Mercury Marathon-Seapro 60-60 Service Manual

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Cleanliness and Care of

Outboard Motor

A marine power product is a combination of many ma-

chined, honed, polished and lapped surfaces with toler-

ances that are measured in the ten thousands of an

inch./mm When any product component is serviced, care

and cleanliness are important. Throughout this manual, it

should be understood that proper cleaning, and protection

of machined surfaces and friction areas is a part of the re-

pair procedure. This is considered standard shop practice

even if not specifically stated.

Whenever components are removed for service, they

should be retained in order. At the time of installation, they

should be installed in the same locations and with the same

mating surfaces as when removed.

Before raising or removing and outboard engine from a

boat, the following precautions should be adhered to:

(1) Check that flywheel is secured to end of crankshaft with

a locknut and lifting eye is threaded into flywheel a mini-

mum of 5 turns.

(2) Connect a hoist of suitable strength to the lifting eye.

In addition, personnel should not work on or under an out-

board which is suspended. Outboards should be attached

to work stands, or lowered to ground as soon as possible.

We reserve the right to make changes to this manual with-

out prior notification.

Refer to dealer service bulletins for other pertinent informa-

tion concerning the products described in this manual.

Service Manual Outline

Section

- General Information & Specifications

Section

- Electrical & Ignition

Part A - Ignition System

Part B - Battery, Charging System &

Part C - Timing/Synchronizing &

Part D - Wiring Diagrams

Section

- Fuel Systems

Part A - Carburetion

Part B - Fuel Pump

Part C - Fuel Enrichment

Part D - Oil Injection

Section

- Powerhead

Section

- Mid-Section

Part A - Clamp/Swivel Brackets and

Part B - Power Trim (Design I)

Part C - Power Trim (Design II)

Part D - Power Trim (Design III)

Part E - Power Trim (Design IV)

Part F - Manual Tilt (Design I, II, III)

Part G - Manual Tilt (Design IV)

Section

- Lower Unit

Part A - Standard Gear Housing

Part B - 60 Big Foot, 60 SeaPro &

Part C - Jet Drive

Section

- Outboard Installation/

Attachments

Part A - Ride-Guide Steering -

Part B - Tiller Handle and Co-Pilot

Part C - Rewind Starter

Starting System

Adjusting

Driveshaft Housing

Marathon Gear Housing

Throttle/Shift Cables &

Electrical Connections

90-817643R1 DECEMBER 1996

Table of Contents

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Mercury Marathon-Seapro 60-60

Page 1 Cleanliness and Care of Service Manual Outline Outboard Motor Section - General Information & Specifications Section - Electrical & Ignition A marine power product is a combination of many ma- chined, honed, polished and lapped surfaces with toler- Part A - Ignition System ances that are measured in the ten thousands of an Part B - Battery, Charging System &...
Page 2 This service manual has been written and published by the strength markings. Mismatched or incorrect fasteners can Service Department of Mercury Marine to aid our dealers’ result in damage or malfunction, or possibly personal inju- mechanics and company service personnel when servic- ry.
Page 3 GENERAL INFORMATION and SPECIFICATIONS 50557...
Page 4: Table Of Contents
Stainless Steel Race Propellers – Conditions Affecting Operation ....1-21 Available from Mercury Performance Detonation: Causes and Prevention ..1-21 Products .
Page 5: Propeller Information
Section Section Heading Propeller Information General Information and Specifications For in-depth information on marine propellers and boat Electrical & Ignition performance – written by marine engineers – see your Au- Fuel Systems thorized Dealer for the illustrated “What You Should Know Powerhead About Quicksilver Propellers...
Page 6: Master Specifications
Master Specifications Model 45 Jet/50/55 Marathon-Seapro/60/60 Marathon-Seapro/60 Bigfoot HORSEPOWER Model 50 50 (37) (KW) Model 55 55 (41) Model 60 60 (45) Model 45 Jet 60 (45) OUTBOARD Electric Start (ELPTO) 217.0 lbs. (98.4kg) (ELO) WEIGHT 213.0 lbs. (96.6kg) Manual Start (ML) 213.0 lbs.
Page 7 Model 45 Jet/50/55 Marathon-Seapro/60/60 Marathon-Seapro/60 Bigfoot STARTING Manual Start – All Models Recoil Starter Electric Start – Optional – All Models SYSTEM Starter Draw (Under Load) 125 Amperes Battery Rating Min. Reserve Cap. Rating of 100 Min. and CCA of 350 Amperes IGNITION Type Capacitor Discharge...
Page 8: Powerhead
Reed Block Powerhead Reed Stop Opening (Max.) ..0.020 in. (0.50 mm) Specifications Crankshaft Runout (Max.) ..0.003 in. (0.08 mm) Block Taper (Max.) ... 0.003 in.
Page 9: Cowl Removal
Cowl Removal Filling Oil Injection System Remove fill cap (a) from the oil tank and fill tank with oil. Re- tighten the fill cap. 50552 50553 Use Quicksilver NMMA Certified TC-W3 or TC-WII 2-Cycle Outboard Oil. Quicksilver Certified TC-W3 Outboard Oil is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or va- rying grades of gasoline.
Page 10: Propeller Selection
Propeller Selection Propeller Installation 1. Select a propeller that will allow the engine to operate WARNING at or near the top of the recommended full throttle RPM range (listed in “Specifications,” preceding) with a nor- To avoid accidental starting, which could result in per- mal load.
Page 11: Trim "In" Angle Adjustment
3. While aligning splines, place Quicksilver propeller and Water test the boat not using the trim adjustment pin. If un- tab washer on propeller shaft in this order. desirable and/or unsafe steering conditions are experi- enced (boat runs with nose down), install trim adjustment 4.
Page 12: Propeller Information Chart
Propeller Information Chart 50/55 MODELS Wide Open Throttle RPM: 5000-5500 Recommended Transom Height: Short Shaft 16-1/2 in. (41.9 cm), Long Shaft 21 in. (53.3 cm) Right Hand Rotation Gear Reduction: 1.64:1 Thrust Hub: 73345A 1 Approx. Approx. Speed No. of Gross Boat Boat Range...
Page 13: Propeller Information Chart
Alum 2400 + 18 + 1-22 48-77338A40 Steel 2800 + 19 + 1-20 48-17310A 5 50-60 MODELS Stainless Steel Race Propellers – Available from Mercury Performance Products No. of Propeller Diameter Pitch Blades Rotation Part Number 48-66106 48-66108 48-66110 GENERAL INFORMATION: Propeller-Drive Hub: 43676 Diffuser Rings: Alum Propellers –...
Page 14: Power Trim System (Models With Power Trim)
Power Trim System Trim System Design II (Models with Power Trim) GENERAL INFORMATION NOTE: 50/60 models are not equipped with Trim System Design I. See chart below. Model Design I Design II Design III 40 (4cyl) 50/60 50158 50146 Trim System Design III The power trim system is filled at the manufacturer and is ready for use.
Page 15: Checking Trim System Fluid Level
CHECKING TRIM SYSTEM FLUID LEVEL TRIMMING OUTBOARD “OUT” (“UP”) CHARACTER- ISTICS IMPORTANT: This trim system is pressurized. Remove fill screw when outboard is trimmed to the full “up” po- WARNING sition. Retighten fill screw securely. Excessive trim “out” also may reduce the stability of 1.
Page 16: Trim Tab Adjustment
Trim Tab Adjustment Boat Performance 1. Check trim tab position as follows: TEST INSTRUCTIONS a. Operate boat at the speed at which it would nor- WARNING mally be operated. A tight grip on the steering wheel/tiller handle is b. If the boat pulls to the right (starboard), the trailing always advisable and is required when accelerating, edge of trim tab must be moved to the right.
Page 17 BOAT TEST CHART (Example) Acceleration Propeller Propeller Break Loose Wind during Run Water Time Diameter Temperature Comments in Seconds During Condition During Direction ( F) Turns Acceleration Pitch ” x 5450 slight 3” 5700 chop ” x *WOT is wide-open-throttle 5.
Page 18: Lubrication Points
Lubrication Points Item Type of Fresh Water Salt Water Description Lubricant Frequency Frequency Throttle/Shift Linkage Pivot Points Upper Shift Quicksilver Shaft 2-4-C w/Te- Every Every flon 60 Days 30 Days Swivel Pin Marine Ride Guide Lubricant Steering Cable Tilt Tube Steering SAE 30W Every...
Page 19: Ride Guide Steering Cable And Pivot Point Lubrication
50551 7 - Propeller Shaft Lubrication (a) 50157 3 - Swivel Pin Grease Fittings RIDE GUIDE STEERING CABLE and PIVOT POINTS LUBRICATION WARNING Core of steering cable (transom end) must be fully retracted into cable housing before lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur.
Page 20: Gear Housing Lubrication
GEAR HOUSING LUBRICATION 5. Note color of gear lubricant. White or cream color indi- cates presence of water in lubricant. Gear lubricant NOTE: Refer to “Specifications,” for gear housing lubricant which has been drained from a gear housing recently capacity. in operation will have a yellowish color due to lubricant agitation/aeration.
Page 21: Periodic Inspection
Periodic Inspection Flushing Outboard Cooling System Conduct a periodic, systematic inspection to uncover and WARNING correct a failure before it can cause inconvenience or me- chanical damage. Inspection interval is based on average When flushing, be certain that area in vicinity of pro- operating conditions in recreation service.
Page 22: Following Complete Submersion
4. Start engine and idle in neutral. Then increase engine SUBMERGED ENGINE (FRESH WATER) speed, not to exceed 2500 RPM. (PLUS SPECIAL INSTRUCTIONS) 5. Flush or service engine as required. Be sure adequate 1. Recover engine as quickly as possible. cooling water is provided.
Page 23: Out-Of-Season Outboard Storage
Out-of-Season Outboard Storage 10. If the water pickup is clogged, the speedometer will be inoperative. Clean the pickup with a piece of wire or blow out with compressed air. Before blowing out with WARNING air, disconnect the tubing from the speedometer. As a safety precaution, when boat is in storage, 11.
Page 24: How Weather Affects Engine Performance
30% relative humidity at detonation. This, of course, enhances overall reliability and 77 F (25 C) temperature and a barometric pressure of durability of the engine. 29.61 inches of mercury. 1-20 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996...
Page 25: Conditions Affecting Operation
Conditions Affecting Operation Detonation generally is thought of as spontaneous ignition, but it is best described as a noisy explosion in an unburned 1. Proper positioning of the weight inside the boat (per- portion of the fuel/air charge after the spark plug has fired. sons and gear) has a significant effect on the boat’s Detonation creates severe, untimely, shock waves in the performance, for example:...
Page 26: Water Pressure Check
(21-35 kPa) prior to 2500 RPM (due to poppet valve The engine serial number is located on the starboard side opening.) of the swivel bracket (as on all Mariner/Mercury models) and also on the cylinder head (a). 3. At 2500 RPM, water pressure should not exceed 12 psi (83 kPa).
Page 27: Painting Procedures
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or 8. Use Ditzler Urethane DU9000 for Mercury Black, equivalent (Xylene or M.E.K.). DU34334 for Mariner Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray 4.
Page 28: Decal Application
DECAL APPLICATION Decal Application 1. Mix ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. Decal Removal NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure 1.
Page 29 ELECTRICAL and IGNITION 51123 IGNITION SYSTEM...
Page 30 Page Table of Contents Ignition Components Page Removal and Installation ..... . . 2A-7 Description ........2A-1 Flywheel .
Page 31: Description
Description Test Procedures The outboard ignition system is alternator-driven with dis- Direct Voltage Adapter (DVA) Tests tributor-less capacitor discharge. Major components of the ignition system are the flywheel, stator, trigger, switch box, WARNING ignition coils and spark plugs. The stator assembly is mounted stationary below the fly- DANGER –...
Page 32: Test Sequence
Test Sequence 2-B) Check ignition switch/wiring, as follows: CAUTION 1-A) Check primary input voltage to coils (See Test Chart) To prevent engine from starting, remove spark plug leads from ALL spark plugs and ground leads to en- 1. If voltage readings to coil(s) are BELOW specification, gine.
Page 33: Ignition System Test Chart
Ignition System Test Chart IMPORTANT: BEFORE attempting the ignition system checks, following, thoroughly read the preceding pages of these instructions to become familiar with the proper Automatic Distributorless Ignition (ADI) test sequence and pro- cedures (particularly any “Safety Warnings” and “Cautions”). ALL tests are performed with lead wires connected – terminals exposed.
Page 34: Stator Test
55/60 MARATHON/SEAPRO – (398-9873A-5 printed WARNING on the stator) USA S/N 0G277479 and BELOW When testing or servicing the ignition system, high BELGIUM S/N (Not Available at Time of Printing) voltage is present, be extremely cautious! DO NOT TOUCH OR DISCONNECT any ignition parts while en- 45 JET, 50/60 ELECTRIC –...
Page 35: Ignition Coil Test
IGNITION COIL TEST ADI Ignition using a RED IMPORTANT: Ohmmeter tests can only detect certain Stator with an Adapter faults in the ignition coil. Replace ignition coil, if ohm- meter readings (listed in chart, following) are not as Module specified. If coil tests OK, and coil is still suspected of being faulty, use Multi-Meter/DVA Tester (91-99750) or Red stators require an adapter module that is con- a voltmeter (capable of measuring 400 volts DC, or...
Page 36: Red Stator With Adaptor And Ignition Coils
NOTE: If using a meter with a built -in DVA, place selector RED Stator with Adaptor and switch in the DVA/400 VDC position. Ignition Coils Red stators require an adapter module that is NOTE: connected between the stator and switch box. With- out the adapter module, the voltage supplied by the RED Stator DVA Test stator would exceed the voltage capability of the...
Page 37: Ignition (Key) Switch Test
Ignition (Key) Switch Test Ignition Components Removal and Installation 1. Disconnect remote control wiring harness and instru- ment panel connector. Flywheel NOTE: Wiring diagram for control boxes is located in SEC- TION 2D. REMOVAL 2. Set ohmmeter on R x 1 scale for the following tests: 1.
Page 38: Installation
INSTALLATION BLACK and RED Stator WARNING REMOVAL Engine could possibly start when turning flywheel 1. Remove flywheel; refer to “Flywheel Removal”. during installation; therefore, disconnect (and isolate) 2. Remove screws (a). spark plug leads from spark plugs to prevent engine from starting.
Page 39: Black Stator Installation
BLACK STATOR INSTALLATION RED STATOR INSTALLATION 1. Install stator as shown. IMPORTANT: The stator must be oriented as shown to obtain correct system voltage. 1. Position red stator so appropriate arrow on decal points aft. 2. Secure stator with four (4) attaching screws re- tained from disassembly.
Page 40: Trigger
3. Disconnect trigger leads (a) from switch box (b) and re- move trigger. 54981 a - Electrical Plate Grommet b - Blue Lead of Stator Adaptor 51123 c - Stator Harness d - Black Ground Lead of Stator Adaptor INSTALLATION e - Stator Adaptor f - Sta-Straps 1.
Page 41: Ignition Coils
2. Connect trigger leads (a) to switch box (b); refer to wir- Switch Box ing diagrams in Section 2D. 1. Refer to wiring diagrams in Section 2D when connect- ing wires. 51123 3. Install stator; refer to “Stator Installation”, preceding. 4.
Page 42 ELECTRICAL 11669 BATTERY, CHARGING SYSTEM and STARTING SYSTEM...
Page 43 Table of Contents Page Page Battery ........2B-1 Starting System .
Page 44: Battery
Specific Gravity Readings Battery Use a hydrometer (a) to measure specific gravity of electro- Precautions lyte in each cell. When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas escapes thru holes in vent plugs and may form an explosive atmosphere around bat- tery if ventilation is poor.
Page 45: Specific Gravity Cell Comparison Test
Specific gravity of electrolyte varies not only with percent- Charging A Discharged Battery age of acid in liquid but also with temperature.As tempera- The following basic rules apply to any battery charging situ- ture drops, electrolyte contracts, so that specific gravity in- ation: creases.
Page 46: Winter Storage Of Batteries
Winter Storage of Batteries Some models are equipped with either a voltage regulator or a voltage regulator/rectifier. The voltage regulator Battery companies are not responsible for battery damage, senses battery voltage and allows the correct amount of di- either in winter storage or in dealer stock, if the following rect current to charge the battery.
Page 47: Battery Charging System Troubleshooting
Battery Charging System Stator Ohms Test Troubleshooting (Alternator Coils Only) NOTE: Stator can be tested without removing from engine. A fault in the battery charging system usually will cause the battery to become undercharged. Check battery electro- 1. Disconnect both yellow (stator leads) from voltage reg- lyte level, and charge battery.
Page 48: Alternator System Test
16 AMPERE STATOR REGULATED SYSTEMS 1. Check battery voltage at battery with engine running. Test Leads Resistance Scale Reading (OHMS) (x_______) 2. If battery voltage is above 14.5 volts, replace voltage regulator/rectifier. Check condition of battery as over- Between Yellow .17 –...
Page 49 10. A reading of 18 amperes (16 amp system) or 9 am- peres (9 amp system) at 3000 RPM indicates the charging system is functioning properly and the battery being discharging current due to the amperage draw on the system is greater than the amperage output of the engine charging system.
Page 50: Ampere Battery Charging Wiring Diagram (Rectifier Models)
9 Ampere Battery Charging Wiring Diagram (RECTIFIER MODELS) Black Blue Gray Yellow RED SLEEVE 51249 IMPORTANT: After electrical connections are made, coat all terminal connections using Quicksilver Liquid a - Stator/Alternator Assembly Neoprene (92-25711), to avoid corrosion. b - Rectifier c - 20 Ampere Fuse (Remote Control Harness) d - Starter Solenoid e - GRAY Wire to Tachometer...
Page 51: Ampere Battery Charging Wiring Diagram (Regulator Models)
9 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quicksilver Liquid Neoprene (92-25711), to avoid corrosion. (REGULATOR MODELS) Black Blue Gray Yellow RED SLEEVE a - Stator/Alternator Assembly b - Regulator c - 20 Amp Fuse (Remote Control Harness) d - Starter Solenoid e - Gray Wire to Tachometer f - To Battery (+) Positive Terminal...
Page 52: Ampere Battery Charging Diagram With Battery Isolator (Rectifier Models)
9 Ampere Battery Charging Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quicksilver Liquid with Battery Isolator Neoprene (92-25711), to avoid corrosion. (RECTIFIER MODELS) Black Blue Gray Yellow RED SLEEVE a - Stator/Alternator Assembly b - Rectifier c - 20 Amp Fuse d - Starter Solenoid e - Gray Wire to Tachometer...
Page 53: 15/16 Ampere Battery Charging Diagram With Battery Isolator
15/16 Ampere Battery Charging IMPORTANT: After electrical connections are made, coat all terminal connections using Quicksilver Liquid Diagram with Battery Isolator Neoprene (92-25711), to avoid corrosion. Black Blue Gray Yellow RED SLEEVE a - Stator/Alternator Assembly b - Voltage Regulator c - 20 Amp Fuse d - Starter Solenoid e - Gray Wire to Tachometer...
Page 54: Rectifier Test
Rectifier Test WARNING Disconnect battery leads from battery before testing rectifier. NOTE: Rectifier can be tested without removing from en- gine. 1. Disconnect all wires from terminals on rectifier. 2. Use an ohmmeter (R x 1000 scale) and perform the fol- lowing test.
Page 55: Starting System
The neutral start switch opens the start circuit when the Starting System shift control lever is not in neutral. This prevents accidental starting when engine is in gear. Starting System Components CAUTION The starting system consists of the following components. The starter motor may be damaged if operated contin- 1.
Page 56 The following “Starting Circuit Troubleshooting Flow Chart” is designed as an aid to troubleshooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “Test Points” (called out in the chart) are numbered in diagram below. RED SLEEVE RED SLEEVE NEUTRAL START SWITCH...
Page 57 * Battery Voltage TEST 2 a. Disconnect black ground wire(s) from Test Point 2. b. Connect voltmeter between common engine ground and Test Point 2. No voltage reading; c. Turn ignition key to “Start” position. proceed to TEST 3. 12 Volt Reading* TEST 3 a.
Page 58: Starter Motor
Disassembly Starter Motor 1. Remove 2 thru bolts and commutator end cap, taking Removal care not to lose brush springs. CAUTION Disconnect battery leads from battery before remov- ing starter. 1. Disconnect battery leads from battery. 2. Disconnect black cable. 3.
Page 59: Cleaning And Inspection
4. Remove components from armature. b. Clean the commutator slots after undercutting. c. De-burr the commutator lightly with No. 00 sand- paper, then clean the commutator. d. Check the armature on a growler for shorts. See “Testing”, following. 9. Open-circuited armatures often can be saved where and open circuit is obvious and repairable.
Page 60: Armature Test For Ground
ARMATURE TEST FOR GROUND TESTING NEGATIVE BRUSHES FOR GROUND 1. Set ohmmeter to (R x 1 scale). Place one lead of ohm- Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter meter on armature core (or shaft) and other lead on on the negative brush and the other lead on the end cap commutator, as shown.
Page 61: Starter Solenoid Test
STARTER SOLENOID TEST Test starter solenoid as follows: 1. Disconnect all leads from solenoid terminals. 2. Use an ohmmeter, set to (R x 1 scale) and connect be- tween solenoid terminals 1 and 2. 3. Connect a 12-volt supply between solenoid terminals 3 and 4.
Page 62 4. Construct a brush retainer tool as shown. 11658 a - Washer b - Helix Threads c - Armature Shaft d - Drive End Cap e - Drive Assembly f - Spring g - Spacer 3. Install locknut (a). Brush Retainer Tool Layout (Full Size) 11659 18-Gauge Sheet Metal METRIC...
Page 63: Installation
5. Place springs and brushes into brush holder and hold Installation in place with brush retainer tool. 1. Install 2 rubber collars and 2 rubber bumpers. 6. Lubricate bushing with one drop of SAE 10W oil. DO NOT over-lubricate. 11645 a - Rubber Collars b - Rubber Bumpers 2.
Page 64 ELECTRICAL and IGNITION 51046 TIMING/SYNCHRONIZING/ADJUSTING...
Page 65 Table of Contents Page Timing/Synchronizing/Adjusting ....2C-1 Specifications ......2C-1 Special Tools .
Page 66: Timing/Synchronizing/Adjusting
Timing/Synchronizing/ Adjusting Specifications 5000 - 5500 RPM FULL THROTTLE RPM IDLE TIMING 2 - 6 ATDC IDLE RPM IN 650 - 750 RPM (FORWARD GEAR) MAXIMUM TIMING 50/60-22 BTDC 55-16 BTDC @ 5000RPM 50/60-24 BTDC 55-18 BTDC (@ Cranking Speed) SPARK PLUG TYPE NGK BP8H-N-10 * 50/55/60...
Page 67: Carburetor Synchronization
Carburetor Synchronization d. Look into throats of carburetors and verify all throttle shutters are completely closed. Tighten four (4) synchronizing screws (b). (MODELS WITH ONE PIECE THROTTLE LINK ROD) a. Remove four (4) attaching screws from sound box cover and remove cover. b.
Page 68: Timing Adjustments
4. Hold throttle arm at idle position. Adjust cam follower Timing Adjustments so that a clearance of .005 in.-.040 in.(0.13 mm-1.02 mm) exists between roller (e) of cam follower and CAUTION throttle cam (f). Tighten screw (a) securing cam follow- Engine may be timed while cranking engine with start- er motor.
Page 69: Maximum Timing
MAXIMUM TIMING 3. Hold throttle arm at idle position (throttle cable barrel removed from barrel retainer). Adjust idle timing screw 1. Hold control arm (a) so that maximum spark advance (a) to attain an engine idle RPM of 650-750 RPM in screw (b) is against stop.
Page 70 ELECTRICAL AND IGNITION 51127 WIRING DIAGRAMS...
Page 71 Page Table of Contents Key/Choke Switch Continuity Test Page (COMMANDER 2000 Side Mount Remote Control) Wiring Diagram ....... 2D-9 Model 45 Jet Electric Start Wiring Diagram...
Page 72: Model 45 Jet Electric Start Wiring Diagram
Model 45 Jet Electric Start Wiring Diagram BLACK BLUE BROWN GREY GREEN PURPLE WHITE YELLOW LIGHT (–) 1 - Stator 2 - Trigger 3 - Switch Box 4 - Voltage Regulator/Rectifier 5 - Starter 53471 6 - Starter Solenoid 7 - Battery 8 - Engine Harness 9 - RPM Limiter 10- Warning Module...
Page 73: Model 50/60 Electric Start Wiring Diagram (Rectifier Models)
Model 50/60 Electric Start Wiring Diagram (RECTIFIER MODELS) a - Stator b - Trigger c - Switch Box d - Ignition Coil Cylinder No. 1 e - Ignition Coil Cylinder No. 2 f - Ignition Coil Cylinder No. 3 g - Starter Motor h - Starter Solenoid i - Rectifier j - Fuse Holder (20 Amp Fuse)
Page 74: Model 50/60 Electric Start Wiring Diagram (Regulator Models)
Model 50/60 Electric Start Wiring Diagram (REGULATOR MODELS) a - Stator b - Trigger c - Switch Box d - Ignition Coil Cylinder No. 1 e - Ignition Coil Cylinder No. 2 f - Ignition Coil Cylinder No. 3 g - Starter Motor h - Starter Solenoid i - Regulator j - Fuse Holder (20 Amp Fuse)
Page 75 Model 50/60 Electric Start Tiller Handle Wiring Diagram BLACK BLUE BROWN GREY GREEN PURPLE WHITE YELLOW LIGHT (–) a - Stator b - Trigger c - Switch Box d - Ignition Coil Cylinder No. 1 e - Ignition Coil Cylinder No. 2 f - Ignition Coil Cylinder No.
Page 76: Wiring Diagram
Model 55 Manual Start Wiring Diagram a - Stator b - Trigger c - Switch Box d - Ignition Coil Cylinder No. 1 e - Ignition Coil Cylinder No. 2 f - Ignition Coil Cylinder No. 3 g - Temperature Switch h - Overheat Warning Module i - Warning Horn j - Stop Button...
Page 77 55/60 Manual Start with RED Stator Wiring Diagram a - Stator b - Terminal Block c - Adaptor d - Ground e - Switch Box f - RPM Limiter g - Audio Horn h - Insulate Unused Red Lead and Secure with Sta-Strap BLK = Black BLU = Blue...
Page 78 50/60 Electric Start with RED Stator Wiring Diagram a - 16 Amp Red Stator b - Switch Box c - Stator Adaptor d - Ground Connection e - Voltage Regulator f - Insulate Unused Red Lead (–) BLK = Black BLU = Blue BRN = Brown GRY = Gray...
Page 79: Model 50/60 Power Trim Wiring Diagram
Model 50/60 Power Trim Wiring Diagram a - Power Trim b - Power Trim Relay c - Engine Starter Motor Solenoid d - Rectifier e - Cowl Mounted Trim Switch f - Red (+) Battery Cable g - Fuse Holder (20 Amp Fuse) h - Engine Wiring Harness Connector i - Remote Control Wiring Harness Connector BLACK...
Page 80: Key/Choke Switch Continuity Test
Key/Choke Switch Continuity Test (COMMANDER 2000 Side Mount Remote Control) 23894 “OFF” BLK/YEL - BLK “RUN” RED - PUR “START” RED - PUR - YEL/RED PUSH (CHOKE)* RED - YEL/BLK *Key switch must be positioned to “RUN” or “START” and key pushed in to actuate choke, for this continuity test.
Page 81: Wiring Diagram
COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Wiring Harness Connector f - Warning Horn g - Trim/Tilt Switch BLACK BLUE...
Page 82 COMMANDER Side Mount Remote Control (Power Tilt Electric Start with Warning Horn) Wiring Diagram a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness e - Wiring Harness Connector f - Warning Horn g - Trim/Tilt Switch h - Wire Retainer i –...
Page 83: Wiring Diagram
COMMANDER 2000 Side Mount Remote Control (Elec- tric Start with Warning Horn) Wiring Diagram a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Wiring Harness Connector f - Warning Horn BLACK BLUE BROWN...
Page 84 FUEL SYSTEMS 51046 CARBURETION...
Page 85 Table of Contents Page Specifications ....... . . 3A-1 Special Tools .
Page 86: Specifications
Specifications Special Tools Idle RPM 650-700 Part No. Description (in “Forward” Gear) 91-36392 Carburetor Scale Float Level 9/16 in. (14.3mm) Fuel Pump Pressure (@ W.O.T.) 4-7 PSI (28-43 kPa) 90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-1...
Page 87: Attenuator Plate
Attenuator Plate 3A-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 88 Attenuator Plate TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SOUND ATTENUATOR SCREW Drive Tight CAP PLUG SEAL SOUND ATTENUATOR PLATE SCREW 135.5 ROLLER SCREW Drive Tight WASHER TUBING (4-1/4 IN.) STA-STRAP GASKET THROTTLE LINK 90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-3...
Page 89: Wme Carburetor Specifications
WME Carburetor Specifications Carburetor Number Stamped at TOP of Carburetor Mounting Flange Carburetor Number Location Model H.P. Main Jet Bowl Vent Jet WME 43-1 Top Carburetor WME 43-2 Center Carburetor .048 .090 WME 43-3 Bottom Carburetor WME 45-1 Top Carburetor WME 45-2 Center Carburetor .062...
Page 90: Notes
Notes: 90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-5...
Page 91: Carburetor
Carburetor Loctite 271 (92-809820) Loctite 7649 Primer (92-809824) 3A-6 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 92 Carburetor TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR (TOP) CARBURETOR (CENTER) 50 - WME-43 CARBURETOR (BOTTOM) CARBURETOR (TOP) 55/60 SeaPro/Marathon CARBURETOR (CENTER) CARBURETOR (BOTTOM) WME-44 CARBURETOR (TOP) 60 - WME-45 CARBURETOR (CENTER) BEACHING/PONTOON/BIG FOOT CARBURETOR (BOTTOM) FORMULA/MAGNUM III SCREW–throttle adjustment (UPPER/BOTTOM) THROTTLE SHAFT (UPPER)
Page 93: Carburetion
Carburetion Troubleshooting Charts Fuel System Troubleshooting PROBLEM 1: ENGINE TURNS OVER BUT WILL NOT START OR STARTS HARD Troubles, that are caused by items 1-thru-5, listed below, WHEN COLD may give the impression that a problem exists in the fuel Possible Cause Corrective Action system:...
Page 94 PROBLEM: ENGINE FLOODS PROBLEM 1: ENGINE IDLES ROUGH AND STALLS Possible Cause Corrective Action PROBLEM 2: ENGINE RUNS UNEVEN OR Dirt or foreign particles Flush out inlet seat and SURGES are preventing inlet clean inlet needle. PROBLEM 3: ENGINE WILL NOT ACCELERATE needle from seating.
Page 95 CHECKING FOR RESTRICTED FUEL FLOW CAUSED PROBLEM 1: ENGINE IDLES ROUGH AND BY ANTI-SIPHON VALVES STALLS While anti-siphon valves are helpful from a safety stand- PROBLEM 2: ENGINE RUNS ENEVEN OR point, they clog, they may be too small, or they may have SURGES too heavy a spring.
Page 96: Carburetor Adjustments
Carburetor Adjustments CARBURETOR FLOAT ADJUSTMENT 1. Remove carburetor as outlined in “Carburetor Remov- al,” following. INITIAL STARTING ADJUSTMENT 2. Remove fuel bowl and gasket and check float level us- Turn idle mixture screw in (clockwise) until it seats LIGHT- ing a carburetor scale. LY--then back-off (each carburetor) 1-1/4 turns.
Page 97: Wme Carburetor Specifications
WME Carburetor Specifications Carburetor Number Stamped at TOP of carburetor mounting flange. Model Carburetor Number H.P. Main Jet Bowl Vent Jet WME-23 .052 .092 WME-26 .048 .090 WME-27 .060 None WME-22 A or B .070 .090 WME-35 .068 None WME-28 .062 .090 WME-43...
Page 98: Carburetor Removal
Carburetor Removal Carburetor Disassembly Remove four screws and lift off attenuator. Remove fuel bowl. Remove six screws and remove carburetors. Disconnect linkages and fuel and primer lines. 51119 a - Fuel Bowl Remove float pin and remove float. Remove fuel bowl gasket. 50527 a - Attenuator Screw (4) b - Carburetor Screw (6)
Page 99 Remove fuel inlet needle. Remove main jet plug and gasket. Remove stem gasket. Remove main jet. 51116 51116 a - Main Jet Plug and Gasket a - Fuel Inlet Needle b - Main Jet b - Stem Gasket NOTE: It is not necessary to disassemble carburetor be- Remove mixing chamber cover and gasket.
Page 100: Cleaning And Inspection
Cleaning and Inspection Spring tension on stud. 1. Carefully inspect carburetor body and fuel bowl for cracks, stripped threads, plugged or restricted pas- sages and passage plugs that show signs of leakage. 2. Thoroughly clean all carburetor parts with a mild clean- ing solution (that will not damage rubber or plastic) to remove dirt, and varnish that may have accumulated.
Page 101 Install main jet. Attach Spring Clip on Inlet Needle to metal float tab and place needle into its seat. Install main jet plug and gasket. 51116 a - Main Jet [Torque 14 lb. in (1.6 N·m)] b - Main Jet Plug and Gasket [Torque 22 lb. in. (2.5 N·m)] 51115 Install stem gasket.
Page 102: Carburetor Installation
Install float bowl. Carburetor Installation Install carburetors, attenuator plate, connect linkages, and fuel and primer lines. Install sound attenuator. 51116 a - Fuel Bowl b - Screw (4) Torque 18 lb in. (2.1 N·m) 50527 a - Attenuator Brackets (2) b - Carburetor Screw (6) Torque 100 lb.
Page 103 FUEL SYSTEMS FUEL PUMP...
Page 104 Table of Contents Page Specifications ....... . . 3B-1 Fuel Pump (50/60) .
Page 105: Specifications
Specifications Fuel Pump Pressure (@ W.O.T.) 4-7 PSI (28-43 kPa) 90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-1...
Page 106: Fuel Pump (50/60)
Fuel Pump (50/60) Perfect Seal (92-34227-1) A – To Carburetor B – To Crankcase C – To Oil Pump 3B-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 107 Fuel Pump (50/60) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP ASSEMBLY DIAPHRAGM KIT RUBBER CHECK VALVE CHECK VALVE RETAINER SPRING SPRING DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump SCREW–fuel pump to crankcase BASE HOSE FUEL FILTER FUEL LINE STA-STRAP...
Page 108: Fuel Pump (55/60 Seapro/Marathon)
Fuel Pump (55/60 Seapro/Marathon) Perfect Seal (92-34227-1) A – To Carburetor B – To Crankcase 3B-4 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 109 Fuel Pump (55/60 Seapro/Marathon) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FUEL PUMP ASSEMBLY DIAPHRAGM KIT RUBBER CHECK VALVE CHECK VALVE RETAINER SPRING SPRING DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump SCREW–fuel pump to crankcase BASE HOSE (10 )(14-1/4 ) STA-STRAP HOSE...
Page 110: Fuel Pumps
CHECKING FOR RESTRICTED FUEL FLOW CAUSED WARNING BY ANTI-SIPHON VALVES FIRE AND EXPLOSION HAZARD. Observe fire preven- While anti-siphon valves are helpful from a safety stand- point, they clog, they may be too small, or they may have tion rules, particularly NO SMOKING. Before servicing too heavy a spring.
Page 111: Troubleshooting Fuel Pump
Troubleshooting Fuel Pump PROBLEM: LACK of FUEL PUMP PRESSURE Possible Cause Corrective Action PROBLEM: AIR BUBBLES IN FUEL LINE An anti-siphon valve Read “Checking for Possible Cause Corrective Action Restricted Fuel Flow Low fuel in fuel tank. Fill tank Caused by Anti-Siphon Valves”...
Page 112: Fuel Pump Removal
Fuel Pump Removal Fuel Pump Disassembly 1. Remove oil tank from outboard. Refer to Section 8A 1. Remove bolts (a) and chamber plate (b). “Oil Injection System.” 2. Remove fuel “inlet” hose, (a) “outlet” hose, (b) and pulse hose (d). 3.
Page 113: Fuel Pump Reassembly
Fuel Pump Reassembly Check Valve Assembly 1. Insert retainer (a) thru plastic disc (b) and rubber check valve (c). 23601 23601 2. Install check valves and retainers into fuel pump body. 23610 Fuel Pump Assembly 1. Assemble remaining components as shown in “Fuel Pump Exploded View”.
Page 114: Fuel Pump Exploded View
NOTE: In fuel pump reassembly, remember that respec- Fuel Pump Exploded View tive diaphragms go against the mating surfaces of the fuel pump body, and respective gaskets are between the dia- IMPORTANT: Align all gasket and diaphragm aligning phragms and end caps. Gaskets should always be re- tabs with fuel pump aligning tabs during reassembly.
Page 115: Fuel Tank
Fuel Tank Fuel Tank Components Maintenance The inside of the fuel tank should be cleaned once each season. Dirt or water may have entered the fuel tank during refilling. Clean the tank by flushing with clean, lead-free gasoline or kerosene. If a fuel restriction problem is encountered, the fuel filter on end of outlet tube may be obstructed.
Page 116: Fuel Line And Primer Bulb Assembly
Fuel Line and Primer Bulb Assembly REF. DESCRIPTION FUEL LINE ASSEMBLY PRIMER BULB ASSEMBLY CHECK VALVE, inlet FITTING, outlet CLAMP, primer bulb to check valve (LARGE) CLAMP, fuel line to check valve (SMALL) CONNECTOR, fuel tank (OUTLET) CONNECTOR, engine (INLET) CLAMP, fuel line to connector BAYONET BODY ASS’Y (FUEL TANK END)
Page 117: Maintenance
Maintenance 2. To install fuel line clamps, grip hose clamp with pliers and push down on hook with screwdriver until hooks in- Periodically check fuel line and primer bulb for cracks, terlock. breaks, restrictions or chafing. Check all fuel line connec- Installing Fuel Line Clamps tions for tightness.
Page 118 FUEL SYSTEMS ENRICHMENT...
Page 119 Table of Contents Page Enrichener System ......3C-1 Enrichener Valve Test ..... . . 3C-2 3C-0 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 120: Enrichener System
Enrichener System The enrichener system provides the engine with extra fuel charge for ease of starting cold engine. The system con- sists of an electrically operated enrichener valve which is connected by a hose to the intake manifold. Fuel is gravity fed to the valve from the float bowl of the top carburetor via a hose.
Page 121: Enrichener Valve Test
IMPORTANT: Use of enrichener if engine is warm could result in engine flooding ENRICHENER VALVE TEST Push key (or choke button) in. Valve should click Click No Click Squeeze primer bulb until bulb is firm. Remove lower hose from fit- Check for battery voltage to YELLOW/BLACK wire at terminal ting on enrichener valve.
Page 122 FUEL SYSTEMS 51203 OIL INJECTION...
Page 123 Table of Contents Page Page Operation of the Injection System ....3D-1 Outboard Operation ......3D-10 Oil Injection System .
Page 124: Operation Of The Injection System
2. Oil Injection Pump Operation of the Injection The crankshaft driven oil pump is a constant ratio oil System pump which provides an oil fuel mixture. 3. Check Valve Vent The oil injection system delivers a oil mixture thru a con- Provides air to oil reservoir for proper venting and also stant ratio oil pump.
Page 125: Oil Injection Flow System (Fixed Ratio Oil Pump)
Oil Injection Flow System (Fixed Ratio Oil Pump) Warning Module Fill Cap Fuel Filter Vent Carburetor Fuel Pump Level Sight Gauge 2 PSI Check Valve Fuel Line Connector Oil Pump 51202 3D-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 126: Pump Drive Assembly (Fixed Ratio Oil Pump)
Pump Drive Assembly (Fixed Ratio Pump Drive System (Fixed Ratio Oil Oil Pump) Pump) 51203 a - O-Rings b - Driven Gear c - Drive Gear 51203 d - Crankshaft a - Bleed Screw e - Oil Pump b - Oil Outlet c - Oil Pump d - Oil Inlet 51203...
Page 127: Oil Pump To Powerhead Assembly (Fixed Ratio Oil Pump)
Oil Pump to Powerhead Assembly (Fixed Ratio Oil Pump) 51203 TORQUE SPECIFICATIONS 2-4-C With Teflon (92-825407A12) 60 lb. in. (7.0 N·m) 1 - Bolt 2 - Oil Pump 3 - O-Rings 4 - Bushing 5 - Bearing 6 - Bushing 7 - Driven Gear 3D-4 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996...
Page 128: Oil Injection Flow System (Variable Ratio Oil Pump)
Oil Injection Flow System (Variable Ratio Oil Pump) 52049 a - Fill Cap b - Vent c - Warning Module d - Fuel Filter e - Carburetors f - Fuel Pump g - 2 psi Check Valve h - Oil Pump i - Fuel Line Connector j - Low Oil Sensor k - Oil Level Sight Gauge...
Page 129: Pump Drive Assembly (Variable Ratio Oil Pump)
Pump Drive Assembly (Variable Ratio Pump Drive System (Variable Ratio Oil Pump) Oil Pump) 52044 52046 a - Oil Outlet a - O–Rings b - Oil Pump b - Driven Gear c - Oil Inlet c - Drive Gear d - Bleed Screw d - Crankshaft e - Oil Pump 52044...
Page 130: Oil Pump To Powerhead Assembly (Variable Ratio Oil Pump)
Oil Pump to Powerhead Assembly (Variable Ratio Oil Pump) 52046 TORQUE SPECIFICATIONS 2-4-C With Teflon (92-825407A12) 60 lb. in. (7.0 N·m) 1 - Bolt 2 - Oil Pump 3 - O-Rings 4 - Bushing 5 - Bearing 6 - Bushing 7 - Driven Gear 90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-7...
Page 131: Set Up Instructions For Oil Injection System
Filling Oil Injection System with Oil Set Up Instructions for Oil Injection System Quicksilver 2-Cycle Outboard Oil is recommended for this oil injection system. In an emergency, whin Quicksilver oil is not available, substitute a high quality 2-cycle outboard CAUTION oil that meets BIA ratings TC-W and TC-WII, shown on oil container.
Page 132: Bleeding Air From Oil Injection System
Bleeding Air From Oil Injection Outboard Operation System 1. Check oil level in oil tank. 2. A 50:1 gasoline/oil mixture must be used during break- CAUTION in or after extended storage. If air exists in either oil pump hose (inlet or outlet), the 3.
Page 133: Required Side Mount Remote Control Or Ignition Key Switch Assembly
Required Side Mount Remote Control Oil Injection System or Ignition Key Switch Assembly Troubleshooting Chart Boats Equipped with a Side Mount Remote Control A Quicksilver Commander Series Side Mount Remote Troubleshooting the Oil Injection Control equipped with a warning horn, must be used with this outboard.
Page 134: Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft
1. Check oil level in oil tank. If oil level is approximately Installing Drive Gear (For Oil 14.5 fl. oz. (435 ml) or less, the problem is low oil level. Injection Pump) Onto Add oil to oil tank. NOTE: There is a safety reserve of oil left in the oil tank af- Crankshaft ter the low oil warning is sounded that allows enough oil for approximately 1.5 hours of full throttle operation.
Page 135: Oil Warning Module
3. Connect PURPLE, TAN and both BLUE leads at Oil Warning Module respective bullet connectors. Secure warning module BLACK lead to switch box mounting bolt and install Removal/Installation warning module.Tighten bolts securely. 1. Disconnect battery cables. 50430 51204 51084 a - Warning Module b - Warning Module Leads c - Screws 2.
Page 136: Engine Mounted Oil Reservoir
3. Disconnect oil hose and low oil sensor wires (BLUE) at Engine Mounted Oil bullet connectors. Remove oil reservoir. Reservoir Removal 1. Disconnect battery cables. 51203 a - Oil Tank Wires (BLUE) b - Oil Hose 4. Remove oil level sensor from oil reservoir. CAUTION Oil level sensor is FRAGILE.
Page 137: Installation
Installation 3. Install starter/oil tank bracket. 1. Install oil level sensor and secure in place. 51204 a - Oil Level Sensor 51080 b - Screw (Tighten Securely) a - Starter/Oil Tank Bracket 2. Connect sensor oil level wires (BLUE) at bullet connec- b - Bolts tors.
Page 138 POWERHEAD 51081...
Page 139 Table of Contents Page Page Specifications ........Powerhead Reassembly and Installation .
Page 140: Specifications
Specifications Special Tools General Part No. Description Type Two-Stroke Cycle 91-52344 Flywheel Holder 91-24161 Protector Cap Displacement 51.8 cu. in. (849 cc) 91-73687A1 Flywheel Puller Cylinder Bore 91-90455 Lifting Eye *91-24697 Piston Ring Expander Diameter Standard 2.955 in. (75.057 mm) 91-74607A2 Piston Pin Tool Diameter .015 Oversize...
Page 141: Cylinder Block And Crankcase
Cylinder Block and Crankcase 24 25 Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Loctite Master Gasket (92-12564-2) 2-4-C With Teflon (92-825407A12) 4-2 - POWERHEAD 90-817643R1 DECEMBER 1996...
Page 142 Cylinder Block and Crankcase TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK SCREW 18.5 25.0 SCREW 18.5 25.0 CHECK VALVE HOSE (16 ) CHECK VALVE (PRESS-IN) CARRIER ASSEMBLY CHECK VALVE ADJUSTING SCREW JAM NUT DOWEL PIN (LOCATING) DOWEL PIN (BEARING RACE) COVER SCREW...
Page 143 Cylinder Block and Crankcase 24 25 Loctite 271 (92-809820) Loctite PST Pipe Sealant (92-809822) Loctite Master Gasket (92-12564-2) 2-4-C With Teflon (92-825407A12) 4-4 - POWERHEAD 90-817643R1 DECEMBER 1996...
Page 144 Cylinder Block and Crankcase TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m PIPE PLUG Drive Tight TEMPERATURE SENDER RETAINER SCREW Drive Tight WASHER WASHER WASHER WING NUT 50/60 Hand Tight ELBOW ELBOW (55) COVER FITTING (50/60) COVER O-RING SCREW LIFTING EYE SCREW (55MM )
Page 145: Induction Manifold And Reed Block
Induction Manifold and Reed Block 20 21 2 Cycle Outboard Oil (92-13249A24) Perfect Seal (92-34227-1) 4-6 - POWERHEAD 90-817643R1 DECEMBER 1996...
Page 146 Induction Manifold and Reed Block TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GASKET LOWER END CAP ASSEMBLY OIL SEAL OIL SEAL O-RING SCREW 18.5 25.0 BRACKET ASSEMBLY STUD WASHER WASHER 50/60 WING NUT Hand Tight SCREW 18.5 25.0 INDUCTION MANIFOLD ELBOW (Qty.
Page 147: Crankshaft, Pistons And Connecting Rods
Crankshaft, Pistons and Connecting Rods 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) 4-8 - POWERHEAD 90-817643R1 DECEMBER 1996...
Page 148 Crankshaft, Pistons and Connecting Rods TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CRANKSHAFT ASSEMBLY BALL BEARING RETAINING RING DRIVER GEAR ROLLER BEARING ASSEMBLY (TOP) OIL SEAL ROLLER BEARING ASSEMBLY (CENTER) PISTON ASSEMBLY (STANDARD) PISTON ASSEMBLY (.015 O.S.) PISTON ASSEMBLY (.030 O.S.) LOCK RING PISTON RING (STANDARD)
Page 149: Throttle Lever And Linkage
Throttle Lever and Linkage 2-4-C With Teflon (92-825407A12) 4-10 - POWERHEAD 90-817643R1 DECEMBER 1996...
Page 150 Throttle Lever and Linkage TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m THROTTLE LEVER ADJUSTING SCREW JAM NUT ADJUSTING SCREW WASHER Drive Tight then Back Off 1/2 Turn BUSHING JAM NUT SWIVEL BUSHING SPRING WASHER SPARK ADVANCE LEVER SPARK ADVANCE ROD SWIVEL BASE SWIVEL BALL...
Page 151: Powerhead Torque Sequence
Powerhead Torque Sequence INTAKE MANIFOLD TORQUE SEQUENCE Install bolts and torque to 18 lb. ft. (24.5 N·m) PE-51085 CRANKCASE COVER AND LOWER END CAP COV- ER TORQUE SEQUENCE Torque bolts to 18 lb. ft. (24.5 N·m) PE-51085 PE-51086 4-12 - POWERHEAD 90-817643R1 DECEMBER 1996...
Page 152: General Information
2. Disconnect control/trim harness and fuel line. 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 com- ponents. If complete disassembly is not necessary, start reassembly at point disassembly was stopped.
Page 153 4. Remove control cables. 6. Remove electrical box cover. PE-51088 a - Shift Cable b - Throttle Cable 5. Remove bolt and rubber grommet. PE-51089 7. Remove battery cables and starter bracket. PE-51082 a - Bolt b - Fuel Connector c - Rubber Grommet PE-51080 a - Positive Cable...
Page 154 8. Disconnect wires and remove oil tank. 10. Remove cover (a). PE-51088 a - Oil Tank Wires (Blue) b - Power Trim Wires (Blue/White) and (Green/White) c - Oil Hose (From Tank) 9. Remove ground wire to powerhead. Disconnect wires from trim relay module(s).
Page 155: Powerhead Disassembly
12. Install lifting eye (p/n 91-90455) into flywheel a mini- Powerhead Disassembly mum of five turns. Lift powerhead from drive shaft housing allowing shift linkage to slide off shift rail guide. Removing Engine Components Remove the following engine components: Component/Assembly Section Starter Motor Ignition Switch Box...
Page 156 2. Remove thermostat components. 4. Remove check valves and holders. PE-51087 a - Bolts b - Thermostat Cover c - Thermostat Gasket d - Thermostat e - Poppet Valve f - Spring 3. Remove intake manifold and reed block manifold. PE-51227c a - Check Valve/Holders 5.
Page 157: Crankshaft Disassembly
6. Remove crankcase cover bolts. Crankshaft Disassembly 1. Remove roller bearing assemblies from crankshaft. PE-51085 a - Bolts (14) b - Lower End Cap 7. Remove crankcase cover from cylinder block. 8. Remove end cap. PE-51085 a - Roller Bearing Race b - Roller Bearing c - Retaining Ring 2.
Page 158 3. Remove connecting rod/piston assembly from crank- 6. Remove piston rings. Always install new piston rings. shaft; re-attach caps to respective rod as each is re- moved. CAPS MUST BE INSTALLED IN SAME DI- RECTION ON SAME ROD, or mating surface will not seat properly.
Page 159 8. Remove piston pin. 11. Press crankshaft bearing as shown. PE-51086 a - Piston Pin b - Piston Pin Tool (91-74607A2) 9. Remove piston pin needle bearings (29 per piston pin) and locating washers (“a” 2 per piston) as shown. PE-51081 12.
Page 160: Cleaning And Inspection
Cleaning and Inspection CAUTION If crankcase cover and cylinder block is to be sub- Cylinder Block and Crankcase Cover merged in a very strong cleaning solution, it will be necessary to remove the crankcase cover/cylinder IMPORTANT: Crankcase cover and cylinder block are block bleed system from cover/cylinder block to pre- matched, line-bored assembly should not be mis- vent damage to hoses and check valves.
Page 161: Check Valves
Measure cylinder bore inside diameter (with an inside TO CHECK: Inspect check valves by looking through hole. micrometer) of each cylinder, as shown below. Check If light can be seen the nylon ball is bad (probably melted); for tapered, out-of-round (“egg-shaped”) and oversize REPLACE valve.
Page 162: Cleaning Piston Ring Grooves
CLEANING PISTON RING GROOVES PISTON PISTON SKIRT CYL. BORE IMPORTANT: The piston rings are half – keystone rings SIZE DIAMETER FINISH HONE – (tapered on the top side) – follow cleaning and in- Standard 2.950 in. 2.955 in. spection carefully! Chromed ring is installed on top. Piston (74.93 mm) (75.057 mm)
Page 163: Connecting Rods
Thermostat · Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearings. Recheck surfaces of crank- Wash thermostat with clean water. Using a thermostat tes- shaft. Replace crankshaft if surfaces cannot be proper- ter, similar to the one shown, test thermostat as follows: ly “...
Page 164: Reed Blocks
Reed Blocks If the opening exceeds .020 in. (0.5 mm), or if the reed is chipped, cracked or otherwise damaged, replace. NOTE: Do not disassemble reed block unless necessary. .020 PE-51089 PE-51089 CAUTION a - Reed Block b - Reed (3 Sets) Replace locking tab-Washer.
Page 165: Powerhead Reassembly And Installation
Powerhead Reassembly and CAUTION Installation Any GREASE used for bearings INSIDE the powerhead MUST BE gasoline soluble. Use only Quicksilver Needle Bearing Assembly Lubricant. DO NOT use General Information 2-4-C Marine Lubricant, or other lubricants inside the powerhead, or damage may occur. Before proceeding with powerhead reassembly, be sure that all parts to be reused have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspec-...
Page 166 2. Install needle bearings. 4. Push sleeve from piston using piston pin tool. PE-51081 a - Needle Bearings (29) b - Sleeve [from Piston Pin Tool (91-74607A2)] 3. Place locating rings on connecting rod, carefully place piston over end of rod. Refer to scribed identification number for matching rod to piston and direction of as- PE-51080 sembly (which side of rod is “UP”).
Page 167: Piston Ring Installation
6. Install new piston pin lockrings (each side of piston) us- Piston Ring Installation ing Lockring Tool (p/n 91-77109A1). IMPORTANT: Piston ring side with letter or mark must 7. Make sure lockrings are properly seated in piston be facing up. grooves.
Page 168 1. Install piston ring in appropriate groove on piston using 4. Remove connecting rod cap from connecting rod be- Piston Ring Expander Tool. Spread rings just enough ing installed. to slip over piston. 5. Install each piston with “UP” identification facing fly- Top Groove –...
Page 169: Crankshaft Installation
Crankshaft Installation CAUTION 1. If lower bearing and gear were removed from crank- Any grease used for bearings INSIDE the powerhead shaft, slide gear in place (note keyway and key in gear MUST BE gasoline soluble. Use only Quicksilver to crankshaft assembly). Install gear to crankshaft us- Needle Bearing Assembly Lubricant.
Page 170 6. Position cylinder block and piston rods as shown. In- Installing Rods to Crankshaft sert locating pins (a). 1. Oil rod and bearing cage with 2-cycle oil. 2. Pull rod into place and install bearing cages as shown. PE-51080 PE-51088 NOTE: Clean rod bolt/rod cap bolt holes of oil and debris Flywheel End Lower End...
Page 171: Connecting Rod Cap Alignment
Connecting Rod Cap Alignment Crankcase Cover to Block 1. Check each connecting rod for correct alignment by 1. Install upper seal to crankshaft. carefully running fingernails up and down edge of rod cap. If not aligned, a ridge can be seen or felt at the separating line.
Page 172 3. Install end cap assembly (lubricate seals with 2-cycle 5. Insert clean bolts (note 2 sizes) and finger tighten. engine oil) to block. Apply Perfect Seal to flange of end 6. Torque bolts to 18 lb. ft. (24.5 N·m) following sequence cap (a).
Page 173: Intake/Reed Block Manifold Installation
Intake/Reed Block Manifold Installa- 3. Install reed block manifold and intake manifold with gasket to cylinder block. tion 1. Place engine on repair stand or on bench. NOTE: Powerhead repair stand p/n 91-25821A1 can be used. Can only be installed one way. PE-51225 4.
Page 174: Thermostat Cover Installation
Thermostat Cover Installation Powerhead Installation 1. Install thermostat components into cylinder block. 1. Install lifting eye (p/n 91-90455) into flywheel a mini- Torque bolts to 18 lb. ft. (24.5 N·m). mum of 5 turns. Install powerhead to driveshaft hous- ing. Slide shift slide on rail while lowering powerhead 50/60 Models on splines of drive shaft.
Page 175 2. Install Powerhead bolts. Torque to 28 lb.ft. (38.0 N·m). 4. Reattach ground wire to powerhead. Connect wires from trim relay switch. Connect tel tale hose. Design 1 PE-51082 Design 2 PE-51088 3. Install cover. Torque bolts to 80 lb. in. (9.0 N·m). 54244 a - Module(s) b - Ground Lead...
Page 176 6. Install oil tank. 9. Install bolt and rubber grommet. 7. Install battery cables and starter bracket. PE-51082 PE-51080 a - Bolt b - Fuel Connector a - Positive Cable c - Rubber Grommet b - Ground Cable c - Bracket 10.
Page 177: Test Run Procedure
11. Reconnect trim switch. Test Run Procedure CAUTION When engine is started, IMMEDIATELY check that wa- ter pump is operating. Operation of water pump is indi- cated by water discharging from “tell tale”. 1. While test running outboard, check powerhead as- sembly for leaks and/or unusual noises.
Page 178 MID-SECTION 50557 CLAMP/SWIVEL BRACKETS and DRIVE SHAFT HOUSING...
Page 179 Table of Contents Page Mid-Section Components ..... . . 5A-1 Swivel Bracket Components ....5A-1 Mid-Section Components .
Page 180: Mid-Section Components
Mid-Section Components Swivel Bracket Components 1 - Swivel Bracket 2 - Bushing (2) 3 - Oil Seal 4 - Bushing 5 - Grease Fitting 6 - Washer (2) 7 - Yoke 8 - Retaining Ring 9 - Roll Pin 10 - Steering Arm 11 - Bracket 12 - Locking Plate 13 - Bolt (2)
Page 181 Mid-Section Components Transom Bracket Components (55 Model) 1 - Transom Bracket 2 - Grease Fitting 3 - Pin 4 - Transom Bracket 5 - Lock Lever 6 - Spring 7 - Bushing 8 - Spring 9 - Lever 10 - Roll Pin 11 - Washer (2) 12 - Bracket 13 - Anode...
Page 182: Transom Bracket Components (50/60 Models)
Mid-Section Components Transom Bracket Components (50/60 Models) 1 - Transom Bracket 2 - Grease Fitting 3 - Pin 4 - Transom Bracket 5 - Tilt Lock Lever 6 - Spring 7 - Bushing 8 - Spring 9 - Lever 10 - Roll Pin 11 - Washer (2) 12 - Bracket 13 - Anode Plate...
Page 183: Drive Shaft Housing Components
Mid-Section Components Drive Shaft Housing Components 1 - Drive shaft Housing 2 - Seal 3 - Bolt (4) 4 - Exhaust Tube 5 - Gasket 6 - Pin 7 - Exhaust Plate 8 - Bolt 9 - Lock Nut (2) 10 - Washer (2) 11 - Washer (2) 12 - Bolt (4)
Page 184: Disassembly
Disassembly Reassembly Remove shock system assembly (refer to Section 5C) from Tilt Lock Lever/Transom Bracket non power trim models. Apply Quicksilver 2-4-C Marine Lubricant to tilt lock lever Remove power trim assembly (refer to Section 5B) from shank, spacer and bushing prior to reassembly. power trim models.
Page 185 Lubricate outboard tilt tube using Quicksilver 2-4-C Marine Install and secure yoke and washer using snap ring. Lubricant and install into swivel bracket. Secure transom brackets into place using fiber washers and lock nuts. 51078 a - Tilt Tube b - Fiber Washer c - Lock Nuts 51079 a - Washer...
Page 186: Drive Shaft Housing
Install clamp. Drive Shaft Housing Secure transom bracket assembly to transom. Install drive shaft housing to transom bracket assembly. Secure using bolts and components as shown. 51097 a - Clamp b - Bolts [220 lb. in. (24 N·m)] Install shift linkage assembly and new gasket to drive shaft housing.
Page 187 MID-SECTION 50158 POWER TRIM (DESIGN 1)
Page 188 Table of Contents Page Page Power Trim General Information ... . 5B-1 Power Trim System Removal ... . . 5B-21 Description .
Page 189: Power Trim General Information
Make sure that water level is above gear housing Power Trim General water intake holes whenever engine is running. Information Operating “up” circuit will actuate the “up” solenoid (located under engine cowl) and close the electric motor circuit. The electric motor will drive the pump, Description thus forcing automatic transmission fluid thru internal passageways into the “up”...
Page 190: Trailering Outboard
Trailering Outboard Trim “In” Angle Adjustment WARNING WARNING Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to the cient water supply to water pump causing water full “in” trim angle [not using trim adjustment pin pump and/or powerhead overheating damage.
Page 191: Power Trim System Components
NOTE: It is recommended that “ALL” O-rings be re- Power Trim System placed when servicing tilt system. Components 1 - Trim Rod Torque Specifications 2 - Dowel Pin (Upper) 3 - Upper Pivot Pin 4 - Rod Wiper 35 lb. in. (4.0 N·m) 5 - O-ring .671 in.
Page 192: Power Trim Flow Diagrams Design
Power Trim Flow Diagrams Design 1 51638 5B-4 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 193 Design 1 51637 90-817643R1 DECEMBER 1996 MID-SECTION - 5B-5...
Page 194 Design 1 51639 5B-6 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 195 Design 1 51640 90-817643R1 DECEMBER 1996 MID-SECTION - 5B-7...
Page 196 Design 1 51641 5B-8 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 197 Design 1 51642 90-817643R1 DECEMBER 1996 MID-SECTION - 5B-9...
Page 198 Design 1 51643 5B-10 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 199: Determine If Problem Is Electrical Or
Troubleshooting Determine if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys- tem is at fault. Trouble Chart Outboard will not trim up or down. Determine if Power Trim pump Outboard trims up, will not trim motor operates when appro- down.
Page 200: Hydraulic System Troubleshooting
Hydraulic System Troubleshooting Leak Down Check – Pump and Manifold Assembly Support outboard with tilt lock lever when servicing power trim system. NOTE: Scribe (d) pump housing halves before disas- sembly. IMPORTANT: After debris or failed components have been found (during troubleshooting proce- 1.
Page 201: Assembly
Leak Down Check – Pilot Valve Leakage Past Ball and Seat – Piston Assembly Assembly 1. Debris or chips between check ball and seat (a), Unit will trim to full or near full DOWN position and usually imbedded in rubber valve seat. then will begin to trim UP while trim switch is held in “DOWN”...
Page 202: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard falls to full down position with manu- al release valve closed. Example a: Outboard lowers more than one tilt pin hole in eight hours. Example b: Outboard lowers during acceler- ation. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings...
Page 203: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed decelera- tion. Inspect Manual Release Valve. Result Result Manual release valve and O-rings Manual release valve and/or O- appear to be OK. Replace O-rings ring damage and proceed.
Page 204: Electrical System Troubleshooting
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram Black Blue Brown Gray Green Purple White Yellow a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector 23891 e - Wiring Harness Connector...
Page 205: Power Trim System Wiring Diagram
Power Trim System Wiring Diagram Black Blue Green White 50285 a - To Power Trim Pump Motor b - Relay Switch “UP” c - Relay Switch “DOWN” d - Engine Starter Motor Solenoid e - Cowl Trim Switch f - Fuse Holder (20 Amp Fuse) g - Engine Wiring Harness Connector h - Remote Control Wiring Harness 90-817643R1 DECEMBER 1996...
Page 206: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is Ok)
Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) *Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 207: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is Ok)
Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) *Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 208: Troubleshooting The "Down" And "Up" Circuits
Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)* *Remote Control Not Equipped with Trailer Button Check in-line fuse (under cowl) to see if fuse is blown. Blown Fuse: Fuse Not Blown: Correct problem that caused Connect Voltmeter red lead to fuse to blow.
Page 209: Power Trim System Removal
5. Use suitable punch to remove (DRIVE UP) lower Power Trim System Removal dowel pin. Retain dowel pin. Support outboard with tilt lock lever when servicing power trim system. 1. Disconnect power trim harness from outboard wiring harness. 2. Remove screw and clip securing wiring harness to clamp bracket.
Page 210: Power Trim System Disassembly
7. Tilt power trim assembly (top first) out from clamp 9. Remove O-ring from fill cap. bracket and remove assembly. 51194 Power Trim System Disassembly Trim Rod Removal 1. Secure power trim assembly in soft jawed vise. 2. Open manual release valve three or four turns (counterclockwise) and position trim rod to full up position.
Page 211: Trim Rod Disassembly
4. Remove trim rod assembly from cylinder. 6. Remove O-ring from memory piston. 51196 a - O-ring b - Memory Piston 7. Remove trim system from vise and empty fluid into appropriate container. 51196 5. Remove memory piston from cylinder using lock- ring pliers (shown) or suitable tool.
Page 212 4. Place trim rod into soft jawed vise and apply heat CAUTION to shock piston using torch lamp (P/N 91-63209). Do not remove check ball components from trim 5. Loosen trim rod piston using spanner wrench (1/4 rod piston. Removal and reinstallation of check in.
Page 213: Trim "Motor" Removal
Trim “Motor” Removal 4. Remove motor and harness from reservoir. 1. Secure power trim assembly in soft jawed vise. 2. Remove cap, washer and grommet from reser- voir assembly. 51196 Trim “Motor” Disassembly 1. Remove end cap from motor housing. Note posi- 51195 a - Cap tion of washers on armature.
Page 214: Reservoir Assembly Removal
2. Remove O-ring from end frame. Reservoir Assembly Removal 3. Place scribe mark on motor housing and end CAUTION frame as reassembly reference, as shown. DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE. THIS VALVE IS PRESET AT FAC- TORY FOR PRECISE REVERSE THRUST PRES- SURE AND DOES NOT REQUIRE ADJUSTMENT.
Page 215: Oil Pump Removal
3. Remove four screws securing reservoir to man- Oil Pump Removal ifold. IMPORTANT: The oil pump is not rebuildable. If oil pump is defective, replace as an assembly. 1. Remove screw, oil pump and O-rings from man- ifold. 51193 a - Screw 4.
Page 216: Cleaning And Inspection Of Trim Rod Components
2. Slowly remove manifold from cylinder. Note posi- 3. Remove O-rings from cylinder. tion of above trim check ball assembly and re- 4. Remove filter. move. 54745 54743 a - O-rings b - Filter Cleaning and Inspection of Trim Rod Components IMPORTANT: Components must be dirt and lint free.
Page 217: Motor And Electrical Tests/Repair
Inspect check valve for debris; clean debris from MOTOR ASSEMBLED check valve if found. If debris cannot be cleaned from Connect Ohmmeter (R x 1 scale) leads as shown. If check valve, replace trim rod piston as an assembly. switch is good, full continuity (zero ohms) will be indi- Clean trim rod and components with parts cleaner cated.
Page 218: Armature Tests
Armature Tests Power Trim System Reassembly TEST FOR SHORTS Check armature on a Growler (follow Growler man- ufacturer’s test instructions). Indication of a short re- Manifold Installation quires replacement of armature. IMPORTANT: Filter must be installed in trim cylin- der with ridge of filter housing facing out. TEST FOR GROUND Use an Ohmmeter (R x 1 scale).
Page 219: Oil Pump Installation
2. Install check ball components (a) into manifold. 4. Secure manifold to cylinder using screws, torque to 100 lb. in. (11.2 N·m). 54746 a - Trim Cylinder b - Manifold c - Screw Oil Pump Installation 1. Secure power trim unit in soft jawed vise. 2.
Page 220: Trim Motor Reassembly
Trim Motor Reassembly 3. Align scribe mark on housing with mark on end frame. 1. Apply Quicksilver Marine Lubricant (2-4-C) to ar- 4. Install lubricated O-ring to end frame. mature shaft and insert into end frame. 51195 a - Armature Shaft b - Washer 51194 c - End Frame...
Page 221: Reservoir Installation
IMPORTANT: When installing motor, wires (black, 3. Install end cap, O-ring and foam pad to cylinder. orange) must rest in cavity of cylinder allowing 4. Torque screws to 13 lb. ft. (1.5 N·m). motor to seat properly. 51194 a - Manifold b - Cavity 51195 Reservoir Installation...
Page 222 6. Place drive shaft into oil pump. 10. Install lubricated O-rings and “E” clip to manual release valve. 7. Install lubricated O-ring to base of reservoir. 8. Carefully guide reservoir (with motor) down onto drive shaft. 51196 a - “E” Clip b - O-ring c - Manual Release Valve 11.
Page 223: Trim Rod Reassembly
Trim Rod Reassembly 4. Apply Loctite Grade A (271) to threads of trim rod and install trim rod piston. Tighten piston securely 1. Install lubricated O-rings and rod wiper to end using spanner wrench (1/4 in. x 5/16 in. long peg). cap.
Page 224: Trim Rod Installation
Trim Rod Installation 4. Install trim rod into cylinder. 1. Place trim cylinder in soft jawed vise. 2. Fill trim cylinder three inches (76.2mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid or; (ATF) Type F, FA or Dexron II. 3.
Page 225: Bleeding Power Trim Unit
Power Trim Unit Installation Bleeding Power Trim Unit 1. Apply Special Lubricant 101 (92-13872A1) to IMPORTANT: Manual release valve must be in the lower pivot pin hole and pivot pin surface. closed position during power trim bleeding and operation. 2. Start lower pivot pin into pivot pin bore and posi- tion lower dowel pin (RETAINED) in its respective 1.
Page 226 4. Using a suitable punch, drive lower pivot pin into 7. Using a suitable mallet, drive upper pivot pin into clamp bracket and trim cylinder assembly until swivel bracket and through trim ram until pivot pin pivot pin is flush with outside surface. is flushed with swivel bracket.
Page 227 MID-SECTION 50158 POWER TRIM (DESIGN II)
Page 228 Table of Contents Page Page Power Trim General Information ... . 5C-1 COMMANDER 2000 Side Mount Remote Description ......5C-1 Control (Power Trim/Tilt Electric Start with Trimming Characteristics...
Page 229: Power Trim General Information
Power Trim General WARNING Information Excessive engine trim angle will result in insuffi- cient water supply to water pump causing water pump and/or powerhead overheating damage. Description Make sure that water level is above gear housing The Power Trim system consists of an electric motor, water intake holes whenever engine is running.
Page 230: Trailering Outboard
Trailering Outboard Trim “In” Angle Adjustment WARNING WARNING Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to the cient water supply to water pump causing water full “in” trim angle [not using trim adjustment pin pump and/or powerhead overheating damage.
Page 231 NOTE: It is recommended that “ALL” O-rings be re- Power Trim System placed when servicing tilt system. Components 1 - Trim Rod 2 - Dowel Pin 3 - Pivot Pin 4 - Rod Wiper 5 - O-ring .671 in. I.D. 6 - Cylinder Cap 7 - O-ring 1.864 in.
Page 232: Design Ii
Power Trim Flow Diagrams Design II 51644 5C-4 - MID-SECTION 90-8i7643R1 DECEMBER 1996...
Page 233: Design Ii
Design II 51645 90-817643R1 DECEMBER 1996 MID-SECTION - 5C-5...
Page 234: Design Ii
Design II 51646 5C-6 - MID-SECTION 90-8i7643R1 DECEMBER 1996...
Page 235: Design Ii
Design II 51647 90-817643R1 DECEMBER 1996 MID-SECTION - 5C-7...
Page 236: Design Ii
Design II 51648 5C-8 - MID-SECTION 90-8i7643R1 DECEMBER 1996...
Page 237: Design Ii
Design II 51649 90-817643R1 DECEMBER 1996 MID-SECTION - 5C-9...
Page 238 Design II 51650 5C-10 - MID-SECTION 90-8i7643R1 DECEMBER 1996...
Page 239: Troubleshooting
Troubleshooting Determining if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys- tem is at fault. Trouble Chart Outboard will not trim up or down. Determine if Power Trim pump Outboard trims up, will not trim motor operates when appro- down.
Page 240: Hydraulic System Troubleshooting
Hydraulic System Troubleshooting Leak Down Check – Pump and Man- ifold Assembly Support outboard with tilt lock lever when servicing power trim system. NOTE: Scribe (d) pump housing halves before disas- sembly. Check pump for problems as follows: IMPORTANT: After debris or failed components have been found (during troubleshooting proce- 1.
Page 241: Assembly
Leak Down Check – Pilot Valve As- Leakage Past Ball and Seat – Piston sembly Assembly 1. Debris or chips between valve and seat (a), usu- Unit will trim to full or near full DOWN position and ally imbedded in rubber valve seat. then will begin to trim UP while trim switch is held in “DOWN”...
Page 242: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard falls to full down position with manu- al release valve closed. Example a: Outboard lowers more than one tilt pin hole in eight hours. Example b: Outboard lowers during acceler- ation. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings...
Page 243: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed decelera- tion. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings ring damage appear to be OK. Replace O-rings and proceed.
Page 244: Electrical System Troubleshooting
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram Black Blue Brown Gray Green Purple White Yellow a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector 23891 e - Wiring Harness Connector...
Page 245: Power Trim System Wiring Diagram
Power Trim System Wiring Diagram Black Blue Green White POWER TRIM MODULE 90-817643R1 DECEMBER 1996 MID-SECTION - 5C-17...
Page 246: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is Ok)
Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 247: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is Ok)
Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3.
Page 248: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)
Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)* Check in-line fuse (under cowl) to see if fuse is blown. Blown Fuse: Fuse Not Blown: Correct problem that caused Connect Voltmeter red lead to fuse to blow. Point 3 and black lead to ground. Replace fuse.
Page 249: Power Trim System Removal
5. Use suitable punch to remove (DRIVE UP) lower Power Trim System Removal dowel pin. Retain dowel pin. Support outboard with tilt lock lever when servicing power trim system. 1. Disconnect power trim harness form outboard wiring harness. 2. Remove screw and clip securing wiring harness to clamp bracket.
Page 250: Power Trim System Disassembly
7. Tilt power trim assembly (top first) out from clamp Power Trim System bracket and remove assembly. Disassembly Trim Rod Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE. THIS VALVE IS PRESET AT FAC- TORY FOR PRECISE REVERSE THRUST PRES- SURE AND DOES NOT REQUIRE ADJUSTMENT.
Page 251: Trim Rod Disassembly
4. Remove trim rod assembly from cylinder. 6. Remove O-ring from memory piston. 51196 a - O-ring b - Memory Piston 7. Remove trim system from vise and empty fluid into appropriate container. 51196 5. Remove memory piston from cylinder using lock- ring pliers (Craftsman P/N 4735) or suitable tool.
Page 252 4. Place trim rod into soft jawed vise and apply heat CAUTION to loosen piston using torch lamp (P/N 91-63209). Do not remove check ball components from trim 5. Loosen trim rod piston using trim spanner span- rod piston. Removal and re-installation of check ner wrench (1/4 in.
Page 253: Trim "Motor" Removal
Trim “Motor” Removal 4. Remove motor harness from reservoir. 1. Secure power trim assembly in soft jawed vise. 2. Remove cap, washer and grommet from reser- voir assembly. 51196 Trim Motor Disassembly 51195 1. Remove end cap from motor housing. Note posi- a - Cap tion of washers on armature.
Page 254: Reservoir Assembly Removal
2. Remove O-ring from end frame. Reservoir Assembly Removal 3. Place scribe mark on motor housing and end CAUTION frame as re-assembly reference, as shown. DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE. THIS VALVE IS PRESET AT FAC- TORY FOR PRECISE REVERSE THRUST PRES- SURE AND DOES NOT REQUIRE ADJUSTMENT.
Page 255: Oil Pump/Manifold Removal
3. Remove four screws securing reservoir to man- Oil Pump/Manifold Removal ifold. 1. Remove screw, oil pump, O-rings and check valve components from manifold. 51006 51193 a - Screws (4) 4. Remove reservoir from manifold. 5. Remove drive shaft from oil pump. 51007 a - O-rings (3) b - Oil Pump...
Page 256: Cleaning And Inspection Of Trim Rod Components
IMPORTANT: Removal of O-ring (e) from manifold 4. Remove O-rings from cylinder. will result in damage to O-ring. O-ring MUST be replaced after removal. 3. Remove check valve components from manifold. 51008 a - O-rings Cleaning and Inspection of Trim Rod Components 51736 IMPORTANT: Components must be dirt and lint free.
Page 257: Motor And Electrical Tests/Repair
Motor and Electrical Tests/ Repair Trim Pump Motor Test WARNING Do not perform this test near flammables (or ex- plosives), as a spark may occur when making connections. 1. Disconnect orange (motor) wire and black (mo- tor) wire from relay switch wiring harness. 2.
Page 258: Armature Tests
Armature Tests Power Trim System Reassembly TEST FOR SHORTS Manifold/Oil Pump Installation Check armature on a Growler (follow Growler man- ufacturer’s test instructions). Indication of a short re- IMPORTANT: Install spring, check valve and O- quires replacement of armature. ring into manifold. Position components in place using sleeve to seat in place.
Page 259: Trim Motor Reassembly
2. Install O-rings on cylinder and secure manifold 4. Install check valve components and O-rings to assembly to cylinder using screws. Torque manifold. Secure oil pump to manifold using bolt. screws to 100 lb. in. (11.3 N·m). Torque bolt to 90 lb. in. (10.2 N·m). 51006 51008 51007...
Page 260 2. Guide armature and end frame into housing as 6. Install end cap to housing. Torque nuts to 25 lb. in. shown. (2.8 N·m). 51194 a - End Cap b - Motor Housing c - Wave Washer d - Washer 51196 IMPORTANT: When installing motor, wires (black, 3.
Page 261: Reservoir Installation
Reservoir Installation 5. Install grommet, washer and screw cap to cylin- der end cap. Tighten screw securely. 1. Connect trim motor wires to harness. 2. Insert motor into reservoir. Motor must be seated properly prior to end cap installation. 51195 a - Screw Cap b - Washer c - Grommet...
Page 262: Trim Rod Reassembly
9. Secure reservoir to manifold using four screws. Trim Rod Reassembly Torque screws to 70 lb. in. (7.7 N·m). 1. Install lubricated O-rings and rod wiper to end cap. 51193 a - Screw 10. Install “E” clip, lubricated O-rings and to manual 51145 release valve.
Page 263: Trim Rod Installation
4. Apply Loctite Grade A (271) to threads of trim rod Trim Rod Installation and install rod piston. Tighten piston securely us- 1. Place trim cylinder in soft jawed vise. ing trim cylinder spanner wrench (1/4 in. x 5/16 in. long peg).
Page 264: Bleeding Power Trim Unit
4. Install trim rod into cylinder. Bleeding Power Trim Unit IMPORTANT: Manual release valve must be in the closed position during power trim bleeding and operation. 1. Secure power trim unit in soft jawed vise. 2. Remove fill screw. Add Quicksilver Power Trim and Steering Fluid (92-90100A12) or Automatic Transmission Fluid (ATF) Type F, FA or Dexron II up to threads of reservoir.
Page 265: Power Trim Unit Installation
Power Trim Unit Installation 4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until 1. Apply Special Lubricant 101 (92-13872A1) to pivot pin is flush with outside surface. lower pivot pin hole and pivot pin surface. 2.
Page 266 6. Apply Special Lubricant 101 (92-13872A1) to sur- 8. Drive upper dowel pin (a) into its hole until seated. face of upper pivot pin, pivot pin bore and trim ram bore. 51147 9. Recheck fluid level. 10. Power trim may now be operated to lower out- 51148 board to desired position.
Page 267 MID-SECTION 51486 POWER TRIM (DESIGN 3)
Page 268 Table of Contents Page Page Special Tools ......5D-1 Power Trim System Removal .
Page 269: Special Tools
Will lift bow of boat, usually increasing top speed. Special Tools Transfers steering torque harder to port (left) on in- Description Part No. stallations below 23 in. transom height. Torch Lamp 91-63209 Increases clearance over submerged objects. Spanner Wrench 91-74951 In excess, can cause “porpoising”...
Page 270: Trailering Outboard
Operating “Down” circuit will actuate the “down” relay Trim “In” Angle Adjustment (located under engine cowl) and close the electric motor circuit (motor will run in opposite direction of the WARNING “Up” circuit). The electric motor will drive the pump, Operating some boats with engine trimmed to the forcing fluid thru internal passageways into the full “in”...
Page 271 Power Trim System Components 1 - Tilt/Trim Cylinder 2 - Reservoir/Motor Housing 3 - Piston Rod 4 - Upper Pivot Shaft 5 - Cross Pin 6 - O-ring 7 - End Cap Seal 8 - End Cap 9 - O-ring 10- O-ring 11- Piston Assembly 12- O-ring...
Page 272: Troubleshooting
Troubleshooting Determining if Problem is Electrical or Hydraulic When a problem is encountered with the Power Trim system, the first step is to determine whether the mal- function is in the “electrical system” or the “hydraulic system.” Refer to the following chart to determine which system is at fault.
Page 273: Hydraulic System Troubleshooting
Hydraulic System Troubleshooting Leak Down Check - Pump and Manifold Assembly Support outboard with tilt lock lever when servicing power trim system. NOTE: Scribe (d) pump housing and manifold before disassembly. After debris or failed components have been found (during troubleshooting procedures) dis- 1.
Page 274: Leak Down Check - Pilot Valve Assembly
Leak Down Check - Pilot Valve Leaks Past Ball and Seat - Piston Assembly Assembly 1. Debris or chips between valve and seat (a), usu- Unit will trim to full or near full down position and then ally imbedded in rubber valve seat. will begin to trim up while trim switch is held in ‘‘DOWN”...
Page 275: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard falls to full down position with manu- al release valve closed. Example a: Outboard lowers more than one tilt bolt hole in eight hours. Example b: Outboard lowers during acceler- ation. Inspect Manual Release Valve. Result Result Manual release valve and/or O- Manual release valve and O-rings...
Page 276: Troubleshooting Flow Diagram
Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and/or trails out during high speed decelera- tion. Inspect Manual Release Valve. Results Results Manual release valve and/or O- Manual release valve and O-rings ring damage. appear to be OK. Replace O-rings and proceed.
Page 277: Electrical System Troubleshooting
Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram DOWN Black Blue Brown Gray Green Purple White Yellow a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector 23891 e - Wiring Harness Connector...
Page 278: Power Trim System Wiring Diagram
Power Trim System Wiring Diagram Black Negative (–) Blue Trim Motor (UP) Green Trim Motor (DOWN) Positive (+) BLU/WHT Blue/White Trim Switch to UP Relay Wiring From GRN/WHT Side Mount Green/White Trim Switch to DOWN Relay Remote Control Harness Power Trim Engine Harness Motor...
Page 279: Troubleshooting The "Down" Circuit* (When "Up" Circuit Is
Troubleshooting the “Down” Circuit* (When “Up” Circuit is OK) *Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground. Depress the “Down” trim button. Battery Voltage Indicated: No Voltage Indicated: Down Relay is Defective. Replace and retest. Connect Voltmeter red lead to Point 4 and black lead to ground.
Page 280: Troubleshooting The "Up" Circuit* (When "Down" Circuit Is
Troubleshooting the “Up” Circuit* (When “Down” Circuit Is OK) *Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground. Depress the “Up” trim button. Battery Voltage Indicated: No Voltage Indicated: UP Relay is defective. Replace and retest. Connect Voltmeter red lead to Point 7 and black lead to ground.
Page 281: Troubleshooting The "Down" And "Up" Circuits (All Circuits Inoperative)
Troubleshooting the “Down” and “Up” Circuits (All Circuits Check in-line fuse (under cowl) to see if fuse is blown Inoperative)* *Remote Control NOT Equipped with Trailer Button Blown Fuse: Fuse Not Blown: Correct problem that caused Connect Voltmeter red lead to fuse to blow.
Page 282: Power Trim System Removal
Inspect cross pin hole and pivot pin hole for damage. Power Trim System Removal 6. Use suitable punch to remove (DRIVE UP) lower Support outboard with tilt lock lever when servicing dowel pin. Retain dowel pin. power trim system. 1. Disconnect power trim harness from outboard wiring harness.
Page 283: Power Trim System Disassembly
8. Tilt power trim assembly (top first) out from clamp Power Trim System bracket and remove assembly. Disassembly Trim Rod Removal 1. Secure power trim assembly in soft jawed vise. 2. Open manual release valve three turns maxi- mum (counterclockwise) and position trim rod to full up position.
Page 284: Trim Rod Disassembly
5. Remove memory piston from cylinder using lock- Trim Rod Disassembly ring pliers (Craftsman P/N 4735) or suitable tool. 1. Place trim rod assembly on clean work surface. 2. Remove screws securing plate to trim rod piston and O-ring. 3. Remove check ball components from trim rod pis- ton.
Page 285 4. Place trim rod into soft jawed vise and apply heat CAUTION to shock piston using torch lamp (a) (P/N 91-63209). Do not remove check ball components (a) from trim rod piston. Removal and re-installation of 5. Loosen trim rod piston using spanner wrench (1/4 check valve could result in improper operating in.
Page 286: Trim "Motor" Removal
Trim “Motor” Removal Trim “Motor” Disassembly 1. Secure power trim assembly in soft jawed vise. 1. Remove armature from motor frame. Note posi- tion of washers on armature. 2. Remove screws securing end cap to reservoir and remove end cap. 51486 a - Armature b - Motor Frame...
Page 287: Manifold Removal
3. Remove four screws securing reservoir to man- Manifold Removal ifold. 1. Remove screws and manifold from cylinder. 51193 a - Screws (4) 4. Remove reservoir from manifold. 51007 a - Trim Cylinder 5. Remove drive shaft from oil pump. b - Manifold c - Screw (2) 2.
Page 288: Cleaning And Inspection Of Trim Rod Components
3. Remove O-rings from cylinder. Motor and Electrical Tests/Repair Trim Pump Motor Test WARNING Do not perform this test near flammables (or ex- plosives), as a spark may occur when making connections. 1. Disconnect green (motor) wire and blue (motor) wire from trim system wiring harness.
Page 289: Checking And Cleaning Commutator
CHECKING AND CLEANING COMMUTATOR 1. Install check valve components into manifold. If commutator (a) is worn it can be turned down on an armature conditioner tool or on a lathe. Clean commutator with “00” sandpaper. 51560 Power Trim System a - O-ring (0.114 I.D.) Reassembly b - Spool c - O-ring (0.301 I.D.) (3 each)
Page 290: Trim Motor Reassembly
51007 b - Screws [100 lb. in. (11 N·m)] (2) 3. Secure power trim unit in soft jawed vise. 51484 a - End Cap Bushing. Lubricate with Quicksilver 2-4-C Trim Motor Reassembly Lubricant b - Brush (2) 1. Place brush tension springs on outer ends of c - Commutator brush housings to release tension on brushes.
Page 291: Reservoir Installation
Reservoir Installation 5. Secure reservoir to manifold using four screws. Torque screws to 70 lb. in. (7.7 N·m). 1. Torque end cap screws to 13 lb. ft. (1.5 N·m). 51193 a - Screws (4) 6. Install lubricated O-rings and “E” clip to manual release valve.
Page 292: Trim Rod Reassembly
Trim Rod Reassembly 4. Apply Loctite Grade A (271) to threads of trim rod and install rod piston. Tighten piston securely us- 1. Install lubricated O-rings and rod wiper to end ing spanner wrench (1/4 in. x 5/16 in. long peg). cap.
Page 293 Trim Rod Installation 4. Install trim rod into cylinder. 1. Place trim cylinder in soft jawed vise. 2. Fill trim cylinder three inches (76.2mm) from top of cylinder using Quicksilver Power Trim and Steering Fluid or; (ATF) Type F, FA or Dexron II. 3.
Page 294: Purging Power Trim Unit
Power Trim Unit Installation Purging Power Trim Unit 1. Apply Special Lubricant 101 (92-13872A1) to Manual release valve must be in full closed posi- lower pivot pin bore and pivot pin surface. tion during power trim purging and operation. 2. Start lower pivot pin into pivot pin bore and posi- 1.
Page 295 4. Using a suitable punch, drive lower pivot pin into 6. Apply Special Lubricant (92-13872A1) to surface clamp bracket and trim cylinder assembly until of upper pivot pin, pivot pin bore and trim ram pivot pin is flush with outside surface. bore.
Page 296 7. Using a suitable mallet, drive upper pivot pin into 8. Drive upper retaining pin (a) in until seated. swivel bracket and through trim ram until pivot pin is flush with swivel bracket. 51505 9. Recheck fluid level. 10. Power trim may now be operated to lower out- 51515 board to desired position.
Page 297 MID-SECTION 55331 POWER TRIM (DESIGN 4)
Page 298 Table of Contents Page Page Special Tools ......5E-1 Power Trim System Removal .
Page 299: Special Tools
Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Expanding Rod P/N CG 41-11 4. Collet P/N CG 41-14 90-817643R1 DECEMBER 1996 MID-SECTION - 5E-1...
Page 300 POWER TRIM COMPONENTS Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. 5E-2 - MID SECTION 90-817643R1 DECEMBER 1996...
Page 301 POWER TRIM COMPONENTS TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O RING REBUILD KIT O RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG Drive Tight MANUAL RELEASE ASSEMBLY Drive Tight...
Page 302: Theory Of Operation
Theory Of Operation WARNING The Power Trim system consists of an electric motor, Excessive engine trim angle will result in insuffi- pressurized fluid reservoir, pump and trim cylinder. cient water supply to water pump causing water pump and/or powerhead overheating damage. The remote control (or trim panel) is equipped with a Make sure that water level is above gear housing switch that is used for trimming the outboard “up”...
Page 303: Trailering Outboard
Trailering Outboard Tilting Outboard Up and Down Manually WARNING WARNING Excessive engine trim angle will result in insuffi- cient water supply to water pump causing water Before loosening the manual release valve, make pump and/or powerhead overheating damage. sure all persons are clear of engine as engine will Make sure that water level is above gear housing drop to full “down”...
Page 304 POWER TRIM FLOW DIAGRAMS TRIM UP CIRCUIT Reservoir Oil Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) 2800 (75-125) Tilt Relief Pressure min. 250-400 (40-60) 540-990 (75-125) a - Piston Rod m - Shuttle Valve...
Page 305: Trim Up
Trim Up When the trim switch is activated in the “up” position, the electric motor (c) begins to rotate the pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the pas- sages for the up circuit.
Page 306 TILT CIRCUIT Reservoir Oil Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 307: Tilt Up
Tilt Up In the “up” mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t) clears or un- covers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt relief piston (s) to open the tilt pressure relief valve (r).
Page 308: Maximum Tilt
MAXIMUM TILT Reservoir Oil Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 309 Maximum Tilt With the piston rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylinder (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston’s “pin” opens the tilt relief valve (r).
Page 310 DOWN CIRCUIT Reservoir Oil Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) 2800 (75-125) Tilt Relief Pressure min. 250-400 (40-60) 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 311: Down Mode
Down Mode When the trim switch is activated in the “down” posi- tion, the electric motor (c) will rotate the pump (j) in the opposite direction. With the pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump (j).
Page 312: Shock Function Up
SHOCK FUNCTION UP Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 313 Shock Function Up Oil inside the down cavity is locked in a static position by the closed pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear the piston rod (a) will try to rapid- ly extend from the cylinder (w), the pressure in- creases inside the trim cylinder down cavity and con-...
Page 314: Shock Function Return
SHOCK FUNCTION RETURN Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 315 Shock Function Return After the engine clears the under water object, the weight of the engine will increase the oil pressure be- tween the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity.
Page 316 MANUAL RELEASE Down Pressure 525-880 Reservoir Oil Return Oil Filtered Oil Í Í Í Í Impact Relief Pressure #22 880-1110 (40-60) 1220-1420 (75-125) Up Pressure 1625 (40-60) Tilt Relief Pressure 2800 (75-125) 250-400 (40-60) min. 540-990 (75-125) a - Piston Rod m - Shuttle Valve b - End Cap n - Up Pressure Operated Valve...
Page 317: Manual Tilt
Manual Tilt To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3-4 turns. With the valve backed out, the internal pas- sages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allowing the engine to be raised or lowered.
Page 318: Troubleshooting
Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting proce- dure) it is recommended that unit be disas- sembled completely and ALL O-rings be re- placed. Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re-as- sembly.
Page 319: Hydraulic System Troubleshooting Flow Chart
Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION Manual release valve and Manual release valve Inspect manual release valve O-rings appear to be O.K. - and O-ring damaged Clean and reinstall manual release valve Trim will not hold...
Page 320: Hydraulic System Troubleshooting Flow Chart
Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage Suction seat assembly ap- Debris and/or damage pears O.K. - Clean and rein- identified stall suction seat assembly Replace suction seat Trim will not hold assembly Trim system holds reverse thrust...
Page 321: Hydraulic System Troubleshooting Flow Chart
Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED Manual release valve Inspect manual release valve Manual release valve and O- and O-ring damaged rings appear to be O.K. - Clean and reinstall manual release valve Replace manual re- Trim system leaks...
Page 322: Hydraulic System Troubleshooting Flow Chart
Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis- ton O-ring and cylinder bore Cylinder bore appears Cylinder bore appears rough and/or debris smooth with no debris found in cylinder Replace memory pis- Trim leaks down ton and shock piston O-rings Trim system does not leak down: Test-...
Page 323: Troubleshooting The Power Trim Electrical System (Wiring Diagram)
Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch (Remote Control (Panel Mounted) Mounted) BLU/WHT Fuse Holder GRN/WHT BLU/WHT or PUR GRN/WHT or GRN Fuse Holder – RED/PUR Battery GRN/WHT Solenoid BLU/WHT Down Relay LT. GRN/WHT GRN/WHT 14 BLK LT.
Page 324: Troubleshooting The Power Trim Electrical System
Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch “UP” is inopera- 1. Open wire between Wire Connection (1) 1. Check for an open connection or cut . tive, but the Cowl Switch “UP”...
Page 325: Power Trim System Removal
3. Remove the trilobe pin. Power Trim System Removal 4. Drive out the upper pivot pin. 1. Tilt outboard to the full up position and support with tilt lock pin. a - Trilobe Pin 55464 b - Upper Pivot Pin a - Tilt Lock Pin 5.
Page 326: Power Trim Disassembly
6. Use suitable punch to remove (Drive Up) lower Power Trim Disassembly pin. Retain dowel pin. IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP” position (fully ex- tended) prior to fill/drain plug, or manual release valve removal.
Page 327: Trim Motor Removal
Trim Motor Removal Pump and Components Removal 1. Secure power trim assembly in a soft jaw vise. 1. Remove pressure operated plugs on pump. Re- move spring and check valve/poppet (both 2. Remove four (4) screws to remove motor/reser- sides). Use special tool CG 41-11 and special tool voir.
Page 328: Manifold Removal
2. Remove three (3) screws to remove pump. Re- 2. Remove tilt relief components. move filter and filter seal under pump. Remove suction seat assembly. 51008 a - Spring b - Poppet c - Spool Housing d - Trim Limit Spool Shock Rod Removal a - Screws (3) b - Filter Seal...
Page 329: Shock Rod Disassembly
3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove o-ring from shock rod piston. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
Page 330 10. Remove inner o-ring from shock rod piston. CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).
Page 331: Memory Piston Removal
Memory Piston Removal 2. Remove o-ring from memory piston. 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or suitable tool. 51144 a - O-Ring b - Memory Piston 51144 b.
Page 332: Cleaning/Inspection/Repair
Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced.
Page 333: Reassembly
Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1 90-817643R1 DECEMBER 1996 MID-SECTION - 5E-35...
Page 334: O-Ring Sizes
O-ring Sizes 4, 22 12, 17, 18 15, 20 Cutaway View of O-Ring Width O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 5E-36 - MID SECTION 90-817643R1 DECEMBER 1996...
Page 335: O-Ring Description And Sizes
O-ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring (412585) Cyl. Cap, Inner12586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap8134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in.
Page 336: Power Trim Reassembly
4. Clamp shock rod in soft jawed vise. Power Trim Reassembly 5. Position cylinder end cap onto rod as shown. IMPORTANT: Lubricate all o-rings with Quicksil- ver Power Trim Fluid (92-90100A12). If not avail- able, use automotive (ATF) automatic transmis- sion fluid.
Page 337: Shock Rod Installation
9. Remove shock rod assembly from vise. Shock Rod Installation 10. Install ball, seat, and spring (five sets) to shock 1. Place trim cylinder in soft jawed vice. rod piston. 2. Install lubricated O-ring to memory piston and 11. Secure components with plate. Torque screws to place into cylinder.
Page 338: Trim Limit Assembly Installation
Trim Limit Assembly Installation Manifold Installation 1. Lubricate all O-rings. Install spring, poppet spool housing and trim limit spool into manifold. 1. Install dowel pin and two (2) lubricated O-rings NOTE: There are two different size springs used in into trim cylinder. this manifold.
Page 339: Oil Pump Installation
3. Install the two (2) long screws and torque to 100 Oil Pump Installation lb. in. (11 N m). 1. Install spring, ball, lubricated O-ring and plastic seat to manifold. 2. Check to see that O-rings are placed on bottom of pump.
Page 340: Pressure Operated Assembly Installation 5E-42
Pressure Operated Assembly Reservoir/Motor Installation Installation 3. Install coupler into top of pump. Make sure reser- voir seal is in the reservoir groove and place res- IMPORTANT: Inspect poppet assembly for debris ervoir onto pump/manifold assembly. Install in the area shown. If debris is found on poppet re- ground strap under screw shown Torque screws place poppet.
Page 341: Bleeding Power Trim Unit
Bleeding Power Trim Unit Installation of Power Trim System 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until even with the bottom of 1. Lubricate lower pivot pin, mounting holes with the fill hole. Reinstall plug. 2-4-C Marine Lubricant.
Page 342 4. Apply 2-4-C Marine Lubricant ( 92-90018A12) to 6. Apply 2-4-C Marine Lubricant (92-90018A12) to lower pivot pin. Using a suitable punch, drive low- surface of upper pivot pin, pivot pin bore and trim ram bore. er pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside sur- face.
Page 343 8. Drive trilobe pin (a) into its hole until seated. 10. Route trim harness through clamp bracket and cowling. 55464 a - Trilobe Pin 55264 a - Trim Harness 9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode as shown.
Page 344 MID-SECTION MANUAL TILT SYSTEM (DESIGN I, II, III)
Page 345: Manual Tilt System Components
Table of Contents Page Manual Tilt System Components (Design One and Two) ......5F-1 Quicksilver Lubricant/Sealant Application Points...
Page 346 Manual Tilt System Components (Design One and Two) 1 - Shock Rod Cylinder Torque Specification 2 - Accumulator 3 - Shock Rod 35 lb. ft. (47 N·m) 4 - Valve Block 5 - Dowel Pin 100 lb. in. (11.5 N·m) 6 - Pivot Pin 7 - Rod Wiper 8 - O-ring .671 in.
Page 347: Torque Specification
Manual Tilt System Components (Design Three) 1 - Shock Rod Cylinder Torque Specification 2 - Accumulator 3 - Shock Rod 35 lb. ft. (47 N·m) 4 - Valve Block 5 - Dowel Pin 100 lb. in. (11.5 N·m) 6 - Pivot Pin 7 - Rod Wiper 8 - O-ring .671 in.
Page 348: Manual Tilt Flow Diagrams Design
Manual Tilt Flow Diagrams Design 1 51651 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-3...
Page 349 Design 1 51652 5F-4 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 350 Design 1 51653 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-5...
Page 351 Design 1 51654 5F-6 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 352 Design 1 51655 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-7...
Page 353: Manual Tilt Flow Diagrams Design
Manual Tilt Flow Diagrams Design 2 51656 5F-8 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 354 Design 2 51657 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-9...
Page 355 Design 2 51658 5F-10 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 356 Design 2 51659 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-11...
Page 357 Design 2 51660 5F-12 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 358: Manual Tilt Flow Diagrams Design
Manual Tilt Flow Diagrams Design 3 51661 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-13...
Page 359 Design 3 51662 5F-14 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 360 Design 3 51663 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-15...
Page 361 Design 3 51664 5F-16 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 362 Design 3 51665 90-817643R1 DECEMBER 1996 MID-SECTION - 5F-17...
Page 363: Hydraulic System Troubleshooting
2. Check for external leaks in the manual tilt system. Hydraulic System Replace defective part(s) if leak is found. Troubleshooting IMPORTANT: If cut or damaged O-rings are found, Refer to disassembly/reassembly instructions (fol- inspect machined surfaces for scoring, burrs or debris.
Page 364: Troubleshooting Flow Chart
Troubleshooting Flow Chart Outboard falls to full down position with manual re- lease valve lever in LOCK/RUN (up) position. Ex- ample a: Outboard lowers more than one tilt pin hole in eight hours, Example b: Outboard lowers during acceleration. CAUTION Tilt ram must be in full “up”...
Page 365 Troubleshooting Flow Chart (Continued) Outboard will not hold tilted position in reverse and/or trails out during high speed deceleration with manual release valve lever in the lock/run (up) position. CAUTION Tilt ram must be in full “up” position and accumu- lator removed before manual tilt system disas- sembly.
Page 366: Manual Tilt System Removal
3. Use suitable punch to remove (DRIVE DOWN) Manual Tilt System Removal upper dowel pin. Retain dowel pin. CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard. WARNING Service or installation of the tilt system may re- sult in loss of pressure in the shock cylinder.
Page 367: Manual Tilt System Disassembly
6. Use suitable punch to drive out lower pivot pin. Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitro- gen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumu- 51144 lator only when shock rod is in full up position. a - Pivot Pin Accumulator Removal 7.
Page 368 4. If plunger can be compressed into accumulator Shock Rod Removal by hand, accumulator is defective. Replace accu- 1. Remove cylinder end cap assembly using span- mulator. ner wrench [1/4 in. x 5/16 in. long pegs]. 51145 2. Remove shock rod assembly. 51143 a - Plunger 5.
Page 369: Shock Rod Disassembly
3. Remove memory piston from cylinder using lock Shock Rod Disassembly ring pliers (Craftsman P/N 4735) or suitable tool. 1. Place shock rod assembly on clean work surface. 2. Remove plate and O-ring. 3. Remove check ball components from shock rod piston.
Page 370 4. Place shock rod into soft jawed vise and apply CAUTION heat to loosen piston using torch lamp (P/N 91-63209). Do not remove check ball components from shock rod piston. Removal and reinstallation of 5. Loosen shock rod piston using spanner wrench check valve could result in improper operating [1/4 in.
Page 371: Valve Block Removal
12. Place end cap on clean work surface. Valve Block Removal 13. Remove rod wiper, inner O-ring, and outer O-ring. 1. Remove valve block from shock rod cylinder. 51147 51146 a - Screws (2) b - Valve Block c - Shock Rod Cylinder 2.
Page 372: Valve Block Disassembly
4. Remove reservoir assembly. Valve Block Disassembly 1. Remove slow trim valve assembly. 2. Remove hydraulic oil transfer valve components. 51142 a - Screw b - Flat Spring c - Ball 5. Remove cam assembly. 51143 a - Transfer Valves (2) b - Slow trim Valve Assembly (Plug or Screw Plug) 3.
Page 373: Manual Tilt System Cleaning And Inspection
Manual Tilt System Cleaning and Inspection 1. It is recommended that all O-rings exposed dur- ing disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air. Do not use cloth rags. 3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity.
Page 374 6. Install spool, spring, lubricated O-ring and screw plug (surge valve assembly) into valve block. 7. Torque screw plug to 75 lb. in. (8.5 N·m). 51142 a - Plunger b - Ball c - Spring (Small) d - Spring (Large) e - O - ring f - Plug (Design 3) 51142...
Page 375: Valve Block Installation
Valve Block Installation 3. Install lubricated O-ring. 1. Install lubricated O-rings. 51148 a - O-rings (2) 2. Install valve block to shock rod cylinder. Torque 51145 screws to 100 lb. in. (11.5 N·m). Shock Rod Reassembly 1. Install lubricated O-rings. 2.
Page 376 3. Install lubricated O-ring. 8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs). 51199 a - O-ring b - Shock Piston 4. Clamp shock rod in soft jawed vise. 51146 5. Position cylinder end cap onto rod as shown. a - Shock Rod Piston b - Spanner Wrench 9.
Page 377: Shock Rod Installation
Shock Rod Installation 6. Refill cylinder to top. 1. Place cylinder/manifold assembly into soft jawed CAUTION vise. End cap must not make contact with shock rod 2. Fill cylinder to top using Quicksilver Power Trim piston when tightening. Shock rod piston must and Steering Fluid or;...
Page 378: Instructions For Making Retaining Tool
Instructions for Making Retaining Tool 3/16 in. x 3 in. (5 x 7.5 cm) Steel Plate 3/8 in. x 13 in. (10mm x 33cm) Threaded Rod 4 in. x 1/4 in. min. (10cm x 6.4mm) minimum Channel Iron 10 in. (25 cm) 1 in.
Page 379: Bleeding Manual Tilt System
3. Bleed unit by pushing rod down slowly (18-20 se- Bleeding Manual Tilt System conds per stroke) until stopped at base. Wait until IMPORTANT: While bleeding tilt system, time all air bubbles exit accumulator base. must be allowed between each stroke to allow air bubbles to dissipate.
Page 380 7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), re- cycle unit 2-3 more times using short strokes. No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise.
Page 381 3. Reinstall manual tilt system. Reconnect release 6. Apply 2-4-C w/Teflon Marine Lubricant valve link rod. (92-90018A12) to surface of upper pivot pin, pivot pin hole and shock rod hole. 51148 a - Pivot Pin b - Pivot Pin Bore c - Shock Rod Bore 7.
Page 382 MID-SECTION MANUAL TILT SYSTEM (DESIGN 4)
Page 383 Table of Contents Page Page Special Tools ....... . . 5G-1 Manual Tilt System Tilt Up...
Page 384: Special Tools
Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 90-817643R1 DECEMBER 1996 MID-SECTION - 5G-1...
Page 385 MANUAL TILT COMPONENTS Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5G-2 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 386 MANUAL TILT COMPONENTS TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – MANUAL TRIM ASSEMBLY – MANUAL TRIM BEACHING ASSEMBLY SHOCK ROD ASSEMBLY SHOCK ROD ASSEMBLY (BEACHING) MEMORY PISTON ASSEMBLY O RING REBUILD KIT-Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY...
Page 387 MANUAL TRIM FLOW DIAGRAMS Up Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...
Page 388: Tilt Up
Tilt Up With the engine in the down position, the accumulator piston (d) will be at the top of the accumulator (c) with the gas at maximum pressure. To raise the engine, the camshaft lever (f) is rotated all the way down. The internal shaft connected to the camshaft lever will move the push rods, opening the accumulator check valve (e), both fast transfer valves (h &...
Page 389 Down Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...
Page 390: Tilt Down
Tilt Down With the engine tilted up, the piston inside the accu- mulator piston (d) will be at the bottom of the accumu- lator (c) and the gas pressure is low. To lower the en- gine, the camshaft lever (f) is rotated down, the internal cam will cause the push rods to open the ac- cumulator check valve (e), both fast transfer valves (h &...
Page 391: Slow Tilt Down Under High Thrust
Slow Tilt Down Under High Thrust a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...
Page 392 Slow Tilt Down Under High Thrust To tilt the engine down under high thrust conditions [where the propeller thrust forces the shock rod down, creating higher pressure below the memory piston (m)] the camshaft lever (f) is rotated slightly down- ward.
Page 393: Under Water Strike
Under Water Strike (Valves Open) a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...
Page 394 Under Water Strike With Valves Open Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the interconnecting passage. The rapid fluid flow will increase the pressure below the surge valve (k), causing the valve to move, closing the oil return passage back into the accumulator (c).
Page 395: Shock Function
Shock Function (Valve Closed) Accumulator Gas Pressure 400 PSI a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston...
Page 396: With Valves Closed
Shock Function With Valves Closed Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the closed up fast transfer valve (j), the closed down slow transfer valve (i) and closed down fast transfer valve (h).
Page 397: Shock Function Return
Shock Function Return a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...
Page 398 Shock Function Return After the drive clears the object, the shock return valve (o) will allow the oil to flow from between the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to its original running position.
Page 399: Hydraulic System Troubleshooting
3. Check for discharged accumulator. 35 to 50 lb. ft. Hydraulic System (47-68 N·m) of pulling force must be attained Troubleshooting when tilting outboard from full “down” to full“up” position. If more than 50 lb. ft. (68 N·m) of force is Refer to disassembly/reassembly instructions (fol- required, replace accumulator.
Page 400: Manual Tilt System Removal
3. Position piece of wood under transom bracket Manual Tilt System Removal instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper CAUTION dowel pin. Retain dowel pin. Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard.
Page 401: Manual Tilt System Disassembly
6. Use suitable punch to drive out lower pivot pin. Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitro- gen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumu- 51144 lator only when shock rod is in full up position. a - Pivot Pin Accumulator Removal 1.
Page 402: Shock Rod Removal
6. If plunger can be compressed into accumulator Shock Rod Removal by hand, accumulator is defective. Replace accu- 1. Unscrew cylinder end cap assembly using span- mulator. ner wrench [1/4 in. x 5/16 in. long pegs]. 51145 2. Remove shock rod assembly from cylinder. 51143 a - Plunger 7.
Page 403: Shock Rod Disassembly
3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove O-ring. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
Page 404 Remove inner O-ring. CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod in soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209). 6.
Page 405: Valve Block Removal
Valve Block Removal Memory Piston Removal 1. Remove two screws from the shock rod cylinder 1. Remove memory piston from cylinder using one to separate the valve block. of two methods: a. Using lock ring pliers (Craftsman P/N 4735) or (Snap-on P/N SRP4).
Page 406: Valve Block Disassembly
2. Remove O-ring from memory piston. 3. Remove surge valve assembly. 51144 a - O-Ring b - Memory Piston a - Spool b - Spring c - O-ring Valve Block Disassembly d - Screw Plug 1. Remove check retainer plug and components. 4.
Page 407 REASSEMBLY - O-RING AND SEAL PLACEMENT NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all O-rings be replaced when servicing tilt system. 5G-24 - MID-SECTION 90-817643R1 DECEMBER 1996...
Page 408: Actual O-Ring Sizes
Actual O-ring Sizes 4, 14 6 (2) 11 & 13 Cutaway View of O-Ring Width 8 (2) O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 90-817643R1 DECEMBER 1996 MID-SECTION - 5G-25...
Page 409: O-Ring Description And Sizes
O-ring Description and Sizes O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width Wiper Ring (412585) Cyl. Cap, Inner (412586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm) Cyl. Cap (408134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in.
Page 410: Manual Tilt System Cleaning And Inspection
VALVE BODY CHECK REASSEMBLY Manual Tilt System Cleaning 1. Install lubricated O-ring, plunger, steel ball and and Inspection conical spring to valve block. 1. It is recommended that all O-rings exposed dur- ing disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air.
Page 411: Check Retainer Reassembly
CHECK RETAINER REASSEMBLY Valve Block Installation 1. Install plunger, spring (large), ball, spring (small), 1. Install lubricated O-rings and dowel pins. and plug into valve block. 51148 a - O-rings (2) b - Dowel Pins (2) 51142 2. Install valve block to shock rod cylinder. Insert screws to shock rod cylinder and torque to 100 lb.
Page 412: Shock Rod Reassembly
Shock Rod Reassembly 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod as shown. 1. Install lubricated O-rings to end cap. 2. Install rod wiper. 51146 51145 a - Rod Wiper b - Inner O-ring c - Outer O-ring CAUTION hen installing shock rod piston, spanner...
Page 413: Shock Rod Installation And Fluid Filling Procedure
9. Install ball, seat, and spring (five sets) to shock Shock Rod Installation and Fluid Fill- rod piston. ing Procedure 10. Secure components with plate. Torque screws to NOTE: There are two ways for the filling procedure. 35 lb.in. (3.9 N m). The first is the easiest and less time consuming.
Page 414 6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) and screw cylinder cap down. 7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap to 45 lb.
Page 415: Instructions For Making
Filling Procedure Option Two Instructions for Making Retaining Tool 3/16 in x 3 in. (5 x 7.5 cm) Steel Plate 3/8 in. x 13 in. (10mm x 33cm) Threaded Rod 4in. x 1/4 in. min. (10cm x 6.4mm) minimum Channel Iron 10 in.
Page 416: Bleeding Manual Tilt System
3. Bleed unit by pushing rod down slowly (18-20 se- Bleeding Manual Tilt System conds per stroke) until stopped at base. Wait until IMPORTANT: While bleeding tilt system, time all air bubbles exit accumulator base. must be allowed between each stroke to allow air bubbles to dissipate.
Page 417 7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), re- cycle unit 2-3 more times using short strokes. No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise.
Page 418: Manual Tilt System Installation
4. Using a suitable punch, drive lower pivot pin into Manual Tilt System clamp bracket and trim cylinder assembly until Installation pivot pin is flush with outside surface. 1. Apply 2-4-C Marine Lubricant to lower pivot pin hole and pivot pin surface. 2.
Page 419: Manual Release Valve Adjustment
6. Apply 2-4-C Marine Lubricant (92-90018A12) to 8. Drive upper dowel pin (a) into its hole until seated. surface of upper pivot pin, pivot pin hole and shock rod hole. 51147 a - Dowel Pin 51148 a - Pivot Pin 9.
Page 420 LOWER UNIT 51114 STANDARD GEAR HOUSING...
Page 421 Table of Contents Page Page Drive Shaft and Water Pump Components ..6A-1 Gear Housing Re-assembly ....6A-13 Torque Specifications .
Page 422 Drive Shaft and Water Pump Components 1 - Gear Housing 2 - Drain Screw 3 - Screw 4 - Washer 5 - Dowel Pin (Hollow) 6 - Dowel Pin (Solid) 7 - Pipe Plug 8 - Roller Bearing 9 - Pinion Gear 10- Nut 11- Shift Shaft 12- Retaining Ring...
Page 423: Torque Specifications
Propeller Shaft Components (O.D.) 42 43 (I.D.) 40- Shim Set 51114 41- Tapered Roller Bearing 42- Forward Gear 43- Roller Bearing 44- Cam Follower 45- Guide 46- Spring 47- Clutch Torque Specifications 48- Cross Pin 49- Spring 55 lb. ft. (75 N·m) 50- Propeller Shaft 275 lb.
Page 424 Special Tools New Tools Required for 50-60 Gear Housing Part No. Description 91-14311A2 Bearing Preload Tool 91-817057A1 Backlash Indicator Tool 91-19660--1 Backlash Indicator Update Kit 91-24273 Mandrel 91-27780 Puller 91-37241 Universal Puller Plate 91-37312* Driver Head 91-37323* Driver Rod 91-43506 Bearing Retaining Tool 91-46068A1 Puller Jaws...
Page 425 19660-1 51043 91-19660--1 Backlash Indicator Tool 51043 91-817009 Driver Cup (Forward Gear Bearing Race) 51043 91-817005 Bearing Installer (Forward Gear Needle Bearing) 51043 91-817011 Needle Bearing Installer (Bearing Carrier) 51043 51043 91-817006 Seal Installer (Water Pump Base) 51270 51043 91-817007 Seal Installer (Bearing Carrier) Ref.
Page 426: Draining And Inspecting Gear Lubricant
Draining and Inspecting Gear Lubricant WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove two vent plugs and one fill/drain plug (with gaskets).
Page 427: Propeller Removal
Propeller Removal Gear Housing Removal WARNING WARNING If gear housing is not removed from outboard, before To prevent accidental engine starting, remove (and attempting to remove or install the propeller, remove isolate) spark plug leads from spark plugs before re- (and isolate) spark plug leads from spark plugs to pre- moving gear housing.
Page 428: Gear Housing Disassembly
Gear Housing Disassembly Water Pump 1. If water tube seal (a) stayed on water tube (inside of dri- veshaft housing) when gear housing was removed, then pull seal from water tube. Replace water tube seal (a) if damaged. 2. Remove 6 bolts (b), washers (c) and isolators (d) (De- sign 1).
Page 429: Bearing Carrier And Propeller Shaft
8. Remove (and discard) seals (a), if damaged. Bearing Carrier and Propeller Shaft 1. Drain lubricant; refer to “Draining and Inspecting Gear Lubricant”. 2. Remove bolts (a). 51205 9. Remove seal and plate if damaged or worn. 51117 3. With propeller shaft horizontal, pull carrier to break seal with gear housing.
Page 430 4. Replace reverse gear if gear teeth or clutch teeth on re- 7. If bearing (c) is rusted or does not roll freely, replace verse gear are chipped or worn. If reverse gear must bearing. Remove bearing and oil seals. Discard oil be replaced, pinion and sliding clutch should also be in- seals.
Page 431: Propeller Shaft Disassembly
Propeller Shaft Disassembly 1. Remove spring (a). Push out cross pin (e). 51265 a - Cam Follower b - Guide Block 51265 c - Spring d - Sliding Clutch e - Jaws 4. Check bearing surfaces of propeller shaft. If shaft is worn/pitted, replace shaft and corresponding bearing.
Page 432: Pinion Gear, Driveshaft And Forward Gear
Pinion Gear, Driveshaft and Forward 7. Replace forward gear tapered roller bearing (a) and race if either bearing or race are rusted or damaged; Gear or if bearing does not roll freely after cleaning in sol- vent. Remove bearing from gear using Universal Pull- 1.
Page 433: Lower Driveshaft Bearing
Lower Driveshaft Bearing Shift Shaft 1. Remove lower driveshaft bearing using tool 1. Remove shift shaft coupler (a) and spacer (b). (91-817058A1) with bushing installed. 51271 2. Remove shift shaft bushing (a) and shift shaft (b). Pro- tect shift shaft to prevent spline damage. 51205 51260 3.
Page 434: Gear Housing Reassembly
4. Remove shift shaft bushing (a) and clip (b) from shift shaft (c). Replace shift shaft if splines are twisted or damaged on either end of shaft. Remove (and discard) O-ring (d) if damaged. 51264 51270 5. Remove (and discard) seal (a) if damaged. 3.
Page 435: Propeller Shaft
5. Install shift shaft assembly (a); insert splines into shift 2. Install cross pin. cam. 51268 a - Cross Pin b - Cam Follower c - Apply Pressure in This Direction 3. Install spring. NOTE: Spring windings must lay flat with no overlapping in clutch groove after installation.
Page 436: Forward Gear Bearing Race
Forward Gear Bearing Race 3. Install small diameter oil seal (a). Seal lip faces away from shoulder on Installer Tool. Press seal in until In- 1. Place shim(s) retained from disassembly into housing. staller Tool bottoms. If shim(s) were lost or damaged, or a new gearcase is being assembled, start with a .010 in.
Page 437: Reverse Gear
Installation Note: If service tools are not available, the fol- Reverse Gear lowing reference dimensions apply for installing bearing 1. Lubricate I.D. of bearing (a) with Quicksilver Needle and seals to proper depths. Bearing Assembly Lubricant. Use Installer Tool and press onto gear until bearing bottoms.
Page 438: Forward Gear
Forward Gear Lower Driveshaft Bearing Installation Press new propshaft bearing into gear. Lubricate O.D. of 1. Lubricate O.D. of bearing race with Quicksilver Needle bearing with Quicksilver Needle Bearing Assembly Lubri- Bearing Assembly Lubricant. cant before installation. Press until Installer Tool bottoms. 2.
Page 439: Upper Driveshaft Bearing Installation
Upper Driveshaft Bearing Installation Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer 1. Press upper driveshaft bearing (a) onto driveshaft. Lu- and Driveshaft Installation bricate I.D. of bearing with Quicksilver Needle Bearing Assembly Lubricant before pressing in place. NOTE: If shim(s) were lost or are not reusable (damaged), start with approximately .015 in.
Page 440: Pinion Gear Location And Forward Gear Backlash
Pinion Gear Location and Forward 3. Measure distance (a). Gear Backlash 4. Increase distance (a) by 1 in. (25.4mm). 5. Rotate driveshaft 10 revolutions. This properly seats upper driveshaft tapered roller bearing. DETERMINING PINION GEAR LOCATION NOTE: Read entire procedure before attempting any change in shim thickness.
Page 441: Determining Forward Gear Backlash
7. The correct clearance between the gauging surface DETERMINING FORWARD GEAR BACKLASH (b) and the pinion gear (c) is .025 in. (0.64mm). NOTE: Read entire procedure before attempting any 8. To obtain .025 in. (0.64mm), add or subtract shims be- change in shim thickness.
Page 442: Bearing Carrier And Propeller Shaft Installation
7. Install components. Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carrier. 2. Lubricate O-ring (a) and areas (b) with Quicksilver Special Lubricant 101 (P/N 92-13872A1). 3. Install bearing carrier and propeller shaft assembly into gear housing. Use care not to displace cam follow- er (c).
Page 443: Water Pump Re-Assembly And Installation
Water Pump Re-assembly and 0.04 in. (1.02 mm) Installation 1. Place seal (a) on longer shoulder side (b) of tool. 2. Press into water pump base until tool bottoms. Seal Bottom 51285 a - Seal (Install with spring visible when installed.) b - Seal (Install with spring visible when installed.) If installation tool is not available, press seals in as shown 51043...
Page 444 7. If removed previously, re-install seal (a) and plate (b). 10. Lubricate I.D. of cover with Quicksilver Needle Bearing Assembly Lubricant (P/N 92-42649A1). Install gasket (a) with bead (b) towards cover. 51290 11. Rotate driveshaft clockwise and push cover down. Se- cure cover.
Page 445: Gear Housing Pressure Test
12. If water tube seal (a) stayed on water tube (inside of 3. Rotate driveshaft, prop shaft and move shift rod while driveshaft) pull seal from water tube. housing is pressurized to check for leaks. 13. Lubricate I.D. of water tube seal (a) with Quicksilver 2-4-C Marine Lubricant (P/N 92-90018A12) and in- stall.
Page 446: Gear Housing Installation
3. Insert lubricant tube in “Fill” hole, then remove “Vent” Gear Housing Installation plugs and gaskets (b and c). 4. Fill until excess lubricant flows out of “Vent” hole (b). WARNING 5. Replace this “Vent” plug and gasket and continue to fill Disconnect (and isolate) spark plug leads before in- until lubricant flows from second “Vent”...
Page 447: Propeller Installation
11. Check shift operation. CAUTION a. Gear housing should not engage when propeller Do not lubricate top of driveshaft. Excess lubricant will shaft is turned clockwise when in forward gear. not allow driveshaft to fully engage crankshaft. Tight- b. Propeller shaft will rotate freely in either direction ening the gear housing fasteners (if excess lubricant when gearcase is in neutral.
Page 448: Trim Tab Adjustment And Replacement
3. Tighten propeller nut to 55 lb.ft. (75 N·m). Bend 2. The trim tab will offset (balance) some of the “steering load” that is caused by “propeller torque” at higher tabs against nut. speeds. If at higher speeds the boat turns more easily to the left, loosen bolt, move the trim tab (trailing edge) to the left (when viewed from behind);...
Page 449 LOWER UNIT 791-H 60 BIG FOOT, 60 SEAPRO/MARATHON GEAR HOUSING (4-1/4 inch Torpedo, 2.3:1 Gear Ratio)
Page 450 Table of Contents Page Page Notes ........6B-1 Propeller Shaft Reassembly .
Page 451: Notes
Notes: 90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-1...
Page 452 Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot) 39 40 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) 6B-2 - LOWER UNIT 90-817643R1 DECEMBER 1996...
Page 453: Gear Housing (Drive Shaft)
Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING (LONG) GEAR HOUSING ASSEMBLY DOWEL PIN (FRONT) OILER TUBE DRAIN SCREW SCREW (MAGNETIC) WASHER-Sealing DOWEL PIN (REAR) TRIM TAB SCREW 30.0 WASHER CARRIER ANODE...
Page 454 Gear Hsg. (Drive Shaft) (60 SeaPro/Marathon/Big Foot) 39 40 Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Loctite 7649 Primer (92-809824) 2-4-C With Teflon (92-825407A12) 6B-4 - LOWER UNIT 90-817643R1 DECEMBER 1996...
Page 455: Gear Housing (Propeller Shaft)
Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING GEAR HOUSING ASSEMBLY SHIM ASSEMBLY DRIVE SHAFT ASSEMBLY WEAR SLEEVE ASSEMBLY COVER ASSEMBLY GASKET GASKET OIL SEAL (LOWER) OIL SEAL (UPPER) GASKET WATER PUMP ASSEMBLY FACE PLATE...
Page 456 Gear Hsg. (Prop Shaft)(60 Seapro/Marathon/Big Foot) Loctite 271 (92-809820) Super Duty Gear Lubricant (92-13783A24) Anti-Corrosion Grease (92-78376A6) 2-4-C With Teflon (92-825407A12) 6B-6 - LOWER UNIT 90-817643R1 DECEMBER 1996...
Page 457 Gear Hsg. (Prop Shaft)(60 Seapro/Marathon/Big Foot) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING GEAR HOUSING ASSEMBLY TAPERED ROLLER BEARING ASSEMBLY FORWARD GEAR ROLLER BEARING CAM FOLLOWER ASSEMBLY BALL SPRING CLUTCH CROSS PIN SPRING PROPELLER SHAFT REVERSE GEAR BEARING CARRIER ASSEMBLY O-RING...
Page 458: Special Tools
6. Remove gear housing. Special Tools Part No. Description 91-46086A1 Puller Jaws 91-85716 Puller Bolt 91-34569A1 Slide Hammer 91-36569 Mandrel* 91-15755 Mandrel* 91-37323 Driver Rod* 91-56775 Drive Shaft Holding Tool 91-37241 Universal Puller Plate 91-83165M Bearing Puller Assembly 91-31106 Mandrel 91-31108 Oil Seal Driver 91-37350...
Page 459: Draining And Inspecting Gear Housing Lubricant
2. Place a block of wood, as shown, to prevent pro- peller from rotating and to protect hands during re- moval of nut. 3. Remove nut and pull components from shaft. 53922 a - Oil Level Screw b - Fill/Drain Screw c - Vent Screw 2.
Page 460: Water Pump
7. Inspect impeller. Replace impeller if any of the Water Pump following conditions exist: 1. If water tube seal stayed on water tube (inside of – Impeller blade(s) are cracked, torn, or worn. drive shaft housing) when gear housing was removed, pull water tube seal from water tube.
Page 461: Bearing Carrier And Propeller Shaft
11. Remove water pump base. Bearing Carrier and Propeller Shaft 1. Drain lubricant from gear housing; refer to “Drain- ing and Inspecting Gear Housing Lubricant.” 2. Remove bolts and washers or self locking nuts if applicable. 19226 a - Water Pump Base 12.
Page 462 5. Lift reverse gear, thrust bearing and thrust washer 9. If bearing is rusted or does not roll freely, replace from bearing carrier. bearing. Remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). 6. Replace reverse gear if gear teeth or clutch teeth Discard oil seals.
Page 463 11. Remove spring. 14. Replace cam follower if worn or pitted. 15. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: a. Improper shift cable adjustment. b. Engine idle speed too high while shifting. c.
Page 464: Pinion Gear, Drive Shaft, And Forward Gear
6. Replace bearing if it is rusted or does not roll free- Pinion Gear, Drive Shaft, and Forward ly; use a punch and hammer to remove bearing. Gear 1. Hold drive shaft using Drive Shaft Holding Tool (91-56775); remove (and discard) pinion nut. 2.
Page 465: Upper Drive Shaft Bearing
8. Replace drive shaft if splines are worn or twisted. Upper Drive Shaft Bearing 9. If bearing surface is damaged, replace drive shaft 1. Replace upper drive shaft bearing and sleeve if ei- and corresponding bearing. ther are rust stained, or if bearing will not roll freely. Remove bearing and then sleeve using Puller As- IMPORTANT: Do not tighten vise against drive sembly (91-83165M) with suitable jaws.
Page 466: Oil Sleeve
IMPORTANT: Upper drive shaft bearing/sleeve IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve removal. Refer and oil sleeve do not have to be removed for lower to “Upper Drive Shaft Bearing,” preceding. drive shaft bearing race removal. Oil Sleeve Lower Drive Shaft Bearing Race 1.
Page 467: Shift Shaft
4. Remove shift cam from housing. Shift Shaft 5. Replace shift cam if worn. 1. Remove shift shaft coupler nylon spacer. 53925 a - Shift Shaft Coupler 51117 b - Spacer a - Shift Cam 2. Remove bolts. Note: If shift shaft splines are rough, shift shaft seal lips wil be cut during removal/installation.
Page 468: Forward Gear Bearing Race
Forward Gear Bearing Race Reassembly IMPORTANT: Retain shim(s) for reassembly. If Forward Gear Bearing Race shims are damaged, replace with new shims of equal thickness. 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear hous- 1.
Page 469: Bearing Carrier Reassembly
5. Assemble components as shown. 8. Apply Loctite 271 on bottom half of threads of bolts; install bolts and torque to 60 lb. in. (6.5 N·m). 53928 a - Shift Shaft c - Shift Shaft Bushing b - “E” Clip 6.
Page 470 4. Place smaller diameter seal on longer shoulder of 8. Install O-ring. Oil Seal Driver (91-31108) with seal lip away from 9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate shoulder. seal lips with 2-4-C w/Teflon (92-825407A12). Lu- 5. Protect lip on front side of bearing carrier using bricate outside diameter of bearing and bearing Bearing Installation Tool (91-13945).
Page 471: Forward Gear Reassembly
12. Install thrust bearing . Coat thrust bearing with Forward Gear Reassembly Quicksilver Gear Lubricant (92-13783A24). 1. Press bearing onto gear (press only on inner race of bearing). 51869 a - Mandrel (91-37350) b - Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon 19168 2.
Page 472: Propeller Shaft Reassembly
Propeller Shaft Reassembly Drive Shaft Wear Sleeve Installation 1. Install components into propeller shaft in 1. Install new rubber ring. sequence shown. 2. Apply a light coat of Loctite 271 on outside diameter of rubber ring. 19154 a - Spring c - 3 Metal Balls* 19152 b - Guide Block...
Page 473: Lower Drive Shaft Bearing Race Installation
4. Press sleeve onto drive shaft using Wear Sleeve Lower Drive Shaft Bearing Race Installation Tool (91-14310A1); continue pressing Installation until surface contacts surface. IMPORTANT: Lower drive shaft bearing cup can be installed with or without upper drive shaft bear- ing/sleeve and oil sleeve installed.
Page 474: Oil Sleeve Installation
IMPORTANT: Oil sleeve must be installed prior to Oil Sleeve Installation upper drive bearing installation. 1. Install oil sleeve with tab positioned as shown. IMPORTANT: Upper drive shaft bearing/sleeve can be installed with or without lower drive shaft bearing cup installed. 3.
Page 475: Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, And Drive Shaft Installation
2. With gear housing positioned up right (drive shaft Forward Gear, Lower Drive Shaft vertical), install Bearing Preload Tool (91-14311A1) Bearing, Pinion Gear, and Drive Shaft over drive shaft in sequence shown. Installation 1. Install components in sequence shown. a - Adaptor: Bearing surfaces clean and free of nicks b - Thrust Bearing: Oiled and able to move freely c - Thrust Washer: Clean and free of nicks and bends d - Spring...
Page 476 6. Assemble Pinion Gear Locating Tool (91-12349A2) 10. Install the number “3” locating disc against bearing as shown; do not tighten collar retaining bolt at this carrier shoulder in gear housing. time. 11. Position access hole as shown. a - Arbor b - Gauging Block;...
Page 477: Determining Forward Gear Backlash . 6B-27
5. Install components as shown. DETERMINING FORWARD GEAR BACKLASH NOTE: Read entire procedure before attempting any change in shim thickness. 1. Obtain correct pinion gear depth; refer to “Deter- mining Pinion Gear Depth,” preceding. 2. Install Bearing Preload Tool (91-14311A1) on drive shaft;...
Page 478: Bearing Carrier And Propeller Shaft Installation
7. Lightly turn drive shaft back-and-forth (no move- 3. Lubricate o-ring and mating surfaces with 2-4-C ment should be noticed at propeller shaft). w/Teflon (92-825407A12). 8. Dial Indicator registers amount of backlash, which 4. Install bearing carrier and propeller shaft into must be between specification shown in chart.
Page 479: Water Pump Reassembly And Installation
3. Place seal on shorter shoulder side of Oil Seal Water Pump Reassembly and Driver (91-13949) with seal lip toward shoulder. Installation 4. Apply Loctite 271 on O.D. of seal; press seal into 1. Place seal on longer shoulder side of Oil Seal water pump base until tool bottoms.
Page 480 7. Install components as shown. 9. Install gasket, drive key and impeller. 19220 a - Gasket b - Drive Key 19217 c - Impeller a - Water Pump Base 10. Lubricate I.D. of cover with Quicksilver 2-4–C w/ b - Bolts and Washers; Apply Loctite 271 on bottom 1/2 ofThreads and Torque to 60 lb.
Page 481: Gear Housing Pressure Test
Gear Housing Pressure Test Filling Gear Housing With 1. Remove vent plug and install pressure test gauge Lubricant NOTE: Gear housing lubricant capacity is 22.5 fl. oz. (665.2ml). WARNING If gear housing is installed on engine, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller.
Page 482: Propeller Installation
6. Replace this lubricant “Vent” screw and gasket 2. Install components as shown. only and continue filling until excess starts to flow out of second lubricant “Vent” screw hole. 51801 a - Thrust Hub; Flat Surface Toward Propeller b - Propeller 3.
Page 483: Gearcase Installation
Gearcase Installation CAUTION Do not use lubricant on top of drive shaft. Excess WARNING lubricant, that is trapped in clearance space, will Disconnect (and isolate) spark plug leads from not allow drive shaft to fully engage with spark plugs before installing gear housing onto crankshaft.
Page 484: Trim Tab Adjustment
53922 a - Bolts and Washers (4) b - Locknut and Washer 16. Check shift operation as follows: 53925 a. Place shift lever in forward gear. Gear housing a - Nylon Spacer should ratchet when propeller shaft is turned b - Shift Shaft Coupler; Used on Models NOT Equipped with clockwise and resistance should be felt when Power Trim propeller shaft is turned counterclockwise.
Page 485 LOWER UNIT JET DRIVE...
Page 486 Table of Contents Page Page Notes ........6C-1 Worn (Dull) Impeller .
Page 487: Notes
Notes: 90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-1...
Page 488: Jet Pump Assembly
JET PUMP ASSEMBLY 2-4-C With Teflon (92-825407A12) 6C-2 - LOWER UNIT 90-817643R1 DECEMBER 1996...
Page 489 JET PUMP ASSEMBLY TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – JET PUMP ASSEMBLY HOUSING-Pump HOSE-lube IMPELLER HOUSING-Intake LINER DRIVESHAFT SLEEVE Drive Tight SHIM TAB WASHER SCREW (1/4-20 x .875) 11.5 SCREW (1/4-20 x .875) SCREW (1/4-20 x .625) SCREW (.312-18 x 1.25) 17.5 BRACKET...
Page 490: Jet Components
JET COMPONENTS Loctite 271 (92-809820) Liquid Neoprene (92-25711--2) 2-4-C With Teflon (92-825407A12) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m REV LIMITER HARNESS–Adaptor–Rev Limiter BRACKET SCREW (M6 x 16) SCREW (M5 x 25) GREASE KIT IMPELLER WATER PUMP GASKET (UPPER) SEAL FACE PLATE...
Page 491: Selecting A Boat Best Suited For Jet Power
Selecting A Boat That Is Best Engine Horsepower Selection Suited For Jet Power A boat operating at slow speed requires considerably more depth than one which is planing on the surface Too obtain the best performance from the jet drive, the of the water.
Page 492: Transom Height Of The Boat
SETTING OUTBOARD MOUNTING HEIGHT ON Transom height of the boat BOATS WITH “V” BOTTOM HULLS Outboards with jet drives will be mounted approxi- 1. Measure the width of the leading edge on the water mately 7 inches higher on the transom than propeller intake housing.
Page 493: Water Testing
SETTING OUTBOARD MOUNTING HEIGHT ON When operating the boat, the outboard drive shaft BOATS WITH FLAT BOTTOM HULLS should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water 1. Place (center) the outboard on the boat transom so intake.
Page 494: Shift Cable Installation
4. Attach the brass barrel (c) to the bracket with bolt Water testing and locknut. Tighten the bolt until it seats against the barrel, then back-off the bolt 1/4 turn. Hold bolt Checking for Cavitation (Continued) from turning, and tighten locknut on bolt. The barrel must be free to pivot.
Page 495: Lubricating The Drive Shaft Bearing
Lubricating The Drive Shaft Impeller Removal and Bearing Installation Recommended Lubrication - Use 2-4-C w/Teflon. REMOVAL IMPORTANT: It is important that you do not use a 1. Shift outboard to NEUTRAL (N) position. general-all-purpose grease for this bearing. The lubricant we recommend is a water resistant 2.
Page 496 INSTALLATION 3. After setting the impeller height, tighten the impel- ler nut snug with a wrench. Secure impeller nut by 1. Grease the drive shaft, shear key, and impeller bending tabs (a) against the flats on the impeller bore. Place the plastic sleeve (a) inside the impel- nut.
Page 497: Steering Pull Adjustment
Steering Pull Adjustment Worn (Dull) Impeller The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins (a) 1/16 in. (1.5mm) toward the starboard side of the outboard.
Page 498: Flushing The Cooling System
2. Remove the liner. If the liner is tight, tap on the inner Flushing The Cooling System edge of the liner with a long drift punch through the Use Quicksilver accessory hose coupling Part Number intake grate. 24789A1. NOTE: Apply grease to the liner mounting bolt threads 1.
Page 499: Bearing Carrier Removal
4. Straighten the bent tabs (a) on the impeller nut re- Bearing Carrier Removal tainer and remove the impeller nut (b). NOTE: Water pump assembly must be removed be- 5. Pull impeller straight off the shaft. If the impeller is fore bearing carrier can be removed.
Page 500: Bearing Carrier Disassembly
2. Remove 4 bolts securing bearing carrier to jet Bearing Carrier Reassembly drive. Installing Lower Seals Install seals into bearing carrier as follows: 1. Install O-ring seals (a) into the top seats of the three passage holes. 2. Install spiral retaining ring (b) into the inner ring groove.
Page 501: Installing Upper Seals
Installing Upper Seals Installing Drive Shaft Ball Bearing 1. Install spiral retaining ring (a) into the inner ring 1. If removed, install the bearing thrust ring (a) into groove of the upper seal housing. the groove on the drive shaft. 2.
Page 502 7. Install spacer (c), and the upper seal housing (b) being careful not to damage the O-ring seals as they pass the snap ring groove. Only finger pres- sure should be necessary to push in the housing. 5. Grease the upper seals and inside bore of the bearing carrier to ease entry of the seal housing.
Page 503: Installing Jet Drive To Drive Shaft Housing
4. Apply Loctite 271 to retaining bolts (4) and torque Installing Jet Drive to Drive to 60 lb. in. (6.8 N·m). Shaft Housing Reassembling Water Pump to Jet Drive NOTE: Replace cover if thickness of steel at discharge slots is 0.060 in. (1.524mm) or less, or if groove(s) (oth- er than impeller sealing groove) in cover roof are more than 0.030 in.
Page 504: Installing Jet Drive To Drive Shaft Housing 6C-18
Installing Jet Drive to Drive Shaft a - Bolt and Washer [Torque to 22.5 N·m)] 5. Grease the drive shaft, shear key, and impeller Housing bore. Place the plastic sleeve (a) inside the impel- 1. Apply a light coat of 2-4-C w/Teflon to the drive ler (b) and install impeller, shear key (c), shims (d) shaft splines.
Page 505 7. After setting the impeller height, tighten the impel- NOTE: If the outboard is used in salt water, apply ler nut snug with a wrench. Secure impeller nut by Quicksilver Anti-Corrosion Grease around the entire bending tabs (a) against the flats on the impeller mounting flange on the water intake housing and also to the threads on the six mounting bolts.
Page 506: Jet Drive Tiller Handle Adaptor Kit
2. Check to see if the shift cable will slide through the Jet Drive Tiller Handle drilled hole. If necessary, use a file to remove any Adaptor Kit extra metal from the hole. Installation Instructions NOTE: This kit must be used in conjunction with the recommended Quicksilver tiller handle kit.
Page 507 4. Lubricate the shift cable. Slide the cable boot onto 8. Drill the shift cable retainer mounting hole as fol- the cable. lows: a. Remove air box cover off the carburetors. Re- install after installation. b. Lay a straight ruler above the corner radius and across the flat side of the cable opening in the bottom cowl.
Page 508 12. Fasten the shift cable retainer to the bottom cowl 13. Attach the shift cable to the outer flange hole. with the mounting hardware shown. Tighten lock- IMPORTANT: Do not over-tighten. Shift Cable must nut, then back-off the locknut 1/4 turn. be free to pivot.
Page 509: Shift Cable Adjustment
17. Install the throttle cable as follows: Shift Cable Adjustment a. Rotate the throttle grip to the IDLE position. WARNING b. loosen the set screw (a) in the cable barrel. The shift cable must be adjusted to lock the re- c.
Page 510 OUTBOARD INSTALLATION/ ATTACHMENTS 50331 RIDE-GUIDE STEERING - THROTTLE/SHIFT CABLES & ELECTRICAL CONNECTIONS...
Page 511 Table of Contents Page Page Installing Outboard Motor on Transom ... 7A-1 Transom Mounted Ride-Guide Attaching Kit Determining Recommended Installation ....... . . 7A-13 Outboard Mounting Height .
Page 512: Installing Outboard Motor On Transom
Locate Centerline of Boat Transom Installing Outboard Motor on Transom Locate (and mark with a pencil) vertical centerline (a) of boat transom, as shown. Determining Recommended Outboard Mounting Height It is recommended for best-all-around boating perform- ance, the outboard should be mounted with the anti-venti- lation plate parallel to and at the same level as the boat bot- tom.
Page 513: Drilling Outboard Mounting Holes (Electric Start Models)
Lifting Outboard (Manual Start IMPORTANT: using “Transom Drill Fixture” (91-98234A2), use drill guide holes marked “A” when Models) drilling outboard mounting holes. Remove cowling from outboard. Use lifting eye on out- board and lift outboard on boat transom. 51456 1. Secure (tape) “Outboard Mounting Template” (located in center of Installation Manual) to outside of boat tran- Drilling Outboard Mounting Holes som.
Page 514 Outboard Mounting Hardware Installation B Use for easy removal and installation of outboard. 51509 a - Mounting Bolts (4) b - Flat Washers (4) c - Locknuts (4) 51462 d - Transom Clamp Retainers With Mounting Hardware a - Tighten Transom Clamp Handels e - Shims - Transom Clamp Retainers (If Required) b - Part Number 812433-C1 Fasten outboard to boat transom following installation A or...
Page 515 Installation B Retainers installed. Fastening outboard for easy removal and installation. Mark hole location. 51394 Outboard can be easily removed and installed. 51393 Drill four 3/8 in. (9.5mm) holes and fasten transom clamp retainers to transom. Add shims (if necessary) to allow for a small amount of clearance between transom clamps and retainers.
Page 516: Steering Cable Installation
Outboard installed. Installation must be water-tight, and outboard should be checked for tightness on the transom during opera- tion. Failure to bolt outboard to transom (using 4 bolts and locknuts, as shown) may result in damage to boat and/or loss of outboard and possible injury to occu- pants of boat.
Page 517: Cable Installation To Tilt Tube - Cable Routed On Starboard Side Of Boat
Ride-Guide steering cable can be routed on either side of 1. Lubricate inside of outboard tilt tube (a) and steering boat. If steering cable is routed on starboard side of boat, cable end (b) with Quicksilver 2-4-C Marine Lubricant. cable attaches to port outboard. If steering cable is routed 2.
Page 518: Cable Installation To Tilt Tube - Cable Routed On Port Side Of Boat
Cable Installation to Tilt Tube - Cable 1. Lubricate inside of outboard tilt tube (a) and steering cable end (b) with Quicksilver 2-4-C w/Teflon Marine Routed on Port Side of Boat Lubricant. 2. Insert steering cable end thru outboard tilt tube and se- TILT TUBE REVERSAL cure with steering cable attaching nut (c).
Page 519: Arm/Bracket
Lubricate hole in end of cable with Quicksilver 2-4-C w/Te- MODELS WITH TWO-PIECE STEERING flon Marine Lubricant. Assemble steering link rod to steer- ARM/BRACKET ing cable end using 2 flat washers and nylon insert locknut. Starboard Cable Entry Into Tilt Tube Tighten locknut until it seats [DO NOT exceed 120 lb.
Page 520: Maintenance Instructions
Maintenance Instructions Maintenance is the owner’s responsibility and must be per- formed at intervals specified. Normal Service - Every 50 hours of operation or 60 days (whichever comes first). a - Coupler b - Rubber Sleeve *Severe Service - Every 25 hours of operation or 30 days c - Steering Eye (whichever comes first).
Page 521: Installation
Installation IMPORTANT: Lubricate all moving parts with Quicksil- ver 2-4-C w/Teflon Marine Lubricant. IMPORTANT: All 50-60 models with one piece top cowl MODELS WITH FORGED TWO HOLE STEERING require a minimum centerline distance of 21 in. ARM AND ONE PIECE TOP COWL (533mm) during dual outboard installation to assure interference-free movement.
Page 522: Models With Two Hole Two Piece Steering Arm/Bracket And One Piece Top Cowl
MODELS WITH TWO HOLE TWO PIECE STEERING IMPORTANT: Lubricate all moving parts with Quicksil- ARM/BRACKET AND ONE PIECE TOP COWL ver 2-4-C w/Teflon Marine Lubricant. IMPORTANT: All 50-60 models with one piece top cowl require a minimum centerline distance of 21 in. (533mm) during dual outboard installation to assure interference-free movement.
Page 523: Ride-Guide Steering Attachment
Ride-Guide Steering Attachment 2. If necessary, adjust trim tab as follows: Extension Couplers a. Shift outboard into neutral and make sure ignition key is at “OFF” position. b. Remove plastic cap from rear of drive shaft hous- Outboard Center Required Coupler(s) Between Line Distance Steering Eyes (Shown Below) ing and loosen bolt and trim tab.
Page 524: Transom Mounted Ride-Guide Attaching Kit Installation
3. Place Ride-Guide yoke on pivot block and secure with Transom Mounted Ride- 7/16 in. x 1-3/4 in bolt and locknut, as shown in Figures Guide Attaching Kit 1 and 2. Torque locknut to 10 lb.ft. (13.5 N·m), then back off 1/4 turn. Installation 4.
Page 525: Clevis Attaching Kit Installation
NOTE: When drilling thru transom, be sure that holes are Clevis Attaching Kit drilled perpendicular to transom. Installation 6. With attaching kit positioned as outlined preceding, use 3 holes in transom bracket as a guide and drill NOTE: This kit is used to attach Ride-Guide cable to out- three 11/32 in.
Page 526: Steering Cable Installation
Steering Cable Installation NOTE: Some Ride-Guide steering cables may not be equipped with locking sleeve and cotter pin. If cable being 1. Lubricate steering cable end with Quicksilver 2-4-C w/ installed does not have these parts, disregard instructions Teflon Marine Lubricant. to install them.
Page 527: Remote Control Installation
1. Position remote control handle into neutral detent. Remote Control Installation 2. Manually shift outboard into neutral (propeller will ro- IMPORTANT: Connect control cables to remote control tate freely). and mount remote control BEFORE attaching control 3. Route shift cable (a) thru control cable grommet (b). cables to engine.
Page 528: Throttle Cable Installation And Adjustment To Engine
Throttle Cable Installation and Connecting Remote Control Wiring Adjustment to Engine Harness to Engine Wiring Harness (Electric Start Models) 1. Shift remote control into neutral. Route remote control harness or key switch harness along 2. Route throttle cable (a) thru control cable grommet (b). side of boat to engine, fastening harness to boat.
Page 529: Power Trim Wiring Connections (Models Equipped)
Route remote control harness or key switch harness (d) Power Trim Wiring Connections along side oil tank (e) and out of bottom cowl thru opening (Models So Equipped) (f) in battery cable grommet. Make bullet connector wiring connection, between remote control wiring harness/key switch wiring harness and en- gine wiring.
Page 530 OUTBOARD INSTALLATION/ ATTACHMENTS TILLER HANDLE and CO-PILOT...
Page 531 Table of Contents Page Notes: ........7B-1 Steering Handle Kit .
Page 532: Notes
Notes: 90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-1...
Page 533: Steering Handle Kit
Steering Handle Kit 2-4-C With Teflon (92-825407A12) 2-4-C Soapy Water Solution (Obtain Locally) 7B-2 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996...
Page 534 Steering Handle Kit TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m STEERING ARM BUSHING HOUSING PLATE GASKET SCREW (1/2 IN.) Drive Tight SCREW (3/5 IN.) Drive Tight CLAMP SCREW WING NUT THROTTLE HANDLE/STOP SWITCH KIT STOP SWITCH SCREW Drive Tight GRIP J-CLAMP...
Page 535 Steering Handle Kit Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 7B-4 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996...
Page 536 Steering Handle Kit TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m BRACKET STUD TAB WASHER 47.5 STOP HARNESS CABLE PLUG GROMMET COVER SCREW Drive Tight HORN PLUG STOP SWITCH LANYARD RETAINER CABLE STUD WASHER SHIFT LEVER SCREW TAB WASHER BUSHING WASHER (BELLEVILLE) WASHER (PLASTIC)
Page 537 Steering Handle Kit Loctite 271 (92-809820) 2-4-C With Teflon (92-825407A12) 7B-6 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996...
Page 538 Steering Handle Kit TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m WASHER SHIFT ROD ROD END BUSHING WASHER COTTER PIN DETENT ASSEMBLY STUD KNOB CO-PILOT LEVER CO-PILOT DRIVER WASHER BRAKE DISC ARM (TOP) ARM (BOTTOM) HARNESS ASSEMBLY KEY SWITCH TRIM SWITCH SWITCH ASSEMBLY SCREW...
Page 539: Tiller Handle Adaptor Kit (Jet 45)
Tiller Handle Adaptor Kit (JET 45) Loctite 271 (92-809820) A – Drive tight and then back off 1/4 turn. B – Tighten until snug and then tighten an additional 1/8 turn. TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m –...
Page 540: Tiller Arm/Shift Lever Removal
Tiller Arm/Shift Lever Removal 4. Release latch and remove throttle cable with grommet from bottom cowl. 1. Remove battery cables from battery. 51084 2. Remove outboard cowling. 51093 3. Remove nut securing throttle cable to engine. a - Rubber Grommet b - Throttle Cable 5.
Page 541 6. Remove cover. 8. Remove plug from tiller handle bracket. 51608 a - Cover b - Screw (4) 51608 7. Disconnect stop switch wire at bullet connector and a - Plug screw securing ground wire. 9. Remove bolt and nut from tiller handle bracket. 51608 a - Stop Switch Wire (Bullet Connector) 51608...
Page 542: Tiller Handle Disassembly
10. Remove tiller handle, 2 nylon bushings, stainless steel Tiller Handle Disassembly spacer and 2 flat washers from bracket. 1. Using a flat tip screwdriver, carefully pry/push rubber grip off tiller handle. 51606 51603 a - Tiller Handle a - Grip b - Nylon bushing (2) b - Tiller Handle c - Stainless Steel Spacer...
Page 543 3. Cut sta-strap securing stop switch harness and re- 5. Remove throttle cable anchor screws and remove move screw from harness J-clip. cable guide. 51602 51603 a - Sta-Strap a - Anchor Screws b - Screw b - Throttle Cable Guide 4.
Page 544 7. Unscrew (counterclockwise) stainless conduit from til- 9. Remove cover plate and gasket from tiller handle. ler handle. 10. Remove bolt from throttle friction assembly. 51604 51603 a - Cover Plate b - Gasket (below plate) c - Screws d - Throttle Friction Assembly a - Conduit e - Bolt 8.
Page 545: Tiller Arm Reassembly
12. Drive out drift pin and remove throttle gear from throttle 3. Slide cover and friction device onto throttle arm. arm. 51604 51602 a - Throttle Arm b - Gear a - Gear c - Throttle Friction Device b - Drift Pin d - Cover 4.
Page 546 6. Install gasket and cover plate over gear assembly. DO 9. Retract throttle cable into gear assembly until approxi- NOT OVERTIGHTEN attaching screws. mately 17 in. (43 cm) extends from the tiller arm. 51604 51604 a - Cover Plate a - Cable [Extends 17 in. (43 cm)] b - Gasket (Below Cover) 10.
Page 547 11. Slide brass barrel over throttle cable tube. Secure bar- 13. Position throttle arm slot to face stop harness exit hole rel to tube with allen screw approximately 3.5 in. (89 in tiller handle. Route stop switch harness through twist mm) from stainless conduit.
Page 548: Tiller Arm/Shift Lever Installation
15. Sta-strap harness to throttle arm. Tiller Arm/Shift Lever Installation 1. Install shift lever with detent assembly to bracket. CAUTION Allow enough slack in harness (rotate throttle grip in both directions) before securing harness to handle as- sembly with J-clip. 16.
Page 549 3. Reinstall plug. 5. Install Cover. 51608 a - Cover b - Screw (4) 51608 6. Install cotter key and components to shift rod. a - Plug 4. Connect stop switch wire at bullet connector and se- cure ground wire to handle with screw. Design 2 Design 1 54256...
Page 550: Shift Link Rod Installation And Adjustment To Engine
7. Install throttle cable with grommet. Shift Link Rod Installation and Adjustment to Engine 1. Position shift handle to neutral. 2. Manually shift outboard (shift actuator lever) to neutral. Propeller turns freely in both directions. 3. Adjust shift link rod end to slip over shift actuator bolt with slight preload toward reverse.
Page 551: Throttle Cable Installation And Adjustment
Throttle Cable Installation and 4. Holding throttle lever against idle stop, adjust throttle cable to slip into upper hole of barrel receptacle with a Adjustment very light preload of throttle lever against idle stop. Ap- ply small amount of Loctite 271 to threads of set screw. 1.
Page 552: Co-Pilot Installation
Co-Pilot Installation 3. Install brake disk and brake. NOTE: To install Co-Pilot kit, tiller handle must be removed and battery cables disconnected. 1. Install brake disk on swivel bracket. Position “bottom up” lever, brake disk and “top up” lever onto swivel bracket.
Page 553 6. Holding components in place (lever facing forward), in- 2. Install tiller handle to studs with shift rod positioned thru stall lock nut and torque to 75 lb. in. (8 N·m). Secure cowl opening as shown. knob to lever with bolt. Design 2 Design 1 51095...
Page 554: Wiring Harness Connection
4. Install rubber grommet to throttle cable and install into 2. Route wiring harness thru rubber grommet. Note, light bottom cowl. Note, a light lubricant on grommet will aid oil on rubber grommet will aid in wiring harness instal- in installation over shift rod. lation.
Page 555 4. Reconnect battery cables. 5. Adjust co-pilot tension by moving handle to port (loos- en) or starboard (tighten). Locknut on co-pilot stud may have to be adjusted to attain desired tension on tiller arm. 51084 MORE LESS 51095 7B-24 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996...
Page 556 OUTBOARD INSTALLATION/ ATTACHMENTS REWIND STARTER...
Page 557 Table of Contents Page Notes ........7C-1 Rewind Starter Components .
Page 558: Notes
Notes: 90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7C-1...
Page 559 Starter Assembly (MANUAL – 55) 2 Cycle Outboard Oil (92-13249A24) 2-4-C With Teflon (92-825407A12) 7C-2 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996...
Page 560 Starter Assembly (MANUAL – 55) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HANDLE ASSEMBLY REST SEAL SCREW SPACER BUSHING GROMMET WASHER INTERLOCK CABLE SCREW Drive Tight WASHER COTTER PIN SCREW Drive Tight COTTER PIN WASHER – RECOIL STARTER STARTER HOUSING SPRING INTERLOCK LEVER...
Page 561: Rewind Starter Disassembly
Rewind Starter Disassembly 6. Remove cam retainer. WARNING When disassembling and reassembling rewind start- er, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Remove retaining clip and attaching screw which se- cures shift interlock cable to starter housing. 2.
Page 562: Cleaning And Inspection
8. Remove starter sheave. Cleaning and Inspection 1. Clean components in solvent and dry with compressed air. 2. Inspect rewind spring for kinks, burrs, corrosion of breakage. 3. Inspect starter sheave, rope guide and starter housing for nicks, grooves, cracks, wear or distortion, especial- ly area of rope travel.
Page 563: Adjusting Rewind Spring Tension
2. Install starter sheave to housing and secure in place 4. Reinstall cam retainer and secure with screws (3). with screw. Torque to 135 lb. in. (15.3 N·m). 28374 51605 a - Screws (3) b - Cam Retainer a - Starter Sheave b - Screw 3.
Page 564: Starter Interlock Cable Adjustment
NOTE: Check operation of rewind and rewind tension be- Starter Interlock Cable Adjustment fore outboard installation. IMPORTANT: Lubricate core wire of interlock cable 3. Place rewind starter on engine. with light oil prior to making adjustments. 4. Pull starter rope thru bracket, handle, and starter rope While rotating the propeller shaft, place the gear shift retainer.

Mercury Marathon-Seapro 60-60 Service Manual

General Information 1

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Electrical and Ignition 2

Electrical and Ignition 2

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