Mercury 225 EFI Service Manual
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Mercury 225 EFI Service Manual

3.0 litre work, electronic fuel injection
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Table of Contents

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225/250
3.0 Litre Work
Electronic
Fuel Injection
Starting Model Year 2002
Starting Serial Number 0T409000

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Summary of Contents for Mercury 225 EFI

  • Page 1 225/250 3.0 Litre Work Electronic Fuel Injection Starting Model Year 2002 Starting Serial Number 0T409000...
  • Page 2 Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers.
  • Page 3 It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings.
  • Page 4 Service Manual Outline General Information & Specifications Section 1 - General Information & Specifications A - Specifications B - Maintenance Electrical C - General Information D - Outboard Installation Section 2 - Electrical A - Ignition Fuel System B - Charging & Starting System C - Timing, Synchronizing &...
  • Page 5 ......1A-4 Specifications Model 3 Liter Work/225 EFI/250 EFI HORSEPOWER Model 3 Liter Work 200 (149.1)
  • Page 6 SPECIFICATIONS REEDS Model 3 Liter Work/225 EFI/ 250 EFI Reed Type Steel Reed Stand 0pen (Max.) 0.020 in. (0.50 mm) Reed Stop (Max.) Not Adjustable Power Trim (Total Tilt Range) SECTION Power Trim (Tilt Range) Maximum Allowable Leak down in 24 hrs.
  • Page 7 1-1/2 – 4-1/2 psi (10.3 – 30.8 kPa) – @ 5000 RPM 8 – 10 psi (54.8 – 68.5 kPa) Minimum Recommended Oil Quicksilver or Mercury Precision Lubri- INJECTION cants NMMA/BIA Certified TC-W3 2 Cycle Outboard Oil Oil Tank Capacity 3 gal.
  • Page 8 SPECIFICATIONS Mercury/Quicksilver Lubricants and Sealants Mercury Part Number Description Quicksilver Part Number Needle Bearing Assy. Lubricant 92-802868A1 [8 oz. (226.8 grams)] tube Dielectric Grease 92-823506-1 92-823506-1 [8 oz. (226.8 grams)] can Loctite 271 – Thread Locker 92-809819 92-809819 (10 ml) tube...
  • Page 9 SPECIFICATIONS Mercury Part Number Description Quicksilver Part Number RTV 587 Silicone Sealer 92-809825 92-809825 [3 oz. (85.05 grams)] Obtain Locally Loctite 262 Obtain Locally Premium Gear Lubricant 92-802846A1 92-802846Q1 [1 Quart (0.94 liter)] Loctite 7649 Primer 92-809824 92-809824 [4.5 oz (127.57 grams)]...

  • Page 10: Table Of Contents

    MAINTENANCE IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Specifications ......1B-1 Fuel System .
  • Page 11 MAINTENANCE Special Tools 1. Grease Gun 91-37299A1 2. Flushing Attachment 44357A2 Mercury/Quicksilver Lubricants and Sealants NOTE: See Section 1A for lubricants and sealants chart. Page 1B-2 90-884294 OCTOBER 2001...

  • Page 12: Inspection And Maintenance Schedule

    MAINTENANCE Inspection and Maintenance Schedule Before Each Use 1. Check that lanyard stop switch stops the engine. 2. Visually inspect the fuel system for deterioration or leaks. 3. Check outboard for tightness on transom. 4. Check steering system for binding or loose components. 5.

  • Page 13: Flushing Engine

    MAINTENANCE Flushing Engine Flushing Cooling System – Using Cowl Flush Plug After each us in salt, polluted or muddy water, flush the internal water passages of the outboard with fresh water. This will help prevent a buildup of deposits from clogging the internal water passages.

  • Page 14: Fuel System

    MAINTENANCE 9. Stop engine, turn water off and remove flushing attachment from gear housing. IMPORTANT: While and after flushing, keep outboard in upright position until all wa- ter has drained from drive shaft housing to prevent water from entering the power- head via drive shaft housing and exhaust ports.

  • Page 15: Corrosion Control Anode

    MAINTENANCE 4. Remove filter by turning the filter in the direction of the arrow (clockwise). Tip the filter to drain fluid in a suitable container. 5. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten securely by hand.

  • Page 16: Battery Inspection

    MAINTENANCE Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. 1. Turn off the engine before servicing the battery. 2. Add water as necessary to keep the battery full. 3.

  • Page 17: Lubrication Points

    MAINTENANCE Lubrication Points Lubricate Point 1 with Special Lubricant 101. 1. Trim Rod Ball Ends – Turn the ball ends to work the lubricant into the ball sockets. Lubricate Point 2 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. 2.

  • Page 18: Checking Power Trim Fluid

    MAINTENANCE 6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b). WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant.

  • Page 19: Gear Case Lubrication

    MAINTENANCE Gear Case Lubrication When adding or changing gear case lubricant, visually check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance. If water is noticed, have the gear case checked by your dealer.

  • Page 20: Storage Preparation

    MAINTENANCE Storage Preparation The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage (two months or longer).
  • Page 21 MAINTENANCE POSITIONING OUTBOARD FOR STORAGE Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gear case could freeze and cause damage to the outboard.
  • Page 22 Serial Number Location ....1C-1 Model 3 Liter Work/225 EFI/250 EFI Conditions Affecting Performance ..

  • Page 23: Conditions Affecting Performance

    30% relative humidity, at 77 F (25 C) temperature and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce engine power.

  • Page 24: Boat

    GENERAL INFORMATION Boat WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the boat (persons and gear) has a significant effect on the boat’s performance, for example: a. Shifting weight to the rear (stern) (1.) Generally increases top speed. (2.) If in excess, can cause the boat to porpoise. (3.) Can make the bow bounce excessively in choppy water.
  • Page 25 GENERAL INFORMATION 3. Increases clearance over submerged objects. 4. In excess, can cause porpoising and/or ventilation. 5. If trimmed out beyond the water pickup, reduced water supply can cause overheating resulting in engine damage. TRIMMING OUTBOARD “IN” (“DOWN”) CHARACTERISTICS WARNING Excessive speed at minimum trim “in”...

  • Page 26: Engine

    GENERAL INFORMATION Engine DETONATION Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-like “rattling” or “plinking” sound. Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug has fired.

  • Page 27: Following Complete Submersion

    GENERAL INFORMATION Following Complete Submersion Salt Water Submersion Due to the corrosive effect of salt water on internal engine components, complete disas- sembly is necessary before any attempt is made to start the engine. Submerged While Running When an engine is submerged while running, the possibility of internal engine damage is greatly increased.
  • Page 28 GENERAL INFORMATION a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard side of engine. b. Drain any water from hose and reconnect. c. If water was present in hose, check for water in the remote oil tank. Drain tank if water is present.

  • Page 29: Model 3 Liter Work/225 Efi/250 Efi Powerhead Front View

    GENERAL INFORMATION Model 3 Liter Work/225 EFI/250 EFI Powerhead Front View 59029 Throttle Plate Assembly VST Drain Plug Fuel Hose [43 psi 2 psi (296 kPa 14 kPa)] 10 - Smartcraft Harness Connector to Fuel Rail 11 - Fuel Injector Harness Connector...

  • Page 30: Model 3 Liter Work/225 Efi/250 Efi Powerhead Starboard View

    GENERAL INFORMATION Model 3 Liter Work/225 EFI/250 EFI Powerhead Starboard View Starter Motor 16 - Detonation Sensor Connector (200 EFI Only) Vapor Separator Tank (VST) Vent Hose 17 - Thermostat Discharge Hose Throttle Plate Assembly 18 - #5 Cylinder Oil Pump Harness Connector...

  • Page 31: Model 3 Liter Work/225 Efi/250 Efi Powerhead Port View

    GENERAL INFORMATION Model 3 Liter Work/225 EFI/250 EFI Powerhead Port View 59030 Fuel Pressure Test Point 19 - Block Pressure Hose Fuel Out to Fuel Rail 20 - Oil Reservoir [0.74 qt. (0.70 Liter)] Fuel Pressure Regulator 21 - 4 psi (27 kPa) Check Valve...

  • Page 32: Model 3 Liter Work/225 Efi/250 Efi Powerhead Top View

    GENERAL INFORMATION Model 3 Liter Work/225 EFI/250 EFI Powerhead Top View 59024 60 Ampere Alternator 12 - Throttle Plate Adjustment Screw (Sealed at Factory) Port Thermostat Discharge Hose 13 - Throttle Plate Assembly Port Thermostat [120 F (48.8 C)] 14 -...

  • Page 33: Model 3 Liter Work/225 Efi/250 Efi Powerhead Aft View

    GENERAL INFORMATION Model 3 Liter Work/225 EFI/250 EFI Powerhead Aft View 59034 60 Ampere Alternator 17 - #2 Ignition Coil Starboard Thermostat [120 F (48.8 C)] 18 - Temperature Sensor (Analog) Starboard Temperature Sensor (Digital) Har- 19 - Port Temperature Sensor (Digital)

  • Page 34: Painting Procedures

    600 to 1000 grit sand paper should be used to smooth the surface area. It is then recommended that the entire cowl then be painted, to achieve an even luster, using normal Mercury Marine approved paint and procedures. Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris.
  • Page 35 7. Allow a minimum of one hour drying time and no more than one week before top coat- ing assemblies. 8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio.

  • Page 36: Decal Application

    GENERAL INFORMATION Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while remov- ing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4.
  • Page 37 GENERAL INFORMATION DECAL APPLICATION 1. Mix ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation.
  • Page 38 OUTBOARD MOTOR INSTALLATION IMPORTANT INFORMATION Section 1D - Outboard Motor Installation Table of Contents Installation Specifications ....1D-1 Shift Cable ......1D-9 Lifting Outboard .

  • Page 39: Installing Outboard To Boat Transom

    OUTBOARD MOTOR INSTALLATION Installing Outboard to Boat Transom Determining Recommended Outboard Mounting Height 26 in. (660mm) 25 in. (635mm) 24 in. (609mm) 23 in. Outboard (584mm) Mounting Height (See 22 in. NOTE Below) (560mm) 21 in. (533mm) 20 in. (508mm) 19 in.

  • Page 40: Installing Outboard

    OUTBOARD MOTOR INSTALLATION Installing Outboard Drilling Outboard Mounting Holes 1. Attach (tape) engine mounting template (located with the installation manual) to boat transom. IMPORTANT: If using Transom Drilling Fixture (91-98234A2), use drill guide holes marked “A” when drilling outboard mounting holes. Centerline of Transom Transom Drilling Fixture (91-98234A2) 2.

  • Page 41: Securing Outboard To Boat Transom

    OUTBOARD MOTOR INSTALLATION Securing Outboard To Boat Transom 1. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding and install outboard to the nearest recommended mounting height. 2. Fasten outboard with provided mounting hardware shown. 1/2 in. Diameter Bolts Flat Washers(4) Marine Sealer - Apply to Flat Washers(4) Shanks of Bolts, Not...

  • Page 42: Steering Link Rod

    OUTBOARD MOTOR INSTALLATION 2. Insert steering cable into tilt tube. 57832 3. Torque nut to 35 lb. ft. (47.5 N·m). 57833 Steering Link Rod 1. Install steering link rod per illustration. 57834 Special Bolt (10-849838) Torque to 20 lb-ft (27 N·m) Nylon Insert Locknut (11-826709113) Torque to 20 lb-ft (27 N·m) Flat Washer (2) Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then...

  • Page 43: Electrical, Hoses And Control Cables

    OUTBOARD MOTOR INSTALLATION Electrical, Hoses and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch as- sembly must be wired with a warning horn. This warning horn is used with the en- gine warning system. Installation Note Open the front clamp assembly.

  • Page 44: Battery Cables

    OUTBOARD MOTOR INSTALLATION Battery Cables SINGLE OUTBOARD (–) RED Sleeve (Positive) BLACK Sleeve (Negative) Starting Battery DUAL OUTBOARD Connect a common ground cable (wire size same as engine battery cables) between NEGATIVE (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between Negative (–) Terminals 90-884294 OCTOBER 2001 Page 1D-7...

  • Page 45: Fuel Hose Connection

    OUTBOARD MOTOR INSTALLATION Fuel Hose Connection Fuel Hose Size – Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate fuel line/fuel tank pickup for each engine. Fasten remote fuel hose to fitting with hose clamp. Oil Hose Connections Connect the remote oil hoses to the engine hose connections as shown.

  • Page 46: Shift Cable

    OUTBOARD MOTOR INSTALLATION Shift Cable Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gear cases can be identified by a “L”...

  • Page 47: Installation

    OUTBOARD MOTOR INSTALLATION Installation IMPORTANT: Step 1 must be followed for proper adjustment of the shift cable. 1. Locate the center point of the slack or lost motion that exists in the shift cable as fol- lows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position.
  • Page 48 OUTBOARD MOTOR INSTALLATION 2. Position remote control and outboard into neutral. 3. Slide the shift cable anchor pin forward until resistance is felt, then slide anchor pin toward rear until resistance is felt. Center the anchor pin between resistance points. Anchor Pin 4.

  • Page 49: Throttle Cable

    OUTBOARD MOTOR INSTALLATION Throttle Cable INSTALLATION 1. Position remote control into neutral. 2. Attach throttle cable to the throttle lever. Secure with washer and locknut. Nylon Washer Locknut – Tighten locknut then back off locknut 1/4 turn 3. Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw against the stop.

  • Page 50: Front Clamp Reassembly

    OUTBOARD MOTOR INSTALLATION 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse. b. Return remote control to neutral. Place a thin piece of paper between idle adjust- ment screw and idle stop.

  • Page 51: Oil Injection Set-Up

    OUTBOARD MOTOR INSTALLATION Oil Injection Set-Up CAUTION Be careful not to get dirt or other contamination in tanks, hoses or other compo- nents of the oil injection system during installation. Installing Remote Oil Tank 1. The remote oil tank should be installed in an area in the boat where there is access for refilling.

  • Page 52: Filling

    The Premium Plus Oil is specially formulated and tested to not only maintain a high level of performance but also increase the durability of the engine. This special blend, developed by Mercury Marine, contains more than twice the additives used in standard blends and ensures the greatest protection for your engine.

  • Page 53: Priming The Oil Pump

    OUTBOARD MOTOR INSTALLATION Priming the Oil Pump IMPORTANT: Before starting engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose, or internal passages. NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed, it is recommended all air be purged from oil pump/oil lines using gearcase leakage tester (FT-8950).

  • Page 54: Priming Procedure - Method 1

    OUTBOARD MOTOR INSTALLATION Conditions Requiring Priming the Oil Pump Condition Priming Procedure New engine Use Method 1 or 2 Rebuilt Powerhead Use Method 1 or 2 New Powerhead Use Method 1 or 2 Oil system ran out of oil Use Method 3 Oil drained from oil supply hose feeding pump Use Method 3 Oil pump removed...

  • Page 55: Purging Air From The Engine Oil Reservoir

    OUTBOARD MOTOR INSTALLATION Purging Air From the Engine Oil Reservoir 1. Loosen the fill cap on the engine oil reservoir. 2. Start the engine. Run the engine until all the air has been vented out of the reservoir and oil starts to flow out of the reservoir. Re-tighten fill cap. Fill Cap Trim In Stop Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal...

  • Page 56: Trim Tab Adjustment

    OUTBOARD MOTOR INSTALLATION Trim Tab Adjustment Propeller steering torque may cause your boat to pull in one direction. This steering torque results from your outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering torque and can be adjusted within limits to reduce any unequal steering effort.
  • Page 57 IGNITION ELECTRICAL Section 2A - Ignition Table of Contents Specifications ......2A-2 Ignition Coil Ohms Test .

  • Page 58: Specifications

    IGNITION Specifications IGNITION Type Digital Inductive SYSTEM Spark Plug Type NGK BPZ8HS-10 Spark Plug Gap 0.040 in. (1.0 mm) Ignition Coil Ohms Test 58903 BLACK METER LEAD Secondary EST Low Secondary Primary Battery + Tower PIN A PIN B Ground Pin E Pin C Pin D...

  • Page 59: Manifold Absolute Pressure (Map) Sensor Ohms Test

    IGNITION Manifold Absolute Pressure (MAP) Sensor Ohms Test 58904 BLACK METER LEAD BLK/ORG PPL/YEL PIN A PIN B PIN C BLK/ORG 95000 – 105000 3900 – 4100 PIN A RED METER RED METER 95000 – 105000 95000 – 105000 LEAD PIN B PPL/YEL 3900 –...

  • Page 60: Port And Starboard Temperature Sensors; Air Temperature Sensor

    IGNITION Port and Starboard Temperature Sensors; Air Temperature Sensor An ohms test of the temperature sensors would be as follows: Disconnect temperature sensor harness and check continuity with digital or analog ohm- meter test leads between both connector pins. With engine at temperature (F ) indicated, ohm readings should be as indicated 10%.

  • Page 61: Special Tools

    IGNITION Special Tools 1. DMT 2000 Digital Tachometer Multimeter 91-854009A1 2. Cylinder Timing Decal 91-853883-1 NOTE: Decal can be used to help troubleshoot ignition timing by determining the timing of individual cylinders. 3. Digital Diagnostic Terminal (DDT) 91-823686A2 4. Software Cartridge 91-880118A2 90-884294 OCTOBER 2001 Page 2A-5...
  • Page 62 IGNITION 5. DDT Reference Manual 90-881204--1 6. Adaptor Harness 84-822560A5 7. Spark Gap Tester 91-850439 55117 8. Timing Light 91-99379 9. Crank Shaft Protector Cap 91-24161 Page 2A-6 90-884294 OCTOBER 2001...
  • Page 63 IGNITION 10. Flywheel Puller 91-849154T1 55117 11. Flywheel Holder 91-52344 12. Heat Lamp 91-63209 90-884294 OCTOBER 2001 Page 2A-7...

  • Page 64: Coil Plate Assembly

    IGNITION Coil Plate Assembly Page 2A-8 90-884294 OCTOBER 2001...
  • Page 65 IGNITION Coil Plate Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft COIL MOUNTING PLATE IGNITION COIL SCREW 11.3 HI-TENSION CABLE BOOT SPARK PLUG (NGK#BPZ8HS10) COIL HARNESS CABLE SCREW (M6 x 10) WASHER GROMMET WASHER BUSHING SCREW (.312-18 x 1-1/4) SENSOR-BLOCK PRESSURE [0-50 psi (0-345 kPa)] FITTING CLIP STA-STRAP...

  • Page 66: Electrical Plate Assembly

    IGNITION Electrical Plate Assembly Page 2A-10 90-884294 OCTOBER 2001...
  • Page 67 IGNITION Electrical Plate Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft SOLENOID MOUNTING PLATE SOLENOID GROMMET SCREW (M6 x 25) BUSHING RELAY ASSEMBLY DECAL-TRIM RELAY BRACKET BUSHING GROMMET ENGINE HARNESS FUSE (3 – 20 AMP) (1 – 15 AMP) FUSE COVER SCREW (M6 x 14) J-CLIP GROUND WIRE (BLACK)
  • Page 68 IGNITION Electrical Plate Assembly Page 2A-12 90-884294 OCTOBER 2001...
  • Page 69 IGNITION Electrical Plate Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft BATTERY CABLE CONNECTOR CONNECTOR (6 PIN PLUG) INSULATOR BOOT (RED) CABLE (YELLOW/BLACK) SCREW (M6 x 35) 90-884294 OCTOBER 2001 Page 2A-13...

  • Page 70: Theory Of Operation

    IGNITION Theory of Operation When the ignition key switch is turned to the “RUN” position, battery voltage is applied to both the Electronic Control Module (ECM) through the purple wire and the main power relay through the red/purple wire. As the ECM receives the “RUN” signal, it internally com- pletes the ground circuit of the main relay, for a short period of time, energizing the fuel pump for start-up.

  • Page 71: Ignition Component Description

    IGNITION Ignition Component Description Fuses The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. 1.

  • Page 72: Charging System Alternator

    IGNITION Charging System Alternator Battery charging system, including the regulator, is contained within the belt driven alter- nator. At cranking speeds, electrical power for the engine is provided by the boat battery – minimum recommended size is 490 Cold Cranking Amperes (CCA) or 630 Marine Cranking Amperes (MCA).

  • Page 73: Electronic Control Module

    IGNITION Electronic Control Module (ECM) The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal 91-823686A2 using adaptor harness 84-822560A5. The ECM performs the following functions: Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold pressure and coolant temperature.

  • Page 74: Flywheel

    IGNITION Flywheel Flywheel has 54 teeth under the flywheel ring gear which the crank position sensor uses to provide engine rpm and crankshaft position information the ECM. 59070 Flywheel Crank Position Sensor Crank Position Sensor Crank Position Sensor monitors 54 teeth on flywheel, thus determining crankshaft posi- tion, and sends crankshaft position angle and engine speed signals to ECM.

  • Page 75: Throttle Position Sensor (Tps)

    IGNITION Throttle Position Sensor (TPS) The TPS transmits throttle angle information to the ECM which varies the injector pulse width accordingly. Should the sensor fail, the warning horn will sound. RPM will be re- duced by the ECM. TPS settings are not adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal through the ECM.

  • Page 76: Cylinder Head Temperature Sensor

    IGNITION Cylinder Head Temperature Sensor Two (2) temperature sensors are used to provide temperature information to the ECM. One sensor is mounted in each cylinder head. The ECM uses this information to increase injector pulse width for cold starts and to retard timing in the event of an over-heat condition.

  • Page 77: Port And Starboard Temperature Sensors; Air Temperature Sensor

    IGNITION Port and Starboard Temperature Sensors; Air Temperature Sensor An ohms test of the temperature sensors would be as follows: Disconnect temperature sensor harness and check continuity with digital or analog ohm- meter test leads between both connector pins. With engine at temperature (F ) indicated, ohm readings should be as indicated 10%.

  • Page 78: Manifold Absolute Pressure (Map) Sensor

    IGNITION Manifold Absolute Pressure (MAP) Sensor The MAP sensor is located on top of the air plenum. The ECM regulates fuel flow, in part, based on manifold absolute pressure. The MAP sensor becomes more critical in engine running quality as the engine is operated at higher altitudes (i.e. mountain lakes). Should the MAP sensor fail, the ECM will default to a value of approximately 14.7 psi.

  • Page 79: Ignition Troubleshooting And Fault Chart

    IGNITION Ignition Troubleshooting and Fault Chart CAUTION To protect against meter and/or component damage, observe the following pre- cautions: DO NOT reverse battery cable connections. The battery negative cable is (–) ground. DO NOT “spark” battery terminals with battery cable connections to check po- larity.
  • Page 80 IGNITION Symptom Cause Action 1. Engine cranks but will 1.7 ECM not functioning Check for proper operation by not start (continued) using Inductive Timing Light 91-99379. Check battery voltage (RED/YEL Lead) @ ignition coils. Check for blown fuse (C15). Check battery voltage to fuse from main power relay (PURPLE Lead).
  • Page 81 IGNITION Symptom Cause Action 3. Engine idle is rough 3.1 Fouled spark plug Replace spark plug: if carbon bridges electrode gap or if it is completely black. If it is not firing and is wet with fuel. Note: If spark plug is grey or com- pletely black with aluminum specs, this indicates a scuffed piston.
  • Page 82 IGNITION Symptom Cause Action 7. Speed Reduction (RPM 7.1 Low battery voltage Check battery and/or alternator. reduced) ECM requires 8 volts mini- Check electrical connections. Fuel Pump requires 9 volts 7.2 Overheat condition Check water pump impeller/cooling system. 7.3 Oil pump electrical failure Check electrical connection.

  • Page 83: Ignition Coil Ohms Test

    IGNITION Ignition Coil Ohms Test 58903 BLACK METER LEAD Secondary EST Low Secondary Primary Battery + Tower PIN A PIN B Ground Pin E Pin C Pin D Secondary 850 – 1200 Tower Continuity Continuity Continuity Continuity 8500 – 29000 – 11000 –...

  • Page 84: Manifold Absolute Pressure (Map) Sensor Ohms Test

    IGNITION Manifold Absolute Pressure (MAP) Sensor Ohms Test 58904 BLACK METER LEAD BLK/ORG PPL/YEL PIN A PIN B PIN C BLK/ORG 95000 – 105000 3900 – 4100 PIN A RED METER RED METER 95000 – 105000 95000 – 105000 LEAD PIN B PPL/YEL 3900 –...

  • Page 85: Efi Detonation Control System (200 Work Model Only)

    IGNITION EFI Detonation Control System (200 Work Model only) The detonation control circuit is located in the ECM. This circuit monitors 2 detonation (knock) sensors; 1 each located in each cylinder head. When detonation is initially de- tected, timing is retarded. If detonation continues, fuel mixture is richened. Use DDT to monitor Knock Volts (Press Keys 1, 3, 1) 59034 Detonation Sensor (1 per cylinder head)

  • Page 86: Ignition Component Removal And Installation 2A-30

    IGNITION Ignition Component Removal and Installation Flywheel Removal 1. Remove flywheel cover off engine. 2. Remove alternator belt. 3. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer. 59071 Flywheel Holder (91-52344) Flywheel 4. Install Flywheel Puller (91-849154T1) into flywheel. CAUTION Do not hammer on end of puller center bolt to remove flywheel, or damage may result to crankshaft or bearings.

  • Page 87: Flywheel Installation

    IGNITION Flywheel Installation IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry. 1. Reinstall flywheel on crankshaft. Secure flywheel with flat washer and locknut. While holding flywheel with Flywheel Holder (91-52344), torque flywheel nut to 120 Ib. ft. (163 N m). 59073 Flywheel Holder (91-52344) Torque Nut to 120 lb.

  • Page 88: Ignition Coil Installation

    IGNITION Ignition Coil Installation 1. Secure coil with 2 bolts. Torque bolts to 70 lb. in. (8 Nm). 2. Reconnect coil harness. 3. Reconnect spark plug lead to spark plug. Electronic Control Module Removal 1. Disconnect 3 Control Module harness connectors. 2.

  • Page 89: Temperature Sensor Removal

    IGNITION Temperature Sensor Removal ANALOG TEMPERATURE SENSOR 1. Remove screw and retaining plate. 2. Disconnect bullet connector and remove sensor. DIGITAL TEMPERATURE SENSOR 1. Disconnect wire harness for PORT and STARBOARD sensors. 2. Unscrew sensor from cylinder head. 59037 Bullet Connector (hidden) Digital Temperature Sensor Analog Temperature Sensor...

  • Page 90: Air Temperature Sensor Removal

    IGNITION Air Temperature Sensor Removal 1. Disconnect sensor harness connector. 2. Unscrew sensor from air plenum. 59025 Air Temperature Sensor Harness Connector Air Temperature Sensor Installation 1. Install sensor into air plenum. Torque sensor to 14 lb. in. (1.6 Nm). 2.

  • Page 91: Crank Position Sensor Removal

    IGNITION Crank Position Sensor Removal 1. Disconnect sensor harness. 2. Remove screws securing sensor to engine. 59070 Crank Position Sensor Harness Connector Crank Position Sensor Installation 1. Secure sensor to engine with 2 screws. Torque screws to 45 lb. in. (5 Nm). 2.
  • Page 92 CHARGING & STARTING SYSTEM ELECTRICAL Section 2B – Charging & Starting System Table of Contents Specifications ......2B-2 Alternator Belt Tension Adjustment .

  • Page 93: Specifications

    CHARGING & STARTING SYSTEM Specifications CHARGING Alternator Output (Regulated) 35 - 41 Amperes @ 2000 RPM @ Battery SYSTEM 36 - 44 Amperes @ 2000 RPM @ Alternator Brush Length Std Exposed Length: 0.413 in. (10.5 mm) Min. Exposed Length: 0.059 in. (1.5 mm) Voltage Output 13.5 to 15.1 Volts Regulator Current Draw...

  • Page 94: Special Tools

    CHARGING & STARTING SYSTEM Special Tools 1. Volt/Ohm Meter 91-99750A1 or DMT 2000 Digital Tachometer Multimeter 91-854009A1 Volt/Ohm Meter 91-99750A1 DMT 2000 Digital Tachometer Multimeter 91-854009A1 2. Ammeter (60 Ampere minimum) (Obtain locally) 3. Flywheel Holder 91-52344 54964 4. Protector Cap 91-24161 (Used with Puller 91-73687A1) 5.

  • Page 95: Battery Cable Size

    Replacement Parts WARNING Electrical, ignition and fuel system components on your Mercury Outboard are designed and manufactured to comply with U. S. Coast Guard Rules and Regula- tions to minimize risks of fire and explosions. Use of replacement electrical, igni- tion or fuel system components, which do not comply with these rules and regu- lations, could result in a fire or explosion hazard and should be avoided.

  • Page 96: Battery

    CHARGING & STARTING SYSTEM Battery Precautions CAUTION If battery acid comes in contact with skin or eyes, wash skin immediately with a mild soap. Flush eyes with water immediately and see a doctor. When charging batteries, an explosive gas mixture forms in each cell. Part of this gas es- capes through holes in vent plugs and may form an explosive atmosphere around battery if ventilation is poor.

  • Page 97: Winter Storage Of Batteries

    CHARGING & STARTING SYSTEM 4. To check battery voltage while cranking engine with electric starting motor, place RED (+) lead of tester on POSITIVE (+) battery terminal and BLACK (–) lead of tester on NEGATIVE (–) battery terminal. If the voltage drops below 9-1/2 volts while cranking, the battery is weak and should be recharged or replaced.

  • Page 98: Flywheel Removal And Installation

    CHARGING & STARTING SYSTEM Flywheel Removal and Installation Removal 1. Remove flywheel cover from engine. WARNING Engine could possibly start when turning flywheel during removal and installa- tion; therefore, disconnect (and isolate) spark plug leads from spark plugs to pre- vent engine from starting.

  • Page 99: Installation

    CHARGING & STARTING SYSTEM Installation IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry. 1. Install flywheel. 2. Install flywheel washer and nut. 3. Hold flywheel with Flywheel Holder (91-52344). Torque nut to 125 lb-ft (169.5 Nm). 59073 Flywheel Holder (91-52344) Page 2B-8 90-884294 OCTOBER 2001...

  • Page 100: Notes

    CHARGING & STARTING SYSTEM Notes: 90-884294 OCTOBER 2001 Page 2B-9...

  • Page 101: Flywheel/Alternator

    CHARGING & STARTING SYSTEM Flywheel/Alternator Page 2B-10 90-884294 OCTOBER 2001...

  • Page 102: System Components

    CHARGING & STARTING SYSTEM Flywheel/Alternator TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. ALTERNATOR SPRING BEARING BELT TENSIONER ARM ASSY BUSHING SCREW (M10 x 45) PULLEY SCREW (M10 x 35) BELT FLYWHEEL NUT (0.625–18) WASHER PLUG CABLE WASHER SCREW (M10 x 50) SCREW (M6 x 12) System Components The battery charging system consists of the alternator, battery, ignition switch, starter so-...

  • Page 103: Precautions

    CHARGING & STARTING SYSTEM Precautions The following precautions must be observed when working on the alternator system. Fail- ure to observe these precautions may result in serious damage to the alternator system. 1. Do not attempt to polarize the alternator. 2.

  • Page 104: Diagnosis Of Alternator System On Engine

    CHARGING & STARTING SYSTEM Diagnosis of Alternator System on Engine 1. If problem is an undercharged battery, verify condition has not been caused by exces- sive accessory current draw or by accessories which have accidentally been left on. 2. Check physical condition and state of charge of battery. Battery must be at least 75% (1.230 specific gravity) of fully charged to obtain valid results in the following tests.

  • Page 105: Alternator System Circuitry Test

    CHARGING & STARTING SYSTEM Alternator System Circuitry Test Using a 0-20 volt DC voltmeter, perform the following tests: Output Circuit 1. Connect POSITIVE (+) voltmeter lead to alternator terminal B (output terminal). Con- nect NEGATIVE (–) lead to case ground on alternator. 2.

  • Page 106: Sensing Circuit

    CHARGING & STARTING SYSTEM Sensing Circuit 1. Unplug RED and PURPLE lead connector from alternator. 2. Connect POSITIVE (+) voltmeter lead to RED lead and NEGATIVE (–) voltmeter lead to ground. 3. Voltmeter should indicate battery voltage. If correct voltage is not present, check sensing circuit (RED lead) for loose or dirty connections or damaged wiring.

  • Page 107: Voltage Output

    CHARGING & STARTING SYSTEM Voltage Output 1. Using a 0-20 volt DC voltmeter, connect POSITIVE (+) lead of voltmeter to TERMINAL B of alternator and NEGATIVE (–) lead of voltmeter to engine ground. 2. Start engine and allow to warm up. Increase engine RPM from idle to 2000. Normal voltage output should be 14.1 –...

  • Page 108: Current Output

    CHARGING & STARTING SYSTEM Current Output NOTE: Before conducting current output test, assure that all boat electrical accessories are turned OFF. 1. With engine shut off, install ammeter with clamp-on current probe (capable of reading 60+ amperes) onto alternator charging conductor (10 AWG Red Wire). 2.

  • Page 109: Current Output Troubleshooting

    CHARGING & STARTING SYSTEM Current Output Troubleshooting Current Output is Low Battery Cables are loose or corroded Defective Battery (Open Circuit) Defective Alternator Current Output is High Accessories turned on Defective Battery (Internal Short) Defective Alternator Repair Removal 1. Remove top cowling. 2.
  • Page 110 CHARGING & STARTING SYSTEM Installation 1. Secure alternator to engine block with attaching bolts. Torque top bolt to 40 lb-ft (54 Nm). Torque bottom nut to 35 lb-ft (47.5 Nm). 2. Rotate belt tensioner and install alternator belt in groove of flywheel and alternator pulley.

  • Page 111: Alternator Belt Tension Adjustment

    CHARGING & STARTING SYSTEM Alternator Belt Tension Adjustment Correct alternator belt tension is maintained by a belt tensioner assembly. 59024 Belt Tensioner Assembly Page 2B-20 90-884294 OCTOBER 2001...

  • Page 112: Starter System

    CHARGING & STARTING SYSTEM Starter System NOTE: Early production engines will be equipped with centrifugal bendix type starter mo- tors. Later production engines will be equipped with solenoid driven bendix type starter motors. Starter Motor Amperes Draw STARTING Electric Start – All Models Centrifugal Bendix SYSTEM Starter Draw (Under Load)

  • Page 113: Starter Motor (Centrifugal Bendix)

    CHARGING & STARTING SYSTEM Starter Motor (Centrifugal Bendix) Liquid Neoprene 2-4-C Marine Lubricant With Teflon Page 2B-22 90-884294 OCTOBER 2001...
  • Page 114 CHARGING & STARTING SYSTEM Starter Motor (Centrifugal Bendix) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft STARTER MOTOR DRIVE KIT DRIVE DRIVE END PLATE THRU BOLT WASHER ARMATURE BRUSH SET BRUSH HOLDER SCREW END CAP COLLAR RUBBER STOP SCREW (1/4-20 x 5/8) WIRE ASSEMBLY (BLACK) LOCKWASHER BATTERY CABLE (POSITIVE)

  • Page 115: Troubleshooting The Starter Circuit (Centrifugal Bendix)

    CHARGING & STARTING SYSTEM Troubleshooting the Starter Circuit (Centrifugal Bendix) Before beginning the troubleshooting flow chart, verify the following conditions: 1. Battery is fully charged. 2. Control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4.

  • Page 116: Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix)

    CHARGING & STARTING SYSTEM Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix) Starter Motor Does Not Turn SAFETY WARNING: Disconnect YELLOW (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (Rx1 scale) and connect meter leads between NEGATIVE (-) battery post and common pow- erhead ground.

  • Page 117: Flow Chart (Continued)

    CHARGING & STARTING SYSTEM Flow Chart (continued) TEST 7 a. Connect voltmeter between common engine and Test Point 1. b. Turn ignition key to “Start” position. 12 Volt Reading* No voltage reading: Defective starter solenoid Should hear solenoid click: proceed to TEST 8 TEST 8 a.

  • Page 118: Starter Removal (Centrifugal Bendix)

    CHARGING & STARTING SYSTEM Starter Removal (Centrifugal Bendix) CAUTION Disconnect battery leads from battery before removing starter. 1. Disconnect BLACK ground cable from starter. 2. Disconnect BLACK (with YELLOW sleeve) cable from starter. 3. Remove 4 bolts and upper and lower starter clamps. Lift starter from engine. 59044 BLACK ground cable Lower Mount Bolts...

  • Page 119: Starter Disassembly (Centrifugal Bendix)

    CHARGING & STARTING SYSTEM Starter Disassembly (Centrifugal Bendix) 1. Remove starter as outlined in Starter Removal. 2. Remove 2 through bolts from starter. 11646 Through Bolts Commutator End Cap 3. Tap commutator end cap to loosen and remove from frame. Do not lose brush springs. 4.
  • Page 120 CHARGING & STARTING SYSTEM 5. Remove armature (with drive end cap) from starter frame. 6. Remove locknut and remove drive assembly from armature shaft. Hold armature shaft with wrench on hex portion of drive assembly 7. Remove parts from shaft. 11658 Locknut Spacer...

  • Page 121: Starter Cleaning, Inspection And Testing

    CHARGING & STARTING SYSTEM Starter Cleaning, Inspection and Testing CLEANING AND INSPECTION 1. Clean all starter motor parts. 2. Check pinion teeth for chips, cracks or excessive wear. 3. Replace the drive clutch spring and/or collar if tension is not adequate or if wear is excessive.
  • Page 122 CHARGING & STARTING SYSTEM TESTING Armature Test for Shorts Check armature for short circuits by placing on growler and holding hack saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Re- check after cleaning between commutator bars. If saw blade still vibrates, replace arma- ture.
  • Page 123 CHARGING & STARTING SYSTEM Checking Positive Brushes and Terminal Set ohmmeter to (R x 1 scale). Connect meter leads between POSITIVE brushes. Meter must indicate full continuity or zero resistance. If resistance is indicated, inspect lead to brush and lead to POSITIVE terminal solder connection. If connection cannot be repaired, brushes must be replaced.

  • Page 124: Starter Reassembly

    CHARGING & STARTING SYSTEM Starter Reassembly 1. If brushes were removed, replace as follows: a. Install POSITIVE brushes (along with POSITIVE terminal) into commutator end cap. 11660 End Cap Positive Brushes Positive Terminal Insulating Bushing Washer Split Washer Hex Nut Long Brush Lead Push Lead into Slot 90-884294 OCTOBER 2001...
  • Page 125 CHARGING & STARTING SYSTEM b. Install NEGATIVE brushes (along with brush holder). 11656 Positive (+) Brushes Negative (–) Brushes Brush Holder Bolts (fasten negative brushes and holder) 2. If removed, reinstall parts on armature shaft. Use a new locknut and tighten securely on end of shaft.
  • Page 126 CHARGING & STARTING SYSTEM 6. To prevent damage to brushes and springs when installing commutator end cap, it is recommended that a brush retaining tool be made as shown: 18-Gauge Sheet Metal METRIC SCALE 3” = 76.2mm = 50.8mm 2” = 44.5mm 1-3/4”...
  • Page 127 CHARGING & STARTING SYSTEM 8. Place springs and brushes into brush holder and hold in place with brush retainer tool. 11661 Bushing Retainer Tool Bushing (do not over lubricate) 9. Install armature into starter frame and align match marks (a). Install commutator end cap onto starter frame and align match marks (b).
  • Page 128 CHARGING & STARTING SYSTEM STARTER SOLENOID TEST 1. Disconnect all wires from solenoid. 2. Use an ohmmeter (R x1 scale) and connect meter leads between solenoid terminals 1 and 2. 3. Connect a 12-volt power supply between solenoid terminals 3 and 4. Solenoid should click and meter should read 0 ohms (full continuity).

  • Page 129: Starter Motor (Solenoid Driven Bendix)

    CHARGING & STARTING SYSTEM Starter Motor (Solenoid Driven Bendix) 58430 Page 2B-38 90-884294 OCTOBER 2001...
  • Page 130 CHARGING & STARTING SYSTEM Starter Motor (Solenoid Driven Bendix) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft THRU BOLT 12.5 SCREWS END CAP BUSHING BRUSH PLATE ASSEMBLY ARMATURE FIELD FRAME SOLENOID SHIELD CUSHION PLANETARY GEARS PLUG DISC SHIFT FORK GEAR/CLUTCH ASSEMBLY BEARING HOUSING SCREW DRIVE GEAR...

  • Page 131: Troubleshooting The Solenoid Driven Bendix Starter Circuit

    CHARGING & STARTING SYSTEM Troubleshooting the Solenoid Driven Bendix Starter Circuit Before beginning the troubleshooting flow chart, verify the following conditions: 1. Confirm that battery is fully charged. 2. Check that control lever is in “NEUTRAL” position. 3. Check terminals for corrosion and loose connections. 4.

  • Page 132: Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)

    CHARGING & STARTING SYSTEM Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix) Starter Motor Does Not Turn TEST 1 With ignition key in START position, check for battery volt- age at TEST POINT 1. Voltage indicated and solenoid clicks No voltage indicated Voltage indicated and solenoid does not click Go to TEST 2 Check for starter motor ground at Test Point 10...
  • Page 133 CHARGING & STARTING SYSTEM 12 Volt Reading No voltage reading: Defective starter solenoid proceed to TEST 5 TEST 5 12 Volt Reading* a. Connect voltmeter between common Neutral start switch is open or YELLOW/RED engine ground and Test Point 5. No voltage reading: wire is open between Test Points 5 and 4.

  • Page 134: Starter Removal (Solenoid Driven Bendix)

    CHARGING & STARTING SYSTEM Starter Removal (Solenoid Driven Bendix) CAUTION Disconnect battery leads from battery before removing starter. 1. Disconnect battery cables from battery. 2. Disconnect wires from starter solenoid terminals. 3. Remove starter trunion mounting bolts and remove starter from engine. 59038 Starter Solenoid Mounting Bolts...
  • Page 135 CHARGING & STARTING SYSTEM 2. Secure BLACK cables (with RED sleeves) to POSITIVE (+) terminal on starter sole- noid. Torque nut to 55 lb-in (6 Nm). 59038 Top Bolts [Torque to 23 lb-ft (31 Nm)] Bottom Bolts [Torque to 21 lb-ft (28.5 Nm)] BLACK Cable (with RED sleeve) Nut [Torque to 55 lb-in (6 Nm)] Starter Solenoid...

  • Page 136: Disassembly (Solenoid Driven Bendix Starter) 2B-45

    CHARGING & STARTING SYSTEM Disassembly (Solenoid Driven Bendix Starter) 1. Remove brush lead from solenoid and through bolts from end frame. 58434 Brush Lead Brush Plate Screws Through Bolts End Frame Starter Solenoid 2. Remove armature and field frame from drive housing. NOTE: Permanent magnets inside field frame will be holding armature in place.
  • Page 137 CHARGING & STARTING SYSTEM 3. Remove shield and cushion from drive housing. 58432 Shield Cushion Drive Housing 4. Remove 3 screws retaining starter solenoid. Remove solenoid from drive housing. 5. Remove snap ring and gear from starter shaft. 58436 Drive Housing Snap Ring Starter Solenoid Pinion Gear...
  • Page 138 CHARGING & STARTING SYSTEM 6. Remove planetary gear and clutch assembly from drive housing. 7. Remove solenoid arm, metal disc and plug from drive housing. 58437 Planetary Gear and Metal Disc Clutch Assembly Solenoid Arm Drive Housing Plug 8. Inspect drive housing needle bearing for roughness. If bearing is worn or damaged, bearing can be removed by using an appropriate mandrel to drive/press bearing from drive housing.

  • Page 139: Cleaning And Inspection

    CHARGING & STARTING SYSTEM Cleaning and Inspection IMPORTANT: Do not use grease dissolving solvents to clean electrical compo- nents, planetary gears or drive clutch. Solvent will damage insulation and wash the lubricant out of the clutch drive and gears. Use clean rags and compressed air to clean components.

  • Page 140: Reassembly (Solenoid Driven Bendix Starter) 2B-49

    CHARGING & STARTING SYSTEM Reassembly (Solenoid Driven Bendix Starter) 1. Install solenoid arm with planetary gear and clutch assembly into drive housing. 58438 Solenoid Arm Planetary Gear and Clutch Assembly Drive Housing 2. Install metal disc and plug into drive housing. 58433 Metal Disc Plug...
  • Page 141 CHARGING & STARTING SYSTEM 3. Attach solenoid arm to starter solenoid. Install starter solenoid in drive housing and secure with 3 screws. Torque screws to 40 lb-in (4.5 N.m). 4. Install drive gear and secure with snap ring. 5. Reinstall rubber bumpers on housing. 58436 Drive Housing Drive Gear...
  • Page 142 CHARGING & STARTING SYSTEM 7. Install field frame over armature. 8. While holding brushes back, slide brush plate onto armature while aligning brush lead grommet with slot in field frame. 9. Secure end plate to brush assembly with 2 screws. Torque screws to 30 lb-in (3.4 Nm) NOTE: Prior to installing field frame assembly into drive housing, align slot in field frame with plug in drive housing.
  • Page 143 CHARGING & STARTING SYSTEM 10. Install field frame and end frame in drive housing. 11. Install through bolts and brush lead. Torque through bolts to 110 lb-in (12.5 Nm). Torque brush nut to 55 lb-in (6 Nm). 58434 End Frame Field Frame Drive Housing Through Bolts [Torque to 110 lb-in (12.5 Nm)]...

  • Page 144: Commander 2000 Key Switch Test

    CHARGING & STARTING SYSTEM Commander 2000 Key Switch Test 1. Disconnect remote control wiring harness and instrument panel connector. 2. Set ohmmeter on R x 1 scale for the following tests. 3. If meter readings are other than specified in the following tests, verify that switch and not wiring is faulty.
  • Page 145 TIMING, SYNCHRONIZING & ADJUSTING ELECTRICAL Section 2C - Timing, Synchronizing & Adjusting Table of Contents Specifications ......2C-1 Maximum Throttle Adjustment .
  • Page 146 TIMING, SYNCHRONIZING & ADJUSTING Special Tools 1. Digital Diagnostic Terminal (DDT) 91-823686A2 2. Software Cartridge 91-880118A2 3. DDT Reference Manual 90-881204-1 4. Adaptor Harness 84-822560A5 (use with DDT) Page 2C-2 90-884294 OCTOBER 2001...
  • Page 147 TIMING, SYNCHRONIZING & ADJUSTING Adjustments IMPORTANT: All throttle linkage adjustments have been set at factory and appro- priately secured to prevent unnecessary readjustment. These factory settings en- able this engine to meet federally mandated emission standards and should not be tampered with.
  • Page 148 TIMING, SYNCHRONIZING & ADJUSTING Timing All timing adjustments are controlled by the Electronic Control Module (ECM). No external mechanical timing adjustments can be made. Actual engine timing can be monitored by using a Digital Diagnostic Terminal (DDT). Ignition timing at idle, whether in gear or in neutral, will vary. The ECM will use ignition timing to maintain an rpm of approximately 700 in neutral and 625 in forward gear.
  • Page 149 TIMING, SYNCHRONIZING & ADJUSTING Throttle Position Sensor The Throttle Position Sensor (TPS) is not adjustable. The Throttle Position Sensor func- tion can be monitored by using the DDT. All voltages should be within specifications listed. Voltage progression from idle to wide open throttle should be smooth. If voltage is out of specification or progression is erratic, TPS should be replaced.
  • Page 150 TIMING, SYNCHRONIZING & ADJUSTING Throttle Plate Screw IMPORTANT: Do not adjust throttle plate stop screw from factory setting. However, should the throttle plate require adjustment, use the throttle plate stop screw to set the total throttle plate clearance @ 0.040 in. (1.0 mm) or 0.020 in. (0.50 mm) each side.
  • Page 151 ... . . 2D-66 Standard Information Display Screens 2D-23 3 Liter Work/225 EFI/250 EFI Display of Range and Depth Information 2D-25 Wiring Diagram ......

  • Page 152: Power Trim Wiring Diagram

    WIRING DIAGRAMS Power Trim Wiring Diagram Tach. Connector Trim Pump and Motor Key Switch Assembly DOWN Solenoid Trim Switch UP Solenoid Trim Sender Bottom Cowl Switch Start Solenoid 20 Ampere Fuse To Battery Engine Harness To Alternator Remote Control Harness Page 2D-2 90-884294 OCTOBER 2001...

  • Page 153: Instrument Wiring Connections

    WIRING DIAGRAMS Instrument Wiring Connections Wire Color Where To BLACK GROUND Speedometer Tachometer TAN/WHT = TAN/WHITE OIL LIGHT TAN/BLK = TAN/BLACK TEMPERATURE LIGHT Temperature/Oil TEMPERATURE GAUGE PURPLE IGNITION 12 VOLT Volt Meter GRAY TACHOMETER BRN/WHT = BROWN/WHITE TRIM GAUGE TAN/BLU = TAN/BLUE VISUAL WARNING KIT (OPT.) 58912...

  • Page 154: Commander 3000 Classic Panel Remote Control

    WIRING DIAGRAMS Commander 3000 Classic Panel Remote Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red Tan = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...

  • Page 155: Commander 3000 Panel Remote Control

    WIRING DIAGRAMS Commander 3000 Panel Remote Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...

  • Page 156: 4000 Series Mechanical Panel Control

    WIRING DIAGRAMS 4000 Series Mechanical Panel Control BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark...

  • Page 157: Instrument/Lanyard Stop Switch Wiring Diagram

    WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram BLK=BLACK BLU=BLUE BRN=BROWN GRN=GREEN GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW 52204 Ignition/Choke Switch Lanyard Stop Switch Lead Not Used on Outboard Installations Retainer Tachometer Trim Indicator Gauge (Optional) Temperature Gauge Remote Control Power Trim Harness Connector Connect Wires Together w/Screw and Nut (2 Places);...

  • Page 158: Oil Level Gauge Wiring Diagram

    WIRING DIAGRAMS Oil Level Gauge Wiring Diagram To 12 Volt Source PURPLE Wire (Connect to Trim Indicator Gauge “I” [or POSITIVE (+) 12 Volt Source that is Turned “ON” and “OFF” with Ignition Switch]) Oil Level Gauge BLACK Wire (Connects to NEGATIVE Ground) To Ground BLACK Wire (From Gauge to Oil Clip Connector) LIGHT BLUE Sender Lead to Gauge...

  • Page 159: Notes

    WIRING DIAGRAMS Notes: 90-884294 OCTOBER 2001 Page 2D-9...

  • Page 160: Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)

    WIRING DIAGRAMS Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) BLK=BLACK BATT GND BLU=BLUE BRN=BROWN GRN=GREEN SENDER GRY=GRAY PUR=PURPLE RED=RED TAN=TAN WHT=WHITE YEL=YELLOW 52205 PORT INSTALLATION Ignition/Choke Switch Lanyard Stop Switch Lead not used on Outboard Installations Retainer Tachometer Trim Indicator Gauge Temperature Gauge Remote Control Page 2D-10...
  • Page 161 WIRING DIAGRAMS IMPORTANT: On installations where gauge options will not be used, tape back and isolate unused wiring harness leads BATT GND SENDER STARBOARD INSTALLATION 52206 Synchronizer Gauge Synchronizer Module Lanyard Switch (Isolation) Diode Y Harness Power Trim Harness Connector Connect Wires together with Screw and Nut (4 Places);...

  • Page 162: Qsi Gauge Wiring Diagrams

    WIRING DIAGRAMS QSI Gauge Wiring Diagrams Tachometer Wiring Diagram Tachometer dial on back side of case must be set to position number 4. WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. 51106 Connect to +12 Volt +12 Volt Light Switch Wire Position Light Bulb to the Switched Position...

  • Page 163: Water Temperature Gauge

    WIRING DIAGRAMS Water Temperature Gauge WIRING DIAGRAM A Use this wiring diagram when using a separate light switch for instrument lighting. SEND Connect to + 12 Volt +12 Volt Light Switch Wire Position Light Bulb to the Switched Position Connect to NEGATIVE (–) Ground Connect to TAN Lead located at the Tachometer Receptacle on Commander Side Mount Remote Control or TAN Lead coming from Accessory Ignition/ Choke Assembly.

  • Page 164: Oil Level Gauge Wiring

    WIRING DIAGRAMS Route TAN lead on starboard side of engine to engine/remote control harness. Connect as shown. IMPORTANT: Tape back and isolate any unused wiring harness leads. 28086 Lead from Temperature Sender Engine/Remote Control Harness Oil Level Gauge Wiring LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting.
  • Page 165 WIRING DIAGRAMS LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch. (In- strument lights are on when ignition key switch is turned on.) 51112 Position Light Bulb to the Unswitched Position Sender SENDER WIRING 51108...

  • Page 166: Engine Synchronizer Wiring Diagram

    WIRING DIAGRAMS Engine Synchronizer Wiring Diagram LIGHT BULB POSITION A Use this position when using a separate light switch for instrument lighting. SEND 51105 +12 Volt Light Switch Wire Position Light Bulb to the Unswitched Position LIGHT BULB POSITION B Use this position when instrument lighting is wired directly to the ignition key switch.

  • Page 167: Maintenance

    WIRING DIAGRAMS Synchronizer wiring can be accomplished two different ways as an option to the user. Wiring Diagram – Gauge needle to point toward slow running engine GRY=GRAY WHT=WHITE BLK=BLACK PUR=PURPLE 51107 Tachometer Starboard Engine Synchronizer Gauge Tachometer Port Engine Synchronizer Module Wiring Diagram –...

  • Page 168: Warning System Signals

    WIRING DIAGRAMS Warning System Signals NOTE: The warning system signals which includes audible and visual indicator involving the horn and gauges will identify the potential problems listed in the chart Problem Horn Monitor Display Guardian Acti- Engine Speed vated Reduction Activated Power Up/System Check Single Beep...

  • Page 169: Guardian Protection System

    WIRING DIAGRAMS Guardian Protection System The guardian protection system monitors critical engine functions and will reduce engine power accordingly in an attempt to keep the engine running within safe operating parameters. IMPORTANT: The Guardian System cannot guarantee that powerhead damage will not occur when adverse operating conditions are encountered.
  • Page 170 WIRING DIAGRAMS Engine Overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum allowable RPM. The system will limit the engine speed to within the allowable range. If the overspeed condition continues, the Engine Guardian System will place the engine in power reduction.

  • Page 171: Analog Gauge Panel Mount Remote Control Wiring Installation

    WIRING DIAGRAMS Analog Gauge Panel Mount Remote Control Wiring Installation BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White Liquid Neoprene YEL = Yellow...

  • Page 172: System Monitor V2.0

    WIRING DIAGRAMS System Monitor V2.0 Basic Operation The System Monitor is an LCD multi-function display gauge. A variety of displays can be activated using the button. Pressing the button scrolls the following displays: fuel used, tachometer (RPM), fuel flow, power trim position, engine temp, water pressure, battery voltage, traveling range (if calibrated), and water depth (if equipped with transducer).

  • Page 173: Standard Information Display Screens

    WIRING DIAGRAMS NOTE: If you see the flashing message, (A) “nonE” after the Auto–detection occurs, the gauge can not find an engine. Please check wiring for correct connection. If you receive one of the following other flashing messages: (B) “Stbd”or, (C) “noSt” refer to the “Set–Up Errors Section”.
  • Page 174 WIRING DIAGRAMS FUEL FLOW SCREEN The System Monitor displays current estimated individual engine fuel consumption in Gallons per hour (Gal/hr) or Liters per hour (Ltr/hr). Gal/h TRIM POSITION SCREEN Displays trim position of the propulsion unit up to the maximum trim position, and then dis- plays trailer position.

  • Page 175: Display Of Range And Depth Information

    WIRING DIAGRAMS OIL PRESSURE SCREEN Displays engine oil pressure in Psi or Bar. BATTERY VOLTAGE SCREEN Displays voltage level (condition) of battery. Volt Display of Range and Depth Information RANGE SCREEN Displays estimated traveling range based on current fuel consumption and fuel remaining in the tank that is connected to the system.

  • Page 176: Warning System

    WIRING DIAGRAMS SHALLOW WATER ALARM FEATURE You can set an alarm to trigger whenever the boat moves into water shallower than the alarm level. Setting Shallow Water Alarm. 1. The water depth screen must be displayed. Be sure Depth is turned on in Cal2 . Refer to Cal2 Calibration Section for details.

  • Page 177: Warning Display Screens

    WIRING DIAGRAMS Warning Display Screens The engine has an “Engine Guardian System”. The ECM Engine control module monitors the critical sensors on the engine for any early indications of problems. The Guardian System will respond to a problem by reducing engine speed in order to maintain a safe operating condi- tion.
  • Page 178 WIRING DIAGRAMS If no water is coming out of the water pump indicator hole, or flow is intermittent, stop engine and check cooling water intake holes for obstruction. If no obstruction is found, this may indicate a blockage in the cooling system or a water pump problem. Have the outboard checked by your dealer.
  • Page 179 WIRING DIAGRAMS ALARM – WATER IN FUEL The Bell and Fuel Icon will appear and the warning horn will begin sounding a series of four beeps every two minutes when water in the water-separating fuel filter reaches the full level. On some engines water can be removed from the filter.

  • Page 180: Cal1 Calibration

    WIRING DIAGRAMS CAL1 Calibration Cal1 Display Calibrations: Trim Pop up Screen (On or Off) Trim Calibration English or Metric Units Selection Range Units Selection (On or Off) Depth, Trim, Engine Temperature, Oil Pressure, Oil Temperature, Water Pressure, Volts, Engine Hours, and Data Simulator pages.
  • Page 181 WIRING DIAGRAMS Calibration 10.0 – The word “Trim” and the down and up arrows should be blinking. Trim the unit out to the maximum trim (not trailer) position. Press the button to save. Press button to advance to the Calibration 25.0 setting. Trim Calibration 25.0 –...

  • Page 182: Cal2 Calibration

    Select the PSI input of the Pitot water pressure sensor on the engine. Press the button to select 1 = 100 PSI or 2 = 200 PSI. The standard PSI input on production Mercury product is 100 PSI. Certain High Performance applications may require a 200 Psi input.
  • Page 183 WIRING DIAGRAMS FUEL TANK CALIBRATION: NOTE: There are three methods to set up fuel tank level monitoring feature: First: Do nothing. Linear readout based on raw sensor values. This mode does not factor in irregular tank shapes. Second: By following the tank calibration procedure described on pages 33–35, but with- out actually adding fuel.
  • Page 184 WIRING DIAGRAMS Selecting “1” will bring up the following calibration screens. Calibration 0% – The “0 percent” display alternates between percent of tank capacity and quantity of fuel to add based on total capacity entered in Cal2. Add fuel to total quantity dis- played and push the button to save.

  • Page 185: Master Reset Command

    WIRING DIAGRAMS At this point you have completed tank 1 calibration and you will see “t2”. Change “t20” to a 1 (on). Press the button, you will see a blinking tank icon. Using the button, select which tank you want tank 2 to be, (oil, fuel or water/waste). Press the button to continue.

  • Page 186: System Tach & Speed

    The intention is to make initial setup easier. If gauge shows a warning of “No Starboard Engine” or “Multiple Starboard Engines”, engine will need to be properly selected (Port and Stbd) using a Mercury engine diagnostic tool. “Master Reset” and “Auto detect” again. (See page 45 for “Master Reset”).

  • Page 187: Speedometer Display Screens

    WIRING DIAGRAMS Speedometer Display Screens Speedometer NOTE: NOT ALL SCREENS MAY APPLY TO YOUR ENGINE TYPE. When the ignition is turned on, the speedometer will show the last screen that was dis- played before the ignition was turned off. MODE Press to change display screens.

  • Page 188: Tachometer Display Screens

    WIRING DIAGRAMS Tachometer Display Screens Tachometer VOLT 22.3 13.6 USED FUEL 22.0 3200 WATER NOTE: NOT ALL SCREENS MAY APPLY TO YOUR ENGINE TYPE. When the ignition is turned on, the tachometer will display the last screen that was dis- played before the ignition was turned off.

  • Page 189: Troll Control

    WIRING DIAGRAMS Troll Control BASIC OPERATION Speedometer Tachometer TROLL TROLL TROLL TROLL – – Actual Speed Set Speed Actual Speed Set Speed With troll control you can maintain a trolling speed of 550 to1000 rpm without using the throttle. NOTE: Troll control may not be available on all engine models. NOTE: Troll control min/max range may change depending on engine type.

  • Page 190: Warning System

    WIRING DIAGRAMS SETTING TROLL CONTROL Tachometer Speedometer TROLL TROLL TROLL – TROLL – Actual Speed Set Speed Actual Speed Set Speed 1. With the engine running, shift engine into gear. Set engine speed at idle. TROLL TROLL 2. Push in the button to bring up the troll control display screen.

  • Page 191: Alarm Messages

    WIRING DIAGRAMS Alarms Warnings – When a problem is detected, the warning horn sounds and the name of the offending alarm appears on the display. If problem can cause immediate engine damage – the horn will sound continuously and the Engine Guardian System will respond to the problem by limiting engine power. Im- mediately reduce throttle speed to idle and refer to the warning messages on the fol- lowing pages that tell what to do.
  • Page 192 WIRING DIAGRAMS OVERHEAT The overheat alarm message appears and the warning horn begins sounding continuously. The Engine Guardian System will start limiting engine power. If the engine overheats, immediately reduce throttle speed to idle. Shift engine into neu- tral. Check for an obstruction covering the water intake holes on the engine. NOTE: The throttle will have to be returned to idle to reset the system.
  • Page 193 WIRING DIAGRAMS If the warning signals stop and a steady stream of water is coming out of the water pump indica- tor hole, return engine to normal operation. If the warning system is activated repeatedly, have the outboard checked by your dealer. OVERSPEED (a) This message is displayed and the warning horn begins sounding continuously to inform the driver that the engine speed exceeded the maximum allowable RPM.
  • Page 194 WIRING DIAGRAMS BATTERY (a) When the electrical system is not charging, or the battery charge is low, the warning message is designed to come on and the Engine Guardian System will start limiting engine power. If the message appears immediately after starting, it is possible that the engine alternator can re- charge the battery after operating awhile.

  • Page 195: Auto-Detection Engine Function

    WIRING DIAGRAMS WARNING NO STARBOARD ENGINE (a) Informs you that the Instrument does not see the starboard engine computer. Usually indicates that no data is being transferred from the engine’s computer to the gauge. (Check wiring, also make sure both terminator resistors are installed in the bus). Make sure both ECM’s are not configured for port location using a DDT or Quicksilver Diagnostic Tool.

  • Page 196: Tachometer Calibration

    WIRING DIAGRAMS Tachometer Calibration Quick Cal – This calibration for setting lighting and contrast. TROLL MODE 1. Press in the buttons for up to 2 seconds to get to Quick Cal screen. MODE 2. Press to advance through the lighting and contrast sections. Cal1 –...
  • Page 197 WIRING DIAGRAMS Choosing edit allows you to calibrate the gauge to the stan- CALIBRATION dard 0–10 unit trim and 11–25 trailer position scale. TRIM CALIBRATION [SKIP] [EDIT] TRIM FULL DOWN THEN PRESS PLUS (+) BUTTON [SAVE] [DFLT] [SKIP] TRIM FULL UP THEN PRESS PLUS (+) BUTTON [SAVE] [DFLT]...
  • Page 198 WIRING DIAGRAMS WATER PSI SCREEN? Do you want to turn on the water pressure screen? [NO] [SAVE] [YES] TRIM AND RPM SCREEN? Do you want to turn on the trim and RPM split screen? [NO] [SAVE] [YES] RPM SCREEN? Do you want to turn on the digital RPM screen? [NO] [SAVE] [YES]...
  • Page 199 WIRING DIAGRAMS TACH CALIBRATION – CAL 2 LEVEL SPEED OPTION This section lets you configure the following speed sensors. [SKIP] [EDIT] PITOT SENSOR? Select pitot transducer type. You can choose 100 or 200 PSI. (100 PSI is the most common) [SAVE] [NO] [YES]...

  • Page 200: Speedometer Calibration

    WIRING DIAGRAMS FILL TO 1/2 THEN PRESS PLUS You can choose to have tank at 1/2 and hit SAVE, or hit DFLT and BUTTON a default value will be entered based on the capacity of the tank. [DFLT] [SKIP] [SAVE] FILL TO 3/4 THEN PRESS PLUS You can choose to have tank at 3/4 and hit SAVE, or hit DFLT and BUTTON...
  • Page 201 WIRING DIAGRAMS SPEEDOMETER CALIBRATION CAL 1 LEVEL REMOTE LCD LIGHT? Enables you to set the lighting levels on all the SC1000 simulta- neously from this gauge. [YES] [NO] [SAVE] REMOTE LCD CONTRAST? Enables you to control the contrast from another System TACH/ Speed simultaneously from this gauge.

  • Page 202: Smartcraft Gauge Operation

    WIRING DIAGRAMS AIR TEMP? Are you using a air temp. sensor? [SAVE] [NO] [YES] GPS? Do you have a GPS sensor installed? [NO] [SAVE] [YES] USE GPS SPEED? Use the GPS input to drive the speed display? [SAVE] [NO] [YES] WATER TEMPERATURE ADJUST Adjust water temp.

  • Page 203: Speedometer Display Screen

    WIRING DIAGRAMS Speedometer Display Screen Speedometer When the ignition is turned on, the speedometer will show the last screen that was dis- played before the ignition was turned off. NOTE: Readings can be displayed in English or Metric. Refer to Calibration. MODE Press to change display screens.

  • Page 204: Tachometer Display Screens

    WIRING DIAGRAMS Tachometer Display Screens Tachometer When the ignition is turned on, the tachometer will display the last screen that was dis- played before the ignition was turned off. MODE Press to change display screens. You can revert back to the previous screen by MODE pressing and holding for 2 seconds.

  • Page 205: Troll Control

    WIRING DIAGRAMS Troll Control Tachometer Speedometer TROLL TROLL TROLL TROLL – – Actual Speed Set Speed Actual Speed Set Speed Flashing Signal “TR” BASIC OPERATION With Troll control you can maintain a trolling speed of 450 to1000 rpm without using the throttle.

  • Page 206: Warning System

    WIRING DIAGRAMS EXITING TROLL CONTROL There are three ways to turn off the troll control: MODE Press the button when in the troll display screen. Move the throttle to a different speed. Shift outboard into neutral. Warning System Display Screens Engine Guardian System Alarm Signal “AL”...

  • Page 207: Alarm Messages

    WIRING DIAGRAMS Alarm Messages These messages will appear and the horn will sound if there is a problem detected in one of the outboard systems. NOTE: The warning system will alert the operator to the potential problems listed in the chart.
  • Page 208 WIRING DIAGRAMS NOTE: If you are in a stranded situation, stopping the engine and allowing it to cool back down will usually allow some additional low speed (idle) running time before the engine starts to overheat again. The overheat problem must be corrected before you can resume normal operation. PRESSURE Water Pump Indicator Hole This alarm message is displayed and the warning horn begins sounding continuously to...
  • Page 209 WIRING DIAGRAMS RESERVE OIL LOW (a) This message will appear and the warning horn will begin sounding a series of four beeps every two minutes to inform the driver that the oil level is critically low in the engine mounted oil reservoir tank.
  • Page 210 WIRING DIAGRAMS BATTERY (a) The warning message is designed to come on and the Engine Guardian System will start limiting engine power when the electrical system is not charging or the battery charge is low. If the message appears immediately after starting, it is possible that the engine alter- nator can recharge the battery after operating awhile.

  • Page 211: Tachometer Calibration

    WIRING DIAGRAMS Tachometer Calibration NOTE: When calibrating multi tachometers (multi engines) turn ignition on for all the tachometers. Simple Calibration – This calibration for setting lighting and a few other common screens can be made while engine is running. TROLL MODE 1.
  • Page 212 WIRING DIAGRAMS Display boat speed in KN (knots), KPH (kilometers per hour), CALIBRATION MPH (miles per hour). Press + or – to select setting. Press SPEED UNITS KN - KPH - MPH MODE to save. [SAVE] [DOWN] [UP] Press MODE to skip to the next display. Press + (edit) if your CALIBRATION adding or deleting any external sensor to the SmartCraft Sys- EXTERNAL SENSORS...
  • Page 213 WIRING DIAGRAMS Add the capacity of the oil tank. Press + or – to select. Press CALIBRATION MODE to save. OIL TANK CAPACITY CAPACITY = XX.XX [DOWN] [SAVE] [UP] This calibration accurately adjusts the oil level sending unit in CALIBRATION the oil tank.

  • Page 214: Speedometer Calibration

    WIRING DIAGRAMS If the trim setting is not reading correctly, the trim sensor can CALIBRATION be re-calibrated to correct the setting. TRIM CALIBRATION Pressing DFLT (default) during edit will return to original value [SKIP] [EDIT] setting Press MODE to skip to the next display. Press + (edit) to cali- CALIBRATION brate the sensor.
  • Page 215 WIRING DIAGRAMS If the clock display is correct , press MODE to skip. CALIBRATION To set or reset the clock Press + TIME [SKIP] [EDIT] Select 12 hour or 24 hour clock set. Press – or + to select. Press MODE to save. CALIBRATION TIME FORMAT 12H –...

  • Page 216: Smartcraft Gauge Test Specifications

    WIRING DIAGRAMS SmartCraft Gauge Test Specifications Test Equipment Required: 1. Test Harness 84-875233A2 (a). 2. DMT 2000 Digital Tachometer Multimeter 91-854009A1 (b). NOTE: Connect negative DMT lead to BLACK/ORANGE lead on test harness 84-875233A2 for all tests. Use positive DMT lead on all other test harness leads to deter- mine if individual sensors are within specifications.

  • Page 217: Liter Work/225 Efi/250 Efi Wiring Diagram

    3 Liter Work/225 EFI/250 EFI Wiring Diagram 7 8 9 10 15 16 1 - Low Oil Switch 2 - Shift Switch 30 85 86 8787a A B C D E F G H A B C D E F G H J K...
  • Page 218 FUEL PUMP FUEL SYSTEM Section 3A - Fuel Pump Table of Contents Specifications ......3A-2 Checking Fuel Pump Lift (Vacuum) .

  • Page 219: Specifications

    4 psi (27.4 kPa) . Special Tools 1. Fuel Pressure Gauge (0–15 psi) (Obtain Locally) 57721 2. Anaolg or Digital Vacuum Gauge (0 – 10 inches of vacuum mercury). Obtain Locally 59157 Digital Vacuum Gauge Page 3A-2...

  • Page 220: Notes

    FUEL PUMP Notes: 90-884294 OCTOBER 2001 Page 3A-3...

  • Page 221: Fuel Pump Assembly

    FUEL PUMP Fuel Pump Assembly Page 3A-4 90-884294 OCTOBER 2001...
  • Page 222 FUEL PUMP Fuel Pump Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft FUEL PUMP ASSEMBLY DIAPHRAGM KIT DIAPHRAGM RETAINER SPRING SPRING DIAPHRAGM GASKET-BOOST GASKET-PULSE GASKET PLATE FITTING SCREW–FUEL PUMP (M5 x 40) SCREW–PUMP TO CRANKCASE (M6 x 50) BASE ELBOW STA STRAP HOSE CONNECTOR HOSE...

  • Page 223: Fuel Pump Description/Operation

    FUEL PUMP Fuel Pump Description/Operation The fuel pump is a crankcase-pressure-operated, diaphragm-type pump. Crankcase pul- sating pressure (created by the up-and-down movement of piston) is transferred to fuel pump by way of a passage (hole) between crankcase and fuel pump. When piston is in an upward motion, a vacuum is created in the crankcase, thus pulling in on the fuel pump diaphragm.

  • Page 224: Checking Fuel Pump Lift (Vacuum)

    FUEL PUMP Checking Fuel Pump Lift (Vacuum) The square fuel pump is designed to lift fuel (vertically) about 60 in. (1524 mm) if there are no other restrictions in the system using a fuel hose that is 5/16 in. (7.9 mm) minimum diameter.

  • Page 225: Fuel Pump Capability Test

    The vacuum gauge should rise to or exceed the maximum normal reading of 2.5 inches vacuum (mercury). If it fails to reach this minimum number, the pump needs servicing or there is a lack of crankcase pressure to operate the pump.

  • Page 226: Fuel Pump Removal/Disassembly

    FUEL PUMP Fuel Pump Removal/Disassembly IMPORTANT: Fuel pump diaphragm and gaskets should not be re-used once fuel pump is disassembled. 1. Disconnect fuel hoses from fuel pump. 2. Disconnect pulse hose. 3. Remove two mounting screws. 4. Remove fuel pump from engine. 59042 Fuel Inlet Fuel hose from fuel pump to Fuel/Water Separator...

  • Page 227: Cleaning/Inspection

    FUEL PUMP Cleaning/Inspection 1. Clean fuel pump housing, check valves, pulse chamber and pump base in solvent and dry all but check valves with compressed air. 2. Inspect each check valve for splits or chips. 3. Inspect boost springs for weakness or breakage. 4.
  • Page 228 FUEL PUMP 2. Install check valves and retainers into fuel pump body. 58887 3. With retainer installed in pump body, break retainer rod from retainer by bending side- ways. 23601 Retainer Cap 4. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap rod down into retainer until flush with top of retainer.
  • Page 229 FUEL PUMP 5. Place boost spring into pump body and place cap onto boost spring. 50161 Boost Spring Pump Body 6. Assemble remainder of components as shown and install retaining screws through to align. 59040 Reverse View of Pump Body INSTALLATION 1.
  • Page 230 FUEL INJECTION FUEL SYSTEM Section 3B - Fuel Injection Table of Contents Specifications ......3B-2 Detonation Control System Test Special Tools...

  • Page 231: Specifications

    FUEL INJECTION Specifications FUEL Idle RPM INJECTION – All Models Wide Open Throttle (WOT) RPM – All Models 5000 – 5800 Float Adjustment (Vapor Separator) Float Level Preset @ Factory Injectors – All Models (Quantity) – Injectors are Crank Angle Driven by ECM –...

  • Page 232: Special Tools

    FUEL INJECTION Special Tools 1. Fuel Pressure Gauge 91-852087A3 (a) or Fuel Pressure Gauge 91-881834A1 (b). 55294 58879 2. Digital Diagnostic Terminal (DDT) 91-823686T2 3. Software Cartridge 91-880118A2 4. DDT Reference Manual 90-881204-1 90-884294 OCTOBER 2001 Page 3B-3...
  • Page 233 FUEL INJECTION 5. Adaptor Harness 84-822560A5 (use with DDT) 6. Remote Starter Switch 91-52024A1 7. DMT 2000 Digital Tachometer Multi-meter 91-854009A1 8. Inductive Timing Light 91-99379 9. Spark Gap Tester 91-850439T 55117 10. Strap Wrench 91-24937A1 Page 3B-4 90-884294 OCTOBER 2001...

  • Page 234: Notes

    FUEL INJECTION 11. Tamper Proof Torx Screw Set 91-881828 58685 Notes: 90-884294 OCTOBER 2001 Page 3B-5...

  • Page 235: Fuel Management System

    FUEL INJECTION Fuel Management System Page 3B-6 90-884294 OCTOBER 2001...
  • Page 236 FUEL INJECTION Fuel Management System TORQUE REF. QTY. DESCRIPTION lb-in lb-ft – FUEL MANAGEMENT ASSEMBLY ADAPTOR PLATE GASKET REED BLOCK SCREW (M6 x 1) BUSHING GROMMET SCREW (M8 x 35) WASHER SCREW AIR PLENUM KIT GASKET SCREW BRACKET MAP SENSOR TEMPERATURE SENSOR O-RING THROTTLE BODY...
  • Page 237 FUEL INJECTION Fuel Management System Page 3B-8 90-884294 OCTOBER 2001...
  • Page 238 FUEL INJECTION Fuel Management System TORQUE REF. QTY. DESCRIPTION lb-in lb-ft FUEL TUBE O-RING ELBOW SCREW (10-24 x 0.375) RETAINER O-RING FUEL RAIL HARNESS CLAMP SCREW (M6 x 40) 11.3 90-884294 OCTOBER 2001 Page 3B-9...

  • Page 239: Vapor Separator Components

    FUEL INJECTION Vapor Separator Components Page 3B-10 90-884294 OCTOBER 2001...
  • Page 240 FUEL INJECTION Vapor Separator Components TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m COVER KIT FITTING - STRAIGHT FITTING - STRAIGHT ELBOW FITTING - STRAIGHT O-RING VALVE PLUG SEAL GASKET PRESSURE REGULATOR KIT O-RING KIT WASHER - RUBBER SCREW SCREW GROUND WIRE SCREW...

  • Page 241: Electronic Fuel Injection (Efl) System

    FUEL INJECTION Electronic Fuel Injection (EFl) System Introduction The troubleshooting information provided here consists of preliminary checks (checks to be followed before proceeding with EFI tests), diagrams (fuel flow and electrical wiring), component description (from diagrams), flow charts (low pressure fuel delivery, high pres- sure fuel delivery, fuel delivery vs.

  • Page 242: Fuel Injection System Function

    FUEL INJECTION CAUTION Wipe up fuel spills immediately. CAUTION Depressurize fuel system prior to opening line connections or removing fuel sys- tem components. DANGER Perform the tests in this section in a well ventilated area to avoid being overcome by fuel vapors or poisonous exhaust gases. Fuel Injection System Function Fuel is delivered directly to the engine by way of fuel injectors.

  • Page 243: Electronic Fuel Injection Set Up

    FUEL INJECTION Electronic Fuel Injection Set Up IMPORTANT: Follow EFI Synchronizing/Adjustment section 2C before attempting tests on EFI system. EFI set up procedures must be followed before tests on system are performed (refer to Section 2C). Improper set up can result in poor engine performance (i.e. uncontrollable idle speeds, lean sneezing, low power during acceleration or engine will simply not run.) Failure to properly set up the EFI system can lead to misdirections in solving simple prob- lems in the EFI system.

  • Page 244: Fuel Flow Diagram

    FUEL INJECTION Fuel Flow Diagram 58901 Fuel Rail Electric Fuel Pump Reed Block Plate Assembly Vapor Separator Float Fuel Injectors (6) Needle and Seat Pulse Fuel Pump Vapor Separator to Flywheel Cover Vent Hose Fuel/Water Separator Final Filter Water Sensor Fuel Rail Pressure Port From Fuel Tank Fuel Pressure Regulator...

  • Page 245: Fuel Flow Component Description

    FUEL INJECTION Fuel Flow Component Description Pulse Fuel Pump (d) The pulse fuel pump operates through alternating crankcase pressure to deliver fuel through the water separating filter to the vapor separator. Fuel pressure @ Idle: 2 – 3 psi (13.8 – 20.7 kPa) [Minimum – 1 psi (6.9 kPa)]. Fuel Pressure @ Wide-Open-Throttle: 6 –...

  • Page 246: Efi Electrical Components

    FUEL INJECTION EFI Electrical Components ELECTRONIC CONTROL MODULE (ECM) The ECM is continually monitoring various engine conditions (engine temperature, engine detonation control (Model 200 only), engine throttle opening and climate conditions (induc- tion air temperature, barometric pressure and altitude level) needed to calculate fuel deliv- ery (pulse width length) of injectors.
  • Page 247 FUEL INJECTION ENGINE HEAD TEMPERATURE SENSOR (PORT AND STARBOARD CYLINDER HEAD) The Engine Head Temperature Sensors provide the ECM signals related to engine tem- perature, to determine level of fuel enrichment during engine warm up. The ECM is receiv- ing information at all engine temperatures. Disconnecting the temperature sensors or tem- perature sensor failure will cause the ECM to revert to a default temperature source of 32 F (0 C).

  • Page 248: Efi Fuel Management (Low Pressure Fuel Route)

    FUEL INJECTION EFI Fuel Management (Low Pressure Fuel Route) Install fuel pressure gauge on to VST pres- sure port. Place ignition switch in “OFF” position 30 sec- onds before testing. Place ignition switch in “ON” position and note pressure within 30 seconds (41 to 45 psi; 283 to 310 kPa).

  • Page 249: Efi Fuel Management (High Pressure Fuel Route)

    FUEL INJECTION EFI Fuel Management (High Pressure Fuel Route) Perform low pressure checks before performing checks on high pressure route. Install fuel pressure gauge (P/N 91-852087A3) or (P/N 91-881834A1) on to manifold pressure port. Place ignition switch in “OFF” position 30 seconds before testing.

  • Page 250: Fuel Rail Electrical/Fuel Determination

    FUEL INJECTION Fuel Rail Electrical/Fuel Determination Perform all preliminary checks page 3B-13. Adequate fuel pressure (41 to 45 psi; 283 to 310 kPa) follow Low/High Fuel Route Flow Charts. Run engine @ idle and with DDT, perform cylinder load test. Results Results No RPM change on cylinder(s),...

  • Page 251: Efi System Test Procedures

    FUEL INJECTION EFI System Test Procedures NOTE: A clogged final filter located in fitting above fuel pump will cause low fuel pressure readings at the fuel pressure port. Remove fuel fitting and inspect final filter. Clean and/or replace final filter as necessary. Final Filter Fuel Gauge Connection/Pressure Test IMPORTANT: When checking fuel pressure while engine is running, fuel pressure...

  • Page 252: Vapor Separator Fuel Delivery Test

    FUEL INJECTION 2. Turn ignition key switch to “ON” position. START 3. Operate electric fuel pump (ignition key on). NOTE: Fuel pump will only operate for approximately 2-4 seconds. By turning the key switch to “OFF” and then back to “ON” the pump will operate for 2-4 seconds more. 4.

  • Page 253: Pulse Fuel Pump Delivery Test

    FUEL INJECTION Pulse Fuel Pump Delivery Test Purpose: This test will indicate pulse fuel pump is capable of supplying the low pressure fuel route with ade- quate fuel supply. 1. Place emergency stop switch in OFF position to prevent engine from starting. 2.

  • Page 254: Water Separating Filter Inspection

    FUEL INJECTION Results: If low or no fuel flow is present, inspect fuel hose for restrictions. Inspect anti-siphon valve and boat fuel tank for proper fuel delivery. If fuel flow is present, remove, disassemble and inspect pulse fuel pump. All fragments of failed pump must be located before reassembly. 59042 Pulse Fuel Pump Attaching Screws...

  • Page 255: Vapor Separator Float Test

    FUEL INJECTION Vapor Separator Float Test NOTE: If squeezing the primer bulb in the Vapor Separator Fuel Delivery Test previous provides adequate fuel to the vapor separator, the vapor separator float, needle and seat is functioning properly and the following test does not need to be performed. Purpose: This test will indicate if float is stuck in the up (closed) position.
  • Page 256 FUEL INJECTION Electric Fuel Pump Inlet Filter Check and De-Pressurizing EFI System Procedures Purpose: Checking the inlet filter for obstructions, damage etc. eliminates this component as a possible source of restriction in the system. 1. De-pressurize EFI fuel system by wrapping a clean cloth around pressure port valve and inserting tip of screwdriver into valve, depressing valve core.
  • Page 257 FUEL INJECTION 3. Remove 3 bolts securing vapor separator assembly to manifold. 59047 Bolts 4. Tilt vapor separator assembly out from manifold and remove 9 screws securing cover. 5. Remove vapor separator tank from cover. 6. Pull downward to remove filter from fuel pump. 59055 Inlet Filter 7.

  • Page 258: Pressure Regulator Test

    FUEL INJECTION Pressure Regulator Test NOTE: Low fuel pressure can be caused by inadequate fuel supply, a defective electric fuel pump or fuel pressure regulator. Verify adequate fuel is being supplied to the vapor separator. If fuel supply is proper, inspect final filter inside outlet fuel fitting on vapor sepa- rator for debris.
  • Page 259 FUEL INJECTION Electric Fuel Pump Voltage/Pressure Test NOTE: The Digital Diagnostic Terminal (DDT) can implement a load test for the electric fuel pump. If the electric fuel pump does not appear to run, it is recommended that the DDT load test be performed first before performing the following voltage test. Purpose: If insufficient electrical power is available at the pump, no or low fuel pressure will be developed.

  • Page 260: Injector Electrical Harness Test

    FUEL INJECTION Injector Electrical Harness Test An injector load test can be performed using the Digital Diagnostic Terminal (DDT). An au- dible click will be heard each time an injector is activated. If an injector does not respond to the load test, an ohm test can be made on the harness and the injector(s). 59058 59058 Injector Harness...

  • Page 261: Injector Load Test

    FUEL INJECTION Injector Load Test An injector load test can be performed using the Digital Diagnostic Terminal (DDT). An au- dible click will be heard each time an injector is activated. This test will verify that each in- jector is operating mechanically, not that each injector is allowing the proper amount of fuel to enter each cylinder.

  • Page 262: Air Temperature Sensor And Head Temperature Sensor Test

    FUEL INJECTION Air Temperature Sensor and Head Temperature Sensor Test Purpose: This test eliminates possibilities of improper fuel delivery related to air/head temperature sensors. NOTE: Air/Head Temperature Sensor functioning can be monitored using the Digital Diag- nostic Terminal (DDT). The Air Temperature sensor should indicate ambient air tempera- ture.

  • Page 263: Detonation Control System Test (200 Work Models Only)

    FUEL INJECTION Temperature Sensor Specifications Fahrenheit Centigrade OHMS 1480 1752 2083 2488 2986 3603 4370 5327 6530 8056 10000 12493 15714 19903 25396 32654 –10 55319 –15 72940 Detonation Control System Test (200 Work Models Only) 59034 Knock Sensor Purpose: Determines whether the detonation sensor and circuit located in the ECM is functioning. 1.

  • Page 264: Throttle Position Sensor Test

    FUEL INJECTION Results: As throttle is advanced and engine is under load (in gear), numerical value on DDT display should increase. As throttle is retarded, numerical value should decrease indicating knock sensor/circuit is functioning. If numerical value does not change as throttle setting and load on engine varies, knock sensor or knock circuit in ECM is defective.

  • Page 265: Map Sensor Test

    FUEL INJECTION PRESSURE TEST IMPORTANT: When testing TPS voltage, do not move the drive mechanism (rotor/ wiper). 1. Connect DDT and rotate the key to the “ON” position. 2. Set DDT to read TPS voltage; expand the screen to show Now/Min/Max. NOTE: Test accuracy is improved when TPS is at its lowest voltage reading;...

  • Page 266: Problem Diagnosis

    FUEL INJECTION Problem Diagnosis Condition Possible Source Action Engine Down On Power Or RPM – Failed Ignition Coil Refer to Section 2 Electrical and Ignition Tests. – Low Compression Refer to Section 4 Power Head. – Broken Reed Inspect Reeds. –...
  • Page 267 FUEL INJECTION Condition Possible Source Action Poor Acceleration – Idles Ok, – Timing Not Advancing. Check Timing Advance with DDT. Top Speed Ok (Continued) Engine Surges Between 4000 – Intermittant Ignition Coil Fail- Refer to Section 2A Electrical And 5000 RPM ure.
  • Page 268 FUEL INJECTION Condition Possible Source Action Engine Idles Rough (May Lean – Ignition Coil Failure. Refer to Section 2A Electrical Sneeze) – Acceleration OK; Full and Ignition Tests. Throttle Ok. (continued) – Broken Reed. Inspect Reed Assembly Engine Runs but Slowly Drops –...

  • Page 269: Engine Head Temperature Sensor Installation

    FUEL INJECTION Engine Head Temperature Sensor Removal ANALOG TEMPERATURE SENSOR 1. Remove screw and retaining plate. 2. Disconnect bullet connector and remove sensor. DIGITAL TEMPERATURE SENSOR 1. Disconnect wire harness for PORT and STARBOARD sensors 59037 Bullet Connector (hidden) Digital Temperature Sensor Analog Temperature Sensor Port Sensor Harness...

  • Page 270: Fuel Management Assembly Removal

    FUEL INJECTION Fuel Management Assembly Removal CAUTION Fuel system must be bled off prior to removal of fuel system components. NOTE: Use Fuel/Air Pressure Gauge 91-881834A1 to de-pressurize fuel system. 1. De-pressurize fuel system. 91-881834A1 Fuel Pressure Port Fuel Pressure Gauge 91-881834A1 2.
  • Page 271 FUEL INJECTION 3. Disconnect the following hoses and connectors: 59051 VST Vent Hose VST Electric Fuel Pump Harness Connector Fuel Pressure Regulator Vent Hose Water Sensor Bullet Connector VST Output Fuel Hose Fuel/Water Separator Input Fuel VST Oil Input Hose Hose 4.
  • Page 272 FUEL INJECTION 6. Disconnect throttle cam link rod and the Throttle Position Sensor link rod. 59046 Throttle Cam Link Rod Throttle Position Sensor Link Rod 7. Disconnect the following hoses and connectors: 59058 Air Temperature Sensor MAP Sensor Fuel Injector Harness Con- nector 90-884294 OCTOBER 2001...
  • Page 273 FUEL INJECTION 8. Disconnect oil pump electrical harness, oil pump inlet and outlet hoses. 59039 Electrical Harness Oil Outlet Hose Oil Inlet Hose 9. Remove 12 bolts securing air management assembly to crankcase and remove as- sembly. 59061 Bolts (12 each) Page 3B-44 90-884294 OCTOBER 2001...

  • Page 274: Fuel Rail Removal

    FUEL INJECTION Fuel Rail Removal The fuel rail/injector assembly is attached to the reed block assembly plate by 4 screws. 59057 Fuel Rail/Injector Assembly Reed Block Assembly 1. Remove 4 screws to securing fuel rail/injector assembly to reed block assembly. 59054 Screws 90-884294...
  • Page 275 FUEL INJECTION 2. Lift fuel rail assembly from reed block assembly. 3. Inspect o-rings for cuts and abrasions. Replace if necessary. 59048 Fuel Injectors (6) Fuel Rail Fuel Rail Fuel Inlet Pipe Reed Block Assembly O-Rings 4. Individual fuel injectors and fuel inlet pipe can be removed from fuel rail by removing attaching screws.

  • Page 276: Fuel Rail Installation

    FUEL INJECTION Fuel Rail Installation NOTE: Inspect all o-rings for cuts and abrasions. Applying light oil to all o-rings and o-ring contact surfaces on reed block assembly plate will ease installation of fuel rail assembly. 1. Secure fuel injectors to fuel rail with tamper proof screws. Torque screws to 27 lb. in. [3.0 Nm].
  • Page 277 FUEL INJECTION 4. Secure fuel rail assembly to reed block assembly plate with 4 screws. Torque screws to 65 lb. in. [7.0 Nm]. 59054 Screws [Torque to 65 lb. in. (7.0 Nm)] Page 3B-48 90-884294 OCTOBER 2001...

  • Page 278: Reed Block Assembly Removal

    FUEL INJECTION Reed Block Assembly Removal 1. Remove 12 screws securing air plenum to reed plate assembly. 2. Remove 12 screws securing reed blocks to reed plate assembly. 59045 Screws (2 each per reed block) (M4x16) Air Plenum Screws (12 each) (1/4x20x0.88) Gasket Adaptor Plate Gasket...

  • Page 279: Air Temperature Sensor Removal

    FUEL INJECTION Air Temperature Sensor Removal Disconnect sensor harness and unscrew sensor. 59025 Temperature Sensor Harness Air Temperature Sensor Air Temperature Sensor Installation 1. Carefully thread sensor into air plenum. Torque sensor to 14 lb. in. (1.6 Nm). 2. Reconnect sensor harness. Manifold Absolute Pressure (MAP) Sensor Removal 1.

  • Page 280: Throttle Plate Assembly Removal

    FUEL INJECTION Throttle Plate Assembly Removal NOTE: The throttle plate assembly is calibrated and preset for proper running characteris- tics and emissions at the factory. Other than complete assembly removal from the air ple- num, no further disassembly should be made. Remove 4 bolts securing throttle plate assembly to air plenum and remove assembly.
  • Page 281 FUEL INJECTION 4. Disconnect harness from pump to separate pump from cover. Inspect filter screen for debris. Screen may be pried out of pump and cleaned as required. 5. Inspect seal above fuel pump for cuts or abraisions. Replace seal if necessary. Apply 2-4-C Marine Lubricant with Teflon to seal lips.

  • Page 282: Vapor Separator Reassembly

    FUEL INJECTION Vapor Separator Reassembly NOTE: Inspect VST cover gasket with sealing bead for cuts or abrasions. Replace if nec- essary. Inspect fuel pump seal in VST cover for cuts or abrasions. Replace if necessary. 1. Install gasket w/sealing bead onto vapor separator cover. 2.

  • Page 283: Air Plenum Installation

    FUEL INJECTION 6. Install separator cover with pump onto separator tank. 7. Secure cover to tank with 7 screws. Torque screws to 30 lb. in. (3.5 Nm). 58784 Screws [Torque to 30 lb. in. (3.5 Nm)] Air Plenum Installation Secure plenum to crankcase with 12 bolts. Torque bolts to 125 lb. in. (14 Nm). in sequence shown 56144 Air Plenum...

  • Page 284: Vapor Separator (Vst) Installation

    FUEL INJECTION Vapor Separator (VST) Installation 1. Install ground lead between VST and air plenum. 2. Install 3 bolts securing VST to air plenum. Torque bolts to 140 lb. in. (16 Nm). 59047 VST Ground Lead Bolts [Torque to 140 lb. in. (16 Nm)] 3.

  • Page 285: Water Separating Filter Assembly Removal

    FUEL INJECTION Water Separating Filter Assembly Removal NOTE: To inspect or replace water separator, it is not necessary to remove inlet fuel line. 1. Remove water sensor lead from bottom of separator. 2. With wipe towels available, use Strap Wrench (91-24937A1) to remove water separa- tor.

  • Page 286: Throttle Position Sensor Removal

    FUEL INJECTION Throttle Position Sensor Removal NOTE: Vapor Separator has been removed for visual clarity. 1. Remove throttle position sensor (TPS) harness connector. 2. Remove sensor link rod. 3. Remove 3 screws securing sensor. 59046 Sensor Harness Connector Retaining Screws Sensor Link Rod Throttle Position Sensor Throttle Position Sensor Installation...

  • Page 287: Oil Reservoir Removal

    FUEL INJECTION Oil Reservoir Removal 1. Disconnect low oil sensor bullet connectors (BLUE leads). 2. Remove sta-strap securing reservoir hose to oil pump and remove hose. Plug hose to prevent leakage. 3. Remove oil input hose to oil reservoir from check valve. 4.

  • Page 288: Fuel Pressure Regulator Removal

    FUEL INJECTION Fuel Pressure Regulator Removal 1. Disconnect boat battery from engine harness. CAUTION Fuel system must be bled off prior to removal of fuel system components. NOTE: Use Fuel/Air Pressure Gauge 91-881834A1 to de-pressurize fuel system. 1. De-pressurize fuel system. 91-881834A1 59053 Fuel Pressure Port...

  • Page 289: Fuel Pressure Regulator Disassembly

    FUEL INJECTION Fuel Pressure Regulator Disassembly 1. Inspect O-rings for cuts and abraisions. Replace as required. 2. Inspect fuel filter for debris. Clean with solvent as required. 58789 O-Rings Filter Fuel Pressure Regulator Reassembly 1. Reinstall fuel regulator into vapor separator. 2.

  • Page 290: Efi System Cleaning And Inspection

    FUEL INJECTION EFI System Cleaning and Inspection Cleaning 1. Clean all non-electrical metal parts using a good grade solvent. 2. Use a soft bristle brush for removing large accumulations of dirt or grease and oil. 3. Varnish type coating of induction manifold parts may be removed using carburetor cleaner.
  • Page 291 OIL INJECTION FUEL SYSTEM Section 3C - Oil Injection Table of Contents Specifications ......3C-1 Priming the Oil Pump .

  • Page 292: Operation Of The Oil Injection System

    OIL INJECTION CAUTION Be careful not to get dirt or other contamination in tanks, hoses or other compo- nents of the oil injection system during installation. Operation of the Oil Injection System The oil injection system delivers oil mixture on engine demand, from 120:1 at idle to 50:1 at wide open throttle.
  • Page 293 OIL INJECTION Notes: 90-884294 OCTOBER 2001 Page 3C-3...

  • Page 294: Oil Injection Components

    OIL INJECTION Oil Injection Components Page 3C-4 90-884294 OCTOBER 2001...
  • Page 295 OIL INJECTION Oil Injection Components TORQUE REF. QTY. DESCRIPTION lb-in lb-ft OIL RESERVOIR ASSEMBLY DECAL-RESERVOIR SCREW [0.164-18 x 1-1/4 IN) Drive Tight WASHER CAP ASSEMBLY GASKET SWITCH ASSEMBLY–LOW OIL SCREW (M8 x 35) WASHER GROMMET BUSHING TUBING (7 IN) (17.7 CM) STA-STRAP FITTING HOSE...
  • Page 296 OIL INJECTION Oil Injection Components REMOTE OIL TANK Holds 3 gallons (11.5 liters) of oil. NOTE: Some boats may be equipped with optional 1.8 gallon (7.0 liters) oil tank. The tank is pressurized by air from crankcase pressure thus forcing oil up the outlet hose to the oil reservoir on engine.
  • Page 297 OIL INJECTION Oil Injection Flow System 58888 Remote Oil Tank Vapor Separator Tank Oil Pick-up Tube Oil Inlet to Oil Pump Filter Oil Injection Pump 4 PSI Check Valve Oil Outlet Hose to Vapor Separator Tank Oil Reservoir Low Oil (Float) Sensor (Inside Reser- voir) 90-884294 OCTOBER 2001 Page 3C-7...

  • Page 298: Oil Pump Removal And Installation

    OIL INJECTION Oil Pump Removal and Installation REMOVAL 1. Disconnect the wiring harness from the pump. 2. Disconnect the oil hoses. NOTE: Plug oil supply hose from oil reservoir to prevent spillage. 3. Remove three bolts and remove pump. 59039 Oil Pump Bushing (3) Rubber Grommet (3) –...
  • Page 299 OIL INJECTION Engine Oil Reservoir Removal and Installation REMOVAL 1. Disconnect the oil hoses. Plug the hoses to prevent spillage. 2. Disconnect the BLUE with BLACK STRIPE wire leads. 3. Remove three bolts securing oil tank to powerhead and remove tank. 59030 Oil Reservoir Bushing (3)

  • Page 300: Priming The Oil Pump

    OIL INJECTION Priming the Oil Pump NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed, it is recommended all air be purged from oil pump/oil lines using gearcase leakage tester (FT-8950). Connect the leakage tester to the inlet t-fitting on the onboard oil reservoir. While clamping off the inlet hose, manually pressurize the reservoir to 10 psi.

  • Page 301: Priming Procedure - Method 1

    OIL INJECTION Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos- tic Software Cartridge Part. No. 91-880118--1. Conditions Requiring Priming the Oil Pump Condition Priming Procedure New engine Use Method 1 or 2 Rebuilt Powerhead Use Method 1 or 2 New Powerhead Use Method 1 or 2 Oil system ran out of oil...

  • Page 302: Remote Oil Hose Connections

    OIL INJECTION Prime the oil injection pump as follows: 1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until it fells firm. 2. Turn the ignition key switch to the “ON” position. 3. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward gear 3 to 5 times.

  • Page 303: Filling The Oil Tanks

    OIL INJECTION CONNECTING OIL HOSE WITHOUT BLUE STRIPE 1. Remove shipping cap from fitting and connect hose. Fasten hose with sta-strap. 59039 Oil Hose Without Blue Stripe Filling the Oil Tanks 1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance Manual.

  • Page 304: Oil Warning Systems

    No lubricating oil is being supplied to the engine. NOTE: As an option, Mercury Monitor or SmartCraft Gauges may be used to provide low oil information or oil pump operation information. Page 3C-14...

  • Page 305: Oil System Troubleshooting

    OIL INJECTION Oil System Troubleshooting Low Oil Warning System is Activated Problem Problem Problem Problem Oil leaks out of Low oil level in en- Oil level is not low Low oil level in engine exhaust gine oil reservoir and in either tank oil reservoir but not low or #6 cylinder also remote oil tank...
  • Page 306 EMISSIONS FUEL SYSTEM Section 3D – Emissions Table of Contents Exhaust Emissions Standards ....3D-1 Emissions Information ......3D-4 What Are Emissions? .

  • Page 307: Oxides Of Nitrogen - Nox

    EMISSIONS Oxides of Nitrogen - NOx NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion chambers when temperatures are too high.

  • Page 308: Stratified Vs Homogenized Charge

    EMISSIONS Stratified vs Homogenized Charge At certain operating conditions, DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models exclusively use a homogenized charge. The difference between the two is: Homogenized Charge A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder.

  • Page 309: Stratified Charge

    EMISSIONS Stratified Charge A stratified charge engine only pulls air through the transfer system. The fuel required for combustion is forced into the cylinder through an injector placed in the top of the cylinder (head). The injector sprays a fuel/air mixture in the form of a fuel cloud into the cylinder. Surrounding this cloud is air supplied by the transfer system.

  • Page 310: Dealer Responsibility

    EPA Emission Regulations: All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards.

  • Page 311: Manufacturer's Certification Label

    Valve Clearance (Cold) mm Exhaust: N/A Spark Ignition (SI) Family example FEL: Represents (Mercury Marine) statement of the maximum emissions out- put for the engine family Timing specifications when adjustable Month and Year of Production Valve Clearance (Four Stroke engines only)

  • Page 312: Service Replacement Certification Label

    EMISSIONS Service Replacement Certification Label IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification label. If this label is mis- sing or damaged, contact Mercury Marine Service for replacement if appropriate.
  • Page 313 POWERHEAD POWERHEAD Section 4A - Powerhead Table of Contents Specifications ......4A-2 Cylinder Bores .

  • Page 314: Specifications

    POWERHEAD Specifications Block Type ....... . . 60 V, 2 Cycle Displacement .

  • Page 315: Special Tools

    POWERHEAD Special Tools 1. Lifting Eye 91-90455 2. Flywheel Holder 91-52344 91–52344 54964 3. Protector Cap 91-24161 4. Flywheel Puller 91-849154T1 55117 5. Powerhead Stand 812549T 6. Piston Ring Expander 91-24697 7. Lockring Removal Tool 91-52952A1 90-884294 OCTOBER 2001 Page 4A-3...

  • Page 316: Powerhead Repair Stand

    POWERHEAD 8. Piston Pin Tool 91-74607A1 9. Universal Puller Plate 91-37241 10. Snap Ring Pliers 91-24283 11. Lockring Installation Tool 91-91-79109A3 12. Piston Ring Compressor 91-818773 (for 2.5 Liter) 13. Compression Tester 91-29287 54965 Powerhead Repair Stand A powerhead repair stand may be purchased from: Bob Kerr’s Marine Tool Co.

  • Page 317: Notes

    POWERHEAD Notes: 90-884294 OCTOBER 2001 Page 4A-5...

  • Page 318: Cylinder Block Assembly

    POWERHEAD Cylinder Block Assembly Loctite PST Pipe Sealant Loctite 680 Loctite Master Gasket 2-4-C Marine Lubricant with Teflon 2 Cycle Outboard Oil Page 4A-6 90-884294 OCTOBER 2001...
  • Page 319 POWERHEAD Cylinder Block Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CYLINDER BLOCK SCREW (M8 X 40) 28.5 COVER STUD–POWERHEAD (M10 X 1.5 X 64) STUD–POWERHEAD (M10 X 1.5 X 155) WATER DEFLECTOR CHECK VALVE CENTER MAIN PIN DOWEL PIN–LOCATING STOP PLUG SCREW (M8 X 35) 28.5 SCREW (M10 X 1.5)
  • Page 320 POWERHEAD Cylinder Block Assembly Loctite PST Pipe Sealant Loctite 680 Loctite Master Gasket 2-4-C Marine Lubricant with Teflon 2 Cycle Outboard Oil Page 4A-8 90-884294 OCTOBER 2001...
  • Page 321 POWERHEAD Cylinder Block Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft TEMPERATURE SENSOR O-RING SCREW (M6 X 12) CLAMP TPS LEVER SCREW (M6 X 25) BUSHING GROMMET WASHER SCREW (M6 x 25) THROTTLE POSITION SENSOR SCREW PIPE PLUG LINK CLIP SCREW (M6 X 14) STA-STRAP CLIP TPS COVER...

  • Page 322: Exhaust Adaptor Plate

    POWERHEAD Exhaust Adaptor Plate Loctite PST Pipe Sealant (92-809822) 3M Permabond #3MO8155 (Obtain Locally) 2-4-C Marine Lubricant with Teflon A = TO BLOCK Page 4A-10 90-884294 OCTOBER 2001...
  • Page 323 POWERHEAD Exhaust Adaptor Plate TORQUE REF. QTY. DESCRIPTION lb-in lb-ft EXHAUST PLATE GASKET GASKET (LOWER) SEAL CHECK VALVE FITTING PIPE PLUG DRAIN CHECK VALVE DOWEL PIN COVER SCREW (M8 X 35) CARRIER GROMMET POPPET SPRING RELIEF VALVE PLATE ASSEMBLY GASKET DIAPHRAGM WASHER SCREW (10-16 X 3/4 IN.)

  • Page 324: Crankshaft, Pistons And Connecting Rods

    POWERHEAD Crankshaft, Pistons and Connecting Rods 2 Cycle Outboard Oil 2-4-C Marine Lubricant with Teflon Page 4A-12 90-884294 OCTOBER 2001...
  • Page 325 POWERHEAD Crankshaft, Pistons and Connecting Rods TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CRANKSHAFT ASSEMBLY WEAR SLEEVE BALL BEARING (LOWER) RETAINING RING RING–SEALING WOODRUFF KEY O-RING BEARING RACE ROLLER BEARING PISTON (STARBOARD) PISTON (PORT) LOCK RING PISTON RING SET PISTON RING (LOWER) CONNECTING ROD ASSEMBLY 1st Torque: 15 lb-in 2nd Torque: 20 lb-ft...

  • Page 326: Starboard Bleed System Routing

    POWERHEAD Starboard Bleed System Routing Page 4A-14 90-884294 OCTOBER 2001...
  • Page 327 POWERHEAD Starboard Bleed System Routing TORQUE REF. QTY. DESCRIPTION lb-in lb-ft TUBING [15-1/2 IN (39.3 CM)] CHECK VALVE (90 ) TUBING [16-1/2 IN (3.8 CM)] TUBING [15 IN (38.1 CM)] CLIP SCREW (10 – 16 X 1/2) CHECK VALVE 90-884294 OCTOBER 2001 Page 4A-15...

  • Page 328: Port Bleed System Routing

    POWERHEAD Port Bleed System Routing Page 4A-16 90-884294 OCTOBER 2001...
  • Page 329 POWERHEAD Port Bleed System Routing TORQUE REF. QTY. DESCRIPTION lb-in lb-ft CHECK VALVE PIPE PLUG TUBING [20.5 IN (52 CM)] CHECK VALVE CHECK VALVE (90 DEGREE) TUBING [13 IN (33 CM)] CHECK VALVE PIPE PLUG CLIP SCREW (10 – 16 X 1/2) TUBING [11 IN (27.9 CM)] TUBING [22.5 IN (57 CM)] 90-884294 OCTOBER 2001...

  • Page 330: Torque Sequence

    POWERHEAD Torque Sequence CRANKCASE COVER BOLTS 55986 Add light oil to threads and bolt face: 8 Bolts (3/8 in. - 16 in.) 38 lb. ft. (51.5 N·m) Bolts (M8 x 1.25 x 35) 28 lb. ft. (38 N·m) Page 4A-18 90-884294 OCTOBER 2001...
  • Page 331 POWERHEAD CYLINDER HEAD BOLTS Apply light oil to threads and bolt face: 30 lb. ft. (40.7 N·m) and rotate 90 52132 POWERHEAD TO ADAPTOR PLATE ATTACHING NUT Torque nuts to 25 lb. ft. (33.8 Nm) Starboard Side Front Port Side 90-884294 OCTOBER 2001 Page 4A-19...

  • Page 332: General Information

    POWERHEAD General Information Powerhead “Disassembly” and “Reassembly” instructions are printed in a sequence that should be followed to assure best results when removing or replacing powerhead compo- nents. If complete disassembly is not necessary, start reassembly at point disassembly was stopped.

  • Page 333: Powerhead Removal From Driveshaft Housing

    POWERHEAD Powerhead Removal from Driveshaft Housing 1. Disconnect battery cables from battery terminals. 2. Remove top cowling. 3. Remove two screws which secure remote control harness retainer and remove retainer. 57841 Screws Retainer 4. Remove bottom cowls. 59075 Screws Access Cover to Lower Screw 90-884294 OCTOBER 2001 Page 4A-21...
  • Page 334 POWERHEAD 5. Disconnect and/or remove the following: 59026 Remote Oil Tank Pressure Hose Remote Control Harness Power Trim Wires Negative Battery Cable Positive Battery Cable SmartCraft Harness Connector Page 4A-22 90-884294 OCTOBER 2001...
  • Page 335 POWERHEAD 6. Disconnect and/or remove the following: 59030 Oil Supply Hose Shift Lever Bracket Assembly Water Pressure Hose (GREY) Starboard Thermostat Discharge Hose 90-884294 OCTOBER 2001 Page 4A-23...
  • Page 336 POWERHEAD 7. Disconnect the following: 59028 Water Pressure Sensor Hose (GREY)(for Digital Gauges) (If not previously dis- connected) Engine Flush Hose Tell-Tale Hose Starboard Thermostat Discharge Hose Page 4A-24 90-884294 OCTOBER 2001...
  • Page 337 POWERHEAD 8. Slide outboard shift lever into neutral position. 9. Remove throttle cable and shift cable from control cable anchor bracket. Throttle Cable Shift Cable 10. Disconnect input fuel line, water pressure hose and speedometer hose. Input Fuel Hose Water Pressure Hose (GRAY) (Analog Gauges) Speedometer Hose (BLACK) (Analog Gauges) Hose Clamp 90-884294 OCTOBER 2001...
  • Page 338 POWERHEAD 11. Remove 10 nuts and 10 washers (5 each side) from powerhead base. 52373 Nuts and Washers (5 each side) 12. Remove plastic cap from center of flywheel and install Lifting Eye 91-90455 into flywheel at least 5 full turns. Using a hoist, lift powerhead assembly from driveshaft housing. 59076 Lifting Eye 91-90455 Page 4A-26...

  • Page 339: Removing Engine Components

    POWERHEAD Removing Engine Components NOTE : Engine components can be removed individually or in some cases as an assembly. Removing Engine Components Individually Section 2 Starter Motor *Electronic Control Module *Ignition Coils *Starter Solenoid *Trim Relays Alternator Flywheel Section 3 Air Plenum Fuel Rail and Injectors Vapor Separator Assembly...

  • Page 340: Vapor Separator Tank (Vst) Removal

    POWERHEAD Vapor Separator Tank (VST) Removal CAUTION Depressurize fuel system prior to opening line connections or removing fuel sys- tem components. 1. Use Fuel/Air Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-881834A1 to de- pressurize fuel system. Direct fuel into suitable container. 2.
  • Page 341 POWERHEAD 3. Disconnect the following hoses and connectors: 59051 VST Vent Hose VST Electric Fuel Pump Harness Connector Fuel Pressure Regulator Vent Hose Water Sensor Bullet Connector VST Output Fuel Hose Fuel/Water Separator Input Fuel VST Oil Input Hose Hose 4.

  • Page 342: Air Plenum Removal

    POWERHEAD 6. Disconnect throttle cam link rod and the Throttle Position Sensor link rod. 59046 Throttle Cam Link Rod Throttle Position Sensor Link Rod Air Plenum Removal 1. Disconnect the following hoses and connectors: 59058 Air Temperature Sensor MAP Sensor Fuel Injector Harness Con- nector Page 4A-30...
  • Page 343 POWERHEAD 2. Disconnect oil pump electrical harness, oil pump inlet and outlet hoses and oil tank pres- sure hose. 59039 Electrical Harness Oil Inlet Hose Oil Outlet Hose Oil Tank Pressure Hose 3. Remove 12 bolts securing air management assembly to crankcase and remove assem- bly.
  • Page 344 POWERHEAD Ignition Coil Plate and Harness Removal Disconnect the following: Temperature Gauge Bullet Connectors (Hidden) Port Temperature Sensor Connector Water Pressure Sensor Connector Starboard Temperature Sensor Connector Ignition Coil Harness Connector Bolts (4) Spark Plug Leads (Use proper tool to remove spark plug boot to avoid damage to boot) Water Pressure Hose (Disconnect) Page 4A-32...

  • Page 345: Starter Motor

    POWERHEAD Starter Motor Disconnect and/or remove the following: 59044 59038 Centrifugal Bendix Starter BLACK (with YELLOW sleeve) + 12 volt cable Solenoid Driven Bendix Starter Starter Solenoid Upper Mount Bolts BLACK (with RED sleeve) + 12 volt Lower Mount Bolts cable BLACK ground cable 90-884294 OCTOBER 2001...

  • Page 346: Electrical Plate Removal

    POWERHEAD Electrical Plate Removal Disconnect and/or remove the following: 59078 Crank Position Sensor Connector Trim Motor Bullet Connectors ECM Screws (3) Solenoid Plate Screws (3) Page 4A-34 90-884294 OCTOBER 2001...

  • Page 347: Alternator Removal

    POWERHEAD Alternator Removal 58907 Rotate Belt Tensioner with 3/8 in. Drive and Remove Belt Remove Alternator Output Lead and Harness Connector Remove Ground Lead Screw Remove 3 Bolts and Remove Alternator Assembly 90-884294 OCTOBER 2001 Page 4A-35...

  • Page 348: Powerhead Disassembly

    POWERHEAD Powerhead Disassembly 1. Place powerhead in repair stand or on a bench. 2. Remove thermostat covers and washers. Cover Washer 3. Remove cylinder heads from engine block. 52214 Cylinder Head Engine Block Page 4A-36 90-884294 OCTOBER 2001...
  • Page 349 POWERHEAD 4. Remove reed block housing from cylinder block. 5. Inspect reeds as outlined in “Cleaning and Inspection”. Reed Block Housing Reed Block Adapter Plate Air Plenum 90-884294 OCTOBER 2001 Page 4A-37...
  • Page 350 POWERHEAD LOWER END CAP 1. Remove lower end cap bolts. 52325 Crankcase Attaching End Cap Bolts 2. Remove bolts which secure crankcase cover to cylinder block. 55977 Crankcase Cover 3. Remove crankcase end cap. Page 4A-38 90-884294 OCTOBER 2001...
  • Page 351 POWERHEAD CRANKCASE COVER REMOVED 55978 4. Use Powerhead Stand (91-30591A1) for rotating crankshaft to desired position for re- moval of connecting rods. 5. Using an awl or electric pencil, scribe the cylinder identification number on each con- necting rod as shown. Reassemble connecting rods in same cylinder. 52347 90-884294 OCTOBER 2001 Page 4A-39...
  • Page 352 POWERHEAD 6. Use a 3/8 in. 12 point socket to remove connecting rod bolts, then remove rod cap, roller bearings and bearing cage from connecting rod. 52316 Connecting Rod Bolts 7. Push piston out of cylinder block. 8. After removal, reassemble each piston and connecting rod assembly. CAUTION Each connecting rod and end cap are a matched machined set and must never be mismatched.
  • Page 353 POWERHEAD 11. Using an awl, scribe identification number of connecting rod on inside of piston. Reas- semble piston on same connecting rod. 55968 Scribe Identification Number 12. Using tool (91-52952A1), remove piston pin lockrings from both ends of piston pin. Nev- er re-use piston pin lockrings.
  • Page 354 POWERHEAD IMPORTANT: Warming the piston dome using a torch lamp will ease removal and in- stallation of piston pin. 13. Support piston and tap out piston pin using service tool (91-92973A1) as shown. 55957 Piston Pin Piston Pin Tool (91-92973A1) 14.
  • Page 355 POWERHEAD 15. Remove lower end cap from crankshaft. 16. Remove and discard O-ring seal from end cap. 17. Remove oil seals from end cap by driving seals out with a punch and hammer. 51849 O-ring Seal 18. Inspect roller bearing in upper end cap as outlined in “Cleaning and Inspection”. NOTE : If roller bearing is damaged, replace roller bearing carrier assembly.
  • Page 356 POWERHEAD 19. Remove crankshaft and place in powerhead stand as shown. IMPORTANT: DO NOT remove crankshaft sealing rings from crankshaft, unless re- placement of a sealing ring(s) is necessary. Usually, crankshaft sealing rings do not require replacement, unless broken. CAUTION Safety glasses should be worn when removing or installing crankshaft sealing rings.
  • Page 357 POWERHEAD Inspect crankshaft ball bearing as outlined in “Cleaning and Inspection,” following. IMPORTANT: DO NOT remove crankshaft ball bearing, unless replacement is re- quired. 22. Remove lower ball bearing from crankshaft as follows: a. Remove retaining ring using a pair of snap ring pliers. 55983 Crankshaft Ball Bearing Pliers...
  • Page 358 POWERHEAD Water Pressure Relief Valve Components 1. Remove and inspect water pressure relief valve components for debris or damage. Re- place components as required. Exhaust Plate Carrier Grommet Poppet/Relief Valve Spring Gasket Inner Plate Diaphragm Washer 10 - Screw [Torque to 25 lb. in. (3 Nm)] 11 - Gasket 12 -...

  • Page 359: Cleaning And Inspection

    POWERHEAD Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored assem- bly and never should be mismatched by using a different crankcase cover or cylinder block. CAUTION If crankcase cover or cylinder block is to be submerged in a very strong cleaning solution, it will be necessary to remove the crankcase cover/cylinder block bleed system from crankcase cover/cylinder block to prevent damage to hoses and check valves.

  • Page 360: Cylinder Bores

    POWERHEAD Cylinder Bores 1. Inspect cylinder bores for scoring, scuffing or a transfer of aluminum from piston to cylin- der wall. Scoring or scuffing, if NOT TOO SEVERE, can normally be removed by honing. If a transfer of aluminum has occurred, an acidic solution containing muriatic acid (i.e. “TIDY BOWL CLEANER”) should be applied to the areas of the cylinder bore where transfer of aluminum has occurred.

  • Page 361: Pistons And Piston Rings

    POWERHEAD 3. Measure cylinder bore diameter (with a snap gauge micrometer) of each cylinder, as shown below. Check for tapered, out-of-round (egg-shaped) and oversize bore. 52324 200/225/250 Models Model Cylinder Block Finish Hone 200/225/250 3.6265 in. (92.1131 mm) 0.015 in. (0.38 mm) Oversize 3.6415 in.
  • Page 362 POWERHEAD CLEANING PISTON RING GROOVES Keystone (tapered) ring grooves CAUTION Care must be taken not to scratch the side surfaces of the ring groove. Scratching the side surface of the ring groove will damage the ring groove. 1. Use a bristle brush and carbon remover solution to remove carbon from side surfaces. 2.

  • Page 363: Cylinder Heads

    POWERHEAD Cylinder Heads 1. Inspect internal surface of cylinder heads for possible damage (as a result of piston or foreign material striking cylinder heads). IMPORTANT: Cylinder head warpage should not exceed 0.005 in. (0.127 mm) over the ENTIRE length of the cylinder head. If measured warpage, as determined on a surface block, exceeds 0.005 in.

  • Page 364: Crankshaft (And End Cap) Bearings

    POWERHEAD Crankshaft (and End Cap) Bearings IMPORTANT: When overhauling powerhead assembly, it is recommended that all crankshaft bearings – upper/lower, center main, connecting rod and wrist pin bear- ings – be replaced to ensure optimum powerhead performance and longevity. 1. After cleaning crankshaft, grasp outer race of crankshaft ball bearing (installed on lower end of crankshaft) and attempt to work race back-and-forth.

  • Page 365: Reed Block Assembly

    POWERHEAD Reed Block Assembly IMPORTANT: DO NOT remove reeds from reed blocks, unless replacement is neces- sary. DO NOT turn used reeds over for re-use. Replace reeds in sets only. 1. Thoroughly clean gasket surfaces of reed blocks and reed block housing. Check for deep grooves, cracks and distortion that could cause leakage.
  • Page 366 POWERHEAD 4. Water Marks: When bearing surfaces are subjected to water contamination, a bearing surface “etching” occurs. This etching resembles the size of the bearing. 51853 5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping. Spalling will be most evident on the thrust portion of the connecting rod in line with the “I”...

  • Page 367: Thermostats (120 F) (49 C)

    POWERHEAD 7. Uneven Wear: Uneven wear could be caused by a bent connecting rod. 51853 Uneven Wear Between Arrows 8. If necessary, clean connecting rod bearing surfaces, as follows: a. Be sure that “etched” marks on connecting rod (crankshaft end) are perfectly aligned with “etched”...

  • Page 368: Powerhead Reassembly And Installation

    During reassembly, lubricate parts with 2-Cycle Outboard Oil whenever “light oil” is speci- fied. Mercury/Quicksilver part numbers of lubricants, sealers and locking compounds are listed in “Mercury/Quicksilver Lubricants and Sealants” located in section 1A, and special tools are listed in “Powerhead General Information,” preceding.
  • Page 369 POWERHEAD 1. If removed, press lower crankshaft ball bearing onto crankshaft as shown. Be sure bear- ing is pressed firmly against shoulder. 2. Reinstall retaining ring using a suitable pair of Snap Ring Pliers. 55983 51852 Crankshaft Suitable Mandrel Crankshaft Ball Bearing Press Retaining Ring 3.
  • Page 370 POWERHEAD 6. Place center main crankshaft roller bearings on upper and lower main bearing journals as shown. 7. Install center main bearing races as shown. 8. Secure center main bearing races together with retaining rings. Make sure retaining ring bridges the separating lines of the bearing race. 58989 58991 Flywheel End...

  • Page 371: Crankshaft Installation

    POWERHEAD 10. Install oil seal into upper bearing carrier as follows: a. Apply a light film of 2-4-C Marine Lubricant with Teflon to outer diameter of upper end cap oil seal. This will ease seal installation into carrier. Lubricate oil seal lip with 2-4-C Marine Lubricant with Teflon. c.
  • Page 372 POWERHEAD Install crankshaft as follows: 1. Lubricate crankshaft sealing rings with light oil. 2. Check cylinder block to be sure that dowel pins are in place. 55992 Dowel Pins 3. Position all crankshaft seal ring gaps straight up. 4. Align hole in each center main bearing race with dowel pin. 5.
  • Page 373 POWERHEAD Piston and Connecting Rod Reassembly 1. Place needle bearings on a clean piece of paper and lubricate with 2-4-C Marine Lubri- cant with Teflon. NOTE : There are 34 needle bearings per piston. 2. Place sleeve which is part of piston pin tool (91-92973A1) into connecting rod and install needle bearings around sleeve as shown.

  • Page 374: Piston And Piston Ring Combinations

    POWERHEAD 6. Install new piston pin lockrings (one each end of piston pin) with Lockring Installation Tool (91-93004A2). 7. Make sure lockrings are properly seated in piston grooves. 55963 51086 Lockring Installation Tool (91-93004A2) Lockring Piston and Piston Ring Combinations Pistons with two half keystone (half tapered) rings 0.078 in.

  • Page 375: Piston Installation

    Feeler Gauge Ring End Gap IMPORTANT: 3 Liter Work/225 EFI/250 EFI engines have top and bottom indicated pis- ton rings and should be installed accordingly. The top ring is marked T1 and the bot- tom ring is marked T2. The “T” represents the top side of of the ring. The bottom ring is stepped to trap oil and bring it into the cylinder bores on the upward stroke.
  • Page 376 POWERHEAD 4. Check piston rings to be sure that they fit freely in ring groove. 5. Lubricate piston, rings and cylinder wall with 2-Cycle Outboard Oil. 52319 Piston Ring Expander (91-24697) Dot Side “Up” on Piston Ring 6. Rotate each piston ring so end of ring is aligned with locating pin as shown. 7.
  • Page 377 POWERHEAD 10. Apply 2-4-C Marine Lubricant with Teflon to bearing surface of connecting rod and install bearing assembly as shown. IMPORTANT: It is recommended that connecting rod bolts not be reused. 11. Place connecting rod cap on connecting rod. Apply light oil to threads and face of con- necting rod bolts.
  • Page 378 POWERHEAD Connecting Rod Cap Alignment Check each connecting rod cap for correct alignment. If not aligned, a ridge can be seen or felt at the separating line as shown below. Correct any misalignment. 52381 Side View Incorrect – Cap on Backwards End View Incorrect –...

  • Page 379: Crankcase Cover Installation

    POWERHEAD Crankcase Cover Installation 1. Thoroughly remove all oil from mating surfaces of crankcase cover and cylinder block with Loctite 7649 Primer. 55984 Crankcase Cover Remove all Oil 2. Apply a thin, even coat of Loctite Master Gasket on mating surfaces of cylinder block. 58993 Loctite Master Gasket 90-884294 OCTOBER 2001...
  • Page 380 POWERHEAD 3. Place crankcase cover in position on cylinder block. Turn the 8 center main bolts in a LITTLE at a time, (following torque sequence) compressing crankshaft seal rings until crankshaft cover has been drawn down to cylinder block. Tighten eight bolts evenly in three progressive steps (following torque sequence).

  • Page 381: Assembly Of Reed Blocks To Reed Block Adaptor Plate

    POWERHEAD Assembly of Reed Blocks to Reed Block Adaptor Plate NOTE : Air plenum gasket is beaded on 1 side. Bead side of the gasket faces the air plenum. Torque to 90 lb. in. (10 Nm) Reed Block (6) Cylinder Block Cover Adaptor Plate Air Plenum Gasket (bead faces air plenum) Air Plenum...
  • Page 382 POWERHEAD 1. If removed, install water pressure relief valve components as shown. Torque bolts to specifications. 50803 Cover Washer Bolt - 150 lb. in. Screw - 25 lb. in. (3 Nm) (17 Nm) Spring Gasket 10 - Poppet Valve Relief Valve Plate 11 - Grommet Diaphragm...
  • Page 383 NOTE : The 3 Liter 200 Work cylinder heads are low compression in design and can be iden- tified by the casting number 812851C13. The 225 EFI and 250 EFI cylinder heads can be identified by the casting number 812851C15.
  • Page 384 POWERHEAD 2. Install thermostat assembly into each cylinder head. 3. Install temperature sensors into STARBOARD and PORT cylinder heads. 59037 Temperature Sensor (Port) (Over- Port Thermostat heat) Starboard Thermostat Temperature Sensor (Analog Tem- Temperature Sensor (Starboard) perature Gauge) (Overheat) Bolt [Torque to 17 lb. ft. (23.

  • Page 385: Notes

    POWERHEAD Notes: 90-884294 OCTOBER 2001 Page 4A-73...
  • Page 386 POWERHEAD Throttle Lever and Shift Platform Assembly 2-4-C Marine Lubricant with Teflon Page 4A-74 90-884294 OCTOBER 2001...
  • Page 387 POWERHEAD Throttle Lever and Shift Platform Assembly TORQUE REF. QTY. DESCRIPTION lb-in lb-ft THROTTLE CONTROL LEVER SCREW (M8 x 35) WASHER BUSHING SCREW (M6 x 55) PIN INSERT SWIVEL BUSHING LINK ANCHOR BRACKET LATCH SCREW-DRIVE SCREW (M8 x 25) CLAMP SCREW (M8 x 25) ROLLER GUIDE SWITCH...

  • Page 388: Powerhead Installation On Driveshaft Housing

    POWERHEAD Powerhead Installation On Driveshaft Housing 1. Install Lifting Eye (91-90455) into flywheel. WARNING BE SURE that Lifting Eye is threaded into flywheel a minimum of five (5) turns BE- FORE lifting powerhead. 2. Using a hoist, lift powerhead high enough to allow removal of powerhead from repair stand.
  • Page 389 POWERHEAD 6. Install 10 flat washers,and 10 locknuts which secure powerhead to exhaust extension plate/driveshaft housing. Torque locknuts in 3 progressive steps until secured. 7. Disconnect hoist from Lifting Eye and remove Lifting Eye from flywheel. 8. Reinstall plastic cap into center of flywheel cover. 52373 Locknuts and Washers –...
  • Page 390 POWERHEAD 9. Reconnect and/or reinstall the following: 59026 Remote Oil Tank Pressure Hose Remote Control Harness Power Trim Wires Negative Battery Cable Positive Battery Cable SmartCraft Harness Connector Page 4A-78 90-884294 OCTOBER 2001...
  • Page 391 POWERHEAD 10. Reinstall the following: 59030 Oil Supply Hose Shift Lever Bracket Assembly Water Pressure Hose (GREY) Starboard Thermostat Discharge Hose 90-884294 OCTOBER 2001 Page 4A-79...
  • Page 392 POWERHEAD 11. Reconnect the following: 59028 Water Pressure Sensor Hose (GREY)(for Digital Gauges) Engine Flush Hose Tell-Tale Hose Starboard Thermostat Discharge Hose Page 4A-80 90-884294 OCTOBER 2001...
  • Page 393 POWERHEAD 12. Install bottom cowls. 59075 Screws Access Cover to Lower Screw 13. Reconnect input fuel line, water pressure hose and speedometer hose. Input Fuel Hose Speedometer Hose (BLACK) (Ana- log Gauges) Water Pressure Hose (GRAY) (Ana- log Gauges) Hose Clamp 90-884294 OCTOBER 2001 Page 4A-81...

  • Page 394: Shift Cable

    POWERHEAD Shift Cable Install cables into the remote control following the instructions provided with the remote con- trol. NOTE : Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral. COUNTER ROTATION OUTBOARDS Counter rotating (left hand) gear cases can be identified by a “L”...

  • Page 395: Installation

    POWERHEAD Installation IMPORTANT: Step 1 must be followed for proper adjustment of the shift cable. 1. Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position.
  • Page 396 POWERHEAD 2. Position remote control and outboard into neutral. 3. Slide the shift cable anchor pin forward until resistance is felt, then slide anchor pin to- ward rear until resistance is felt. Center the anchor pin between resistance points. Anchor Pin 4.

  • Page 397: Throttle Cable

    POWERHEAD Throttle Cable INSTALLATION 1. Position remote control into neutral. 2. Attach throttle cable to the throttle lever. Secure with washer and locknut. Nylon Washer Locknut – Tighten locknut then back off locknut 1/4 turn 3. Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw against the stop.

  • Page 398: Front Clamp Reassembly

    POWERHEAD 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to ro- tate the propeller shaft while shifting into reverse. b. Return remote control to neutral. Place a thin piece of paper between idle adjust- ment screw and idle stop.

  • Page 399: Engine Break-In Procedure

    POWERHEAD Engine Break-in Procedure IMPORTANT: Prior to initially starting engine, oil pump prime sequence must be acti- vated using the Digital Diagnostic Terminal (DDT). Initiating the oil pump prime se- quence will vacate any air in the oil output hose and mix oil with fuel in the vapor sepa- rator thus preventing scoring of internal components during initial startup.
  • Page 400 COOLING POWERHEAD Section 4B - Cooling Table of Contents Specifications ....... . 4B-2 Water Flow Diagram .

  • Page 401: Specifications

    COOLING Specifications Thermostat ... 143 F (61.7 C) Water Pressure Idle 1.5 – 4.5 PSI (10.3 – 30.8 kPa) Poppet Valve Opening 6.0 – 7.0 PSI (41.3 – 48.2 kPa) W.O.T.

  • Page 402: Digital Port And Starboard Temperature Sensor

    COOLING Digital Port and Starboard Temperature Sensors An ohms test of the temperature sensors would be as follows: Disconnect temperature sensor harness and check continuity with digital or analog ohm- meter test leads between both connector pins. With engine at temperature (F ) indicated, ohm readings should be as indicated 10%.

  • Page 403: Analog Temperature Sensor

    COOLING Analog Temperature Sensor TAN/BLACK sensor lead (in port analog temperature sensor) provides signal for optional temperature gauge. An ohms test of the analog temperature sensor (in port cylinder head) would be as follows: Insert digital or analog ohmmeter test leads into both TAN/BLACK sensor leads. With en- gine at temperature (F ) indicated, ohm readings should be as indicated 10%.

  • Page 404: Special Tools

    COOLING Special Tools 1. DMT 2000 Digital Tachometer Multimeter P/N 91-854009A1 2. Water Pressure Gauge 91-79250A2 56725 90-884294 OCTOBER 2001 Page 4B-5...

  • Page 405: Water Flow

    COOLING Water Flow Description Cooling water enters the cooling system through the lower unit water inlets. The pump assembly forces water through the water tube and exhaust adapter plate passages filling the power head central water chamber (located behind the exhaust cavity). Water enters the exhaust cover cavity through 2 holes near the top of the exhaust cover.

  • Page 406: Water Flow Diagram

    COOLING 3 Liter Work/225 EFI/250 EFI Water Flow Diagram 59162 1. Water Inlet 2. Water Pump 3. Wall of Water – If water level height is insufficient, water pump may draw in air resulting in an overheated engine. 4. Strainer – Exhaust cooling water.

  • Page 407: Notes

    COOLING Notes: Page 4B-8 90-883728 JULY 2001...

  • Page 408: Troubleshooting

    COOLING Troubleshooting Thermostat Test 1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and corrosion damage that could cause leakage. Replace parts as necessary. 2. Remove and discard gasket from each thermostat. 3. Wash thermostats with clean water. 4.

  • Page 409: Water Pressure Check

    COOLING Water Pressure Check Water pressure may be checked by attaching a test pressure gauge to the top of the engine block. A water pressure line (GRAY colored) is provided that exits at the front of the lower cowl. A dash style gauge may be connected to this line to register water pressure. WARNING Shut off engine and refer to troubleshooting chart if water pressure is not within specification.

  • Page 410: Water Pump Cleaning And Inspection

    COOLING Water Pump Cleaning and Inspection 1. Inspect the water tube coupling for wear or damage. If necessary replace. Water Tube Coupling 2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller blades. Replace the impeller if this condition is found. 3.

  • Page 411: Problem Diagnosis

    COOLING Problem Diagnosis Condition Recommended Range Possible Cause Pressure below specification @ 1.5 – 4.5 PSI (10.3 – 30.8 kPa) Poppet valve spring defective idle (weak, broken, missing) Defective poppet valve seal Thermostat stuck open Severe internal leak Low output water pump Inlet restriction Pressure above 5 psi (34.2kPa) 1.5 –...
  • Page 412 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING MID-SECTION Section 5A – Clamp/Swivel Brackets & Drive Shaft Housing Table of Contents Swivel Bracket and Steering Arm ....5A-2 Drive Shaft Housing and Dyna-Float Suspension 5A-8 Transom Brackets...

  • Page 413: Swivel Bracket And Steering Arm

    CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket and Steering Arm Loctite 271 2-4-C Marine Lubricant with Teflon Page 5A-2 90-884294 OCTOBER 2001...
  • Page 414 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Swivel Bracket and Steering Arm TORQUE REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SWIVEL BRACKET O RING BUSHING SPACER OIL SEAL (LOWER) GREASE FITTING BUSHING THRUST WASHER BOTTOM YOKE (LONG – CARBON STEEL) BOTTOM YOKE (XL–STAINLESS STEEL) RETAINING RING STRIKER PLATE...

  • Page 415: Transom Brackets

    CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Brackets 2-4-C Marine Lubricant with Teflon Page 5A-4 90-884294 OCTOBER 2001...
  • Page 416 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Transom Brackets TORQUE REF. QTY. DESCRIPTION lb-in lb-ft TRANSOM BRACKET (STARBOARD) TRANSOM BRACKET (PORT) GREASE FITTING (PORT) TILT TUBE NUT (1 IN.-14) O-RING WAVE WASHER NUT (7/8-14) BOLT WASHER WASHER TILT LOCK LEVER ASSEMBLY SPRING BUSHING SPRING...

  • Page 417: Drive Shaft Housing And Exhaust Tube

    CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing and Exhaust Tube Loctite 271 Perfect Seal Loctite 680 2-4-C Marine Lubricant with Teflon Page 5A-6 90-884294 OCTOBER 2001...
  • Page 418 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing and Exhaust Tube TORQUE REF. QTY. DESCRIPTION lb-in lb-ft DRIVE SHAFT HOUSING (LONG) DRIVE SHAFT HOUSING (X/XX–LONG) STUD (M12 x 1.75 x 54) LONG/X-LONG SCREW (M12 x 35) 61.0 GROMMET WASHER NUT (M12 x 1.75) 74.5 PLUG...

  • Page 419: Drive Shaft Housing And Dyna-Float Suspension

    CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING Drive Shaft Housing and Dyna-Float Suspension Refer to “Powerhead Removal” section to remove powerhead. Refer to “Lower Unit Removal” in this section to remove lower unit. Removal and Disassembly 1. Remove shift shaft from driveshaft housing by pulling straight up on shaft. 2.
  • Page 420 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING SHIFT LINKAGE ASSEMBLY Shift Shaft Assembly Bushing (3) Lock Nut (2) Washer (2) 1. Remove upper mount nuts and flat washers. 2. Pull mount bolts through mounts and remove mounts. 58004 Upper Mount Nuts 3.
  • Page 421 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 4. While applying upward pressure on rear of adaptor plate, use a mallet and a piece of hardwood against the adaptor plate to loosen gasket adhesion. Adaptor Plate 5. Remove 2 bolts securing water tube to adaptor plate and remove tube. Remove 6 bolts securing exhaust tube to adaptor plate.
  • Page 422 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 6. While tilting adaptor plate/exhaust tube assembly, use a piece of hardwood and a mal- let to loosen gasket adhesion. Remove exhaust tube. Hardwood Adaptor Plate Exhaust Tube 7. Remove all gasket material from driveshaft housing and related components. 8.

  • Page 423: Reassembly And Installation

    CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 10. Remove lower mount nuts and rubber caps. 52308 Lower Mount Nuts Rubber Caps 11. Remove drive shaft housing from swivel bracket by pulling alternately from top to bot- tom on housing. 12. Remove upper and lower mounts by lifting them out of drive shaft housing. Reassembly and Installation 1.
  • Page 424 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 3. Position exhaust tube and gasket on adaptor plate. Secure both to plate with 6 bolts. Torque bolts to 21 Ib. ft. (28.5 Nm). 4. Secure tube to adaptor plate with 2 bolts. Torque bolts to 80 lb. in. (9 Nm). Exhaust Tube Gasket Water Tube...
  • Page 425 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 7. Apply a small amount of Perfect Seal onto metal portion of upper dyna-float mounts. 8. Position mounts on drive shaft housing plate. 9. Install a rubber washer onto each upper mount, followed by a metal washer. 10.
  • Page 426 CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING 19. Install lower mount retainers and secure each retainer with 2 bolts. Secure ground strap with the nearest retainer bolt and flat washer. Torque bolts to 20 lb. ft. (27 Nm). 20. Install lower mount covers and secure each cover with a screw. 52308 52307 Lower Mount Retainer...
  • Page 427 POWER TRIM - DESIGN II MID-SECTION Section 5B – Power Trim - (Oildyne) Table of Contents Power Trim Specifications ....5B-1 Removal ......5B-28 Special Tools .

  • Page 428: Special Tools

    POWER TRIM - DESIGN II Special Tools 1. Alignment Tool 91-11230 17238 2. Trim Rod Removal Tool 91-44486A1 51337 3. Trim Rod Guide Removal Tool 91-44487A1 51337 4. Power Trim Test Gauge Kit 91-52915A6 73835 5. Lock-Ring Pliers P/N SRP-4 (Snap-On) Page 5B-2 90-884294 OCTOBER 2001...
  • Page 429 POWER TRIM - DESIGN II 6. Adaptor Fitting 91-82278A2 and 91-82278A3 54458 7. Spanner Wrench 91-74951 51337 8. Multi-Meter DVA Tester 91-99750A1 or DMT 2000 Digital Tachometer Multi-meter 91-854009A1 Multi-Meter DVA Tester 91-99750A1 DMT 2000 Digital Tachometer Multi-meter 91-854009A1 90-884294 OCTOBER 2001 Page 5B-3...

  • Page 430: Power Trim Components (Oildyne)

    POWER TRIM - DESIGN II Power Trim Components (Oildyne) Page 5B-4 90-884294 OCTOBER 2001...
  • Page 431 POWER TRIM - DESIGN II Power Trim Components (Oildyne) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft – POWER TRIM ASSEMBLY–Complete TRIM MOTOR ARMATURE END FRAME SCREW (M6 x 30) LOCKWASHER DRIVE SHAFT CHECK VALVE KIT 13.5 RELIEF VALVE ASSEMBLY SHAFT KIT (Includes. Ref. #26) GROOVE PIN TILT CYLINDER ASSEMBLY END CAP (Includes.

  • Page 432: Power Trim Motor (Oildyne)

    POWER TRIM - DESIGN II Power Trim Motor (Oildyne) 58446 58449 TORQUE REF. QTY. DESCRIPTION lb.in. lb.ft. N·m – POWER TRIM MOTOR BRUSH AND SEAL KIT ARMATURE KIT END FRAME Page 5B-6 90-884294 OCTOBER 2001...

  • Page 433: Power Trim - General Information

    POWER TRIM - DESIGN II Power Trim - General Information Description The Power Trim System consists of an electric motor, pressurized fluid reservoir, pump, tilt cylinder, and two trim rams. The remote control (or trim panel) has switches that trim the outboard “Up” or “Down” and tilt the engine for “Trailering”.

  • Page 434: Trailering Outboard

    POWER TRIM - DESIGN II TRIMMING OUTBOARD “DOWN” (IN): WARNING Excessive speed at minimum trim “In” may result in undesirable and/or unsafe steering conditions. Test for handling characteristics after any adjustment is made to the trim angle (and tilt pin location). Aids planing, particularly with heavy loads.

  • Page 435: Trim "In" Angle Adjustment

    POWER TRIM - DESIGN II Trim “In” Angle Adjustment WARNING Boat operation with outboard trimmed to the full “In” trim angle [not using the trim angle adjustment bolt] at planing speed may result in undesirable and/or un- safe steering conditions. A water test for handling/steering conditions is re- quired after any trim angle adjustments.

  • Page 436: Anode Plate

    POWER TRIM - DESIGN II Anode Plate Anode plate is a self-sacrificing alloy plate that is consumed gradually by corrosion while providing protection to the midsection and power trim from galvanic corrosion. Replace anode plate when it is 50% consumed. 58445 Anode Plate IMPORTANT: Do not paint or place protective coating on anode plate, or corrosion...
  • Page 437 POWER TRIM - DESIGN II TO FILL: IMPORTANT: This trim system is pressurized. Remove “Fill” plug only when out- board is tilted to the full “Up” position or the trim/tilt rams are fully extended. Re- tighten “Fill” plug before tilting outboard down or retracting tilt/trim rams. Remove “Fill”...

  • Page 438: Trim Circuit

    POWER TRIM - DESIGN II Trim Circuit When the up button is activated the electric motor (1) will rotate the oil pump gears (2). As the oil pump gears begin to rotate, oil is drawn through the up circuit suction check valve (3) and into the pump, supplying flow for the up circuit.
  • Page 439 POWER TRIM - DESIGN II Trim Circuit Ä Ä Ä Ä Ä Ä High Pressure Low Pressure Electric Motor Oil Pump/Gears Up Circuit Suction Check Valve Down Circuit Suction Check Valve Shuttle Spool Down Circuit Pressure Operated Valve Tilt Cylinder Up Circuit Pressure Operated Valve Trim Cylinders...

  • Page 440: Tilt Circuit

    POWER TRIM - DESIGN II Tilt Circuit In the up mode, as the trim rams (1) reach the limit of their travel, the mechanical check valve (2) of the trim relief valve, in the port trim ram piston (3), contacts the cylinder cap. The “pin”...
  • Page 441 POWER TRIM - DESIGN II Tilt Circuit Ä Ä Ä Ä High Pressure Low Pressure Trim Cylinders Trim Relief Valve Port Trim ram Tilt Cylinder Pump/Gears Up Circuit Suction Check Valve Electric Motor 90-884294 OCTOBER 2001 Page 5B-15...

  • Page 442: Down Circuit

    POWER TRIM - DESIGN II Down Circuit When you depress the down button, the power trim pump (1) is activated in the opposite direction. As the oil pump gears begin to rotate, oil is drawn through the down circuit suc- tion check valve (2) and into the pump, suppling flow for the down circuit.
  • Page 443 POWER TRIM - DESIGN II Down Circuit Ä Ä Ä Ä Ä Ä Ä Ä High Pressure Low Pressure Pump/Gears Down Circuit Suction Check Valve Down Pressure Regu- lating valve Reservoir Up Circuit Suction Check Valve Shuttle Spool Up Circuit Pressure Operated Valve Trim Cylinders Tilt Cylinder...
  • Page 444 POWER TRIM - DESIGN II Trail Over System Should the outboard motor strike a submerged object with light steady pressure, while in forward motion, oil will build up sufficient pressure in the top of the tilt cylinder (4) to open the piston trail over relief valve (7) (600 psi).

  • Page 445: Trail Over And Shock Absorber

    POWER TRIM - DESIGN II Trail Over and Shock Absorber Ä Ä Ä Ä High Pressure Up Circuit Pressure Operated Valve Down Circuit Pressure Operated Valve Manual Tilt Valve Tilt Cylinder Shock Piston Memory Piston Impact Relief & Trail over Valves Return Valve 90-884294 OCTOBER 2001 Page 5B-19...
  • Page 446 POWER TRIM - DESIGN II Manual Tilt System If the outboard motor is to be raised or lowered manually, turn the manual release (tilt) valve (1) counterclockwise approximately 3 turns to the full out position. When in the full (out) position, oil in the tilt cylinder (2) can flow freely from the up side to the down side or from the down side to the up side.

  • Page 447: Manual Tilt

    POWER TRIM - DESIGN II Manual Tilt Ä Ä Ä Ä Low Pressure Manual Release Valve Tilt Cylinder Reservoir Pump Up Pressure Operated Valve Down Pressure Oper- ated Valve Trim Relief Valve Impact Relief Valves 90-884294 OCTOBER 2001 Page 5B-21...

  • Page 448: Troubleshooting

    POWER TRIM - DESIGN II Troubleshooting IMPORTANT: Determine if Electrical or Hydraulic problem exists. IMPORTANT: Acceptable power trim leak down should not exceed 1 in. (25.4 mm) (when measured at the tilt ram) in a 24 hour period. HYDRAULIC SYSTEM TROUBLESHOOTING CONDITION OF TRIM SYSTEM PROBLEM Trim motor runs;...
  • Page 449 POWER TRIM - DESIGN II ELECTRICAL SYSTEM TROUBLESHOOTING CONDITION OF TRIM SYSTEM PROBLEM A. Trim motor does not run when trim button is depressed. 1, 2, 4, 5, 6, 7, 8 B. Trim system trims opposite of buttons. C. Cowl mounted trim buttons do not activate trim system. 2, 4, 5, 6, 7 PROBLEM 1.

  • Page 450: Power Trim System With Relays And 2 Wire Trim Motor

    POWER TRIM - DESIGN II Power Trim System with Relays and 2 Wire Trim Motor 53794 UP Relay DOWN Relay BLK = Black BLU = Blue GRN = Green RED = Red WHT = White Page 5B-24 90-884294 OCTOBER 2001...

  • Page 451: Electrical System Troubleshooting

    POWER TRIM - DESIGN II Electrical System Troubleshooting General Checks Before troubleshooting the Power Trim electrical system, check the following: 1. Check for disconnected wires. 2. Make certain all connections are tight and corrosion free. 3. Check that plug-in connectors are fully engaged. 4.

  • Page 452: Troubleshooting The "Up" Circuit

    POWER TRIM - DESIGN II Troubleshooting the “Up” Circuit Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. No Voltage Indicated: Battery Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 7 and black lead to ground.

  • Page 453: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)

    POWER TRIM - DESIGN II Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative) Check in-line fuse (under cowl) to see if fuse is blown. Fuse Not Blown: Blown Fuse: Connect Voltmeter red lead to Correct problem that caused Point 3 and black lead to fuse to blow.

  • Page 454: Power Trim Assembly Removal And Installation

    POWER TRIM - DESIGN II Power Trim Assembly Removal and Installation Removal 1. Remove clamps on transom bracket to free power trim wiring. 2. Raise outboard to full “Up” position and engage tilt lock lever. 3. Remove trim indicator. 58448 50605 Clamps Tilt Lock Lever...
  • Page 455 POWER TRIM - DESIGN II IMPORTANT: Support outboard as shown above to prevent engine from tipping when power trim retaining pin is removed. SUPPORT TOOL 3/8 in. diameter metal rod (a used shift shaft works well) 14” 2” 1/4” Drill holes for retaining clips METRIC CONVERSION 14 in.
  • Page 456 POWER TRIM - DESIGN II IMPORTANT: Cross pin should not be reused. Replace with new cross pin. NOTE: 6 trim mounting bolts should not be reused. Replace with new patch lock bolts. 6. Drive out cross pin, push out upper swivel pin, and remove 3 bolts and washers in port clamp bracket.

  • Page 457: Installation

    POWER TRIM - DESIGN II Installation NOTE: Upper swivel pin bushings in swivel bracket should be inspected for wear and re- placed as required. The trim rod shoes in the swivel bracket should also be replaced. 1. Paint any exposed metal surfaces to prevent corrosion. 2.
  • Page 458 POWER TRIM - DESIGN II 6. Connect trim motor wires to relays. Refer to Wiring Diagrams in this manual. Route trim wires as specified in this manual. NOTE: The 2 power leads going to the trim motor should be encapsulated with conduit tubing.

  • Page 459: Testing Power Trim System With Test Gauge Kit (91-52915A6)

    POWER TRIM - DESIGN II Testing Power Trim System With Test Gauge Kit (91-52915A6) IMPORTANT: This test will not locate problems in the trim system. The test will show if the system is correct after a repair. If minimum pressures are not obtain- able, the trim system requires additional repair.
  • Page 460 POWER TRIM - DESIGN II 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 Brass Fitting Test Gauge Assembly Tilt Pin (Position in Hole Shown) Hose Hose (Not Used) 6. Reinstall fill plug. 7. Run trim “UP”. 8.
  • Page 461 POWER TRIM - DESIGN II CAUTION Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could result in transom bracket failure and possible injury. 9. Move outboard “IN” until hole in swivel bracket “ear” aligns with the 3rd tilt hole in tran- som bracket.

  • Page 462: Down" Pressure Check

    POWER TRIM - DESIGN II “DOWN” Pressure Check IMPORTANT: Insure battery is fully charged before performing tests. 1. Tilt outboard to full “Up” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed pressure from reservoir. 3. Remove circlip securing manual release valve and unscrew release valve from trim assembly.
  • Page 463 POWER TRIM - DESIGN II 5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor. 54459 Brass Fitting Test Gauge Assembly Tilt Pin (Position in Hole Shown) Hose Hose (Not Used) OPEN Valve CLOSE Valve 6. Reinstall fill plug. 7.

  • Page 464: Hydraulic Repair

    POWER TRIM - DESIGN II Hydraulic Repair TRIM ROD REMOVAL AND REPAIR NOTE: Power Trim does not have to be removed from outboard to remove trim rods. 1. Tilt outboard to full “UP” position and engage tilt lock lever. 2. Slowly remove “Fill” plug to bleed reservoir pressure. 3.

  • Page 465: Trim Rod End Cap Seal

    POWER TRIM - DESIGN II CLEANING AND INSPECTION - TRIM RODS AND CAPS CAUTION Do not remove check valve. Check valve is preset to operate at a specific pres- sure. Removal and installation of check valve could result in improper operating pressure and possible system damage.
  • Page 466 POWER TRIM - DESIGN II TRIM ROD INSTALLATION IMPORTANT: Components must be free of dirt and lint. Any debris in the system can cause system to malfunction. NOTE: Install trim rod with check valve in the port (left) cylinder. 1. Apply ATF Dexron III or Power Trim and Steering Fluid on all O-rings and seals before installation.

  • Page 467: Tilt Ram

    POWER TRIM - DESIGN II Tilt Ram REMOVAL - TILT ROD ASSEMBLY ONLY NOTE: Tilt Rod Assembly can be removed from cylinder without removing entire power trim system from outboard. TILT RAM COMPONENTS Tilt Cylinder Rod Shock Springs – (1 is RED for low speed trail Scraper Seal over)

  • Page 468: Disassembly

    POWER TRIM - DESIGN II TILT RAM REMOVAL - POWER TRIM SYSTEM REMOVED FROM OUTBOARD CAUTION Insure trim system is depressurized prior to tilt ram removal. 1. Remove cross pin. 2. Remove lower swivel pin. 51355 51366 Cross Pin (Remove as shown) Lower Swivel Pin (Remove as shown) Disassembly 1.
  • Page 469 POWER TRIM - DESIGN II 2. Clamp tilt rod in a soft jawed vise. Remove bolt or nut as applicable to disassemble rod assembly. Remove O-ring. 51378 51340 Stud/Nut O-Ring IMPORTANT: Design 1 tilt rod assembly can be used to replace a Design 2 tilt rod assembly.

  • Page 470: Memory Piston Removal

    POWER TRIM - DESIGN II 4. Remove end cap from tilt rod. 51376 End Cap Memory Piston Removal 1. Remove memory piston from cylinder using Snap-On lock ring pliers SRP-4 or similar tool. 2. Remove o-ring from memory piston. SRP-4 (Snap-On) 51144 Memory Piston O-Ring...

  • Page 471: Cleaning/Inspection/Repair

    POWER TRIM - DESIGN II Cleaning/Inspection/Repair 1. Inspect all internal parts for damage or wear. Clean and replace parts as necessary. 2. Inspect tilt rod for scratches. Replace scraper seal in rod end cap if tilt rod is scratched or worn. 3.
  • Page 472 POWER TRIM - DESIGN II REASSEMBLY IMPORTANT: Components must be clean for reassembly. Any debris in the system can cause the system to malfunction. NOTE: Refer to “Tilt Ram Components” for proper O-ring sizes. 1. Apply ATF Dexron III or Power Trim and Steering Fluid on O-rings prior to reassembly. 2.
  • Page 473 POWER TRIM - DESIGN II 7. Install components on rod. 51363 51340 Piston O-ring Check Valve Assembly (7) Washer Locknut [Torque to 95 lb. ft. (129 N m)] 8. Clamp cylinder in a soft jawed vise and install tilt rod assembly. Use spanner wrench and tighten end cap securely.
  • Page 474 POWER TRIM - DESIGN II TILT RAM ASSEMBLY INSTALLATION 1. Lubricate alignment tool (91-11230) and shaft. Use ATF Dexron III or Power Trim and Steering Fluid. Alignment Tool (91-11230) Shaft 2. Align tilt ram and housing using alignment tool. 3. Install shaft. 51348 58603 Alignment Tool (91-11230)

  • Page 475: Power Trim Disassembly

    POWER TRIM - DESIGN II Power Trim Disassembly IMPORTANT: Power trim is pressurized. Trim rams must be in the full up position (fully extended) prior to fill/drain plug or manual release valve removal. 1. Remove reservoir cap to drain oil. 2.

  • Page 476: Trim Motor Removal

    POWER TRIM - DESIGN II 4. Inspect reservoir cover O-ring for cuts or abraisions. Replace O-ring as required. 58605 O-Ring Trim Motor Removal 1. Secure power trim assembly in a soft jaw vise. 2. Remove 2 screws securing motor and remove motor. Remove motor O-ring (yellow) and coupler.

  • Page 477: Pump And Component Removal

    POWER TRIM - DESIGN II Pump and Component Removal 1. Remove 3 screws securing oil pump. NOTE: There are no serviceable parts within the oil pump. Failure of or damage to internal components of the pump requires pump assembly replacement. 2.
  • Page 478 POWER TRIM - DESIGN II IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet. Inspect o-rings on both seats and spool for cuts or abraisions. Replace o-rings as required. 58607 Poppet Assembly Debris on Rubber Seat Neoprene Seat Spool...

  • Page 479: Motor And Electrical Tests/Repair

    POWER TRIM - DESIGN II Motor and Electrical Tests/Repair Trim Pump Motor Test WARNING Do not perform this test near flammable materials, as a spark may occur while making electrical connections. 1. Connect a 12 volt power supply to motor wires; one motor lead to POSITIVE (+) bat- tery terminal and the other motor lead to the NEGATIVE (–) battery terminal.

  • Page 480: Armature Tests

    POWER TRIM - DESIGN II 2. Remove frame and armature from end cap. Use care not to drop armature. 53779 Armature End Cap Armature Tests TEST FOR SHORTS Check armature on a Growler per the Growler manufacturer’s instructions. Replace ar- mature if a short is indicated.

  • Page 481: Motor Repair

    POWER TRIM - DESIGN II CHECKING AND CLEANING COMMUTATOR 1. If commutator is worn, replace armature. 53775 Commutator FIELD TESTS IMPORTANT: Commutator end of armature must be installed in brushes when per- forming the following tests. Ohmmeter Resistance Scale Reading* Leads Between (Ohms) (x____________)
  • Page 482 POWER TRIM - DESIGN II CLEANING AND INSPECTION Inspect O-rings and replace if necessary. Carefully inspect power cord for cuts or tears which will allow water to enter motor. If cord is cut or torn, replace motor and power cord as an assembly.
  • Page 483 POWER TRIM - DESIGN II END CAP INSPECTION 1. Inspect seal and O-ring for cuts and abraisions. 2. Inspect bushing for wear. If bushing appears to be excessively worn – grooves, scratches, etc. – replace END FRAME ASSEMBLY (COMPLETE). 53785 53783 Seal (Apply 2-4-C Marine Lubricant with Teflon to seal lips) O-ring...

  • Page 484: Reassembly

    POWER TRIM - DESIGN II Reassembly IMPORTANT: Components must be clean. Any debris in power trim system can cause system to malfunction. 1. Install armature into end cap/brush card assembly. 53779 53784 Armature Shim End Cap Assembly Armature (Spread brushes to install armature into end cap) 2.
  • Page 485 POWER TRIM - DESIGN II IMPORTANT: Attach Vise Grip pliers to armature shaft before installing frame as- sembly. The Vise Grip pliers will prevent the armature from being drawn out of the brush card assembly by the frame magnets while installing the frame assembly. 3.

  • Page 486: Reassembly - Motor And Pump

    POWER TRIM - DESIGN II Reassembly - Motor and Pump NOTE: Drive shaft is a loose part and may fall out of position. 1. Install pump into power trim manifold. Insure O-rings are in proper locations. Secure with 3 screws. Torque screws to 60 lb. in. (7 N·m). 58609 Oil Pump Screws (3) Torque to 60 lb.
  • Page 487 POWER TRIM - DESIGN II 4. Reinstall reservoir cover. Verify cover O-ring is in place and in serviceable condition. Secure cover with 4 screws. Torque screws to 60 lb. in. (7 Nm). 58605 58606 O-Ring Reservoir Cover Screws [Torque to 60 lb. in. (7 Nm)] 5.

  • Page 488: Priming Power Trim System

    POWER TRIM - DESIGN II Priming Power Trim System 1. Fill system with Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) Dexron III. Refer to “Fill, Check, and Purge” on page 5B-10. IMPORTANT: Run Trim System in short “jogs” until pump motor primes and trim system moves.

  • Page 489: Digital Trim Sender

    POWER TRIM - DESIGN II Trim Indicator Gauge Needle Adjustment 1. Turn ignition key to “RUN” position. 2. Tilt outboard to full “IN” position. Needle of trim indicator gauge should be in full “IN” position. 3. If not, tilt outboard to full “OUT” position to gain access to trim sender and engage tilt lock lever.

  • Page 490: Troubleshooting Digital Trim Sender

    POWER TRIM - DESIGN II Troubleshooting Digital Trim Sender Trim sender requires a 5 vdc reference signal from ECU. With the ignition switch in the RUN position and using an appropriate probe (paper clip, etc.) inserted in parallel at the trim sender bullet connectors, this voltage can be checked as follows: Voltmeter Sender Harness...

  • Page 491: Trim Indicator Wiring Diagrams

    POWER TRIM - DESIGN II Trim Indicator Wiring Diagrams Wiring Diagram - For boats equipped with Quicksilver Commander Series side mount remote control. Wiring Diagram - For boats equipped with Quicksilver Ignition/Choke and Main Harness Assembly. 22908 Trim Indicator Remote Control Trim Sender Engine Ground To Engine...
  • Page 492 RIGHT HAND NON-RATCHETING LOWER UNIT Section 6A – Right Hand Non-Ratcheting Table of Contents Gear Housing Specifications (Standard Rotation) 6A-1 Pinion Bearing ......6A-46 Special Tools .

  • Page 493: Special Tools

    RIGHT HAND NON-RATCHETING Special Tools 1. Gear Housing Cover Nut Tool 91-61069 2. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716 3. Slide Hammer Puller 91-34569A1 4. Bearing Removal and Installation Kit 91-31229A5. This kit contains the following tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plate 91-29310; Mandrel 91-38628;...
  • Page 494 RIGHT HAND NON-RATCHETING 7. Puller Plate 91-29310 8. Mandrel 91-38628 9. Driver Rod 91-37323 10. Universal Puller Plate 91-37241 11. Driveshaft Holding Tool 91-56775 12. Oil Seal Driver 91-31108 13. Forward Gear Bearing Tool 91-877321A1 14. Bearing Driver Cup 91-31106 15.
  • Page 495 RIGHT HAND NON-RATCHETING 16. Backlash Indicator Rod 91-53459 for (1.75:1 ratio) and 91-78473 for (1.87:1 ratio) 17. Dial Indicator 91-58222A1 18. Bearing Retainer Tool 91-43506 19. Bearing Preload Tool 91-14311A2 Plate (44307) Bolt (10-12580) Adaptor (N.S.S.) Nut (11-13953) Bearing (N.S.S.) Set Screw (10-12575) Washer (N.S.S.)
  • Page 496 RIGHT HAND NON-RATCHETING 23. Leakage Tester FT8950 24. Oil Seal Driver 91-817569 25. Water Pump Alignment Pins 91-821571A1 26. Bearing Adaptor Installation Tool 91-18605A2 90-884294 OCTOBER 2001 Page 6A-5...

  • Page 497: Gear Housing (Drive Shaft)(Standard Rotation)

    RIGHT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Standard Rotation) 4.75 IN/120.65MM TORPEDO DIA. Loctite 271 Loctite 7649 Primer 2-4-C Marine Lubricant With Teflon Page 6A-6 90-884294 OCTOBER 2001...
  • Page 498 RIGHT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Standard Rotation) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BASIC) FILLER BLOCK PITOT TUBE ANODE SCREW ROLLER BEARING DOWEL PIN SCREW ASSEMBLY SEALING WASHER HOSE(LONG - 7 IN) HOSE (X-LONG - 12 IN) HOSE(XX-LONG - 17 IN) CONNECTOR COVER...

  • Page 499: Gear Housing (Prop Shaft)(Standard Rotation)

    RIGHT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Standard Rotation) 4.75 IN/120.65MM TORPEDO DIA. Premium Gear Lubricant Anti-Corrosion Grease 2-4-C Marine Lubricant With Teflon Page 6A-8 90-884294 OCTOBER 2001...
  • Page 500 RIGHT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Standard Rotation) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING (BASIC) PLUG SHIFT CRANK SHAFT SHIFT SPOOL COTTER PIN SLEEVE FORWARD/PINION GEAR SET (1.75:1 - 12/21) SHIM SET TAPERED ROLLER BEARING RETAINING RING ROLLER BEARING SPRING SLIDING CLUTCH DETENT PIN...

  • Page 501: General Service Recommendations

    RIGHT HAND NON-RATCHETING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveal that disassembly is required for replacement of one or more components.

  • Page 502: Removal, Disassembly, Cleaning And Inspection - Standard Rotation

    RIGHT HAND NON-RATCHETING Removal, Disassembly, Cleaning and Inspection – Standard Rotation Removal WARNING Disconnect high tension leads from spark plugs and remove spark plugs from engine before removing gear housing from driveshaft housing. 1. Disconnect high tension leads from spark plugs and remove spark plugs from engine. 2.
  • Page 503 RIGHT HAND NON-RATCHETING 7. While pressing in on speedometer hose junction, pull out on hose to disconnect. 57735 Press in on Junction Pull out on Hose 8. Loosen the side mounting locknuts. (Do not attempt to remove one nut before oppo- site side is loosened sufficiently, or gear housing could be damaged.) 52374 Side Mounting Locknuts (2 each side)

  • Page 504: Draining And Inspecting Gear Housing Lubricant

    RIGHT HAND NON-RATCHETING Draining and Inspecting Gear Housing Lubricant 1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical position. NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later models.

  • Page 505: Water Pump

    RIGHT HAND NON-RATCHETING Water Pump REMOVAL AND DISASSEMBLY 1. Remove the water seal, water tube coupling assembly, and the water pump screws. 57944 Water Seal Water Tube Coupling Water Pump Screws (4) 2. Carefully slide the water pump straight up off of the drive shaft. It may be necessary to encourage the water pump up by gently prying up on its mounting flanges with a couple of screwdrivers.
  • Page 506 RIGHT HAND NON-RATCHETING 3. Remove the impeller, impeller key, the face plate and gaskets. Discard the gaskets. 70605 Impeller Water Pump Face Plate Impeller Key Gasket (1 each side of face plate) CLEANING AND INSPECTION 1. Inspect the water tube coupling assembly for wear or damage. If necessary replace the worn or damaged components, especially the two O-rings on the inside, one at the top and one at the bottom.

  • Page 507: Oil Seal Carrier Assembly

    RIGHT HAND NON-RATCHETING 4. Inspect impeller side seal surfaces and ends of impeller blades for cracks, tears and wear. Replace impeller if any of these conditions are found. 5. Inspect impeller bonding to impeller hub. 6. Inspect impeller for glazed or melted appearance (caused by operation without suffi- cient water supply).
  • Page 508 RIGHT HAND NON-RATCHETING OIL SEAL CARRIER ASSEMBLY - COMPONENT DISASSEMBLY NOTE: Complete the instructions in this section only if the assembly components have been found to be defective and are in need of repair or replacement. 1. Remove the o-ring. 70501 O-ring Oil Seals (2)
  • Page 509 RIGHT HAND NON-RATCHETING OIL SEAL CARRIER ASSEMBLY – COMPONENT REASSEMBLY The oil seals in the carrier assembly are the same diameter. The bottom (first) seal lip faces down; the top (second) seal lip faces up. Apply 2-4-C Marine Lubricant with Teflon to seal lips and between seals.
  • Page 510 RIGHT HAND NON-RATCHETING 2. Remove the bearing carrier retainer following step a or b as follows: CAUTION DO NOT drill into the gear housing retainer threads when using the following pro- cedure for removing the retainer a. If the retainer is corroded in place, drill 4 holes in the retainer and fracture the re- tainer with a chisel.
  • Page 511 RIGHT HAND NON-RATCHETING 3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing carrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER. NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat to loosen the carrier.
  • Page 512 RIGHT HAND NON-RATCHETING 4. Inspect reverse gear to pinion gear wear pattern (should be even and smooth). If not, replace reverse gear and pinion gear. 5. Check clutch jaws on reverse gear for damage. Replace reverse gear, if damage is found on clutch jaws.
  • Page 513 RIGHT HAND NON-RATCHETING IMPORTANT: The bearing MUST BE replaced if removed from gear. 5. Place the universal puller plate between the thrust washer and bearing as shown and press on the plate until it bottoms. 23351 Universal Puller Plate (91-37241) Thrust Washer Bearing 6.
  • Page 514 RIGHT HAND NON-RATCHETING NOTE: Inspection of the bearing surfaces on the propeller shaft where the needles of the bearing carrier needle bearing rolls, gives an indication of the condition of the needle bearing inside the bearing carrier. Replace needle bearing in the bearing carrier if the prop shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em- bedded particles.
  • Page 515 RIGHT HAND NON-RATCHETING BEARING CARRIER ASSEMBLY Component Reassembly NOTE: Complete the instructions in this section only if the assembly components have been disassembled and repaired or replaced. 1. Clean all of the components with a suitable solvent and dry the parts thoroughly using compressed air.
  • Page 516 RIGHT HAND NON-RATCHETING 5. Thoroughly clean the bore in which the first seal is to be pressed. 6. Assemble the first seal (with the lips of the seal facing away from the driver shoulder) onto the long end of the oil seal driver. 7.
  • Page 517 RIGHT HAND NON-RATCHETING 13. Install the thrust washer and a new ball bearing onto the reverse gear. Press on the inner race of the ball bearing using the pilot washer until the bearing bottoms out on the gear. 23346 Pilot Washer Thrust Hub (91-36571) Reverse Gear...

  • Page 518: Drive Shaft Assembly

    RIGHT HAND NON-RATCHETING 16. Lubricate the O-ring with 2-4-C Marine Lubricant with Teflon and install the O-ring onto the bearing carrier. 2-4-C Marine Lubricant With Teflon 23354 O-ring Bearing Carrier Drive Shaft Assembly REMOVAL 1. Remove the drive shaft pinion nut as follows: a.
  • Page 519 RIGHT HAND NON-RATCHETING e. If the drive shaft is broken, place propeller shaft nut wrench onto the propeller shaft splines, hold shift shaft in forward gear and loosen, (but do not fully un- screw), the pinion nut by rotating prop shaft counterclockwise to turn gears, thus loosening the pinion nut.
  • Page 520 RIGHT HAND NON-RATCHETING NOTE: If pinion gear is seized onto the driveshaft, place gearcase in vise using soft jaw vise covers. Place a block of wood on gear housing mating surface. Use a mallet and care- fully tap gear housing away from drive shaft. CAUTION Do not strike gear housing hard with mallet or allow gear housing to fall.
  • Page 521 RIGHT HAND NON-RATCHETING DISASSEMBLY 1. Both upper and lower tapered roller bearings can be removed from the drive shaft in one operation. Using the bottom bearing cup removed from the gearcase, place the cup on top of a vise leaving the vise jaws open enough to allow the drive shaft to slide through.
  • Page 522 RIGHT HAND NON-RATCHETING REASSEMBLY NOTE: Complete the instructions in this section only if the components have been disas- sembled 1. Apply a light coat of Premium Gear Lubricant on l.D. of drive shaft tapered bearing. Apply High Pressure Grease (such as Chicago Manufacturing and Distributing Lube #3) to the O.D.

  • Page 523: Propeller Shaft Assembly And Forward Gear Bearing Cup

    RIGHT HAND NON-RATCHETING Propeller Shaft Assembly and Forward Gear Bearing Cup REMOVAL 1. Tilt the propeller shaft to the port side of the gear housing and remove the shaft by pulling it straight up and out. 58016 Propeller Shaft Assembly Shift Spool Shift Crank Thrust Washer (Reverse Gear)
  • Page 524 RIGHT HAND NON-RATCHETING PROPELLER SHAFT ASSEMBLY - Component Disassembly NOTE: When accomplishing the next step, all of the parts are free to come apart. Work closely over a work bench to ensure that the parts are not dropped or damaged and to avoid personal injury 1.
  • Page 525 RIGHT HAND NON-RATCHETING 4. Inspect the propeller shaft splines at both ends for a broken, worn, or twisted condi- tion. Replace the propeller shaft if any of these conditions exists. 5. Inspect the surface of the propeller shaft where the bearing carrier seal lips contact the shaft.

  • Page 526: Forward Gear Assembly

    RIGHT HAND NON-RATCHETING 9. Measure propeller shaft FORWARD to REVERSE shoulder length. If measurement is under 2.040 in. (51.82mm), replace propeller shaft. 2.040 in. (51.82mm) 23355 10. Inspect REVERSE thrust washer for wear or taper. Measure thickness of washer. If thickness is LESS than 0.240 in.
  • Page 527 RIGHT HAND NON-RATCHETING 4. Inspect the needle bearings on the inside of the forward gear and the bearing surface on the propeller shaft. If either the needle bearing or the bearing surface of the propel- ler shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has embedded particles, replace the propeller shaft and remove and replace the needle bearing in the forward gear as outlined in the next section.
  • Page 528 RIGHT HAND NON-RATCHETING 3. If inspection determines that replacement of propeller shaft needle bearings is re- quired, remove bearing as follows: a. Clamp forward gear in a soft jaw vise securely. b. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and hammer to remove bearing.

  • Page 529: Shift Spool Assembly

    RIGHT HAND NON-RATCHETING 2. Install retaining ring into groove of forward gear by starting at one end of retaining ring and working it around until seated in groove. 57905 Retaining Ring Groove in Forward Gear Shift Spool Assembly INSPECTION 1. Clean the assembly with a suitable solvent and dry the parts using compressed air. 2.
  • Page 530 RIGHT HAND NON-RATCHETING NOTE: If the spool spins freely and has the proper clearance, it will not be necessary to disassemble and reassemble the spool. If the spool does not function properly, proceed with the following disassembly procedures. SHIFT SPOOL DISASSEMBLY NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts due to an improperly functioning shift spool assembly or debris in the gear housing and/or shift spool assembly.

  • Page 531: Propeller Shaft Assembly

    RIGHT HAND NON-RATCHETING Propeller Shaft Assembly COMPONENT REASSEMBLY 1. Install the sliding clutch on the propeller shaft. Align cross pin holes in the clutch with the slot in the propeller shaft. 2. Assemble the forward gear assembly to the propeller shaft. 3.

  • Page 532: Shift Shaft Assembly

    RIGHT HAND NON-RATCHETING Shift Shaft Assembly REMOVAL NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank inside the gear case) without removing any of the internal components of the gear hous- ing. 1.
  • Page 533 RIGHT HAND NON-RATCHETING SHIFT SHAFT ASSEMBLY - Component Disassembly and Inspection 1. Slide the bushing assembly off the shift shaft. Remove the coupler from the shaft. 57954 Shift Shaft Bushing Assembly O-ring Shift Shaft Gasket Rubber Washer 2. Clean all components with a suitable solvent and dry thoroughly with compressed air. a.
  • Page 534 RIGHT HAND NON-RATCHETING 3. Inspect the shift shaft splines and oil seal surface for corrosion and/or excessive wear. Replace the shift shaft if either if these conditions are found. 57948 Oil Seal Surface Spline SHIFT SHAFT ASSEMBLY - Component Reassembly 1.

  • Page 535: Pinion Bearing

    RIGHT HAND NON-RATCHETING Pinion Bearing REMOVAL NOTE: Inspect the bearing surface on the drive shaft where the needles of the lower pin- ion bearing roll. The condition of the drive shaft at this location gives an indication of the condition of the needle bearing. Replace lower pinion bearing (needles and race as a set) if the drive shaft is pitted, grooved scored, worn unevenly, discolored from overheating, or has embedded particles.

  • Page 536: Gear Housing Reassembly

    RIGHT HAND NON-RATCHETING Gear Housing Reassembly Gear Housing Inspection 1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush. Dry the gear housing thoroughly using compressed air. Insure that all sealants, lock- ing agents and debris are removed. 2.

  • Page 537: Pinion Bearing

    RIGHT HAND NON-RATCHETING Pinion Bearing INSTALLATION IMPORTANT: Install only a new pinion bearing. Do not reinstall a pinion bearing that has been previously removed from a gear housing. 1. Lubricate the bore into which the pinion bearing is to be installed with Premium Gear Lubricant.

  • Page 538: Forward Gear Bearing Cup

    RIGHT HAND NON-RATCHETING Forward Gear Bearing Cup INSTALLATION Forward Gear Backlash – .017 in. to .028 in. (0.43mm to 0.71mm) NOTE: If the forward gear, forward gear bearing and cup, or gear housing were not re- placed, install the same quantity of shims that were taken out when cup was removed. If the forward gear, forward gear bearing/cup, or gear housing were replaced, install 0.020 in.

  • Page 539: Shift Shaft Assembly

    RIGHT HAND NON-RATCHETING 3. Press the bearing cup into the gear housing using the installation tool as follows: IMPORTANT: Verify that the bearing cup is positioned as straight as possible to avoid cocking it in the bore while pressing it in. Premium Gear Lubricant 50791 Hex-Head Screw...
  • Page 540 RIGHT HAND NON-RATCHETING 2. Install the shift shaft assembly into the gear housing as shown. Engage the splined end of the shift shaft with the shift crank. Verify O-ring is positioned properly and lubri- cated with 2-4-C Marine Lubricant with Teflon. Secure shift shaft bushing with 2 screws.

  • Page 541: Propeller Shaft Assembly

    RIGHT HAND NON-RATCHETING Propeller Shaft Assembly INSTALLATION 1. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end of the propeller shaft assembly to the left (port) side of gear housing and rotate the shift shaft from reverse to neutral while installing shaft.

  • Page 542: Drive Shaft And Pinion Gear

    RIGHT HAND NON-RATCHETING Drive Shaft and Pinion Gear INSTALLATION NOTE: If the original shims were not retained or if pinion gear, drive shaft, drive shaft up- per tapered roller bearing and cup, or gear housing were replaced, start off by installing a 0.038 in.
  • Page 543 RIGHT HAND NON-RATCHETING 2. Apply Loctite 271 to the threads of the pinion gear nut and place the pinion gear nut into the MR slot of the pinion nut adapter. NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear. 3.
  • Page 544 RIGHT HAND NON-RATCHETING 8. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and the pinion nut adaptor in position. 9. Torque the pinion nut to 75 lb. ft. (102 Nm) by turning the drive shaft using the drive shaft nut wrench and torque wrench.

  • Page 545: Gear Location/Backlashes/Checking And Adjustment

    RIGHT HAND NON-RATCHETING Gear Location/Backlashes/Checking and Adjustment Drive Shaft - Bearing Preload Tool INSTALLATION 1. Install the components from the Bearing Preload Tool Kit (91-14311A2), over the drive shaft in the order shown. 70496 Top Nut with Threaded Pipe Spring Thrust Washer (2 Required) (12-18448) Thrust Bearing Thrust Washer...

  • Page 546: Pinion Gear Location

    RIGHT HAND NON-RATCHETING 3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom nut away from top nut. 57937 Distance 1 in. (25.4mm) Bottom nut [screwed down approximately 1 in. (25.4mm)] Pinion Gear Location CHECKING AND ADJUSTING Pinion Depth –...
  • Page 547 RIGHT HAND NON-RATCHETING 6. If the average pinion gear height is not correct, remove the bearing preload tool, the drive shaft retainer and the drive shaft tapered roller bearing cup. (The cup can be removed by wiggling the drive shaft back and forth or by turning gear housing and shaking it.) Add or subtract shims beneath the cup to obtain the proper average pinion gear height.
  • Page 548 RIGHT HAND NON-RATCHETING UPPER DRIVESHAFT BEARING CLEARANCE 1. When the correct pinion gear height is achieved, remove pinion nut, upper retainer and driveshaft. 2. Apply Premium Gear Lubricant to O.D. of the driveshaft lower bearing cup and install cup into the gear case. 3.

  • Page 549: Bearing Carrier Assembly

    RIGHT HAND NON-RATCHETING 9. With new shim(s) under lower bearing cup, reinstall upper bearing cup and torque cup retainer to 100 lb. ft. (135.5 Nm). Recheck drive shaft clearance. NOTE: Install a NEW pinion nut with Loctite 271 AFTER all clearances are correct. 10.
  • Page 550 RIGHT HAND NON-RATCHETING 3. Verify that the “V” shaped tab aligns with the “V” notch in bearing carrier. 70714 Tab Washer “V” Tab 4. Lubricate the bearing carrier retainer threads with 2-4-C Marine Lubricant with Teflon. Start the retainer into the gear housing threads and screw it down fully by hand. 2-4-C Marine Lubricant with Teflon 70715 Bearing Carrier Retainer...

  • Page 551: Forward Gear Backlash

    RIGHT HAND NON-RATCHETING Forward Gear Backlash CHECKING 1. Apply forward pressure to propeller shaft as follows: a. Attach puller jaws and puller bolt onto bearing carrier bosses and propeller shaft. 70719 Puller Jaws (91-46086A1) Puller Bolt (91-85716) b. Torque the puller bolt to 45 lb. in. (5 Nm). Rotate drive shaft three full turns clock- wise and retorque the bolt to 45 lb.

  • Page 552: Reverse Gear Backlash

    RIGHT HAND NON-RATCHETING 3. Take the backlash readings by lightly turning the drive shaft back and forth, (no move- ment should be noticed at the propeller shaft). a. Observe the dial indicator and record the reading. b. Loosen the indicator tool and rotate the drive shaft 90 degrees in a clockwise di- rection.
  • Page 553 RIGHT HAND NON-RATCHETING 2. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and touching the “I” mark on the dial indicator tool. Tighten the indicator tool onto the drive shaft and rotate the drive shaft so that the needle in the dial makes at least one full revolution and comes to “0”...

  • Page 554: Drive Shaft - Bearing Preload Tool

    RIGHT HAND NON-RATCHETING Drive Shaft - Bearing Preload Tool REMOVAL CAUTION Before loosening the top nut allen screws of the bearing preload tool, screw the bottom nut up as close as possible to the top nut. 1. Remove the dial indicator and its supporting tooling. 2.

  • Page 555: Bearing Carrier Assembly

    RIGHT HAND NON-RATCHETING Bearing Carrier Assembly Final Installation 1. Remove the Bearing Carrier and lubricate the following as specified: a. Lubricate the carrier O-ring with 2-4-C Marine Lubricant with Teflon. b. Lubricate both the forward and aft outer diameters of the bearing carrier and gear case area where carrier will seat with 2-4-C Marine Lubricant with Teflon.
  • Page 556 RIGHT HAND NON-RATCHETING 4. Verify the “V” shaped tab aligns with the “V” notch in bearing carrier. 70714 Tab Washer “V” Tab 5. Fill the bearing carrier retainer nut threads and corresponding gear housing threads with 2-4-C Marine Lubricant with Teflon. Start the retainer into the gear housing threads and screw it down fully by hand.
  • Page 557 RIGHT HAND NON-RATCHETING IMPORTANT: Before torquing bearing carrier retainer, gear case must be bolted to drive shaft housing or securely fastened in a gear case holding fixture to avoid pos- sible damage to gear housing. 6. Torque the bearing carrier retainer to 210 lb. ft. (285 Nm). If one tab does not align up in space between two of the notches, continue to tighten retainer until alignment is achieved.

  • Page 558: Oil Seal Carrier Assembly

    RIGHT HAND NON-RATCHETING Oil Seal Carrier Assembly Installation NOTE: Apply hand pressure only to install the oil seal carrier into position. Do not hammer it into position. 1. Lubricate the oil seal carrier oil seal lips, space between seals and O-ring with 2-4-C Marine Lubricant with Teflon and install the oil seal carrier over the drive shaft and into the gear case.
  • Page 559 RIGHT HAND NON-RATCHETING 2. Place a small amount of 2-4-C Marine Lubricant with Teflon on the flat surface of the impeller key and install the key onto the drive shaft keyway. IMPORTANT: When using an impeller whose blades have taken a set, face the curl of the blades in a counterclockwise direction.
  • Page 560 RIGHT HAND NON-RATCHETING 6. Hand start two (2) fasteners into the water pump assembly and remove the water pump locating pins. Install the remaining 2 fasteners. Run all fasteners down and torque to 60 lb. in. (7 Nm). 7. Lightly lubricate the O-rings in the water tube coupling with 2-4-C Marine Lubricant with Teflon.

  • Page 561: Gear Lubricant Filling Instructions

    RIGHT HAND NON-RATCHETING Gear Lubricant Filling Instructions 1. Inspect “Fill” and “Vent” sealing washers for cuts or abrasions. Replace washers if necessary. 2. Clean any metal debris from magnet on “Fill” plug. IMPORTANT: Never apply lubricant to gear housing without first removing Vent screw, or gear housing cannot be filled because of trapped air.

  • Page 562: Propeller Installation

    RIGHT HAND NON-RATCHETING NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft splines, place a propeller onto propeller shaft. Shift gearcase into FORWARD and turn propeller counterclockwise as the gear housing is being pushed toward driveshaft hous- ing.
  • Page 563 RIGHT HAND NON-RATCHETING 2. Place forward thrust hub over propeller shaft with shoulder side toward propeller. 3. Place propeller on propeller shaft and slide it up against thrust hub. 4. Place continuity washer (if equipped) onto shoulder of rear thrust hub. 5.

  • Page 564: Speedometer Tube Installation

    RIGHT HAND NON-RATCHETING Speedometer Tube Installation 1. Route speedometer tube from gearcase around lower yoke and push into junction. Junction should be secured to yoke with sta-strap. 2. Route speedometer tube from swivel tube around lower yoke and push into junction. After insertion of speedometer tubes into junction, pull on each tube to verify that they are locked into junction.
  • Page 565 LEFT HAND NON-RATCHETING LOWER UNIT Section 6B – Left Hand Non-Ratcheting Table of Contents Gear Housing Specifications (Counter Rotation) 6B-1 Gear Location/Backlashes Checking and Special Tools ....... . 6B-2 Adjustment .

  • Page 566: Special Tools

    LEFT HAND NON-RATCHETING Special Tools 1. Propeller Shaft 44-93003 and Load Washer 12-37429 2. Bellville Washer 12-54048 3. Needle Bearing Driver 91-15755 4. Oil Seal Driver 91-31108 5. Universal Puller Plate 91-37241 6. Bearing Retainer Tool 91-43506 7. Backlash Indicator Rod 91-53459 Page 6B-2 90-884294 OCTOBER 2001...
  • Page 567 LEFT HAND NON-RATCHETING 8. Drive Shaft Nut Wrench 91-56775 9. Bearing Carrier Retainer Wrench 91-61069 10. Torque Wrench (lb. in.) 91-66274 11. Backlash Indicator Rod 91-78473 12. Puller Bolt 91-85716 and Puller Jaws 91-46086A1 13. Dial Indicator Holding Tool 91-89897 14.
  • Page 568 LEFT HAND NON-RATCHETING 15. Forward Gear Installation Tool 91-815850 16. Puller Jaws 91-816242 17. Guide Plate 91-816243 18. Bearing Driver 91-816244 19. Oil Seal Driver 91-817569 20. Water Pump Alignment Pins 91-821571A1 Page 6B-4 90-884294 OCTOBER 2001...
  • Page 569 LEFT HAND NON-RATCHETING 21. Pinion Gear Shimming Tool 91-12349A2 22. Bearing Preload Tool 91-14311A2 Plate (44307) Bolt (10-12580) Adaptor (N.S.S.) Nut (11-13953) Bearing (N.S.S.) Set Screw (10-12575) Washer (N.S.S.) Sleeve (23-13946) Spring (24-14111) 23. Bearing Adaptor Installation Tool 91-18605A2 90-884294 OCTOBER 2001 Page 6B-5...
  • Page 570 LEFT HAND NON-RATCHETING 24. Bearing Removal and Installation Tool 91-31229A7 – Includes Driver Head 91-36569: Driver Head Rod 91-37323; Nut 11-24156; Pilot Washer 91-36571; Pilot Plate 91-29310; Puller/Driver Head 91-38628; Mandrel 91-30366; Plate 91-29310; Driver Head 91-32325; Puller Shaft 91-31229; Washer 91-34961. 25.
  • Page 571 LEFT HAND NON-RATCHETING 28. Pinion Nut Adaptor 91-61067A3 29. Drive Shaft Adaptor 91-61077 30. Leakage Tester FT8950 90-884294 OCTOBER 2001 Page 6B-7...

  • Page 572: Gear Housing (Drive Shaft)(Counter Rotation)

    LEFT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Counter Rotation) 4.75 IN/120.65MM TORPEDO DIA. Loctite 271 Loctite 7649 Primer 2-4-C Marine Lubricant with Teflon Page 6B-8 90-884294 OCTOBER 2001...
  • Page 573 LEFT HAND NON-RATCHETING Gear Housing (Drive Shaft)(Counter Rotation) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING FILLER BLOCK PITOT TUBE ANODE SCREW ROLLER BEARING DOWEL PIN SCREW ASSEMBLY SEALING WASHER CONNECTOR (X-LONG - 12 IN.) CONNECTOR (XX-LONG - 17 IN) CONNECTOR COVER GASKET...

  • Page 574: Gear Housing (Prop Shaft)(Counter Rotation)

    LEFT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Counter Rotation) 4.75 IN/120.65MM TORPEDO DIA. Gear Lubricant Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon Page 6B-10 90-884294 OCTOBER 2001...
  • Page 575 LEFT HAND NON-RATCHETING Gear Housing (Prop Shaft)(Counter Rotation) TORQUE REF. QTY. DESCRIPTION lb-in lb-ft GEAR HOUSING PLUG SHIFT CRANK SHIFT SPOOL SPOOL SLEEVE COTTER PIN SHIM SET BEARING ADAPTOR ASSEMBLY ROLLER BEARING THRUST WASHER THRUST BEARING REVERSE GEAR (1.75:1 - 12/21) ROLLER BEARING SPRING SLIDING CLUTCH...

  • Page 576: General Service Recommendations

    LEFT HAND NON-RATCHETING General Service Recommendations There may be more than one way to “disassemble” or “reassemble” a particular part(s), therefore, it is recommended that the entire procedure be read prior to repair. IMPORTANT: Read the following before attempting any repairs. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more compo- nents.

  • Page 577: Removal, Disassembly, Cleaning And Inspection Of

    LEFT HAND NON-RATCHETING Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing REMOVAL WARNING Disconnect high tension leads from spark plugs and remove spark plugs from engine before removing gear housing from driveshaft housing. 1. Disconnect high tension leads from spark plugs and remove spark plugs from engine. 2.
  • Page 578 LEFT HAND NON-RATCHETING 7. While pressing in on speedometer hose junction, pull out on hose to disconnect. 57735 Press in on Junction Pull out on Hose 8. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo- site side is loosened sufficiently, or gear housing could be damaged.) Side Mounting Locknuts 9.
  • Page 579 LEFT HAND NON-RATCHETING DRAINING AND INSPECTING GEAR HOUSING LUBRICANT 1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical position, as shown. NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later models.

  • Page 580: Pre-Disassembly Inspection

    LEFT HAND NON-RATCHETING Pre-Disassembly Inspection Propeller Shaft INSPECTION 1. Check for a bent propeller shaft as follows: a. Rotate the propeller shaft while observing the dial indicator. If the deflection is more than 0.009 in. (0.23 mm), a bent propeller shaft is indicated. 2.

  • Page 581: Water Pump

    LEFT HAND NON-RATCHETING Water Pump REMOVAL AND DISASSEMBLY 1. Remove the water seal, water tube coupling assembly, and the water pump screws. 57944 Water Seal Water Tube Coupling Water Pump Screws (4) 2. Carefully slide the water pump straight up off of the drive shaft. It may be necessary to encourage the water pump up by gently prying up on its mounting flanges with a couple of screwdrivers.
  • Page 582 LEFT HAND NON-RATCHETING 3. Remove the impeller, impeller key, the face plate and gaskets, (discard the gaskets). 70605 Impeller Impeller Key Water Pump Face Plate Gasket (1 each side of face plate) CLEANING AND INSPECTION 1. Inspect the water tube coupling assembly for wear or damage. If necessary replace the worn or damaged components especially the two O-rings on the inside, one at the top and one at the bottom.

  • Page 583: Oil Seal Carrier Assembly

    LEFT HAND NON-RATCHETING 4. Inspect impeller side seal surfaces and ends of impeller blades for cracks, tears and wear. Replace impeller if any of these conditions are found. 5. Inspect impeller bonding to impeller hub. 6. Inspect impeller for glazed or melted appearance (caused by operation without suffi- cient water supply).
  • Page 584 LEFT HAND NON-RATCHETING OIL SEAL CARRIER ASSEMBLY - COMPONENT DISASSEMBLY NOTE: Complete the instructions in this section only if the assembly components have been found to be defective and are in need of repair or replacement. 1. Remove the o-ring. 70501 O-ring Oil Seals (2)
  • Page 585 LEFT HAND NON-RATCHETING OIL SEAL CARRIER ASSEMBLY – COMPONENT REASSEMBLY The oil seals in the carrier assembly are the same diameter. The bottom (first) seal lip faces down; the top (second) seal lip faces up. Apply 2-4-C Marine Lubricant with Teflon to seal lips and between seals.
  • Page 586 LEFT HAND NON-RATCHETING 2. Remove the bearing carrier retainer following step a or b as follows: CAUTION DO NOT drill into the gear housing retainer threads when using the following pro- cedure for removing the retainer a. If the retainer is corroded in place, drill 4 holes in the retainer and fracture the re- tainer with a chisel.
  • Page 587 LEFT HAND NON-RATCHETING 3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing carrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER. NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat to loosen the carrier.
  • Page 588 LEFT HAND NON-RATCHETING 5. Remove the aft thrust bearing. 50786 Thrust Bearing 6. Remove the aft thrust collar. 50787 Thrust Collar Page 6B-24 90-884294 OCTOBER 2001...
  • Page 589 LEFT HAND NON-RATCHETING 7. Lift up on the propeller shaft and push down on the forward thrust collar to remove the two keepers. 50826 50778 Thrust Collar Keepers (2) 8. Remove the forward thrust collar. 50784 Thrust Collar 90-884294 OCTOBER 2001 Page 6B-25...
  • Page 590 LEFT HAND NON-RATCHETING 9. Remove the forward thrust bearing. 50783 Thrust Bearing 10. Form a tool using a 1/8 in. (3 mm) wire as shown in the following figure and remove the forward gear bearing adaptor. 50786 Wire Tool Forward Gear Bearing Adaptor 11.
  • Page 591 LEFT HAND NON-RATCHETING 12. Remove the O-ring from inside the gear housing. 13. Remove the forward gear, thrust race, and the thrust bearing (between the gear and the race). 14. Remove the forward gear shim. 50783 Forward Gear Installation Tool (91-815850) Thrust Race Forward Gear Shim...
  • Page 592 LEFT HAND NON-RATCHETING BEARING CARRIER ASSEMBLY - INSPECTION 1. Clean the assembly and all components with a suitable solvent and dry the parts thor- oughly using compressed air. NOTE: If any of the following items are found to be defective complete the appropriate instruction(s) in “Bearing Carrier Assembly”, ‘Component Disassembly and Inspection’...
  • Page 593 LEFT HAND NON-RATCHETING 4. Inspect the forward gear for pitted, chipped, broken teeth, hairline fractures, and ex- cessive or uneven wear. Replace the forward gear and the pinion gear if any defects are found. 5. Inspect the outer hub of the forward gear for excessive wear or damage. Replace the forward and the pinion gear if either of these conditions exist.
  • Page 594 LEFT HAND NON-RATCHETING BEARING CARRIER ASSEMBLY - COMPONENT DISASSEMBLY AND INSPECTION NOTE: Complete the instructions in this section only if the assembly components have been found to be defective. NOTE: Inspection of the bearing surfaces on the propeller shaft where the needles of the bearing carrier needle bearing rolls, gives an indication of the condition of the needle bearing inside the bearing carrier.
  • Page 595 LEFT HAND NON-RATCHETING BEARING CARRIER ASSEMBLY - COMPONENT REASSEMBLY NOTE: Complete the instructions in this section only if the assembly components have been disassembled and repaired or replaced. 1. Clean all of the components with a suitable solvent and dry the parts thoroughly using compressed air.
  • Page 596 LEFT HAND NON-RATCHETING 7. Press on the oil seal driver until the driver bottoms onto the aft face of the bearing carrier. 50788 Oil Seal Oil Seal Driver (91-31108) (long end) Bearing Carrier 8. Apply a thin film of Loctite 271 to the outer diameter of the second seal. 9.

  • Page 597: Forward Gear Bearing Adaptor Assembly

    LEFT HAND NON-RATCHETING 11. Wipe up all of the excess Loctite. Do not allow any of the excess Loctite to spread to other parts of the assembly. 12. Lubricate the seal lips and fill the area between the seals with 2-4-C Marine Lubricant with Teflon.
  • Page 598 LEFT HAND NON-RATCHETING FORWARD GEAR BEARING ADAPTOR ASSEMBLY - COMPONENT DISASSEMBLY AND REASSEMBLY NOTE: Complete the instructions in this section only if the needle bearing in the bearing adaptor is defective and the adaptor is to be reused. 1. Disassemble the adaptor as follows: a.

  • Page 599: Drive Shaft Assembly

    LEFT HAND NON-RATCHETING Drive Shaft Assembly REMOVAL 1. Remove the drive shaft pinion nut as follows: a. Place the drive shaft bearing retainer wrench onto the drive shaft. Do not loosen the retainer at this time. b. Insert the pinion nut adapter, with the MR slot facing the pinion gear, into the gear housing.
  • Page 600 LEFT HAND NON-RATCHETING e. If the drive shaft is broken, place propeller shaft nut wrench onto the propeller shaft splines, hold shift shaft in forward gear and loosen, (but do not fully un- screw), the pinion nut by rotating prop shaft counterclockwise to turn gears, thus loosening the pinion nut.
  • Page 601 LEFT HAND NON-RATCHETING 4. Form a small hook on a stiff piece of wire and attempt to hook onto the top side of the gear and pull it out. It may be necessary to slightly move the propeller shaft from side- to-side to dislodge the pinion gear.
  • Page 602 LEFT HAND NON-RATCHETING 5. Remove lower drive shaft bearing cup and shims using slide hammer puller (34569A1) (retain shims for re-installation). Slide Hammer Puller (91-34569A1) Lower Drive Shaft Bearing Cup DISASSEMBLY 1. Both upper and lower tapered roller bearings can be removed from the drive shaft in one operation.
  • Page 603 LEFT HAND NON-RATCHETING DRIVE SHAFT ASSEMBLY - INSPECTION 1. Clean all parts with a suitable solvent and dry the parts using compressed air. DO NOT spin the bearings. 2. The condition of the drive shaft bearing cup is an indication of the condition of the ta- pered roller bearing on the drive shaft.

  • Page 604: Propeller Shaft Assembly

    LEFT HAND NON-RATCHETING Propeller Shaft Assembly REMOVAL CAUTION Hold onto the propeller shaft assembly in the following step to avoid personal in- jury and/or dropping components when turning the gear housing over. 1. While holding onto the propeller shaft, turn the gear housing over so that the bore opening is facing down.
  • Page 605 LEFT HAND NON-RATCHETING 3. Locate and retain the thrust race and thrust bearing which could be on top of the re- verse gear (if not, they may be stuck to the reverse gear bearing adaptor). 58014 Thrust Bearing and Race PROPELLER SHAFT ASSEMBLY - COMPONENT DISASSEMBLY IMPORTANT: When accomplishing the next step, all of the parts are free to come apart.
  • Page 606 LEFT HAND NON-RATCHETING 2. Remove detent pin. 3. Remove the cross pin that goes through the clutch dog. Remove the reverse gear and slide the clutch off of the propeller shaft. 58012 58018 Detent Pin Cross Pin Reverse Gear Assembly Spool Clutch Page 6B-42...
  • Page 607 LEFT HAND NON-RATCHETING PROPELLER SHAFT ASSEMBLY - COMPONENT INSPECTION 1. Clean all the parts with a suitable solvent and dry the parts thoroughly using com- pressed air, being careful not to spin bearings. 2. Inspect the sliding clutch jaws for damage. Jaws must not be chipped or rounded off. Replace the clutch if they are.

  • Page 608: Reverse Gear Assembly

    LEFT HAND NON-RATCHETING 6. Inspect the propeller shaft for a bent condition. a. V-Blocks and Dial Indicator (1.) Position the propeller shaft bearing surfaces on V-blocks. (2.) Adjust the height of V-blocks to level the propeller shaft. (3.) Position the dial indicator tip just forward of the propeller shaft splines. 52727 Check Movement with Dial Indicator (91-58222A1) Here 7.
  • Page 609 LEFT HAND NON-RATCHETING NOTE: The needle bearing in the reverse gear should not be removed unless damage has been found. Inspect to ensure that all of the needles are present and in position. The needles may have become dislodged while removing the gear from the propeller shaft (and/or while removing the propeller shaft assembly from the gear housing).
  • Page 610 LEFT HAND NON-RATCHETING REVERSE GEAR ASSEMBLY - COMPONENT REASSEMBLY NOTE: Complete the instructions in this section only if the assembly components have been disassembled and repaired or replaced. IMPORTANT: The appearance of the forward and reverse gear is almost identical. The forward gear has a shorter hub and is slightly smaller in diameter.

  • Page 611: Shift Spool Assembly

    LEFT HAND NON-RATCHETING Shift Spool Assembly INSPECTION 1. Clean the assembly with a suitable solvent and dry the parts using compressed air. 2. Inspect the shift spool assembly for damage. Small nicks and burrs may be smoothed. If any parts are damaged or worn beyond repair it will be necessary to replace the complete shift spool assembly.
  • Page 612 LEFT HAND NON-RATCHETING SHIFT SPOOL ASSEMBLY - COMPONENT DISASSEMBLY NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts of the assembly due to an improperly functioning shift spool assembly or debris in the gear housing and/or shift spool assembly.
  • Page 613 LEFT HAND NON-RATCHETING SHIFT SPOOL ASSEMBLY - ADJUSTMENT NOTE: If the shift spool assembly has been disassembled and reassembled (as in the previous two sections) skip the following instructions (1 through 4). NOTE: If the shift spool assembly has not been disassembled and reassembled, do all of the following steps.

  • Page 614: Reverse Gear Bearing Adaptor Assembly

    LEFT HAND NON-RATCHETING Reverse Gear Bearing Adaptor Assembly REMOVAL 1. Remove the reverse gear bearing adaptor using the tools as shown in the next figure. Remove, measure and make note of the shim thickness. If the shims are not dam- aged, they may be reused.
  • Page 615 LEFT HAND NON-RATCHETING REVERSE GEAR BEARING ADAPTOR ASSEMBLY - COMPONENT DISASSEMBLY AND REASSEMBLY NOTE: Complete the instructions in this section only if the needle bearing in the bearing adaptor is defective and the adaptor is to be reused. 1. Disassemble the adaptor as follows: a.

  • Page 616: Shift Shaft Assembly

    LEFT HAND NON-RATCHETING Shift Shaft Assembly REMOVAL NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank inside the gear case) without removing any of the internal components of the gear hous- ing. 1.
  • Page 617 LEFT HAND NON-RATCHETING SHIFT SHAFT ASSEMBLY - Component Disassembly and Inspection 1. Slide the bushing assembly off the shift shaft. Remove the coupler from the shaft. 57954 Shift Shaft Bushing Assembly O-ring Shift Shaft Gasket Rubber Washer 2. Clean all components with a suitable solvent and dry thoroughly with compressed air. a.
  • Page 618 LEFT HAND NON-RATCHETING 3. Inspect the shift shaft splines and oil seal surface for corrosion and/or excessive wear. Replace the shift shaft if either if these conditions are found. 57948 Oil Seal Surface Spline SHIFT SHAFT ASSEMBLY - Component Reassembly 1.

  • Page 619: Pinion Bearing

    LEFT HAND NON-RATCHETING Pinion Bearing REMOVAL NOTE: Inspect the bearing surface on the drive shaft where the needles of the lower pin- ion bearing roll. The condition of the drive shaft at this location gives an indication of the condition of the needle bearing. Replace lower pinion bearing (needles and race as a set) if the drive shaft is pitted, grooved scored, worn unevenly, discolored from overheating, or has embedded particles.

  • Page 620: Gear Housing Reassembly

    LEFT HAND NON-RATCHETING Gear Housing Reassembly Gear Housing Inspection 1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush. Dry the gear housing thoroughly using compressed air. Insure that all sealants, lock- ing agents and debris are removed. 2.

  • Page 621: Pinion Bearing

    LEFT HAND NON-RATCHETING Pinion Bearing INSTALLATION IMPORTANT: Install only a new pinion bearing. Do not reinstall a pinion bearing that has been previously removed from a gear housing. 1. Lubricate the bore into which the pinion bearing is to be installed with Premium Gear Lubricant.

  • Page 622: Reverse Gear Bearing Adaptor Assembly

    LEFT HAND NON-RATCHETING Reverse Gear Bearing Adaptor Assembly INSTALLATION NOTE: If the reverse gear, reverse gear adaptor, large thrust bearing, or bearing race in the gear housing were not replaced, install the same shim(s) (or the same thickness of shim(s) that were taken out when adaptor was removed. If the reverse gear, reverse gear adaptor, large thrust bearing, bearing race, or gear housing were replaced, install 0.008 in.
  • Page 623 LEFT HAND NON-RATCHETING 4. Position the reverse gear (without the thrust race or thrust bearing) into the gear hous- ing and into the adaptor. 50781 Reverse Gear 5. Press the bearing adaptor into the gear housing using the installation tool as follows: IMPORTANT: Be sure that the bearing adaptor is positioned as straight as possible to avoid cocking it in the bore while pressing it in.

  • Page 624: Shift Shaft Assembly

    LEFT HAND NON-RATCHETING Shift Shaft Assembly INSTALLATION 1. Place the shift crank onto the locating pin in the forward section of the gear housing. Ensure that the shift crank faces towards the left (port) side of the gear housing. 50314 Shift Crank Locating Pin 2.

  • Page 625: Gear Location/Backlashes Checking And Adjustment

    LEFT HAND NON-RATCHETING NOTE: If the pinion bearing needle bearings have fallen out, install 18 needles into needle bearing outer race. Use 2-4-C Marine Lubricant with Teflon, to help hold needles in place. 23142 2-4-C Marine Lubricant with Teflon Rollers (18) Roller Bearing Outer Race Gear Location/Backlashes Checking and Adjustment Reverse Gear...

  • Page 626: Drive Shaft And Pinion Gear

    LEFT HAND NON-RATCHETING 2. Install the reverse gear into the gear housing and into the reverse gear bearing adap- tor. 50884 Reverse Gear Thrust Bearing Thrust Race (under Bearing) Reverse Gear Bearing Adaptor Drive Shaft and Pinion Gear INSTALLATION NOTE: If the original shims were not retained or if pinion gear, drive shaft, drive shaft up- per tapered roller bearing and cup, or gear housing were replaced, start off by installing a 0.038 in.
  • Page 627 LEFT HAND NON-RATCHETING 2. Apply Loctite 271 to the threads of the pinion gear nut and place the pinion gear nut into the MR slot of the pinion nut adapter. NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear. 3.
  • Page 628 LEFT HAND NON-RATCHETING 9. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and the pinion nut adaptor in position. 10. Torque the pinion nut to 70 lb. ft. (95 Nm) by turning the drive shaft using the drive shaft nut wrench and torque wrench.

  • Page 629: Gear Location/Backlashes/Checking And Adjustment

    LEFT HAND NON-RATCHETING Gear Location/Backlashes/Checking and Adjustment Drive Shaft - Bearing Preload Tool INSTALLATION 1. Install the components from the Bearing Preload Tool Kit (91-14311A1), over the drive shaft in the order shown. 70496 Top Nut with Threaded Pipe Spring Thrust Washer (2 Required) (12-18448) Thrust Bearing Thrust Washer...

  • Page 630: Pinion Gear Location

    LEFT HAND NON-RATCHETING 3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom nut away from top nut. 57937 Distance 1 in. (25.4mm) Bottom nut [screwed down approximately 1 in. (25.4mm)] Pinion Gear Location CHECKING AND ADJUSTING Pinion Depth –...
  • Page 631 LEFT HAND NON-RATCHETING 7. If the average pinion gear height is not correct, remove the bearing preload tool, the drive shaft retainer and the drive shaft tapered roller bearing cup. (The cup can be removed by wiggling the drive shaft back and forth or by turning gear housing and shaking it.) Add or subtract shims beneath the cup to obtain the proper average pinion gear height.
  • Page 632 LEFT HAND NON-RATCHETING Drive Shaft - Bearing Preload Tool REMOVAL CAUTION Before loosening the top nut allen screws of the bearing preload tool, screw the bottom nut up as close as possible to the top nut. 1. Remove the dial indicator and its supporting tooling. 2.
  • Page 633 LEFT HAND NON-RATCHETING UPPER DRIVESHAFT BEARING CLEARANCE 1. When the correct pinion gear height is achieved, remove pinion nut, upper retainer and driveshaft. 2. Apply Premium Gear Lubricant to O.D. of the driveshaft lower bearing cup and install cup into the gear case. 3.

  • Page 634: Reverse Gear Backlash

    LEFT HAND NON-RATCHETING 9. With new shim(s) under lower bearing cup, reinstall upper bearing cup and torque cup retainer to 100 lb. ft. (135.5 Nm). Recheck drive shaft clearance. NOTE: Install a NEW pinion nut with Loctite 271 AFTER all clearances are correct. 10.
  • Page 635 LEFT HAND NON-RATCHETING 2. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and touching the “I” mark on the dial indicator tool. Tighten the indicator tool onto the drive shaft and rotate the drive shaft so that the needle in the dial makes at least one full revolution and comes to “0”...

  • Page 636: Forward Gear/Bearing Carrier Assembly

    LEFT HAND NON-RATCHETING NOTE: If backlash needs to be adjusted, (see Checking Reverse Gear Backlash), adding 0.001 in. (0.03 mm) shims will reduce the gear backlash by approximately 0.001 in. (0.03mm). Subtracting 0.001 in. (0.03mm) shims will increase backlash by approximate- ly the same amount.
  • Page 637 LEFT HAND NON-RATCHETING 2. Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust race onto forward gear bearing adaptor. Premium Gear Lubricant 55220 Bearing Adaptor Thrust Washer Thrust Bearing 3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor assembly.
  • Page 638 LEFT HAND NON-RATCHETING NOTE: Verify load washer is installed on propeller shaft prior to installing forward gear assembly 4. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying downward pressure to bearing adaptor, remove installation tool from assembly. 55431 Forward Gear Bearing Adaptor Load Washer...
  • Page 639 LEFT HAND NON-RATCHETING 6. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing. Install the tab washer with the external tab inserted into the hole in the gear housing. 50779 Gear Housing Tab Washer Alignment Hole (not seen) “V”...
  • Page 640 LEFT HAND NON-RATCHETING 8. Lubricate the bearing carrier retainer threads with 2-4-C Marine LUbricant with Teflon. Start the retainer into the gear housing threads and screw it down fully by hand. 2-4-C Marine Lubricant with Teflon 50881 Bearing Carrier Retainer 9.
  • Page 641 LEFT HAND NON-RATCHETING NOTE: Drill a 3/8 (22.2mm) diameter hole through the side (PROPELLER NUT END) of a 5 x 2 (127mm x 50.8mm) long piece of PVC pipe. A screwdriver may be inserted thru pipe into propeller shaft splines to prevent PVC pipe from turning while tightening re- taining nut.

  • Page 642: Forward Gear Backlash

    LEFT HAND NON-RATCHETING Forward Gear Backlash CHECKING NOTE: If the bearing preload tool has not already been set up, see “Drive Shaft - Bearing Preload Tool”, ‘Installation’ section first. 1. Install a dial indicator as shown in the following figure. 57939 Nuts (4) (Obtain Locally) Threaded Rod [3/8 in.
  • Page 643 LEFT HAND NON-RATCHETING NOTE: By adding or subtracting 0.001 in. (0.03mm) shim, the backlash will change approximately 0.001 in. (0.03mm). 7. Remove the propeller nut, washer, and the pinion nut adaptor. a. If the Backlash is to Specification, skip the next step (7b), and go on to step 8 following.

  • Page 644: Propeller Shaft Assembly

    LEFT HAND NON-RATCHETING Propeller Shaft Assembly Component Reassembly IMPORTANT: The appearance of the forward and reverse gear is almost identical. The forward gear has a shorter hub and is slightly smaller in diameter. REVERSE FORWARD 4 (10.2cm) 3.75 (9.5cm) 50885 Shorter Hub 1.
  • Page 645 LEFT HAND NON-RATCHETING 4. Assemble the cross pin through the sliding clutch, through the propeller shaft and through the shift spool shaft hole. 5. Install detent pin in third hole in clutch. 58012 Propeller Shaft Sliding Clutch Cross Pin Reverse Gear Shift Spool Assembly Detent Pin 6.

  • Page 646: Propeller Shaft Assembly

    LEFT HAND NON-RATCHETING Propeller Shaft Assembly Installation 1. Lubricate the large thrust bearing with Premium Gear Lubricant and position first the thrust race then the bearing into the gear housing onto the reverse gear bearing adap- tor. Premium Gear Lubricant 50882 Thrust Bearing Thrust Race...
  • Page 647 LEFT HAND NON-RATCHETING 3. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end of the propeller shaft assembly to the left (port) side of gear housing and begin to lower it into the gear housing. 50888 Shift Actuating Spool Shift Crank...
  • Page 648 LEFT HAND NON-RATCHETING 5. Slowly move the propeller shaft to the center of the housing and lower the reverse gear into the bearing adaptor. The shift spool should engage with the shift crank as the propeller shaft centers itself. 50885 Reverse Gear Bearing Adaptor Shift Spool...

  • Page 649: Drive Shaft And Pinion Gear

    LEFT HAND NON-RATCHETING Drive Shaft and Pinion Gear Final Installation NOTE: Verify upper and lower driveshaft bearing shims are installed 1. Place the shim(s) into the drive shaft housing bore at the location shown. 70620 Shims 2. Install lower tapered bearing cup. NOTE: For ease of installation, glue the washer to the pinion gear, using 3M Adhesive, Bellows Adhesive, or equivalent.
  • Page 650 LEFT HAND NON-RATCHETING 9. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and the pinion nut adaptor in position. 10. Torque the pinion nut by turning the drive shaft using the drive shaft nut wrench and torque wrench with the appropriate socket to 70 lb.

  • Page 651: Bearing Carrier Assembly

    LEFT HAND NON-RATCHETING Bearing Carrier Assembly Final Installation 1. Install appropriate spacer shim into the gear housing. 50782 Shim 2. Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust race onto forward gear bearing adaptor. Premium Gear Lubricant 55220 Bearing Adaptor Thrust Washer...
  • Page 652 LEFT HAND NON-RATCHETING 3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor assembly. 55221 Forward Gear Installation Tool (91-815850) Forward Gear/Bearing Adaptor Assembly 4. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying downward pressure to bearing adaptor, remove installation tool from assembly. 55202 Forward Gear Bearing Adaptor Page 6B-88...
  • Page 653 LEFT HAND NON-RATCHETING 5. Ensure that the top of the bearing adaptor is clean and install the small thrust race on top of the bearing adaptor. 50880 Thrust Race Forward Gear Bearing Adaptor Forward Gear 6. Lubricate the small thrust bearing with Premium Gear Lubricant and install it on top of the thrust race.
  • Page 654 LEFT HAND NON-RATCHETING 7. Assemble the thrust collar with its STEPPED SIDE DOWN toward the small thrust bearing. 50784 Thrust Collar Small Thrust Bearing 8. Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the keepers.
  • Page 655 LEFT HAND NON-RATCHETING 50778 Thrust Collar Keepers 9. Install the second thrust collar with its STEPPED SIDE UP. 50787 Propeller Shaft Thrust Collar 90-884294 OCTOBER 2001 Page 6B-91...
  • Page 656 LEFT HAND NON-RATCHETING 10. Lubricate the second thrust bearing with Premium Gear Lubricant and install it to the top of the thrust collar. Premium Gear Lubricant 50786 Thrust Bearing Thrust Collar 11. Lubricate the second small thrust bearing race with Premium Gear Lubricant. Assemble it to the surface inside of the bearing carrier as shown.
  • Page 657 LEFT HAND NON-RATCHETING 12. Lubricate the large O-ring with 2-4-C Marine Lubricant with Teflon and assemble into the gear housing as shown following. 2-4-C Marine Lubricant with Teflon 50886 O-ring 13. Prepare the bearing carrier for installation as follows: a. Lubricate the outer diameter of the bearing carrier with 2-4-C Marine Lubricant with Teflon.
  • Page 658 LEFT HAND NON-RATCHETING 15. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing and then install the tab washer with the external tab inserted into the hole in the gear housing. 70713 Gear Case Alignment Hole “V”...
  • Page 659 LEFT HAND NON-RATCHETING 17. Fill the bearing carrier retainer nut threads and corresponding gear housing threads (360 ) with 2-4-C Marine Lubricant with Teflon. Start the retainer into the gear housing threads and screw it down fully by hand. 2-4-C Marine Lubricant with Teflon 70715 Bearing Carrier Retainer IMPORTANT: Before torquing bearing carrier retainer, gear case must be bolted to...

  • Page 660: Oil Seal Carrier Assembly

    LEFT HAND NON-RATCHETING 19. Bend one tab aft (outward) into a space between two of the notches of the retainer. Bend all the remaining tabs forward (inward). 70490 Bearing Carrier Retainer Notches Alignment Tabs (Bend Inward) Oil Seal Carrier Assembly Installation NOTE: Apply hand pressure only to install the oil seal carrier into position.

  • Page 661: Water Pump Assembly

    LEFT HAND NON-RATCHETING Water Pump Assembly Installation NOTE: The gaskets/face plate hole pattern is not symmetrical. If the holes of the gaskets/ face plate do not align with the screw holes of the gear case and/or each other, one or more of the parts is upside down.
  • Page 662 LEFT HAND NON-RATCHETING 4. Install the 2 water pump locating pins through the gaskets and face plate. 5. Apply a light coat of 2-4-C Marine Lubricant with Teflon to the inside of the pump cover. Position the water pump body over the drive shaft and water pump locating pins. Ro- tate the drive shaft in a clockwise direction, while pushing down on the water pump body to ease the water pump over the impeller blades.
  • Page 663 LEFT HAND NON-RATCHETING 9. Using tool provided in seal kit (26-816575A2) or water pump kit (817275A3), press seal down over drive shaft (DO NOT GREASE DRIVE SHAFT) until tool seats against pump housing. 57945 Tool Seal If tool is not available, lightly press seal against housing until a height of 0.350 in. 0.030 in.

  • Page 664: Gear Lubricant Filling Instructions

    LEFT HAND NON-RATCHETING Gear Lubricant Filling Instructions 1. Inspect “Fill” and “Vent” sealing washers for cuts or abrasions. Replace washers if necessary. 2. Clean any metal debris from magnet on “Fill” plug. IMPORTANT: Never apply lubricant to gear housing without first removing Vent screw, or gear housing cannot be filled because of trapped air.
  • Page 665 LEFT HAND NON-RATCHETING 6. Shift gear housing into NEUTRAL and place guide block anchor pin into NEUTRAL position Left Hand Rotation Outboard Reverse Gear Forward Gear Guide Block Anchor Pin 7. Position gear housing so that the driveshaft is protruding into driveshaft housing. NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft splines, place a propeller onto propeller shaft.

  • Page 666: Propeller Installation

    LEFT HAND NON-RATCHETING Propeller Installation WARNING When installing or removing propeller, because of the engine’s ease in starting, VERIFY that the remote control is in NEUTRAL position and that the key switch is “OFF.” Place a block of wood between the anti-cavitation plate and propeller to prevent accidental starting and to protect hands from propeller blades while removing or installing nut.

  • Page 667: Speedometer Tube Installation

    LEFT HAND NON-RATCHETING Speedometer Tube Installation 1. Route speedometer tube from gearcase around lower yoke and push into junction. Junction should be secured to yoke with sta-strap. 2. Route speedometer tube from swivel tube around lower yoke and push into junction. After insertion of speedometer tubes into junction, pull on each tube to verify that they are locked into junction.

  • Page 668: Ride Guide Steering Cable/Attaching Kit Installation (92876A10)

    ATTACHMENTS / CONTROL LINKAGE ATTACHMENTS / CONTROL LINKAGE Section 7 Table of Contents Ride Guide Steering Cable/Attaching Kit Installation Installation Requirements ....7-10 (92876A10) .

  • Page 669: Maintenance Instructions

    ATTACHMENTS / CONTROL LINKAGE STEERING LINK ROD INSTALLATION IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a” - Part Number 10-849838) and self locking nuts (“b” & “c” - Part Number 11-826709113). These locknuts must nev- er be replaced with common nuts (non locking) as they will work loose and vibrate off freeing the link rod to disengage.

  • Page 670: Ride Guide Steering Cable/Attaching Kit Installation

    ATTACHMENTS / CONTROL LINKAGE NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional lubrication at initial installation. WARNING Core of each steering cable (transom end) must be fully retracted into cable hous- ing before lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur.

  • Page 671: Super Ride-Guide Steering Kit Installation

    ATTACHMENTS / CONTROL LINKAGE CAUTION Marine sealer must be used on shanks of bolts to make a water-tight installation. IMPORTANT: DO NOT use an impact driver when tightening transom bolts. Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard to transom with 4 bolts, flat washers and locknuts, as shown.

  • Page 672: Steering Cable Mounting Tube Installation

    ATTACHMENTS / CONTROL LINKAGE Steering Cable Mounting Tube Installation IMPORTANT: Spacers must be installed between outboard swivel bracket and mounting bracket for steering cable mounting tube to provide proper spacing be- tween steering cables. Secure mounting bracket for steering cable mounting tube on to swivel bracket of out- board.

  • Page 673: Installing Steering Cables

    ATTACHMENTS / CONTROL LINKAGE Installing Steering Cables IMPORTANT: Lubricate inside of outboard tilt tube, inside of steering cable mount- ing tube and rubber O-ring seal (located in outboard tilt tube) with 2-4-C Marine Lu- bricant with Teflon before installing steering cables. Lubricate inside of outboard tilt tube and inside of steering cable mounting tube with 2-4-C Marine Lubricant with Teflon.

  • Page 674: Coupler Installation

    ATTACHMENTS / CONTROL LINKAGE Coupler Installation WARNING Locknuts must be used with bolts to secure steering cables to coupler. Failure to adhere to this requirement could result in steering system failure. Slide coupler (a) onto steering cable ends and secure each steering cable to coupler with bolt (b) and locknut (c) as shown.
  • Page 675 ATTACHMENTS / CONTROL LINKAGE STEERING SYSTEM TENSION ADJUSTMENT IMPORTANT: After this dual steering cable attachment kit is installed, there must be proper tension in forward mounted steering cable tor this attachment kit to oper- ate properly. Not enough tension will cause slack (or play) in steering system. Too much tension will cause steering cables to bind.

  • Page 676: Maintenance Instructions

    ATTACHMENTS / CONTROL LINKAGE WARNING After installation is complete [and before operating outboard(s)], check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left. Check steering through full range (left and right) at all tilt angles to assure interference-free movement.

  • Page 677: Ride Guide Steering Cable/Attaching Kit Installation

    ATTACHMENTS / CONTROL LINKAGE Ride Guide Steering Cable/Attaching Kit Installation (92876A9) Dual Cable - Dual Outboard WARNING Quicksilver Super Ride-Guide Steering (dual cables) MUST BE USED with this at- taching kit. Failure to adhere to this requirement could result in steering system failure.

  • Page 678: Parallel Routed Steering Cables And Attaching Kit Installation

    ATTACHMENTS / CONTROL LINKAGE Parallel Routed Steering Cables and Attaching Kit Installation (Both Steering Cables Routed Together Down Starboard Side of Boat) SUPER RIDE-GUIDE STEERING KIT INSTALLATION IMPORTANT: Steering cable must be installed into tilt tube of port outboard before outboard is mounted on boat transom.
  • Page 679 ATTACHMENTS / CONTROL LINKAGE Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 locking tab washers. Be sure longer threaded end of tube is toward starboard side of boat. Temporarily adjust tube, so that longer threaded end of tube extends out the same dis- tance as the outboard tilt tube.
  • Page 680 ATTACHMENTS / CONTROL LINKAGE Place a mark (a) on steering cable mounting tube (b) 5/8 in. (16 mm) from end of mounting tube. Slide plastic spacer (c), O-ring (d) and cap (e) over steering cable. 5/8 in. (16 mm) 51890 Thread cap (e) onto steering cable mounting tube, up to mark (a).
  • Page 681 ATTACHMENTS / CONTROL LINKAGE STEERING LINK ROD INSTALLATION WARNING Steering link rods MUST BE secured between outboard steering arm and steering cable end, using special washer head bolt (10-849838) and two nylon insert lock- nuts (11-826709113), as shown. Both special washer head bolt and nylon insert locknuts MUST BE tightened as specified.
  • Page 682 ATTACHMENTS / CONTROL LINKAGE STEERING ARM EXTENSION BRACKET INSTALLATION Secure a steering arm extension bracket to each outboard’s steering arm. 51889 Steering Arm (Port Outboard Shown) Extension Bracket Locking Retainer (2 Each Bracket) Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to 23 lb. ft. (31 Nm), Then Bend Corner Tabs of Locking Retainers Up Against Flats on Each Bolt WARNING Locking retainer corner tabs MUST BE bent up and against flats on each bolt that...
  • Page 683 ATTACHMENTS / CONTROL LINKAGE Lubricate ball joint in steering eyes, with SAE 30W Motor Oil (obtain locally). Assemble steering coupler between outboard steering arm extension brackets, using special washer head bolts (10-849838) provided and nylon insert locknuts as shown. IMPORTANT: With assembled steering coupler installed and before tightening spe- cial washer head bolts/locknuts, check outboard alignment.
  • Page 684 ATTACHMENTS / CONTROL LINKAGE STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES) IMPORTANT: For proper operation of this dual cable - dual outboard steering instal- lation, there MUST BE proper tension in the steering system. NOT ENOUGH ten- sion will cause slack (play) in steering system. TOO MUCH tension will cause steer- ing cables to bind.

  • Page 685: Opposite Side Routed Steering Cables And Attaching Kit Installation

    ATTACHMENTS / CONTROL LINKAGE WARNING After installation is complete (and before operating outboard(s)), check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left. Check steering thru full range (left and right) at all tilt angles to assure interference-free movement.
  • Page 686 ATTACHMENTS / CONTROL LINKAGE Temporarily adjust tube, so that longer threaded end of tube extends out the same dis- tance as the outboard tilt tube. Do not tighten adjustment nuts at this time. 51891 Steering Cable Mounting Tube (End of Tube with Longer Threads Toward Center of Boat Transom) Mounting Bracket Locking Tab Washers (2)
  • Page 687 ATTACHMENTS / CONTROL LINKAGE Thread cap (e) onto steering cable mounting tube, up to mark (a). 51888 STEERING CABLE INSTALLATION - PORT OUTBOARD IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo- cated inside tilt tube with 2-4-C Marine Lubricant with Teflon, before installing steering cable.
  • Page 688 ATTACHMENTS / CONTROL LINKAGE Lubricate holes in ends of steering cables, with 2-4-C Marine Lubricant with Teflon. As- semble steering link rods to steering cable ends of each outboard, using flat washers and nylon insert locknuts. Tighten locknuts until they seat [DO NOT exceed 120 lb. in. (13.5 Nm) of torque], then back nut off 1/4 turn.
  • Page 689 ATTACHMENTS / CONTROL LINKAGE STEERING ARM EXTENSION BRACKET INSTALLATION Secure a steering arm extension bracket to each outboard’s steering arm. 51889 Steering Arm (Port Outboard Shown) Extension Bracket Locking Retainer (2 Each Bracket) Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to 23 lb. ft. (31 Nm), Then Bend Corner Tabs of Locking Retainers Up Against Flats on Each Bolt WARNING Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that...
  • Page 690 ATTACHMENTS / CONTROL LINKAGE Lubricate ball joint in steering eyes with SAE 30W Motor Oil (obtain locally). Assemble steering coupler between outboard steering arm extension brackets, using special washer head bolts (10-849838) provided and nylon insert locknuts, as shown. IMPORTANT: With assembled steering coupler installed and before tightening spe- cial washer head bolts/locknuts, check outboard alignment.
  • Page 691 ATTACHMENTS / CONTROL LINKAGE STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES) IMPORTANT: For proper operation of this dual cable - dual outboard steering instal- lation, there MUST BE proper tension in the steering system. NOT ENOUGH ten- sion will cause slack (play) in steering system. TOO MUCH tension will cause steer- ing cables to bind.

  • Page 692: Trim Tab Adjustment

    ATTACHMENTS / CONTROL LINKAGE Trim Tab Adjustment DUAL OUTBOARD - COUNTER ROTATION INSTALLATION 1. Shift outboard into neutral and make sure ignition key is at “OFF” position. 2. Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab. 3.

  • Page 693: Maintenance Instructions

    ATTACHMENTS / CONTROL LINKAGE WARNING When 2 couplers are connected together with coupler link rod, a lock washer must be used on each side of coupler link rod, and link rod must be torqued to 20 Ib. ft. (27 Nm) into end of each coupler. 51890 Couplers Connected Together Lock washers...
  • Page 694 ATTACHMENTS / CONTROL LINKAGE 5. Inspection and lubrication of steering head assembly (rotary or straight rack) should be performed once each year (by your Authorized Dealer) or whenever steering mount and/or steering head are disassembled, or if steering effort has increased. Lu- bricate with 2-4-C Marine Lubricant with Teflon.

  • Page 695: Transom Mounted Ride Guide Attaching Kit Installation (73770A1)

    ATTACHMENTS / CONTROL LINKAGE Transom Mounted Ride Guide Attaching Kit Installation (73770A1) Attaching Kit Installation 1. Lubricate both holes in pivot block (Figure 1) with 2-4-C Marine Lubricant with Teflon. 2. Place pivot block on pivot spacer and secure to transom bracket with 3/8 in. x 2-1/2 in.
  • Page 696 ATTACHMENTS / CONTROL LINKAGE 3. Place Ride-Guide yoke on pivot block and secure with 7/16 in. x 1-3/4 in. (11.1 mm x 44.5 mm) bolt and locknut, as shown in Figures 1 and 2. Torque locknut to 10 Ib. ft. (13.5 Nm), then back off 1/4-turn. Figure 2 Transom Backing Plate Bolt [5/16 in.
  • Page 697 ATTACHMENTS / CONTROL LINKAGE b. Position attaching kit on transom so that transom bracket is centered on the 15 in. (38.1 mm) (Figure 1) at a height where the center of Ride-Guide yoke is even with, or not more than 1/2 in. (12.7 mm) above top edge of transom. (Figure 3) Figure 3 Ride-Guide Yoke 0 in.

  • Page 698: Maintenance Instructions

    ATTACHMENTS / CONTROL LINKAGE WARNING After installation is completed (and before operating outboard), check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left. Check steering through full range (left and right) at all tilt angles to assure interference-free movement.

  • Page 699: Clevis Attaching Kit Installation (A-70599A5)

    ATTACHMENTS / CONTROL LINKAGE Clevis Attaching Kit Installation (A-70599A5) NOTE: This kit is used to attach Ride-Guide cable to outboard steering arm ONLY when “Transom Mounted Ride-Guide Attaching Kit” is being used. If Ride-Guide cable is installed through outboard tilt tube, then “Steering Link Rod” must be used. Installation Instructions 1.
  • Page 700 COLOR DIAGRAMS COLOR DIAGRAMS Table of Contents 225/250/3.0 Litre Work EFI 2002 Model Year Typical SmartCraft Dual Outboard Installation Wiring Diagram ......Page 8-3 2002 Model Year .
  • Page 701 COLOR DIAGRAMS Notes: Page 8-2 90-884294 OCTOBER 2001...

  • Page 702: 225/250/3.0 Litre Work Efi 2002 Model Year

    COLOR DIAGRAMS 225/250/3.0 LITRE WORK EFI WIRING DIAGRAM 2002 MODEL YEAR 90-884294 OCTOBER 2001 Page 8-3...
  • Page 703 225/250/3.0 Litre Work EFI 2002 Model Year 1. ECM 35. Cowl Mounted Trim Switch 2. Top ECM Connector 36. To Remote Control Trim Switch 3. Middle ECM Connector 37. 12 Volt Accessory Power 4. Bottom ECM Connector 38. To Analog Temperature Gauge 5.
  • Page 704 1 9 17 1 9 17 12 22 59138...
  • Page 705 COLOR DIAGRAMS TYPICAL SMARTCRAFT SYSTEM TACHOMETER & SYSTEM SPEEDOMETER INSTALLATION WITH SYSTEM LINK GAUGES 2002 MODEL YEAR 90-884294 OCTOBER 2001 Page 8-5...

  • Page 706: Typical Smartcraft System Tachometer & System

    Typical SmartCraft System Tachometer & System Speedometer with System Link Gauges 2002 Model Year 1. 8-Pin Digital Sensor Harness Extension, Connect 27. Analog Tachometer Harness (Not Used on CAN to 8-Pin SmartCraft Harness on Engine Installation) 2. Digital Speedometer Sensor 28.
  • Page 707 59265...

  • Page 708: Typical Smartcraft System Monitor/Tachometer

    COLOR DIAGRAMS TYPICAL SMARTCRAFT SYSTEM MONITOR/TACHOMETER INSTALLATION WITH SYSTEM LINK GAUGES 2002 MODEL YEAR 90-884294 OCTOBER 2001 Page 8-7...
  • Page 709 Typical SmartCraft System Monitor/Tachometer with System Link Gauges 2002 Model Year 1. 8-Pin Digital Sensor Harness Extension, Connect 27. 4-Pin Digital Sensor Harness Connection to to 8-Pin SmartCraft Harness on Engine Paddle Wheel 2. Digital Speedometer Sensor 28. Digital Connections to Oil Sender 3.
  • Page 710 59266...

  • Page 711: Typical Smartcraft Dual Outboard Installation 2002 Model Year

    COLOR DIAGRAMS TYPICAL SMARTCRAFT DUAL OUTBOARD INSTALLATION 2002 MODEL YEAR 90-884294 OCTOBER 2001 Page 8-9...
  • Page 712 Typical SmartCraft Dual Outboard Installation 2002 MY 1. 8-Pin Harness from Port Outboard 28. 10-Pin Control Area Network (CAN) Connection from System Tachometer Starboard Outboard to 2. Digital Sensor Harness Extension Port Outboard Junction Box 3. Digital Speedometer Sensor Port Outboard 29.
  • Page 713 59276...

  • Page 714: 225/250/3.0 Litre Work Efi 2002 Model Year

    COLOR DIAGRAMS 225/250/3.0 LITRE WORK EFI OIL & FUEL FLOW DIAGRAM 2002 MODEL YEAR 90-884294 OCTOBER 2001 Page 8-11...
  • Page 715 225/250/3.0 Litre Work EFI Oil & Fuel Flow 2002 Model Year 1. Fuel inlet from primer bulb 2. Engine Pulse Fuel Pump 3. Fuel line to Water Separating Fuel Filter - 2-8 psi (14-55 kPa) 4. Water Separating Fuel Filter in Vapor Separator Tank (VST) Assembly 5.
  • Page 716 58847...

  • Page 717: Water Flow Diagram

    COLOR DIAGRAMS 225/250/3.0 LITRE WORK EFI WATER FLOW DIAGRAM 2002 MODEL YEAR 90-884294 OCTOBER 2001 Page 8-13...
  • Page 718 225/250/3.0 Litre Work EFI Water Flow 2002 Model Year 1. Water Inlet 2. Water Pump 3. Wall of Water - If water level height is insufficient, water pump may draw in air resulting in an overheated engine 4. Strainer - Exhaust cooling water 5.
  • Page 719 59162...

This manual is also suitable for:

250 efi3 liter work 225 efi3 liter work 250 efi

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