear Housing Driveshaft Needle Bearing REASSEMBLY/INSTALLATION CAUTION If driveshaft needle bearing failure has occurred, and original bearing race has turned in the gear housing, gear housing must be replaced. Loose fitting needle bearing will move out of position and cause repeated failures.
Page 433 LEFT HAND NON-RATCHETING Bearing Carrier, Forward Gear and Bearing Adaptor REASSEMBLY 1. Using suitable mandrel, press forward gear bearing into bearing adaptor until bearing is flush with lip of adaptor. Suitable Mandrel Forward Gear Bearing Bearing Adaptor PROPELLER SHAFT NEEDLE ROLLER BEARING AND OIL SEAL INSTALLATION 1.
Page 434 LEFT HAND NON-RATCHETING 3. With seal lip facing towards bearing, press inner seal using long end of mandrel (91-31108) into bearing carrier until mandrel shoulder bottoms out on bearing carrier. 51881 Inner Seal Mandrel (91-31108) Bearing Carrier Mandrel Shoulder 4. With seal lip facing towards mandrel, press outer seal using short end of mandrel (91-31108) into bearing carrier until mandrel shoulder bottoms out on bearing carrier.
Page 435 LEFT HAND NON-RATCHETING REVERSE GEAR AND BEARING CUP ADAPTOR REASSEMBLY 1. With reverse gear teeth facing down, use mandrel (91-86943) to press propeller shaft needle bearing (NUMBERS/LETTERS UP) into reverse gear until short shoulder on mandrel bottoms on reverse gear. NOTE: If gear housing has been replaced or inspection determines that reverse gear bearing adapter must be replaced, assemble and install as follows: 2.
Page 436 LEFT HAND NON-RATCHETING Reverse Gear Bearing Adaptor Assembly INSTALLATION NOTE: If the reverse gear, reverse gear adaptor, large thrust bearing, or bearing race in the gear housing were not replaced, install the same shim(s) (or the same thickness of shim(s)) that were taken out when adaptor was removed. If the reverse gear, reverse gear adaptor, large thrust bearing, bearing race, or gear housing were replaced, install 0.008 in.
Page 437 LEFT HAND NON-RATCHETING 4. Position the reverse gear (without the thrust race or thrust bearing) into the gear hous- ing and into the adaptor. 5. Install PILOT RING (91-18603) over DRIVER TOOL (91-18605) and seat pilot ring in gearcase against inner ledge. Thread RETAINER (91-18604) into bearing carrier threads.
Page 438 LEFT HAND NON-RATCHETING Driveshaft and Pinion Gear REASSEMBLY/INSTALLATION 1. Apply a light coat of Quicksilver Super Duty Gear Lubricant on l.D. of driveshaft tapered bearing. 2. Thread a used pinion nut onto end of driveshaft. Leave approximately 1/16 in. (2 mm) of nut threads exposed.
Page 439 LEFT HAND NON-RATCHETING 9. Install bearing race and bearing retainer. 51880 Shim(s) Bearing Race Bearing Retainer (Word “OFF” must be visible); Torque to 100 lb. ft. (135.5 Nm) Bearing Retainer Tool (91-43506) 10. Use a socket and breaker bar to hold pinion nut (pad area where flex handle will con- tact gear housing while torquing nut).
Page 440 LEFT HAND NON-RATCHETING Pinion Gear Depth DETERMINING PINION GEAR DEPTH NOTE: Read entire procedure before attempting any change in shim thickness. IMPORTANT: Reverse gear assembly must be installed in gear housing when checking pinion gear depth or an inaccurate measurement will be obtained. 1.
Page 441 LEFT HAND NON-RATCHETING 5. Measure distance (a) and increase that distance by 1 in. (25.4 mm) by turning bottom nut away from top nut. 1 in. (25.4 mm) 51870 Distance Adaptor Ledge 6. Turn driveshaft clockwise 2 or more turns to seat driveshaft bearings. 7.
Page 442 LEFT HAND NON-RATCHETING NOTE: Bearing Preload Tool (91-14311A1) should remain installed on driveshaft after setting pinion gear depth as it is required to properly check forward gear and reverse gear backlash. Reverse Gear DETERMINING REVERSE GEAR BACKLASH NOTE: Reverse gear backlash is adjustable using shims; it can be checked as follows: 1.
Page 443 LEFT HAND NON-RATCHETING 9. Dial Indicator registers amount of backlash, which should be 0.030 in. to 0.050 in. (0.76 mm to 1.27 mm). 51880 Stud Adaptor (from 91-14311A1) Stud Backlash Indicator Tool (91-78473) Dial Indicator Holder (91-89897) Dial Indicator (91-58222A1) Dial Indicator Pointer NOTE: If reverse gear backlash is not within specifications, then gear case is not properly assembled or component(s) within gear case are excessively worn and must be replaced...
Page 444 LEFT HAND NON-RATCHETING 2. Assemble BEARING CARRIER, BEARING ADAPTOR, THRUST WASHER, THRUST BEARING, and FORWARD GEAR onto propeller shaft. 3. Position shim against shoulder in gear case. 55103 55104 Bearing Carrier Bearing Adaptor Thrust Washer Thrust Bearing Forward Gear Shim (PLACE IN GEARCASE FIRST) Shoulder Shim 4.
Page 445 LEFT HAND NON-RATCHETING 7. Tighten nut to 45 lb. in. (5 Nm). This will seat the forward gear against the forward thrust bearing and tends to hold the propeller shaft from moving when measuring backlash. NOTE: Bearing Preload Tool (91-44307A1) should still be installed from having previous- ly been used to determine pinion gear depth and reverse gear backlash.
Page 446 LEFT HAND NON-RATCHETING 12. If backlash is less than the specifications, then a larger shim should be installed. Con- versely, if the backlash indicated is greater than specifications, then a smaller shim should be installed. NOTE: By adding or subtracting 0.002 in. (0.051 mm) shim, the backlash will change ap- proximately 0.002 in.
Page 447 LEFT HAND NON-RATCHETING 2. Place a small amount of Quicksilver 2-4-C w/Teflon Lubricant on actuator rod and install cam follower. Actuator Rod Cam Follower 3. Slide clutch actuator assembly into propeller shaft. Align cross pin slot in actuator rod with cross pin slot in clutch/propeller shaft. 51875 Cam Follower Clutch Actuator Rod...
Page 448 LEFT HAND NON-RATCHETING 6. Install cross pin retaining spring onto sliding clutch as follows: IMPORTANT: DO NOT over-stretch retaining spring when installing onto sliding clutch. a. Install spring. (1.) Spirally wrap spring into groove on sliding clutch. (2.) Position spring in groove so that straight end of spring is against the side of groove.
Page 449 LEFT HAND NON-RATCHETING 13. Install appropriate spacer shim into the gear housing. 14. Apply Quicksilver Super Duty Gear Lubricant to to thrust bearing and install thrust bearing and thrust race onto forward gear bearing adaptor. 55220 50782 Shim Bearing Adaptor Thrust Washer Thrust Bearing 15.
Page 450 LEFT HAND NON-RATCHETING 17. Install thrust race on top of bearing adaptor. 18. Apply Quicksilver Super Duty Gear Lubricant to small thrust bearing and install bear- ing on thrust race. 55107 55108 Thrust Race Thrust Bearing 19. Install thrust collar with its STEPPED SIDE DOWN toward the small thrust bearing. 20.
Page 451 LEFT HAND NON-RATCHETING 21. Install second thrust collar with its stepped side UP. 22. Apply Quicksilver Super Duty Gear Lubricant to the second thrust bearing and install it on top of the second thrust collar. 55112 Thrust Collar Thrust Bearing Thrust Collar 23.
Page 452 LEFT HAND NON-RATCHETING 25. Apply Quicksilver 2-4-C w/Teflon Marine Lubricant to: a. Outer diameter of bearing carrier which contacts gear case. b. Space between carrier oil seals. 26. Apply Quicksilver Super Duty Gear Lubricant to bearing carrier needle bearing. 27. Install bearing carrier into gear housing. 28.
Page 453 LEFT HAND NON-RATCHETING 32. Bend one lock tab of tab washer into cover nut (only one will align). 33. Bend remaining tabs of tab washer toward front of gear housing. 34. Use Shift Shaft Bushing Tool (91-31107) and torque shift shaft bushing to 50 Ib. ft. (68 Nm).
Page 454 LEFT HAND NON-RATCHETING 3. Install divider block if removed. Use RTV Sealer to seal seams between divider block and gear housing. 4. Install a new water pump base gasket and install water pump base. 51866 51878 Divider Block Water Pump Base Gasket Hole (MUST be positioned as shown) 5.
Page 455 LEFT HAND NON-RATCHETING CAUTION A visual inspection of impeller drive key MUST BE made to determine that drive key is on flat of driveshaft after impeller is installed. If key has moved off flat of driveshaft, repeat Steps 7 and 8. 7.
Page 456 LEFT HAND NON-RATCHETING Gear Lubricant Filling Instructions 1. Remove any gasket material from “Fill” and “Vent” screws and gear housing. 2. Install new gaskets on “Fill” and “Vent” screws. IMPORTANT: Never apply lubricant to gear housing without first removing “Vent” screw, or gear housing cannot be filled because of trapped air.
Page 457 LEFT HAND NON-RATCHETING 7. Position gear housing so that the driveshaft is protruding into driveshaft housing. NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear housing is being pushed toward driveshaft housing.
Page 458 LEFT HAND NON-RATCHETING 1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Quicksilver products: -- Anti-Corrosion Grease (92-78376A6) -- Special Lubricant 101 (92-13872A1) -- 2-4-C Marine Lubricant (92-90018A12) -- Perfect Seal (92-34227--1) 2.
Page 459 ATTACHMENTS / CONTROL LINKAGE ATTACHMENTS / CONTROL LINKAGE Section 7A Table of Contents Ride Guide Steering Cable/Attaching Kit Installation Installation Requirements ....7-10 (92876A1) .
Page 460 ATTACHMENTS / CONTROL LINKAGE STEERING LINK ROD INSTALLATION IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a” - Part Number 10-14000) and self locking nuts (“b” & “c” - Part Number 11-34863). These locknuts must never be replaced with common nuts (non locking) as they will work loose and vibrate off freeing the link rod to disengage.
Page 461: Ride Guide Steering Cable/Attaching Kit Installation (92876A1)
ATTACHMENTS / CONTROL LINKAGE NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional lubrication at initial installation. WARNING Core of each steering cable (transom end) must be fully retracted into cable hous- ing before lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur.
Page 462: Super Ride-Guide Steering Kit Installation
ATTACHMENTS / CONTROL LINKAGE CAUTION Marine sealer must be used on shanks bolts to make a water-tight installation. IMPORTANT: DO NOT use an impact driver when tightening transom bolts. Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard to transom with 4 bolts, flat washers and locknuts, as shown.
Page 463: Steering Cable Mounting Tube Installation
ATTACHMENTS / CONTROL LINKAGE Steering Cable Mounting Tube Installation IMPORTANT: Spacers (b) must be installed between outboard swivel bracket and mounting bracket for steering cable mounting tube to provide proper spacing be- tween steering cables. Secure mounting bracket for steering cable mounting tube on to swivel bracket of out- board.
Page 464: Installing Steering Cables
ATTACHMENTS / CONTROL LINKAGE Installing Steering Cables IMPORTANT: Lubricate inside of outboard tilt tube, inside of steering cable mount- ing tube and rubber O-ring seal (located in outboard tilt tube) with Quicksilver 2-4-C w/Teflon before installing steering cables. Lubricate inside of outboard tilt tube and inside of steering cable mounting tube with Quicksilver 2-4-C w/Teflon.
Page 465: Coupler Installation
ATTACHMENTS / CONTROL LINKAGE Coupler Installation WARNING Locknuts must be used with bolts to secure steering cables to coupler. Failure to adhere to this requirement could result in steering system failure. Slide coupler (a) onto steering cable ends and secure each steering cable to coupler with bolt (b) and locknut (c) as shown.
Page 466 ATTACHMENTS / CONTROL LINKAGE STEERING SYSTEM TENSION ADJUSTMENT IMPORTANT: After this dual steering cable attachment kit is installed, there must be proper tension in forward mounted steering cable tor this attachment kit to oper- ate properly. Not enough tension will cause slack (or play) in steering system. Too much tension will cause steering cables to bind.
Page 467: Maintenance Instructions
ATTACHMENTS / CONTROL LINKAGE NOTE: Cable attaching nuts with a “V” groove around the outer circumference of the nut are self locking and do not require locking sleeves. WARNING After installation is complete [and before operating outboard(s)], check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left.
Page 468: Ride Guide Steering Cable/Attaching Kit Installation (92876A6)
ATTACHMENTS / CONTROL LINKAGE Ride Guide Steering Cable/Attaching Kit Installation (92876A6) Dual Cable - Dual Outboard WARNING Quicksilver Super Ride-Guide Steering (dual cables) MUST BE USED with this at- taching kit. Failure to adhere to this requirement could result in steering system failure.
Page 469: Parallel Routed Steering Cables And Attaching Kit Installation
ATTACHMENTS / CONTROL LINKAGE Install upper bolts so that hex head end of bolts is on the inside of boat transom. Parallel Routed Steering Cables and Attaching Kit Installation (Both Steering Cables Routed Together Down Starboard Side of Boat) SUPER RIDE-GUIDE STEERING KIT INSTALLATION IMPORTANT: Steering cable must be installed into tilt tube of port outboard before outboard is mounted on boat transom.
Page 470 ATTACHMENTS / CONTROL LINKAGE WARNING Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that secures mounting bracket for steering cable mounting tube to outboard swivel bracket, to prevent bolts from turning out. Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 locking tab washers.
Page 471 ATTACHMENTS / CONTROL LINKAGE Place a mark (a) on steering cable mounting tube (b) 5/8 in. (16 mm) from end of mounting tube. Slide plastic spacer (c), O-ring (d) and cap (e) over steering cable. 5/8” (16 mm) 51890 Thread cap (e) onto steering cable mounting tube, up to mark (a). 51890 STEERING CABLE INSTALLATION - PORT OUTBOARD IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-...
Page 472 ATTACHMENTS / CONTROL LINKAGE STEERING LINK ROD INSTALLATION WARNING Steering link rods MUST BE secured between outboard steering arm and steering cable end, using special washer head bolt (10-14000) and two nylon insert lock- nuts (11-34863), as shown. Both special washer head bolt and nylon insert lock- nuts MUST BE tightened as specified.
Page 473 ATTACHMENTS / CONTROL LINKAGE STEERING ARM EXTENSION BRACKET INSTALLATION Secure a steering arm extension bracket to each out- board’s steering arm. 51889 Steering Arm (Port Outboard Shown) Extension Bracket Locking Retainer (2 Each Bracket) Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to 23 lb. ft. (31 Nm), Then Bend Corner Tabs of Locking Retainers Up Against Flats on Each Bolt WARNING Locking retainer corner tabs MUST BE bent up and against flats on each bolt that...
Page 474 ATTACHMENTS / CONTROL LINKAGE Lubricate ball joint in steering eyes, with SAE 30W Motor Oil. Assemble steering coupler between outboard steering arm extension brackets, using special washer head bolts (10-14000) provided and nylon insert locknuts as shown. IMPORTANT: With assembled steering coupler installed and before tightening spe- cial washer head bolts/locknuts, check outboard alignment.
Page 475 ATTACHMENTS / CONTROL LINKAGE STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES) IMPORTANT: For proper operation of this dual cable - dual outboard steering instal- lation, there MUST BE proper tension in the steering system. NOT ENOUGH ten- sion will cause slack (play) in steering system. TOO MUCH tension will cause steer- ing cables to bind.
Page 476: Opposite Side Routed Steering Cables And Attaching Kit Installation
ATTACHMENTS / CONTROL LINKAGE WARNING After installation is complete [and before operating outboard(s)], check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left. Check steering thru full range (left and right) at all tilt angles to assure interference-free movement.
Page 477 ATTACHMENTS / CONTROL LINKAGE Temporarily adjust tube, so that longer threaded end of tube extends out the same dis- tance as the outboard tilt tube. Do not tighten adjustment nuts at this time. 51891 Steering Cable Mounting Tube (End of Tube with Longer Threads Toward Center of Boat Transom) Mounting Bracket Locking Tab Washers (2)
Page 478 ATTACHMENTS / CONTROL LINKAGE Thread cap (e) onto steering cable mounting tube, up to mark (a). 51888 STEERING CABLE INSTALLATION - PORT OUTBOARD IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo- cated inside tilt tube with 2-4-C w/Teflon, before installing steering cable. Lubricate inside of port outboard’s tilt tube and rubber O-ring seal (a) with 2-4-C w/Teflon.
Page 479 ATTACHMENTS / CONTROL LINKAGE Lubricate ball joints in steering link rods with SAE 30W Motor Oil. Secure link rods to out- board steering arms, using special washer head bolts (10-14000) provided and nylon in- sert locknuts as shown. Torque special bolts to 20 lb. ft. (27 Nm) then torque locknuts to 20 Ib.
Page 480 ATTACHMENTS / CONTROL LINKAGE STEERING ARM EXTENSION BRACKET INSTALLATION Secure a steering arm extension bracket to each out- board’s steering arm. 51889 Steering Arm (Port Outboard Shown) Extension Bracket Locking Retainer (2 Each Bracket) Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to 23 lb. ft. (31 Nm), Then Bend Corner Tabs of Locking Retainers Up Against Flats on Each Bolt WARNING Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that...
Page 481 ATTACHMENTS / CONTROL LINKAGE Lubricate ball joint in steering eyes with SAE 30W Motor Oil. Assemble steering coupler between outboard steering arm extension brackets, using special washer head bolts (10-14000) provided and nylon insert locknuts, as shown. IMPORTANT: With assembled steering coupler installed and before tightening spe- cial washer head bolts/locknuts, check outboard alignment.
Page 482 ATTACHMENTS / CONTROL LINKAGE STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES) IMPORTANT: For proper operation of this dual cable - dual outboard steering instal- lation, there MUST BE proper tension in the steering system. NOT ENOUGH ten- sion will cause slack (play) in steering system. TOO MUCH tension will cause steer- ing cables to bind.
Page 483: Trim Tab Adjustment
ATTACHMENTS / CONTROL LINKAGE Trim Tab Adjustment DUAL OUTBOARD - COUNTER ROTATION INSTALLATION 1. Shift outboard into neutral and make sure ignition key is at “OFF” position. 2. Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab. 3.
Page 484: Maintenance Instructions
ATTACHMENTS / CONTROL LINKAGE WARNING When 2 couplers are connected together with coupler link rod, a lock washer must be used on each side of coupler link rod, and link rod must be torqued to 20 Ib. ft. (27 N·m) into end of each coupler. 51890 Couplers Connected Together Lock washers...
Page 485 ATTACHMENTS / CONTROL LINKAGE 5. Inspection and lubrication of steering head assembly (rotary or straight rack) should be performed once each year (by your Authorized Dealer) or whenever steering mount and/or steering head are disassembled, or if steering effort has increased. Lu- bricate with 2-4-C w/Teflon.
Page 486: Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
ATTACHMENTS / CONTROL LINKAGE Transom Mounted Ride Guide Attaching Kit Installation (73770A1) Attaching Kit Installation 1. Lubricate both holes in pivot block (Figure 1) with Quicksilver 2-4-C w/Teflon. 2. Place pivot block on pivot spacer and secure to transom bracket with 3/8 in. x 2-1/2 in.
Page 487 ATTACHMENTS / CONTROL LINKAGE 3. Place Ride-Guide yoke on pivot block and secure with 7/16 in. x 1-3/4 in. (11.1 mm x 44.5 mm) bolt and locknut, as shown in Figures 1 and 2. Torque locknut to 10 Ib. ft. (13.5 Nm), then back off 1/4-turn.
Page 488 ATTACHMENTS / CONTROL LINKAGE b. Position attaching kit on transom so that transom bracket is centered on the 15 in. (38.1 mm) (Figure 1) at a height where the center of Ride-Guide yoke is even with, or not more than 1/2 in. (12.7 mm) above top edge of transom. (Figure 3) Figure 3 Ride-Guide Yoke 0 in.
Page 489: Maintenance Instructions
ATTACHMENTS / CONTROL LINKAGE WARNING After installation is completed (and before operating outboard), check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left. Check steering thru full range (left and right) at all tilt angles to assure interference-free movement.
Page 490: Clevis Attaching Kit Installation (A-70599A2)
ATTACHMENTS / CONTROL LINKAGE Clevis Attaching Kit Installation (A-70599A5) NOTE: This kit is used to attach Ride-Guide cable to outboard steering arm ONLY when “Transom Mounted Ride-Guide Attaching Kit” is being used. If Ride-Guide cable is installed thru outboard tilt tube, then “Steering Link Rod” must be used. Installation Instructions 1.
Page 491 COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 2.5 Litre OptiMax 2000 Model Year Analog Typical SmartCraft Control Area Network (CAN) Wiring Diagram ......Page 8-3 Installation 2001 Model Year .
Page 492 COLOR DIAGRAMS Page 8-2 90-857138R1 MAY 2000...
Page 493: Litre Optimax 2000 Model Year Analog
COLOR DIAGRAMS 2.5 LITRE OPTIMAX 2000 MODEL YEAR ANALOG WIRING DIAGRAM 90-859494R1 JUNE 2000 Page 8-3...
Page 494 1. ECM 38. Accessory Power 2. Ignition Coils 39. Check Engine Light 3. Fuel Injectors 40. DDT Test Port 4. Direct Injectors 41. SmartCraft Harness (8 pin) 5. Oil Pump 6. MAP Sensor 7. Block Pressure Sensor 8. Water Sensor 9.
Page 495 2.5 Litre OptiMax 2000 Model Year Analog 13 16 1 9 17 8 10 24 1 9 17 8 10 24...
Page 496 COLOR DIAGRAMS 2.5 LITRE OPTIMAX 2000 MODEL YEAR DIGITAL WIRING DIAGRAM 90-859494R1 JUNE 2000 Page 8-5...
Page 497 1. ECM 38. Optional Analog Tacometer Signal Wire 2. Ignition Coils 39. Check Engine Light 3. Fuel Injectors 40. To Boat Harness, Brown/White Connection to SmartCraft Data Link (ECM) 4. Direct Injectors 41. DDT Test Port 5. Oil Pump 42. SmartCraft Data Link Connection 6.
Page 498 2.5 Litre OptiMax 2000 Model Year Digital 13 16 1 9 17 8 10 24 1 9 17 8 10 24...
Page 499: Wiring Diagram
COLOR DIAGRAMS 2.5 LITRE OPTIMAX 2001 MODEL YEAR WIRING DIAGRAM 90-859494R1 JUNE 2000 Page 8-7...
Page 500 1. ECM 37. Data Buss (10 Pin) Control Area Network (CAN) 2. Ignition Coils 38. DDT Test Port 3. Coil Drivers 39. SmartCraft Data Link Connection 4. Fuel Injectors 40. To Boat Harness, Brown/White Connection to SmartCraft Data Link (ECM) 5.
Page 501 2.5 Litre OptiMax 2001 Model Year...
Page 502: Typical Smartcraft (Non Can) Installation 2000 Model Year
COLOR DIAGRAMS TYPICAL SMARTCRAFT (NON CAN) INSTALLATION 2000 MODEL YEAR 90-859494R1 JUNE 2000 Page 8-9...
Page 503 1. 8-Pin Digital Sensor Harness Extension Connection to Engine Wiring Harness 2. Digital Speedometer Sensor 3. Digital Trim Sender 4. 6-Pin Digital Sensor Harness 5. Connection for Analog Temperature Sender 6. Connections to Trim Relays 7. Connection to SmartCraft Data Link (ECM) Two Wire Harness 8.
Page 504 Typical SmartCraft (Non CAN) Installation 2000 Model Year...
Page 505: Installation 2001 Model Year
COLOR DIAGRAMS TYPICAL SMARTCRAFT (CAN) INSTALLATION 2001 MODEL YEAR 90-859494R1 JUNE 2000 Page 8-11...
Page 506 1. 8-Pin Digital Sensor Harness Extension, Connect to 8-Pin SmartCraft Harness on Engine 2. Digital Speedometer Sensor 3. Digital Trim Sender 4. 6-Pin Digital Sensor Harness 5. Connection for Analog Temperature Sender 6. Connections to Trim Relays 7. Connection for Analog Trim Sender 8.
Page 507 Typical SmartCraft (CAN) Installation 2001 Model Year...
Page 508: Fuel & Air Flow Diagram
COLOR DIAGRAMS 2.5 LITRE OPTIMAX 2000 & 2001 MODEL YEAR FUEL & AIR FLOW DIAGRAM 90-859494R1 JUNE 2000 Page 8-13...
Page 509 1. Fuel inlet from primer bulb 2. Engine Pulse Fuel Pump 3. Fuel line to Water Separating Fuel Filter – 2-8 psi (14-55 kPa) 4. Water Separating Fuel Filter in Vapor Separator Tank (VST) Assembly 5. Fuel outlet from VST 6.
Page 510 2.5 Litre OptiMax Fuel and Air Flow 2000 & 2001 Models 58621...
Page 511: Water Flow Diagram
COLOR DIAGRAMS 2.5 LITRE OPTIMAX 2000 & 2001 MODEL YEAR WATER FLOW DIAGRAM 90-859494R1 JUNE 2000 Page 8-15...
Page 512 1. Water Inlet 2. Water Pump 3. Wall of Water – If water level height is insufficient, water pump may draw in air resulting in an overheated engine 4. Water Tube 5. Cylinder Head Cover – Removed from head for illustration, normally part of head casting 6.
Page 513 2.5 Litre OptiMax 2000 & 2001 Model Year Water Flow 58627...
Page 514 SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Master Specifications ......1A-1 Propeller Information Charts .
Page 515 SPECIFICATIONS Model 115/135/150/175 DFI PISTON 3.4925 in. .0005 in. DIAMETER (88.7095 mm .0127 mm) Using a micrometer, measure dimension “A” at location shown. Dimension “A” Dimension should be 3.4925 in. .0005 for a STAN- “A” at Right DARD size piston (new) Dimension “A” Angle (90 ) will be 0.001 –...
Page 516 SPECIFICATIONS Model 115/135/150/175 DFI FUEL Fuel Pressure PUMP Crankcase Pump – @ Idle Normal – 2-3 psi (13.7 – 20.5 kPa) Minimum – 1 psi (6.8 kPa) – @ WOT Maximum – 10 psi (68.5 kPa) Normal – 8-10 psi (41.0 – 54.8 kPa) Minimum –...
Page 517 SPECIFICATIONS Model 115/135/150/175 DFI TIMING Full Throttle RPM Range (115/135) 5000 - 5500 (150/175 5250 - 5750 Idle RPM (In Forward Gear) Maximum Timing: @ Wide OPEN Not Adjustable Controlled by ECM Idle Timing Not Adjustable Controlled by ECM Throttle Position Sensor 3.20 - 4.90 VDC @ Idle 0.10 - 1.50 VDC...
Page 518 SPECIFICATIONS Model 115/135/150/175 DFI Steering Pivot Range SECTION Tilt Pin Adjustment Positions Allowable Transom Thickness 2-3/8 in. (6.03 cm) POWER TRIM Design I (Showa) Trim “UP” 1300 PSI (91kg/cm Maximum Pressure Trim “DOWN” 500 PSI (35kg/cm Minimum Pressure Design II (Oildyne) Trim ”UP”...
Page 519 SPECIFICATIONS Propeller Information Charts Optimax 115 Wide Open Throttle RPM: 5000-5500 Gear Reduction: 2.00:1 No. of Gross Boat Boat Speed Propeller Diameter Pitch Blades Model Wgt. (lbs) Length (mph) Part Number 13.75 Trophy+ Up to 1600 Up to 18 56-63 48-825944A47 13.75...
Page 520 SPECIFICATIONS Optimax 135 Wide Open Throttle RPM: 5000-5500 Gear Reduction: 2.00:1 No. of Gross Boat Boat Speed Propeller Diameter Pitch Blades Model Wgt. (lbs) Length (mph) Part Number 13.75 Trophy+ Up to 1900 Up to 18 56-63 48-825944A47 13.75 Laser II 1800 –...
Page 521 SPECIFICATIONS Optimax 150 Wide Open Throttle RPM: 5250-5750 Gear Reduction: 1.87:1 No. of Gross Boat Boat Speed Propeller Diameter Pitch Blades Model Wgt. (lbs) Length (mph) Part Number 14.62 Tempest+ Up to 1800 Up to 18 66-74 48-825868A47 13.75 Trophy+ Up to 1900 Up to 19 64-71...
Page 522 SPECIFICATIONS Optimax 175 Wide Open Throttle RPM: 5250-5750 Gear Reduction: 1.87:1 No. of Gross Boat Boat Speed Propeller Diameter Pitch Blades Model Wgt. (lbs) Length (mph) Part Number 14.62 Tempest+ Up to 2100 Up to 18 66-74 48-825868A47 13.75 Trophy+ Up to 2300 Up to 19 64-71...

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Optimax 135 Optimax 150 Optimax 175

Mercury Optimax 115 Service Manual

Important Information 1

Important Information 1

Important Information 1

Electrical 2

Electrical 2

Electrical 2

Electrical 2

Fuel System

Fuel System

Fuel System

Specifications 4

MID-Section

MID-Section

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Summary of Contents for Mercury Optimax 115