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Mercury/Mariner 25 MARATHON Service Manual

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SERVICE
MANUAL
MODELS
Mercury/Mariner
20 JET S 20 S 25
25 MARATHON S 25 SEAPRO
With Serial Numbers
United States
. . . . . . .
0G044027 and Above
Belgium
. . . . . . . . . . .
09807909 and Above
1998, Mercury Marine
90-826883R2 JUNE 1998
Printed in U.S.A.

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Summary of Contents for Mercury/Mariner 25 MARATHON

  • Page 1 SERVICE MANUAL MODELS Mercury/Mariner 20 JET S 20 S 25 25 MARATHON S 25 SEAPRO With Serial Numbers United States ..0G044027 and Above Belgium ...
  • Page 2 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In- ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con- cerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.
  • Page 3 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 Important Information Section 1 - Important Information A - Specifications B - Maintenance Electrical C - General Information D - Outboard Installation Section 2 - Electrical A - Ignition Fuel System B - Charging & Starting System C - Timing, Synchronizing &...
  • Page 5 SPECIFICATIONS IMPORTANT INFORMATION Section 1A - Specifications Table of Contents Master Specifications ......1A-2 90-826883R2 JUNE 1998 Page 1A-1...
  • Page 6 SPECIFICATIONS Master Specifications Model 15XD/20 Jet /20/25 HORSEPOWER Model 20 Jet 20 (14.9) (KW) Model 20 20 (14.9 Model 25 25 (18.7) OUTBOARD 15 in. (38 cm) 114 lbs - 52 kg WEIGHT 20 in. (51 cm) 117 lbs - 53 kg 20 Jet 124 lbs - 56 kg CYLINDER...
  • Page 7 SPECIFICATIONS Master Specifications GEAR Forward - Neutral - Reverse Full Shift HOUSING Gear Ratio 2.25:1 Gearcase Capacity 8.8 fl.oz. (260 ml) Lubricant Type Quicksilver Gear Lube Premium Blend Forward Gear - No. of Teeth-Type Pinion Gear - No. of Teeth-Type Pinion Foreword Gear Backlash Not Adjustable...
  • Page 8 SPECIFICATIONS Type Capacitor Discharge Ignition Spark Plug Type (NGK) NGK BP8H-N-10 Spark Plug Gap 0.040 in. (1.0 mm) Spark Plug Hex 18 mm Firing Order 20 Jet 1994 THRU 1998 20/25 1994 THRU 1996 Electronic Spark Advance Idle @ 750 50 RPM (In Forward Gear) 2 B.T.D.C (Not Adjustable)
  • Page 9 CATIONS 4500 - 5500 5000 - 6000 Idle Mixture Screw Adjustment (Preset-Turns Out) 1/4 Turn 20 Jet 1-1/2 1/2 Turn 25/25 Seapro/25 Marathon 1-1/4 1/4 Turn Float Level 1.0 in. (25.4 mm) Main Jet Size 1994 thru 1996 -20 (WMC-44) 0.044 in.

  • Page 10: Table Of Contents

    MAINTENANCE IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Table of Contents ......1B-1 Battery Inspection .
  • Page 11 MAINTENANCE Quicksilver Lubricant/Sealant 1. Quicksilver Anti-Corrosion Grease P/N 92-78376A6 2. 2-4-C Marine Lubricant with Teflon P/N 92-825407A12 3. SAE 30W Motor Oil P/N 92-97959 4. Quicksilver Gear Lubricant P/N 92-19007A24 Page 1B-2 90-826883R2 JUNE 1998...

  • Page 12: Before Each Use

    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 13: Flushing The Cooling System

    MAINTENANCE Flushing The Cooling System 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. Use a Quicksilver accessory (or equivalent) flushing attachment. WARNING To avoid possible injury when flushing, remove the propeller.

  • Page 14: Fuel System

    MAINTENANCE 4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is receiving an adequate supply of cooling water. 5. Check for a steady stream of water flowing out of the water pump indicator hole. Con- tinue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at all times.

  • Page 15: Corrosion Control Anode

    MAINTENANCE INSTALLATION 1. Push the filter element (with open end toward cover) into cover. 2. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the cover. 3. Visually inspect for fuel leakage around the sight bowl by squeezing the primer bulb until firm, forcing fuel into the sight bowl.

  • Page 16: Spark Plug Inspection

    MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. 1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. 2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered or fouled.

  • Page 17: Fuse Replacement -- Electric Start Remote Control Models

    MAINTENANCE Fuse Replacement - - Electric Start Remote Control Models The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload.
  • Page 18 MAINTENANCE 4. Tilt Tube -- Lubricate fittings. 5. Lubricate the throttle and shaft cables, moving components and pivot locations. WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked.

  • Page 19: Gear Case Lubrication

    MAINTENANCE Lubricate Point 8 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubri- cant with Teflon. 8. 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 to the shaft.

  • Page 20: Draining Gear Case

    MAINTENANCE Draining Gear Case 1. Place outboard in a vertical operating position. 2. Place drain pan below outboard. 3. Remove fill/drain plug (a) and vent plug (b) and drain lubricant. Checking Lubricant Level and Refilling Gear Case 1. Place outboard in a vertical operating position. 2.

  • Page 21: Storage Preparations

    MAINTENANCE 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Storage Preparations Fuel System IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a for- mation of acid during storage and can damage the fuel system. If the gasoline be- ing used contains alcohol, It is advisable to drain as much of the remaining gaso- line as possible from the fuel tank, remote fuel line, and engine fuel system.

  • Page 22: Gear Case

    MAINTENANCE 4. Rotate the flywheel manually several times to distribute the storage seal in the cylin- ders. Reinstall spark plugs. Gear Case Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage Store outboard in an upright position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case...
  • Page 23 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - General Information Table of Contents Table of Contents ......1C-1 Fresh Water Submersion (Special Instructions) 1C-5 Serial Number Location...
  • Page 24 GENERAL INFORMATION Conditions Affecting Performance Weather It is a known fact that weather conditions exert a profound effect on power output of inter- nal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated RPM under a specific combination of weather con- ditions.
  • Page 25 GENERAL INFORMATION Due to the horsepower/RPM characteristics of an engine, this will result in further loss of horsepower at the propeller with another decrease in boat speed. This secondary loss, however, can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended RPM.
  • Page 26 GENERAL INFORMATION CAVITATION Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow back and collapse when striking the surface of the propeller blade resulting in the ero- sion of the propeller blade surface.

  • Page 27: Propeller Selection

    GENERAL INFORMATION Following Complete Submersion Submerged While Running (Special Instructions) When an engine is submerged while running, the possibility of internal engine damage is greatly increased. If, after engine is recovered and with spark plugs removed, engine fails to turn over freely when turning flywheel, the possibility of internal damage (bent con- necting rod and/or bent crankshaft) exists.
  • Page 28 GENERAL INFORMATION For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed.
  • Page 29 GENERAL INFORMATION Propeller Removal/Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating pro- peller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller 1.
  • Page 30 GENERAL INFORMATION 5. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lu- bricant with Teflon. IMPORTANT: To prevent the propeller hub from corroding and seizing to the pro- peller shaft, especially in salt water, always apply a coat of the recommended lubri- cant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed.
  • Page 31 GENERAL INFORMATION 8. Place a block of wood between gear case and propeller and tighten propeller nut. Compression Check 1. Remove spark plugs. 2. Install compression gauge in spark plug hole. 3. Hold throttle plate at W.O.T. 4. Crank the engine over until the compression reading peaks on the gauge. Record the reading.
  • Page 32 GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne par- ticles. Use eye and breathing protection with proper ventilation. PROPELLERS 1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch- Brite, disc or belts.
  • Page 33 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 34 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 35 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents Table of Contents ......1D-1 Remote Control Installation .

  • Page 36: Outboard Remote Control

    OUTBOARD MOTOR INSTALLATION WARNING Using an outboard that exceeds the maximum horsepower limit of a boat can: 1. cause loss of boat control 2. place too much weight at the transom altering the designed flotation characteristics of the boat or 3. cause the boat to break apart particularly around the transom area.

  • Page 37: Installing Outboard

    OUTBOARD MOTOR INSTALLATION Installing Outboard 1. Measure the transom height of your boat. The boat bottom should be aligned or be within 1 in. (25mm) above the anti-ventilation plate (a) of the outboard. 0 -1in. (0 - 25mm) a - Anti-Ventilation Plate 2.

  • Page 38: Steering Cable And Steering Link Rod Installation 1D-4

    OUTBOARD MOTOR INSTALLATION Steering Cable and Steering Link Rod Installation Installing Ride Guide Steering Cable to the Outboard IMPORTANT: Before installing steering cable into tilt tube, lubricate entire cable end with Quicksilver 2-4-C w/Teflon Marine Lubricant (92-825407A12). 1. Lubricate the entire cable end. a - Quicksilver 2-4-C Marine Lubricant with Teflon 2.

  • Page 39: Steering Link Rod Installation

    OUTBOARD MOTOR INSTALLATION 4. Thread cap up to the 1/4 in. (6.4mm) mark. a - Cap 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”...

  • Page 40: Remote Control Installation

    OUTBOARD MOTOR INSTALLATION WARNING After installation is complete (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) and at all tilt angles to assure interference-free movement.

  • Page 41: Throttle Cable Installation

    OUTBOARD MOTOR INSTALLATION a. With remote control shifted into forward the propeller shaft should lock solidly in gear. If it does not, adjust the cable barrel closer to the engine shift lever. b. Shift remote control into neutral. The propeller shaft should turn freely without drag.

  • Page 42: Remote Wiring Harness Connection To Engine

    OUTBOARD MOTOR INSTALLATION 6. Place the rubber seal ( side with holes towards front)) onto the control cables and install control cables, barrel holder and rubber seal into the cable holder as shown. 7. Lock the barrel holder in place with the cable retainer latch. a - Rubber Seal b - Cable Retainer Latch Remote Wiring Harness Connection to Engine...
  • Page 43 OUTBOARD MOTOR INSTALLATION 2. Position the remote wiring harness and battery cables thru the bottom cowl rubber grommet as shown. 3. Plug the remote wiring harness into the engine wiring harness connector. 4. Secure the connection together using retainer. a - Rubber Grommet b - Remote Wiring Harness c - Engine Harness Connector d - Retainer...

  • Page 44: Battery Cable Connections

    OUTBOARD MOTOR INSTALLATION Battery Cable Connections SINGLE OUTBOARD (- -) a - RED Sleeve (POSITIVE) b - BLACK Sleeve (NEGATIVE) c - Starting Battery DUAL OUTBOARD 1. Connect a common ground cable (wire size same as engine battery cables) between negative (--) terminals on starting batteries.

  • Page 45: Tilt Pin Adjustment

    OUTBOARD MOTOR INSTALLATION Flo-Torq I Drive Hub Propellers a - Forward Thrust Hub b - Propeller c - Rear Thrust Hub d - Propeller Nut -- Tighten Flo-Torq II Drive Hub Propellers a - Forward Thrust Hub b - Replaceable Drive Sleeve c - Propeller d - Rear Thrust Hub e - Propeller Nut -- Tighten...

  • Page 46: Placing Tilt Pin In Upper Holes

    OUTBOARD MOTOR INSTALLATION Placing Tilt Pin in Upper Holes 1. Lift the bow out of the water. 2. Generally increase top speed. 3. Increase clearance over submerged objects or a shallow bottom. 4. Increase steering torque or pull to the left at a normal installation height (with the nor- mal right hand rotation propeller).
  • Page 47 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents Specifications ....... 2A-2 Ignition Switch Box .

  • Page 48: Specifications

    IGNITION Specifications Type Capacitor Discharge Ignition Spark Plug Type (NGK) NGK BP8H-N-10 Spark Plug Gap 0.040 in. (1.0 mm) Spark Plug Hex 18 mm Firing Order 20 Jet 1994 THRU 1998 20/25 1994 THRU 1996 Electronic Spark Advance Idle @ 750 ± 50 RPM (In Forward Gear) 4°±2°B.T.D.C (Not Adjustable) Fast Idle Speed...

  • Page 49: Special Tools

    IGNITION Special Tools 1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 2. Flywheel Holder P/N 90-24937A1. 3. Flywheel Puller P/N 91-83164M. 4. Flywheel Holder 91-52344 54964 5. Spark Gap Board 91-850439 55117 90-826883 R2 JUNE 1998 Page 2A-3...

  • Page 50: Ignition/Electrical Components

    IGNITION Ignition/Electrical Components Dielectric Grease (92-823506--1) Loctite 271 (92-809820) Liquid Neoprene (92-25711--2) A=ALTERNATOR VERSION ONLY Page 2A-4 90-826883R2 JUNE 1998...
  • Page 51 IGNITION Ignition/Electrical Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m COVER--ignition coil SCREW--ignition coil cover (M5x.8x55) STATOR ASSEMBLY (20/25--USA-S/N-0G437999 & BELOW) (BEL-S/N-9926999 & BELOW) STATOR ASSEMBLY (20/25--USA-S/N-0G438000 & UP) (BEL-S/N-9927000 & UP) STATOR ASSEMBLY (JET 20) SCREW--stator attaching (M5x.8x25) SCREW--stator attaching (M5x12) CLIP...

  • Page 52: Ignition Description

    IGNITION Ignition Description The ignition system is an alternator driven capacitor discharge system. Major compo- nents of the ignition system are the flywheel, stator, trigger coil, switch box, 2 ignition coils and 2 spark plugs. The flywheel has permanent magnets mounted in both the outer rim and the center hub. The BLACK stator assembly is mounted below the flywheel and has a low speed (LS) and a high speed (HS) capacitor charging coil.

  • Page 53: Electronic Spark Advance

    IGNITION Electronic Spark Advance 20/25 OUTBOARDS SERIAL NUMBER: USA 0G044027 THRU 0G437999 BELGIUM 09807909 THRU 09926999 20 JET OUTBOARDS USA 0G044027 THRU 0G760299 BELGIUM 09807909 THRU 09016999 The spark timing is controlled by an electronic circuit within the engine switch box. The trigger assembly is positioned for maximum advance.

  • Page 54: Stator

    IGNITION MECHANICAL SPARK ADVANCE Spark timing is changed (advanced/retarded) by rotating the trigger coil, which changes the trigger coil position in relation to the magnets in the center hub of the flywheel. Stator The ignition stator located under the flywheel contains two stator windings. One low speed winding and one high speed winding.

  • Page 55: Ignition Coil

    IGNITION Ignition Coil The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the ignition switch box. The voltage is multiplied by the coil until it can jump the spark plug gap. Ignition coil maximum output approximately 35000 volts. 52642 Positive (+) Primary Terminal Negative Terminal...
  • Page 56 IGNITION MECHANICAL SPARK ADVANCE (BLACK STATOR) The ignition switch box receives an AC current from the low and high speed stator assem- bly. This current is rectified and changed to a DC current where it will be stored in the inter- nal capacitor.

  • Page 57: Electronic Spark Advance

    IGNITION Electronic Spark Advance Set-Up Timing 5500 RPM 28°B.T.D.C. 25°B.T.D.C. @3000 ±200 5800 R.P.M. 6200 RPM 15°B.T.D.C. 750 ±50 R.P.M. Approx. 3-5°B.T.D.C. 6000 7000 5000 1000 2000 3000 4000 Engine Speed - RPM 90-826883 R2 JUNE 1998 Page 2A-11...

  • Page 58: Ignition Test Procedures

    IGNITION Ignition Test Procedures Direct Voltage Adapter (DVA) WARNING DANGER - - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine.

  • Page 59: Ignition Troubleshooting

    IGNITION Ignition Troubleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine. WARNING When testing or servicing the ignition system, high voltage is present.
  • Page 60 IGNITION 6. Engine Hard to Start when Cold Defective Trigger Assembly Defective Ignition Switch Box 7. Engine Misfires @ Low RPM but Runs Smooth Defective Harness or (loose connections) @ High RPM Defective Switch Box Defective Stator 8. Engine Starts Hard when Hot Defective Switch Box or Trigger 9.

  • Page 61: Electronic Spark Advance

    IGNITION Ignition Troubleshooting Electronic Spark Advance WARNING DANGER - - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark plug lead should be grounded to engine.

  • Page 62: Mechanical Spark Advance

    IGNITION (+) Terminal R x 1 W Test 7 Test 7 Ignition Coils Ignition Coils BLACK (--) Terminal (“ +” ) wire discon- (“ +” ) wire discon- Spark Plug Tower nected) R x 100 W 8.5 - 12 BLACK (+) Terminal NOTE: Copper is an excellent conductor, however resistance may notably vary between low and high temperature.

  • Page 63: Ignition Troubleshooting (Red Stator)

    IGNITION Ignition Troubleshooting (RED Stator) TOOL : MULTIMETER/DVA TESTER 91-99750 Multimeter Resistance Scale Tested Part Connected To Wires (ohms) Stator (GREEN/ GREEN/WHITE WHITE and WHITE/GREEN R x 1 370 - 445 wires disconnected WHITE/GREEN BLACK from switch boxes) Trigger (BROWN/ BROWN/YELLOW YELLOW and BROWN/WHITE...
  • Page 64 BATTERY CHARGING AND STARTING SYSTEMS ELECTRICAL Section 2B - Battery Charging and Starting Systems Table of Contents Specifications ....... 2B-1 Commander 2000 Key Switch Test .

  • Page 65: Electric Start Components

    BATTERY CHARGING AND STARTING SYSTEMS Electric Start Components 2 Cycle Outboard Oil (92-13249A24) Liquid Neoprene (92-25711--2) A=LOCAL ELECTRIC ONLY B=SERVICE ONLY Page 2B-2 90-826883R2 JUNE 1998...
  • Page 66 BATTERY CHARGING AND STARTING SYSTEMS Electric Start Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m RECTIFIER SCREW (#10-16x5/8 IN.) Drive Tight NUT (#10-32 Brass) NUT (#10-32 Brass) CABLE ASSEMBLY (Red) STARTER SOLENOID ASSEMBLY BUSHING GROMMET WIRE ASSEMBLY--yellow SCREW (M6x1x25 hex head cap) NUT (#8-32 Brass) NUT (1/4-20)

  • Page 67: Battery

    BATTERY CHARGING AND STARTING SYSTEMS Battery Precautions When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes thru holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor. This explosive gas may remain in or around battery for several hours after it has been charged.

  • Page 68: Electrolyte Level

    BATTERY CHARGING AND STARTING SYSTEMS Hydrometer measures percentage of sulfuric acid in battery electrolyte in terms of specific gravity. As a battery drops from a charged to a discharged condition, acid leaves the solu- tion and chemically combines with the plates, causing a decrease in specific gravity of electrolyte.

  • Page 69: Charging A Discharged Battery

    BATTERY CHARGING AND STARTING SYSTEMS Charging A Discharged Battery The following basic rules apply to any battery charging situation: 1. Any battery may be charged at any rate (in amperes) as long as spilling of electrolyte (from violent gassing) does not occur and as long as electrolyte temperature does not exceed 125°F (52°C).

  • Page 70: Voltage Regulator Test

    BATTERY CHARGING AND STARTING SYSTEMS Voltage Regulator Test Lamps Burn Out When Engine RPM is Increased The voltage regulator is defective. Replace regulator. Lamps Burn Dim at Wide-Open-Throttle 1. Run engine at mid-range (approximately 3000 RPM) with 3 number 94 lamps con- nected to voltage regulator output leads.

  • Page 71: Alternator Amperes Output

    BATTERY CHARGING AND STARTING SYSTEMS Alternator Amperes Output Amperage output can be measured by installing a 10 ampere (minimum) amp meter in series between the rectifier and the battery or by clamping an inductive type amp meter (10 amp minimum) over the RED output lead from the rectifier to the battery. BLACK Stator (2 Magnet Flywheel) AMPERES (Approximate) Idle...

  • Page 72: Battery Charging System Troubleshooting

    BATTERY CHARGING AND STARTING SYSTEMS Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become under- charged. Check battery electrolyte level, and charge battery. See “ Electrolyte Level” , and “ Charging a Discharged Battery” . If battery will NOT accept a satisfactory charge, replace battery.

  • Page 73: Rectifier Test

    BATTERY CHARGING AND STARTING SYSTEMS Rectifier Test WARNING Disconnect battery leads from battery before testing rectifier. *NOTE: Rectifier can be tested without removing from engine. 07300 Rectifier Test (continued) Connect RED meter lead to ground, BLACK lead alternately to terminals “ a”and “ c” . Continuity Indicated No Continuity Indicated Connect BLACK meter lead to ground, RED...

  • Page 74: Starting System

    BATTERY CHARGING AND STARTING SYSTEMS Starting System STARTER MOTOR AMPERES DRAW STARTER MOTOR NO LOAD NORMAL PART NO. AMP. DRAW AMP. DRAW 50-90983A1 15 AMPS 55 AMPS Starter Motor Teeth STARTING SYSTEM COMPONENTS The starting system consists of the following components. 1.
  • Page 75 BATTERY CHARGING AND STARTING SYSTEMS To Rectifier 53056 Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (w/YELLOW sleeve) cable from starter solenoid test point 1 BEFORE making tests to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads between NEGATIVE (-) battery post and common pow- erhead ground.
  • Page 76 BATTERY CHARGING AND STARTING SYSTEMS * Battery Voltage TEST 2 a. Connect voltmeter between common engine ground and Test Point 2. b. Push start switch. No voltage reading; proceed to TEST 3. 12 Volt Reading* TEST 3 a. Connect voltmeter between common engine ground and Test Point 3. Check BLACK ground wire for poor connec- b.

  • Page 77: Commander 2000 Key Switch Test

    BATTERY CHARGING AND STARTING SYSTEMS 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: CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: POSITION BLK/YEL YEL/RED...

  • Page 78: Emergency Stop Switch

    BATTERY CHARGING AND STARTING SYSTEMS Emergency Stop Switch (Lanyard Type) IMPORTANT: Refer to Section 2D “Wiring Diagrams” for wiring connections. 1. Disconnect emergency stop switch leads from engine wiring. 2. Use an ohmmeter and perform the following tests. “RUN” “OFF” NO CONTINUITY CONTINUITY (¥...

  • Page 79: Starter Motor

    BATTERY CHARGING AND STARTING SYSTEMS Starter Motor Disassembly 1. Remove 2 thru bolts from starter. Bolts 2. Lightly tap on end of shaft and lower end cap with rubber mallet. Do not loose brush springs. 53235 Lower End Cap Washers Bolts 3.

  • Page 80: Cleaning And Inspection

    BATTERY CHARGING AND STARTING SYSTEMS 5. Remove parts from shaft. 53228 Locknut Spacer Spring Drive Assembly Drive End Cap Armature Shaft Helix Threads Washer Cleaning and Inspection 1. If brushes are pitted, chipped or worn to less than 3/16 in. (4.8mm), replace brushes. IMPORTANT: DO NOT clean the starter drive assembly or armature shaft while starter motor is installed on outboard.

  • Page 81: Testing Motor Armature

    BATTERY CHARGING AND STARTING SYSTEMS Testing Motor Armature TESTING ARMATURE FOR SHORTS 1. Place armature in a growler and switch growler on. 2. Hold hack saw blade over armature core while rotating armature. 3. If saw blade vibrates, armature is shorted. Retest after cleaning between commutator bars.

  • Page 82: Starter Motor Reassembly

    BATTERY CHARGING AND STARTING SYSTEMS Starter Motor Reassembly 1. Reinstall brush assembly. 53075 Brush End Cap Fiber Washer Metal Washer 2. Apply a drop of SAE 10W oil to to helix threads on armature shaft. DO NOT over lubri- cate. 53080 Helix Threads 3.
  • Page 83 BATTERY CHARGING AND STARTING SYSTEMS 5. Position armature into starter frame so that commutator end of armature is at end of starter frame where permanent magnets are recessed 1-5/16 in. (33.3mm). Align marks as shown. 1-5/16 in. 53082 Alignment Marks Bottom Edge of Permanent Magnets 6.

  • Page 84: Starter Solenoid Test

    BATTERY CHARGING AND STARTING SYSTEMS 8. Install lower end cap onto starter frame. 53083 Alignment Mark; Must Align with Slot Slot Lower End Cap Starter Solenoid Test Test starter solenoid as follows: 1. Disconnect all leads from solenoid terminals. 2. Use an ohmmeter, set to (R x 1 scale) and connect between solenoid terminals 3 and 3.

  • Page 85: Flywheel Ring Gear

    BATTERY CHARGING AND STARTING SYSTEMS Flywheel Ring Gear Installation IMPORTANT: Before installing ring gear on flywheel, inspect gear and flywheel for paint runs which will prevent ring gear from laying flat against flywheel. 1. Inspect (and remove) any paint runs on ring gear and/or mounting surface on fly- wheel.

  • Page 86: Neutral Start Switch (Electric Start Tiller Handle Shift Models)

    BATTERY CHARGING AND STARTING SYSTEMS Neutral Start Switch (Electric Start Tiller Handle Shift Models) 1. Mount neutral start switch onto control platform with 2 bolts and plate. 2. Torque mounting bolts to 5 lb. in. (0.6 N· m). 53077 Neutral Start Switch Plate Bolts [Torque to 5 lb in.

  • Page 87: Tiller Handle Start Button

    BATTERY CHARGING AND STARTING SYSTEMS Tiller Handle Start Button 1. The tiller handle start button assembly is secured to the tiller handle by 2 semi-loops which snap fit onto the tiller throttle shaft. To remove the button assembly, pry the as- sembly away from the tiller handle with a flat tip screw driver.

  • Page 88: Choke Solenoid

    BATTERY CHARGING AND STARTING SYSTEMS Choke Solenoid Installation IMPORTANT: New gasket MUST be positioned as shown when being installed. 1. Install new gasket with solenoid plate assembly. 2. Secure assembly with 2 screws. Torque screws to 18 lb. in. (2.0 N· m). 53209 Gasket Solenoid Plate...

  • Page 89: Battery Cables/Engine Wiring Harness (Remote Electric Start Models)

    BATTERY CHARGING AND STARTING SYSTEMS Battery Cables/Engine Wiring Harness (Remote Electric Start Models) 1. Slide battery cables through sleeve. 53066 Battery Cables Sleeve 2. Thread battery cable/sleeve through wire retainer of engine wiring harness. Verify 1 in. (25.4mm) of sleeve remains to the outside of wire retainer. 1 in.
  • Page 90 BATTERY CHARGING AND STARTING SYSTEMS 3. Remove carburetor as outlined in Section 3. 4. Thread engine wiring harness first and then battery cable/sleeve through opening in bottom cowl. 53210 Harness Battery Cable/Sleeve Opening 5. Route engine wiring harness and battery cable/sleeve (under carburetor location) around to PORT side of cylinder block.
  • Page 91 BATTERY CHARGING AND STARTING SYSTEMS 6. Push wire retainer into opening of bottom cowl and secure with clip. 53068 Clip 7. Secure harness and battery cable/sleeve with sta-strap just inside bottom cowl. 8. Reinstall carburetor as outlined in Sec 3A. 53226 Sta-strap 9.

  • Page 92: Battery Cables (Tiller Handle Push Button Electric Start Models)

    BATTERY CHARGING AND STARTING SYSTEMS 10. Plug remote control harness connector into engine wiring harness connector and se- cure with harness connector retainer. 53064 Remote Control Harness Engine Harness Retainer Battery Cables (Tiller Handle Push Button Electric Start Models) Installation 1.
  • Page 93 BATTERY CHARGING AND STARTING SYSTEMS 2. Slide battery cables through sleeve. 3. Slide harness clamp over battery cable sleeve and position cables into bottom cowl. 4. Position harness clamp onto clamp bracket in bottom cowl. Tighten clamp securely. 53067 Clamp Bracket 5.

  • Page 94: Plug Harness (Battery Charging Kit)

    BATTERY CHARGING AND STARTING SYSTEMS Plug Harness (Battery Charging Kit) Installation 1. Install plug harness through fuel fitting opening in bottom cowl. 2. Route harness along PORT side of engine to rectifier. 53063 Harness 3. Refer to Section 2D for wiring connections. Emergency Stop Switch (Lanyard Type) Installation 1.
  • Page 95 TIMING/SYNCHRONIZING/ADJUSTING ELECTRICAL Section 2C - Timing/Synchronizing/Adjusting Table of Contents Specifications ....... . 2C-1 20 Jet/20/25 Models (Non Marathon/SeaPro) 2C-10 Special Tools...

  • Page 96: Special Tools

    TIMING/SYNCHRONIZING/ADJUSTING Special Tools 1. DMT 2000 Service Tachometer 91-854009A1* 2. Timing Light 91-99379* *May be obtained locally. Page 2C-2 90-826883R2 JUNE 1998...

  • Page 97: Timing/Synchronizing

    TIMING/SYNCHRONIZING/ADJUSTING Timing/Synchronizing/Adjusting Tiller Handle & Side Shift Models NOTE: Timing/Synchronizing adjustments are the same for tiller and side shift models unless otherwise specified. 1. Check all electrical connections to ensure they are tight and secure (including battery connections on electric start models). 2.

  • Page 98: Side Shift Models: Adjusting Tiller Handle

    TIMING/SYNCHRONIZING/ADJUSTING 6. Turn idle speed screw “In” until the cam follower just makes contact with throttle cam then turn “In” one additional turn to slightly open throttle plate. 28194 a - Cam Follower b - Idle Speed Screw c - Throttle Cam d - Side Shift Model Shown NOTE: The throttle return spring on cam follower plate should just contact the fuel pump housing at wide open throttle position.

  • Page 99: Tiller Shift Models: Adjusting Link Rod

    TIMING/SYNCHRONIZING/ADJUSTING Tiller Shift Models: Adjusting Link Rod 52912 a - Contact Point (spring to just contact fuel pump housing) b - Throttle Return Spring c - Throttle Link Rod 8. Remove access plug from carburetor air intake cover. 9. Turn idle mixture screw in (clockwise) until LIGHTLY seated then back out to an initial setting (See Specifications Chart) 28195 a - Access Plug...

  • Page 100: Starting Procedure

    TIMING/SYNCHRONIZING/ADJUSTING Starting Procedure 15XD/25 SEAPRO/MARATHON MODELS ONLY NOTE: Outboards equipped with a thermostat will have a “Sporadic” tell tail water dis- charge. Pull choke to full “OUT” position and start the engine. Immediately after the engine starts, push the choke knob to “Full In” position. Check for water at the tell tale and at the idle relief holes.
  • Page 101 TIMING/SYNCHRONIZING/ADJUSTING ELECTRONIC SPARK ADVANCE MODELS 20/25 1994 THRU 1996 AND 20 JET 1994 THRU 1998 1. Using approved test procedure, place the outboard in “Forward” gear and check set-up timing. (If not within specifications, adjustment will be required). BTDC 28192 a - Timing Mark b - Side Shift Model Shown WARNING...

  • Page 102: Adjusting Idle Speed

    TIMING/SYNCHRONIZING/ADJUSTING MECHANICAL SPARK ADVANCE MODELS 20 JET/20/25 1997 AND NEWER 1. Using approved test procedure, place the outboard in “Forward” gear and check the maximum and idle timing. (If not within specifications, adjustment will be required) IDLE BTDC 54966 a - Timing Mark b - Maximum Timing Jam Nut c - Maximum Timing Screw d - Idle Timing Jam Nut...
  • Page 103 TIMING/SYNCHRONIZING/ADJUSTING 3. Adjust idle speed screw in “Forward” gear to specification. 28194 Side Shift Model Shown a - Idle Speed Screw b - Side Shift Model Shown NOTE: When setting idle mixture, DO NOT adjust leaner than necessary to attain reason- ably smooth idling.

  • Page 104: Timing/Synchronizing/Adjusting - Remote Control Models

    TIMING/SYNCHRONIZING/ADJUSTING 20 Jet/20/25 Models (Non Marathon/SeaPro) 1. With the engine in “Neutral”, and the primer enrichener pushed to the “Full In” and “Full Clockwise” position, adjust the fast idle speed screw per specification. 52789 a - Fast Idle Speed Screw b - Primer Enrichener 2.
  • Page 105 TIMING/SYNCHRONIZING/ADJUSTING 3. Manually pull throttle lever to “Full Aft” position until the stop tab on the throttle arm contacts the stop tab on the shift platform. 52798 a - Stop Tab b - Shift Platform Stop Tab c - Throttle Lever 4.
  • Page 106 TIMING/SYNCHRONIZING/ADJUSTING 5. Turn idle speed screw “In” until the cam follower just makes contact with throttle cam then turn “In” one additional turn to slightly open throttle plate. a - Idle Speed Screw b - Cam Follower c - Throttle Cam NOTE: The throttle return spring on cam follower plate should just contact the fuel pump housing at wide open throttle position.

  • Page 107: Shift And Throttle Cable Installation To The Outboard

    TIMING/SYNCHRONIZING/ADJUSTING 6. Manually push throttle lever forward until it contacts the throttle stop on shift platform. Verify that the throttle plate can achieve wide open throttle and that no preload exists on the throttle return spring behind the cam follower plate. (Adjust throttle link rod if necessary) 52799 a - Throttle Stop...

  • Page 108: Shift Cable Installation

    TIMING/SYNCHRONIZING/ADJUSTING Shift Cable Installation 1. Move the remote control handle into full reverse position. 2. Place the engine shift lever into reverse position (toward rear) while rotating propeller. The propeller shaft will not rotate in either direction when in reverse position. 3.

  • Page 109: Throttle Cable Installation

    TIMING/SYNCHRONIZING/ADJUSTING Throttle Cable Installation NOTE: Attach Shift cable to engine prior to attaching throttle cable. 1. Position the remote control handle forward, to wide-open-throttle position. 2. Install the throttle cable onto the throttle pin. lock in place with retainer latch. 3.

  • Page 110: Starting Procedure

    TIMING/SYNCHRONIZING/ADJUSTING 6. Place the rubber seal (“a” side with holes towards front)) onto the control cables and install control cables, barrel holder and rubber seal into the cable holder as shown. 7. Lock the barrel holder in place with the cable retainer latch. a - Rubber Seal b - Retainer Latch Starting Procedure...

  • Page 111: Adjusting Idle Speed

    TIMING/SYNCHRONIZING/ADJUSTING MANUAL START REMOTE CONTROL MODELS 1. Turn primer enrichener knob fully “Clockwise” and “Pull” to “Full Out” position two (2) times, waiting approximately five (5) seconds between pulls, leaving the knob out after second pull. NOTE: Outboards equipped with a thermostat will have a “Sporadic” tell tail water dis- charge.
  • Page 112 WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams Table of Contents Manual Start Models (Electronic Advance) Manual Start Ignition Wiring Diagram(RED Stator) Model 20/25 (19941/2 THRU 1997) Model 20 Jet/20/25 (1999 and NEWER) ..2D-8 Model 20 Jet (19941/2 THRU 1998) .

  • Page 113: Manual Start Models (Electronic Advance)

    WIRING DIAGRAMS Manual Start Models (Electronic Advance) Model 20/25 (1994 THRU 1997) Model 20 Jet (1994 THRU 1998) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Charging Coils b - Stator c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder...

  • Page 114: Electric Start Models With Tiller Handle Start Button (Electronic Advance) Model 20/25 (19941/2 Thru 1997)

    WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (Electronic Advance) Model 20/25 (1994 THRU 1997) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator b - Trigger c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder...

  • Page 115: Electric Models Equipped With Remote Control (Electronic Advance) Model 20/25 (19941/2 Thru 1997)

    WIRING DIAGRAMS Electric Models Equipped with Remote Control (Electronic Advance) Model 20/25 (1994 THRU 1997) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator b - Trigger c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Rectifier...

  • Page 116: Manual Start Models (Mechanical Advance) Model 20/25 (1998)

    WIRING DIAGRAMS Manual Start Models (Mechanical Advance) Model 20/25 (1998) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator b - Trigger c - Switch Box d - Ignition Coil Top Cylinder e - Ignition Coil Bottom Cylinder f - Stop Switch...

  • Page 117: Electric Start Models With Tiller Handle Start Button (Mechanical Advance) Model 20/25 (1998)

    WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (Mechanical Advance) Model 20/25 (1998) BLK = Black BRN = Brown GRY = Gray GRN = Green RED = Red WHT = White YEL = Yellow a - Charging Coils b - Stator c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder...

  • Page 118: Electric Models Equipped With Remote Control (Mechanical Advance) Model 20/25 (1998)

    WIRING DIAGRAMS Electric Models Equipped with Remote Control (Mechanical Advance) Model 20/25 (1998) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Charging Coils b - Stator c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Rectifier...
  • Page 119 WIRING DIAGRAMS Manual Start Ignition Wiring Diagram(RED Stator) Model 20 Jet/20/25 (1999 and NEWER) GRN/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator b - Trigger c - Switch Box...

  • Page 120: Manual Start Wiring Diagram (Red Stator) Model 20/25 (1999 And Newer)(Work Model)

    WIRING DIAGRAMS Manual Start Wiring Diagram (RED Stator) Model 20/25 (1999 and NEWER)(Work Model) GRN/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator b - Trigger c - Switch Box...

  • Page 121: Electric Start Models With Tiller Handle Start Button

    WIRING DIAGRAMS Electric Start Models with Tiller Handle Start Button (RED Stator) Model 20/25 (1999 and NEWER) GRN/YEL BLK/YEL BLK/YEL J7 J6 BLK/YEL BLK/YEL – YEL/RED BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator...

  • Page 122: Electric Models Equipped With Remote Control (Red Stator) Model 20/25 (1999 And Newer)

    WIRING DIAGRAMS Electric Models Equipped with Remote Control (RED Stator) Model 20/25 (1999 and NEWER) GRN/YEL BLK/YEL BLK/YEL YEL/BLK – YEL/RED BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Stator b - Trigger c - Switch Box...

  • Page 123: Optional Electrical Accessories Wiring Diagrams 2D-12

    WIRING DIAGRAMS Optional Electrical Accessories Wiring Diagrams a - Manual Start Model with Lighting Coil and Unregulated AC Voltage b - Terminal Block c - Manual Start Model with Battery Charging Kit d - Rectifier e - Manual Start Model with Voltage Regulator f - Voltage Regulator Page 2D-12 90-826883R2 JUNE 1998...

  • Page 124: Commander Remote Control (Electric Start)

    WIRING DIAGRAMS Commander Remote Control (Electric Start) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Remote Control Harness Connector 90-826883R2 JUNE 1998...

  • Page 125: Commander 2000 Remote Control (Manual)

    WIRING DIAGRAMS Commander 2000 Remote Control (Manual) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - RUN – OFF Switch b - Emergency Stop Switch 23893 c - Stop Switch Harness Page 2D-14 90-826883R2 JUNE 1998...

  • Page 126: Commander 2000 Remote Control (Electric Start)

    WIRING DIAGRAMS Commander 2000 Remote Control (Electric Start) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW 23890 a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Wiring Harness Connector 90-826883R2 JUNE 1998...

  • Page 127: Commander 3000 Panel Mount Control

    WIRING DIAGRAMS Commander 3000 Panel Mount Control BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW a - Neutral Interlock Switch b - Emergency Stop Switch Page 2D-16 90-826883R2 JUNE 1998...
  • Page 128 CATIONS 4500 - 5500 5000 - 6000 Idle Mixture Screw Adjustment (Preset-Turns Out) 1/4 Turn 20 Jet 1-1/2 1/2 Turn 25/25 Seapro/25 Marathon 1-1/4 1/4 Turn Float Level 1.0 in. (25.4 mm) Main Jet Size 1994 thru 1996 -20 (WMC-44) 0.044 in.

  • Page 129: Carburetor (20/25/Jet 20)

    CARBURETOR/FUEL PUMP Carburetor (20/25/JET 20) L= CONTENTS OF PRIMER/INJECTOR KIT, PART NO. 1395-9844A1, REFERENCE NO. 26 Page 3A-2 90-826883R2 JUNE 1998...
  • Page 130 CARBURETOR/FUEL PUMP Carburetor (20/25/JET 20) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR (WMC-52 - 20HP) CARBURETOR (WMC-53 - 25HP) CARBURETOR (WMC-44 - 20HP) CARBURETOR (WMC-45 - 25HP)(JET 20) THROTTLE VALVE (20HP) THROTTLE VALVE (25HP/JET 20) THROTTLE SHAFT (20-WMC-44) THROTTLE SHAFT (25-WMC-45)(JET 20) THROTTLE SHAFT(20/25HP)(WMC52/52A/53/53A) FUEL BOWL...

  • Page 131: Carburetor (Seapro/Marathon 15/25 & Super 15)

    CARBURETOR/FUEL PUMP Carburetor (Seapro/Marathon 15/25 & Super 15) Page 3A-4 90-826883R2 JUNE 1998...
  • Page 132 CARBURETOR/FUEL PUMP Carburetor (Seapro/Marathon 15/25 & Super 15) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR (WMC-54) CARBURETOR (WMC-46A) CARBURETOR (WMC-56) THROTTLE VALVE (WMC–46/46A/54/54A) THROTTLE VALVE (WMC-56/56A) THROTTLE SHAFT FUEL BOWL FLOAT VALVE–inlet needle JET–main fuel (.076) (WMC–46) JET–main fuel (.080) (WMC–46A/54/54A) JET–main fuel (.046) (WMC–56/56A) PLUG–jet retainer...

  • Page 133: Carburetor Adjustments

    CARBURETOR/FUEL PUMP Carburetor Adjustments Carburetor Number Stamped at Top of Carburetor Mounting Flange Carburetor Number Model Main Jet Bowl Back Float Pre-Set Idle H.P. Size Vent Jet Drag Jet Setting Mixture Screw (Open) WMC - 43 .080 None None 1.0 in. 1-1/2 Turns Commercial (25.4 mm)

  • Page 134: High Altitude Jet Chart

    CARBURETOR/FUEL PUMP High Altitude Jet Chart Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet (1524m) above sea level. Between 2000 feet (609.6m) and 5000 feet (1524m) the reduction of the main fuel jet(s) may result in improved performance and fuel economy.

  • Page 135: Carburetor Float Adjustment

    CARBURETOR/FUEL PUMP Carburetor Float Adjustment 1 in. (25.4 mm) 17111 Carburetor Scale (91-36392) Measured from bottom of float 52646 Float Float Hinge Float Pin Bend Float Arm Here to Adjust Float Level Needle Page 3A-8 90-826883R2 JUNE 1998...
  • Page 136 CARBURETOR/FUEL PUMP Carburetor Adjustments 1. Place outboard in water. 2. Check tiller handle cable adjustment for full throttle movement in both “Forward” and “Reverse” gears. Adjust jam nuts for proper travel and to eliminate any slack. 57049 Jam Nuts INITIAL CARBURETOR ADJUSTMENTS Idle Speed Screw (Models So Equipped) 1.
  • Page 137 CARBURETOR/FUEL PUMP 3. Back idle speed screw off of cam follower. 4. Turn idle speed screw inward (clockwise) until it “just touches” cam follower, then inward an additional 1/2 turn to slightly open throttle plate. 57070 Idle Speed Screw Cam Follower Page 3A-10 90-826883R2 JUNE 1998...
  • Page 138 CARBURETOR/FUEL PUMP LOW SPEED MIXTURE SCREW 1. Remove access plug from carburetor air intake cover (models so equipped). 57072 Access Plug Intake Cover 2. Turn low speed mixture screw slowly inward (clockwise) until it seats lightly, then back screw out (counterclockwise) 1–1/2 to 1–3/8 turns(turning mixture screw in tight will damage needle and seat).
  • Page 139 CARBURETOR/FUEL PUMP IDLE WIRE ADJUSTMENT 1. Push primer/fast idle knob completely in and rotate fully counterclockwise. 2. Shift engine to “Neutral”. 57037 3. Adjust screw (a) to remove all clearance between idle wire (b) and trigger. 57070 Screw Idle Wire 4.
  • Page 140 CARBURETOR/FUEL PUMP IDLE ADJUSTMENT Low speed Mixture Adjustment 1. Start engine and allow to warm up (run for several minutes). Throttle engine back to idle for about one minute to allow RPM to stabilize. 2. Push primer/fast idle knob completely in and rotate knob fully counterclockwise. 57037 3.
  • Page 141 CARBURETOR/FUEL PUMP IDLE SPEED ADJUSTMENT (MODELS EQUIPPED WITH IDLE SCREW) 1. With engine running at idle in “Forward” gear, make sure primer/fast idle knob is pushed completely in and rotate fully counterclockwise to stop. 2. Adjust idle speed screw (a) to obtain recommended idle speed (see specifications). 57070 Idle Speed Screw IDLE SPEED ADJUSTMENT (MODELS NOT EQUIPPED WITH AN IDLE SPEED SCREW)

  • Page 142: Fuel System

    CARBURETOR/FUEL PUMP Fuel System Troubleshooting General Information Problems that are thought to be caused by the fuel system may, in reality, be something completely different. Items, that are shown in the list on the right, could give the impres- sion that there is a problem in the fuel system 1.
  • Page 143 CARBURETOR/FUEL PUMP Possible Cause Corrective Action Improperly mixed fuel. Contaminants(water, dirt, Check fuel in tank and replace if necessary. etc.) in fuel. Fuel tank air vent closed or restricted. Check air vent on tank. Vent must be open all-the- way and free from any contaminants. A pinched, cut or restricted fuel line.
  • Page 144 CARBURETOR/FUEL PUMP Problem: Engine Floods Possible Cause Corrective Action Dirt or debris are preventing inlet needle from Flush out inlet seat and clean inlet needle. seating. Worn inlet needle. Replace Punctured float Replace. Incorrect float setting Reset float. Problem: Engine Runs Too Rich Possible Cause Corrective Action Fuel level too high.

  • Page 145: Carburetor Removal

    CARBURETOR/FUEL PUMP Carburetor Removal NOTE: Air intake cover has been removed for visual clarity. 1. Loosen primer cam retaining screw. 2. Remove retaining clip. 57069 Screw Retaining Clip 3. Push down on primer arm and pull primer knob, bezel and slide block out of bottom cowl.

  • Page 146: Carburetor Installation

    CARBURETOR/FUEL PUMP Carburetor Installation 1. Install carburetor with new gasket onto mounting studs. Start attaching nuts but do not tighten. 57067 Gasket Nuts 2. Install primer assembly onto carburetor. Position alignment hole on assembly over post on bottom of carburetor. 57066 Alignment Hole Post...
  • Page 147 CARBURETOR/FUEL PUMP 3. Install air cover onto carburetor and secure with 2 screws. 4. Tighten carburetor attaching nuts. 57075 Screws Nuts 5. Secure fuel line to carb with sta-strap. 6. Reconnect link wire to fast idle lever. 57070 Fuel Line Sta-strap Link Wire Page 3A-20...
  • Page 148 CARBURETOR/FUEL PUMP 7. Push down on primer arm and insert primer knob, bezel and slide block into primer assembly. 57068 Primer Arm Primer Knob Bezel Slide Block 8. Tighten screw to secure slide block in place. 9. Align notch in back side of bezel with tab on bottom cowl and secure bezel in place with retaining clip.

  • Page 149: Fuel Pump

    CARBURETOR/FUEL PUMP Fuel Pump Removal and Disassembly IMPORTANT: Fuel pump check valve diaphragm and gasket should NOT be re-used once the fuel pump is disassembled. 1. Remove 5 screws securing fuel pump assembly to carburetor. 2. Separate fuel pump components. Cleaning and Inspection 1.

  • Page 150: Primer System

    CARBURETOR/FUEL PUMP Primer System The primer system provides extra fuel to the outboard whenever the primer knob is pulled out. The primer system components should be inspected carefully for serviceability. The diaphragm and gaskets should be inspected for cuts or abrasions. Replace accordingly. The primer check ball and springs should be inspected for debris or varnish which restrict free movement.

  • Page 151: Servicing Sight Bowl Fuel Filter

    CARBURETOR/FUEL PUMP Servicing Sight Bowl Fuel Filter WARNING Exercise extreme caution when cleaning fuel filter elements. Gasoline is extreme- ly flammable and highly explosive under certain conditions. Always stop the en- gine and DO NOT smoke or allow open flames in the area while cleaning fuel filter elements.
  • Page 152 EMISSIONS FUEL SYSTEM Section 3B - Emissions Table of Contents Table of Contents ......3C-1 Stratified Charge .

  • Page 153: 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 154: Outboard Hydrocarbon Emissions Reductions

    EMISSIONS OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1/3% # PER YEAR OVER 9 MODEL YEARS 2000 90-826883R2 JUNE 1998 Page 3B-3...

  • Page 155: 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 156: 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 157: Dealer Responsibility

    EMISSIONS Dealer Responsibility: When performing service on all 1998 and later outboards that carry a certification, atten- tion must be given to any adjustments that are made that affect emission levels. Adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards.

  • Page 158: Decal Location

    EMISSIONS Emission Control 1999 Information PART # 37-856984 5 This engine conforms to 1999 Model Year Idle Speed (in gear): 750 RPM U.S. EPA regulations for marine SI engines. Timing: Idle: 6 BTDC WOT: 25 BTDC Refer to Owners Manual for required maintenance.
  • Page 159 POWERHEAD POWERHEAD Section 4 - Powerhead Table of Contents Specifications ....... . . Seals .

  • Page 160: Specifications

    POWERHEAD Specifications HORSEPOWER Model 20 Jet 20 (14.9) (KW) Model 20 20 (14.9 Model 25 25 (18.7) CYLINDER Type Two Cylinder - Two Cycle BLOCK Displacement 24.4 cu. in. (400 cc) STROKE Length 2.362 in. (60 mm) CYLINDER Diameter (Standard) 2.562 in.

  • Page 161: Special Tools

    POWERHEAD Special Tools 1. Powerhead Stand 91-25821A1 2. Piston Pin Tool 91-76160A2 3. Piston Ring Expander 91-24697 4. Torque Wrench (0 -- 200lb. ft.) 91-32610* 5. Torque Wrench (0 -- 150lb. in.) 91-66274* 90-826883R2 JUNE 1998 Page 4-3...
  • Page 162 POWERHEAD 6. Flywheel Puller 91-83164M Bolts 10mm (3) 91-83191M 7. Compression Tester 91-29287 Page 4-4 90-826883R2 JUNE 1998...

  • Page 163: Cylinder Block And Covers

    POWERHEAD Cylinder Block and Covers 36 37 Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Loctite Master Gasket (92-12564-2) 2-4-C With Teflon (92-825407A12) SIDE SHIFT AND TILLER SHIFT ONLY 90-826883R2 JUNE 1998 Page 4-5...
  • Page 164 POWERHEAD Cylinder Block and Covers TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m CYLINDER BLOCK STUD (M6x1x32) Drive Tight ELBOW (45 deg.) STUD (M6x1x50) (Commercial) Drive Tight DOWEL PIN SCREW (60 MM) 40.7 STUD (M6x1x32) Drive Tight STUD Drive Tight SCREW...

  • Page 165: Crankshaft, Pistons And Flywheel

    POWERHEAD Crankshaft, Pistons and Flywheel Loctite 271 (92-809820) 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) A=ELECTRIC START MODELS ONLY 90-826883R2 JUNE 1998 Page 4-7...
  • Page 166 POWERHEAD Crankshaft, Pistons and Flywheel TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m DECAL--warning (NOT A SERVICE PART) DECAL--warning (NOT A SERVICE PART) SCREW--flywheel to crankshaft 57.5 78.0 WASHER--flywheel screw FLYWHEEL RING GEAR--flywheel ELECTRIC SCREW (M5x.8x13) OIL SEAL--crankshaft-upper (Qty. of 2 used on Electric RC) ROLLER BEARING--upper KEY--flywheel drive CRANKSHAFT ASSEMBLY...

  • Page 167: Torque Sequence

    POWERHEAD Torque Sequence 1. Exhaust Cover [140 lb. in. (15.8 N· m)] 2. Crankcase Cover [30.0 lb. ft. (41.1 N· m)] 3. Cylinder Block Cover [140 lb. in. (15.8 N· m)] 90-826883R2 JUNE 1998 Page 4-9...

  • Page 168: Powerhead Removal

    POWERHEAD Powerhead Removal 1. Remove the following components/assemblies referring to the listed service manual sections: Component/Assembly Section Rewind Starter Flywheel and Ignition/Electrical Components 2A/B Throttle/Shift Mechanism 7A/B/C Carburetor 2. Disconnect tell-tale hose from bottom cowl. 57073 Tell-tale Hose 3. Remove 4 bolts. 57076 Bolts (2 each side) Page 4-10...
  • Page 169 POWERHEAD 4. Remove 6 bolts securing powerhead. 57077 Bolts (3 each side) 5. Rock powerhead to break gasket and lift powerhead from drive shaft housing. 6. Place powerhead on bench or powerhead stand (91-25821A1) mounted in vise. 53203 53197 Powerhead Stand (91-25821A1) 90-826883R2 JUNE 1998 Page 4-11...

  • Page 170: Powerhead Disassembly

    POWERHEAD Powerhead Disassembly Cylinder Block 1. Remove 3 bolts and remove intake manifold/reed block. 57079 Bolts Intake Manifold/Reed Block IMPORTANT: Reed block can be inspected without disassembling. If inspection of reed block indicates that replacement of a part is necessary, entire reed block as- sembly must be replaced as individual parts are not sold separately.
  • Page 171 POWERHEAD 4. Remove 2 bolts and remove thermostat cover. 57081 Bolts (2) Cover 5. Remove thermostat (if equipped). 6. Remove 5 bolts and remove cylinder block cover. 57082 Bolts Cover Thermostat (if equipped) 90-826883R2 JUNE 1998 Page 4-13...
  • Page 172 POWERHEAD 7. Remove 9 bolts and separate exhaust cover and exhaust manifold from cylinder block. 57084 Bolts (9) Exhaust Cover Exhaust Manifold NOTE: If engine is suspected of having been overheated or spark plugs are grayish col- ored (a sign of possible water intrusion), inspect exhaust manifold for warpage or for prop- er placement and integrity of gaskets which will allow water to enter cylinders through ex- haust ports.
  • Page 173 POWERHEAD 9. Remove 4 bolts and 2 transfer covers -- Port Side. 57085 Transfer Covers 10. Remove 6 bolts which secure crankcase cover to cylinder block. 57090 Bolts (6) 90-826883R2 JUNE 1998 Page 4-15...
  • Page 174 POWERHEAD 11. Use soft mallet to break seal between crankcase cover and cylinder block. 57086 12. Lift crankcase cover from block. 57087 Page 4-16 90-826883R2 JUNE 1998...

  • Page 175: Crankshaft

    POWERHEAD Crankshaft 1. Remove cylinder block from crankshaft assembly. 57088 2. Slide upper and lower roller bearings and seals off of crankshaft. Discard seals. 57089 Crankshaft Seal (Upper) Bearing Crankshaft Seal (Lower) 90-826883R2 JUNE 1998 Page 4-17...
  • Page 176 POWERHEAD CENTER MAIN BEARING REMOVAL 1. Remove retaining ring from groove of center main bearing race. 57092 Retaining Ring 2. Remove center main bearing races and center main bearing halves. Remove main bearing thrust washers. 57093 Bearing Halves Thrust Washers Page 4-18 90-826883R2 JUNE 1998...
  • Page 177 POWERHEAD PISTON AND ROD DISASSEMBLY CAUTION Eye protection MUST BE worn while removing piston pin lockrings. IMPORTANT: Identify upper (#1) and lower (#2) pistons and connecting rods. Store piston pin, piston pin needle bearings, locating washers, connecting rod bearings, rod caps and bolts together with corresponding piston and connecting rod for reassembly.
  • Page 178 POWERHEAD IMPORTANT: Keep the same connecting rod, cap, cage and roller bearings (if re- used) together and install them in their original location on the crankshaft. 3. Remove (and discard) rod bolts and remove piston and rod assembly from crank- shaft.
  • Page 179 POWERHEAD IMPORTANT: Piston pin needle bearings and locating washers will fall out when piston is removed from connecting rod. 5. Slide piston pin tool from piston and remove piston, needle bearings and locating washers. 57101 Needle Bearings Locating Washers 6. Remove (and discard) coupling seal using: Snap On* Expanding Rod (CG 40-4) Snap On Collet (CG 40-A6) Slide Hammer (91-34569A1)

  • Page 180: Powerhead Cleaning And Inspection

    POWERHEAD Powerhead Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored as- sembly and must be replaced as a set. 1. Thoroughly clean cylinder block and crankcase cover with Quicksilver Power Tune Engine Cleaner (91-92-15104A12).

  • Page 181: Exhaust Manifold And Exhaust Cover

    POWERHEAD 57103 Decompression Ports Exhaust Manifold and Exhaust Cover 1. Remove all carbon deposits and gasket material from exhaust manifold and cover. 2. Inspect for grooves, cracks or distortion that could cause leakage. Replace parts as required. Cylinder Bore CHROME BORE - - ALL MODELS S/N OG202749 AND BELOW Cylinder bores which are chrome cannot be bored or efficiently honed.
  • Page 182 POWERHEAD 4. Check each cylinder bore for an out-of -round “ egged shaped”cylinder. A maximum of 0.003 in. (0.076mm) is allowable. If out-of-round is more than 0.003 in. (0.076 mm), cylinder block and crankcase cover must be replaced. MERCOSIL BORE - - ALL MODELS S/N OG202750 AND ABOVE 1.
  • Page 183 POWERHEAD STANDARD CYLINDER BORE DIAMETER 20/25/20 JET BORE TYPE STANDARD BORE DIAMETER ALL MODELS S/N OG202749 The cylinder bores are chrome 2.562 in. (65.01 mm) AND BELOW and cannot be rebored or effi- ciently honed. Check each cylin- der bore for an out-of -round “...
  • Page 184 POWERHEAD Crankshaft 1. Inspect crankshaft to drive shaft splines for wear. 2. Check crankshaft for straightness -- runout -- 0.003 in. (0.076 mm). 3. Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or scratched. If top crankshaft sealing surface is severely worn, replace crankshaft. If bottom crankshaft sealing surface is worn, replace crankshaft coupling seal.

  • Page 185: Seals

    POWERHEAD Seals It is recommended that all seals be replaced as a standard rebuilding procedure. NOTE: Both top and bottom crankshaft seals face down when installed on crankshaft. 53200 Top Crankshaft Seal Bottom Crankshaft Seal Bearings ROLLER BEARINGS 1. Clean roller bearing with solvent and dry with compressed air. 2.

  • Page 186: Connecting Rod

    POWERHEAD Connecting Rod 1. Check connecting rods for alignment by placing rods on a surface plate. If light can be seen under any portion of machined surfaces, if rod has a slight wobble on plate, or if a 0.002 in. (0.051 mm) feeler gauge can be inserted between any machined sur- face and surface plate, rod is bent and must be discarded 57126 Feeler Gauge...
  • Page 187 POWERHEAD 4. Water Marks: When bearing surfaces are subjected to water contamination, a bear- ing surface “ etching”occurs. This etching resembles the size of the bearing. 51853 5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping. Spalling will be most evident on the thrust portion of the connecting rod in line with the “...
  • Page 188 POWERHEAD 7. Uneven Wear: Uneven wear could be caused by a bent connecting rod. 51853 Uneven Wear CAUTION Crocus cloth MUST BE USED to clean bearing surface at CRANKSHAFT END OF CONNECTING ROD. 320 grit Carborundum cloth MUST BE USED to clean bearing surface at PISTON PIN END OF CONNECTING ROD.

  • Page 189: Pistons

    POWERHEAD Pistons IMPORTANT: If engine was submerged while engine was running, piston and/or connecting rod may be bent. If piston pin is bent, piston must be replaced. If piston pin is bent, connecting rod must be checked for straightness. 1. Inspect pistons for scoring and excessive piston skirt wear. 2.

  • Page 190: Reed Block

    POWERHEAD MEASURING PISTON 1. Measure piston skirt at right angle (90° ) to piston pin centerline. 0.50 in. (12.7mm) 57106 Standard Piston Diameter 20/25/20 JET 2.5583 in-- 2.5593 in. (64.98 mm -- 65.00 mm) PISTON CLEARANCE MINIMUM BORE MEASUREMENT -- MAXIMUM PISTON MEASUREMENT = PISTON CLEARANCE PISTON CLEARANCE 0.003 in.

  • Page 191: Bleed System

    POWERHEAD REED OPENING 1. Check reeds for preload and stand open conditions. Stand open should not exceed 0.007 in. (0.178 mm). Replace reed block assembly if necessary. Reed Reed Stop Lock Washer Screw Reed Block Seal (Vulcanized to Reed Block) NOTE: Reed Stop Opening is not adjustable.

  • Page 192: Thermostat

    POWERHEAD Thermostat Wash thermostat with clean water. Using a thermostat tester, similar to the one shown, test thermostat as follows: · Open thermostat valve, then insert a thread between valve and thermostat body. Allow valve to close against thread. · Suspend thermostat (from thread) and thermometer inside tester so that neither touches the container.

  • Page 193: Powerhead Reassembly

    POWERHEAD Powerhead Reassembly General Information Before proceeding with powerhead reassembly, be sure that all parts to be reused have been carefully cleaned and thoroughly inspected, as outlined in “ Cleaning and Inspec- tion” . Parts, which have not been properly cleaned (or which are questionable), can se- verely damage an otherwise perfectly good powerhead within a few minutes of operation.
  • Page 194 POWERHEAD 1. If removed, reinstall new crankshaft carrier as follows: a. Apply a thin coat of Loctite 271 to carrier surface on crankshaft. b. Square the carrier with crankshaft and using a 7/8 in. deep well socket and ham- mer, carefully seat carrier onto crankshaft. Loctite 271 (92-809820) 57107 Carrier...
  • Page 195 POWERHEAD NOTE: Bearing race halves retainer ring groove faces toward flywheel end of crankshaft. 4. Reinstall bearing race halves. Secure halves with retainer ring. NOTE: Install retainer ring so that ring bridges both fracture lines of bearing race. 57109 Race Halves Retainer Ring 90-826883R2 JUNE 1998 Page 4-37...
  • Page 196 POWERHEAD 5. Check center main thrust washers for wear as follows: a. Push thrust washers and center main bearing toward either end of crankshaft. b. Use a feeler gauge and check clearance between crankshaft and thrust washers. c. If clearance between crankshaft and thrust washers is greater than 0.030 in. (0.762 mm), replace thrust washers.
  • Page 197 POWERHEAD NOTE: If the tip of an awl can be inserted between the needle bearings, one or more needles are missing and must be replaced. 57111 c. Install upper locating washer. 57113 Locating Washer d. Slide piston onto connecting rod, centering piston pin bore over sleeve. e.
  • Page 198 POWERHEAD Apply light oil to piston pin and place piston pin onto tool. 2 Cycle Outboard Oil (92-826666A24) 57115 Piston Pin Piston Pin Tool (91-76160A2) g. Support bottom of piston and hold piston pin tool up against piston pin. h. Drive piston pin into piston pin bore (with a soft face mallet) until pin is flush with piston.
  • Page 199 POWERHEAD Move piston pin tool to top of piston pin bore and center piston pin in piston. 57116 Piston Pin Tool (91-76160A2) 7. Install new lockrings into grooves in both ends of piston pin bore. 37117 Lockring 90-826883R2 JUNE 1998 Page 4-41...
  • Page 200 POWERHEAD 8. Install connecting rods onto crankshaft as follows: a. Apply 2-4-C w/Teflon Marine Lubricant to connecting rod big-end bearings. IMPORTANT: Replace roller bearing halves as a set. DO NOT use old and new halves together. b. Place both halves of connecting rod big-end roller bearing onto crank pin. 2-4-C With Teflon (92-825407A12) 57118 Roller Bearing...
  • Page 201 POWERHEAD IMPORTANT: Clean connecting rod bolts with solvent and dry with compressed air. Inspect threads for damage. If threads are not damaged, bolts may be reused. Ap- ply light oil to threads prior to installation. c. Observe connecting rod/cap fracture line for correct alignment. Secure connect- ing rod (with v-notch of rod toward flywheel end of crankshaft) onto crankshaft with rod cap and bolts.
  • Page 202 POWERHEAD d. Correct piston installation: 57120 Intake Side Exhaust Side 9. Install new piston rings using Piston Ring Expander (91-24697). Install RECTANGU- LAR ring first in bottom ring groove. Install HALF-KEYSTONE ring in top ring groove. Align piston rings with each respective ring groove locating pin. 57121 Piston Ring Expander (91-24697) Rectangular Ring...
  • Page 203 POWERHEAD 10. Apply outboard oil to upper and lower roller bearings and install bearings on crank- shaft. Numbered side of bearing should face UP or OUT on bearings. 11. Install new upper and lower crankshaft seals. Both seal lips face down. Apply 2-4-C w/Teflon to seal lips.

  • Page 204: Cylinder Block

    POWERHEAD Cylinder Block CAUTION Piston rings must be properly positioned with locating pin between piston ring end gaps. Improperly positioned piston rings will break during installation. 1. Lubricate piston rings, piston and cylinder wall with light oil. 2. Keeping crankshaft horizontal, guide pistons into cylinder bores. 3.
  • Page 205 POWERHEAD 7. Clean crankcase sealing surfaces according to Loctite Master Gasket instructions. Apply a continuous bead of Loctite sealant along the inside of the mounting bolt holes of crankcase cover. 57123 Sealant 8. Place crankcase cover onto cylinder block and secure with 6 bolts. Torque bolts to 30.0 lb.
  • Page 206 POWERHEAD 9. Rotate crankshaft several times to assure free operation. 10. If disassembled, assemble reed block as follows: a. Torque reed stop screws to 25 lb. in. (2.8 N· m) b. Lubricate seal with 2-4-C w/Teflon and install reed block onto cylinder block. 2-4-C With Teflon (92-825407A12) 57080 Screws [Torque to 25 lb.
  • Page 207 POWERHEAD 12. Route upper and lower bleed hoses to their respective fittings as shown. 13. Install starboard transfer port covers with new seals. Torque attaching bolts to 40 lb. in. (9.0 N· m). 57078 Upper Bleed Hose Lower Bleed Hose Transfer Port Covers 14.
  • Page 208 POWERHEAD 15. Install exhaust manifold and exhaust cover with new gaskets. Torque bolts to 140 lb. in. (15.8 N· m) in torque sequence shown. 57084 Exhaust Manifold Exhaust Cover 16. Install cylinder block cover with thermostat and new gaskets. Torque bolts to 140 lb. in.

  • Page 209: Powerhead Installation

    POWERHEAD Powerhead Installation 1. Verify powerhead base surface and driveshaft housing mating surfaces are free of old gasket material. 2. Install powerhead with new gasket onto driveshaft housing. NOTE: It may be necessary to rotate propeller shaft slightly to align crankshaft splines with driveshaft splines.

  • Page 210: Set-Up And Test-Run Procedures

    POWERHEAD 5. Install tell-tale hose and attach hose to fitting on bottom cowl. 57073 Tell-Tale Hose 6. Install the following components/assemblies referring to the listed service manual sections. Component/Assembly Section Carburetor Throttle/Shift Mechanism 7A/B/C Electrical/Ignition Components and Flywheel 2A/B Rewind Starter Set-Up and Test-Run Procedures CAUTION When engine is started, IMMEDIATELY check for fuel leaks and water leaks.
  • Page 211 CLAMP AND SWIVEL BRACKET MIDSECTION Section 5 - CLAMP and SWIVEL BRACKET Table of Contents Clamp Bracket Assembly ..... 5A-2 Swivel Bracket Assembly .

  • Page 212: Clamp Bracket Assembly

    CLAMP AND SWIVEL BRACKET Clamp Bracket Assembly 23 24 2-4-C With Teflon (92-825407A12) Page 5-2 90-826883R2 JUNE 1998...
  • Page 213 CLAMP AND SWIVEL BRACKET Clamp Bracket Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m CLAMP BRACKET (STBD.) (BLACK) CLAMP BRACKET (STBD.) (GRAY) CLAMP BRACKET (STBD.) (TRACKER GRAPHITE GRAY) CLAMP BRACKET (PORT) (BLACK) CLAMP BRACKET (PORT) (GRAY) CLAMP BRACKET (PORT) (TRACKER GRAPHITE GRAY) THUMB SCREW ASSEMBLY RIVET...

  • Page 214: Swivel Bracket Assembly

    CLAMP AND SWIVEL BRACKET Swivel Bracket Assembly NO TAG Loctite 271 (92-809820) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) A=REMOTE CONTROL MODELS ONLY B=TILLER HANDLE MODELS ONLY Page 5-4 90-826883R2 JUNE 1998...
  • Page 215 CLAMP AND SWIVEL BRACKET Swivel Bracket Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m ROD--reverse hook 14.1 HANDLE WASHER BRAKE PLATE BRAKE DISC SWIVEL HEAD PLATE (Included W/Ref. #36) BRAKE DISC SCREW (M6x1x14) (Included W/Ref. #36) 12.0 15.8 SWIVEL BRACKET...

  • Page 216: Drive Shaft Housing Assembly

    CLAMP AND SWIVEL BRACKET Drive Shaft Housing Assembly Loctite 271 (92-809820) A=SERVICE ONLY Page 5-6 90-826883R2 JUNE 1998...

  • Page 217: Drive Shaft Housing Disassembly/Reassembly

    CLAMP AND SWIVEL BRACKET Drive Shaft Housing Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SEAL--adaptor plate ADAPTOR PLATE ASSEMBLY GASKET--adaptor plate SCREW (M6x1x20) BRACKET--upper mount EXHAUST TUBE (Part of Ref. #2) HOUSING ASSEMBLY--water tube SPACER--water tube SEAL--water tube SCREW (M5x.8x16) WATER TUBE (SHORT SHAFT)
  • Page 218 GEAR HOUSING LOWER UNIT Section 6A - - Gear Housing Table of Contents Specifications ......6A-1 Cam Follower .

  • Page 219: Quicksilver Lubricants And Service Aids

    GEAR HOUSING Quicksilver Lubricants and Service Aids Part No. Description 92-809819 Loctite “ 271” 92-850736A1 2-4-C w/Teflon 92-809824 Loctite Primer “ 7649” 92-850737A1 Super Duty Gear Lubricant Special Tools 1. Universal Puller Plate 91-37241 2. Leakage Tester FT8950 3. Bearing Puller & Installation Tool 91-31229A7 a.
  • Page 220 GEAR HOUSING e. Mandrel 91-36571 4. Bearing Puller Tool 91-27780 5. Slide Hammer 91-34569A1 6. Bearing Carrier Tool 91-93843--1 91-93843--1 7. Bearing Cup Puller 91-44385 56812 8. Bushing Removal Tool 91-824787 90-826883R2 JUNE 1998 Page 6A-3...
  • Page 221 GEAR HOUSING 9. Driveshaft Seal Installation Tool 91-858775 10. Bearing Carrier Prop Shaft Seal Installation Tool 91-858776 11. Bearing Carrier Prop Shaft Bearing Installation Tool 91-858777 Page 6A-4 90-826883R2 JUNE 1998...
  • Page 222 GEAR HOUSING Notes: 90-826883R2 JUNE 1998 Page 6A-5...

  • Page 223: Gear Housing (Drive Shaft)

    GEAR HOUSING Gear Housing (Drive Shaft) Loctite “ 271”(92-809819) Super Duty Gear Lubricant (92-850737A1) Loctite Primer “ 7649”(92-809824) 2-4-C w/Teflon (92-850736A1) Page 6A-6 90-826883R2 JUNE 1998...
  • Page 224 GEAR HOUSING Gear Housing (Drive Shaft) TORQUE REF. REF. QTY. DESCRIPTION lb-in. lb-ft GEAR HOUSING ASSEMBLY SLEEVE SEAL--gear housing ROLLER BEARING--upper DOWEL PIN (.187 x .53) SCREW (.375 x.25) WASHER--sealing SCREEN--water inlet-port SCREW (M5 x 40) DRAIN SCREW--magnetic WASHER SCREEN--starboard NUT (M5) ROLLER BEARING ASSEMBLY PINION GEAR (12-29)

  • Page 225: Gear Housing (Propeller Shaft)

    GEAR HOUSING Gear Housing (Propeller Shaft) Loctite “ 271”(92-809819) Super Duty Gear Lubricant (92-850737A1) Anti-Corrosion Grease (92-850735A1) 2-4-C w/Teflon (92-850736A1) Page 6A-8 90-826883R2 JUNE 1998...
  • Page 226 GEAR HOUSING Gear Housing (Propeller Shaft) TORQUE REF. REF. QTY. DESCRIPTION lb-in. lb-ft GEAR HOUSING ASSEMBLY TRIM TAB BOLT (M8x30) 17.1 23.2 WASHER TAPERED ROLLER BEARING FORWARD GEAR (12-29) BUSHING CAM FOLLOWER SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR (12-29) BEARING CARRIER ASSEMBLY 80.0 108.5...

  • Page 227: General Service Recommendations

    GEAR HOUSING 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 components.

  • Page 228: Draining And Inspecting Gear Lubricant

    GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. With gear housing in normal running position, place a clean pan under housing and remove vent plug and fill/drain plug (with gaskets).

  • Page 229: Gear Housing Removal

    GEAR HOUSING Gear Housing Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs BEFORE removing gear housing. 1. Tilt outboard to full “ UP”position. 9.9/15 Bigfoot (4 Stroke) 2. Remove reverse hook guide assembly from lower shift shaft. 3.
  • Page 230 GEAR HOUSING NOTE: A flat washer is located on the shift shaft near the top of the shaft. This washer may slide off shift shaft when gear case is removed. Do not lose washer as washer is necessary for reassembly. 51187 a-Flat Washer 5.

  • Page 231: Disassembly

    GEAR HOUSING Disassembly IMPORTANT: It is recommended that, during complete disassembly of gear housing, all O-rings and oil seals be replaced, regardless of their appearance. Bearing Carrier 1. Remove 3 screws which secure the O-ring retainer plate and O-ring to the bearing carrier.

  • Page 232: Propeller Shaft

    GEAR HOUSING NOTE: When using a screwdriver to remove carrier seals, be careful not to scar carrier seal surface. If carrier seal surface is damaged, replace carrier. 6. Secure bearing carrier in a vise. Using a screwdriver, pry out both seals from bearing carrier.

  • Page 233: Water Pump

    GEAR HOUSING WARNING Use caution when removing cam follower. As the cross-pin is remove the cam fol- lower can shoot out of the propeller shaft as a high speed projectile. 5. Push against cam follower. Use a punch or awl to push cross-pin out of sliding clutch. 6.
  • Page 234 GEAR HOUSING 5. Remove face plate and base gasket. 6. Remove shift shaft from housing. 56809 56810 a-Cover b-Nylon Washer c-Impeller d-Nylon Washer e-Key f-Shift Shaft g-Face Plate h-Base Gasket NOTE: Replace impeller if: · Impeller blades are cracked, torn or worn. ·...

  • Page 235: Shift Shaft

    GEAR HOUSING Shift Shaft 1. Pull shift shaft assembly from gear housing. 2. Remove and replace outer O-ring from shift shaft retainer. a-Shift Shaft g-Spring b-Boot h-Washer c-Retainer i-Roll Pin d-O-ring (outer) j-Driver Pin e-O-ring (inner) k-Shift Cam f-Washer Drive Shaft and Pinion Gear 1.

  • Page 236: Upper Drive Shaft And Bearing/Seals

    GEAR HOUSING Upper Drive Shaft and Bearing/Seals 1. Using Water Pump Cartridge Puller (91-27780), as shown, remove the driveshaft oil seals from gear housing. 91-27780 a-Oil Seals b-Water Pump Cartridge Puller 2. Using suitable mandrel drive upper drive shaft bearing through gearcase sleeve to the bottom of gearcase.

  • Page 237: Lower Drive Shaft Bearing/Cup

    GEAR HOUSING Lower Drive Shaft Bearing/Cup 1. Fasten bearing cup puller on a threaded rod as shown. 2. Tighten hex nut and draw the bearing cup puller up into bearing cup until lip on tool snaps over the top side of bearing cage. Remove threaded rod assembly. 3.

  • Page 238: Cleaning And Inspection

    GEAR HOUSING Cleaning and Inspection Gear Housing/Bearing Carrier Castings 1. Thoroughly clean gear housing/bearing carrier castings. Be sure all old gasket material is removed from mating surfaces and that carbon deposits have been removed from ex- haust passages. 2. Inspect castings for cracks or fractures. 3.

  • Page 239: Cam Follower

    GEAR HOUSING Cam Follower 1. Inspect cam follower for wear or galling. If wear is present, inspect corresponding shift cam for wear. Replace if worn. 52822 Clutch 1. Replace clutch if jaws are rounded or chipped. Rounded jaws may be caused by the fol- lowing: ·...

  • Page 240: Shift Shaft

    GEAR HOUSING Shift Shaft 1. Inspect shift shaft retainer for cracks and replace if necessary. 2. Inspect shift cam face for wear. Replace if worn. 53034 a-Shift Cam b-Shift Shaft Retainer Reverse And Forward Gear 1. Inspect gear teeth for pitting, uneven wear, scoring, etc. Replace gear if any damage is found.
  • Page 241 GEAR HOUSING 3. Inspect FORWARD gear tapered bearing and race for rust, roughness, pitting, spalling or excessive wear (looseness). NOTE: DO NOT remove tapered bearing from FORWARD gear unless replacement is nec- essary as removal process will damage bearing. 4. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and a suitable mandrel (5/8 in.

  • Page 242: Pinion Gear

    GEAR HOUSING Pinion Gear 1. Inspect pinion gear teeth for breakage, rust, chipping or excessive wear. 2. If pinion gear teeth are damaged, inspect FORWARD and REVERSE gear for damage. 3. Replace gears as required. 52991 a-Pinion Gear Driveshaft IMPORTANT: If upper drive shaft bushing or lower drive shaft needle bearing race ap- pear to be spinning in their respective bores, the gear housing should be replaced.

  • Page 243: Bearing Carrier

    GEAR HOUSING Bearing Carrier 1. If inspection of bearing area on propeller shaft determines that replacement of bearing inside of bearing carrier is required, remove bearing from bearing carrier. 2. Secure bearing carrier in a vise, DO NOT clamp onto threaded portion of bearing carrier. 3.
  • Page 244 GEAR HOUSING 2. Install lower driveshaft bearing cup into driveshaft bore of gear housing as follows: · Assemble bearing cup as shown. · Draw bearing cup up to shoulder of gearcase housing using cup puller (91-44385) as shown 91-44385 91-44385 11-24156 12-34961 91-29310...

  • Page 245: Shift Shaft

    GEAR HOUSING Shift Shaft 1. Install shift shaft assembly into gear housing assembly. 56914 a-Shift Shaft Assembly b-Boot c-Retainer d-O-ring (outer) e-O-ring (inner) f-Washer g-Spring h-Washer i-Roll Pin j-Driver Pin k-Shift Cam Page 6A-28 90-826883R2 JUNE 1998...

  • Page 246: Forward Gear Installation

    GEAR HOUSING Forward Gear Installation 1. Install forward gear bearing race into gear housing. 2. Apply a light coat of Super Duty Gear Lubricant to forward gear bearing race bore in pro- peller shaft cavity. 3. Position tapered bearing race squarely over bearing bore in front portion of propeller shaft cavity.
  • Page 247 GEAR HOUSING 9. Remove nut from propeller shaft, then remove bearing carrier, propeller shaft and man- drel from propeller shaft cavity. 10. Apply a light coat of oil on tapered bearing race. 11. Place forward gear on a press with gear teeth down. 12.

  • Page 248: Pinion And Driveshaft

    GEAR HOUSING Pinion and Driveshaft 1. Place lower drive shaft tapered roller bearing into bearing cup. 2. Place pinion gear into gear housing with teeth of pinion meshed with teeth of forward gear. 3. Insert driveshaft into gear housing while holding pinion in place with other hand. Rotate driveshaft back and forth to align splines on driveshaft with splines in pinion gear.
  • Page 249 GEAR HOUSING 3. Insert flat end of cam follower into propeller shaft. a-Spring b-Flat End of Cam Follower 4. Place cam follower against a solid object and push against cam follower to compress spring. 5. Insert a punch thru the cross-pin holes in sliding clutch (between cam follower and spring).

  • Page 250: Bearing Carrier

    GEAR HOUSING Bearing Carrier 1. Apply a small amount of oil into bearing bore in bearing carrier. 2. Position bearing carrier on a press (with the threaded side down). 3. Place propeller shaft bearing into aft end of bearing carrier with lettered end of bearing 4.

  • Page 251: Bearing Carrier/Propeller Shaft Installation 6A-34

    GEAR HOUSING Bearing Carrier/Propeller Shaft Installation 1. Apply a small amount of 2-4-C w/Teflon between lips of propeller shaft oil seals. Apply 2-4-C w/Teflon to threads, O-ring groove and pilot diameter. 2. Slide reverse gear into bearing carrier assembly. Slide bearing carrier assembly over propeller shaft and thread it into propeller shaft cavity as-far-as possible by hand (LEFT HAND THREAD).

  • Page 252: Water Pump

    GEAR HOUSING Water Pump 1. Slide a new face plate gasket and face plate over driveshaft and position them on gear housing. 2. Install nylon washer over driveshaft and set it flat against face plate. 3. Place impeller drive key on flat of driveshaft. 4.

  • Page 253: Gear Housing Installation

    GEAR HOUSING Gear Housing Installation 9.9/15 Bigfoot (4 - Stroke) WARNING To prevent accidental engine starting remove (and isolate) spark plug leads from spark plugs before installing gear housing IMPORTANT: If water tube has been removed, follow installation procedure in Sec- tion 5.
  • Page 254 GEAR HOUSING 6. Secure gear housing to drive shaft house with four (4) screws. Torque screws to 40 lb-ft (54.2 Nm). 56804 a-Screws (4) Torque to 40 lb-ft (54.2 Nm) 7. Thread (retained) “ jam”nut onto lower shift to expose five (5) threads above the nut. 8.
  • Page 255 GEAR HOUSING 11. Lift and hold reverse lock hook in the full up position. 12. Slide reverse hook guide up shift shaft to make contact with loop of reverse lock link rod. DO NOT bend link rod. Tighten guide bolt/nut to a torque of 50 lb-in. (5.7 Nm). a-Reverse Hook Guide b-Bolt/Nut - Torque to 50 lb-in.
  • Page 256 GEAR HOUSING 20/25 (2 Stroke) 17. While turning drive shaft in a clockwise direction, pull up lightly on shift shaft until gear housing is in forward gear (propeller shaft turns clockwise). 18. Install flat washer (retained) onto shift shaft. 51187 a-Washer IMPORTANT: Verify water tube (inside drive shaft housing) is connected to the water tube seal in the adaptor plate.
  • Page 257 GEAR HOUSING 25. Secure shift rod to horizontal shift shaft with retainer. 57047 a-Retainer 26. Check shift operation as follows: · Place shift lever in FORWARD. Gear housing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller is turned coun- terclockwise.

  • Page 258: Trim Tab Adjustment And Replacement

    GEAR HOUSING Trim Tab Adjustment and Replacement IMPORTANT: The trim tab made of a special alloy to aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Do not paint or place protective coating on the trim tab, or trim tab corro- sion protection function will be lost.

  • Page 259: Filling Gear Housing With Lubricant

    GEAR HOUSING Filling Gear Housing with Lubricant 1. Place outboard in a vertical operating position. 2. Remove vent plug from vent hole. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole. a-Vent Hole b-Lubricant Tube 4.
  • Page 260 JET DRIVE LOWER UNIT Section 6B - Jet Drive Table of Contents Jet Pump Assembly (S/N 0G157845 & Below) . . . 6B-2 Worn (Dull) Impeller ......6B-21 Jet Linkage (S/N 0G157845 &...

  • Page 261: Jet Pump Assembly (S/N 0G157845 & Below)

    JET DRIVE Jet Pump Assembly (S/N 0G157845 & Below) Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) Page 6B-2 90-826883R2 JUNE 1998...
  • Page 262 JET DRIVE Jet Pump Assembly (S/N 0G157845 & Below) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m JET PUMP ASSEMBLY (BLACK) JET PUMP ASSEMBLY (GRAY) HOUSING--pump HOSE--lube IMPELLER HOUSING--intake LINER DRIVESHAFT SLEEVE ADAPTOR BASE--pump SCREW (10-32 x 1) SCREW (.375-16 x 1-1/4) 23.0 31.2...

  • Page 263: Jet Linkage (S/N 0G157845 & Below)

    JET DRIVE Jet Linkage (S/N 0G157845 & Below) 11 12 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m COTTER PIN ROD END BUSHING WASHER NUT (1/4-28) SHIFT ROD ROD END SPACER SCREW (1/4-20 x 3/4) WASHER WASHER BUSHING LEVER ASSEMBLY SCREW...

  • Page 264: Jet Water Pump Components

    JET DRIVE Jet Water Pump Components Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m FACE PLATE WASHER-impeller KEY-Impeller Drive IMPELLER WASHER-impeller O RING-water pump WATER PUMP ASSEMBLY INSERT SEAL-water tube RING-driveshaft - rubber SCREW (M6 x 16) SCREW (M5 x 16)

  • Page 265: Jet Pump Assembly (S/N 0G157846 & Up)

    JET DRIVE Jet Pump Assembly (S/N 0G157846 & Up) Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) Page 6B-6 90-826883R2 JUNE 1998...
  • Page 266 JET DRIVE Jet Pump Assembly (S/N 0G157846 & Up) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m JET PUMP ASSEMBLY HOUSING--pump HOSE--lube IMPELLER HOUSING--intake LINER DRIVESHAFT SLEEVE Drive Tight ADAPTOR BASE--pump SCREW (10-32 x 1) SCREW (.375-16 x 1-1/4) 29.9 SCREW (.312-18 x 2) 12.9...

  • Page 267: Jet Linkage (S/N 0G157846 & Up)

    JET DRIVE Jet Linkage (S/N 0G157846 & Up) Loctite 271 (92-809820) Page 6B-8 90-826883R2 JUNE 1998...
  • Page 268 JET DRIVE Jet Linkage (S/N 0G157846 & Up) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m LOCKWASHER SHIFT HANDLE (Use without Ref. #4) SHIFT HANDLE (Use with Ref. #4) SPACER--sleeve ROD END SPRING WASHER COTTER PIN SHIFT LEVER SCREW (10-32 x 3/4) SCREW (10-32 x 2-1/2) SHIFT ROD...

  • Page 269: Selecting A Boat That Is Best Suited For Jet Power 6B-10

    JET DRIVE Selecting A Boat That Is Best Suited For Jet Power To obtain the best performance from the jet drive, the boat should have the following fea- tures: 1. The boat should be as light as possible. 2. The boat should have hull and transom that is designed for use with a jet drive. 3.

  • Page 270: Transom Height Of The Boat

    JET DRIVE Transom Height of the Boat Outboards with jet drives will be mounted approximately 7 inches higher on the transom than propeller driven outboards. This requires outboards that have a 15 in. shaft length to be installed on boats having a 22 in. transom height and outboards that have a 20 in. shaft length to be installed on boats having a 27 in.
  • Page 271 JET DRIVE 2. Place (center) the outboard on the boat transom so that the transom brackets are rest- ing on top of the transom. Temporarily fasten the outboard to the transom using two C-clamps. 3. Position the outboard in a vertical position. 4.

  • Page 272: Water Testing

    JET DRIVE SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH FLAT BOTTOM HULLS 1. Place (center) the outboard on the boat transom so that the transom brackets are rest- ing on top of the transom. Temporarily fasten the outboard to the transom using two C-clamps.
  • Page 273 JET DRIVE Test run the boat. If cavitation occurs (air enters the pump causing loss of thrust, engine over-speeds erratically), the first thing to try is lowering the outboard height 1/4 in. This can be accomplished by elongating the drilled mounting holes in the boat transom by 1/4 If cavitation still exists after lowering the outboard 1/4 in.

  • Page 274: Shift Link Rod Adjustment

    JET DRIVE Shift Link Rod Adjustment WARNING The shift link rod must be adjusted to lock the reverse gate against unexpected engagement (caused by water pressure hitting the gate) while operating the boat in forward. Activation of the reverse gate will cause sudden unexpected stopping of the boat.

  • Page 275: Lubricating The Drive Shaft Bearing

    JET DRIVE Lubricating the Drive Shaft Bearing Recommended Lubrication - Use Quicksilver 2-4-C w/Teflon, or Lubriplate 630-AA Grease. IMPORTANT: It is important that you do not use a general-all-purpose grease for this bearing. The lubricant we recommend is a water resistant grease of the proper consistency for this application.

  • Page 276: Impeller Removal And Installation

    JET DRIVE Impeller Removal and Installation REMOVAL 1. Shift outboard to NEUTRAL (N) position. 2. Remove spark plug leads to prevent engine from starting. 3. Remove the water intake housing that is fastened with six screws. 4. Straighten the bent tabs on the impeller nut retainer and remove the impeller nut. 5.
  • Page 277 JET DRIVE INSTALLATION 1. Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve (a) in- side the impeller (b) and install impeller, shear key (c), shims (d) nut retainer (e), and impeller nut (f). Turn the nut tight on the shaft to remove any play between the impeller and shaft.
  • Page 278 JET DRIVE 3. After setting the impeller height, tighten the impeller nut snug with a wrench. Secure impeller nut by bending tabs (a) against the flats on the impeller nut. Tabs 4. Reinstall the water intake housing with six bolts. Check clearance around the impeller to make sure the water intake housing is centered and not rubbing against the liner.

  • Page 279: Steering Pull Adjustment

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

  • Page 280: Worn (Dull) Impeller

    JET DRIVE Worn (Dull) Impeller The intake of gravel through the pump can round off and wear the leading edges on the impeller. Some conditions you may experience from a worn impeller are (1) a noticeable performance loss, especially on acceleration, (2) difficultly getting the boat on plane, or (3) an increase in engine RPM at wide open throttle.

  • Page 281: Liner Replacement

    JET DRIVE Liner Replacement 1. Mark the liner mounting bolts for reassembly into the same holes. Remove the bolts. 2. Remove the liner. If the liner is tight, tap on the inner edge of the liner with a long drift punch through the intake grate.

  • Page 282: Jet Drive Removal And Installation

    JET DRIVE Jet Drive Removal and Installation Removal 1. Remove water intake and impeller. Refer to Impeller Removal and Installation preced- ing. 2. Disconnect the shift linkage. Remove 5 bolts (shown) securing jet drive to drive shaft housing and remove jet drive. Installation 1.

  • Page 283: Water Pump Removal And Installation

    JET DRIVE Water Pump Removal and Installation Removal 1. Remove water pump assembly as shown. Installation IMPORTANT: If impeller being installed has been previously used and vanes have taken a “set,”do not install the impeller with the vanes reversed from their previous “set”...

  • Page 284: Bearing Carrier Removal And Installation

    JET DRIVE Bearing Carrier Removal and Installation Removal 1. Remove water pump assembly and water pump base. 2. Remove 2 screws securing bearing carrier to jet drive. Remove bearing carrier. Installation Reinstall bearing carrier as shown. Screws (2) Apply Loctite 271 to Threads, Torque to 30 lb.

  • Page 285: Single Bearing System (Large Diameter Bearing)

    JET DRIVE Single Bearing System (Large Diameter Bearing) 1. If removed, install the bearing thrust ring into the groove on the drive shaft. 2. Install collar onto the drive shaft. Press the new ball bearing onto the drive shaft, pressing against the inner race only. Press collar over the thrust ring (a), locking it in its groove.

  • Page 286: Installing Drive Shaft

    JET DRIVE Installing Drive Shaft 1. Lubricate the seals and inside bore of the bearing carrier (a). 2. Place the drive shaft (“ b”impeller end facing up) into a vise. 3. Heat the bearing carrier (a) until it feels warm to the touch. 4.

  • Page 287: Installing Upper Seal Housing

    JET DRIVE Installing Upper Seal Housing Single Bearing System 1. Grease the upper O-ring seals and inside bore of the bearing carrier to ease entry of the seal housing. 2. Large Diameter Bearing Type Only: Install thrust washer (d) -- [GRAY teflon coating side of thrust washer FACES ball bearing] -- on top of bearing.
  • Page 288 THROTTLE/SHIFT LINKAGE CONTROLS Section 7A - Throttle/Shift Linkage Table of Contents Throttle and Shift Linkage (Tiller Handle Shift) . . . 7A-2 Throttle Cam/Control Lever ....7A-10 Control Cables Reassembly...

  • Page 289: Throttle And Shift Linkage (Tiller Handle Shift)

    THROTTLE/SHIFT LINKAGE Throttle and Shift Linkage (Tiller Handle Shift) 2-4-C With Teflon (92-825407A12) A=LOCAL ELECTRIC ONLY Page 7A-2 90-826883R2 JUNE 1998...
  • Page 290 THROTTLE/SHIFT LINKAGE Throttle and Shift Linkage (Tiller Handle Shift) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m SWITCH--interlock SCREW (M3.5x0.6x16 hex wsh) 20.0 LINK interlock LEVER--interlock control SCREW (M6x1x25 hex hd cap) 13.6 PLAIN WASHER (62x.255x.03) BUSHING LEVER--backplate LEVER--horizontal shift shaft (PORT) SHIFT SHAFT (HORIZONTAL)

  • Page 291: Control Cables (Tiller Handle Shift)

    THROTTLE/SHIFT LINKAGE Control Cables (Tiller Handle Shift) Removal/Installation Refer to Section 7B for removal and installation instructions Control Platform Removal/Disassembly 1. Disconnect control cables from anchor bracket and pulley as outlined in Section 7B. 2. Disconnect throttle link rod from ball joint of primary throttle lever. 57031 Cables Bracket...
  • Page 292 THROTTLE/SHIFT LINKAGE 3. Disconnect shift link rod from ball joint of gear shift lever. 57033 Shift Link Rod Gear Shift Lever Shift Lever 4. Remove 3 bolts and control platform. 57034 Bolts Control Platform 90-826883R2 JUNE 1998 Page 7A-5...
  • Page 293 THROTTLE/SHIFT LINKAGE 5. Remove nuts and flat washers. 57040 Nuts Flat Washers 6. Disassemble control platform. 53174 Bolts (2) -- Torque to 120 lb. in. (13.6 N· m) Flatwashers (2) Primary Gear Bushing (Long) Mount Bolts -- Torque to 120 lb. in. (13.6 N· m) Control Platform Bushing (Short) Detent Spring...

  • Page 294: Reassembly/Installation

    THROTTLE/SHIFT LINKAGE Reassembly/Installation 1. Install short bushing and long bushing on control platform. 2. Install detent spring and detent ball into recess of control platform. 3. Lubricate bushings and area of platform traveled by gears with 2-4-C w/Teflon. 57038 2-4-C With Teflon (92-825407A12) Short Bushing Long Bushing Platform...
  • Page 295 THROTTLE/SHIFT LINKAGE 7. Install primary gear over long bushing as shown. 8. Secure primary gear with bolt and flat washer. Torque bolt to 120 lb. in. (13.6 N· m). 9. Lubricate gear teeth with 2-4-C w/Teflon. 57040 2-4-C With Teflon (92-825407A12) Primary Gear Bolt and Flat Washer -- Torque to 120 lb.
  • Page 296 THROTTLE/SHIFT LINKAGE 11. Adjust shift link rod to a length of 5-1/2 in. (13.9 cm) as measured between ball joint centerlines. 12. Connect shift link rod between joints of secondary lever and shift shaft lever. 57033 Shift Link Rod -- Adjust to length of 5-1/2 in. (13.9 cm) Shift Shaft Lever Secondary Lever 13.

  • Page 297: Throttle Cam/Control Lever

    THROTTLE/SHIFT LINKAGE Throttle Cam/Control Lever Removal 1. Refer to Section 7B for removal of throttle cables. 2. Remove bolt and flat washer securing cam/lever to powerhead. 57041 Bolt Washer Cam/Lever Throttle Cam/Control Lever Reassembly 1. Position spring over hub of throttle cam. Spring ends must straddle tab. 57042 Spring Ends Page 7A-10...
  • Page 298 THROTTLE/SHIFT LINKAGE 2. Lubricate bushing with 2-4-C w/Teflon and install bushing and wave washer. 2-4-C With Teflon (92-825407A12) 57050 Bushing Wave Washer 3. Install control lever onto throttle cam assembly so that tab of control lever is positioned between ends of spring. 57043 Control Lever Ends of Spring...

  • Page 299: Installation

    THROTTLE/SHIFT LINKAGE Installation 1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover with bolt. Torque bolt to 120 lb. in. (13.6 N· m). 2. Connect timing link between ball joints of control lever and trigger assembly. 57041 Throttle Cam Control Lever Flat Washer...

  • Page 300: Neutral Interlock Control Lever

    THROTTLE/SHIFT LINKAGE Neutral Interlock Control Lever Reassembly/Installation 1. Lubricate bushing with 2-4-C w/Teflon and install bushing. 2-4-C With Teflon (92-825407A12) 57045 Bushing 2. Secure interlock lever components with bolt onto mounting boss of crankcase cover. 57044 Interlock lever Flat washer Bolt -- Torque to 120 lb.

  • Page 301: Horizontal Shift Shaft

    THROTTLE/SHIFT LINKAGE Horizontal Shift Shaft Removal 1. Remove nut securing access cover to port side of bottom cowl. Remove cover. 57035 Access Cover 2. Lift up and remove lever securing horizontal shift shaft. 56915 Lever Page 7A-14 90-826883R2 JUNE 1998...

  • Page 302: Installation

    THROTTLE/SHIFT LINKAGE 3. Pull out and remove horizontal shift shaft. 57046 Horizontal Shift Shaft Installation 1. Install horizontal shift shaft/shift lever assembly into opening in STARBOARD side of crankcase cover. 57046 Horizontal Shift Shaft Shift Lever 90-826883R2 JUNE 1998 Page 7A-15...
  • Page 303 THROTTLE/SHIFT LINKAGE 2. Secure end of shift shaft to yoke of horizontal shift shaft with lever 57047 Lever 3. Reinstall access cover and secure with nut and bolt. Torque nut to 50 lb. in. (5.6 N· m). 57035 Access Cover Nut -- Torque to 50 lb.
  • Page 304 TILLER HANDLE CONTROLS Section 7B - Tiller Handle Table of Contents Tiller Handle Assembly ..... . . 7B-2 Removal ....... . 7B-5 Control Cables .

  • Page 305: Tiller Handle Assembly

    TILLER HANDLE Tiller Handle Assembly Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) Page 7B-2 90-826883R2 JUNE 1998...
  • Page 306 TILLER HANDLE Tiller Handle Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m TILLER HANDLE (BLACK) TILLER HANDLE TILLER HANDLE (GRAY) SHIFT TILLER HANDLE (BLACK) SIDE SHIFT TILLER HANDLE (GRAY) COVER KIT (TILLER HANDLE SHIFT) COVER KIT (SIDE SHIFT) PULLEY CASE SCREW (#10-16x1/2 IN.)

  • Page 307: Control Cables

    TILLER HANDLE Control Cables Removal 1. Place tiller handle twist grip in NEUTRAL position. 2. Remove throttle link rod from throttle cam and primary throttle lever. 57031 Link Rod Throttle Cam Primary Throttle Lever 3. Loosen jam nuts which secure control cables to anchor bracket. 4.
  • Page 308 TILLER HANDLE 5. Remove nut securing access cover and remove cover 57035 Access Cover 6. Disconnect stop button wires -- BLACK/YELLOW and BLACK. 57036 BLACK/YELLOW BLACK 90-826883R2 JUNE 1998 Page 7B-5...

  • Page 309: Tiller Handle Removal/Disassembly

    TILLER HANDLE Tiller Handle Removal/Disassembly Removal 1. Remove 2 bolts securing tiller handle to anchor bracket and remove tiller handle as- sembly. 57037 Bolts 2. Remove bushing, flatwashers (2). wave washer and tiller handle washer. Remove re- tainer and bolt. 53248 Bushing Flat Washer (2)
  • Page 310 TILLER HANDLE 3. Slide tiller tube out of pulley case. 53256 Tiller Tube Pulley Case 4. Remove pulley case assembly from tiller handle and remove cover bolt. 53262 Pulley Case Assembly Cover Bolt 5. Remove cover and lift pulley assembly from case. Replace cables as required. 53257 Cover Pulley Assembly...

  • Page 311: Installation

    TILLER HANDLE Installation 1. Wrap cables around pulley. Top cable wraps and locks in top groove. Bottom cable wraps and locks in bottom groove. 2. Place pulley and cable assembly into pulley case. 53257 Pulley Top Cable Bottom Cable 3. Install pulley cover and secure cover with bolt. 53262 Cover Bolt (Drive Tight)
  • Page 312 TILLER HANDLE 5. Secure tiller tube in handle with retainer and bolt. Torque bolt to 50 lb. in. (5.6 N· m). 6. Install tiller washer (tab aligns with slot in handle), plain washer, wave washer, plain washer and flanged bushing over cable/harness assembly. 53248 Retainer Bolt -- Torque to 50 lb.

  • Page 313: Control Cables

    TILLER HANDLE 11. Pull on cable ends to remove slack and secure tiller handle to anchor bracket with plate and 2 bolts. Torque bolts to 80 lb. in. (9.0 N· m). 57037 Plate Bolts -- Torque to 80 lb. in. (9.0 N· m) Control Cables Installation 1.
  • Page 314 TILLER HANDLE 3. Rotate tiller handle to FORWARD gear position. 4. Route remaining cable below primary gear pulley and secure cable into outer groove of pulley. Place cable jacket into lower notch of cable anchor bracket. 5. Rotate tiller handle twist grip to NEUTRAL. 6.
  • Page 315 SIDE SHIFT CONTROLS Section 7C - Side Shift Table of Contents Throttle And Shift Linkage (Side Shift) ..7C-2 Installation ....... 7C-6 Throttle Cables (Side Shift Models) .

  • Page 316: Throttle And Shift Linkage (Side Shift)

    SIDE SHIFT Throttle And Shift Linkage (Side Shift) 2-4-C With Teflon (92-825407A12) Page 7C-2 90-826883R2 JUNE 1998...
  • Page 317 SIDE SHIFT Throttle and Shift Linkage (Side Shift) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m LINK--interlock LEVER (20/25) (JET 20 - S/N-G157846 & UP) LEVER (JET 20 - S/N-G157845 & BELOW) SCREW (M6x1x25) 13.6 WASHER BUSHING LEVER--backplate SPRING--detent NOT USED ON JET 20...

  • Page 318: Throttle Cables (Side Shift Models)

    SIDE SHIFT Throttle Cables (Side Shift Models) Removal/Installation Refer to Section 7B for removal and installation instructions Throttle Cam/Control Lever Removal 1. Refer to Section 7B for removal of throttle cables. 2. Remove bolt and flat washer securing cam/lever to powerhead. 57065 Throttle Cam Control Lever...

  • Page 319: Throttle Cam/Control Lever

    SIDE SHIFT Throttle Cam/Control Lever Reassembly 1. Position spring assembly over hub of throttle cam. 57042 Inner Spring Ends 2. Lubricate bushing with 2-4-C w/Teflon and install bushing and wave washer. 57042 2-4-C With Teflon (92-825407A12) Bushing Wave Washer 90-826883R2 JUNE 1998 Page 7C-5...

  • Page 320: Installation

    SIDE SHIFT 3. Install control lever onto throttle cam assembly so that tab of control lever is positioned between ends of inner spring. 57043 Control Lever Ends of Inner Spring Installation 1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover with bolt.
  • Page 321 SIDE SHIFT 3. Connect throttle cables to throttle cam and throttle cable anchor bracket as outlined in “ Throttle Cable”-- “ Installation” , preceding. 57063 Throttle Cables Throttle Cam Bracket 90-826883R2 JUNE 1998 Page 7C-7...

  • Page 322: Neutral Interlock Control Lever

    SIDE SHIFT Neutral Interlock Control Lever Reassembly/Installation 1. Lubricate bushing with 2-4-C w/Teflon and install bushing. 2-4-C With Teflon (92-825407A12) 57045 Bushing 2. Secure interlock lever components with bolt onto mounting boss of crankcase cover. 57064 Interlock Lever Flat Washer Bolt -- Torque to 120 lb.

  • Page 323: Horizontal Shift Shaft

    SIDE SHIFT Horizontal Shift Shaft Reassembly/Installation 1. Install horizontal shift shaft/shift lever assembly into opening in STARBOARD side of crankcase cover. 57046 Horizontal Shift Shaft Shift Lever 2. Secure horizontal shift shaft to shift rod with lever . 57047 Lever Horizontal Shift Shaft Shift Rod 90-826883R2 JUNE 1998...
  • Page 324 SIDE SHIFT 3. Install rubber grommet into opening in starboard side of bottom cowl. 4. Secure shift handle onto end of horizontal shift shaft with screw and flat washer. Torque screw to 50 lb. in. (5.6 N· m). 57061 Grommet Shift Handle Screw Washer...
  • Page 325 MANUAL STARTER OUTBOARD MOTOR INSTALLATION/ATTACHMENTS Section 8 - Manual Starter Table of Contents Specifications ......Starter Rope Replacement .

  • Page 326: Starter Assembly (Manual)

    MANUAL STARTER Starter Assembly (Manual) Cyanacrylate Adhesive (purchase locally) 2-4-C With Teflon (92-825407A12) A - - 30 lb. in. (3.5 N· m) B - - 110 lb. in. (12.5 N· m) Page 8-2 90-826883R2 JUNE 1998...
  • Page 327 MANUAL STARTER Starter Assembly (Manual) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m RECOIL STARTER ASSEMBLY (USA-0G/BEL- & BELOW RECOIL STARTER ASSEMBLY (USA-0G/BEL- & UP HOUSING--starter (USA-0G/BEL- & BELOW HOUSING--starter (USA-0G/BEL- & UP SCREW (1/4-20) 11.0 15.3 RETAINING RING PAD--felt SPRING--starter...

  • Page 328: Rewind Starter Assembly

    MANUAL STARTER Rewind Starter Assembly Removal CAUTION DO NOT turn or cock fuel filter assembly when removing. Remove fuel filter by pulling straight down. Turning or cocking fuel filter may break fuel line connec- tion on filter. 1. Pry fuel filter from starter rope guide. DO NOT turn or cock filter; pull straight down. 53246 Filter 56800...
  • Page 329 MANUAL STARTER 3. Remove 3 bolts and lift rewind starter from engine. Bolts Rewind Starter Installation 1. Secure rewind starter to engine with 3 bolts. Apply Loctite 242 to threads of 3 mount- ing bolts. Torque bolts to 110 lb. in. (12.4 N· m). Loctite 242 (92-809821) Bolts -- Torque to 110 lb.
  • Page 330 MANUAL STARTER 2. Snap interlock link rod into lower lock lever. 56803 Link Rod Lock Lever CAUTION Push filter straight up when installing. Turning or cocking filter may break fuel line connection on filter. 3. Push ball of fuel filter into socket of rope guide. DO NOT turn or cock fuel filter. 53247 Filter Guide...

  • Page 331: Starter Rope Replacement

    MANUAL STARTER Starter Rope Replacement 1. Remove rewind starter from engine, as outlined previously. NOTE: If starter is broken, remove all remaining rope from sheave. 2. Disengage starter interlock from starter sheave. 3. Pull starter rope handle out from rewind starter about 1 ft. (30.5cm) and tie a knot at this point to prevent rope from being pulled back into rewind starter.
  • Page 332 MANUAL STARTER 5. Install starter handle on new rope cut to a length of 66 in. (1676 mm). Tie a knot into end of rope. Place knot into recess of rope retainer. Install rope retainer into starter handle. 53233 Handle Knot Retainer CAUTION...
  • Page 333 MANUAL STARTER 7. While holding sheave in this position, lift knot from recess and pull all remaining rope from sheave. 57053 Sheave Knot Recess 8. Turn sheave COUNTERCLOCKWISE until stop, indicating spring is wound tight. 9. Slowly turn sheave CLOCKWISE (with spring tension) until knot recess is aligned with rope hole in starter housing.
  • Page 334 MANUAL STARTER 10. Push end of new rope through rope holes in starter housing and starter sheave. Pull end of rope out of knot recess. 57056 Rope Holes Knot Recess 11. Tie a knot into end of rope and pull knot back into knot recess. 57057 Knot Knot Recess...

  • Page 335: Disassembly

    MANUAL STARTER Disassembly WARNING When disassembling rewind starter, SAFETY GLASSES MUST BE WORN in case spring should uncoil out of housing. 1. Remove starter rope as outlined previously. 2. With rope removed, allow sheave to slowly unwind to release spring tension. 3.

  • Page 336: Cleaning And Inspection

    MANUAL STARTER Cleaning and Inspection 1. Clean rewind spring assembly with solvent and dry with compressed air. 2. Inspect rewind spring (without removing spring from retainer) for kinks, burrs or break- age. Replace assembly if necessary. 3. Inspect cam tension spring for damage. Replace as necessary. 4.
  • Page 337 MANUAL STARTER 3. Install starter sheave into housing aligning notches in sheave with appropriate loca- tions on recoil spring. 57060 Sheave Alignment Notches 4. Secure cam to housing with bolt. Torque bolt to 70 lb. in. (7.9 N· m). 57055 2-4-C With Teflon (92-825407A12) Bolt NOTE: If, after tightening cam retaining bolt, sheave does not move freely, sheave is not...

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