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Mercury 40 FourStroke Service Manual

Mercury 40 FourStroke Service Manual

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30/40

FourStroke

Starting Model Year 1999

Starting Serial Number 0G760300

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Page 1 30/40 FourStroke Starting Model Year 1999 Starting Serial Number 0G760300...
Page 2 Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers.
Page 3: Cleanliness And Care Of Outboard Motor
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 Motor Installation Section 2 - Electrical A - Ignition Fuel System B - Charging & Starting System C - Timing,Synchronizing &...
Page 5 Specifications ......1A-1 Mercury/Quicksilver Lubricants and Sealants 1A-11 Propeller Information Charts ....
Page 6 SPECIFICATIONS Type Capacitor Discharge Ignition Spark Plug: Type NGK DPR6EA-9 0.035 in. (0.9 mm) Hex Size 18 mm Torque 150 lb-in. (17 Nm) Hole Size 12mm Firing Order 1-2-3 Ignition Timing: @ Idle (800 rpm) 10 A.T.D.C IGNITION @ WOT (6000 rpm) 28 B.T.D.C SYSTEM 660 - 710 Ω...
Page 7 SPECIFICATIONS ENRICHMENT Auto Enrichener Resistance 15 - 25 Ohms (YEL/BLK - YEL/BLK) CONTROL Electrothermal Ram Projection 0.3 in. (7mm) after 5 min. of power SYSTEM Readings taken @ 68 F (20 C). Fuel Pump Type Mechanical Water Cooled (Plunger/Diaphragm) FUEL Fuel Pump: SYSTEM Pressure...
Page 8 SPECIFICATIONS Compression Ratio 9.7:1 Cylinder Compression* 180 - 210 psi (Peak) COMPRESSION (Electric Models Only, Cold Engine @ RATIO W.O.T.) PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) CONNECTING Oil Clearance (Big End) 0.0008 - 0.0020 in. (0.020 - 0.052 mm) Small End Inside Diameter 0.6293 - 0.6298 in.
Page 9 SPECIFICATIONS Warp Limit 0.004 in. (0.1 mm) * Lines indicate 56899 straight edge measurement CYLINDER HEAD Camshaft Bore Inside Diameter “a” 1.4567 - 1.4577 in. (37.000 - 37.025 mm) 56900 Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust 0.010 - 0.014 in.
Page 10 SPECIFICATIONS Valve Dimensions “C” “B” “D” “A” Margin Thickness Seat Width Head Diameter Face Width Outside Diameter 0.6288 - 0.6296 in. ROCKER SHAFT (15.971 - 15.991 mm) Inside Diameter of Bore 0.6299 - 0.6306 in. ROCKER ARM (16.000 - 16.018 mm) Valve Opening Temperature 136 F - 143 F (58 C - 62 C) THERMOSTAT...
Page 11 SPECIFICATIONS Gear Ratio 2.00:1 Gearcase Capacity 14.9 fl oz (440 mL) Lubricant Type Premium Blend Gear Lube Forward Gear Number of Teeth 26 Spiral/Bevel Pinion Gear GEAR HOUSING Number of Teeth 13 Spiral/Bevel (2.00:1) Pinion Height 0.025 in. (0.64 mm) Forward Gear Backlash No Adjustment Water Pressure (Warm Engine)
Page 12 SPECIFICATIONS Propeller Information Charts Mercury/Mariner 30 (4-Stroke) 2.00:1 Non-Bigfoot Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.00:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller...
Page 13 SPECIFICATIONS Mercury/Mariner 40 (4-Stroke) 2.00:1 Non-Bigfoot Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.00:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wgt.
Page 14 SPECIFICATIONS Mercury/Mariner 40 (4-Stroke) 2.3:1 Bigfoot Special soft rubber hub propellers designed to reduce clutch rattle Wide Open Throttle rpm: 5500-6000 Recommended Transom Heights : 20”, 25” Right Hand Rotation Standard Gear Reduction : 2.31:1 IMPORTANT: These specially designed rubber hub propellers are rated for 60 horsepower MAXIMUM.
Page 15 SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Mercury Part Number Description Quicksilver Part Number Needle Bearing Assy. Lubricant [8 92-802868A1 oz. (226.8 grams)] tube Dielectric Grease 92-823506-1 92-823506-1 [8 oz. (226.8 grams)] can Loctite 271 – Thread Locker 92-809819 92-809819 (10 ml) tube...
Page 16 SPECIFICATIONS Mercury Part Number Description Quicksilver Part Number RTV 587 Silicone Sealer 92-809825 92-809825 [3 oz. (85.05 grams)] Obtain Locally Loctite 262 Obtain Locally Premium Gear Lubricant 92-802846A1 92-802846Q1 [1 Quart (0.94 liter)] Loctite 7649 Primer 92-809824 92-809824 [4.5 oz (127.57 grams)]...
Page 17 SPECIFICATIONS Torque Chart Diameter x Fastener Location Torque Length (mm) lb-in. lb-ft.. Ignition Coil Mounting Nuts Coil Mount Plate Screw (Rear) M6 x 25 Coil Mount Plate Screw M6 x 30 Coil Plate Ground Screw M6 x 10 Spark Plug 12 mm Charging &...
Page 18 SPECIFICATIONS Diameter x Fastener Location Torque Length (mm) lb-in. lb-ft. Lubrication Oil Pump Mounting Screws M6 x 40 Oil Pump Cover Screws M6 x 16 Mid-Section Top Cowl Latch Screw/Nut M4 x 14 Drive Tight Top Rear Cowl Latch Screw/Nut M6 x 16 Bottom Cowl Screws M6 x 30...
Page 19 SPECIFICATIONS Diameter x Fastener Location Torque Length (mm) lb-in. lb-ft. Manual Tilt Assist Plug, Velocity Valve Plug, Plunger (2) Shock Rod Piston Piston Spring Plate Screws Cylinder End Cap Tilt Cylinder/Reservoir Screws Accumulator Non-Bigfoot Gear Housing Pinion Nut Bearing Carrier Screws M8 x 25 25.5 Vent, Fill/Drain Screw...
Page 20: Table Of Contents
Fuel Filter ......1B-11 Mercury/Quicksilver Lubricants and Sealants 1B-2 Fuel Line Inspection ....
Page 21: Special Tools
MAINTENANCE Special Tools 1. Crankcase Oil Pump P/N 90265A5 2. Oil Filter Wrench P/N 91-802653Q1 3. Flushing Attachment P/N 44357A2 Mercury/Quicksilver Lubricants and Sealants NOTE: See section 1A for lubricants and sealants chart. Page 1B-2 90-857046R1 NOVEMBER 2001...
Page 22: Inspection And Maintenance Schedule
MAINTENANCE Inspection And Maintenance Schedule To keep your outboard in the best operating condition, it is important that your outboard re- ceive the periodic inspections and maintenance listed in the Inspection and Maintenance Schedule. We urge you to keep it maintained properly to ensure the safety of you and your passengers and retain its dependability.
Page 23: Every 300 Hours Of Use Or Three Years
MAINTENANCE 15. Remove engine deposits with Power Tune Engine Cleaner. 16. Check tightness of bolts, nuts, and other fasteners. Every 300 Hours of Use or Three Years, Whichever Occurs First 1. Replace water pump impeller (more often if overheating occurs or reduced water pres- sure is noted).
Page 24: Steering Link Rod Fasteners
MAINTENANCE Steering Link Rod Fasteners WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown over- board exposing them to serious injury or death. IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a”...
Page 25: Corrosion Control Anode
MAINTENANCE Corrosion Control Anode Your outboard has control anodes at different locations. An anode helps protect the out- board against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals. Each anode requires periodic inspection especially in salt water which will accelerate the erosion.
Page 26: Spark Plug Inspection And Replacement
MAINTENANCE Spark Plug Inspection and Replacement Inspect spark plugs at the recommended intervals. WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl.
Page 27: Fuse Replacement - Electric Start Models
MAINTENANCE Fuse Replacement – Electric Start Models IMPORTANT: Always carry spare 20 AMP Fuses. The electric starting circuit is protected from overload by a 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. If the cause is not found, the fuse may blow again.
Page 28: Lubrication Points
MAINTENANCE Lubrication Points Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the pro- peller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from cor- roding and seizing to the shaft.
Page 29: Checking Power Trim Fluid
MAINTENANCE 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. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death.
Page 30: Fuel System
MAINTENANCE Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system. Before servicing any part of the fuel system, stop engine and disconnect the battery.
Page 31: Changing Engine Oil
MAINTENANCE Changing Engine Oil Oil Changing Procedure Pump Method 1. Place the outboard in an vertical upright position. 2. Remove dipstick and slide adaptor tube/pump down dipstick tube. Pump out the engine oil into an appropriate container. 90265A5 Crankcase Oil Pump Drain Plug Method 1.
Page 32: Changing Oil Filter
MAINTENANCE Changing Oil Filter 1. Place a rag or towel below the oil filter to absorb any spilled oil. 2. Unscrew old filter by turning the filter counterclockwise. 3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.
Page 33: Changing Gear Case Lubricant
MAINTENANCE Changing Gear Case Lubricant 3-1/4 In. (83mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
Page 34: 4-1/4 In. (108Mm) Diameter Gear Case
MAINTENANCE 4-1/4 In. (108mm) Diameter Gear Case When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
Page 35 MAINTENANCE CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE Gear Case Lubricant Capacity 24 fl oz (710 ml) 1. Place outboard in a vertical operating position. 2. Remove the front vent plug and rear vent plug. 3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent hole.
Page 36: Storage Preparation
MAINTENANCE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, cor- rosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out-of- season storage or prolonged storage (two months or longer).
Page 37: Positioning Outboard For Storage
MAINTENANCE Positioning Outboard for Storage Store outboard in an upright (vertical) 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 entered the propeller exhaust outlet in the gear case, could freeze and cause damage to the outboard.
Page 38 GENERAL INFORMATION IMPORTANT INFORMATION Section 1C - GENERAL INFORMATION Table of Contents Serial Number Location ....1C-2 Power Trim System ..... . 1C-15 Conditions Affecting Performance .
Page 39: Serial Number Location
All values are corrected to the pow- er that the engine will produce at sea level, at 30% relative humidity, at a temperature of 77 F (25 C) and a barometric pressure of 29.61 inches of mercury. Page 1C-2...
Page 40: Boat
GENERAL INFORMATION Summer conditions of high temperature, low barometric pressure and high humidity all com- bine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.) Nothing will regain this speed for the boater, but the coming of cool, dry weather.
Page 41 GENERAL INFORMATION BOTTOM For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth in fore-and-aft direction. 1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the side.
Page 42: Engine
GENERAL INFORMATION Engine DETONATION Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired.
Page 43: Following Complete Submersion
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 connecting rod and/or bent crankshaft) exists.
Page 44: Model 30/40 (4-Stroke) Powerhead Views Front View
GENERAL INFORMATION Model 30/40 (4-Stroke) Powerhead Front View 59244 Remote Control and Engine Harness Connection Fuse – 20 Amp. Negative Battery Cable DDT Test Port Fuel Connection Battery Cables Throttle and Shift Cables Remote Control Harness Intake Manifold 90-857046R1 NOVEMBER 2001 Page 1C-7...
Page 45: Starboard View
GENERAL INFORMATION Model 30/40 (4-Stroke) Powerhead Starboard View 59245 Lifting Eye Engine Harness Connection to Remote Control Harness Intake Manifold Shift Arm (Non Bigfoot) Shift Linkage Throttle Cam Throttle Lever Page 1C-8 90-857046R1 NOVEMBER 2001...
Page 46: Port View
GENERAL INFORMATION Model 30/40 (4-Stroke) Powerhead Port View 59247 Starter Motor Negative Battery Cable Access Port, Water Pressure/Temperature Sender Accessory Thermostat Housing Voltage Regulator Ignition Coils Oil Dip Stick Engine Coolant Temperature (ECT) Sender Oil Filter Oil Pressure Port Positive Battery Cable 90-857046R1 NOVEMBER 2001 Page 1C-9...
Page 47: Top View
GENERAL INFORMATION Model 30/40 (4-Stroke) Powerhead Top View 59251 Cam Shaft Timing Gear Timing Belt Crank Position Sensor Flywheel Remote Control and Engine Harness Connection Enrichener Valve Page 1C-10 90-857046R1 NOVEMBER 2001...
Page 48: Aft View
GENERAL INFORMATION Model 30/40 (4-Stroke) Powerhead Aft View 59250 Valve Cover Crankcase Breather Hose Oil Fill Plug Fuel Pump (Water Cooled) 90-857046R1 NOVEMBER 2001 Page 1C-11...
Page 49: Propeller Selection
GENERAL INFORMATION Propeller Selection For in-depth information on marine propellers and boat performance - written by marine en- gineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers and Boat Performance Information” (Part No. 90-86144). 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).
Page 50: Propeller Removal/Installation
GENERAL INFORMATION Propeller Removal/Installation 3-1/4 In. (83mm) Diameter Gear Case 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 start- ing and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.
Page 51: 4-1/4 In. (108Mm) Diameter Gear Case
GENERAL INFORMATION 4-1/4 In. (108mm) Diameter Gear Case 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 start- ing and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.
Page 52: Power Trim System
GENERAL INFORMATION Power Trim System General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trim and tilt range several times to remove any air from the system. The trim system is pressurized and is not externally vented. Power Trim Operation With most boats, operating around the middle of the “trim”...
Page 53: Trim "In" Angle Adjustment
GENERAL INFORMATION 4. Increase steering torque or pull to the left at a normal installation height (with the normal right hand rotation propeller). 5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation. 6. Cause engine overheating if any water intake holes are above the water line. Trim “In”...
Page 54: Trim Tab Adjustment
GENERAL INFORMATION Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help to compensate for this steering torque in many cases and can be adjusted within limits to reduce any unequal steering effort.
Page 55: Compression Check
GENERAL INFORMATION Compression Check CAUTION Compression/Cylinder Leakage Tests Must be performed with the ignition/injection system disabled. To do this, the lanyard stop switch MUST BE placed to the “OFF” position. IMPORTANT: Compression check should be done with throttle in WOT position. 1.
Page 56: Cylinder Leakage Testing
GENERAL INFORMATION Cylinder Leakage Testing CAUTION Compression/Cylinder Leakage Tests Must be performed with the ignition/injection system disabled. To do this, the lanyard stop switch MUST BE placed to the “OFF” position. NOTE: Cylinder leakage testing*, along with compression testing, can help the mechanic pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine cylinder.
Page 57: Water Pressure Measurement
GENERAL INFORMATION Water Pressure Measurement 1. Warm up engine. 2. Remove plug. 3. Attach hose fitting and water pressure gauge to cylinder block. NOTE: Water pressure measurements should be done on a warm engine with thermostat operating 140 F (60 C). Water Pump Pressure 22-89772 91-79250A2...
Page 58: Painting Procedures
7. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four col- ors with Ditzler DU5 catalyst mixed 1:1 ratio.
Page 59: Decal Removal/Application
GENERAL INFORMATION CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Us- ing 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 sensitive to scratches and abrasions for a few days.
Page 60 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 61 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents Electric Fuel Pump ..... . 1D-1 Wiring Harness .
Page 62: Start In Gear Protection
OUTBOARD MOTOR INSTALLATION Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine.
Page 63: Lifting Outboard
OUTBOARD MOTOR INSTALLATION Lifting Outboard Use lifting eye on engine. Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate the entire cable end. 2-4-C with Teflon 2. Insert steering cable into tilt tube. 3. Torque nut to 35 lb. ft. (47.5 Nm). 90-857046R1 NOVEMBER 2001 Page 1D-3...
Page 64: Steering Cable Seal
OUTBOARD MOTOR INSTALLATION Steering Cable Seal 1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install seal components. 2. Thread cap to the mark. 1/4 in. (6.4mm) 1/4 in. (6.4 mm) Mark Plastic Spacer O-Ring Seal Steering Link Rod 1.
Page 65: Installing Outboard Thumb Screw Models
OUTBOARD MOTOR INSTALLATION Installing Outboard – Thumb Screw Models WARNING Outboard must be fastened to boat transom one of two ways: 1. permanently fas- tened to transom with thumb screws, and mounting bolts (provided), or 2. secured to the transom using the optional outboard mounting kit (shown below). Should the outboard strike an underwater object or be steered into a sharp turn, failure to fas- ten outboard correctly to the boat transom with mounting bolts or optional mount- ing kit could result in outboard ejecting suddenly off boat transom causing serious...
Page 66 OUTBOARD MOTOR INSTALLATION Installing Outboard – Non Thumb Screw Models 1. Attach (tape) engine mounting template to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Install the outboard so that the anti-ventilation plate is in-line or within 1 in. (25 mm) be- low the bottom of the boat.
Page 67: Wiring Harness
OUTBOARD MOTOR INSTALLATION Wiring Harness IMPORTANT: Warning Horn Requirement – The remote control or key switch assem- bly must be wired with a warning horn. This warning horn is used with the engine warning system. 1. Route wiring harness into bottom cowl. Wiring Harness 2.
Page 68: Battery Cable Connections
OUTBOARD MOTOR INSTALLATION Battery Cable Connections SINGLE OUTBOARD (–) Red Sleeve (Positive) Black Sleeve (Negative) Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between nega- tive (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) - Connect Between Negative (–) Terminals...
Page 69: Shift And Throttle Cable Installation
OUTBOARD MOTOR INSTALLATION Shift and Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote con- trol. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.
Page 70 OUTBOARD MOTOR INSTALLATION 5. Push in on the cable end until resistance is felt. 6. While pushing in on the cable end, adjust the cable barrel (b) to attain the measured dis- tance (a) taken in Step 3. Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 Cable Barrel 7.
Page 71: Throttle Cable Installation
OUTBOARD MOTOR INSTALLATION Throttle Cable Installation 1. Position remote control into neutral. 2. Fit throttle cable through rubber grommet. 3. Install throttle cable with retainer pin. Lock retainer pin in place. 4. Place throttle cable onto the throttle lever pin. Lock in place with retainer. Throttle Cable Retainer 90-857046R1 NOVEMBER 2001...
Page 72 OUTBOARD MOTOR INSTALLATION 5. Adjust cable barrel until the center of the roller lines up with the alignment mark on the cam. Cable Barrel Alignment Mark Roller 6. Fasten control cables with the cable latch. Page 1D-12 90-857046R1 NOVEMBER 2001...
Page 73: Trim-In Stop Adjustment Power Trim Models 1D-13
OUTBOARD MOTOR INSTALLATION Trim-In Stop Adjustment – Power Trim Models If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis.
Page 74: Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
OUTBOARD MOTOR INSTALLATION Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK = Black BLU = Blue BRN = Brown BATT GRY = Gray GRN = Green SENDER ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light...
Page 75 OUTBOARD MOTOR INSTALLATION IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused wiring harness leads. BATT SENDER STARBOARD INSTALLATION 52654 Lanyard/Diode Connect Wires Together with Screw and Hex Nut (4 Places);Apply Quicksilver Liquid Neo- “Y”...
Page 76 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents Specifications ......2A-2 Component Resistance Tests .
Page 77: Specifications
IGNITION Specifications Type Capacitor Discharge Ignition Spark Plug: Type NGK DPR6EA-9 0.035 in. (0.9 mm) Hex Size 18 mm Torque 150 lb-in. (17 Nm) Hole Size 12mm Firing Order 1-2-3 Ignition Timing: @ Idle (800 rpm) 10 A.T.D.C IGNITION @ WOT (6000 rpm) 28 B.T.D.C SYSTEM 660 - 710 Ω...
Page 78: Special Tools
IGNITION Special Tools 1. Flywheel Holder P/N 91-83163M 2. Flywheel Puller P/N 91-83164M 3. Timing Light P/N 91-99379 4. Direct Voltage Adapter P/N 91-89045 90-857046R1 NOVEMBER 2001 Page 2A-3...
Page 79 IGNITION 5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 6. Digital Diagnostic Tester 91-823686A2 7. Cartridge 91-822608--5 8. DDT Reference Manual 90-881204--2 Page 2A-4 90-857046R1 NOVEMBER 2001...
Page 80 IGNITION 9. DDT Cable 10’ (3.05m) Extension 84-825003A1 10. DDT Test Harness 84-822560A7 11. DDT Test Harness 84-822560A10 90-857046R1 NOVEMBER 2001 Page 2A-5...
Page 81: Flywheel
IGNITION FLYWHEEL Loctite 222 4-Stroke Outboard Oil Page 2A-6 90-857046R1 NOVEMBER 2001...
Page 82 IGNITION FLYWHEEL TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FLYWHEEL COVER ELECTRIC SCREW (M6 x 25) DECAL-EPA Information FLYWHEEL (ELECTRIC) FLYWHEEL (MANUAL) DECAL-Warning Spinning flywheel DECAL-Timing Marks DECAL-Warning-Neutral WASHER SCREW (M5 x 25) (MANUAL) SCREW (M5 x 30) (ELECTRIC) STATOR (OG 960499 and Below) STATOR (OG 960500 and Up) LOAD RING...
Page 83: Electrical Components
IGNITION ELECTRICAL COMPONENTS Dielectric Grease Loctite Pipe Sealant With Teflon Page 2A-8 90-857046R1 NOVEMBER 2001...
Page 84 IGNITION ELECTRICAL COMPONENTS TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SOLENOID ASSEMBLY BUSHING GROMMET NUT (8-32) (ELECTRIC) NUT (1/4-20) BATTERY CABLE (POSITIVE) INSULATOR BOOT CABLE BATTERY CABLE (NEGATIVE) STARTER MOTOR (See breakdown on Starter Motor) SCREW (M8 x 45) (ELECTRIC) 21.5 29.5 SCREW (M8 x 25) (MANUAL)
Page 85: Ignition Description
IGNITION Ignition Description The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI ignition system does not incorporate mechanically operated points, therefore mak- ing this CDI unit virtually maintenance free.
Page 86: Crank Position Sensor
IGNITION % Spark Cut-Out 6250 6281 6313 6. Over Heat Protection: Limits engine RPM to 2000 if the engine temperature exceeds 192.2 F (89 C). The ECM will sound the over heat warning horn (a continuous tone) and turn on the optional Over Heat Warning lamp. Over heat warning will subside if the engine temperature drops below 183.2 F (84 C) and engine RPM is momentarily dropped below 1000 RPM as a reset condition.
Page 87: Flywheel Assembly
IGNITION Flywheel Assembly The flywheel assembly contains six permanently charged magnet segments which are bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a south pole providing a 12 pole system. Ignition Coils S/N OG960499 and Below S/N OG960500 and Up The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the...
Page 88: Ignition Troubleshooting
IGNITION CAUTION To protect against meter and/or component damage, observe the following precautions: 400 VDC* test position (or higher) MUST BE used for all tests. INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+) recep- tacle of meter DO NOT CHANGE meter selector switch position while engine is running and/or be- ing “cranked”.
Page 89: Ignition Diagnostic Procedures
IGNITION Multimeter Ohm Checks Tested Part Multimeter Wires Connected To: Meter Scale Meter Reading Green/White (2) R x 1 Ω Stator Charge Coil 660 - 710 Black White/Green (1) Power Bobbin Yel/Blk R x 1 Ω Charge Coil 6.7-7.1 Black Yel/Blk Stator Battery Charge R x 1 Ω...
Page 90: Recommended Test
IGNITION *Recommended Test (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. No Spark Condition (All Cylinders) Crank Position Sensor Stator (ECM) Stop Circuit Short to Ground: a - stop circuit lead b - lanyard stop switch c - tiller handle stop button (if supplied)
Page 91 IGNITION *Recommended Test (cont.) (1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair PROBLEM/CONDITION Probable Cause *Perform Test No. Engine Misfires At High RPM Low Oil Pressure/Engine Over Heating: a - timing retards and fluctuates, rpm will remain below 2000 rpm Ignition Coil/High Tension Lead(s) Spark Plug Cap(s)
Page 92: Troubleshooting With The Digital Diagnostical Terminal
DDT Test Harness (84-822560A10) The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines. Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car- tridge.
Page 93: Component Resistance Tests
IGNITION Component Resistance Tests When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes. NOTE: Refer to section 1C General Information (powerhead reference views) for location of sensors. NOTE: If using DMT 2000 turn the selector switch to Ω. Allow the meter to auto-range. NOTE: Readings listed are taken at 68 F (20 C).
Page 94: Spark Plug Cap Removal
IGNITION IGNITION COIL (PRIMARY) S/N OG960499 and Below S/N OG960500 and Up METER TEST LEADS METER SCALE READING BLACK 0 18 0 24 0.18 - 0.24 BLK/WHT BLACK Spark Plug Cap Removal NOTE: High tension cables must have spark plug cap removed before testing. Cap contains 5k ohm resistor.
Page 95: Spark Plug Cap Resistor Test-P/N Vdfp 2A-20
IGNITION Spark Plug Cap Resistor Test-P/N VDFP METER TEST LEADS METER SCALE READING BLACK RX1K RX1K WIRE END PLUG END Spark Plug Cap Resistor Test-P/N VDO5FP METER TEST LEADS METER SCALE READING BLACK RX1K RX1K 3 5 - 5 2 3.5 - 5.2 WIRE END PLUG END...
Page 96: Engine Coolant Temperature (Ect) Sensor
IGNITION Engine Coolant Temperature (ECT) Sensor 1. Place the engine coolant temperature sensor in a container filled with water. 2. Place a thermometer in the water and slowly heat the water. 3. Measure the resistance when the specified temperature is reached. If the reading is out of specification, replace the sensor.
Page 97: Flywheel Removal/Installation
IGNITION Flywheel Removal and Installation WARNING Engine could possibly start when turning flywheel during removal and installation. To prevent this type of accidental engine starting and possible serious injury, al- ways remove spark plug leads from spark plugs. Removal 1. Remove flywheel cover (manual start models refer to section 8). Screw (4) M6 x 25 Flywheel Cover Page 2A-22...
Page 98 IGNITION 2. Loosen flywheel nut. Hold flywheel using flywheel holder (91-83163M). 3. Remove nut and washer. 91-83163M Flywheel Holder (91-83163M) Breaker Bar with 30 mm Socket Washer 4. Loosen flywheel using puller (91-83164M). Remove flywheel and key. 91-83164M Flywheel Puller (91-83164M) Flywheel 90-857046R1 NOVEMBER 2001 Page 2A-23...
Page 99: Installation
IGNITION Installation 1. Place flywheel key into slot. 2. Install flywheel. Apply oil to threads on crankshaft. 3. Install washer and nut. 4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque. 91-83163M Flywheel Washer Torque Wrench (with 30mm socket) Flywheel Holder (91-83163M) Flywheel Nut Torque 116 lb.
Page 100: Stator Removal/Installation
IGNITION Stator Removal and Installation 1. Remove stator harness from j-clips (s/n OG960499 and below). 2. Remove cable tie from bundled wire connectors (s/n OG960499 and below). 3. Disconnect stator wires. 4. Remove stator mounting screws. 5. Reverse steps for installation (refer to wiring diagram Section 2D for correct stator wire connections).
Page 101: Timing Belt
IGNITION Timing Belt Removal 1. Remove flywheel and stator as outlined previously in this section. 2. Remove timing belt from driven gear and drive gear. Timing Belt Page 2A-26 90-857046R1 NOVEMBER 2001...
Page 102: Installation
IGNITION Installation Timing Belt Installation Notes: Protect the timing belt from water and oil. Use care not to scratch the belt. Do not use any metal device to help stretch the belt onto the driven gear. 1. Align marks on drive and driven gear with marks on cylinder block as shown. 2.
Page 103: Ecm Removal/Installation
IGNITION ECM Removal and Installation 1. Remove and install ECM as shown. Screw (3) M6 x 40 Harness Clip ECM Mounting Screw Torque 45 lb. in. (5 N·m) Page 2A-28 90-857046R1 NOVEMBER 2001...
Page 104: Ignition Coil Removal/Installation
IGNITION Ignition Coil Removal and Installation 1. Disconnect spark plug leads from spark plugs. 2. Remove bundled wires from J-clip. Cut cable tie securing wire connectors. Disconnect wires (BLK/WHT). These steps are required for s/n OG960499 and below. 3. Disconnect ignition coil harness connectors (s/n OG960500 and up). 4.
Page 105: Voltage Regulator Removal/Installation
IGNITION Voltage Regulator Removal and Installation 1. Remove bundled wire connectors from j-clip (s/n OG960499 and below). 2. Remove cable tie (s/n OG960499 and below). 3. Disconnect voltage regulator wires. 4. Remove mounting screws and ground wires. 5. Reverse steps for installation (refer to wiring diagram section 2D for correct wire con- nections).
Page 106 IGNITION Crank Position Sensor Removal and Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor mounting screws. 3. Reverse steps for installation. Crank Position Sensor Harness Connector Screw (2) M5x16 Crank Position Sensor Mounting Screw Torque 45 lb. in. (5 N·m) 90-857046R1 NOVEMBER 2001 Page 2A-31...
Page 107: Engine Coolant Temperature (Ect) Sensor Removal/Installation
IGNITION Engine Coolant Temperature (ECT) Sensor Removal/Installation 1. Disconnect sensor from wiring harness. 2. Remove sensor from exhaust cover. 3. Reverse steps for installation. Tighten to specified torque. CAUTION Over-tightening the engine coolant temperature sensor can lead to failing the plas- tic threads.
Page 108 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B - Charging & Starting System Table of Contents Specifications ......2B-1 Rectifier/Regulator (P/N 854514) Diode Test 2B-9...
Page 109 CHARGING & STARTING SYSTEM STARTER MOTOR TORQUE REF. QTY. DESCRIPTION lb-in lb-ft STARTER MOTOR THRU BOLT DRIVE KIT ARMATURE PINION DRIVE CAP COMMUTATOR CAP BRUSH & SPRING KIT BRUSH HOLDER SCREW DECAL-Warning-High voltage Page 2B-2 90-857046R1 NOVEMBER 2001...
Page 110: Recommended Battery
CHARGING & STARTING SYSTEM Battery Recommended Battery A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA). For operation below 32 F (0 C) a rating of 1000 Marine Cranking Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended.
Page 111: Battery Charging System
CHARGING & STARTING SYSTEM Battery Charging System Description (15 Ampere) The battery charging system components are the stator battery charge coils, regulator and battery. Alternating current (generated in battery charge coils) flows to the regulator, which changes the alternating current to a regulated direct current for charging the battery. Wiring Diagram (15 Ampere) (S/N OG960499 and Below) Blk = Black Blu = Blue...
Page 112 CHARGING & STARTING SYSTEM Wiring Diagram (15 Ampere) (S/N OG960500 and Up) BLK = Black RED = Red GRY = Gray YEL = Yellow Stator Voltage Regulator/Rectifier Connector To Engine Ground To Battery Positive (Red) Terminal To Battery Negative (Black) Terminal 90-857046R1 NOVEMBER 2001 Page 2B-5...
Page 113 CHARGING & STARTING SYSTEM Alternator System Test 6 Ampere Stator CAUTION When testing any charging system, the technician must use an ammeter capable of reading the maximum current output for the test being performed or higher. Fail- ure to use a amp meter that can handle the specific current load could possibly damage the meter being used.
Page 114 CHARGING & STARTING SYSTEM 15 Ampere Stator 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check con- dition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge the battery. If battery can NOT be satisfacto- rily charged, replace battery.
Page 115: Stator Ohms Test
CHARGING & STARTING SYSTEM Stator Ohms Test STATOR (BATTERY CHARGE COIL) 6 Amp. Stator METER READING METER TEST LEADS SCALE BLACK 0 9 1 1 0.9 - 1.1 15 Amp. Stator METER READING METER TEST LEADS SCALE BLACK 0 22 0 24 0.22 - 0.24 Page 2B-8 90-857046R1 NOVEMBER 2001...
Page 116 CHARGING & STARTING SYSTEM Rectifier/Regulator (P/N 854514) Diode Test Analog Meter NOTE: Voltage regulator/rectifier specifications are given for informational purposes only, use the appropriate troubleshooting techniques previously mentioned to find the faulty com- ponent in the charging system. Blk = Black Gry = Gray Red = Red Yel = Yellow...
Page 117 CHARGING & STARTING SYSTEM Digital Meter NOTE: Voltage regulator/rectifier specifications are given for informational purposes only, use the appropriate troubleshooting techniques previously mentioned to find the faulty com- ponent in the charging system. Blk = Black Gry = Gray Red = Red Yel = Yellow S/N OG960499 and Below S/N OG960500 and Up...
Page 118: Starting System Components
CHARGING & STARTING SYSTEM Starting System Components Description The function of the starting system is to crank the engine. The battery supplies electrical energy to crank the starter motor. When the ignition switch is turned to “START” position, the starter solenoid is activated and completes the starting circuit between the battery and starter The neutral start switch opens the start circuit when the shift control lever is not in neutral.
Page 119: Troubleshooting The Starting Circuit
CHARGING & STARTING SYSTEM Troubleshooting the Starting Circuit Before beginning the starting circuit troubleshooting flow chart, following, check first for the following conditions: 1. Make sure that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3.
Page 120 CHARGING & STARTING SYSTEM Starting Circuit Troubleshooting Flow Chart The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any exist- ing malfunction. Location of “TEST POINTS” (called out in the chart) are numbered in dia- gram below.
Page 121 CHARGING & STARTING SYSTEM * Battery Voltage TEST 2 a. Disconnect BLACK ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. No voltage reading; c. Turn ignition key to “Start” position. proceed to TEST 3. 12 Volt Reading* TEST 3 a.
Page 122 CHARGING & STARTING SYSTEM Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads and black starter motor lead from starter terminal. 2. Remove upper mounting screws and loosen bottom screw. Lift starter motor in an upward direction and remove.
Page 123 CHARGING & STARTING SYSTEM Disassembly IMPORTANT: Before separating components mark them with an awl or marker. This will ensure proper orientation during reassembly. 1. Remove 2 through bolts and commutator end cap, taking care not to lose brush springs. Thru Bolts Commutator End Cap Brush Springs I.D.
Page 124 CHARGING & STARTING SYSTEM 3. Pull armature from starter frame. Washer Spring Pinion Stopper (2) Pinion Drive End Cap Armature Shaft Washer 90-857046R1 NOVEMBER 2001 Page 2B-17...
Page 125 CHARGING & STARTING SYSTEM Cleaning and Inspection 1. Clean all motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is ex- cessive.
Page 126 CHARGING & STARTING SYSTEM Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Re- check after cleaning between commutator bars. If saw blade still vibrates, replace armature. ARMATURE TEST FOR GROUND 1.
Page 127 CHARGING & STARTING SYSTEM CHECKING POSITIVE BRUSHES AND TERMINALS 1. Connect ohmmeter (R x 1 scale) leads between positive brushes. 2. Ohmmeter must indicate full continuity (zero resistance). If resistance is indicated, check lead to positive terminal solder connection. If connection cannot be repaired, brushes must be replaced.
Page 128: Brush Replacement
CHARGING & STARTING SYSTEM Brush Replacement IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in length Positive (+) Terminal Long Brush Lead Push Lead Into Slot Insulating Washer Flat Washer Lock Washer Positive (+) Brushes Negative (–) Brushes Brush Holder Bolts (Fasten Negative Brushes and Holder)
Page 129 CHARGING & STARTING SYSTEM Reassembly 1. Lubricate helix threads and drive end cap bushing with SAE 10W oil. 2. Install the pinion, pinion stopper, spring, second pinion stopper, washer, and NEW nut onto armature shaft. 3. Lightly clamp the armature in a vise and torque nut to specified torque. Nut (New) Washer Spring...
Page 130 CHARGING & STARTING SYSTEM 4. Construct a brush retainer tool as shown. Brush Retainer Tool Layout (Full Size) 18-Gauge Sheet Metal METRIC SCALE 3” = 76.2mm 2” = 50.8mm 1-3/4” = 44.5mm 1-11/16” = 42.9mm 3/4” = 19.1mm 1/2” = 12.7mm Brush Retainer Tool Side View (Full Size) 90-857046R1 NOVEMBER 2001 Page 2B-23...
Page 131 CHARGING & STARTING SYSTEM 5. Place springs and brushes into brush holder and hold in place with brush retainer tool. 6. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate Brush Retainer Tool Bushing 7. Position armature into starter frame so that commutator end of armature is at end of starter frame where permanent magnets are recessed 1 in.
Page 132 CHARGING & STARTING SYSTEM Installation 1. Secure starter to block with (3) mounting screws. Tighten screws to specified torque. Secure NEGATIVE battery lead and starter motor lead as shown. Starter Mounting Screw (3) M8 x 45 Negative Battery Lead Starter Motor Lead Starter Motor Mounting Screw Torque 22 lb.
Page 133 TIMING, SYNCHRONIZING, & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing, & Adjusting Table of Contents Specifications ......2C-1 Carburetor Synchronization .
Page 134 TIMING, SYNCHRONIZING, & ADJUSTING Special Tools 1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1 2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1 with Filters P/N 35-18206 3. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1 4. Timing Light P/N 91-99379...
Page 135 TIMING, SYNCHRONIZING, & ADJUSTING 5. Digital Diagnostic Tester 91-823686A2 6. DDT Cartridge 91-822608-–5 and DDT Reference Manual 90-859769. 91-822608-–5 90-859769 7. DDT Cable 10’ (3.05m) Extension 84-825003A1 8. DDT Test Harness 84-822560A7 and 84-822560A10 84-822560A10 84-822560A7 9. Tubing Clamp P/N 91-804063 90-857046R1 NOVEMBER 2001 Page 2C-3...
Page 136 TIMING, SYNCHRONIZING, & ADJUSTING Timing WARNING To prevent personal injury or possible death, from loss of balance or stability while servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure to follow one of the recommended servicing procedures may result in the person falling overboard or causing personal injury from fall in boat.
Page 137 TIMING, SYNCHRONIZING, & ADJUSTING 2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within specification window, refer to Diagnostic Test Procedures Section 2A.) 10 ATDC Timing Mark (Full Retarded) 3. Slowly increase the engine RPM while watching the ignition timing marks. The timing should increase to the maximum timing specification “Full Advance”...
Page 138 2. Install intake manifold hose adaptor in each plug hole. Tighten securely. NOTE: Intake manifold hose adaptors are provided with the Carburetor Tuner. Intake Manifold Plugs (3) Intake Manifold Hose Adaptor (3) Intake Manifold Hose Adaptor (3) From Mercury Filled Carb Tuner Page 2C-6 90-857046R1 NOVEMBER 2001...
Page 139 4. Pinch off enrichener lines between carburetors with a tubing clamp. CAUTION When using the old style mercury filled carb. tuner (p/n 91-809641A1) install filters (p/n 35-18206) in each line. This will prevent mercury from being drawn into carbure- tors during an abrupt throttle change. 91-804063...
Page 140 TIMING, SYNCHRONIZING, & ADJUSTING SYNCHRONIZING CARBURETORS 1. With the outboard in water, start engine and allow to warm up. Shift the outboard to neutral. 2. Connect a tachometer to the engine. 3. Adjust idle RPM screw on bottom carburetor to obtain an idle setting of 1000 RPM in neutral.
Page 141 TIMING, SYNCHRONIZING, & ADJUSTING 4. Read the vacuum of cylinder #3. It’s not important to be at any specific vacuum setting. 5. Adjust the carburetor synchronization screws of cylinders #2 and #1 to match the base vacuum of cylinder #3. NOTE: Keep viewing the tachometer, as the engine RPM may fluctuate during adjustments.
Page 142 TIMING, SYNCHRONIZING, & ADJUSTING CAUTION When using the old style mercury filled carb. tuner (91-809641A1) install filters (3) in each line. This will prevent mercury from being drawn into carburetors during an abrupt throttle change. WARNING When revving the engine move the throttle cam to increase RPM. Do not use remote control or tiller handle twist throttle to increase RPM.
Page 143 WIRING DIAGRAMS ELECTRICAL Section 2D - Wiring Diagrams Table of Contents 30/40 ELPT ......2D-2 Without Light Switch .
Page 144: 30/40 Elpt
WIRING DIAGRAMS 30/40 ELPT A B C D YEL_RED TAN_LTBLU BLK_DKBLU TAN_BLK TAN_WHT BLK_YEL – BLK_ORG BLK_GRN BLK_WHT RED_WHT TAN_GRN LTBLU DKBLU YEL_BLK YEL_BLK WHT_GRN GRN_WHT RED_PPL GRN_WHT LTBLU_WHT Trim Down Relay Cowl Mounted Trim Switch Crank Position Sensor Fuse-20A Acc. and Trim Temperature Sensor To Remote Trim Switch Oil Switch...
Page 145: 30/40 Ehpt
WIRING DIAGRAMS 30/40 EHPT YEL_RED TAN_LTBLU BLK_DKBLU TAN_BLK TAN_WHT BLK_YEL –1 BLK_ORG BLK_GRN BLK_WHT RED_WHT TAN_GRN LTBLU DKBLU YEL_BLK YEL_BLK WHT_GRN GRN_WHT RED_PPL GRN_WHT LTBLU_WHT YEL_RED BLK_YEL YEL_BLK – BLK_YEL BLK_YEL 57184 BLK_YEL BLK_YEL Cowl Mounted Trim Switch Fuse-20A Acc. and Trim Crank Position Sensor To Remote Trim Switch Temperature Sensor...
Page 146: 30/40 Mh
WIRING DIAGRAMS 30/40 MH A B C D LTBLU TAN_LTBLU BLK_DKBLU TAN_LTBLU TAN_LTBLU BLK_YEL BLK_YEL BLK_YEL BLK_YEL BLK_YEL BLK_ORG BLK_GRN BLK_WHT YEL_BLK YEL_BLK RED_WHT YEL_BLK YEL_BLK TAN_GRN LTBLU DKBLU YEL_BLK YEL_BLK YEL_BLK YEL_BLK YEL_BLK YEL_BLK WHT_GRN WHT_GRN WHT_GRN GRN_WHT GRN_WHT GRN_WHT 57186 Push Button Stop Switch...
Page 147: 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 Wiring Harness Connector Tachometer/Accessories Harness Connector Ignition/Choke Switch Emergency Stop Switch Neutral Start Switch 90-857046R1 NOVEMBER 2001 Page 2D-5...
Page 148: Commander 3000 Panel Mount Control
WIRING DIAGRAMS Commander 3000 Panel Mount Control BLK/YEL BLU/WHT Â Â Â Â Â Â Â Â Â GRN/WHT YEL/RED BLK=BLACK BLU=BLUE YEL/RED BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL/RED YEL=YELLOW YEL/RED Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made, (use of electrical butt connector) verify connection is secure and sealed for moisture proof connection.
Page 149: Instrument/Lanyard Stop Switch Wiring Diagram
WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram IMPORTANT: On installations where gauge options will not be used, tape back any unused wiring harness leads. BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red...
Page 150: Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK = Black BLU = Blue BRN = Brown BATT GRY = Gray GRN = Green SENDER ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light...
Page 151 WIRING DIAGRAMS IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused wiring harness leads. BATT SENDER STARBOARD INSTALLATION 52654 Lanyard/Diode Connect Wires Together with Screw and Hex Nut (4 Places);Apply Liquid Neoprene to Con- “Y”...
Page 152: Commander 2000 Key Switch Test
WIRING DIAGRAMS 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: BLK = Black PUR = Purple RED = Red YEL = Yellow CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: POSITION BLK/YEL...
Page 153: Instrument Wiring Connections
WIRING DIAGRAMS Instrument Wiring Connections Without Light Switch NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK TO THE HARNESS. Speedometer Tachometer Temperature/Oil Warning Panel Volt Meter TAN/WHT TAN/BLK 51820 Tachometer Receptacle-From Control Box or Wire Where To Ignition/Choke Switch BLK=BLACK GROUND...
Page 154: Oil Pressure Wiring Diagram
WIRING DIAGRAMS NOTE: Refer to individual oil pressure gauge instructions for proper installation procedures for installing gauge in boat. 1. Install LIGHT BLUE sensor lead to oil pressure gauge as shown. NOTE: Normal oil pressure readings will be as follows: Outboard at normal operating tem- perature –...
Page 155: Qsi Gauge Wiring Diagrams
WIRING DIAGRAMS QSI Gauge Wiring Diagrams Tachometer Wiring Diagram Tachometer dial on back side of case must be set to position number 4. WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. 51106 PURPLE or WHITE - Connect to Positive (+) 12 Volt Light Switch Wire - 12 Volt Position Light Bulb to the Switched Position...
Page 156: Water Temperature Gauge
WIRING DIAGRAMS Water Temperature Gauge WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. SEND PURPLE - Connect to Positive (+) 12 Volt Light Switch Wire - 12 Volt Position Light Bulb to the Switched Position BLACK - Connect to Negative (-) Ground TAN - Connect to TAN lead located at the tachometer receptacle on Com- mander Side Mount Remote Control or TAN lead coming from Accessary Igni-...
Page 157: Engine Synchronizer Wiring Diagram
WIRING DIAGRAMS Route TAN lead on starboard side of engine to engine/remote control harness. Connect as shown. IMPORTANT: Tape back and isolate any unused wiring harness leads. 28086 Lead from Temperature Sender Engine/Remote Control Harness Engine Synchronizer Wiring Diagram LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting.
Page 158 WIRING DIAGRAMS Synchronizer wiring can be accomplished two different ways as an option to the user. Wiring Diagram – Gauge needle to point toward slow running engine 52566 Tachometer - Starboard Engine Synchronizer Gauge Tachometer - Port Engine Synchronizer Box Wiring Diagram –...
Page 159 WIRING DIAGRAMS CLEANING GAUGES Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with a soft cloth moistened with water. The gauge may be scored or damaged if wiped with abra- sive material (sand, saline or detergent compounds, etc.) or washed with solvents such as trichloroethylene, turpentine, etc.
Page 160: Remote Wiring Harness Connection To Engine
WIRING DIAGRAMS Remote Wiring Harness Connection to Engine Electric Start Remote Control Model 1. Route the remote wiring harness to the back of the engine block as shown. Remote Wiring Harness 2. Connect wiring. Place harness into the holder. BLU/WHT BLU/WHT GRN/WHT GRN/WHT...
Page 161: Remote Key
WIRING DIAGRAMS Remote Key 1. Connect the remote key harness and engine harness, secure harness in holder. BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White...
Page 162: Power Trim Switch Wiring Diagram
WIRING DIAGRAMS Power Trim Switch Wiring Diagram GRN/WHT LT. GRN/WHT LT. GRN/WHT BLU/WHT LT. BLU/WHT LT. BLU/WHT GRN = Green BLU = Blue RED = Red WHT = White Trim Switch Starter Relay Page 2D-20 90-857046R1 NOVEMBER 2001...
Page 163 FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Table of Contents ..... . . 3A-1 Fuel Pump Installation .
Page 164 FUEL PUMP FUEL PUMP (S/N OG960499 AND BELOW) Loctite 242 Page 3A-2 90-857046R1 NOVEMBER 2001...
Page 165 FUEL PUMP FUEL PUMP TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL FILTER STA–STRAP TUBING (14 IN.) TUBING (19 IN.) FUEL CONNECTOR – O RING FUEL PUMP SCREW Drive Tight O RING DIAPHRAGM SCREW Drive Tight CHECK VALVE DIAPHRAGM SPRING SPRING...
Page 166 FUEL PUMP FUEL PUMP (S/N OG960500 AND UP) Loctite 242 Page 3A-4 90-857046R1 NOVEMBER 2001...
Page 167 FUEL PUMP FUEL PUMP TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP SCREW Drive Tight DIAPHRAGM/O RING KIT SPRING SPRING PLUNGER COWL DEFLECTOR SCREW (M6 x 30) TUBING (13 IN.) TUBING (6 IN.) HOSE J CLIP TUBING (14 IN.) FUEL FILTER TUBING (19 IN.) STA–STRAP...
Page 168 FUEL PUMP Fuel Pump Operation S/N OG960499 and Below NOTE: S/N OG960499 and below can be updated with the new water cooled fuel pump. The fuel pump is a diaphragm pump which is mechanically driven off of the rocker arm. The pump base insulates the fuel pump from the heat of the engine block.
Page 169 FUEL PUMP Fuel Pump Removal S/N OG960499 and Below 1. Cut sta-straps and remove fuel pump inlet and outlet hoses. 2. Remove fuel pump mounting screws and cowl deflector. 3. Separate fuel pump from cylinder head cover. Outlet Fuel Hose Inlet Fuel Hose Mounting Screw (2) M6 x 30 Cowl Deflector...
Page 170 FUEL PUMP Fuel Pump Installation S/N OG960499 and Below 1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to specified torque. 2. Connect fuel lines to pump and secure with new sta-straps. Loctite 242 Outlet Fuel Hose Inlet Fuel Hose Cap on Unused Outlet Cowl Deflector...
Page 171 FUEL PUMP S/N OG960500 and Up (Installation) 1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to specified torque. 2. Connect fuel lines to pump and secure with new sta-straps. 59250 Loctite 242 Inlet Fuel Hose (from fuel filter) Outlet Fuel Hose (to carburetors) Fuel Cooler Water Inlet Hose (from exhaust cover) Fuel Cooler Water Outlet Hose (to tell-tale outlet)
Page 172 FUEL PUMP Fuel Pump Disassembly IMPORTANT: Before separating fuel pump components mark each component with an awl or marker. This will ensure the components are oriented correctly during reas- sembly. 1. Remove screws to separate pump cover, cover seal, diaphragm and valve body from pump base.
Page 173 FUEL PUMP Cleaning/Inspection/Repair (All Serial Numbers) 1. Inspect fuel filter for cracks/clogs, replace if necessary. 2. Inspect springs for damage, replace if necessary. 3. Inspect cover seal and diaphragm, replace if damaged. Cover Seal Diaphragm Check Valve Inspection/Replacement (S/N OG960499 and Below) 1.
Page 174 FUEL PUMP Check Valve Inspection/Replacement (S/N OG960500 and Up) 1. Inspect the check valves for damage, replace if necessary. REMOVAL 2. If replacement is needed remove old check valves by grabbing the seal and pulling. 58831 Check Valve/Seal Assembly (2) INSTALLATION 1.
Page 175 FUEL PUMP Fuel Pump Assembly 1. Assemble springs, diaphragm, and plunger onto pump base. Diaphragm Diaphragm Spring Pump Body Spring Plunger 2. Line up slots and compress assembly. 3. Insert pin into hole. Pump Body Slots 4. Rotate plunger 90 to offset slots. 53615 Slots Aligned Slots Offset...
Page 176 FUEL PUMP 5. Assemble valve body, diaphragm, seal, and cover to pump base. Be sure to line up I.D. marks that were made before disassembly. Apply Loctite 242 to screws and secure with nuts. NOTE: Seal installs in one direction only. 28378 Loctite 242 Screws (4) M5 x 40...
Page 177 CARBURETOR FUEL SYSTEM Section 3B - Carburetor Table of Contents Specifications ......3B-1 Idle Speed .
Page 178 CARBURETOR Special Tools 1. Carburetor Scale P/N 91-36392. 2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1. Page 3B-2 90-857046R1 NOVEMBER 2001...
Page 179 CARBURETOR Notes: 90-857046R1 NOVEMBER 2001 Page 3B-3...
Page 180 CARBURETOR FUEL LINES (S/N OG960499 and Below) Page 3B-4 90-857046R1 NOVEMBER 2001...
Page 181 CARBURETOR FUEL LINES TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HOSE HOSE LINKAGE BUSHING CABLE TIE HOSE HOSE PROTECTIVE SLEEVE 90-857046R1 NOVEMBER 2001 Page 3B-5...
Page 182 CARBURETOR FUEL LINES (S/N OT178500 and Up) Page 3B-6 90-857046R1 NOVEMBER 2001...
Page 183 CARBURETOR FUEL LINES TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HOSE HOSE LINKAGE BUSHING CABLE TIE HOSE HOSE & SLEEVE CONNECTOR FITTING (45 DEGREE) HOSE HOSE (3-1/2 IN.) HOSE (90MM) CLIP STA-STRAP WASHER COTTER PIN Y-CONNECTOR 90-857046R1 NOVEMBER 2001 Page 3B-7...
Page 184 CARBURETOR CARBURETOR (S/N OT178499 and Below) Page 3B-8 90-857046R1 NOVEMBER 2001...
Page 185 CARBURETOR CARBURETOR TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CARBURETOR (TOP) CARBURETOR (CENTER) CARBURETOR (BOTTOM) SCREW PLATE GASKET ENRICHENER O RING PLATE JET (IDLE) JET (SLOW) RUBBER PLUG JET (MAIN) FLOAT VALVE MAIN NOZZLE FLOAT FLOAT PIN GASKET FLOAT BOWL (TOP) FLOAT BOWL (CENTER/BOTTOM) SCREW DRAIN SCREW...
Page 186 CARBURETOR CARBURETOR (S/N OT178500 and Up) Page 3B-10 90-857046R1 NOVEMBER 2001...
Page 187 CARBURETOR CARBURETOR TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CARBURETOR (TOP) CARBURETOR (CENTER) CARBURETOR (BOTTOM) SCREW PLATE GASKET ENRICHENER O RING PLATE IDLE MIXTURE SCREW O-RING SPRING JET (SLOW) O-RING PLUG JET (MAIN) MAIN NOZZLE FLOAT VALVE FLOAT FLOAT PIN SCREW GASKET FLOAT BOWL (TOP) FLOAT BOWL (CENTER/BOTTOM)
Page 188 CARBURETOR INTAKE Page 3B-12 90-857046R1 NOVEMBER 2001...
Page 189 CARBURETOR INTAKE TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW AIR INTAKE O RING PLATE ISOLATOR (40) ISOLATOR (30) PLUG SOUND ATTENUATOR SCREW (M6 x 20) BUSHING STA-STRAP SEAL O RING DOWEL PIN SCREW (M6 x 25) BREATHER HOSE STA-STRAP 90-857046R1 NOVEMBER 2001 Page 3B-13...
Page 190: Carburetor Adjustments
CARBURETOR Carburetor Adjustments Float Level 1. With carburetor turned upside down and carb scale seated on inner edge, check float level from top of float to float bowl flange as shown. Float Height 0.47-0.63 in. (12.0-16.0 mm) Idle Speed NOTE: Outboard should be completely warmed up for the idle speed adjustment. NOTE: Turning the idle speed adjustment screw clockwise will increase idle speed.
Page 191 CARBURETOR Idle Mixture Screw Adjustment NOTE: Access to idle mixture screws can only be made by removing the sealing plug. Dril- ling a small hole in the center of the plug and using an awl to pry out the plug must be done with extreme caution.
Page 192: Carburetor Removal
CARBURETOR Carburetor Removal 1. Disconnect auto enrichener wires, breather hose, and fuel supply lines. Auto Enrichener Wires (Yellow) Breather Hose Fuel Supply Line Page 3B-16 90-857046R1 NOVEMBER 2001...
Page 193: Carburetor Disassembly
CARBURETOR 2. Remove intake and carburetor mounting screws. Intake Mounting Screw (3)-M6x20 Carburetor Mounting Screw (6) Carburetor Disassembly Carburetors Not Equipped With Bowl Vent Hoses 1. Remove sound attenuator, air intake and plate from carburetor assembly. Sound Attenuator Screw (6) Air Intake Carburetor Assembly Plate...
Page 194 CARBURETOR 2. Remove auto enrichener. Auto Enrichener Plate Screw O-Ring 3. Remove fuel lines and unsnap linkage. Linkage Fuel Lines Page 3B-18 90-857046R1 NOVEMBER 2001...
Page 195 CARBURETOR Carburetors Equipped With Bowl Vent Hoses 1. Remove sound attenuator and plate from carburetor assembly. Sound Attenuator Carburetor Assembly Plate Isolator 2. Remove auto enrichener. 59258 Auto Enrichener Plate Screw O-Ring 90-857046R1 NOVEMBER 2001 Page 3B-19...
Page 196 CARBURETOR 1. Remove fuel hoses and disconnect the throttle linkage. 59260 59259 Linkage Fuel Lines Enrichener/Balance Hoses Bowl Vent Hoses Enrichener Vent Hose Page 3B-20 90-857046R1 NOVEMBER 2001...
Page 197 CARBURETOR DISASSEMBLY CONTINUED (ALL MODELS) 2. Remove float bowl. 3. Remove plunger, spring, and gasket. Screws (4) Float Bowl Plunger Spring Gasket Retaining Screw 4. Remove float, plug, nozzles and jets. NOTE: Earlier models are likely equipped with the old style float.. Screw Plug Float Pin...
Page 198 CARBURETOR 5. Remove cover and gasket. Screws (3) Cover Gasket Idle jet Page 3B-22 90-857046R1 NOVEMBER 2001...
Page 199 CARBURETOR Inspection 1. Inspect needle and piston valve. Replace if worn or damaged. 2. Measure auto enrichener resistance. Replace if out of specification. Auto Enrichener Resistance 15-25 Ω @ 68 F (20 C) 3. Perform piston valve height test below. Piston Valve Height Test: a.
Page 200 CARBURETOR 6. Inspect float, replace if cracked or damaged. Old Style Float New Style Float CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance. Use a petroleum based solvent for cleaning and blow out all passages with compressed air.
Page 201: Carburetor Reassembly
CARBURETOR Carburetor Reassembly 1. Install idle jet (if equipped), gasket, and cover. Screws (3) Cover Gasket Idle jet 2. Install jets, nozzles, plug and float. NOTE: Earlier models are likely equipped with the old style float.. Screw Plug Float Pin Slow Jet Old Style Float Main Jet...
Page 202 CARBURETOR 3. Install plunger and spring. 4. Install gasket bowl and float. Screws (4) Spring Float Bowl Gasket Plunger Retaining Screw Page 3B-26 90-857046R1 NOVEMBER 2001...
Page 203 CARBURETOR Carburetors Not Equipped With Bowl Vent Hoses 5. Install fuel hoses and throttle linkage. Secure hoses with cable ties where shown. Linkage Fuel Hoses 90-857046R1 NOVEMBER 2001 Page 3B-27...
Page 204 CARBURETOR Carburetors Equipped With Bowl Vent Hoses 1. Install hoses and throttle linkage. Secure hoses with cable ties where shown. 59260 59259 Throttle Linkage Fuel Hoses Enrichener/Balance Hoses Bowl Vent Hoses Enrichener Vent Hose 2. Install auto enrichener. Auto Enrichener Plate Screw O-Ring...
Page 205 CARBURETOR 3. Install air intake and plate onto carburetor assembly. Sound Attenuator Screw (6) Air Intake Carburetor Assembly Plate Isolator 90-857046R1 NOVEMBER 2001 Page 3B-29...
Page 206: Carburetor Installation
CARBURETOR Carburetor Installation 1. Install intake and carburetor mounting screws. Intake Mounting Screw (3)-M6 x 20 Carburetor Mounting Screw (6) Carburetor Mounting Screw Torque 70 lb. in. (8 N·m) Page 3B-30 90-857046R1 NOVEMBER 2001...
Page 207 CARBURETOR 2. Connect auto enrichener wires, breather hose, fuel supply hose, and bowl vent hoses. Auto Enrichener Wires (Yellow) Breather Hose Fuel Supply Hose Bowl Vent Hose (if equipped) Through Hole in Adaptor Plate NOTE: Carburetor synchronization is required after rebuilding carburetors. Refer to section 2C, Timing/Synchronizing/Adjusting.
Page 208 EMISSIONS FUEL SYSTEM Section 3C – Emissions Table of Contents Exhaust Emissions Standards ... . 3C-2 Homogenized Charge ....3C-4 What Are Emissions? .
Page 209: Exhaust Emissions Standards
EMISSIONS Exhaust Emissions Standards Through the Environmental Protection Agency (EPA), the federal government has estab- lished exhaust emissions standards for all new marine engines sold in the U.S. What Are Emissions? Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running.
Page 210: Stoichiometric (14.7:1) Air/Fuel Ratio
EMISSIONS Stoichiometric (14.7:1) Air/Fuel Ratio In the search to control pollutants and reduce exhaust emissions, engineers have discov- ered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions.
Page 211: Stratified Vs Homogenized Charge
EMISSIONS STRATIFIED VS HOMOGENIZED CHARGE DFI engines use a stratified charge inside the combustion chamber to aid in reducing emis- sions. All other models use a homogenized charge. The difference between the two is: 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 212: 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 213: Emissions Information
EMISSIONS Emissions Information Manufacturer’s Responsibility: Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA). A certifica- tion decal/emissions control information label, showing emission levels and engine specifi- cations directly related to emissions, must be placed on each engine at the time of manufac- ture.
Page 214: Epa Emission Regulations
EMISSIONS EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is con- tingent on certain adjustments being set to factory standards.
Page 215: Decal Location For 1999 Models
Intake: 0.15 – 0.25 Cold Valve Clearance (mm) Exhaust: 0.25 – 0.35 a-Family Example b-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family c-Timing specifications when adjustable d-Recommended spark plug for best engine performance e-Valve Clearance (Four Stroke engines only)
Page 216: Decal Location For 2000 And Newer Models
Intake: 0.15 – 0.25 Cold Valve Clearance (mm) Exhaust: 0.25 – 0.35 j-Family Example k-FEL: Represents (Mercury Marine) statement of the maximum emissions output for the engine family l-Timing specifications when adjustable m-Recommended spark plug for best engine performance n-Valve Clearance (Four Stroke engines only)
Page 217: Service Replacement Certification Label
EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine out- boards have a visible and legible emission certification label. If this label is missing or damaged, contact Mercury Marine Service for replacement if appropriate.
Page 218 CYLINDER HEAD POWERHEAD Section 4A - Cylinder Head Table of Contents Table of Contents ..... . . 4A-1 Valve Removal .
Page 219: Specifications
CYLINDER HEAD Specifications Camshaft Dimensions 1.214 - 1.222 in. (30.83 - 31.03 mm) Intake “A” 1.214 - 1.222 in. (30.83 - 31.03 mm) Exhaust “A” 1.020 - 1.028 in. (25.90 - 26.10 mm) Intake “B” 1.020 - 1.028 in. (25.90 - 26.10 mm) Exhaust “B”...
Page 220 CYLINDER HEAD Warp Limit 0.004 in. (0.1 mm) * Lines indicate 56899 straight edge measurement CYLINDER HEAD Camshaft Bore Inside Diameter “a” 1.4567 - 1.4577 in. (37.000 - 37.025 mm) 56900 Valve/Valve Seat/Valve Guides: Valve Clearance (cold) Intake 0.006 - 0.010 in. (0.15 - 0.25 mm) Exhaust 0.010 - 0.014 in.
Page 221 CYLINDER HEAD Valve Dimensions “C” “B” “D” “A” Margin Thickness Seat Width Head Diameter Face Width ROCKER SHAFT Outside Diameter 0.6288 - 0.6296 in. (15.971 - 15.991 mm) Inside Diameter of Bore 0.6299 - 0.6306 in. ROCKER ARM (16.000 - 16.018 mm) Page 4A-4 90-857046R1 NOVEMBER 2001...
Page 222: Special Tools
CYLINDER HEAD Special Tools 1. Flywheel Holder P/N 91-83163M 2. Valve Guide Remover P/N 91-809495A1 3. Valve Guide Installer Bushing P/N 91-809496A1 4. Valve Guide Reamer P/N 91-809497A1 5. Valve Spring Compressor P/N 91-809494A1 6. Valve Seat Cutter Kit (Obtain Locally). 90-857046R1 NOVEMBER 2001 Page 4A-5...
Page 223: Cylinder Head
CYLINDER HEAD CYLINDER HEAD 4-Stroke Outboard Oil Page 4A-6 90-857046R1 NOVEMBER 2001...
Page 224 CYLINDER HEAD CYLINDER HEAD TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER HEAD (ELECTRIC) – CYLINDER HEAD (MANUAL) CYLINDER HEAD GUIDE SCREW M6 X 8 GASKET OIL SEAL PIPE PLUG O RING COVER BREATHER PIPE DECAL-Servicing Referral DECAL-Engine Oil/Valve Clearance SCREW (M9 x 1.5 x 95) 35.0 SCREW (M6 x 25)
Page 225: Camshaft/Oil Pump
CYLINDER HEAD CAMSHAFT/OIL PUMP 4-Stroke Outboard Oil Loctite 222 Page 4A-8 90-857046R1 NOVEMBER 2001...
Page 226 CYLINDER HEAD CAMSHAFT/OIL PUMP TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (M8 x 40 x 1.25) WASHER BELT GEAR-Driven DOWEL PIN CAMSHAFT (MANUAL) CAMSHAFT (ELECTRIC) OIL PUMP ASSEMBLY O RING O RING O RING SCREW (M6 x 35) 90-857046R1 NOVEMBER 2001 Page 4A-9...
Page 227: Intake/Exhaust Valves
CYLINDER HEAD INTAKE/EXHAUST VALVES 4-Stroke Outboard Oil Page 4A-10 90-857046R1 NOVEMBER 2001...
Page 228 CYLINDER HEAD INTAKE/EXHAUST VALVES TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m EXHAUST VALVE INTAKE VALVE SEAL–Valve Stem VALVE SPRING–Outer RETAINER–Valve Spring ROCKER ARM SCREW 13.5 ROCKER SHAFT PLUG BRACKET SPRING BRACKET SPRING SEAL PIN - CAM THRUST SCREW (M8 x 23) 13.3 SPRING - Overload (If Equipped) 13.3...
Page 229: Torque Sequence
CYLINDER HEAD Torque Sequence Page 4A-12 90-857046R1 NOVEMBER 2001...
Page 230: Valve Cover
CYLINDER HEAD Valve Cover NOTE: Valves should be adjusted when engine is cold. WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Removal 1.
Page 231 CYLINDER HEAD 4. Disconnect the crankcase breather hose, vent hose, and fuel pump in/out hoses. 5. Disconnect fuel cooler in/out hoses (If equipped). IMPORTANT: The hose fittings on the fuel pump can break if you try twisting or pull- ing off the hoses. Remove fuel pump hoses by slowly prying them off using a small screwdriver.
Page 232: Installation
CYLINDER HEAD Installation 1. Install valve cover seal into groove. 2. If removed, reinstall baffle plate. Tighten screws securely. Baffle Plate Screw (4) M4 x 10 Cover Seal 90-857046R1 NOVEMBER 2001 Page 4A-15...
Page 233 CYLINDER HEAD 3. Reinstall the valve cover. Tighten screws to the specified torque. 4. Install coils. Refer to section 2A - Ignition Coil Installation. 5. Install fuel pump. Refer to section 3C - Fuel Pump Installation. 6. Connect fuel pump in/out hoses, fuel cooler in/out hoses, crankcase breather and vent hose.
Page 234 CYLINDER HEAD 8. Install flywheel cover/manual starter components (if equipped). Tighten screws to speci- fied torque. NOTE: Refer to section 8 for installation of manual starter. Flywheel Cover Screw (4) M6 x 25 Flywheel Cover Screw Torque 75 lb. in. (8.5 N·m) 90-857046R1 NOVEMBER 2001 Page 4A-17...
Page 235: Valve Clearance Adjustment
CYLINDER HEAD Valve Clearance Adjustment NOTE: Valve should be adjusted when the engine is cold. WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. Checking Valve Clearance 1.
Page 236: Adjusting Valves
CYLINDER HEAD Adjusting Valves 1. Perform the following adjustment steps: a. Turn the driven gear and align the “1 / ∆” mark on the driven gear with the “∆” mark on the cylinder block. b. Adjust the intake and exhaust valve clearance for cylinder #1. c.
Page 237: Timing Belt
CYLINDER HEAD Timing Belt Removal 1. Remove flywheel and stator. Refer to section 2B Charging and Starting System. 2. Remove timing belt from driven gear and drive gear. Timing Belt Page 4A-20 90-857046R1 NOVEMBER 2001...
Page 238: Installation
CYLINDER HEAD Installation Timing Belt Installation Notes: Protect the timing belt from water and oil. Use care not to scratch the belt. Do not use any metal device to help stretch the belt onto the driven gear. 1. Align marks on drive and driven gear with marks on cylinder block as shown. 2.
Page 239: Cylinder Head Removal
CYLINDER HEAD Cylinder Head Removal WARNING Engine could possibly start when turning flywheel during adjustment. To prevent this type of accidental engine starting and possible serious injury, always remove spark plug leads from spark plugs. 1. Remove valve cover. Refer to Valve Cover Removal. 2.
Page 240 CYLINDER HEAD 5. Separate cylinder head from cylinder block. NOTE: Cylinder head gasket is not reusable. Gasket (Discard) Dowel Pins (2) (Retain) 90-857046R1 NOVEMBER 2001 Page 4A-23...
Page 241: Cylinder Head Disassembly
CYLINDER HEAD Cylinder Head Disassembly Rocker Arm Assembly Removal 1. Remove screws securing rocker arm shaft to cylinder head. Remove rocker arm assem- bly and retainers. Screws (4) M8 x 30 Rocker Arm Assembly Oil Pump Removal 1. Refer to section 4C - Oil Pump Removal. Page 4A-24 90-857046R1 NOVEMBER 2001...
Page 242: Camshaft Removal
CYLINDER HEAD Camshaft Removal 1. Hold driven gear using tool (91-83163M) and loosen screw. Remove screw, washer, driven gear and dowel pin. NOTE: The camshaft can be removed from the top without removing the cylinder head from the engine. 91-83163M Holder 91-83163M Driven Gear Screw M8 x 40...
Page 243: Valve Removal
CYLINDER HEAD Valve Removal VALVE COMPONENTS Valve Valve Seal Valve Spring Spring Retainer Valve Keepers REMOVING VALVES NOTE: Anytime a valve is removed, replace the valve seal. 1. Compress valve springs using tool (91-809494A1). Remove valve keepers and valves. 91-809494A1 58256 Valve Spring Compressor (P/N 91-809494A1) Valve Keepers...
Page 244: Rocker Shaft And Rocker Arm
CYLINDER HEAD Rocker Shaft and Rocker Arm 1. Measure rocker shaft diameter. Replace shaft if out of specification. Rocker Shaft Diameter 0.6288 - 0.6296 in. (15.971 -15.991 mm) 2. Measure rocker arm inside diameter. Replace rocker arms if out of specification. 55804 Rocker Arm Inside Diameter 0.6299 - 0.6306 in.
Page 245: Cleaning/Inspection/Repair
CYLINDER HEAD Cleaning/Inspection/Repair Camshaft Manual start models are equipped with a cam shaft featuring a compression release mechanism. The compression relief mechanism releases a percentage of the cylinder compression during engine cranking, which lowers the starter rope pull force. At cranking speeds (RPM) the cam shaft decompression levers rest against the side of the exhaust cam lobes, protruding out from the heal of the lobe.
Page 246 CYLINDER HEAD 3. Measure the cam lobe length (a) and width (b). Cam Lobe Specifications Intake 1.214 - 1.222 in. (30.83 - 31.03 mm) Exhaust 1.214 - 1.222 in. (30.83 - 31.03 mm) Intake 1.020 - 1.028 in. (25.90 -26.10 mm) Exhaust 1.020 - 1.028 in.
Page 247: Cylinder Head
CYLINDER HEAD Cylinder Head 1. Inspect the cylinder head for the following conditions: Mineral deposits/corrosion in water passage ways. Carbon deposits in combustion chamber (use round scraper to clean away depos- its). Be careful not to scratch or remove material. 2.
Page 248: Valve Guide Replacement
CYLINDER HEAD Valve Guide Replacement 1. Heat the cylinder head in an oven to 390 F (200 C). This will help to ease guide removal and installation and to maintain correct interference fit. 2. Remove the valve guide using a valve guide remover. Valve Guide Remover (91-809495A1) 3.
Page 249: Valves
CYLINDER HEAD Valves 1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned valves. 2. Measure the valve stem diameter to check for wear. Replace valves if not within specifi- cation. Valve Stem Diameter Intake Valve 0.2156 - 0.2161 in.
Page 250: Valve Springs
CYLINDER HEAD 5. Measure valve stem runout, replace if out of specification. Valve Stem Runout Limit (Max.) Intake Valve 0.0006 in. (0.016 mm) Exhaust Valve Valve Springs 1. Check each spring under load on a spring tester. Replace any weak springs. 2.
Page 251 CYLINDER HEAD 3. Check each spring on a flat surface using a square. Rotate spring and check space be- tween the top coil and square. Replace valve springs if not in specification. Valve Spring Tilt Specification “a” Less than 0.06 in. (1.7 mm) Page 4A-34 90-857046R1 NOVEMBER 2001...
Page 252: Valve Seat Reconditioning
CYLINDER HEAD Valve Seat Reconditioning Clean the carbon deposits from the combustion chambers and valve seats and check for pitting. Several different types of equipment are available for reseating valve seats. Follow the equipment manufacturer’s instructions. Measure valve seat width (a). Resurface the valve seat if not in specification. Reface valve seat, use a 60 , 45 , 15 valve seat cutter.
Page 253: Valve Refacing Steps
CYLINDER HEAD Valve Refacing Steps Condition: The valve seat is centered on valve face but it is too wide. Valve Seat Cutter Set Desired Results 15 Cutter To reduce valve seat Li htl Lightly width idth 60 Cutter Condition: The valve seat is in the middle of the valve face but it is too narrow. Valve Seat Cutter Set Desired Results 45 Cutter...
Page 254: Cylinder Head Reassembly
CYLINDER HEAD Condition: Valve seat is too narrow and is located near the bottom edge of the valve face. Valve Seat Cutter Set Desired Results 60 Cutter, First To center the seat and to in- crease its Width it Width 45 Cutter Cylinder Head Reassembly Valve Installation...
Page 255: Camshaft Oil Seal Installation
CYLINDER HEAD INSTALLING VALVES NOTE: Always use new valve seals. 1. Apply engine oil to the valves and valve seats. 2. Compress the valve spring and retainer and install the valve keepers around the valve stem. You may have to tap lightly on the end of the valve to seat the keepers. NOTE: Valve springs are symmetrical and may be installed in either direction.
Page 256: Camshaft Installation
CYLINDER HEAD Camshaft Installation 1. Apply engine oil to the main journals (4 places) on the camshaft. 2. Slide camshaft into cylinder head (threaded end towards driven gear). NOTE: Camshaft retaining pin groove must align with retaining pin hole in cylinder head. 3.
Page 257: Oil Pump Installation
CYLINDER HEAD Oil Pump Installation 1. Refer to section 4C - Oil Pump Installation. Rocker Arm Shaft Assembly 1. Apply engine oil to the rocker shaft and arms. 2. Locate the end of the rocker shaft that gets installed towards driven gear (oil holes will line-up with the mating oil holes in the cylinder head).
Page 258: Rocker Arm Shaft Installation
CYLINDER HEAD Rocker Arm Shaft Installation 1. Install the rocker arm shaft assembly as shown. 2. Install rocker arm retainers on rocker shaft as shown. Tighten screws to the specified torque. NOTE: Leave all adjustment screws loose at this time. 58987 4-Stroke Outboard Oil Mounting Screw (4)-M8 x 30...
Page 259: Cylinder Head Gasket
CYLINDER HEAD Cylinder Head Gasket 1. Install new cylinder head gasket and dowel pins. Gasket (New) Dowel Pin (2) Page 4A-42 90-857046R1 NOVEMBER 2001...
Page 260: Cylinder Head Installation
CYLINDER HEAD Cylinder Head Installation 1. Apply engine oil to the threads of each screw and seat surface. 2. Fasten cylinder head with screws shown. Do not tighten. 4-Stroke Outboard Oil Screw (8) M9 x 95 Flange Screw (4) M6 x 25 90-857046R1 NOVEMBER 2001 Page 4A-43...
Page 261 CYLINDER HEAD 3. Torque center screws (first) in sequence and in two steps. 4. Torque the cylinder head and carburetor intake manifold screws in sequence and in two steps. 5. Refer to “Timing Belt Installation” preceding, and install timing belt. 6.
Page 262 CYLINDER BLOCK/CRANKCASE POWERHEAD Section 4B - Cylinder Block/Crankcase Table of Contents Specifications ......4B-2 Thermostat .
Page 263: Specifications
CYLINDER BLOCK/CRANKCASE Specifications Type 4 Stroke Cycle – Over Head Camshaft CYLINDER Displacement 45.6 cu. in. (747 cc) BLOCK Number of Cylinders STROKE Length 2.953 in. (75 mm) Diameter Standard 2.5591 in. (65 mm) Oversize-0.010 in. (0.25 mm) 2.5689 in. (65.25 mm) CYLINDER Oversize-0.020 in.
Page 264: Special Tools
CYLINDER BLOCK/CRANKCASE Special Tools 1. Oil Filter Wrench (P/N 91-802653) 2. Flywheel Holder (P/N 91-83163M) 3. Flywheel Puller (P/N 91-83164M) 4. Powerhead Stand (P/N 91-855662A1) 5. Piston Ring Compressor (P/N FT2997) 6. Piston Ring Expander (P/N 91-24697) 90-857046R1 NOVEMBER 2001 Page 4B-3...
Page 265: Crankshaft
CYLINDER BLOCK/CRANKCASE CRANKSHAFT 4-stroke Outboard Oil Page 4B-4 90-857046R1 NOVEMBER 2001...
Page 266 CYLINDER BLOCK/CRANKCASE CRANKSHAFT TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CRANKSHAFT OIL SEAL OIL SEAL CONNECTING ROD BOLT 12.5 BEARING (BROWN) BEARING (BLACK) BEARING (BLUE) PISTON PISTON RING (TOP) PISTON RING (SECOND) PISTON OIL RING PISTON PIN RETAINER 90-857046R1 NOVEMBER 2001 Page 4B-5...
Page 267: Cylinder Block And Crankcase
CYLINDER BLOCK/CRANKCASE CYLINDER BLOCK AND CRANKCASE Loctite PST Pipe Sealant Loctite Master Gasket 4 Stroke Oil A = TO FUEL PUMP COOLER B = TO FITTING IN ADAPTOR PLATE Page 4B-6 90-857046R1 NOVEMBER 2001...
Page 268 CYLINDER BLOCK/CRANKCASE CYLINDER BLOCK AND CRANKCASE TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CYLINDER BLOCK DOWEL PIN PLUG PIPE PLUG (1/2-14) PIPE PLUG (3/4-14) BEARING (BROWN) BEARING (BLACK) BEARING (BLUE) NIPPLE 29.5 SCREW (M8 X 82) SCREW (M6 X 35) GASKET OIL FILTER GASKET EXHAUST COVER...
Page 269: Torque Sequence
CYLINDER BLOCK/CRANKCASE Torque Sequence Exhaust Cover Crankcase Cover Intake Manifold Powerhead Page 4B-8 90-857046R1 NOVEMBER 2001...
Page 270: Powerhead Removal
CYLINDER BLOCK/CRANKCASE Powerhead Removal WARNING The possibility exists that the engine could start when turning the flywheel. To avoid possible serious injury, always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. On electric start models, disconnect the battery cables from the battery. Remove battery cables from engine.
Page 271 CYLINDER BLOCK/CRANKCASE 7. Push retainer up and slide over to disengage the vertical shift shaft. REMOTE CONTROL MODEL (NON - BIGFOOT) Retainer 8. Remove the shift guide bracket screws. TILLER HANDLE MODEL 58479 Shift Guide Bracket Screw (2) M6 x 25 Page 4B-10 90-857046R1 NOVEMBER 2001...
Page 272 CYLINDER BLOCK/CRANKCASE 9. Disconnect the crankcase vent hose. 10. Disconnect inlet hose from fuel pump. 59250 Crankcase Vent Hose Fuel Pump Inlet hose 11. Remove powerhead mounting bolts. 12. Lift powerhead from driveshaft housing. Powerhead Mounting Bolts (4 Each Side) M8 x 45 Hoist 90-857046R1 NOVEMBER 2001 Page 4B-11...
Page 273: Removing Powerhead Components
CYLINDER BLOCK/CRANKCASE Removing Powerhead Components 1. Place powerhead on bench. Ignition Components 1. Refer to Section 2A for removal of the following ignition components. a. Flywheel b. Stator c. Timing Belt d. Ignition Coils e. ECM Crank Position Sensor g. Temperature Sensor Charging and Starting System Components 1.
Page 274: Cylinder Block Disassembly
CYLINDER BLOCK/CRANKCASE Cylinder Block Disassembly 1. Remove the drive gear components. Load Ring (Discard) Drive Gear Woodruff Key 2. Remove exhaust cover and gasket. 3. Remove oil filter. 91-802653 Screw and Washer (10) M6 x 35 Thermostat Cover Gasket (Discard) Thermostat Exhaust Cover Gasket...
Page 275: Crankcase And Crankshaft Removal
CYLINDER BLOCK/CRANKCASE Crankcase and Crankshaft Removal 1. Remove crankcase cover and dowel pins. 56875 Screw and Washer (8)-M8 x 82 Screw and Washer (8)-M6 x 35 Crankcase Cover Dowel Pin (2) 2. With a rubber or plastic hammer, lightly strike the crankcase cover in order to separate it from the block.
Page 276 CYLINDER BLOCK/CRANKCASE 3. Use a 5/16 in. 12 point socket and remove connecting rod bolts and caps. NOTE: Each connecting rod , cap and bearing are a matched set. They must not be inter- changed. 4. Remove carbon ridge from the cylinder bore using a burr knife. Push out the connecting rod/piston assembly.
Page 277 CYLINDER BLOCK/CRANKCASE 7. Remove crankshaft from block. 56877 Crankshaft Upper Oil Seal Lower Oil Seal NOTE: Do not interchange main bearings, re-install in their original locations. 8. Remove main bearing halves from crankcase cover and cylinder block. 56878 Main Bearing Halves-Crankcase Cover (4) Main Bearing Halves-Cylinder Block (4) Page 4B-16 90-857046R1 NOVEMBER 2001...
Page 278: Inspection
CYLINDER BLOCK/CRANKCASE Inspection Cylinder Bore MEASURING CYLINDER BORE 1. Measure the cylinder bore diameter at three locations in both X and Y axis. 2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be nec- essary to re-bore the cylinder to accept the oversize piston.
Page 279: Piston
CYLINDER BLOCK/CRANKCASE Piston 1. Inspect piston wall wear/damage. Replace if necessary. 2. Measure the piston at a point 0.2 in (5.0 mm) from the bottom. Replace if out of specifica- tion. Piston Diameter 0.2 in. (5.0 mm) Piston Diameter “a” Piston Size Diameter Standard...
Page 280: Piston Pin
CYLINDER BLOCK/CRANKCASE Piston Pin 1. Measure piston pin diameter. Replace piston pin if out of specification. 55839 Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm) 1. Place the piston pin into the connecting rod and check for free play. There should be no noticeable free play.
Page 281: Crankshaft
CYLINDER BLOCK/CRANKCASE PISTON RING END GAP CLEARANCE 1. Measure piston ring end gap clearance. Replace piston ring if out of specification. 53747 Push Piston Rings into Cylinder 0.8 in. (20 mm) Deep. Push in the Rings Using the Piston. Piston Ring End Gap 0.006 - 0.012 in.
Page 282: Checking Main Bearing Clearance
CYLINDER BLOCK/CRANKCASE Checking Main Bearing Clearance IMPORTANT: Do not interchange the main bearings. Reinstall in their original posi- tion. 1. Clean all the old sealing material from the split line on the crankcase cover and cylinder block. 2. Clean all the oil from the following areas: Main bearing surfaces on the cylinder block and crankcase cover.
Page 283 CYLINDER BLOCK/CRANKCASE 6. Install crankcase cover. Apply oil to the cover bolts and torque cover bolts in sequence and in two steps. Crankcase Cover Bolt Torque 1st Torque: 11 lb-ft. (15 Nm) Center Bolts Qty. 8 Center Bolts Qty. 8 (M8x82) 2nd Torque: 22 lb-ft.
Page 284: Checking Connecting Rod Bearing Clearance
CYLINDER BLOCK/CRANKCASE Checking Connecting Rod Bearing Clearance IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings in their original position. 1. Clean all the oil from the connecting rod bearing surfaces and connecting rod journals on the crankshaft. NOTE: Refer to instructions in Cylinder Block Reassembly for selecting and installing con- necting rod bearings.
Page 285: Thermostat
CYLINDER BLOCK/CRANKCASE 4. Remove the connecting rod cap. Measure the compressed plastigauge to check the connecting rod oil clearance. Replace bearings if oil clearance is not in specification. 53810 Connecting Rod Oil Clearance 0.0008 – 0.0020 in. (0.020 - 0.052 mm) Thermostat 1.
Page 286: Cylinder Block Reassembly
CYLINDER BLOCK/CRANKCASE Cylinder Block Reassembly Selecting New Main Bearings 1. Locate the main bearing code letters on the cylinder block. 2. Refer to the following reference chart to select the correct main bearings. 3. Use the color coded main bearings that match the main bearing code letter. Main Bearing Code Main Bearing Color Code Letter...
Page 287: Main Bearing Installation
CYLINDER BLOCK/CRANKCASE Main Bearing Installation IMPORTANT: Do not interchange used main bearings. Reinstall in their original posi- tion. 1. Check clearance of each bearing, as outlined in Main Bearing Clearance procedure. 2. Clean all the oil from the main bearing surfaces on the cylinder block and crankcase cover.
Page 288: Installing Connecting Rod Bearings
CYLINDER BLOCK/CRANKCASE Selecting New Connecting Rod Bearings 1. Locate the connecting rod bearing code letter that is scribed on the side of the connect- ing rod. 2. Refer to the following reference chart to select the correct connecting rod bearings. 3.
Page 289: Connecting Rod Installation
CYLINDER BLOCK/CRANKCASE Connecting Rod Installation 1. Lubricate the piston pin with oil and assemble the piston to the connecting rod. Always use new circlips. IMPORTANT: Install the split end of the circlip into the groove first, push the other end down until it snaps into the groove.
Page 290: Piston Ring Installation
CYLINDER BLOCK/CRANKCASE Piston Ring Installation IMPORTANT: Use caution when installing piston rings to avoid scratching piston. 1. Install the oil ring components as shown. Spread rings just enough to slip over piston. 2. Install the second and top compression rings (“T” side up). Spread rings just enough to slip over piston.
Page 291: Piston Installation
CYLINDER BLOCK/CRANKCASE Piston Installation NOTE: Cylinder bores must be clean before installing pistons. Clean with light honing, as necessary. After honing, clean cylinder bores with water and detergent. After cleaning, swab cylinder bores several times with engine oil and a clean cloth, then wipe with a clean dry cloth.
Page 292 CYLINDER BLOCK/CRANKCASE 2. Install upper and lower oil seals on crankshaft. Position oil seal lips as shown. 3. Carefully lower crankshaft into place. IMPORTANT: Make sure the lower oil seal notch is positioned into the groove in the crankcase. 58273 Upper Oil Seal Lower Oil Seal (Raised Rib) Oil Seal Groove...
Page 293: Crankcase Cover Installation
CYLINDER BLOCK/CRANKCASE Crankcase Cover Installation 1. Clean off all oil from the contacting surfaces of the crankcase cover and cylinder block. IMPORTANT: Make sure the contacting surface of the crankcase cover and cylinder block are clean before applying gasket sealant. 2.
Page 294: Thermostat And Exhaust Cover Installation
CYLINDER BLOCK/CRANKCASE Thermostat and Exhaust Cover Installation 1. Install oil filter. Tighten to specified torque using wrench p/n 91-802653. 2. Install exhaust cover along with the thermostat and thermostat cover. Use new gaskets. 3. Tighten screws to the first torque value in the sequence shown below. Repeat this procedure for the second torque value.
Page 295: Drive Gear Installation
CYLINDER BLOCK/CRANKCASE Drive Gear Installation 1. Install the drive gear components. NOTE: Load ring is for one time use and must be replaced if flywheel is removed. Load Ring Drive Gear Drive Key Page 4B-34 90-857046R1 NOVEMBER 2001...
Page 296: Installing Powerhead Components
CYLINDER BLOCK/CRANKCASE Installing Powerhead Components 1. Reinstall cylinder head. Refer to Section 4A Cylinder Head Installation. IGNITION COMPONENTS 1. Refer to Section 2A for installation of the following ignition components. a. Flywheel b. Stator c. Timing Belt d. Ignition Coils e.
Page 297: Powerhead Installation
CYLINDER BLOCK/CRANKCASE Powerhead Installation CAUTION When lubricating the driveshaft splines do not allow any grease on top of the drive- shaft. Grease on top of the driveshaft will force the shaft down when installing the gearcase, causing the pinion gear to bind with the forward gear. This can result in damage or failure of the gears.
Page 298 CYLINDER BLOCK/CRANKCASE 3. Re-connect throttle/shift linkage and control cable anchor bracket. Torque fasteners to specified torque. Remote Control Model (Bigfoot Gearcase) 58254 Control Cable Anchor Bracket Screw (2) M6 x 16 Throttle/Shift Lever Throttle/Shift Lever Screw (1) M8 x 70 Throttle/Shift Lever Mounting Screw Torque 100 lb-in.
Page 299 CYLINDER BLOCK/CRANKCASE Non Bigfoot Model 5. Push retainer up and slide over to engage the vertical shift shaft. Retainer 6. Reconnect hoses. Use sta-straps to fasten all hose connections. 59250 Crankcase Vent Hose Fuel Pump Inlet hose Page 4B-38 90-857046R1 NOVEMBER 2001...
Page 300: Tiller Handle Models
CYLINDER BLOCK/CRANKCASE 7. Reconnect the power trim harness wires. 8. Install spark plugs 9. Install bottom cowl. Tighten screws to specified torque. Screw (6)-M6 x 30 Lower Cowl Screw-M6 x 60 Bottom Cowl Screw Torque 60 lb-in. (7 Nm) 10. Connect battery cables to battery terminals (red goes to positive terminal). 11.
Page 301 LUBRICATION POWERHEAD Section 4C - Lubrication Table of Contents Specifications ......4C-1 Cleaning and Inspection .
Page 302 LUBRICATION CAMSHAFT/OIL PUMP Page 4C-2 90-857046R1 NOVEMBER 2001...
Page 303 LUBRICATION CAMSHAFT/OIL PUMP TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CAMSHAFT DOWEL PIN OIL PUMP ASSEMBLY O-RING O-RING O-RING O-RING SCREW (M6 X 16) SCREW (M6 X 40) 90-857046R1 NOVEMBER 2001 Page 4C-3...
Page 304 LUBRICATION Oil Pump Identification There was a change made to the oil pump starting with the following serial numbers: ELECTRIC S/N OT427437 and up MANUAL S/N 0T426439 and up The oil hole on the new style pump is elongated into an oval shape. Old Style Oil Pump - Circular Hole New Style Oil Pump - Oval Hole Oil Pump Removal...
Page 305 LUBRICATION Oil Pump Disassembly 1. If screws cannot be loosened with a screwdriver, heat them with a non-flame type heat source (heat lamp). This will loosen the Loctite sealant on the screw threads. Remove screws. Screw (2) 2. Disassemble oil pump. Cover Seal Outer Rotor Inner Rotor...
Page 306 LUBRICATION Cleaning and Inspection Oil Pump 1. Check oil pump components for pitting, scratches, and for the following measurements. Replace oil pump if worn or out of specification. 2. Using a feeler gauge, measure the following oil pump clearances: a. Between outer rotor and pump housing (a). b.
Page 307 LUBRICATION Oil Pump Reassembly 1. Reassemble the oil pump assembly. 2. Lubricate the outer and inner rotors thoroughly with engine oil. Cover Seal Outer Rotor Inner Rotor Shaft Cross Pin 3. Fasten cover with two screws. Apply Loctite 222 to threads. Tighten screws to the speci- fied torque.
Page 308 LUBRICATION Oil Pump Installation 1. Place O-ring seals on the oil pump. Lubricate the O-rings with oil. 2. Prime the oil pump by pouring approximately 1 fl oz (30 ml) of engine oil into the oil pump body. 58260 O-Ring Seals 30 ml of Engine Oil IMPORTANT: When the oil pump mounting surface gets close to the mating surface of the cylinder head, do not twist/turn oil pump from side to side.
Page 309 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Specifications ......5A-1 Adaptor Plate .
Page 310: Transom Bracket
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket 2-4-C Marine Lubricant with Teflon Page 5A-2 90-857046R1 NOVEMBER 2001...
Page 311 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Bracket TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft TRANSOM BRACKET (PORT) GREASE FITTING GROOVE PIN TRANSOM BRACKET (STARBOARD) TILT LOCK LEVER SPRING NYLINER SPRING KNOB GROOVE PIN WASHER ANCHOR BRACKET ANODE ASSEMBLY SCREW (M6 x 25) WASHER SCREW (30 MM) SCREW (35 MM)
Page 312: Swivel Bracket
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket A = TORQUE NUT 120 LB. (13.5 N_M) AND THEN BACK OFF 1/4 TURN. 2-4-C Marine Lubricant with Teflon Page 5A-4 90-857046R1 NOVEMBER 2001...
Page 313 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft LINK ROD SCREW (1-1/2 IN.) 27.0 WASHER NON HANDLE WASHER NUT (.375-24) 13.5 PUCK BUSHING SWIVEL BRACKET BEARING GREASE FITTING (Quantity 3 required on Handle Versions) DECAL-Co-Pilot DECAL-Serial Overlaminate BUSHING (LOWER)
Page 314 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Driveshaft Housing Page 5A-6 90-857046R1 NOVEMBER 2001...
Page 315 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Driveshaft Housing TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft SEAL–water tube DRIVESHAFT HOUSING (SHORT) DRIVESHAFT HOUSING (LONG) EXHAUST PIPE (SHORT) EXHAUST PIPE (LONG) SCREW–Adaptor Plate SCREW (M8 x 45) DRAIN PLUG 17.5 23.5 GASKET BUMPER GROMMET (LONG) STUD (NON-BIGFOOT) STUD (BIGFOOT)
Page 316 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Adaptor Plate Loctite PST Pipe Sealant With Teflon 4 Stroke Outboard Oil Page 5A-8 90-857046R1 NOVEMBER 2001...
Page 317 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Adaptor Plate TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft DIPSTICK DIPSTICK TUBE SEAL ADAPTOR PLATE PLUG TUBING (17 IN.) FITTING STA-STRAP STA-STRAP SEAL–driveshaft (NON-BIGFOOT) SEAL–driveshaft (BIGFOOT) BUSHING (NON-BIGFOOT) PLUG–oil passage GROMMET (NON-BIGFOOT) GASKET O RING SCREW (M6 x 20) BODY–oil pressure relief PLATE-Top Oil Pickup...
Page 318: Steering Arm
CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon Page 5A-10 90-857046R1 NOVEMBER 2001...
Page 319 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Steering Arm TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft STRAP MOUNT WASHER (BIGFOOT) SCREW (M6 x 20) BUMPER BUMPER (BIGFOOT) RETAINING RING STEERING ARM BRACKET TAB WASHER NON HANDLE SCREW (M10 x 30) 32.5 SCREW (M12 x 154) 32.5 SPACER (SHORT) SPACER (LONG)
Page 320 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl 2-4-C Marine Lubricant with Teflon Page 5A-12 90-857046R1 NOVEMBER 2001...
Page 321 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Bottom Cowl TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft BOTTOM COWL (SHORT-PORT) BOTTOM COWL (LONG-PORT) BOTTOM COWL (SHORT-STBD.) BOTTOM COWL (LONG-STBD.) SCREW (M6 X 30) WASHER SEAL WASHER GASKET SCREW (M6 x 60) FITTING-TELLTALE BOOT STA-STRAP LEVER-COWL LATCH BUSHING...
Page 322 POWER TRIM MID-SECTION Section 5B - Power Trim Table of Contents Special Tools ......5B-2 Trim Motor Removal .
Page 323: Special Tools
POWER TRIM Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers Snap-On P/N SRP2 3. Expanding Rod P/N CG 41-11* 4. Collet P/N CG 41-14* 5. Heat Lamp P/N 91-63209 Page 5B-2 90-857046R1 NOVEMBER 2001...
Page 324 POWER TRIM Notes: 90-857046R1 NOVEMBER 2001 Page 5B-3...
Page 325: Power Trim
POWER TRIM Power Trim Loctite 242 NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use auto- motive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. Page 5B-4 90-857046R1 NOVEMBER 2001...
Page 326 POWER TRIM Power Trim TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft – POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O RING REBUILD KIT O RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT (NON-BIGFOOT) TRIM LIMIT VALVE KIT (BIGFOOT) PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG MANUAL RELEASE ASSEMBLY...
Page 327: Theory Of Operation
POWER TRIM Theory Of Operation The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and trim cylinder. The remote control (or trim panel) is equipped with a switch that is used for trimming the outboard “up” and “down”, and for tilting the outboard for shallow water operation (at slow speed) or for “trailering”.
Page 328: Trailering Outboard
POWER TRIM TRIMMING OUTBOARD “DOWN” (“IN”) WARNING Excessive speed at minimum trim “In” may cause undesirable and/or unsafe steer- ing conditions. Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle (tilt pin relocation). Will help planing off, particularly with a heavy load.
Page 329: Power Trim Flow Diagrams
POWER TRIM Power Trim Flow Diagrams TRIM UP CIRCUIT Reservoir Oil Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 Up Pressure 880 1110 psi (30 60 hp) 1625 psi (30 60 hp) 1220 1420 psi (75 125 hp) 2800 psi (75 125 hp) Tilt Relief Pressure...
Page 330 POWER TRIM Trim Up When the trim switch is activated in the up position, the electric motor (c) begins to rotate the oil pump gears (j). The oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i).
Page 331: Tilt Circuit
POWER TRIM Tilt Circuit Reservoir Oil Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 Up Pressure 880 1110 psi (30 60 hp) 1625 psi (30 60 hp) 1220 1420 psi (75 125 hp) 2800 psi (75 125 hp) minimun Tilt Relief Pressure...
Page 332 POWER TRIM Tilt Up In the up mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage, and if required, causes the tilt relief piston (s) to open the tilt pressure relief valve (r). This valve lowers the amount of pressure available to lift the outboard motor.
Page 333: Maximum Tilt
POWER TRIM Maximum Tilt Reservoir Oil Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880 1110 psi (30 60 hp) 1220 1420 psi (75 125 hp) Up Pressure Tilt Relief Pressure 1625 psi (30 60 hp) 250 400 psi (30 60 hp) 2800 psi (75 125 hp) 500 700 psi (40 60 hp Bigfoot)
Page 334 POWER TRIM Maximum Tilt With the piston rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylinder (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston’s “pin” opens the tilt relief valve (r). Up pressure flows into the trim relief passage, and returns back into the reservoir.
Page 335: Down Circuit
POWER TRIM Down Circuit Reservoir Oil Filtered Feed Oil Í Í Í Return Oil Í Í Í Oil Under Pressure Impact Relief Pressure #22 880 1110 psi (30 60 hp) 1220 1420 psi (75 125 hp) Tilt Relief Pressure Up Pressure 250 400 psi (30 60 hp) 1625 psi (30 60 hp) 500 700 psi (40 60 hp Bigfoot)
Page 336 POWER TRIM Down Mode When the trim switch is activated in the down position, the electric motor (c) will rotate the pump (j) in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump (j).
Page 337: Shock Function
POWER TRIM Shock Function Up Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880 1110 psi (30 60 hp) 1220 1420 psi (75 125 hp) Tilt Relief Pressure 250 400 psi (30 60 hp) Up Pressure 1625 psi (30 60 hp) 500 700 psi (40 60 hp Bigfoot)
Page 338 POWER TRIM Shock Function Up Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear, the piston rod (a) will try to rapidly extend from the cylinder (w), and the pressure increases inside the trim cylinder down cavity and connecting passages.
Page 339: Shock Function Return
POWER TRIM Shock Function Return Reservoir Oil Return Oil Í Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880 1110 psi (30 60 hp) 1220 1420 psi (75 125 hp) Tilt Relief Pressure Up Pressure 250 400 psi (30 60 hp) 1625 psi (30 60 hp) 500 700 psi (40 60 hp Bigfoot) 2800 psi (75 125 hp)
Page 340 POWER TRIM Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure between the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity.
Page 341: Manual Release
POWER TRIM Manual Release Down Pressure 525 880 psi Reservoir Oil Return Oil Filtered Oil Í Í Í Í Impact Relief Pressure #22 880 1110 psi (30 60 hp) 1220 1420 psi (75 125 hp) Tilt Relief Pressure Up Pressure 250 400 psi (30 60 hp) 1625 psi (30 60 hp) 500 700 psi (40 60 hp Bigfoot)
Page 342 POWER TRIM Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are connected together. These passages connect both the cylinder down and up cavities to- gether, along with the reservoir, allowing the engine to be raised or lowered.
Page 343: Troubleshooting
POWER TRIM Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during trouble- shooting procedure), it is recommended that unit be disassembled completely and ALL O-rings be replaced. Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re-assembly.
Page 344: Hydraulic System Troubleshooting Flow Chart
POWER TRIM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Manual release valve and Manual release Inspect manual release valve. O-rings appear to be O.K. - valve and O-ring Clean and reinstall manual damaged.
Page 345 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage. Suction seat assembly Debris and/or damage appears O.K. - Clean and identified. reinstall suction seat assembly. Replace suction seat Trim will not hold assembly.
Page 346 POWER TRIM Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Manual release valve Inspect manual release valve. Manual release valve and O- and O-ring damaged. rings appear to be O.K. - Clean and reinstall manual release valve.
Page 347 POWER TRIM Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore appears Cylinder bore appears rough and/or debris smooth with no debris. found in cylinder. Replace memory pis- ton and shock piston Trim leaks down. O-rings.
Page 348: Troubleshooting The Power Trim Electrical System
POWER TRIM Troubleshooting the Power Trim Electrical System BLU/WHT GRN/WHT BLU/WHT or PUR GRN/WHT or GRN RED/PUR – RED/PUR GRN/WHT BLU/WHT GRN/WHT GRN/WHT 14 BLK GRN/WHT LT. BLU/WHT LT.BLU/WHT BLUE 14 BLK LT. BLU/WHT Trim Switch (Remote Control Mounted) Up Relay Trim Switch (Panel Mounted) Solenoid Fuse Holder...
Page 349 POWER TRIM Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inopera- 1. Open wire between Wire Connection (1) 1. Check for an open connection or cut tive, but the Cowl Switch and Trim Switch.
Page 350: Power Trim System Removal
POWER TRIM Power Trim System Removal 1. Tilt outboard to the full up position and support with tilt lock pin. 2. Disconnect the power trim wire harness and remove clamp. 55264 55464 Tilt Lock Pin Power Trim Wire Harness Clamp Harness 3.
Page 351: Power Trim Disassembly
POWER TRIM 6. Use suitable punch to remove lower trilobe pin. Retain trilobe pin. 7. Use suitable punch to drive out lower pivot pin. 51144 51144 Lower Trilobe Pin Lower Pivot Pin Power Trim Disassembly IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual release valve removal.
Page 352: Trim Motor Removal
POWER TRIM Trim Motor Removal 1. Secure power trim assembly in a soft jaw vise. 2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler. Screw (4) Reservoir Reservoir Seal Coupler Manifold Assembly Pump and Components Removal 1.
Page 353: Manifold Removal
POWER TRIM IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet replace poppet. 2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly. Debris Under Valve Tip Rubber Seat Screw (3) Filter Seal...
Page 354: Shock Rod Removal
POWER TRIM Shock Rod Removal 1. Unscrew end cap assembly from cylinder using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. 2. Remove shock rod assembly from cylinder. Shock Rod Disassembly NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper ring.
Page 355 POWER TRIM 3. Remove check ball components from shock rod piston. 4. Remove o-ring from shock rod piston. 51147 Spring (5) Seat (5) Ball (5) O-ring CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston.
Page 356 POWER TRIM 8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot be cleaned from check valve, replace shock piston as an assembly. 9. Clean shock and components with compressed air. 10. Remove inner o-ring from shock rod piston. 51199 Shock Piston O-ring...
Page 357: Memory Piston Removal
POWER TRIM Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (P/N 91-822778A3) or suitable tool. 51144 b. Blowing compressed air into manual release valve hole using air nozzle. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied.
Page 358: Cleaning/Inspection/Repair
POWER TRIM Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-809880A1. Lubricate all o-rings with Power Trim Fluid.
Page 359: Reassembly
POWER TRIM Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1. Page 5B-38 90-857046R1 NOVEMBER 2001...
Page 360: O-Ring Sizes
POWER TRIM O-ring Sizes Cutaway View of O-Ring Width O-RINGS SHOWN ARE ACTUAL O.D. I.D. SIZE 90-857046R1 NOVEMBER 2001 Page 5B-39...
Page 361 POWER TRIM O-ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring (412585) Cyl. Cap, Inner12586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap8134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) Shock Piston2579) 1.6 in.
Page 362: Power Trim Reassembly
POWER TRIM Power Trim Reassembly IMPORTANT: Lubricate all o-rings with Power Trim Fluid. If not available, use automo- tive (ATF) automatic transmission fluid. Shock Rod Reassembly 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 3. Install lubricated o-rings to shock piston. 51145 51199 Rod Wiper...
Page 363 POWER TRIM CAUTION When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 to threads on shock rod. Install shock rod piston. 7.
Page 364: Shock Rod Installation
POWER TRIM Shock Rod Installation 1. Place trim cylinder in soft jawed vice. 2. Install lubricated o-ring to memory piston and place into cylinder. Push memory piston all the way to bottom. 3. Fill cylinder three inches (76.2 mm) from top of cylinder using Power Trim and Steering Fluid.
Page 365: Trim Limit Assembly Installation
POWER TRIM Trim Limit Assembly Installation 1. Lubricate all O-rings. Install spring, poppet, spool housing and trim limit spool into man- ifold. NOTE: There are three different size springs used in this manifold. The heavy spring is used on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The light spring is used on 30-60 hp outboards.
Page 366: Manifold Installation
POWER TRIM Manifold Installation 1. Install dowel pin and two (2) lubricated o-rings into trim cylinder. O-Ring (2) Dowel Pin 2. Align the trim cylinder and pump/reservoir assembly together. 3. Install the two (2) long screws and tighten to specified torque. 51146 Trim Cylinder Assembly Reservoir/Manifold Assembly...
Page 367: Oil Pump Installation
POWER TRIM Oil Pump Installation 1. Install spring, ball, lubricated o-ring and plastic seat to manifold. 2. Check to see that o-rings are placed on bottom of pump. 3. Install filter and filter seal under pump. Install pump onto manifold. Tighten screws to specified torque.
Page 368 POWER TRIM Pressure Operated Assembly Installation IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. 1. Lubricate o-rings. 2. Install spool, seat (with o-ring), check valve/poppet, spring and plug (with o-ring) into pump.
Page 369: Reservoir/Motor Installation
POWER TRIM Reservoir/Motor Installation 1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and place reservoir onto pump/manifold assembly. Install ground strap under screw shown Tighten screws to specified torque. Screw (4) Torque to 80 lb-in. (9 Nm) Reservoir Reservoir Seal Coupler...
Page 370: Bleeding Power Trim Unit
POWER TRIM Bleeding Power Trim Unit 1. Secure power trim unit in soft jawed vise. 2. Fill reservoir to bottom of fill hole using Power Trim and steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. 3. Close the manual release valve. (Turn full clockwise). 4.
Page 371 POWER TRIM 3. Position trim cylinder assembly (bottom first) between clamp brackets. 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assem- bly until pivot pin is flush with outside surface. 51147 55467 2-4-C Marine Lubricant with Teflon Trim Cylinder Assembly Lower Pivot Pin 5.
Page 372 POWER TRIM 6. Apply 2-4-C Marine Lubricant with Teflon to surface of upper pivot pin, pivot pin bore and trim ram bore. 51148 2-4-C Marine Lubricant with Teflon Pivot Pin Pivot Pin Bore Trim Ram Bore 7. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket.
Page 373 POWER TRIM 9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode, as shown. 10. Route trim harness through clamp bracket and cowling. 55465 55264 Sacrificial Anode Ground Strap Bracket Trim Harness 11. Secure trim harness with clamp, as shown. 55264 Clamp Page 5B-52...
Page 374 MANUAL TILT ASSIST MID-SECTION Section 5C - Manual Tilt Assist Table of Contents Special Tools ......5C-1 Valve Block Removal .
Page 375: Manual Tilt Components
MANUAL TILT ASSIST Manual Tilt Components Loctite 271 2-4-C Marine Lubricant with Teflon NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use auto- motive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. Page 5C-2 90-857046R1 NOVEMBER 2001...
Page 376 MANUAL TILT ASSIST Manual Tilt Components TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft SHOCK ROD ASSEMBLY MEMORY PISTON ASSEMBLY O RING REBUILD KIT-Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY CAM KIT VELOCITY VALVE KIT CHECK SYSTEM REPAIR KIT –...
Page 377: Manual Trim Flow Diagrams
MANUAL TILT ASSIST Manual Trim Flow Diagrams Up Circuit Shock Rod Down Circuit Slow Transfer Valve End Cap Up Circuit Fast Transfer Valve Accumulator Surge Valve Accumulator Piston Cylinder Accumulator Check Valve Memory Piston Camshaft Lever Shock Piston Manifold Shock Return Valve Down Circuit Fast Transfer Valve Impact Relief Valve Page 5C-4...
Page 378 MANUAL TILT ASSIST Up Circuit With the engine in the down position, the accumulator piston (d) will be at the top of the accu- mulator (c) with the gas at maximum pressure. To raise the engine, the camshaft lever (f) is rotated all the way down.
Page 379: Down Circuit
MANUAL TILT ASSIST Down Circuit Shock Rod Down Circuit Slow Transfer Valve End Cap Up Circuit Fast Transfer Valve Accumulator Surge Valve Accumulator Piston Cylinder Accumulator Check Valve Memory Piston Camshaft Lever Shock Piston Manifold Shock Return Valve Down Circuit Fast Transfer Valve Impact Relief Valve Page 5C-6 90-857046R1 NOVEMBER 2001...
Page 380 MANUAL TILT ASSIST Down Circuit With the engine tilted up, the piston inside the accumulator piston (d) will be at the bottom of the accumulator (c) and the gas pressure is low. To lower the engine, the camshaft lever (f) is rotated down, the internal cam will cause the push rods to open the accumulator check valve (e), both fast transfer valves (h &...
Page 381: Slow Tilt Down Under High Thrust
MANUAL TILT ASSIST Slow Tilt Down Under High Thrust Shock Rod Down Circuit Slow Transfer Valve End Cap Up Circuit Fast Transfer Valve Accumulator Surge Valve Accumulator Piston Cylinder Accumulator Check Valve Memory Piston Camshaft Lever Shock Piston Manifold Shock Return Valve Down Circuit Fast Transfer Valve Impact Relief Valve Page 5C-8...
Page 382 MANUAL TILT ASSIST Slow Tilt Down Under High Thrust To tilt the engine down under high thrust conditions [where the propeller thrust forces the shock rod down, creating higher pressure below the memory piston (m)], the camshaft lever (f) is rotated slightly downward. The internal shaft connected to the lever will open the down circuit slow transfer valve (i) allowing oil under pressure into the cavity around the shaft.
Page 383: Under Water Strike (Valves Open)
MANUAL TILT ASSIST Under Water Strike (Valves Open) Shock Rod Down Circuit Slow Transfer Valve End Cap Up Circuit Fast Transfer Valve Accumulator Surge Valve Accumulator Piston Cylinder Accumulator Check Valve Memory Piston Camshaft Lever Shock Piston Manifold Shock Return Valve Down Circuit Fast Transfer Valve Impact Relief Valve Page 5C-10...
Page 384 MANUAL TILT ASSIST Under Water Strike (Valves Open) Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the intercon- necting passage.
Page 385: Shock Function (Valve Closed)
MANUAL TILT ASSIST Shock Function (Valve Closed) Accumulator Gas Pressure 400 PSI Shock Rod Down Circuit Slow Transfer Valve End Cap Up Circuit Fast Transfer Valve Accumulator Surge Valve Accumulator Piston Cylinder Accumulator Check Valve Memory Piston Camshaft Lever Shock Piston Manifold Shock Return Valve Down Circuit Fast Transfer Valve...
Page 386 MANUAL TILT ASSIST Shock Function (Valves Closed) Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the closed up circuit fast transfer valve (j), the closed down circuit slow transfer valve (i) and closed down circuit fast transfer valve (h).
Page 387: Shock Function Return
MANUAL TILT ASSIST Shock Function Return Shock Rod Down Circuit Slow Transfer Valve End Cap Up Circuit Fast Transfer Valve Accumulator Surge Valve Accumulator Piston Cylinder Accumulator Check Valve Memory Piston Camshaft Lever Shock Piston Manifold Shock Return Valve Down Circuit Fast Transfer Valve Impact Relief Valve Page 5C-14 90-857046R1 NOVEMBER 2001...
Page 388 MANUAL TILT ASSIST Shock Function Return After the drive clears the object, the shock return valve (o) will allow the oil to flow from be- tween the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to its original running position.
Page 389: Hydraulic System Troubleshooting
MANUAL TILT ASSIST Hydraulic System Troubleshooting Refer to disassembly/reassembly instructions (following) if disassembly is required when servicing. IMPORTANT: After debris or failed components have been found (during trouble- shooting procedure), it is recommended that unit be disassembled completely and all o-rings be replaced. Check ball components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reassembly.
Page 390 MANUAL TILT ASSIST 2. Check for external leaks in the manual tilt system. Replace defective part(s) if leak is found. IMPORTANT: If cut or damaged o-rings are found, inspect machined surfaces for scoring, burrs or debris. 3. Check for discharged accumulator. 35 to 50 lb-ft (47-68 Nm) of pulling force must be at- tained when tilting outboard from full “down”...
Page 391: Manual Tilt System Removal
MANUAL TILT ASSIST Manual Tilt System Removal CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent acci- dental starting while servicing outboard. WARNING Service or installation of the tilt system may result in loss of pressure in the shock cylinder.
Page 392 MANUAL TILT ASSIST 3. Position piece of wood under transom bracket (instead of tilt lock) for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper trilobe pin. Retain trilobe pin. 4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot pin. 51144 51144 Pivot Pin...
Page 393: Manual Tilt System Disassembly
MANUAL TILT ASSIST 8. Tilt shock absorber assembly (TOP FIRST) out from clamp bracket and remove assembly. 51144 Manual Tilt System Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitrogen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized.
Page 394: Shock Rod Removal
MANUAL TILT ASSIST 5. Once accumulator is removed, remove o-ring, conical spring, steel ball and plunger. 51145 Conical Spring Steel Ball Plunger O-ring Shock Rod Removal 1. Unscrew cylinder end cap assembly using spanner wrench [1/4 in. x 5/16 in. long pegs]. 2.
Page 395 MANUAL TILT ASSIST 1. Place shock rod assembly on clean work surface. 2. Remove three (3) screws and remove plate from shock rod piston. 51143 Screw (3) Plate Shock Rod Piston 3. Remove check ball components from shock rod piston. 4.
Page 396 MANUAL TILT ASSIST CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).
Page 397: Valve Block Removal
MANUAL TILT ASSIST 11. Remove cylinder end cap assembly from shock rod. 12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper. 13. Place end cap on clean work surface. 14. Remove rod wiper, inner o-ring, and outer o-ring. 51147 51145 Rod Wiper...
Page 398: Memory Piston Removal
MANUAL TILT ASSIST Memory Piston Removal 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers. Snap-On SRP2 51144 b. Blowing compressed air into center o-ring hole. WARNING Memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to place cylinder as shown below could result in personal injury.
Page 399: Valve Block Disassembly
MANUAL TILT ASSIST Valve Block Disassembly 1. Remove check retainer plug and components. 2. Remove hydraulic oil transfer valve plugs and components. 3. Remove surge valve assembly. 51142 Transfer Valve Plug Assembly (2) Check Retainer Plug or Screw Assembly Spool Spring O-ring Velocity Valve...
Page 400: Reassembly - O-Ring And Seal Placement
MANUAL TILT ASSIST Reassembly - O-Ring and Seal Placement 11 12 NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use auto- motive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. 90-857046R1 NOVEMBER 2001 Page 5C-27...
Page 401: Actual O-Ring Sizes
MANUAL TILT ASSIST Actual O-Ring Sizes Cutaway View of O-Ring Width O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE Page 5C-28 90-857046R1 NOVEMBER 2001...
Page 402: O-Ring Description And Sizes
MANUAL TILT ASSIST O-Ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) Shock Piston 1.6 in.
Page 403 MANUAL TILT ASSIST CAM SHAFT REASSEMBLY IMPORTANT: Cam shaft O-ring must be lubricated using 2-4-C Marine Lubricant with Teflon. 1. Install lubricated o-ring and back up seal to cam. 2. Install shaft seal in valve block with lips facing out. 3.
Page 404 MANUAL TILT ASSIST VELOCITY VALVE REASSEMBLY 1. Install spool, spring, lubricated o-ring and screw plug (surge valve assembly) into valve block. 2. Torque velocity valve to 75 lb-in. (8.5 Nm). Spool Spring O-ring Velocity Valve - Torque to 75 lb-in. (8.5 Nm) CHECK RETAINER REASSEMBLY 1.
Page 405: Valve Block Installation
MANUAL TILT ASSIST VALVE PLUG REASSEMBLY 1. Install plunger, steel ball, spring, lubricated o-ring and screw plug. Torque screw plugs to 75 lb-in. (8.5 Nm). 51142 Plunger (2) Steel Ball (2) Spring (2) O-ring (2) Screw Plug (2) Torque to 75 lb-in. (8.5 Nm) Valve Block Installation 1.
Page 406: Shock Rod Reassembly
MANUAL TILT ASSIST Shock Rod Reassembly 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 3. Install lubricated o-rings to shock piston. 51145 51199 Rod Wiper Inner O-ring Outer O-ring Shock Piston O-ring O-ring 4. Clamp shock rod in soft jawed vise. 5.
Page 407 MANUAL TILT ASSIST CAUTION hen installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in. (6.4mm x8mm) long pegs to avoid damage to shock rod piston. 6. Apply Loctite 271 to threads on shock rod. 7. Install shock rod piston. 8.
Page 408: Shock Rod Installation And Fluid Filling Procedure Option One
MANUAL TILT ASSIST Shock Rod Installation and Fluid Filling Procedure - Option One NOTE: There are two ways for the filling procedure. The first is the easiest and less time consuming. 1. Place trim cylinder in soft jawed vice. 2. With manifold cam lever closed (Up Position), fill cylinder and manifold to top with Power Trim and Steering fluid, or (ATF) automatic transmission fluid.
Page 409 MANUAL TILT ASSIST 8. Open and close cam lever, watching for bubbles coming from accumulator check ball hole. When bubbles stop, fill accumulator opening to top with fluid. Grease threads on accumulator and opening with 2-4-C Marine Lubricant with Teflon. Start accumulator in threads and open cam lever (Down Position).
Page 410: Fluid Filling Procedure Option Two
MANUAL TILT ASSIST Fluid Filling Procedure - Option Two INSTRUCTIONS FOR MAKING RETAINING TOOL 3/16 in. x 3 in. (5 x 7.5 cm) Steel Plate 3/8 in. x 13 in. (10 mm x 33 cm) Threaded Rod 4in. x 1/4 in. min. (10cm x 6.4 mm) minimum Channel Iron 10 in.
Page 411 MANUAL TILT ASSIST FILLING AND BLEEDING PROCEDURE IMPORTANT: While bleeding tilt system, time must be allowed between each stroke to allow air bubbles to dissipate. 1. With shock rod in the full up position and manifold cam lever open (facing down), secure tilt system to retaining tool and container.
Page 412 MANUAL TILT ASSIST 4. During up stroke, pull up on rod slowly 3 in. (76 mm) from base. 5. Wait until all air bubbles to exit accumulator base. 50433 6. Slowly cycle unit 5-8 times (round trip per cycle) using short strokes 3 in. (76 mm) from base allowing bubbles to disappear during each stroke.
Page 413: Manual Tilt System Installation
MANUAL TILT ASSIST 11. With cam lever remaining open (facing down), remove tilt assembly from oil and secure in soft jawed vise. Torque accumulator to 35 lb-ft (47 Nm). 50433 Manual Tilt System Installation 1. Lubricate lower pivot pin mounting holes with 2-4-C Marine Lubricant with Teflon. 2.
Page 414 MANUAL TILT ASSIST 3. Reinstall manual tilt system, bottom first. Reconnect release valve link rod. 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assem- bly until pivot pin is flush with outside surface. 51147 51144 2-4-C Marine Lubricant with Teflon...
Page 415 MANUAL TILT ASSIST 6. Apply 2-4-C Marine Lubricant with Teflon to surface of upper pivot pin, pivot pin hole and shock rod hole. 7. Using a mallet, drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket.
Page 416: Manual Release Valve Adjustment
MANUAL TILT ASSIST 9. Install sacrificial anode. 55465 Sacrificial Anode 10. Check manual release cam adjustment. Cam must open and close freely. Adjust link rod as necessary. Manual Release Valve Adjustment 1. With outboard in full up position, place tilt lock lever forward. 2.
Page 417 NON-BIGFOOT GEAR HOUSING LOWER UNIT Section 6A - Non-Bigfoot Gear Housing Table of Contents Specifications ......6A-1 Shift Shaft .
Page 418 NON-BIGFOOT GEAR HOUSING Special Tools 1. Bearing 31-85560 54978 2. Driver 91-13779 3. Bearing Puller & Installation Tool 91-31229A7 a. Nut 11-24156 b. Washer (2) 12-34961 c. Plate 91-29310 d. Shaft 91-31229 4. Bearing Puller Tool 91-27780 5. Mandrel 91-36571 Page 6A-2 90-857046R1 NOVEMBER 2001...
Page 419 NON-BIGFOOT GEAR HOUSING 6. Universal Puller Plate 91-37241 7. Driver Head 91-37312 8. Driver 91-817011 9. Driver Rod 91-37323 90-857046R1 NOVEMBER 2001 Page 6A-3...
Page 420 NON-BIGFOOT GEAR HOUSING 10. Drive Shaft Holding Tool a. 2-stroke models 91-825196 b. 4-stroke models 91-83180M 11. Mandrel 91-825197 12. Driver 91-817007 13. Mandrel 91-825198 14. Pilot 91-825199 15. Spring Hook 91-825200A1 Page 6A-4 90-857046R1 NOVEMBER 2001...
Page 421 NON-BIGFOOT GEAR HOUSING 16. Driver 91-826872 17. Leakage Tester FT8950 90-857046R1 NOVEMBER 2001 Page 6A-5...
Page 422 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2:1 Gear Ratio) Loctite “271” Loctite “405” (Purchase Locally) Premium Gear Lubricant Loctite Primer “7649” 2-4-C Marine Lubricant with Teflon 3.44 IN./135MM TORPEDO DIA. Page 6A-6 90-857046R1 NOVEMBER 2001...
Page 423 NON-BIGFOOT GEAR HOUSING Gear Housing (Driveshaft)(2:1 Gear Ratio) TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft – GEAR HOUSING (SHORT) – GEAR HOUSING (LONG) GEAR HOUSING (BASIC) SEAL/PLATE KIT PLATE (Part Of Ref #2) SCREW (.375-16 x .25) WASHER-Sealing DRAIN SCREW WASHER-Sealing PINION GEAR (13 TEETH) BEARING ASSEMBLY-Roller CUP (Part Of Ref #10)
Page 424 NON-BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2:1 Gear Ratio) 3.44 IN./135MM TORPEDO DIA. Loctite “271” Premium Gear Lubricant 2-4-C Marine Lubricant with Teflon Page 6A-8 90-857046R1 NOVEMBER 2001...
Page 425 NON-BIGFOOT GEAR HOUSING Gear Housing (Propeller Shaft)(2:1 Gear Ratio) TORQUE REF. QTY. DESCRIPTION lb-in. lb-ft – GEAR HOUSING (SHORT) – GEAR HOUSING (LONG) GEAR HOUSING (BASIC) DOWEL PIN GASKET Water Tube TUBE PLUG–RUBBER SCREEN–Water Inlet TRIM TAB SCREW (M8 x 20) 21.5 WASHER FORWARD GEAR ASSEMBLY (26 TEETH)
Page 426 NON-BIGFOOT 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 427 NON-BIGFOOT 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. 1. With gear housing in normal running position, place a clean pan under housing and re- move vent plug and fill/drain plug (with gaskets).
Page 428 1. Remove (and isolate) spark plug leads from spark plugs. 2. Shift into NEUTRAL. 2-Stroke Models MERCURY/MARINER 30/40, AND 40/50, FORCE 40/50 3. Loosen jam nut. Unscrew attaching nut to separate shift shaft. 52832...
Page 429 NON-BIGFOOT GEAR HOUSING 4-Stroke Models MERCURY/MARINER 25, 30/40, AND 45/50 4. Disconnect shift shaft by un-snapping retainer to lower clip and sliding retainer to the left. Retainer Lower Clip 5. Make a scribe line showing alignment of trim tab to gear case and remove trim tab screw and washer.
Page 430 NON-BIGFOOT GEAR HOUSING 6. Remove nut and washer in trim tab cavity. 52835 Nut and Washer 7. Remove mounting screws securing gear case to drive shaft housing. 52836 Screw (4) Page 6A-14 90-857046R1 NOVEMBER 2001...
Page 431 NON-BIGFOOT GEAR HOUSING Disassembly Water Pump NOTE: If water tube seal remained in drive shaft housing, remove seal from housing and reinstall on water pump cover. 1. Remove screws securing pump cover. 52830 Water Tube Seal Screw (4) NOTE: Replace cover if thickness of steel at discharge slots is 0.060 in. (1.524 mm) or less, or if groove(s)(other than impeller sealing groove) in cover roof are more than 0.030 in.
Page 432 NON-BIGFOOT GEAR HOUSING 2. Remove cover, washer (above impeller), impeller, key and washer (below impeller). 3. Remove cover gasket, base plate and base gasket. 52692 Cover Nylon Washer (above impeller) Impeller Nylon Washer (below impeller) Cover Gasket Face Plate Base Gasket 4.
Page 433 NON-BIGFOOT GEAR HOUSING 5. Remove and/or replace exhaust deflector plate if damaged. 52832 Deflector Plate Bearing Carrier and Propeller Shaft 1. Remove bearing carrier attaching bolts and locking tab washers or flat washers. Discard tab washers. Screw (2), Tab Washer (2) or Flat Washer (2) Tab Washer (2) Style 2 2.
Page 434 NOTE: When removing propeller shaft assembly, cam follower may dislodge. Retrieve fol- lower from gear housing. 3. Remove propeller shaft assembly. 52864 Propeller Shaft Models Drive Shaft Holding Tool 4-Stroke Mercury/Mariner 91-83180M 25, 30/40, and 45/50 2-Stroke Force 40/50 91-825196 Mercury/Mariner...
Page 435 NON-BIGFOOT GEAR HOUSING 2. Remove drive shaft assembly and pinion gear. 3. Remove forward gear. Forward Gear 4. Remove shift shaft assembly. 52870 52841 Shift Shaft Assembly 90-857046R1 NOVEMBER 2001 Page 6A-19...
Page 436 NON-BIGFOOT GEAR HOUSING 5. Insert pinion bearing race puller (91-825200A1) through gear case and position inside of pinion bearing race. Insert driver (91-13779) into puller through drive shaft cavity and drive out race. 91-13779 91-825200A1 52844 Puller (91-825200A1) Driver (91-13779) 6.
Page 437 NON-BIGFOOT GEAR HOUSING Water Pump Seals NOTE: All gaskets, seals and o-rings should be replaced as a normal repair procedure dur- ing gear case disassembly. NOTE: DO NOT use a screwdriver to remove seals from carrier, as carrier may be dam- aged.
Page 438 NON-BIGFOOT GEAR HOUSING 3. With lip of ribbed neoprene O.D. seal facing towards small shoulder of Mandrel (91-825197), press seal into carrier until mandrel bottoms on carrier. 91-825197 52853 Seal (Ribbed Neoprene) Lip Facing Up Mandrel (91-825197) 4. Install a new o-ring on the carrier. Apply a light coat of 2-4-C Marine Lubricant with Teflon to the new o-ring.
Page 439 NON-BIGFOOT GEAR HOUSING Inspection Drive Shaft Upper Bearing 1. Inspect bearing for rust, roughness or discoloration from lack of lubricant. 2. DO NOT remove bearing from drive shaft unless bearing must be replaced, as removal process will damage bearing. 3. If bearing must be replaced, position drive shaft assembly in vise (jaws of vise support- ing only bearing) and while holding drive shaft, strike top of drive shaft with lead hammer and drive bearing off.
Page 440 NON-BIGFOOT GEAR HOUSING Pinion Gear Bearing 1. Inspect bearing for rust, roughness or discoloration from lack of lubricant. 2. If bearing is damaged, bearing and race must be replaced as an assembly. 3. If race appears to have spun in drive shaft bore, gear case housing must be replaced. 52823 Bearing Race...
Page 441 NON-BIGFOOT GEAR HOUSING 3. Inspect propeller shaft forward gear bearing surface to determine condition of forward gear needle bearing. If bearing surface is discolored (from lack of lubricant), pitted or worn, propeller shaft and bearing should be replaced. 52846 52874 Bearing Surface Bearing 4.
Page 442 NON-BIGFOOT GEAR HOUSING 6. Inspect forward gear tapered bearing and race for rust, roughness or excessive wear (looseness). 7. If bearing is in serviceable condition, DO NOT remove bearing from gear, as removal process will damage bearing. 8. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and suitable mandrel.
Page 443 NON-BIGFOOT GEAR HOUSING Shift Shaft 1. Inspect shift cam for wear or galling. Replace cam if necessary. 2. If cam is worn, inspect cam follower in end of propeller shaft for wear. 52845 Cam Follower Shift Cam 3. Inspect shift shaft boot for deterioration. 4.
Page 444 NON-BIGFOOT GEAR HOUSING Propeller Shaft Disassembly 1. Remove propeller shaft from carrier and disassemble shaft. Prop Shaft Retaining Spring Clutch Dog Cross Pin Cam Follower Spring Cam Follower 2. Remove reverse gear and bearing from carrier with Puller (91-27780). 91-27780 52840 Reverse Gear and Bearing Puller (91-27780)
Page 445 NON-BIGFOOT GEAR HOUSING Propeller Shaft and Carrier Inspection Clutch 1. Inspect clutch jaws for chips or rounding off. 2. If wear is present, inspect corresponding forward or reverse gear matching jaws for simi- lar wear. Replace appropriate components as required. 52824 Cam Follower 1.
Page 446 NON-BIGFOOT GEAR HOUSING Reverse Gear Bearing 1. Inspect bearing for rust, roughness or excessive wear (looseness). 2. If bearing is in serviceable condition, DO NOT remove bearing from gear as removal will damage bearing. 3. If bearing must be replaced, remove bearing from gear using Universal Puller Plate (91-37241) and Driver (91-37312).
Page 447 NON-BIGFOOT GEAR HOUSING Bearing Carrier NEEDLE BEARING 1. The condition of the carrier needle bearing can be determined by inspecting its running surface on the propeller shaft. 2. If the shaft is discolored (from lack of oil) or pitted, replace bearing and shaft. 3.
Page 448 NON-BIGFOOT GEAR HOUSING 7. Apply Loctite 271 to O.D. of small diameter seal. 8. With seal lip facing away from large shoulder of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier. 91-817007 Loctite “271” 52862 Seal Mandrel (91-817007) Page 6A-32 90-857046R1 NOVEMBER 2001...
Page 449 NON-BIGFOOT GEAR HOUSING 9. Apply Loctite 271 to O.D. of large diameter seal. 10. With seal lip FACING TOWARDS SMALL SHOULDER of Mandrel 91-817007, press seal into carrier until mandrel bottoms on carrier. 91-817007 52863 Loctite “271” Seal Mandrel (91-817007) Installation Note: If service tools are not available, the following reference dimensions ap- ply for installing bearing and seals to proper depths.
Page 450 NON-BIGFOOT GEAR HOUSING 11. Bearing carrier o-ring should be inspected for cuts and abrasions. NOTE: It is a good repair procedure to replace all o-rings and seals regardless of appear- ance. 12. Apply 2-4-C Marine Lubricant with Teflon to O.D. of bearing carrier and also to o-ring. Install o-ring onto bearing carrier.
Page 451 NON-BIGFOOT GEAR HOUSING Gear Housing Reassembly IMPORTANT: This gear case assembly does not have have any shims for the gear as- semblies. Backlash cannot be adjusted. The mechanic must verify that all bearing races are firmly seated in the gear case during reassembly and that all gear case com- ponents are in serviceable condition.
Page 452 NON-BIGFOOT GEAR HOUSING Pinion Bearing Race 1. Apply Premium Gear Lubricant to O.D. of race. 2. Position race in gear housing (NUMBERS UP - TAPERED SIDE FACING DOWN). 3. Draw race up into housing until seated. 11-24156 91-31229 91-29310 12-34961 31-85560 91-825199 91-825198...
Page 453 NON-BIGFOOT GEAR HOUSING Forward Gear 1. Apply Premium Gear Lubricant to O.D. of race. Install forward gear bearing race into housing using Mandrel 91-36571 and propeller shaft. Use a lead hammer on prop shaft to prevent damage to threads. Bearing carrier should be installed to keep prop shaft cen- tered while seating race.
Page 454 2. Position pinion bearing into race while installing drive shaft and pinion gear into housing. 3. Apply Loctite 271 to pinion nut threads. 4. Install new pinion nut, with recessed shoulder toward the pinion gear. Models Drive Shaft Holding Tool 4-Stroke 91-83180M Mercury/Mariner 25, 30/40, and 45/50 2-Stroke Force 40/50 91-825196 Mercury/Mariner 30/40, 40/50 5.
Page 455 NON-BIGFOOT GEAR HOUSING Propeller Shaft 1. Slide clutch (short shoulder faces forward gear) over propeller shaft aligning cross pin hole with slot in propeller shaft. 2. Insert cam follower spring into propeller shaft. Prop Shaft Retaining Spring Clutch Dog Cross Pin Cam Follower Spring Cam Follower 3.
Page 456 NON-BIGFOOT GEAR HOUSING NOTE: Apply 2-4-C Marine Lubricant with Teflon to cam follower before installation into the propshaft. This will prevent the cam follower from falling out during installation of the prop- shaft assembly into the gearcase. 6. Install cam follower. 52826 2-4-C Marine Lubricant with Teflon Cam Follower...
Page 457 NON-BIGFOOT GEAR HOUSING Bearing Carrier 1. Install carrier into gear case. 2. Discard the original tab washers or the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long screws on models listed. Install thicker flat washers and longer screws. 25 (2 Cylinder - 4 Stroke) 0G621670 and below 45/50 (4 Cylinder - 4 Stroke) Non Big Foot...
Page 458 NON-BIGFOOT GEAR HOUSING 4. Tighten screws to specified torque. Loctite “271” Screw (2) Bearing Carrier Screw Torque 19 lb-ft. (25.5 Nm) Water Pump 1. Apply 2-4-C Marine Lubricant with Teflon to seal carrier O-ring and seal lips. Install seal carrier. 2.
Page 459 NON-BIGFOOT GEAR HOUSING 3. Install base gasket, base plate, pump cover gasket (NEOPRENE STRIP FACES UP), nylon washer and impeller key. 52868 Base Gasket Base Plate Cover Gasket Neoprene Strip Nylon Washer IMPORTANT: If the old impeller is re-used it must be installed in original (clockwise) direction of rotation.
Page 460 NON-BIGFOOT GEAR HOUSING 5. Lubricate I.D. of impeller housing with 2-4-C Marine Lubricant with Teflon. 6. Rotate drive shaft clockwise while pushing impeller housing cover down over impeller. 7. Apply Loctite 271 to bottom threads of screws. Install screws and tighten to specified torque.
Page 461 NON-BIGFOOT GEAR HOUSING Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. Tighten securely. 2. Pressurize housing to 10-12 psi (69-83 kPa) and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and move shift rod while housing is pressurized to check for leaks.
Page 462 NON-BIGFOOT GEAR HOUSING Gear Housing Installation WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto drive shaft housing. 1. Position shift lever in NEUTRAL gear position. 2. Tilt engine to full “Up” position. Engage tilt lock lever. 3.
Page 463 52834 Coupler Nut Jam Nut Spray Plate 4-Stroke Models MERCURY/MARINER 25, 30/40, AND 45/50 8. Connect shift shaft by sliding retainer to the right and snapping into upper “locked” position. 53859 Retainer Clip 90-857046R1 NOVEMBER 2001...
Page 464 NON-BIGFOOT GEAR HOUSING 9. Install locknut and washer. Torque nut to specified torque. 52833 Locknut and Washer Nut Torque 40 lb-ft (54 Nm) 10. Check shift operation. a. In NEUTRAL, propeller shaft should turn freely in either direction. b. In FORWARD, propeller shaft SHOULD NOT TURN COUNTERCLOCKWISE. c.
Page 465 NON-BIGFOOT GEAR HOUSING Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is 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 466 NON-BIGFOOT GEAR HOUSING Filling Gear Housing with Lubricant NOTE: Gear housing lubricant capacity is approximately 14.9 fl oz (440 ml). WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing.
Page 467 BIGFOOT GEAR HOUSING LOWER UNIT Section 6B - Bigfoot Gear Housing Table of Contents Specifications ......6B-1 Forward Gear Bearing Race .
Page 468 BIGFOOT GEAR HOUSING Special Tools 1. Pinion Gear Locating Tool (91-12349A2) Disc1 Disc 3 Disc 2 55079 2. Bearing Installation Tool (91-13945) 3. Oil Seal Driver (91-13949) 4. Bearing Race Tool (91-14308A1) 5. Bearing Installation (91-14309A1) 6. Wear Sleeve Installation Tool (91-14310A1) Page 6B-2 90-857046R1 NOVEMBER 2001...
Page 469 BIGFOOT GEAR HOUSING 7. Bearing Preload Tool (91-14311A2) 8. Mandrel (91-15755)* 73815 9. Backlash Indicator Tool (91-19660--1) 2.07:1 Gear Ratio (14/29) 19660-1 10. Mandrel (91-31106) 11. Oil Seal Driver (91-31108) 12. Treaded Rod (91-31229) and Nut (91-24156)* 13. Slide Hammer (91-34569A1) 90-857046R1 NOVEMBER 2001 Page 6B-3...
Page 470 BIGFOOT GEAR HOUSING 14. Mandrel (91-36569)* 15. Universal Puller Plate (91-37241) 73652 16. Driver Rod (91-37323)* 74184 17. Mandrel (91-37350) 18. Puller Jaws (91-46086A1) 19. Driver Shaft Holding Tool (91-56775, 2-Stroke), (91-56775, 40/50 4-Stroke, 747cc/935cc), (91-877840A1, 40/50/60 4-Stroke, 995cc), (91-804776A1, 75/90 4-Stroke) 20.
Page 471 BIGFOOT GEAR HOUSING 21. Backlash Indicator Tool (91-78473) 2.31:1 Gear Ratio (13/30) 22. Puller Bolt (91-85716) 23. Dial Indicator Adaptor Kit (91-83155) 24. Bearing Puller Assembly (91-83165M) 25. Bearing Installation Tool (91-856875A1) 56783 26. Bearing Installation Tool (91-877321A1) * From Bearing Removal and Installation Kit (91-31229A7) 90-857046R1 NOVEMBER 2001 Page 6B-5...
Page 472 BIGFOOT GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.31:1 GEAR RATIO) 4.25 IN./107.95MM TORPEDO DIA. BIGFOOT 40 41 Loctite 271 Premium Gear Lubricant 2-4-C Marine Lubricant with Teflon Page 6B-6 90-857046R1 NOVEMBER 2001...
Page 473 BIGFOOT GEAR HOUSING GEAR HOUSING (DRIVE SHAFT)(2.31:1 GEAR RATIO) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING – GEAR HOUSING ASSEMBLY DOWEL PIN (FRONT) OILER TUBE DRAIN SCREW WASHER-Sealing DOWEL PIN (REAR) TRIM TAB SCREW (.437-14 x 1.25) WASHER CARRIER NEEDLE BEARING ANODE SCREW (M6 x 40)
Page 474 BIGFOOT GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.31:1 GEAR RATIO) 4.25 IN./107.95MM TORPEDO DIA. BIGFOOT 49 47 67 68 Loctite 271 Premium Gear Lubricant 2-4-C Marine Lubricant with Teflon Page 6B-8 90-857046R1 NOVEMBER 2001...
Page 475 BIGFOOT GEAR HOUSING GEAR HOUSING (PROP SHAFT)(2.31:1 GEAR RATIO) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING ASSEMBLY TAPERED ROLLER BEARING ASSEMBLY FORWARD GEAR (30 TEETH) ROLLER BEARING RETAINING RING CAM FOLLOWER ASSEMBLY BALL SLIDE SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR (30 TEETH) BEARING CARRIER ASSEMBLY...
Page 476 BIGFOOT 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 477 BIGFOOT GEAR HOUSING Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and re- move the two vent screws and one fill/drain screw (with gaskets).
Page 478 BIGFOOT GEAR HOUSING Removal WARNING To prevent accidental engine starting, remove (and isolate) spark plug leads from spark plugs before removing gear housing. IMPORTANT: 90 hp (4-Stroke) models, when removing or installing gearcase care- fully guide driveshaft through drive shaft bushing to avoid scoring bushing surface. 1.
Page 479 BIGFOOT GEAR HOUSING Disassembly Water Pump NOTE: If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was removed, pull water tube seal from water tube. NOTE: Newer models will not have the isolators installed on the water pump. 1.
Page 480 BIGFOOT GEAR HOUSING 6. Inspect impeller. Replace impeller if any of the following conditions exist: Impeller blade(s) are cracked, torn, or worn. Impeller is glazed or melted (caused by operation without sufficient water supply). Rubber portion of impeller is not bonded to impeller hub. 7.
Page 481 BIGFOOT GEAR HOUSING 10. Remove water pump base using flat screwdrivers to lightly pry up on base. 19226 Water Pump Base 11. Remove (and discard) seals (IT MAY BE BENEFICIAL TO CLAMP THE WATER PUMP BASE IN A VISE WHILE REMOVING SEALS). 19195 Seals 12.
Page 482 BIGFOOT GEAR HOUSING Bearing Carrier and Propeller Shaft 1. Remove fasteners. 51117 Fasteners 2. With propeller shaft horizontal, pull carrier (using tool shown) to break seal with gear housing. 3. Remove bearing carrier/propeller shaft components as an assembly by pulling back on the propshaft.
Page 483 BIGFOOT GEAR HOUSING 5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust bearing and thrust washer if rusted or damaged. 6. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or chipped.
Page 484 BIGFOOT GEAR HOUSING 8. If propshaft roller bearing is rusted or does not roll freely, replace bearing. If replacement is necessary, remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. NOTE: From Bearing Removal and Installation Kit (91-31229A7). 91-37323 91-36569 58205...
Page 485 BIGFOOT GEAR HOUSING 10. Remove spring. 51876 Spring 11. Apply constant pressure to cam follower in order to prevent it and internal components from ejecting out of the propeller shaft during removal of the cross pin from the clutch. 51800 Cross Pin Cam Follower 90-857046R1 NOVEMBER 2001...
Page 486 BIGFOOT GEAR HOUSING 12. Remove components from propeller shaft. 13. Replace cam follower if worn or pitted. 14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: Improper shift cable adjustment. Engine idle speed too high while shifting.
Page 487 BIGFOOT GEAR HOUSING Pinion Gear, Drive Shaft, and Forward Gear 1. Hold drive shaft using Drive Shaft Holding Tool. Remove (and discard) pinion nut. Model Drive Shaft Holding Tool 40/50 Bigfoot (4-Stroke, 747cc/935cc) 91-56775 40/50/60 Bigfoot (4-Stroke, 995cc) 91-877840A1 75/90/115 EFI (4-Stroke) 91-804776A1 60 Bigfoot (2-Stroke) 91-56775...
Page 488 BIGFOOT GEAR HOUSING 6. Replace forward gear needle bearing if it is rusted or does not roll freely. 7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and ham- mer to remove bearing. 57905 19203 Retaining Ring Forward Gear Needle Bearing 8.
Page 489 BIGFOOT GEAR HOUSING 9. Replace drive shaft if splines are worn or twisted. 10. If bearing surface is damaged, replace drive shaft and corresponding bearing. IMPORTANT: Do not tighten vise against drive shaft. 11. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard) sleeve using Universal Puller Plate (91-37241) and mallet.
Page 490: Upper Drive Shaft Bearing
BIGFOOT GEAR HOUSING Upper Drive Shaft Bearing 1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws. 91-83165M 19177 Upper Drive Shaft Bearing Sleeve...
Page 491: Oil Sleeve
BIGFOOT GEAR HOUSING Oil Sleeve 1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws. 91-83165M 19222 Oil Sleeve Puller Assembly (91-83165M) 90-857046R1 NOVEMBER 2001 Page 6B-25...
Page 492: Lower Drive Shaft Bearing Race
BIGFOOT GEAR HOUSING Lower Drive Shaft Bearing Race IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be re- moved for lower drive shaft bearing race removal. IMPORTANT: Retain shim(s) for reassembly. 1. Remove bearing race and shim(s) using bearing race tool (91-14308A1). 91-14308A1 19171 Bearing Race...
Page 493 BIGFOOT GEAR HOUSING Shift Shaft 1. Remove shift shaft coupler and nylon spacer. 75 (2-Stroke) Tiller Model Shown 53925 Shift Shaft Coupler Spacer 2. Remove shift shaft bushing screws. 53926 Screw (2) M6 x 1 NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing. 3.
Page 494 BIGFOOT GEAR HOUSING 4. Remove shift cam from housing. 5. Replace shift cam if worn. 60 (2-Stroke) Bigfoot Shown 51117 Shift Cam 6. Remove shift shaft bushing and clip from shift shaft. 7. Replace shift shaft if splines are worn or shaft is twisted. 8.
Page 495: Forward Gear Bearing Race
BIGFOOT GEAR HOUSING Forward Gear Bearing Race IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1). 27653 91-34569A1 Race Shim(s) Slide Hammer (91-34569A1) 90-857046R1 NOVEMBER 2001 Page 6B-29...
Page 496 BIGFOOT GEAR HOUSING Reassembly Forward Gear Bearing Race NOTE: Propshaft should be vertical when installing bearing race. 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s). 2.
Page 497 BIGFOOT GEAR HOUSING 5. Assemble components as shown. 53928 Shift Shaft “E” Clip Shift Shaft Bushing 6. Install shift cam. Align hole in shift cam with shift shaft pilot bore in gear housing. 60 Bigfoot, 75/90/100/115/125 (2-Stroke) 51117 Shift Cam (marked with “UP” and part number) Shift Shaft Pilot Bore 60 Bigfoot, 75/90/100/115/125 (2-Stroke) &...
Page 498 BIGFOOT GEAR HOUSING 40/50 Bigfoot (4-Stroke,747cc/935cc), 40/50/60 Bigfoot (4-Stroke, 995cc) 850307 51117 Shift Cam (Numbers Down) Shift Shaft Pilot Bore 7. Install shift shaft assembly. Insert splines into shift cam. 53932 Shift Shaft Assembly Splines 8. Apply Loctite 271 to bottom half of threads on each screw. Install screws and tighten to specified torque.
Page 499: Bearing Carrier Reassembly
BIGFOOT GEAR HOUSING Bearing Carrier Reassembly 1. Lubricate O.D. of bearing and bearing carrier bore with 2-4-C Marine Lubricant with Teflon. 2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945). 3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carri- er, until bearing bottoms out.
Page 500 BIGFOOT GEAR HOUSING 4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108) with seal lip away from shoulder. 5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Apply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms. 91-31108 91-13945 Loctite “271”...
Page 501 BIGFOOT GEAR HOUSING 8. Install O-ring. Lubricate O-ring and propshaft seal lips with 2-4-C Marine Lubricant with Teflon. 9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 2-4-C Marine Lubricant with Teflon. 10.
Page 502 BIGFOOT GEAR HOUSING 12. Install thrust bearing. Coat thrust bearing with Premium Gear Lubricant. 19168 Premium Gear Lubricant Thrust Bearing 13. Apply Premium Gear Lubricant to bearing surface of reverse gear and install reverse gear. 19202 Premium Gear Lubricant Reverse Gear Bearing Surface Page 6B-36 90-857046R1 NOVEMBER 2001...
Page 503: Forward Gear Reassembly
BIGFOOT GEAR HOUSING Forward Gear Reassembly 1. Apply 2-4-C Marine Lubricant with Teflon to the I.D. of the bearing. Press bearing onto gear using suitable mandrel (press only on inner race of bearing). Because the gear hub is longer than the bearing, a tube type mandrel should be used to install the bearing. This will allow the bearing to bottom out on the gear.
Page 504 BIGFOOT GEAR HOUSING 6 Jaw Reverse Clutch 56784 Stamped “6” Numbered end of Needle Bearing 6 Jaw Reverse Clutch 3. Apply Premium Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing. Press needle bearing into forward gear (using forward gear bearing installer tool) until tool bot- toms out on gear.
Page 505: Propeller Shaft Reassembly
BIGFOOT GEAR HOUSING Propeller Shaft Reassembly 1. Install components into propeller shaft in sequence shown. NOTE: When installing the clutch make sure the ratcheting clutch teeth (angled) are toward forward gear, and non-ratcheting (square on both sides) are toward reverse gear. 51265 2-4-C Marine Lubricant with Teflon Assembly Sequence...
Page 506: Drive Shaft Wear Sleeve Installation
BIGFOOT GEAR HOUSING 3. Install spring. DO NOT allow spring coils to overlap each other. 51876 Spring Drive Shaft Wear Sleeve Installation 1. Install new rubber ring. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. 19152 Loctite “271”...
Page 507 BIGFOOT GEAR HOUSING 4. Press sleeve onto driveshaft using Wear Sleeve Installation Tool (91-14310A1). Continue pressing until the upper and lower part of the tool make surface to surface contact. 5. Remove excess Loctite from assembled shaft. 91-14310A1 19166 Drive Shaft Wear Sleeve Installation Tool (91-14310A1) Upper part of tool (Surface C) Lower part of tool (Surface D)
Page 508 BIGFOOT GEAR HOUSING Drive Shaft Lower Bearing Race Installation 1. Lubricate O.D. of bearing race with 2-4-C Marine Lubricant with Teflon. 2. Install shim(s) and bearing race into housing. If shim(s) were lost or a new gear housing is being assembled, start with 0.025 in. (0.635 mm) shim(s). NOTE: Verify shim(s) are not cocked when drawing up race.
Page 509: Oil Sleeve Installation
BIGFOOT GEAR HOUSING Oil Sleeve Installation 1. Install oil sleeve with tab positioned as shown. 53934 Oil Sleeve Drive Shaft Upper Bearing Installation 1. Lubricate I.D. of bearing sleeve and O.D. of bearing with 2-4-C Marine Lubricant with Teflon. 2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1). 91-13781 19164 2-4-C Marine Lubricant with Teflon...
Page 510 BIGFOOT GEAR HOUSING 3. Install bearing/sleeve into housing. IMPORTANT: Oil sleeve must be installed prior to upper driveshaft bearing installa- tion. IMPORTANT: Lower driveshaft bearing cup pilots the mandrel (13780) during installa- tion of the upper driveshaft bearing/sleeve. Lower bearing cup must be installed prior to installing upper bearing/sleeve.
Page 511 BIGFOOT GEAR HOUSING Forward Gear, Drive Shaft Lower Bearing, Pinion Gear, and Drive Shaft Installation 1. Install components per assembly sequence shown. 19175 Loctite “271” Premium Gear Lubricant Assembly Sequence: Forward Gear/Bearing: Apply Premium Gear Lube to bearing rollers. Drive Shaft Lower Tapered Roller Bearing: Apply Premium Gear Lube to bearing rollers.
Page 512 BIGFOOT GEAR HOUSING Pinion Gear Depth and Forward Gear Backlash DETERMINING PINION GEAR DEPTH NOTE: Read entire procedure before attempting any change in shim thickness. IMPORTANT: Forward gear assembly pilots the end of the pinion gauge and must be installed in gear housing when checking pinion gear depth. Without it an inaccurate measurement will be obtained.
Page 513 BIGFOOT GEAR HOUSING 6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown. Do not tighten collar re- taining screw at this time. Install gauging block with numbers away from split collar. Arbor Split Collar Gauging Block Collar Retaining Screw Screw (2) Snap Ring 7.
Page 514 BIGFOOT GEAR HOUSING 10. Install locating disc against bearing carrier shoulder in gear housing. 11. Position access hole as shown. Disc 3 24643 Locating Disc Access Hole 12. Determine pinion gear depth by inserting a feeler gauge through access hole in locating disc.
Page 515 BIGFOOT GEAR HOUSING DETERMINING FORWARD GEAR BACKLASH NOTE: Read entire procedure before attempting any change in shim thickness. 1. To obtain correct pinion gear depth, refer to “Determining Pinion Gear Depth,” preced- ing. 2. Install Bearing Preload Tool (91-14311A2) on drive shaft. Refer to “Determining Pinion Gear Depth,”...
Page 516 BIGFOOT GEAR HOUSING 6. Install components as shown. 51117 Threaded Rod (Obtain Locally) Washers Nuts Dial Indicator Adaptor Kit (91-83155) Dial Indicator (91-58222A1) Backlash Indicator Tool 7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indi- cator Tool.
Page 517 BIGFOOT GEAR HOUSING 8. Grasp the driveshaft pre-load tool bolt head and lightly turn drive shaft back-and-forth (no movement should be noticed at propeller shaft). 9. Dial Indicator registers amount of backlash, which must be between specification shown in chart. DIAL INDICATOR READING MODEL...
Page 518 BIGFOOT GEAR HOUSING 3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with 2-4-C Marine Lubricant with Teflon. 4. Install bearing carrier and propeller shaft into housing with the word “TOP” (located on flange) toward top of housing. 5.
Page 519 BIGFOOT GEAR HOUSING Water Pump Reassembly and Installation 1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver (91-13949) with seal lip away from shoulder. 2. Apply Loctite 271 on O.D. of seal. Press seal into water pump base until tool bottoms. 91-13949 Loctite “271”...
Page 520 BIGFOOT GEAR HOUSING 3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. 4. Apply Loctite 271 on O.D. of seal. Press seal into water pump base until tool bottoms. 5.
Page 521 BIGFOOT GEAR HOUSING IMPORTANT: To prevent cutting the seal lips remove any burrs or sharp edges from the dri- veshaft splines before installing water pump base assembly. 7. Install components as shown. Apply Loctite 271 on bottom half of screw threads and tighten to specified torque (in sequence shown).
Page 522 BIGFOOT GEAR HOUSING 10. Lubricate I.D. of cover with 2-4-C Marine Lubricant with Teflon. 11. Rotate drive shaft clockwise and push impeller housing down (over impeller) until it con- tacts water pump base. 12. Apply Loctite 271 to bottom threads of cover screws. Install cover screws and tighten to specified torque.
Page 523 BIGFOOT GEAR HOUSING Gear Housing Pressure Test 1. Remove vent plug and install pressure test gauge. 2. Pressurize housing to 10-12 psi (69-83 kPa) and observe gauge for 5 minutes. 3. Rotate drive shaft, prop shaft and shift shaft while housing is pressurized to check for leaks.
Page 524 BIGFOOT GEAR HOUSING Filling Gear Housing With Lubricant NOTE: Gear housing lubricant capacity is 24 fl oz (710 mL). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing.
Page 525 BIGFOOT GEAR HOUSING Gearcase Installation WARNING Disconnect (and isolate) spark plug leads from spark plugs before installing gear housing onto drive shaft housing. Failure to follow this warning could result in acci- dental engine starting and possible injury. 1. Position outboard shift linkage into forward gear position. Models 40-60 Bigfoot (4-Stroke EFI) Remote Control Model Shown Shift Lever...
Page 526 BIGFOOT GEAR HOUSING Models 60 Bigfoot (2-Stroke) Shift Block Models 75/90/100/115/125 (2-Stroke) 19879 Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail. Rail Models 75/90/115EFI (4-Stroke) Shift Block Page 6B-60 90-857046R1 NOVEMBER 2001...
Page 527 BIGFOOT GEAR HOUSING 2. Tilt engine to full up position and engage tilt lock lever. 3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direc- tion. 4. Install water tube seal. Apply 2-4-C Marine Lubricant with Teflon to I.D. of seal. 5.
Page 528 BIGFOOT GEAR HOUSING CAUTION Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clear- ance space, will not allow drive shaft to fully engage with crankshaft. Subsequently, tightening the gear housing fasteners (while lubricant is on top of drive shaft) will load the drive shaft/crankshaft and damage either or both the power head and gear housing.
Page 529 BIGFOOT GEAR HOUSING 9. Shift gear housing into forward gear position. In forward gear the gear housing will ratch- et when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft is rotated counterclockwise. 10. Apply Loctite Grade 271 on threads of gear housing retaining screws. NOTE: During installation of gear housing, it may be necessary to move the shift block (lo- cated under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines.
Page 530 BIGFOOT GEAR HOUSING Trim Tab Adjustment and Replacement IMPORTANT: The trim tab is now painted and does NOT aid in protecting the drive shaft housing and gear housing from galvanic corrosion (corrosion and pitting of metal surfaces). Side anodes now provide protection. Do not paint or place protec- tive coating on the side anodes, or corrosion protection function will be lost.
Page 531 THROTTLE/SHIFT LINKAGE ATTACHMENTS/CONTROL LINKAGE Section 7A - Throttle/Shift Linkage Table of Contents Linkage (Non Bigfoot) ....7A-2 Linkage (Bigfoot) ......7A-4 90-857046R1 NOVEMBER 2001 Page 7A-1...
Page 532 THROTTLE/SHIFT LINKAGE LINKAGE (NON BIGFOOT) 2-4-C Marine Lubricant with Teflon Page 7A-2 90-857046R1 NOVEMBER 2001...
Page 533 THROTTLE/SHIFT LINKAGE LINKAGE (NON BIGFOOT) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (M8 x 70) 11.3 SCREW (M6 x 55) ELECTRIC RETAINER THROTTLE LEVER BUSHING RETAINER SHIFT LEVER BRACKET NON HANDLE LATCH SCREW (M6 x 16) SLEEVE SHIFT ROD THROTTLE CAM SPACER...
Page 534 THROTTLE/SHIFT LINKAGE LINKAGE (BIGFOOT) 12 13 2-4-C Marine Lubricant with Teflon Page 7A-4 90-857046R1 NOVEMBER 2001...
Page 535 THROTTLE/SHIFT LINKAGE LINKAGE (BIGFOOT) TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (M8 x 70) 11.3 SCREW (M6 x 55) RETAINER THROTTLE LEVER BUSHING RETAINER SHIFT LEVER BRACKET LATCH SCREW (M6 x 16) SLEEVE SHIFT ROD GUIDE-Shift Rod SHIFT LINK NYLINER WASHER...
Page 536 TILLER HANDLE ATTACHMENTS/CONTROL LINKAGE Section 7B - Tiller Handle Table of Contents Tiller Handle ......7B-2 Cleaning/Inspection/Repair .
Page 537: Tiller Handle
TILLER HANDLE TILLER HANDLE 2-4-C Marine Lubricant with Teflon Page 7B-2 90-857046R1 NOVEMBER 2001...
Page 538 TILLER HANDLE TILLER HANDLE TORQUE REF. QTY. DESCRIPTION lb-in lb-ft COVER KIT PULLEY CASE SCREW (10-16 x 1/2 IN. Self Tapping) THROTTLE CABLE (30-1/2 IN.) THROTTLE CABLE (41-1/2 IN.) SLEEVE SCREW (M8 x 25) 15.3 COVER BUSHING ARM–Steering Handle RETAINER SCREW (M5 x 16) SCREW (M6 x 25) LOCK–Throttle...
Page 539: Tiller Handle Assembly Removal
TILLER HANDLE Tiller Handle Assembly Removal 1. Remove lower cowl. Screws-M6x30 (6) Screw-M6x60 2. Remove shift handle. Shift Handle Bushing Screw-M8x35 Page 7B-4 90-857046R1 NOVEMBER 2001...
Page 540 TILLER HANDLE 3. Loosen the jam nuts and disconnect the throttle cables from the throttle lever. Throttle Cable (Long) Throttle Cable (Short) 4. Disconnect the tiller handle wiring. 5. Remove two screws securing the tiller handle. Remove the tiller handle assembly from the outboard.
Page 541: Tiller Handle Disassembly
TILLER HANDLE Tiller Handle Disassembly 1. Pry the two clips out of the hand grip. 2. Remove the side cover. Clips (2) Side Cover 3. Pull the tiller arm, along with the throttle cables and wiring, from the tiller bracket. Tiller Arm Throttle Cables/Wiring Tiller Bracket...
Page 542 TILLER HANDLE 4. Remove retainer and slide out the tiller tube assembly. 5. Remove the throttle friction knob assembly. Retainer Throttle Friction Knob Assembly Tiller Tube Assembly 6. Use a flat tip screwdriver to pry/push the rubber grip off the handle. 7.
Page 543: Cleaning/Inspection/Repair
TILLER HANDLE 9. Remove cover and disconnect throttle cables from pulley. Cover Throttle Cables Pulley Cleaning/Inspection/Repair 1. Inspect throttle cables for bending/damage and replace if necessary. 2. Inspect steering handle arm for cracks/damage and replace if necessary. Page 7B-8 90-857046R1 NOVEMBER 2001...
Page 544: Tiller Handle Reassembly
TILLER HANDLE Tiller Handle Reassembly 1. Wrap cables around pulley as shown Short Throttle Cable (30-1/2 in.) Place in Top Groove Long Throttle Cable (40-1/2 in.) Place in Bottom Groove Pulley 2. Place pulley and cables into case. Install cover with screw. Pulley Cover Screw 10-16x...
Page 545 TILLER HANDLE 5. Check to make sure tiller tube is recessed in the end of the handle 7/8 in. (22.2mm). 7/8 in. (22.2mm) 7/8 in. (22.2 mm) 6. Insert the engine stop switch harness through the tiller tube. Engine Stop Switch Harness 7.
Page 546 TILLER HANDLE 9. Place pulley assembly into arm. 10. Slide the tiller tube into the arm. Position the throttle friction knob into its slot. 11. Match the end of the tiller tube with the slots in the pulley assembly. Insert the tiller tube end into the pulley assembly.
Page 547 TILLER HANDLE 15. Pull the throttle cables and wiring into the bracket. Tiller Bracket 16. Push the arm into the tiller bracket. Secure the arm by installing the cover and screws. Tighten screws to specified torque. Cover Screw (2) M8 x 25 Arm Cover Screw Torque 135 lb.
Page 548 TILLER HANDLE CAUTION Wiring passing through the hand grip opening must be protected from chaffing or being cut, by using the wiring conduit described in the following steps. Failure to protect wiring as described could result in electrical system failure. 17.
Page 549: Tiller Handle Installation
TILLER HANDLE Tiller Handle Installation 1. Install tiller handle, new tab washer, and screws. Tighten screws to specified torque. 2. Bend tabs onto flats of screws. Tiller Handle Tab Washer Screw (2) M10 x 90 Tiller Handle Mounting Screw Torque 35 lb.
Page 550 TILLER HANDLE ELECTRIC START TILLER HANDLE WIRING DIAGRAM-30/40 (4-STROKE) TAN_LTBLU YEL_RED BLK_YEL – YEL_RED BLK = Black 1 2 3 4 5 6 7 8 BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink YEL_RED PUR = Purple...
Page 551 TILLER HANDLE 5. Rotate throttle grip to idle position. 6. Insert the anchor on the shorter throttle cable into the anchor slot on the throttle lever. 7. Secure cable in position by tightening jam nuts onto bracket (finger tighten only). 8.
Page 552 TILLER HANDLE 10. Rotate throttle grip to the wide open throttle position. The throttle stop screw should be contacting the plate. If there is a gap between the throttle stop screw and plate, loosen the jam nut on the shorter throttle cable, turn the adjustment nut clockwise, tighten the jam nut finger tight, and rotate the throttle grip to full throttle.
Page 553 TILLER HANDLE 12. Cables, wires, and shift rod should be routed through grommet as shown. Seat grommet between cowl halves. Fuel Connector Shift Rod Battery Cables Tiller Handle Harness Wires Throttle Cables Remote Key Harness 13. Assemble the shift rod into the shift handle by sliding the rod into the hole. Shift Rod Shift Handle 14.
Page 554 MANUAL STARTER MANUAL STARTER Section 8 Table of Contents Manual Starter ......Cleaning and Inspection .
Page 555: Manual Starter
MANUAL STARTER MANUAL STARTER 2-4-C Marine Lubricant with Teflon Page 8-2 90-857046R1 NOVEMBER 2001...
Page 556 MANUAL STARTER MANUAL STARTER TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – RECOIL STARTER ASSEMBLY RECOIL HOUSING SEAL ROLLER BUSHING WASHER SCREW (M6 x 30) WASHER-Finger Spring SPRING STARTER SHEAVE DOG-CAM SPRING RETAINING RING SPRING SCREW (1/4-20) 15.3 STARTER CORD SPRING INTERLOCK LEVER...
Page 557: Interlock Cable Adjustment
MANUAL STARTER Interlock Cable Adjustment IMPORTANT: Lubricate core wire of interlock cable with light oil prior to making adjustments. 1. While rotating the propeller shaft, place the gear shift lever into REVERSE. 2. Return the gear shift lever to NEUTRAL without going past neutral detent. 3.
Page 558: Manual Starter Removal
MANUAL STARTER Manual Starter Removal 1. Remove the adjustment screw from the rewind housing. 2. Remove the retaining clip from the start interlock. 3. Remove the interlock cable. Adjustment Screw Retaining Clip 4. Remove screws and manual starter. Screw (4) M6x25 Manual Starter 90-857046R1 NOVEMBER 2001 Page 8-5...
Page 559: Manual Starter Disassembly
MANUAL STARTER Manual Starter Disassembly WARNING When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Remove cam retainer. 2. Remove cam, interlock lever, and springs. Screw (3) 10-16x.625 (1/4 in. Hex) Spring (Cam) Cam Retainer Interlock Lever...
Page 560 MANUAL STARTER 5. Remove cam and spring. 6. Remove starter sheave assembly from recoil housing. Screw Spring Starter Sheave Assembly Recoil Housing 7. Remove rope from starter sheave assembly. NOTE: If re-using rope leave end knot tied. Knot 90-857046R1 NOVEMBER 2001 Page 8-7...
Page 561: Cleaning And Inspection
MANUAL STARTER 8. Remove springwasher and spring assembly from starter sheave. 9. Remove retaining rings, pawls, and springs from starter sheave. Springwasher Retaining Ring (2) Spring Assembly Pawl (2) Starter Sheave Spring (2) Cleaning and Inspection 1. Clean components in solvent and dry with compressed air. 2.
Page 562: Rewind Starter Reassembly
MANUAL STARTER 5. Inspect starter rope for wear. Replace as necessary. NOTE: Rope measures 66 in. (1.68 m) long Rewind Starter Reassembly WARNING When reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1.
Page 563: Adjusting Rewind Spring Tension
MANUAL STARTER 3. Install starter sheave assembly into recoil housing. NOTE: Looped end of spring must engage “V” notch in hub of recoil housing. 4. Secure cam and starter sheave assembly to recoil housing. NOTE: Cam should be positioned as shown with “x” facing up. Recoil Housing Spring Starter Sheave Assembly...
Page 564 MANUAL STARTER 2. Back sheave off until knot recess in sheave aligns with rope bushing. Rope Bushing Knot Recess 3. Thread starter rope thru knot recess in starter sheave, rope guide, and starter housing. Place knot into recess. Starter Rope Knot 90-857046R1 NOVEMBER 2001 Page 8-11...
Page 565 MANUAL STARTER 4. Allow starter rope to pull back into starter until about 1 ft. (30.5cm) of rope is left. Tie a overhand knot at this point to prevent rope from being pulled back into rewind starter. 5. Route starter rope through starter handle. Tie a knot into end of rope and secure in rope retainer.
Page 566 MANUAL STARTER 8. Install cam retainer. Drive screws tight. NOTE: Cam should be held with some pre-load until retainer is seated. Cam Retainer Screw (3) 10-16x.625 NOTE: Hold interlock lever back and check the operation of the rewind and rewind tension before installation.
Page 567: Manual Starter Installation
MANUAL STARTER Manual Starter Installation 1. Secure manual starter with screws. Screws (4) - M6x25 Manual Starter Manual Starter Screw Torque 60 lb. in. (7 N·m) 2. Install interlock cable onto cam boss and secure with retaining clip. 3. Secure interlock cable to rewind housing with adjustment screw. NOTE: Interlock cable should be adjusted after installation.
Page 568 COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 30/40 (4-Stroke) Tiller Handle Electric 30/40 (4-Stroke) Remote Control Electric Wiring Diagram ......Wiring Diagram .
Page 569 COLOR DIAGRAMS Notes: Page 9-2 90-857046R1 NOVEMBER 2001...
Page 570: 30/40 (4-Stroke) Tiller Handle Electric
COLOR DIAGRAMS 30/40 (4-STROKE) TILLER HANDLE ELECTRIC COLOR WIRING DIAGRAM 2001 MODELS (S/N 0T178500 AND UP) 90-857046R1 NOVEMBER 2001 Page 9-3...
Page 571 30/40 (4-Stroke) Tiller Handle Electric 2001 Models and Newer (S/N 0T178500 and Up) 1. ECM 2. Crank Position Sensor 3. Temperature Sensor 4. Oil Switch 5. DDT Connection 6. Auto Enrichener 7. Stator 8. Tachometer Signal (Secondary) 9. Voltage Regulator 10.
Page 572 UYRVR...
Page 573: 30/40 (4-Stroke) Tiller Handle Manual
COLOR DIAGRAMS 30/40 (4-STROKE) TILLER HANDLE MANUAL COLOR WIRING DIAGRAM 2001 MODELS (S/N 0T178500 AND UP) 90-857046R1 NOVEMBER 2001 Page 9-5...
Page 574 30/40 (4-Stroke) Tiller Handle Manual 2001 Models and Newer (S/N 0T178500 and Up) 1. ECM 2. Crank Position Sensor 3. Temperature Sensor 4. Oil Switch 5. DDT Connection 6. Auto Enrichener 7. Stator 8. Alternator (Lighting Coil) 9. Warning Horn 10.
Page 575 UYRXQ...
Page 576: 30/40 (4-Stroke) Remote Control Electric
COLOR DIAGRAMS 30/40 (4-STROKE) REMOTE CONTROL ELECTRIC COLOR WIRING DIAGRAM 2001 MODELS (S/N 0T178500 AND UP) 90-857046R1 NOVEMBER 2001 Page 9-7...
Page 577 30/40 (4-Stroke) Remote Control Electric 2001 Models and Newer (S/N 0T178500 and Up) 1. ECM 2. Crank Position Sensor 3. Temperature Sensor 4. Oil Switch 5. DDT Connection 6. Auto Enrichener 7. Stator 8. Tachometer Signal 9. Voltage Regulator 10. Starter 11.
Page 578 UYRXR...
Page 579: 30/40 (4 Stroke) Oil Flow Diagram
COLOR DIAGRAMS 30/40 (4-STROKE) OIL FLOW DIAGRAM 90-857046R1 NOVEMBER 2001 Page 9-9...
Page 580 30/40 (4-Stroke) Oil Flow Diagram 1. Sump 2. Oil Pick-up 3. Oil Passages in Adapter Plate 4. Oil Passages in Cylinder Block 5. Oil Passages In Cylinder Head 6. Oil Pump 7. Oil Pressure Regulator 8. Oil Filter 9. Crankshaft 10.
Page 582: 30/40 (4 Stroke) Water Flow Diagram
COLOR DIAGRAMS 30/40 (4-STROKE) WATER FLOW DIAGRAM 90-857046R1 NOVEMBER 2001 Page 9-11...
Page 583 30/40 (4-Stroke) Water Flow Diagram 1. Water Inlet 2. Water Pump 3. Driveshaft Housing 4. Water Tube 5. Adapter Plate 6. Cylinder Block 7. Cylinder Head 8. Water Jacket Cover 9. Thermostat 10. Fuel Cooler 11. Fuel Pump 12. Tell-Tale 13.
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30 fourstroke

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