Mariner 30 JET 40 (4 CYL) Service Manual

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SERVICE

Printed in U.S.A.

MANUAL

United States

Belgium

Canada

1996, Mercury Marine

MODELS

30 JET

40 (4 CYL)

With Serial Numbers

. . . . . . .

0C159200 and Above

. . . . . . . . . . .

9570305 and Above

. . . . . . . . . . . .

0A748269 and Above

90-814676R1 DECEMBER 1996

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Table of Contents

Troubleshooting

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Summary of Contents for Mariner 30 JET 40 (4 CYL)

Page 1 SERVICE MANUAL MODELS 30 JET 40 (4 CYL) With Serial Numbers United States ..0C159200 and Above Belgium ... 9570305 and Above Canada ... . 0A748269 and Above 1996, Mercury Marine 90-814676R1 DECEMBER 1996...
Page 2 We could not possibly know of and advise the service Notice trade of all conceivable procedures by which a ser- Throughout this publication, “Dangers”, “Warnings” vice might be performed and of the possible hazards and “Cautions” (accompanied by the International and/or results of each method.
Page 3 Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch./mm. When any product component is serv- iced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure.
Page 4: Important Information
Service Manual Outline Important Section 1 - Important Information Information Section 2 - Electrical & Ignition A - Ignition System B - Battery, Charging System & Starting System C - Timing, Synchronizing & Adjustment Electrical & Ignition D - Wiring Diagrams Section 3 - Fuel System &...
Page 5 IMPORTANT INFORMATION 50332 GENERAL INFORMATION and SPECIFICATIONS...
Page 6: Table Of Contents
Table of Contents Page Propeller Information ..... . How to Use this Manual ....General Specifications .
Page 7: Propeller Information
Propeller Information For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers and Boat Performance Information” (Part No. 90-86144). How to Use this Manual The manual is divided into SECTIONS (shown, right) which represents major components and systems.
Page 8: General Specifications
General Specifications Model Horsepower Engine Type 4 Cylinder, In-Line, Two-Stroke Full Throttle RPM Range 5000-5500 Idle RPM Range (in Forward Gear) 600-700 Piston Displacement 44 cu. in. (721cc) Cylinder Bore Standard 2.565 in. (65.151mm) Stroke 2.125 in. (53.975mm) Ignition Type Thunderbolt Capacitor Discharge Firing Order 1-3-2-4...
Page 9: Propeller Selection
Coat the propeller shaft with Quicksilver Anti-Corro- Propeller Selection sion Grease or 2-4-C Marine Lubricant with Teflon. 1. Select a propeller that will allow the engine to op- IMPORTANT: To prevent the propeller hub from erate at or near the top of the recommended full corroding and seizing to the propeller shaft, es- throttle RPM range (listed in “Specifications,”...
Page 10: Trim "In" Angle Adjustment
Trim “In” Angle Adjustment Power Trim System (Models with Power Trim) WARNING General Information Operating some boats with outboard trimmed to the full “in” trim angle [not using trim adjustment The power trim system is filled at the manufacturer bolt (a)] at planing speed will cause undesirable and is ready for use.
Page 11: Checking Trim System Fluid Level
Checking Trim System Fluid Level Trimming (Models with Power Trim) IMPORTANT: This trim system is pressurized. Remove fill screw when outboard is trimmed to NOTE: Because varying hull designs react differently the full “up” position. Retighten fill screw secure- in various degrees of rough water, it is recommended to experiment with trim positions to determine wheth- 1.
Page 12: Trim Tab Adjustment
3. In excess, can cause boat to veer to the left or Boat Performance right (bow steer). Test Instructions 4. Transfers steering torque harder to right (or less to the left) on single outboard installations. WARNING 5. Improves planing speed acceleration. A tight grip on the steering wheel/tiller handle is always advisable and is required when accelerat- ing, decelerating or when trimming the boat.
Page 13: Boat Test Chart (Example)
4. The top speed WOT (wide-open-throttle) test 6. Prop “break loose” (sudden higher RPM), if not should be done with the boat normally loaded (to excessive, in some cases can be beneficial dur- duplicate actual running conditions). Operate ing acceleration. If undesirable “break loose” oc- boat in gear at WOT and check RPM.
Page 14: Lubrication Points
Lubrication Points Item Fresh Water Salt Water Description Type of Lubricant Frequency Frequency Throttle/Shift Linkage Pivot Points Upper Shift Shaft Quic sil er Quicksilver Quic sil er 2-4-C 2-4-C E ery E ery Every E ery E ery Every Tilt Lock Lever 60 Days 30 Days M ri e...
Page 15: Ride-Guide Steering Cable And Pivot Points Lubrication
26474 8 - Propeller Shaft Lubrication 50157 3 - Tilt Lock Lever Grease Fitting 4 - Swivel Pin Grease Fittings Ride-Guide Steering Cable and Pivot Points Lubrication WARNING Core of steering cable (transom end) must be ful- ly retracted into cable housing before lubricating cable.
Page 16: Gear Housing Lubrication
Gear Housing Lubrication 5. Note color of gear lubricant. White or cream color indicates presence of water in lubricant. Gear lu- NOTE: Refer to “Specifications,” for gear housing lu- bricant which has been drained from a gearcase bricant capacity. recently in operation will have a yellowish color due to lubricant agitation/aeration.
Page 17: Periodic Inspection
Periodic Inspection Flushing Outboard Cooling System Conduct a periodic, systematic inspection to uncover and correct a failure before it can cause inconve- nience or mechanical damage. Inspection interval is WARNING based on average operating conditions in utility ser- When flushing, be certain that area in vicinity of vice.
Page 18: Following Complete Submersion
5. Flush or service engine as required. Be sure ade- Submerged Engine (Fresh Water) quate cooling water is provided. (Plus Special Instructions) a. Water must be discharged thru “tell-tale.” 1. Recover engine as quickly as possible. IMPORTANT: Prevent engine overheating. If wa- 2.
Page 19: Out-Of-Season Outboard Storage
10. If the water pickup is clogged, the speedometer Out-of-Season Outboard will be inoperative. Clean the pickup with a piece Storage of wire or blow out with compressed air. Before blowing out with air, disconnect the tubing from WARNING the speedometer. 11.
Page 20: How Weather Affects Engine Performance
In pointing out the practical consequences of weath- How Weather Affects Engine er effects, an engine--running on a hot, humid sum- Performance mer day--may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk spring or fall day.
Page 21: Conditions Affecting Operation
Conditions Affecting Detonation: Causes and Operation Prevention 1. Proper positioning of the weight inside the boat Detonation in a 2-cycle engine somewhat resembles (persons and gear) has a significant effect on the the “pinging” heard in an automobile engine. It can be boat’s performance, for example: otherwise described as a tin-like “rattling”...
Page 22: Compression Check
Detonation usually can be prevented, provided that 6. Compression check is important because an en- 1) the engine is correctly set up and 2) diligent main- gine with low or uneven compression cannot be tenance is applied to combat the detonation causes, tuned successfully to give peak performance.
Page 23: Painting Procedure
Industries DX330 Wax and Grease Remover or 8. Use Ditzler Urethane DU9000 for Mercury Black, equivalent (Xylene or M.E.K.). DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray 4. If bare metal has been exposed, use Quicksil- White.
Page 24: Decal Application
DECAL APPLICATION Decal Application 1. Mix ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solu- Decal Removal tion. NOTE: Leave protective masking, if present, on the 1. Mark decal location before removal to assure face of decal until final steps of decal installation.
Page 25 ELECTRICAL AND IGNITION 54637 IGNITION SYSTEM...
Page 26 Table of Contents Page Ignition System ......2A-1 Description ......2A-1 Ignition Troubleshooting .
Page 27: Ignition System
Ignition System Red Stator Models Black Stator Models Adapter Module Description The ignition system is alternator-driven with distribu- The switch discharges the capacitor voltage into the tor-less capacitor discharge. Major components of ignition coil at the correct time and in firing order se- the ignition system are the flywheel, stator assembly, quence.
Page 28: Checking For Loss Spark
Troubleshooting Test Equipment Ignition Troubleshooting WARNING Multimeter / DVA Tester 91-99750 DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components and/or metal test probes while engine is running and/or being “cranked”. STAY CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individu- al spark plug lead should be grounded to engine.
Page 29: Ignition Troubleshooting (Engines With Black Stator)
Ignition Troubleshooting (Engines With Black Stator) Troubleshooting Sequence Chart – (Engines with Black Stator) Start the ignition troubleshooting by first performing Step 1, then continue the series of steps to locate the problem. Refer to the troubleshooting steps on the following pages. Test Trigger Low or No Voltage at two coils Page 2A-10...
Page 30 Ignition Troubleshooting (Engines With Black Stator) STEP 1 – Primary Voltage At The Ignition Coils Test TEST RESULTS No voltage output or low voltage output on all coils. Go to STEP 2 – Stop Circuit Test. Good voltage on two coils. Go to Trigger Test. Good voltage on all coils.
Page 31 Ignition Troubleshooting (Engines With Black Stator) STEP 3 – Stator Low Speed and High Speed Test Stator Low Speed Test Stator High Speed Test 1. Use Multimeter / DVA Tester 91-99750. 2. Crank engine and observe meter reading. IGNITION VOLTAGE – 9 AMP STATOR Selector Reading At Reading At...
Page 32: Ignition Troubleshooting (Engines With Red Stator)
Ignition Troubleshooting (Engines With Red Stator) Troubleshooting Sequence Chart – (Engine with Red Stator) Start the ignition troubleshooting by first performing Step 1, then continue the series of steps to locate the problem. Refer to the troubleshooting steps on the following pages. Go To Low or No Voltage at all coils Step 2...
Page 33 STEP 2 – Stop Circuit Test Ignition Troubleshooting (Engines With Red Stator) BLK/ STEP 1 – Primary Voltage At The Ignition Coils Test a - Connect (+) Test Lead To BLK/YEL Wire Terminal On Switch Box b - Connect (–) Test Lead To Engine Ground (–) 1.
Page 34 STEP 4 – Switch Box (BLU/WHT Ignition Troubleshooting Wire) Circuit Test (Engines With Red Stator) BLU/ STEP 3 – Switch Box (BLU Wire) Circuit Test a - Connect (+) Test Lead To BLU/WHT Wire Terminal On Switch Box b - Connect (–) Test Lead To Engine Ground 1.
Page 35 7. Disconnect the GRN/WHT and WHT/GRN (sta- Ignition Troubleshooting tor) leads from the adapter module. (Engines With Red Stator) STEP 5 – Stator, Adapter Module, and Switch Box Test Elimination Test BLU/ 8. Measure the resistance between the GRN/WHT and WHT/GRN (stator) leads. Meter Test Leads To –...
Page 36: Ignition Component Testing
Ignition Coil Test Ignition Component Testing Trigger Test 1. Disconnect wires from coil terminals. 2. Pull spark plug lead out of coil tower. 3. Use a VOA meter and perform the following checks. Meter Test Leads To – Scale Reading Between (+) and (–) Coil .02-04 R x 1...
Page 37 Stator Test (Red Stator) Stator Test (Black Stator) Electric Start Engines Manual Start Engines 1. Disconnect all stator leads. 2. Use a VOA meter and perform the following checks. 9 AMP Stator Test Leads To – Scale Reading Blue and Blue/White R x 1000 5.7-8.0 1.
Page 38: Test For Spark
Test For Spark (Cranking) Primary Voltage Test (Engine Running) a - Spark Tester 91-850439 b - Connect Ground Lead To Engine Ground 1. Remove the spark plug leads from the spark plugs. 2. Adjust the spark tester to 1/2 in. (12mm) gap set- ting.
Page 39: Ignition (Key) Switch Test
Ignition (Key) Switch Test Mercury (Tilt) Stop Switch Test 1. Disconnect remote control wiring harness and in- 1. Remove mounting screw that secures mercury strument panel connector. switch to outboard. NOTE: Wiring diagram for control boxes is located in 2. Connect Ohmmeter (R x 1 scale) between black SECTION 2D.
Page 40: Flywheel Removal And Installation
2. Use strap wrench to hold flywheel while removing Flywheel Removal and flywheel nut and washer. Installation Flywheel Removal CAUTION To prevent accidental starting of outboard while removing engine components, on electric start models - remove engine battery cables from bat- tery and verify ignition key is in the “OFF”...
Page 41: Flywheel Installation
2. Use flywheel holder (91-52344) to hold flywheel Flywheel Installation while removing flywheel nut and washer. CAUTION Inspect magnet side of flywheel for any debris clinging to magnets. Installing flywheel with de- bris on magnets will cause damage to flywheel and/or electrical components located under fly- wheel when outboard is initially started.
Page 42 4. Remove 4 screws which secure stator to upper 5. Remove 6 bolts securing electrical box access cap. cover and remove cover. 54644 54645 a - Screws a - Bolts b - Stator b - Access Cover 6. Disconnect stator wiring from their respective ter- minals and remove stator assembly from out- board.
Page 43: Black Stator Assembly Installation
Black Stator Installation 1. Apply Loctite Grade A (92-32609-1) to threads of 4 stator attaching screws. 2. Install stator on upper end cap and torque attach- ing screws to 35 lb. in. (3.9 N·m). 3. Route stator wiring into electrical component box.
Page 44: Red Stator Assembly Installation
Red Stator Installation 3. Install adapter module routing adapter wires through opening in upper right corner of electrical 1. Position stator on powerhead as shown. Secure box. Connect stator, adapter module and switch stator with 4 screws. Apply Loctite 271 to screw box wires per appropriate model wiring diagram threads.
Page 45 Electric Models – Secure adapter module and wir- ing with sta-straps. 54957 a - Sta-Straps b - Adapter Module (Hidden) c - Adapter Module WHITE/GREEN Lead d - Adapter Module GREEN/WHITE Lead e - Stator YELLOW Leads f - Caps g - Adapter Module BLUE Lead h - Adapter Module BLUE/WHITE Lead i - Adapter Module BLACK Lead –...
Page 46 Manual Models – Secure adapter module and wiring with sta-straps. 54955 a - Sta-Straps b - Adapter Module c - Insulator Plug d - Stator BLUE/WHITE Lead (not used) e - Adapter Module WHITE/GREEN Lead f - Adapter Module GREEN/WHITE Lead g - Stator YELLOW Leads h - Terminal Block i - Harness Extension –...
Page 47: Trigger Plate Assembly Removal
Trigger Plate Assembly Removal 6. Remove 6 bolts from electrical box access cover and remove cover. 1. Remove top cowl. 2. Remove 3 bolts securing rewind starter or fly- wheel cover and remove or cover, whichever is applicable. 3. Remove flywheel as outlined in “FLYWHEEL RE- MOVAL AND INSTALLATION”, preceding.
Page 48: Trigger Plate Assembly Installation
Trigger Plate Assembly Installation 4. Reconnect trigger wires to proper terminals of switch box. Refer to wiring diagram, Section 2D. 1. If link rod was removed from trigger, reassemble Torque terminal nuts to 30 lb. in. (3.4 N·m). to trigger. 2.
Page 49: Ignition Coil Removal
Ignition Coil Removal Ignition Coil Installation 1. Remove top cowl. 1. Install spark plug high tension lead/coil tower boot assembly (retained) onto new coil. 2. Remove 6 bolts from electrical box access cover and remove cover. 2. Position secondary coil into electrical box. 3.
Page 50: Switch Box Installation
3. Disconnect all leads from switch box. Switch Box Installation 4. Remove 4 bolts from switch box and remove 1. Secure switch box to electrical component box switch box. with 4 bolts and their respective ground leads. Torque bolts to 40 lb. in. (4.5 N·m). 2.
Page 51 ELECTRICAL AND IGNITION BATTERY, CHARGING SYSTEM and STARTING SYSTEM...
Page 52 Table of Contents Page Battery ........2B-1 Precautions .
Page 53: Battery
Operating Outboard without Battery Battery If desired (or in an emergency), outboards equipped Precautions with an alternator can be started and operated with- out a battery (either disconnected or removed) if When charging batteries, an explosive (hydrogen) “Warning”, below, is followed. gas mixture forms in each cell.
Page 54: Specific Gravity Cell Comparison Test
When using a hydrometer, observe the following Electrolyte Level points: Check electrolyte level in battery regularly. A battery 1. Hydrometer must be clean (inside and out) to in- in use in hot weather should be checked more fre- sure an accurate reading. quently because of more rapid loss of water.
Page 55: Winter Storage Of Batteries
3. If, after prolonged charging, specific gravity of at WARNING least 1.230 on all cells cannot be reached, battery is not in optimum condition and will not provide Hydrogen and oxygen gases are produced dur- optimum performance; however, it may continue ing normal battery operation or charging.
Page 56: Battery Charging System Troubleshooting
Battery Charging System Stator Test (Alternator Coils Only) Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See “Electrolyte Level”, and “Charging a Discharged Bat- tery”, preceding. If battery will NOT accept a satisfactory charge, re- place battery.
Page 57: Voltage Regulator Test
Voltage Regulator Test ELECTRIC START MODELS WITH RECTIFIER LAMPS BURN OUT WHEN ENGINE IS REVVED The voltage regulator is defective. Replace voltage a - Rectifier regulator. b - Red Lead Rectifier must be functioning prop- IMPORTANT: LAMPS BURN DIM AT WIDE-OPEN-THROTTLE erly for accurate test results to be obtained.
Page 58: Electric Start Models With Voltage Regulator/Rectifier
ELECTRIC START MODELS WITH VOLTAGE REG- Connect RED (+) ammeter lead to larger diame- ULATOR/RECTIFIER ter RED lead, and BLACK (–) ammeter lead to POSITIVE on starter solenoid. With engine running at the indicated RPM, the ammeter should indicate the following approxi- mate amperes: AMPERES Idle...
Page 59: Rectifier Test
Rectifier Test NOTE: Rectifier can be tested without removing from engine. WARNING 2. Disconnect all wires from terminals on rectifier. Disconnect battery leads from battery before 3. Use an ohmmeter (R x 1000 scale) and perform testing rectifier. the following test. 1.
Page 60: Starter System
Troubleshooting the Starter Circuit Starter System Before beginning the starter circuit troubleshooting Starter System Components flowchart, following, check first for the following The starter system consists of the following parts: conditions: 1. Battery. 1. Make sure that battery is fully charged. 2.
Page 61: Starter Circuit Troubleshooting Flow Chart
Starter Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect yellow (starter motor) cable from starter solenoid test Point 1 BEFORE making tests 1 thru 7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads between negative (–) battery post and common powerhead ground.
Page 62: Starter Removal And Installation
Installation Starter Removal and Installation 1. Install collars on starter motor, if removed. 2. Connect BLACK ground cable to starter using Removal bolt and lockwasher, if removed. Torque bolt to 85 lb. in. (9.6 N·m). WARNING Before working on outboard, disconnect battery leads from battery and high tension leads from spark plugs.
Page 63: Bosch Starter
5. Remove armature (along with drive end cap) Bosch Starter from starter frame. Disassembly 6. If necessary, remove parts from armature shaft by first removing locknut. Then remove parts 1. Remove starter as outlined in “Starter Removal from shaft. and Installation”, preceding. 2.
Page 64: Starter Cleaning, Inspection And Testing
10. Repair bars, that are not too badly burned, by re- Starter Cleaning, Inspection soldering the leads in bars (using rosin flux sol- and Testing der) and turning down the commutator in a lathe to remove burned material, then undercut the Cleaning and Inspection mica.
Page 65: Checking Positive Brushes And Terminal
Checking Positive Brushes and Testing Negative Brushes for Ground Terminal (Bosch) Set VOA meter to (R x 1 scale). Connect meter leads Set VOA meter to (R x 1 scale). Place one lead of the between positive brushes. Meter must indicate full VOA on the negative brush and the other lead on the continuity or zero resistance.
Page 66: Reassembly
Reassembly Positive Brushes Installed 1. If brushes were removed, replace as follows: a. Install positive brushes (along with positive terminals) into commutator end cap. Positive Brushes Components 11660 a - Positive (+) Terminal b - Long Brush Lead c - Push Lead into Slot b.
Page 67 2. If removed, reinstall parts on armature shaft. Use 6. Lubricate bushing (located in commutator end a new locknut and tighten securely on end of cap) with one drop of SAE 10W oil. DO NOT over- shaft. lubricate. 3. Lubricate helix threads on armature shaft with a 7.
Page 68: Starter Solenoid Test
8. Place springs and brushes into brush holder and Starter Solenoid Test hold in place with brush retainer tool. Test starter solenoid as follows: 1. Disconnect all leads from solenoid terminals. 2. Using an ohmmeter (R x 1 scale), connect leads between solenoid terminals 1 and 2, as shown.
Page 69 ELECTRICAL AND IGNITION 54663 TIMING/SYNCHRONIZING/ADJUSTING...
Page 70 Table of Contents Page Timing/Synchronizing/Adjusting ... . 2C-1 Specifications ......2C-1 Special Tools .
Page 71 3. Install SPARK GAP TESTER (91-63998A1) be- Timing/Synchronizing & tween No. 1 (TOP) spark plug lead and engine Adjusting ground. 4. Connect TIMING LIGHT (91-99379) to No. 1 Specifications (TOP) spark plug lead. IMPORTANT: If carburetors were previously re- Full Throttle RPM Range 5000-5500 moved, it is recommended that they be synchro- Idle RPM (in Forward Gear)
Page 72 NOTE: By holding the throttle/spark arm against the 4. While holding throttle/spark arm against IDLE IDLE RPM SCREW STOP, a constant timing refer- RPM SCREW STOP, rotate actuator plate until ence point is provided while adjusting throttle actua- PRIMARY THROTTLE CAM just touches PRI- tor plate.
Page 73 MAXIMUM TIMING ADJUSTMENT THROTTLE SECONDARY PICK UP ADJUSTMENT (OUTBOARD NOT RUNNING) 1. Advance throttle/spark arm until MAXIMUM SPARK ADVANCE SCREW is against stop. En- 1. With engine not running, advance outboard gage electric starter. If necessary, adjust maxi- throttle lever to hold maximum spark advance mum spark advance screw to align 32 BTDC screw against stop.
Page 74 FULL THROTTLE STOP SCREW ADJUSTMENT 2. Adjust full throttle stop screw to allow full carbure- (OUTBOARD NOT RUNNING) tor shutter opening at wide-open-throttle. Throttle shutters MUST NOT act as a throttle stop. .010” 1. Advance throttle lever to hold full throttle stop - .015”...
Page 75 Carburetor Adjustments IDLE RPM ADJUSTMENT 1. Place outboard in test tank or boat and outboard IDLE MIXTURE SCREW ADJUSTMENT in water. 1. With outboard in test tank or boat and outboard 2. Start outboard and allow to warm up for approxi- in water, preset carburetor idle mixture screw at mately five minutes.
Page 76 ELECTRICAL AND IGNITION 23891 WIRING...
Page 77 Table of Contents Page Wiring Diagram – Model 30 Jet with 16 Amp Black Stator ....2D-1 Wiring Diagram – Model 30 Jet with 16 Amp Red Stator .
Page 78: Wiring Diagram - Model 30 Jet With 16 Amp Black Stator
Wiring Diagram – Model 30 Jet with 16 Amp Black Stator BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT BLU = LIGHT BLUE 53472 1 - Stator...
Page 79: Wiring Diagram - Model 30 Jet With 16 Amp Red Stator
Wiring Diagram – Model 30 Jet with 16 Amp Red Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow LIT = Light...
Page 80: Wiring Diagram - Model 30 Jet Tiller Handle With16 Amp Black Stator
Wiring Diagram – Model 30 Jet Tiller Handle with 16 Amp Black Stator BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT BLU = LIGHT BLUE 53473...
Page 81: Wiring Diagram - Model 30 Jet Tiller Handle With16 Amp Red Stator
Wiring Diagram – Model 30 Jet Tiller Handle with 16 Amp Red Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow...
Page 82: Wiring Diagram - Model 40 Electric Start With 9 Amp Black Stator
Wiring Diagram – Model 40 Electric Start with 9 Amp Black Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light...
Page 83: Wiring Diagram - Model 40 Electric Start With 16 Amp Black Stator
Wiring Diagram – Model 40 Electric Start with 16 Amp Black Stator BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT BLU = LIGHT BLUE 52468 1 - Stator...
Page 84: Wiring Diagram - Model 40 Electric Start With 16 Amp Red Stator
Wiring Diagram – Model 40 Electric Start with 16 Amp Red Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow LIT = Light...
Page 85 Wiring Diagram – Model 40 Electric Start Tiller Handle with 16 Amp Black Stator BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT BLU = LIGHT BLUE 52467...
Page 86 Wiring Diagram – Model 40 Electric Start Tiller Handle with 16 Amp Red Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow...
Page 87: Wiring Diagram - Model 40 Manual Start With Black Stator
Wiring Diagram – Model 40 Manual Start with Black Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light...
Page 88: Wiring Diagram - Model 40 Manual Start With Red Stator
Wiring Diagram – Model 40 Manual Start with Red Stator BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow LIT = Light...
Page 89: Power Trim Wiring Diagram
Power Trim Wiring Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray 50516 GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark 2D-12 - ELECTRICAL AND IGNITION...
Page 90: Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start With Warning Horn) Wiring Diagram
Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow...
Page 91: Commander 2000 Side Mount Remote Control (Electric Start With Warning Horn) Wiring Diagram
Commander 2000 Side Mount Remote Control (Electric Start with Warning Horn) Wiring Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow...
Page 92: Commander 2000 Side Mount Remote Control (Manual) Wiring Diagram
Commander 2000 Side Mount Remote Control (Manual) Wiring Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...
Page 93: Key/Choke Switch Continuity Test (Commander 2000 Side Mount Remote Control)
Key/Choke Switch Continuity Test (Commander 2000 Side Mount Remote Control) BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light...
Page 94: Panel Mount Remote Control Wiring Diagram
Panel Mount Remote Control Wiring Diagram BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White 50148 YEL = Yellow LIT = Light DRK = Dark...
Page 95: Remote Key Switch And Warning Horn
Remote Key Switch and Warning Horn BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark 1091-H...
Page 96 FUEL SYSTEM AND CARBURETION...
Page 97 Table of Contents Page Page Specifications ......Enrichment System (Electric Start Models) 3-17 Special Tools .
Page 98 Specifications Idle RPM (In Forward Gear) 500-600 Float Level Carb Model WMA7B 1/4 in 1/64 in. (6.4mm 0.4mm) Carb Model WMA9 11/16 in 1/64 in. (16.3mm 0.4mm) Float Drop Carb Model WMA7B 1/32 in. to 1/16 in. (0.80mm to 1.6mm) Carb Model WMA9 No Adjustment Special Tools...
Page 99: Fuel System (Carburetor)
Fuel System (Carburetor) 1 - Carburetor Body 2 - Welch Plug 3 - Plug 4 - Throttle Shutter 5 - Spring 6 - Baffle 7 - Float 8 - Pivot Pin 9 - Fuel Bowl 10- Gasket 11- Gasket 12- Needle 13- Main Jet 14- Vent Jet 15- Venturi...
Page 100: Fuel System (Fuel Pump)
Fuel System (Fuel Pump) 1 - Pump Body 2 - Rubber Disk (2) 3 - Plastic Disc (2) 4 - Retainer (2) 5 - Spring 6 - Cap 7 - Diaphragm 8 - Gasket 9 - Spring 10- Cap 11 - Plate Carburetor 12- Gasket 13- Gasket...
Page 101: Fuel Pump
Since any type of anti-siphon device must be located Fuel Pump between the outboard fuel inlet and fuel tank outlet, a simple method of checking [if such a device (or bad General Information fuel) is a problem source] is to operate the outboard with a separate fuel supply which is known to be FUEL PUMP DESCRIPTION/OPERATION good, such as a remote fuel tank.
Page 102: Fuel Pump Removal (Electric Start Model)
Fuel Pump Removal Problem: Lack of Fuel Pump Pressure Possible Cause Corrective Action (Electric Start Model) An Anti-siphon Valve Read “Checking for re- 1. Remove oil tank from outboard. Refer to Section stricted Fuel Flow Caused 8 “Oil Injection System”. by Anti-siphon Valves”...
Page 103: Fuel Pump Disassembly
4. Remove gasket from powerhead. Fuel Pump Disassembly 1. Remove bolts and chamber plate. 52019 a - Bolts 52019 b - Chamber Plate a - Gasket 2. Disassemble fuel pump as shown in “Fuel Pump Exploded View”. 3-6 - FUEL SYSTEM AND CARBURETION 90-814676R1 DECEMBER 1996...
Page 104: Fuel Pump Exploded View (Design 1)
Fuel Pump Exploded View (Design 1) IMPORTANT: Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly. NOTE: Respective diaphragms go against the mat- ing surfaces of the fuel pump body and respective gaskets are between the diaphragms and end caps. Gaskets should always be replaced on fuel pump reassembly.
Page 105: Cleaning And Inspection
3. With retainer installed in pump body, break re- Cleaning and Inspection tainer rod from retainer by bending sideways. 1. Clean fuel pump housing, chamber plate and pump base, then dry with compressed air. 2. Inspect spring coils for damage. 3.
Page 106: Fuel Pump Installation (Design 1)
3. Connect hoses as shown. Secure hoses with sta- Fuel Pump Installation straps. (Design 1) 1. Install gasket on fuel pump base. 52024 a - Gasket b - Base 52014 a - Inlet Hose 2. Install pump and secure with screws. Torque b - Outlet Hose screws to 60 lb.
Page 107: Fuel Pump Exploded View (Design 2)
Fuel Pump Exploded View (Design 2) IMPORTANT: Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly. NOTE: Respective diaphragms go against the mat- ing surfaces of the fuel pump body and respective gaskets are between the diaphragms and end caps. Gaskets should always be replaced on fuel pump reassembly.
Page 108: Cleaning And Inspection
3. Break rod from retainer cap and reinstall rod into Cleaning and Inspection cap. Using a hammer and punch, tap rod down 1. Clean fuel pump housing, chamber plate and into retainer until flush with top of retainer. pump base, then dry with compressed air. 2.
Page 109: Carburetion System
Carburetion System Problem: Engine Floods Possible Cause Corrective Action Fuel System - Troubleshooting Dirt or foreign particles Flush out inlet seat and are preventing inlet clean inlet needle. Problems, which sometimes are thought to be needle from seating. caused by the fuel system, may be something com- Worn inlet needle.
Page 110: Checking For Restricted Fuel Flow
Problem 1: Engine Idles Rough and Stalls Problem: Rough Idle Problem 2: Engine Runs Uneven or Surges Possible Cause Corrective Action If related to reed-block, in- Replace reeds. Problem 3: Engine Will Not Accelerate dicates excessive preload Possible Cause Corrective Action in reeds.
Page 111: Idle Mixture Screw Adjustment
Idle Mixture Screw Adjustment FLOAT LEVEL AND FLOAT DROP ADJUSTMENT 1. Place outboard in test tank or place boat and out- Metal tab controls float level. Plastic tab limits float board in water. drop. Bending tab (a) towards needle (when float is 2.
Page 112: Float Drop (Wma7B Carburetor Only)
FLOAT DROP Main (High Speed) Jet Adjustment (WMA7B CARBURETOR ONLY) The carburetor is equipped with a fixed high speed jet 1. Float drop measurement of 1/32 in. (0.793mm) to and normally no adjustment is required. However, 1/16 in. (1.587mm) from bottom of float and top extreme changes in weather (temperature and hu- of fixed jet as shown.
Page 113: Vent Jet
Vent Jet High Altitude Jetting The vent jet supplies less than atmosphere pressure The carburetor jets installed at the manufacturer is to the fuel bowl at mid-range, which results in im- for outboard operation at sea level through an eleva- proved fuel economy.
Page 114: Enrichment System (Electric Start Models)
Enrichener Hose Routed to Balance Enrichment System Tube (Electric Start Models) The enrichener system (electric start models) pro- vides the engine with a rich fuel charge (supplied from the float bowl of the top carburetor) for starting ease of a cold engine. Enrichener Hose Routed to Carburetor Flanges 50571...
Page 115: Primer System
Primer System Enrichener Valve (Manual Operation) Hose Installation IMPORTANT: Use of enrichener if motor is warm could result in engine flooding. Squeeze primer bulb until bulb is firm. Press button in on enrichener valve and hold approximately 5 sec- onds. Release button. Start outboard. 50571 Description: The primer system consists of a primer bulb that pulls...
Page 116: Enrichment Valve Test
Enrichment Valve Test Push key (or choke but- ton) in. Valve should click No Click Click Check for battery voltage to yellow/black wire at termi- Squeeze primer bulb until bulb is firm. Remove lower hose nal block on engine when key (or choke button) is from fitting on enrichener valve.
Page 117: Fuel Line And Primer Bulb Assembly
Fuel Line Clamp Removal and Fuel Line and Primer Bulb Installation Assembly 1. To remove fuel line clamps, grip clamp with pliers and bend overlapping hook backward. 51115 50165 2. To install fuel line clamps, grip hose clamp with 1 - Fitting pliers and push down on hook with screwdriver 2 - Clamp until hooks interlock.
Page 118: Carburetor Removal (Manual Start Model)
Carburetor Removal Carburetor Disassembly (Manual Start Model) (Top Carburetor) NOTE: Fuel pump can be removed from engine 1. Disconnect fuel hose and primer hose from car- block to aid in carburetor removal. buretor. 1. Remove 4 nuts securing carburetors to power- head.
Page 119 3. Remove 4 screws securing cover plate to carbu- 5. Remove primer fitting, bowl and bowl gasket from retor. carburetor. 52012 52012 a - Screws a - Primer Fitting b - Cover Plate b - Bowl c - Gasket 4. Remove cover plate and gasket. 52018 a - Gasket 3-22 - FUEL SYSTEM AND CARBURETION...
Page 120 NOTE: Carburetor float bowl primer fitting design can 7. Remove float, needle and baffle from carburetor. be identified below. DESIGN #1 DESIGN #2 DESIGN #3 DESIGN #4 52013 a - Float b - Needle c - Baffle 8. Remove main nozzle and venturi from carbure- tor.
Page 121 9. Remove main jet from carburetor. 10. Remove vent jet from carburetor. WMA7B CARB 52015 a - Vent Jet 11. Remove idle mixture screw and spring from car- 52016 buretor. a - Main Jet WMA9 CARB 52015 52026 a - Idle Mixture Screw a - Main Jet b - Spring 3-24 - FUEL SYSTEM AND CARBURETION...
Page 122: Cleaning And Inspection
12. Remove throttle return spring from throttle shaft. 14. Remove throttle shaft from carburetor. 52021 a - Throttle Shaft 52016 a - Throttle Return Spring Cleaning and Inspection b - Throttle Shaft 1. Carefully inspect carburetor body and fuel bowl 13.
Page 123: Carburetor Reassembly
3. Install throttle return spring to throttle shaft. Carburetor Reassembly 1. Install throttle shaft to carburetor. 52021 a - Throttle Shaft 52016 a - Throttle Return Spring 2. Install throttle shaft plate to throttle shaft. Apply b - Throttle Shaft Loctite 271 to threads of screws.
Page 124 5. Install vent jet. Torque to 14 lb. in. (1.6 N·m). 7. Install venturi into carburetor. Install main nozzle into carburetor. Tighten securely. 52015 a - Vent Jet [Torque to 14 lb. in. (1.6 N·m)] 6. Install main jet. Torque to 6 lb. in. (0.7 N·m). WMA7B CARB 52015 a - Venturi...
Page 125 9. Install pivot pin securing float to carburetor. PRIMER FITTING DESIGNS 10. Seat splined portion of pivot pin into carburetor DESIGN #1 DESIGN #2 post. DESIGN #3 DESIGN #4 52013 a - Pivot Pin b - Float c - Post 11.
Page 126 13. Torque screws to 18 lb. in. (2.0 N·m). 15. Connect fuel hose and primer hose to carburetor. Secure fuel hose using sta-strap. 52012 a - Fuel Hose 52012 b - Primer Hose a - Screws 14. Connect throttle linkage to carburetor throttle shaft.
Page 127: Carburetor Installation
3. Connect fuel line and primer line. Secure fuel line Carburetor Installation using sta-strap. 1. Install carburetors to powerhead using new gas- kets. 52022 a - Nuts [Torque to 110 lb. in. (12.4 N·m)] b - Fuel Line 52021 c - Primer Line 2.
Page 128 POWERHEAD 54727...
Page 129 Table of Contents Page Specifications ......Special Tools ......General Information .
Page 130: Specifications
Specifications Special Tools Block Description Part Number Type ....4 Cylinder, 2 Cycle Flywheel Holder 91-52344 Displacement ..44.0 cu in.
Page 131: Throttle Control Linkage
Throttle Control Linkage 2-4-C With Teflon (92-825407A12) 4-2 - POWERHEAD 90-814676R1 DECEMBER 1996...
Page 132 Throttle Control Linkage TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m BRACKET SCREW (1-1/8 IN.) 17.0 LOCKWASHER THROTTLE ACTUATOR LINK ROD SWIVEL BALL SWIVEL BASE Drive Tight; but ac- SCREW (2 IN.) tuator must be free to pivot WASHER WAVE WASHER PLATE...
Page 133: Cylinder Block And Crankcase Assembly
Cylinder Block and Crankcase Assembly Perfect Seal (92-34227-1) Loctite 680 (Obtain Locally) Loctite Master Gasket (92-12564-1) 4-4 - POWERHEAD 90-814676R1 DECEMBER 1996...
Page 134 Cylinder Block and Crankcase Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK/CRANKCASE ASSEMBLY BRACKET–starter motor (UPPER) SCREW–bracket to crankcase (1-7/8 ) 20.3 LOCKWASHER–bracket screw COVER–starter motor (LOWER) SCREW–cover to crankcase (1-7/8 ) 20.3 PLUG DOWEL PIN STUD–carburetor (1-1/4 ) STUD–crankcase to drive shaft housing (1-5/8 ) DOWEL PIN–crankcase to cylinder block...
Page 135: End Caps And Exhaust Cover
End Caps and Exhaust Cover Loctite 271 (Obtain Locally) 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) A=DESIGN I B=DESIGN II C=DESIGN III 4-6 - POWERHEAD 90-814676R1 DECEMBER 1996...
Page 136 End Caps and Exhaust Cover TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TEMPERATURE SWITCH (ELECTRIC) END CAP ASSEMBLY–upper OIL SEAL–upper end cap O-RING–upper end cap BALL BEARING–upper end cap SHIM–upper end cap (.005-10) SCREW–upper end cap (3/4 ) 16.6 22.5 COVER ASSEMBLY–cylinder block...
Page 137: Crankshaft, Pistons And Connecting Rods
Crankshaft, Pistons, and Connecting Rods Loctite 271 (Obtain Locally) 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) 4-8 - POWERHEAD 90-814676R1 DECEMBER 1996...
Page 138 Crankshaft, Pistons and Connecting Rods TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CRANKSHAFT O-RING KEY–crankshaft MAIN BEARING ASSEMBLY (VALVE TYPE) DOWEL PIN–main bearing DOWEL PIN–reed locating SCREW–main bearing NUT–main bearing screw REED SET–matched REED STOP SCREW–reed stop (9/16 ) NUT–reed stop screw PISTON/PISTON PIN (STANDARD) PISTON/PISTON PIN (.015 O.S)
Page 139: Powerhead Torque Sequence And Torque Specifications
Powerhead Torque CRANKCASE COVER BOLTS 17.5 lb. ft. (23.5 N·m) Sequence and Torque Speci- fications CYLINDER BLOCK COVER BOLTS 100 lb. in. (11.5 N·m) EXHAUST COVER 16.5 lb. ft. (22.5 N·m) POWERHEAD TO DRIVESHAFT HOUSING 12.5 lb. ft. (17.0 N·m) 4-10 - POWERHEAD 90-814676R1 DECEMBER 1996...
Page 140: Powerhead Removal From Driveshaft Housing
5. Remove shift and throttle cables from engine. Powerhead Removal from Driveshaft Housing Electric Start Model 1. Disconnect powerhead battery cables from bat- tery. 2. Remove top cowling. 3. Remove Spark Plug leads from spark plugs. 4. Disconnect powerhead and remote control elec- trical harness connector.
Page 141 8. Disconnect two blue low oil level leads at their 11. Remove inlet hose from oil pump. bullet connectors. NOTE: If oil tank contains oil, inlet hose to oil pump must be plugged when disconnected to prevent oil 9. Disconnect blue/white and green/white power leakage.
Page 142 14. Remove three bolts securing flywheel cover to 16. Remove eight nuts securing powerhead to drive- powerhead and remove cover and oil tank shaft housing. assembly. NOTE: Hold oil tank securely when removing from powerhead as oil tank may detach from flywheel cover assembly.
Page 143: Manual Start Model
Manual Start Model 6. Disconnect BLACK/YELLOW stop leads at both bullet connectors. 1. Disconnect any alternator charging leads from 7. Remove three black leads from grounding bolt at battery. aft starboard corner of bottom cowl. 2. Remove top cowl. 8. Remove tell-tale hose from bottom cowl. 3.
Page 144 11. Remove three bolts securing recoil starter to 13. Remove eight nuts securing powerhead to drive- powerhead and remove recoil assembly. shaft housing. 26815 a - Nuts (4 Each Side) 14. Remove plastic cap from center of flywheel and thread lifting eye (91-75132) into flywheel. Using hoist, lift powerhead from driveshaft housing and install on powerhead stand (91-25821A1) or work bench.
Page 145: Powerhead Disassembly
3. Remove three bolts attaching throttle actuator Powerhead Disassembly assembly to crankcase cover. 1. Remove the following components/assemblies referring to the listed service manual sections. Component/Assembly Section Rewind Starter Flywheel Ignition Components Starter Motor Carburetors, Fuel Pump and Fuel Enrichment Valve 2.
Page 146 5. Remove bolts securing upper and lower end 6. Bend back lock tabs on reed cage bolts and cen- caps to cylinder block and crankcase cover. ter main bolt. 54682 a - Bolts b - Upper End Cap 54684 a - Locking Tab Washer b - Reed Cage Bolt c - Center Main Bolt 7.
Page 147 8. Using pry points to aid in removal, lift crankcase cover from cylinder block. 54688 54686 a - Pry Points a - Lower End Cap b - Crankcase Cover 10. Remove oil pump drive gear (electric start mod- 9. Gently tap upper and lower end caps from crank- els only) from crankshaft.
Page 148 11. Remove crankshaft assembly from cylinder 12. Remove 6 screws securing transfer cover to cyl- block. If pry bar is used to aid in removal of crank- inder block and remove cover. shaft assembly, pad surface of block where pry 13.
Page 149 16. Remove 10 bolts from cylinder block cover and 17. Remove 15 bolts from exhaust manifold cover remove cover. Remove temperature switch from and remove manifold cover and baffle plate from cylinder block. cylinder block. 50532 Exhaust Manifold Cover 54692 a - Cylinder Block Cover b - Temperature Switch a - Exhaust Manifold Cover...
Page 150: End Cap Disassembly
3. Inspect ball bearing located in the end cap as out- End Cap Disassembly lined in “Cleaning and Inspection,” following. IMPORTANT: It is recommended that new oil IMPORTANT: DO NOT remove ball bearing from seals be installed in end caps, regardless of ap- end cap unless replacement is required.
Page 151: Crankshaft Disassembly
2. Use Ball Bearing Puller (91-24100A1) and press Crankshaft Disassembly ball bearing from end cap. Inspect ball bearing as outlined in “Cleaning and Inspection,” following. WARNING IMPORTANT: It is recommended that heat be ap- Eye Protection must be worn while removing pis- plied carefully to end cap housing to aid in re- ton rings and piston pin lock rings from pistons.
Page 152 2. Remove piston pin lock rings from both ends of 4. Place Piston Pin Tool (91-76160A2) into top of piston pin bores. Discard lock rings. DO NOT re- piston pin. Support bottom of piston with hand use piston pin lock rings. and tap on end of piston pin tool with mallet, push- ing piston pin out of piston.
Page 153 IMPORTANT: It is recommended that new needle bearings be installed in connecting rod to ensure lasting repair. NOTE: If needle bearings must be reused, store them in numbered container so they can be rein- stalled with same connecting rod. DO NOT intermix needle bearings from one connecting rod with those from another connecting rod.
Page 154: Cleaning And Inspection
c. Localize stroking in the smallest diameter un- Cleaning and Inspection til drill speed is constant throughout length of bore. Maintain firm stone pressure against cylinder wall to assure fast stock removal and Cylinder Block and Crankcase Cover accurate results. Expand stones, as neces- sary, to compensate for stock removal and IMPORTANT: Crankcase cover and cylinder stone wear.
Page 155: Cylinder Bore Size
Cylinder Bore Size 2. Inspect piston ring grooves for wear, burns, dis- tortion or loose piston ring locating pins. Piston Size Cylinder Bore 3. Clean piston dome, ring grooves and piston skirt. Finish Hone Use recessed end of a broken piston ring to clean carbon deposits from ring grooves.
Page 156: Measuring Piston Roundness
Measuring Piston Roundness Piston has a tapered cam profile shape and is not a true diameter. Using a micrometer, measure dimension “A” at loca- tion shown. Dimension should be as indicated in chart following. Dimensions at Right Angle (90 ) to Piston Pin 54706 a - Feeler Gauge b - Reed...
Page 157: Connecting Rods
Connecting Rods b. Water Marks: When bearing surfaces are subjected to water contamination, a bearing 1. Check connecting rod for alignment by placing surface “etching” occurs. This etching re- rods on a surface plate. If light can be seen under sembles the size of the bearing.
Page 158 d. Chatter Marks: Chatter marks are the result e. Uneven Wear: Uneven wear could be of a combination of low speed-low load-cold caused by a bent connecting rod or improper water temperature operation that is aggra- shimming of crankshaft end play [failure to vated by inadequate lubrication and/or im- maintain approximately the same amount of proper fuel.
Page 159: Cleaning Connecting Rods
Cleaning Connecting Rods c. Clean PISTON PIN END of connecting rod, using same method as in Step “b”, preceding, 1. If necessary, clean connecting rod bearing sur- using 320 grit carborundum cloth. faces, as follows: d. Thoroughly wash connecting rods to remove a.
Page 160: Ball Bearing
Powerhead Reassembly WARNING DO NOT spin-dry crankshaft ball bearings with compressed air. General 6. Thoroughly clean (with solvent) and dry crank- Before proceeding with powerhead reassembly, be shaft ball bearings. Recheck surfaces of crank- sure that all parts to be re-used have been carefully shaft.
Page 161: Crankshaft Reassembly
Crankshaft Reassembly 1. Lubricate main bearing outer race with Quicksil- ver Needle Bearing Assembly Lubricant and place needle bearings on race. 54712 a - Snap Ring b - Outer race 54710 Main Bearing Installed a - Outer Race 3. Install main bearing support onto main bearing b - Needle Bearing Assembly Lubricant race.
Page 162 4. Secure both halves of each main bearing race 6. Secure both halves of reed block together with together with two bolts. Torque bolts to 80 lb. in. two screws and nuts. Torque reed block screws (9.0 N·m). to 55 lb. in. (6.2 N·m). 54702 a - Torque Screws (One Each Side) to 55 lb.
Page 163 CAUTION Never inter-mix new needle bearings with used bearings. If any bearing requires replacement, replace all needle bearings. c. Place needle bearings (25 required) around crank pin bearing surface of connecting rod and cap. 54715 a - Connecting Rod Correct Connecting Rod Cap Alignment b - Rod Cap g.
Page 164: Piston Installation
Piston Installation 4. Place upper locating washer over sleeve on pis- ton pin tool, then slide piston pin tool out of sleeve 1. Place a piece of paper on bench and line up pis- (sleeve and washers will hold needle bearings in ton pin needle bearings.
Page 165 7. Secure piston pin in piston by installing new “G” 9. Lubricate rings with light oil and align ring ends type piston lockrings into groove in each end of with locating pins in ring grooves. piston pin bore. Make sure that lockrings are seated in grooves.
Page 166: Crankshaft Seal Installation
Crankshaft Seal Installation SEAL CARRIER REPLACEMENT (DESIGN 1) 1. Thoroughly clean crankshaft splines with solvent NOTE: Crankshafts that use Design 1 and Design 3 and dry with compressed air. lower end caps (shown) have a replaceable seal in the bottom of the crankshaft. This seal protects the 2.
Page 167: End Cap Reassembly
End Cap Reassembly 4. Press ball bearing into lower end cap with press block. LOWER END CAP 1. Install O-Ring Seal into seal groove. 2. Apply Loctite Grade “A” (271) to outer diameter oil seals and press into end cap using proper mandrel as shown.
Page 168: Upper End Cap
UPPER END CAP Cylinder Block Reassembly 1. If removed, press ball bearing into upper end cap 1. Lubricate piston rings, pistons and cylinder walls with press block. with light oil. 2. Rotate and align end of each piston ring with lo- cating pin in ring groove.
Page 169 54724 a - Straight Compressors b - Offset Compressors 54725 Ring Compressors Installed on Pistons (Front a - Straight Compressors View) b - Offset Compressors Ring Compressors Installed on Pistons (Rear View) 4-40 - POWERHEAD 90-814676R1 DECEMBER 1996...
Page 170 4. If removed, place reed block locating pins into 6. Align centermain bearing and reed blocks with lo- cylinder block. cating pins and push centermain bearing and reed blocks downward to seat them in cylinder block. 54726 54728 a - Align Centermain Bearing Support and Reed Blocks with Locating Pins and Push Downward to Seat a - Reed Block Locating Pin b - Main Bearing Support Locating Pin (on Some Models, Pin...
Page 171 8. Slide oil pump drive gear onto crankshaft. Cham- c. With crankshaft against lower end cap, use a fer side of gear goes towards bottom crankshaft feeler gauge and check measurement be- throw. Engage key with slot in gear. tween inner race of upper ball bearing and thrust face of crankshaft.
Page 172 13. Apply a continuous bead of Loctite Master gasket 15. Install centermain bearing and reed block mount- Sealant on cylinder block. ing bolts with locking tabs. Torque bolts to speci- fied torque and bend locking tabs up and against flat of each bolt. a - Cylinder Block b - Loctite Master Gasket Sealant (92-12564-1);...
Page 173 54683 a - Torque Bolts to 200 lb. in. (22.6 N·m) 50532 b - Bottom End Cap Torque Sequence Exhaust Cover 17. Install exhaust cover and divider plate with new 18. Install balance tube with fittings into cylinder gaskets. Apply Loctite Grade “A” (271) to bolt block.
Page 174 21. Install transfer port cover and new gasket. Apply Loctite Grade “A” to screw threads and torque screws to 65 lb. in. (7.3 N·m). a - Transfer Port Cover b - Gaskets c - Screws (6 Each) 22. Install cylinder cover and new gasket. Torque bolts equally in three progressive steps to 100 lb.
Page 175 23. Install temperature switch in cylinder block. NOTE: A plug is provided on cylinder cover which may be removed for installing a Water Pressure Gauge Kit or a Water Temperature Gauge Kit. 50531 Cylinder Block Cover Torque Sequence 54692 a - Plug (Remove for Installation of Water Pressure or Water Temperature Gauge Kit) b - Temperature Switch 24.
Page 176 25. Install throttle/spark control arm assembly. Se- 26. Install throttle actuator assembly to crankcase cure control to cylinder block with bolt. cover. Secure actuator with three bolts. Torque bolts to 150 lb. in. (16.9 N·m). 54681 a - Bolt 54680 b - Throttle/Spark Control Arm a - Bolts [Torque to 150 lb.
Page 177: Installing Powerhead On Driveshaft Housing
5. Using suitable hoist, install powerhead onto Installing Powerhead on driveshaft housing. Driveshaft Housing NOTE: It may be necessary to rotate flywheel slightly to engage crankshaft splines into driveshaft splines 1. Verify gearcase is in neutral (propeller shaft turns when lowering powerhead onto driveshaft housing. freely in both directions).
Page 178 7. Secure lower trim cover to bottom cowl with four bolts and self-locking nuts (2 each side). 54671 a - Bolts (2 Each Side) b - Trim Cover 8. On ELECTRIC START MODELS, reinstall oil tank referring to Section 8. 9.
Page 179: Mid-Section
MID-SECTION 54738 CLAMP/SWIVEL BRACKET AND DRIVE SHAFT HOUSING...
Page 180 Table of Contents Page Swivel Bracket Components ....5A-1 Torque Specifications ....5A-1 Quicksilver Lubricants and Service Aids...
Page 181: Swivel Bracket Components
Torque Specifications Swivel Bracket Components 1 - Bumper 20 lb. ft. (27 N·m) 2 - Steering Arm 3 - Lock Nut 40 lb. ft. (54.2 N·m) 4 - Steering Bracket 5 - Locking Plate Torque until it seats, then back off 1/4 turn. 6 - Bolt (2) 7 - Bolt, Steering Arm (2) 8 - Steering Link...
Page 182: Transom Bracket
Transom Bracket Torque Specifications Components 60 lb. in. (6.8 N· m) 1 - Transom Bracket (2) 25 lb. ft. (33.9 N· m) 2 - Tilt Tube 3 - Cap, Nylon 4 - O-ring Quicksilver Lubricants and Service 5 - Spacer 6 - Lock Nut (2) Aids 7 - Washer (2)
Page 183 Drive Shaft Housing Components 1 - Drive Shaft Housing 2 - Stud 3 - Plug 4 - Stud 5 - Nut (8) 6 - Washer (2) 7 - Nut (2) 8 - Mount, Rubber - Upper (2) 9 - Seal, Upper Mount (2) 10- Washer (2) 11- Washer, Rubber (2) 12- Washer (2)
Page 184 Disassembly Reassembly 1. Remove shock system assembly (refer to Sec- tion 5D) from non power trim models. Tilt Lock Lever/Transom Bracket 2. Remove power trim assembly (refer to Section 5 1. Apply Quicksilver 2-4-C Marine Lubricant to tilt B or 5C) from power trim models. lock lever shank, spacer and bushing prior to re- NOTE: Servicing components such as steering arm, assembly.
Page 185 3. Lubricate outboard tilt tube using Quicksilver 6. Install and secure yoke and washer using snap 2-4-C Marine Lubricant and install into swivel ring. bracket. 4. Secure transom brackets into place using fiber washers and lock nuts. 51078 a - Tilt Tube b - Fiber Washer c - Lock Nuts 51079...
Page 186 Drive Shaft Housing 3. Secure lower mount assembly to drive shaft housing. Secure drive shaft housing to yoke. 1. Secure transom bracket assembly to transom. 2. Install drive shaft housing to transom bracket as- sembly. Secure using bolts and components as shown.
Page 187 5. Place gearcase shift shaft in neutral position 7. Install shift linkage to bottom cowl as shown. (propeller shaft turns freely in both direction) and install to mid-section. Refer to Section 6A. 6. Install shift lever plate and bushing into mid-sec- tion as shown.
Page 188 MID-SECTION 50158 POWER TRIM (DESIGN 1)
Page 189 Table of Contents Page Page Power Trim General Information ... . 5B-1 Power Trim System Removal ... . . 5B-21 Description .
Page 190: Power Trim General Information
Make sure that water level is above gear housing Power Trim General water intake holes whenever engine is running. Information Operating “up” circuit will actuate the “up” solenoid (located under engine cowl) and close the electric motor circuit. The electric motor will drive the pump, Description thus forcing automatic transmission fluid thru internal passageways into the “up”...
Page 191: Trailering Outboard
Trailering Outboard Trim “In” Angle Adjustment WARNING WARNING Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to cient water supply to water pump causing water the full “in” trim angle [not using trim adjustment pump and/or powerhead overheating damage.
Page 192: Power Trim System Components
NOTE: It is recommended that “ALL” O-rings be re- Power Trim System placed when servicing tilt system. Components 1 - Trim Rod Torque Specifications 2 - Dowel Pin (Upper) 3 - Upper Pivot Pin 4 - Rod Wiper 35 lb. in. (4.0 N·m) 5 - O-ring .671 in.
Page 193: Power Trim Flow Diagrams Design
Power Trim Flow Diagrams Design 1 51638 5B-4 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 194 Design 1 51637 90-814676R1 DECEMBER 1996 MID-SECTION - 5B-5...
Page 195 Design 1 51639 5B-6 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 196 Design 1 51640 90-814676R1 DECEMBER 1996 MID-SECTION - 5B-7...
Page 197 Design 1 51641 5B-8 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 198 Design 1 51642 90-814676R1 DECEMBER 1996 MID-SECTION - 5B-9...
Page 199 Design 1 51643 5B-10 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 200: Determine If Problem Is Electrical Or
Troubleshooting Determine if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys- tem is at fault. Trouble Chart Outboard will not trim up or down. Determine if Power Trim pump Outboard trims up, will not trim motor operates when appro- down.
Page 201: Hydraulic System Troubleshooting
Hydraulic System Troubleshooting Leak Down Check – Pump and Manifold Assembly Support outboard with tilt lock lever when servicing power trim system. NOTE: Scribe (d) pump housing halves before disas- sembly. IMPORTANT: After debris or failed components have been found (during troubleshooting proce- 1.
Page 202: Leak Down Check - Pilot Valve Assembly
Leak Down Check – Pilot Valve Leakage Past Ball and Seat – Piston Assembly Assembly 1. Debris or chips between check ball and seat (a), Unit will trim to full or near full DOWN position and usually imbedded in rubber valve seat. then will begin to trim UP while trim switch is held in “DOWN”...
Page 203: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard falls to full down position with manu- al release valve closed. Example a: Outboard lowers more than one tilt pin hole in eight hours. Example b: Outboard lowers during acceler- ation. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings...
Page 204: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed decelera- tion. Inspect Manual Release Valve. Result Result Manual release valve and O-rings Manual release valve and/or O- appear to be OK. Replace O-rings ring damage and proceed.
Page 205: Electrical System Troubleshooting
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram Black Blue Brown Gray Green Purple White Yellow a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector 23891 e - Wiring Harness Connector...
Page 206: Power Trim System Wiring Diagram
Power Trim System Wiring Diagram Black Blue Green White 50285 a - To Power Trim Pump Motor b - Relay Switch “UP” c - Relay Switch “DOWN” d - Engine Starter Motor Solenoid e - Cowl Trim Switch f - Fuse Holder (20 Amp Fuse) g - Engine Wiring Harness Connector h - Remote Control Wiring Harness 90-814676R1 DECEMBER 1996...
Page 207: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is Ok)
Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) *Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 208: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is Ok)
Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) *Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 209: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)
Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)* *Remote Control Not Equipped with Trailer Button Check in-line fuse (under cowl) to see if fuse is blown. Blown Fuse: Fuse Not Blown: Correct problem that caused Connect Voltmeter red lead to fuse to blow.
Page 210: Power Trim System Removal
5. Use suitable punch to remove (DRIVE UP) lower Power Trim System Removal dowel pin. Retain dowel pin. Support outboard with tilt lock lever when servicing power trim system. 1. Disconnect power trim harness from outboard wiring harness. 2. Remove screw and clip securing wiring harness to clamp bracket.
Page 211: Power Trim System Disassembly
7. Tilt power trim assembly (top first) out from clamp 9. Remove O-ring from fill cap. bracket and remove assembly. 51194 Power Trim System Disassembly Trim Rod Removal 1. Secure power trim assembly in soft jawed vise. 2. Open manual release valve three or four turns (counterclockwise) and position trim rod to full up position.
Page 212: Trim Rod Disassembly
4. Remove trim rod assembly from cylinder. 6. Remove O-ring from memory piston. 51196 a - O-ring b - Memory Piston 7. Remove trim system from vise and empty fluid into appropriate container. 51196 5. Remove memory piston from cylinder using lock- ring pliers (shown) or suitable tool.
Page 213 4. Place trim rod into soft jawed vise and apply heat CAUTION to shock piston using torch lamp (P/N 91-63209). Do not remove check ball components from trim 5. Loosen trim rod piston using spanner wrench rod piston. Removal and reinstallation of check (1/4 in.
Page 214: Trim "Motor" Removal
Trim “Motor” Removal 4. Remove motor and harness from reservoir. 1. Secure power trim assembly in soft jawed vise. 2. Remove cap, washer and grommet from reser- voir assembly. 51196 Trim “Motor” Disassembly 1. Remove end cap from motor housing. Note posi- 51195 a - Cap tion of washers on armature.
Page 215: Reservoir Assembly Removal
2. Remove O-ring from end frame. Reservoir Assembly Removal 3. Place scribe mark on motor housing and end CAUTION frame as reassembly reference, as shown. DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE. THIS VALVE IS PRESET AT FAC- TORY FOR PRECISE REVERSE THRUST PRES- SURE AND DOES NOT REQUIRE ADJUSTMENT.
Page 216: Oil Pump Removal
3. Remove four screws securing reservoir to man- Oil Pump Removal ifold. IMPORTANT: The oil pump is not rebuildable. If oil pump is defective, replace as an assembly. 1. Remove screw, oil pump and O-rings from man- ifold. 51193 a - Screw 4.
Page 217: Cleaning And Inspection Of Trim Rod Components
2. Slowly remove manifold from cylinder. Note posi- 3. Remove O-rings from cylinder. tion of above trim check ball assembly and re- 4. Remove filter. move. 54745 54743 a - O-rings b - Filter Cleaning and Inspection of Trim Rod Components IMPORTANT: Components must be dirt and lint free.
Page 218: Motor And Electrical Tests/Repair
Inspect check valve for debris; clean debris from MOTOR ASSEMBLED check valve if found. If debris cannot be cleaned from Connect Ohmmeter (R x 1 scale) leads as shown. If check valve, replace trim rod piston as an assembly. switch is good, full continuity (zero ohms) will be indi- Clean trim rod and components with parts cleaner cated.
Page 219: Armature Tests
Armature Tests Power Trim System Reassembly TEST FOR SHORTS Check armature on a Growler (follow Growler man- ufacturer’s test instructions). Indication of a short re- Manifold Installation quires replacement of armature. IMPORTANT: Filter must be installed in trim cylin- der with ridge of filter housing facing out. TEST FOR GROUND Use an Ohmmeter (R x 1 scale).
Page 220: Oil Pump Installation
2. Install check ball components (a) into manifold. 4. Secure manifold to cylinder using screws, torque to 100 lb. in. (11.2 N·m). 54746 a - Trim Cylinder b - Manifold c - Screw Oil Pump Installation 1. Secure power trim unit in soft jawed vise. 2.
Page 221: Trim Motor Reassembly
Trim Motor Reassembly 3. Align scribe mark on housing with mark on end frame. 1. Apply Quicksilver Marine Lubricant (2-4-C) to ar- 4. Install lubricated O-ring to end frame. mature shaft and insert into end frame. 51195 a - Armature Shaft b - Washer 51194 c - End Frame...
Page 222: Reservoir Installation
IMPORTANT: When installing motor, wires 3. Install end cap, O-ring and foam pad to cylinder. (black, orange) must rest in cavity of cylinder al- 4. Torque screws to 13 lb. ft. (1.5 N·m). lowing motor to seat properly. 51194 a - Manifold b - Cavity 51195 Reservoir Installation...
Page 223 6. Place drive shaft into oil pump. 10. Install lubricated O-rings and “E” clip to manual release valve. 7. Install lubricated O-ring to base of reservoir. 8. Carefully guide reservoir (with motor) down onto drive shaft. 51196 a - “E” Clip b - O-ring c - Manual Release Valve 11.
Page 224: Trim Rod Reassembly
Trim Rod Reassembly 4. Apply Loctite Grade A (271) to threads of trim rod and install trim rod piston. Tighten piston securely 1. Install lubricated O-rings and rod wiper to end using spanner wrench (1/4 in. x 5/16 in. long peg). cap.
Page 225: Trim Rod Installation
Trim Rod Installation 4. Install trim rod into cylinder. 1. Place trim cylinder in soft jawed vise. 2. Fill trim cylinder three inches (76.2mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid or; (ATF) Type F, FA or Dexron II. 3.
Page 226: Bleeding Power Trim Unit
Power Trim Unit Installation Bleeding Power Trim Unit 1. Apply Special Lubricant 101 (92-13872A1) to IMPORTANT: Manual release valve must be in the lower pivot pin hole and pivot pin surface. closed position during power trim bleeding and operation. 2. Start lower pivot pin into pivot pin bore and posi- tion lower dowel pin (RETAINED) in its respective 1.
Page 227 4. Using a suitable punch, drive lower pivot pin into 7. Using a suitable mallet, drive upper pivot pin into clamp bracket and trim cylinder assembly until swivel bracket and through trim ram until pivot pin pivot pin is flush with outside surface. is flushed with swivel bracket.
Page 228 MID-SECTION 50158 POWER TRIM (DESIGN II)
Page 229 Table of Contents Page Page Power Trim General Information ... . 5C-1 Power Trim System Removal ... . . 5C-21 Description .
Page 230: Power Trim General Information
Power Trim General WARNING Information Excessive engine trim angle will result in insuffi- cient water supply to water pump causing water pump and/or powerhead overheating damage. Description Make sure that water level is above gear housing The Power Trim system consists of an electric motor, water intake holes whenever engine is running.
Page 231: Trailering Outboard
Trailering Outboard Trim “In” Angle Adjustment WARNING WARNING Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to cient water supply to water pump causing water the full “in” trim angle [not using trim adjustment pump and/or powerhead overheating damage.
Page 232: Power Trim System Components
NOTE: It is recommended that “ALL” O-rings be re- Power Trim System placed when servicing tilt system. Components 1 - Trim Rod 2 - Dowel Pin 3 - Pivot Pin 4 - Rod Wiper 5 - O-ring .671 in. I.D. 6 - Cylinder Cap 7 - O-ring 1.864 in.
Page 233: Power Trim Flow Diagrams Design
Power Trim Flow Diagrams Design II 51644 5C-4 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 234: Design Ii
Design II 51645 90-814676R1 DECEMBER 1996 MID-SECTION - 5C-5...
Page 235: Design Ii
Design II 51646 5C-6 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 236: Design Ii
Design II 51647 90-814676R1 DECEMBER 1996 MID-SECTION - 5C-7...
Page 237: Design Ii
Design II 51648 5C-8 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 238: Design Ii
Design II 51649 90-814676R1 DECEMBER 1996 MID-SECTION - 5C-9...
Page 239 Design II 51650 5C-10 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 240: Troubleshooting
Troubleshooting Determining if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys- tem is at fault. Trouble Chart Outboard will not trim up or down. Determine if Power Trim pump Outboard trims up, will not trim motor operates when appro- down.
Page 241: Hydraulic System Troubleshooting
Hydraulic System Troubleshooting Leak Down Check – Pump and Man- ifold Assembly Support outboard with tilt lock lever when servicing power trim system. NOTE: Scribe (d) pump housing halves before disas- sembly. Check pump for problems as follows: IMPORTANT: After debris or failed components have been found (during troubleshooting proce- 1.
Page 242: Leak Down Check - Pilot Valve Assembly
Leak Down Check – Pilot Valve As- Leakage Past Ball and Seat – Piston sembly Assembly 1. Debris or chips between valve and seat (a), usu- Unit will trim to full or near full DOWN position and ally imbedded in rubber valve seat. then will begin to trim UP while trim switch is held in “DOWN”...
Page 243: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard falls to full down position with manu- al release valve closed. Example a: Outboard lowers more than one tilt pin hole in eight hours. Example b: Outboard lowers during acceler- ation. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings...
Page 244: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed decelera- tion. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings ring damage appear to be OK. Replace O-rings and proceed.
Page 245: Electrical System Troubleshooting
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram Black Blue Brown Gray Green Purple White Yellow a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector 23891 e - Wiring Harness Connector...
Page 246: Power Trim System Wiring Diagram
Power Trim System Wiring Diagram Black Blue Green White POWER TRIM MODULE 90-814676R1 DECEMBER 1996 MID-SECTION - 5C-17...
Page 247: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is Ok)
Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 248: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is Ok)
Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 249: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)
Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)* Check in-line fuse (under cowl) to see if fuse is blown. Blown Fuse: Fuse Not Blown: Correct problem that caused Connect Voltmeter red lead to fuse to blow. Point 3 and black lead to ground. Replace fuse.
Page 250: Power Trim System Removal
5. Use suitable punch to remove (DRIVE UP) lower Power Trim System Removal dowel pin. Retain dowel pin. Support outboard with tilt lock lever when servicing power trim system. 1. Disconnect power trim harness form outboard wiring harness. 2. Remove screw and clip securing wiring harness to clamp bracket.
Page 251: Power Trim System Disassembly
7. Tilt power trim assembly (top first) out from clamp Power Trim System bracket and remove assembly. Disassembly Trim Rod Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE. THIS VALVE IS PRESET AT FAC- TORY FOR PRECISE REVERSE THRUST PRES- SURE AND DOES NOT REQUIRE ADJUSTMENT.
Page 252: Trim Rod Disassembly
4. Remove trim rod assembly from cylinder. 6. Remove O-ring from memory piston. 51196 a - O-ring b - Memory Piston 7. Remove trim system from vise and empty fluid into appropriate container. 51196 5. Remove memory piston from cylinder using lock- ring pliers (Craftsman P/N 4735) or suitable tool.
Page 253 4. Place trim rod into soft jawed vise and apply heat CAUTION to loosen piston using torch lamp (P/N 91-63209). Do not remove check ball components from trim rod piston. Removal and re-installation of check 5. Loosen trim rod piston using trim spanner span- valve could result in improper operating pres- ner wrench (1/4 in.
Page 254: Trim "Motor" Removal
Trim “Motor” Removal 4. Remove motor harness from reservoir. 1. Secure power trim assembly in soft jawed vise. 2. Remove cap, washer and grommet from reser- voir assembly. 51196 Trim Motor Disassembly 51195 1. Remove end cap from motor housing. Note posi- a - Cap tion of washers on armature.
Page 255: Reservoir Assembly Removal
2. Remove O-ring from end frame. Reservoir Assembly Removal 3. Place scribe mark on motor housing and end CAUTION frame as re-assembly reference, as shown. DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE. THIS VALVE IS PRESET AT FAC- TORY FOR PRECISE REVERSE THRUST PRES- SURE AND DOES NOT REQUIRE ADJUSTMENT.
Page 256: Oil Pump/Manifold Removal
3. Remove four screws securing reservoir to man- Oil Pump/Manifold Removal ifold. 1. Remove screw, oil pump, O-rings and check valve components from manifold. 51006 51193 a - Screws (4) 4. Remove reservoir from manifold. 5. Remove drive shaft from oil pump. 51007 a - O-rings (3) b - Oil Pump...
Page 257: Cleaning And Inspection Of Trim Rod Components
IMPORTANT: Removal of O-ring (e) from man- 4. Remove O-rings from cylinder. ifold will result in damage to O-ring. O-ring MUST be replaced after removal. 3. Remove check valve components from manifold. 51008 a - O-rings Cleaning and Inspection of Trim Rod Components 51736 IMPORTANT: Components must be dirt and lint...
Page 258: Motor And Electrical Tests/Repair
Motor and Electrical Tests/ Repair Trim Pump Motor Test WARNING Do not perform this test near flammables (or ex- plosives), as a spark may occur when making connections. 1. Disconnect orange (motor) wire and black (mo- tor) wire from relay switch wiring harness. 2.
Page 259: Armature Tests
Armature Tests Power Trim System Reassembly TEST FOR SHORTS Manifold/Oil Pump Installation Check armature on a Growler (follow Growler man- ufacturer’s test instructions). Indication of a short re- IMPORTANT: Install spring, check valve and O- quires replacement of armature. ring into manifold. Position components in place using sleeve to seat in place.
Page 260: Trim Motor Reassembly
2. Install O-rings on cylinder and secure manifold 4. Install check valve components and O-rings to assembly to cylinder using screws. Torque manifold. Secure oil pump to manifold using bolt. screws to 100 lb. in. (11.3 N·m). Torque bolt to 90 lb. in. (10.2 N·m). 51006 51008 51007...
Page 261 2. Guide armature and end frame into housing as 6. Install end cap to housing. Torque nuts to 25 lb. shown. in. (2.8 N·m). 51194 a - End Cap b - Motor Housing c - Wave Washer d - Washer 51196 3.
Page 262: Reservoir Installation
Reservoir Installation 5. Install grommet, washer and screw cap to cylin- der end cap. Tighten screw securely. 1. Connect trim motor wires to harness. 2. Insert motor into reservoir. Motor must be seated properly prior to end cap installation. 51195 a - Screw Cap b - Washer c - Grommet...
Page 263: Trim Rod Reassembly
9. Secure reservoir to manifold using four screws. Trim Rod Reassembly Torque screws to 70 lb. in. (7.7 N·m). 1. Install lubricated O-rings and rod wiper to end cap. 51193 a - Screw 51145 10. Install “E” clip, lubricated O-rings and to manual a - Rod Wiper release valve.
Page 264: Trim Rod Installation
4. Apply Loctite Grade A (271) to threads of trim rod Trim Rod Installation and install rod piston. Tighten piston securely us- 1. Place trim cylinder in soft jawed vise. ing trim cylinder spanner wrench (1/4 in. x 5/16 in. long peg).
Page 265: Bleeding Power Trim Unit
4. Install trim rod into cylinder. Bleeding Power Trim Unit IMPORTANT: Manual release valve must be in the closed position during power trim bleeding and operation. 1. Secure power trim unit in soft jawed vise. 2. Remove fill screw. Add Quicksilver Power Trim and Steering Fluid (92-90100A12) or Automatic Transmission Fluid (ATF) Type F, FA or Dexron II up to threads of reservoir.
Page 266: Power Trim Unit Installation
Power Trim Unit Installation 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until 1. Apply Special Lubricant 101 (92-13872A1) to pivot pin is flush with outside surface. lower pivot pin hole and pivot pin surface. 2.
Page 267 6. Apply Special Lubricant 101 (92-13872A1) to 8. Drive upper dowel pin (a) into its hole until seated. surface of upper pivot pin, pivot pin bore and trim ram bore. 51147 9. Recheck fluid level. 10. Power trim may now be operated to lower out- 51148 board to desired position.
Page 268 MID-SECTION 51486 POWER TRIM (DESIGN 3)
Page 269 Table of Contents Page Page Special Tools ......5D-1 Power Trim System Removal .
Page 270: Special Tools
Will lift bow of boat, usually increasing top speed. Special Tools Transfers steering torque harder to port (left) on in- Description Part No. stallations below 23 in. transom height. Torch Lamp 91-63209 Increases clearance over submerged objects. Spanner Wrench 91-74951 In excess, can cause “porpoising”...
Page 271: Trailering Outboard
Operating “Down” circuit will actuate the “down” relay Trim “In” Angle Adjustment (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of WARNING the “Up” circuit). The electric motor will drive the Operating some boats with engine trimmed to pump, forcing fluid thru internal passageways into the full “in”...
Page 272: Power Trim System Components
Power Trim System Components 1 - Tilt/Trim Cylinder 2 - Reservoir/Motor Housing 3 - Piston Rod 4 - Upper Pivot Shaft 5 - Cross Pin 6 - O-ring 7 - End Cap Seal 8 - End Cap 9 - O-ring 10- O-ring 11- Piston Assembly 12- O-ring...
Page 273: Troubleshooting
Troubleshooting Determining if Problem is Electrical or Hydraulic When a problem is encountered with the Power Trim system, the first step is to determine whether the mal- function is in the “electrical system” or the “hydraulic system.” Refer to the following chart to determine which system is at fault.
Page 274: Hydraulic System Troubleshooting
Hydraulic System Troubleshooting Leak Down Check - Pump and Manifold Assembly Support outboard with tilt lock lever when servicing power trim system. NOTE: Scribe (d) pump housing and manifold before disassembly. After debris or failed components have been found (during troubleshooting procedures) dis- 1.
Page 275: Assembly
Leak Down Check - Pilot Valve Leaks Past Ball and Seat - Piston Assembly Assembly 1. Debris or chips between valve and seat, usually Unit will trim to full or near full down position and then imbedded in rubber valve seat. will begin to trim up while trim switch is held in ‘‘DOWN”...
Page 276: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard falls to full down position with manu- al release valve closed. Example a: Outboard lowers more than one tilt bolt hole in eight hours. Example b: Outboard lowers during acceler- ation. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings...
Page 277: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed decelera- tion. Inspect Manual Release Valve. Results Results Manual release valve and/or O- Manual release valve and O-rings ring damage. appear to be OK. Replace O-rings and proceed.
Page 278: Electrical System Troubleshooting
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram DOWN Black Blue Brown Gray Green Purple White Yellow a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector 23891 e - Wiring Harness Connector...
Page 279: Power Trim System Wiring Diagram
Power Trim System Wiring Diagram Black Negative (–) Blue Trim Motor (UP) Green Trim Motor (DOWN) Positive (+) BLU/WHT Blue/White Trim Switch to UP Relay Wiring From GRN/WHT Side Mount Green/White Trim Switch to DOWN Relay Remote Control Harness Power Trim Engine Harness Motor...
Page 280: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is
Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) *Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Down Relay is Defective. Replace and retest. Connect Voltmeter red lead to Point 4 and black lead to ground.
Page 281: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is
Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) *Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: UP Relay is defective. Replace and retest. Connect Voltmeter red lead to Point 7 and black lead to ground.
Page 282: Troubleshooting The "Down" And "Up" Circuits
Troubleshooting the “Down” and “Up” Circuits (All Circuits Check in-line fuse (under cowl) to see if fuse is blown Inoperative)* *Remote Control NOT Equipped with Trailer Button Blown Fuse: Fuse Not Blown: Correct problem that caused Connect Voltmeter red lead to fuse to blow.
Page 283: Power Trim System Removal
Inspect cross pin hole and pivot pin hole for damage. Power Trim System Removal 6. Use suitable punch to remove (DRIVE UP) lower Support outboard with tilt lock lever when servicing dowel pin. Retain dowel pin. power trim system. 1. Disconnect power trim harness from outboard wiring harness.
Page 284: Power Trim System Disassembly
8. Tilt power trim assembly (top first) out from clamp Power Trim System bracket and remove assembly. Disassembly Trim Rod Removal 1. Secure power trim assembly in soft jawed vise. 2. Open manual release valve three turns maxi- mum (counterclockwise) and position trim rod to full up position.
Page 285: Trim Rod Disassembly
5. Remove memory piston from cylinder using lock- Trim Rod Disassembly ring pliers (Craftsman P/N 4735) or suitable tool. 1. Place trim rod assembly on clean work surface. 2. Remove screws securing plate to trim rod piston and O-ring. 3. Remove check ball components from trim rod piston.
Page 286 4. Place trim rod into soft jawed vise and apply heat CAUTION to shock piston using torch lamp (a) (P/N 91-63209). Do not remove check ball components (a) from trim rod piston. Removal and re-installation of 5. Loosen trim rod piston using spanner wrench check valve could result in improper operating (1/4 in.
Page 287: Trim "Motor" Removal
Trim “Motor” Removal Trim “Motor” Disassembly 1. Secure power trim assembly in soft jawed vise. 1. Remove armature from motor frame. Note posi- tion of washers on armature. 2. Remove screws securing end cap to reservoir and remove end cap. 51486 a - Armature b - Motor Frame...
Page 288: Manifold Removal
3. Remove four screws securing reservoir to man- Manifold Removal ifold. 1. Remove screws and manifold from cylinder. 51193 a - Screws (4) 51007 4. Remove reservoir from manifold. a - Trim Cylinder b - Manifold 5. Remove drive shaft from oil pump. c - Screw (2) 2.
Page 289: Cleaning And Inspection Of Trim Rod Components
3. Remove O-rings from cylinder. Motor and Electrical Tests/Repair Trim Pump Motor Test WARNING Do not perform this test near flammables (or ex- plosives), as a spark may occur when making connections. 1. Disconnect green (motor) wire and blue (motor) wire from trim system wiring harness.
Page 290: Checking And Cleaning Commutator
CHECKING AND CLEANING COMMUTATOR 1. Install check valve components into manifold. If commutator (a) is worn it can be turned down on an armature conditioner tool or on a lathe. Clean commutator with “00” sandpaper. 51560 Power Trim System a - O-ring (0.114 I.D.) Reassembly b - Spool c - O-ring (0.301 I.D.) (3 each)
Page 291: Trim Motor Reassembly
51007 b - Screws [100 lb. in. (11 N·m)] (2) 3. Secure power trim unit in soft jawed vise. 51484 a - End Cap Bushing. Lubricate with Quicksilver 2-4-C Lubricant Trim Motor Reassembly b - Brush (2) c - Commutator 1.
Page 292: Reservoir Installation
Reservoir Installation 5. Secure reservoir to manifold using four screws. Torque screws to 70 lb. in. (7.7 N·m). 1. Torque end cap screws to 13 lb. ft. (1.5 N·m). 51193 a - Screws (4) 6. Install lubricated O-rings and “E” clip to manual release valve.
Page 293: Trim Rod Reassembly
Trim Rod Reassembly 4. Apply Loctite Grade A (271) to threads of trim rod and install rod piston. Tighten piston securely us- 1. Install lubricated O-rings and rod wiper to end ing spanner wrench (1/4 in. x 5/16 in. long peg). cap.
Page 294: Trim Rod Installation
Trim Rod Installation 4. Install trim rod into cylinder. 1. Place trim cylinder in soft jawed vise. 2. Fill trim cylinder three inches (76.2mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid or; (ATF) Type F, FA or Dexron II. 3.
Page 295: Purging Power Trim Unit
Power Trim Unit Installation Purging Power Trim Unit 1. Apply Special Lubricant 101 (92-13872A1) to Manual release valve must be in full closed posi- lower pivot pin bore and pivot pin surface. tion during power trim purging and operation. 2. Start lower pivot pin into pivot pin bore and posi- 1.
Page 296 4. Using a suitable punch, drive lower pivot pin into 6. Apply Special Lubricant (92-13872A1) to surface clamp bracket and trim cylinder assembly until of upper pivot pin, pivot pin bore and trim ram pivot pin is flush with outside surface. bore.
Page 297 7. Using a suitable mallet, drive upper pivot pin into 8. Drive upper retaining pin (a) in until seated. swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 51505 9. Recheck fluid level. 10. Power trim may now be operated to lower out- 51515 board to desired position.
Page 298 MID-SECTION 55331 POWER TRIM (DESIGN 4)
Page 299 Table of Contents Page Page Special Tools ......5E-1 Power Trim System Removal .
Page 300: Special Tools
Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Expanding Rod P/N CG 41-11 4. Collet P/N CG 41-14 90-814676R1 DECEMBER 1996 MID-SECTION - 5E-1...
Page 301 POWER TRIM COMPONENTS Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. 5E-2 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 302 POWER TRIM COMPONENTS TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O RING REBUILD KIT O RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG Drive Tight MANUAL RELEASE ASSEMBLY Drive Tight...
Page 303: Theory Of Operation
Theory Of Operation WARNING The Power Trim system consists of an electric motor, Excessive engine trim angle will result in insuffi- pressurized fluid reservoir, pump and trim cylinder. cient water supply to water pump causing water pump and/or powerhead overheating damage. The remote control (or trim panel) is equipped with a Make sure that water level is above gear housing switch that is used for trimming the outboard “up”...
Page 304: Trailering Outboard
Trailering Outboard Tilting Outboard Up and Down Manually WARNING WARNING Excessive engine trim angle will result in insuffi- cient water supply to water pump causing water Before loosening the manual release valve, make pump and/or powerhead overheating damage. sure all persons are clear of engine as engine will Make sure that water level is above gear housing drop to full “down”...
Page 305 POWER TRIM FLOW DIAGRAMS TRIM UP CIRCUIT Reservoir Oil Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) 2800 (75-125) Tilt Relief Pressure min. 250-400 (40-60) 540-990 (75-125) a - Piston Rod m - Shuttle Valve...
Page 306: Trim Up
Trim Up When the trim switch is activated in the “up” position, the electric motor (c) begins to rotate the pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the pas- sages for the up circuit.
Page 307 TILT CIRCUIT Reservoir Oil Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 308: Tilt Up
Tilt Up In the “up” mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t) clears or un- covers 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).
Page 309: Maximum Tilt
MAXIMUM TILT Reservoir Oil Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 310 Maximum Tilt With the piston rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylin- der (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).
Page 311 DOWN CIRCUIT Reservoir Oil Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) 2800 (75-125) Tilt Relief Pressure min. 250-400 (40-60) 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 312: Down Mode
Down Mode When the trim switch is activated in the “down” posi- tion, the electric motor (c) will rotate the pump (j) in the opposite direction. With the 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 313: Shock Function Up
SHOCK FUNCTION UP Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 314 Shock Function Up Oil inside the down cavity is locked in a static position by the closed 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 rap- idly extend from the cylinder (w), the pressure in- creases inside the trim cylinder down cavity and con-...
Page 315: Shock Function Return
SHOCK FUNCTION RETURN Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 316 Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure be- tween 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 317 MANUAL RELEASE Down Pressure 525-880 Reservoir Oil Return Oil Filtered Oil Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 318: Manual Tilt
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 pas- sages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allow- ing the engine to be raised or lowered.
Page 319: Troubleshooting
Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting proce- dure) it is recommended that unit be disas- sembled completely and ALL O-rings be re- placed. Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re-as- sembly.
Page 320: Hydraulic System Troubleshooting Flow Chart
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 valve Inspect manual release valve O-rings appear to be O.K. - and O-ring damaged Clean and reinstall manual release valve Trim will not hold...
Page 321: Hydraulic System Troubleshooting Flow Chart
Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage Suction seat assembly ap- Debris and/or damage pears O.K. - Clean and rein- identified stall suction seat assembly Replace suction seat Trim will not hold assembly Trim system holds reverse thrust...
Page 322: Hydraulic System Troubleshooting Flow Chart
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 Replace manual re- Trim system leaks...
Page 323: Hydraulic System Troubleshooting Flow Chart
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- Trim leaks down ton and shock piston O-rings Trim system does not leak down: Test-...
Page 324: Troubleshooting The Power Trim Electrical System (Wiring Diagram)
Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch (Remote Control (Panel Mounted) Mounted) BLU/WHT Fuse Holder GRN/WHT BLU/WHT or PUR GRN/WHT or GRN Fuse Holder – RED/PUR Battery GRN/WHT Solenoid BLU/WHT Down Relay LT. GRN/WHT GRN/WHT 14 BLK LT.
Page 325: Troubleshooting The Power Trim Electrical System
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 “UP”...
Page 326: Power Trim System Removal
3. Remove the trilobe pin. Power Trim System Removal 4. Drive out the upper pivot pin. 1. Tilt outboard to the full up position and support with tilt lock pin. a - Trilobe Pin 55464 b - Upper Pivot Pin a - Tilt Lock Pin 5.
Page 327: Power Trim Disassembly
6. Use suitable punch to remove (Drive Up) lower Power Trim Disassembly pin. Retain dowel pin. IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully extended) prior to fill/drain plug, or manual re- lease valve removal.
Page 328: Trim Motor Removal
Trim Motor Removal Pump and Components Removal 1. Secure power trim assembly in a soft jaw vise. 1. Remove pressure operated plugs on pump. Re- move spring and check valve/poppet (both 2. Remove four (4) screws to remove motor/reser- sides). Use special tool CG 41-11 and special tool voir.
Page 329: Manifold Removal
2. Remove three (3) screws to remove pump. Re- 2. Remove tilt relief components. move filter and filter seal under pump. Remove suction seat assembly. 51008 a - Spring b - Poppet c - Spool Housing d - Trim Limit Spool Shock Rod Removal a - Screws (3) b - Filter Seal...
Page 330: Shock Rod Disassembly
3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove o-ring from shock rod piston. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
Page 331 10. Remove inner o-ring from shock rod piston. 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 332: Memory Piston Removal
Memory Piston Removal 2. Remove o-ring from memory piston. 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or suitable tool. 51144 a - O-Ring b - Memory Piston 51144 b.
Page 333: Cleaning/Inspection/Repair
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.
Page 334: Reassembly
Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1 90-814676R1 DECEMBER 1996 MID-SECTION - 5E-35...
Page 335: O-Ring Sizes
O-ring Sizes 4, 22 12, 17, 18 15, 20 Cutaway View of O-Ring Width O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 5E-36 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 336: O-Ring Description And Sizes
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.
Page 337: Power Trim Reassembly
4. Clamp shock rod in soft jawed vise. Power Trim Reassembly 5. Position cylinder end cap onto rod as shown. IMPORTANT: Lubricate all o-rings with Quicksil- ver Power Trim Fluid (92-90100A12). If not avail- able, use automotive (ATF) automatic transmis- sion fluid.
Page 338: Shock Rod Installation
9. Remove shock rod assembly from vise. Shock Rod Installation 10. Install ball, seat, and spring (five sets) to shock 1. Place trim cylinder in soft jawed vice. rod piston. 2. Install lubricated O-ring to memory piston and 11. Secure components with plate. Torque screws to place into cylinder.
Page 339: Trim Limit Assembly Installation
Trim Limit Assembly Installation Manifold Installation 1. Lubricate all O-rings. Install spring, poppet spool housing and trim limit spool into manifold. 1. Install dowel pin and two (2) lubricated O-rings NOTE: There are two different size springs used in into trim cylinder. this manifold.
Page 340: Oil Pump Installation
3. Install the two (2) long screws and torque to 100 Oil Pump Installation lb. in. (11 N m). 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.
Page 341: Pressure Operated Assembly Installation 5E-42
Pressure Operated Assembly Reservoir/Motor Installation Installation 3. Install coupler into top of pump. Make sure reser- voir seal is in the reservoir groove and place res- IMPORTANT: Inspect poppet assembly for debris ervoir onto pump/manifold assembly. Install in the area shown. If debris is found on poppet re- ground strap under screw shown Torque screws place poppet.
Page 342: Bleeding Power Trim Unit
Bleeding Power Trim Unit Installation of Power Trim System 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until even with the bottom of 1. Lubricate lower pivot pin, mounting holes with the fill hole. Reinstall plug. 2-4-C Marine Lubricant.
Page 343 4. Apply 2-4-C Marine Lubricant (92-90018A12) to 6. Apply 2-4-C Marine Lubricant (92-90018A12) to lower pivot pin. Using a suitable punch, drive low- surface of upper pivot pin, pivot pin bore and trim ram bore. er pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside sur- face.
Page 344 8. Drive trilobe pin (a) into its hole until seated. 10. Route trim harness through clamp bracket and cowling. 55464 a - Trilobe Pin 55264 a - Trim Harness 9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode as shown.
Page 345 MID-SECTION MANUAL TILT SYSTEM (DESIGN I, II, III)
Page 346 Table of Contents Page Manual Tilt System Components (Design One and Two) ......5F-1 Quicksilver Lubricant/Sealant Application Points...
Page 347: Torque Specification
Manual Tilt System Components (Design One and Two) 1 - Shock Rod Cylinder Torque Specification 2 - Accumulator 3 - Shock Rod 35 lb. ft. (47 N·m) 4 - Valve Block 5 - Dowel Pin 100 lb. in. (11.2 N·m) 6 - Pivot Pin 7 - Rod Wiper 8 - O-ring .671 in.
Page 348: Manual Tilt System Components (Design Three)
Manual Tilt System Components (Design Three) 1 - Shock Rod Cylinder Torque Specification 2 - Accumulator 3 - Shock Rod 35 lb. ft. (47 N·m) 4 - Valve Block 5 - Dowel Pin 100 lb. in. (11.2 N·m) 6 - Pivot Pin 7 - Rod Wiper 8 - O-ring .671 in.
Page 349: Manual Tilt Flow Diagrams Design 1
Manual Tilt Flow Diagrams Design 1 51651 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-3...
Page 350 Design 1 51652 5F-4 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 351 Design 1 51653 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-5...
Page 352 Design 1 51654 5F-6 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 353 Design 1 51655 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-7...
Page 354: Manual Tilt Flow Diagrams Design 2
Manual Tilt Flow Diagrams Design 2 51656 5F-8 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 355 Design 2 51657 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-9...
Page 356 Design 2 51658 5F-10 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 357 Design 2 51659 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-11...
Page 358 Design 2 51660 5F-12 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 359: Manual Tilt Flow Diagrams Design 3
Manual Tilt Flow Diagrams Design 3 51661 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-13...
Page 360 Design 3 51662 5F-14 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 361 Design 3 51663 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-15...
Page 362 Design 3 51664 5F-16 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 363 Design 3 51665 90-814676R1 DECEMBER 1996 MID-SECTION - 5F-17...
Page 364: Hydraulic System Troubleshooting
2. Check for external leaks in the manual tilt system. Hydraulic System Replace defective part(s) if leak is found. Troubleshooting IMPORTANT: If cut or damaged O-rings are Refer to disassembly/reassembly instructions (fol- found, inspect machined surfaces for scoring, burrs or debris. lowing) if disassembly is required when servicing.
Page 365: Troubleshooting Flow Chart
Troubleshooting Flow Chart Outboard falls to full down position with manual re- lease valve lever in LOCK/RUN (up) position. Ex- ample a: Outboard lowers more than one tilt pin hole in eight hours, Example b: Outboard lowers during acceleration. CAUTION Tilt ram must be in full “up”...
Page 366 Troubleshooting Flow Chart (Continued) Outboard will not hold tilted position in reverse and/or trails out during high speed deceleration with manual release valve lever in the lock/run (up) position. CAUTION Tilt ram must be in full “up” position and accumu- lator removed before manual tilt system disas- sembly.
Page 367: Manual Tilt System Removal
3. Use suitable punch to remove (DRIVE DOWN) Manual Tilt System Removal upper dowel pin. Retain dowel pin. CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard. WARNING Service or installation of the tilt system may re- sult in loss of pressure in the shock cylinder.
Page 368: Manual Tilt System Disassembly
6. Use suitable punch to drive out lower pivot pin. Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitro- gen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumu- 51144 lator only when shock rod is in full up position. a - Pivot Pin Accumulator Removal 7.
Page 369: Shock Rod Removal
4. If plunger can be compressed into accumulator Shock Rod Removal by hand, accumulator is defective. Replace accu- 1. Remove cylinder end cap assembly using span- mulator. ner wrench [1/4 in. x 5/16 in. long pegs]. 51145 2. Remove shock rod assembly. 51143 a - Plunger 5.
Page 370: Shock Rod Disassembly
3. Remove memory piston from cylinder using lock Shock Rod Disassembly ring pliers (Craftsman P/N 4735) or suitable tool. 1. Place shock rod assembly on clean work surface. 2. Remove plate and O-ring. 3. Remove check ball components from shock rod piston.
Page 371 4. Place shock rod into soft jawed vise and apply CAUTION heat to loosen piston using torch lamp (P/N 91-63209). Do not remove check ball components from shock rod piston. Removal and reinstallation of 5. Loosen shock rod piston using spanner wrench check valve could result in improper operating [1/4 in.
Page 372: Valve Block Removal
12. Place end cap on clean work surface. Valve Block Removal 13. Remove rod wiper, inner O-ring, and outer 1. Remove valve block from shock rod cylinder. O-ring. 51147 51146 a - Screws (2) b - Valve Block c - Shock Rod Cylinder 2.
Page 373: Valve Block Disassembly
4. Remove reservoir assembly. Valve Block Disassembly 1. Remove slow trim valve assembly. 2. Remove hydraulic oil transfer valve components. 51142 a - Screw b - Flat Spring c - Ball 5. Remove cam assembly. 51143 a - Transfer Valves (2) b - Slow trim Valve Assembly (Plug or Screw Plug) 3.
Page 374: Manual Tilt System Cleaning And Inspection
Manual Tilt System Cleaning and Inspection 1. It is recommended that all O-rings exposed dur- ing disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air. Do not use cloth rags. 3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity.
Page 375 6. Install spool, spring, lubricated O-ring and screw plug (surge valve assembly) into valve block. 7. Torque screw plug to 75 lb. in. (8.5 N·m). 51142 a - Plunger b - Ball c - Spring (Small) d - Spring (Large) e - O-ring f - Plug (Design 3) 51142...
Page 376: Valve Block Installation
Valve Block Installation 3. Install lubricated O-ring. 1. Install lubricated O-rings. 51148 a - O-rings (2) 51145 2. Install valve block to shock rod cylinder. Torque screws to 100 lb. in. (11.2 N·m). Shock Rod Reassembly 1. Install lubricated O-rings. 2.
Page 377 3. Install lubricated O-ring. 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). 51199 a - O-ring b - Shock Piston 51146 4. Clamp shock rod in soft jawed vise. a - Shock Rod Piston 5.
Page 378: Shock Rod Installation
Shock Rod Installation 6. Refill cylinder to top. 1. Place cylinder/manifold assembly into soft jawed CAUTION vise. End cap must not make contact with shock rod 2. Fill cylinder to top using Quicksilver Power Trim piston when tightening. Shock rod piston must and Steering Fluid or;...
Page 379: Instructions For Making Retaining Tool
Instructions for Making Retaining Tool 3/16 in. x 3 in. (5 x 7.5 cm) Steel Plate 3/8 in. x 13 in. (10mm x 33cm) Threaded Rod 4 in. x 1/4 in. min. (10cm x 6.4mm) minimum Channel Iron 10 in. (25 cm) 1 in.
Page 380: Bleeding Manual Tilt System
3. Bleed unit by pushing rod down slowly (18-20 se- Bleeding Manual Tilt System conds per stroke) until stopped at base. Wait until IMPORTANT: While bleeding tilt system, time all air bubbles exit accumulator base. must be allowed between each stroke to allow air bubbles to dissipate.
Page 381: Manual Tilt System Installation
7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), re- cycle unit 2-3 more times using short strokes. No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise.
Page 382 3. Reinstall manual tilt system. Reconnect release 6. Apply 2-4-C Marine Lubricant (92-90018A12) to valve link rod. surface of upper pivot pin, pivot pin hole and shock rod hole. 51148 a - Pivot Pin b - Pivot Pin Bore c - Shock Rod Bore 51144 7.
Page 383 MID-SECTION MANUAL TILT SYSTEM (DESIGN 4)
Page 384 Table of Contents Page Page Special Tools ......5G-1 Manual Tilt System Reassembly .
Page 385: Special Tools
Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 90-814676R1 DECEMBER 1996 MID-SECTION - 5G-1...
Page 386 MANUAL TILT COMPONENTS Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5G-2 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 387 MANUAL TILT COMPONENTS TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – MANUAL TRIM ASSEMBLY – MANUAL TRIM BEACHING ASSEMBLY SHOCK ROD ASSEMBLY SHOCK ROD ASSEMBLY (BEACHING) MEMORY PISTON ASSEMBLY O RING REBUILD KIT-Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY...
Page 388 MANUAL TRIM FLOW DIAGRAMS Up Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...
Page 389: Tilt Up
Tilt Up With the engine in the down position, the accumula- tor piston (d) will be at the top of the accumulator (c) with the gas at maximum pressure. To raise the en- gine, the camshaft lever (f) is rotated all the way down.
Page 390 Down Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...
Page 391: Tilt Down
Tilt Down With the engine tilted up, the piston inside the accu- mulator piston (d) will be at the bottom of the accumu- lator (c) and the gas pressure is low. To lower the en- gine, the camshaft lever (f) is rotated down, the internal cam will cause the push rods to open the ac- cumulator check valve (e), both fast transfer valves (h &...
Page 392: Slow Tilt Down Under High Thrust
Slow Tilt Down Under High Thrust a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...
Page 393 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 slow transfer valve (i) allowing oil under pressure into the cavity around the shaft.
Page 394 Under Water Strike (Valves Open) a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...
Page 395: Under Water Strike With Valves Open
Under Water Strike With 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 interconnecting passage. The rapid fluid flow will increase the pressure below the surge valve (k), causing the valve to move, closing the oil return passage back into the accumulator (c).
Page 396 Shock Function (Valve Closed) Accumulator Gas Pressure 400 PSI a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston...
Page 397: Shock Function With Valves Closed
Shock Function With 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 fast transfer valve (j), the closed down slow transfer valve (i) and closed down fast transfer valve (h).
Page 398: Shock Function Return
Shock Function Return a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...
Page 399 Shock Function Return After the drive clears the object, the shock return valve (o) will allow the oil to flow from between the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to its original running position.
Page 400: Hydraulic System Troubleshooting
3. Check for discharged accumulator. 35 to 50 lb. ft. Hydraulic System (47-68 N·m) of pulling force must be attained Troubleshooting when tilting outboard from full “down” to full “up” position. If more than 50 lb. ft. (68 N·m) of force Refer to disassembly/reassembly instructions (fol- is required, replace accumulator.
Page 401: Manual Tilt System Removal
3. Position piece of wood under transom bracket Manual Tilt System Removal instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper CAUTION dowel pin. Retain dowel pin. Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard.
Page 402: Manual Tilt System Disassembly
6. Use suitable punch to drive out lower pivot pin. Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitro- gen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumu- 51144 lator only when shock rod is in full up position. a - Pivot Pin Accumulator Removal 1.
Page 403: Shock Rod Removal
6. If plunger can be compressed into accumulator Shock Rod Removal by hand, accumulator is defective. Replace accu- 1. Unscrew cylinder end cap assembly using span- mulator. ner wrench [1/4 in. x 5/16 in. long pegs]. 51145 2. Remove shock rod assembly from cylinder. 51143 a - Plunger 7.
Page 404: Shock Rod Disassembly
3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove O-ring. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
Page 405 10. Remove inner 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. 5. Place shock rod in soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).
Page 406: Valve Block Removal
Valve Block Removal Memory Piston Removal 1. Remove two screws from the shock rod cylinder 1. Remove memory piston from cylinder using one to separate the valve block. of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or (Snap-on P/N SRP4). a a a 51146 a - Screws (2)
Page 407: Valve Block Disassembly
2. Remove O-ring from memory piston. 3. Remove surge valve assembly. 51144 a - O-Ring b - Memory Piston a - Spool b - Spring c - O-ring Valve Block Disassembly d - Screw Plug 1. Remove check retainer plug and components. 4.
Page 408 REASSEMBLY - O-RING AND SEAL PLACEMENT NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5G-24 - MID-SECTION 90-814676R1 DECEMBER 1996...
Page 409: Actual O-Ring Sizes
Actual O-ring Sizes 4, 14 6 (2) 11 & 13 Cutaway View of O-Ring Width 8 (2) O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 90-814676R1 DECEMBER 1996 MID-SECTION - 5G-25...
Page 410: O-Ring Description And Sizes
O-ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring (412585) Cyl. Cap, Inner (412586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap (408134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in.
Page 411: Manual Tilt System Cleaning And Inspection
VALVE BODY CHECK REASSEMBLY Manual Tilt System Cleaning 1. Install lubricated O-ring, plunger, steel ball and and Inspection conical spring to valve block. 1. It is recommended that all O-rings exposed dur- ing disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air.
Page 412: Check Retainer Reassembly
CHECK RETAINER REASSEMBLY Valve Block Installation 1. Install plunger, spring (large), ball, spring (small), 1. Install lubricated O-rings and dowel pins. and plug into valve block. 51148 a - O-rings (2) b - Dowel Pins (2) 51142 2. Install valve block to shock rod cylinder. Insert screws to shock rod cylinder and torque to 100 lb.
Page 413: Shock Rod Reassembly
Shock Rod Reassembly CAUTION 1. Install lubricated O-rings to end cap. hen installing shock rod piston, spanner wrench must have1/4 in. x 5/16 in. (6.4mm x8mm) 2. Install rod wiper. long pegs to avoid damage to shock rod piston. 6. Apply Loctite Grade “A” (271) to threads on shock rod.
Page 414: Shock Rod Installation And Fluid Filling Procedure
Shock Rod Installation and Fluid Fill- 6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) and ing Procedure screw cylinder cap down. NOTE: There are two ways for the filling procedure. 7.
Page 415: Instructions For Making Retaining Tool
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. (10mm x 33cm) Threaded Rod 4in. x 1/4 in. min. (10cm x 6.4mm) minimum Channel Iron 10 in.
Page 416: Bleeding Manual Tilt System
3. Bleed unit by pushing rod down slowly (18-20 se- Bleeding Manual Tilt System conds per stroke) until stopped at base. Wait until IMPORTANT: While bleeding tilt system, time all air bubbles exit accumulator base. must be allowed between each stroke to allow air bubbles to dissipate.
Page 417 7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), re- cycle unit 2-3 more times using short strokes. No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise.
Page 418: Manual Tilt System Installation
4. Using a suitable punch, drive lower pivot pin into Manual Tilt System clamp bracket and trim cylinder assembly until Installation pivot pin is flush with outside surface. 1. Apply 2-4-C Marine Lubricant to lower pivot pin hole and pivot pin surface. 2.
Page 419: Manual Release Valve Adjustment
6. Apply 2-4-C Marine Lubricant (92-90018A12) to 8. Drive upper dowel pin (a) into its hole until seated. surface of upper pivot pin, pivot pin hole and shock rod hole. 51147 a - Dowel Pin 51148 a - Pivot Pin 9.
Page 420: Lower Unit
LOWER UNIT 50508 GEAR HOUSING...
Page 421 Table of Contents Page Page Special Tools ......6A-1 Gear Housing Reassembly ....6A-16 Quicksilver Lubricants and Service Aids .
Page 422: Special Tools
Special Tools Quicksilver Lubricants and Service Aids Description Part No. Cover Nut Tool 91-91947 Description Part No. Slide Hammer 91-34568A1 Special Lubricant 101 92-13872A1 Puller Jaws 91-46086A1 Loctite Grade “A” (271) 92-32609-1 Puller 91-27780 Needle Bearing Assembly 92-42649A-1 Lubricant Universal Puller Plate 91-37241 Gear Lube Mandrel...
Page 423: Gear Housing Assembly - Drive Shaft Components
Gear Housing Assembly - Drive Shaft Components 1 - Gear Housing Lubrication/Sealant Application 2 - Speedometer Hose Points 3 - Dowel Pin (2) 4 - Stud (3) 5 - Stud (2) 2-4-C Marine Lubricant 6 - Needle Bearing (P/N 92-90018A12) 7 - Water Inlet 8 - Screw Special Lubricant 101 (P/N 92-13872A1)
Page 424: Gear Housing Assembly - Propeller Shaft Components
Gear Housing Assembly - Propeller Shaft Components 1 - Gear Housing Torque Specifications 2 - Shift Cam (Number Side Toward Top of Gear Case) 3 - Shim(s) 100 lb. ft. (135.6 N·m) 4 - Bearing and Race 5 - Forward Gear 60 lb.
Page 425: Draining And Inspecting Gear Housing Lubricant
Draining and Inspecting Gear Housing Lubricant WARNING If gear housing is installed on outboard, discon- nect (and isolate) spark plug leads to avoid acci- dental starting when working near propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove vent screw and gasket (a) and fill/drain screw and gasket (b).
Page 426: Gear Housing Removal
4. Place a block of wood between gear case and 4. Remove four lock nuts (a) securing gear housing propeller to hold propeller and remove propeller to drive shaft housing (one not shown). nut. 5. Remove gear housing. 5. Remove propeller and components from shaft. Flo-Torq I Drive Hub Propellers a - Forward Thrust Hub b - Propeller Nut Retainer...
Page 427: Water Pump Removal
3. Remove seal (a) from drive shaft. Water Pump Removal NOTE: Outboard S/N 0C245675 and above will not 1. Remove centrifugal slinger (a) and three lock have seal on drive shaft due to improved lower end nuts and washers (b). cap design.
Page 428 4. Remove nylon washer (a), and seal (b). 6. Remove impeller (a) and drive key (b) from drive shaft. If necessary use a punch and hammer to drive impeller upward off drive shaft. In extreme instances, the impeller center hub must be split with chisel.
Page 429: Bearing Carrier And Propeller Shaft Removal
9. Remove water pump base and gasket. Bearing Carrier and Propeller Shaft Removal 10. Inspect base and replace if cracked, distorted, or melted. IMPORTANT: For proper retention between hous- ing and cover nut, it is recommended that PLAS- TIC cover nut NOT be reused. Replace as re- quired.
Page 430 3. Remove bearing carrier from gear housing using 6. Remove cross pin. puller jaws and bolt. 7. Remove remaining components from propeller shaft. 54763 a - Bearing Carrier 54766 b - Puller Jaws (19-46086A1) a - Punch c - Puller Bolt (91-85716) b - Cross Pin c - Sliding Clutch 4.
Page 431: Drive Shaft And Pinion Gear Removal
10. Inspect reverse gear ball bearing. If bearing is 11. Inspect bearing (a). If bearing is rusted or does rusted or does not roll freely, replace bearing. not roll freely, replace bearing. 54770 a - Bearing b - Mandrel (91-24273) Drive Shaft and Pinion Gear Removal 1.
Page 432: Lubrication Sleeve Removal
5. If tapered drive shaft bearing is rusted or does not Lubrication Sleeve Removal roll freely, or if race is damaged, replace bearing 1. Remove lubrication sleeve using puller. and race as an assembly. 54772 a - Universal Puller Plate (91-37241) b - Press c - Tapered Bearing 6.
Page 433: Forward Gear And Bearing Removal
Forward Gear and Bearing Removal 4. Replace bearing (a) if it is rusted or does not roll freely. Use punch and hammer to remove bear- 1. If tapered forward gear bearing is rusted or does ing. not roll freely, or if race is damaged, replace bear- ing and race as an assembly.
Page 434: Drive Shaft Needle Bearing Removal
3. Remove components from shift shaft. Drive Shaft Needle Bearing Removal 1. If bearing is rusted or does not roll freely, replace bearing. 54780 a - Mandrel (91-37312) b - Needle Bearing 54778 a - Rubber Washer Cleaning and Inspection b - Bushing c - Seal Surface d - “E”...
Page 435: Needle Bearing
2. Bearing should be free of rust stains. Propeller Shaft 3. Attempt to work inner bearing race in-and-out. 1. Replace propeller shaft if any of the following There should not be excessive play. conditions exist: 4. Lubricate bearing with Quicksilver Gear Lube. a.
Page 436: Sliding Clutch
Sliding Clutch Water Pump Components 1. Inspect sliding clutch. Check reverse gear slide 1. Inspect impeller. Replace impeller if any of the clutch jaws, if jaws are rounded replace as nec- following conditions exist: essary. Rounded clutch jaws can be caused by Impeller blade(s) are cracked, torn, or worn.
Page 437: Shift Shaft
Shift Shaft Shift Shaft Bushing Reassembly and Installation 1. Inspect shift shaft and cam. Replace compo- nents if any of the following exists: 1. Press new oil seal (a) into bushing with lip of seal away from threaded end of bushing. Install new Corroded or worn shift shaft splines (both ends).
Page 438: Lubrication Sleeve Installation
5. Place shift cam (Number Side Up) into gear housing and install shift shaft assembly. Torque bushing to 17 lb. in. (23 N·m). 54791 a - Tab (Position Towards Front of Gearcase) Forward Gear and Bearing 54777 Reassembly a - Shift Shaft Bushing Tool (91-23033) b - Shift Shaft 1.
Page 439: Bearing Carrier Reassembly
2. Press tapered bearing onto forward gear. 54794 54793 a - Mandrel (91-37321 b - Needle Bearing a - Mandrel (MUST Contact Inner Bearing Race Only) (91-38628) c - Seal Edge b - Inner Bearing Race MUST BE Tight Against Shoulder of Gear 2.
Page 440: Forward Gear Race Installation
3. Apply Loctite Grade “A” onto O.D. of seals and Drive Shaft Reassembly and press into bearing carrier. Installation 4. Apply 2-4-C Marine Lubricant onto I.D. of seals 1. Press tapered bearing onto drive shaft until inner 5. Lubricate O.D. of ball bearing with Quicksilver bearing race bottoms on shoulder.
Page 441: Checking Pinion Gear Depth
4. Apply Loctite Grade “A” onto threads of new pin- ion nut and install components. 5. Clamp drive shaft in soft jawed vise and torque pinion nut to 50 lb. ft. (67.8 N·m). 50507 a - Apply Pressure in Direction of Arrow b - Shimming Tool c - Feeler Gauge d - Obtain .025 in.
Page 442: Bearing Carrier Installation
3. Insert guide block (a) into propeller shaft. Cross 6. Install spring (a). pin hole (b) MUST align with hole (c). 54805 54802 7. Place propeller shaft into forward gear. 4. Apply thin coat of Quicksilver Needle Bearing As- sembly Lubricant on flat side (a) of cam follower (b), and install cam follower.
Page 443 4. Push bearing carrier into gear housing while ro- 7. Install cover nut (a) with the word “OFF” visible. tating drive shaft to engage pinion gear teeth with Torque cover nut to 100 lb. ft. (136 N·m) using reverse gear teeth. cover nut tool (91-91947) (b).
Page 444: Checking Forward Gear Backlash
Checking Forward Gear Backlash 6. Lightly turn drive shaft back-and-forth (no move- ment should be noticed at propeller shaft). NOTE: Read entire procedure before attempting any 7. Dial indicator registers amount of backlash. change in shim thickness. Backlash should be between .007 in. and .010 in. 1.
Page 445 3. Install gasket (a) and O-ring (b). 5. Install seal and washer. Apply Quicksilver 2-4-C Marine Lubricant to I.D. of insert and seal. 54813 54755 4. Coat insert area of water pump body with Quick- a - Cupped Nylon Washer (Cupped Side Towards Seal) silver 2-4-C Marine Lubricant and install insert (a) b - Seal making sure locating tab (b) enters hole in body.
Page 446: Gear Housing Installation
IMPORTANT: When performing gear housing re- 10. Install locking nuts and washers (a) and centrifu- pair that requires removal of water pump impel- gal slinger (b). ler, it is recommended that the impeller be re- placed. If it is necessary, however, to re-use the impeller, DO NOT install in reverse to original rotation, or premature impeller failure will occur.
Page 447 4. Install rubber seal (a) to drive shaft. 8. Install water tube (a) into drive shaft housing and insert into seal located at bottom of exhaust plate. NOTE: Outboard S/N 0C295675 and above will not have seal on drive shaft due to improved lower end cap design.
Page 448: Filling Gear Housing With Lubricant
Filling Gear Housing with Propeller/Trim Tab Lubricant Installation 1. Install new gaskets on fill and vent screws. WARNING 2. With gear housing in vertical position, fill gear Remove (and isolate) spark plug leads from case thru “Fill” hole (a) using Quicksilver Gear spark plugs when installing propeller.
Page 449 5. Install trim tab (a). Torque bolt to 20 lb. ft. (27.1 7. Check shift operation as follows: N·m). a. Place shift lever in forward gear. Gear hous- 6. Install nylon plug (b). ing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller shaft is turned counter- clockwise.
Page 450 LOWER UNIT JET DRIVE...
Page 451 Table of Contents Page Page Notes ........6B-1 Worn (Dull) Impeller .
Page 452: Notes
Notes: 90-814676R1 DECEMBER 1996 LOWER UNIT - 6B-1...
Page 453: Jet Pump Assembly
Jet Pump Assembly 2-4-C With Teflon (92-825407A12) 6B-2 - LOWER UNIT 90-814676R1 DECEMBER 1996...
Page 454 Jet Pump Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HOUSING–pump HOSE–lube IMPELLER HOUSING–intake LINER SHAFT–drive SLEEVE–shaft SHIM TAB WASHER SCREW (1/4-20 x .75) 10.8 SCREW (1/4-20 x .875) SCREW (1/4-20 x .625) SCREW (.312-18 x 1.25) BRACKET 13.3 18.1...
Page 455: Selecting A Boat Best Suited For Jet Power
Selecting A Boat That Is Best Engine Horsepower Suited For Jet Power Selection To obtain the best performance from the jet drive, the A boat operating at slow speed requires considerably boat should have the following features: more depth than one which is planing on the surface of the water.
Page 456: Transom Height Of The Boat
SETTING OUTBOARD MOUNTING HEIGHT ON Transom Height of the Boat BOATS WITH “V” BOTTOM HULLS Outboards with jet drives will be mounted approxi- 1. Measure the width of the leading edge on the wa- mately 7 inches higher on the transom than propeller ter intake housing.
Page 457: Water Testing
SETTING OUTBOARD MOUNTING HEIGHT ON When operating the boat, the outboard drive shaft BOATS WITH FLAT BOTTOM HULLS should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water 1. Place (center) the outboard on the boat transom intake.
Page 458: Shift Cable Installation
4. Attach the brass barrel to the bracket with bolt and Water testing locknut. Tighten the bolt until it seats against the barrel, then back-off the bolt 1/4 turn. Hold bolt Checking for Cavitation (Continued) from turning, and tighten locknut on bolt. The bar- rel must be free to pivot.
Page 459: Lubricating The Drive Shaft Bearing
Lubricating The Drive Shaft Impeller Removal and Bearing Installation Recommended Lubrication - Use Quicksilver 2-4-C REMOVAL w/Teflon, or Lubriplate 630-AA Grease. 1. Shift outboard to NEUTRAL (N) position. IMPORTANT: It is important that you do not use a general-all-purpose grease for this bearing. The 2.
Page 460 INSTALLATION 3. After setting the impeller height, tighten the impel- ler nut snug with a wrench. Secure impeller nut by 1. Grease the drive shaft, shear key, and impeller bending tabs against the flats on the impeller nut. bore. Place the plastic sleeve inside the impeller and install impeller, shear key, shims nut retainer, and impeller nut.
Page 461: Steering Pull Adjustment
Steering Pull Adjustment Worn (Dull) Impeller The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1/16 in. (1.5mm) toward the star- board side of the outboard.
Page 462: Liner Replacement
Liner Replacement Jet Drive Removal and Installation REMOVAL 1. Remove 2 locknuts and bolt securing jet drive to drive shaft housing and remove jet drive. INSTALLATION 1. Install the exhaust tube seal into the jet drive. 2. Install jet drive with bolt and locknuts as shown. 1.
Page 463: Water Pump Removal And Installation
Water Pump Removal and Bearing Carrier Removal and Installation Installation REMOVAL REMOVAL 1. Remove water pump assembly as shown. 1. Remove water assembly. INSTALLATION 2. Remove 4 bolts securing bearing carrier to jet IMPORTANT: If impeller being installed has been drive, and remove bearing carrier.
Page 464: Bearing Carrier Disassembly
Bearing Carrier Disassembly Bearing Carrier Reassembly 1. Remove the large beveled snap ring from the Installing Lower Seals bearing carrier. 2. Heat the bearing carrier with a torch only until you Install seals into bearing carrier as follows: can barely touch it. 1.
Page 465: Installing Upper Seals
Installing Upper Seals Installing Drive Shaft Ball Bearing 1. Install spiral retaining ring into the inner ring 1. If removed, install the bearing thrust ring into the groove of the upper seal housing. groove on the drive shaft. 2. Spread a film of grease around the inside bore of 2.
Page 466 5. Grease the upper seals and inside bore of the 7. Install spacer, and the upper seal housing being bearing carrier to ease entry of the seal housing. careful not to damage the O-ring seals as they pass the snap ring groove. Only finger pressure 6.
Page 467: Jet Drive Tiller Handle Adaptor Kit
2. Install the shift cable to the jet drive. Use the exist- Jet Drive Tiller Handle ing mounting hardware supplied with the out- Adaptor Kit board. Adjust shift cable after kit is installed. Installation Instructions NOTE: This kit must be used in conjunction with the recommended Quicksilver tiller handle kit.
Page 468 4. Slide the shift cable through the drilled hole. 8. Rotate the shift cable retainer so that the set screw is facing out and the slot is facing up. 5. Position the cable boot 1/2 in. (12 mm) out of the drilled hole.
Page 469 13. Fasten the anchor plate to the shift cable retainer. 16. Refer to the parts provided with your tiller handle kit and install the neutral start switch to the retain- IMPORTANT: Do not over-tighten. Shift cable re- er. Do not tighten screws at this time. tainer must be free to pivot.
Page 470: Shift Cable Adjustment
c. Loosen the upper mounting screw for the neu- Shift Cable Adjustment tral start switch. Rotate the neutral start switch up, then lower the switch until the roller acti- WARNING vates the switch (clicks). Fasten switch at this position. The shift cable must be adjusted to lock the re- verse gate against unexpected engagement (caused by water pressure hitting the gate) while operating the boat in forward.
Page 471 OUTBOARD MOTOR INSTALLATION/ ATTACHMENTS 50331 OUTBOARD MOTOR INSTALLATION/ATTACHMENTS...
Page 472 Table of Contents Page Page Installing Outboard Motor on Transom ..7A-1 Transom Mounted Ride Guide Attaching Kit Determining Recommended Outboard Installation (73770A1) ....7A-15 Mounting Height .
Page 473: Locate Centerline Of Boat Transom
Locate Centerline Of The Installing Outboard On Boat Boat Transom Transom Models Without Transom Clamp Handles Locate (and mark with pencil) the vertical centerline of boat transom. a - Centerline of Transom NOTE: Dimensions “A” & “B” and “C” & “D” are equal length.
Page 474 NOTE: If using “Transom Drilling Fixture” (P/N Installing Outboard On Boat 91-98234A2), use holes (f) when drilling outboard Transom Models With mounting holes. Transom Clamp Handles e - Centerline of Transom f - Use These Drilling Holes NOTE: On some boats because of transom interfer- ence, it may be necessary to install the steering cable before fastening the outboard to the transom.
Page 475: Optional Outboard Mounting Kit
IMPORTANT: Outboards with transom clamp FASTENING OUTBOARD TO THE BOAT handles can be secured to the boat transom, us- TRANSOM ing optional Quicksilver Accessory Outboard IMPORTANT: Read the preceding WARNING be- Mounting Kit (“ C” P/N 812432A4), to allow for fore installing outboard.
Page 476: 19609A2) Installation
19608A-3 Ride Guide Steering Single Cable - Single Attaching Kit Installation – Steering Outboard Ride Guide Cable Routed for Starboard Entry Steering Attaching Kit into Outboard Tilt Tube (P/N 19608A3 and Refer to “Quicksilver Accessories Guide” to deter- P/N 19609A2) Installation mine correct length of steering cable and remote con- trol cables.
Page 477: Installing Steering Link Rod
3. Place a mark (a) on tilt tube 1/4 in. (6.4mm) from Lubricate ball joint in steering link rod with SAE 30W port end of tube. Slide plastic spacer (b), O-ring Motor Oil. Secure link rod to outboard steering arm, (c) and cap (d) over steering cable end, to tilt tube using special washer head bolt (P/N 10-14000) pro- on outboard.
Page 478: 19609A-2 Ride Guide Steering Attaching Kit Installation - Steering Cable Routed For Port Entry Into Outboard Tilt Tube
19609A-2 Ride Guide Steering Installing Ride Guide Cable to Attaching Kit Installation - Steering Outboard Tilt Tube Cable Routed for Port Entry into IMPORTANT: Before installing steering cable Outboard Tilt Tube into tilt tube, lubricate entire cable end with Quicksilver 2-4-C Marine Lubricant. TILT TUBE REVERSAL NOTE: Ride Guide Steering Cable is lubricated at the factory and requires no additional lubrication at initial...
Page 479: Installing Steering Link Rod
Installing Steering Link Rod Maintenance Instructions Maintenance inspection is the owner’s responsibility WARNING and must be performed at intervals specified. Steering link rod MUST BE secured between out- Normal Service – Every 50 hours of operation or 60 board steering arm/bracket and steering cable days (whichever comes first) end, using special washer head bolt (P/N *Severe Service –...
Page 480: Single Cable - Dual Outboard Ride Guide Steering Kit (P/N 97933A4) Installation
Installation Requirements Single Cable - Dual Outboard Ride Guide Steering Kit (P/N IMPORTANT: The distance from each outboard’s centerline to the side of transom opening or gun- 97933A4) Installation nel MUST BE a minimum of 16 in. (406mm). Dual outboard installation requires steering bracket This kit contains all necessary parts to connect both replacement P/N 19617 from kit.
Page 481: Steering Cable Installation - Cable Routed
Steering Cable Installation - Cable Installing Steering Link Rod Routed Down Starboard Side of Boat WARNING to Port Outboard Steering link rod MUST BE secured between out- IMPORTANT: Before installing steering cable board steering arm/bracket and steering cable into tilt tube, lubricate entire cable end with end, using special washer head bolt (P/N Quicksilver 2-4-C Marine Lubricant.
Page 482: Steering Cable Installation - Cable Routed Down Port Side Of Boat To Starboard Outboard
Steering Cable Installation - Cable Installing Steering Cable Routed Down Port Side of Boat to IMPORTANT: Before installing steering cable Starboard Outboard into tilt tube, lubricate entire cable end with Quicksilver 2-4-C Marine Lubricant. TILT TUBE REVERSAL NOTE: Ride Guide Steering Cable is lubricated at the factory and requires no additional lubrication at initial CAUTION installation.
Page 483: Installing Steering Link Rod
Installing Steering Link Rod WARNING NOTE: Steering link rod and components from Ride- After installation is complete (and before operat- Guide Attaching Kit (P/N 17432A6) must be used ing outboard), check that boat will turn to right when steering cable is routed down starboard side of when steering wheel is turned right and that boat boat to port outboard.
Page 484: Steering Coupler Assembly
Steering Coupler Assembly Assemble steering coupler between outboard steer- ing brackets, as shown on the following pages. Position outboards so that they are facing straight IMPORTANT: With assembled steering coupler forward. (Distance between threaded hole centers of installed and before tightening special washer steering arms/brackets MUST BE equal to distance head bolts/locknuts, check outboard alignment.
Page 485: Steering Coupler Installation
Steering Coupler Installation IMPORTANT: Dual outboard installation requires a minimum outboard centerline distance of 21 in. (533mm) to assure interference-free movement. IMPORTANT: Lubricate all moving parts with Quicksilver 2-4-C Multi-Purpose Lubricant. 50137 Steering cable routed on starboard side of boat connected to port outboard. Steering cable routed on port side of boat connected to starboard outboard.
Page 486: Ride-Guide Steering Attachment Extension Couplers
Ride-Guide Steering Attachment IMPORTANT: Trim tabs MUST BE set in the same position on both outboards. Extension Couplers c. If boat pulls to the right, adjust trailing edges of both trim tabs to the right. If boat pulls to the Required Coupler(s) Outboard Center Between Steering Eyes...
Page 487: Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
2. Place pivot block on pivot spacer and secure to Transom Mounted Ride transom bracket with 3/8 in. x 2-1/2 in. bolt, flat Guide Attaching Kit washer and locknut, as shown in Figure 1. Torque locknut to 20 lb. ft. (27 N·m). Installation (73770A1) Attaching Kit Installation 1.
Page 488: Clevis Attaching Kit Installation (P/N 70599A4)
NOTE: When drilling thru transom, be sure that holes 7. Use a marine-type sealer on three 5/16 in. x 3-1/4 are drilled perpendicular to transom. in. bolts. Secure attaching kit to transom, using transom backing plate, 3 bolts (with sealer) and 6.
Page 489: Maintenance Instructions
3. Install clevis to steering cable as shown. 4. Install clevis to middle hole in steering bracket as shown. a - Clevis b - Steering Cable c - Bolt, 3/8” - 24 x 1-3/8” (Lubricate Unthreaded Area) d - Locknut [Clevis to Steering Cable; Torque to 120 lb. 50137 (14 N·m)] a - Clevis...
Page 490: Steering Cable Installation
Steering Cable Installation 5. Torque Ride-Guide cable attaching nut (which secures cable to guide tube) to 35 lb. ft. (41.5 1. Lubricate steering cable end with Quicksilver N·m) (below). Install locking sleeve over cable at- 2-4-C Marine Lubricant. taching nut and secure with cotter pin. Spread ends of cotter pin.
Page 491: Selecting Steering Cable And Remote Control Cables
2. Lubricate all steering system pivot points (and exposed portion of steering cable core) with Quicksilver 2-4-C Marine Lubricant. Lubricate at intervals specified preceding. 3. Check steering system components for wear (at intervals intervals specified, preceding). Replace worn parts. 4. Check steering system fasteners (at intervals specified, preceding) to be sure that they are torqued to correct specifications.
Page 492: Throttle Cable Installation And Adjustment To Engine
3. Route shift cable (a) thru control cable grommet Throttle Cable Installation and (b). Adjustment to Engine 4. Adjust barrel (c) of shift cable to attain the same 1. Shift remote control into neutral. distance between barrel and hole in end of shift cable guide as exists between barrel receptacle 2.
Page 493: Connecting Remote Control Wiring Harness To Engine Wiring Harness (Electric Start Models)
Connecting Remote Control Wiring Plug remote control wiring harness into engine har- ness connector (b) and push connection into retainer. Harness to Engine Wiring Harness (Electric Start Models) Route remote control harness or key switch harness down side of boat to engine, fastening harness to boat.
Page 494: Power Trim Wiring Connections (Models So Equipped)
Power Trim Wiring Connections Battery Connections (Models So Equipped) CAUTION Make bullet connector wiring connection, between Failure to observe correct polarity when con- remote control wiring harness/key switch wiring har- necting battery cables to battery, will result in ness and engine wiring. damage to the charging system.
Page 495: Connecting Remote Control Stop Switch Wiring To Engine Wiring (Manual Start Models)
Connecting Remote Control Stop Switch Wiring to Engine Wiring (Manual Start Models) 1. Locate the engine mounted stop switch wiring harness in the bottom cowl and disconnect the black/yellow wire that goes to the switch box. 2. Route the remote control wiring harness (e) into the bottom cowl thru the wiring grommet .
Page 496 OUTBOARD MOTOR INSTALLATION/ ATTACHMENTS 50505 TILLER HANDLE AND CO-PILOT...
Page 497 Table of Contents Page Tiller Handle Components ....7B-1 Torque Specifications ....7B-1 Quicksilver Lubricants and Service Aids 7B-1...
Page 498: Tiller Handle Components
Quicksilver Lubricants and Service Tiller Handle Components Aids 1 - Steering Arm 2 - Washer 2-4-C Marine Lubricant* 3 - Nut 4 - Grip 5 - Cap Loctite Grade “A” (271)* 6 - Plate *See Quicksilver Accessories Guide for part num- 7 - Gasket 8 - Screw (4) bers.
Page 499: Tiller Handle Throttle Cable Replacement
5. Install throttle cable. Tiller Handle Throttle Cable a. Position drive rod flat surface parallel to work Replacement surface. 1. Remove tiller handle from outboard. 2. Remove throttle twist grip. 3. Loosen screws (a) securing cable guide (b) to throttle cable (c). 54821 54819 a - Drive Rod...
Page 500 c. Install throttle cable into tiller handle port until e. Rotate drive rod counterclockwise 1/4 turn movement is felt in drive rod. (90 ) until flat surface becomes parallel with work surface. 54823 1/4 Turn d. Rotate drive rod counterclockwise 1/8 turn 54823 (45 ) until flat surface becomes parallel with Measure distance between tiller handle port...
Page 501 g. Install throttle handle to tiller handle. Align 6. Install washer, nut and end cap to throttle grip. “IDLE” on throttle handle with arrow on tiller Tighten nut snuggly allowing grip to turn freely. handle without moving drive rod. Recheck 7.
Page 502: Tiller Handle Installation
3. Secure tiller handle assembly to studs of out- Tiller Handle Installation board steering arm using tab washers (a) and (ELECTRIC START MODEL SHOWN) locknuts (b). Torque locknuts to 33 lb. ft. (45 N·m) and bend tab washers against hex of locknuts. 1.
Page 503: Shift Link Rod Installation
Shift Link Rod Installation 5. Check shift link rod adjustment as follows: a. Place outboard shift lever in “F” (Forward) 1. Place shift lever (located on tiller handle) in “N” position. Propeller should not rotate in a (Neutral) position. COUNTERCLOCKWISE direction. If propel- ler does rotate COUNTERCLOCKWISE, CAUTION length of shift link rod must be reduced and...
Page 504 3. Place barrel receptacle (c) onto throttle barrel (d). 5. Place end of throttle cable (c) on peg of throttle Route throttle cable (e) around port side of out- lever (d). board and position throttle cable through center opening in rubber grommet (b). 54834 6.
Page 505: Lanyard Stop Switch Wiring
8. With throttle lever (a) held lightly against stop Lanyard Stop Switch Wiring (b) and throttle twist grip at “IDLE”, turn set screw 1. Route Lanyard Stop Switch and Neutral Start of throttle cable barrel in until it bottoms-out on Switch wiring through bushing as shown.
Page 506: Neutral Start Switch Wiring
3. Connect lanyard stop switch wiring harness as Neutral Start Switch Wiring shown. NOTE: Electric Start Models 1. Remove ground lead (f) from solenoid terminal (e). 54839 a - Black/Yellow Lead from Mercury Stop Switch b - Black/Yellow Lead from Outboard Wiring Harness c - Black/Yellow Leads from Lanyard Stop Switch 54840 d - Black Lead (to Outboard Ground)
Page 507: Battery Connections
3. Reinstall electrical box cover (c). Battery Connections CAUTION Failure to observe correct polarity when con- necting battery cable to battery, will result in damage to the charging system. 1. A battery with a minimum reserve capacity rating of 100 minutes (minimum cold cranking rating of 350 amperes) is recommended.
Page 508: Co-Pilot Installation Instructions
6. Secure link rod to pilot rod with flat washer and Co-Pilot Installation locknut. Tighten locknut until it seats. DO NOT Instructions exceed 120 lb. in. (13.6 N·m), then back off 1/4-turn. 1. Thread friction device (a) onto starboard end of 7.
Page 509: Shift Interlock Adjustment
3. Interlock actuator (b) must align with rise of inter- Shift Interlock Adjustment lock cam (c) while shift lever is in the neutral posi- (MANUAL START MODEL) tion. 4. Tighten cable attaching screw securely. CAUTION DO NOT shift into “R” (reverse gear) position when engine is not running, as shifting mecha- nism could be damaged.
Page 510 OUTBOARD MOTOR INSTALLATION/ ATTACHMENTS 54845 REWIND STARTER...
Page 511 Table of Contents Page Rewind Starter Components ....7C-1 Torque Specifications ....7C-1 Quicksilver Lubricants and Service Aids 7C-1...
Page 512: Rewind Starter Components
Rewind Starter Components 1 - Nut (Left Hand Thread) 2 - Tab Washer 3 - Starter Housing 4 - Starter Sheave 5 - Starter Pawl 6 - Screw (3) 7 - Lockwasher (3) 8 - Screw (2) 9 - Nut (2) 10- Plate 11- Spring 12- Bushing...
Page 513: Rewind Starter Disassembly
4. Bend lock tabs (a) away from nut (b). Rewind Starter Disassembly 5. Remove nut (“b” left hand thread-turn clockwise WARNING to remove) while supporting rewind assembly. When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing.
Page 514: Cleaning And Inspection
7. Remove spring retaining plate. 9. Remove rewind spring by placing sheave over 2 pieces of wood (2 x 4’s) with spring facing down. Tap top of sheave with a mallet. This will cause rewind spring to drop out of sheave. 54847 8.
Page 515: Rewind Starter Reassembly
Rewind Starter Reassembly WARNING When reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. Installing Used Rewind Spring 54851 1. Lubricate rewind spring with low temperature a - Push Rewind Spring into Recess while Turning Sheave grease.
Page 516: Rope Installation
Rope Installation 5. Lubricate all components with low temperature grease. 1. Route rope thru hole in sheave. 2. Tie a knot in end of rope and place knot in recess (a). 3. Wind rope (b) clockwise onto sheave (when viewed from rewind spring side of sheave). 54853 4.
Page 517 7. Install spring bushing (a) and shaft bushing (b). 10. Push starter rope thru rope guide (a) then place sheave assembly into rewind housing. 54847 8. Install spring retainer plate (a) over sheave shaft. Use a thin shaft screwdriver to engage tab into in- ner loop of rewind spring.
Page 518: Adjusting Rewind Spring Tension
Adjusting Rewind Spring Tension NOTE: Check operation of rewind starter before bending tabs against nut. 1. Tie a slip knot in starter rope approximately 12 in. 6. Check rewind operation as follows: (305mm) from end of rope. a. Slowly pull starter rope outward. Pawl must 2.
Page 519 8. Install rewind starter on engine with 3 screws and 10. Pull starter rope thru cowl panel and install han- lockwashers. Torque to 100 lb. in. (11 N·m). dle and rope retainer. 9. Install and adjust shift interlock cable as outlined 11.
Page 520: Oil Injection System
OIL INJECTION SYSTEM 50444...
Page 521 Table of Contents Page Operation of the Oil Injection System ..Oil Injection Components ....Oil Injection Flow System .
Page 522: Operation Of The Oil Injection System
3. Check Valve Vent Operation of the Oil Injection Provides air to oil reservoir for proper venting of System reservoir. Check valve prevents oil from leaking out of reservoir where outboard is tilted forward. The oil injection system delivers an oil mixture of 50:1 4.
Page 523: Oil Injection Flow System
Oil Injection Flow System 50444 8-2 - OIL INJECTION SYSTEM 90-814676R1 DECEMBER 1996...
Page 524: Pump Drive Assembly
Pump Drive Assembly 50448 50448 Pump Drive System 50448 90-814676R1 DECEMBER 1996 OIL INJECTION SYSTEM - 8-3...
Page 525: Oil Pump To Powerhead Assembly
Oil Pump to Powerhead Assembly 1 - Bolt (2 Each) 2 - Oil Pump 3 - O-ring (Large) 4 - O-ring (Small) 5 - Bearing 6 - Driven Gear Torque Specifications 45 lb. in. (5.1 N·m) Quicksilver Lubrication/Sealant Application Points Loctite Grade A (92-32609-1) Needle Bearing Assembly Lubricant (92-42649A-1)
Page 526: Set Up Instructions For Oil Injection System
Bleeding Air from Oil Injection Set Up Instructions for Oil System Injection System CAUTION CAUTION If air exists in either oil pump hose (inlet or out- Oil injected engines additionally, must be run on let), the air MUST BE bled from the hose(s) or en- a 50:1 gasoline/oil mixture in the fuel tank for the gine damage may occur.
Page 527: Operation Of The Oil Injection System
Operation of the Oil Injection System Required Side Mount Remote Control or Ignition Key Switch Assembly to 1. Check oil level in oil tank. be Used with Engines Equipped with 2. Make sure a remote gasoline and oil mixture of Oil Injection 50:1 is used during the initial break-in of the en- gine or after extended storage.
Page 528: Oil Injection System Troubleshooting Chart
Oil Injection System Troubleshooting NOTE: There is a safety reserve of oil left in the oil tank after the low oil warning is sounded that allows Chart you enough oil for approximately 30 minutes of full throttle operation. TROUBLESHOOTING THE OIL INJECTION 2.
Page 529: Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft
Installing Drive Gear (for Oil Injection Oil Pump Volume (Flow) Test Pump) Onto Crankshaft NOTE: The following specifications are determined with the outboard running off a remote fuel supply 1. Refer to Section 4A (Powerhead) for proper dis- with pre-mix fuel. The oil pump output hose must be assembly of components.
Page 530: Oil Warning Module
5. Disconnect warning module PURPLE, TAN and Oil Warning Module both BLUE leads from their respective bullet con- nectors. Remove warning module BLACK ground lead from the upper right switch box Removal mounting bolt. 1. Disconnect engine battery cables from battery. 6.
Page 531: Installation
Installation Engine Mounted Oil Reservoir 1. Connect warning module PURPLE, TAN and both BLUE leads to their respective bullet con- nectors. Secure warning module BLACK ground lead to upper right switch box mounting bolt. Removal Torque bolt to 40 lb. in. (4.5 N·m). 1.
Page 532: Installation
5. Tilt oil reservoir to gain access to bottom of oil res- Installation ervoir. 1. Connect oil outlet hose to elbow fitting on oil res- 6. Remove screw securing oil level sensor in bot- ervoir. Secure hose with STA-STRAP. tom of oil reservoir and remove sensor. 2.

Mariner 30 JET 40 (4 CYL) Service Manual

Important 1

Electrical and Ignition 2

Electrical and Ignition 2

Electrical and Ignition 2

Fuel System and Carburetion

Powerhead

MID-Section

MID-Section

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Mariner 30 JET 40 (4 CYL)