225/250 3.0 Litre Work: Electronic Fuel Injection

Srvc Man-ME 3.
OL Work 225/250 10/16/01 2:38 PM Page 1
225/250
3.0 Litre Work 225/250 EFI

3.0 Litre Work
Electronic
Fuel Injection
90-884294 OCTOBER 2001

Starting Model Year 2002
Starting Model Year 2002
Starting Serial Number 0T409000
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com
Frankston Road W6250 Pioneer Road (Parc Industriel de Petit-Rechain)
P.O. Box 80 Fond du Lac, WI 54936-1939 USA B-4822 Verviers/Belgium
Dandenong, Victoria 3175 Australia
©2001, Mercury Marine. All rights reserved. Printed in U.S.A. 90-884294 OCTOBER 2001
Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal in-
jury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual

This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these prod-
ucts, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which in-
cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-884294 OCTOBER 2001 Page i

It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the met-
ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mis-
matched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations when-
ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
Cleanliness and Care of Outboard Motor

A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manu-
al, it should be understood that proper cleaning, and protection of machined surfaces and
friction areas is a part of the repair 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.
Personnel should not work on or under an outboard 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 without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.
Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explana-
tory.
EXAMPLE:
90-878079R1 OCTOBER 2000 LOWER UNIT - 6A-7
Revision No. 1 Section Description
Month of Printing Section Number
Year of Printing Part of Section Letter
Page Number
Page ii 90-884294 OCTOBER 2001
Service Manual Outline
Section 1 - General Information & Specifications
General Information
& Specifications 1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Electrical
2
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Fuel System
3
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Fuel Injection
Powerhead
4
C - Oil Injection
D - Emissions
Section 4 - Powerhead
A - Powerhead
Mid-Section
5
B - Cooling
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
Gear Housing
6
B - Power Trim
Section 6 - Gear Housing
A - Right Hand Non-Ratcheting
B - Left Hand Non-Ratcheting
Attachment/Control Linkage
7
Section 7 - Attachments/Control Linkage
Section 8 - Color Diagrams Color Diagrams
8
90-884294 OCTOBER 2001 Page iii

SPECIFICATIONS
IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Sealants and
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Specifications
Model 3 Liter Work/225 EFI/250 EFI

HORSEPOWER Model 3 Liter Work 200 (149.1)
(KW) Model 225 EFI 225 (167.8)
Model 250 EFI 250 (186.5)
Full Throttle RPM (All Models) 5000 – 5800
Idle RPM (In Gear) (All Models) 625 ± 50
RPM Limiter
All Models Refer to System Information in the
Digital Diagnostic Terminal (DDT) for
latest information
OUTBOARD Model 3 Liter Work/225 EFI/250 EFI
WEIGHT – 20 in. (50.8 cm) Shaft 458.0 lbs. (207.7 kg)
– 25 in. (63.5 cm) Shaft 463.0 lbs. (210.0 kg)
– 30 in. (76.2 cm) Shaft 479.0 lbs. (217.3 kg)
CYLINDER Model 3 Liter Work/225 EFI/250 EFI
BLOCK Type V–6 Cylinder, Two Cycle, Loop
Charged
Displacement 185.9 cu. in. (3047 cc)
Thermostat 120 °F (48.8 °C)
STROKE Length (All Models) 3.00 in. (76.2 mm)
CYLINDER Models 3 Liter Work/225 EFI/250 EFI
BORE Diameter (Std) 3.625 in. (92.075 mm)
Taper/Out of Round/Maximum Wear 0.003 in. (0.076 mm)
Bore Type Cast Iron
CRANKSHAFT Maximum Runout 0.006 (0.152 mm)
PISTON Piston Type Aluminum
Models 3 Liter Work/225 EFI/250 EFI
Standard 3.621 in. ± 0.0005 in.
(91.973 mm ± 0.0127 mm)
0.015 in. (0.381 mm) Oversize 3.636 in. ± 0.0005 in.
(92.3544 mm ± 0.0127 mm)
0.030 in. (0.762 mm) Oversize 4.383 in. ± 0.0005 in.
(111.328 ± 0.0127 mm)
COMPRESSION All Models – Using a fully charged bat- 90 – 110 psi
tery, throttle shutters wide open and (616.3 – 753.5 kPa)
cylinder block warm Variance between cylinders should not
exceed 15 psi (102.7 kPa)
90-884294 OCTOBER 2001 Page 1A-1

SPECIFICATIONS
REEDS Model 3 Liter Work/225 EFI/ 250 EFI

Reed Type Steel
Reed Stand 0pen (Max.) 0.020 in. (0.50 mm)
Reed Stop (Max.) Not Adjustable
MID Power Trim (Total Tilt Range) 75°
SECTION Power Trim (Tilt Range) 20°
Maximum Allowable Leak down in 24
hrs. 1 in. (25.4 mm)
Tilt Pin Adjustment Positions 5
Steering Pivot Range 60°
Allowable Transom Thickness 2-3/8 in. (6.03 cm) Maximum
FUEL Fuel Gasoline w/Oil Injection
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil Quicksilver or Mercury Precision Lubri-
cants NMMA/BIA Certified TC-W3
2 Cycle Outboard Oil
Gasoline/Oil Ratio 50:1 (25:1 Break-In) ECM Controlled –
no premix
STARTING Electric Start – All Models
SYSTEM Centrifugal Bendix
Starter Draw (Under Load) 165 Amperes
Starter Load (No Load) 30 Amperes
Minimum Brush Length 0.25 in. (25.4 mm)
Solenoid Driven Bendix
Battery Rating Min. 630 Marine Cranking Amps
(MCA) or 490 Cold Cranking Amps
(CCA)
IGNITION Type Digital Inductive
SYSTEM Spark Plug Type Champion QL77CC
Spark Plug Gap 0.040 in. (1.0 mm)
Firing Order 1-2-3-4-5-6
Idle Timing Not Adjustable; Controlled by ECM
Maximum Timing Not Adjustable; Controlled by ECM
Throttle Position Sensor Not Adjustable; Controlled by ECM
CHARGING Alternator Output (Regulated) 42 – 48 Amperes @ 2000 rpm @ Bat-
SYSTEM tery
52 – 60 Amperes @ 2000 rpm @ Al-
ternator
Brush Length Std. Exposed Length: 0.413 in. (10.5
mm)
Min. Exposed Length: 0.059 in. (1.5
mm)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw 0.15 mA (Ign, Switch Off)
30.0 mA (Ign. Switch On)

(CCA)
Page 1A-2 90-884294 OCTOBER 2001

SPECIFICATIONS
GEAR Gear Ratio

HOUSING – All Models (Standard) 1.75:1 (12/21 teeth)
– All Models (High Altitude) 1.87:1 (15/28 teeth)
Gearcase Capacity
– 1.75:1/1.87:1 28 fl oz (828.0 ml)
Pinion Height
– All Models 0.025 in. (0.64 mm)
Forward Gear Backlash
– 1.75:1/1.87:1 0.017 in. – 0.028 in.
(0.43 mm – 0.71 mm)
Reverse Gear Backlash
– Standard Rotation 0.028 in. to 0.052 in.
(0.71 mm to 1.32 mm)
– Counter Rotation 0.040 in. to 0.060 in.
(1.0 mm to 1.52 mm)
Water Pressure @ RPM
– @ Idle 1-1/2 – 4-1/2 psi (10.3 – 30.8 kPa)
– @ 5000 RPM 8 – 10 psi (54.8 – 68.5 kPa) Minimum
OIL Recommended Oil Quicksilver or Mercury Precision Lubri-
INJECTION cants NMMA/BIA Certified TC-W3
2 Cycle Outboard Oil
Oil Tank Capacity 3 gal. (11.4 Liter)
Approx. Time
– All Models 6.0 hrs. Approx.
Reserve Capacity/Approx. Time 1.5 qt. (1.45 Liter) 30 – 35 min.
Oil Pump Output

– All Models 26cc during auto prime time period
FUEL Idle RPM
INJECTION – All Models 625 ± 50
Wide Open Throttle (WOT) RPM
– All Models 5000 – 5800
Float Adjustment (Vapor Separator)
Float Level Preset @ Factory
Injectors
– All Models (Quantity) 6
– Injectors are Crank Angle
Driven by ECM
– #1 Cylinder RED + BRN Leads
– #2 Cylinder RED + WHT Leads
– #3 Cylinder RED + ORG Leads
– #4 Cylinder RED + YEL Leads
– #5 Cylinder RED + LT BLUE Leads
– #6 Cylinder RED + PUR Leads
Line Pressure @ Injectors 41 psi – 45 psi (283 kPa – 310 kPa)
Injector Resistance 12.3 ohms ± 0.5 ohms
Electric Fuel Pump Resistance 0.7 ± 0.3 ohms
Electric Fuel Pump Amperage Draw 4 amperes ± 0.5 amperes
90-884294 OCTOBER 2001 Page 1A-3

SPECIFICATIONS
Mercury/Quicksilver Lubricants and Sealants
Description Mercury Part Number Quicksilver Part Number
Needle Bearing Assy. Lubricant

92-802868A1 N/A
[8 oz. (226.8 grams)] tube
Dielectric Grease
92-823506-1 92-823506-1
[8 oz. (226.8 grams)] can
Loctite 271 – Thread Locker

92-809819 92-809819
(10 ml) tube
Loctite 567 PST Pipe Sealant

92-809822 92-809822
(50 ml) tube
Loctite Master Gasket Kit 92-12564-2 92-12564-2
2 Cycle Premium Outboard Oil

92-802815A1 92-802815Q1
[1 Gallon (3.7 liter)]
Perfect Seal
92-34227-1 92-34227-1
[16 oz. (0.45 kg)] can
Liquid Neoprene
92-25711-3 92-25711-3
[8 oz. (226.8 grams)] can
Cyanacrylate Adhesive Obtain Locally Obtain Locally
Bellows Adhesive N/A 92-86166Q1
Loctite 680 Retaining Compound

92-809833 92-809833
(10 ml) tube
Loctite 222 Thread Locker

92-809818 92-809818
(10 ml) tube
3M Permabond #3M08155 Obtain Locally Obtain Locally
Loctite 242 Thread Locker

92-809821 92-809821
(10 ml) tube
Loctite 609 Obtain Locally Obtain Locally
SAE 30W Oil Obtain Locally Obtain Locally
Page 1A-4 90-884294 OCTOBER 2001

SPECIFICATIONS
Description Mercury Part Number Quicksilver Part Number
RTV 587 Silicone Sealer

92-809825 92-809825
[3 oz. (85.05 grams)]
Premium Gear Lubricant

92-802846A1 92-802846Q1
[1 Quart (0.94 liter)]
Loctite 7649 Primer

92-809824 92-809824
[4.5 oz (127.57 grams)]
Anti-Corrosion Grease
92-802867A1 92-802867Q1
2-4-C with Teflon

92-802859A1 92-802859Q1
Loctite Quick Tite Obtain Locally Obtain Locally
Isopropyl Alcohol Obtain Locally Obtain Locally
Hot Glue Obtain Locally Obtain Locally
Special Lubricant 101

92-802865A1 92-802865Q1
4 Stroke 10W30 Outboard Oil

92-802833A1 92-802833Q1
4 Cycle 25W40 Engine Oil

92-802837A1 92-802837Q1
Power Trim & Steering Fluid

92-802880A1 92-802880Q1
[8 oz. (226.8 grams)]
Engine Coupler Spline Grease

92-802869A1 92-802869Q1
[14 oz. (0.39 kg)] cartridge
Fuel System Treatment & Stabilizer

92-802875A1 92-802875Q1
[12 oz. (355 ml)]
Corrosion Guard
92-802878-55 92-802878Q55
[11 oz. (325 ml)] Spray Can
90-884294 OCTOBER 2001 Page 1A-5

MAINTENANCE
Section 1B - Maintenance B
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Gear Case Lubricant Capacity . . . . . . . . . 1B-1 Fuel Line Inspection . . . . . . . . . . . . . . . . . . 1B-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Water Separating Fuel Filter –
Quicksilver Lubricant/Sealant . . . . . . . . . . . . . 1B-2 EFI Models . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Inspection and Maintenance Schedule . . . . . 1B-4 Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-7
Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-4 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . 1B-7
After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Every 100 Hours of Use or Once Yearly, Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . 1B-8
Whichever Occurs First . . . . . . . . . . . . . . . 1B-4 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Flushing Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Checking Power Trim Fluid . . . . . . . . . . . . . . . 1B-10
Flushing Cooling System – Using Cowl Gear Case Lubrication . . . . . . . . . . . . . . . . . . . 1B-11
Flush Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . . 1B-12
Flushing Cooling System –
Using Flushing Attachment 44357A2 . . . . 1B-5
Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.75:1 28.0 fl. oz. (828.0 ml)
1.87:1 28.0 fl. oz. (828.0 ml)
90-884294 OCTOBER 2001 Page 1B-1

MAINTENANCE
Special Tools
1. Grease Gun 91-37299A1
2. Flushing Attachment 44357A2
Mercury/Quicksilver Lubricants and Sealants

NOTE: See Section 1A for lubricants and sealants chart.
Page 1B-2 90-884294 OCTOBER 2001

MAINTENANCE
Inspection and Maintenance Schedule

Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear
case with fresh water if operating in salt water.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Replace water separating fuel filter – EFI models.
4. Check corrosion control anodes. Check more frequently when used in salt water.
5. Drain and replace gear case lubricant.
6. Lubricate splines on the drive shaft and shift shaft.∗
7. Check power trim fluid.
8. Inspect battery.
9. Check control cable adjustments.∗
10. Check tightness of bolts, nuts, and other fasteners.
∗ These items should be serviced by an authorized dealer.
Every 300 Hours of Use or Every Three Years, Whichever Occurs First
Replace water pump impeller (more often if overheating occurs or reduced water pres-
sure is noted).∗
∗ This item should be serviced by an authorized dealer.
90-884294 OCTOBER 2001 Page 1B-3

MAINTENANCE
Flushing Engine
Flushing Cooling System – Using Cowl Flush Plug
After each us in salt, polluted or muddy water, flush the internal water passages of the
outboard with fresh water. This will help prevent a buildup of deposits from clogging the
internal water passages.
NOTE: Engine can be stopped or running at idle speed when flushing the cooling system.
Do not flush engine using a water system that exceeds 45 psi.
1. Remove the plug from fitting in the bottom cowl.
2. Attach a water hose to the fitting. Turn water on and flush for 3 to 5 minutes.
Flushing Cooling System – Using Flushing Attachment 44357A2
WARNING
When flushing, verify that area in vicinity of propeller is clear and that no person
is standing nearby – to avoid possible injury. It is recommended to remove pro-
peller as a precautionary measure.
CAUTION
It is recommended that the front water pickups on the leading end of the torpedo
be blocked off (duct tape, etc.) while applying water to side mounted water pick-
ups during powerhead flushing or engine testing to prevent possible engine
overheat from air injestion.
1. Install Flushing Attachment 44357Q2 (or equivalent tool) on the gear housing from
the FRONT side, positioning the rubber cups over the water intake openings.
2. Connect hose [1/2 in. (12.7 mm) I.D. or larger] between flushing attachment and water
tap.
IMPORTANT: To prevent water pump damage, do not start or run engine unless
cooling water is flowing.
3. With the outboard in the normal operating position (vertical), partially open water tap
(IT IS NOT NECESSARY to use full water pressure) and adjust water flow so that
there is a significant water loss around the rubber cups.
4. Start engine and idle in NEUTRAL. Increase engine speed, not to exceed 2500 RPM.
5. Flush or service engine as required. Verify adequate cooling water is provided.
6. Water must be discharged thru “tell tale.”
IMPORTANT: Prevent engine overheating. If water flow is insufficient, stop engine
and determine cause before continuing.
7. Flush until discharge water is clear. In saltwater areas, run outboard 3 to 5 minutes.
8. Stop engine before turning off water.
Page 1B-4 90-884294 OCTOBER 2001

MAINTENANCE
9. Stop engine, turn water off and remove flushing attachment from gear housing.
IMPORTANT: While and after flushing, keep outboard in upright position until all wa-
ter has drained from drive shaft housing to prevent water from entering the power-
head via drive shaft housing and exhaust ports.
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel sys-
tem.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of deterioration or damage. If any of these conditions is found, the fuel line or primer
bulb must be replaced.
IMPORTANT: Visually inspect for fuel leakage from the filter connections by
squeezing the primer bulb until firm, forcing fuel into the filter.
Water Separating Fuel Filter – EFI Models
NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
1. This filter removes moisture and also debris from the fuel. If the filter becomes filled
with water, the water can be removed. If the filter becomes plugged with debris, the
filter must be replaced with a new filter.
59030
a - Fuel/Water Separator Filter
Remove and replace filter as follows:

2. Turn ignition key switch to OFF position.
3. Disconnect wire at bottom of filter.
90-884294 OCTOBER 2001 Page 1B-5

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

The gear case has two corrosion control anodes (a). Another anode (b) is installed on the
bottom of the transom bracket assembly. An anode helps protect the outboard against
galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard
metals.
b
Each anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is com-
pletely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
Spark Plug Inspection and Replacement

Inspect spark plugs at the recommended intervals.
WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark
plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel
vapors under the engine cowl. To avoid damaging spark plug boots, do not use
any sharp object or metal tool such as pliers, screwdriver, etc. to remove spark
plug boots.
1. Remove the spark plug leads by twisting the rubber boots slightly and pulling off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart.

4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs
finger tight, and tighten 1/4 turn or torque to 20 lb-ft (27 Nm).
Page 1B-6 90-884294 OCTOBER 2001

MAINTENANCE
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting
capability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to posi-
tive and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Fuse Replacement
IMPORTANT: Always carry spare SFE 15 and 20 AMP fuses.
The electrical wiring circuits on the outboard are protected from overload by fuses in the
wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is
broken, replace the fuse. Replace fuse with a new fuse with the same rating.
2. The fuses and circuits are identified as follows:
1. Smart Craft Data Bus Circuit - SFE 15 Ampere Fuse
2. Fuel Injector Harness, Electric Fuel Pump and Oil Pump - SFE 20 Ampere Fuse
3. Main Power Relay, Remote Control Harness and Power Trim - SFE 20 Ampere Fuse
4. Ignition Coils - SFE 20 Ampere Fuse
1 3
2 4
59026
90-884294 OCTOBER 2001 Page 1B-7

MAINTENANCE
Lubrication Points
Lubricate Point 1 with Special Lubricant 101.
1. Trim Rod Ball Ends – Turn the ball ends to work the lubricant into the ball sockets.
1
1
Lubricate Point 2 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
2. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the
propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub
from corroding and seizing to the shaft.
2
Lubricate Points 3 through 6 with 2-4-C Marine Lubricant with Teflon or Special Lubricant
101.
3. Swivel Bracket – Lubricate through fitting.
4. Tilt Support Lever – Lubricate through fitting.
4
5. Tilt Tube – Lubricate through fitting.
5 57834
Page 1B-8 90-884294 OCTOBER 2001

MAINTENANCE
6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the
steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b).
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube
before adding lubricant. Adding lubricant to steering cable when fully extended
could cause steering cable to become hydraulically locked. An hydraulically
locked steering cable will cause loss of steering control, possibly resulting in se-
rious injury or death.
Lubricate Points 7 With Light Weight Oil.
7. Steering Link Rod Pivot Points – Lubricate pivot points.
6-b 6-a
Checking Power Trim Fluid

8. Tilt outboard to the full up position and engage the tilt support lock.
9. Remove fill cap and check fluid level. The fluid level should be even with the bottom
of the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.
90-884294 OCTOBER 2001 Page 1B-9

MAINTENANCE
Gear Case Lubrication

When adding or changing gear case lubricant, visually check for the presence of water
in the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer. Water in the lubricant may
result in premature bearing failure, or in freezing temperatures, will turn to ice and damage
the gear case.
DRAINING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Place drain pan below outboard.
3. Remove vent plug and fill/drain plug and drain lubricant.
2 1
GEAR CASE LUBRICANT CAPACITY

Gear case lubricant capacity is approximately 28.0 fl. oz. (828 ml).
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Remove vent plug (a).
3. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent
hole (c).
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer (a) before removing
the lubricant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer (d).
a
c
d
1-5 b
Page 1B-10 90-884294 OCTOBER 2001

MAINTENANCE
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust,
corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of
season storage or prolonged storage (two months or longer).
CAUTION
Never start or run your outboard (even momentarily) without water circulating
through all the cooling water intake holes in the gear case to prevent damage to
the water pump (running dry) or overheating of the engine.
FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a for-
mation of acid during storage and can damage the fuel system. If the gasoline be-
ing used contains alcohol, It is advisable to drain as much of the remaining gaso-
line as possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (sta-
bilized) fuel to help prevent formation of varnish and gum. Proceed with following instruc-
tions.
1. Portable Fuel Tank – Pour the required amount of Fuel System Treatment & Stabilizer
(follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix sta-
bilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Fuel System Treat-
ment & Stabilizer (follow instructions on container) into a separate container and mix
with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment for circulating cooling
water. Run the engine at 2000 rpm for 10 minutes to allow treated fuel to fill the fuel
system.
PROTECTING INTERNAL ENGINE COMPONENTS
Electronic Fuel Injection (EFI) Models
NOTE: Make sure the fuel system has been prepared for storage.
1. Remove the spark plugs and add approximately one ounce (30ml) of engine oil into
each spark plug hole. Rotate the flywheel manually several times to distribute the oil
in the cylinders. Reinstall spark plugs.
2. Remove the water separating fuel filter and empty contents into a suitable container.
Refer to Maintenance Section for removal and installation of filter. Replace fuel filter
annually, or every 100 Hours of operation, or if large amount of fuel contamination is
present.
PROTECTING EXTERNAL OUTBOARD COMPONENTS
1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule.
2. Touch up any paint nicks. See your dealer for touch-up paint.
3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes).
GEAR CASE
Drain and refill the gear case lubricant (refer to maintenance procedure).
90-884294 OCTOBER 2001 Page 1B-11

MAINTENANCE
POSITIONING OUTBOARD FOR STORAGE

Store outboard in an upright (vertical) position to allow water to drain out of outboard.
CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or
rain water that may have entered the propeller exhaust outlet in the gear case
could freeze and cause damage to the outboard.
BATTERY STORAGE
1. Follow the battery manufacturers instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
Page 1B-12 90-884294 OCTOBER 2001

GENERAL INFORMATION
Section 1C - General Information C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1 Model 3 Liter Work/225 EFI/250 EFI
Conditions Affecting Performance . . . . . . . . . 1C-2 Powerhead Port View . . . . . . . . . . . . . . . . . . . . 1C-10
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Model 3 Liter Work/225 EFI/250 EFI
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Powerhead Top View . . . . . . . . . . . . . . . . . . . . 1C-11
Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Model 3 Liter Work/225 EFI/250 EFI
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Powerhead Aft View . . . . . . . . . . . . . . . . . . . . . 1C-12
Engine Compression . . . . . . . . . . . . . . . . . . 1C-5 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-13
Following Complete Submersion . . . . . . . . . . 1C-6 Color Impregnated Top Cowls . . . . . . . . . . 1C-13
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-6 Cleaning & Painting Aluminum
Submerged While Running . . . . . . . . . . . . 1C-6 Propellers & Gear Housings . . . . . . . . . . . 1C-13
Model 3 Liter Work/225 EFI/250 EFI Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Powerhead Front View . . . . . . . . . . . . . . . . . . . 1C-8 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Model 3 Liter Work/225 EFI/250 EFI Instructions for “Wet” Application . . . . . . . 1C-15
Powerhead Starboard View . . . . . . . . . . . . . . . 1C-9
Serial Number Location

The engine serial number is located on the top of the engine block. A serial number is also
located on the starboard side of the swivel bracket.
a OGXXXXXX
19XX
b
XXXX
c
e
d
XX
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
90-884294 OCTOBER 2001 Page 1C-1

GENERAL INFORMATION
Conditions Affecting Performance

Weather
Weather conditions exert a profound effect on power output of internal combustion en-
gines. Established horsepower ratings refer to the power that the engine will produce at
its rated RPM under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards
Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the compu-
tation of horsepower from data obtained on the dynamometer. All values are corrected
to the power that the engine will produce at sea level, at 30% relative humidity, at 77 °F
(25 °C) temperature and a barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure and high humidity all
combine to reduce engine power. This is reflected in decreased boat speeds – as much
as 2 or 3 mph. Nothing will regain this speed for the boater but the coming of cool, dry
weather.
In pointing out the consequences of weather effects, an engine – running on a hot, humid
summer day – may loose as much as 14% of the horsepower it would produce on a dry,
brisk spring or fall day. The horsepower that any internal combustion engine produces
depends upon the density of the air that it consumes, and this density is dependent upon
the temperature of the air, its barometric pressure and water vapor (or humidity) content.
Accompanying this weather-inspired loss of power is a second but more subtle loss. At
rigging time in early spring, the engine was equipped with a propeller that allowed the en-
gine to run within its recommended RPM range at full throttle. With the coming of the sum-
mer weather and the consequent drop in available horsepower, this propeller will, in ef-
fect, become too large. Consequently, the engine operates at less than its recommended
RPM.
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss
can be regained by switching to a smaller pitch propeller that allows the engine to run
again at recommended RPM.
To obtain optimum engine performance under changing weather conditions, the engine
MUST be propped to allow it to operate at or near the top end of the recommended maxi-
mum RPM range at wide-open-throttle with a normal boat load.
This will allow the engine to develop full power while operating in an RPM range that dis-
courages damaging detonation.
Page 1C-2 90-884294 OCTOBER 2001

GENERAL INFORMATION
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant
effect on the boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in choppy water.
(4.) Will increase the danger of the following wave splashing into the boat when
coming off plane.
b. Shifting weight to the front (bow)
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer back-and-forth (bow steer).
BOTTOM
1. Boat Bottom: For maximum speed, a boat bottom should be nearly a flat plane where
it contacts the water and particularly straight and smooth in fore-and-aft direction.
a. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from
the side. When boat is planing, “hook” causes more lift on bottom near transom
and allows bow to drop, thus greatly increasing wetted surface and reducing boat
speed. “Hook” frequently is caused by supporting boat too far ahead of transom
while hauling on a trailer or during storage.
b. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom
is convex in fore-and-aft direction when viewed from the side, and boat has strong
tendency to porpoise.
c. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of motor’s gear
housing increase skin friction and cause speed loss. Clean surfaces when neces-
sary.
d. Gear Housing: If unit is left in the water, marine vegetation may accumulate over
a period of time. This growth MUST be removed from unit before operation, as it
may clog the water inlet holes in the gear housing and cause the engine to over-
heat.
Trim
TRIMMING OUTBOARD “OUT” (“UP”)
WARNING
Excessive trim “out” also may reduce the stability of some high speed hulls. To
correct instability at high speed, reduce the power GRADUALLY and trim the out-
board “in” slightly before resuming high speed operation. (Rapid reduction in
power will cause a sudden change of steering torque and may cause additional
momentary boat instability.)
1. Will lift bow of boat, generally increasing top speed.
2. Transfers steering torque harder to left on single outboard installations below 23 in.
(584mm) transom height.
90-884294 OCTOBER 2001 Page 1C-3

GENERAL INFORMATION
3. Increases clearance over submerged objects.

4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced water supply can cause overheating
resulting in engine damage.
TRIMMING OUTBOARD “IN” (“DOWN”) CHARACTERISTICS
WARNING
Excessive speed at minimum trim “in” may cause undesirable and/or unsafe
steering conditions. Each boat should be tested for handling characteristics after
any adjustment is made to the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or right (bow steer).
4. Transfers steering torque harder to right (or less to the left) on single outboard installa-
tions.
5. Improves planing speed acceleration (by moving trim adjustment bolt one hole closer
to transom).
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in addition-
al boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle
on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles
flow back and collapse when striking the surface of the propeller blade resulting in the ero-
sion of the propeller blade surface. If allowed to continue, eventual blade failure (break-
age) will occur.
VENTILATION
Ventilation occurs when air is drawn from the water’s surface (excessive trim out angle)
or from the engine exhaust flow (wrong propeller/propeller hardware installed or gear
case labyrinth seal worn) into the propeller blades. These air bubbles strike the propeller
blade surface and cause erosion of the blade surface. If allowed to continue, eventual
blade failure (breakage) will occur.
Page 1C-4 90-884294 OCTOBER 2001

GENERAL INFORMATION
Engine
DETONATION
Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine.
It can be otherwise described as a tin-like “rattling” or “plinking” sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark
plug has fired. Detonation creates severe shock waves in the engine, and these shock
waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston
rings or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 2-cycle application are as
follows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine RPM below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot – incorrect reach – cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
51115
Engine Compression
Engine compression should be checked with engine block warm, throttle shutter wide
open, all spark plugs removed and using a fully charged battery. Normal compression for
all cylinders should be 90 – 110 psi (616.3 – 753.5 kPa). Cylinders should not vary more
than 15 psi (103.4 kPa) between one another. A variance of more than 15 psi would indi-
cate the need for a power head inspection/disassembly.
90-884294 OCTOBER 2001 Page 1C-5

GENERAL INFORMATION
Following Complete Submersion

Salt Water Submersion
Due to the corrosive effect of salt water on internal engine components, complete disas-
sembly is necessary before any attempt is made to start the engine.
Submerged While Running
When an engine is submerged while running, the possibility of internal engine damage
is greatly increased. If, after engine is recovered and with spark plugs removed, engine
fails to turn over freely when turning flywheel, the possibility of internal damage (bent con-
necting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be dis-
assembled.
SUBMERGED ENGINE (FRESH WATER)
IMPORTANT: Engine should be run within 2 hours after recovery, or serious inter-
nal damage may occur. If unable to start engine in this period, disassemble engine
and clean all parts. Apply oil as soon as possible.
NOTE: If sand has entered the air intake on the engine, do not attempt to the start the
engine. Sand will cause internal engine damage. disassembly is required to clean all in-
ternal engine components of sand.
1. Recover engine from water as quickly as possible.
2. Remove cowling.
3. Clean the exterior of the outboard with fresh water.
4. Dry all wiring and electrical components using compressed air.
5. Drain water from fuel system as follows:
a. Disconnect remote fuel hose from engine.
b. EFI Models – Remove drain plug from vapor separator and drain fuel/water. Rein-
stall plug after draining.
c. EFI Models – Remove the water separating fuel filter and empty contents.
6. Remove spark plugs and get as much water as possible out of powerhead. Most water
can be eliminated by placing engine in a horizontal position (with spark plug holes
down) and rotating flywheel.
7. Pour alcohol into intake through air plenum (alcohol will absorbed water). Again rotate
flywheel.
8. Turn engine over (place spark plug openings down) and pour engine oil into throat of
carburetors while rotating flywheel to distribute oil throughout crankcase.
9. Again turn engine over and pour approximately one teaspoon of engine oil into each
spark plug opening. Again rotate flywheel to distribute oil in cylinders.
10. Remove and clean fuel pump assembly.
11. Dry all wiring and electrical components using compressed air.
12. Disassemble the engine starter motor and dry the brush contacts, armature and other
corrodible parts.
13. Reinstall spark plugs and fuel pump.
14. Drain water from the oil injection system as follows:
Page 1C-6 90-884294 OCTOBER 2001

GENERAL INFORMATION
a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard
side of engine.
b. Drain any water from hose and reconnect.
c. If water was present in hose, check for water in the remote oil tank. Drain tank if
water is present.
15. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
16. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should
be run within 2 hours after recovery of outboard from water, or serious internal dam-
age may occur. If unable to start engine in this period, disassemble engine and clean
all parts. Apply oil as soon as possible.
90-884294 OCTOBER 2001 Page 1C-7

GENERAL INFORMATION
Model 3 Liter Work/225 EFI/250 EFI Powerhead Front View
16
3
15
14 4
5
7
13
12
8
11 9
10
59029
1 - Throttle Plate Assembly 9 - VST Drain Plug

2 - Fuel Hose [43 psi ± 2 psi (296 kPa ± 14 kPa)] 10 - Smartcraft Harness Connector
to Fuel Rail 11 - Fuel Injector Harness Connector
3 - Fuel Pressure Test Point 12 - Oil Pump
4 - Electric Fuel Pump (inside VST) 13 - Oil Pump Harness Connector
5 - Vapor Separator Tank (VST) 14 - Electronic Control Module
6 - Oil Input Hose to VST 15 - Starter Motor
7 - Electric Fuel Pump Harness Connector 16 - Vapor Separator Tank (VST) Vent Hose
8 - Fuel Regulator Vacuum Hose
Page 1C-8 90-884294 OCTOBER 2001

GENERAL INFORMATION
Model 3 Liter Work/225 EFI/250 EFI Powerhead Starboard

View
22 3
24 2
23
21
25 1
26
20
19 27
28 9
8 4
5
29
18 6
17
10
14 13 12
7
16
15
11
1 - Starter Motor 16 - Detonation Sensor Connector (200 EFI Only)

2 - Vapor Separator Tank (VST) Vent Hose 17 - Thermostat Discharge Hose
3 - Throttle Plate Assembly 18 - #5 Cylinder
4 - Oil Pump Harness Connector 19 - #3 Cylinder
5 - Oil Pump 20 - Temperature Sensor (Engine Overheat)
6 - Fuel Injector Harness Connector 21 - #1 Cylinder
7 - SmartCraft Harness Connector 22 - Starboard Thermostat [120 °F (48.8 °C)]
8 - Oil Pump Output Hose 23 - Engine Harness Connector
9 - Negative Battery Cable 24 - Crank Position Sensor Connector
10 - Digital Speedometer Pressure Sensor 25 - Electronic Control Module (ECM)
11 - Trim Motor Bullet Connectors 26 - Digital Diagnostic Terminal Connector
12 - Trim DOWN Relay 27 - 20 Ampere Fuses (3); 15 Ampere Fuse (1)
13 - Trim UP Relay 28 - Positive Battery Cable
14 - Main Power Relay 29 - Starter Solenoid
15 - Poppet Valve Assembly
90-884294 OCTOBER 2001 Page 1C-9

GENERAL INFORMATION
Model 3 Liter Work/225 EFI/250 EFI Powerhead Port View

10
4 7
6
11
5
8
2 9
3
1
36 12
13
35
14
34
20 15
30 33
31
32
29 21
28
22 16
27
25
26
24
17
23
18
19
59030
1 - Fuel Pressure Test Point 19 - Block Pressure Hose
2 - Fuel Out to Fuel Rail 20 - Oil Reservoir [0.74 qt. (0.70 Liter)]
3 - Fuel Pressure Regulator 21 - 4 psi (27 kPa) Check Valve
4 - Throttle Plate Assembly 22 - Throttle Cable Anchor Pin
5 - Vapor Separator Vent Hose 23 - Shift Interrupt Switch
6 - Fuel Outlet to Fuel /Water Separator 24 - Shift Cable Slide
7 - Throttle Position Sensor 25 - Oil Inlet Hose
8 - Oil Reservoir Fill Cap 26 - Oil Filter
9 - Low Oil Sensor 27 - Water Sensor
10 - 60 Ampere Alternator 28 - Fuel/Water Separator
11 - Port Thermostat [120 °F (48.8 °C)] 29 - VST Drain Plug
12 - #2 Cylinder 30 - Electric Fuel Pump (inside Vapor Separator)
13 - Temperature Sender (Analog Gauge) 31 - Vapor Separator Tank (VST)
14 - Temperature Sensor (Digital) 32 - Idle Stop Screw
15 - #4 Cylinder 33 - Fuel Inlet Hose to Pulse Pump
16 - #6 Cylinder 34 - Wide Open Throttle Stop Screw
17 - Powerhead Flush Hose 35 - Pulse Pump Vacuum Hose
18 - Thermostat Discharge Hose 36 - Pulse Fuel Pump
Page 1C-10 90-884294 OCTOBER 2001

GENERAL INFORMATION
Model 3 Liter Work/225 EFI/250 EFI Powerhead Top View

22 1 2 3
21
20
4
19
5
18
6
7
15
8
14
17
12
16
10
13 11 59024
1 - 60 Ampere Alternator 12 - Throttle Plate Adjustment Screw (Sealed at

2 - Port Thermostat Discharge Hose Factory)
3 - Port Thermostat [120 °F (48.8 °C)] 13 - Throttle Plate Assembly
4 - Low Oil Sensor 14 - Manifold Air Pressure (MAP) Sensor
5 - Oil Reservoir Fill Cap 15 - Air Temperature Sensor Harness Connector
6 - Throttle Position Sensor 16 - Air Temperature Sensor
7 - Pulse Fuel Pump Vacuum Hose 17 - Starter Motor
8 - Fuel Outlet Hose to Fuel/Water Separator 18 - Crank Position Sensor
9 - Vapor Separator Vent Hose 19 - Belt Tensioner
10 - Vapor Separator Tank (VST) 20 - Belt Tension Release Slot
11 - Fuel Hose to Fuel Rail [43 psi ± 2 psi 21 - Starboard Thermostat [120 °F (48.8 °C)]
(296 kPa ± 14 kPa)] 22 - Starboard Thermostat Discharge Hose
90-884294 OCTOBER 2001 Page 1C-11

GENERAL INFORMATION
Model 3 Liter Work/225 EFI/250 EFI Powerhead Aft View

1
31
16
3 4
30
5
15
17 6
29 18
7
28 14
19
20
8
13
27
21
9
12
25
26
10
24 22
11
23 59034
1 - 60 Ampere Alternator 17 - #2 Ignition Coil
2 - Starboard Thermostat [120 °F (48.8 °C)] 18 - Temperature Sensor (Analog)
3 - Starboard Temperature Sensor (Digital) Har- 19 - Port Temperature Sensor (Digital)
ness Connector 20 - #4 Ignition Coil
4 - #1 Cylinder 21 - #6 Ignition Coil
5 - Starboard Temperature Sensor (Digital) 22 - Cylinder Block Flush Hose
6 - #3 Cylinder 23 - Flush Adaptor Plug
7 - Starboard Detonation Sensor (200 Work 24 - Block Pressure Hose
Only) 25 - Detonation Sensor Harness Connector
8 - #5 Cylinder 26 - #6 Cylinder
9 - Detonation Sensor Harness Connector 27 - Port Detonation Sensor (200 Work Only)
10 - Starboard Thermostat Discharge Hose 28 - #4 Cylinder
11 - Tell–Tale Hose 29 - #2 Cylinder
12 - #5 Ignition Coil 30 - Port Temperature Sensor (Digital) Harness
13 - #3 Ignition Coil Connector
14 - #1 Ignition Coil 31 - Port Thermostat [120 °F (48.8 °C)]
15 - Ignition Coil Harness Connector
16 - Water Pressure Sensor
Page 1C-12 90-884294 OCTOBER 2001

GENERAL INFORMATION
Painting Procedures
Color Impregnated Top Cowls
The Model Year 2002 3 Liter V-6 EFI, 2.5 Liter Optimax and 3 Liter Optimax top cowls are
constructed of a new material in which the exterior color is impregnated to a depth of
approximately 1/16 in. (1.58 mm).
MAINTENANCE
The cowl can be cleaned using a mild non-abrasive soap. The surface luster can be pre-
served by using a non-abrasive automotive polish (polish designed for clear coat finishes)
and buffing with a terry cloth type towel. Abrasive type polishes or cleaners should not be
used as they will damage the cowl finish.
REPAIR
Light scratches should be removed by using a non-abrasive automotive polish (polish de-
signed for clear coat finishes) and buffing with a terry cloth type towel. Abrasive type polish-
es should not be used as they will damage the cowl finish.
Medium scratches can be removed by using 600 to 1000 grit sandpaper. The surface luster
can then be restored by using a non-abrasive automotive polish (polish designed for clear
coat finishes) and buffing with a terry cloth type towel. Abrasive type polishes should not
be used as they will damage the cowl finish.
For deep scratches or for those that penetrate through the exterior finish, automotive body
filler can be used to fill the damaged area. 600 to 1000 grit sand paper should be used to
smooth the surface area. It is then recommended that the entire cowl then be painted, to
achieve an even luster, using normal Mercury Marine approved paint and procedures.
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne par-
ticles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite,
disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover
or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver’s Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Mercury/Quicksilver’s EDP Propeller Black.
90-884294 OCTOBER 2001 Page 1C-13

GENERAL INFORMATION
GEAR HOUSINGS
The following procedures should be used in refinishing gear housings. This procedure will
provide the most durable paint system available in the field. The materials recommended
are of high quality and approximate marine requirements. The following procedure will
provide a repaint job that compares with a properly applied factory paint finish. It is recom-
mended that the listed materials be purchased from a local Ditzler Automotive Finish Sup-
ply Outlet. The minimum package quantity of each material shown following is sufficient
to refinish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove
paint blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not prop-
erly adhere to the surface nor will the coating be sufficiently thick to resist future
paint blistering.
6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufac-
turers instructions, allowing proper induction period for permeation of the epoxy prim-
er and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coat-
ing assemblies.
8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and
DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four
colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.
CAUTION
Be sure to comply with instructions on the label for ventilation and respirators.
Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off
for five minutes and apply another even coat of one half to one mil film thickness.
This urethane paint will dry to the touch in a matter of hours, but will remain sensi-
tive to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode.
10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to
maintain good continuity circuitry between trim tab and gear housing.
Page 1C-14 90-884294 OCTOBER 2001

GENERAL INFORMATION
Decal Application
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while remov-
ing old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for “Wet” Application
NOTE: The following decal installation instructions are provided for a “Wet” installation.
All decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia. DO NOT use a soap that con-
tains petroleum based solvents.
** Automotive Body Filler Squeegee
SERVICE TIP: Placement of decals using the “Wet” application will allow time to
position decal. Read entire installation instructions on this technique before pro-
ceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct
sunlight. Air and surface temperature should be between 60 °F (15 °C) and 100 °F
(38 °C) for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean applica-
tion surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface
thoroughly with clean water.
90-884294 OCTOBER 2001 Page 1C-15

GENERAL INFORMATION
DECAL APPLICATION
1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as
wetting solution.
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal
installation. This will ensure that the vinyl decal keeps it’s shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing
from “adhesive side” of decal.
3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed
wetting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position pre-wetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting
solution with overlapping strokes to the outer edge of the decal. Continue going over
the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface.
7. Wipe decal surface with soft paper towel or cloth.
8. Wait 10 - 15 minutes.
9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at
a 180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with
stick pin and press out the entrapped air or wetting solution with your thumb (moving to-
ward the puncture).
Page 1C-16 90-884294 OCTOBER 2001

OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation D
Table of Contents
Installation Specifications . . . . . . . . . . . . . . . . . 1D-1 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Counter Rotation Outboards . . . . . . . . . . . 1D-9
Installing Outboard to Boat Transom . . . . . . . 1D-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-10
Determining Recommended Outboard Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12
Mounting Height . . . . . . . . . . . . . . . . . . . . . . 1D-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12
Installing Outboard . . . . . . . . . . . . . . . . . . . . . . 1D-3 Front Clamp Reassembly . . . . . . . . . . . . . . 1D-13
Drilling Outboard Mounting Holes . . . . . . . 1D-3 Oil Injection Set-Up . . . . . . . . . . . . . . . . . . . . . . 1D-14
Securing Outboard To Boat Transom . . . . 1D-4 Installing Remote Oil Tank . . . . . . . . . . . . . 1D-14
Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Priming the Oil Pump . . . . . . . . . . . . . . . . . 1D-16
Electrical, Hoses and Control Cables . . . . . . 1D-6 Priming Procedure – Method 1 . . . . . . . . . 1D-17
Installation Note . . . . . . . . . . . . . . . . . . . . . . 1D-6 Purging Air From the Engine Oil
Remote Wiring Harness . . . . . . . . . . . . . . . 1D-6 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Trim In Stop Adjustment . . . . . . . . . . . . . . . . . . 1D-18
Fuel Hose Connection . . . . . . . . . . . . . . . . 1D-8 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-19
Oil Hose Connections . . . . . . . . . . . . . . . . . 1D-8 Models Without Power Steering . . . . . . . . 1D-19
Speedometer Tubing Connection . . . . . . . 1D-8 Models With Power Steering . . . . . . . . . . . 1D-19
Water Pressure Tubing Connection . . . . . 1D-8
Installation Specifications
a
a
b
a – Transom Opening – Minimum

Single Engine – 33-3/8 in. (848 mm)
Dual Engines – 59-3/4 in. (1518 mm)
b – Engine Center Line For Dual Engine
26 in. (660mm) Minimum
Lifting Outboard
Electric Start Models – Remove plastic cap from flywheel hub. Thread lifting ring into
flywheel a minimum of 5 turns. Replace plastic cap after installation.
50048
90-884294 OCTOBER 2001 Page 1D-1

Installing Outboard to Boat Transom

Determining Recommended Outboard Mounting Height
26 in.
(660mm)
25 in. b
(635mm)
24 in.
(609mm)
e
Outboard 23 in.
Mounting
(584mm) c
Height (See
NOTE Below) 22 in. b
(560mm)
e
21 in.
(533mm) a
20 in. d
(508mm)
19 in.
(482mm)
NOTE: Add 5 in. (127mm) for XL mod- 10 20 30 40 50 60 70 80

els and 10 in. (254mm) for XXL models Maximum Boat Speed Anticipated
to listed outboard mounting height.
NOTICE TO INSTALLER:
1. The outboard should be mounted high enough on the transom so that the exhaust re-
lief hole will stay at least 1 in. (25.4 mm) above the water line when the engine is run-
ning at idle speed. This will prevent exhaust restriction.
2. The mounting height (e) of the outboard must not exceed 25 in. (635 mm) for L mod-
els, 30 in. (762 mm) for XL models and 35 in. (889 mm) for XXL models. Mounting the
outboard higher may cause damage to the gear case components.
a. This solid line is recommended to determine the outboard mounting height. In-
creasing the height of outboard generally will provide the following: 1) Less steer-
ing torque, 2) more top speed, 3) greater boat stability, but, 4) will cause more prop
“break loose” which may be particularly noticeable when planing off or with heavy
load.
b. These broken lines represent the extremes of known successful outboard mount-
ing height dimensions.
c. This line may be preferred to determine outboard mounting height dimension, if
maximum speed is the only objective.
d. This line may be preferred to determine outboard mounting height dimension for
dual outboard installation.
e. Outboard mounting height (height of outboard transom brackets from bottom of
boat transom). For heights over 22 in. (560mm), a propeller, that is designed for
surfacing operation is usually preferred.
Page 1D-2 90-884294 OCTOBER 2001

Installing Outboard
Drilling Outboard Mounting Holes
1. Attach (tape) engine mounting template (located with the installation manual) to boat
transom.
IMPORTANT: If using Transom Drilling Fixture (91-98234A2), use drill guide holes
marked “A” when drilling outboard mounting holes.
a - Centerline of Transom
b - Transom Drilling Fixture (91-98234A2)
2. Mark and drill four 17/32 in. (13.5mm) mounting holes.
90-884294 OCTOBER 2001 Page 1D-3

Securing Outboard To Boat Transom

1. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding
and install outboard to the nearest recommended mounting height.
2. Fasten outboard with provided mounting hardware shown.
d
b
a - 1/2 in. Diameter Bolts d - Flat Washers(4)

(4) e - Marine Sealer - Apply to
b - Flat Washers(4) Shanks of Bolts, Not
c - Locknuts (4) Threads
Steering Cable
STARBOARD SIDE ROUTED CABLE
1. Lubricate O-ring seal and entire cable end.
95
95 2-4-C Marine Lubricant with Teflon
Page 1D-4 90-884294 OCTOBER 2001

2. Insert steering cable into tilt tube.
57832
3. Torque nut to 35 lb. ft. (47.5 N·m).
57833
Steering Link Rod

1. Install steering link rod per illustration.
b 57834
a - Special Bolt (10-849838) Torque to 20 lb-ft (27 N·m)

b - Nylon Insert Locknut (11-826709113) Torque to 20 lb-ft (27 N·m)
c - Flat Washer (2)
d - Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then
Back Nut Off 1/4 Turn
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” – Part Number 10-849838)
and self locking nuts (“b” & “c” – Part Number 11-826709113). These locknuts must
never be replaced with common nuts (non locking) as they will work loose and vi-
brate off freeing the link rod to disengage
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown
overboard exposing them to serious injury or death.
90-884294 OCTOBER 2001 Page 1D-5

Electrical, Hoses and Control Cables

IMPORTANT: Warning Horn Requirement – The remote control or key switch as-
sembly must be wired with a warning horn. This warning horn is used with the en-
gine warning system.
Installation Note
Open the front clamp assembly.
57841
Remote Wiring Harness

1. Connect wiring. Place harness into the holder.
BLU/WHT BLU/WHT
GRN/WHT GRN/WHT a
TAN TAN b
BRN/WHT BRN/WHT
c
59027
a - Power Trim Connections

b - Wire Connection For Non SmartCraft Water Temp Gauge
c - Connection For Non SmartCraft Analog Trim Gauge
d - Harness Holder (Located in Cowl) – Place Wiring Harness and Battery
Cables into Holder
Page 1D-6 90-884294 OCTOBER 2001

Battery Cables
SINGLE OUTBOARD
(+)
b
c
(–)
a - RED Sleeve (Positive)

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

Fuel Hose Connection

Fuel Hose Size – Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate
fuel line/fuel tank pickup for each engine.
Fasten remote fuel hose to fitting with hose clamp.
Oil Hose Connections
Connect the remote oil hoses to the engine hose connections as shown. Fasten hose con-
nections with sta-straps.
Speedometer Tubing Connection
This outboard has a speedometer water pick-up located in the leading edge of the gear
case. If you want to use this water pickup for the speedometer, connect the water tubing
as shown.
Water Pressure Tubing Connection
If the boat is equipped with a water pressure gauge, make the water connection to this
tubing as shown.
h c
d e
f
g
i
j
l k b a
a - Remote Fuel Hose

b - Hose Clamp – Secure Remote Fuel Hose
c - Oil Hoses with Blue Stripe - Secure With Sta-Strap
d - Oil Hoses without Blue Stripe - Secure With Sta-Strap
e - Sta-Strap (2) - Secure Oil Hoses
f - Speedometer Water Pickup Tubing (Black Color)
g - Water Pressure Tubing (Gray Color)
h - Coupler – Push In on End of Coupler to Disconnect Plug or Tubing
i - Plug – Remove when Making Coupler Connection
j - Barb Hose Fitting (2) Provided with Outboard – Install this fitting into Coupler, if
a Rubber Hose Connection is Required
k - Speedometer Hose – Insert the barb hose fitting (j) into Coupler and Connect
Hose
l - Water Pressure Tube – Insert into coupler, pull on tube to verify that it is locked
Page 1D-8 90-884294 OCTOBER 2001

Shift Cable
Install cables into the remote control following the instructions provided with the remote
control.
NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move
when the remote control handle is moved out of neutral.
COUNTER ROTATION OUTBOARDS
Counter rotating (left hand) gear cases can be identified by a “L” stamped into the end of
the propeller shaft.
The Quicksilver Dual Engine Console Mount Control, P/N 88688A22 or 88688A52, is re-
quired to shift the counter rotation outboard. The installation instructions shipped with the
control explain the procedure required to connect this control to a counter rotation out-
board.
IMPORTANT: If the counter rotation outboard is rigged similar to a standard rota-
tion outboard OR if a standard rotation outboard is rigged similar to a counter rota-
tion outboard, the reverse gear and bearing in the gear case must function as for-
ward gear. THE REVERSE GEAR/BEARING ARE NOT DESIGNED TO CARRY THE
SUSTAINED LOADS THAT ARE GENERATED WHEN RUNNING UNDER CONSTANT
HIGH RPM AND THRUST CONDITIONS.
OUTBOARD SHIFTING DIRECTION
On counter rotation outboards, the shift linkage moves in the opposite direction compared
to a standard rotation outboard.
STANDARD ROTATION GEAR OUTBOARDS
Forward Gear Reverse Gear

Reverse Gear Forward Gear
90-884294 OCTOBER 2001 Page 1D-9

Installation
IMPORTANT: Step 1 must be followed for proper adjustment of the shift cable.
1. Locate the center point of the slack or lost motion that exists in the shift cable as fol-
lows:
a. Move the remote control handle from neutral into forward and advance the handle
to full speed position. Slowly return the handle back to the neutral. Place a mark
(a) on the cable against the cable end guide.
b. Move the remote control handle from neutral into reverse and advance the handle
to full speed position. Slowly return the handle back to the neutral. Place a mark
(b) on the cable against the cable end guide.
c. Make a center mark (c), midway between marks (“a” and “b”). Align the cable end
guide against this center mark when installing cable to the engine.
STANDARD ROTATION OUTBOARDS
a

a
d. Return remote control handle to neutral. The propeller should turn freely without
drag. If not, adjust barrel closer to cable end guide. Repeat steps a thru d.
Page 1D-10 90-884294 OCTOBER 2001

2. Position remote control and outboard into neutral.

N
3. Slide the shift cable anchor pin forward until resistance is felt, then slide anchor pin
toward rear until resistance is felt. Center the anchor pin between resistance points.
a - Anchor Pin
4. Align the shift cable end guide with the center mark as instructed in Step 1.
5. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder.
6. Secure shift cable with shift cable retainer.
a c
d
a - Cable Barrel c - Locknut – Tighten locknut

b - Shift Cable Retainer then back off locknut 1/4 turn
d - Nylon Washer
7. Check shift cable adjustments as follows:
a. With remote control in forward, the propshaft should lock solidly in gear. If not, ad-
just cable barrel closer to cable end guide.
b. Shift remote control into neutral. The propshaft should turn freely without drag. If
not, adjust barrel away from cable end guide. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propshaft should lock
solidly in gear. If not, adjust barrel away from cable end guide. Repeat steps a
through c.
drag. If not, adjust barrel closer to cable end guide. Repeat steps a through d.
90-884294 OCTOBER 2001 Page 1D-11

Throttle Cable
INSTALLATION
1. Position remote control into neutral.
N
2. Attach throttle cable to the throttle lever. Secure with washer and locknut.
a - Nylon Washer
b - Locknut – Tighten locknut then back off locknut 1/4 turn
3. Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw
against the stop.
b
a - Cable Barrel – Adjust To Hold Idle Stop Screw Against Stop

b - Idle Stop Screw
Page 1D-12 90-884294 OCTOBER 2001

4. Check throttle cable adjustment as follows:

a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to
rotate the propeller shaft while shifting into reverse.
F N R
b. Return remote control to neutral. Place a thin piece of paper between idle adjust-
ment screw and idle stop. Adjustment is correct when the paper can be removed
without tearing, but has some drag on it. Readjust cable barrel if necessary.
IMPORTANT: The idle stop screw must be touching the stop.
b
a
a - Idle Stop Screw b - Idle Stop
5. Lock the barrel holder in place with the cable latch.
Front Clamp Reassembly

IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables,
fuel hose, and oil hoses routed between clamp and engine attachment point, to re-
lieve stress and prevent hoses from being kinked or pinched.
1. Place the neoprene wrap over the wiring, hoses, and control cables as shown.
2. Fasten clamp together with two screws.
b
a - Neoprene Wrap b - Screw (2)
90-884294 OCTOBER 2001 Page 1D-13

Oil Injection Set-Up

CAUTION
Be careful not to get dirt or other contamination in tanks, hoses or other compo-
nents of the oil injection system during installation.
Installing Remote Oil Tank

1. The remote oil tank should be installed in an area in the boat where there is access
for refilling.
The tank should be restrained to keep it from moving around, causing possible damage.
An acceptable means of restraining the tank would be the use of eye bolts and an elastic
retaining strap about the mid-section of the tank taking care that any metal hooks do not
puncture the tank.
Keep in mind, when installing in tight areas, that this tank will be under pressure when the
engine is operating and will expand slightly.
2. Oil hoses when routed through engine well, must be able to extend to the hose fittings
on engine.
3. Oil hoses must be arranged so they cannot become pinched, kinked, sharply bent or
stretched during operation of the engine.
Page 1D-14 90-884294 OCTOBER 2001

Filling
Mercury Marine recommends the use of “Mercury Precision Premium Plus ”or “Quicksilver Pre-
mium Plus” 2-Cycle Oil NMMA Certified TC-W3.
The Premium Plus Oil is specially formulated and tested to not only maintain a high level
of performance but also increase the durability of the engine. This special blend, developed
by Mercury Marine, contains more than twice the additives used in standard blends and
ensures the greatest protection for your engine.
Periodically consult with your dealer to get the latest gasoline and oil recommendations.
If “Mercury Precision Premium Plus” or “Quicksilver Premium Plus” Outboard Oil is not
available, you may substitute another brand of 2-Cycle outboard oil that is NMMA Certified
TC-W3. Nationally recognized brands are recommended. Continued use of inferior 2-Cycle
outboard oil can dramatically reduce engine life. Damage from use of inferior oils that are
not NMMA Certified TC-W3 will not be covered under the limited warranty.
1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance
Manual. Tighten fill cap.
a - Remote Oil Tank b - Fill Cap
2. Remove cap and fill engine oil reservoir with oil. Reinstall the fill cap.
b
a - Engine Oil Reservoir b - Fill Cap
90-884294 OCTOBER 2001 Page 1D-15

Priming the Oil Pump

IMPORTANT: Before starting engine for the first time, prime the oil injection pump.
Priming will remove any air that may be in the pump, oil supply hose, or internal passages.
NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed,
it is recommended all air be purged from oil pump/oil lines using gearcase leakage tester
(FT-8950). Connect the leakage tester to the inlet t-fitting on the onboard oil reservoir.
While clamping off the inlet hose, manually pressurize the reservoir to 10 psi. Using the
Digital Diagnostic Terminal 91-823686A2, activate the oil pump prime sequence. Main-
tain the 10 psi pressure throughout the auto prime sequence. When the auto prime is
completed, remove the leakage tester and refill the onboard oil reservoir.
59033
Priming the oil pump (filling pump and hoses using pressure) is required on new or rebuilt
power heads and any time maintenance is performed on the oiling system that allows air
into the oil system.
There are three methods for priming the oil pump:
METHOD 1 – SHIFT SWITCH ACTIVATION PRIME
This method does three things:
a. Fills the oil pump, oil supply hose feeding pump and oil hoses going to the crank-
case and air compressor.
b. Activates break-in oil ratio.
c. Initiates a new 120 minute engine break-in cycle.
Refer to priming procedure following.
METHOD 2 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – RESET BREAK-IN
This method is the same as Method 1, except the run history and fault history are erased
from the ECM.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part. No. 91-880118A2.
METHOD 3 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – OIL PUMP PRIME
This method fills the oil pump, oil supply hose feeding pump, and oil hose going to vapor
separator.
tic Software Cartridge Part. No. 91-880118A2.
Page 1D-16 90-884294 OCTOBER 2001

Conditions Requiring Priming the Oil Pump

Condition Priming Procedure
New engine Use Method 1 or 2
Rebuilt Powerhead Use Method 1 or 2
New Powerhead Use Method 1 or 2
Oil system ran out of oil Use Method 3
Oil drained from oil supply hose feeding pump Use Method 3
Oil pump removed Use Method 3
Oil injection hoses drained Use Method 3
Priming Procedure – Method 1

METHOD 1 – SHIFT SWITCH ACTIVATION PRIME PROCEDURE
Before starting engine for the first time, prime the oil pump. Priming will remove any
air that may be in the pump, oil supply hose, or internal passages.
b a
a - Oil Injection Pump b - Oil Supply Hose
CAUTION
To prevent damage to the fuel pump, fill the engine fuel system with fuel. Other-
wise the fuel pump will run without fuel during the priming process.
Prime the oil injection pump as follows:
1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it feels firm.
2. Turn the ignition key switch to the “ON” position.
3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F
NOTE: It may take a few minutes for the pump to complete the priming process.
90-884294 OCTOBER 2001 Page 1D-17

Purging Air From the Engine Oil Reservoir

1. Loosen the fill cap on the engine oil reservoir.
2. Start the engine. Run the engine until all the air has been vented out of the reservoir
and oil starts to flow out of the reservoir. Re-tighten fill cap.
a
a - Fill Cap
Trim In Stop Adjustment

Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further “in” or “under”. This
greater trim “under” capability is desirable to improve acceleration, reduce the angle and
time spend in a bow high boat during planing off, and in some cases, may be necessary
to plane off a boat with aft live wells, given the variety of available propellers and height
range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position
to avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering”
or “over steering” and inefficiently consumes horsepower. In this condition, if attempting
a turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may
result.
In rare circumstances, the owner may decide to limit the trim under. This can be accom-
plished by purchasing a stainless steel tilt pin (17-49930A1) and inserting it through what-
ever pin hole is desired. The non-stainless steel shipping bolt should not be used in this
application other than on a temporary basis.
WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim
position as soon as boat is on plane to avoid possible ejection due to boat spin-
out. Do not attempt to turn boat when engine is trimmed extremely under or in.
a - Tilt Pin
Page 1D-18 90-884294 OCTOBER 2001

Trim Tab Adjustment

Propeller steering torque may cause your boat to pull in one direction. This steering torque
results from your outboard not being trimmed so the propeller shaft is parallel to the water
surface. The trim tab can help compensate for this steering torque and can be adjusted
within limits to reduce any unequal steering effort.
Models Without Power Steering
Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat
left and right and note the direction the boat turns more easily.
If adjustment is necessary, loosen trim tab bolt until trim tab moves freely (does not rub
against locking ridges). DO NOT strike tab to make adjustments. Make small adjustments
at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the
left. If the boat turns more easily to the right move the trailing edge of trim tab to the right.
Position trim tab in one of the locating grooves BEFORE tightening bolt to prevent dam-
age to holding mechanism. Torque bolt to 40 lb-ft (54 Nm) and retest.
Models With Power Steering
Trim tab adjustment is not required. The trailing edge of the trim tab should be set straight
back.
90-884294 OCTOBER 2001 Page 1D-19

IGNITION
ELECTRICAL
Section 2A - Ignition
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Coil Ohms Test . . . . . . . . . . . . . . . . 2A-27 2
Ignition Coil Ohms Test . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP)
2A-2 Manifold Absolute Pressure (MAP) Sensor
Ohms Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-28
A
Sensor Ohms Test . . . . . . . . . . . . . . . . . . . . 2A-3 Idle Speed Control . . . . . . . . . . . . . . . . . . . . 2A-28
Port and Starboard Temperature Sensors; RPM-Limit Circuit . . . . . . . . . . . . . . . . . . . . . 2A-28
Air Temperature Sensor . . . . . . . . . . . . . . . 2A-4 EFI Detonation Control System
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 (200 Work Model only) . . . . . . . . . . . . . . . . 2A-29
Coil Plate Assembly . . . . . . . . . . . . . . . . . . . . . 2A-8 Detonation Circuit Test . . . . . . . . . . . . . . . . 2A-29
Electrical Plate Assembly . . . . . . . . . . . . . . . . . 2A-10 Ignition Component Removal and Installation 2A-30
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-14 Flywheel Removal . . . . . . . . . . . . . . . . . . . . 2A-30
Ignition Component Description . . . . . . . . . . . 2A-15 Flywheel Installation . . . . . . . . . . . . . . . . . . 2A-31
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Coil Removal . . . . . . . . . . . . . . . . . 2A-31
Charging System Alternator . . . . . . . . . . . . 2A-16 Ignition Coil Installation . . . . . . . . . . . . . . . . 2A-32
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Electronic Control Module Removal . . . . . 2A-32
Electronic Control Module . . . . . . . . . . . . . 2A-17 Electronic Control Module Installation . . . 2A-32
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-18 Temperature Sensor Removal . . . . . . . . . 2A-33
Crank Position Sensor . . . . . . . . . . . . . . . . 2A-18 Engine Head Temperature Sensor
Throttle Position Sensor (TPS) . . . . . . . . . 2A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-33
Throttle Position Sensor (TPS) Air Temperature Sensor Removal . . . . . . 2A-34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-19 Air Temperature Sensor Installation . . . . . 2A-34
Cylinder Head Temperature Sensor . . . . . 2A-20 Manifold Absolute Pressure (MAP)
Air Temperature Sensor . . . . . . . . . . . . . . . 2A-20 Sensor Removal . . . . . . . . . . . . . . . . . . . . . 2A-34
Port and Starboard Temperature Sensors; Manifold Absolute Pressure (MAP) Sensor
Air Temperature Sensor . . . . . . . . . . . . . . . 2A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-34
Manifold Absolute Pressure (MAP) Crank Position Sensor Removal . . . . . . . . 2A-35
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-22 Crank Position Sensor Installation . . . . . . 2A-35
Ignition Troubleshooting and Fault Chart . . . 2A-23
90-884294 OCTOBER 2001 Page 2A-1

IGNITION
Specifications
SYSTEM Spark Plug Type NGK BPZ8HS-10
Ignition Coil Ohms Test
58903
BLACK METER LEAD

Secondary EST EST Low Secondary Primary Battery +
Tower PIN A PIN B Low Ground Pin E
Pin C Pin D
Secondary X No No 850 – 1200 No No
Tower Continuity Continuity ohm Continuity Continuity
EST No X 8500 – No 29000 – 11000 –
PIN A Continuity 12000 Continuity 39000 21000
ohm ohm ohm
EST Low No 8500 – X No 39000 – 21000 –
RED PIN B Continuity 12000 Continuity 49000 31000
METER ohm ohm ohm
LEAD Secondary 850 – 1200 No No X No No
Low ohm Continuity Continuity Continuity Continuity
Pin C
Primary No 20000 – 31000 – No X 13000 –
Ground Continuity 30000 41000 Continuity 23000
Pin D ohm ohm ohm
Battery + No 11000 – 21000 – No 13000 – X
Pin E Continuity 21000 31000 Continuity 23000
ohm ohm ohm
EST = Electronic Spark Trigger

EST Low = Return ground path for the trigger signal to the ECM
Page 2A-2 90-884294 OCTOBER 2001

IGNITION
Manifold Absolute Pressure (MAP) Sensor Ohms Test
58904
BLACK METER LEAD

BLK/ORG YEL PPL/YEL
PIN A PIN B PIN C
BLK/ORG X 95000 – 105000 3900 – 4100
PIN A ohm ohm
RED METER
LEAD YEL 95000 – 105000 X 95000 – 105000
PIN B ohm ohm
PPL/YEL 3900 – 4100 95000 – 105000 X
PIN C ohm ohm
Crank Position Sensor Resistance Test

Between 2 pins of Crank Position Sensor 300 – 350 ohms
Connector
Throttle Position Sensor Specifications

Idle 0.19 – 1.0 VDC
Wide Open Throttle 3.45 – 4.63 VDC
90-884294 OCTOBER 2001 Page 2A-3

IGNITION
Port and Starboard Temperature Sensors; Air Temperature Sensor

An ohms test of the temperature sensors would be as follows:
Disconnect temperature sensor harness and check continuity with digital or analog ohm-
meter test leads between both connector pins. With engine at temperature (F°) indicated,
ohm readings should be as indicated ±10%. There should be no continuity between each
connector pin and ground.
Temperature Sensor Specifications

Fahrenheit Centigrade OHMS
257 125 340
248 120 390
239 115 450
230 110 517
221 105 592
212 100 680
203 95 787
194 90 915
185 85 1070
176 80 1255
167 75 1480
158 70 1752
149 65 2083
140 60 2488
131 55 2986
122 50 3603
113 45 4370
104 40 5327
95 35 6530
86 30 8056
77 25 10000
68 20 12493
59 15 15714
50 10 19903
41 5 25396
32 0 32654
14 –10 55319
5 –15 72940
Page 2A-4 90-884294 OCTOBER 2001

IGNITION
Special Tools
1. DMT 2000 Digital Tachometer Multimeter 91-854009A1
2. Cylinder Timing Decal 91-853883-1

NOTE: Decal can be used to help troubleshoot ignition timing by determining the timing
of individual cylinders.
3. Digital Diagnostic Terminal (DDT) 91-823686A2
4. Software Cartridge 91-880118A2
90-884294 OCTOBER 2001 Page 2A-5

IGNITION
5. DDT Reference Manual 90-881204--1
6. Adaptor Harness 84-822560A5
7. Spark Gap Tester 91-850439
55117
8. Timing Light 91-99379
9. Crank Shaft Protector Cap 91-24161
Page 2A-6 90-884294 OCTOBER 2001

IGNITION
10. Flywheel Puller 91-849154T1
55117
11. Flywheel Holder 91-52344
12. Heat Lamp 91-63209
90-884294 OCTOBER 2001 Page 2A-7

IGNITION
Coil Plate Assembly
Page 2A-8 90-884294 OCTOBER 2001

IGNITION
Coil Plate Assembly

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 COIL MOUNTING PLATE
2 6 IGNITION COIL
3 12 SCREW 100 11.3
4 6 HI-TENSION CABLE
5 12 BOOT
6 6 SPARK PLUG (NGK#BPZ8HS10) 20 27
7 1 COIL HARNESS
8 2 CABLE
9 3 SCREW (M6 x 10) 60 7
10 3 WASHER
11 4 GROMMET
12 4 WASHER
13 4 BUSHING
14 4 SCREW (.312-18 x 1-1/4) 20 27
15 1 SENSOR-BLOCK PRESSURE [0-50 psi (0-345 kPa)]
16 1 FITTING
17 1 CLIP
18 AR STA-STRAP
19 1 TUBING [18 IN. (45.7 CM)]
20 2 WASHER
21 1 CLIP
90-884294 OCTOBER 2001 Page 2A-9

IGNITION
Electrical Plate Assembly
Page 2A-10 90-884294 OCTOBER 2001

IGNITION

TORQUE
REF.
REF
1 1 SOLENOID MOUNTING PLATE
2 1 SOLENOID
3 2 GROMMET
4 5 SCREW (M6 x 25) 35 4
5 2 BUSHING
6 3 RELAY ASSEMBLY
7 3 DECAL-TRIM RELAY
8 3 BRACKET
9 3 BUSHING
10 3 GROMMET
11 1 ENGINE HARNESS
12 1 FUSE (3 – 20 AMP) (1 – 15 AMP)
13 1 FUSE COVER
14 1 SCREW (M6 x 14)
15 1 J-CLIP
16 1 GROUND WIRE (BLACK)
17 3 SCREW (M6 x 12) 100 11.3
18 1 TRIM HARNESS
19 1 HARNESS-SMARTCRAFT
20 1 PLUG (MALE)
21 1 WASHER
22 2 CAP NUT
23 1 NUT (5/16-18) 50 5.5
24 1 NUT (10-32)(BRASS) 8 0.9
25 2 LOCKWASHER
26 1 CLIP
27 1 CLIP
28 1 ECM
29 3 SCREW (M6 x 25) 70 8
30 3 BUSHING
31 3 GROMMET
32 3 WASHER
33 1 CLIP
34 3 SCREW (M6 x 10)
35 1 SENSOR-FUEL PRESSURE
36 1 FITTING-STRAIGHT
37 1 CLIP
38 1 BRACKET
39 1 GROMMET
40 1 BUSHING
41 1 SCREW (M6 x 25)
42 AR STA-STRAP
43 1 CABLE
44 1 SCREW (M8 x 20) 18 24.5
90-884294 OCTOBER 2001 Page 2A-11

IGNITION
Page 2A-12 90-884294 OCTOBER 2001

IGNITION

TORQUE
REF.
REF
45 1 BATTERY CABLE
46 1 CONNECTOR
47 2 CONNECTOR (6 PIN PLUG)
48 5 INSULATOR BOOT (RED)
49 2 CABLE (YELLOW/BLACK)
50 1 SCREW (M6 x 35) 35 4
90-884294 OCTOBER 2001 Page 2A-13

IGNITION
Theory of Operation
When the ignition key switch is turned to the “RUN” position, battery voltage is applied to
both the Electronic Control Module (ECM) through the purple wire and the main power
relay through the red/purple wire. As the ECM receives the “RUN” signal, it internally com-
pletes the ground circuit of the main relay, for a short period of time, energizing the fuel
pump for start-up. As the engine is cranked with the starter motor, the ECM receives the
run signal from the Crank Position Sensor (CPS) and completes the ground circuit to the
main relay for engine operation. With the main relay closed (completed circuit), D.C. cur-
rent from the battery/charging system is transferred through the 20 ampere main relay
fuse to the positive terminal of all ignition coil primary windings. The negative terminals
of the ignition coil primaries are connected to engine ground through the coils’ internal
driver, which is triggered by the ECM. With the coil drivers closed, a electric magnetic field
is allowed to build up within the ignition coil. As the flywheel rotates, the CPS senses the
location of the 54 teeth on the flywheel and supplies the trigger signal information to the
ECM. The ECM utilizes the CPS information and determines when to remove the trigger
signal from the coil driver of each ignition coil. The coil driver then opens the coil primary
ground circuit, allowing it’s magnetic field to rapidly collapse across the coil secondary
winding, which induces a high voltage charge (50,000 volts) that fires the spark plug.
Page 2A-14 90-884294 OCTOBER 2001

IGNITION
Ignition Component Description

Fuses
The electrical wiring circuits on the outboard are protected from overload by fuses in the
wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is
broken, replace the fuse. Replace fuse with a new fuse with the same rating.
2. The fuses and circuits are identified as follows:
a. Smart Craft Data Bus Circuit - SFE 15 Ampere Fuse
b. Fuel Injector Harness, Electric Fuel Pump and Oil Pump - SFE 20 Ampere Fuse
c. Main Power Relay, Remote Control Harness and Power Trim - SFE 20 Ampere Fuse
d. Ignition Coils - SFE 20 Ampere Fuse
a c
b d
59035
90-884294 OCTOBER 2001 Page 2A-15

IGNITION
Charging System Alternator

Battery charging system, including the regulator, is contained within the belt driven alter-
nator. At cranking speeds, electrical power for the engine is provided by the boat battery
– minimum recommended size is 490 Cold Cranking Amperes (CCA) or 630 Marine
Cranking Amperes (MCA). Above 550 RPM, all electrical power is provided by the alter-
nator. Should engine rpm drop below 550 RPM, the alternator is not capable of providing
sufficient output and the battery becomes the primary source of electrical power. Alterna-
tor output (when hot) to the battery @ 2000 RPM is approximately 35 - 41 amperes.
a
59067
a - Alternator
Ignition Coil
Each module contains an ignition coil and amplifier circuitry which produces approximate-
ly 50,000 volts at the spark plugs.
Page 2A-16 90-884294 OCTOBER 2001

IGNITION
Electronic Control Module (ECM)

The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop
running.
The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal
91-823686A2 using adaptor harness 84-822560A5.
The ECM performs the following functions:
• Calculates the precise fuel and ignition timing requirements based on engine speed,
throttle position, manifold pressure and coolant temperature.
• Controls fuel injectors for each cylinder and ignition for each cylinder.
• Controls all alarm horn functions.
• Supplies tachometer signal to gauge.
• Controls RPM limit function.
• Contains detonation control circuitry (200 Work Model only)
• Records engine running information.
59026
a - Electronic Control Module (ECM)
90-884294 OCTOBER 2001 Page 2A-17

IGNITION
Flywheel
Flywheel has 54 teeth under the flywheel ring gear which the crank position sensor uses
to provide engine rpm and crankshaft position information the ECM.
59070
a - Flywheel b - Crank Position Sensor
Crank Position Sensor
Crank Position Sensor monitors 54 teeth on flywheel, thus determining crankshaft posi-
tion, and sends crankshaft position angle and engine speed signals to ECM. If crank posi-
tion sensor should fail, engine will stop running.
b
59070
a - Crank Position Sensor b - Crank Position Sensor Connector
Crank Position Sensor Resistance Test
Between 2 pins of Crank Position Sensor 300 – 350 ohms
Connector
Page 2A-18 90-884294 OCTOBER 2001

IGNITION
Throttle Position Sensor (TPS)

The TPS transmits throttle angle information to the ECM which varies the injector pulse
width accordingly. Should the sensor fail, the warning horn will sound. RPM will be re-
duced by the ECM. TPS settings are not adjustable. TPS settings can be monitored with
the Digital Diagnostic Terminal through the ECM. Voltage change should be smooth from
idle to wide open throttle. If voltage change is erratic, TPS is defective.
59031
a - Throttle Position Sensor (TPS) c - Roller
b - Throttle Stop Screw d - Pocket
Throttle Position Sensor Specifications

Idle 0.19 – 1.0 VDC
Wide Open Throttle 3.45 – 4.63 VDC
Throttle Position Sensor (TPS) Troubleshooting

If the throttle position sensor is out of the intended operating range when the engine is
started, the Electronic Control Module (ECM) will sense that the Throttle Position Sensor
(TPS) has failed. The warning horn will sound, check engine light will illuminate, DDT will
indicate failed TPS and the engine will go into RPM reduction. When the engine is started,
the throttle arm on the engine must be against the throttle stop screw. Do not move throttle
or fast idle control lever forward.
• Check throttle cable adjustment. The throttle stop screw on the throttle arm must be
against the throttle stop on the cylinder block when the engine is started. Pre-load the
throttle cable barrel 1 or 2 turns if necessary.
• Verify driver is not pushing on throttle (if foot throttle is used) or advancing the throttle
only on the control box.
• Check throttle cam to roller adjustment. If the roller is not down in the pocket/valley
area on the cam, there is a tendency for the roller to ride up or down on the cam which
causes the TPS link arm to push/pull on the TPS lever resulting in changing values.
90-884294 OCTOBER 2001 Page 2A-19
IGNITION
Cylinder Head Temperature Sensor

Two (2) temperature sensors are used to provide temperature information to the ECM.
One sensor is mounted in each cylinder head.
The ECM uses this information to increase injector pulse width for cold starts and to retard
timing in the event of an over-heat condition. Should a temperature sensor fail, the ECM
will default to a temperature value of 32 °F (0 °C).
59037
a - Cylinder Temperature Sensor (PORT)
b - Cylinder Temperature Sensor (STARBOARD)
Air Temperature Sensor
The air temperature sensor is mounted on top of the air plenum. The ECM regulates fuel
flow, in part, based on manifold air temperature. As air temperature increases, the ECM
decreases fuel flow. Should the air temperature sensor fail, the ECM will default to a tem-
perature value of 32 °F (0 °C).
59025
a - Air Temperature Sensor
Page 2A-20 90-884294 OCTOBER 2001

IGNITION
Port and Starboard Temperature Sensors; Air Temperature Sensor


257 125 340
248 120 390
239 115 450
230 110 517
221 105 592
212 100 680
203 95 787
194 90 915
185 85 1070
176 80 1255
167 75 1480
158 70 1752
149 65 2083
140 60 2488
131 55 2986
122 50 3603
113 45 4370
104 40 5327
95 35 6530
86 30 8056
77 25 10000
68 20 12493
59 15 15714
50 10 19903
41 5 25396
32 0 32654
14 –10 55319
5 –15 72940
90-884294 OCTOBER 2001 Page 2A-21

IGNITION
Manifold Absolute Pressure (MAP) Sensor

The MAP sensor is located on top of the air plenum. The ECM regulates fuel flow, in part,
based on manifold absolute pressure. The MAP sensor becomes more critical in engine
running quality as the engine is operated at higher altitudes (i.e. mountain lakes). Should
the MAP sensor fail, the ECM will default to a value of approximately 14.7 psi.
The MAP sensor’s DDT readout will vary according to altitude, throttle plate opening and
barometric pressure. However, for a given location and weather conditions (I.E. altitude
and barometric pressure), the MAP sensor readout between engines should be approxi-
mately the same when the ignition key is turned to the “ON” position. For example, if two
engines indicate 15 psi when the key is turned “ON” and a third engine indicates 10 psi,
the third engine’s MAP sensor would be suspect. When the engines are started, MAP sen-
sor readout should drop. When the engines are initially accelerated, the MAP sensor
readout will drop momentarily and then begin to rise. Throttle plate opening will also affect
the MAP readout. Refer to Section 2C for correct throttle plate clearance.
The Digital Diagnostic Terminal (DDT) can be used to determined whether the MAP sen-
sor is functioning properly. As throttle is advanced, numerical value on DDT display
should increase. As throttle is retarded, numerical value should decrease indicating MAP
sensor is functioning. If numerical value does not change as throttle setting varies, MAP
sensor is defective.
NOTE: If MAP sensor is not functioning, #4 LED indicator light on DDT will be illuminated.
59025
a - Manifold Absolute Pressure (MAP) Sensor
Page 2A-22 90-884294 OCTOBER 2001

IGNITION
Ignition Troubleshooting and Fault Chart

CAUTION
To protect against meter and/or component damage, observe the following pre-
cautions:
• DO NOT reverse battery cable connections. The battery negative cable is (–)
ground.
• DO NOT “spark” battery terminals with battery cable connections to check po-
larity.
• DO NOT disconnect battery cables while engine is running.
Before troubleshooting the ignition system, check the following:
1. Make sure that electrical harness and ignition switch are not the source of the prob-
lem.
2. Check that plug-in connectors are fully engaged and terminals are free of corrosion.
3. Make sure that wire connections are tight and free of corrosion.
4. Check all electrical components, that are grounded directly to engine, and all ground
wires to see that they are grounded to engine.
5. Check for disconnected wires and short and open circuits.
Symptom Cause Action

1. Engine cranks but won’t 1.0 Lanyard stop switch in Reset lanyard stop switch.
start wrong position.
1.1 Weak battery or bad starter Replace/charge battery.
motor, battery voltage drops Inspect condition of starter motor.
below 8 volts while cranking Check condition of battery termi-
(ECM cuts out below 8volts) nals and cables.
(Fuel pump requires 9volts)
1.2 No fuel Check that primer bulb is firm. Key-
on engine to verify that fuel pump
runs for 2 seconds and then turn off.
Measure fuel pressure
1.3 Flywheel misaligned during Remove flywheel and inspect.
installation
1.4 Blown fuse Replace fuse. Inspect engine har-
ness and electrical components.
1.5 Main Power Relay not Listen for relay to “click” when the
functioning key switch is turned on.
1.6 Spark Plugs Remove spark plugs from each
cylinder.
Connect spark plug leads to Spark
Gap Tester 91-830230T.
Crank engine or use DDT output
load test for each ignition coil and
observe spark. If no spark is pres-
ent, replace appropriate ignition
coil. If spark is present, replace
spark plugs.
90-884294 OCTOBER 2001 Page 2A-23

IGNITION

1. Engine cranks but will 1.7 ECM not functioning Check for proper operation by
not start (continued) using Inductive Timing Light
91-99379.
Check battery voltage
(RED/YEL Lead) @ ignition
coils.
Check for blown fuse (C15).
Check battery voltage to fuse
from main power relay
(PURPLE Lead).
Check for shorted stop wire
(BLK/YEL).
Check crank position sensor
setting [0.025 in. – 0.040 in.
(0.64 mm – 1.02 mm)] from
flywheel or for defective crank
position sensor.
Defective ECM.
Power Supply:
Clean and inspect remote control
male and female harness connec-
tors.
1.8 Crank Position Sensor not – Sensor faulty.

functioning – Bad connection
– Air gap incorrect
2. Engine cranks, starts 2.0 Abnormally high friction in Check for scuffed piston or other
and stalls engine sources of high friction.
2.1 Air in fuel system/lines Crank and start engine several

times to purge.
2.2 TPS malfunction Check motion of throttle arm. Stop
nuts should contact block at idle
and WOT. Check TPS set-up. Must
connect DDT with adapter harness
(84-822560A5) to ECM.
2.3 Remote control to engine Clean and inspect male and fe-
harness connection is poor male connectors.
Page 2A-24 90-884294 OCTOBER 2001

IGNITION

3. Engine idle is rough 3.1 Fouled spark plug Replace spark plug: if carbon
bridges electrode gap or if it is
completely black. If it is not firing
and is wet with fuel.
Note: If spark plug is grey or com-
pletely black with aluminum specs,
this indicates a scuffed piston.
3.2 Failed fuel injector Refer to specifications for ohm
test.
3.3 Bad coil/weak spark Refer to specifications for ohm

test.
3.4 Flywheel misaligned during Remove flywheel and inspect.
installation
4. Engine idles fast (rpm 4.1 Fuel leak Check for fuel entering induction
>700) or surges manifold.
Fuel pump diaphragm leaking and/
or Vapor Separator flooding over.
4.2 Improper set-up Check throttle cable & cam roller
adjustment.
5. Engine runs rough below 5.1 Fouled spark plug See 3.1
3000 rpm
5.2 Throttle misadjusted Check throttle cam setup on induc-
tion manifold. Inspect linkage and
roller.
If throttle plate stop screws have
been tampered with, contact Mer-
cury Marine Service Department
for correct adjustment procedures.
5.3 Bad coil/weak spark See 3.3
5.4 TPS malfunction See 2.2
6. Engine runs rough above 6.1 Fouled spark plug See 3.1
3000 rpm
6.2 Speed Reduction See 7
6.4 TPS malfunction See 2.2
90-884294 OCTOBER 2001 Page 2A-25

IGNITION

7. Speed Reduction (RPM 7.1 Low battery voltage Check battery and/or alternator.
reduced) ECM requires 8 volts mini- Check electrical connections.
mum
Fuel Pump requires 9 volts
7.2 Overheat condition Check water pump impeller/cooling
system.
7.3 Oil pump electrical failure Check electrical connection.
7.4 TPS failure See 2.2
If TPS fails, rpm is reduced
to idle
8. Engine RPM reduced to 8.1 TPS failed See 2.2
idle only 8.2 Battery voltage below 9.5 Use DDT to monitor system
volts
9. Loss of spark on 1 cylin- 9.1 Loose wire or pin in connec- Check connectors.
der tors between ECM and coil pri-
mary. Replace coil.
9.2 Faulty ignition coil. Replace spark plug.
9.3 Faulty spark plug. Replace spark plug wire.
9.4 Faulty spark plug wire
Note: If spark plug is partially
fouled or the plug gap is too
small, the DDT may indicate the
incorrect cylinder as having an
ignition fault. Example: If the
DDT indicates an ignition fault
on cylinder #4, the problem may
be on the prior cylinder in the
firing order – I.E. cylinder num-
ber #3.
Page 2A-26 90-884294 OCTOBER 2001

IGNITION
Ignition Coil Ohms Test
58903
BLACK METER LEAD

Secondary EST EST Low Secondary Primary Battery +
Tower PIN A PIN B Low Ground Pin E
Pin C Pin D
Secondary X No No 850 – 1200 No No
Tower Continuity Continuity ohm Continuity Continuity
EST No X 8500 – No 29000 – 11000 –
PIN A Continuity 12000 Continuity 39000 21000
ohm ohm ohm
EST Low No 8500 – X No 39000 – 21000 –
RED PIN B Continuity 12000 Continuity 49000 31000
METER ohm ohm ohm
LEAD Secondary 850 – 1200 No No X No No
Low ohm Continuity Continuity Continuity Continuity
Pin C
Primary No 20000 – 31000 – No X 13000 –
Ground Continuity 30000 41000 Continuity 23000
Pin D ohm ohm ohm
Battery + No 11000 – 21000 – No 13000 – X
Pin E Continuity 21000 31000 Continuity 23000
ohm ohm ohm
EST = Electronic Spark Trigger

EST Low = Return ground path for the trigger signal to the ECM
90-884294 OCTOBER 2001 Page 2A-27

IGNITION
Manifold Absolute Pressure (MAP) Sensor Ohms Test
58904
BLACK METER LEAD

BLK/ORG YEL PPL/YEL
PIN A PIN B PIN C
BLK/ORG X 95000 – 105000 3900 – 4100
PIN A ohm ohm
RED METER
LEAD YEL 95000 – 105000 X 95000 – 105000
PIN B ohm ohm
PPL/YEL 3900 – 4100 95000 – 105000 X
PIN C ohm ohm
Idle Speed Control

The ECM varies the timing and the fuel flow based on the throttle opening to maintain an
idle speed of 650 rpm ± 50 rpm.
RPM-Limit Circuit
The rpm limit circuitry is contained within the ECM. When the rpm limit point is reached
(this point will vary between engine models), a warning horn will sound. If the rpm contin-
ues to increase, ignition spark will be cut to cylinders #1, #3 and #5. If the rpm still contin-
ues to rise, fuel and ignition spark will be cut to all cylinders.
Page 2A-28 90-884294 OCTOBER 2001

IGNITION
EFI Detonation Control System (200 Work Model only)

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

Detonation Circuit Test
1. Turn key switch to RUN position (do not start engine). With Digital Diagnostic Terminal
connected to engine, DDT should indicate over 6 volts for knock voltage output.
2. Start engine and run at idle. DDT indicated knock voltage output should drop below
1.0 volt. If voltage does not drop below 1.0 volt, knock circuit within ECM is defective.
90-884294 OCTOBER 2001 Page 2A-29

IGNITION
Ignition Component Removal and Installation

Flywheel Removal
1. Remove flywheel cover off engine.
2. Remove alternator belt.
3. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and
washer.
59071
a - Flywheel Holder (91-52344)
b - Flywheel
4. Install Flywheel Puller (91-849154T1) into flywheel.
CAUTION
Do not hammer on end of puller center bolt to remove flywheel, or damage may
result to crankshaft or bearings. Do not use heat to aid flywheel removal as fly-
wheel may be damaged.
59072
a - Flywheel
b - Flywheel Puller (91-849154T1)
Page 2A-30 90-884294 OCTOBER 2001

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

Ignition Coil Removal
WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark plug
boots. Damaged spark plug boots can emit sparks which can ignite fuel vapors
under the engine cowl. To avoid damaging spark plug boots, do not use any sharp
object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.
1. Disconnect spark plug lead from spark plug.
2. Disconnect coil harness connector.
3. Remove 2 bolts securing ignition coil and remove coil.
59036
a - Spark Plug Lead c - Bolts

b - Harness Connector
90-884294 OCTOBER 2001 Page 2A-31

IGNITION
Ignition Coil Installation

1. Secure coil with 2 bolts. Torque bolts to 70 lb. in. (8 Nm).
2. Reconnect coil harness.
3. Reconnect spark plug lead to spark plug.
Electronic Control Module Removal
1. Disconnect 3 Control Module harness connectors.
2. Remove 3 bolts securing module and remove module.
59026
a - Harness Connectors c - Control Module
b - Bolts (3)
Electronic Control Module Installation

1. Secure module with 3 bolts. Torque bolts to 70 lb. in. (8 Nm).
2. Reconnect 3 module harness connectors.
Page 2A-32 90-884294 OCTOBER 2001

IGNITION
Temperature Sensor Removal

ANALOG TEMPERATURE SENSOR
1. Remove screw and retaining plate.
2. Disconnect bullet connector and remove sensor.
DIGITAL TEMPERATURE SENSOR
1. Disconnect wire harness for PORT and STARBOARD sensors.
2. Unscrew sensor from cylinder head.
f
g
a
d e
c
59037
a - Bullet Connector (hidden) e - Digital Temperature
b - Analog Temperature Sensor Sensor
c - Retainer f - Port Sensor Harness
d - Retainer Screw g - Starboard Sensor Har-
ness
Engine Head Temperature Sensor Installation
1. Install sensor into pocket.
2. Secure sensor with retainer and screw. Ground (BLACK) lead of sensor is secured
with retainer screw. Torque retainer screw to 16.5 lb. ft. (22.4 Nm).
3. Reconnect sensor bullet connector.
1. Install sensors into cylinder heads. Torque sensors to 14 lb. in. (1.6 Nm).
2. Reconnect sensor harness connectors.
90-884294 OCTOBER 2001 Page 2A-33

IGNITION
Air Temperature Sensor Removal

1. Disconnect sensor harness connector.
2. Unscrew sensor from air plenum.
b
59025
b - Harness Connector
Air Temperature Sensor Installation
1. Install sensor into air plenum. Torque sensor to 14 lb. in. (1.6 Nm).
2. Reconnect sensor harness.
Manifold Absolute Pressure (MAP) Sensor Removal
1. Disconnect MAP harness.
2. Remove bolt securing MAP retainer.
3. Remove MAP sensor.
c b
a
59025
a - Manifold Absolute Pressure (MAP) Sensor
b - Bolt
c - Harness Connector
Manifold Absolute Pressure (MAP) Sensor Installation
1. Install sensor into air plenum.
2. Secure sensor with retainer and bolt. Torque bolt to 35 lb. in. (3.9 Nm).
3. Reconnect MAP harness.
Page 2A-34 90-884294 OCTOBER 2001

IGNITION
Crank Position Sensor Removal

1. Disconnect sensor harness.
2. Remove screws securing sensor to engine.
b
59070
a - Crank Position Sensor b - Harness Connector
Crank Position Sensor Installation
1. Secure sensor to engine with 2 screws. Torque screws to 45 lb. in. (5 Nm).
90-884294 OCTOBER 2001 Page 2A-35

CHARGING & STARTING SYSTEM
ELECTRICAL
Section 2B – Charging & Starting System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Alternator Belt Tension Adjustment . . . . . . . . 2B-20
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21 B
Battery Cable Size . . . . . . . . . . . . . . . . . . . . . . 2B-4 Starter Motor Amperes Draw . . . . . . . . . . . 2B-21
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 2B-4 Starter System Components . . . . . . . . . . . 2B-21
Recommended Battery . . . . . . . . . . . . . . . . . . . 2B-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Starter Motor (Centrifugal Bendix) . . . . . . . . . 2B-22
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5 Troubleshooting the Starter Circuit
Charging a Discharged Battery . . . . . . . . . . . . 2B-5 (Centrifugal Bendix) . . . . . . . . . . . . . . . . . . . . . 2B-24
Winter Storage of Batteries . . . . . . . . . . . . . . . 2B-6 Starter Circuit Troubleshooting Flow Chart
Flywheel Removal and Installation . . . . . . . . . 2B-7 (Centrifugal Bendix) . . . . . . . . . . . . . . . . . . 2B-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Flow Chart (continued) . . . . . . . . . . . . . . . . 2B-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Starter Removal (Centrifugal Bendix) . . . . . . 2B-27
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Starter Installation (Centrifugal Bendix) . . . . . 2B-27
Flywheel/Alternator . . . . . . . . . . . . . . . . . . . . . . 2B-10 Starter Disassembly (Centrifugal Bendix) . . . 2B-28
System Components . . . . . . . . . . . . . . . . . . . . 2B-11 Starter Cleaning, Inspection and Testing . 2B-30
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Starter Reassembly . . . . . . . . . . . . . . . . . . . 2B-33
Alternator Description . . . . . . . . . . . . . . . . . . . . 2B-12 Starter Motor (Solenoid Driven Bendix) . . . . . 2B-38
Diagnosis of Alternator System on Engine . . 2B-13 Troubleshooting the Solenoid Driven Bendix
Alternator System Circuitry Test . . . . . . . . . . . 2B-14 Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-40
Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Starter Circuit Troubleshooting Flow Chart
Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . 2B-15 (Solenoid Driven Bendix) . . . . . . . . . . . . . . 2B-41
Voltage Output . . . . . . . . . . . . . . . . . . . . . . 2B-16 Starter Removal (Solenoid Driven Bendix) . . 2B-43
Current Output . . . . . . . . . . . . . . . . . . . . . . . 2B-17 Starter Installation (Solenoid Driven Bendix) 2B-43
Current Output Troubleshooting . . . . . . . . 2B-18 Disassembly (Solenoid Driven Bendix Starter) 2B-45
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 2B-48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18 Reassembly (Solenoid Driven Bendix Starter) 2B-49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19 Commander 2000 Key Switch Test . . . . . . . . 2B-53
90-884294 OCTOBER 2001 Page 2B-1

Specifications
CHARGING Alternator Output (Regulated) 35 - 41 Amperes @ 2000 RPM @ Battery

SYSTEM 36 - 44 Amperes @ 2000 RPM @
Alternator
Brush Length Std Exposed Length: 0.413 in. (10.5 mm)
Min. Exposed Length: 0.059 in. (1.5 mm)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw 0.15 mA (Ign. Switch Off)
30.0 mA (Ign. Switch On)
Battery Rating Min. 630 Marine Cranking Amps (MCA) or
490 Cold Cranking Amps (CCA)
Page 2B-2 90-884294 OCTOBER 2001

Special Tools
1. Volt/Ohm Meter 91-99750A1 or DMT 2000 Digital Tachometer Multimeter 91-854009A1
a b
a - Volt/Ohm Meter 91-99750A1

b - DMT 2000 Digital Tachometer Multimeter 91-854009A1
2. Ammeter (60 Ampere minimum) (Obtain locally)

54964
4. Protector Cap 91-24161 (Used with Puller 91-73687A1)
5. Flywheel Puller 91-73687A1 or 91-849154T1
a - Puller 91-73687A1
b - Puller 91-849154T1
90-884294 OCTOBER 2001 Page 2B-3

Battery Cable Size

If standard (original) battery cables are replaced with longer cables, the wire gauge size must increase. See
chart below for correct wire gauge size.
Î
Î Wire Gage Size
Battery Cable Length
Battery Cable Wire Gage Size

Mercury/Mariner Outboards
Battery Cable Length
8 ft. 9 ft. 10ft. 11ft. 12ft. 13ft. 14ft. 15ft. 16ft. 17ft. 18ft. 19ft. 20ft. 21ft. 22ft. 23ft. 24ft.
2.4m 2.7m 3.0m 3.4m 3.7m 4.0m 4.3m 4.6m 4.9m 5.2m 5.5m 5.8m 6.1m 6.4m 6.7m 7.0m 7.3m
Models Wire Gage Size No. SAE

6-25 Hp #8* #8 #6 #6 #6 #6 #4 #4 #4 #4 #4 #4 #4 #4 #2 #2 #2
30-115 #6* #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Hp
125-250 #6* #6 #4 #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2
Hp (ex-
cept
DFI)
DFI #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Models
* = Standard (original) Cable Length and wire gage size.
Replacement Parts
WARNING
Electrical, ignition and fuel system components on your Mercury Outboard are
designed and manufactured to comply with U. S. Coast Guard Rules and Regula-
tions to minimize risks of fire and explosions. Use of replacement electrical, igni-
tion or fuel system components, which do not comply with these rules and regu-
lations, could result in a fire or explosion hazard and should be avoided.
Recommended Battery
A 12 volt marine starting battery with a minimum Cold Cranking amperage rating of 490
amperes or 630 (minimum) Marine Cranking amperes should be used.
CAUTION
Deep-cycle batteries are not suitable for use as engine starting batteries or for
use as accessory batteries that are connected to high output engine charging
systems. Deep-cycle battery life may be shortened by high output engine charg-
ing systems. Refer to individual battery maker instructions for specific battery
charging procedures and applications.
Page 2B-4 90-884294 OCTOBER 2001

Battery
Precautions
CAUTION
If battery acid comes in contact with skin or eyes, wash skin immediately with a
mild soap. Flush eyes with water immediately and see a doctor.
When charging batteries, an explosive gas mixture forms in each cell. Part of this gas es-
capes through holes in vent plugs and may form an explosive atmosphere around battery
if ventilation is poor. This explosive gas may remain in or around battery for several hours
after it has been charged. Sparks or flames can ignite this gas and cause an internal ex-
plosion which may shatter the battery.
The following precautions should be observed to prevent an explosion.
1. DO NOT smoke near batteries being charged or which have been charged very re-
cently.
2. DO NOT break live circuits at terminals of batteries because a spark usually occurs
at the point where a live circuit is broken. Always be careful when connecting or dis-
connecting cable clamps on chargers. Poor connections are a common cause of elec-
trical arcs which cause explosions.
3. DO NOT reverse polarity of battery terminal to cable connections.
Charging a Discharged Battery

WARNING
Hydrogen and oxygen gases are produced during normal battery operation or
charging. Sparks or flame can cause this mixture to ignite and explode, if they are
brought near the vent openings. Sulphuric acid in battery can cause serious
burns, if spilled on skin or in eyes. Flush or wash away immediately with clear
water.
The following basic rule applies to any battery charging situation:
1. Any battery may be charged at any rate (in amperes) or as long as spewing of electro-
lyte (from violent gassing) does not occur and for as long as electrolyte temperature
does not exceed 125 °F (52 °C). If spewing of electrolyte occurs, or if electrolyte tem-
perature exceeds 125 °F, charging rate (in amperes) must be reduced or temporarily
halted to avoid damage to the battery.
2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes),
all cells are gassing freely (not spewing liquid electrolyte), and no change in specific
gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte
temperature with electrolyte level at 3/16 in. (4.8 mm) over plate, unless electrolyte
loss has occurred (from age or over-filling) in which case specific gravity reading will
be lower. For most satisfactory charging, lower charging rates in amperes are recom-
mended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be
reached, battery is not in optimum condition and will not provide optimum perform-
ance; however, it may continue to provide additional service, if it has performed satis-
factorily in the past.
90-884294 OCTOBER 2001 Page 2B-5

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

Battery companies are not responsible for battery damage either in winter storage or in
dealer stock if the following instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sul-
fate and dirt from top surface by running water over top of battery. Be sure, however,
that vent caps are tight beforehand, and blow off all excess water thoroughly with com-
pressed air. Check water level, making sure that plates are covered.
2. When adding distilled water to battery, be extremely careful not to fill more than 3/16
in. (4.8 mm) above perforated baffles inside battery. Battery solution or electrolyte ex-
pands from heat caused by charging. Overfilling battery will cause electrolyte to over-
flow (if filled beyond 3/16″ above baffles).
3. Grease terminal bolts well with 2-4-C Marine Lubricant with Teflon and store battery
in a COOL-DRY place. Remove battery from storage every 30-45 days, check water
level and put on charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check battery for reason and recharge. When
gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrom-
eter, which can be purchased locally.
5. Repeat preceding charging procedure every 30-45 days, as long as battery is in stor-
age, for best possible maintenance during inactive periods to ensure a good service-
able battery in spring. When ready to place battery back in service, remove excess
grease from terminals (a small amount is desirable on terminals at all times), recharge
again as necessary and reinstall battery.
Page 2B-6 90-884294 OCTOBER 2001

Flywheel Removal and Installation

Removal
1. Remove flywheel cover from engine.
WARNING
Engine could possibly start when turning flywheel during removal and installa-
tion; therefore, disconnect (and isolate) spark plug leads from spark plugs to pre-
vent engine from starting.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with flywheel holder (91-52344), remove flywheel nut and
washer.
59071
4. Install a crankshaft Protector Cap (91-24161) on end of crankshaft, then install Fly-
wheel Puller (91-849154T1) into flywheel.
5. Hold flywheel tool with wrench while tightening bolt down on protector cap. Tighten
bolt until flywheel comes free.
59072
a - Flywheel Puller (91-849154T1)
NOTE: Neither heat or hammer should be used on flywheel to aid in removal as damage
to flywheel or electrical components under flywheel may result.
6. Remove flywheel. Inspect flywheel for cracks or damage.
90-884294 OCTOBER 2001 Page 2B-7

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

Notes:
90-884294 OCTOBER 2001 Page 2B-9

Flywheel/Alternator
Page 2B-10 90-884294 OCTOBER 2001

Flywheel/Alternator
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 ALTERNATOR
2 1 SPRING
3 1 BEARING
4 1 BELT TENSIONER ARM ASSY
5 3 BUSHING
6 1 SCREW (M10 x 45) 15 20
7 1 PULLEY
8 1 SCREW (M10 x 35) 25 34
9 1 BELT
10 1 FLYWHEEL
11 1 NUT (0.625–18) 125 170
12 1 WASHER
13 1 PLUG
14 1 NUT
15 1 CABLE
16 1 WASHER
17 1 SCREW (M10 x 50) 40 54
18 1 SCREW (M6 x 12) 40 54
System Components
The battery charging system consists of the alternator, battery, ignition switch, starter so-
lenoid and the wiring which connects these components.
c
BLK
aa
BLK
YEL/RED
d
RED
RED
RED
RED
RED
BLK RED
RED
BLK
RED PPL
RED RED
RED RED
bb
59049
a - Alternator c - 20 Ampere Fuse
b - Battery d - Starter Solenoid
90-884294 OCTOBER 2001 Page 2B-11

Precautions
The following precautions must be observed when working on the alternator system. Fail-
ure to observe these precautions may result in serious damage to the alternator system.
1. Do not attempt to polarize the alternator.
2. Do not short across or ground any of the terminals on the alternator, except as specifi-
cally instructed.
3. Never disconnect the alternator output lead, regulator harness or battery cables when
the alternator is being driven by the engine.
4. Always remove NEGATIVE (–) battery cable from battery before working on alternator
system.
5. When installing battery, be sure to connect the NEGATIVE (–) (GROUNDED) battery
cable to NEGATIVE (–) battery terminal and the POSITIVE (+) battery cable to POSI-
TIVE (+) battery terminal.
6. When using a charger or booster battery, connect it in parallel with existing battery
(POSITIVE to POSITIVE; NEGATIVE to NEGATIVE).
Alternator Description
The alternator employs a rotor, which is supported in 2 end frames by ball bearings, and
is driven at 2.5 times engine speed. The rotor contains a field winding enclosed between
2 multiple-finger pole pieces. The ends of the field winding are connected to 2 brushes
which make continuous sliding contact with the slip rings. The current (flowing through
the field winding) creates a magnetic field that causes the adjacent fingers of the pole
pieces to become alternate north and south magnetic poles.
A 3-phase stator is mounted directly over the rotor pole pieces and between the 2 end
frames. It consists of 3 windings wound 120° electrically out-of-phase on the inside of a
laminated core. The windings are connected together on one end, while the other ends
are connected to a full-wave rectifier bridge.
The rectifier bridge contains 8 diodes which allows current to flow from ground, through
the stator and to the output terminal, but not in the opposite direction.
When current is supplied to the rotor field winding, and the rotor is turned, the movement
of the magnetic fields created induces an alternating current into the stator windings. The
rectifier bridge changes this alternating current to direct current which appears at the out-
put terminal. A diode trio is connected to the stator windings to supply current to the regu-
lator and the rotor field during operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that
senses the voltage at the battery and regulates the field current to maintain alternator volt-
age for properly charging the battery. Current output of the alternator does not require reg-
ulation, as maximum current output is self-limited by the design of the alternator. As long
as the voltage is regulated within the prescribed limits, the alternator cannot produce ex-
cessive current. A cutout relay in the voltage regulator also is not required, as the rectifier
diodes prevent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor
field to initially start the alternator charging. Once the alternator begins to produce output,
field current is supplied solely by the diode trio.
The alternator is equipped with 2 fans which induce air flow through the alternator to re-
move heat created by the rectifier and stator.
Page 2B-12 90-884294 OCTOBER 2001

Diagnosis of Alternator System on Engine

1. If problem is an undercharged battery, verify condition has not been caused by exces-
sive accessory current draw or by accessories which have accidentally been left on.
2. Check physical condition and state of charge of battery. Battery must be at least 75%
(1.230 specific gravity) of fully charged to obtain valid results in the following tests. If
not, charge battery before testing system.
3. Inspect entire alternator system wiring for defects. Check all connections for tightness
and cleanliness, particularly battery cable clamps and battery terminals.
IMPORTANT: RED output lead from alternator must be tight. A darkened RED
sleeve indicates lead was loose and becoming hot.
4. Check alternator drive belt for cracks and fraying. Replace if necessary. Check belt
tension.
90-884294 OCTOBER 2001 Page 2B-13

Alternator System Circuitry Test

Using a 0-20 volt DC voltmeter, perform the following tests:
Output Circuit
1. Connect POSITIVE (+) voltmeter lead to alternator terminal B (output terminal). Con-
nect NEGATIVE (–) lead to case ground on alternator.
2. Shake alternator wiring harness. Meter should indicate battery voltage and should not
vary. If proper reading is not obtained, check for loose or dirty connections or dam-
aged wiring.
59069
a - Terminal B
Page 2B-14 90-884294 OCTOBER 2001

Sensing Circuit
1. Unplug RED and PURPLE lead connector from alternator.
2. Connect POSITIVE (+) voltmeter lead to RED lead and NEGATIVE (–) voltmeter lead
to ground.
3. Voltmeter should indicate battery voltage. If correct voltage is not present, check
sensing circuit (RED lead) for loose or dirty connections or damaged wiring.
59065
a - Sense Lead (RED)
90-884294 OCTOBER 2001 Page 2B-15

Voltage Output
1. Using a 0-20 volt DC voltmeter, connect POSITIVE (+) lead of voltmeter to TERMINAL
B of alternator and NEGATIVE (–) lead of voltmeter to engine ground.
2. Start engine and allow to warm up. Increase engine RPM from idle to 2000. Normal
voltage output should be 14.1 – 15.0 volts.
NOTE: If alternator is under-charging, check connections. If alternator is over-charging,
replace alternator.
59068
a - Terminal B
Page 2B-16 90-884294 OCTOBER 2001

Current Output
NOTE: Before conducting current output test, assure that all boat electrical accessories
are turned OFF.
1. With engine shut off, install ammeter with clamp-on current probe (capable of reading
60+ amperes) onto alternator charging conductor (10 AWG Red Wire).
2. Start engine and allow to warm up.
3. Battery voltage should be between 14.2 and 15.0 VDC for all engine RPMs.
Alternator output current should correspond with graph below. Example: If engine is
revolving at 2000 RPM current meter should be approximately 14.5 ± 3 Amps.
59066
a - Ammeter (DMT 2000 Digital Tachometer Multimeter 91-854009A1)
b - Clamp-On Current Probe (91-802650)
c - Alternator Charging Conductor (10 AWG Red Wire)
NOTE: Alternator amperage output can vary by as much as 10% due to heat buildup from
the numbers listed below. Alternator output listed below was with a battery loaded at 12.6
volts.
RPM AMPS @ ALTERNATOR AMPS @ BATTERY ENGINE DRAW AMPS

600 21 16 5
1000 37 31 6
1500 44 36 8
2000 48 39 9
2500 50 40 10
3000 51 41 10
3500 51 41 10
4000 52 42 10
4500 52 42 10
5000 52 42 10
5500 52 42 10
5750 52 42 10
90-884294 OCTOBER 2001 Page 2B-17

Current Output Troubleshooting

Current Output is Low Battery Cables are loose or corroded
Defective Battery (Open Circuit)
Defective Alternator
Current Output is High Accessories turned on
Defective Battery (Internal Short)
Defective Alternator
Repair
Removal
1. Remove top cowling.
2. Disconnect battery cables from battery.
3. Disconnect wiring harness from alternator.
4. Remove belt from alternator.
5. Remove attaching bolts.
a
59067
a - Attaching Bolt b - Harnesses
Page 2B-18 90-884294 OCTOBER 2001

Installation
1. Secure alternator to engine block with attaching bolts. Torque top bolt to 40 lb-ft (54
Nm). Torque bottom nut to 35 lb-ft (47.5 Nm).
2. Rotate belt tensioner and install alternator belt in groove of flywheel and alternator
pulley.
59024
a - Belt Tensioner (Rotate Counterclockwise)

3. Reconnect electrical harness to alternator.
a
59067
a - Top Bolt [Torque to 40 lb-ft (54 Nm)]
b - Harnesses
90-884294 OCTOBER 2001 Page 2B-19

Alternator Belt Tension Adjustment

Correct alternator belt tension is maintained by a belt tensioner assembly.
59024
a - Belt Tensioner Assembly
Page 2B-20 90-884294 OCTOBER 2001

Starter System
NOTE: Early production engines will be equipped with centrifugal bendix type starter mo-
tors. Later production engines will be equipped with solenoid driven bendix type starter
motors.
Starter Motor Amperes Draw
(CCA)
Starter System Components

Battery
Starter Solenoid
Neutral Start Switch
Starter Motor
Ignition Switch
Description
Purpose – to crank the engine. The battery supplies electricity to activate the starter mo-
tor. When the ignition switch is turned to the “START” position, the starter solenoid is ener-
gized and completes the starter circuit between the battery and starter.
The neutral start switch opens the starter circuit when the shift control lever is not in neu-
tral thus preventing accidental starting when the engine is in gear.
CAUTION
The starter motor may be damaged if operated continuously. DO NOT operate
continuously for more than 30 seconds. Allow a 2 minute cooling period between
starting attempts.
90-884294 OCTOBER 2001 Page 2B-21

Starter Motor (Centrifugal Bendix)
25
25
95
25
25 Liquid Neoprene
95 2-4-C Marine Lubricant With Teflon
Page 2B-22 90-884294 OCTOBER 2001

Starter Motor (Centrifugal Bendix)

TORQUE
REF.
REF
1 1 STARTER MOTOR
2 1 DRIVE KIT
3 1 DRIVE
4 1 DRIVE END PLATE
5 2 THRU BOLT 70 8
6 1 WASHER
7 1 ARMATURE
8 1 BRUSH SET
9 2 BRUSH HOLDER
10 2 SCREW
11 1 END CAP
12 2 COLLAR
13 2 RUBBER STOP
14 1 SCREW (1/4-20 x 5/8)
15 1 WIRE ASSEMBLY (BLACK)
16 1 LOCKWASHER
17 1 NUT
18 1 BATTERY CABLE (POSITIVE)
19 1 DECAL-Warning-High Voltage
90-884294 OCTOBER 2001 Page 2B-23

Troubleshooting the Starter Circuit (Centrifugal Bendix)

Before beginning the troubleshooting flow chart, verify the following conditions:
1. Battery is fully charged.
2. Control lever is in “NEUTRAL” position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 20 amp fuse.
NOTE: Location of test points (called out in flow chart) are numbered below.
b
2 7
6 1
a
3
e
4
d
5
58064
a - Starter Solenoid d - Ignition Switch
b - Starter e - 20 Ampere Fuse
c - Neutral Start Switch f - Battery
Page 2B-24 90-884294 OCTOBER 2001

Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix)

Starter Motor Does Not Turn
SAFETY WARNING: Disconnect YELLOW (starter motor)

cable from starter solenoid test point 1 BEFORE making
tests 1-thru-7 to prevent unexpected engine cranking.
TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (-) battery post and common pow-
erhead ground.
No Continuity Indicated - There is an open circuit in the Continuity Indicated

BLACK NEGATIVE (-) battery cable between the NEGATIVE (-) Proceed to TEST 2
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.
Test 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 2.
proceed to TEST 3. c. Turn ignition key to “Start” position.
TEST 3 12 Volt Reading*

a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 3. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to “Start” position. Proceed to TEST 7.
No voltage reading: 12 Volt Reading

Proceed to TEST 4 Defective starter solenoid
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
No voltage reading: engine ground and Test Point 4. Neutral start switch is open or YELLOW/RED
Proceed to TEST 5 b. Turn ignition key to “Start” position. wire is open between Test Points 4 and 3.
TEST 5
No voltage reading: Connect voltmeter between common 12 Volt Reading*
Proceed to Test 6. engine ground and Test Point 5 Defective ignition switch.
TEST 6
Check for voltage between common engine ground and Test Point 6.
No voltage reading: 12 Volt Reading*

Check RED wire between battery (+) Check fuse in RED wire between Test Points
POSITIVE terminal and Test Point 6.
5 and 6.
Check for open RED wire between Test Points
5 and 6.
*Battery Voltage
90-884294 OCTOBER 2001 Page 2B-25

Flow Chart (continued)
TEST 7
a. Connect voltmeter between common engine and Test Point 1.
b. Turn ignition key to “Start” position.

Defective starter solenoid Should hear solenoid click: proceed to TEST 8
TEST 8
a. Reconnect BLACK cable (with YELLOW sleeve) to starter solenoid Test
Point 1.
b. Connect voltmeter between common engine ground and Test Point 7.
c. Turn ignition key to “Start” position.
No voltage reading:
12 Volt Reading*
Check BLACK cable (with YELLOW
sleeve) for poor connection or open circuit. If starter motor does not turn, check starter motor.
*Battery Voltage
Page 2B-26 90-884294 OCTOBER 2001

Starter Removal (Centrifugal Bendix)

CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect BLACK ground cable from starter.
2. Disconnect BLACK (with YELLOW sleeve) cable from starter.
3. Remove 4 bolts and upper and lower starter clamps. Lift starter from engine.
c
e
a
f
b
59044
a - BLACK ground cable d - Lower Mount Bolts
b - BLACK (with YELLOW e - Upper Clamp
sleeve) + 12 volt cable f - Lower Clamp
c - Upper Mount Bolts
Starter Installation (Centrifugal Bendix)

1. Slide rubber collars on starter.
2. If the removed starter was equipped with a spacer replace spacer on upper collar.
a a
b
11645
a - Rubber Collar b - Spacer (If Equipped)
3. Install starter to engine with starter clamps. Make sure that BLACK ground cable is
fastened, along with lower mounting bolts. Torque bolts to 210 lb. in. (23.5 N·m).
4. Reconnect yellow cable to positive (+) terminal on starter.
5. Reconnect BLACK ground cable to terminal on starter.
90-884294 OCTOBER 2001 Page 2B-27

Starter Disassembly (Centrifugal Bendix)

1. Remove starter as outlined in Starter Removal.
2. Remove 2 through bolts from starter.
a
b
11646
a - Through Bolts
b - Commutator End Cap
3. Tap commutator end cap to loosen and remove from frame. Do not lose brush springs.
4. Brush replacement is recommended if brushes are pitted, chipped or worn to less than
0.25 in. (6.4 mm). If necessary, remove brushes as follows:
a. Remove hex nut and washers from POSITIVE (+) terminal and remove POSITIVE
brushes and terminal as an assembly.
b. Remove 2 bolts securing NEGATIVE (–) brushes and brush holder to end cap.
b a c
e
e
c
b
d
11656
a - Brush Holder
b - Positive Brushes
c - Negative Brushes
d - Positive Terminal
e - Bolts (fasten negative brushes and holder)
Page 2B-28 90-884294 OCTOBER 2001

5. Remove armature (with drive end cap) from starter frame.

6. Remove locknut and remove drive assembly from armature shaft.
a - Hold armature shaft with wrench on hex portion of drive assembly

7. Remove parts from shaft.
e f g
a b c d 11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer
90-884294 OCTOBER 2001 Page 2B-29

Starter Cleaning, Inspection and Testing

CLEANING AND INSPECTION
1. Clean all starter motor parts.
2. Check pinion teeth for chips, cracks or excessive wear.
3. Replace the drive clutch spring and/or collar if tension is not adequate or if wear is
excessive.
4. Inspect brush holder for damage or for failure to hold brushes against commutator.
5. Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in length.
6. Inspect the armature conductor (commutator bar junction) for a tight connection. A
loose connection (excessive heat from prolonged cranking melts solder joints) results
in a burned commutator bar.
7. Resurface and undercut a rough commutator as follows:
CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the insulation between the commutator
bars 1/32 in. (0.8mm) to the full width of the insulation and so that the undercut
is flat.
b. Clean the commutator slots after undercutting.
c. Sand the commutator lightly with No. 00 sandpaper to remove burrs, then clean
the commutator.
d. Recheck the armature on a growler for shorts as specified in the following proce-
dure (“Testing”).
8. Open-circuited armatures often can be repaired. The most likely place for an open cir-
cuit is at the commutator bars, as a result of long cranking periods. Long cranking peri-
ods overheat the starter motor so that solder in the connections melts and is thrown
out. The resulting poor connections then cause arcing and burning of the commutator
bars.
9. Repair bars, that are not excessively burned, by resoldering the leads in bars (using
rosin flux solder) and turning down the commutator in a lathe to remove burned mate-
rial, then undercut the mica.
10. Clean out the copper or brush dust from slots between the commutator bars.
11. Check the armature for ground. See the following procedure (“Testing”).
Page 2B-30 90-884294 OCTOBER 2001

TESTING
Armature Test for Shorts
Check armature for short circuits by placing on growler and holding hack saw blade over
armature core while armature is rotated. If saw blade vibrates, armature is shorted. Re-
check after cleaning between commutator bars. If saw blade still vibrates, replace arma-
ture.
11669
Armature Test for Ground
1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core or shaft
and other lead on commutator.
2. If meter indicates continuity, armature is grounded and must be replaced.
11675
90-884294 OCTOBER 2001 Page 2B-31

Checking Positive Brushes and Terminal

Set ohmmeter to (R x 1 scale). Connect meter leads between POSITIVE brushes. Meter
must indicate full continuity or zero resistance. If resistance is indicated, inspect lead to
brush and lead to POSITIVE terminal solder connection. If connection cannot be repaired,
brushes must be replaced.
11673
a - Positive (+) Brushes
Testing Negative Brushes for Ground

Set ohmmeter to (R x1 scale). Place one lead of the ohmmeter on the NEGATIVE brush
and the other lead on the end cap (bare metal). If the meter indicates NO continuity, re-
place the NEGATIVE brush. Repeat this procedure on the other NEGATIVE brush.
11674
a - Negative (–) Brushes
b - End Cap
Page 2B-32 90-884294 OCTOBER 2001

Starter Reassembly
1. If brushes were removed, replace as follows:
a. Install POSITIVE brushes (along with POSITIVE terminal) into commutator end
cap.
b
i
h
d
f c
g
11660
a - End Cap
b - Positive Brushes
c - Positive Terminal
d - Insulating Bushing
e - Washer
f - Split Washer
g - Hex Nut
h - Long Brush Lead
i - Push Lead into Slot
90-884294 OCTOBER 2001 Page 2B-33

b. Install NEGATIVE brushes (along with brush holder).
c
b
a
d
d
b
a
11656
a - Positive (+) Brushes
b - Negative (–) Brushes
c - Brush Holder
d - Bolts (fasten negative brushes and holder)
2. If removed, reinstall parts on armature shaft. Use a new locknut and tighten securely
on end of shaft.
e f g
a b c d 11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer
3. Lubricate helix threads on armature shaft with a drop of SAE 10W Oil (obtain locally).
4. Lubricate bushing in drive end plate with a drop of SAE 10W Oil (obtain locally).
5. Position armature into starter frame.
Page 2B-34 90-884294 OCTOBER 2001

6. To prevent damage to brushes and springs when installing commutator end cap, it is
recommended that a brush retaining tool be made as shown:
18-Gauge Sheet Metal METRIC SCALE

3” = 76.2mm
2” = 50.8mm
1-3/4” = 44.5mm
1-11/16” = 42.9mm
3/4” = 19.1mm
1/2” = 12.7mm
7. Lubricate bushing (located in commutator end cap) with one drop of SAE 10W Oil (ob-
tain locally). DO NOT over lubricate.
90-884294 OCTOBER 2001 Page 2B-35

8. Place springs and brushes into brush holder and hold in place with brush retainer tool.
11661
a - Bushing Retainer Tool
b - Bushing (do not over lubricate)
9. Install armature into starter frame and align match marks (a). Install commutator end
cap onto starter frame and align match marks (b). Remove brush retainer tool. Install
through bolts and torque to 70 lb. in. (8.0 N·m).
c c
11648
a - Alignment Marks
b - Alignment Marks
c - Bolts [Torque to 70 lb. in. (8 N m)]
Page 2B-36 90-884294 OCTOBER 2001

STARTER SOLENOID TEST

1. Disconnect all wires from solenoid.
2. Use an ohmmeter (R x1 scale) and connect meter leads between solenoid terminals
1 and 2.
3. Connect a 12-volt power supply between solenoid terminals 3 and 4. Solenoid should
click and meter should read 0 ohms (full continuity).
4. If meter does not read 0 ohms (full continuity), replace solenoid.
b
1 3
a
a
b
2
51809
a - 12 Volt Supply
b - VOA Leads
90-884294 OCTOBER 2001 Page 2B-37

Starter Motor (Solenoid Driven Bendix)

1
3
2
5
4
12 14
13
9
10
11
23 15
24
16 18
24
25
17
21 19
20
21
22
22 58430
Page 2B-38 90-884294 OCTOBER 2001

Starter Motor (Solenoid Driven Bendix)

TORQUE
REF.
REF
1 2 THRU BOLT 110 12.5
2 2 SCREWS 30 3.4
3 1 END CAP
4 1 BUSHING
5 1 BRUSH PLATE ASSEMBLY
6 1 ARMATURE
7 1 FIELD FRAME
8 1 SOLENOID
9 1 SHIELD
10 1 CUSHION
11 3 PLANETARY GEARS
12 1 PLUG
13 1 DISC
14 1 SHIFT FORK
15 1 GEAR/CLUTCH ASSEMBLY
16 1 BEARING
17 1 HOUSING
18 3 SCREW 40 4.5
19 1 DRIVE GEAR
20 1 SNAP RING
21 2 MOUNTING COLLAR
22 2 STOP
23 2 NUT 55 6.0
24 2 WASHER
25 1 NUT 20 2.3
90-884294 OCTOBER 2001 Page 2B-39

Troubleshooting the Solenoid Driven Bendix Starter Circuit

Before beginning the troubleshooting flow chart, verify the following conditions:
1. Confirm that battery is fully charged.
2. Check that control lever is in “NEUTRAL” position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 20 amp fuse.
Location of “Test Points” (called out in flow chart) are numbered below.
10
TO ALTERNATOR
9
8
1
STARTER
BATTERY
STARTER
SOLENOID
4
2
SLAVE SOLENOID
20 AMP FUSE 3
7
6 5
IGNITION SWITCH
NEUTRAL START SWITCH
(LOCATED IN CONTROL HOUSING)
58431
Solenoid Driven Bendix Starter Circuit
Page 2B-40 90-884294 OCTOBER 2001

Starter Circuit Troubleshooting Flow Chart (Solenoid Driven Bendix)

Starter Motor Does Not Turn
TEST 1
With ignition key in START position, check for battery volt-
age at TEST POINT 1.
Voltage indicated and solenoid clicks No voltage indicated Voltage indicated and solenoid does not click
Go to TEST 2 Check for starter motor ground at Test Point 10

Voltage indicated at Test Point 9
is 9.5 volts or greater.
Good ground Bad ground – clean cable ends

Voltage indicated at Test Point 9 or replace ground cable
is less than 9.5 volts.
Defective starter solenoid

Defective starter motor Defective starter solenoid
SAFETY WARNING: Disconnect BLACK with RED sleeve (starter motor)

cable from slave solenoid test point 7 BEFORE making tests 1–thru–7 to
prevent unexpected engine cranking.
TEST 2
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.
No Continuity Indicated – There is an open circuit in the Continuity Indicated

BLACK NEGATIVE (–) battery cable between the NEGATIVE (–) Proceed to TEST 3
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.
Test 3
a. Disconnect BLACK ground wire(s) from Test Point 3.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 3.
proceed to TEST 4. c. Turn ignition key to “Start” position.
TEST 4 12 Volt Reading*

a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 4. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to “Start” position. Proceed to TEST 8.
90-884294 OCTOBER 2001 Page 2B-41

No voltage reading: 12 Volt Reading

proceed to TEST 5 Defective starter solenoid
TEST 5
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 5. Neutral start switch is open or YELLOW/RED
No voltage reading: wire is open between Test Points 5 and 4.
proceed to TEST 6 b. Turn ignition key to “Start” position.
TEST 6
Connect voltmeter between common 12 Volt Reading*
No voltage reading:
engine ground and Test Point 6 Defective ignition switch.
proceed to TEST 7
TEST 7
Check for voltage between common engine ground and Test Point 7.

Check BLACK cable with RED Check fuse in RED wire between Test Points
sleeve between battery(+) 6 and 7.
POSITIVE terminal and Test Point 8 Check for open RED wire between Test
and Test Point 7. Points 6 and 7.
TEST 8
a. Connect voltmeter between common engine ground and Test Point 2.
b. Turn ignition key to “Start” position.

Defective slave solenoid Should hear solenoid click: proceed to TEST 9
TEST 9
a. Reconnect BLACK cable (with RED sleeve) to slave solenoid Test
Point 7.
b. Connect voltmeter between common engine ground and Test Point 7.
c. Turn ignition key to “Start” position.
No voltage reading:
Check BLACK cable (with RED sleeve) for
poor connection or open circuit.
*Battery Voltage
Page 2B-42 90-884294 OCTOBER 2001

Starter Removal (Solenoid Driven Bendix)

CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect battery cables from battery.
2. Disconnect wires from starter solenoid terminals.
3. Remove starter trunion mounting bolts and remove starter from engine.
b a
59038
a - Starter Solenoid
b - Mounting Bolts
Starter Installation (Solenoid Driven Bendix)

1. Secure starter to engine with 4 bolts. Use right top bolt to attach BLACK NEGATIVE.
Torque top attaching bolts to 23 lb-ft (31 Nm). Torque bottom attaching bolts to 21 lb-ft.
(28.5 Nm).
90-884294 OCTOBER 2001 Page 2B-43

2. Secure BLACK cables (with RED sleeves) to POSITIVE (+) terminal on starter sole-
noid. Torque nut to 55 lb-in (6 Nm).
e
c a
59038
a - Top Bolts [Torque to 23 lb-ft (31 Nm)]
b - Bottom Bolts [Torque to 21 lb-ft (28.5 Nm)]
c - BLACK Cable (with RED sleeve)
d - Nut [Torque to 55 lb-in (6 Nm)]
e - Starter Solenoid
Page 2B-44 90-884294 OCTOBER 2001

Disassembly (Solenoid Driven Bendix Starter)

1. Remove brush lead from solenoid and through bolts from end frame.
e
b
a
c
58434
a - Brush Lead d - Brush Plate Screws
b - Through Bolts e - End Frame
c - Starter Solenoid
2. Remove armature and field frame from drive housing.
NOTE: Permanent magnets inside field frame will be holding armature in place.
d
e
58430
a - End Frame and Bearing
b - Screws (2) [Internal Torx – Snap On E6 Socket]
c - Brush Holder
d - Armature
e - Field Frame
90-884294 OCTOBER 2001 Page 2B-45

3. Remove shield and cushion from drive housing.
58432
a - Shield
b - Cushion
c - Drive Housing
4. Remove 3 screws retaining starter solenoid. Remove solenoid from drive housing.
5. Remove snap ring and gear from starter shaft.
b
d
58436
a - Drive Housing d - Snap Ring
b - Starter Solenoid e - Pinion Gear
c - Screws (3) [ Internal
Torx– Snap On E6
Socket]
Page 2B-46 90-884294 OCTOBER 2001

6. Remove planetary gear and clutch assembly from drive housing.

7. Remove solenoid arm, metal disc and plug from drive housing.
d
c
58437
a - Planetary Gear and d - Metal Disc
Clutch Assembly e - Solenoid Arm
b - Drive Housing
c - Plug
8. Inspect drive housing needle bearing for roughness. If bearing is worn or damaged,
bearing can be removed by using an appropriate mandrel to drive/press bearing from
drive housing.
NOTE: If bearing has spun in drive housing bore, drive housing must be replaced.
58439
a - Needle Bearing
b - Drive Housing
90-884294 OCTOBER 2001 Page 2B-47

Cleaning and Inspection

IMPORTANT: Do not use grease dissolving solvents to clean electrical compo-
nents, planetary gears or drive clutch. Solvent will damage insulation and wash the
lubricant out of the clutch drive and gears. Use clean rags and compressed air to
clean components.
1. Test over-running clutch action of drive. Pinion should turn freely in over-running di-
rection and must not slip in cranking direction.
2. Inspect pinion teeth for wear.
3. Inspect spring for tension and drive collar for wear.
4. Check that bearings roll freely. If any roughness is felt, replace bearing.
5. Inspect planetary gear assembly. Gears must mesh easily and roll freely with no bind-
ing.
Page 2B-48 90-884294 OCTOBER 2001

Reassembly (Solenoid Driven Bendix Starter)

1. Install solenoid arm with planetary gear and clutch assembly into drive housing.
b
58438
a - Solenoid Arm
b - Planetary Gear and Clutch Assembly
c - Drive Housing
2. Install metal disc and plug into drive housing.
a
b
58433
a - Metal Disc
b - Plug
90-884294 OCTOBER 2001 Page 2B-49

3. Attach solenoid arm to starter solenoid. Install starter solenoid in drive housing and
secure with 3 screws. Torque screws to 40 lb-in (4.5 N.m).
4. Install drive gear and secure with snap ring.
5. Reinstall rubber bumpers on housing.
c
e
a
58436
a - Drive Housing d - Drive Gear
b - Starter Solenoid e - Snap Ring
c - Screw (3) [Torque to f - Bumpers
40 lb-in (4.5 N.m)
6. Install cushion and shield in drive housing.
c
58432
a - Shield
b - Cushion
c - Drive Housing
Page 2B-50 90-884294 OCTOBER 2001

7. Install field frame over armature.

8. While holding brushes back, slide brush plate onto armature while aligning brush lead
grommet with slot in field frame.
9. Secure end plate to brush assembly with 2 screws. Torque screws to 30 lb-in (3.4 Nm)
NOTE: Prior to installing field frame assembly into drive housing, align slot in field frame
with plug in drive housing.
d
c
58435
a - Armature
b - Field Frame Grommet Slot
c - Brush Plate
d - Brush Lead Grommet
e - End Plate
f - Screws [Torque to 30 lb-in (3.4 Nm)]
g - Field Frame Plug Slot
90-884294 OCTOBER 2001 Page 2B-51

10. Install field frame and end frame in drive housing.

11. Install through bolts and brush lead. Torque through bolts to 110 lb-in (12.5 Nm).
Torque brush nut to 55 lb-in (6 Nm).
b
d c
f
a
58434
a - End Frame
b - Field Frame
c - Drive Housing
d - Through Bolts [Torque to 110 lb-in (12.5 Nm)]
e - Brush Lead
f - Brush Nut [Torque to 55 lb-in (6 Nm)]
Page 2B-52 90-884294 OCTOBER 2001

Commander 2000 Key Switch Test

1. Disconnect remote control wiring harness and instrument panel connector.
2. Set ohmmeter on R x 1 scale for the following tests.
3. If meter readings are other than specified in the following tests, verify that switch and
not wiring is faulty. If wiring checks ok, replace switch.
IMPORTANT: Key switch must be positioned to “RUN” or “START” and key pushed
in to actuate choke for this test.
KEY CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:

POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK
OFF
RUN
START
CHOKE*
90-884294 OCTOBER 2001 Page 2B-53

TIMING, SYNCHRONIZING & ADJUSTING
ELECTRICAL
Section 2C - Timing, Synchronizing & Adjusting
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Maximum Throttle Adjustment . . . . . . . . . . 2C-4
C
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Throttle Position Sensor . . . . . . . . . . . . . . . 2C-5
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Throttle Cam Adjustment . . . . . . . . . . . . . . 2C-3 Throttle Cable Installation . . . . . . . . . . . . . 2C-5
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Throttle Plate Screw . . . . . . . . . . . . . . . . . . 2C-6
Specifications
EFI MODELS Idle RPM
– All Models 625 ± 50
– All Models 5000 – 5800
SYSTEM Spark Plug Type Champion QL77CC
Firing Order 1-2-3-4-5-6
Throttle Position Sensor
@ Idle* 0.19 – 1.0 vdc
@ W.O.T.* 3.45 – 4.63 vdc
TIMING Idle Timing
– All Models 0° – 6° BTDC
Maximum Timing @ W.O.T.*

– All Models 22° BTDC
*NOTE: Although the Throttle Position Sensor voltage and the idle and maximum timing
settings are not adjustable, they can be monitored by using a Digital Diagnostic Terminal
(DDT).
90-884294 OCTOBER 2001 Page 2C-1

Special Tools
1. Digital Diagnostic Terminal (DDT) 91-823686A2
3. DDT Reference Manual 90-881204-1
4. Adaptor Harness 84-822560A5 (use with DDT)
Page 2C-2 90-884294 OCTOBER 2001

Adjustments
IMPORTANT: All throttle linkage adjustments have been set at factory and appro-
priately secured to prevent unnecessary readjustment. These factory settings en-
able this engine to meet federally mandated emission standards and should not be
tampered with. However, should certain components fail, it may be necessary to
reset throttle linkage to approximate factory settings.
Throttle Cam Adjustment
1. Loosen cam follower screw, using Snap-On Tool TTXR25E, allowing cam follower to
move freely.
2. Allow roller to rest on throttle cam. Adjust idle stop screw on throttle arm to align
curved radius on throttle cam with center of roller. Tighten jam nut.
3. While holding throttle arm against idle stop, move cam follower arm until a 0.005 in.
to 0.020 in. (0.13 mm to 0.51 mm) clearance exists between roller and throttle cam.
Tighten cam follower screw.
a b
59031
a - Cam Follower Screw
b - Roller
c - Throttle Cam
d - Idle Stop Screw
e - Throttle Arm
f - Jam Nut
90-884294 OCTOBER 2001 Page 2C-3

Timing
All timing adjustments are controlled by the Electronic Control Module (ECM). No external
mechanical timing adjustments can be made.
Actual engine timing can be monitored by using a Digital Diagnostic Terminal (DDT).
Ignition timing at idle, whether in gear or in neutral, will vary.
The ECM will use ignition timing to maintain an rpm of approximately 700 in neutral and
625 in forward gear. An engine that is cold will require more timing advance than an engine
that is at normal operating temperature.
Engine timing at idle should be between 0° to 6° BTDC with the engine at normal operating
temperature.
Engine timing at 5000 rpm should be approximately 22° BTDC for all models.
Maximum Throttle Adjustment
1. Hold throttle arm against full throttle stop screw. Adjust full throttle stop screw to allow
full throttle valve opening, while maintaining a clearance of 0.020 in. (0.50 mm) be-
tween arm of throttle shaft and stop on throttle assembly. Tighten locknut.
2. Check for slight free play (roller lifter from cam) between roller and cam at full throttle
to prevent linkage from binding. Readjust full throttle stop screw, if necessary.
0.020 in.
(0.050 mm)
a
b
59032
a - Throttle Arm c - Throttle Shaft Arm
b - Full Throttle Stop d - Stop
Screw e - Locknut
Page 2C-4 90-884294 OCTOBER 2001

Throttle Position Sensor

The Throttle Position Sensor (TPS) is not adjustable. The Throttle Position Sensor func-
tion can be monitored by using the DDT. All voltages should be within specifications listed.
Voltage progression from idle to wide open throttle should be smooth. If voltage is out of
specification or progression is erratic, TPS should be replaced.
IGNITION Throttle Position Sensor

SYSTEM @ Idle 0.19 – 1.0 vdc
@ W.O.T. 3.45 – 4.63 vdc
Idle Speed
The idle speed is not adjustable. Idle speed is controlled by the ECM by advancing or re-
tarding the ignition timing to maintain an idle rpm of approximately 700 in neutral and 625
in gear.
Throttle Cable Installation
1. With end of throttle cable connected to throttle lever, hold throttle lever against idle
stop. Adjust throttle cable barrel to slip into barrel recess of control cable anchor
bracket, with a light preload of throttle lever against idle stop. Lock barrel in place.
IMPORTANT: Excessive preload on throttle cable will cause difficulty when shifting
from “FORWARD” to “NEUTRAL” (readjust throttle cable barrel, if necessary).
d b
c
a
a - Throttle Lever c - Cable Barrel – Adjust

b - Idle Stop To Hold Idle Stop
Screw Against Stop
d - Idle Stop Screw
2. Check preload on throttle cable by placing a thin piece of paper between idle stop
screw and idle stop. Preload is correct when paper can be removed without tearing,
but has some drag on it (readjust throttle barrel, if necessary).
b
a
90-884294 OCTOBER 2001 Page 2C-5

Throttle Plate Screw

IMPORTANT: Do not adjust throttle plate stop screw from factory setting. However,
should the throttle plate require adjustment, use the throttle plate stop screw to set
the total throttle plate clearance @ 0.040 in. (1.0 mm) or 0.020 in. (0.50 mm) each
side.
a
59025
a - 0.020 in. (0.50 mm) each side

b - Throttle Plate Stop Screw
Page 2C-6 90-884294 OCTOBER 2001

WIRING DIAGRAMS
ELECTRICAL
Section 2D – Wiring Diagrams
Table of Contents
2
Power Trim Wiring Diagram . . . . . . . . . . . . . . 2D-2 Warning System . . . . . . . . . . . . . . . . . . . . . . 2D-26
D
Instrument Wiring Connections . . . . . . . . . . . . 2D-3 Warning Display Screens . . . . . . . . . . . . . . 2D-27
Commander 3000 Classic Panel Remote CAL1 Calibration . . . . . . . . . . . . . . . . . . . . . 2D-30
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 CAL2 Calibration . . . . . . . . . . . . . . . . . . . . . 2D-32
Commander 3000 Panel Remote Control . . . 2D-5 Master Reset Command . . . . . . . . . . . . . . 2D-35
4000 Series Mechanical Panel Control . . . . . 2D-6 System Tach & Speed . . . . . . . . . . . . . . . . . . . 2D-36
Instrument/Lanyard Stop Switch Basic Operation and Features . . . . . . . . . 2D-36
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7 Speedometer Display Screens . . . . . . . . . 2D-37
Oil Level Gauge Wiring Diagram . . . . . . . . . . 2D-8 Tachometer Display Screens . . . . . . . . . . . 2D-38
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9 Troll Control . . . . . . . . . . . . . . . . . . . . . . . . . 2D-39
Instrument/Lanyard Stop Switch Wiring Warning System . . . . . . . . . . . . . . . . . . . . . . 2D-40
Diagram (Dual Outboard) . . . . . . . . . . . . . . . . . 2D-10 Alarm Messages . . . . . . . . . . . . . . . . . . . . . 2D-41
QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . 2D-12 Auto-Detection Engine Function . . . . . . . . 2D-45
Tachometer Wiring Diagram . . . . . . . . . . . 2D-12 Master Reset Command . . . . . . . . . . . . . . 2D-45
Water Temperature Gauge . . . . . . . . . . . . 2D-13 Tachometer Calibration . . . . . . . . . . . . . . . . 2D-46
Oil Level Gauge Wiring . . . . . . . . . . . . . . . . 2D-14 Speedometer Calibration . . . . . . . . . . . . . . 2D-50
Engine Synchronizer Wiring Diagram . . . 2D-16 SmartCraft Gauge Operation . . . . . . . . . . . . . 2D-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-17 Basic Operation and Features . . . . . . . . . 2D-52
Warning System Signals . . . . . . . . . . . . . . . . . 2D-18 Speedometer Display Screen . . . . . . . . . . 2D-53
Guardian Protection System . . . . . . . . . . . . . . 2D-19 Tachometer Display Screens . . . . . . . . . . . 2D-54
Guardian System Operation with Gauges 2D-19 Troll Control . . . . . . . . . . . . . . . . . . . . . . . . . 2D-55
Guardian System Activation . . . . . . . . . . . 2D-19 Warning System . . . . . . . . . . . . . . . . . . . . . . 2D-56
Analog Gauge Panel Mount Remote Control Alarm Messages . . . . . . . . . . . . . . . . . . . . . 2D-57
Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . 2D-21 Tachometer Calibration . . . . . . . . . . . . . . . . 2D-61
System Monitor V2.0 . . . . . . . . . . . . . . . . . . . . 2D-22 Speedometer Calibration . . . . . . . . . . . . . . 2D-64
Basic Operation . . . . . . . . . . . . . . . . . . . . . . 2D-22 SmartCraft Gauge Test Specifications . . . . . . 2D-66
Initial Power Up (Or After Master Reset) . 2D-22 Test Equipment Required: . . . . . . . . . . . . . 2D-66
Standard Information Display Screens . . 2D-23 3 Liter Work/225 EFI/250 EFI
Display of Range and Depth Information 2D-25 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-67
90-884294 OCTOBER 2001 Page 2D-1

WIRING DIAGRAMS
Power Trim Wiring Diagram
cc
bb
aa
dd
m
m
ll
ee
ff
gg
kk
hh
j i
a - Tach. Connector h - Trim Pump and Motor

b - Key Switch Assembly i - DOWN Solenoid
c - Trim Switch j - UP Solenoid
d - Trim Sender k - Bottom Cowl Switch
e - Start Solenoid l - 20 Ampere Fuse
f - To Battery m - Engine Harness
g - To Alternator n - Remote Control Harness
Page 2D-2 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Instrument Wiring Connections

Wire Color Where To
BLK = BLACK GROUND Speedometer Tachometer
TAN/WHT = TAN/WHITE OIL LIGHT
TAN/BLK = TAN/BLACK TEMPERATURE LIGHT
TAN = TAN TEMPERATURE GAUGE Temperature/Oil
PUR = PURPLE IGNITION 12 VOLT Volt Meter
GRY = GRAY TACHOMETER
BRN/WHT = BROWN/WHITE TRIM GAUGE
TAN/BLU = TAN/BLUE VISUAL WARNING KIT (OPT.)
aa bb
c
58912
Figure 1 – Without Light Switch
NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED
BACK TO THE HARNESS.
Speedometer Tachometer
Temperature/Oil
To 12V Volt Meter
aa bb
c
58913
Figure 2 – With Light Switch

a - Tachometer Receptacle - From Control Box or Ignition/Choke Switch
b - Tachometer Wiring Harness
c - Lead to Optional Visual Warning Kit (Taped Back to Harness)
d - Light Switch
90-884294 OCTOBER 2001 Page 2D-3

WIRING DIAGRAMS
Commander 3000 Classic Panel Remote Control

BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
Tan = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
< F R >
RED
PURPLE
GREEN
aa
a - Neutral Interlock Switch
Page 2D-4 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Commander 3000 Panel Remote Control

BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
RED
PURPLE
GREEN
aa
90-884294 OCTOBER 2001 Page 2D-5

WIRING DIAGRAMS
4000 Series Mechanical Panel Control

BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
d
RED/PURPLE
BLUE/WHITE
GREEN/WHITE aa
58629

b - Solder Connections covered with shrink tube
c - Emergency Stop Switch Harness
d - Trim Harness
Page 2D-6 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Instrument/Lanyard Stop Switch Wiring Diagram

BLK=BLACK f
BLU=BLUE g
BRN=BROWN
GRN=GREEN
GRY=GRAY
PUR=PURPLE dd
RED=RED
TAN=TAN
WHT=WHITE ee
YEL=YELLOW
cc aa
bb
jj
kk
h
ii
jj
52204
a - Ignition/Choke Switch
b - Lanyard Stop Switch
c - Lead Not Used on Outboard Installations
d - Retainer
e - Tachometer
f - Trim Indicator Gauge (Optional)
g - Temperature Gauge
h - Remote Control
i - Power Trim Harness Connector
j - Connect Wires Together w/Screw and Nut (2 Places); Apply Liquid Neoprene
to Connections and Slide Rubber Sleeve over each Connection.
k - Lead to Optional Visual Warning Kit
IMPORTANT: On installations where gauge options will not be used, tape back any
unused wiring harness leads.
90-884294 OCTOBER 2001 Page 2D-7

WIRING DIAGRAMS
Oil Level Gauge Wiring Diagram

ee
d ff
cc
gg
bb
aa
q
rr
pp ss hh
oo t
nn
jj
m
m l
k ii
a - To 12 Volt Source
b - PURPLE Wire (Connect to Trim Indicator Gauge “I” [or POSITIVE (+) 12 Volt
Source that is Turned “ON” and “OFF” with Ignition Switch])
c - Oil Level Gauge
d - BLACK Wire (Connects to NEGATIVE Ground)
e - To Ground
f - BLACK Wire (From Gauge to Oil Clip Connector)
g - LIGHT BLUE Sender Lead to Gauge
h - Wiring Harness (LT. BLU. and BLACK)
i - Screw (10-16 x 5/8 in.)
j - Spring
k - Oil Clip Connector
l - Adaptor Housing
m - Screw (10-16 x 1/4 in.)
n - Spring
o - Screw (10-16 x 5/8 in.)
p - BLACK Wire
q - Oil Level Sender Unit
r - Oil Pick-Up Tube
s - WHITE Lead (from Oil Level Sender)
t - Screw (10-16 x 5/8 in.)
Page 2D-8 90-884294 OCTOBER 2001

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

WIRING DIAGRAMS
Instrument/Lanyard Stop Switch Wiring Diagram (Dual

Outboard)
d kk dd
cc b
gg
BLK=BLACK l
BATT GND
BLU=BLUE d
BRN=BROWN
GRN=GREEN SENDER
GRY=GRAY
PUR=PURPLE ee
RED=RED aa
TAN=TAN
WHT=WHITE
YEL=YELLOW
ff
nn
oo
hh nn
52205 PORT INSTALLATION
a - Ignition/Choke Switch
b - Lanyard Stop Switch
c - Lead not used on Outboard Installations
d - Retainer
e - Tachometer
f - Trim Indicator Gauge
g - Temperature Gauge
h - Remote Control
Page 2D-10 90-884294 OCTOBER 2001

WIRING DIAGRAMS
IMPORTANT: On installations where gauge options will not be used, tape back and
isolate unused wiring harness leads
gg
BATT GND
ii
SENDER
aa
ee
jj
ff
oo
m
m
STARBOARD INSTALLATION 52206
i - Synchronizer Gauge
j - Synchronizer Module
k - Lanyard Switch (Isolation) Diode
l - Y Harness
m - Power Trim Harness Connector
n - Connect Wires together with Screw and Nut (4 Places); Apply Liquid Neo-
prene to Connections and slide Rubber Sleeve over each Connection.
o - Lead to Visual Warning Kit
90-884294 OCTOBER 2001 Page 2D-11

WIRING DIAGRAMS
QSI Gauge Wiring Diagrams

Tachometer Wiring Diagram
Tachometer dial on back side of case must be set to position number 4.
WIRING DIAGRAM A
Use this wiring diagram when using a separate light switch for instrument lighting.
b
c
a d
51106
a - Connect to +12 Volt
b - +12 Volt Light Switch Wire
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground
WIRING DIAGRAM B
Use this wiring diagram when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key switch is turned on.)
b
a
c
51106
b - Position Light Bulb to the Unswitched Position
c - Connect to NEGATIVE (–) Ground
Page 2D-12 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Water Temperature Gauge

WIRING DIAGRAM A
Use this wiring diagram when using a separate light switch for instrument lighting.
b
c
d
a
SEND
e
a - Connect to + 12 Volt
b - +12 Volt Light Switch Wire
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground
e - Connect to TAN Lead located at the Tachometer Receptacle on Commander
Side Mount Remote Control or TAN Lead coming from Accessory Ignition/
Choke Assembly.
WIRING DIAGRAM B
Use this wiring diagram when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key is turned on.)
b
c
a
SEND
d 51105
c - Connect to NEGATIVE (–) Ground
d - Connect to TAN Lead located at the Tachometer Receptacle on Commander
Side Mount Remote Control or TAN Lead coming from Accessory Ignition/
Choke Assembly
90-884294 OCTOBER 2001 Page 2D-13

WIRING DIAGRAMS
Route TAN lead on starboard side of engine to engine/remote control harness. Connect
as shown.
IMPORTANT: Tape back and isolate any unused wiring harness leads.
28086
a - Lead from Temperature Sender
b - Engine/Remote Control Harness
Oil Level Gauge Wiring

LIGHT BULB POSITION A
Use this position when using a separate light switch for instrument lighting.
b
51109
a - +12 Volt Light Switch Wire
b - Position Light Bulb to the Switched Position
Page 2D-14 90-884294 OCTOBER 2001

WIRING DIAGRAMS
LIGHT BULB POSITION B

Use this position when instrument lighting is wired directly to the ignition key switch. (In-
strument lights are on when ignition key switch is turned on.)
a
51112
a - Position Light Bulb to the Unswitched Position
b - Sender
SENDER WIRING
a
51108
b - Connect to NEGATIVE (–) Ground
90-884294 OCTOBER 2001 Page 2D-15

WIRING DIAGRAMS
Engine Synchronizer Wiring Diagram

LIGHT BULB POSITION A
Use this position when using a separate light switch for instrument lighting.
b
SEND
51105
a - +12 Volt Light Switch Wire
LIGHT BULB POSITION B

Use this position when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key switch is turned on.)
a
51106
a - Position Light Bulb to the Switched Position
b - Sender
Page 2D-16 90-884294 OCTOBER 2001

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

a cc
bb
GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE 51107
a - Tachometer Starboard Engine
b - Synchronizer Gauge
c - Tachometer Port Engine
d - Synchronizer Module
Maintenance
Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with
a soft cloth moistened with water. The gauge may be scored or damaged if wiped with
abrasive material (sand, saline or detergent compounds, etc.) or washed with solvents
such as trichloroethylene, turpentine, etc.
90-884294 OCTOBER 2001 Page 2D-17

WIRING DIAGRAMS
Warning System Signals

NOTE: The warning system signals which includes audible and visual indicator involving
the horn and gauges will identify the potential problems listed in the chart
Problem Horn Monitor Display Guardian Acti- Engine Speed

vated Reduction Activated
Power Up/System Check Single Yes N/A No

Beep
Low Oil 4 Beep... 2 Yes No No
Minutes Off
Oil Pump Electrical Yes Yes Yes
Failure (See Guardian System)
Over Heat Continuous Yes Yes Yes
Beep (See Guardian System)
Water In Fuel 4 Beep... 2 Yes No
Minutes Off
Over Speed Continuous Yes Yes Yes
Beep (See Guardian System)
Coolant Sensor Failure No Yes No No
MAP Sensor Failure No Yes No No
Air Temperature Sensor Fail- No Yes No No
ure
Ignition Coil Failure No Yes No No
Injector Failure No Yes No No
Horn Failure N/A Yes No
Battery Voltage too high No Yes Yes Yes
(16V) or too low (11V) or (See Guardian System)
very low (9.5V)
Throttle Sensor Failure Continuous Yes Yes Yes
Intermittant (See Guardian System)
Beeping
Block Water Pressure Yes Yes Yes Yes
(See Guardian System)
Calculated Oil Level Critical Yes Yes Yes Yes
Page 2D-18 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Guardian Protection System

The guardian protection system monitors critical engine functions and will reduce engine
power accordingly in an attempt to keep the engine running within safe operating parameters.
IMPORTANT: The Guardian System cannot guarantee that powerhead damage will
not occur when adverse operating conditions are encountered. The Guardian Sys-
tem is designed to (1) warn the boat operator that the engine is operating under ad-
verse conditions and (2) reduce power by limiting maximum rpm in an attempt to
avoid or reduce the possibility of engine damage. The boat operator is ultimately
responsible for proper engine operation.
Guardian System Operation with Gauges
Smartcraft Gauge/Monitor System will sound warning horn and display the
warning message.
Guardian System Activation

Warning Horn
Function Sound Description
Cooling System Problem Continuous Engine Guardian System is activated. Power
limit will very with level of overheat. Shift out-
board into neutral and check for a steady stream
of water coming out of the water pump indicator
hole. If no water is coming out of the water pump
indicator hole or flow is intermittent, stop engine
and check water intake holes for obstruction. The
Guardian system must be RESET before engine
will operate at higher speeds. Moving throttle
lever back to idle resets the system.
Oil Level Is Critically Low Continuous Engine Guardian System is activated. Power
limit will limit engine speed. The oil level is criti-
cally low in the engine mounted oil reservoir
tank. Refill the engine mounted oil reservoir tank
along with the remote oil tank.
Oil Pump Failure Continuous Engine Guardian System is activated. Power

limit will limit engine speed. The warning horn is
activated if the oil pump should ever stop func-
tioning electrically. No lubricating oil is being
supplied to the engine.
90-884294 OCTOBER 2001 Page 2D-19

WIRING DIAGRAMS
Engine Overspeed Continuous The warning horn is activated any time engine
speed exceeds the maximum allowable RPM.
The system will limit the engine speed to within
the allowable range. If the overspeed condition
continues, the Engine Guardian System will
place the engine in power reduction. The Guard-
ian system must be RESET before engine can
resume full power. Moving throttle lever back to
idle resets the system. Engine overspeed indi-
cates a condition that should be corrected.
Overspeed could be caused by incorrect propel-
ler pitch, engine height, trim angle, etc.
Sensor out of Range Continuous Engine Guardian System is activated. Power

limit may activate at full throttle speed.
Intermittent Beep Engine Guardian System is activated. Power

limit may restrict engine speed to idle.
Page 2D-20 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Analog Gauge Panel Mount Remote Control Wiring

Installation
aa b
b
qr
f
25
ee
cc dd gg h
h
i
t
j sr
k n
o
m
n
op
l
st
p
q
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
25 Liquid Neoprene YEL = Yellow
LIT = Light
DRK = Dark
a - (+) 12 Volt Terminal j - Multi-Function Adapter Har-
b - (–) Ground Terminal ness
c - Speedometer k - To Fuel Sender (Optional)
d - Tachometer l - To Oil Sender (Optional)
e - Tachometer Signal Terminal m - Two Wire Harness
f - Connect Wires Together with n - Ignition/Choke Switch
Screw and Hex Nut (3 o - Low Oil Sender Lead
Places); Apply Liquid Neo- p - Over Temperature Switch
prene to Connections and Lead
Slide Rubber Sleeve Over q - Panel Mount Remote Control
Each Connection. r - To Engine
g - Power Trim Connector s - To Engine
h - Horn t - Neutral Safety Switch Lead
i - 8 Pin Harness Connector
90-884294 OCTOBER 2001 Page 2D-21

WIRING DIAGRAMS
System Monitor V2.0
Basic Operation
The System Monitor is an LCD multi-function display gauge. A variety of displays can be
activated using the button.
Pressing the button scrolls the following displays: fuel used, tachometer (RPM), fuel
flow, power trim position, engine temp, water pressure, battery voltage, traveling range (if
calibrated), and water depth (if equipped with transducer).
The System Monitor will power up when the ignition is turned on.
The display includes a backlight which allows you to read it at night. The backlight bright-
ness is adjustable using button.
In the event of a warning alarm, the warning icon(s) will be displayed.

The System Monitor can be calibrated to display both the English or the Metric system. The
System Monitor can also be calibrated so that the trim position is displayed whenever the
propulsion unit is trimmed. Refer to Cal.1 Calibration Section for details.
Initial Power Up (Or After Master Reset)
Unit will display software level then flash the word “SEt” in conjunction with engine icon.
Press the button.

The unit will begin it’s “Auto–detection” of engine type procedure. In this procedure System
Monitor checks with the engine control module (ECM) to see what type of engine you have
and presets the data monitoring screens accordingly, (e.g., If System Monitor detects an in-
board engine connected to the data network it will turn off all engine/drive TRIM functions as
these functions are not used in an inboard engine installation). The intention is to make initial
setup easier.
NOTE: If “2001” comes up during auto detect the gauge has detected that your engine
is a pre 2002 model. You will need to manually select your engine type. Use the
button to scroll through the choices. Stnd = Stern Drive, Inbd = Inboard, JEtd = Jet Drive,
Out2 = Outboard 2 Stroke, Out4 = Outboard 4 Stroke. Press to continue.
Page 2D-22 90-884294 OCTOBER 2001

WIRING DIAGRAMS
NOTE: If you see the flashing message, (A) “nonE” after the Auto–detection occurs, the
gauge can not find an engine. Please check wiring for correct connection. If you receive one
of the following other flashing messages: (B) “Stbd”or, (C) “noSt” refer to the “Set–Up Errors
Section”.
A)
B)
C)
Standard Information Display Screens

START UP SCREEN
At power up, a momentary (1 second) screen displays the current System Monitor software
version, followed by a 4 second display showing hours of engine use.
Hrs
NOTE: NOT ALL SCREENS MAY APPLY TO YOUR ENGINE TYPE.

NOTE: Screens can be turned on/off in Cal1. Refer to the Cal1 calibration section for details.
RPM SCREEN
Tachometer – Displays engine speed in Revolutions Per Minute (RPM).
RPM
FUEL USED SCREEN

The System Monitor displays approximate fuel used since the last reset.
Gal Gal
Fuel Used Reset will return display back to 0. You can preform a Fuel Used Reset any-
time by pressing and buttons together momentarily.
90-884294 OCTOBER 2001 Page 2D-23

WIRING DIAGRAMS
FUEL FLOW SCREEN

The System Monitor displays current estimated individual engine fuel consumption in Gallons
per hour (Gal/hr) or Liters per hour (Ltr/hr).
Gal/h
TRIM POSITION SCREEN

Displays trim position of the propulsion unit up to the maximum trim position, and then dis-
plays trailer position. 0 = down, 10 = maximum trim, and 25 = full trailer.
TRIM
NOTE: The System Monitor may be calibrated so that trim is displayed whenever the trim
switch is used. Refer to the Cal1 Calibrations Section for details.
ENGINE TEMPERATURE SCREEN
Displays the engine temperature in degrees Fahrenheit (°F) or Celsius (°C).
NOTE: You can change the units of measure within Cal1. Refer to the Cal1 Calibration
Section for details.
WATER PRESSURE SCREEN
Displays cooling system water pressure of the engine in Psi or Bar.
Psi
OIL TEMPERATURE SCREEN

Displays the engine oil temperature in degrees Fahrenheit (°F) or Celsius (°C).
Page 2D-24 90-884294 OCTOBER 2001

WIRING DIAGRAMS
OIL PRESSURE SCREEN

Displays engine oil pressure in Psi or Bar.
Psi
BATTERY VOLTAGE SCREEN

Displays voltage level (condition) of battery.
Volt
Display of Range and Depth Information

RANGE SCREEN
Displays estimated traveling range based on current fuel consumption and fuel remaining
in the tank that is connected to the system. The number displayed is an estimate of the dis-
tance you can travel on the remaining fuel at current boat speed.
Range
Miles
NOTE: To activate this screen, you must perform the fuel tank calibration in Cal2. Refer
to the Cal2 Calibration Section for details.
NOTE: You must have a speed input device connected to the system (paddle wheel or pitot
pressure transducer).
WATER DEPTH SCREEN
Displays the depth of water under the transducer (if connected).
Depth
Ft
90-884294 OCTOBER 2001 Page 2D-25

WIRING DIAGRAMS
SHALLOW WATER ALARM FEATURE

You can set an alarm to trigger whenever the boat moves into water shallower than the
alarm level.
Setting Shallow Water Alarm.
1. The water depth screen must be displayed. Be sure Depth is turned on in Cal2. Refer
to Cal2 Calibration Section for details.
2. Press both and buttons together for 3 seconds.
3. The alarm on or off menu will appear.
4. Press the button to toggle to ON.
Depth
5. Push button to save.

6. The depth number will be flashing. Press the button to set the flashing number
to desired alarm depth. 100 ft. maximum depth and 2 ft. minimum depth.
Depth
7. Push button to save.

Warning System
NOTE: Alarm warnings may vary depending on your engine type. Some warnings listed
may not apply to your engine. Please consult your engines owners manual for a complete
list of engine warnings.
The System Monitor warning system incorporates the display screen, the warning horn and
the Guardian Protection system. The warning horn is located inside the remote control or is
part of the ignition key switch wiring harness.
• Alarms Warnings – When a problem is detected, the warning horn sounds and the
offending icon appears on the display.
If problem can cause immediate engine damage – The horn will sound continuously
and the Engine Guardian System will respond to the problem by limiting engine power.
Immediately reduce throttle speed to idle and refer to the warning messages on the fol-
lowing pages that tell you what to do about it.
If problem will not cause immediate engine damage – The horn will sound but not con-
tinuously. Refer to the warning messages on the following pages that tell you what to
do about it.
• Engine Guardian System – Monitors the critical sensors on the engine for any early
indications of problems. The system will respond to a problem by reducing engine pow-
er in order to maintain a safe operating condition.
NOTE: If the mode button is pressed to a different screen, the flashing alarm signal will remain
flashing to indicate there still is a problem.
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WIRING DIAGRAMS
Warning Display Screens

The engine has an “Engine Guardian System”. The ECM Engine control module monitors
the critical sensors on the engine for any early indications of problems. The Guardian System
will respond to a problem by reducing engine speed in order to maintain a safe operating condi-
tion. The System Monitor will display the alarm.
The warning system will alert the operator to the potential problems. Refer to the pages
following for explanation of the problem and the correct action to take.
ALARM – OVERHEAT
The Bell and Temperature icons are displayed and the warning horn begins sounding con-
tinuously to inform the driver that there is insufficient water pressure in the cooling system.
The Engine Guardian System will start limiting engine power.
If the engine overheats, immediately reduce throttle speed to idle. Shift into neutral. If out-
board: check for a steady stream of water coming out of the water pump indicator hole.
NOTE: The throttle will have to be returned to idle to reset the system.
If no water is coming out of the water pump indicator hole or flow is intermittent, stop engine
and check cooling water intake holes for obstruction. If no obstruction is found, this may indicate
a blockage in the cooling system or a water pump problem. Operating the engine while over-
heated will cause engine damage.
If a steady stream of water is coming out of the water pump indicator hole and the warning
horn continues to sound, there still may be insufficient cooling water or an engine problem.
Stop engine. Operating the engine while overheated will cause engine damage.
The overheat problem must be corrected before you can resume normal operation.
NOTE: If you are in a stranded situation, stopping the engine and allowing it to cool back
down will usually allow some additional low speed (idle) running time before the engine starts
to overheat again.
ALARM – LOW WATER PRESSURE
The Bell and Water Pressure icons are displayed and the warning horn begins sounding contin-
uously to inform the driver that there is insufficient water pressure in the cooling system. The
Engine Guardian System will start limiting engine power.
Some causes of insufficient cooling water pressure are (1) obstructed cooling water intake
holes (2) blockage in the cooling system or a water pump problem. Running the engine with
the cooling water intake holes out of the water.
If the warning system is activated, immediately reduce throttle speed to idle. Shift engine into
neutral and check for a steady stream of water coming out of the water pump indicator hole.
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If no water is coming out of the water pump indicator hole, or flow is intermittent, stop engine
a blockage in the cooling system or a water pump problem. Have the outboard checked by
your dealer. Operating the engine without adequate cooling water pressure will overheat the
engine.
If the warning signals stop and a steady stream of water is coming out of the water pump indica-
tor hole, return engine to normal operation. If the warning system is activated repeatedly, have
the outboard checked by your dealer.
ALARM – LOW OIL RESERVE – OUTBOARD 2 STROKE
The bell and oil icons are displayed and the warning horn begins sounding a series of four
beeps every two minutes to inform the driver that the oil level is critically low in the engine
mounted oil reservoir tank. When the oil level gets close to empty, the horn begins sound-
ing continuously and the Engine Guardian System will start limiting engine power.
The engine mounted oil reservoir tank along with the remote oil tank will have to be refilled
(refer to Fuel & Oil Section).
ALARM – OIL PUMP FAULT
The Bell, Engine and oil icons are displayed and the warning horn begins sounding continuous-
ly to inform the driver that the oil pump has stopped functioning electrically. No lubricating oil
is being supplied to the engine. Stop the engine as soon as possible. The Engine Guardian
system will start limiting the engine power. Consult your dealer for assistance.
ALARM – ENGINE OVERSPEED

The Bell icon is displayed and the warning horn begins sounding continuously to inform the
driver that the engine speed exceeded the maximum allowable RPM. The system will automat-
ically reduce the engine speed to within the allowable limit.
NOTE: Engine speed should never reach the maximum limit to activate the system unless the
propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty.
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WIRING DIAGRAMS
ALARM – WATER IN FUEL

The Bell and Fuel Icon will appear and the warning horn will begin sounding a series of four
beeps every two minutes when water in the water-separating fuel filter reaches the full level.
On some engines water can be removed from the filter. Refer to Maintenance Section for filter
removal.
ALARM – LOW FUEL

The Bell and Fuel Icon will appear and the warning horn will sound a series of four beeps. This
alarm occurs when there is less than 1/8 of the total fuel capacity left. Once the four beeps have
sounded, this alarm will not reoccur unless the condition still exists after next key up.
ALARM – ENGINE MALFUNCTION
The Bell and Engine Icon will appear to inform the driver that an engine problem has occurred.
If the warning system senses that the problem could cause permanent engine damage, the
Engine Guardian System will start limiting engine power.
INSTALLATION ERROR DETECTION

1. System Monitor flashes a “nonE” message when there is no communication between
System Monitor and an ECM. Check for loose wiring. Preform master reset and try auto
detecting again. (Refer to Page 45 for Master Reset.)
2. System Monitor flashes a “Stbd” message when there is more than one Stbd ECM pres-
ent on the SmartCraft network. Need to configure ECM’s to proper engine location using
DDT or Quicksilver Diagnostics Tool.
3. System Monitor flashes a “noSt” message when there are no Stbd ECM’s present on the
SmartCraft network. Need to configure ECM’s to proper engine location using DDT or
Quicksilver Diagnostics Tool.
A)
B)
C)
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CAL1 Calibration
Cal1 Display Calibrations:
•Trim Pop up Screen (On or Off)
•Trim Calibration
•English or Metric Units Selection
•Range Units Selection
•(On or Off) Depth, Trim, Engine Temperature, Oil Pressure, Oil
Temperature, Water Pressure, Volts, Engine Hours, and Data
Simulator pages.
CAL1 HEADER SCREEN
1. Turn ignition key to the on position.
2. Press and hold and for 3 seconds to bring up the Cal1 calibration screen.
Release the buttons to enter Cal1.
3. Press the button to advance through the Cal1 calibration functions.
4. Press and hold and for 3 seconds to save changes and exit the Cal1 cal-
ibration screen.
Press the button to move to the next calibration screen.

NOTE: Pressing the button while in this header screen, will “transfer” you straight into
Cal2.
TRIM POP UP SCREEN (ON OR OFF)
If you want the power trim display screen to pop up as you trim the propulsion unit, cali-
brate as follows: With the pop up screen displayed and the number “flashing”, press the
button to select 1=ON or 0=off.
Trim
Press the button to save and move to the next function.

Set the trim sensor as follows:
Calibration 0.0 – The word “Trim” and down arrow should be blinking. Use the trim switch and
trim the unit to the full Down/In position. Press the button to save. Press the
button to advance to the Calibration 10.0 setting.
Trim
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Calibration 10.0 – The word “Trim” and the down and up arrows should be blinking. Trim the
unit out to the maximum trim (not trailer) position. Press the button to save. Press
the button to advance to the Calibration 25.0 setting.
Trim
Calibration 25.0 – The word “Trim” and up arrow should be blinking. Use the trim switch and
trim the unit out to the maximum trailer position. Press the button to save. Press the
button to move to the next function.
Trim
ENGLISH OR METRIC READINGS SELECTION

The System Monitor allows you to display reading in the SAE (standard) English system or
the Metric system. Press the button to toggle between units.
SAE English System Metric System
C
F
Bar
Psi
Gal Ltr M
Ft

RANGE READINGS SELECTION
The System Monitor allows you to display reading in Miles, Nautical Miles or Kilometers.
Press the button to toggle between units.
Range
Miles
Miles NMiles
Km

DATA PAGE SELECTIONS
Select if you would like to display Depth, Trim, Engine Temperature, Oil Pressure, Oil Temper-
ature, Water Pressure, Volts, Engine Hours, and Data Simulator pages or not.
NOTE: The engine connected may not support all screen functions.
Press the button to toggle between units.
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CAL2 Calibration
CAL2 Display Calibrations:
•Paddle Wheel Speed Sensor Frequency Setting
•Pitot Water Pressure Speed Sensor Input Setting
•Pitot Water Pressure Speed Sensor Multiplier
•Fuel Tank Calibration
CAL2 HEADER SCREEN

1. Turn ignition key to the on position.
2. Press and hold and , System Monitor will first display Cal1,and then after
6 seconds will display Cal2. Release the buttons to enter the Cal2 calibration screen.
3. Press the button to advance through the Cal2 calibration functions.
4. Press and hold and for 3 seconds to get out of the Cal2 calibration screen.
PITOT WATER PRESSURE SENSOR INPUT SETTING (SPD1 OR SPD2)

Select the PSI input of the Pitot water pressure sensor on the engine. Press the button
to select 1 = 100 PSI or 2 = 200 PSI. The standard PSI input on production Mercury product
is 100 PSI. Certain High Performance applications may require a 200 Psi input.

PITOT WATER PRESSURE SENSOR MULTIPLIER (1.XX)
This multiplier can be used to adjust the pitot speed to match speed as measured on GPS
or radar gun. Press the button to select change.
Frequency can be changed to match requirements of different sensors. 4.9 (hz/Mile) is the fre-
quency of the paddle wheel speed sensor provided by Mercury Marine.
Miles
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FUEL TANK CALIBRATION:

NOTE: There are three methods to set up fuel tank level monitoring feature:
First: Do nothing. Linear readout based on raw sensor values. This mode does not factor
in irregular tank shapes.
Second: By following the tank calibration procedure described on pages 33–35, but with-
out actually adding fuel. System Monitor will supply an estimated range value based on
linear interpolation of the sensor range values. This mode does not factor in irregular tank
shapes.
Third: By following the tank calibration procedure described on pages 33–35 completely
System Monitor will display an estimated range value that factors in the tank shape.
1. Scroll using the key until you see “t1”. This tells you that you have entered tank
1 calibration.
2. Press once more.
3. You will see the word “no” and the gas tank icon. Enter the capacity of tank 1 in gallons
using the key.
NOTE: The word “no” will not go away unless the gauge sees a tank connected to the system.
With no tank connected you will not be able to enter a capacity.
4. Press once more.
5. You will see “t2”. This tells you that you have entered tank 2 calibration.
6. Press once more.
7. You will see the word “no” and the gas tank icon. Enter the capacity of tank 2 in gallons
using the key.
NOTE: The word “no” will not go away unless the gauge sees a tank connected to the system.
With no tank connected you will not be able to enter a capacity.
NOTE: Tank 2 does not have to be a fuel tank. It could represent an oil tank for example. See
page 35 for tank 2 selection.
Select whether you want to calibrate the fuel tank “t1”. (The gauge will not let you calibrate
the fuel tank until the capacity had been entered). Press the button to select 0= off or
1= on.
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Selecting “1” will bring up the following calibration screens.

Calibration 0% – The “0 percent” display alternates between percent of tank capacity and
quantity of fuel to add based on total capacity entered in Cal2. Add fuel to total quantity dis-
played and push the button to save. Press the button to advance to the Calibra-
tion 25% setting.
Gal
Calibration 25% – The “25 percent” display alternates between percent of tank capacity
and quantity of fuel to add based on total capacity entered in Cal2. Add fuel to total quantity
displayed and press the button to save. Press the button to advance to the
Calibration 50% setting.
Gal
Calibration 75% setting.
Gal
Calibration FULL setting.
Gal
Calibration FULL – The “FULL percent” display alternates between percent of tank capac-
ity and quantity of fuel to add based on total capacity entered in Cal2.
Gal
Add fuel to fill tank and press the button to save. Press the button to move
to the next function.
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At this point you have completed tank 1 calibration and you will see “t2”.
Change “t20” to a 1 (on). Press the button, you will see a blinking tank icon. Using the
button, select which tank you want tank 2 to be, (oil, fuel or water/waste). Press the
button to continue.
NOTE: If you choose oil or water/waste, no further cal will be needed.

Repeat tank calibration procedure described on page 34 and 35 if calibration of the second tank
is desired.
Master Reset Command
Master Reset: You can return the gauge back to factory presets through the Master Reset
command.
IMPORTANT: Performing a master reset will reset the unit back to all factory defaults,
thus eliminating any installation calibrations performed during set up of product.
1. Hold in and for approximately 12 seconds. You will see the word “dFLt”
let go of the buttons.
2. Immediately press and hold in and again until the unit counts down to
zero “0”.
3. The “SEt” message flashing on the screen indicates that the unit has been reset to
factory defaults.
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WIRING DIAGRAMS
System Tach & Speed

Tachometer Speedometer
3 4 40
2 5 30 50
20 60
1 6
10 70
0 7 0 80
Basic Operation and Features

Power up: Each gauge will power up when the ignition is turned on. Gauges will stay on
as long as the ignition is on.
On first time power up of gauge or after a “Master Reset”, gauge will show “Auto detect”. Upon
pressing the mode button, gauge will automatically determine engine type. This will preset the
data monitoring screens accordingly. The intention is to make initial setup easier. If gauge
shows a warning of “No Starboard Engine” or “Multiple Starboard Engines”, engine will need
to be properly selected (Port and Stbd) using a Mercury engine diagnostic tool. “Master Reset”
and “Auto detect” again. (See page 45 for “Master Reset”).
Lights: The brightness and contrast are adjustable.
Buttons: The MODE button is used for selecting information screens. The “+” and “–” but-
tons are used for setting engine speed during troll control and setting gauge calibrations.
Troll Control: Allows the operator to set and control the idle speed of the engine for trol-
ling without using the throttle.
Engine Guardian System: Monitors the critical sensors on the engine for any early indications
of problems. The system will respond to a problem by reducing engine speed in order to main-
tain a safe operating condition.
Warning System: The system will sound the warning horn and display the warning message.
Digital Display Screen: Displays the following engine information.
Tachometer Display Screen: Speedometer Display Screen:
DEPENDING ON ENGINE TYPE DEPENDING ON ENGINE TYPE Speed
Engine Break–in Fuel Used
Engine Temperature COG/SOG – If GPS Input
Oil Psi Distance and fuel to way point –
Trim and RPM if way point programmed into optional GPS
Trim and Water Pressure Clock – Air/Sea Temp
Water Pressure Inst. and Ave. Fuel Economy
Battery Voltage and Engine Hours Trip Odometer
Fuel Flow and Fuel Used Fuel Tank Levels
RPM Oil Tank Levels
Fresh Water Tank2 or Level(s)
Waste Water Level(s) or
Dual Engine
Trim and RPM Synchronizer –
Fuel Range
Fuel Economy
Trip Odometer
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Speedometer Display Screens
Speedometer
1
30
40
50 6
2 20 60
10 70
7
0
3 80
8
4
9
5

When the ignition is turned on, the speedometer will show the last screen that was dis-
played before the ignition was turned off.
Press MODE to change display screens. You can revert back to the previous screen by press-
ing and holding MODE for 2 seconds. This will reverse the display rotation.
NOTE: Readings can be displayed in English (U.S.) or Metric. Refer to Calibrations.
NOTE: Descriptions are necessarily in order on the gauge. Order changes depending on
engine type.
1. Clock - Temp – Clock, air temperature and water temperature. The air and water temper-
ature sensors will have to be connected to obtain display readings.
2. Fuel Level – Displays the amount of fuel remaining.
3. Oil Level – Displays the amount of engine oil remaining, or water/waste tank level (if
attached).
4. RPM Synchronizer – Dual Engines Only – Monitors the revolutions of both engines.
5. Trim Synchronizer – Dual Engines Only – Displays the trim position of both engines. Sim-
plifies keeping trim levels equal.
6. Traveling Range – The estimated traveling range is based on boat speed, fuel consump-
tion and fuel remaining in the tank. The numbers displayed indicates an estimate of the
distance you can travel with the remaining fuel. Speed input required (Paddle Wheel, Pitot
Pressure or GPS).
7. Fuel Economy – The display shows average “AVG” fuel consumption as well as
Instantaneous “INST” fuel economy. The numbers displayed indicate miles per gallon
“MPG” or kilometer per liter “KM/L”.
Fuel Reset – To reset, select the display screen and press MODE and TROLL
– buttons.
8. Trip Odometer – Tells how far you’ve gone since you last reset the gauge to zero. Trip
Reset – To reset, select the display screen and press MODE and TROLL– buttons.
9. Digital Speedometer – Can display boat speed in miles per hour, kilometer per hour,
or nautical miles per hour. The (LCD) digital speedometer will continue to increase
even if “StEt” is at maximum. The speedometer will use the paddle wheel for its low
speed readings but will switch to the speedo or GPS (if connected) for high speed
readings. (Transition point setting described in Cal2, page 51.)
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Tachometer Display Screens

Tachometer
1
3 4
ENG 2 5
2 °F
VOLT HRS
1 6
13.6 22.3 7
0 7
3 FUEL USED
2.4 22.0
8
PSI
4
3200 9
5 WATER
PSI

When the ignition is turned on, the tachometer will display the last screen that was dis-
Press MODE to change display screens. You can revert back to the previous screen by press-
ing and holding MODE for 2 seconds. This will reverse the display rotation.
NOTE: Readings can be displayed in English (U.S.) or Metric. Refer to Calibration.
1. Engine Break-in – Displays time remaining on the break-in period of a new engine. This
screen will automatically disappear after the break-in period is complete.
2. Temperature – Displays engine coolant temperature from Cold to Hot.
3. Power Trim Angle: Displays trim angle of the outboard or sterndrive up to the maxi-
mum trim angle, and then displays the trailer angle. 0 = down, 10 = maximum trim,
and 25 = full trailer.
4. Power Trim Angle - Water Pressure – Displays trim angle of the engine and cooling
system water pressure.
5. Water Pressure: Displays cooling system water pressure at the engine.
6. Oil Pressure (Not Shown Above) – Displays engine oil pressure in units of Psi or
Bar.
7. Battery Voltage – Displays voltage level (condition) of battery. Also records the run-
ning time of engine.
8. Fuel Flow – Displays engine fuel use in gallons per hour or liters per hours.
9. Digital Tachometer: Displays engine speed in Revolutions Per Minute (RPM).
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Troll Control
BASIC OPERATION
3 4
2 5
1 6
0 7
0 80
TROLL TROLL TROLL TROLL

– + – +
Actual Speed Set Speed Actual Speed Set Speed

a TR
With troll control you can maintain a trolling speed of 550 to1000 rpm without using the
throttle.
NOTE: Troll control may not be available on all engine models.
NOTE: Troll control min/max range may change depending on engine type.
You can set the troll control by using either the tachometer or speedometer. Tachometer
will set the speed in RPM and speedometer will set the speed in MPH, Kph or KN.
You can shut off troll control anytime by pushing the MODE button when in the troll display
screen or by moving the throttle.
If you have troll control set at a desired speed and then you shut off the troll control, the system
remembers the set speed and will return to that speed when re-engaged.
The display screen will revert back to the previous screen after 10 seconds of no activity. Push
the TROLL
+ or TROLL
– button to reactivate the display screen.
When the troll control is engaged and you are out of the troll control screen, a flashing signal
“TR” (a) will appear in the upper left corner of the display to indicate troll control is still running.
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SETTING TROLL CONTROL

3 4
2 5
1 6
0 7 0 80
TROLL TROLL TROLL

– + – TROLL
+

a b
1. With the engine running, shift engine into gear. Set engine speed at idle.
TROLL TROLL
2. Push in the + or – button to bring up the troll control display screen.
3. Press MODE to engage (turn on) the troll control.
4. Use the TROLL
+
TROLL
– buttons to set the desired speed. Use (+) to increase speed and
(–) to decrease speed.
5. If you set troll control to a higher speed than the troll rpm can bring the boat to, the TROLL
SPEED TOO FAST (a) message will appear. Reduce troll speed.
6. If you set troll control to a slower speed than the troll rpm can bring the boat to, the TROLL
SPEED TOO SLOW (b) message will appear. Increase troll speed.
EXITING TROLL CONTROL
There are three ways to turn off the troll control:
• Press the MODE button when in the troll display screen.
• Move the throttle to a different speed.
• Shift engine into neutral.
Warning System
3 4
2 5
1 6
0 7 0 80
b a
c
2 AR
a - Display Screens c - Alarm Signal “AL”

b - Engine Guardian Sys-
tem
NOTE: Warnings may be different depending on engine type. Please consult your engine
owners manual for a complete list of failures.
The SmartCraft warning system incorporates the display screens the warning horn and the
Guardian Protection system. The warning horn is located inside the remote control or is part
of the ignition key switch wiring harness.
Page 2D-40 90-884294 OCTOBER 2001
WIRING DIAGRAMS
name of the offending alarm appears on the display.
If problem can cause immediate engine damage – the horn will sound continuously and
the Engine Guardian System will respond to the problem by limiting engine power. Im-
mediately reduce throttle speed to idle and refer to the warning messages on the fol-
lowing pages that tell what to do.
If problem will not cause immediate engine damage – The horn will sound but not con-
tinuously. Refer to the warning messages on the following pages that tell what to do.
The alarm message will stay displayed until the mode button is pressed. If there are
multiple alarms, these will cycle on the display at five-second intervals.
If the mode button is pressed to a different screen, the flashing alarm signal “AL” will
appear in the upper right corner to indicate there still is a problem.
• Engine Guardian System – Monitors the critical sensors on the engine for any early
indications of problems. The system will respond to a problem by reducing engine pow-
er in order to maintain a safe operating condition. The display screen will show the per-
cent of power available.
Alarm Messages
These messages will appear and the horn will sound if there is a problem detected in one
of the engine systems.
NOTE: The warning system will alert the operator to the potential problems listed in the
chart. Refer to the page listed for explanation of the problem and the correct action to take.
PROBLEM TACHOMETER SPEEDOMETER ENGINE HORN
DISPLAY DISPLAY GUARDIAN ONLY
SYSTEM
ACTIVATED
BATTERY *
ENGINE DATA BUS
FAULT – HORN
FAULT – IGNITION
FAULT – INJECTOR
FAULT – OIL PUMP
FAULT – SENSOR *
FAULT – WATER TEMP
LOW FUEL
LOW OIL
OIL TEMP
OIL PSI
OVERHEAT
OVER SPEED
PRESSURE
RESERVE OIL
WATER IN FUEL
FLASH CHECK SUM
MAP
MAT
TPS
* Throttle and manifold pressure sensors only
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OVERHEAT
The overheat alarm message appears and the warning horn begins sounding continuously.
If the engine overheats, immediately reduce throttle speed to idle. Shift engine into neu-
tral. Check for an obstruction covering the water intake holes on the engine.
3 4
2 5
1 6 a
0 7
a - Water Pump Indicator Hole

a blockage in the cooling system or a water pump problem. Operating the engine while over-
heated will cause engine damage.
Operating the engine while overheated will cause engine damage.
down will usually allow some additional low speed (idle) running time before the engine starts
to overheat again.
PRESSURE
This alarm message is displayed and the warning horn begins sounding continuously to inform
the driver that there is insufficient water pressure in the cooling system. The Engine Guardian
System will start limiting engine power.
Some causes of insufficient cooling water pressure are (1) obstructed cooling water intake
holes (2) blockage in the cooling system or a water pump problem (3) running the engine with
the cooling water intake holes out of the water.
3 4
2 5
1 6
a
0 7

If the warning system is activated, immediately reduce throttle speed to idle. Shift engine into
neutral and check for a steady stream of water coming out of the water pump indicator hole.
a blockage in the cooling system or a water pump problem. Operating the engine without ade-
quate cooling water pressure will overheat the engine.
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WIRING DIAGRAMS
If the warning signals stop and a steady stream of water is coming out of the water pump indica-
tor hole, return engine to normal operation. If the warning system is activated repeatedly, have
the outboard checked by your dealer.
OVERSPEED (a)
This message is displayed and the warning horn begins sounding continuously to inform the
driver that the engine speed exceeded the maximum allowable RPM. The system will auto-
matically reduce the engine speed to within the allowable limit.
NOTE: Your engine speed should never reach the maximum limit to activate the system unless
the propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty
WATER IN FUEL (b)
This message will appear and the warning horn will begin sounding a series of four beeps every
two minutes when water in the water-separating fuel filter reaches the full level. Water can be
removed from the filter. Refer to Maintenance Section for filter removal.
FAULT-HORN (c)
This message informs you that the warning horn is not functioning correctly.
RESERVE OIL LOW – 2 STROKE OUTBOARD ONLY (d)
This message is displayed and the warning horn begins sounding a series of four beeps every
two minutes to inform the driver that the oil level is critically low in the engine mounted oil reser-
voir tank. When the oil level gets close to empty, the horn begins sounding continuously and
the Engine Guardian System will start limiting engine power. The display shows percent of re-
serve oil that’s remaining.
The engine mounted oil reservoir tank along with the remote oil tank will have to be refilled
(Refer to Fuel & Oil Section).
FAULT-OIL PUMP (e)
driver that the oil pump has stopped functioning electrically. No lubricating oil is being supplied
to the engine. Stop the engine as soon as possible. The Engine Guardian system will start limit-
ing the engine power.
FAULT-INJECTOR (f)
This alarm informs you if one or more of the fuel injectors have stop functioning electrically.
FAULT-IGNITION (g)
This alarm informs you that a problem has developed in the ignition system.
2
3 4 d
5
a 1 6
0 7 e
b
f
c
g
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WIRING DIAGRAMS
BATTERY (a)
When the electrical system is not charging, or the battery charge is low, the warning message
is designed to come on and the Engine Guardian System will start limiting engine power. If the
message appears immediately after starting, it is possible that the engine alternator can re-
charge the battery after operating awhile. If this message appears while driving or comes on
after starting and continues to be displayed, check engine to determine the cause of the prob-
lem and to avoid being stranded with a dead battery. To help the alternator recharge the battery
quickly, reduce the load on the electrical system by turning off any unneeded accessories.
ENGINE DATA BUS (b)
This message tells you that the data communication link between the tachometer and engine
is not connected.
LOW FUEL LEVEL (c)
This message serves as a warning that the fuel level in the fuel tank is critically low. You
should stop for fuel immediately to avoid running out.
LOW OIL LEVEL – OUTBOARD 2 STROKE ONLY (d)
This message serves as a warning that the oil level in the remote oil tank is low. You should
stop and refill the oil tank immediately to avoid running out.
FAULT-SENSOR (e)
This message informs you if one of the sensors is not functioning correctly
If the throttle sensor has failed, the warning horn will sound a continuous beeping and the
engine will not reach its full power.
If the throttle sensor and manifold pressure sensor both fail, the warning horn will sound a con-
tinuous beeping and the engine speed will stay at idle.
If the temperature or block pressure sensor should fail, the Engine Guardian System will limit
the maximum engine power to 75 percent.
FAULT-WATER TEMP (f)
This message informs you that the sensor for measuring outside lake/sea water temperature
is not functioning correctly.
a 2
3 4
E F
d
5
1 6
0 7
b e
c F f
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WARNING NO STARBOARD ENGINE (a)

Informs you that the Instrument does not see the starboard engine computer. Usually indicates
that no data is being transferred from the engine’s computer to the gauge. (Check wiring, also
make sure both terminator resistors are installed in the bus). Make sure both ECM’s are not
configured for port location using a DDT or Quicksilver Diagnostic Tool.
WARNING MULTIPLE STARBOARD ENGINE (b)
Informs you that the instruments are recognizing multiple engines as starboard.
In multiple engine applications, each engine must first be assigned a position (starboard, port,
starboard2 or port2) with a Quicksilver Diagnostic Tool before the system will function properly.
If you have a dual engine application, you must first program the port engine with a Quicksilver
Diagnostic Tool.
OIL TEMPERATURE (c)
This overheat alarm message appears and the warning horn begins sounding continuously.
OIL PRESSURE (d)
This alarm message is displayed and the warning horn begins sounding continuously to in-
form the driver that there is insufficient oil pressure.
a no starboard
engine
3 4
2 5
b muliple starboard engines 1 6
0 7
c OIL TEMP
d OIL PRESSURE
Auto-Detection Engine Function

AUTO–DETECTION ENGINE FUNCTION – System tach and speed come standard with
the “Engine Auto–detection Screen” this screen lets the gauge on its initial power up
automatically detect which engine type you are using and preconfigure the gauge to
match that vessel type.
Master Reset Command
MASTER RESET – By pressing TROLL – and TROLL
+ simultaneously for approximately 10
seconds (Until the graphic bars “collide”). You will be able to restore the unit back to facto-
ry presets.
WARNING: After a master reset all previously saved data will be lost (example: cal-
ibrations, clock settings, and trip logs).
MASTER RESET
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Tachometer Calibration
Quick Cal – This calibration for setting lighting and contrast.
TROLL
1. Press in the MODE and + buttons for up to 2 seconds to get to Quick Cal screen.
2. Press MODE to advance through the lighting and contrast sections.
Cal1 – This calibration level lets you turn on and off the system screens. You may configure
the system to display as little or as much information as you prefer.
1. Press in the MODE and TROLL+ buttons and hold for approximately 7 seconds until you
see the calibration1 (Cal1) screen.
2. Press MODE to advance through the calibration selections.
Cal2 – This calibration level lets you configure the system sensor inputs.
TROLL
1. Press in the MODE and + buttons and hold for approximately 10 seconds for calibra-
tion2 (Cal2) screen.
TACH CALIBRATION – CAL 1 LEVEL

If yes is selected, then screen changes made on this SC1000
REMOTE SCREENS? tach will effect any other SC1000 tach in the system.
NOTE: all tach will need to have this screen turned to “Yes” for this function
[NO] [SAVE] [YES]
to work.
If yes is selected, then lighting levels made on this SC1000 tach
REMOTE LCD LIGHT?
will effect any other SC1000 tach in the system.
NOTE: all tach will need to have this screen turned to “Yes” for this function
[NO] [SAVE] [YES]
to work.
If yes is selected, then contrast levels made on this SC1000 tach
REMOTE LCD CONTRAST?
will effect any other SC1000 tach in the system.
[NO] [SAVE] [YES] NOTE: all tach will need to have this screen turned to “Yes” for this function
to work.
TRIM POPUP?
Do you want power trim display screen to pop up momentarily
when you trim the engine?
[NO] [SAVE] [YES]
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CALIBRATION Choosing edit allows you to calibrate the gauge to the stan-
TRIM CALIBRATION dard 0–10 unit trim and 11–25 trailer position scale.
[SKIP] [EDIT]
TRIM FULL DOWN

THEN PRESS PLUS (+) BUTTON
[DFLT] [SKIP] [SAVE]
TRIM FULL UP
TRIM TO TRAILER POINT

DISPLAY UNITS
Lets you change units of measure between English (standard)
or Metric.
[DOWN] [SAVE] [UP]
SPEED UNITS
Lets you select speed units. You can choose from MPH (Miles
Per Hour), KN (Nautical Miles Per Hour) or KMH (Kilometers Per
[DOWN] [SAVE] [UP] Hour).
DEPTH SCREEN? Do you want to turn on the depth screen? (Remember: You must
have a Smart Craft depth transducer connected to the system for
[NO] [SAVE]
this screen to operate)
[YES]
ENGINE TEMP SCREEN?

Do you want to turn on the engine temp screen?
[NO] [SAVE] [YES]
OIL TEMP SCREEN?

Do you want to turn on the oil temp screen?
[NO] [SAVE] [YES]
OIL PRESS SCREEN?

Do you want to turn on the oil pressure screen?
[NO] [SAVE] [YES]
TRIM AND PSI SCREEN?

Do you want to turn on the trim and water pressure split screen?
[NO] [SAVE] [YES]
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WATER PSI SCREEN?

Do you want to turn on the water pressure screen?
[NO] [SAVE] [YES]
TRIM AND RPM SCREEN?

Do you want to turn on the trim and RPM split screen?
[NO] [SAVE] [YES]
RPM SCREEN?
Do you want to turn on the digital RPM screen?
[NO] [SAVE] [YES]
SIMULATOR MODE?
Do you want to turn on a simulation mode? (used for demonstra-
tion purposes).
[NO] [SAVE] [YES]
EXIT?
Do you want to exit calibration? Or jump straight into calibration
level 2?
[NO] [SAVE] [CAL2]
EXTERNAL SENSORS
This section lets you enable or disable the following external
sensor inputs.
[SKIP] [EDIT]
PITOT SENSOR?
Is the boat equipped with a pitot sensor to measure boat speed?
[NO] [SAVE] [YES]
PADDLE SENSOR?
Is the boat equipped with a paddle wheel to measure boat
speed?
[NO] [SAVE] [YES]
TRIM SENSOR?
Is the boat equipped with a trim sensor?
[NO] [SAVE] [YES]
SEA TEMP?
Is the boat equipped with a water temperature sensor?
[NO] [SAVE] [YES]
INVERT STEERING Is steering angle showing up on the link gauge opposite the direc-
tion that it should be? If it is then this feature will reverse the signal
so it is displayed properly.
[NO] [SAVE] [YES]
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TACH CALIBRATION – CAL 2 LEVEL
SPEED OPTION
This section lets you configure the following speed sensors.
[SKIP] [EDIT]
PITOT SENSOR?
Select pitot transducer type. You can choose 100 or 200 PSI.
(100 PSI is the most common)
[NO] [SAVE] [YES]
PITOT SENSOR MULTIPLIER

Adjust the pitot pressure sensor for correcting display readings
that are to high/low.
[DOWN] [SAVE] [UP]
PADDLE SENSOR PULSE FACTOR

Adjust paddle wheel frequency for display readings that are to
high/low.
[DOWN] [SAVE] [UP]
PADDLE TO PITOT TRANSITION

Set the speed at which the gauge stops looking at the paddle
wheel and starts using pitot to measure boat speed.
[DOWN] [SAVE] [UP]
There are three methods for calibrating System Tach fuel tank level monitoring feature:
First: Do nothing. Linear readout based on raw sensor values. This mode does not factor
in irregular tank shapes.
Second: By following the tank calibration procedure (following), but without actually add-
ing fuel. Calibrate fuel tank by pressing the ”dEFLt” button. System Tach will supply an
estimated range value based on linear interpolation of the sensor range values. This
mode does not factor in irregular tank shapes.
Third: By following the tank calibration procedure (following) completely System Tach will
display an estimated range value that factors in the tank shape.
FUEL TANK CAPACITY

Lets you enter the capacity of your boats fuel tank. This option
is the same for tank 1 as it is for tank 2.
[DOWN] [SAVE] [UP]
CALIBRATION FUEL TANK Lets you enter the mode where you can calibrate your fuel tank.
Fuel tank calibration procedure is the same for tank 1 as it is for
tank 2.
[SKIP] [EDIT]
FILL TO 1/4 THEN PRESS PLUS BUT-

TON You can choose to have tank at 1/4 and hit SAVE, or hit DFLT and
a default value will be entered based on the capacity of the tank.
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FILL TO 1/2 THEN PRESS PLUS

BUTTON You can choose to have tank at 1/2 and hit SAVE, or hit DFLT and
FILL TO 3/4 THEN PRESS PLUS

BUTTON You can choose to have tank at 3/4 and hit SAVE, or hit DFLT and
FILL TO FULL THEN PRESS PLUS

BUTTON You can choose to have tank at full and hit SAVE, or hit DFLT and
DEPTH SENSOR OFFSET Lets you electronically configure a depth offset. Entering a nega-
tive number gives you a water line offset. A positive number gives
[UP]
you a keel offset.
[DOWN] [SAVE]
DEPTH ALARM
Lets you enter a depth value. When the depth transducer reads
that value or below, the shallow water alarm will sound.
[DOWN] [SAVE] [UP]
EMPTY TANK THEN PRESS PLUS BUT- You can choose to have an empty tank and hit SAVE, or hit DFLT
TON
and a default value will be entered based on the capacity of the
tank.
Speedometer Calibration
Quick Cal – This calibration for setting lighting and contrast.
TROLL
1. Press in the MODE and + buttons for up to 2 seconds to get to Quick Cal screen.
2. Press MODE to advance through the lighting and contrast sections.
Cal1 – This calibration level lets you turn on and off the system screens. You may configure
the system to display as little or as much information as you prefer.
Cal2 – This calibration level lets you configure the system sensor inputs.
TROLL
1. Press in the MODE and + buttons and hold for approximately 10 seconds for calibra-
tion2 (Cal2) screen.
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SPEEDOMETER CALIBRATION CAL 1 LEVEL
REMOTE LCD LIGHT?

Enables you to set the lighting levels on all the SC1000 simulta-
neously from this gauge.
[NO] [SAVE] [YES]
REMOTE LCD CONTRAST?

Enables you to control the contrast from another System TACH/
Speed simultaneously from this gauge.
[NO] [SAVE] [YES]
TIME
Allows you to set the time.
[NO] [SKIP] [EDIT]
TIME FORMAT
Choose between a 12 hour and 24 hour format.
[DOWN] [SAVE] [UP]
USE GPS TIME?

If you have a GPS connected this feature enables the gauge to
let the GPS update the gauges internal clock.
[DOWN] [SAVE] [UP]
CALIBRATION HOUR 12:00 AM

Adjust the gauges internal clock to match your local time. First
set the hours then press MODE button to set the minutes.
[DOWN] [SAVE] [UP]
DISPLAY UNITS
Lets you change units of measurement between English (stan-
dard) or Metric.
[DOWN] [SAVE] [UP]
SPEED UNITS Lets you select the units at which speed is displayed. You can
choose from MPH (Miles Per Hour), KTS (Knots), or KMH (Kilo-
[SAVE] [UP]
meters Per Hour).
[DOWN]
TO WAY POINT SCREEN?

If you have a GPS connected you can turn on the screen that
shows your distance and fuel to a way point.
[NO] [SAVE] [YES]
SIMULATOR MODE?
Do you want to turn on a simulation mode? (Used for demonstra-
tion purposes).
[NO] [SAVE] [YES]
EXIT?
Do you want to exit calibration? Or jump straight into calibration
level 2?
[NO] [YES] [CAL2]
EXTERNAL SENSORS
This lets you enable or disable external sensor inputs.
[SKIP] [EDIT]
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AIR TEMP?
Are you using a air temp. sensor?
[NO] [SAVE] [YES]
GPS?
Do you have a GPS sensor installed?
[NO] [SAVE] [YES]
USE GPS SPEED?

Use the GPS input to drive the speed display?
[NO] [SAVE] [YES]
WATER TEMPERATURE
ADJUST Adjust water temp. transducer to match actual sea water tem-
perature.
[DOWN] [SAVE] [UP]
SmartCraft Gauge Operation

Basic Operation and Features

Power up: Each gauge will power up when the ignition is turned on. Gauges will stay on
as long as the ignition is on.
Lights: The brightness and contrast are adjustable. Refer to Gauge Calibration following.
Buttons: The MODE button is used for selecting information screens. The + and – but-
tons are used for setting engine speed during troll control and setting gauge calibrations.
Troll Control: Allows the operator to set and control the idle speed of the engine for trol-
ling without using the throttle.
Engine Guardian System: Monitors the critical sensors on the engine for any early in-
dications of problems. The system will respond to a problem by reducing engine speed
in order to maintain a safe operating condition.
Warning System – System will sound the warning horn and display warning message.
Gauge Calibrations
Digital Display Screen: Displays the following engine information.
Tachometer Display Screen: Speedometer Display Screen:
Digital Tachometer Clock and Temperature
Hour Meter Fuel Tank Level(s)
Power Trim Angle Oil Tank Level(s)
Fuel Flow Fuel Economy
Engine Temperature Fuel Range
Battery Voltage Trip Odometer
Water Pressure Digital Speedometer
Barometer Reading
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Speedometer Display Screen

Speedometer
1 6
2 7
3 8
4 9
5 10
When the ignition is turned on, the speedometer will show the last screen that was dis-
NOTE: Readings can be displayed in English or Metric. Refer to Calibration.
Press MODE to change display screens. You can revert back to the previous screen by
pressing and holding MODE for 2 seconds. This will reverse the display rotation.
1. Clock - Temp – Clock, air temperature and water temperature. The air and water tem-
perature sensors will have to be connected to obtain display readings.
2. Fuel Level – Displays the amount of fuel remaining.
3. Oil Level – Displays the amount of engine oil remaining.
4. RPM Synchronizer – Dual Engines – Monitors the revolutions of both engines. Allows
throttle adjustments to keep each running uniformly.
5. Trim Synchronizer – Dual Engines – Displays the trim position of both engines. Simplifies
keeping trim levels equal.
6. Traveling Range: The estimated traveling range is based on current fuel consump-
tion and fuel remaining in the tank .The numbers displayed indicates an estimate of
the distance you can travel with the remaining fuel.
7. Fuel Economy – The display shows average “AVG” fuel consumption as well as
instantaneous “INST” fuel economy. The numbers displayed indicate miles per gal-
lon “MPG” or kilometer per liter “KM/L”. Reset – To reset, select the display screen and
press MODE and TROLL– buttons.
8. Trip Odometer: Tells how far you’ve gone since you last set the gauge to zero. Trip Reset
– To reset, select the display screen and press MODE and TROLL – buttons.
9. Digital Speedometer: Can display boat speed in miles per hours, Kilometers per
hour, or knots. The digital speedometer will continue to increase even if needle is at
maximum. The speedometer will use the paddle wheel for its low speed readings but
will switch to the speedo or GPS (if connected) for high speed readings.
10. Barometer: Shows the barometer pressure reading only at the time the ignition was
turned on.
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Tachometer Display Screens

Tachometer
1
6
2
7
3
8
4 ° F
9
5
When the ignition is turned on, the tachometer will display the last screen that was dis-
Press MODE to change display screens. You can revert back to the previous screen by
pressing and holding MODE for 2 seconds. This will reverse the display rotation.
NOTE: Readings can be displayed in English or Metric. Refer to Calibration.
1. Engine Break in – Displays time remaining on the break-in period of a new engine.
This screen will automatically disappear after the break-in period is complete.
2. Power Trim Angle - Water Pressure – Displays trim angle of the outboard and cool-
ing system water pressure.
3. Fuel Flow – Displays engine fuel use.
4. Temperature – Displays engine coolant temperature from Cold to Hot.
5. Battery Voltage – Displays voltage level (condition) of battery.
6. Water Pressure: Displays cooling system water pressure at the engine.
7. Power Trim Angle: Displays trim angle of the outboard up to the maximum trim angle,
and than displays the trailer angle. 0 = DOWN; 10 = FULL TRIM; and 25 = FULL
TRAILER.
8. Digital Tachometer: Displays engine speed in Revolutions Per Minute (RPM)
9. Hour Meter: Records the running time of the engine
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Troll Control
TROLL TROLL TROLL TROLL

– + – +
a TR
a - Flashing Signal “TR”

BASIC OPERATION
With Troll control you can maintain a trolling speed of 450 to1000 rpm without using the
throttle.
You can set the trolling control by using either the tachometer or speedometer. Tachome-
ter will set the speed in RPM and speedometer will set the speed in MPH.
You can shut off troll control anytime by pushing the MODE button when in the troll display
screen or moving the throttle.
If you have troll control set at a desired speed and then you shut off the troll control, the
system remembers the set speed and will return to that speed when re-engaged.
The display screen will revert back to the previous screen after 10 seconds of no activity.
Push the TROLL
+ or TROLL
– button to reactivate the display screen.
When the troll control is engaged and you are out of the troll control screen, a flashing
signal “TR” will appear in the upper left corner of the display to tell you troll control is still
running.
TO SET TROLL CONTROL
1. With the engine running, shift outboard into gear. Set engine speed at idle.
TROLL TROLL
2. Push in the + or – button to bring up the troll control display screen.
3. Press MODE to engage (turn on) the troll control.
4. Use the TROLL
+
TROLL
– buttons to set the desired speed. Use (+) to increase speed and
(–) to decrease speed.
5. If you set troll control to a higher speed than the troll rpm can bring the boat to, the
TROLL SPEED TOO FAST message will appear. Reduce troll speed.
6. If you set troll control to a slower speed than the troll rpm can bring the boat to, the
TROLL SPEED TOO SLOW message will appear. Increase troll speed.
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EXITING TROLL CONTROL

There are three ways to turn off the troll control:
• Press the MODE button when in the troll display screen.
• Move the throttle to a different speed.
• Shift outboard into neutral.
Warning System
a
b
c
a - Display Screens
b - Engine Guardian System
c - Alarm Signal “AL”
The SmartCraft warning system incorporates the display screens the warning horn and
the Guardian Protection system. The warning horn is located inside the remote control
or is part of the ignition key switch wiring harness.
name of the offending alarm appears on the display.
If problem can cause immediate engine damage – the horn will sound continuous-
ly and the Engine Guardian System will respond to the problem by limiting engine
power. Immediately reduce throttle speed to idle and refer to the warning mes-
sages on the following pages that will tells you what to do about it.
If problem will not cause immediate engine damage – The horn will sound but not
continuous.
The alarm message will stay displayed until the mode button is pressed. If there
are multiple alarms, these will cycle on the display at five second intervals.
If the mode button is pressed to a different screen, the flashing alarm signal “AL”
will appear in the upper right corner to indicate there still a problem.
• Engine Guardian System – Monitors the critical sensors on the engine for any
early indications of problems. The system will respond to a problem by reducing
engine power in order to maintain a safe operating condition. The display screen
will show the percent of power loss.
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Alarm Messages
These messages will appear and the horn will sound if there is a problem detected in one
of the outboard systems.
NOTE: The warning system will alert the operator to the potential problems listed in the
chart. Refer to explanations following.
PROBLEM TACHOMETER SPEEDOMETER ENGINE
DISPLAY DISPLAY GUARDIAN
SYSTEM
ACTIVATED
BATTERY *
ENGINE DATA BUS
FAULT – HORN
FAULT – IGNITION
FAULT – INJECTOR
FAULT – OIL PUMP
FAULT – SENSOR *
FAULT – SPEEDO
FAULT – WATER TEMP
LOW FUEL
LOW OIL
OVERHEAT
OVER SPEED
PRESSURE
RESERVE OIL
UNIT MISMATCH
(MULTI ENGINE)
WATER IN FUEL
* Throttle and manifold pressure sensors only
OVERHEAT

The overheat alarm message appears and the warning horn begins sounding continuous-
ly. The Engine Guardian System will start limiting engine power.
If the engine overheats, immediately reduce throttle speed to idle. Shift outboard into neu-
tral and check for a steady stream of water coming out of the water pump indicator hole.
If no water is coming out of the water pump indicator hole or flow is intermittent, stop en-
gine and check cooling water intake holes for obstruction. If no obstruction is found, this
may indicate a blockage in the cooling system or a water pump problem. Operating the
engine while overheated will cause engine damage.
Stop engine. Operating the engine while overheated will cause engine damage.
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down will usually allow some additional low speed (idle) running time before the engine
starts to overheat again.
PRESSURE

This alarm message is displayed and the warning horn begins sounding continuously to
inform the driver that there is insufficient water pressure in the cooling system. The Engine
Guardian System will start limiting engine power.
Some causes of insufficient cooling water pressure are (1) obstructed cooling water in-
take holes (2) blockage in the cooling system or a water pump problem (3) running the
outboard with the cooling water intake holes out of the water.
If the warning system is activated, immediately reduce throttle speed to idle. Shift out-
board into neutral and check for a steady stream of water coming out of the water pump
indicator hole.
If no water is coming out of the water pump indicator hole or flow is intermittent, stop en-
gine and check cooling water intake holes for obstruction. If no obstruction is found, this
may indicate a blockage in the cooling system or a water pump problem. Stop engine.
Operating the engine without adequate cooling water pressure will overheat the engine.
If the warning signals stop and a steady stream of water is coming out of the water pump
indicator hole, return engine to normal operation.
OVERSPEED (a)
driver that the engine speed has exceeded the maximum allowable RPM. The system will
automatically reduce the engine speed to within the allowable limit.
NOTE: Your engine speed should never reach the maximum limit to activate the system unless
the propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty.
WATER IN FUEL (b)
This message will appear and the warning horn will begin sounding a series of four beeps
every two minutes when water in the water separating fuel filter reaches the full level. The
water can be removed from the filter.
FAULT-HORN (c)
This message informs you that warning horn is not functioning correctly.
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RESERVE OIL LOW (a)

This message will appear and the warning horn will begin sounding a series of four beeps
every two minutes to inform the driver that the oil level is critically low in the engine mounted
oil reservoir tank. When the oil level gets close to empty, the horn begins sounding continu-
ously and the Engine Guardian System will start limiting engine power. The display shows
percent of reserve oil that’s remaining.
The engine mounted oil reservoir tank along with the remote oil tank will have to be refilled.
FAULT-OIL PUMP (b)
This message is displayed and the warning horn begins sounding continuously to inform
the driver that the oil pump has stopped functioning electrically. No lubricating oil is being
supplied to the engine. Stop the engine as soon as possible. The Engine Guardian system
will start limiting the engine power.
FAULT-INJECTOR (c)
This alarm informs you if one or more of the fuel injectors have stopped functioning electri-
cally.
FAULT-IGNITION (d)
This alarm informs you that a problem has developed in the ignition system.
FAULT-WATER TEMP (e)
This message informs you that the sensor (located in the paddle wheel) for measuring
outside lake/sea water temperature is not functioning. Two possible things to check for
are: 1) Check the wiring going to the paddle wheel, 2) If the paddle wheel is not being used
or if only one paddle wheel is used for duel engine setup, edit the corresponding tachome-
ter calibration to delete the water temp sensor.
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BATTERY (a)
The warning message is designed to come on and the Engine Guardian System will start
limiting engine power when the electrical system is not charging or the battery charge is
low. If the message appears immediately after starting, it is possible that the engine alter-
nator can recharge the battery after operating awhile. If this message appears while driv-
ing or comes on after starting and continued to be displayed, the electrical system must
be checked to determine the cause of the problem to avoid being stranded with a dead
battery. To help the alternator recharge the battery quickly, you can reduce the load on
the electrical system by turning off any unneeded accessories.
ENGINE DATA BUS (b)
This message tells you the data communication link between the tachometer and engine
is not connected. Check for disconnected wires. Be sure the gray and brown/white wires
are connected to the diagnostic port plug on the engine. See SmartCraft Gauge Wiring.
UNIT MISMATCH (c)
(Multi Engines) This message tells you that the tachometers are not calibrated alike. (For
example, this could happen if one tachometer readings are in English and the another is
in Metric. Re-calibrate the tachometers.
NOTE: When calibrating multi tachometers, have all the tachometers powered up at the
same time while calibrating.
c
LOW FUEL LEVEL (d)
This message tells you that the fuel level in the fuel tank is critically low. Stop for fuel im-
mediately to avoid running out. The engine must be shut off to reset the warning system.
LOW OIL LEVEL (e)
This message tells you that the oil level in the remote oil tank is low. Stop and refill the
oil tank immediately to avoid running out. The engine must be shut off to reset the warning
system.
FAULT-SENSOR (f)
This message informs you if one of the sensors is not functioning correctly.
If the throttle sensor has failed, the warning horn will sound a continuous beeping and the
engine will not reach its full power.
If the throttle sensor and manifold pressure sensor both fail, the warning horn will sound
a continuous beeping and the engine speed will stay at idle.
If the temperature or block pressure sensor should fail, the Engine Guardian System will
limit the maximum engine power by 25 percent.
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Tachometer Calibration
NOTE: When calibrating multi tachometers (multi engines) turn ignition on for all the
tachometers.
Simple Calibration – This calibration for setting lighting and a few other common screens
can be made while engine is running.
TROLL
1. Press in the MODE and + buttons for calibration screen.
Advanced Calibration – This calibration goes through the entire mode selections.
1. Turn ignition key to the off position.
TROLL TROLL
2. Hold + – and turn ignition on.
3. Press and hold MODE for 2 seconds to bring up the calibration screen.
CALIBRATION
Press – or + to adjust level. Press MODE to save setting
BRIGHTNESS
[DOWN] [SAVE] [UP]
CALIBRATION Do you want the same brightness level for all SmartCraft
BRIGHTNESS gauges? Press + for yes. Press MODE for no.
SET ALL INSTRUMENTS?
[ NO ] [ YES ]
CALIBRATION Press – or + to adjust level. Press MODE to save setting

CONTRAST
[DOWN] [SAVE] [UP]
CALIBRATION Do you want the same contrast level for all SmartCraft
CONTRAST gauges? Press + for yes. Press MODE for no.
[ NO ] [ YES ]
CALIBRATION Multi Engine – Do you want tachometer display screens to

CONTROL OPTIONS advance together? Press + or – to select. Press MODE to
REMOTE SCREEN ? YES – NO
[UP] save.
[DOWN] [SAVE]
Do you want power trim angle display screen to pop up when-

CALIBRATION
CONTROL OPTIONS ever you trim the outboard ? Press + or – to select. Press
TRIM POP UP ? YES – NO MODE to save.
[DOWN] [SAVE] [UP]
Match tachometer to the correct engine. Press + to select

CALIBRATION
ENGINE POSITION engine. Press MODE to save.
SINGLE-PORT-CENTER-STARBOARD
[DOWN] [SAVE] [UP]
Select display readings in English or Metric. Press + or – to

CALIBRATION
DISPLAY UNITS select Press MODE to save.
ENGLISH - METRIC
[DOWN] [SAVE] [UP]
90-884294 OCTOBER 2001 Page 2D-61

WIRING DIAGRAMS
Display boat speed in KN (knots), KPH (kilometers per hour),

CALIBRATION
SPEED UNITS MPH (miles per hour). Press + or – to select setting. Press
KN - KPH - MPH MODE to save.
[DOWN] [SAVE] [UP]
CALIBRATION Press MODE to skip to the next display. Press + (edit) if your
EXTERNAL SENSORS adding or deleting any external sensor to the SmartCraft Sys-
tem.
[SKIP] [EDIT] Editing External Sensors
Add Yes or No for each sensor
CALIBRATION No = not used Yes = in use
EXTERNAL SENSORS Press + or – for correct setting
SPEEDO SENSOR ? YES/NO
Press MODE to save and advance to next sensor
[DOWN] [SAVE] [UP]
CALIBRATION
EXTERNAL SENSORS
PADDLE WHEEL SENSOR ? YES/NO
[DOWN] [SAVE] [UP]
CALIBRATION
EXTERNAL SENSORS
WATER TEMP SENSOR ? YES/NO
[DOWN] [SAVE] [UP]
CALIBRATION
Add the capacity of the fuel tank. Press + or – to select.
FUEL TANK CAPACITY Press MODE to save.
CAPACITY = XX.XX
[DOWN] [SAVE] [UP]
CALIBRATION This calibration sets the fuel level of the tank.

FUEL TANK CALIBRATION NOTE: If the fuel tank is not calibrated, fuel range cannot be
displayed
[SKIP] [EDIT] Press MODE to skip to the next display. Press + (edit) to
calibrate the fuel tank.
CALIBRATING Pressing DFLT (default) during edit will return to original value
EMPTY TANK
THEN PRESS PLUS (+) BUTTON setting
Calibrate the fuel tank as follows:
1. Empty the fuel tank, Press + to save
2. Fill tank to 1/4 full, Press + to save.
CALIBRATING 1/4 VALUE
FILL TO X.X G. 3. Fill tank to 1/2 full, Press + to save
THEN PRESS PLUS (+) BUTTON 4. Fill tank to 3/4 full, Press + to save.
[DFLT] [SKIP] [SAVE] 5. Fill tank to full, Press + to save.
The fuel tank is now calibrated
FILL TO X.X G.

FILL TO X.X G.
CALIBRATING FULL
FILL TANK TO FULL
Page 2D-62 90-884294 OCTOBER 2001

WIRING DIAGRAMS
Add the capacity of the oil tank. Press + or – to select. Press

CALIBRATION
OIL TANK CAPACITY MODE to save.
CAPACITY = XX.XX
[DOWN] [SAVE] [UP]
CALIBRATION This calibration accurately adjusts the oil level sending unit in
OIL TANK CALIBRATION the oil tank.
Press MODE to skip to the next display. Press + (edit) to
[SKIP] [EDIT] calibrate the oil tank.
Pressing DFLT (default) during edit will return to original value
CALIBRATING setting
EMPTY TANK
THEN PRESS PLUS (+) BUTTON Calibrate the oil tank as follows:
1. Empty the oil tank, Press + to save
2. Fill tank to 1/4 full, Press + to save.
3. Fill tank to 1/2 full, Press + to save
FILL TO X.X G. 4. Fill tank to 3/4 full, Press + to save.
THEN PRESS PLUS (+) BUTTON 5. Fill tank to full, Press + to save.
[DFLT] [SKIP] [SAVE] The oil tank is now calibrated

FILL TO X.X G.

FILL TO X.X G.
CALIBRATING FULL
FILL TANK TO FULL
CALIBRATION If the speedometer is not reading correctly, the speed sensors

SPEED SENSORS can be re-calibrated to correct the setting.
Press MODE to skip to the next display. Press + (edit) to cali-
[SKIP] [EDIT] brate the sensors.
Increasing or decreasing the multiplier will increase or de-
CALIBRATION crease the speed reading
PITOT SENSOR
Press – or + for changing setting. Press MODE to save.
MULTIPLIER 1.00
[DOWN] [SAVE] [UP]
CALIBRATION
PADDLE WHEEL SENSOR
MULTIPLIER 1.00
[DOWN] [SAVE] [UP]
90-884294 OCTOBER 2001 Page 2D-63

WIRING DIAGRAMS
CALIBRATION If the trim setting is not reading correctly, the trim sensor can
TRIM CALIBRATION be re-calibrated to correct the setting.
Pressing DFLT (default) during edit will return to original value
[SKIP] [EDIT] setting
Press MODE to skip to the next display. Press + (edit) to cali-
CALIBRATION brate the sensor.
TRIM FULL UP
1. Trim outboard full up, than Press + to save.
[DFLT] [SKIP] [SAVE] 2. Trim outboard to the point where the trim cylinders takes over,
than Press + to save.
3. Trim outboard full down, than Press + to save.
CALIBRATION
TRIM TO TRAILER POINT
CALIBRATION
TRIM FULL UP
CALIBRATION Do you want to exit the calibration mode? Press + for yes.
Press MODE for no.
EXIT ? [ YES ]
[ NO ]
Speedometer Calibration
Simple Calibration – This calibration for setting lighting and setting the clock can be
made while engine is running.
TROLL
1. Press in the MODE and + buttons for calibration screen.
Advanced Calibration – This calibration goes through the entire mode selections.
1. Turn ignition key to the off position.
TROLL TROLL
2. Hold + – and turn ignition key to the on position.
3. Press and hold MODE for 2 seconds to bring up the calibration screen.
CALIBRATION
BRIGHTNESS
[DOWN] [SAVE] [UP]
Do you want the same brightness level for all SmartCraft

CALIBRATION
BRIGHTNESS gauges? Press + for yes. Press MODE for no.
[ NO ] [ YES ]

CALIBRATION
CONTRAST
[DOWN] [SAVE] [UP]
Do you want the same contrast level for all SmartCraft

CALIBRATION
CONTRAST gauges? Press + for yes. Press MODE for no.
[ NO ] [ YES ]
Page 2D-64 90-884294 OCTOBER 2001

WIRING DIAGRAMS
CALIBRATION If the clock display is correct , press MODE to skip.

TIME To set or reset the clock Press +
[SKIP] [EDIT]
Select 12 hour or 24 hour clock set.

CALIBRATION Press – or + to select. Press MODE to save.
TIME FORMAT
12H – M,D,Y, or 24H – D,M,Y
[UP] Press – or + to enable or disable GPS time calibration. If a GPS
[DOWN] [SAVE]
navigation receiver is connected to the gauges, NMEA data
will set the time automatically. Press MODE to save.
CALIBRATION
NMEA
ENABLE or DISABLE Press – or + to add UTC correction. MODE to save. (Hour off-
[DOWN] [SAVE] [UP] set from universal time constant)
CALIBRATION
UTC ZONE Press – or + to set the hour
UTC CORRECTION = X H Press MODE to save.
[DOWN] [SAVE] [UP]
CALIBRATION HOUR
4:15 PM Press – or + to set the minute

Press MODE to save.
[DOWN] [SAVE] [UP]
CALIBRATION MINUTE
4:15 PM
[DOWN] [SAVE] [UP]
CALIBRATION Press MODE to skip to the next display. Press + (edit) if your
EXTERNAL SENSORS adding or deleting any external sensor to the SmartCraft Sys-
tem.
[SKIP] [EDIT] Editing External Sensors
Chose Yes or No for each sensor
CALIBRATION No = not used Yes = in use
EXTERNAL SENSORS Press + or – for correct setting
AIR SENSOR SENSOR ? YES/NO
Press MODE to save and advance to next sensor
[DOWN] [SAVE] [UP]
CALIBRATION
EXTERNAL SENSORS
GPS CONNECTED ? YES/NO
[DOWN] [SAVE] [UP]
If YES was saved
CALIBRATION Chose Yes or No if you want the speedometer

EXTERNAL SENSORS to read GPS speed
USE GPS SPEED ? YES/NO
[DOWN] [SAVE] [UP]
CALIBRATION Do you want to exit the calibration mode? Press + for yes.
Press MODE for no.
EXIT ? [ YES ]
[ NO ]
90-884294 OCTOBER 2001 Page 2D-65

WIRING DIAGRAMS
SmartCraft Gauge Test Specifications

Test Equipment Required:
1. Test Harness 84-875233A2 (a).
2. DMT 2000 Digital Tachometer Multimeter 91-854009A1 (b).
NOTE: Connect negative DMT lead to BLACK/ORANGE lead on test harness
84-875233A2 for all tests. Use positive DMT lead on all other test harness leads to deter-
mine if individual sensors are within specifications.
b
a
57738
SENSOR RED TEST LEAD BLACK TEST LEAD RANGE

Trim Yellow Black/Orange 2.7 vdc UP – 0.6 vdc
DOWN
Fuel Sender Pink/Black Black/Orange 0.65 vdc FULL – 2.92 vdc
EMPTY
Lake Temperature Tan/Orange Black/Orange 2.5 vdc @ room temp.
(Voltage decreases as
temperature increases)
+5 vdc Sensor Power Purple/Yellow Black/Orange 4.9 vdc – 5.1 vdc
Pitot Pressure White/Orange Black/Orange 0.5 vdc static
(voltage increases with
pressure)
Oil Sender Light Blue/Black Black/Orange 0.63 vdc FULL – 2.89 vdc
EMPTY
Paddle Wheel Frequency Gray/Blue Black/Orange Set meter to Hz and spin
paddle wheel or set meter
to AC volts and spin
paddle wheel. Hz or AC
volts should increase as
wheel spins faster.
Page 2D-66 90-884294 OCTOBER 2001

19 21
3 Liter Work/225 EFI/250 EFI Wiring Diagram 6
7 8 9 10 18
11 14 15 16
1 - Low Oil Switch
1 2 3 4 5 50 12 13 17 B
2 - Shift Switch
20
30 85 86 8787a
A B C D E F G H A B A B C D E F G H J K
A B C D E F G H 1 2 3 4 5 6 7 8
1 2 A B A B 30 85 86 8787a
3 - Crank Position Sensor
YEL/RED
A B
WHT/ORG
BLK
4 - Oil Pump
BRN/WHT
BLK
RED/BLK
DKBLU
PPL/GXL
PPL
WHT
DKBLU
BLK/ORG
RED
RED/FLEX
GRY/BLU
WHT
TAN/ORG
PNK/BLK
RED/GXL
BLK/WHT
PPL/YEL
TAN/PPL
RED/WHT/GXL
RED/WHT
RED/WHT
LTBLU/BLK
RED/FLEX
GRY
RED
RED/BLU
RED
RED/PPL
RED
BLK
RED/BLK
RED
RED/YEL
BLK/ORG
YEL/RED
LTBLU
BLK
BLK/RED
RED/FLEX
RED/GXL
RED/PPL
PPL/GXL
BLK
RED/PPL
YEL/PPL
5 - Fuel Pump
50
RED
RED
RED
WHT
YEL/RED
BLK
TAN/LTBLU
RED/BLU
BLK/YEL
BLK
LTBLU/BLK
RED/BLU
RED
TAN
PPL
6 - Main Power Relay
RED/FLEX
7 - 20 Amp Fuse – Fuel Injector Harness, Electric Fuel Pump, and Oil Pump
YEL/RED
RED/FLEX
8 - 20 Amp Fuse – Ignition Coils
9 - 20 Amp Fuse – Main Power Relay, Remote Control Harness and Power Trim A B C
A B C
10 - 15 Amp Fuse – Smart Craft Data Bus Circuit

11 - Accessory Power
BLK
44 45 46 47 48 49
RED/BLK
PPL
12 - Remote Control
GRY
13 - To Temp Analog Gauge
14 - Boat Harness
15 - Water In Fuel Sensor
RED/FLEX
22
16 - DDT Terminal
17 - Data Bus (SmartCraft)
1 2 1 2 1 2 1 2 1 2 1 2 BLK
52
18 - Slave Solenoid DKBLU 30
ORG/PNK
RED/BLU
RED/BLU
PPL/PNK
RED/PNK
DKBLU/PNK
RED/BLU
RED/BLU
RED/BLU
85
YEL/PNK
LTBLU/WHT
BRN/PNK
RED/BLU
19 - 60 Amp Alternator
23
BLK 86
87
20 - Starter Solenoid RED
BLK 87a
21 - Solenoid Driven Bendix
Starter GRN 30
RED/PPL
GRN/WHT 85
22 - To 12V Battery BLK
RED
86
87 24
23 - Trim Up Relay BLK 87a
24 - Trim Down Relay

25 - Trim Pump BLK
BLK
26 - Cowl Mounted Trim Switch BLK 50
27 - Remote Control Trim Switch BLK
GRN
28 - Port Knock Sensor
25
1 1 BRN/PNK
2 2 RED/PNK
29 - Stbd Knock Sensor 3 3 ORG/PNK
DKBLU
30 - Temp Sensor Gauge 4 4

5 5
YEL/PNK
DKBLU/PNK
31 - Port Head Temp Sensor 6 6 PPL/PNK RED/PPL 1
32 - Air Temp Sensor

7 7
8 8
RED/BLU
RED/BLU
GRN/WHT
BLU/WHT
2
3 26
33 - Stbd Head Temp Sensor 9 9
10 10
RED/BLU
RED/BLU GRN/WHT
34 - Throttle Position Sensor 11 11
12 12
RED/BLU
RED/BLU LTBLU/WHT 27
35 - Block Pressure Sensor
28
BLK/RED A
36 - MAP Sensor A GRN/BRN
BLK/RED A A BLK/RED WHT/BLU B
WHT/BLU B B WHT/BLU
37 - ECM B
C
BLK/GRN
BLK/WHT C C BLK/WHT
BLK D D A
38 - #6 Ignition Coil
29
WHT/BLK WHT/BLK BLK/WHT
D BLK/WHT
WHT/BLK B
E RED/YEL
39 - #5 Ignition Coil
40 - #4 Igintion Coil 43 GRN/BRN
GRN/RED
A
B
A
B
GRN/BRN
GRN/RED
TAN
30
GRN/ORG C C GRN/ORG
GRN A
41 - #3 Igintion Coil
31
GRN/YEL D D GRN/YEL
BLK/ORG B
GRN/BLU E E GRN/BLU
42 - #2 Ignition Coil A GRN/RED GRN/PPL F F GRN/PPL
B TAN/GRN A
32
BLK/GRN BLK/GRN G G BLK/GRN
43 - #1 Ignition Coil C BLK RED/YEL H H RED/YEL BLK/ORG B
D BLK/WHT BLK/WHT J J BLK/WHT
44 - #1 Fuel Injector E RED/YEL K K
45 - #2 Fuel Injector 42 TAN
BLK/ORG
A
B
33
46 - #3 Fuel Injector
PPL/YEL A
47 - #4 Fuel Injector
34
LTBLU/WHT B
A GRN/ORG
BLK/ORG C
48 - #5 Fuel Injector B BLK/GRN
C BLK
49 - #6 Fuel Injector D BLK/WHT BLK/ORG A
50 - To Ground
41
E RED/YEL PPL/YEL
WHT/GRN
B
C 35
51 - Early Production
BLK/ORG A
Centrifugal
36
BLK
BLK
LTBLU/BLK
LTBLU/WHT
BLK
YEL B
DKBLU/PNK
LTBLU/BLK
TAN/LTBLU
TAN/ORG
BLK/RED
BRN/WHT
BLK/WHT
PNK/BLK
GRN/ORG
TAN/PPL
WHT/BLK
WHT/BLU
ORG/PNK
GRN/BRN
BLK/ORG
WHT/ORG
BLK/RED
GRY/BLU
GRN/RED
PPL/YEL
RED/PNK
BRN/PNK
Bendix Starter PPL/YEL C
GRN/BLU
TAN/GRN
RED/BLU
RED/BLU
GRN/PPL
GRN/YEL
BLK/GRN
PPL/PNK
YEL/PNK
WHT/GRN
YEL/PPL
A
DKBLU
GRN/YEL
BLK/YEL
DKBLU
LTBLU
B
WHT
WHT
WHT
BLK/GRN
RED
GRY
PPL
52 - 12V Battery
YEL
TAN
GRN
BLK
BLK
C BLK
BLK
D BLK/WHT
Negative Lead E RED/YEL
40
BLK
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
A GRN/BLU
50
B BLK/GRN
C BLK
D BLK/WHT
39
E RED/YEL
51
4BLK
6BLK_YEL_ENDS
14RED_GXL
14RED
18YEL_RED
14RED
14RED
18RED
10RED
C B A
A GRN/PPL
B BLK/GRN
C BLK
D BLK/WHT
E RED/YEL
38 37 6BLK_YEL_ENDS
90-884294 OCTOBER 2001 Page 2D-67

FUEL PUMP
FUEL SYSTEM
Section 3A - Fuel Pump
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Checking Fuel Pump Lift (Vacuum) . . . . . . . . 3A-7
Fuel Pump Pressure @ W.O.T. . . . . . . . . . 3A-2 Fuel Pump Capability Test . . . . . . . . . . . . . 3A-8
Fuel Pump Pressure @ Idle . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-2
3A-2
Fuel System Leak Test . . . . . . . . . . . . . . . .
Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . .
3A-8
3A-8 3
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . .
3A-3
3A-4
Fuel Pump Removal/Disassembly . . . . . .
Cleaning/Inspection . . . . . . . . . . . . . . . . . . .
3A-9
3A-10
A
Fuel Pump Description/Operation . . . . . . . . . 3A-6 Reassembly/lnstallation . . . . . . . . . . . . . . . 3A-10
Checking for Restricted Fuel Flow Caused
by Anti-Siphon Valves . . . . . . . . . . . . . . . . . . . . 3A-6
90-884294 OCTOBER 2001 Page 3A-1

FUEL PUMP
Specifications
Fuel Pump Pressure @ W.O.T.
Maximum – 10 psi (68.5 kPa)
Normal – 8-10 psi (41.0 – 54.8 kPa)
Minimum – 3 psi (20.5 kPa)
Fuel Pump Pressure @ Idle
Normal – 2-3 psi (13.7 – 20.5 kPa)
Minimum – 1 psi (6.8 kPa)
NOTE: Electric fuel pump pressure, if used in conjunction with engine mechanical fuel
pump, must be limited to no more than 4 psi (27.4 kPa).
Special Tools
1. Fuel Pressure Gauge (0–15 psi) (Obtain Locally)
57721
2. Anaolg or Digital Vacuum Gauge (0 – 10 inches of vacuum mercury). Obtain Locally
59157
a - Digital Vacuum Gauge
Page 3A-2 90-884294 OCTOBER 2001

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

FUEL PUMP
Fuel Pump Assembly
Page 3A-4 90-884294 OCTOBER 2001

FUEL PUMP
Fuel Pump Assembly

TORQUE
REF.
REF
1 1 FUEL PUMP ASSEMBLY
2 1 DIAPHRAGM KIT
3 2 DIAPHRAGM
4 2 RETAINER
5 1 SPRING
6 1 CAP
7 1 SPRING
8 1 CAP
9 1 DIAPHRAGM
10 1 GASKET-BOOST
11 1 GASKET-PULSE
12 1 GASKET
13 1 PLATE
14 1 FITTING
15 2 SCREW–FUEL PUMP (M5 x 40) 55 6.0
16 2 SCREW–PUMP TO CRANKCASE (M6 x 50) 55 6.0
17 1 BASE
18 1 ELBOW
19 AR STA STRAP
20 1 HOSE
21 1 CONNECTOR
22 1 HOSE
23 1 CAP
24 1 HOSE/SLEEVE
25 1 HOSE [16 IN. (40.6 CM)]
26 1 INLINE CONNECTOR
27 1 CLAMP
28 1 HOSE
29 1 TUBING [15 IN. (38 CM)]
30 1 TUBING [28 IN. (71 CM)]
31 AR STA STRAP
32 1 CONDUIT
90-884294 OCTOBER 2001 Page 3A-5

FUEL PUMP
Fuel Pump Description/Operation

The fuel pump is a crankcase-pressure-operated, diaphragm-type pump. Crankcase pul-
sating pressure (created by the up-and-down movement of piston) is transferred to fuel
pump by way of a passage (hole) between crankcase and fuel pump.
When piston is in an upward motion, a vacuum is created in the crankcase, thus pulling
in on the fuel pump diaphragm. The inlet check valve (in fuel pump) is opened and fuel
(from fuel tank) is drawn into fuel pump.
Downward motion of the piston forces the air mixture out of the crankcase into the cylin-
der. This motion also forces out on the fuel pump diaphragm, which, in turn, closes the
inlet check valve (to keep fuel from returning to fuel tank) and opens the outlet check
valve, thus forcing fuel to the VST (EFI models) or carburetors.
Checking for Restricted Fuel Flow Caused by Anti-Siphon

Valves
While anti-siphon valves may be helpful from a safety stand-point, they clog with debris,
they may be too small, or they may have too heavy a spring. Summarizing, the pressure
drop across these valves can, and often does, create operational problems and/or power-
head damage by restricting fuel to the fuel pump and VST. Some symptoms of restricted
(lean) fuel flow, which could be caused by use of an anti-siphon valve, are:
1 - Loss of fuel pump pressure
2 - Loss of power
3 - High speed surging
4 - Preignition/detonation (piston dome erosion)
5 - Outboard cuts out or hesitates upon acceleration
6 - Outboard runs rough
7 - Outboard quits and cannot be restarted
8 - Outboard will not start
9 - Vapor lock
Since any type of anti-siphon device must be located between the outboard fuel inlet and
fuel tank outlet, a simple method of checking [if such a device (or bad fuel) is a problem
source] is to operate the outboard with a separate fuel supply which is known to be good,
such as a remote fuel tank.
If after using a separate fuel supply it is found that the anti-siphon valve is the cause of
the problem, there are 2 solutions to the problem: 1) replace the anti-siphon valve with
one that has lighter spring tension or 2) replace it with a solenoid-operated fuel shut off
valve.
Page 3A-6 90-884294 OCTOBER 2001

FUEL PUMP
Checking Fuel Pump Lift (Vacuum)

The square fuel pump is designed to lift fuel (vertically) about 60 in. (1524 mm) if there
are no other restrictions in the system using a fuel hose that is 5/16 in. (7.9 mm) minimum
diameter. As restrictions are added, such as filters, fittings, valves etc., the amount of fuel
pump lift decreases.
Fuel pump vacuum and air bubbles in the fuel supply can be checked with a vacuum
gauge, a t-fitting and a clear piece of fuel hose. Connect the clear hose between the inlet
fitting on the pulse driven fuel pump and the vacuum gauge t-fitting, keeping the t-fitting
as close as possible to the pump. Connect the fuel line from the fuel tank to the remaining
connection on the t-fitting.
b d
59157
e
a - Pulse Driven Fuel Pump c - Vacuum Gauge (Digital)
b - Clear hose connected between d - Tubing Clamp (91-804063)
pulse pump and “Tee” fitting e - Fuel supply hose from fuel tank
90-884294 OCTOBER 2001 Page 3A-7

FUEL PUMP
Fuel Pump Capability Test

Before proceeding with the system vacuum test, confirm that the pulse fuel pump is capa-
ble of supplying the required vacuum. To do this, start the engine, pinch off/restrict the fuel
supply hose between the vacuum gauge and fuel tank. The vacuum gauge should rise
to or exceed the maximum normal reading of 2.5 inches vacuum (mercury). If it fails to
reach this minimum number, the pump needs servicing or there is a lack of crankcase
pressure to operate the pump.
Normal Reading 2.5 in. of vacuum (mercury) or higher, proceed to

fuel system leak test
Reading below 2.5 in. of vacuum (mercury) • Pump check valves defective, replace
valves
• Pump diaphragm defective, replace
diaphragms
• Air leak in pump, rebuild pump with new
gasket, check fitting for leaks
• Low crankcase pressure, check for
crankcase leaks or plugged pulse pump
pressure/vacuum passageways
Fuel System Leak Test

This test is done with the engine running, and the tubing clamp removed. The clear hose
that was installed previously is used to view the fuel flow to the pulse pump.
No air bubbles seen in clear hose No air leaks, perform vacuum test (following)
Air bubbles seen in clear hose Air leak on intake side of fuel system –
• Pickup tube in fuel tank leaking
• Outlet fitting at fuel tank leaking
• Fuel inlet hose not properly clamped at
fitting
• Leaking fuel tank valve
• Fuel line from kicker engine connected into
fuel line of main engine
Vacuum Test
The vacuum test is normally performed at an idle speed. As engine RPM increases, there
will be a slight increase in vacuum; this increase should not exceed normal readings at
any RPM.
Normal Reading Below 2.5 in. of vacuum (mercury)
Reading below 2.5 in. of vacuum (mercury) Restriction within the fuel system –
• Restricted anti-siphon valve
• Restricted or malfunctioning primer bulb
• Kinked or collapsed fuel hose
• Plugged water separating fuel filter (in the
boat)
• Restriction in fuel line thru-hull fitting
• Restriction in fuel tank switching valves
• Plugged fuel tank pick-up screen
Page 3A-8 90-884294 OCTOBER 2001

FUEL PUMP
Fuel Pump Removal/Disassembly

IMPORTANT: Fuel pump diaphragm and gaskets should not be re-used once fuel
pump is disassembled.
1. Disconnect fuel hoses from fuel pump.
2. Disconnect pulse hose.
3. Remove two mounting screws.
4. Remove fuel pump from engine.
b
59042
a - Fuel Inlet
b - Fuel hose from fuel pump to Fuel/Water Separator
c - Pulse hose
d - Mounting screws
5. Disassemble fuel pump.
59040
a - Reverse View of Pump Body
90-884294 OCTOBER 2001 Page 3A-9

FUEL PUMP
Cleaning/Inspection
1. Clean fuel pump housing, check valves, pulse chamber and pump base in solvent and
dry all but check valves with compressed air.
2. Inspect each check valve for splits or chips.
3. Inspect boost springs for weakness or breakage.
4. Inspect fuel pump housing, pulse chamber and base for cracks or rough gasket sur-
face and replace if any are found.
5. Inspect fitting on fuel pump housing for loosening or any signs of fuel or air leaks. Re-
place or tighten fitting if a leak is found.
Reassembly/lnstallation
ASSEMBLY
NOTE: The new repair kits contain check valves made of a plastic material, impervious
to damage from additives. When repairing the fuel pump discard old rubber and small
plastic check valve disks, and install one new plastic disk under each retainer. Caution
must be taken not to push the check valve retainer to tightly against the check valve, this
may cause valve to deform.
CORRECT INCORRECT 57861
a - Check Valve Retainer

b - Check Valve (Plastic)
1. Insert retainer through plastic check valve.

b
23601
a - Retainer
b - Plastic Check Valve
Page 3A-10 90-884294 OCTOBER 2001

FUEL PUMP
2. Install check valves and retainers into fuel pump body.
58887
3. With retainer installed in pump body, break retainer rod from retainer by bending side-
ways.
23601
a - Rod
b - Retainer Cap
4. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap
rod down into retainer until flush with top of retainer.
23601
a - Rod
b - Retainer Cap
90-884294 OCTOBER 2001 Page 3A-11

FUEL PUMP
5. Place boost spring into pump body and place cap onto boost spring.
50161
a - Boost Spring
b - Pump Body
c - Cap
6. Assemble remainder of components as shown and install retaining screws through

to align.
59040
a - Reverse View of Pump Body
INSTALLATION
1. Install pump onto engine. Torque to 55 Ib. in. (6 N·m).
2. Install hoses onto proper fittings and secure with sta-straps.
3. Run engine and check for leaks.
Page 3A-12 90-884294 OCTOBER 2001

FUEL INJECTION
FUEL SYSTEM
Section 3B - Fuel Injection
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Detonation Control System Test
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 (200 Work Models Only) . . . . . . . . . . . . . . . 3B-34
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Management System . . . . . . . . . . . . . . . .
3B-5
3B-6
Throttle Position Sensor Test . . . . . . . . . . .
MAP Sensor Test . . . . . . . . . . . . . . . . . . . . .
3B-35
3B-36 3
Vapor Separator Components . . . . . . . . . . . . .
Electronic Fuel Injection (EFl) System . . . . . .
3B-10
3B-12
Problem Diagnosis . . . . . . . . . . . . . . . . . . .
Engine Head Temperature Sensor Removal
3B-37
3B-40
B
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Engine Head Temperature
Using the Test Procedures . . . . . . . . . . . . . 3B-12 Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . 3B-40
EFI System Tests . . . . . . . . . . . . . . . . . . . . . 3B-12 Fuel Management Assembly Removal . . . . . 3B-41
Safety Precautions . . . . . . . . . . . . . . . . . . . 3B-12 Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . 3B-45
Fuel Injection System Function . . . . . . . . . 3B-13 Fuel Rail Installation . . . . . . . . . . . . . . . . . . 3B-47
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . 3B-13 Reed Block Assembly Removal . . . . . . . . 3B-49
Ignition Spark Check . . . . . . . . . . . . . . . . . . 3B-13 Reed Block Assembly Installation . . . . . . . 3B-49
Electronic Fuel Injection Set Up . . . . . . . . 3B-14 Air Temperature Sensor Removal . . . . . . 3B-50
Fresh Quality Fuel . . . . . . . . . . . . . . . . . . . . 3B-14 Air Temperature Sensor Installation . . . . . 3B-50
Low Battery Voltage . . . . . . . . . . . . . . . . . . 3B-14 Manifold Absolute Pressure (MAP)
Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . . 3B-15 Sensor Removal . . . . . . . . . . . . . . . . . . . . . 3B-50
Fuel Flow Component Description . . . . . . . . . 3B-16 Manifold Absolute Pressure (MAP)
EFI Electrical Components . . . . . . . . . . . . 3B-17 Sensor Installation . . . . . . . . . . . . . . . . . . . . 3B-50
EFI Fuel Management Throttle Plate Assembly Removal . . . . . . . 3B-51
(Low Pressure Fuel Route) . . . . . . . . . . . . . . . 3B-19 Throttle Plate Assembly Installation . . . . . 3B-51
EFI Fuel Management Vapor Separator Disassembly . . . . . . . . . . 3B-51
(High Pressure Fuel Route) . . . . . . . . . . . . . . . 3B-20 Vapor Separator Reassembly . . . . . . . . . . 3B-53
Fuel Rail Electrical/Fuel Determination . . . . . 3B-21 Air Plenum Installation . . . . . . . . . . . . . . . . 3B-54
EFI System Test Procedures . . . . . . . . . . . . . . 3B-22 Vapor Separator (VST) Installation . . . . . . 3B-55
Fuel Gauge Connection/Pressure Test . . 3B-22 Water Separating Filter Assembly
Vapor Separator Fuel Delivery Test . . . . . 3B-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-56
Pulse Fuel Pump Delivery Test . . . . . . . . . 3B-24 Water Separating Filter Assembly
Water Separating Filter Inspection . . . . . . 3B-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-56
Vapor Separator Float Test . . . . . . . . . . . . 3B-26 Throttle Position Sensor Removal . . . . . . 3B-57
Electric Fuel Pump Inlet Filter Check and Throttle Position Sensor Installation . . . . . 3B-57
De-Pressurizing EFI System Procedures 3B-27 Oil Reservoir Removal . . . . . . . . . . . . . . . . 3B-58
Pressure Regulator Test . . . . . . . . . . . . . . . 3B-29 Oil Reservoir Installation . . . . . . . . . . . . . . 3B-58
Electric Fuel Pump Voltage/Pressure Test 3B-30 Fuel Pressure Regulator Removal . . . . . . 3B-59
Injector Electrical Harness Test . . . . . . . . . 3B-31 Fuel Pressure Regulator Disassembly . . 3B-60
Injector Load Test . . . . . . . . . . . . . . . . . . . . 3B-32 Fuel Pressure Regulator Reassembly . . . 3B-60
Fuel Rail Assembly Leakage Test . . . . . . . 3B-32 EFI System Cleaning and Inspection . . . . . . . 3B-61
Air Temperature Sensor and Head Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-61
Temperature Sensor Test . . . . . . . . . . . . . . 3B-33 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-61
90-884294 OCTOBER 2001 Page 3B-1

FUEL INJECTION
Specifications
FUEL Idle RPM
INJECTION – All Models 650 ± 50
– All Models 5000 – 5800
Injectors
– All Models (Quantity) 6
– Injectors are Crank Angle
Driven by ECM
– #1 Cylinder RED + BRN Leads
– #2 Cylinder RED + WHT Leads
– #3 Cylinder RED + ORG Leads
– #4 Cylinder RED + YEL Leads
– #5 Cylinder RED + LT. BLUE Leads
– #6 Cylinder RED + PUR Leads
Line Pressure @ Injectors 41 psi – 45 psi (283 kPa – 310 kPa)
Injector Resistance 12.3 ohms ± 0.5 ohms
Electric Fuel Pump Resistance 0.7 ± 0.3 ohms
Electric Fuel Pump Amperage Draw 4 amperes ± 0.5 amperes
Page 3B-2 90-884294 OCTOBER 2001

FUEL INJECTION
Special Tools
1. Fuel Pressure Gauge 91-852087A3 (a) or Fuel Pressure Gauge 91-881834A1 (b).
55294 58879
2. Digital Diagnostic Terminal (DDT) 91-823686T2
4. DDT Reference Manual 90-881204-1
90-884294 OCTOBER 2001 Page 3B-3

FUEL INJECTION
5. Adaptor Harness 84-822560A5 (use with DDT)
6. Remote Starter Switch 91-52024A1
7. DMT 2000 Digital Tachometer Multi-meter 91-854009A1
8. Inductive Timing Light 91-99379
9. Spark Gap Tester 91-850439T
55117
10. Strap Wrench 91-24937A1
Page 3B-4 90-884294 OCTOBER 2001

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

FUEL INJECTION
Fuel Management System
Page 3B-6 90-884294 OCTOBER 2001

FUEL INJECTION

TORQUE
REF.
REF
– 1 FUEL MANAGEMENT ASSEMBLY
1 1 ADAPTOR PLATE
2 1 GASKET
3 6 REED BLOCK
4 12 SCREW (M6 x 1) 90 10
5 6 BUSHING
6 6 GROMMET
7 3 SCREW (M8 x 35) 140 16
8 6 WASHER
9 3 SCREW
10 1 AIR PLENUM KIT
11 1 GASKET
12 1 SCREW 80 9
13 1 BRACKET
14 1 MAP SENSOR
15 1 TEMPERATURE SENSOR
16 3 O-RING
17 1 THROTTLE BODY
18 4 SCREW 100 11.3
19 1 O-RING
20 1 THROTTLE ARM
21 1 ROLLER
22 1 RETAINING RING
23 1 SCREW (M5 x 16) Drive Tight
24 1 WASHER
25 1 STAR WASHER
26 1 CAM ASSEMBLY
27 1 THREADED BALL
28 1 SWIVEL BUSHING
29 1 BUSHING
30 1 SCREW (M8 x 40) 145 16.4
31 1 ELBOW
32 1 OIL PUMP
33 2 BRACKET
34 6 SCREW
35 4 SCREW 65 7.3
36 4 WASHER Drive Tight
37 4 GROMMET
38 4 BUSHING
39 1 FUEL RAIL
40 7 RETAINER
41 7 SCREW (8-32 x 0.38)
42 6 FUEL INJECTOR
43 12 O-RING
90-884294 OCTOBER 2001 Page 3B-7

FUEL INJECTION
Page 3B-8 90-884294 OCTOBER 2001

FUEL INJECTION

TORQUE
REF.
REF
44 1 FUEL TUBE
45 2 O-RING
46 1 ELBOW
47 1 SCREW (10-24 x 0.375)
48 1 RETAINER
49 2 O-RING
50 1 FUEL RAIL HARNESS
51 2 CLAMP
52 12 SCREW (M6 x 40) 100 11.3
90-884294 OCTOBER 2001 Page 3B-9

FUEL INJECTION
Vapor Separator Components
Page 3B-10 90-884294 OCTOBER 2001

FUEL INJECTION
Vapor Separator Components

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 COVER KIT
2 1 FITTING - STRAIGHT
4 2 ELBOW
6 1 O-RING
7 1 VALVE
8 1 CAP
9 1 CAP
10 1 PLUG
11 1 SEAL
12 1 GASKET
13 1 PRESSURE REGULATOR KIT
14 1 O-RING KIT
15 1 WASHER - RUBBER
16 2 SCREW 22 2.5
17 1 SCREW 22 2.5
18 1 GROUND WIRE
19 7 SCREW 30 3.5
20 1 FLOAT KIT
21 1 FLOAT PIN
22 1 INLET VALVE
23 1 SCREW 40 4.5
24 1 FUEL FILTER
25 1 PROBE
26 1 FUEL BAFFLE
27 3 SCREW 40 4.5
28 1 FUEL PUMP KIT
29 1 SLEEVE
30 1 BOWL KIT
31 1 SEAL
32 1 PLUG KIT
33 1 O-RING
34 1 SCREW (M6 x 8) Drive Tight
90-884294 OCTOBER 2001 Page 3B-11

FUEL INJECTION
Electronic Fuel Injection (EFl) System

Introduction
The troubleshooting information provided here consists of preliminary checks (checks to
be followed before proceeding with EFI tests), diagrams (fuel flow and electrical wiring),
component description (from diagrams), flow charts (low pressure fuel delivery, high pres-
sure fuel delivery, fuel delivery vs. electrical delivery), problem diagnosis, and a series of
test and check procedures that will help isolate problems associated with the fuel injection
system. Each test/check (listed) can be completed without major fuel system disassembly.
Using the Test Procedures
Read the entire test before beginning to perform outlined procedures. Study the RESULTS
material prior to testing. This will help in determining that each test is providing desired
results.
EFI System Tests
• EFI Electrical System and ECM Check
• Fuel Gauge Connection/Pressure Test
• Vapor Separator Fuel Delivery Test
• Vapor Separator Float Test
• Water Separating Filter Flow Test
• Pulse Fuel Pump Delivery Test
• Final Filter Check
• Fuel Pressure Regulator Test
• Electric Fuel Pump Test
• Injector Electrical Test
• Injector Fuel Delivery Test
• Injector Operating Test
• Induction Manifold Leak Check
• Sensor Tests
Safety Precautions
CAUTION
Always use approved safety glasses or goggles when working on pressurized fuel
systems.
DANGER
Motor fuels are extremely flammable. Do not show open sparks or flames when
working near fuel systems.
WARNING
To avoid potential fire hazards, use extreme caution when connecting and discon-
necting fuel line connections and test adaptors. Do not allow fuel to spill on hot
engine parts or on live electrical connections.
Page 3B-12 90-884294 OCTOBER 2001

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

Fuel is delivered directly to the engine by way of fuel injectors. These injectors are provided
with a constant supply of fuel (41 to 45 psi; 283 to 310 kPa) delivered to the fuel rail. The
injectors are opened and closed electronically by the Electronic Control Module (ECM).
The ECM receives input signals from various sensors in the EFI system which in turn trans-
mits controlling outputs (open/close) to the injectors. The length of time the injectors stay
open is considered pulse width. The pulse width will widen (richer) or narrow (leaner) de-
pending on signals ECM receives from sensors, to allow efficient operation at all speeds
and conditions.
IMPORTANT: The following preliminary steps MUST BE FOLLOWED before at-
tempting EFI problem diagnosis.
Preliminary Checks
Ignition Spark Check
Purpose: This test determines if the ignition system is delivering usable spark to the spark plugs. By perform-
ing this test, the probable cause can be isolated to either the ignition system or fuel system.
1. Disconnect all spark plug wires from spark plugs.
2. Connect Spark Gap Tester (91-850439T1) to a good ground on engine. Connect Spark
Plug Extensions (91-877870A1) between tester and spark plug leads.
3. Connect Remote Starter Switch (91-52024A1) to starter solenoid.
a. Connect RED lead from switch to large positive (+) terminal with RED banded
cable attached [(+) cable from battery].
b. Connect BLACK lead from switch to small terminal with YELLOW/RED lead at-
tached.
4. Turn ignition key switch to the “ON” position.
ON
OFF START
5. Look at spark gap tester viewing port for presence of good quality spark.
A steady, blue spark should be present at each spark plug wire. If a good spark is present,
problem may not be ignition related. If good spark is not present, problem may be ignition
related. Troubleshoot ignition system. Refer to appropriate ignition section in this service
manual.
90-884294 OCTOBER 2001 Page 3B-13

FUEL INJECTION
Electronic Fuel Injection Set Up

IMPORTANT: Follow EFI Synchronizing/Adjustment section 2C before attempting
tests on EFI system.
EFI set up procedures must be followed before tests on system are performed (refer to
Section 2C). Improper set up can result in poor engine performance (i.e. uncontrollable
idle speeds, lean sneezing, low power during acceleration or engine will simply not run.)
Failure to properly set up the EFI system can lead to misdirections in solving simple prob-
lems in the EFI system.
Fresh Quality Fuel
Using a remote fuel tank containing a major brand of premium unleaded gasoline, test run
the outboard to eliminate any problems related to restricted fuel supply (clogged lines, mal-
functioning anti-siphon valve, etc.) and/or marginal gasoline.
Low Battery Voltage
Low battery voltage can cause EFI system to deliver fuel in an inconsistent manner.
Inspect battery connections and charging system, refer to Section 2B. The EFI system re-
quires a substantial amount of voltage to function properly. Operating engine at a low RPM
for an extended period of time while operating numerous electrical accessories can cause
low voltage.
Page 3B-14 90-884294 OCTOBER 2001

FUEL INJECTION
Fuel Flow Diagram
b
a
p
q
o n
m d
k
j
i
h
f e
g
58901
a - Fuel Rail j - Electric Fuel Pump

b - Reed Block Plate Assembly k - Vapor Separator Float
c - Fuel Injectors (6) l - Needle and Seat
d - Pulse Fuel Pump m - Vapor Separator to Flywheel Cover Vent
e - Fuel/Water Separator Hose
f - Water Sensor n - Final Filter
g - From Fuel Tank o - Fuel Rail Pressure Port
h - Vapor Separator p - Fuel Pressure Regulator
i - Electric Fuel Pump Filter q - Fuel Pressure Regulator Vent Hose
90-884294 OCTOBER 2001 Page 3B-15

FUEL INJECTION
Fuel Flow Component Description

Pulse Fuel Pump (d)
The pulse fuel pump operates through alternating crankcase pressure to deliver fuel
through the water separating filter to the vapor separator.
Fuel pressure @ Idle: 2 – 3 psi (13.8 – 20.7 kPa) [Minimum – 1 psi (6.9 kPa)].
Fuel Pressure @ Wide-Open-Throttle: 6 – 8 psi (41.4 – 55.2) [Minimum: 4 psi (27.6 kPa)].
Water Separating Filter (e)
The water separating filter protects the fuel injectors from water and debris. The filter con-
tains a sensor probe which monitors water level in the filter. If water is above the sensor
probe, the warning horn will begin a series of beeps.
Vapor Separator (h)
The vapor separator is a fuel reservoir which continuously blends and circulates fresh fuel
and oil.
a. Fuel Inlet – Fresh fuel delivered from the water separator by the crankcase
mounted pulse fuel pump. The amount of fuel allowed to enter the vapor separator
is controlled by a needle/seat and float assembly mounted in the cover of the vapor
separator.
b. Oil Inlet – Oil delivered by ECM controlled oil pump.
c. Fuel Pressure Regulator Inlet – Unused fuel/oil mixture being recirculated from the
pump back into the vapor separator.
Final Filter (n)
The final filter is located above the electric fuel pump in the brass fuel fitting. The filter col-
lects debris and prevents them from flowing into the fuel rail and injectors.
Electric Fuel Pump (Inside Vapor Separator) (j)
The electric fuel pump runs continuously while providing fuel in excess of engine de-
mands. The excess fuel is circulated through the fuel rail to the fuel pressure regulator and
back to the vapor separator. Normal fuel pressure is 41 – 45 psi (283 to 310 kPa).
Fuel Injectors (c)
The fuel injectors are located on the fuel rail. The injector valve body consists of a solenoid
actuated needle and seat assembly. The injector receives signals from the EFI Electronic
Control Module. These signals determine how long the needle is lifted from the seat (pulse
width) allowing a measured fuel flow. The pulse width will widen (richer) or narrow (leaner)
depending on various signals received from sensors connected to the EFI ECM. The ECM
receives a signal from the crank position sensor to fire each injector accordingly.
A 12 wire harness connects the fuel injectors to the ECM. The RED wire is at 12 volts and
connects to all injectors. The BLUE, YELLOW, WHITE, BROWN, PURPLE and ORANGE
wires each go to individual injectors and are normally at 12 volts for a zero differential. To
fire the injectors this voltage is brought down to near ground creating a potential across
the injectors.
Fuel Pressure Regulator (p)
The fuel pressure regulator is located on top of the vapor separator and is continuously
regulating fuel pressure produced by the electric fuel pump. The electric pump is capable
of producing 90 psi (621 kPa) of fuel pressure. The pressure regulator limits fuel pressure
at the injectors to 41 to 45 psi (283 to 310 kPa).
Page 3B-16 90-884294 OCTOBER 2001

FUEL INJECTION
EFI Electrical Components

ELECTRONIC CONTROL MODULE (ECM)
The ECM is continually monitoring various engine conditions (engine temperature, engine
detonation control (Model 200 only), engine throttle opening and climate conditions (induc-
tion air temperature, barometric pressure and altitude level) needed to calculate fuel deliv-
ery (pulse width length) of injectors. The pulse width is constantly adjusted (rich/lean con-
ditions) to compensate for operating conditions, such as cranking, cold starting, climate
conditions, altitude, acceleration and deceleration, allowing the outboard to operate effi-
ciently at all engine speeds.
12 Volt Battery - The 12 volt battery provides power to the ECM through the main power
relay.
IMPORTANT: When disassembling EFI System DISCONNECT BATTERY CABLES.
In the “start” position, injector pulse widths are increased as engine head temperature is
reduced to provide adequate fuel for quick start up.
Fuel Injectors - A 12 wire harness connects the fuel injectors to the ECM. The red wire
is at 12 volts and connects to all injectors. The BLUE, YELLOW, WHITE, BROWN, PUR-
PLE and ORANGE wires each go to individual injectors and are normally at 12 volts for
a zero differential. To fire the injectors this voltage is brought down to near ground creating
a potential across the injectors.
Electric Fuel Pump - The ECM contains a fuel pump driver circuit that provides power to
the electric fuel pump. The fuel pump does not have its negative terminal (–) “BLACK/RED
wire” grounded to the pump housing. The fuel pump positive terminal (+) “RED wire” and
the negative terminal (–) are at 12 volts with the ignition switch in the off position for a zero
differential. When the pump is on, the negative terminal is brought down to near ground
(i.e. 1.5 volts).
SENSOR INTERACTION WITH THE ECM
IMPORTANT: DO NOT run engine for extended periods of time with sensors discon-
nected or bypassed (shorted). Serious engine damage may result.
AIR TEMPERATURE SENSOR
The air temperature sensor transmits manifold absolute air temperature, through full RPM
range, to the ECM. As air temperature increases “sensor” resistance decreases causing
the ECM to decrease fuel flow (leaner mixture). Disconnecting the air temperature sensor
or temperature sensor failure will cause the ECM to revert to a default temperature source
of 32° F (0° C).
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The map sensor is a non-serviceable sensor mounted on top of the air plenum. The MAP
sensor is used to sense changes in manifold absolute pressure. The MAP sensor is func-
tioning through the full RPM range and is continually signaling induction manifold pressure
readings to the ECM. The ECM in turn determines fuel flow as signals are received. The
MAP sensor’s operation can be monitored using the DDT. With the engine running, as the
throttle is increased or decreased, the MAP sensor’s DDT display should change. If no
change occurs, MAP sensor is not functioning properly.
90-884294 OCTOBER 2001 Page 3B-17

FUEL INJECTION
ENGINE HEAD TEMPERATURE SENSOR (PORT AND STARBOARD CYLINDER HEAD)

The Engine Head Temperature Sensors provide the ECM signals related to engine tem-
perature, to determine level of fuel enrichment during engine warm up. The ECM is receiv-
ing information at all engine temperatures. Disconnecting the temperature sensors or tem-
perature sensor failure will cause the ECM to revert to a default temperature source of 32
°F (0 °C). The temperature sensors can be monitored with the DDT.
THROTTLE POSITION SENSOR (TPS)
The TPS transmits throttle angle information to the ECM which varies the injector pulse
width accordingly. Should the sensor fail, the dash mounted CHECK ENGINE light will illu-
minate and the warning horn will sound. RPM will be reduced by the ECM. The TPS is not
adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal. Voltage
change should be smooth from idle to wide open throttle. If voltage change is erratic, the
TPS is defective.
IGNITION Throttle Position Sensor

SYSTEM @ Idle 0.19 – 1.0 vdc
@ W.O.T. 3.45 – 4.63 vdc
WATER SENSING SYSTEM

The system consists of a water separating fuel filter (port side powerhead) and a sensing
probe (bottom of filter).
WATER SENSING SYSTEM FUNCTION
1. The filter separates the accumulated water from the fuel.
2. A voltage is always present at sensing probe. When water reaches top of probe it com-
pletes the circuit to ground.
3. The completed circuit activates the warning horn which intermittantly sounds.
The system can be tested by disconnecting the TAN wire from sensor probe and holding
to a good engine ground connection for 10 seconds.
Page 3B-18 90-884294 OCTOBER 2001

FUEL INJECTION
EFI Fuel Management (Low Pressure Fuel Route)
• Install fuel pressure gauge on to VST pres-

sure port.
• Place ignition switch in “OFF” position 30 sec-
onds before testing.
• Place ignition switch in “ON” position and
note pressure within 30 seconds (41 to 45 psi;
283 to 310 kPa).
Pump does not run No or low fuel pressure Fuel pressure above 45 psi (310 kPa)
Follow High Pressure Fuel Perform Vapor Separator Fuel Follow High Pressure Fuel
Route Flow Chart. Delivery Test . Route Flow Chart.
Results Results
No or little fuel flow from vapor Fuel flows freely from vapor
separator. separator.
Inspect float system of vapor Follow High Pressure Fuel

separator. Route Flow Chart.
Check fuel/water separator.
Perform Water Separating Fil-

ter Flow Test.
Results Results
Low or no fuel flow from water Fuel flows freely from water separat-
separating inlet hose. Reconnect ing filter inlet hose. Reconnect hose.
hose.
Perform Pulse Fuel Pump De- Replace water separating filter.

livery Test.
Results Results
Fuel flows freely from pulse

pump inlet hose. No fuel flow to pulse fuel pump.
See pulse pump removal and Check for restrictions, holes or loose
inspection section 3A. Locate connections from fuel supply.
all fragments of failed pump
before reassembly.
90-884294 OCTOBER 2001 Page 3B-19

FUEL INJECTION
EFI Fuel Management (High Pressure Fuel Route)
• Perform low pressure checks before performing

checks on high pressure route.
• Install fuel pressure gauge (P/N 91-852087A3) or
(P/N 91-881834A1) on to manifold pressure port.
• Place ignition switch in “OFF” position 30 seconds
before testing.
• Place ignition switch in “ON” position and note pres-
sure (41 to 45 psi; 283 to 310 kPa).
Fuel pressure above 45 psi (310 kPa) No or low fuel pressure Pump does not run
Clogged or faulty fuel pressure Perform Final Filter Check Perform Electric Fuel Pump Volt-
regulator remove and replace. age Test .
Results Results
Final filter OK. Final filter clogged.
Perform pump inlet filter check Inlet filter clogged.

Clean or replace final filter.
Inlet filter OK. Clean or replace final filter.
Perform Fuel Pressure Regulator Test

.
Results Results
Steady stream of fuel [pressure Low or no fuel flow.

still below 41 psi (283 kPa).
Perform Electric Fuel Pump

Replace fuel regulator. Voltage Test .
Results Results
Voltage from ECM driver circuit OK. Low or inconsistent voltage

from ECM driver circuit.
Replace fuel pump. Replace ECM.
Page 3B-20 90-884294 OCTOBER 2001

FUEL INJECTION
Fuel Rail Electrical/Fuel Determination
• Perform all preliminary checks page 3B-13.

• Adequate fuel pressure (41 to 45 psi; 283 to
310 kPa) follow Low/High Fuel Route Flow
Charts.
• Run engine @ idle and with DDT, perform
cylinder load test.
Results Results
No RPM change on cylinder(s), RPM decreases (on each cylinder).

indicating problem in cylinder(s).
Perform Fuel Injector load test. Fuel delivery OK.
Results Results
Fuel Injector has audible click. Fuel Injector does not have audible click.
Injector is functioning properly Defective injector or broken cir-

cuit to injector.
Perform Ignition Coil load test.

Perform Induction Manifold
Disassembly and inspection.
Results Results
Weak or no ignition spark Ignition spark OK
Replace defective coil, spark plug Perform compression check on

or wiring problem cylinder.
Results Results
Low or no compression on cylinder. Compression OK.
Inspect cylinder bore. Refer to Check:

Section 4 for disassembly. 1) Damaged reeds
2) End cap seals
NOTE: Injector filters must be 3) Crankcase split line leak
inspected prior to reassembly. 4) Crankshaft sealing rings
90-884294 OCTOBER 2001 Page 3B-21

FUEL INJECTION
EFI System Test Procedures

NOTE: A clogged final filter located in fitting above fuel pump will cause low fuel pressure
readings at the fuel pressure port. Remove fuel fitting and inspect final filter. Clean and/or
replace final filter as necessary.
a - Final Filter
Fuel Gauge Connection/Pressure Test
IMPORTANT: When checking fuel pressure while engine is running, fuel pressure
may fluctuate. Fuel pressure fluctuation [i.e. 41 to 45 psi (283 to 310 kPa)] is com-
mon, as the regulated pressure is a differential between fuel rail and manifold vacu-
um.
Purpose: Checking fuel manifold pressure ensures that fuel under usable pressure is available to the fuel
injectors. This test isolates the probable cause as either a fuel delivery or EFI electrical system failure.
IMPORTANT: Fuel pressure should be monitored through full RPM range to deter-
mine fuel supply problems at high engine speeds.
1. Connect fuel pressure gauge to VST pressure port.
b a
59053
a - Pressure Port c - Direct fuel into suitable

b - Fuel Pressure Gauge container
(91-881834A1)
Page 3B-22 90-884294 OCTOBER 2001

FUEL INJECTION
2. Turn ignition key switch to “ON” position.

ON
OFF START
3. Operate electric fuel pump (ignition key on).

NOTE: Fuel pump will only operate for approximately 2-4 seconds. By turning the key
switch to “OFF” and then back to “ON” the pump will operate for 2-4 seconds more.
4. Take reading on fuel pressure gauge.
Results: If pressure reading is 41 to 45 psi (283 to 310 kPa), the electric fuel pump is providing fuel with
enough pressure to be used by the injectors. Pump malfunction is not the cause of EFI trouble.
If fuel pressure is well below 41 psi (283 kPa), fuel delivery to electric fuel pump, fuel pump
failure or other related problem exists. Inspect final filter for debris.
If fuel pressure is above 45 psi (310 kPa) go to fuel pressure regulator test.
Vapor Separator Fuel Delivery Test
Purpose: Verifying there is adequate fuel flow to the electric fuel pump (through full RPM range) will deter-
mine components in low pressure fuel system are functioning correctly.
1. Remove vapor separator drain plug and place a clean container under drain.
2. Prime fuel line primer bulb.
59052
Results: Fuel should flow when plug is removed and continue to flow as primer bulb is pumped. If fuel flow is
not present, inspect pulse fuel pump, water separator filter or VST float and needle valve.
If fuel flow is present, go to High Pressure Flow Chart.
90-884294 OCTOBER 2001 Page 3B-23

FUEL INJECTION
Pulse Fuel Pump Delivery Test

Purpose: This test will indicate pulse fuel pump is capable of supplying the low pressure fuel route with ade-
quate fuel supply.
1. Place emergency stop switch in OFF position to prevent engine from starting.
2. Remove fuel inlet hose from fuel/water separator.
59050
3. Turn ignition key switch to “START” and operate starter motor for 10 to 20 seconds.
Results: Fuel should flow freely from hose. Refer to Fuel/Water Separator Inspection and/or Vapor Sepa-
rator Float Test.
If fuel does not flow from hose:
4. Remove inlet hose to pulse fuel pump and put end into clean container.
5. Squeeze primer bulb several times.
59056
a - Inlet Fuel Hose
Page 3B-24 90-884294 OCTOBER 2001

FUEL INJECTION
Results: If low or no fuel flow is present, inspect fuel hose for restrictions. Inspect anti-siphon valve and boat
fuel tank for proper fuel delivery. If fuel flow is present, remove, disassemble and inspect pulse fuel
pump. All fragments of failed pump must be located before reassembly.
59042
a - Pulse Fuel Pump b - Attaching Screws
Water Separating Filter Inspection
Remove fuel/water separator filter. Inspect filter for debris. Replace filter as required.
3. Crank engine over with starter.
59052
Results: If fuel flow is present, fuel is being delivered to electric fuel pump. If fuel is not present, refer to Vapor
Separator Float Test.
90-884294 OCTOBER 2001 Page 3B-25

FUEL INJECTION
Vapor Separator Float Test

NOTE: If squeezing the primer bulb in the Vapor Separator Fuel Delivery Test previous
provides adequate fuel to the vapor separator, the vapor separator float, needle and seat
is functioning properly and the following test does not need to be performed.
Purpose: This test will indicate if float is stuck in the up (closed) position.
NOTE: If float is stuck down, vapor separator will over flow causing a rich condition.
2. Turn ignition key switch to “START” position and operate starter motor for 15 to 20 sec-
onds.
ON
OFF START
59052
Results: If fuel flow is low or not present, remove, disassemble and inspect float assembly. See vapor separa-
tor disassembly.
Page 3B-26 90-884294 OCTOBER 2001

FUEL INJECTION
Electric Fuel Pump Inlet Filter Check and De-Pressurizing EFI System
Procedures
Purpose: Checking the inlet filter for obstructions, damage etc. eliminates this component as a possible
source of restriction in the system.
1. De-pressurize EFI fuel system by wrapping a clean cloth around pressure port valve
and inserting tip of screwdriver into valve, depressing valve core. Let fuel drain from
valve.
b 59053
a - Pressure Port b - Drain Plug
2. Remove drain plug from vapor separator and allow fuel to drain into suitable container.
59052
90-884294 OCTOBER 2001 Page 3B-27

FUEL INJECTION
3. Remove 3 bolts securing vapor separator assembly to manifold.
a
a
59047
a - Bolts
4. Tilt vapor separator assembly out from manifold and remove 9 screws securing cover.
5. Remove vapor separator tank from cover.
6. Pull downward to remove filter from fuel pump.
59055
a - Inlet Filter
7. Inspect filter for debris or damage.

Results: If filter is clogged with debris, clean filter with solvent and compressed air or replace filter. Reas-
semble vapor separator to manifold and recheck fuel pressure. If pressure is still below 41 psi (283
kPa), perform fuel Pressure Regulator Test.
Page 3B-28 90-884294 OCTOBER 2001

FUEL INJECTION
Pressure Regulator Test

NOTE: Low fuel pressure can be caused by inadequate fuel supply, a defective electric
fuel pump or fuel pressure regulator. Verify adequate fuel is being supplied to the vapor
separator. If fuel supply is proper, inspect final filter inside outlet fuel fitting on vapor sepa-
rator for debris. If filter is clean, perform amperage draw test on electric fuel pump. If am-
perage draw is within specifications, replace fuel pressure regulator.
Purpose: This test will determine if a weak, plugged or open pressure regulator is causing inadequate fuel
pressure in the system.
1. Connect pressure gauge 91-881834A1 to EFI test port.
91-881834A1
59053
a - Test Port
2. Turn ignition key switch to “ON” position and check fuel pressure reading on gauge.
If pressure reading is below 41 psi (283 kPa) replace regulator.
ON
OFF START
90-884294 OCTOBER 2001 Page 3B-29

FUEL INJECTION
Electric Fuel Pump Voltage/Pressure Test

NOTE: The Digital Diagnostic Terminal (DDT) can implement a load test for the electric
fuel pump. If the electric fuel pump does not appear to run, it is recommended that the DDT
load test be performed first before performing the following voltage test.
Purpose: If insufficient electrical power is available at the pump, no or low fuel pressure will be developed.
1. Disconnect electric fuel pump harness connector.
2. Set volt meter to read battery voltage and connect black test lead to BLACK wire in the
fuel pump connector, positive test lead to positive wire (RED/BLUE) of fuel pump con-
nector (engine harness end).
59029
a - Fuel Pump Harness Connector – Positive test lead to RED/BLUE wire and
Negative test lead to BLACK wire (engine harness end)
3. Turn key to RUN position. Battery voltage will be applied to the RED/BLUE lead for
about 2 seconds.
Results: If battery voltage is not present, inspect battery, battery connections and harness for corrosion, dam-
age or loose connections. If correct battery voltage is present, replace electric pump.
NOTE: If electric fuel pump runs but fuel pressure is low, perform amperage draw test on
electric pump. Amperage draw should be 4 amperes ± 0.5 amperes. If amperage draw is
high, replace pump.
Page 3B-30 90-884294 OCTOBER 2001

FUEL INJECTION
Injector Electrical Harness Test

An injector load test can be performed using the Digital Diagnostic Terminal (DDT). An au-
dible click will be heard each time an injector is activated. If an injector does not respond
to the load test, an ohm test can be made on the harness and the injector(s).
59058 59058
a - Injector Harness
Injector Resistance
#1 Cylinder – RED + BRN Leads
#2 Cylinder – RED + WHT Leads
#3 Cylinder – RED + ORG Leads 12.3 ohms ± 0.5 ohms
#4 Cylinder – RED + YEL Leads
#5 Cylinder – RED + LT. BLUE Leads
#6 Cylinder – RED + PUR Leads
90-884294 OCTOBER 2001 Page 3B-31

FUEL INJECTION
Injector Load Test

An injector load test can be performed using the Digital Diagnostic Terminal (DDT). An au-
dible click will be heard each time an injector is activated. This test will verify that each in-
jector is operating mechanically, not that each injector is allowing the proper amount of fuel
to enter each cylinder. Refer to DDT Reference Manual 90-881204–1 for test procedures.
Fuel Rail Assembly Leakage Test
Purpose: This test will determine if the supply tube or injector o-rings are leaking or if an injector is stuck open.
1. Remove 4 screws securing throttle plate assembly to air plenum and remove assem-
bly.
a a
59025
a - Screws b - Throttle Plate Assembly
2. Put ignition key switch in “ON” position. Electric fuel pump should run for approximately
2 seconds.
ON
OFF START
3. While pump is running, observe fuel rail.

Results: If leakage is observed, refer to Fuel Rail Removal. Replace o-rings and/or injectors as required.
Page 3B-32 90-884294 OCTOBER 2001

FUEL INJECTION
Air Temperature Sensor and Head Temperature Sensor Test

Purpose: This test eliminates possibilities of improper fuel delivery related to air/head temperature sensors.
NOTE: Air/Head Temperature Sensor functioning can be monitored using the Digital Diag-
nostic Terminal (DDT). The Air Temperature sensor should indicate ambient air tempera-
ture. The Head Temperature sensor should indicate cylinder head water temperature. The
ECM will revert to a default temperature of 32° F (0° C) if it should lose either air or head
temperature sensor signal. The sensors can also be tested using a DMT2000 Digital Multi-
meter 91-854009A1.
a
b
b
59025
59037
a - Air Temperature Sensor b - Head Temperature Sensor

1. Disconnect and remove temperature sensors from engine.
2. Connect DMT (91-854009A1) to leads of sensor.
3. Place sensor in ice water while monitoring meter reading. Use chart (below) for refer-
ence.
Results: Resistance does not change inversely with temperature change. Replace defective temperature
sensor. Resistance changes inversely with temperature change. Temperature sensor OK.

257 125 340
248 120 390
239 115 450
230 110 517
221 105 592
212 100 680
203 95 787
194 90 915
185 85 1070
176 80 1255
90-884294 OCTOBER 2001 Page 3B-33

FUEL INJECTION

167 75 1480
158 70 1752
149 65 2083
140 60 2488
131 55 2986
122 50 3603
113 45 4370
104 40 5327
95 35 6530
86 30 8056
77 25 10000
68 20 12493
59 15 15714
50 10 19903
41 5 25396
32 0 32654
14 –10 55319
5 –15 72940
Detonation Control System Test (200 Work Models Only)
a
a
59034
a - Knock Sensor
Purpose: Determines whether the detonation sensor and circuit located in the ECM is functioning.
1. Place outboard in water, connect Digital Diagnostic Terminal (DDT) to engine.
NOTE: If either knock sensor is not functioning, #4 LED indicator light on DDT will be illumi-
nated.
2. Start engine, allow to warm up. Using SPECIAL FUNCTIONS portion of DDT, access
KNOCK OUTPUT LOAD TEST.
Page 3B-34 90-884294 OCTOBER 2001

FUEL INJECTION
Results: As throttle is advanced and engine is under load (in gear), numerical value on DDT display should
increase. As throttle is retarded, numerical value should decrease indicating knock sensor/circuit is
functioning. If numerical value does not change as throttle setting and load on engine varies, knock
sensor or knock circuit in ECM is defective.
Throttle Position Sensor Test
59030
a - Throttle Position Sensor

Purpose: Determines whether Throttle Position Sensor is functioning properly through the use of the Digital
Diagnostic Terminal (DDT). The Throttle Position Sensor is not adjustable.
NOTE: If throttle position sensor is not functioning, #4 LED indicator light on DDT will be
illuminated.
2. Start engine, allow to warm up. Using DATA MONITOR portion of DDT, access TPI
VOLTS.
Results: As throttle is advanced, numerical value on DDT display should increase. As throttle is retarded,
numerical value should decrease.
HEAT TEST
With engine at idle, heat the TPS (with a hot air gun) below the electrical connection until
warm to the touch. Watch for any one or a combination of the following symptoms:
• RPM change
• Check engine light illumination
• Momentary warning horn signal
• TPS voltage value change (1/2 volt) on DDT
NOTE: Excessive heat will damage TPS.
90-884294 OCTOBER 2001 Page 3B-35

FUEL INJECTION
PRESSURE TEST
IMPORTANT: When testing TPS voltage, do not move the drive mechanism (rotor/
wiper).
1. Connect DDT and rotate the key to the “ON” position.
2. Set DDT to read TPS voltage; expand the screen to show Now/Min/Max.
NOTE: Test accuracy is improved when TPS is at its lowest voltage reading; this may be
idle or WOT depending on model year.
3. Clear the minimum/maximum values on the DDT – press the “0” button.
4. Watch the DDT readings while pressing below the electrical connection point on the
TPS cover.
a
a - Press on cover below electrical connection
5. Voltage reading should change:
• Less than a couple of digits (i.e. 1.90 v to 1.92 v)
NOTE: Version 5.0 cartridge gives 3 decimal point (millivolts) accuracy if below 1 volt.
• Less than 10 millivolts (i.e. 0.293 v to 0.285 v)
Replace any TPS that fails either test.
MAP Sensor Test
59025
a - MAP Sensor
Purpose: Determines whether the Manifold Absolute Pressure (MAP) Sensor is functioning properly through
the use of the Digital Diagnostic Terminal (DDT).
NOTE: If MAP sensor is not functioning, #4 LED indicator light on DDT will be illuminated.
2. Start engine, allow to warm up. Using DATA MONITOR portion of DDT, access MAP
PSI.
Results: As throttle is advanced, numerical value on DDT display should increase. As throttle is retarded,
numerical value should decrease indicating MAP sensor is functioning. If numerical value does not
change as throttle setting varies, MAP sensor is defective. The ECM would revert to a default of
approximately 14.7 PSI (near sea level) should it not receive a signal from the MAP sensor.
Page 3B-36 90-884294 OCTOBER 2001

FUEL INJECTION
Problem Diagnosis
Condition Possible Source Action
Engine Down On Power Or RPM – Failed Ignition Coil Refer to Section 2 Electrical and
Ignition Tests.
– Low Compression Refer to Section 4 Power Head.
– Broken Reed Inspect Reeds.
– Fuel Delivery Problem Follow Low/High Pressure Fuel

Route Flow Charts and Fuel Rail
Electrical/Fuel Determination
Flow Chart.
– Fuel Rail Leak Perform Fuel Rail Leak Test.
– Vapor Separator Flooding Check for fuel coming out of va-

Over, Engine Running Rich. por separator vent hose.
– Cylinder Head Temperature Check cylinder head temperature

Sensor Circuit Failed. sensor.
Poor Acceleration – Idles Ok, – Improper EFI Set Up. Refer to Section 2 Electrical and
Top Speed Ok Ignition for proper EFI set up pro-
cedures.
– Water Covering Idle Relief Boats with extended transoms or

Exhaust Ports. low engine mount can cause en-
gine to load up on acceleration.
– T.P.S. Failure. Refer to page 3B-33.
– MAP Sensor Failure Refer to page 3B-34.
– R.F.I. Problem* Install BPZ8HS-10 Spark Plugs.
90-884294 OCTOBER 2001 Page 3B-37

FUEL INJECTION

Poor Acceleration – Idles Ok, – Timing Not Advancing. Check Timing Advance with DDT.
Top Speed Ok (Continued)
Engine Surges Between 4000 – Intermittant Ignition Coil Fail- Refer to Section 2A Electrical
And 5000 RPM ure. and Ignition for tests.
– Final Filter Clogging. Perform Final Filter Check.
– T.P.S. Check TPS Operation with DDT
– Injector Connector Problem. Perform DDT Load Test and

Ohms Test.
– Vapor Separator Flooding Check for fuel coming out of va-

Over. por separator vent hose.
– Injector Filter Clogged. Must be determined by elimina-

tion; mechanical, electrical and
load tests
Engine Idles Ok But Stumbles At – Improper EFI Setup. Refer to Section 2C Electrical
Off Idle Speeds and Ignition for proper EFI set up
procedures.
– Failed Ignition Coil. Refer to Section 2A Electrical

and Ignition Tests.
– Failed Or Disconnected EFI Perform EFI sensor tests.

Sensors.
– Fuel Delivery Problem. Follow Low/High Pressure Fuel

Route Flow Charts and Fuel Rail
Electrical/Fuel Determination
Flow Chart.
– Manifold Fuel Leak. Perform Induction Manifold Leak

Check.
– R.F.I.* Problem. Install BPZ8HS-10 Spark Plugs.
Check manifold cover gasket,

– Induction Manifold Air Leak. manifold to reed block housing
gasket and reed block housing to
crankcase gasket.
– MAP Sensor Failure. Refer to page 3B-34.

Engine Idles Rough (May Lean – Improper EFI Setup. Refer to Section 2C Electrical
Sneeze) – Acceleration Ok; Full and Ignition for proper EFI set up
Throttle Ok procedures.
– MAP Sensor Failure. Refer to page 3B-34.
Page 3B-38 90-884294 OCTOBER 2001

FUEL INJECTION

Engine Idles Rough (May Lean – Ignition Coil Failure. Refer to Section 2A Electrical
Sneeze) – Acceleration OK; Full and Ignition Tests.
Throttle Ok. (continued)
– Broken Reed. Inspect Reed Assembly
Engine Runs but Slowly Drops – Restrictions in Fuel System Install remote gas tank with
RPM then Dies. between Tank and Engine. fresh, high quality fuel.
– Clogged Final Filter. Perform Final Filter Check.
Follow Low Pressure Fuel Route

– Pulse Fuel Pump Failure. Flow Chart.
Follow High Pressure Fuel Route

– Electric Fuel Pump Delivery Flow Chart.
Failure.
Engine Stops for No Apparent – Battery Undercharged. Check battery connections, un-
Reason or Does Not Start. der charged battery or worn out
battery.
– EFI Harness Connections. Check EFI harness connector for

improper connection.
– Ignition System Failure. Refer to Section 2A Electrical

and Ignition Tests.
– Pulse Fuel Pump Failure. Follow Low Pressure Fuel Route

Flow Chart.
– Electric Fuel Pump Failure. Follow High Pressure Fuel Route

Flow Chart.
– ECM Failure. The DDT (91-823686T2) will

monitor information coming from
sensors or switches to the ECM
and will indicate if the sensor or
switch is defective. For a more
thorough analysis of the ECM,
refer to EFI Tester Manual
91-11001A2.
Engine Stops for No Apparent – Restriction in Fuel System Check fuel pressure on fuel rail
Reason, but will Restart. at the RPM that failure occurs.
*R.F.I. Radio Frequency Interference. High voltage can alter signals ECM receives from sensors causing im-
proper fuel delivery. Route all sensor wires away from high voltage leads (i.e. spark plug leads)
90-884294 OCTOBER 2001 Page 3B-39

FUEL INJECTION
Engine Head Temperature Sensor Removal

1. Remove screw and retaining plate.
2. Disconnect bullet connector and remove sensor.
1. Disconnect wire harness for PORT and STARBOARD sensors
g
a
b
d
f e
e c
59037
a - Bullet Connector (hidden) e - Digital Temperature
b - Analog Temperature Sensor Sensor
c - Retainer f - Port Sensor Harness
d - Retainer Screw g - Starboard Sensor Har-
ness
Engine Head Temperature Sensor Installation

1. Install sensor into pocket.
2. Secure sensor with retainer and screw. Ground (BLACK) lead of sensor is secured with
retainer screw. Torque retainer screw to 16.5 lb. ft. (22.4 Nm).
3. Reconnect sensor bullet connector.
1. Install sensors into cylinder heads. Torque sensors to 14 lb. in. (1.6 Nm).
2. Reconnect sensor harness connectors.
Page 3B-40 90-884294 OCTOBER 2001

FUEL INJECTION
Fuel Management Assembly Removal

CAUTION
Fuel system must be bled off prior to removal of fuel system components.
NOTE: Use Fuel/Air Pressure Gauge 91-881834A1 to de-pressurize fuel system.
1. De-pressurize fuel system.
b a
91-881834A1
a - Fuel Pressure Port b - Fuel Pressure Gauge 91-881834A1

2. Place suitable container underneath vapor separator drain plug and remove plug.
59052
a - Drain Plug
90-884294 OCTOBER 2001 Page 3B-41

FUEL INJECTION
3. Disconnect the following hoses and connectors:
a
c
f
59051
a - VST Vent Hose e - VST Electric Fuel Pump Harness
b - Fuel Pressure Regulator Vent Hose Connector
c - VST Output Fuel Hose f - Water Sensor Bullet Connector
d - VST Oil Input Hose g - Fuel/Water Separator Input Fuel
Hose
4. Remove ground lead between VST and air plenum.
5. Remove 3 bolts securing VST to air plenum and remove VST.
a
b
b
b
59047
a - VST Ground Lead b - VST Attaching Bolts
Page 3B-42 90-884294 OCTOBER 2001

FUEL INJECTION
6. Disconnect throttle cam link rod and the Throttle Position Sensor link rod.
b
a
59046
a - Throttle Cam Link Rod b - Throttle Position Sensor Link Rod
b
a
59058
b - MAP Sensor
c - Fuel Injector Harness Con-
nector
90-884294 OCTOBER 2001 Page 3B-43

FUEL INJECTION
8. Disconnect oil pump electrical harness, oil pump inlet and outlet hoses.
b
c
59039
a - Electrical Harness
b - Oil Outlet Hose
c - Oil Inlet Hose
9. Remove 12 bolts securing air management assembly to crankcase and remove as-
sembly.
59061
a - Bolts (12 each)
Page 3B-44 90-884294 OCTOBER 2001

FUEL INJECTION
Fuel Rail Removal

The fuel rail/injector assembly is attached to the reed block assembly plate by 4 screws.
a b
59057
a - Fuel Rail/Injector Assembly b - Reed Block Assembly
1. Remove 4 screws to securing fuel rail/injector assembly to reed block assembly.
a a
59054
a - Screws
90-884294 OCTOBER 2001 Page 3B-45

FUEL INJECTION
2. Lift fuel rail assembly from reed block assembly.

3. Inspect o-rings for cuts and abrasions. Replace if necessary.
a b a a
d
e
c
59048
a - Fuel Injectors (6) d - Fuel Rail

b - Fuel Rail Fuel Inlet Pipe e - Reed Block Assembly
c - O-Rings
4. Individual fuel injectors and fuel inlet pipe can be removed from fuel rail by removing
attaching screws. Use Tamper Proof Torx Screw Set 91-881828 to remove screws.
a a a
58792
a - Fuel Injector Attaching Screws
b - Fuel Inlet Pipe Attaching Screw
Page 3B-46 90-884294 OCTOBER 2001

FUEL INJECTION
Fuel Rail Installation

NOTE: Inspect all o-rings for cuts and abrasions. Applying light oil to all o-rings and o-ring
contact surfaces on reed block assembly plate will ease installation of fuel rail assembly.
1. Secure fuel injectors to fuel rail with tamper proof screws. Torque screws to 27 lb. in.
[3.0 Nm].
2. Secure fuel inlet pipe to fuel rail with tamper proof screw. Torque screw to 65 lb. in. [7.0
Nm].
a a a
58792
a - Fuel Injector Attaching Screws [Torque to 27 lb. in. (3.0 Nm)]
b - Fuel Inlet Pipe Attaching Screw [Torque to 65 lb. in. (7.0 Nm)]
3. Apply light oil to all o-rings and o-ring contact surfaces on reed block assembly plate
to ease installation of fuel rail assembly.
a b a a
d
e
c
f f f f
58881
a - Fuel Injectors (6) d - Fuel Rail
b - Fuel Rail Fuel Inlet Pipe e - Reed Block Assembly
c - O-Rings f - O-Ring Contact Surface
90-884294 OCTOBER 2001 Page 3B-47

FUEL INJECTION
4. Secure fuel rail assembly to reed block assembly plate with 4 screws. Torque screws
to 65 lb. in. [7.0 Nm].
a a
59054
a - Screws [Torque to 65 lb. in. (7.0 Nm)]
Page 3B-48 90-884294 OCTOBER 2001

FUEL INJECTION
Reed Block Assembly Removal

1. Remove 12 screws securing air plenum to reed plate assembly.
2. Remove 12 screws securing reed blocks to reed plate assembly.
c
f
e
d
59045
a - Screws (2 each per reed block) (M4x16)
b - Air Plenum
c - Screws (12 each) (1/4x20x0.88)
d - Gasket
e - Adaptor Plate
f - Gasket
g - Reed Block (6 each)
Reed Block Assembly Installation
NOTE: The gasket between the air plenum and the adaptor plate has a sealing bead which
faces toward the air plenum during assembly. Gaskets may be reused if they do not show
signs of tears, abrasions or oil saturation. Replace gaskets if necessary.
1. Secure reed block assembly to adaptor plate with 2 screws. Torque screws to 105 lb.
in. (11.8 Nm).
2. Secure air plenum and adaptor plate/reed block assembly to cylinder block crankcase
with 12 screws. Torque screws to 15 lb. ft. (20 Nm).
90-884294 OCTOBER 2001 Page 3B-49

FUEL INJECTION
Air Temperature Sensor Removal

Disconnect sensor harness and unscrew sensor.
a
59025
a - Temperature Sensor Harness b - Air Temperature Sensor
Air Temperature Sensor Installation
1. Carefully thread sensor into air plenum. Torque sensor to 14 lb. in. (1.6 Nm).
Manifold Absolute Pressure (MAP) Sensor Removal
1. Disconnect MAP sensor harness connector.
2. Remove sensor retaining screw.
a
c
59025
a - MAP Harness Connector
b - Retaining Screw
c - MAP Sensor
Manifold Absolute Pressure (MAP) Sensor Installation
1. Secure MAP sensor with screw. Torque screw to 80 lb. in. (9.0 Nm).
Page 3B-50 90-884294 OCTOBER 2001

FUEL INJECTION
Throttle Plate Assembly Removal

NOTE: The throttle plate assembly is calibrated and preset for proper running characteris-
tics and emissions at the factory. Other than complete assembly removal from the air ple-
num, no further disassembly should be made.
Remove 4 bolts securing throttle plate assembly to air plenum and remove assembly.
a
a
a - Bolts b - Throttle Plate Assembly
Throttle Plate Assembly Installation

Secure throttle plate assembly to air plenum with 4 bolts. Torque bolts to 100 lb. in. (11.5
Nm).
Vapor Separator Disassembly
1. Remove 7 screws securing separator cover and remove cover.
2. Inspect seal in fuel pump chamber of separator tank for cuts and abraisions. Replace
seal if necessary. If seal is serviceable, apply 2-4-C Marine Lubricant with Teflon to seal
lips.
a a a
b
a
a a
a
58784 58783
a - Screws (7 each) b - Seal
3. Fuel pump may be removed from cover by wiggling slightly while pulling outward.
IMPORTANT: DO NOT twist pump during removal as wire harness may be damaged.
90-884294 OCTOBER 2001 Page 3B-51

FUEL INJECTION
4. Disconnect harness from pump to separate pump from cover. Inspect filter screen for
debris. Screen may be pried out of pump and cleaned as required.
5. Inspect seal above fuel pump for cuts or abraisions. Replace seal if necessary. Apply
2-4-C Marine Lubricant with Teflon to seal lips.
b
d
c
a
58786
a - Filter Screen c - Pump
b - Harness Connector d - Seal (Seal shoulder
faces OUT)
6. Loosen screw securing float assembly and remove float. Inspect float for deterioration
or fuel retention. Replace float as required.
7. Remove gasket and inspect imbedded neoprene sealing bead on both sides of gasket
for cuts or abraisions. Replace gasket/seal assembly as required.
a
c
b 58787 58783
a - Screw
b - Float
c - Gasket
d - Sealing bead
Page 3B-52 90-884294 OCTOBER 2001

FUEL INJECTION
Vapor Separator Reassembly

NOTE: Inspect VST cover gasket with sealing bead for cuts or abrasions. Replace if nec-
essary. Inspect fuel pump seal in VST cover for cuts or abrasions. Replace if necessary.
1. Install gasket w/sealing bead onto vapor separator cover.
2. Secure float, needle and pivot pin assembly to separator cover with screw. Torque
screw to 10 lb. in. (1.0 Nm)
3. Apply 2-4-C Marine Lubricant with Teflon to lips of seal in separator cover.
a
c e
b 58787 58783
a - Screw [Torque to 10 lb. in. (1.0 Nm)]

b - Float
c - Gasket
d - Sealing Bead
e - Seal (Seal shoulder faces OUT)
4. Connect electrical harness to fuel pump. Inspect fuel pump filter screen for debris. Re-
move screen and clean as required.
5. Seat fuel pump and harness into separator cover being careful not to pinch harness.
a
c
d
b
58786
a - Harness
b - Filter
c - Seal
d - Fuel Pump
90-884294 OCTOBER 2001 Page 3B-53

FUEL INJECTION
6. Install separator cover with pump onto separator tank.

7. Secure cover to tank with 7 screws. Torque screws to 30 lb. in. (3.5 Nm).
a a a
a
a a
a
58784
a - Screws [Torque to 30 lb. in. (3.5 Nm)]
Air Plenum Installation
Secure plenum to crankcase with 12 bolts. Torque bolts to 125 lb. in. (14 Nm). in sequence
shown
9
a 10
6 5
2 1
b
3 4
7 8
11 12
56144
a - Air Plenum
b - Bolts [Torque to 125 lb. in. (14 Nm)]
Page 3B-54 90-884294 OCTOBER 2001

FUEL INJECTION
Vapor Separator (VST) Installation

1. Install ground lead between VST and air plenum.
2. Install 3 bolts securing VST to air plenum. Torque bolts to 140 lb. in. (16 Nm).
a
b
b
b
59047
a - VST Ground Lead b - Bolts [Torque to 140 lb. in. (16 Nm)]
3. Reconnect the following hoses and connectors:
a
c
f
59051

b - Fuel Pressure Regulator Connector
Vent Hose f - Water Sensor Bullet Connector
c - VST Output Fuel Hose g - Fuel/Water Separator Input Fuel
d - VST Oil Input Hose Hose
90-884294 OCTOBER 2001 Page 3B-55

FUEL INJECTION
Water Separating Filter Assembly Removal

NOTE: To inspect or replace water separator, it is not necessary to remove inlet fuel line.
1. Remove water sensor lead from bottom of separator.
2. With wipe towels available, use Strap Wrench (91-24937A1) to remove water separa-
tor.
91-24937A1
b 59047
a - Water Separator
b - Water Sensor Lead
Water Separating Filter Assembly Installation

IMPORTANT: Apply a light coat of outboard oil to the rectangular sealing ring on the
water separator before installation.
1. After applying oil to sealing ring of water separator, install separator onto bracket.
2. HAND TIGHTEN SEPARATOR. DO NOT use strap wrench or other tool to tighten sep-
arator.
3. Reconnect water sensor lead to bottom of separator.
Page 3B-56 90-884294 OCTOBER 2001

FUEL INJECTION
Throttle Position Sensor Removal

NOTE: Vapor Separator has been removed for visual clarity.
1. Remove throttle position sensor (TPS) harness connector.
2. Remove sensor link rod.
3. Remove 3 screws securing sensor.
d
b
a c
59046
a - Sensor Harness Connector c - Retaining Screws
b - Sensor Link Rod d - Throttle Position Sensor
Throttle Position Sensor Installation
1. Secure sensor with 3 screws. Torque screws to 70 lb. in. (8.0 Nm).
3. Reconnect sensor link rod.
90-884294 OCTOBER 2001 Page 3B-57

FUEL INJECTION
Oil Reservoir Removal

1. Disconnect low oil sensor bullet connectors (BLUE leads).
2. Remove sta-strap securing reservoir hose to oil pump and remove hose. Plug hose
to prevent leakage.
3. Remove oil input hose to oil reservoir from check valve.
4. Remove 3 screws and remove reservoir.
d
e
b a
59063
a - Bullet Connectors
b - Reservoir Hose
c - Oil Input Hose
d - Screws
e - Oil Reservoir
Oil Reservoir Installation
1. Secure oil reservoir to engine with 3 screws. Torque screws to 14 lb. ft. (19 Nm).
2. Secure oil reservoir hose to oil pump with sta-strap.
3. Secure oil input hose to check valve with sta-strap.
4. Reconnect low sensor bullet connectors.
Page 3B-58 90-884294 OCTOBER 2001

FUEL INJECTION
Fuel Pressure Regulator Removal

1. Disconnect boat battery from engine harness.
CAUTION
Fuel system must be bled off prior to removal of fuel system components.
NOTE: Use Fuel/Air Pressure Gauge 91-881834A1 to de-pressurize fuel system.
1. De-pressurize fuel system.
91-881834A1
59053
a - Fuel Pressure Port
2. Remove fuel regulator vent hose from pressure regulator.
3. Remove 2 screws securing regulator to separator and remove regulator.
a
b
59064
a - Fuel Pressure Regulator c - Screws
b - Regulator Vent Hose
90-884294 OCTOBER 2001 Page 3B-59

FUEL INJECTION
Fuel Pressure Regulator Disassembly

1. Inspect O-rings for cuts and abraisions. Replace as required.
2. Inspect fuel filter for debris. Clean with solvent as required.
58789
a - O-Rings
b - Filter
Fuel Pressure Regulator Reassembly

1. Reinstall fuel regulator into vapor separator.
2. Secure regulator with 2 screws. Drive screws tight.
3. Reconnect regulator vent hose.
Page 3B-60 90-884294 OCTOBER 2001

FUEL INJECTION
EFI System Cleaning and Inspection

Cleaning
1. Clean all non-electrical metal parts using a good grade solvent.
2. Use a soft bristle brush for removing large accumulations of dirt or grease and oil.
3. Varnish type coating of induction manifold parts may be removed using carburetor
cleaner.
4. Wiring harnesses can be wiped down with a slightly solvent dampened rag.
5. Clean all fuel passages in induction manifold.
6. Dry all components using clean lint free cloths that are free of abrasives such as metal
shavings or dirt.
7. Compressed air may be used to dry parts if the air used is free of moisture and unlubri-
cated.
Inspection
1. Look at entire system for signs of an obvious problem such as poor condition of wire
insulation, leaking fitting, cracked or loose hoses and lines.
2. Look for fuel or oil leaks wherever these fluids are used (i.e. fuel filter cap, fuel pump,
vapor separator cap, etc.).
3. Check for signs of tampering or abuse such as modifications to wiring or hose routing.
4. Look at main connector between engine harness and ECM box for missing, corroded
or bent contact pins and socket. Check for dislodged grommet in ECM where harness
enters box.
5. Look at all sensors (throttle position, air temperature and water temperature) connec-
tors and harnesses for bad connections or poor insulation conditions such as fraying,
stripping, cracks or signs of abrasion wear.
6. Look for loose, missing or damaged mounting hardware such as stripped threads on
screws.
7. Look at sensors for signs of wear or damage such as cracks, chips, etc.
8. Look at filter housing for cracks, holes or other damage. Check for secure mounting.
9. Look at vapor separator for leaks, cracks, pitting or other damage.
10. Check all rubber mounting grommets for swelling tears, cracks or other conditions that
would render parts unserviceable.
11. Check vapor separator float for signs of fuel entry in the float. Look at needle for wear
of point.
12. Look at injectors for signs of plugging or looseness in fit with induction manifold.
13. Look at throttle linkage for bends, kinking or binding. Check spring for kinks.
14. Inspect all rubber seals and gaskets for swelling, cracks or slices that would cause im-
proper sealing.
90-884294 OCTOBER 2001 Page 3B-61

OIL INJECTION
FUEL SYSTEM
Section 3C - Oil Injection
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 Priming the Oil Pump . . . . . . . . . . . . . . . . . 3C-10
Operation of the Oil Injection System . . . . . . 3C-2 Priming Procedure – Method 1 . . . . . . . . . 3C-11
Final Checks Before Operation of Engine
Checking Operation of the Oil Injection
3C-2 Remote Oil Hose Connections . . . . . . . . .
Filling the Oil Tanks . . . . . . . . . . . . . . . . . . .
3C-12
3C-13 3
System (Engine Running) . . . . . . . . . . . . .
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3C-2
3C-3
Purging Air From the Engine Oil Reservoir
and Remote Oil Hose . . . . . . . . . . . . . . . . . 3C-13
C
Oil Injection Components . . . . . . . . . . . . . . . . . 3C-4 Oil Warning Systems . . . . . . . . . . . . . . . . . . 3C-14
Oil Pump Removal and Installation . . . . . 3C-8 Oil System Troubleshooting . . . . . . . . . . . . . . 3C-15
Engine Oil Reservoir Removal and Low Oil Warning System is Activated . . . 3C-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9
Specifications
OIL Recommended Oil Quicksilver TC-W3
INJECTION Oil Tank Capacity 3 gal. (11.4 Liter)
Approx. Time
– All Models 6.6 hrs. Approx.
Reserve Capacity/Approx. Time 0.74 qt. (0.70 Liter) 20–25 min.
Oil Pump Output

– All Models 26cc during auto prime time period
90-884294 OCTOBER 2001 Page 3C-1

OIL INJECTION
CAUTION
Be careful not to get dirt or other contamination in tanks, hoses or other compo-
nents of the oil injection system during installation.
Operation of the Oil Injection System

The oil injection system delivers oil mixture on engine demand, from 120:1 at idle to 50:1
at wide open throttle.
Oil is stored inside a remote oil tank in the boat. This tank holds enough oil for approxi-
mately 150 gallons of fuel at wide open throttle.
Crankcase pressure forces oil from the remote oil tank into the engine oil reservoir. The
engine oil reservoir feeds oil to the oil pump. The engine oil reservoir contains enough oil
for 20–25 minutes of full throttle running after the remote oil tank is empty. The warning
horn will sound if the oil level in the engine oil reservoir is low.
The oil pump is ECM driven and pumps oil to the vapor separator tank where it mixes with
fuel supplied by the engine mounted pulse pump.
The ECM is programmed to automatically increased the oil supply to the engine during
the initial engine break-in period. The oil ratio during the first 120 minutes is 100:1 @ idle
and 40:1 @ wide open throttle. After the first 120 minutes, the oil ratio changes to 120:1
@ idle and 50:1 @ wide open throttle.
Final Checks Before Operation of Engine
• Make sure fill cap gaskets are in place and caps are tight on engine oil reservoir and
remote oil tank.
• Be certain the warning horn is installed and is operational. Refer to Instrument and
Warning Horn Installation.
• Each time the key switch is turned from the “OFF” to “ON” position (engine not run-
ning); the warning horn will sound momentarily. This tells you the warning system for
the oil injection system is functional and the warning horn is operational. If warning
horn does not sound or horn stays on when key is turned to the “ON” position, refer to
oil injection system troubleshooting chart following to correct the problem.
Checking Operation of the Oil Injection System (Engine Running)

1. Operate engine following the break-in procedure outlined in the Operation and Main-
tenance Manual. If warning horn should sound an intermittent “beep,” “beep,” “beep”
during operation, this indicates low oil level in the engine mounted oil reservoir. Refer
to troubleshooting following, to correct the problem.
2. After engine has been run for a short time, check that no oil is leaking out of engine
oil reservoir fill cap.
Page 3C-2 90-884294 OCTOBER 2001

OIL INJECTION
Notes:
90-884294 OCTOBER 2001 Page 3C-3

OIL INJECTION
Oil Injection Components
Page 3C-4 90-884294 OCTOBER 2001

OIL INJECTION

TORQUE
REF.
REF
1 1 OIL RESERVOIR ASSEMBLY
2 1 DECAL-RESERVOIR
3 1 SCREW [0.164-18 x 1-1/4 IN) Drive Tight
4 1 WASHER
5 1 CAP ASSEMBLY
6 1 GASKET
7 1 SWITCH ASSEMBLY–LOW OIL
8 3 SCREW (M8 x 35) 15 20
9 3 WASHER
10 3 GROMMET
11 3 BUSHING
12 1 TUBING (7 IN) (17.7 CM)
13 AR STA-STRAP
14 1 FITTING
15 1 HOSE
16 1 FILTER
17 1 HOSE
18 2 CONNECTOR
19 2 PLUG
20 1 TUBING (22 IN.) (55.8 CM)
90-884294 OCTOBER 2001 Page 3C-5

OIL INJECTION

REMOTE OIL TANK a
Holds 3 gallons (11.5 liters) of oil.
NOTE: Some boats may be equipped with optional 1.8 gallon (7.0 liters) oil tank.
The tank is pressurized by air from crankcase pressure thus forcing oil up the outlet hose
to the oil reservoir on engine.
OIL PICK UP TUBE b
A filter screen is located in end of tube to prevent dirt or other particles from entering the
system.
FILTER c
Directional filter designed to prevent impurities from entering oil reservoir.
4 PSI CHECK VALVE d
If oil flow to reservoir is obstructed and injection pump continues to pump oil, the 4 PSI
valve will open to allow air to enter reservoir to prevent a vacuum.
OIL RESERVOIR e
The oil reservoir feeds the oil pump and contains enough oil for 20–25 minutes of full
throttle running after the remote tank is empty. The warning horn will sound if the oil level
in oil reservoir is low.
LOW OIL (FLOAT) SENSOR f

If oil level drops in oil reservoir, the sensor will signal the Electronic Control Module (ECM)
to sound the warning horn.
VAPOR SEPARATOR TANK (VST) g
Contains electric fuel pump which pumps fuel @ 43 psi ± 2 psi (296.5 kPa ±13.8 kPa) to
the fuel rail. Oil supplied by the electric oil pump is mixed with fuel supplied by the engine
pulse pump in the VST.
OIL INLET HOSE h

Hose that carries oil from oil reservoir to electric oil pump.
OIL INJECTION PUMP i

Injection pump is electrically operated and controlled by the ECM. Pump varies oil ratio
from 120:1 at idle to 50:1 at wide open throttle.
OIL OUTLET HOSE j

Hose that carries oil from electric fuel pump to mix with fuel in vapor separator.
Page 3C-6 90-884294 OCTOBER 2001

OIL INJECTION
Oil Injection Flow System
e
d
i h
j c
b a
58888
a - Remote Oil Tank g - Vapor Separator Tank
b - Oil Pick-up Tube h - Oil Inlet to Oil Pump
c - Filter i - Oil Injection Pump
d - 4 PSI Check Valve j - Oil Outlet Hose to Vapor Separator
e - Oil Reservoir Tank
f - Low Oil (Float) Sensor (Inside Reser-
voir)
90-884294 OCTOBER 2001 Page 3C-7

OIL INJECTION
Oil Pump Removal and Installation

REMOVAL
1. Disconnect the wiring harness from the pump.
2. Disconnect the oil hoses.
NOTE: Plug oil supply hose from oil reservoir to prevent spillage.
3. Remove three bolts and remove pump.
a
g
e
d
c
59039 b
a - Oil Pump
b - Bushing (3)
c - Rubber Grommet (3) – Insert into Hole
d - Washer (3)
e - Bolt (3) – Torque to 140 lb. in. (16 Nm)
f - Wiring Harness
g - Sta-Straps
INSTALLATION
1. Install pump as shown.
2. Reconnect the oil hoses. Refer to Oil Injection Hose Installation for correct location.
Fasten hoses to pump fittings with sta-straps.
3. Connect the wiring harness.
4. Refill the oil system. Refer to Priming the Oil Pump.
Page 3C-8 90-884294 OCTOBER 2001

OIL INJECTION
Engine Oil Reservoir Removal and Installation

REMOVAL
1. Disconnect the oil hoses. Plug the hoses to prevent spillage.
2. Disconnect the BLUE with BLACK STRIPE wire leads.
3. Remove three bolts securing oil tank to powerhead and remove tank.
l
i
h
a e
g f
d c
j
59030
a - Oil Reservoir
b - Bushing (3)
c - Rubber Grommet (3) – Insert into Holes
d - Decal
e - Bolt (3) – Torque to 170 lb. in. (19 Nm)
f - Washer (3)
g - Washer
h - Screw (Drive Tight)
i - Low Oil Switch (Normally Closed Circuit)
j - Tubing [22 in. (55.8 cm)]
k - Cap
l - Gasket
INSTALLATION
1. Install oil reservoir as shown.
2. Fasten the oil hoses with sta-straps.
3. Connect the BLUE with BLACK STRIPE wire leads.
4. Refill the oil system. Refer to Priming the Oil Pump.
90-884294 OCTOBER 2001 Page 3C-9

OIL INJECTION
Priming the Oil Pump

NOTE: If a new powerhead is being installed or oil hoses/oil pump has been removed,
it is recommended all air be purged from oil pump/oil lines using gearcase leakage tester
(FT-8950). Connect the leakage tester to the inlet t-fitting on the onboard oil reservoir.
While clamping off the inlet hose, manually pressurize the reservoir to 10 psi. Using the
Digital Diagnostic Terminal 91-823686A2, activate the oil pump prime sequence. Main-
tain the 10 psi pressure throughout the auto prime sequence. When the auto prime is
completed, remove the leakage tester and refill the onboard oil reservoir.
59033
a - Gearcase Leakage Tester
Priming the oil pump (filling pump and hoses using pressure) is required on new or rebuilt
power heads and any time maintenance is performed on the oiling system that allows air
into the oil system.
There are three methods for priming the oil pump:
METHOD 1 – SHIFT SWITCH ACTIVATION PRIME
This method does three things:
a. Fills the oil pump, oil supply hose feeding pump and oil hoses going to the crank-
case and air compressor.
b. Activates break-in oil ratio.
c. Initiates a new 120 minute engine break-in cycle.
Refer to priming procedure following.
METHOD 2 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – RESET BREAK-IN
This method is the same as Method 1, except the run history and fault history are erased
from the ECM.
tic Software Cartridge Part 91-880118A2.
METHOD 3 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – OIL PUMP PRIME
This method fills the oil pump, oil supply hose feeding pump, and oil hoses going to the
crankcase and air compressor.
Page 3C-10 90-884294 OCTOBER 2001

OIL INJECTION
tic Software Cartridge Part. No. 91-880118--1.
Conditions Requiring Priming the Oil Pump

Condition Priming Procedure
New engine Use Method 1 or 2
Rebuilt Powerhead Use Method 1 or 2
New Powerhead Use Method 1 or 2
Oil system ran out of oil Use Method 3
Oil drained from oil supply hose feeding pump Use Method 3
Oil pump removed Use Method 3
Oil injection hoses drained Use Method 3
Priming Procedure – Method 1

METHOD 1 – SHIFT SWITCH ACTIVATION PRIME PROCEDURE
Before starting engine for the first time, prime the oil pump. Priming will remove any
air that may be in the pump, oil supply hose, or internal passages.
59039
a - Oil Injection Pump
b - Oil Supply Hose
CAUTION
To prevent damage to the fuel pump, fill the engine fuel system with fuel. Other-
wise the fuel pump will run without fuel during the priming process.
90-884294 OCTOBER 2001 Page 3C-11

OIL INJECTION
Prime the oil injection pump as follows:

1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it fells firm.
2. Turn the ignition key switch to the “ON” position.
3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F
NOTE: It may take a few minutes for the pump to complete the priming process.
Remote Oil Hose Connections
NOTE: Oil hose with BLUE stripe contains a directional filter which is designed to trap any
debris in the oil before the oil reaches the engine oil reservoir. The filter is marked with
an arrow denoting direction of flow of oil and should be installed accordingly. Should en-
gine oil reservoir oil level drop while remote oil tank oil level is normal, oil flow through
inline filter has been reduced by debris and filter must be replaced.
CONNECTING OIL HOSE WITH BLUE STRIPE
1. Remove shipping cap from fitting and connect oil hose. Fasten hose with sta-strap.
59030
a - Directional Oil Filter b - Oil Hose with Blue
Stripe
Page 3C-12 90-884294 OCTOBER 2001

OIL INJECTION
CONNECTING OIL HOSE WITHOUT BLUE STRIPE

1. Remove shipping cap from fitting and connect hose. Fasten hose with sta-strap.
59039
a - Oil Hose Without Blue Stripe
Filling the Oil Tanks

1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance
Manual. Tighten fill cap.
2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
3. Remove air from remote oil hose. Refer to Purging Air from the Engine Oil Reservoir
and Remote Oil Hose.
c
a
a
bb
a - Fill Cap c - Fill Cap

b - Engine Oil Reservoir
Purging Air From the Engine Oil Reservoir and Remote Oil Hose
NOTE: Before starting engine, make sure the oil pump has been primed.
1. Start the engine. Run the engine until all the air has been vented out of the reservoir
and oil starts to flow out of the reservoir. Re-tighten fill cap.
a
a - Fill Cap
90-884294 OCTOBER 2001 Page 3C-13

OIL INJECTION
Oil Warning Systems

Warning Horn
Function Sound Description
Start Up One Beep Normal System Test
Oil level is low in the engine mounted oil reservoir
Low Oil Reserve Four Beeps every 2 tank. Refill the engine mounted oil reservoir tank
Minutes along with the remote oil tank. Refer to Fuel & Oil
Section.
Engine Guardian System is activated. Power
Oil Level is Critically Low Continuous limit will allow a fast idle. The oil level is critically
low in the engine mounted oil reservoir tank. Re-
fill the engine mounted oil reservoir tank along
with the remote oil tank. Refer to Fuel and Oil
Section.
Engine Guardian System is activated. Power
Oil Pump Failure Continuous limit will allow a fast idle. The warning horn is
activated if the oil pump should ever stop func-
tioning electrically. No lubricating oil is being
supplied to the engine.
NOTE: As an option, Mercury Monitor or SmartCraft Gauges may be used to provide low
oil information or oil pump operation information.
Page 3C-14 90-884294 OCTOBER 2001

OIL INJECTION
Oil System Troubleshooting

Low Oil Warning System is Activated
Problem Problem Problem Problem
Low oil level in en- Oil level is not low Oil leaks out of
Low oil level in engine
gine oil reservoir and in either tank exhaust
oil reservoir but not low
also remote oil tank or #6 cylinder
in remote oil tank
Note: Oil level in engine Disconnect BLUE/
oil reservoir should be BLACK wires going
Refill both oil tanks. Pulse hose and
up to the fill cap to the low oil float
Purge air from en- oil supply hose
switch in the engine
gine oil tank. Refer are reversed
oil reservoir. Check
to procedure
switch for continuity
Boat oil tank is
Air was never purged from Purge air from engine oil tank. mounted higher
engine oil tank Refer to procedure than pulse hose
fitting on engine
and oil tank is
Fill cap is leaking air on re- Caps on remote tank must be over-filled
mote tank sealed and installed tight
Remote oil hoses blocked or Check hoses for a kink or

punctured leakage
Restricted oil outlet filter in re-

Remove filter and clean
mote oil tank
Restricted oil inlet filter in oil

hose before engine oil reser- Replace oil filter
voir
Air leak in upper portion on

Replace tube
the oil pickup tube
Faulty pressure check valve.

Replace check valve
Located in engine at end of
(black without blue stripe) re-
mote oil hose
No Continuity Continuity
Check for open wire between
Remove engine oil reservoir oil float switch and ECM
cap and use wire to pull float
to top of travel
No Continuity Continuity
Oil Float switch is faulty. Re- Float in oil tank is faulty. Re-
place switch place oil tank
90-884294 OCTOBER 2001 Page 3C-15

EMISSIONS
FUEL SYSTEM
Section 3D – Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . . . . . . 3D-1 Emissions Information . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
What Are Emissions? . . . . . . . . . . . . . . . . . . . . . . 3D-1 Manufacturer’s Responsibility: . . . . . . . . . . . . . . 3D-4
Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 Dealer Responsibility: . . . . . . . . . . . . . . . . . . . . . . 3D-5
Carbon Monoxide – CO . . . . . . . . . . . . . . . . . . . . 3D-1
Oxides of Nitrogen - NOx . . . . . . . . . . . . . . . . . . . 3D-2
Owner Responsibility: . . . . . . . . . . . . . . . . . . . . . . 3D-5
EPA Emission Regulations: . . . . . . . . . . . . . . . . . 3D-5 3
Controlling Emissions . . . . . . . . . . . . . . . . . . . . . . 3D-2
Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . . . . 3D-2
Manufacturer’s Certification Label . . . . . . . . . . . . . . 3D-6
Service Replacement Certification Label . . . . . . . . 3D-7
D
Outboard Hydrocarbon Emissions Reductions . . . 3D-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7
Stratified vs Homogenized Charge . . . . . . . . . . . . . 3D-3 Date Code Identification . . . . . . . . . . . . . . . . . . . . 3D-7
Homogenized Charge . . . . . . . . . . . . . . . . . . . . . . 3D-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7
Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4 Decal Location: . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7
Exhaust Emissions Standards

Through the Environmental Protection Agency (EPA), the federal government has estab-
lished exhaust emissions standards for all new marine engines sold in the United States.
What Are Emissions?
Emissions are what comes out of the exhaust system in the exhaust gas when the engine
is running. They are formed as a result of the process of combustion or incomplete com-
bustion. To understand exhaust gas emissions, remember that both air and fuel are made
of several elements. Air contains oxygen and nitrogen among other elements; gasoline
contains mainly hydrogen and carbon. These four elements combine chemically during
combustion. If combustion were complete, the mixture of air and gasoline would result in
these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environ-
ment. However, combustion is not usually complete. Also, potentially harmful gases can
be formed during and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful
gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards
become more stringent each year. Standards are set primarily with regard to three emis-
sions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).
Hydrocarbons – HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned
during combustion in combination with oxygen. But they are not totally consumed. Some
pass through the combustion chamber and exit the exhaust system as unburned gases
known as hydrocarbons.
Carbon Monoxide – CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxy-
gen during the combustion process. If the carbon in the gasoline could combine with
enough oxygen (one carbon atom with two oxygen atoms), it would come out of the en-
gine in the form of carbon dioxide (CO2). CO2 is a harmless gas. However, carbon often
combines with insufficient oxygen (one carbon atom with one oxygen atom). This forms
carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion and
is a dangerous, potentially lethal gas.
90-884294 OCTOBER 2001 Page 3D-1

EMISSIONS
Oxides of Nitrogen - NOx

NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that
makes up the air going into the engine. Under extremely high temperatures it combines
with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion
chambers when temperatures are too high. NOx itself is not harmful, but when exposed
to sunlight it combines with unburned hydrocarbons to create the visible air pollutant
known as smog. Smog is a serious problem in California as well as many other heavily
populated areas of the United States.
Controlling Emissions
There are two principle methods of reducing emissions from a two-stroke-cycle marine
engine. The first method is to control the air/fuel ratio that goes into the combustion cham-
ber. The second is to control the time when this air/fuel mixture enters the combustion
chamber. Timing is important, to prevent any unburned mixture from escaping out of the
exhaust port.
Stoichiometric (14.7:1) Air/Fuel Ratio
In the search to control pollutants and reduce exhaust emissions, engineers have discov-
ered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio
of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1
provides the best control of all three elements in the exhaust under almost all conditions.
The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio.
At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer
than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves
might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1.
However, there is also NOx to consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combus-
tion temperatures raise the NOx content of the exhaust. However, enrichening the air/fuel
ratio to decrease combustion temperatures or reduce NOx also increases HC and CO,
as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and
CO - is to keep the air/fuel ratio as close to 14.7:1 as possible.
Outboard Hydrocarbon Emissions Reductions

8 1/3% per Year Over 9 Model Years
120
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08
Page 3D-2 90-884294 OCTOBER 2001

EMISSIONS
Stratified vs Homogenized Charge

At certain operating conditions, DFI engines use a stratified charge inside the combustion
chamber to aid in reducing emissions. All other models exclusively use a homogenized
charge. The difference between the two is:
Homogenized Charge
A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder.
This mixing occurs inside the carburetor venturi, reed blocks, crankcase and/or combus-
tion chamber. Additional mixing occurs as the fuel is forced through the transfer system
into the cylinder.
The homogenized charge has an air/fuel ratio of approximately 14.7:1 and is uniform
throughout the cylinder.
90-884294 OCTOBER 2001 Page 3D-3

EMISSIONS
Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel required for
combustion is forced into the cylinder through an injector placed in the top of the cylinder
(head). The injector sprays a fuel/air mixture in the form of a fuel cloud into the cylinder.
Surrounding this cloud is air supplied by the transfer system. As the cloud is ignited and
burns, the surrounding air provides almost complete combustion before the exhaust port
opens.
A stratified charge engine concentrates a rich mixture in the vicinity of the spark plug (air/
fuel ratio is less than 14.7:1). Elsewhere, the mixture is very lean or is comprised of air
only.
Emissions Information
Manufacturer’s Responsibility:
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family and certi-
fy these engines with the United States Environmental Protection Agency (EPA). A certifi-
cation decal/emissions control information label, showing emission levels and engine
specifications directly related to emissions, must be placed on each engine at the time
of manufacture.
Page 3D-4 90-884294 OCTOBER 2001

EMISSIONS
Dealer Responsibility:
When performing service on all 1998 and later outboards that carry a certification, atten-
tion must be given to any adjustments that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner
that maintains emission levels within the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or
allow emission levels to exceed their predetermined factory specifications.
Exceptions include manufacturers prescribed changes, such as that for altitude adjust-
ments. Also included would be factory authorized:
• Installation of performance style gear housings by Mercury Marine.
• Service replacement parts modified, changed or superceded by Mercury Marine.
Owner Responsibility:
The owner/operator is required to have engine maintenance performed to maintain emis-
sion levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horse-
power or allow emissions levels to exceed their predetermined factory specifications.
Single engine exceptions may be allowed with permission from the EPA for racing and
testing.
EPA Emission Regulations:
All new 1998 and later outboards manufactured by Mercury Marine are certified to the
United States Environmental Protection Agency as conforming to the requirements of the
regulations for the control of air pollution from new outboard motors. This certification is
contingent on certain adjustments being set to factory standards. For this reason, the fac-
tory procedure for servicing the product must be strictly followed and, whenever practica-
ble, returned to the original intent of the design.
The responsibilities listed above are general and in no way a complete listing of the rules
and regulations pertaining to the EPA laws on exhaust emissions for marine products. For
more detailed information on this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww
90-884294 OCTOBER 2001 Page 3D-5

EMISSIONS
Manufacturer’s Certification Label:

The certification label must be placed on each engine at the time of manufacture and must
be replaced in the same location if damaged or removed. Shown below is a typical certifi-
cation label and is not representative of any one model. Label shown below is not to scale;
(shown at twice the normal size).
Emission Control a
Information
This engine conforms to 2002 Model Year U.S. EPA regulations for Marine SI engines.
Refer to Owners Manual for required maintenance
j Idle Speed (in gear): 650 RPM Family: 2M9XM03.01C0 b
i 225 HP 3047 cc FEL: 195.43 GM/KW-HR c
Timing (in degrees): Idle – 0 – 9° ATDC
WOT – 20° BTDC d
h
Standard Spark Plug: NGK BPZ8HS-10 JUN
g Gap: 0.040 in. (1.0 mm) e
2001
Intake: N/A
f Valve Clearance (Cold) mm
Exhaust: N/A
a - Spark Ignition (SI)

b - Family example
c - FEL: Represents (Mercury Marine) statement of the maximum emissions out-
put for the engine family
d - Timing specifications when adjustable
e - Month and Year of Production
f - Valve Clearance (Four Stroke engines only)
g - Recommended spark plug for best engine performance
h - Cubic Centimeter
i - Engine Horsepower rating
j - Idle Speed (In Gear)
2 M9X M 03.0 1 C 0
Type of Product
Regulation Technology 0=General Outboard
Model Year Type J=Sport Jet
2=2002 M=Marine
1=Old H=High Performance
2=New Cycle Type
Manufacturer 3=Sport Jet
Mercury Marine C=2 Stroke
Displacement G=4 Stroke
Liter
Cubic Inch
Page 3D-6 90-884294 OCTOBER 2001

EMISSIONS
Service Replacement Certification Label

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine
outboards have a visible and legible emission certification label. If this label is mis-
sing or damaged, contact Mercury Marine Service for replacement if appropriate.
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label
over the old label. Use a suitable solvent to remove any traces of the old label adhesive
from the display location.
Date Code Identification
Cut and remove a “V” notch through the month of engine manufacture before installing
the new label. The month of manufacture can be found on the old label. If the label is mis-
sing or the date code illegible, contact Mercury Marine Technical Service for assistance.
Emission Control 3047 2002

Information cc PART # 37–804670-02
This engine conforms to 2002 Model Year Idle Speed (in gear): 650 RPM
U.S. EPA regulations for marine SI engines.
Refer to Owners Manual Timing: Idle – 0 – 9° ATDC
for required maintenance WOT – 20° BTDC
Family: 2M9XM03.01C0 Spark Plug: NGK BPZ8HS-10
Gap: 0.040 in. (1.0 mm)
Valve Clearance (Cold) mm

FEL: 195.43 GM/KW-HR Intake: N/A Exhaust: N/A
225 HP
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
a
a - “V” Notch
b - Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.
Decal Location:
Model Service Part No. Location on Engine
2002 Merc/Mar 3.0 L V6 (200 H.P.) 37-804670-02 Starboard side of Air Handler
Assembly
(EFI)
Assembly
(EFI)
Assembly
(EFI)
90-884294 OCTOBER 2001 Page 3D-7

POWERHEAD
POWERHEAD
Section 4A - Powerhead
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . 4A-48
Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Pistons and Piston Rings . . . . . . . . . . . . . . 4A-49
Reed Valve Opening . . . . . . . . . . . . . . . . . . 4A-2 Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . 4A-51
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-51
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Crankshaft (and End Cap) Bearings . . . . 4A-52
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Reed Block Assembly . . . . . . . . . . . . . . . . . 4A-53
Powerhead Repair Stand . . . . . . . . . . . . . . 4A-4 End Bearing Bleed System . . . . . . . . . . . . 4A-53
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Assembly . . . . . . . . . . . . . . . . .
4A-5
4A-6
Connecting Rods . . . . . . . . . . . . . . . . . . . . .
Thermostats (120°F) (49°C) . . . . . . . . . . .
4A-53
4A-55
4
Exhaust Adaptor Plate . . . . . . . . . . . . . . . . . . . 4A-10 Powerhead Reassembly and Installation . . . 4A-56 A
Crankshaft, Pistons and Connecting Rods . . 4A-12 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-56
Starboard Bleed System Routing . . . . . . . . . . 4A-14 Crankshaft Installation . . . . . . . . . . . . . . . . 4A-59
Port Bleed System Routing . . . . . . . . . . . . . . . 4A-16 Piston and Connecting Rod Reassembly 4A-61
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-18 Piston and Piston Ring Combinations . . . 4A-62
General Information . . . . . . . . . . . . . . . . . . . . . 4A-20 Piston Installation . . . . . . . . . . . . . . . . . . . . 4A-63
Powerhead Removal from Driveshaft Crankcase Cover Installation . . . . . . . . . . . 4A-67
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-21 Assembly of Reed Blocks to Reed Block
Removing Engine Components . . . . . . . . . . . 4A-27 Adaptor Plate . . . . . . . . . . . . . . . . . . . . . . . . 4A-69
Removing Engine Components Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-73
Individually . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27 Throttle Lever and Shift Platform Assembly . 4A-74
Vapor Separator Tank (VST) Removal . . . 4A-28 Powerhead Installation On Driveshaft
Air Plenum Removal . . . . . . . . . . . . . . . . . . 4A-30 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-76
Ignition Coil Plate and Harness Removal 4A-32 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-82
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . 4A-33 Counter Rotation Outboards . . . . . . . . . . . 4A-82
Electrical Plate Removal . . . . . . . . . . . . . . 4A-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-83
Alternator Removal . . . . . . . . . . . . . . . . . . . 4A-35 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-85
Powerhead Disassembly . . . . . . . . . . . . . . . . . 4A-36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-85
Water Pressure Relief Valve Components 4A-46 Front Clamp Reassembly . . . . . . . . . . . . . . 4A-86
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4A-47 Engine Break-in Procedure . . . . . . . . . . . . . . . 4A-87
Cylinder Block and Crankcase Cover . . . 4A-47 Gasoline/Oil Break-In Mixture . . . . . . . . . . 4A-87
Special Service Information . . . . . . . . . . . . 4A-47 Break-In Procedure . . . . . . . . . . . . . . . . . . . 4A-87
90-884294 OCTOBER 2001 Page 4A-1

POWERHEAD
Specifications
Block
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° V, 2 Cycle
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 153 cu. in. (2.5 Litre)
Reed Valve Opening
Reed Stand Open (Max.) . . . . . . . . . . . . . . . 0.020 in. (0.50 mm)
Cylinder Bore
Dia. Standard . . . . . . . . . . . . . . . . . . . . . . . . . 3.501 in. (88.925 mm)
Dia. 0.015 in. Oversize . . . . . . . . . . . . . . . . . 3.516 in. (89.306 mm)
Taper/Out of Round Max. . . . . . . . . . . . . . . . 0.003 in. (0.0762 mm)
Piston
Dia. Standard . . . . . . . . . . . . . . . . . . . . . . . . . 3.494 in. ± .001 in. (88.748 mm ± .025 mm)
Dia. 0.015 in. Oversize . . . . . . . . . . . . . . . . . 3.509 in. ± .001 in. (89.129 mm ± .025 mm)
IMPORTANT: Using a micrometer, measure dimension “B” at location shown. Dimen-

sion “B” should be 0.008 in. or less than dimension “A”.
Dimension “A”
at Right Angle
(90°) to Piston
Pin
1/2 in.
(12.7mm)
Dimension “B” ( in
line with Piston Pin)
Page 4A-2 90-884294 OCTOBER 2001

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

POWERHEAD
8. Piston Pin Tool 91-74607A1
9. Universal Puller Plate 91-37241
10. Snap Ring Pliers 91-24283
11. Lockring Installation Tool 91-91-79109A3
12. Piston Ring Compressor 91-818773 (for 2.5 Liter)
13. Compression Tester 91-29287
54965
Powerhead Repair Stand
A powerhead repair stand may be purchased from:
Bob Kerr’s Marine Tool Co.
P.O. Box 1135
Winter Garden, FL 32787
Telephone: (305) 656-2089
Page 4A-4 90-884294 OCTOBER 2001

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

POWERHEAD
Cylinder Block Assembly

9 Loctite PST Pipe Sealant 33 Loctite 680
12 Loctite Master Gasket 95 2-4-C Marine Lubricant with Teflon
9
14 2 Cycle Outboard Oil
Page 4A-6 90-884294 OCTOBER 2001

POWERHEAD

TORQUE
REF.
REF
1 1 CYLINDER BLOCK
2 4 SCREW (M8 X 40) 21 28.5
3 2 COVER
4 4 STUD–POWERHEAD (M10 X 1.5 X 64)
5 6 STUD–POWERHEAD (M10 X 1.5 X 155)
6 6 WATER DEFLECTOR
7 6 CHECK VALVE
8 3 CENTER MAIN PIN
9 1 DOWEL PIN–LOCATING
10 6 STOP PLUG
11 14 SCREW (M8 X 35) 21 28.5
12 8 SCREW (M10 X 1.5) Note A
13 1 ELBOW
14 1 TEMPERATURE SENSOR 14 1.6
15 2 PIN
16 1 OIL LINE RETAINER
17 10 WASHER
18 10 NUT 50 69
19 1 SENSOR – CRANK POSITION
20 2 SCREW (M5 X 16) 100 11
21 1 LOWER END CAP
22 1 O-RING
23 2 OIL SEAL
24 4 SCREW (M6 X 20) 38 51.5
25 1 PLATE ASSEMBLY
26 3 MOUNT
27 3 SCREW (M10 X 45) 38 51.5
28 2 SCREW (M6 X 12)
29 1 GROMMET – SPLIT
30 6 WASHER
31 1 RETAINER
32 1 CLAMP
33 1 SCREW (M6 X 12)
34 2 SEAL – CYLINDER HEAD
35 6 SEAL
36 2 CYLINDER HEAD
37 2 SEAL – THERMOSTAT
38 2 THERMOSTAT
39 2 GASKET – THERMOSTAT COVER
40 2 COVER – THERMOSTAT
41 4 SCREW (M6 X 25) 100 11
42 40 SCREW (M8 X 50) Note B
Note A – Torque bolts to 30 lb. ft. (40.5 Nm) and then rotate 90°
Note B – Torque bolts to 20 lb. ft. (27 Nm) and then rotate 90°
90-884294 OCTOBER 2001 Page 4A-7

POWERHEAD

9 Loctite PST Pipe Sealant 33 Loctite 680
12 Loctite Master Gasket 95 2-4-C Marine Lubricant with Teflon
9
Page 4A-8 90-884294 OCTOBER 2001

POWERHEAD

TORQUE
REF.
REF
43 2 TEMPERATURE SENSOR
44 2 O-RING
45 2 SCREW (M6 X 12)
46 2 CLAMP
47 1 TPS LEVER
48 3 SCREW (M6 X 25) 55 6
49 3 BUSHING
50 3 GROMMET
51 3 WASHER
52 3 SCREW (M6 x 25) 35 4
53 1 THROTTLE POSITION SENSOR
54 1 SCREW
55 1 PIPE PLUG
56 1 LINK
57 1 CLIP
58 1 SCREW (M6 X 14) 16 22
59 AR STA-STRAP
60 1 CLIP
61 1 TPS COVER
62 1 BRACKET
63 2 FITTING
64 1 HOSE (STARBOARD)
65 1 HOSE (PORT)
90-884294 OCTOBER 2001 Page 4A-9

POWERHEAD
Exhaust Adaptor Plate
9 Loctite PST Pipe Sealant (92-809822)

62 3M Permabond #3MO8155 (Obtain Locally)
95
A = TO BLOCK
9
95
28 95
9
27 9
41
21
95
95
62
Page 4A-10 90-884294 OCTOBER 2001

POWERHEAD
Exhaust Adaptor Plate

TORQUE
REF.
REF
1 1 EXHAUST PLATE
2 1 GASKET
3 1 GASKET (LOWER)
4 1 SEAL
5 1 CHECK VALVE FITTING
6 1 PIPE PLUG
7 2 DRAIN CHECK VALVE
8 4 DOWEL PIN
9 1 COVER
10 2 SCREW (M8 X 35) 150 17
11 1 CARRIER
12 1 GROMMET
13 1 POPPET
14 1 SPRING
15 1 RELIEF VALVE PLATE ASSEMBLY
16 2 GASKET
17 1 DIAPHRAGM
18 1 WASHER
19 1 SCREW (10-16 X 3/4 IN.) 25 3
20 6 SCREW (M8 X 35) 25 34
21 1 IDLE EXHAUST BOOT
22 2 CLAMP
23 1 FITTING – TELL TALE
24 1 PLUG
25 1 WASHER
26 1 FITTING
27 1 CHECK VALVE
28 1 O-RING
29 1 NUT
30 1 SHIFT LINK
31 1 SLIDE
32 1 NUT
33 1 BUSHING
34 1 UPPER SHIFT SHAFT
35 1 BUSHING
36 1 COUPLING
37 1 HOSE (INLET)
38 1 GROMMET SPLIT
39 2 WASHER
40 1 TUBING (3 IN.)
41 2 FITTING
90-884294 OCTOBER 2001 Page 4A-11

POWERHEAD
Crankshaft, Pistons and Connecting Rods
14

Page 4A-12 90-884294 OCTOBER 2001

POWERHEAD
Crankshaft, Pistons and Connecting Rods

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 CRANKSHAFT ASSEMBLY
2 1 WEAR SLEEVE
3 1 BALL BEARING (LOWER)
4 1 RETAINING RING
5 1 RING–SEALING
6 1 WOODRUFF KEY
7 7 O-RING
8 2 BEARING RACE
9 2 ROLLER BEARING
3 PISTON (STARBOARD)
10
3 PISTON (PORT)
11 12 LOCK RING
12 6 PISTON RING SET
13 6 PISTON RING (LOWER)
14 6 CONNECTING ROD ASSEMBLY
1st Torque: 15 lb-in
2nd Torque: 20 lb-ft
15 12 SCREW (1-1/4 IN.) Turn screw addition-
al 90 degrees after
2nd torque.
16 12 BEARING CAGE
17 96 ROLLER BEARING
18 12 THRUST WASHER
19 204 NEEDLE ROLLER BEARING
20 1 MAIN BEARING (UPPER)
21 1 OIL SEAL
22 1 O-RING
90-884294 OCTOBER 2001 Page 4A-13

POWERHEAD
Starboard Bleed System Routing
2 7
2 1 3
7
2
7
6
4
Page 4A-14 90-884294 OCTOBER 2001

POWERHEAD
Starboard Bleed System Routing

TORQUE
REF.
REF
1 1 TUBING [15-1/2 IN (39.3 CM)]
2 3 CHECK VALVE (90°)
3 1 TUBING [16-1/2 IN (3.8 CM)]
4 1 TUBING [15 IN (38.1 CM)]
5 1 CLIP
6 1 SCREW (10 – 16 X 1/2)
7 3 CHECK VALVE
90-884294 OCTOBER 2001 Page 4A-15

POWERHEAD
Port Bleed System Routing
4
2 5
1 7
8
2 5
3
12
1
8
9
6 5
1 10
11
8
5
1
Page 4A-16 90-884294 OCTOBER 2001

POWERHEAD
Port Bleed System Routing

TORQUE
REF.
REF
1 3 CHECK VALVE
2 2 PIPE PLUG
3 1 TUBING [20.5 IN (52 CM)]
4 1 CHECK VALVE
5 3 CHECK VALVE (90 DEGREE)
6 1 TUBING [13 IN (33 CM)]
7 1 CHECK VALVE
8 2 PIPE PLUG
9 1 CLIP
10 1 SCREW (10 – 16 X 1/2)
11 1 TUBING [11 IN (27.9 CM)]
12 1 TUBING [22.5 IN (57 CM)]
90-884294 OCTOBER 2001 Page 4A-17

POWERHEAD
Torque Sequence
CRANKCASE COVER BOLTS
a
8 7
13
13 14
14
99 10
10
1 4
66 77
44 1
22 33
3 2
88 55
11
11 12
12
5 6
b
55986
a - Add light oil to threads and bolt face: 8 Bolts (3/8 in. - 16 in.)
38 lb. ft. (51.5 N·m)
b - Bolts (M8 x 1.25 x 35) 28 lb. ft. (38 N·m)
Page 4A-18 90-884294 OCTOBER 2001

POWERHEAD
CYLINDER HEAD BOLTS

Apply light oil to threads and bolt face: 30 lb. ft. (40.7 N·m) and rotate 90°
20 18
16 14
12 10
1 3
7 5
6 8
4 2
9 11
13 15
17 19
52132
POWERHEAD TO ADAPTOR PLATE ATTACHING NUT
Torque nuts to 25 lb. ft. (33.8 Nm)
2
4
6 Starboard Side
8 9
Front
7
10
3 Port Side
5
1
90-884294 OCTOBER 2001 Page 4A-19

POWERHEAD
General Information
Powerhead “Disassembly” and “Reassembly” instructions are printed in a sequence that
should be followed to assure best results when removing or replacing powerhead compo-
nents. If complete disassembly is not necessary, start reassembly at point disassembly was
stopped. (Refer to “Table of Contents,” preceding.) Usually, complete disassembly of pow-
erhead will be required.
If major powerhead repairs are to be performed, remove powerhead from drive shaft hous-
ing. Removal of powerhead is not required for 1) inspection of cylinder walls and pistons
(refer to “Powerhead Removal and Disassembly,” following, and remove cylinder heads and
exhaust cover), 2) minor repairs on components, such as ignition system, carburetors, reed
blocks and cylinder heads and checking operation of thermostats.
Page 4A-20 90-884294 OCTOBER 2001

POWERHEAD
Powerhead Removal from Driveshaft Housing

1. Disconnect battery cables from battery terminals.
2. Remove top cowling.
3. Remove two screws which secure remote control harness retainer and remove retainer.
a a
57841
a - Screws b - Retainer
4. Remove bottom cowls.
59075
a - Screws b - Access Cover to Lower Screw
90-884294 OCTOBER 2001 Page 4A-21

POWERHEAD
5. Disconnect and/or remove the following:
e d
c 59026
a - Remote Oil Tank Pressure Hose
b - Remote Control Harness
c - Power Trim Wires
d - Negative Battery Cable
e - Positive Battery Cable
f - SmartCraft Harness Connector
Page 4A-22 90-884294 OCTOBER 2001

POWERHEAD
6. Disconnect and/or remove the following:
d
c
b
59030
a - Oil Supply Hose
b - Shift Lever Bracket Assembly
c - Water Pressure Hose (GREY)
d - Starboard Thermostat Discharge Hose
90-884294 OCTOBER 2001 Page 4A-23

POWERHEAD
7. Disconnect the following:
d
a
59028
a - Water Pressure Sensor Hose (GREY)(for Digital Gauges) (If not previously dis-
connected)
b - Engine Flush Hose
c - Tell-Tale Hose
Page 4A-24 90-884294 OCTOBER 2001

POWERHEAD
8. Slide outboard shift lever into neutral position.

9. Remove throttle cable and shift cable from control cable anchor bracket.
a
a
a - Throttle Cable
b - Shift Cable
10. Disconnect input fuel line, water pressure hose and speedometer hose.
b c
a
a - Input Fuel Hose

b - Water Pressure Hose (GRAY) (Analog Gauges)
c - Speedometer Hose (BLACK) (Analog Gauges)
d - Hose Clamp
90-884294 OCTOBER 2001 Page 4A-25

POWERHEAD
11. Remove 10 nuts and 10 washers (5 each side) from powerhead base.
a
a
a
a a
52373
a - Nuts and Washers (5 each side)
12. Remove plastic cap from center of flywheel and install Lifting Eye 91-90455 into flywheel
at least 5 full turns. Using a hoist, lift powerhead assembly from driveshaft housing.
59076
a - Lifting Eye 91-90455
Page 4A-26 90-884294 OCTOBER 2001

POWERHEAD
Removing Engine Components

NOTE : Engine components can be removed individually or in some cases as an assembly.
Removing Engine Components Individually
Section 2
Starter Motor
*Electronic Control Module
*Ignition Coils
*Starter Solenoid
*Trim Relays
Alternator
Flywheel
Section 3
Air Plenum
Fuel Rail and Injectors
Vapor Separator Assembly
Pulse Fuel Pump
Oil Pump
Oil Reservoir
Section 7
Shift Cable Latch Assembly
Control Cable Anchor Bracket
*All ignition and electrical components should remain attached to the electrical plate and
removed as an assembly.
90-884294 OCTOBER 2001 Page 4A-27

POWERHEAD
Vapor Separator Tank (VST) Removal

CAUTION
Depressurize fuel system prior to opening line connections or removing fuel sys-
tem components.
1. Use Fuel/Air Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-881834A1 to de-
pressurize fuel system. Direct fuel into suitable container.
2. Remove VST drain plug and allow fuel to empty into suitable container.
59053
a - Fuel Pressure Gauge 91-881834A1
b - Fuel Pressure Test Port
c - Drain Plug
Page 4A-28 90-884294 OCTOBER 2001

POWERHEAD
a
c
f
59051
b - Fuel Pressure Regulator Vent Hose Connector
c - VST Output Fuel Hose f - Water Sensor Bullet Connector
d - VST Oil Input Hose g - Fuel/Water Separator Input Fuel
Hose
4. Remove ground lead between VST and air plenum.
5. Remove 3 bolts securing VST to air plenum and remove VST.
a
b
b
b
59047
a - VST Ground Lead b - VST Attaching Bolts
90-884294 OCTOBER 2001 Page 4A-29

POWERHEAD
6. Disconnect throttle cam link rod and the Throttle Position Sensor link rod.
b
a
59046
a - Throttle Cam Link Rod b - Throttle Position Sensor Link Rod
Air Plenum Removal
b
a
59058
b - MAP Sensor
c - Fuel Injector Harness Con-
nector
Page 4A-30 90-884294 OCTOBER 2001

POWERHEAD
2. Disconnect oil pump electrical harness, oil pump inlet and outlet hoses and oil tank pres-
sure hose.
b
c
d
59039
a - Electrical Harness c - Oil Inlet Hose
b - Oil Outlet Hose d - Oil Tank Pressure Hose
3. Remove 12 bolts securing air management assembly to crankcase and remove assem-
bly.
59061
a - Bolts (12 each)
90-884294 OCTOBER 2001 Page 4A-31

POWERHEAD
Ignition Coil Plate and Harness Removal

Disconnect the following:
a c
d
b
f
f
e
g
f f
h
a - Temperature Gauge Bullet Connectors (Hidden)

b - Port Temperature Sensor Connector
c - Water Pressure Sensor Connector
d - Starboard Temperature Sensor Connector
e - Ignition Coil Harness Connector
f - Bolts (4)
g - Spark Plug Leads (Use proper tool to remove spark plug boot to avoid damage
to boot)
h - Water Pressure Hose (Disconnect)
Page 4A-32 90-884294 OCTOBER 2001

POWERHEAD
Starter Motor
Disconnect and/or remove the following:
c a b
g
e c
d
d
f 59044
59038
a - Centrifugal Bendix Starter f - BLACK (with YELLOW sleeve) + 12

b - Solenoid Driven Bendix Starter volt cable
c - Upper Mount Bolts g - Starter Solenoid
d - Lower Mount Bolts h - BLACK (with RED sleeve) + 12 volt
e - BLACK ground cable cable
90-884294 OCTOBER 2001 Page 4A-33

POWERHEAD
Electrical Plate Removal

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

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

POWERHEAD
Powerhead Disassembly
1. Place powerhead in repair stand or on a bench.
2. Remove thermostat covers and washers.
a - Cover
b - Washer
3. Remove cylinder heads from engine block.
b
a
52214
a - Cylinder Head
b - Engine Block
Page 4A-36 90-884294 OCTOBER 2001

POWERHEAD
4. Remove reed block housing from cylinder block.

5. Inspect reeds as outlined in “Cleaning and Inspection”.
a
b
a - Reed Block Housing

b - Reed Block
c - Adapter Plate
d - Air Plenum
90-884294 OCTOBER 2001 Page 4A-37

POWERHEAD
LOWER END CAP

1. Remove lower end cap bolts.
a
a
52325
a - Crankcase Attaching End Cap Bolts
2. Remove bolts which secure crankcase cover to cylinder block.
55977
a - Crankcase Cover
3. Remove crankcase end cap.
Page 4A-38 90-884294 OCTOBER 2001

POWERHEAD
CRANKCASE COVER REMOVED
55978
4. Use Powerhead Stand (91-30591A1) for rotating crankshaft to desired position for re-
moval of connecting rods.
5. Using an awl or electric pencil, scribe the cylinder identification number on each con-
necting rod as shown. Reassemble connecting rods in same cylinder.
52347
90-884294 OCTOBER 2001 Page 4A-39

POWERHEAD
6. Use a 3/8 in. 12 point socket to remove connecting rod bolts, then remove rod cap, roller
bearings and bearing cage from connecting rod.
a
52316
a - Connecting Rod Bolts
7. Push piston out of cylinder block.

8. After removal, reassemble each piston and connecting rod assembly.
CAUTION
Each connecting rod and end cap are a matched machined set and must never be
mismatched.
9. Inspect pistons as outlined in “Cleaning and Inspection,” following.

10. Use Piston Ring Expander (91-24697) to remove piston rings. Always install new piston
rings.
55967
55966
Page 4A-40 90-884294 OCTOBER 2001

POWERHEAD
11. Using an awl, scribe identification number of connecting rod on inside of piston. Reas-
semble piston on same connecting rod.
55968
a - Scribe Identification Number
12. Using tool (91-52952A1), remove piston pin lockrings from both ends of piston pin. Nev-
er re-use piston pin lockrings.
55969
a - Lockring
90-884294 OCTOBER 2001 Page 4A-41

POWERHEAD
IMPORTANT: Warming the piston dome using a torch lamp will ease removal and in-
stallation of piston pin.
13. Support piston and tap out piston pin using service tool (91-92973A1) as shown.
55957
a - Piston Pin
b - Piston Pin Tool (91-92973A1)
14. Remove piston pin needle bearings (34 per piston) and locating washers (2 per piston)
as shown.
IMPORTANT: It is recommend that new needle bearings be used at reassembly for
lasting repair. However, if needle bearings must be re-used, keep each set of bearings
identified for reassembly on same connecting rod.
55958
a - Needle Bearing Locating Washers
Page 4A-42 90-884294 OCTOBER 2001

POWERHEAD
15. Remove lower end cap from crankshaft.

16. Remove and discard O-ring seal from end cap.
17. Remove oil seals from end cap by driving seals out with a punch and hammer.
b
a
51849
a - O-ring
b - Seal
18. Inspect roller bearing in upper end cap as outlined in “Cleaning and Inspection”.
NOTE : If roller bearing is damaged, replace roller bearing carrier assembly.
a
c
51473
a - O-Ring
b - Seal
c - Carrier
90-884294 OCTOBER 2001 Page 4A-43

POWERHEAD
19. Remove crankshaft and place in powerhead stand as shown.

IMPORTANT: DO NOT remove crankshaft sealing rings from crankshaft, unless re-
placement of a sealing ring(s) is necessary. Usually, crankshaft sealing rings do not
require replacement, unless broken.
CAUTION
Safety glasses should be worn when removing or installing crankshaft sealing
rings.
20. Remove retaining ring as shown.
58991 58992
a - Sealing Rings
b - Retaining Ring
21. Remove bearing race halves and roller bearings from crankshaft.
IMPORTANT: Keep same bearing races and roller bearings together.
a
58989
a - Bearing Race Halves
b - Roller Bearings
Page 4A-44 90-884294 OCTOBER 2001

POWERHEAD
Inspect crankshaft ball bearing as outlined in “Cleaning and Inspection,” following.

IMPORTANT: DO NOT remove crankshaft ball bearing, unless replacement is re-
quired.
22. Remove lower ball bearing from crankshaft as follows:
a. Remove retaining ring using a pair of snap ring pliers.
c
55983
a - Crankshaft Ball Bearing
b - Pliers
c - Retaining Ring
b. Press crankshaft out of lower ball bearing as shown.
aa
bb
c
dd
51081
a - Press
b - Powerhead Stand (91-812549A1)
c - Crankshaft Ball Bearing
d - Universal Puller Plate (91-37241)
90-884294 OCTOBER 2001 Page 4A-45

POWERHEAD
Water Pressure Relief Valve Components

1. Remove and inspect water pressure relief valve components for debris or damage. Re-
place components as required.
1
2
3
4
5
6
7
8
9
10
12 11
13
1 - Exhaust Plate
2 - Carrier
3 - Grommet
4 - Poppet/Relief Valve
5 - Spring
6 - Gasket
7 - Inner Plate
8 - Diaphragm
9 - Washer
10 - Screw [Torque to 25 lb. in. (3 Nm)]
11 - Gasket
12 - Outer Cover
13 - Bolts [Torque to 20 lb. ft. (27 Nm)]
Page 4A-46 90-884294 OCTOBER 2001

POWERHEAD
Cleaning and Inspection

Cylinder Block and Crankcase Cover
IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored assem-
bly and never should be mismatched by using a different crankcase cover or cylinder
block.
CAUTION
If crankcase cover or cylinder block is to be submerged in a very strong cleaning
solution, it will be necessary to remove the crankcase cover/cylinder block bleed
system from crankcase cover/cylinder block to prevent damage to hoses and check
valves.
1. Thoroughly clean cylinder block and crankcase cover. Be sure that all sealant and old
gaskets are removed from matching surfaces. Be sure that carbon deposits are re-
moved from exhaust ports.
2. Inspect cylinder block and crankcase cover for cracks or fractures.
3. Check gasket surfaces for nicks, deep grooves, cracks and distortion that could cause
compression leakages.
4. Check all water and oil passages in cylinder block and crankcase cover to be sure that
they are not obstructed and that plugs are in place and tight.
Special Service Information

Grooves in Cylinder Block Caused By Crankshaft Sealing Rings
Grooves in cylinder block caused by crankshaft sealing rings are not a problem, except if
installing a new crankshaft and the new sealing rings on crankshaft do not line up with exist-
ing grooves in cylinder block. If installing a new crankshaft, refer to crankshaft installation,
Powerhead Reassembly section to determine if powerhead can be used.
90-884294 OCTOBER 2001 Page 4A-47

POWERHEAD
Cylinder Bores
1. Inspect cylinder bores for scoring, scuffing or a transfer of aluminum from piston to cylin-
der wall. Scoring or scuffing, if NOT TOO SEVERE, can normally be removed by honing.
If a transfer of aluminum has occurred, an acidic solution containing muriatic acid (i.e.
“TIDY BOWL CLEANER”) should be applied to the areas of the cylinder bore where
transfer of aluminum has occurred. After the acidic solution has removed the transferred
aluminum, thoroughly flush the cylinder bore(s) to remove any remaining acid. Cylinder
walls may now be honed to remove any glaze and to aid in the seating of new piston
rings.
HONING PROCEDURE
a. When cylinders are to be honed, follow the hone manufacturer’s recommendations
for use of the hone and cleaning and lubrication during honing.
b. For best results, a continuous flow of honing oil should be pumped into the work
area. If pumping oil is not practical, use an oil can. Apply oil generously and frequent-
ly on both stones and work area.
CAUTION
When honing cylinder block, remove hone frequently and check condition of cylin-
der walls. DO NOT hone any more than absolutely necessary, as hone can remove
cylinder wall material rapidly.
c. Start stroking at smallest diameter. Maintain firm stone pressure against cylinder
wall to assure fast stock removal and accurate results.
d. Localize stroking in the smallest diameter until drill speed is constant throughout
length of bore. Expand stones, as necessary, to compensate for stock removal and
stone wear. Stroke at a rate of 30 complete cycles per minute to produce best
cross-hatch pattern. Use honing oil generously.
e. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff
bristle brush and rinse thoroughly with hot water. A good cleaning is essential. If any
of the abrasive material is allowed to remain in the cylinder bore, it will cause rapid
wear of new piston rings and cylinder bore in addition to bearings. After cleaning,
bores should be swabbed several times with engine oil and a clean cloth, then wiped
with a clean, dry cloth. Cylinders should not be cleaned with kerosene or gasoline.
Clean remainder of cylinder block to remove excess material spread during honing
operation.
2. Hone all cylinder walls just enough to de-glaze walls.
Page 4A-48 90-884294 OCTOBER 2001

POWERHEAD
3. Measure cylinder bore diameter (with a snap gauge micrometer) of each cylinder, as
shown below. Check for tapered, out-of-round (egg-shaped) and oversize bore.
52324
200/225/250 Models
Model Cylinder Block Finish Hone
200/225/250 3.6265 in. (92.1131 mm)
0.015 in. (0.38 mm) Oversize 3.6415 in. (92.4941 mm)
0.030 in. (0.76 mm) Oversize 3.6565 in. (92.8751 mm)
4. If a cylinder bore is tapered, out-of-round or worn more than 0.003 in. (0.076 mm) from
standard “Cylinder Block Finish Hone” diameter (refer to chart, preceding), it will be nec-
essary to re-bore that cylinder(s) to 0.015 in. (0.381 mm) oversize 0.030 in. (0.762 mm)
oversize and install oversize piston(s) and piston rings during reassembly.
NOTE : The weight of an oversize piston is approximately the same as a standard size pis-
ton; therefore, it is not necessary to re-bore all cylinders in a block just because one cylinder
requires re-boring.
5. After honing and thoroughly cleaning cylinder bores, apply light oil to cylinder walls to
prevent rusting .
Pistons and Piston Rings

IMPORTANT: If engine was submerged while engine was running, piston pin and/or
connecting rod may be bent. If piston pin is bent, piston must be replaced. (Piston
pins are not sold separately because of matched fit into piston.) If piston pin is bent,
connecting rod must be checked for straightness (refer to “Connecting Rods,” fol-
lowing, for checking straightness).
1. Inspect pistons for scoring and excessive piston skirt wear.
2. Check tightness of piston ring locating pins. Locating pins must be tight.
3. Thoroughly clean pistons. Carefully remove carbon deposits from pistons, with a soft
wire brush or carbon remove solution. Do not burr or round off machined edges.
Inspect piston ring grooves for wear and carbon accumulation. If necessary, scrape carbon
from piston ring grooves being careful not to scratch sides of grooves. Refer to proce-
dure following for cleaning piston ring grooves.
90-884294 OCTOBER 2001 Page 4A-49

POWERHEAD
CLEANING PISTON RING GROOVES

Keystone (tapered) ring grooves
CAUTION
Care must be taken not to scratch the side surfaces of the ring groove. Scratching
the side surface of the ring groove will damage the ring groove.
1. Use a bristle brush and carbon remover solution to remove carbon from side surfaces.
2. A tool can be made for cleaning the inner diameter of the tapered ring grooves. The tool
can be made from a broken tapered piston ring with the side taper removed to enable
the inside edge of the ring to reach the inner diameter of the groove. Carefully scrape
carbon from inner diameter of ring grooves. Care must be taken not to damage the
grooves by scratching the side surfaces of the grooves.
Piston with two half keystone (half tapered) rings
Enlarged View of
a Piston Ring Grooves
a - Ring Grooves
MEASURING PISTON ROUNDNESS

Piston has a barrel profile shape and is not a true diameter.
1. Using a micrometer, measure dimension “A” at location shown. Dimension “A” should
be as indicated in chart following.
Piston Dimension “A”

Standard Piston 3.6210 in. ± .0005 in.
(91-9734 mm ± .0127 mm)
0.015 in. Oversize Piston 3.636 in. ± .0005 in.
(92.354 mm ± .0127 mm)
0.030 in. Oversize Piston 3.651 in. ± .0005 in.
(92.735 mm ± .0127 mm)
2. Using a micrometer, measure dimension “A” at location shown. Dimension “A” should
be 3.6210 in. ± 0.0005 in. for a STANDARD size piston.
a
1.0 in.
(25.4 mm)
a - Dimension “A” at RIGHT Angle (90°) to Piston Pin
Page 4A-50 90-884294 OCTOBER 2001

POWERHEAD
Cylinder Heads
1. Inspect internal surface of cylinder heads for possible damage (as a result of piston or
foreign material striking cylinder heads).
IMPORTANT: Cylinder head warpage should not exceed 0.005 in. (0.127 mm) over the
ENTIRE length of the cylinder head. If measured warpage, as determined on a surface
block, exceeds 0.005 in. (0.127 mm) or a discontinuity of up to 0.005 in. (0.127 mm)
exists in a 1.0 in. (25.4 mm) portion of the cylinder head’s surface length, then the cyl-
inder head must be replaced.
2. Replace cylinder head(s) as necessary.
3. Thoroughly clean gasket surfaces of exhaust divider plate.
4. Inspect exhaust divider plate for deep grooves, cracks or distortion that could cause
leakage. Replace parts as necessary.
Crankshaft
1. Inspect crankshaft to drive shaft splines for wear. Replace crankshaft if necessary.
2. Check crankshaft for straightness. Maximum runout is 0.002 in. (0.0508 mm). Replace
as necessary.
3. Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or
scratched. Replace as necessary.
4. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear
and/or overheating. (Refer to “Connecting Rods”.)
5. If necessary, clean crankshaft surfaces with crocus cloth.
bb
cc cc
52323
a - Crankshaft Journals
b - Crocus Cloth
c - Work Cloth “Back-and-Forth”
WARNING
DO NOT spin-dry crankshaft ball bearing with compressed air.
6. Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearing. Re-
check surfaces of crankshaft. Replace crankshaft, if surfaces cannot be properly
“cleaned up.” If crankshaft will be re-used, lubricate surfaces of crankshaft with light oil
to prevent rust. DO NOT lubricate crankshaft ball bearing at this time.
90-884294 OCTOBER 2001 Page 4A-51

POWERHEAD
Crankshaft (and End Cap) Bearings

IMPORTANT: When overhauling powerhead assembly, it is recommended that all
crankshaft bearings – upper/lower, center main, connecting rod and wrist pin bear-
ings – be replaced to ensure optimum powerhead performance and longevity.
1. After cleaning crankshaft, grasp outer race of crankshaft ball bearing (installed on lower
end of crankshaft) and attempt to work race back-and-forth. There should not be exces-
sive play.
2. Lubricate ball bearing with light oil. Rotate outer bearing race. Bearing should have
smooth action and no rust stains. If ball bearing sounds or feels “rough” or has “catches,”
remove and discard bearing. (Refer to “Powerhead Removal and Disassembly - Crank-
shaft Removal and Disassembly”.)
52326
a - Lower Crankshaft Ball Bearing
3. Thoroughly clean (with solvent) and dry crankshaft center main roller bearings. Lubri-
cate bearings with 2-Cycle Outboard Oil.
CAUTION
DO NOT intermix halves of upper and lower crankshaft center main roller bearings.
Replace bearings in pairs only.
4. Thoroughly inspect center main roller bearings. Replace bearings if they are rusted,
fractured, worn, galled or badly discolored.
a 52153
a - Center Main Roller Bearing
5. Clean (with solvent) and dry crankshaft roller bearing that is installed in upper end cap.
Lubricate bearing with light oil.
6. Thoroughly inspect upper crank shaft roller bearing. If roller bearing is rusted, fractured,
worn, galled, badly discolored or loose inside of end cap replace end cap and roller bear-
ing as an assembly.
a - Upper Roller Bearing
Page 4A-52 90-884294 OCTOBER 2001

POWERHEAD
Reed Block Assembly

IMPORTANT: DO NOT remove reeds from reed blocks, unless replacement is neces-
sary. DO NOT turn used reeds over for re-use. Replace reeds in sets only.
1. Thoroughly clean gasket surfaces of reed blocks and reed block housing. Check for
deep grooves, cracks and distortion that could cause leakage. Replace parts as neces-
sary.
2. Inspect reed block neoprene surface for wear, cuts or abraisions. Replace reed block(s)
as required.
3. Check for chipped and broken reeds.
56023
Allowable reed opening is 0.020 in. (0.51 mm) or less. Replace reeds if either reed is stand-
ing open more than 0.020 in. (0.51 mm).
End Bearing Bleed System
1. Check rubber bleed hoses. Replace any hose that is cracked, cut or deteriorating.
2. Check operation of lower end cap check valve. If valve is working properly, air can be
drawn through check valve “one way” only. If air can pass through a check valve both
ways, valve is not working properly and must be replaced.
Connecting Rods
1. Check connecting rods for alignment by placing rods on a surface plate. If light can be
seen under any portion of machined surfaces, if rod has a slight wobble on plate, or if
a 0.002 in. (0.051 mm) feeler gauge can be inserted between any machined surface and
surface plate, rod is bent and must be discarded.
2. Overheating: Overheating is visible as a bluish bearing surface color that is caused by
inadequate lubrication or excessive RPM.
3. Rust: Rust formation on bearing surfaces causes uneven pitting of surface(s).
a 51853
a - Pitting
90-884294 OCTOBER 2001 Page 4A-53

POWERHEAD
4. Water Marks: When bearing surfaces are subjected to water contamination, a bearing
surface “etching” occurs. This etching resembles the size of the bearing.
51853
5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping.
Spalling will be most evident on the thrust portion of the connecting rod in line with the
“I” beam. General bearing surface deterioration could be caused by or accelerated by
improper lubrication.
a
a 51853
a - Spalling
6. Chatter Marks: Chatter marks are the result of a combination of low speed - low load
- cold water temperature operation, aggravated by inadequate lubrication and/or im-
proper fuel. Under these conditions, the crankshaft journal is hammered by the connect-
ing rod. As ignition occurs in the cylinder, the piston pushes the connecting rod with tre-
mendous force, and this force is transferred to the connecting rod journal. Since there
is little or no load on the crankshaft, it bounces away from the connecting rod. The crank-
shaft then remains immobile for a split second until the piston travel causes the connect-
ing rod to catch up to the waiting crankshaft journal, then hammers it. The repetition of
this action causes a rough bearing surface(s) which resembles a tiny washboard. In
some instances, the connecting rod crank pin bore becomes highly polished. During op-
eration, the engine will emit a “whirr” and/or “chirp” sound when it is accelerated rapidly
from idle speed to approximately 1500 RPM, then quickly returned to idle. If the preced-
ing conditions are found, replace both the crankshaft and connecting rod(s).
a
a 51853
a - Chatter Marks Between Arrows
Page 4A-54 90-884294 OCTOBER 2001

POWERHEAD
7. Uneven Wear: Uneven wear could be caused by a bent connecting rod.
aa 51853
a - Uneven Wear Between Arrows
8. If necessary, clean connecting rod bearing surfaces, as follows:
a. Be sure that “etched” marks on connecting rod (crankshaft end) are perfectly aligned
with “etched” marks on connecting rod cap. Tighten connecting rod cap attaching
bolts securely.
CAUTION
Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of connect-
ing rod. DO NOT use any other type of abrasive cloth.
b. Clean CRANKSHAFT END of connecting rod by using CROCUS CLOTH placed
in a slotted 3/8 in. (9.5 mm) diameter shaft, as shown. Chuck shaft in a drill press
and operation press at high speed while keeping connecting rod at a 90° angle to
slotted shaft.
IMPORTANT: Clean connecting rod just enough to clean up bearing surfaces. DO
NOT continue to clean after marks are removed from bearing surfaces.
51083
c. Clean PISTON PIN END of connecting rod, using same method as in Step “b”, pre-
ceding, but using 320 grit carborundum cloth instead of crocus cloth.
d. Thoroughly wash connecting rods to remove abrasive grit. Recheck bearing sur-
faces of connecting rods. Replace any connecting rod(s) that cannot be properly
“cleaned up.” Lubricate bearing surfaces of connecting rods (which will be re-used)
with light oil to prevent rust.
Thermostats (120°F) (49°C)
1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and
corrosion damage that could cause leakage. Replace parts as necessary.
2. Remove and discard gasket from each thermostat.
3. Wash thermostats with clean water.
4. Using a thermostat tester, similar to the one shown, test each thermostat as follows:
a. Open thermostat valve, then insert a thread between valve and thermostat body. Al-
low valve to close against thread.
b. Suspend thermostat (from thread) and thermometer inside tester so that neither
touches the container. Bottom of thermometer must be even with bottom of thermo-
stat to obtain correct temperature of thermostat opening.
c. Fill thermostat tester with water to cover thermostat.
90-884294 OCTOBER 2001 Page 4A-55

POWERHEAD
d. Plug tester into electrical outlet.

e. Observe temperature at which thermostat begins to open. (Thermostat will drop off
thread, that was installed in Step “a”, when it starts to open.) Thermostat must begin
to open when temperature reaches 118°-122 °F (48°-50 °C).
f. Continue to heat water until thermostat is completely open.
g. Unplug thermostat tester.
h. Replace thermostat if it fails to open at the specified temperature, or if it does not fully
open.
NOTE : BE SURE that water in thermostat tester is allowed to cool sufficiently [below 110 °F
(43 °C)] before testing the other thermostat.
51087
Powerhead Reassembly and Installation

General
Before proceeding with powerhead reassembly, be sure that all parts to be re-used have
been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspection,”
preceding. Parts, which have not been properly cleaned (or which are questionable), can
severely damage an otherwise perfectly good powerhead within the first few minutes of op-
eration. All new powerhead gaskets MUST BE installed during reassembly.
During reassembly, lubricate parts with 2-Cycle Outboard Oil whenever “light oil” is speci-
fied. Mercury/Quicksilver part numbers of lubricants, sealers and locking compounds are
listed in “Mercury/Quicksilver Lubricants and Sealants” located in section 1A, and special
tools are listed in “Powerhead General Information,” preceding.
A torque wrench is essential for correct reassembly of powerhead. DO NOT attempt to
reassemble powerhead without using a torque wrench. Attaching bolts for covers, housings
and cylinder heads MUST BE torqued by tightening bolts in 3 progressive steps (following
specified torque sequence) until specified torque is reached (see “Example,” following).
EXAMPLE: If cylinder head attaching bolts require a torque of 30 Ib. ft. (41 N·m), a) tighten
all bolts to 10 Ib. ft. (13.5 Nm), following specified torque sequence, b) tighten all bolts to
20 Ib. ft. (27 Nm), following torque sequence, then finally c) tighten all bolts to 30 Ib. ft. (41
Nm), following torque sequence.
Page 4A-56 90-884294 OCTOBER 2001

POWERHEAD
1. If removed, press lower crankshaft ball bearing onto crankshaft as shown. Be sure bear-
ing is pressed firmly against shoulder.
2. Reinstall retaining ring using a suitable pair of Snap Ring Pliers.
dd ea
cc
aa bb
51852 55983
a - Crankshaft c - Suitable Mandrel
b - Crankshaft Ball Bearing d - Press
e - Retaining Ring
3. If removed, spread new crankshaft sealing rings just enough to slide over crankshaft
journal.
4. Use Piston Ring Expander (91-24697) and install crankshaft sealing rings into groove.
a a
51854 b
52320
a - Crankshaft Sealing Rings
b - Piston Ring Expander (91-24697)
5. Lubricate center main crankshaft roller bearings and races with light oil.
14
a
b
14 2 Cycle Outboard Oil 52318

a - Install so hole is toward DRIVE SHAFT end of crankshaft
b - Verify retaining ring bridges the separating lines of the bearing race
90-884294 OCTOBER 2001 Page 4A-57

POWERHEAD
6. Place center main crankshaft roller bearings on upper and lower main bearing journals
as shown.
7. Install center main bearing races as shown.
8. Secure center main bearing races together with retaining rings. Make sure retaining ring
bridges the separating lines of the bearing race.
a
b 58989 58991
a - Flywheel End c - Center Main Bearing Races
b - Drive Shaft End
9. Install oil seals into lower end cap as follows:
a. Apply a thin bead of Loctite 271 to outer diameter on 2 lower end cap oil seals.
b. Use suitable mandrel to press one oil seal (lip facing down) into lower end cap until
firmly seated. Remove any excess Loctite.
c. Press second oil seal (lip facing down) until firmly seated on first oil seal. Remove
any excess Loctite.
d. Lubricate oil seal lips with 2-4-C Marine Lubricant with Teflon.
e. Lubricate O-ring seal surface on end cap with 2 cycle oil. Install o-ring over lower end
cap.
95
a
7
7 Loctite 271
ba
51849
14
a - Oil Seal b - O-ring
Page 4A-58 90-884294 OCTOBER 2001

POWERHEAD
10. Install oil seal into upper bearing carrier as follows:

a. Apply a light film of 2-4-C Marine Lubricant with Teflon to outer diameter of upper end
cap oil seal. This will ease seal installation into carrier.
b. Lubricate oil seal lip with 2-4-C Marine Lubricant with Teflon.
c. Use a suitable mandrel, press oil seal into bearing carrier (lip facing down) until bot-
tomed out on shoulder of carrier.
d. Lubricate O-ring seal surface on end cap with 2-4-C Marine Lubricant with Teflon
and install on carrier.
95
95
95 2-4-C With Teflon 51473
a - Oil Seal
b - Bearing Carrier
c - O-ring
Crankshaft Installation
SPECIAL INFORMATION
Installing A New Crankshaft Assembly Into Cylinder Block
Check the crankshaft sealing ring mating surfaces in the cylinder block and crankcase cover
for wear grooves that were caused by the crankshaft sealing rings from the previous crank-
shaft. If wear grooves are present, the sealing rings on the new crankshaft will have to fit
into the grooves without binding the crankshaft.
Before installing crankshaft, remove any burrs that may exist on groove edges.
Lubricate sealing rings with light oil and install new crankshaft as instructed.
Install upper and lower end caps and then inspect fit between sealing rings and grooves.
Temporarily install crankcase cover and rotate crankshaft several times to check if sealing
rings are binding against crankshaft. (You will feel a drag on the crankshaft.) If sealing rings
are binding, recheck grooves for burrs. If this does not correct the problem, it is recom-
mended that the cylinder block be replaced.
90-884294 OCTOBER 2001 Page 4A-59

POWERHEAD
Install crankshaft as follows:

1. Lubricate crankshaft sealing rings with light oil.
2. Check cylinder block to be sure that dowel pins are in place.
55992
a - Dowel Pins
3. Position all crankshaft seal ring gaps straight up.

4. Align hole in each center main bearing race with dowel pin.
5. Gently push crankshaft down into position making sure that the dowel pins are lined up
with the holes in center main bearings and crankshaft seal rings are in place.
55993
6. Lubricate lower crankshaft end (oil seal area) with light oil, then install lower end cap.
Secure end cap to cylinder block with attaching bolts. DO NOT tighten end cap bolts at
this time.
52328
a - Lower End Cap
Page 4A-60 90-884294 OCTOBER 2001

POWERHEAD
Piston and Connecting Rod Reassembly

1. Place needle bearings on a clean piece of paper and lubricate with 2-4-C Marine Lubri-
cant with Teflon.
NOTE : There are 34 needle bearings per piston.
2. Place sleeve which is part of piston pin tool (91-92973A1) into connecting rod and install
needle bearings around sleeve as shown.
3. Place locating washers on connecting rod.
IMPORTANT: Position connecting rod part number facing towards flywheel.
Carefully position piston over end of rod. Make sure locating washers remain in place.
a
b
a
55960
a - Sleeve (Part of Tool Assy. 91-92973A1)
b - Locating Washers
4. Insert piston pin tool (91-92973A1) and push sleeve out of piston. Keep piston pin tool
in piston.
5. Use a mallet and tap piston pin into piston and push piston pin tool out.
b c
55961 55962
a - Piston Pin Tool c - Piston Pin
(91-92973A1) d - Piston Pin Tool
b - Sleeve
90-884294 OCTOBER 2001 Page 4A-61

POWERHEAD
6. Install new piston pin lockrings (one each end of piston pin) with Lockring Installation
Tool (91-93004A2).
7. Make sure lockrings are properly seated in piston grooves.
a
aa
51086 55963
a - Lockring Installation Tool (91-93004A2)

b - Lockring
Piston and Piston Ring Combinations

Pistons with two half keystone (half tapered) rings
0.078 in. (1.98 mm)
aa bb
0.078 in. (1.98 mm)
55964
a - Half Keystone (half tapered) Piston Ring

b - Enlarged View of Piston Ring Grooves
Page 4A-62 90-884294 OCTOBER 2001

POWERHEAD
Piston Installation
1. Before installing new piston rings, check gap between ring ends by placing each ring
in its respective cylinder, then pushing ring about 1/2 in. (12.7 mm) into cylinder using
piston to assure proper position.
2. Check end gap of each new piston ring with a feeler gauge. End gap must be within
0.010 in. to 0.018 in. (0.25 mm to 0.46 mm). If end gap is greater, check other piston rings
in cylinder bore, until rings (within tolerance) are found.
IMPORTANT: Piston ring side with dot or letter must be facing up.
aa
c e
d
f
52317
a - Piston Ring e - Dot or Letter
b - Dots (Faces Up) f - Piston Ring
c - Feeler Gauge
d - Ring End Gap
IMPORTANT: 3 Liter Work/225 EFI/250 EFI engines have top and bottom indicated pis-
ton rings and should be installed accordingly. The top ring is marked T1 and the bot-
tom ring is marked T2. The “T” represents the top side of of the ring. The bottom ring
is stepped to trap oil and bring it into the cylinder bores on the upward stroke.
58126
a - T1 top ring
b - T2 bottom ring
c - Step
3. Use Piston Ring Expander (91-24697) and install piston rings (dot side up) on each pis-
ton. Spread rings just enough to slip over piston.
90-884294 OCTOBER 2001 Page 4A-63

POWERHEAD
4. Check piston rings to be sure that they fit freely in ring groove.
5. Lubricate piston, rings and cylinder wall with 2-Cycle Outboard Oil.
52319
a - Piston Ring Expander (91-24697)
b - Dot Side “Up” on Piston Ring
6. Rotate each piston ring so end of ring is aligned with locating pin as shown.
7. Install Piston Ring Compressor.
8. Remove screws and connecting rod cap from piston rod assembly being installed.
IMPORTANT: Piston must be correctly installed and positioned as shown.
Pistons marked with the word “UP” and with the letter “P” or “S” on top of piston.
Pistons with the letter “P” must be installed in the port side of engine and the word “UP” fac-
ing toward top of engine.
Pistons with the letter “S” must be installed in the starboard side of engine and the word “UP”
toward top of engine.
9. Coat cylinder bore with 2-cycle oil. Match piston assembly with cylinder it was removed
from, and position piston as described below. Push piston into cylinder.
UP UP
CYL 2 CYL 1 14
P S
UP UP
CYL 4 CYL 3
P S
UP UP
CYL 6 CYL 5
P S
14 2 Cycle Outboard Oil 52328
Page 4A-64 90-884294 OCTOBER 2001

POWERHEAD
10. Apply 2-4-C Marine Lubricant with Teflon to bearing surface of connecting rod and install
bearing assembly as shown.
IMPORTANT: It is recommended that connecting rod bolts not be reused.
11. Place connecting rod cap on connecting rod. Apply light oil to threads and face of con-
necting rod bolts. Thread connecting rod bolts finger-tight while checking for correct
alignment of the rod cap as shown.
IMPORTANT: Connecting rod and connecting rod caps are matched halves. Do not
torque screws before completing the following procedure.
• Run a pencil lightly over ground area.
• If pencil stops at fracture point, loosen bolts, retighten, and check again.
NOTE : If you still feel the fracture point, discard the rod.
12. Tighten connecting rod bolts (using a 3/18 in. - 12 point socket). First torque to 15 lb.
in. (1.7 N·m) then 30 lb. ft. (41 N·m). Turn each bolt an additional 90° after 2nd torque
is attained. Recheck alignment between rod cap and rod as shown.
95
52316
95 2-4-C With Teflon
a - Connecting Rod Screws
13. Rotate crankshaft several times (using powerhead stand) to assure free operation (no
binds and catching).
90-884294 OCTOBER 2001 Page 4A-65

POWERHEAD
Connecting Rod Cap Alignment

Check each connecting rod cap for correct alignment. If not aligned, a ridge can be seen
or felt at the separating line as shown below. Correct any misalignment.
a c
b d
52381
a - Side View Incorrect – Cap on Backwards
b - End View Incorrect – Cap on Backwards
c - Side View Correct
d - End View Correct
Page 4A-66 90-884294 OCTOBER 2001

POWERHEAD
Crankcase Cover Installation

1. Thoroughly remove all oil from mating surfaces of crankcase cover and cylinder block
with Loctite 7649 Primer.
b b
55984
a - Crankcase Cover
b - Remove all Oil
2. Apply a thin, even coat of Loctite Master Gasket on mating surfaces of cylinder block.
58993
a - Loctite Master Gasket
90-884294 OCTOBER 2001 Page 4A-67

POWERHEAD
3. Place crankcase cover in position on cylinder block. Turn the 8 center main bolts in a
LITTLE at a time, (following torque sequence) compressing crankshaft seal rings until
crankshaft cover has been drawn down to cylinder block. Tighten eight bolts evenly in
three progressive steps (following torque sequence).
4. Install remaining crankcase cover flange bolts.
5. Tighten end cap bolts to specified torque.
a
8 7
13 14
9 10
1 4
6 7
4 1
c
2 3 52132
3 2 52132
8 5
11 12
5 6
b
55986
a - Apply Light Oil to Threads of Bolt Face; 8 Bolts (M10 x 1.5 x 80); Torque bolts
to 30 lb. ft. (41 Nm) and rotate 90°
b - 14 Bolts; (M8 x 1.25 x 35); Torque bolts to 28 lb. ft. (38 Nm)
c - Lower End Cap Bolts – Torque to 85 lb. in. (9.5 Nm)
Page 4A-68 90-884294 OCTOBER 2001

POWERHEAD
Assembly of Reed Blocks to Reed Block Adaptor Plate
a
b
NOTE : Air plenum gasket is beaded on 1 side. Bead side of the gasket faces the air plenum.
a - Torque to 90 lb. in. (10 Nm)
b - Reed Block (6)
c - Cylinder Block Cover
d - Adaptor Plate
e - Air Plenum Gasket (bead faces air plenum)
f - Air Plenum
g - Torque to 100 lb. in. (11.5 Nm)
90-884294 OCTOBER 2001 Page 4A-69

POWERHEAD
1. If removed, install water pressure relief valve components as shown. Torque bolts to
specifications.
12
12
11
11
10
13
13
3 99
4
55
77
3 88
1
50803
1 - Cover 7 - Washer
2 - Bolt - 150 lb. in. 8 - Screw - 25 lb. in. (3 Nm)
(17 Nm) 9 - Spring
3 - Gasket 10 - Poppet Valve
4 - Relief Valve Plate 11 - Grommet
5 - Diaphragm 12 - Carrier
6 - Water Deflector 13 - Washer
Page 4A-70 90-884294 OCTOBER 2001

POWERHEAD
CYLINDER HEAD INSTALLATION

NOTE : The 3 Liter 200 Work cylinder heads are low compression in design and can be iden-
tified by the casting number 812851C13. The 225 EFI and 250 EFI cylinder heads can be
identified by the casting number 812851C15.
1. Install each cylinder head to engine block with thermostat pocket “UP”. Apply light oil
to cylinder head bolt threads and torque bolts to 20 Ib. ft. (27 Nm) then turn an additional
90°.
20 18
16 14
12 10
1 3
7 5
6 8
4 2
9 11
13 15
17 19
52132
a - Cylinder Head Casting Number Location
90-884294 OCTOBER 2001 Page 4A-71

POWERHEAD
2. Install thermostat assembly into each cylinder head.

3. Install temperature sensors into STARBOARD and PORT cylinder heads.
b
f
59037
a - Temperature Sensor (Port) (Over- d - Port Thermostat
heat) e - Starboard Thermostat
b - Temperature Sensor (Analog Tem- f - Temperature Sensor (Starboard)
perature Gauge) (Overheat)
c - Bolt [Torque to 17 lb. ft.
(23. Nm)]
NOTE : The temperature sensors provide continuous temperature information to the ECM
while the engine is running. Should temperature reach approximately 180 °F 82 °C), the
ECM will activate a warning horn and warning light.
Page 4A-72 90-884294 OCTOBER 2001

POWERHEAD
Notes:
90-884294 OCTOBER 2001 Page 4A-73

POWERHEAD
Throttle Lever and Shift Platform Assembly
95
Page 4A-74 90-884294 OCTOBER 2001

POWERHEAD
Throttle Lever and Shift Platform Assembly

TORQUE
REF.
REF
1 1 THROTTLE CONTROL LEVER
2 1 SCREW (M8 x 35) 21 28
3 1 WASHER
4 1 BUSHING
5 2 SCREW (M6 x 55)
6 2 NUT
7 2 CAP
8 1 PIN INSERT
9 1 NUT 50 5.5
10 1 SWIVEL BUSHING
11 1 LINK
12 1 ANCHOR BRACKET
13 1 LATCH
14 2 SCREW-DRIVE
15 2 CUP
16 2 SCREW (M8 x 25) 18 24
17 1 CLAMP
18 1 SCREW (M8 x 25) 20 27
19 1 ROLLER GUIDE
20 1 SWITCH
21 1 STA-STRAP
22 1 SCREW (M3.5 x 20)
23 1 WASHER
24 1 WASHER
25 1 WASHER
90-884294 OCTOBER 2001 Page 4A-75

POWERHEAD
Powerhead Installation On Driveshaft Housing

1. Install Lifting Eye (91-90455) into flywheel.
WARNING
BE SURE that Lifting Eye is threaded into flywheel a minimum of five (5) turns BE-
FORE lifting powerhead.
2. Using a hoist, lift powerhead high enough to allow removal of powerhead from repair
stand. Remove powerhead from repair stand, being careful not to damage drive shaft
housing gasket surface of powerhead.
3. Place a new gasket around powerhead studs and into position on base of powerhead.
IMPORTANT: DO NOT apply lubricant to top of driveshaft as this will prevent drive-
shaft from fully engaging into crankshaft.
4. Apply a small amount of 2-4-C Marine Lubricant with Teflon onto driveshaft splines.
NOTE : Verify shift shaft is properly installed in gearcase/driveshaft housing before instal-
ling powerhead.
5. Use hoist to lower powerhead onto driveshaft housing. It may be necessary to turn fly-
wheel (aligning crankshaft splines with driveshaft splines) so that powerhead will be fully
installed.
59076
a - Lifting Eye (90-90455)
Page 4A-76 90-884294 OCTOBER 2001

POWERHEAD
6. Install 10 flat washers,and 10 locknuts which secure powerhead to exhaust extension

plate/driveshaft housing. Torque locknuts in 3 progressive steps until secured.
7. Disconnect hoist from Lifting Eye and remove Lifting Eye from flywheel.
8. Reinstall plastic cap into center of flywheel cover.
a
a
a
a a
52373
a - Locknuts and Washers – Torque nuts to 20 lb. ft. (27 N m)
90-884294 OCTOBER 2001 Page 4A-77

POWERHEAD
9. Reconnect and/or reinstall the following:
e d
c 59026
a - Remote Oil Tank Pressure Hose
b - Remote Control Harness
c - Power Trim Wires
d - Negative Battery Cable
e - Positive Battery Cable
f - SmartCraft Harness Connector
Page 4A-78 90-884294 OCTOBER 2001

POWERHEAD
10. Reinstall the following:
d
c
b
59030
a - Oil Supply Hose
b - Shift Lever Bracket Assembly
c - Water Pressure Hose (GREY)
90-884294 OCTOBER 2001 Page 4A-79

POWERHEAD
11. Reconnect the following:
d
a
59028
a - Water Pressure Sensor Hose (GREY)(for Digital Gauges)
b - Engine Flush Hose
c - Tell-Tale Hose
Page 4A-80 90-884294 OCTOBER 2001

POWERHEAD
12. Install bottom cowls.

a
59075
a - Screws b - Access Cover to Lower Screw
13. Reconnect input fuel line, water pressure hose and speedometer hose.
b c
a
a - Input Fuel Hose c - Speedometer Hose (BLACK) (Ana-

b - Water Pressure Hose (GRAY) (Ana- log Gauges)
log Gauges) d - Hose Clamp
90-884294 OCTOBER 2001 Page 4A-81

POWERHEAD
Shift Cable
Install cables into the remote control following the instructions provided with the remote con-
trol.
NOTE : Install the shift cable to the engine first. The shift cable is the first cable to move when
the remote control handle is moved out of neutral.
Counter rotating (left hand) gear cases can be identified by a “L” stamped into the end of
the propeller shaft.
The Dual Engine Console Mount Control (88688A22 or 88688A52) is required to shift the
counter rotation outboard. The installation instructions shipped with the control explain the
procedure required to connect this control to a counter rotation outboard.
IMPORTANT: If the counter rotation outboard is rigged similar to a standard rotation
outboard OR if a standard rotation outboard is rigged similar to a counter rotation
outboard, the reverse gear and bearing in the gear case must function as forward
gear. THE REVERSE GEAR/BEARING ARE NOT DESIGNED TO CARRY THE SUS-
TAINED LOADS THAT ARE GENERATED WHEN RUNNING UNDER CONSTANT HIGH
RPM AND THRUST CONDITIONS.
OUTBOARD SHIFTING DIRECTION
On counter rotation outboards, the shift linkage moves in the opposite direction compared
to a standard rotation outboard.
STANDARD ROTATION GEAR OUTBOARDS

Page 4A-82 90-884294 OCTOBER 2001

POWERHEAD
Installation
IMPORTANT: Step 1 must be followed for proper adjustment of the shift cable.
1. Locate the center point of the slack or lost motion that exists in the shift cable as follows:
a. Move the remote control handle from neutral into forward and advance the handle
to full speed position. Slowly return the handle back to the neutral. Place a mark (a)
on the cable against the cable end guide.
b. Move the remote control handle from neutral into reverse and advance the handle
to full speed position. Slowly return the handle back to the neutral. Place a mark (b)
on the cable against the cable end guide.
c. Make a center mark (c), midway between marks (“a” and “b”). Align the cable end
guide against this center mark when installing cable to the engine.
STANDARD ROTATION OUTBOARDS
a

a
drag. If not, adjust barrel closer to cable end guide. Repeat steps a thru d.
90-884294 OCTOBER 2001 Page 4A-83

POWERHEAD
2. Position remote control and outboard into neutral.

N
3. Slide the shift cable anchor pin forward until resistance is felt, then slide anchor pin to-
ward rear until resistance is felt. Center the anchor pin between resistance points.
a - Anchor Pin
4. Align the shift cable end guide with the center mark as instructed in Step 1.
5. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder.
6. Secure shift cable with shift cable retainer.
a c
d
a - Cable Barrel c - Locknut – Tighten locknut then

b - Shift Cable Retainer back off locknut 1/4 turn
d - Nylon Washer
7. Check shift cable adjustments as follows:
a. With remote control in forward, the propshaft should lock solidly in gear. If it does not,
adjust cable barrel closer to cable end guide.
b. Shift remote control into neutral. The propshaft should turn freely without drag. If not,
adjust barrel away from cable end guide. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propshaft should lock
solidly in gear. If not, adjust barrel away from cable end guide. Repeat steps a
through c.
drag. If not, adjust barrel closer to cable end guide. Repeat steps a through d.
Page 4A-84 90-884294 OCTOBER 2001

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

b - Idle Stop Screw
90-884294 OCTOBER 2001 Page 4A-85

POWERHEAD
4. Check throttle cable adjustment as follows:

a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to ro-
tate the propeller shaft while shifting into reverse.
F N R
b. Return remote control to neutral. Place a thin piece of paper between idle adjust-
ment screw and idle stop. Adjustment is correct when the paper can be removed
without tearing, but has some drag on it. Readjust cable barrel if necessary.
IMPORTANT: The idle stop screw must be touching the stop.
b
a
5. Lock the barrel holder in place with the cable latch.
Front Clamp Reassembly

IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables,
fuel hose, and oil hoses routed between clamp and engine attachment point, to re-
lieve stress and prevent hoses from being kinked or pinched.
1. Place the neoprene wrap over the wiring, hoses, and control cables as shown.
2. Fasten clamp together with two screws and retainer.
b
a - Neoprene Wrap
b - Screws
Page 4A-86 90-884294 OCTOBER 2001

POWERHEAD
Engine Break-in Procedure

IMPORTANT: Prior to initially starting engine, oil pump prime sequence must be acti-
vated using the Digital Diagnostic Terminal (DDT). Initiating the oil pump prime se-
quence will vacate any air in the oil output hose and mix oil with fuel in the vapor sepa-
rator thus preventing scoring of internal components during initial startup.
CAUTION
Severe damage to the engine can result by not complying with the Engine Break-In
Procedure.
Gasoline/Oil Break-In Mixture

MODELS WITH ELECTRONIC FUEL INJECTION (EFI)
Do not use pre-mixed gas and oil during break-in. Oil from the oil injection system will supply
adequate lubrication during engine break-in.
Break-In Procedure
FIRST HOUR
• Avoid continuous operation at idle speed for more then ten minutes.
• Run the engine the majority of time between 3000 and 4500 RPM approximately
three quarter throttle.
• Vary engine speed; change engine speed approximately every 2 minutes.
• Avoid trimming the outboard out (up) beyond a vertical trim position during operation.
• Allow engine to warm-up for 30-60 seconds.
• Short bursts of full throttle for periods up to 10 seconds are acceptable.
NEXT THREE HOURS
• Change engine speed every 10 minutes.
NOTE : It is the driver’s responsibility to always drive in a safe manner. Improper trim angle
of the outboard when driving at speed can be difficult and dangerous. The purpose of speci-
fying trim angle is to help guide the operator in determining how to put the proper load on
the engine. They are intended to be guidelines and do not suggest or require unsafe boat
operation.
90-884294 OCTOBER 2001 Page 4A-87

COOLING
POWERHEAD
Section 4B - Cooling
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9
Digital Port and Starboard Temperature Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Water Pressure Check . . . . . . . . . . . . . . . . . . . . . . . 4B-10
Analog Temperature Sensor . . . . . . . . . . . . . . . . 4B-4
Water Pump Cleaning and Inspection . . . . . . . . . . 4B-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5
Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B-6
4B-6
Problem Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-12 4
B
90-884294 OCTOBER 2001 Page 4B-1

COOLING
Specifications
Thermostat . . . . . . . . . . . 143 °F (61.7 °C)
Water Pressure
Idle 1.5 – 4.5 PSI
(10.3 – 30.8 kPa)
Poppet Valve Opening 6.0 – 7.0 PSI
(41.3 – 48.2 kPa)
W.O.T. 8 – 10 PSI (54.8 – 68.5 kPa)
Minimum
a c
a - Analog Temperature Sensor (EFI c - Digital Temperature Sensor for Starboard

Models) and optional gauge sender Head
b - Digital Temperature Sensor for Port
Head
Page 4B-2 90-884294 OCTOBER 2001

COOLING
Digital Port and Starboard Temperature Sensors


257 125 340
248 120 390
239 115 450
230 110 517
221 105 592
212 100 680
203 95 787
194 90 915
185 85 1070
176 80 1255
167 75 1480
158 70 1752
149 65 2083
140 60 2488
131 55 2986
122 50 3603
113 45 4370
104 40 5327
95 35 6530
86 30 8056
77 25 10000
68 20 12493
59 15 15714
50 10 19903
41 5 25396
32 0 32654
14 –10 55319
5 –15 72940
90-884294 OCTOBER 2001 Page 4B-3

COOLING
Analog Temperature Sensor

TAN/BLACK sensor lead (in port analog temperature sensor) provides signal for optional
temperature gauge.
An ohms test of the analog temperature sensor (in port cylinder head) would be as follows:
Insert digital or analog ohmmeter test leads into both TAN/BLACK sensor leads. With en-
gine at temperature (F°) indicated, ohm readings should be as indicated ±10%.
270
255
240
225
210
195
Temperature Sensor
Temperature (F )
180
°
165
150
135
120
105
90
75
60
45
30
15
0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2
Resistance (k)
Temperature Sensor
Between Black and each TAN/BLK wire. No
Continuity
Between each lead and ground No
Continuity
Between each TAN/BLK wire Resistance will vary with temperature
Page 4B-4 90-884294 OCTOBER 2001

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

COOLING
Water Flow
Description
Cooling water enters the cooling system through the lower unit water inlets. The pump
assembly forces water through the water tube and exhaust adapter plate passages filling
the power head central water chamber (located behind the exhaust cavity). Water enters
the exhaust cover cavity through 2 holes near the top of the exhaust cover.
Water exits the exhaust cover cavity through 4 slots (2 each side) filling the water pas-
sages around the cylinders. Water flows around each bank of cylinders to the top of the
cylinder block.
Water flow exiting the cylinder block is controlled by the thermostats (1 in each cylinder
head) and the poppet valve (located at the bottom starboard side of powerhead). At low
RPM (below 1500 RPM), the thermostats control water flow depending upon engine tem-
perature. When the thermostats are open, water passes through the cylinder heads and
exits to the drive shaft housing. At higher RPM (above 1500 RPM) the poppet valve will
control the water flow.
Water that passes through the poppet valve enters water passages in the adaptor plates.
Water passes through the adaptor plates into the driveshaft housing.
Water dumped into the drive shaft housing builds up a wall of water around the exhaust
tube. This performs 2 functions:
• Helps silence the exhaust
• Prevents air from being drawn into the pump
Water exits the engine in 3 locations:
• Excess water from the wall of water exits around anodes on the gear housing.
• A portion of the water that passes through the thermostats exits out the tell tail.
• Water exits through two 1/8 in. (3.175 mm) holes in the lower adaptor plate into the
exhaust.
To allow complete passage filling and to prevent steam pockets, all cooling passages are
interconnected. Small passages are incorporated to allow the cooling system to drain.
Page 4B-6 90-884294 OCTOBER 2001

COOLING
3 Liter Work/225 EFI/250 EFI Water Flow Diagram
11
7
1
1 17
6 9
2
3
4 10
11
14
1
16
17
5
16
14 1
59162
7 12 15 1. Water Inlet
2. Water Pump
3. Wall of Water – If water level height is insufficient, water pump may draw in air resulting in an overheated engine.
4. Strainer – Exhaust cooling water.
13 5. Main Water Feed to Powerhead from Water Tube
6. Rubber Water Dams – If missing may result in uneven cooling of cylinders and scuffed pistons.
8 7. Cylinder Head Cover – Removed from head for illustration, normally part of head casting.
8. Thermostat (2) 143 °F (61.7 °C) – If stuck closed, engine will overheat at low speed. If stuck open, engine will not warm up at idle speed.
9. Poppet Valve – Controls water flow at high RPM. If poppet valve is stuck open at low rpm, the engine will not reach proper operating temperature (run cold) and will run rough at idle.
10. Primary water discharge into driveshaft housing.
11. Water discharge into exhaust relief passage.
12. Water Pressure Sensor
13. Check Valve for powerhead flush
14. Water passing through thermostats dump into adaptor plate, then discharges down the exhaust.
15. Tell-Tale Outlet
16. Excess water from wall of of water around exhaust bucket exits around anodes.
17. Water exiting exhaust discharge.
90-884294 OCTOBER 2001 Page 4B-7

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

COOLING
Troubleshooting
Thermostat Test
1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and
corrosion damage that could cause leakage. Replace parts as necessary.
2. Remove and discard gasket from each thermostat.
3. Wash thermostats with clean water.
4. Using a thermostat tester, similar to the one shown, test each thermostat as follows:
a. Open thermostat valve, then insert a thread between valve and thermostat body. Al-
low valve to close against thread.
b. Suspend thermostat (from thread) and thermometer inside tester so that neither
touches the container. Bottom of thermometer must be even with bottom of thermo-
stat to obtain correct temperature of thermostat opening.
c. Fill thermostat tester with water to cover thermostat.
d. Plug tester into electrical outlet.
e. Observe temperature at which thermostat begins to open. (Thermostat will drop off
thread, that was installed in Step “a”, when it starts to open.) Thermostat must begin
to open when temperature reaches 140 °-145 °F (60 °-63 °C).
f. Continue to heat water until thermostat is completely open.
g. Unplug thermostat tester.
h. Replace thermostat, if it fails to open at the specified temperature, or if it does not
fully open.
NOTE: BE SURE that water in thermostat tester is allowed to cool sufficiently [below 110 °F
(43.3 °C)] before testing the other thermostat.
51087
IMPORTANT: DO NOT operate engine without thermostats installed.
90-884294 OCTOBER 2001 Page 4B-9

COOLING
Water Pressure Check

Water pressure may be checked by attaching a test pressure gauge to the top of the engine
block.
A water pressure line (GRAY colored) is provided that exits at the front of the lower cowl.
A dash style gauge may be connected to this line to register water pressure.
WARNING
Shut off engine and refer to troubleshooting chart if water pressure is not within
specification. DO NOT exceed 3000 RPM in neutral.
Idle 1.5 – 4.5 PSI

(10.3 – 30.8 kPa)
Poppet Valve Opening 6 – 7 PSI
(41.1 – 47.9 kPa)
W.O.T. 8 – 10 PSI (54.9 – 68.5 kPa)
Minimum
Page 4B-10 90-884294 OCTOBER 2001

COOLING
Water Pump Cleaning and Inspection

1. Inspect the water tube coupling for wear or damage. If necessary replace.
a - Water Tube Coupling

2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller
blades. Replace the impeller if this condition is found.
3. Inspect for proper bonding between the hub and the impeller. Replace the impeller if im-
proper bonding is found.
a b
a - Hub
b - Impeller
4. Inspect the impeller blades to see if they are cracked, burnt, hard or deformed. Replace
the impeller if the blades are in this condition.
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate. The depth of the groove will not affect wa-
ter pump output.
5. Replace cover and/or face plate if grooves (other than impeller sealing bead groove) are
more than 0.030 in. (0.76 mm) deep.
a
b
70609
a - Water Pump Face Plate
b - Water Pump Cover
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
IMPORTANT: It is recommended that the water pump impeller be replaced whenever
the gearcase is removed for maintenance. However, if it is necessary to re-use the
impeller, DO NOT install in reverse to original rotation as premature impeller failure
will occur.
90-884294 OCTOBER 2001 Page 4B-11

COOLING
Problem Diagnosis
Condition Recommended Range Possible Cause
Pressure below specification @ 1.5 – 4.5 PSI (10.3 – 30.8 kPa) •Poppet valve spring defective
idle (weak, broken, missing)
•Defective poppet valve seal
•Thermostat stuck open
•Severe internal leak
•Low output water pump
•Inlet restriction
Pressure above 5 psi (34.2kPa) 1.5 – 4.5 PSI (10.3 – 30.8 kPa) •Plugged poppet by-pass pas-
@ idle sage or tell-tale
Pressure does not drop between 6 – 7 PSI (41.1 – 47.9 kPa) be- •Wrong poppet valve spring
1000 – 2500 RPM indicating pop- tween 1000 – 2200 RPM •Low output water pump
pet valve has opened •Inlet restriction
•Poppet valve vent hole plugged
or restricted
Poppet valve flutter/water pres- •Wrong poppet valve spring
sure drop does not stabilize prior •Low output water pump
to 2500 RPM •Inlet restriction
•Broken diaphragm in poppet
valve
Pressure is below minimum spec- 8 PSI (54.8 kPa) •Inlet restriction
ification @ W.O.T. •Engine mounted too high on
transom
•Engine trimmed out too far
•Configuration of boat bottom in-
terfering with adequate flow of
water to coolant inlets
•Low output water pump
Pressure higher than normal @ Maximum pressure – 30 PSI •Outlet water passages restricted.
W.O.T., but engine still indicates (206.8 kPa) •Steam pocket has formed at top
overheat condition of powerhead due to lack of cool-
ing water
Page 4B-12 90-884294 OCTOBER 2001

CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING
MID-SECTION
Section 5A – Clamp/Swivel Brackets & Drive Shaft Housing
Table of Contents
Swivel Bracket and Steering Arm . . . . . . . . . . . . . . . 5A-2 Drive Shaft Housing and Dyna-Float Suspension . 5A-8
Transom Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Removal and Disassembly . . . . . . . . . . . . . . . . . 5A-8
Drive Shaft Housing and Exhaust Tube . . . . . . . . . 5A-6 Reassembly and Installation . . . . . . . . . . . . . . . 5A-12
5
A
90-884294 OCTOBER 2001 Page 5A-1

Swivel Bracket and Steering Arm
28
26
27 95 30 29
22
25 32
24
31
23
B
31 95
95 17
A 18
21 16 19
8
95 6
2
20
3
15
7
7
13 14
12
7
6
95
7
1
95 11
95
5
3
9
10
7 Loctite 271
Page 5A-2 90-884294 OCTOBER 2001

Swivel Bracket and Steering Arm

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SWIVEL BRACKET
2 1 O RING
3 2 BUSHING
4 1 SPACER
5 1 OIL SEAL (LOWER)
6 2 GREASE FITTING 85 9.5
7 2 BUSHING
8 1 THRUST WASHER
1 BOTTOM YOKE (LONG – CARBON STEEL)
9
1 BOTTOM YOKE (XL–STAINLESS STEEL)
10 1 RETAINING RING
11 2 STRIKER PLATE
12 2 LOCKWASHER
13 2 NUT 25 34
14 2 SCREW (1/4-28 x 1/2 IN.) 100 11.5
15 1 DECAL-Serial Overlaminate
16 1 TRIM SENDER
17 2 SCREW (10-24 x 3/4 IN.) 15 1.7
18 2 LOCKWASHER
19 2 WASHER
1 SWIVEL PIN/STEERING ARM (LONG – CARBON STEEL)
20
1 SWIVEL PIN/STEERING ARM(XL–STAINLESS STEEL)
21 2 SCREW (M12 x 1.75 x 190)
22 1 BUMPER
23 2 UPPER MOUNT
24 2 WASHER
25 2 WASHER
26 2 NUT 50 68
27 1 CLAMP
28 3 SCREW (M8 x 35) 20 27
29 1 STEERING LINK ASSEMBLY
30 1 SCREW 20 27
31 2 NUT (.375-24)
32 2 WASHER
NOTE: A – Torque nut to 120 lb. in. (13.5 Nm) and then back off 1/4 turn.
NOTE: B – Torque nut to 20 lb. ft. (27 Nm)
90-884294 OCTOBER 2001 Page 5A-3

Transom Brackets
18 17 95
95 5
6
3 15
95 2 4
95 16
15
14
13
19
1 95
7
8
10
11
12
Page 5A-4 90-884294 OCTOBER 2001

Transom Brackets
TORQUE
REF.
REF
1 1 TRANSOM BRACKET (STARBOARD)
2 1 TRANSOM BRACKET (PORT)
3 1 GREASE FITTING (PORT) 80 9
4 1 TILT TUBE
5 1 NUT (1 IN.-14) 45 61
6 1 O-RING
7 2 WAVE WASHER
8 1 NUT (7/8-14) 45 61
9 4 BOLT
10 4 WASHER
11 4 WASHER
12 4 NUT
13 1 TILT LOCK LEVER ASSEMBLY
14 1 SPRING
15 2 BUSHING
16 1 SPRING
17 1 KNOB
18 1 GROOVE PIN
19 1 PIN
90-884294 OCTOBER 2001 Page 5A-5

Drive Shaft Housing and Exhaust Tube
7 Loctite 271 22
19 Perfect Seal
33 Loctite 680
29
95
5 21
30
4 23
28
31 1
20
7
7 95
5
8
3
10 24
19 11
9
16
17
12
2 25
19 13
14 26
5 33
15 9
18 6
23
27
Page 5A-6 90-884294 OCTOBER 2001

Drive Shaft Housing and Exhaust Tube

TORQUE
REF.
REF
1 DRIVE SHAFT HOUSING (LONG)
1
1 DRIVE SHAFT HOUSING (X/XX–LONG)
2 4 STUD (M12 x 1.75 x 54) LONG/X-LONG
3 1 SCREW (M12 x 35) 45 61.0
4 1 GROMMET
5 5 WASHER
6 4 NUT (M12 x 1.75) 55 74.5
7 1 PLUG
8 2 SCREW (M14 x 2 x 178)
9 2 GROUND WIRE
10 2 WASHER
11 2 WASHER
12 2 MOUNT
13 2 WASHER
14 2 NUT 90 122
15 2 CLAMP
16 4 SCREW (M8 x 35) 20 27.0
17 1 LOCKWASHER
18 2 COVER
19 2 SCREW (10-16 x 7/16 IN.) Drive Tight
20 1 SEAL
21 1 EXHAUST TUBE
22 1 STRAINER
23 6 SCREW (M8 x 35) 16.5 22.5
1 WATER TUBE (LONG)
24 1 WATER TUBE (X-LONG)
1 WATER TUBE (XX-LONG)
25 1 SEAL
26 1 CLAMP
27 1 SCREW (1/4-20 x .375)
28 1 SPACER
29 2 DOWEL PIN XX-LONG
30 4 STUD (M12 x 179)
31 1 SCREW (M12 x 160)
90-884294 OCTOBER 2001 Page 5A-7

Drive Shaft Housing and Dyna-Float Suspension

Refer to “Powerhead Removal” section to remove powerhead. Refer to “Lower Unit
Removal” in this section to remove lower unit.
Removal and Disassembly
1. Remove shift shaft from driveshaft housing by pulling straight up on shaft.
2. Remove power trim wiring harness from exhaust adaptor plate.
3. Remove 3 bolts which secure upper mount cover to adaptor plate. Remove cover.
d
e
b
a
c
58005
a - Shift Shaft Linkage

b - Wiring Harness
c - Adaptor Plate
d - Bolts
e - Upper Mount Cover
Page 5A-8 90-884294 OCTOBER 2001

SHIFT LINKAGE ASSEMBLY

b
a c
d
b
c
b d
a - Shift Shaft Assembly

b - Bushing (3)
c - Lock Nut (2)
d - Washer (2)
1. Remove upper mount nuts and flat washers.

2. Pull mount bolts through mounts and remove mounts.
58004
a - Upper Mount Nuts
3. Remove 4 bolts securing exhaust adaptor plate to drive shaft housing.
a
a
58003
a - Bolts
b - Adaptor Plate
90-884294 OCTOBER 2001 Page 5A-9

4. While applying upward pressure on rear of adaptor plate, use a mallet and a piece of
hardwood against the adaptor plate to loosen gasket adhesion.
a
a - Adaptor Plate
5. Remove 2 bolts securing water tube to adaptor plate and remove tube. Remove 6
bolts securing exhaust tube to adaptor plate.
a b
a - Bolts
b - Exhaust Tube
c - Water Tube
Page 5A-10 90-884294 OCTOBER 2001

6. While tilting adaptor plate/exhaust tube assembly, use a piece of hardwood and a mal-
let to loosen gasket adhesion. Remove exhaust tube.
b
a - Hardwood
b - Adaptor Plate
c - Exhaust Tube
7. Remove all gasket material from driveshaft housing and related components.
8. Remove screw, which secure lower mount cover to drive shaft housing, and remove
cover.
9. Remove bolts securing lower mount retainers to drive shaft housing. Remove retain-
ers.
b d
52307 52308
a - Screw c - Bolts
b - Cover d - Lower Mount Retainer
(1 each side)
90-884294 OCTOBER 2001 Page 5A-11

10. Remove lower mount nuts and rubber caps.
b
a
52308
a - Lower Mount Nuts
b - Rubber Caps
11. Remove drive shaft housing from swivel bracket by pulling alternately from top to bot-
tom on housing.
12. Remove upper and lower mounts by lifting them out of drive shaft housing.
Reassembly and Installation

1. Apply a thin coat of 2-4-C Marine Lubricant with Teflon onto inside portion of exhaust
tube seal and water tube grommet.
2. Install exhaust tube seal into driveshaft housing with tapered side of seal facing up.
d
c
95
a

a - Exhaust Tube Seal
b - Driveshaft Housing
c - Water Tube Grommet
d - Leather Bumper
Page 5A-12 90-884294 OCTOBER 2001

3. Position exhaust tube and gasket on adaptor plate. Secure both to plate with 6 bolts.
Torque bolts to 21 Ib. ft. (28.5 Nm).
4. Secure tube to adaptor plate with 2 bolts. Torque bolts to 80 lb. in. (9 Nm).
a - Exhaust Tube
b - Gasket
c - Water Tube
5. Position adaptor plate on top of housing.

6. Secure adaptor plate to drive shaft with 4 bolts. Torque bolts to 25 lb. ft. (34 Nm).
a
a
58003
a - Bolts [Torque to 25 lb. ft. (34 Nm)]
90-884294 OCTOBER 2001 Page 5A-13

7. Apply a small amount of Perfect Seal onto metal portion of upper dyna-float mounts.
8. Position mounts on drive shaft housing plate.
9. Install a rubber washer onto each upper mount, followed by a metal washer.
10. Push bolts through mounts.
b c
19
19 c
b
19 Perfect Seal 58004

a - Dyna-Float Mounts
b - Rubber Washers
c - Metal Washer
11. Install a ground strap onto port lower mount bolt.

NOTE: Apply Perfect Seal along length of lower mount bolts.
12. Insert a mounting bolt through the short end of each lower mount.
13. Position a mount on each lower side of drive shaft housing.
14. Install a flat washer over each lower mounting bolt.
15. Start upper mounting bolts in upper mounts and align lower mounting bolts with holes
in swivel pin yoke. Slide drive shaft housing up against yoke and bumper.
16. Secure upper mounts to steering arm with flat washers and self-locking nuts. Torque
nuts to 50 Ib. ft. (68 Nm).
17. Install ground strap between port lower mount bolt and swivel bracket.
18. Secure lower mounts to swivel pin yoke with self-locking nuts. Torque nuts to 90 Ib.
ft. (122 Nm). Place a rubber cap over each lower mounting bolt head.
a d
c
e
b
52308
a - Lower Mount c - Rubber Cap
b - Nut [Torque to 90 lb. ft. d - Ground Strap (only 1 side)
(122 Nm)] e - Ground Strap (to swivel bracket)
Page 5A-14 90-884294 OCTOBER 2001

19. Install lower mount retainers and secure each retainer with 2 bolts. Secure ground
strap with the nearest retainer bolt and flat washer. Torque bolts to 20 lb. ft. (27 Nm).
20. Install lower mount covers and secure each cover with a screw.
c
e
a
d
52308 52307
a - Lower Mount Retainer d - Cover
b - Bolts [Torque to 20 lb. e - Screw (1 for each cover)
ft. (27 Nm)]
c - Ground Strap
21. Install upper mount cover on adaptor plate. Secure cover with 3 bolts. Torque bolts
to 20 lb. ft. (27 Nm).
22. Route power trim harness thru grommet in adaptor plate.
23. Reinstall shift shaft with bushing into adaptor plate. Apply 2-4-C Marine Lubricant with
Teflon to bushing.
d
c
e
a f
95
b
95 2-4-C Marine Lubricant with Teflon 58005
a - Shift Shaft Linkage e - Power Trim Harness
b - Exhaust Adaptor Plate f - Grommet
c - Upper Mount Cover g - Bushing
d - Bolts [Torque to 20 lb.
ft. (27 Nm)]
90-884294 OCTOBER 2001 Page 5A-15

POWER TRIM - DESIGN II
MID-SECTION
Section 5B – Power Trim - (Oildyne)
Table of Contents
Power Trim Specifications . . . . . . . . . . . . . . . . 5B-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-31
Power Trim Components (Oildyne) . . . . . . . . 5B-4 Testing Power Trim System With
Power Trim Motor (Oildyne) . . . . . . . . . . . . . . 5B-6 Test Gauge Kit (91-52915A6) . . . . . . . . . . 5B-33
Power Trim - General Information . . . . . . . . . 5B-7 “UP” Pressure Check . . . . . . . . . . . . . . . . . 5B-33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-7 “DOWN” Pressure Check . . . . . . . . . . . . . . 5B-36
Trimming Characteristics . . . . . . . . . . . . . . 5B-7 Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . 5B-38
Trailering Outboard . . . . . . . . . . . . . . . . . . . 5B-8 Trim Rod End Cap Seal . . . . . . . . . . . . . . . 5B-39
Tilting Outboard Manually . . . . . . . . . . . . . 5B-8 Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-41
Trim “In” Angle Adjustment . . . . . . . . . . . . 5B-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-42
Striker Plate Replacement . . . . . . . . . . . . . 5B-9 Memory Piston Removal . . . . . . . . . . . . . . 5B-44
Anode Plate . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 5B-45
Trim Indicator Gauge . . . . . . . . . . . . . . . . . 5B-10 Scraper Seal Replacement . . . . . . . . . . . . 5B-45
Check, Fill and Purge - Power
Trim System . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10
Power Trim Disassembly . . . . . . . . . . . . . . . . .
Trim Motor Removal . . . . . . . . . . . . . . . . . .
5B-49
5B-50
5
Trim Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 Pump and Component Removal . . . . . . . . 5B-51 B
Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 Motor and Electrical Tests/Repair . . . . . . . . . . 5B-53
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16 Trim Pump Motor Test . . . . . . . . . . . . . . . . 5B-53
Trail Over and Shock Absorber . . . . . . . . . 5B-19 Motor Disassembly . . . . . . . . . . . . . . . . . . . 5B-53
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5B-54
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5B-22 Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-55
Power Trim System with Relays and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-58
2 Wire Trim Motor . . . . . . . . . . . . . . . . . . . . 5B-24 Reassembly - Motor and Pump . . . . . . . . 5B-60
Electrical System Troubleshooting . . . . . . . . . 5B-25 Priming Power Trim System . . . . . . . . . . . 5B-62
General Checks . . . . . . . . . . . . . . . . . . . . . . 5B-25 Analog Trim Sender Test . . . . . . . . . . . . . . 5B-62
Troubleshooting the “Down Circuit” . . . . . . . . 5B-25 Trim Indicator Gauge Needle Adjustment 5B-63
Troubleshooting the “Up” Circuit . . . . . . . . . . . 5B-26 Digital Trim Sender . . . . . . . . . . . . . . . . . . . 5B-63
Troubleshooting the “Down” and “Up” Circuits Troubleshooting Digital Trim Sender . . . . 5B-64
(All Circuits Inoperative) . . . . . . . . . . . . . . . . . . 5B-27 Trim Indicator Wiring Diagrams . . . . . . . . . . . 5B-65
Power Trim Assembly Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Power Trim Specifications
POWER TRIM (Oildyne)

Trim ”UP” 2000 PSI (91kg/cm2)
Maximum Pressure
Trim “DOWN” 600 PSI (35kg/cm2)
Minimum Pressure
Leak Down Maximum Acceptable Amount of

Leak Down in 24 hours is 1 in.
(25.4 mm)
90-884294 OCTOBER 2001 Page 5B-1

Special Tools
1. Alignment Tool 91-11230
17238
2. Trim Rod Removal Tool 91-44486A1
51337
3. Trim Rod Guide Removal Tool 91-44487A1
51337
4. Power Trim Test Gauge Kit 91-52915A6
73835
5. Lock-Ring Pliers P/N SRP-4 (Snap-On)
Page 5B-2 90-884294 OCTOBER 2001

6. Adaptor Fitting 91-82278A2 and 91-82278A3
54458
7. Spanner Wrench 91-74951
51337
8. Multi-Meter DVA Tester 91-99750A1 or DMT 2000 Digital Tachometer Multi-meter

91-854009A1
a b
a - Multi-Meter DVA Tester 91-99750A1

b - DMT 2000 Digital Tachometer Multi-meter 91-854009A1
90-884294 OCTOBER 2001 Page 5B-3

Power Trim Components (Oildyne)
36
35
33 3 2
34
37
3
20 1
22
25 23
21
25 21 25
24 4
18
20 5
25
18 25 1
32 25 25
19 7 24
6
11 7
25 13 9
26 14 9
17 10
25 11
25 25
25
13 8
14 25
14 25 17
25
14
9 11
13 16 25
25
9
13
28
25 14 29 27
15
9 31
13
11 30
15 25
12
14
Page 5B-4 90-884294 OCTOBER 2001

Power Trim Components (Oildyne)

TORQUE
REF.
REF
– 1 POWER TRIM ASSEMBLY–Complete
1 1 TRIM MOTOR
2 1 ARMATURE
3 1 END FRAME
4 2 SCREW (M6 x 30) 80 9
5 2 LOCKWASHER
6 1 DRIVE SHAFT
7 1 CHECK VALVE KIT 120 13.5
8 1 RELIEF VALVE ASSEMBLY 22 2.5
9 1 SHAFT KIT (Includes. Ref. #26)
10 1 GROOVE PIN
11 1 TILT CYLINDER ASSEMBLY
12 1 END CAP (Includes. Ref. #26) 45 61
13 1 O RING KIT (Includes. Ref. #26)
14 1 SHOCK ROD KIT 95 129
15 1 MEMORY PISTON
16 1 CHECK VALVE REPAIR KIT (Includes. Ref. #26)
17 1 STARBOARD TRIM ROD
18 1 PORT TRIM ROD
19 2 END CAP TRIM ROD 70 95
20 1 RESERVOIR KIT
21 1 PLUG KIT 22 2.5
22 4 SCREW (M6 x 14) 60 7
23 4 WASHER
24 1 PUMP KIT
25 1 POWER TRIM REPAIR KIT
26 1 GROOVE PIN
27 6 SCREW (M10 x 30) 45 61
28 6 WASHER
29 1 ANODE
30 2 SCREW (M6 x 25) 70 8
31 2 WASHER
32 1 SHAFT
33 1 C WASHER
34 2 CLIP
35 2 SCREW (10-16 x 5/8) Drive Tight
36 1 STA-STRAP
37 1 CONDUIT [12 IN. (30.5 CM)]
NOTE: Lubricate all o-rings with ATF Dexron III or Power Trim and Steering Fluid.
90-884294 OCTOBER 2001 Page 5B-5

Power Trim Motor (Oildyne)
58446
58449
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb.in. lb.ft. N·m
– 1 POWER TRIM MOTOR
1 1 BRUSH AND SEAL KIT
2 1 ARMATURE KIT
3 1 END FRAME
Page 5B-6 90-884294 OCTOBER 2001

Power Trim - General Information

Description
The Power Trim System consists of an electric motor, pressurized fluid reservoir, pump,
tilt cylinder, and two trim rams.
The remote control (or trim panel) has switches that trim the outboard “Up” or “Down” and
tilt the engine for “Trailering”. The outboard can be trimmed and tilted under power or
when the outboard is not running.
Trimming Characteristics
NOTE: Because hull designs react differently in varying water conditions, varying the trim
position will often improve the ride and boat handling. When trimming from a mid-trim po-
sition (with outboard trim tab in a straight fore and aft position), expect the following:
TRIMMING OUTBOARD “UP” (OUT):
WARNING
Excessive trim “Out” may reduce the stability of some high speed hulls. To cor-
rect instability, reduce the power gradually and trim the outboard “In” slightly be-
fore resuming high speed operation. A rapid reduction in power will result in a
sudden change of steering torque and may cause additional boat instability.
Will lift boat bow, increasing top speed.
Transfers steering torque harder to port (left) on installations below 23 in. (584.2 mm) tran-
som height.
Increases gearcase clearance over submerged objects.
Excess trim can cause “porpoising” and/or ventilation.
WARNING
Excessive outboard trim angle will result in insufficient water supply causing wa-
ter pump and/or powerhead overheating damage. Insure water level is above wa-
ter intake holes whenever outboard is running.
The “Up” circuit actuates the up relay (under outboard cowl) and closes the motor circuit.
The electric motor drives the pump, forcing fluid thru passageways into the up side of the
trim cylinders.
The trim cylinders position the outboard at the desired trim angle in the 20 degree maxi-
mum trim range. The system will not allow the outboard to be trimmed above the 20 de-
gree trim range as long as the engine RPM is above approximately 2000 RPM.
The outboard can be trimmed above the 20 degree maximum trim angle (for shallow wa-
ter operation, etc.), by keeping the engine RPM below 2000. If the RPM increases over
2000, propeller thrust (if propeller is deep enough) will cause the trim system to return the
outboard to the 20 degree maximum trim position.
90-884294 OCTOBER 2001 Page 5B-7

TRIMMING OUTBOARD “DOWN” (IN):
WARNING
Excessive speed at minimum trim “In” may result in undesirable and/or unsafe
steering conditions. Test for handling characteristics after any adjustment is
made to the trim angle (and tilt pin location).
Aids planing, particularly with heavy loads.
Improves ride in choppy water conditions.
Excess trim “In” can cause “bow steer” (boat veers to left or right).
Transfers steering torque to starboard (right).
Improves acceleration to planing speed.
The “Down” circuit actuates the down relay (under engine cowl) and closes the motor cir-
cuit. The electric motor drives the pump in the opposite direction as the up circuit, forcing
fluid thru passageways into the “down” side of the tilt ram. The tilt ram moves the engine
down to the desired position.
Trailering Outboard
The “Up” circuit first moves the trim cylinders; when the trim cylinders extend fully, the tilt
ram extends to tilt the outboard to the full up position for trailering.
Before the boat is trailered, the operator should check for clearance between the outboard
skeg and pavement to prevent damage to skeg from striking pavement.
If the outboard must be tilted for clearance between skeg and pavement, a device such
as a “Transom Saver” should be installed to prevent stress to boat transom from outboard
weight while the boat/outboard are being trailered.
Tilting Outboard Manually

WARNING
Before opening the manual release valve, insure all persons are clear of outboard
as outboard will drop to full “Down” when valve is opened.
The outboard can be raised or lowered manually by opening the manual release valve
3 to 4 turns counterclockwise. Close manual release valve to hold outboard at the desired
tilt position.
58450
a - Manual Release Valve
Page 5B-8 90-884294 OCTOBER 2001

Trim “In” Angle Adjustment

WARNING
Boat operation with outboard trimmed to the full “In” trim angle [not using the
trim angle adjustment bolt] at planing speed may result in undesirable and/or un-
safe steering conditions. A water test for handling/steering conditions is re-
quired after any trim angle adjustments.
IMPORTANT: Some boat/motor combinations not using the trim angle adjustment
pin and trimmed to the full “In” trim angle position may not exhibit any undesirable
and/or unsafe handling and/or steering characteristics at planing speed. If so, not
using the trim angle adjustment bolt may be advantageous to acceleration and
planing. A water test is required to determine if these characteristics apply to a par-
ticular boat/motor combination.
a 58450
a - Trim Angle Adjustment Bolt
Striker Plate Replacement

Visually inspect striker plates and replace if worn excessively.
c
b
aa
27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut. Torque to 80 lb. in. (9 Nm)
90-884294 OCTOBER 2001 Page 5B-9

Anode Plate
Anode plate is a self-sacrificing alloy plate that is consumed gradually by corrosion while
providing protection to the midsection and power trim from galvanic corrosion. Replace
anode plate when it is 50% consumed.
a 58445
a - Anode Plate
IMPORTANT: Do not paint or place protective coating on anode plate, or corrosion

protection function will be lost.
Trim Indicator Gauge
A Trim Indicator Gauge accessory kit is available for the power trim sender (if not pre-
viously installed).
Check, Fill and Purge - Power Trim System
TO CHECK:
CAUTION
Tilt outboard to full “Up” position and engage tilt lock lever before checking fluid
level. System is pressurized. Extend trim and tilt rams fully to depressurize sys-
tem.
Remove fill plug and O-ring. System is full when oil level is present at filler hole. Tighten
fill plug securely.
NOTE: Automatic Transmission Fluid (ATF) Type F, FA, Dexron II or Dexron III may be
used.
58451
a - Tilt Lock Lever
Page 5B-10 90-884294 OCTOBER 2001

TO FILL:
IMPORTANT: This trim system is pressurized. Remove “Fill” plug only when out-
board is tilted to the full “Up” position or the trim/tilt rams are fully extended. Re-
tighten “Fill” plug before tilting outboard down or retracting tilt/trim rams. Remove
“Fill” plug and O-ring. System is full when oil level is present at fill hole. Tighten
“Fill” plug securely.
aa b
58612
a - Fill Plug and O-ring (remove to fill system, tighten securely)
b - Fill system with Power Trim and Steering Fluid
c - Tilt Lock Lever (engage to support engine in “Up” position)
TO PURGE:
IMPORTANT: Fill plug and O-ring must be tightened securely before purging system.
IMPORTANT: Run Trim System in short “jogs” until pump is primed and trim system
moves. If trim motor is run without priming pump, driveshaft failure could result.
Cycle outboard through entire trim/tilt range 4 times. Check fluid level after purging system.
Push down on outboard when trim rams are slightly extended. If rams retract more than
1/8 in. (3.2 mm), air is present in system. Cycle system again and check fluid level.
90-884294 OCTOBER 2001 Page 5B-11

Trim Circuit
When the up button is activated the electric motor (1) will rotate the oil pump gears (2).
As the oil pump gears begin to rotate, oil is drawn through the up circuit suction check
valve (3) and into the pump, supplying flow for the up circuit. Oil under pressure opens
the up circuit pressure operated valve (8), allowing oil enter the up pressure passages
inside the manifold casting. The oil continues on through the up passages into the bottom
of the cylinders below the pistons, pushing the trim (9) and tilt (10) rams up and out. Oil,
from the pump, is blocked from returning into the reservoir by the closed down suction
check valve (4). Oil, under pressure slides the shuttle spool (5) to the left, against the down
circuit pressure operated valve (6). The shuttle spool will mechanically open the down
pressure operated valve, allowing oil to return into the pump from top of the tilt cylinder
(7). Oil returning from the top side of the tilt cylinder piston flows through an interconnect-
ing passage on the side of the tilt cylinder, through the lower pivot pin (12), past the open
down pressure operated valve, and into the pump, supplying some of the oil required for
the up circuit. Oil returns into the reservoir (11), from the trim rams, through passages cast
inside of the manifold.
Up pressure varies from 850 psi to 1150 psi unloaded to approximately 3000 psi against
full engine thrust.
Page 5B-12 90-884294 OCTOBER 2001

Trim Circuit
b
11
1
3 2
4
11
Ä ÄÄ
ÁÄÁÄÄÁ
Á ÁÁ
10 5 8
6
12
a - High Pressure
b - Low Pressure
1 - Electric Motor
2 - Oil Pump/Gears
3 - Up Circuit Suction
Check Valve
4 - Down Circuit Suction
Check Valve
5 - Shuttle Spool
6 - Down Circuit Pressure
Operated Valve
7 - Tilt Cylinder
8 - Up Circuit Pressure
Operated Valve
9 - Trim Cylinders
10 - Tilt Cylinder Piston
11 - Reservoir
12 - Lower Pivot Pin
90-884294 OCTOBER 2001 Page 5B-13

Tilt Circuit
In the up mode, as the trim rams (1) reach the limit of their travel, the mechanical check
valve (2) of the trim relief valve, in the port trim ram piston (3), contacts the cylinder cap.
The “pin” contact with the cover mechanically opens the shut off valve, allowing the trim
relief valve to bypass oil and perform the following functions.
• Trim Limit
While the engine is running under thrust (at high engine RPM), the high pressure devel-
ops below the pistons. The high pressure will open the check ball on the bottom of the trim
relief valve (850-1150 psi), allowing oil to flow through the port trim ram piston. If the oper-
ator continues to depress the “up” button, the up pressure will not be sufficient to over-
come the propeller thrust, so the trim range is limited to the length of the trim rams. When
the engine thrust falls (low engine rpms), the check ball in the trim relief valve closes, al-
lowing oil flow to extend the tilt cylinder ram into the tilt range.
• Over Trim At High Thrust
As the operator increases the engine rpms when the engine is raised beyond the trim
range, the pressure below the pistons begin to rise. When the pressure is sufficient, the
high pressure will open the check ball on the bottom of the trim relief valve (850-1150 psi),
allowing oil to flow through the port trim ram piston. Oil will continue to flow through the
valve until either the engine contacts the trim rams and the mechanical shut off valve
closes or the engine rpm’s are reduced.
• Maximum Up Pressure Reduction
As the tilt ram extends to its limit, the up pressure below the pistons will increase and open
the trim relief check valve to relief the up pressure. If the up button is not released, the
up flow will continue to dump over relief causing the electric motor to heat up. The thermal
overload switch inside the motor will open, stopping the motor.
Page 5B-14 90-884294 OCTOBER 2001

Tilt Circuit
4
3
6 5
ÄÄ ÄÄ
Á ÁÁ ÁÁ
2 ÁÁ
a - High Pressure
b - Low Pressure
1 - Trim Cylinders
2 - Trim Relief Valve
3 - Port Trim ram
4 - Tilt Cylinder
5 - Pump/Gears
Check Valve
7 - Electric Motor
90-884294 OCTOBER 2001 Page 5B-15

Down Circuit
When you depress the down button, the power trim pump (1) is activated in the opposite
direction. As the oil pump gears begin to rotate, oil is drawn through the down circuit suc-
tion check valve (2) and into the pump, suppling flow for the down circuit. Down circuit oil
pressure is lowered by the down pressure regulating valve (3) (640 psi to 1050 psi) allow-
ing excess oil to return into the reservoir (4). Oil is blocked from returning into the reservoir
by the closed up circuit suction check valve (5). Oil under pressure then moves the shuttle
spool (6) to the right, mechanically opening the “up” pressure operated valve (7), allowing
oil from the bottom of the trim (8) and tilt cylinders (9) to supply oil to the trim pump for the
down circuit. At this same time, oil under pressure opens the down circuit pressure oper-
ated valve (10) allowing oil to exit through the down pressure port. The oil then continues
through the down pressure passage, through the pivot pin (11), and into the interconnect-
ing passage of the tilt cylinder leading to the cavity above the shock piston (12), and
pushes the piston and ram assembly in (down). As the outboard engine contacts the ex-
tended trim rams (13), the weight of the motor, propeller thrust and pump down pressure
will force the trim rams to retract.
Page 5B-16 90-884294 OCTOBER 2001

Down Circuit
a
b
4
3 1 2
4
ÄÄ
Á ÄÄ
ÁÄÄÁ
ÄÄ
13 13
5 Á Á
7 10
6
12
8
8
11
a - High Pressure
b - Low Pressure
1 - Pump/Gears
2 - Down Circuit Suction
Check Valve
3 - Down Pressure Regu-
lating valve
4 - Reservoir
Check Valve
6 - Shuttle Spool
Operated Valve
8 - Trim Cylinders
9 - Tilt Cylinder
Operated Valve
11 - Pivot Pin
12 - Shock Piston
13 - Trim Ram
90-884294 OCTOBER 2001 Page 5B-17

Trail Over System

Should the outboard motor strike a submerged object with light steady pressure, while in
forward motion, oil will build up sufficient pressure in the top of the tilt cylinder (4) to open
the piston trail over relief valve (7) (600 psi). Oil on the bottom side of the cylinder is locked
in by the up circuit pressure operated valve (1) and manual tilt valve (3). Therefore, the
piston trail over relief valve allows the oil from the down side cavity of the trim cylinder to
pass through the piston trail over relief valve, into the area between the tilt ram piston (5)
and the memory piston (6). The return valve (8) allows the oil to return through the piston,
back to the down side cavity as the outboard returns to its normal running position. Propel-
ler thrust and the weight of the outboard provides the return motion for the engine.
Shock System
When a submerged object is hit with great force, oil will build up sufficient pressure in the
top of the tilt cylinder (4) to open both the trail over valve and the piston impact relief valves
(7) (3200 psi). Oil on the bottom side of the cylinder is locked in by the up circuit pressure
operated valve (1) and manual tilt valve (3). Therefore, the piston impact relief valve al-
lows the oil from the down side cavity of the trim cylinder to pass through the piston impact
relief valve, into the area between the tilt ram piston (5) and the memory piston (6). The
return valve (8) allows the oil to return through the piston, back to the down side cavity
as the outboard returns to its normal running position. Propeller thrust and the weight of
the outboard provides the return motion for the engine.
Page 5B-18 90-884294 OCTOBER 2001

Trail Over and Shock Absorber
2 1
ÄÄ ÄÄ
Á ÁÁ Á
ÁÁ Á
7
8
6
3
a - High Pressure
Operated Valve
Operated Valve
3 - Manual Tilt Valve
4 - Tilt Cylinder
5 - Shock Piston
6 - Memory Piston
7 - Impact Relief & Trail
over Valves
8 - Return Valve
90-884294 OCTOBER 2001 Page 5B-19

Manual Tilt System

If the outboard motor is to be raised or lowered manually, turn the manual release (tilt)
valve (1) counterclockwise approximately 3 turns to the full out position. When in the full
(out) position, oil in the tilt cylinder (2) can flow freely from the up side to the down side
or from the down side to the up side. The oil return line into the reservoir (3) is also open,
allowing free oil flow to either side of the tilt cylinder to accommodate the differential oil
capacities between the tilt cylinder up side and down side cavities.
When trimming the outboard in either the up or down position, with the manual tilt valve
open or leaking, little or no movement will occur. Oil pressure from the pump (4) will move
to both, the up cavity and through the manual tilt valve into the down cavity, each cavity
would have equal pressure resulting in little or no movement.
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or
throttling back rapidly, oil in the trim system must be locked in a static position. This is ac-
complished by closing the:
• up (5) pressure operated valve
• down (6) pressure operated valves
• trim relief valve (7)
• trail over valve (8)
• impact relief valves (8)
• manual release valve (1)
Thus, not allowing oil in the system to move in either direction.
Page 5B-20 90-884294 OCTOBER 2001

Manual Tilt
4
3
ÄÄ ÄÄ
Á ÁÁ ÁÁ
ÁÁ
6 5
8
a - Low Pressure
1 - Manual Release Valve
2 - Tilt Cylinder
3 - Reservoir
4 - Pump
5 - Up Pressure Operated
Valve
6 - Down Pressure Oper-
ated Valve
7 - Trim Relief Valve
8 - Impact Relief Valves
90-884294 OCTOBER 2001 Page 5B-21

Troubleshooting
IMPORTANT: Determine if Electrical or Hydraulic problem exists.
IMPORTANT: Acceptable power trim leak down should not exceed 1 in. (25.4 mm)
(when measured at the tilt ram) in a 24 hour period.
HYDRAULIC SYSTEM TROUBLESHOOTING
CONDITION OF TRIM SYSTEM PROBLEM

A. Trim motor runs; trim system does not move up or down. 1, 5, 10, 11
B. Does not trim full down. Up trim OK. 3, 4, 5
C. Does not trim full up. Down trim OK. 1, 5
D. Partial or “Jerky” down/up. 1, 3
E. “Thump” noise when shifting. 3
F. Does not trim under load. 5, 8, 9
G. Does not hold trim position under load. 5, 6, 7
H. Trail out when backing off from high speed. 3, 4
I. Leaks down and does not hold trim. 5, 6, 7
J. Trim motor working hard and trims slow up and down. 8, 9
K. Trims up very slow. 1, 2, 5, 6, 8, 9
L. Starts to trim up from full down position when “IN” trim button is depressed. 3, 4
M. Trim position will not hold in reverse. 3, 4
PROBLEM
1. Low oil level.
2. Pump assembly faulty.
3. Tilt ram piston ball not seated (displaced, dirt).
4. Tilt ram piston O-ring leaking or cut.
5. Manual release valve leaking (check condition of O-rings) (Valve not fully closed).
6. Lower check valve not seating in port side trim ram.
7. Upper check valve not seating in port side trim ram.
8. Check condition of battery.
9. Replace motor assembly.
10. Broken motor/pump drive shaft.
1 2
Á
11. Air pocket under pump.
10
ÄÄ Á
ÁÄ
ÁÁÁÁ Á
3
7 4
External Mounted Hydraulic

5
System 6
Page 5B-22 90-884294 OCTOBER 2001

ELECTRICAL SYSTEM TROUBLESHOOTING
CONDITION OF TRIM SYSTEM PROBLEM

A. Trim motor does not run when trim button is depressed. 1, 2, 4, 5, 6, 7, 8
B. Trim system trims opposite of buttons. 3
C. Cowl mounted trim buttons do not activate trim system. 2, 4, 5, 6, 7
PROBLEM
1. Battery low or discharged.
2. Open circuit in trim wiring.
3. Wiring reversed in remote control, cowl switch or trim leads.
4. Wire harness corroded through.
5. Internal motor problem (brushes, shorted armature).
6. Blown fuse(s).
7. Trim switch failure.
8. Verify relays are functioning correctly.
POWER TRIM RELAY TEST PROCEDURE

The trim motor relay system used on permanent magnet trim systems connect each of
the two wires from the trim motor to either ground or positive in order to allow the motor
to run in both directions.
If the motor will not run in the UP direction, it could be either the UP relay is not making
contact to 12 volts OR the DOWN relay is not making contact to ground. The opposite is
true if the system will not run DOWN. When the system is not energized, both relays
should connect the heavy motor leads to ground.
To test which relay is faulty if the trim system does not operate in one direction:
1. Disconnect the heavy gauge pump wires from the trim control relay.
2. Check for continuity between the heavy leads from the trim relays to ground.
Ohmmeter Resistance Scale Reading*

Leads Between (Ohms) (x____________)
GREEN and Ground 0 Full Continuity (Rx1)
BLUE and Ground 0 Full Continuity (Rx1)
Replace the relay that does not have continuity.

3. Connect a voltmeter to the heavy BLUE lead and to ground. You should have 12 volts
on the BLUE lead when the UP switch is pushed. You should should also have 12 volts
on the GREEN lead when the DOWN switch is pushed. Replace the relay that does
not switch the lead to positive.
90-884294 OCTOBER 2001 Page 5B-23

Power Trim System with Relays and 2 Wire Trim Motor
7
4
3
9
8 6
53794
UP Relay DOWN Relay
BLK = Black
BLU = Blue
10 GRN = Green
RED = Red
WHT = White
Page 5B-24 90-884294 OCTOBER 2001

Electrical System Troubleshooting

General Checks
Before troubleshooting the Power Trim electrical system, check the following:
1. Check for disconnected wires.
2. Make certain all connections are tight and corrosion free.
3. Check that plug-in connectors are fully engaged.
4. Make certain battery is fully charged.
Refer to the preceding four wiring diagrams for connection points when troubleshooting
the electrical systems (Connection points are specified by number.)
Troubleshooting the “Down Circuit”

Connect Voltmeter red lead to
Point 1 and black lead to ground.
Depress the “Down” trim button.
No Voltage Indicated:
Battery Voltage Indicated: Connect Voltmeter red lead to
Connect Voltmeter red lead to Point 4 and black lead to ground.
Point 3. Depress “Down” trim button. If
battery voltage is indicated, wire
is open between Points 4 and 1.
Battery Voltage Indicated: No Voltage Indicated:

•Connect Voltmeter red lead to There is an open circuit be-
Point 2. tween Point 3 and positive (+)
•Depress “Down” trim button. battery terminal.
•Check for loose or corroded
connections.
•Check wires for open.
Battery Voltage Indicated:

•Test UP relay.
Refer to page 5B-13 for relay No Voltage Indicated:
test procedure. Relay Switch is defective.
Relay good: Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
•Pump motor wiring is defec-
cated, trim switch is faulty. If no
tive.
battery voltage, check for loose
•Pump motor is defective. or corroded connection at Point
5 or open circuit in wire supply-
ing current to Point 5.
90-884294 OCTOBER 2001 Page 5B-25

Troubleshooting the “Up” Circuit
Connect Voltmeter red lead to

Point 8 and black lead to ground.
Depress the “Up” trim button.
Battery Voltage Indicated: Connect Voltmeter red lead to
Connect Voltmeter red lead to Point 7 and black lead to ground.
Point 9. Depress “Up” trim button. If bat-
tery voltage is indicated, wire is
open between Points 7 and 8.
Battery Voltage Indicated: No Voltage Indicated:

•Connect Voltmeter red lead to There is an open circuit be-
Point 6. tween Point 9 and positive (+)
•Depress “Up” trim button. battery terminal.
connections.
•Check wires for open.

•Test DOWN relay.
Refer to page 5B-13 for relay
test procedure. No Voltage Indicated:
Relay Switch is defective.
Relay good: No Voltage Indicated:

•Pump motor wiring is defec-
tive. Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
•Pump motor is defective. cated, trim switch is faulty. If no
battery voltage, check for loose
or corroded connection at Point
5 or open circuit in wire supply-
ing current to Point 5.
Page 5B-26 90-884294 OCTOBER 2001

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. Battery voltage should
•Replace fuse.
be indicated.

No Voltage Indicated: •Connect Voltmeter red lead to
Point 8 and black lead to
•Check battery leads for poor ground.
connections or open circuits. •Depress “Up” trim button and
check for battery voltage.
•Check battery charge.
No Voltage Indicated: Battery Voltage Indicated:

Connect red Voltmeter lead to •Check black ground wires for
Point 5, and black lead to poor connection or poor
ground. ground, Point 10.
•Pump motor is faulty. Refer to
“Motor and Electrical Tests/
Repair”, following.

Trim switch is faulty or there is an
Check that voltage is being open circuit in wires (green-white,
supplied to control by performing blue-white) between trim buttons
the following checks: and trim pump.
•DO NOT start engine. •Check trim switch.
•Turn ignition switch to “Run” •Check all trim harness con-
position. nectors for loose or corroded
•Check for voltage at any instru- connections.
ment, using a Voltmeter. •Check for pinched or severed
wires.
Red wire is open between Point Battery Voltage Indicated:
3 and red terminal on back of
the ignition switch. There is an open circuit in wire
between Point 5 and Red ter-
minal on the back of the ignition
connections.
switch.
•Check for open in wire.
90-884294 OCTOBER 2001 Page 5B-27

Power Trim Assembly Removal and Installation

Removal
1. Remove clamps on transom bracket to free power trim wiring.
2. Raise outboard to full “Up” position and engage tilt lock lever.
3. Remove trim indicator.
ba
58448 50605
a - Clamps
b - Tilt Lock Lever
WARNING
Failure to support outboard as shown could result in personal injury and/or dam-
age to outboard or boat.
c
c
b
c 58447
a - Tilt Lock Lever

b - Support Tool
c - Retaining Clips
Page 5B-28 90-884294 OCTOBER 2001

IMPORTANT: Support outboard as shown above to prevent engine from tipping

when power trim retaining pin is removed.
SUPPORT TOOL
3/8 in. diameter metal rod (a used shift shaft works well)
14”
aa a
2”
1/4”
a - Drill holes for retaining clips
METRIC CONVERSION
14 in. = 35.56 cm. 2 in. = 50.8 mm
3/8 in. = 9.5 mm. 1/4 in. = 6.35 mm.
CAUTION
Disconnect battery cables at battery before removing power trim wires from sole-
noids.
4. Disconnect (BLUE and GREEN) bullet connector harness.

5. Open filler cap and release any remaining pressure in the system.
IMPORTANT: Outboards equipped with through-the-tilt-tube steering - remove
steering link arm from end of steering cable and cable retaining nut from tilt tube.
58444 58454
a - Filler Cap
b - Retaining Nut
90-884294 OCTOBER 2001 Page 5B-29

IMPORTANT: Cross pin should not be reused. Replace with new cross pin.
NOTE: 6 trim mounting bolts should not be reused. Replace with new patch lock bolts.
6. Drive out cross pin, push out upper swivel pin, and remove 3 bolts and washers in port
clamp bracket.
bb
aa
58444
58452
a - Cross Pin
b - Upper Swivel Pin
c - Port Transom Bracket Bolts and Washers (3). Remove to release Trim
System from Outboard.
7. Remove 3 bolts and washers and in starboard transom bracket.
c d
a
58453
a - Transom Mount Bolts (2)
b - Tilt Tube Nut (flush with end of thread)
c - Screws (3)
d - Washers (3)
8. Remove outboard transom mounting bolts and loosen tilt tube nut until nut is flush with
end of tilt tube thread. Remove system from outboard.
Page 5B-30 90-884294 OCTOBER 2001

Installation
NOTE: Upper swivel pin bushings in swivel bracket should be inspected for wear and re-
placed as required. The trim rod shoes in the swivel bracket should also be replaced.
1. Paint any exposed metal surfaces to prevent corrosion.
2. Install trim system, starboard transom bracket, and tilt tube nut.
3. Use a 12 volt power source to extend tilt ram up to align upper swivel shaft hole and
end of ram. Connect trim motor wires [BLUE wire to POSITIVE (+), GREEN wire to
NEGATIVE (–)]. If ram extends too far, retract ram by connecting GREEN wire to POS-
ITIVE (+) and BLUE wire to NEGATIVE (–).
4. Install Upper Swivel Pin with slotted end to left (port) side of engine.
e
b
da
fc
a b
58453
a - Screw (6) Torque to 45 lb. ft. (61.0 N·m)
b - Flat washer (6) Install one per screw
c - Tilt Tube Nut
d - Upper Swivel Pin
e - Slotted end
f - Cross hole (in line with slotted end)
IMPORTANT: Cross pin should not be reused. Install a new pin.

5. Position slot on end of swivel shaft in line with hole in tilt ram end. Insert a punch into
tilt ram hole to align cross hole in upper swivel shaft. Tap new cross pin in until flush.
aa
c b
a - Upper Swivel Shaft (Slot is in line with cross hole)

b - Chamfered End of Hole (Faces away from transom)
c - Retaining Pin
d - Tilt Ram End
90-884294 OCTOBER 2001 Page 5B-31

6. Connect trim motor wires to relays. Refer to Wiring Diagrams in this manual. Route
trim wires as specified in this manual.
NOTE: The 2 power leads going to the trim motor should be encapsulated with conduit
tubing.
56921 56922
a - Conduit Tubing
7. Apply marine sealer to shanks of mount bolts and install transom mount bolts.
IMPORTANT: Do not use an impact driver to tighten transom mount bolts.
Apply marine sealer to threads of mount bolts. Secure with flat washers and locknuts. Be
sure installation is watertight.
8. Tighten tilt tube nut securely.
IMPORTANT: Outboards equipped with through-the-tilt-tube steering: Tighten
steering cable retaining nut securely to tilt tube.
58454
a - Steering Cable Retaining Nut
WARNING
Electrical wires passing through cowl openings must be protected from chafing
or being cut. Follow the recommended procedures outlined in Section 1D of this
Manual. Failure to protect wires as described could result in electrical system fail-
ure and/or injury to occupants of boat.
Page 5B-32 90-884294 OCTOBER 2001

Testing Power Trim System With Test Gauge Kit (91-52915A6)

IMPORTANT: This test will not locate problems in the trim system. The test will
show if the system is correct after a repair. If minimum pressures are not obtain-
able, the trim system requires additional repair.
“UP” Pressure Check
IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full “Up” position and engage tilt lock lever.
2. Slowly remove “Fill” plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim
assembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring
onto adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting
into test adaptor securely using teflon tape on threads.
gg
ee d c
c bb
ff aa 54457
a - Test Adaptor (91-822778A2)

b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
f - Brass Fitting
g - Apply Teflon Tape
4. Install Test Adaptor 91-822778A2 into manual release valve hole.
54458
90-884294 OCTOBER 2001 Page 5B-33

5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
ee
aa
d
b
cc
54459
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
6. Reinstall fill plug.

7. Run trim “UP”.
8. Disengage tilt lock lever.
Page 5B-34 90-884294 OCTOBER 2001

CAUTION
Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could
result in transom bracket failure and possible injury.
9. Move outboard “IN” until hole in swivel bracket “ear” aligns with the 3rd tilt hole in tran-
som bracket. Lock engine in trim range by installing a 3/8 in. (9.5 mm) diameter tilt pin
or two 3/8 in. (9.5 mm) hardened bolts and nuts thru the transom brackets and swivel
bracket in the hole shown.
a 54460
a - Tilt Pin Hole (Install Spare Tilt Pin or Hardened Bolts and Nuts)
10. Open valve (a) and close valve (b).
a bb
51374
11. Run trim “UP”. The minimum pressure should be 2000 P.S.I. (140.6 kg/cm2).
12. Run trim “DOWN” to release pressure and remove spare tilt pin or bolts and nuts.
13. Tilt outboard full “UP” and engage tilt lock lever.
14. Slowly remove “Fill” plug to bleed pressure.
15. Remove test gauge hose and adapter.
16. Reinstall Manual Release Valve and secure valve with circlip.
17. Retighten “Fill” plug.
NOTE: If pressure is less than 2000 PSI (140.6 kg/cm 2), troubleshoot system per instruc-
tions on page 5B-22.
90-884294 OCTOBER 2001 Page 5B-35

“DOWN” Pressure Check

IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full “Up” position and engage tilt lock lever.
2. Slowly remove “Fill” plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim
assembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring
onto adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting
into test adaptor securely using teflon tape on threads.
g
a 54457
f e d c b
b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
f - Brass Fitting
g - Apply Teflon Tape
4. Install test adaptor 91-822778A3 into manual release valve hole.
54458
Page 5B-36 90-884294 OCTOBER 2001

5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
ee
aa dd
gg
bb
c ff 54459
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
f - OPEN Valve
g - CLOSE Valve
6. Reinstall fill plug.

7. Run trim “UP”.
8. Disengage tilt lock lever.
9. Open valve (f) and close valve (g).
10. Run trim “DOWN”. Minimum pressure should be 600 P.S.I. (42 kg/cm2).
11. Tilt outboard full “UP” and engage tilt lock lever.
12. Slowly remove “Fill” plug to bleed pressure.
13. Remove test gauge hose and adaptor.
14. Reinstall manual release valve and secure valve with circlip.
15. Retighten “Fill” plug.
NOTE: If pressure is less than 600 PSI (42 kg/cm 2), troubleshoot system per instructions
on Page 5B-22.
90-884294 OCTOBER 2001 Page 5B-37

Hydraulic Repair
TRIM ROD REMOVAL AND REPAIR
NOTE: Power Trim does not have to be removed from outboard to remove trim rods.
1. Tilt outboard to full “UP” position and engage tilt lock lever.
2. Slowly remove “Fill” plug to bleed reservoir pressure.
3. Turn Manual Release Valve 3 to 4 turns (counterclockwise) to bleed remaining pres-
sure.
4. Remove trim rod cylinder caps.
NOTE: Place a clean pan under trim system to catch fluid.
db
a
ca
51337
58450
a - Trim Rod Cylinder Cap
b - Turn Counterclockwise to Remove
c - Removal Tool (91-44487A1)
d - Spanner Wrench (91-74951)
5. Install trim rod removal tool and pull trim rod from cylinder.
aa
27933
a - Trim Rod Removal Tool (91-44486A1)
Page 5B-38 90-884294 OCTOBER 2001

CLEANING AND INSPECTION - TRIM RODS AND CAPS
CAUTION
Do not remove check valve. Check valve is preset to operate at a specific pres-
sure. Removal and installation of check valve could result in improper operating
pressure and possible system damage.
NOTE: Check valve is in port side trim rod only.
NOTE: Certain models may have trim limit reducers installed on the trim rod to limit trim
out angle. Each reducer limits the amount of total trim by 2°. A maximum of 5 reducers
may be installed on each trim rod.
1. Inspect check valve and check valve screen for debris; if debris cannot be removed,
replace trim rod assembly. Clean trim rod with parts cleaner and dry with compressed
air.
aa
51352 c
bb 57886
a - Check Valve
b - Check Valve Screen
c - Trim Limit Reducers
Trim Rod End Cap Seal

1. Inspect trim cap end seal and replace if damaged or if seal does not keep trim rod
clean.
2. Inspect trim cap internal o-ring and replace if damaged or worn.
3. Inspect inner surface of the cap and if worn, replace trim cap.
aa
51343
a - Seal (remove as shown)
4. Install new seal with seal lip up.
90-884294 OCTOBER 2001 Page 5B-39

TRIM ROD INSTALLATION

IMPORTANT: Components must be free of dirt and lint. Any debris in the system
can cause system to malfunction.
NOTE: Install trim rod with check valve in the port (left) cylinder.
1. Apply ATF Dexron III or Power Trim and Steering Fluid on all O-rings and seals before
installation.
2. Install trim rods and caps. Use installation tool (91-44487A1) or spanner wrench
(91-74951) to tighten caps securely – 70 lb. ft. (95 N m ).
a
a
58450
a - Trim Rods
b - Cylinder End Caps
c - Rod End Rollers (lubricate with Anti-Corrosion Grease or
Special Lubricant 101)
Page 5B-40 90-884294 OCTOBER 2001

Tilt Ram
REMOVAL - TILT ROD ASSEMBLY ONLY
NOTE: Tilt Rod Assembly can be removed from cylinder without removing entire power
trim system from outboard.
TILT RAM COMPONENTS
5
1
6
7
13
2 8
3
9
4
10
11
3
12
1 - Tilt Cylinder Rod 9 - Shock Springs – (1 is

2 - Scraper Seal RED for low speed trail
3 - O-ring* over)
4 - Cylinder Cap 10 - Washer
5 - Return Ball 11 - Nut
6 - Shock Piston 12 - Memory Piston
7 - Shock Balls 13 - Housing
8 - Spring Keepers – (1 is
RED)
*O-ring Repair Kit Available, 811607A1 (Includes item 2, Scraper Seal)
90-884294 OCTOBER 2001 Page 5B-41

TILT RAM REMOVAL - POWER TRIM SYSTEM REMOVED FROM OUTBOARD
CAUTION
Insure trim system is depressurized prior to tilt ram removal.
1. Remove cross pin.
2. Remove lower swivel pin.
ba
51355
aa
51366
a - Cross Pin (Remove as shown)
b - Lower Swivel Pin (Remove as shown)
Disassembly
1. Secure tilt ram in a soft jawed vise. Remove tilt rod and cap.
91-74951
cc
aa
51337
bb
51364
a - Cap (Turn Counterclockwise to Remove)
b - Spanner Wrench (91-74951)
c - Tilt Rod - Pull to Remove
Page 5B-42 90-884294 OCTOBER 2001

2. Clamp tilt rod in a soft jawed vise. Remove bolt or nut as applicable to disassemble
rod assembly. Remove O-ring.
aa
b
51378
51340
a - Stud/Nut
b - O-Ring
IMPORTANT: Design 1 tilt rod assembly can be used to replace a Design 2 tilt rod
assembly. Design 1 or Design 2 cylinder assemblies (complete) can be used as re-
placements.
Design 2 will NOT fit a cylinder originally using a Design 1 tilt rod assembly.
Memory Pistons for Design 1 and 2 differ also and must be used only on the cylin-
der the piston was removed from.
3. Remove washer, check valve assemblies, and piston.
NOTE: Check valve held in by roll pin can be cleaned but not removed.
aa
bb
cc
51363
a - Washer
b - Check Valve Assembly (7)
c - Piston
90-884294 OCTOBER 2001 Page 5B-43

4. Remove end cap from tilt rod.
aa
51376
a - End Cap
Memory Piston Removal

1. Remove memory piston from cylinder using Snap-On lock ring pliers SRP-4 or similar
tool.
2. Remove o-ring from memory piston.
SRP-4 (Snap-On)
51144
a - Memory Piston
b - O-Ring
c - Snap-On Pliers SRP-4
Page 5B-44 90-884294 OCTOBER 2001

Cleaning/Inspection/Repair
1. Inspect all internal parts for damage or wear. Clean and replace parts as necessary.
2. Inspect tilt rod for scratches. Replace scraper seal in rod end cap if tilt rod is scratched
or worn.
3. Slight scratches or tool marks less than 0.005 in. (0.1 mm) deep in cylinder are accept-
able.
IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in
Power Trim system could cause system to malfunction.
4. Clean shock rod and components with parts cleaner and dry with compressed air.
5. It is recommended that all O-rings in trim system be replaced.
6. Lubricate all O-rings with Power Trim Fluid. If not available, use automotive (ATF) au-
tomatic transmission fluid.
Scraper Seal Replacement

1. Remove components from end cap.
bb
aa
cc
b
a - Cap
b - O-ring (2)
c - Scraper Seal
90-884294 OCTOBER 2001 Page 5B-45

REASSEMBLY
IMPORTANT: Components must be clean for reassembly. Any debris in the system
can cause the system to malfunction.
NOTE: Refer to “Tilt Ram Components” for proper O-ring sizes.
1. Apply ATF Dexron III or Power Trim and Steering Fluid on O-rings prior to reassembly.
2. Install O-ring on Memory Piston Cup and install in cylinder.
3. Inspect and replace as required 3 O-rings in the bottom of the tilt cylinder.
4. Inspect and replace as required 3 pivot pin O-rings in the manifold.
a
b 58462
a - O-ring
b - Memory Piston Cup
5. Assemble end cap.

6. Install end cap.
d
bb
aa
51376
cc
b
b
a - End Cap
b - O-ring (2)
c - Scraper seal
d - End Cap
Page 5B-46 90-884294 OCTOBER 2001

7. Install components on rod.

e dd
cc
bb
a
cc
51363
51340
a - Piston
b - O-ring
c - Check Valve Assembly (7)
d - Washer
e - Locknut [Torque to 95 lb. ft. (129 N m)]
8. Clamp cylinder in a soft jawed vise and install tilt rod assembly. Use spanner wrench
and tighten end cap securely. Torque end cap to 45 lb. ft. (61 N m).
cc
91-74951
bb
51337
aa
51341
a - Cylinder
b - Tilt Rod Assembly
c - End Cap (Tighten Securely.) Use Spanner Wrench.
90-884294 OCTOBER 2001 Page 5B-47

TILT RAM ASSEMBLY INSTALLATION

1. Lubricate alignment tool (91-11230) and shaft. Use ATF Dexron III or Power Trim and
Steering Fluid.
b
a
a - Alignment Tool (91-11230)
b - Shaft
2. Align tilt ram and housing using alignment tool.

3. Install shaft.
a d
ba
51348 c
58603
a - Alignment Tool (91-11230) c - Groove
b - Shaft d - Hole [Groove (c) will Align with this
Hole]
4. Drive pin in until flush.
aa
51356
a - Pin (Drive Against Knurled End)
Page 5B-48 90-884294 OCTOBER 2001

Power Trim Disassembly

IMPORTANT: Power trim is pressurized. Trim rams must be in the full up position
(fully extended) prior to fill/drain plug or manual release valve removal.
1. Remove reservoir cap to drain oil.
2. Remove manual release valve to drain any remaining oil.
58604
a - Reservoir Cap
b - Manual Release Valve
3. Remove 4 screws securing reservoir cover and remove cover.
a a
58606
a - Screws (4)
b - Reservoir Cover
90-884294 OCTOBER 2001 Page 5B-49

4. Inspect reservoir cover O-ring for cuts or abraisions. Replace O-ring as required.
58605
a - O-Ring
Trim Motor Removal

1. Secure power trim assembly in a soft jaw vise.
2. Remove 2 screws securing motor and remove motor. Remove motor O-ring (yellow)
and coupler.
3. Inspect O-ring for cuts and abraisions. Replace O-ring as required.
58611 58610
a - Screws and Washers
b - O-Ring (YELLOW)
Page 5B-50 90-884294 OCTOBER 2001

Pump and Component Removal

1. Remove 3 screws securing oil pump.
NOTE: There are no serviceable parts within the oil pump. Failure of or damage to internal
components of the pump requires pump assembly replacement.
2. Inspect filter/O-ring assemblies on bottom of oil pump. Replace as required.
a
58609 58608
a - Screws
b - Filter/O-ring Assemblies
3. Remove both plugs in manifold. Remove springs, poppet/check valves and seats
from both sides. Remove spool.
a
b c d
e d
c b a
58607
a - Plugs
b - Springs (2)
c - Poppet/Check Valves (2)
d - Seats (2)
e - Spool
90-884294 OCTOBER 2001 Page 5B-51

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is
found on poppet, replace poppet. Inspect o-rings on both seats and spool for cuts
or abraisions. Replace o-rings as required.
a
c
e
e
f a h
e e
e
d h a f
g
58607
a - Poppet Assembly
b - Debris on Rubber Seat
c - Neoprene Seat
d - Spool
e - O-Rings
f - Spring
g - Cap
h - Seat
Page 5B-52 90-884294 OCTOBER 2001

Motor and Electrical Tests/Repair

Trim Pump Motor Test
WARNING
Do not perform this test near flammable materials, as a spark may occur while
making electrical connections.
1. Connect a 12 volt power supply to motor wires; one motor lead to POSITIVE (+) bat-
tery terminal and the other motor lead to the NEGATIVE (–) battery terminal. Motor
should run. Reverse motor leads between battery terminals. Motor should run.
53774
2. If motor does not run, disassemble and check components.
Motor Disassembly
1. Remove 2 screws.
a a
53774
a - Screw (2)
90-884294 OCTOBER 2001 Page 5B-53

2. Remove frame and armature from end cap. Use care not to drop armature.
aa b
cc
53779
a - Can
b - Armature
c - End Cap
Armature Tests
TEST FOR SHORTS
Check armature on a Growler per the Growler manufacturer’s instructions. Replace ar-
mature if a short is indicated.
TEST FOR GROUND
1. Use an Ohmmeter (Rx1 scale). Connect one lead on armature shaft and other lead
on commutator. If continuity is indicated, armature is grounded. Replace armature.
53786
Page 5B-54 90-884294 OCTOBER 2001

CHECKING AND CLEANING COMMUTATOR

1. If commutator is worn, replace armature.
aa
53775
a - Commutator
FIELD TESTS
IMPORTANT: Commutator end of armature must be installed in brushes when per-
forming the following tests.
Ohmmeter Resistance Scale Reading*

Leads Between (Ohms) (x____________)
BLUE and GREEN Motor Wires 0 (Rx1)
GREEN Motor Wire, and Frame
No Continuity (Rx1)
(Motor Housing)
BLUE Motor Wire and Frame No Continuity (Rx1)
*If specified readings are not obtained, check for:

• defective armature
• dirty or worn brushes
• dirty or worn commutator
If defective components are found, repair or replace component(s) and retest.
Motor Repair
REMOVAL
NOTE: Power Trim System does not have to be removed from outboard to repair/replace
motor.
DISASSEMBLY
Trim outboard to the full “UP” position and engage tilt lock lever. Open reservoir plug to
relieve pressure, then retighten. Use a SNAP ON [ 5 mm (FABLM5)] ball end allen bolt
driver to remove the 2 motor mounting bolts.
Refer to “Motor Disassembly” on page 5B-53 to disassemble motor from pump.
90-884294 OCTOBER 2001 Page 5B-55


Inspect O-rings and replace if necessary. Carefully inspect power cord for cuts or tears
which will allow water to enter motor. If cord is cut or torn, replace motor and power cord
as an assembly. Clean, inspect, and test motor components. Refer to “Brush Replace-
ment”, “Armature Test”, and “Field Tests” for inspection and test procedures.
a bb ee
cc
dd
53779
a - Can
b - Armature
c - Shim
d - Motor End Frame Assembly
e - O-rings
BRUSH REPLACEMENT
If brushes are pitted, chipped, or if distance between the brush pigtail and end of brush
holder slot is 1/16 in. or less, complete motor end must be replaced (brushes are not avail-
able separately). Check brush distance with armature installed.
53784
a - 1/16 in.
Page 5B-56 90-884294 OCTOBER 2001

END CAP INSPECTION

1. Inspect seal and O-ring for cuts and abraisions.
2. Inspect bushing for wear. If bushing appears to be excessively worn – grooves,
scratches, etc. – replace END FRAME ASSEMBLY (COMPLETE).
aa
bb
53783 53785
a - Seal (Apply 2-4-C Marine Lubricant with Teflon to seal lips)
b - O-ring
c - Bushing
3. If trim motor is overheated, a thermoswitch located on the brush card will open. Nor-
mally, this switch will reset itself within 1 minute.
a
53781
a - Thermoswitch
90-884294 OCTOBER 2001 Page 5B-57

Reassembly
IMPORTANT: Components must be clean. Any debris in power trim system can
cause system to malfunction.
1. Install armature into end cap/brush card assembly.
aa
dd
bb
cc
53779 53784
a - Armature
b - Shim
c - End Cap Assembly
d - Armature (Spread brushes to install armature into end cap)
2. Install O-rings in end cap.
aa
aa
53783
53784
a - O-rings
Page 5B-58 90-884294 OCTOBER 2001

IMPORTANT: Attach Vise Grip pliers to armature shaft before installing frame as-
sembly. The Vise Grip pliers will prevent the armature from being drawn out of the
brush card assembly by the frame magnets while installing the frame assembly.
3. Install Vise Grip pliers on armature shaft.
4. Carefully install can over armature.
5. Position harness retainer hole over tab in end cap.
6. Secure frame assembly to end cap with 2 screws.
hh
i ee
ff ii
g
dd
cc
aa
53776
a - Vise Grip Pliers
b - Armature Shaft
c - O-ring
d - End Cap
e - Harness Retainer
f - Retainer Hole
g - O-ring
h - Can
i - Screws (Drive Tight)
90-884294 OCTOBER 2001 Page 5B-59

Reassembly - Motor and Pump

NOTE: Drive shaft is a loose part and may fall out of position.
1. Install pump into power trim manifold. Insure O-rings are in proper locations. Secure
with 3 screws. Torque screws to 60 lb. in. (7 N·m).
b
58609
a - Oil Pump
b - Screws (3) Torque to 60 lb. in. (7 N m)]
IMPORTANT: Install pump with location flat facing towards starboard transom
bracket.
2. Fill pump with ATF Dexron III or Power Trim and Steering Fluid prior to installing motor.
3. Install motor, secure with 2 screws. Torque screw to 80 lb. in. (9 N m). Route wiring;
refer to Wiring Diagrams in this service manual.
NOTE: Verify motor and drive shaft are aligned.
aa
58610 58611
a - Motor
b - O-ring
c - Screw (2) Torque to 80 lb. in. (9 N m).
Page 5B-60 90-884294 OCTOBER 2001

4. Reinstall reservoir cover. Verify cover O-ring is in place and in serviceable condition.
Secure cover with 4 screws. Torque screws to 60 lb. in. (7 Nm).
a
b
c c
58605 58606
a - O-Ring
b - Reservoir Cover
c - Screws [Torque to 60 lb. in. (7 Nm)]
5. Complete reassembly of Power Trim System as outlined in “Installation” on page

5B-31.
90-884294 OCTOBER 2001 Page 5B-61

Priming Power Trim System

1. Fill system with Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF)
Dexron III. Refer to “Fill, Check, and Purge” on page 5B-10.
IMPORTANT: Run Trim System in short “jogs” until pump motor primes and trim
system moves. If trim motor is run without priming pump, drive shaft failure could
result.
Analog Trim Sender Test

1. Check trim sender black lead for proper ground.
2. Trim outboard to full “DOWN” position.
3. Place ignition switch to “ON” position.
4. Disconnect BRN/WHT trim sender wire from trim sender harness.
5. Connect Ohmmeter (Rx1 scale) leads between outboard ground and Point 1 (trim
sender end).
6. Depress “UP” button. Ohmmeter needle should move as the outboard is trimmed up.
If needle does not move, trim sender is defective.
1
1
aa
22908
a - Trim sender
Page 5B-62 90-884294 OCTOBER 2001

Trim Indicator Gauge Needle Adjustment

1. Turn ignition key to “RUN” position.
2. Tilt outboard to full “IN” position. Needle of trim indicator gauge should be in full “IN”
position.
3. If not, tilt outboard to full “OUT” position to gain access to trim sender and engage tilt
lock lever.
4. Loosen trim sender screws and reposition trim sender.
5. Tighten trim sender screws.
cc d
aa
22744
a - Trim Sender
b - Screws, Loosen to Rotate Sender
c - Turn Sender Counterclockwise to raise needle reading
d - Turn Sender Clockwise to lower needle reading
e - Tilt lock lever
Digital Trim Sender

Digital trim senders used with Smartcraft gauges are not adjustable.
58451
a - Digital Trim Sender
90-884294 OCTOBER 2001 Page 5B-63

Troubleshooting Digital Trim Sender

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

RED BLUE 4 – 5 vdc
BLACK BLACK
NOTE: 5vdc reference voltage at the ECU can be monitored by the Digital Diagnostic Ter-
minal. Voltage should be 5 vdc ± 0.1 v. Any other voltage indicates a defective ECU. If ECU
reference voltage is correct, but voltage at trim sender is low or not existent, inspect send-
er wiring and connections.
Voltage at trim sender should rise and fall smoothly as outboard is raised or lowered. Volt-
age at the full UP position should be 4 vdc ± 0.5v. Voltage at the full DOWN position should
be 1.5 vdc ± 0.5 v. With the ignition switch in the RUN position and using an appropriate
probe (paper clip, etc.) inserted in parallel at the trim sender bullet connectors, this voltage
can be checked as follows:
Voltmeter Sender Harness FULL UP FULL DOWN

RED YELLOW 4 vdc ± 0.5v 1.5 vdc ± 0.5v
BLACK BLACK
If voltage is not as indicated or voltage rise and fall is erratic, trim sender is defective.
Page 5B-64 90-884294 OCTOBER 2001

Trim Indicator Wiring Diagrams

Wiring Diagram - For boats equipped with Quicksilver
Commander Series side mount remote control.
aa bb c
Wiring Diagram - For boats equipped with Quicksilver

Ignition/Choke and Main Harness Assembly. gg
aa ff c
22908
a - Trim Indicator
b - Remote Control
c - Trim Sender
d - Engine Ground
e - To Engine
f - Ignition Switch
g - Power Trim Harness
90-884294 OCTOBER 2001 Page 5B-65

RIGHT HAND NON-RATCHETING
LOWER UNIT
Section 6A – Right Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications (Standard Rotation) . 6A-1 Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Forward Gear Bearing Cup . . . . . . . . . . . . . . . . 6A-47
Gear Housing (Drive Shaft)(Standard Rotation) . . 6A-6 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-48
Gear Housing (Prop Shaft)(Standard Rotation) . . . 6A-8 Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-50
General Service Recommendations . . . . . . . . . . . 6A-10 Drive Shaft and Pinion Gear . . . . . . . . . . . . . . . 6A-51
Removal, Disassembly, Cleaning and Inspection Gear Location/Backlashes/Checking and
– Standard Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11 Drive Shaft - Bearing Preload Tool . . . . . . . . . . 6A-54
Draining and Inspecting Gear Housing Pinion Gear Location . . . . . . . . . . . . . . . . . . . . . 6A-55
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Bearing Carrier Assembly . . . . . . . . . . . . . . . . . 6A-58
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Forward Gear Backlash . . . . . . . . . . . . . . . . . . . 6A-60
Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . 6A-16 Reverse Gear Backlash . . . . . . . . . . . . . . . . . . . 6A-61
Bearing Carrier and Propeller Shaft Removal 6A-18 Drive Shaft - Bearing Preload Tool . . . . . . . . . . 6A-63
Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6A-27 Bearing Carrier Assembly . . . . . . . . . . . . . . . . . . . . 6A-64
Propeller Shaft Assembly and Forward Gear Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-64
Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32 Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . . . . 6A-67
Forward Gear Assembly . . . . . . . . . . . . . . . . . . . 6A-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-67
Shift Spool Assembly . . . . . . . . . . . . . . . . . . . . . 6A-38 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . 6A-67
Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-67 6
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-41 Gear Lubricant Filling Instructions . . . . . . . . . . 6A-70
Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-44 Installing Gear Housing to Driveshaft Housing 6A-70 A
Gear Housing Reassembly . . . . . . . . . . . . . . . . . . . 6A-45 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . 6A-71
Gear Housing Inspection . . . . . . . . . . . . . . . . . . 6A-45 Speedometer Tube Installation . . . . . . . . . . . . . 6A-73
Gear Housing Specifications (Standard Rotation)

Ratio Pinion Depth
Backlash Backlash
0.025 in. (0.635 mm) With Tool 0.017 in. to 0.028 in. (0.431 mm
1.75:1 0.030 in. to 0.050 in.
91-12349A2 using Disc #2 and to 0.711 mm) Pointer on line
1.87:1 (0.762 mm to 1.27 mm)
Flat #4 mark #1
Gearcase Lubricant Capacity
All Ratios 27.0 fl. oz. (798.0 ml)
Gearcase Pressure Check
Gearcase without Oil Gearcase should hold 15 psi for 5 minutes without leakage
Gear Ratio Teeth on Pinion Gear Teeth on Forward and Reverse

Gear
1.75:1 12 21
1.87:1 15 28
90-884294 OCTOBER 2001 Page 6A-1

Special Tools
1. Gear Housing Cover Nut Tool 91-61069
2. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716
3. Slide Hammer Puller 91-34569A1
4. Bearing Removal and Installation Kit 91-31229A5. This kit contains the following
tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plate 91-29310;
Mandrel 91-38628; and Driver Rod 91-37323.
5. Pilot 91-36571
6. Puller Rod 91-31229 and Nut 91-24156
Page 6A-2 90-884294 OCTOBER 2001

7. Puller Plate 91-29310
8. Mandrel 91-38628
9. Driver Rod 91-37323
11. Driveshaft Holding Tool 91-56775
12. Oil Seal Driver 91-31108
13. Forward Gear Bearing Tool 91-877321A1
14. Bearing Driver Cup 91-31106
15. Pinion Locating Gear Tool 91-12349A2 or 91-74776
90-884294 OCTOBER 2001 Page 6A-3

16. Backlash Indicator Rod 91-53459 for (1.75:1 ratio) and 91-78473 for (1.87:1 ratio)
17. Dial Indicator 91-58222A1
18. Bearing Retainer Tool 91-43506
19. Bearing Preload Tool 91-14311A2
7
6
4
3
2
1 - Plate (44307) 6 - Bolt (10-12580)

2 - Adaptor (N.S.S.) 7 - Nut (11-13953)
3 - Bearing (N.S.S.) 8 - Set Screw
4 - Washer (N.S.S.) (10-12575)
5 - Spring (24-14111) 9 - Sleeve
(23-13946)
20. Mandrel 91-92788
21. Mandrel 91-15755
22. Dial Indicator Holder 91-89897
Page 6A-4 90-884294 OCTOBER 2001

23. Leakage Tester FT8950
25. Water Pump Alignment Pins 91-821571A1
26. Bearing Adaptor Installation Tool 91-18605A2
90-884294 OCTOBER 2001 Page 6A-5

Gear Housing (Drive Shaft)(Standard Rotation)

33
4.75 IN/120.65MM 95
TORPEDO DIA.
34
35
95
7 Loctite 271 36
32
92 Loctite 7649 Primer
31
44 30 95
46
29
95 45
38 26
43 27
25 95
95
37
95 24 23
42
28
12
40 22 95
13
19
21
41
14
15
39 20
9 7
10 11
3
1 95
6
5
9 11 4
10
95 8
16
5 7
7
17
2
92 18
Page 6A-6 90-884294 OCTOBER 2001

Gear Housing (Drive Shaft)(Standard Rotation)

TORQUE
REF.
REF
1 1 GEAR HOUSING (BASIC)
2 1 PIN
3 1 FILLER BLOCK
4 1 PITOT TUBE
5 2 ANODE
6 1 SCREW 60 7
7 1 NUT
8 1 ROLLER BEARING
9 2 DOWEL PIN
10 2 SCREW ASSEMBLY 60 7
11 2 SEALING WASHER
1 HOSE(LONG - 7 IN)
12 1 HOSE (X-LONG - 12 IN)
1 HOSE(XX-LONG - 17 IN)
13 1 CONNECTOR
14 1 COVER
15 1 GASKET
16 1 PINION GEAR (1.75:1 - 12/21) (Part of 43-859321A3)
17 1 WASHER
18 1 NUT 70 95
19 1 OIL SEAL
20 1 O RING
21 2 SCREW (M6 x 16) 60 7
22 1 RUBBER WASHER
23 1 SHIFT SHAFT (LOWER)
1 DRIVE SHAFT (LONG)
24 1 DRIVE SHAFT (X-LONG)
1 DRIVE SHAFT (XX-LONG)
25 AR SHIM SET
26 1 TAPERED ROLLER BEARING
27 1 CUP
28 1 KEY
29 AR SHIM SET
31 1 CUP
32 1 RETAINER 100 135
33 1 CARRIER ASSEMBLY
34 1 O RING
35 1 OIL SEAL
36 1 OIL SEAL
37 1 WATER PUMP ASSEMBLY
38 1 SEAL
39 1 GASKET
40 1 GASKET
41 1 FACE PLATE
42 1 IMPELLER
43 4 SCREW (M6 x 16) 60 7
44 1 COUPLING ASSEMBLY
45 1 O RING
46 1 O RING
90-884294 OCTOBER 2001 Page 6A-7

Gear Housing (Prop Shaft)(Standard Rotation)
4.75 IN/120.65MM
TORPEDO DIA. 76
47
52 51 48
75 95 87 50
49
54
53 87
56
61
55
57 66
62 87
94
58 68 65
87
59
63 64
60 69
67
73 70 95
95
71
72
95
74
95
95 95
87 Premium Gear Lubricant

94 Anti-Corrosion Grease
Page 6A-8 90-884294 OCTOBER 2001

Gear Housing (Prop Shaft)(Standard Rotation)

TORQUE
REF.
REF
1 1 GEAR HOUSING (BASIC)
47 1 PLUG
48 1 SHIFT CRANK
49 1 SHAFT
50 1 SHIFT SPOOL
51 1 COTTER PIN
52 1 SLEEVE
53 1 FORWARD/PINION GEAR SET (1.75:1 - 12/21)
54 AR SHIM SET
56 1 CUP
57 1 RETAINING RING
58 1 ROLLER BEARING
59 1 SPRING
60 1 SLIDING CLUTCH
61 1 DETENT PIN
62 1 CROSS PIN
63 1 PROPELLER SHAFT
64 1 REVERSE GEAR (1.75:1 - 12/21)
65 1 THRUST SPACER
66 1 THRUST RING
67 1 BALL BEARING
68 1 O RING
69 1 BEARING CARRIER
70 1 ROLLER BEARING
71 1 OIL SEAL (INSIDE)
72 1 OIL SEAL (OUTSIDE)
73 1 TAB WASHER
74 1 COVER 210 285
75 1 ANODIC PLATE
76 1 SCREW 40 54
90-884294 OCTOBER 2001 Page 6A-9

General Service Recommendations

There may be more than one way to “disassemble” or “reassemble” a particular part(s),
therefore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveal that disassembly is required for replacement of one or more components.
Service procedure order in this section is a normal disassembly-reassembly sequence.
It is suggested that the sequence be followed without deviation to assure proper repairs.
When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to “reassembly and installation” of that compo-
nent in the reassembly part of this section. Use the “Table of Contents” (on back of section
divider) to find correct page number.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, be sure that no water is present in air line.
BEARINGS
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing
so that it passes thru the bearing. DO NOT spin bearing with compressed air, as this may
cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Pre-
mium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bear-
ing race in-and-out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condition of rollers and inner bearing race
by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles
and/or discoloration from overheating. Always replace tapered bearing and race as a set.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that
the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded
particles, uneven wear and/or discoloration from overheating. The shaft and bearing must
be replaced, if the conditions described are found.
SHIMS
Keep a record of all shim amounts and location during disassembly to aid in reassembly.
Be sure to follow shimming instructions during reassembly, as gears must be installed to
correct depth and have the correct amount of backlash to avoid noisy operation and pre-
mature gear failure.
SEALS
As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard
to appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter
of all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean
and dry. To ease installation, apply 2-4-C Marine Lubricant with Teflon on all O-rings. To
prevent wear, apply 2-4-C Marine Lubricant with Teflon on l.D. of oil seals.
To prevent corrosion damage after reassembly, apply 2-4-C Marine Lubricant with Teflon
to external surfaces of bearing carrier and cover nut threads prior to installation.
Page 6A-10 90-884294 OCTOBER 2001

Removal, Disassembly, Cleaning and Inspection – Standard

Rotation
Removal
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from
engine before removing gear housing from driveshaft housing.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.
2. Shift engine into NEUTRAL position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller
locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propel-
ler shaft.
5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position.
Remove plastic cap at rear edge of driveshaft housing. Remove bolt that secures trim
tab and remove tab from gear housing.
6. Once trim tab is removed, remove bolt from inside of trim tab cavity.
i
d g
f
a h
b
e
c
51916 51912 52375

a - Tab Washer
b - Propeller Nut
c - Rear Thrust Hub
d - Continuity Washer (if equipped)
e - Propeller Shaft
f - Thrust Hub (forward)
g - Bolt (secures trim tab)
h - Bolt (inside trim tab cavity)
i - Ribs – Align Carefully with Trim Tab while Securing Tab
90-884294 OCTOBER 2001 Page 6A-11

7. While pressing in on speedometer hose junction, pull out on hose to disconnect.
b
a
57735
a - Press in on Junction
b - Pull out on Hose
8. Loosen the side mounting locknuts. (Do not attempt to remove one nut before oppo-
site side is loosened sufficiently, or gear housing could be damaged.)
52374
a - Side Mounting Locknuts (2 each side)
9. Pull gear housing away from driveshaft housing as far as the loosened nuts (in Step
8) will allow, then remove loosened nuts. (DO NOT allow gear housing to fall, as it now
is free.)
10. Pull gear housing from driveshaft housing.
Page 6A-12 90-884294 OCTOBER 2001

Draining and Inspecting Gear Housing Lubricant

1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical
position.
NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later
models.
2. Position a clean drain pan under gear housing and remove “Fill” and “Vent” screws
from gear housing.
bb
a - “Fill” Screw
b - “Vent” Screw
3. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal
particles (resembling powder) indicates normal wear. Presence of larger particles (or
a large quantity of fine particles) indicates need for gear housing disassembly, and
component inspection.
4. Note the color of gear lubricant. White or cream color indicates presence of water in
lubricant. Check drain pan for water separation from lubricant. Presence of water in
gear lubricant indicates the need for disassembly, and inspection of oil seals, seal sur-
faces, O-rings and gear housing components.
NOTE: Gear lubricant drained from a recently run gear case will be a light chocolate
brown in color due to agitation/aeration. Oil which is stabilized will be a clear yellow brown
in color.
90-884294 OCTOBER 2001 Page 6A-13

Water Pump
REMOVAL AND DISASSEMBLY
1. Remove the water seal, water tube coupling assembly, and the water pump screws.
b
a
57944
a - Water Seal
b - Water Tube Coupling
c - Water Pump Screws (4)
2. Carefully slide the water pump straight up off of the drive shaft. It may be necessary
to encourage the water pump up by gently prying up on its mounting flanges with a
couple of screwdrivers.
b b
70487
a - Water Pump Body

b - Screwdrivers
Page 6A-14 90-884294 OCTOBER 2001

3. Remove the impeller, impeller key, the face plate and gaskets. Discard the gaskets.
b
d
70605
a - Impeller c - Water Pump Face Plate

b - Impeller Key d - Gasket (1 each side of face plate)

1. Inspect the water tube coupling assembly for wear or damage. If necessary replace
the worn or damaged components, especially the two O-rings on the inside, one at
the top and one at the bottom.
b 70613
a - Water Tube Adaptor

b - O-rings (2)
IMPORTANT: The circular groove formed by the impeller sealing bead should be
disregarded when inspecting cover and plate. The depth of the groove will not af-
fect water pump output.
2. Inspect face plate and water pump cover for grooves and/or rough surfaces.
3. Replace cover and /or face plate if grooves (other than sealing grooves) are more than
0.030 in. (0.762 mm) deep.
90-884294 OCTOBER 2001 Page 6A-15

4. Inspect impeller side seal surfaces and ends of impeller blades for cracks, tears and
wear. Replace impeller if any of these conditions are found.
5. Inspect impeller bonding to impeller hub.
6. Inspect impeller for glazed or melted appearance (caused by operation without suffi-
cient water supply). Replace impeller if any of these conditions exist.
70500
a - Impeller
b - Hub
IMPORTANT: When completing gear housing repairs, that require removal of water
pump impeller, it is recommended that the impeller be replaced. If it is necessary,
however, to re-use impeller, DO NOT install in reverse to original rotation, or prema-
ture impeller failure will occur.
Oil Seal Carrier Assembly

REMOVAL
1. Remove the oil seal carrier from the gear housing. It may be necessary to gently pry
up on it with two screwdrivers.
a
57940
a - Oil Seal Carrier

b - Screwdrivers
Page 6A-16 90-884294 OCTOBER 2001

OIL SEAL CARRIER ASSEMBLY - COMPONENT DISASSEMBLY

NOTE: Complete the instructions in this section only if the assembly components have
been found to be defective and are in need of repair or replacement.
1. Remove the o-ring.
70501
a - O-ring
b - Oil Seals (2)
2. Remove oil seals.
c
b
70610

b - Oil Seals
c - Screwdriver
90-884294 OCTOBER 2001 Page 6A-17

OIL SEAL CARRIER ASSEMBLY – COMPONENT REASSEMBLY

The oil seals in the carrier assembly are the same diameter. The bottom (first) seal lip
faces down; the top (second) seal lip faces up. Apply 2-4-C Marine Lubricant with Teflon
to seal lips and between seals. Press seal into carrier with suitable mandrel. Second seal
should be pressed in flush with carrier surface.
95
a
a - Bottom Seal (lip faces down)

b - Top Seal (lip faces up)
Bearing Carrier and Propeller Shaft Removal

1. Straighten the tab on the tab washer.
70490
a - Tab on Tab Washer
Page 6A-18 90-884294 OCTOBER 2001

2. Remove the bearing carrier retainer following step a or b as follows:
CAUTION
DO NOT drill into the gear housing retainer threads when using the following pro-
cedure for removing the retainer
a. If the retainer is corroded in place, drill 4 holes in the retainer and fracture the re-
tainer with a chisel. Pry the remaining segments out.
23356
a - Drilled Holes
b. Remove the bearing carrier retainer using the Bearing Carrier Retainer Wrench
(91-61069).
70491
a - Bearing Carrier Retainer Wrench
90-884294 OCTOBER 2001 Page 6A-19

3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing
carrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER.
NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat
to loosen the carrier.
70492
a - Puller Jaws (91-46086A1)

b - Puller Bolt (91-85716)
CLEANING/INSPECTION - BEARING CARRIER

IMPORTANT: It is recommended that all seals and O-rings be replaced (as a normal
1. Clean bearing carrier with solvent and dry with compressed air.
2. Inspect the bearing carrier for signs of excessive corrosion especially in the area
where the bearing carrier touches the gear housing. If excessive corrosion is evident
replace the carrier.
b 50314
a - Bearing Carrier
b - Inspect for Corrosion
CAUTION
DO NOT spin bearings dry with compressed air, as this could cause bearing to
score.
3. Bearing carrier propeller shaft needle bearing condition is determined by propeller
shaft bearing surface condition. (See “Propeller Shaft Inspection.”)
Page 6A-20 90-884294 OCTOBER 2001

4. Inspect reverse gear to pinion gear wear pattern (should be even and smooth). If not,
replace reverse gear and pinion gear.
5. Check clutch jaws on reverse gear for damage. Replace reverse gear, if damage is
found on clutch jaws.
6. Apply light oil to reverse gear bearing. Rotate reverse gear bearing while checking
bearing for rough spots and/or catches. Push in and pull out on reverse gear to check
for bearing side wear. Replace bearing if any of the listed conditions exist.
DISASSEMBLY - BEARING CARRIER

1. Remove and discard O-ring from between bearing carrier and thrust washer.
2. If inspection of reverse gear or reverse gear bearing determines that replacement of
gear or bearing is required, remove gear and bearing as follows:
CAUTION
Clamp onto the reinforcing rib of the bearing carrier ONLY, or damage to the carri-
er may result.
3. Place the bearing carrier in a vise, clamping on the reinforcing rib.
4. Remove the reverse gear, thrust ring, and bearing as an assembly, using a slide ham-
mer puller
d e
a
a - Bearing Carrier Reinforcing Rib
b - Bearing Carrier
c - Slide Hammer Puller (91-34569A1)
d - Reverse Gear
e - Thrust Hub
f - Bearing (not seen) - Located in the Carrier
90-884294 OCTOBER 2001 Page 6A-21

IMPORTANT: The bearing MUST BE replaced if removed from gear.

5. Place the universal puller plate between the thrust washer and bearing as shown and
press on the plate until it bottoms.
23351
a - Universal Puller Plate (91-37241)
b - Thrust Washer
c - Bearing
6. Using a suitable mandrel and the universal puller plate to support the bearing, press
the bearing from the reverse gear as shown.
b
c
23351
a - Universal Puller Plate c - Gear
(91-37241) d - Mandrel
b - Bearing
a. Discard the bearing.

b. Inspect the gear, and thrust washer for excessive wear, cracks, or damage. Re-
place the appropriate components if any of these conditions are found.
Page 6A-22 90-884294 OCTOBER 2001

NOTE: Inspection of the bearing surfaces on the propeller shaft where the needles of the
bearing carrier needle bearing rolls, gives an indication of the condition of the needle
bearing inside the bearing carrier. Replace needle bearing in the bearing carrier if the prop
shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
7. Perform the following step a. or b. as necessary.
a. If Replacing the Needle Bearing and Seals: Remove the needle bearing and
seals with the tools as shown.
a
23140
a - Bearing Driver Rod (91-37323)
b - Needle Bearing
c - Driver Head (91-36569)
d - Oil Seals
(1.) Discard the needle bearing and both seals.

b. If Replacing the Seal Only: Remove the oil seals with a suitable pry bar, being
careful not to damage the bore of the bearing carrier.
23140
a - Oil Seals
b - Pry Bar
(1.) Discard both of the seals.
90-884294 OCTOBER 2001 Page 6A-23

BEARING CARRIER ASSEMBLY Component Reassembly

been disassembled and repaired or replaced.
1. Clean all of the components with a suitable solvent and dry the parts thoroughly using
compressed air. Be careful not to spin the bearing.
2. Lubricate the bore that the needle bearing is pressed into with Premium Gear Lubri-
cant.
3. Assemble the needle bearing (with the numbered end of the bearing towards the driv-
er shoulder), onto the driver.
4. Press the needle bearing into the bearing carrier until the driver bottoms out on the
bearing carrier. Ensure that the numbered side of the needle bearing faces the seal
end (aft end) of the carrier.
87
87 Premium Gear Lubricant 50315
a - Needle Bearing Driver (91-15755)

b - Needle Bearing
c - Bearing Carrier
Page 6A-24 90-884294 OCTOBER 2001

5. Thoroughly clean the bore in which the first seal is to be pressed.

6. Assemble the first seal (with the lips of the seal facing away from the driver shoulder)
onto the long end of the oil seal driver.
7. Press on the oil seal driver until the driver bottoms on the bearing carrier.
50315
a - Oil Seal Driver b - Oil Seal
(91-31108) c - Bearing Carrier
8. Apply a thin film of Loctite 271 to the outer diameter of the second seal.
9. Assemble the second seal (with the lips of the seal facing the driver shoulder) onto
the short end of the driver.
10. Press the oil seal with the driver until the driver bottoms out on the bearing carrier.
a
7
b 95
7 Loctite 271
95 2-4-C Marine Lubricant With Teflon 50315
a - Driver (short end)

b - Oil Seal (lips toward driver shoulder)
c - Bearing Carrier
11. Wipe up all of the excess Loctite. Do not allow any of the excess Loctite to spread to
other parts of the assembly.
12. Lubricate the seal lips and fill the area between the seals with 2-4-C Marine Lubricant
with Teflon.
90-884294 OCTOBER 2001 Page 6A-25
13. Install the thrust washer and a new ball bearing onto the reverse gear. Press on the
inner race of the ball bearing using the pilot washer until the bearing bottoms out on
the gear.
b c
23346
a - Pilot Washer c - Thrust Hub
(91-36571) d - Reverse Gear
b - Ball Bearing
14. Lubricate the bore that the bearing is pressed into with Premium Gear Lubricant.
15. Press the bearing carrier onto the reverse gear and bearing until the bearing bottoms
out in bearing carrier, using the pilot washer to press against the carrier.
87
a - Pilot Washer (91-36571)

b - Bearing Carrier
c - Reverse Gear and Bearing Assembly
Page 6A-26 90-884294 OCTOBER 2001

16. Lubricate the O-ring with 2-4-C Marine Lubricant with Teflon and install the O-ring onto
the bearing carrier.
a
95
95 2-4-C Marine Lubricant With Teflon b
23354
a - O-ring b - Bearing Carrier
Drive Shaft Assembly

REMOVAL
1. Remove the drive shaft pinion nut as follows:
a. Place the drive shaft nut wrench onto the drive shaft. Do not loosen the retainer
at this time.
b. Insert the pinion nut adapter with the MR slot facing the pinion gear into the gear
housing. It may be necessary to slightly lift and rotate the drive shaft to align the
pinion gear nut into the pinion nut adapter slot.
c. Install the bearing carrier into the gear housing backwards to support the prop
shaft and to keep the pinion nut adapter aligned.
d. Place the drive shaft nut wrench over the drive shaft splines and loosen, (but do
not fully unscrew), the pinion nut by rotating the drive shaft counterclockwise.
c
70887
a - Drive Shaft Nut Wrench (91-56775)
b - Drive Shaft Bearing Retainer Wrench (91-43506)
c - Pinion Nut adapter (MR Slot) (91-61067A2)
90-884294 OCTOBER 2001 Page 6A-27

e. If the drive shaft is broken, place propeller shaft nut wrench onto the propeller
shaft splines, hold shift shaft in forward gear and loosen, (but do not fully un-
screw), the pinion nut by rotating prop shaft counterclockwise to turn gears, thus
loosening the pinion nut.
NOTE: The propeller shaft nut wrench is included with the pinion nut adapter kit
b
70607
a - Pinion Nut Adaptor (MR slot) (91-61067A2)
b - Propeller Shaft Nut Wrench (91-61067)
c - Shift Shaft (Turn Clockwise) (Protect shaft splines with soft material)
f. Completely unscrew the drive shaft bearing retainer.

g. Completely unscrew the pinion nut by rotating the drive shaft (or the propeller
shaft) in a counterclockwise direction.
h. Remove all tools.
IMPORTANT: The pinion bearing rollers are free to fall out of the pinion bearing
once the drive shaft is removed. Be careful not to loose the (18) rollers.
2. Remove the drive shaft and all components by pulling the drive shaft straight out of
the gear housing as shown.
a
b
70608
a - Drive Shaft
b - Drive Shaft Retainer, Bearing Cup, Bearing, and Shims
3. Move the prop shaft downward and to the PORT side of the gear case.
4. Retrieve the pinion gear, the washer and the nut from the inside of the gear housing.
Page 6A-28 90-884294 OCTOBER 2001

NOTE: If pinion gear is seized onto the driveshaft, place gearcase in vise using soft jaw
vise covers. Place a block of wood on gear housing mating surface. Use a mallet and care-
fully tap gear housing away from drive shaft.
CAUTION
Do not strike gear housing hard with mallet or allow gear housing to fall.
a
b
57951
a - Wood Block
b - Drive Shaft in Soft Jaw Vise
5. Remove lower drive shaft bearing cup and shims using slide hammer puller
(34569A1) (retain shims for re-installation).
a - Slide Hammer Puller (91-34569A1)

b - Lower Drive Shaft Bearing Cup
90-884294 OCTOBER 2001 Page 6A-29

DISASSEMBLY
1. Both upper and lower tapered roller bearings can be removed from the drive shaft in
one operation. Using the bottom bearing cup removed from the gearcase, place the
cup on top of a vise leaving the vise jaws open enough to allow the drive shaft to slide
through.
2. Place the driveshaft through the cup and vise until the bottom bearing is resting in the
cup. While holding the driveshaft, tap on the top of the shaft with a lead hammer until
the bearings are free. Do not drop the shaft when performing this operation.
a - Lower Bearing Cup Removed from Gear Case

b - Drive Shaft With Both Upper and Lower Bearings
DRIVE SHAFT ASSEMBLY - Inspection

1. Clean all parts with a suitable solvent and dry the parts thoroughly using compressed
air, being careful not to spin the bearings.
2. The condition of the drive shaft bearing cup is an indication of the condition of the ta-
pered roller bearing on the drive shaft. Replace the bearing and bearing cup if the cup
is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
3. Inspect the bearing surface on the drive shaft where the needles of the lower pinion
bearing roll. Replace the drive shaft if it is pitted, grooved, scored, worn unevenly, dis-
colored from overheating, or has embedded particles.
4. Inspect the splines at both ends of the drive shaft for a worn or twisted condition. Re-
place the drive shaft if either condition exists.
5. Inspect the gear for pitting, chipped or broken teeth, hairline fractures, and excessive
or uneven wear. Replace the pinion gear and the forward gear as a set if any de-
fects are found.
6. Inspect driveshaft for groove(s) where water pump base oil seals contact shaft. Re-
place driveshaft if groove(s) are found.
Page 6A-30 90-884294 OCTOBER 2001

REASSEMBLY
NOTE: Complete the instructions in this section only if the components have been disas-
sembled
1. Apply a light coat of Premium Gear Lubricant on l.D. of drive shaft tapered bearing.
Apply High Pressure Grease (such as Chicago Manufacturing and Distributing Lube
#3) to the O.D. of both bearings.
2. Assemble a new tapered roller bearing to the drive shaft with the large O.D. of the
bearing facing the pinion gear end of the drive shaft.
3. Thread a used pinion nut onto end of drive shaft. Leave approximately 1/16″ (2mm)
of nut threads exposed. Drive shaft threads MUST NOT extend beyond nut or thread
damage could result while pressing.
4. Press the tapered roller bearing onto the drive shaft using the universal puller plate
and a suitable mandrel, (an old tapered roller bearing inner race).
c
d
a - Used Pinion Nut

b - Drive Shaft
c - Tapered Bearing(s)
d - Old Bearing Inner Race
e - Universal Puller Plate
90-884294 OCTOBER 2001 Page 6A-31

Propeller Shaft Assembly and Forward Gear Bearing Cup

REMOVAL
1. Tilt the propeller shaft to the port side of the gear housing and remove the shaft by
pulling it straight up and out.
c
b
58016
a - Propeller Shaft Assembly
b - Shift Spool
c - Shift Crank
d - Thrust Washer (Reverse Gear)
2. Remove the forward gear bearing cup and shims. Measure and make note of the shim
thickness. If the shims are not damaged, they may be reused.
d
g h
c e
f
a b
50780
a - Puller Shaft (91-31229)
b - Nut (11-24156)
c - Washer (91-34961)
d - Guide Plate (91-816243)
e - Puller Head (from Slide Hammer Puller Kit 91-34569A1)
f - Jaws (from Slide Hammer Puller Kit)
g - Bearing Cup
h - Shims
Page 6A-32 90-884294 OCTOBER 2001

PROPELLER SHAFT ASSEMBLY - Component Disassembly

NOTE: When accomplishing the next step, all of the parts are free to come apart. Work
closely over a work bench to ensure that the parts are not dropped or damaged and to
avoid personal injury
1. Remove the spring around the clutch being careful not to over-stretch it during remov-
al. If the spring does not coil back to its normal position once it has been removed,
it must be replaced.
2. Remove detent pin.
3. Remove the cross pin that goes through the clutch.
4. Remove the remainder of the components
a
b d
e
58017
a - Spring
b - Cross Pin
c - Shift Spool Assembly
d - Forward Gear Assembly
e - Sliding Clutch
f - Detent Pin (hidden)
PROPELLER SHAFT ASSEMBLY - Component Inspection
1. Clean all the parts with a suitable solvent and dry the parts thoroughly using com-
pressed air, being careful not to spin bearings
2. Inspect the sliding clutch jaws for damage. Jaws must not be chipped or rounded off.
Replace the clutch if they are.
3. Inspect the bearing surfaces on the propeller shaft where the needles of the bearing
carrier needle bearing and the needles of the forward gear needle bearing roll. Re-
place the propeller shaft if it is pitted, grooved, scored, worn unevenly, discolored from
overheating, or has embedded particles.
a b
c
23355
a - Bearing Carrier Needle Bearing Contact Area
b - Forward Gear Needle Bearing Contact Area
c - Splines
90-884294 OCTOBER 2001 Page 6A-33

4. Inspect the propeller shaft splines at both ends for a broken, worn, or twisted condi-
tion. Replace the propeller shaft if any of these conditions exists.
5. Inspect the surface of the propeller shaft where the bearing carrier seal lips contact
the shaft. If the oil seals have made grooves, replace the propeller shaft and oil seals.
a
b 23355
a - Bearing Carrier Seal Contact Area
b - Splines
6. Inspect reverse gear thrust washer surface for wear or taper. If surface is worn or ta-
pered, propeller shaft must be replaced.
a
23355
a - Thrust Washer Surface
7. Inspect the propeller shaft for a bent condition.

a. V-Blocks and Dial Indicator
(1.) Position the propeller shaft bearing surfaces on V-blocks.
(2.) Adjust the height of V-blocks to level the propeller shaft.
(3.) Position the dial indicator tip just forward of the propeller shaft splines.
8. Rotate the propeller shaft and observe the dial indicator movement, If the indicator
in the dial moves more than 0.009 in. (0.23mm), replace the propeller shaft.
a
52727
a - Check Movement with Dial Indicator (91-58222A1) Here
Page 6A-34 90-884294 OCTOBER 2001

9. Measure propeller shaft FORWARD to REVERSE shoulder length. If measurement

is under 2.040 in. (51.82mm), replace propeller shaft.
2.040 in. (51.82mm)
23355
10. Inspect REVERSE thrust washer for wear or taper. Measure thickness of washer. If
thickness is LESS than 0.240 in. (6.1mm), replace washer
0.240 in. (6.096mm)
Forward Gear Assembly

COMPONENT INSPECTION
1. Clean the forward gear assembly and the forward gear bearing cup with a suitable
solvent and dry with compressed air. Be careful not to spin the bearings.
or uneven wear. Replace the forward gear and the pinion gear as a set if any de-
fects are found.
3. Inspect the clutch jaws of the gear for damage. The surfaces must not be chipped or
rounded off. Replace both the forward and pinion gear as a set if any of these con-
ditions exist.
23351
a - Forward Gear Teeth
b - Clutch Jaws
90-884294 OCTOBER 2001 Page 6A-35

4. Inspect the needle bearings on the inside of the forward gear and the bearing surface
on the propeller shaft. If either the needle bearing or the bearing surface of the propel-
ler shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or
has embedded particles, replace the propeller shaft and remove and replace the
needle bearing in the forward gear as outlined in the next section.
a
23355
a - Forward Gear Needle Bearing Contact Area
5. Inspect the tapered roller bearings on the forward gear and the bearing surface on the
forward gear bearing cup. If either the roller bearings or the bearing surface of the for-
ward gear bearing cup is pitted, grooved, scored, worn unevenly, discolored from
overheating, or has embedded particles, replace the forward gear bearing cup and
remove and replace the tapered roller bearings as outlined in the next section.
FORWARD GEAR ASSEMBLY - Component Disassembly

NOTE: Forward gear can only be removed from gear housing after drive shaft and pinion
gear have been removed.
1. Reach into gear housing and lift out forward gear.
IMPORTANT: DO NOT remove tapered bearing or needle bearings from forward
gear unless replacement of bearings is required. (Bearings cannot be reused after
they have been removed.)
2. If inspection determines that replacement of forward gear tapered bearing is required,
separate gear from bearing as follows:
a. Press Universal Puller Plate (91-37241) between forward gear and tapered bear-
ing.
b. Place assembly on press and press gear out of bearing with suitable mandrel.
NOTE: Tapered bearing and race MUST BE replaced as a set.
a c
91-37241
b
51119
a - Forward Gear Bearing
b - Universal Puller Plate (91-37241)
c - Mandrel
Page 6A-36 90-884294 OCTOBER 2001

3. If inspection determines that replacement of propeller shaft needle bearings is re-

quired, remove bearing as follows:
a. Clamp forward gear in a soft jaw vise securely.
b. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch
and hammer to remove bearing.
57905 b
19203
a - Retaining RIng
b - Bearing
FORWARD GEAR ASSEMBLY - Component Reassembly

1. Apply Premium Gear Lubricant to I.D. of forward gear. Press bearing into forward gear
using Forward Gear Bearing Installer Tool until tool contacts gear.
a
87
b
91-877321A1

a - Forward Gear Bearing Installer (91-877321A1)
b - Needle Bearing, Numbered Side Toward Installer Tool
90-884294 OCTOBER 2001 Page 6A-37

2. Install retaining ring into groove of forward gear by starting at one end of retaining ring
and working it around until seated in groove.
a
b
57905
a - Retaining Ring
b - Groove in Forward Gear
Shift Spool Assembly
INSPECTION
1. Clean the assembly with a suitable solvent and dry the parts using compressed air.
2. Inspect the shift spool assembly for damage. Small nicks and burrs may be smoothed.
If any parts are damaged or worn excessively, it will be necessary to replace the com-
plete shift spool assembly. Individual parts are not available for the assembly.
3. Inspect the shift spool for wear in the area where the shift crank comes into contact.
a
b
55694
a - Contact Area
b - Non-Ratcheting Shift Spool
4. Inspect to insure that the spool spins freely (it may be helpful to lightly tap the castle
nut end of the shift spool against a firm surface to align the internal parts).
5. Inspect to insure that the spool has 0.002 - 0.010 (0.05 mm - 0.25 mm) end play. This
end play may be achieved by turning the castle nut clockwise down until it is snug and
then backing off the nut counterclockwise to the first cotter pin slot.
.002 (0.05mm)
to
.010 (0.25mm)
55694
Page 6A-38 90-884294 OCTOBER 2001

NOTE: If the spool spins freely and has the proper clearance, it will not be necessary to
disassemble and reassemble the spool. If the spool does not function properly, proceed
with the following disassembly procedures.
SHIFT SPOOL DISASSEMBLY

NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts
due to an improperly functioning shift spool assembly or debris in the gear housing and/or
shift spool assembly. Individual components for the shift spool are not available as re-
placement parts. If the shift spool does not function properly and the following cleaning
and adjustment procedures do not correct the problem, it will be necessary to order a new
shift spool assembly.
1. Remove and discard the cotter pin.
2. Remove the castle nut and spool.
3. Clamp the spool in a vice being careful not to damage the spool.
4. Unscrew the retainer.
SHIFT SPOOL REASSEMBLY

1. Place the shift spool onto the shift spool shaft.
2. Screw the castle nut down until it touches the washer and a slight resistance is felt.
3. Loosen the castle nut until the cotter pin slot of the nut is aligned with the hole in the
shaft. If, when the castle nut is screwed down, the cotter pin slot is already aligned
at the hole in the shaft, back the castle nut off until the next available slot in the nut
is aligned with the hole in the shaft.
4. Insert a new cotter pin and bend ends of the cotter pin in opposite directions.
5. Verify the spool has 0.002 - 0.010 in. (0.05 mm - 0.25 mm) end play. If it does not, read-
just the castle nut again.
d
a b c 55694
a - Shift Shaft c - Castle Nut
b - Spool d - Cotter Pin
6. If this adjustment did not produce the desired results it will be necessary to disas-
semble, clean, and reassemble the shift spool assembly. If the spool assembly has
already been disassembled and cleaned it will be necessary to replace the shift spool
assembly.
90-884294 OCTOBER 2001 Page 6A-39

Propeller Shaft Assembly

COMPONENT REASSEMBLY
1. Install the sliding clutch on the propeller shaft. Align cross pin holes in the clutch with
the slot in the propeller shaft.
2. Assemble the forward gear assembly to the propeller shaft.
3. Assemble the shift spool assembly to the propeller shaft being sure to align the cross
pin hole of the shift spool shaft with the clutch.
4. Assemble the cross pin through the sliding clutch, through the propeller shaft and
through the shift spool shaft hole.
5. Install detent pin in 3rd hole in clutch.
6. Assemble the cross pin retaining spring over the propeller end of the propeller shaft
and wind it around the clutch over the cross pin hole. Be careful not to distort the spring
while assembling it. Make sure that the spring is wound on so that it does not
cross over on itself and that it lies flat against the clutch once it is assembled.
If it does not lie flat against the clutch, a new spring must be installed.
d f c b
a
58017
a - Sliding Clutch
b - Forward Gear Assembly
c - Cross Pin (hidden)
d - Propeller Shaft
e - Spool and Actuating Shaft Assembly
f - Cross Pin Retaining Spring
g - Detent Pin (hidden)
Page 6A-40 90-884294 OCTOBER 2001

Shift Shaft Assembly

REMOVAL
NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank
inside the gear case) without removing any of the internal components of the gear hous-
ing.
1. Remove the shift shaft bushing screws, and remove the shift shaft and bushing by
pulling both straight out of gear housing.
57934
a - Shift Shaft Bushing Screws
2. Remove the shift crank from the inside of the gear housing. Clean it with a suitable
solvent and dry it thoroughly. Inspect it for wear in the areas that contact the shift spool
and inspect the splines and the diameter that goes over the locating pin for damage
or wear.
d
c 23350
a - Contact Area
b - Shift Crank
c - Splines
d - Diameter for Locating Pin
90-884294 OCTOBER 2001 Page 6A-41

SHIFT SHAFT ASSEMBLY - Component Disassembly and Inspection

1. Slide the bushing assembly off the shift shaft. Remove the coupler from the shaft.
e
b
d 57954
a - Shift Shaft Bushing Assembly

b - O-ring
c - Shift Shaft
d - Gasket
e - Rubber Washer
2. Clean all components with a suitable solvent and dry thoroughly with compressed air.
a. Inspect the shift shaft bushing for cracking, damage, or excessive wear.
b. Inspect the oil seal inside the bushing, the sleeve, and the O-rings on the outside
of the bushing for damage or excessive wear.
c. Inspect the speedometer connector for damage or blockage.
If any of these conditions exist, replace the appropriate components.
b
57932
a - Shift Shaft Bushing

b - Oil Seal (Oil Seal is Replaceable)
c - Speedometer Tube Connector
Page 6A-42 90-884294 OCTOBER 2001

3. Inspect the shift shaft splines and oil seal surface for corrosion and/or excessive wear.
Replace the shift shaft if either if these conditions are found.
b a
57948
a - Oil Seal Surface

b - Spline
SHIFT SHAFT ASSEMBLY - Component Reassembly

1. Lightly lubricate the seat of the O-ring diameter on the bushing and the lip of the oil
seal with 2-4-C Marine Lubricant with Teflon.
2. If the speedometer connector was removed and/or replaced, lightly coat the threads
of the connector with Perfect Seal. Assemble the speedometer connector to the
bushing and torque the connector to 4.5 lb. in. (0.5 Nm).
3. Assemble all components as shown below.
h a
g
b
19
c
95
d
e
19 Perfect Seal
95 2-4-C Marine Lubricant With Teflon f
a - Shift Shaft
b - Speedometer Pressure Hose
c - Bolt (2) [Torque to 60 lb. in. (7 Nm)]
d - Bushing
e - Gasket
f - O-ring
g - Rubber Washer
h - Seal (Lip Faces Up)
90-884294 OCTOBER 2001 Page 6A-43

Pinion Bearing
REMOVAL
NOTE: Inspect the bearing surface on the drive shaft where the needles of the lower pin-
ion bearing roll. The condition of the drive shaft at this location gives an indication of the
condition of the needle bearing. Replace lower pinion bearing (needles and race as a set)
if the drive shaft is pitted, grooved scored, worn unevenly, discolored from overheating,
or has embedded particles.
IMPORTANT: All the needle bearings (18) MUST BE in place inside bearing race
while driving the pinion bearing from the gear housing.
IMPORTANT: Do not reuse the bearing (race or rollers) once it has been removed.
1. Remove and discard the pinion bearing (race and rollers) using tools as shown.
d
c
70614
a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)
Page 6A-44 90-884294 OCTOBER 2001

Gear Housing Reassembly

Gear Housing Inspection
1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush.
Dry the gear housing thoroughly using compressed air. Insure that all sealants, lock-
ing agents and debris are removed.
2. Verify the 2 oil circulation holes in the drive shaft bore and the shift shaft hole are clear
and free of debris.
3. Inspect the gear housing for excessive corrosion, impact or any other damage. Exces-
sive damage and/or corrosion requires replacement of the gear housing.
4. Inspect the bearing carrier retainer threads in the gear housing for corrosion and/or
stripped threads. Damage or corrosion to the threads requires replacement of the
gear housing.
5. Inspect bearing race/cup contact areas for evidence of bearing cup spinning. Check
that bearing cups are not loose in bearing bores. Any one bearing bore in which the
race/cup is loose will require replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the speedometer hole, clean as neces-
sary. Be careful not to enlarge the speedometer hole as this could cause erroneous
speedometer readings.
7. Verify that the locating pins are in place in the gear housing and that the corresponding
holes in the drive shaft housing are not elongated. The drive shaft may break if the
housings are not aligned properly due to missing locating pins or elongated holes.
90-884294 OCTOBER 2001 Page 6A-45

Pinion Bearing
INSTALLATION
IMPORTANT: Install only a new pinion bearing. Do not reinstall a pinion bearing that
has been previously removed from a gear housing.
1. Lubricate the bore into which the pinion bearing is to be installed with Premium Gear
Lubricant.
2. Position the new pinion bearing (with the cardboard shipping sleeve in place) onto the
driver head, with the lettered and numbered side of the bearing oriented upward.
3. Insert the driver with the bearing assembly, into position (by way of the propeller shaft
bore) at the drive shaft bore as shown.
c
e
d
f g
a
87
a - Drive Shaft Pinion Bearing (With Cardboard Shipping

Sleeve)
b - Driver Head (91-38628)
c - Puller Shaft (91-31229)
d - Washer (12-34961)
e - Nut (11-24156)
f - Pilot Washer (91-36571)
g - Puller Plate (91-29310)
4. Install the bearing by screwing down the nut until the bearing is fully seated against
the bore shoulder.
Page 6A-46 90-884294 OCTOBER 2001

Forward Gear Bearing Cup

INSTALLATION
Forward Gear Backlash – .017 in. to .028 in. (0.43mm to 0.71mm)
NOTE: If the forward gear, forward gear bearing and cup, or gear housing were not re-
placed, install the same quantity of shims that were taken out when cup was removed.
If the forward gear, forward gear bearing/cup, or gear housing were replaced, install 0.020
in. (0.51mm) of shims.
NOTE: If backlash has already been checked and it was determined that it needs to be
adjusted, (see Checking Forward Gear Backlash), adding or subtracting 0.001 in.
(0.03mm) shims will change the gear backlash by the same amount.
Example 1 (if backlash is too high)
If Forward Backlash Checks: .040 in. (1.02 mm)
(Subtract): .018 in. (0.46 mm)
Add This Quantity of Shims: .022 in. (0.56 mm)
Provides Backlash of 0.018 (0.46 mm)
Example 2 (if backlash is too low)
Backlash Checks: .010 in. (0.25 mm)
Subtract this Quantity of

Shims: .008 in. (0.30 mm)
Provides Backlash of 0.018 (0.46 mm)
1. Lubricate the bore into which the forward gear bearing cup is to be installed with Pre-
mium Gear Lubricant.
2. Place the shim(s) into forward bore of gear housing.
90-884294 OCTOBER 2001 Page 6A-47

3. Press the bearing cup into the gear housing using the installation tool as follows:
IMPORTANT: Verify that the bearing cup is positioned as straight as possible to
avoid cocking it in the bore while pressing it in.
b
a d
87

a - Hex-Head Screw
b - Bearing Cup Installation Tool (91-18605A1)
c - Driver Cup (91-31106)
d - Shims

INSTALLATION
1. Place the shift crank onto the locating pin in the forward section of the gear housing.
Ensure that the shift crank faces towards the left (port) side of the gear housing.
a
b
50314
a - Shift Crank
b - Locating Pin
Page 6A-48 90-884294 OCTOBER 2001

2. Install the shift shaft assembly into the gear housing as shown. Engage the splined
end of the shift shaft with the shift crank. Verify O-ring is positioned properly and lubri-
cated with 2-4-C Marine Lubricant with Teflon. Secure shift shaft bushing with 2
screws. Torque screws to 60 lb. in. (7 Nm).
57933
b - Screws [Torque to 60 lb. in. (7 Nm)]
NOTE: If the pinion bearing needle bearings have fallen out, install 18 needles into needle
bearing outer race. Use 2-4-C Marine Lubricant with Teflon, to help hold needles in place.
95
a
b
23142
a - Rollers (18)
b - Roller Bearing Outer Race
90-884294 OCTOBER 2001 Page 6A-49


INSTALLATION
1. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end
of the propeller shaft assembly to the left (port) side of gear housing and rotate the
shift shaft from reverse to neutral while installing shaft.
b
a
58016
a - Shift Actuating Spool

b - Shift Crank
c - Propeller Shaft Assembly
2. Operate the shift shaft to ensure that it has been properly installed. The sliding clutch
should move forward when the shift shaft is turned clockwise, and should move aft
when the shift shaft is turned counterclockwise.
3. Slide the rubber washer at top end of shift shaft down so that it just touches the oil seal
in the bushing.
57947
a - Rubber Washer
Page 6A-50 90-884294 OCTOBER 2001

Drive Shaft and Pinion Gear

INSTALLATION
NOTE: If the original shims were not retained or if pinion gear, drive shaft, drive shaft up-
per tapered roller bearing and cup, or gear housing were replaced, start off by installing
a 0.038 in. (0.96 mm) shim(s), for the upper tapered roller bearing.
NOTE: If the original shims were retained (or measurement known) and none of the
above listed parts were replaced, reinstall the same shims or same amount of shims.
1. Place the upper tapered bearing shim(s) into the drive shaft housing bore.
70620
a - Shim(s)
NOTE: For ease of installation, glue the washer to the pinion gear, using 3M Adhesive,
Bellows Adhesive, or equivalent.
NOTE: If the backlash may have to be changed, it is recommended that Loctite 271 NOT
be applied to the pinion nut UNTIL the backlash setting is finalized. DO NOT reuse the
old pinion nut. Install a NEW pinion nut after backlash is finalized.
NOTE: Do not install the lower tapered bearing cup or shim(s) at this time.
90-884294 OCTOBER 2001 Page 6A-51

2. Apply Loctite 271 to the threads of the pinion gear nut and place the pinion gear nut
into the MR slot of the pinion nut adapter.
NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear.
3. Place the pinion gear and washer into the gear housing.
4. Insert the pinion nut adapter (with the nut) into the gear housing.
5. Insert the drive shaft into the gear housing drive shaft bore. It may be necessary to
rotate the drive shaft to engage the drive shaft splines into the pinion gear splines.
6. Start the pinion nut onto the drive shaft threads by rotating the drive shaft until the nut
is snug.
57952
a - Pinion Gear (with the washer glued to it)
b - Pinion Nut Adaptor (91-61067A2)
c - Drive Shaft
7. Install the upper drive shaft tapered roller bearing cup. Apply 2-4-C Marine Lubricant
with Teflon to the retainer threads and install the retainer.
57953
a - Tapered Roller Bearing Cup
b - Drive Shaft Retainer
Page 6A-52 90-884294 OCTOBER 2001

8. Install the bearing carrier into the gear housing backwards to hold the propeller shaft
and the pinion nut adaptor in position.
9. Torque the pinion nut to 75 lb. ft. (102 Nm) by turning the drive shaft using the drive
shaft nut wrench and torque wrench.
57950
a - Pinion Nut Adapter (91-61067A2)

b - Drive Shaft Nut Wrench (91-56775)
c - Bearing Carrier (installed backwards)
10. Remove the bearing carrier, pinion nut adapter and drive shaft nut wrench.
11. Torque the retainer to 100 lb. ft. (135 N·m).
57935
a - Drive Shaft Bearing Retainer Wrench (91-43506)
90-884294 OCTOBER 2001 Page 6A-53

Gear Location/Backlashes/Checking and Adjustment

Drive Shaft - Bearing Preload Tool
INSTALLATION
1. Install the components from the Bearing Preload Tool Kit (91-14311A2), over the drive
shaft in the order shown.
a
b
e
d
g
70496
a - Top Nut with Threaded Pipe
b - Nut
c - Spring
d - Thrust Washer (2 Required) (12-18448)
e - Thrust Bearing
f - Thrust Washer
g - Plate
2. Pull up on the drive shaft and tighten the two (2) allen screws in the top nut of the bear-
ing preload tool.
a a
57936
a - Allen Screws
Page 6A-54 90-884294 OCTOBER 2001

3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom
nut away from top nut.
57937
a - Distance 1 in. (25.4mm)

b - Bottom nut [screwed down approximately 1 in. (25.4mm)]
Pinion Gear Location

CHECKING AND ADJUSTING
Pinion Depth – 0.025 in. (0.64mm)
NOTE: If the bearing preload tool has not already been set up, refer to “Drive Shaft - Bear-
ing Preload Tool”, ‘Installation’ section first.
NOTE: The prop shaft and forward gear can be installed when checking pinion height IF
Pinion Height Tool 91-56048 is used.
1. Place the pinion gear shimming tool into the gear housing.
NOTE: Take the following measurements at 3 locations, rotating the drive shaft 120 de-
grees between each reading (always rotate the drive shaft in a clockwise direction).
2. Insert the thickest feeler gauge that fits snugly between one tooth of the pinion gear
and high point of the shimming tool.
3. Rotate the drive shaft 120 degrees in a clockwise direction and take another reading.
4. Repeat this process until 3 readings have been taken.
5. Add the three readings together and divide the sum by 3 to get the average pinion gear
height. Make note of this average measurement.
The average pinion gear height should be 0.025 in. (0.64mm).
90-884294 OCTOBER 2001 Page 6A-55

6. If the average pinion gear height is not correct, remove the bearing preload tool, the
drive shaft retainer and the drive shaft tapered roller bearing cup. (The cup can be
removed by wiggling the drive shaft back and forth or by turning gear housing and
shaking it.) Add or subtract shims beneath the cup to obtain the proper average pinion
gear height. Reinstall the cup and retainer. Retorque retainer to 100 lb. ft. (135 Nm).
Reinstall the bearing preload tool and rotate the drive shaft at least 3 full turns in a
clockwise direction. Recheck the pinion gear height as in step 5 above. Repeat this
process until the average pinion gear height is within specification.
24643
a - Pinion Gear Shimming Tool (91-12349A2) Using Disc #2
and Flat #4
b - 0.025 in. (0.64mm) Feeler Gauge
Page 6A-56 90-884294 OCTOBER 2001

UPPER DRIVESHAFT BEARING CLEARANCE

1. When the correct pinion gear height is achieved, remove pinion nut, upper retainer
and driveshaft.
2. Apply Premium Gear Lubricant to O.D. of the driveshaft lower bearing cup and install
cup into the gear case.
3. Reinstall driveshaft and pinion gear into gear case.
4. Install the upper drive shaft bearing cup and install and torque the upper bearing re-
tainer to 100 lb. ft. (135 Nm).
5. Torque pinion nut to 70 lb. ft. (95 Nm).
57935
a - Bearing Retainer Tool (91-43506)
6. Push down on drive shaft and check clearance between pinion gear and pinion gear
shimming tool shoulder. Clearance should be 0.020 in - 0.024 in. (0.51 mm - 0.61 mm).
a - Pinion Gear Shimming Tool (91-12349A2) Using Disc #2

and Flat #4
b - Feeler Gauge
NOTE: Do not change shims under upper bearing cup or pinion height will be changed.
7. Maintain the shims as previously set under the upper drive shaft bearing cup.
8. If clearance is not within specifications, remove the upper bearing cup retainer with
tool 91-43506 and remove cup. Leave upper cup shim(s) in place.
NOTE: A 0.001 in. (25.4 mm) change of shims under the lower bearing cup will result in
a 0.001 in. (25.4 mm) change in drive shaft end play.
90-884294 OCTOBER 2001 Page 6A-57

9. With new shim(s) under lower bearing cup, reinstall upper bearing cup and torque cup
retainer to 100 lb. ft. (135.5 Nm). Recheck drive shaft clearance.
NOTE: Install a NEW pinion nut with Loctite 271 AFTER all clearances are correct.
10. If clearance is correct, clean drive shaft threads and apply Loctite 271 and install a
new pinion nut. Torque nut to 75 lb. ft. (102 Nm).
Bearing Carrier Assembly

INSTALLATION - (FOR CHECKING BACKLASHES)
NOTE: If backlashes have already been checked and they are to specification proceed
with “Bearing Carrier Assembly”, ‘Final Installation’ section
1. Place the bearing carrier assembly into the gear housing. It may be necessary to turn
the drive shaft to align the teeth of the pinion and the reverse gears.
57953
a - Bearing Carrier Assembly
2. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing
and then install the tab washer with the external tab inserted into the hole in the gear
housing.
70713
a - Gear Housing Tab Washer Alignment Hole (not seen)

b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer
Page 6A-58 90-884294 OCTOBER 2001

3. Verify that the “V” shaped tab aligns with the “V” notch in bearing carrier.
70714
a - Tab Washer
b - “V” Tab
4. Lubricate the bearing carrier retainer threads with 2-4-C Marine Lubricant with Teflon.
Start the retainer into the gear housing threads and screw it down fully by hand.
95
a - Bearing Carrier Retainer
90-884294 OCTOBER 2001 Page 6A-59


CHECKING
1. Apply forward pressure to propeller shaft as follows:
a. Attach puller jaws and puller bolt onto bearing carrier bosses and propeller shaft.
a
b
70719
b. Torque the puller bolt to 45 lb. in. (5 Nm). Rotate drive shaft three full turns clock-
wise and retorque the bolt to 45 lb. in. (5 Nm).
NOTE: If the bearing preload tool has not already been set up, see “Drive Shaft - Bearing
Preload Tool”, ‘Installation’ section.
2. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to
and touching the “I” mark on the dial indicator tool. Tighten the indicator tool onto the
drive shaft and rotate the drive shaft so that the needle in the dial makes at least one
full revolution and comes to “0” on the dial indicator scale.
e
a
d
b c
57939
a - Nuts (4) (Obtain Locally)
b - Threaded Rod [3/8 in. (9.5mm) obtain locally]
c - Dial Indicator Holding Tool (91-83155)
d - Dial Indicator (91-58222A1)
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.75:1)
Backlash Indicator Rod (91-78473) (for 1.87:1 ratio)
Page 6A-60 90-884294 OCTOBER 2001

3. Take the backlash readings by lightly turning the drive shaft back and forth, (no move-
ment should be noticed at the propeller shaft).
a. Observe the dial indicator and record the reading.
b. Loosen the indicator tool and rotate the drive shaft 90 degrees in a clockwise di-
rection.
c. Repeat step 2 above and take and record another reading. Repeat step 3 until a
total of 4 backlash readings have been taken.
4. Add the four readings together and divide the sum by four. This is your average back-
lash, which should be 0.017 in. - 0.028 in. (0.431 mm - 0.711 mm) (for 1.64:1; 1.75:1
and 1.87 ratios).
5. If backlash is LESS than the specified minimum, REMOVE shim(s) from in front of for-
ward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply
Loctite 271 to threads of nut.
6. If backlash is MORE than the specified MAXIMUM, add shim(s) in front of forward
gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loc-
tite 271 to threads of nut.
NOTE: By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change
approximately 0.001 in. (0.025 mm).
CHECKING
Reverse Gear Backlash – 0.030 in. to 0.050 in. (0.76mm to 1.27mm)
Although reverse gear backlash is not adjustable, it may be checked as follows:
NOTE: Torque cover nut to 210 lb. ft. (285 Nm).
1. Apply backward pressure on the propeller shaft as follows:
a. Install the pinion nut adaptor, washer and propeller nut as shown.
b a
23355
a - Pinion Nut Adaptor (91-61067A2)

b - Washer (12-54048)
c - Prop Nut
b. Torque the propeller nut to 45 lb. in. (5 Nm). Rotate the drive shaft 3 full turns in
a clockwise direction and retorque the propeller nut to 45 lb. in. (5 Nm).
90-884294 OCTOBER 2001 Page 6A-61

e
a
d
b c
57939

3. Take the backlash readings by lightly turning the drive shaft back and forth, so as to
feel the backlash between the gears, (no movement should be noticed at the propeller
shaft).
rection.
lash and it should be 0.030 in. - 0.050 in. (0.76mm - 1.27mm) (for 1.75:1 and 1.87:1
ratios). If backlash is not as indicated, gear case is not properly assembled or parts
are excessively worn and must be replaced before returning gear case to service.
5. Loosen the backlash indicator tool and remove the propeller nut, washer and pinion
nut adaptor. Remove the dial indicator and all its mounting components. Do not re-
move the bearing preload tool. The following instructions give specific instruc-
tions for its removal.
Page 6A-62 90-884294 OCTOBER 2001


REMOVAL
CAUTION
Before loosening the top nut allen screws of the bearing preload tool, screw the
bottom nut up as close as possible to the top nut.
1. Remove the dial indicator and its supporting tooling.
2. Screw the bottom nut of the bearing preload tool until it is as close as possible to top
nut.
3. Loosen the allen screws in the top nut.
4. Remove all components including the water pump face plate.
57936
a - Top Nut (with allen screws)

b - Bottom Nut
c - Water Pump Face Plate
90-884294 OCTOBER 2001 Page 6A-63


Final Installation
1. Remove the Bearing Carrier and lubricate the following as specified:
a. Lubricate the carrier O-ring with 2-4-C Marine Lubricant with Teflon.
b. Lubricate both the forward and aft outer diameters of the bearing carrier and gear
case area where carrier will seat with 2-4-C Marine Lubricant with Teflon.
c. Fill the space between the carrier oil seals with 2-4-C Marine Lubricant with Teflon.
2. Place the bearing carrier assembly into the gear housing. It may be necessary to turn
the drive shaft to align the teeth of the pinion and the reverse gears.
95

housing.
70713
a - Gear Case Alignment Hole

Page 6A-64 90-884294 OCTOBER 2001

4. Verify the “V” shaped tab aligns with the “V” notch in bearing carrier.
70714
a - Tab Washer
b - “V” Tab
5. Fill the bearing carrier retainer nut threads and corresponding gear housing threads
with 2-4-C Marine Lubricant with Teflon. Start the retainer into the gear housing
threads and screw it down fully by hand.
95
90-884294 OCTOBER 2001 Page 6A-65

IMPORTANT: Before torquing bearing carrier retainer, gear case must be bolted to
drive shaft housing or securely fastened in a gear case holding fixture to avoid pos-
sible damage to gear housing.
6. Torque the bearing carrier retainer to 210 lb. ft. (285 Nm). If one tab does not align up
in space between two of the notches, continue to tighten retainer until alignment is
achieved. DO NOT loosen retainer to achieve alignment.
23355
a - Bearing Carrier Retainer Wrench (91-61069)
7. Bend one tab aft (outward) into a space between two of the notches of the retainer.
Bend all the remaining tabs forward (inward).
c b
70490
a - Bearing Carrier
b - Tab
c - Retainer Notches
d - Alignment Tabs (Bend Inward)
Page 6A-66 90-884294 OCTOBER 2001


Installation
NOTE: Apply hand pressure only to install the oil seal carrier into position. Do not hammer
it into position.
1. Lubricate the oil seal carrier oil seal lips, space between seals and O-ring with 2-4-C
Marine Lubricant with Teflon and install the oil seal carrier over the drive shaft and into
the gear case.
a b
c
70501
b - Oil Seal Lips
c - O-ring
Water Pump Assembly

Installation
NOTE: The gaskets/face plate hole pattern is not symmetrical. If the holes of the gaskets/
face plate do not align with the screw holes of the gear case and/or each other, one or
more of the parts is upside down. Determine which part(s) is (are) upside down and turn
the appropriate part(s) over.
1. Install the small hole gasket then the face plate followed by the large hole gasket onto
the gear case.
58011
a - Small Hole gasket
b - Face Plate
c - Large Hole Gasket (GRAY sealing ring faces up)
90-884294 OCTOBER 2001 Page 6A-67

2. Place a small amount of 2-4-C Marine Lubricant with Teflon on the flat surface of the
impeller key and install the key onto the drive shaft keyway.
IMPORTANT: When using an impeller whose blades have taken a set, face the curl
of the blades in a counterclockwise direction. Do not install the impeller with its
blades oriented in a reversed direction from original rotation, or premature impeller
failure will occur.
3. Assemble the water pump impeller onto the drive shaft and down over the key.
b
95

a - Water Pump Impeller
b - Water Pump Impeller Key
4. Install the 2 water pump locating pins through the gaskets and face plate.
5. Apply a light coat of 2-4-C Marine Lubricant with Teflon to the inside of the pump cover.
Position the water pump body over the drive shaft and water pump locating pins. Ro-
tate the drive shaft in a clockwise direction, while pushing down on the water pump
body to ease the water pump over the impeller blades.
c
b
95

a - Water Pump Body
b - Water Pump Alignment Pins (91-821571A1)
c - Drive Shaft (turn clockwise while installing water pump body)
Page 6A-68 90-884294 OCTOBER 2001

6. Hand start two (2) fasteners into the water pump assembly and remove the water
pump locating pins. Install the remaining 2 fasteners. Run all fasteners down and
torque to 60 lb. in. (7 Nm).
7. Lightly lubricate the O-rings in the water tube coupling with 2-4-C Marine Lubricant
with Teflon.
8. Install the water tube coupling assembly to the water pump ensuring that the O-rings
are not damaged during assembly.
IMPORTANT: If seal installed above pump housing is not at the proper height, air
will be drawn into the pump resulting in overheating of the engine.
9. Using tool provided in seal kit (26-816575A2) or water pump kit (817275A3), press
seal down over drive shaft (DO NOT GREASE DRIVE SHAFT) until tool seats against
pump housing.
57945
a - Tool
b - Seal
If tool is not available, lightly press seal against housing until a height of 0.350 in. ± 0.030
in. (8.9mm ± 0.76mm) is obtained.
0.350 in. ± 0.030 in.
57946
90-884294 OCTOBER 2001 Page 6A-69

Gear Lubricant Filling Instructions

1. Inspect “Fill” and “Vent” sealing washers for cuts or abrasions. Replace washers if
necessary.
2. Clean any metal debris from magnet on “Fill” plug.
IMPORTANT: Never apply lubricant to gear housing without first removing Vent
screw, or gear housing cannot be filled because of trapped air. Fill gear housing
ONLY when housing is in a vertical position.
3. Slowly fill housing thru Fill hole with Premium Gear Lubricant until lubricant flows out
of “Vent” hole and no air bubbles are visible.
4. Install Vent screw into Vent hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling Fill screw.
5. Remove grease tube (or hose) from Fill hole and quickly install Fill screw into Fill hole.
Installing Gear Housing to Driveshaft Housing
WARNING
engine before installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt lock lever.
2. Apply a light coat of 2-4-C Marine Lubricant with Teflon onto driveshaft splines.
CAUTION
DO NOT allow lubricant on top of driveshaft. Excess lubricant, that is trapped in
clearance space, will not allow driveshaft to fully engage with crankshaft. Subse-
quently, tightening the gear housing nuts (while excess lubricant is on top of dri-
veshaft) will load the driveshaft/crankshaft and damage either or both the power-
head and gear housing. Top of driveshaft is to be wiped free of lubricant.
3. Apply a light coat of 2-4-C Marine Lubricant with Teflon onto shift shaft splines. (DO
NOT allow lubricant on top of shift shaft.)
4. Apply a thin bead of G.E. Silicone Sealer against the top of divider block.
5. Insert trim tab bolt into hole in rear of gear housing to driveshaft housing machined
surface.
6. Shift gear housing into NEUTRAL and place guide block anchor pin into NEUTRAL
position
Right Hand Rotation Outboard
a - Guide Block Anchor Pin

7. Position gear housing so that the driveshaft is protruding into driveshaft housing.
Page 6A-70 90-884294 OCTOBER 2001

NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft
splines, place a propeller onto propeller shaft. Shift gearcase into FORWARD and turn
propeller counterclockwise as the gear housing is being pushed toward driveshaft hous-
ing.
8. Move gear housing up toward driveshaft housing while aligning shift shaft splines and
water tube with water tube guide (in water pump cover).
9. Place flat washers onto studs (located on either side of driveshaft housing). Start a
nut on these studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab recess. DO NOT tighten bolt at this
time.
11. Recheck shift shaft spline engagement and correct if necessary.
NOTE: Guide block anchor pin should be in FORWARD when gearcase is in FORWARD.
IMPORTANT: Do not force gear case up into place with attaching nuts.
12. Evenly tighten 2 nuts which were started in Step 9. Torque to 55 lb. ft. (75 Nm).
13. After 2 nuts (located on either side of driveshaft housing) are tightened, check shift
operation as follows:
a. Place guide block anchor pin into forward gear position while turning prop shaft.
Rotate flywheel clockwise (viewed from top); propeller shaft should rotate clock-
wise.
b. Place guide block anchor pin into NEUTRAL position. Propeller shaft should ro-
tate freely clockwise/counterclockwise.
c. Place guide block anchor pin into REVERSE gear position. Rotate flywheel clock-
wise (viewed from top); propeller shaft should rotate counterclockwise.
IMPORTANT: If shifting operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
14. Install remaining washers and nuts onto drive shaft studs. Torque to 55 lb. ft. (75 Nm).
15. Torque bolt (started in Step 10) to 45 lb. ft. (61 Nm).
16. Position trim tab or anodic plate in gear housing. Align grooves of trim tab with ribs
in trim tab pocket. Adjust to position in which it had previously been installed, and while
holding trim tab, torque bolt to 40 lb. ft. (54 Nm)
17. Install plastic cap into trim tab bolt opening at rear edge of driveshaft housing.
Propeller Installation
WARNING
When installing or removing propeller, because of the engine’s ease in starting,
be sure that the remote control is in neutral position and that the key switch is
“OFF.” Place a block of wood between the anti-cavitation plate and propeller to
prevent accidental starting and to protect hands from propeller blades while re-
moving or installing nut.
1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with
one of the following Quicksilver products:
-- Anti-Corrosion Grease
-- Special Lubricant 101
-- 2-4-C Marine Lubricant with Teflon
-- Perfect Seal
90-884294 OCTOBER 2001 Page 6A-71

2. Place forward thrust hub over propeller shaft with shoulder side toward propeller.
3. Place propeller on propeller shaft and slide it up against thrust hub.
4. Place continuity washer (if equipped) onto shoulder of rear thrust hub.
5. Place rear thrust hub, tab washer and propeller nut on propeller shaft.
6. Thread propeller nut onto propeller shaft until nut is recessed into tab washer.
7. After propeller nut is recessed into tab washer, tighten nut securely [minimum of 55
Ib. ft. (75 Nm) torque].
8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller
nut. (If tab washer tabs do not align with slots, continue to tighten propeller nut to ob-
tain alignment. DO NOT loosen nut to align tabs.)
aa
f
c d
d e
b
51866 51866
a - Forward Thrust Hub d - Rear Thrust Hub
b - Propeller Shaft e - Tab Washer
c - Continuity Washer (if f - Propeller Nut
Equipped)
CAUTION
DO NOT misinterpret propeller shaft movement with propeller movement. If pro-
peller and propeller shaft together move forward-and-aft, this is normal; how-
ever, propeller should not move forward-and-aft on propeller shaft.
9. After first use, retighten propeller nut and again secure with tab washer (Steps 7 and
8, preceding). Propeller should be checked periodically for tightness, particularly if a
stainless steel propeller is used.
Page 6A-72 90-884294 OCTOBER 2001

Speedometer Tube Installation

1. Route speedometer tube from gearcase around lower yoke and push into junction.
Junction should be secured to yoke with sta-strap.
2. Route speedometer tube from swivel tube around lower yoke and push into junction.
After insertion of speedometer tubes into junction, pull on each tube to verify that they
are locked into junction. If tube pulls out, reinsert into junction.
a
c
d
57736 d 57735
a - Speedometer Tube from Gearcase

b - Junction
c - Sta-strap
d - Speedometer Tube from Swivel Tube
90-884294 OCTOBER 2001 Page 6A-73

LEFT HAND NON-RATCHETING
LOWER UNIT
Section 6B – Left Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications (Counter Rotation) . . 6B-1 Gear Location/Backlashes Checking and
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-61
Gear Housing (Drive Shaft)(Counter Rotation) . . . 6B-8 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-61
Gear Housing (Prop Shaft)(Counter Rotation) . . . 6B-10 Drive Shaft and Pinion Gear . . . . . . . . . . . . . . . 6B-62
General Service Recommendations . . . . . . . . . . . 6B-12 Gear Location/Backlashes/Checking and
Removal, Disassembly, Cleaning and Inspection of Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-65
Counter Rotation (Left Hand) Gear Housing . . . . 6B-13 Pinion Gear Location . . . . . . . . . . . . . . . . . . . . . 6B-66
Pre-Disassembly Inspection . . . . . . . . . . . . . . . . . . 6B-16 Reverse Gear Backlash . . . . . . . . . . . . . . . . . . . 6B-70
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16 Forward Gear/Bearing Carrier Assembly . . . . 6B-72
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17 Forward Gear Backlash . . . . . . . . . . . . . . . . . . . 6B-78
Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . 6B-19 Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6B-80
Bearing Carrier and Propeller Shaft Removal 6B-21 Component Reassembly . . . . . . . . . . . . . . . . . . 6B-80
Forward Gear Bearing Adaptor Assembly . . . 6B-33 Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6B-82
Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6B-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-82
Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . 6B-40 Drive Shaft and Pinion Gear . . . . . . . . . . . . . . . . . . 6B-85
Reverse Gear Assembly . . . . . . . . . . . . . . . . . . 6B-44 Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-85
Shift Spool Assembly . . . . . . . . . . . . . . . . . . . . . 6B-47 Bearing Carrier Assembly . . . . . . . . . . . . . . . . . . . . 6B-87
Reverse Gear Bearing Adaptor Assembly . . . 6B-50 Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-87
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6B-52 Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . . . . 6B-96 6
Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-96
Gear Housing Reassembly . . . . . . . . . . . . . . . . . . . 6B-56 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . 6B-96 B
Gear Housing Inspection . . . . . . . . . . . . . . . . . . 6B-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-96
Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-57 Gear Lubricant Filling Instructions . . . . . . . . . . . 6B-100
Reverse Gear Bearing Adaptor Assembly . . . 6B-58 Installing Gear Housing to Driveshaft Housing 6B-100
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6B-60 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-102
Speedometer Tube Installation . . . . . . . . . . . . . . 6B-103
Gear Housing Specifications (Counter Rotation)

Ratio Pinion Depth
Backlash Backlash
0.025 in. (0.635 mm) With Tool 0.017 in. to 0.028 in. (0.431 mm
1.75:1 0.040 in. to 0.060 in.
91-12349A2 using Disc #2 and to 0.711 mm) Pointer on line
1.87:1 (1.01 mm to 1.52 mm)
Flat #4 mark #1
Gearcase Lubricant Capacity
All Ratios 27.0 fl. oz. (798.0 ml)
Gearcase Pressure Check
Gearcase without Oil Gearcase should hold 15 psi for 5 minutes without leakage
Gear Ratio Pinion Gear Teeth Forward and Reverse Gear Teeth
1.75:1 12 21
1.87:1 15 28
90-884294 OCTOBER 2001 Page 6B-1

Special Tools
1. Propeller Shaft 44-93003 and Load Washer 12-37429
2. Bellville Washer 12-54048
3. Needle Bearing Driver 91-15755
6. Bearing Retainer Tool 91-43506
7. Backlash Indicator Rod 91-53459
Page 6B-2 90-884294 OCTOBER 2001

8. Drive Shaft Nut Wrench 91-56775
9. Bearing Carrier Retainer Wrench 91-61069
10. Torque Wrench (lb. in.) 91-66274
11. Backlash Indicator Rod 91-78473
12. Puller Bolt 91-85716 and Puller Jaws 91-46086A1
13. Dial Indicator Holding Tool 91-89897
14. Forward Gear Bearing Tool 91-86943
90-884294 OCTOBER 2001 Page 6B-3

15. Forward Gear Installation Tool 91-815850
16. Puller Jaws 91-816242
17. Guide Plate 91-816243
18. Bearing Driver 91-816244
20. Water Pump Alignment Pins 91-821571A1
Page 6B-4 90-884294 OCTOBER 2001

21. Pinion Gear Shimming Tool 91-12349A2
22. Bearing Preload Tool 91-14311A2
7
6
4
3
2
1 - Plate (44307) 6 - Bolt (10-12580)

2 - Adaptor (N.S.S.) 7 - Nut (11-13953)
3 - Bearing (N.S.S.) 8 - Set Screw (10-12575)
4 - Washer (N.S.S.) 9 - Sleeve (23-13946)
5 - Spring (24-14111)
23. Bearing Adaptor Installation Tool 91-18605A2
90-884294 OCTOBER 2001 Page 6B-5

24. Bearing Removal and Installation Tool 91-31229A7 – Includes Driver Head 91-36569:
Driver Head Rod 91-37323; Nut 11-24156; Pilot Washer 91-36571; Pilot Plate
91-29310; Puller/Driver Head 91-38628; Mandrel 91-30366; Plate 91-29310; Driver
Head 91-32325; Puller Shaft 91-31229; Washer 91-34961.
25. Slide Hammer Puller 91-34569A1
26. Puller Bolt 91-85716 and Puller Jaws 91-46086A1
27. Dial Indicator 91-58222A1
Page 6B-6 90-884294 OCTOBER 2001

28. Pinion Nut Adaptor 91-61067A3
29. Drive Shaft Adaptor 91-61077
30. Leakage Tester FT8950
90-884294 OCTOBER 2001 Page 6B-7

Gear Housing (Drive Shaft)(Counter Rotation)

33
4.75 IN/120.65MM 95 95
TORPEDO DIA. 34
7 Loctite 271 35
92
36
Loctite 7649 Primer
32
31
30
44
29 95
46
45
95 26
38
27
95
43 25
95
95
37
12
95
42 24 23
28
40 22 13
19 21 7
41 14
7
15
39 20
9
10 11 3
1 95
6
5
9 11 4
10
47 8
16
5 7
7
17
18 2
92
Page 6B-8 90-884294 OCTOBER 2001

Gear Housing (Drive Shaft)(Counter Rotation)

TORQUE
REF.
REF
1 1 GEAR HOUSING
2 1 PIN
3 1 FILLER BLOCK
4 1 PITOT TUBE
5 2 ANODE
6 1 SCREW 60 7
7 1 NUT
8 1 ROLLER BEARING
9 2 DOWEL PIN
10 2 SCREW ASSEMBLY 60 7
11 2 SEALING WASHER
1 CONNECTOR (X-LONG - 12 IN.)
12
1 CONNECTOR (XX-LONG - 17 IN)
13 1 CONNECTOR
14 1 COVER
15 1 GASKET
16 1 PINION GEAR (1.75:1 - 12/21) (PART OF 43-828695A1)
17 1 WASHER
18 1 NUT 70 95
19 1 OIL SEAL
20 1 O RING
21 2 SCREW (M6 x 16) 60 7
22 1 RUBBER WASHER
23 1 SHIFT SHAFT (LOWER)
1 DRIVE SHAFT (X-LONG)
24
1 DRIVE SHAFT (XX-LONG)
25 AR SHIM SET
27 1 CUP
28 1 KEY
29 AR SHIM
31 1 CUP
32 1 RETAINER 100 135
33 1 CARRIER ASSEMBLY
34 1 O RING
35 1 OIL SEAL
36 1 OIL SEAL
37 1 WATER PUMP ASSEMBLY
38 1 SEAL
39 1 GASKET
40 1 GASKET
41 1 FACE PLATE
42 1 IMPELLER
43 4 SCREW (M6 x 16) 60 7
44 1 COUPLING ASSEMBLY
45 1 O RING
46 1 O RING
47 1 DECAL-Counter Rotation
90-884294 OCTOBER 2001 Page 6B-9

Gear Housing (Prop Shaft)(Counter Rotation)
4.75
IN/120.65MM
84
TORPEDO DIA.
48
83
53 49
52
87 50
51
58
54
95
66
60 55 65
64 56
63
87 94
57
87
87
67
59 68 87
61
62 69 95
71
76
72 70
73 78
87
87
74 77
75
74 79
95
73 80
72
81 95
82
95
95
87 Gear Lubricant 95
94 Anti-Corrosion Grease
Page 6B-10 90-884294 OCTOBER 2001

Gear Housing (Prop Shaft)(Counter Rotation)

TORQUE
REF.
REF
1 1 GEAR HOUSING
48 1 PLUG
49 1 SHIFT CRANK
50 1 SHIFT SPOOL
51 1 SPOOL
52 1 SLEEVE
53 1 COTTER PIN
54 AR SHIM SET
55 1 BEARING ADAPTOR ASSEMBLY
56 1 ROLLER BEARING
57 1 THRUST WASHER
58 1 THRUST BEARING
59 1 REVERSE GEAR (1.75:1 - 12/21)
60 1 ROLLER BEARING
61 1 SPRING
62 1 SLIDING CLUTCH
63 1 CROSS PIN
64 1 DETENT PIN
65 1 PROPELLER SHAFT
66 1 FORWARD GEAR (1.75:1 - 12/21)
AR SPACER SHIM .206 IN.
67 AR SPACER SHIM .218 IN.
68 1 ROLLER BEARING
69 1 THRUST RING
70 1 BEARING ADAPTOR ASSEMBLY
71 1 ROLLER BEARING
72 2 THRUST WASHER
73 2 THRUST BEARING
74 2 THRUST RACE
75 2 KEEPER
76 1 O RING
77 1 BEARING CARRIER ASSEMBLY
78 1 ROLLER BEARING
79 1 OIL SEAL (INSIDE)
80 1 OIL SEAL (OUTSIDE)
81 1 TAB WASHER
82 1 COVER 210 285
83 1 ANODIC PLATE
84 1 SCREW 40 54.0
90-884294 OCTOBER 2001 Page 6B-11

General Service Recommendations

There may be more than one way to “disassemble” or “reassemble” a particular part(s),
therefore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more compo-
nents.
Service procedure order in this section is a normal disassembly-reassembly sequence.
It is suggested that the sequence be followed without deviation to assure proper repairs.
When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to “reassembly and installation” of that compo-
nent in the reassembly part of this section. Use the “Table of Contents” (on back of section
divider) to find correct page number.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in air line.
BEARINGS
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing
so that it passes thru the bearing. DO NOT spin bearing with compressed air, as this may
cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Pre-
mium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bear-
ing race in-and-out, while holding outer race, to check for side wear. When inspecting ta-
pered bearings, determine condition of rollers and inner bearing race by inspecting bear-
ing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or
discoloration from over-heating. Always replace tapered bearing and race as a set.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that
the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded
particles, uneven wear and/or discoloration from overheating. The shaft and bearing must
be replaced, if the conditions described are found.
SHIMS
Keep a record of all shim amounts and location during disassembly to aid in reassembly.
Be sure to follow shimming instructions during reassembly, as gears must be installed to
correct depth and have the correct amount of backlash to avoid noisy operation and pre-
mature gear failure.
SEALS
As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard
to appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter
of all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean
and dry. To ease installation, apply 2-4-C Marine Lubricant with Teflon on all O-rings. To
prevent wear, apply 2-4-C Marine Lubricant with Teflon on l.D. of oil seals. To prevent cor-
rosion damage after reassembly, apply 2-4-C Marine Lubricant with Teflon to external sur-
faces of bearing carrier and cover nut threads prior to installation.
Page 6B-12 90-884294 OCTOBER 2001

Removal, Disassembly, Cleaning and Inspection of Counter

Rotation (Left Hand) Gear Housing
REMOVAL
WARNING
engine before removing gear housing from driveshaft housing.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.
2. Shift engine into NEUTRAL position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller
locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propel-
ler shaft.
5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position.
Remove plastic cap at rear edge of driveshaft housing. Remove bolt that secures trim
tab and remove tab from gear housing.
6. Once trim tab is removed, remove bolt from inside of trim tab cavity.
i
g
d
f h
a
c
b
e
c
51916 51912 52375
a - Tab Washer
b - Propeller Nut
c - Rear Thrust Hub
d - Continuity Washer (if equipped)
e - Propeller Shaft
f - Thrust Hub (forward)
g - Bolt (secures trim tab)
h - Bolt (inside trim tab cavity)
i - Ribs – Align Carefully with Trim Tab while Securing Tab
90-884294 OCTOBER 2001 Page 6B-13

7. While pressing in on speedometer hose junction, pull out on hose to disconnect.
b
a
57735
a - Press in on Junction
b - Pull out on Hose
8. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo-
site side is loosened sufficiently, or gear housing could be damaged.)
a - Side Mounting Locknuts
9. Pull gear housing away from drive shaft housing as far as the loosened nuts (in Step
8) will allow, then remove loosened nuts. (DO NOT allow gear housing to fall, as it now
is free.)
10. Pull gear housing from drive shaft housing.
Page 6B-14 90-884294 OCTOBER 2001

DRAINING AND INSPECTING GEAR HOUSING LUBRICANT

1. Place gear housing in a suitable holding fixture or vise with the driveshaft in a vertical
position, as shown.
NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later
models.
2. Position a clean drain pan under gear housing and remove “Fill” and “Vent” screws
from gear housing.
3. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal
particles (resembling powder) indicates normal wear. Presence of larger particles (or
a large quantity of fine particles) indicates need for gear housing disassembly, and
component inspection.
4. Note the color of gear lubricant. White or cream color indicates presence of water in
lubricant. Check drain pan for water separation from lubricant. Presence of water in
gear lubricant indicates the need for disassembly, and inspection of oil seals, seal sur-
faces, O-rings and gear housing components.
IMPORTANT: Gear lubricant drained from a recently run gear case will be a light
chocolate brown in color due to agitation/aeration. Oil which is stabilized will be
a clear yellow brown in color.
a
52377
a - Fill Screw
b - Vent Screw
90-884294 OCTOBER 2001 Page 6B-15

Pre-Disassembly Inspection
Propeller Shaft
INSPECTION
1. Check for a bent propeller shaft as follows:
a. Rotate the propeller shaft while observing the dial indicator. If the deflection is
more than 0.009 in. (0.23 mm), a bent propeller shaft is indicated.
2. Measure propeller shaft endplay. If it is in excess of 0.093 in. (2.36mm), disassemble
gear case and check condition of the reverse shoulder of the propeller shaft, reverse
gear and thrust washer. Replace components as required.
22086
a - Prop Shaft Runout
b - Prop Shaft Endplay
Page 6B-16 90-884294 OCTOBER 2001

Water Pump
REMOVAL AND DISASSEMBLY
1. Remove the water seal, water tube coupling assembly, and the water pump screws.
c
a
57944
a - Water Seal
b - Water Tube Coupling
c - Water Pump Screws (4)
2. Carefully slide the water pump straight up off of the drive shaft. It may be necessary
to encourage the water pump up by gently prying up on its mounting flanges with a
couple of screwdrivers.
b b
70487
a - Water Pump Body
b - Screwdrivers
90-884294 OCTOBER 2001 Page 6B-17

3. Remove the impeller, impeller key, the face plate and gaskets, (discard the gaskets).
b
d
70605
a - Impeller
b - Impeller Key
c - Water Pump Face Plate
d - Gasket (1 each side of face plate)

1. Inspect the water tube coupling assembly for wear or damage. If necessary replace
the worn or damaged components especially the two O-rings on the inside, one at the
top and one at the bottom.
b 70613
a - Water Tube Adaptor
b - O-rings (2)
IMPORTANT: The circular groove formed by the impeller sealing bead should be
disregarded when inspecting cover and plate. The depth of the groove will not af-
fect water pump output.
2. Inspect face plate and water pump cover for grooves and/or rough surfaces.
3. Replace cover and /or face plate if grooves (other than sealing grooves) are more than
0.030 in. (0.762 mm) deep.
Page 6B-18 90-884294 OCTOBER 2001

4. Inspect impeller side seal surfaces and ends of impeller blades for cracks, tears and
wear. Replace impeller if any of these conditions are found.
5. Inspect impeller bonding to impeller hub.
6. Inspect impeller for glazed or melted appearance (caused by operation without suffi-
cient water supply). Replace impeller if any of these conditions exist.
70500
a - Impeller
b - Hub
IMPORTANT: When completing gear housing repairs, that require removal of water
pump impeller, it is recommended that the impeller be replaced. If it is necessary,
however, to re-use impeller, DO NOT install in reverse to original rotation, or prema-
ture impeller failure will occur.

REMOVAL
1. Remove the oil seal carrier from the gear housing. It may be necessary to gently pry
up on it with two screwdrivers.
a
57940
b - Screwdrivers
90-884294 OCTOBER 2001 Page 6B-19

OIL SEAL CARRIER ASSEMBLY - COMPONENT DISASSEMBLY

been found to be defective and are in need of repair or replacement.
1. Remove the o-ring.
70501
a - O-ring
b - Oil Seals (2)
2. Remove oil seals.
c
b
70610
b - Oil Seals
c - Screwdriver
Page 6B-20 90-884294 OCTOBER 2001

OIL SEAL CARRIER ASSEMBLY – COMPONENT REASSEMBLY

The oil seals in the carrier assembly are the same diameter. The bottom (first) seal lip
faces down; the top (second) seal lip faces up. Apply 2-4-C Marine Lubricant with Teflon
to seal lips and between seals. Press seal into carrier with suitable mandrel. Second seal
should be pressed in flush with carrier surface.
95
a
a - Bottom Seal (lip faces down)
b - Top Seal (lip faces up)
Bearing Carrier and Propeller Shaft Removal

1. Straighten the tab on the tab washer.
70490
a - Tab on Tab Washer
90-884294 OCTOBER 2001 Page 6B-21

2. Remove the bearing carrier retainer following step a or b as follows:
CAUTION
DO NOT drill into the gear housing retainer threads when using the following pro-
cedure for removing the retainer
a. If the retainer is corroded in place, drill 4 holes in the retainer and fracture the re-
tainer with a chisel. Pry the remaining segments out.
23356
a - Drilled Holes
b. Remove the bearing carrier retainer using the Bearing Carrier Retainer Wrench
(91-61069).
70491
a - Bearing Carrier Retainer Wrench
Page 6B-22 90-884294 OCTOBER 2001

3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing
carrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER.
NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat
to loosen the carrier.
50786
4. Lift the bearing carrier out of the gear housing. Locate and retain the thrust washer
that may be stuck to the inside surface of the bearing carrier.
50826 50779
a - Thrust Washer
90-884294 OCTOBER 2001 Page 6B-23

5. Remove the aft thrust bearing.
50786
a - Thrust Bearing
6. Remove the aft thrust collar.
50787
a - Thrust Collar
Page 6B-24 90-884294 OCTOBER 2001

7. Lift up on the propeller shaft and push down on the forward thrust collar to remove the
two keepers.
a
b
50778 50826
a - Thrust Collar
b - Keepers (2)
8. Remove the forward thrust collar.
50784
a - Thrust Collar
90-884294 OCTOBER 2001 Page 6B-25

9. Remove the forward thrust bearing.
50783
a - Thrust Bearing
10. Form a tool using a 1/8 in. (3 mm) wire as shown in the following figure and remove
the forward gear bearing adaptor.
50786
a - Wire Tool
b - Forward Gear Bearing Adaptor
11. Shift gear case into forward gear.

NOTE: The thrust race has a tight fit in the gear housing bore. Use the Forward Gear In-
stallation Tool (91-815850) to remove the thrust race and the forward gear together. If this
attempt fails, form a small hook on the end of a stiff piece of wire and while applying heat
to the outside of gear case, pull the thrust race up and out of the gear housing.
Page 6B-26 90-884294 OCTOBER 2001

12. Remove the O-ring from inside the gear housing.

13. Remove the forward gear, thrust race, and the thrust bearing (between the gear and
the race).
14. Remove the forward gear shim.
50783
a - Forward Gear Installation Tool (91-815850)
b - Thrust Race
c - Forward Gear
d - Shim
90-884294 OCTOBER 2001 Page 6B-27

BEARING CARRIER ASSEMBLY - INSPECTION

1. Clean the assembly and all components with a suitable solvent and dry the parts thor-
oughly using compressed air.
NOTE: If any of the following items are found to be defective complete the appropriate
instruction(s) in “Bearing Carrier Assembly”, ‘Component Disassembly and Inspection’
section.
2. Inspect the bearing carrier for signs of excessive corrosion especially in the area
where the bearing carrier touches the gear housing. If excessive corrosion is evident
replace the carrier.
b
50818
a - Bearing Carrier
b - Mating Surfaces
3. The condition of the bearing surface on the propeller shaft in the area that the needle
bearing (in the bearing carrier) rides is an indication of the condition of the needle
bearing in the bearing carrier. Replace the bearing if the surface of the shaft is pitted,
grooved, scored, worn unevenly, discolored from overheating or has embedded metal
particles.
a
50698
a - Propeller Shaft Bearing Contact Area
Page 6B-28 90-884294 OCTOBER 2001

4. Inspect the forward gear for pitted, chipped, broken teeth, hairline fractures, and ex-
cessive or uneven wear. Replace the forward gear and the pinion gear if any defects
are found.
5. Inspect the outer hub of the forward gear for excessive wear or damage. Replace the
forward and the pinion gear if either of these conditions exist.
6. Inspect the clutch jaws of the gear for damage. Surfaces must not be chipped or
rounded off. Replace the forward and the pinion gear if any are found.
23355
a - Reverse Gear Teeth
b - Clutch Jaws
7. Inspect the thrust bearings, collars and forward gear bearing adaptor for excessive
wear in the areas where the thrust bearings come into contact with them. Replace the
appropriate components if they are found to be defective.
8. Inspect the bearing carrier retainer for cracks and/or broken or corroded threads. Re-
place it if any are found.
9. Inspect the large O-ring for damage and/or deterioration. Replace it if either condition
is found.
90-884294 OCTOBER 2001 Page 6B-29

BEARING CARRIER ASSEMBLY - COMPONENT DISASSEMBLY AND INSPECTION

been found to be defective.
NOTE: Inspection of the bearing surfaces on the propeller shaft where the needles of the
bearing carrier needle bearing rolls, gives an indication of the condition of the needle
bearing inside the bearing carrier. Replace needle bearing in the bearing carrier if the prop
shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
1. Perform the following step a. or b. as necessary.
a. If Replacing the Needle Bearing and Seals: Remove the needle bearing and
seals with the tools as shown.
c
a
b
23140
a - Needle Bearing
b - Oil Seals
c - Driver Head (91-36569)
d - Bearing Driver Rod (91-37323)
(1.) Discard the needle bearing and both seals.

b. If Replacing the Seal Only: Remove the oil seals with a suitable pry bar, being
careful not to damage the bore of the bearing carrier.
23140
a - Oil Seals
b - Pry Bar
(1.) Discard both of the seals.
Page 6B-30 90-884294 OCTOBER 2001

BEARING CARRIER ASSEMBLY - COMPONENT REASSEMBLY

1. Clean all of the components with a suitable solvent and dry the parts thoroughly using
compressed air. Be careful not to spin the bearing.
2. Lubricate the bore that the needle bearing is pressed into with Premium Gear Lubri-
cant.
3. Assemble the needle bearing (with the numbered end of the bearing towards the driv-
er shoulder), onto the driver.
4. Press the needle bearing into the bearing carrier until the driver bottoms out on the
bearing carrier. Ensure that the numbered side of the needle bearing faces the seal
end (aft end) of the carrier.
87
a

a - Needle Bearing
b - Bearing Carrier
c - Needle Bearing Driver (91-15755)
5. Thoroughly clean the bore to which the first seal is to be pressed.

6. Assemble the first seal (with the lips of the seal facing away from the driver shoulder)
onto the long end of the oil seal driver.
90-884294 OCTOBER 2001 Page 6B-31

7. Press on the oil seal driver until the driver bottoms onto the aft face of the bearing
carrier.
b
a
50788
a - Oil Seal
b - Oil Seal Driver (91-31108) (long end)
c - Bearing Carrier
8. Apply a thin film of Loctite 271 to the outer diameter of the second seal.
9. Assemble the second seal (with the lips seal facing the driver shoulder) onto the short
end of the driver.
10. Press the oil seal with the driver until the driver bottoms out on the bearing carrier.
a
7
95 b
7 Loctite 271
a - Driver
b - Oil Seal (lips toward driver shoulder)
c - Bearing Carrier
Page 6B-32 90-884294 OCTOBER 2001

11. Wipe up all of the excess Loctite. Do not allow any of the excess Loctite to spread to
other parts of the assembly.
12. Lubricate the seal lips and fill the area between the seals with 2-4-C Marine Lubricant
with Teflon.
Forward Gear Bearing Adaptor Assembly

INSPECTION
1. Thoroughly clean the forward gear bearing adaptor with a suitable solvent and dry it
using compressed air.
NOTE: The condition of the bearing surfaces on the forward gear in the areas that the
bearings of the bearing adaptor and the thrust bearing rides, is an indication of the condi-
tion of the respective bearings. Replace the bearing(s) if the surface of the gear and/or
the thrust washer is pitted, grooved, scored, worn unevenly, discolored from overheating
or has embedded metal particles.
2. Assemble the forward gear to the bearing adaptor. Inspect them for excessive move-
ment or roughness by rotating the gear in the adaptor. Replace the bearing in the
adaptor if either of these conditions exist.
3. Inspect the adaptor for other signs of excessive wear or damage. Replace the adaptor
if any are found.
90-884294 OCTOBER 2001 Page 6B-33

FORWARD GEAR BEARING ADAPTOR ASSEMBLY - COMPONENT DISASSEMBLY AND

REASSEMBLY
NOTE: Complete the instructions in this section only if the needle bearing in the bearing
adaptor is defective and the adaptor is to be reused.
1. Disassemble the adaptor as follows:
a. Remove the bearing from the adaptor using the bearing removal tool. Align the
pins of the tool with the holes of the adaptor and apply pressure to the center of
the tool so that the pressure is equal on both of the pins. Discard the bearing.
b
c
c
d
50874
a - Forward Gear Bearing Adaptor
b - Bearing Removal Tool (91-816245)
c - Pins
d - Universal Puller Plate
2. Assemble the adaptor as follows:

a. Lubricate the bore that the needle bearing is pressed into with 2-4-C Marine Lubri-
cant with Teflon.
b. Assemble the needle bearing to the adaptor with the numbered end of the bearing
facing the driver shoulder.
c. Press the needle bearing into the bearing adaptor using a suitable mandrel until
the bearing bottoms in the adaptor.
Page 6B-34 90-884294 OCTOBER 2001

Drive Shaft Assembly

REMOVAL
1. Remove the drive shaft pinion nut as follows:
a. Place the drive shaft bearing retainer wrench onto the drive shaft. Do not loosen
the retainer at this time.
b. Insert the pinion nut adapter, with the MR slot facing the pinion gear, into the gear
housing. It may be necessary to slightly lift and rotate the drive shaft to align the
pinion gear nut into the pinion nut adapter slot.
c. Install the bearing carrier into the gear housing backwards to support the prop
shaft and to keep the pinion nut adapter aligned.
d. Place the drive shaft nut wrench over the drive shaft splines and loosen, (but do
not fully unscrew), the pinion nut by rotating the drive shaft counterclockwise.
c
70887
a - Drive Shaft Nut Wrench (91-56775)
b - Drive Shaft Bearing Retainer Wrench (91-43506)
c - Pinion Nut adapter (MR Slot) (91-61067A2)
90-884294 OCTOBER 2001 Page 6B-35

e. If the drive shaft is broken, place propeller shaft nut wrench onto the propeller
shaft splines, hold shift shaft in forward gear and loosen, (but do not fully un-
screw), the pinion nut by rotating prop shaft counterclockwise to turn gears, thus
loosening the pinion nut.
NOTE: The propeller shaft nut wrench is included with the pinion nut adapter kit.
c
b
70607
a - Pinion Nut Adaptor (MR slot) (91-61067A2)
b - Propeller Shaft Nut Wrench (91-61067)
c - Shift Shaft (Turn Clockwise) (Protect shaft splines with soft material)
f. Completely unscrew the drive shaft bearing retainer.

g. Completely unscrew the pinion nut by rotating the drive shaft (or the propeller
shaft) in a counterclockwise direction.
h. Remove all tools.
IMPORTANT: The pinion bearing rollers are free to fall out of the pinion bearing
once the drive shaft is removed. Be careful not to loose the (18) rollers.
2. Remove the drive shaft and all components by pulling the drive shaft straight out of
the gear housing as shown.
a
b
70608
a - Drive Shaft
b - Drive Shaft Retainer, Bearing Cup, Bearing, and Shims
3. With propeller shaft facing straight up, rotate shift lever into forward. Pull propeller
shaft up and over towards port side of gear case.
Page 6B-36 90-884294 OCTOBER 2001

4. Form a small hook on a stiff piece of wire and attempt to hook onto the top side of the
gear and pull it out. It may be necessary to slightly move the propeller shaft from side-
to-side to dislodge the pinion gear.
c
a
50884
a - Propeller Shaft
b - Pinion Gear
c - Wire Tool
NOTE: If pinion gear is seized onto the driveshaft, place gearcase in vise using soft jaw
vise covers. Place a block of wood on gear housing mating surface. Use a mallet and care-
fully tap gear housing away from drive shaft.
CAUTION
Do not strike gear housing hard with mallet or allow gear housing to fall.
a
b
57951
a - Wood Block
b - Drive Shaft in Soft Jaw Vise
90-884294 OCTOBER 2001 Page 6B-37

5. Remove lower drive shaft bearing cup and shims using slide hammer puller
(34569A1) (retain shims for re-installation).
a - Slide Hammer Puller (91-34569A1)

b - Lower Drive Shaft Bearing Cup
DISASSEMBLY
1. Both upper and lower tapered roller bearings can be removed from the drive shaft in
one operation. Using the bottom bearing cup removed from the gearcase, place the
cup on top of a vise leaving the vise jaws open enough to allow the drive shaft to slide
through.
2. Place the driveshaft through the cup and vise until the bottom bearing is resting in the
cup. While holding the driveshaft, tap on the top of the shaft with a lead hammer until
the bearings are free. Do not drop the shaft when performing this operation.
a - Lower Bearing Cup Removed from Gear Case

b - Drive Shaft With Both Upper and Lower Bearings
Page 6B-38 90-884294 OCTOBER 2001

DRIVE SHAFT ASSEMBLY - INSPECTION

1. Clean all parts with a suitable solvent and dry the parts using compressed air. DO NOT
spin the bearings.
2. The condition of the drive shaft bearing cup is an indication of the condition of the ta-
pered roller bearing on the drive shaft. Replace the bearing and bearing cup if the cup
is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
3. Inspect the bearing surface on the drive shaft where the needles of the lower pinion
bearing roll. Replace the drive shaft if it is pitted, grooved, scored, worn unevenly, dis-
colored form overheating, or has embedded particles.
4. Inspect the splines at both ends of the drive shaft for a worn or twisted condition. Re-
place the drive shaft if either condition exists.
or uneven wear. Replace the pinion gear and the forward gear if any defects are
found.
6. Inspect driveshaft for groove(s) where water pump base oil seals contact shaft. Re-
place driveshaft if groove(s) are found.
REASSEMBLY
1. Apply a light coat of Premium Gear Lubricant on l.D. of drive shaft tapered bearing.
Apply High Pressure Grease (such as Chicago Manufacturing and Distributing Lube
#3) to the O.D. of both bearings.
2. Assemble a new tapered roller bearing to the drive shaft with the large O.D. of the
bearing facing the pinion gear end of the drive shaft.
3. Thread a used pinion nut onto end of drive shaft. Leave approximately 1/16″ (2mm)
of nut threads exposed. Drive shaft threads MUST NOT extend beyond nut or thread
damage could result while pressing.
4. Press the tapered roller bearing onto the drive shaft using the universal puller plate
and a suitable mandrel, (an old tapered roller bearing inner race).
c
d
a - Used Pinion Nut

b - Drive Shaft
c - Tapered Bearing(s)
d - Old Bearing Inner Race
e - Universal Puller Plate
90-884294 OCTOBER 2001 Page 6B-39


REMOVAL
CAUTION
Hold onto the propeller shaft assembly in the following step to avoid personal in-
jury and/or dropping components when turning the gear housing over.
1. While holding onto the propeller shaft, turn the gear housing over so that the bore
opening is facing down.
2. While moving the propeller shaft to the left (port) side of the gear housing, to allow the
shift spool to disengage from the shift crank, lower the propeller shaft out of the gear
housing.
NOTE: The rollers of the reverse gear bearing adaptor may become dislodged while re-
moving the propeller shaft assembly. If this occurs, inspect the bearing cage to see if it
has been damaged. If it has not been damaged simply snap the rollers back into position.
If it has been damaged it will be necessary to remove and replace the bearing as outlined
in the “Reverse Gear Bearing Adaptor Assembly”, ‘Component Disassembly and Reas-
sembly’ section.
c
58014
a - Propeller Shaft Assembly
b - Shift Spool
c - Shift Crank
Page 6B-40 90-884294 OCTOBER 2001

3. Locate and retain the thrust race and thrust bearing which could be on top of the re-
verse gear (if not, they may be stuck to the reverse gear bearing adaptor).
58014
a - Thrust Bearing and Race
PROPELLER SHAFT ASSEMBLY - COMPONENT DISASSEMBLY

IMPORTANT: When accomplishing the next step, all of the parts are free to come
apart. Work closely over a work bench to ensure that the parts are not dropped or
damaged, and to avoid personal injury.
1. Remove the spring around the clutch being careful not to overstretch it during remov-
al. If the spring does not coil back to its normal position once it has been removed,
it must be replaced.
d c
58015
a - Spring
b - Shift Spool Assembly
c - Reverse Gear Assembly
d - Sliding Clutch
90-884294 OCTOBER 2001 Page 6B-41

2. Remove detent pin.

3. Remove the cross pin that goes through the clutch dog. Remove the reverse gear and
slide the clutch off of the propeller shaft.
58012
e d
c
58018
a - Detent Pin
b - Cross Pin
c - Reverse Gear Assembly
d - Spool
e - Clutch
Page 6B-42 90-884294 OCTOBER 2001

PROPELLER SHAFT ASSEMBLY - COMPONENT INSPECTION

1. Clean all the parts with a suitable solvent and dry the parts thoroughly using com-
pressed air, being careful not to spin bearings.
2. Inspect the sliding clutch jaws for damage. Jaws must not be chipped or rounded off.
Replace the clutch if they are.
58013
a - Jaws
3. Inspect the bearing surfaces on the propeller shaft where the needles of the bearing
carrier needle bearing and the needles of the forward gear needle bearing roll. Re-
place the propeller shaft if it is pitted, grooved, scored, worn unevenly, discolored from
overheating, or has embedded particles.
a b
c
50698
a - Bearing Carrier Needle Bearing Contact Area
b - Reverse Gear Needle Bearing Contact Area
c - Splines
4. Inspect the propeller shaft splines at both ends for a broken, worn, or twisted condi-
tion. Replace the propeller shaft if any of these conditions exists.
5. Inspect the surface of the propeller shaft where the bearing carrier seal lips contact
the shaft. If the oil seals have made grooves, replace propeller shaft and seals.
a
50698
a - Bearing Carrier Seal Contact Area
90-884294 OCTOBER 2001 Page 6B-43

6. Inspect the propeller shaft for a bent condition.

a. V-Blocks and Dial Indicator
(1.) Position the propeller shaft bearing surfaces on V-blocks.
(2.) Adjust the height of V-blocks to level the propeller shaft.
(3.) Position the dial indicator tip just forward of the propeller shaft splines.
a
52727
a - Check Movement with Dial Indicator (91-58222A1) Here
7. Rotate the propeller shaft and observe the dial indicator movement. If the indicator
in the dial moves more than 0.009 in. (0.23mm), replace the propeller shaft.
Reverse Gear Assembly

COMPONENT INSPECTION
1. Clean the reverse gear assembly with a suitable solvent and dry thoroughly with com-
pressed air. Be careful not to spin the bearings.
or uneven wear. Replace the reverse gear if any defects are found.
3. Inspect the clutch jaws of the gear for damage. The surfaces must not be chipped or
rounded off. Replace the reverse gear if any of these conditions exist.
23351
a - Reverse Gear Teeth
b - Clutch Jaws
Page 6B-44 90-884294 OCTOBER 2001

NOTE: The needle bearing in the reverse gear should not be removed unless damage
has been found. Inspect to ensure that all of the needles are present and in position. The
needles may have become dislodged while removing the gear from the propeller shaft
(and/or while removing the propeller shaft assembly from the gear housing). They may
be snapped back into place as long as no damage has occurred to the bearing cage.
4. Inspect the needle bearings on the inside of the reverse gear and the bearing surface
on the propeller shaft. If either the needle bearings, or the bearing surface of the pro-
peller shaft is pitted, grooved, scored, worn unevenly, discolored from overheating,
or has embedded particles, replace the propeller shaft and remove and replace the
needle bearing in the reverse gear as outlined in the next section.
a
50698
a - Forward Gear Needle Bearing Contact Area
REVERSE GEAR ASSEMBLY - COMPONENT DISASSEMBLY

NOTE: Reverse gear can only be removed from gear housing after drive shaft and pinion
gear have been removed.
NOTE: Complete the instructions in this section only if the needle bearing in the gear has
been found to be defective and the reverse gear is to be reused. Bearings that have be-
come dislodged may be snapped back into position. If this is the only problem that exists
it is not necessary to replace the needle bearing.
1. Replace bearing if it is rusted or does not roll freely.
2. Press the reverse gear needle bearing out using a suitable mandrel.
a
50778
a - Reverse Gear Needle Bearing
90-884294 OCTOBER 2001 Page 6B-45

REVERSE GEAR ASSEMBLY - COMPONENT REASSEMBLY

IMPORTANT: The appearance of the forward and reverse gear is almost identical.
The forward gear has a shorter hub and is slightly smaller in diameter.
a REVERSE
FORWARD
3.75″ (9.5cm) 4″ (10.2cm)

50885
a - Shorter Hub
1. Apply Premium Gear Lubricant to I.D. of forward gear. Press the needle bearing into
the reverse gear until tool contacts gear.
87 b

a - Reverse Gear
b - Needle Bearing
c - Bearing Driver (91-86943)
Page 6B-46 90-884294 OCTOBER 2001

Shift Spool Assembly

INSPECTION
1. Clean the assembly with a suitable solvent and dry the parts using compressed air.
2. Inspect the shift spool assembly for damage. Small nicks and burrs may be smoothed.
If any parts are damaged or worn beyond repair it will be necessary to replace the
complete shift spool assembly. Individual parts are not available for the assembly.
3. Inspect the shift spool for wear in the area where the shift crank comes into contact.
b a
23356
a - Contact Area
b - Shift Spool
4. Inspect to insure that the spool spins freely (it may be helpful to lightly tap the forward
[castle nut] end of the shift spool shaft against a firm surface to align the internal parts).
5. Inspect to insure that the spool has no more than 0.002-0.010 (0.05-0.25 mm) end
play.
.002 (0.05mm)
to
.010 (0.25mm)
55694
a - Spool
90-884294 OCTOBER 2001 Page 6B-47

SHIFT SPOOL ASSEMBLY - COMPONENT DISASSEMBLY

NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts
of the assembly due to an improperly functioning shift spool assembly or debris in the gear
housing and/or shift spool assembly. Individual components for the shift spool are not
available as replacement parts. If the shift spool does not function properly (see the pre-
ceding “Shift Spool Assembly - Inspection” section) and the following cleaning and adjust-
ment procedures do not produce the desired results, it will be necessary to order a new
shift spool assembly.
1. Disassemble the shift spool assembly as follows:
a. Remove and discard the cotter pin.
b. Remove the castle nut and the spool.
SHIFT SPOOL ASSEMBLY - COMPONENT INSPECTION
1. Clean all components with a suitable solvent and dry them with compressed air.
2. Inspect each component for wear or damage. If any components are worn beyond
repair, damaged, or broken it will be necessary to replace the complete shift spool as-
sembly. Small nicks or burrs may be smoothed and the parts reused.
SHIFT SPOOL ASSEMBLY - COMPONENT REASSEMBLY
1. Assemble the shift spool and shift spool shaft as follows:
a. Place the shift spool onto the shift spool shaft.
b. Assemble the castle nut and screw it down until it touches the washer and a slight
resistance is felt.
c. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the
hole in the shaft. If, when the castle nut is screwed down, the cotter pin slot is al-
ready aligned at the hole in the shaft, back the castle nut off until the next available
slot in the nut is aligned with the hole in the shaft.
d. Insert a new cotter pin and bend ends of the cotter pin in opposite directions.
d
a b c
55694
a - Shift Spool Shaft
b - Shift Spool
c - Castle Nut
d - Cotter Pin
Page 6B-48 90-884294 OCTOBER 2001

SHIFT SPOOL ASSEMBLY - ADJUSTMENT

NOTE: If the shift spool assembly has been disassembled and reassembled (as in the
previous two sections) skip the following instructions (1 through 4).
NOTE: If the shift spool assembly has not been disassembled and reassembled, do all
of the following steps.
1. Remove and discard the cotter pin.
2. Screw the castle nut down until it touches the washer and a slight resistance is felt.
3. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole
in the shaft. If, when the castle nut is screwed down, the cotter pin slot is not aligned
at the hole in the shaft, back off the castle nut until the next available slot in the nut
is aligned with the hole in the shaft.
4. Insert a new cotter pin and bend ends in opposite directions.
5. Inspect to insure that the spool spins freely (it may be helpful to lightly tap the forward
[castle nut] end of the shift spool shaft against a firm surface to align the internal parts).
6. Inspect to insure that the spool has no more than 0.002-0.010 (0.05-0.25 mm) end
play, if it does adjust the castle nut once again as outlined previously.
0.002 - 0.010 in. (0.05 - 0.25 mm)
7. If this adjustment did not produce the desired results it will be necessary to disas-
semble, clean, and reassemble the shift spool assembly. If the spool assembly has
already been disassembled and cleaned it will be necessary to replace the shift spool
assembly.
90-884294 OCTOBER 2001 Page 6B-49

Reverse Gear Bearing Adaptor Assembly

REMOVAL
1. Remove the reverse gear bearing adaptor using the tools as shown in the next figure.
Remove, measure and make note of the shim thickness. If the shims are not dam-
aged, they may be reused.
a
d c
b
50780
a - Bolt (91-31229)
b - Nut (11-24156)
c - Guide Plate (91-816243)
d - Washer (91-34961)
e - Puller Head (from Slide Hammer Puller Kit 90-34569A1)
f - Jaws (91-816242)
REVERSE GEAR BEARING ADAPTOR ASSEMBLY - INSPECTION

1. Thoroughly clean the reverse gear bearing adaptor with a suitable solvent and dry it
using compressed air.
NOTE: The condition of the bearing surfaces on the reverse gear in the areas that the
bearings of the bearing adaptor and the thrust bearing rides, is an indication of the condi-
tion of the respective bearings. Replace the bearing(s) if the surface of the gear and/or
the thrust washer is pitted, grooved, scored, worn unevenly, discolored from overheating
or has embedded metal particles.
2. Assemble the reverse gear, the thrust bearing, and the thrust race, to the bearing
adaptor. Inspect them for excessive movement or roughness by rotating the gear in
the adaptor. Replace the bearing in the adaptor and/or the thrust bearing if either of
these conditions exist.
3. Inspect the adaptor for other signs of excessive wear or damage. Replace the adaptor
if any are found.
Page 6B-50 90-884294 OCTOBER 2001

REVERSE GEAR BEARING ADAPTOR ASSEMBLY - COMPONENT DISASSEMBLY AND

REASSEMBLY
NOTE: Complete the instructions in this section only if the needle bearing in the bearing
adaptor is defective and the adaptor is to be reused.
1. Disassemble the adaptor as follows:
a. Remove the bearing from the adaptor using a suitable mandrel.
b. Discard the bearing.
2. Assemble the adaptor as follows:
a. Lubricate the bore that the needle bearing is to be pressed into with 2-4-C Marine
Lubricant with Teflon.
b. Position the needle bearing on the adaptor with the numbered end of the bearing
facing the driver shoulder.
c. Press the needle bearing into the bearing adaptor using a suitable mandrel until
the bearing is flush with the face of the adaptor.
b
95

a - Reverse Gear Bearing Adaptor
b - Suitable Mandrel
c - Bearing
90-884294 OCTOBER 2001 Page 6B-51


REMOVAL
NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank
inside the gear case) without removing any of the internal components of the gear hous-
ing.
1. Remove the shift shaft bushing screws, and remove the shift shaft and bushing by
pulling them straight out of gear housing.
57934
a - Shift Shaft Bushing Screws
2. Remove the shift crank from the inside of the gear housing. Clean it with a suitable
solvent and dry it thoroughly. Inspect it for wear in the areas that contact the shift spool
and inspect the splines and the diameter that goes over the locating pin for damage
or wear.
d
c 23350
a - Contact Area
b - Shift Crank
c - Splines
d - Diameter for Locating Pin
Page 6B-52 90-884294 OCTOBER 2001

SHIFT SHAFT ASSEMBLY - Component Disassembly and Inspection

1. Slide the bushing assembly off the shift shaft. Remove the coupler from the shaft.
e
b
d 57954
a - Shift Shaft Bushing Assembly
b - O-ring
c - Shift Shaft
d - Gasket
e - Rubber Washer
2. Clean all components with a suitable solvent and dry thoroughly with compressed air.
a. Inspect the shift shaft bushing for cracking, damage, or excessive wear.
b. Inspect the oil seal inside the bushing, the sleeve, and the O-rings on the outside
of the bushing for damage or excessive wear.
c. Inspect the speedometer connector for damage or blockage.
If any of these conditions exist, replace the appropriate components.
b
57932
a - Shift Shaft Bushing
b - Oil Seal (Oil Seal is Replaceable)
c - Speedometer Tube Connector
90-884294 OCTOBER 2001 Page 6B-53

3. Inspect the shift shaft splines and oil seal surface for corrosion and/or excessive wear.
Replace the shift shaft if either if these conditions are found.
b a
57948
a - Oil Seal Surface
b - Spline
SHIFT SHAFT ASSEMBLY - Component Reassembly

1. Lightly lubricate the seat of the O-ring diameter on the bushing and the lip of the oil
seal with 2-4-C Marine Lubricant with Teflon.
2. If the speedometer connector was removed and/or replaced, lightly coat the threads
of the connector with Perfect Seal. Assemble the speedometer connector to the
bushing and torque the connector to 4.5 lb. in. (0.5 Nm).
3. Assemble all components as shown below.
h a
g
b
19
c
95
d
e
19 Perfect Seal
95 2-4-C Marine Lubricant with Teflon f
a - Shift Shaft
b - Speedometer Pressure Hose
c - Bolt (2) [Torque to 60 lb. in. (7 Nm)]
d - Bushing
e - Gasket
f - O-ring
g - Rubber Washer
h - Seal (Lip Faces Up)
Page 6B-54 90-884294 OCTOBER 2001

Pinion Bearing
REMOVAL
NOTE: Inspect the bearing surface on the drive shaft where the needles of the lower pin-
ion bearing roll. The condition of the drive shaft at this location gives an indication of the
condition of the needle bearing. Replace lower pinion bearing (needles and race as a set)
if the drive shaft is pitted, grooved scored, worn unevenly, discolored from overheating,
or has embedded particles.
IMPORTANT: All the needle bearings (18) MUST BE in place inside bearing race
while driving the pinion bearing from the gear housing.
IMPORTANT: Do not reuse the bearing (race or rollers) once it has been removed.
1. Remove and discard the pinion bearing (race and rollers) using tools as shown.
d
c
70614
a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)
90-884294 OCTOBER 2001 Page 6B-55

Gear Housing Reassembly

Gear Housing Inspection
1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush.
Dry the gear housing thoroughly using compressed air. Insure that all sealants, lock-
ing agents and debris are removed.
2. Verify the 2 oil circulation holes in the drive shaft bore and the shift shaft hole are clear
and free of debris.
3. Inspect the gear housing for excessive corrosion, impact or any other damage. Exces-
sive damage and/or corrosion requires replacement of the gear housing.
4. Inspect the bearing carrier retainer threads in the gear housing for corrosion and/or
stripped threads. Damage or corrosion to the threads requires replacement of the
gear housing.
5. Inspect bearing race/cup contact areas for evidence of bearing cup spinning. Check
that bearing cups are not loose in bearing bores. Any one bearing bore in which the
race/cup is loose will require replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the speedometer hole, clean as neces-
sary. Be careful not to enlarge the speedometer hole as this could cause erroneous
speedometer readings.
7. Verify that the locating pins are in place in the gear housing and that the corresponding
holes in the drive shaft housing are not elongated. The drive shaft may break if the
housings are not aligned properly due to missing locating pins or elongated holes.
Page 6B-56 90-884294 OCTOBER 2001

Pinion Bearing
INSTALLATION
IMPORTANT: Install only a new pinion bearing. Do not reinstall a pinion bearing that
has been previously removed from a gear housing.
1. Lubricate the bore into which the pinion bearing is to be installed with Premium Gear
Lubricant.
2. Position the new pinion bearing (with the cardboard shipping sleeve in place) onto the
driver head, with the lettered and numbered side of the bearing oriented upward.
3. Insert the driver with the bearing assembly, into position (by way of the propeller shaft
bore) at the drive shaft bore as shown.
c
e
d
f g
a
87

a - Drive Shaft Pinion Bearing (With Cardboard Shipping Sleeve)
b - Driver Head (91-38628)
c - Puller Shaft (91-31229)
d - Washer (12-34961)
e - Nut (11-24156)
f - Pilot Washer (91-36571)
g - Puller Plate (91-29310)
4. Install the bearing by screwing down the nut until the bearing is fully seated against
the bore shoulder.
90-884294 OCTOBER 2001 Page 6B-57

Reverse Gear Bearing Adaptor Assembly

INSTALLATION
NOTE: If the reverse gear, reverse gear adaptor, large thrust bearing, or bearing race in
the gear housing were not replaced, install the same shim(s) (or the same thickness of
shim(s) that were taken out when adaptor was removed. If the reverse gear, reverse gear
adaptor, large thrust bearing, bearing race, or gear housing were replaced, install 0.008
in. (0.51 mm) of shims.
1. Lubricate the bore into which the reverse gear bearing adaptor is to be installed with
2-4-C Marine Lubricant with Teflon.
2. Place the shim(s) into reverse bore of gear housing.
3. Position the bearing adaptor in the gear housing.
95

50781
a - Bearing Adaptor
b - Shims
a REVERSE
FORWARD
3.75″ (9.5cm) 4″ (10.2cm)

50885
a - Shorter Hub
Page 6B-58 90-884294 OCTOBER 2001

4. Position the reverse gear (without the thrust race or thrust bearing) into the gear hous-
ing and into the adaptor.
50781
a - Reverse Gear
5. Press the bearing adaptor into the gear housing using the installation tool as follows:
IMPORTANT: Be sure that the bearing adaptor is positioned as straight as possible
to avoid cocking it in the bore while pressing it in.
a. Lubricate the threads of the installation tool with 2-4-C Marine Lubricant with Teflon.
b. Turn the hex-head screw of the installation tool until the bearing adaptor bottoms
out on the gear housing shoulder. DO NOT continue to turn the tool once the screw
resistance goes up noticeably.
95
95 2-4-C Marine Lubricanr with Teflon 50791

a - Hex-Head Screw
b - Bearing Adaptor Installation Tool (91-18605A1)
c - Reverse Gear
c. Remove the installation tool and the reverse gear.
90-884294 OCTOBER 2001 Page 6B-59


INSTALLATION
1. Place the shift crank onto the locating pin in the forward section of the gear housing.
Ensure that the shift crank faces towards the left (port) side of the gear housing.
a
b
50314
a - Shift Crank
b - Locating Pin
2. Install the shift shaft assembly into the gear housing as shown. Engage the splined
end of the shift shaft with the shift crank. Verify O-ring is positioned properly and lubri-
cated with 2-4-C Marine Lubricant with Teflon. Secure shift shaft bushing with 2
screws. Torque screws to 60 lb. in. (7 Nm).
57933
b - Screws [Torque to 60 lb. in. (7 Nm)]
Page 6B-60 90-884294 OCTOBER 2001

NOTE: If the pinion bearing needle bearings have fallen out, install 18 needles into needle
bearing outer race. Use 2-4-C Marine Lubricant with Teflon, to help hold needles in place.
95
a
b
23142
a - Rollers (18)
b - Roller Bearing Outer Race
Gear Location/Backlashes Checking and Adjustment

Reverse Gear
INSTALLATION (FOR CHECKING BACKLASH ONLY)
1. Lubricate the large reverse gear thrust bearing with Premium Gear Lubricant and po-
sition first the thrust race, then the bearing into the gear housing and onto the reverse
gear bearing adaptor.
87

a - Thrust Bearing
b - Thrust Race
c - Reverse Gear Bearing Adaptor
90-884294 OCTOBER 2001 Page 6B-61

2. Install the reverse gear into the gear housing and into the reverse gear bearing adap-
tor.
c b
d
50884
a - Reverse Gear
b - Thrust Bearing
c - Thrust Race (under Bearing)
d - Reverse Gear Bearing Adaptor

INSTALLATION
NOTE: If the original shims were not retained or if pinion gear, drive shaft, drive shaft up-
per tapered roller bearing and cup, or gear housing were replaced, start off by installing
a 0.038 in. (0.96 mm) shim(s), for the upper tapered roller bearing.
NOTE: If the original shims were retained (or measurement known) and none of the
above listed parts were replaced, reinstall the same shims or same amount of shims.
1. Place the upper tapered bearing shim(s) into the drive shaft housing bore.
70620
a - Shim(s)
NOTE: If the backlash may have to be changed, it is recommended that Loctite 271 NOT
be applied to the pinion nut UNTIL the backlash setting is finalized. DO NOT reuse the
old pinion nut. Install a NEW pinion nut after backlash is finalized.
NOTE: Do not install the lower tapered bearing cup or shim(s) at this time.
Page 6B-62 90-884294 OCTOBER 2001

2. Apply Loctite 271 to the threads of the pinion gear nut and place the pinion gear nut
into the MR slot of the pinion nut adapter.
3. Place the pinion gear (with the washer glued to it) into the gear housing.
5. Temporarily install the propeller shaft (without the sliding clutch installed) into reverse
gear.
6. Insert the pinion nut adaptor (with the nut) into the gear housing. It may be necessary
to raise the drive shaft slightly to clear the tool.
is snug.
c
57952
c - Drive Shaft
8. Install the upper drive shaft tapered roller bearing cup. Apply 2-4-C Marine Lubricant
with Teflon to the retainer threads and install the retainer.
57953
a - Upper Tapered Roller Bearing Cup
b - Drive Shaft Retainer
90-884294 OCTOBER 2001 Page 6B-63

10. Torque the pinion nut to 70 lb. ft. (95 Nm) by turning the drive shaft using the drive shaft
nut wrench and torque wrench.
57950
a - Pinion Nut Adapter (91-61067A2)
11. Remove the bearing carrier, pinion nut adapter and drive shaft nut wrench.
12. Torque the retainer to 100 lb. ft. (135 N·m).
57935
13. Remove retainer wrench.
Page 6B-64 90-884294 OCTOBER 2001

Gear Location/Backlashes/Checking and Adjustment

INSTALLATION
1. Install the components from the Bearing Preload Tool Kit (91-14311A1), over the drive
shaft in the order shown.
a
b
e
d
g
70496
a - Top Nut with Threaded Pipe
b - Nut
c - Spring
d - Thrust Washer (2 Required) (12-18448)
e - Thrust Bearing
f - Thrust Washer
g - Water Pump Face Plate (from your gear housing)
2. Pull up on the drive shaft and tighten the two (2) allen screws in the top nut of the bear-
ing preload tool.
a a
57936
a - Allen Screws
90-884294 OCTOBER 2001 Page 6B-65

3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom
nut away from top nut.
57937
a - Distance 1 in. (25.4mm)
b - Bottom nut [screwed down approximately 1 in. (25.4mm)]
Pinion Gear Location

CHECKING AND ADJUSTING
Pinion Depth – 0.025 in. (0.64mm)
NOTE: If the bearing preload tool has not already been set up, refer to “Drive Shaft - Bear-
ing Preload Tool”, ‘Installation’ section first.
NOTE: The prop shaft and reverse gear can be installed when checking pinion height IF
Pinion Height Tool 91-56048 is used.
1. Place the pinion gear shimming tool into the gear housing.
NOTE: Take the following measurements at 3 locations, rotating the drive shaft 120 de-
grees between each reading (always rotate the drive shaft in a clockwise direction).
2. Insert the thickest feeler gauge that fits snugly between one tooth of the pinion gear
and high point of the shimming tool.
3. Rotate the drive shaft 120 degrees in a clockwise direction and take another reading.
4. Repeat this process until 3 readings have been taken.
5. Add the three readings together and divide the sum by 3 to get the average pinion gear
height. Make note of this average measurement.
The average pinion gear height should be 0.025 in. (0.64mm).
6. A. If the (average) pinion gear location does not meet the specification of 0.025 in.
(0.64 mm) continue with the instructions on the following section.
B. If the (average) pinion gear location meets specification, skip the following section
and go on to the “Reverse Gear Backlash”, ‘Checking’ section.
Page 6B-66 90-884294 OCTOBER 2001

7. If the average pinion gear height is not correct, remove the bearing preload tool, the
drive shaft retainer and the drive shaft tapered roller bearing cup. (The cup can be
removed by wiggling the drive shaft back and forth or by turning gear housing and
shaking it.) Add or subtract shims beneath the cup to obtain the proper average pinion
gear height. Reinstall the cup and retainer. Retorque retainer to 100 lb. ft. (135 Nm).
Reinstall the bearing preload tool and rotate the drive shaft at least 3 full turns in a
clockwise direction. Recheck the pinion gear height as in step 5 above. Repeat this
process until the average pinion gear height is within specification.
24643
a - Pinion Gear Shimming Tool (91-12349A2) Using Disc #2 and Flat #4
b - 0.025 in. (0.64mm) Feeler Gauge
90-884294 OCTOBER 2001 Page 6B-67


REMOVAL
CAUTION
Before loosening the top nut allen screws of the bearing preload tool, screw the
bottom nut up as close as possible to the top nut.
1. Remove the dial indicator and its supporting tooling.
2. Screw the bottom nut of the bearing preload tool until it is as close as possible to top
nut.
3. Loosen the allen screws in the top nut.
4. Remove all components.
57936
a - Top Nut (with allen screws)
b - Bottom Nut
c - Plate
Page 6B-68 90-884294 OCTOBER 2001

UPPER DRIVESHAFT BEARING CLEARANCE

1. When the correct pinion gear height is achieved, remove pinion nut, upper retainer
and driveshaft.
2. Apply Premium Gear Lubricant to O.D. of the driveshaft lower bearing cup and install
cup into the gear case.
3. Reinstall driveshaft and pinion gear into gear case.
4. Install the upper drive shaft bearing cup and install and torque the upper bearing re-
tainer to 100 lb. ft. (135 Nm).
5. Torque pinion nut to 70 lb. ft. (95 Nm).
57935
a - Bearing Retainer Tool (91-43506)
6. Push down on drive shaft and check clearance between pinion gear and pinion gear
shimming tool shoulder. Clearance should be 0.020 in - 0.024 in. (0.51 mm - 0.61 mm).
a - Pinion Gear Shimming Tool (91-12349A2) Using Disc #2 and Flat #4

b - Feeler Gauge
NOTE: Do not change shims under upper bearing cup or pinion height will be changed.
7. Maintain the shims as previously set under the upper drive shaft bearing cup.
8. If clearance is not within specifications, remove the upper bearing cup retainer with
tool 91-43506 and remove cup. Leave upper cup shim(s) in place.
NOTE: A 0.001 in. (25.4 mm) change of shims under the lower bearing cup will result in
a 0.001 in. (25.4 mm) change in drive shaft end play.
90-884294 OCTOBER 2001 Page 6B-69

9. With new shim(s) under lower bearing cup, reinstall upper bearing cup and torque cup
retainer to 100 lb. ft. (135.5 Nm). Recheck drive shaft clearance.
NOTE: Install a NEW pinion nut with Loctite 271 AFTER all clearances are correct.
10. If clearance is correct, clean drive shaft threads and apply Loctite 271 and install a
new pinion nut. Torque nut to 70 lb. ft. (95 Nm).

CHECKING
Reverse Gear Backlash Specification: 0.040-0.060 in. (1.01mm-1.5 mm).
NOTE: If the bearing preload tool has not already been set up see “Drive Shaft - Bearing
Preload Tool”, ‘Installation’ section first.
NOTE: The reverse gear bearing adaptor installation tool is used to apply a light preload
to the reverse gear in the following steps.
1. Install the reverse gear bearing adaptor installation tool into the gear housing to hold
the reverse gear against the thrust bearing as follows:
a. Assemble the reverse gear bearing adaptor installation tool into the gear housing
and tighten it by hand until a slight resistance is felt.
b. Torque the adaptor’s driver bolt to 45 lb. in. (5 Nm).
a
b
70973
a - Torque Wrench (91-66274)
b - Driver Bolt
c - Bearing Adaptor Installation Tool (91-18605A1)
d - Reverse Gear
Page 6B-70 90-884294 OCTOBER 2001

e
a
d
b c
57939
f - Backlash Indicator Rod (91-53459) (for 1.75:1 ratio)
3. Take the backlash readings by lightly turning the drive shaft back and forth, so as to
feel the backlash between the gears, (no movement should be noticed at the propeller
shaft).
rection.
lash and it should be 0.040 in. - 0.060 in. (1.0 mm - 1.5 mm) (for 1.75:1 and 1.87:1
ratios).
90-884294 OCTOBER 2001 Page 6B-71

NOTE: If backlash needs to be adjusted, (see Checking Reverse Gear Backlash), adding
0.001 in. (0.03 mm) shims will reduce the gear backlash by approximately 0.001 in.
(0.03mm). Subtracting 0.001 in. (0.03mm) shims will increase backlash by approximate-
ly the same amount.
Example 1 (if backlash is too high)

Backlash checks: .070 in. (1.79 mm)
(subtract) middle
of .050 in. (1.27 mm)
specification:
You get: .020 in. (0.50 mm)
add this quantity of shims
Example 2 (if backlash is too low)
middle of specification: .050 in. (1.27 mm)
Backlash checks: .020 in. (0.50 mm)
(subtract) You get: .030 in. (0.76 mm)
subtract this quantity of shims
5. Loosen the backlash indicator tool and remove the propeller nut, washer and pinion
nut adaptor. Remove the dial indicator and all its mounting components. Do not re-
move the bearing preload tool. The following instructions give specific instruc-
tions for its removal.
Forward Gear/Bearing Carrier Assembly

CHECKING FORWARD GEAR BACKLASH
1. Install the appropriate spacer shim into the gear housing.
55428
a - Shim
Page 6B-72 90-884294 OCTOBER 2001

2. Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust
race onto forward gear bearing adaptor.
87
c

a - Bearing Adaptor
b - Thrust Washer
c - Thrust Bearing
3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor
assembly.
55221
b - Forward Gear/Bearing Adaptor Assembly
90-884294 OCTOBER 2001 Page 6B-73

NOTE: Verify load washer is installed on propeller shaft prior to installing forward gear
assembly
4. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying
downward pressure to bearing adaptor, remove installation tool from assembly.
55431
b - Load Washer
5. Install the bearing carrier over the propeller shaft pushing bearing carrier down until
it is fully seated.
55429
a - Propeller Shaft
b - Bearing Carrier
Page 6B-74 90-884294 OCTOBER 2001

6. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing.
Install the tab washer with the external tab inserted into the hole in the gear housing.
a b
50779
a - Gear Housing Tab Washer Alignment Hole (not seen)
7. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.
70714
a - Tab Washer
b - “V” Tab
90-884294 OCTOBER 2001 Page 6B-75

8. Lubricate the bearing carrier retainer threads with 2-4-C Marine LUbricant with Teflon.
Start the retainer into the gear housing threads and screw it down fully by hand.
95

9. Torque the bearing carrier retainer to 210 lb. ft. (285 Nm) to seat forward gear assem-
bly in gear case.
23355
Page 6B-76 90-884294 OCTOBER 2001

NOTE: Drill a 3/8″ (22.2mm) diameter hole through the side (PROPELLER NUT END)
of a 5″ x 2″ (127mm x 50.8mm) long piece of PVC pipe. A screwdriver may be inserted
thru pipe into propeller shaft splines to prevent PVC pipe from turning while tightening re-
taining nut.
10. Install a 5″ x 2″ (127mm x 50.8mm) long piece of PVC pipe (obtain locally) over propel-
ler shaft and secure it against the bearing carrier with a flat washer and nut.
f
d h
a
g
c
b
e j k
i 51882
a - Prop Nut
b - Flat Washer
c - PVC Pipe [5″ x 2″ (127mm x 50.8mm)]
d - Retainer
e - Tab Washer
f - Bearing Carrier
g - Prop Shaft
h - Bearing Adaptor
i - Shim
j - Forward Gear
k - Load Washer
11. Tighten nut to 45 lb. in. (5 Nm). This will seat the forward gear against the forward
thrust bearing and tends to hold the propeller shaft from moving when measuring
backlash.
90-884294 OCTOBER 2001 Page 6B-77


CHECKING
NOTE: If the bearing preload tool has not already been set up, see “Drive Shaft - Bearing
Preload Tool”, ‘Installation’ section first.
1. Install a dial indicator as shown in the following figure.
e
a
d
b c
57939
2. Align the dial indicator pointer so that it is perpendicular to and touching the “I” mark
on the dial indicator tool. Tighten the indicator tool onto the drive shaft and rotate the
drive shaft so that the needle in the dial makes at least one full revolution and comes
to “0” on the dial indicator scale.
3. Take the backlash readings by lightly turning the drive shaft back and forth.
rection.
4. Add the four readings together and divide the sum by 4. This is your average backlash,
which should be 0.017 in. - 0.028 in. (0.431mm - 0.711mm) (for 1.75:1 and 1.87:1 ra-
tios).
5. If backlash is MORE than the specified MAXIMUM, REMOVE shim(s) from in front of
forward gear bearing race to obtain correct backlash. When reinstalling pinion nut, ap-
ply Loctite 271 to threads of nut.
6. If backlash is LESS than the specified MINIMUM, add shim(s) in front of forward gear
bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite
271 to threads of nut.
Page 6B-78 90-884294 OCTOBER 2001

NOTE: By adding or subtracting 0.001 in. (0.03mm) shim, the backlash will change
approximately 0.001 in. (0.03mm).
7. Remove the propeller nut, washer, and the pinion nut adaptor.
a. If the Backlash is to Specification, skip the next step (7b), and go on to step 8
following.
b. If the Backlash is not to Specification, complete the following instructions to
install a different size spacer shim under the forward gear thrust race.
(1.) Remove the bearing carrier retainer, tab washer, and the bearing carrier.
(2.) Using the hook tool, remove the forward gear bearing adaptor.
(3.) Insert the forward gear installation tool into the forward gear and remove the
forward gear, thrust bearing and thrust race.
(4.) Remove the spacer shim.
(5.) Complete the instruction found in section “Forward Gear/Bearing Carrier As-
sembly”, ‘Installation - (For Checking Forward Gear Backlash)’ section.
(6.) Recheck backlash as outlined in the “Forward Gear Backlash”, ‘Checking’
section.
8. Remove the following items as outlined below:
a. Remove the bearing carrier retainer, tab washer, and the bearing carrier.
b. Using the hook tool remove the forward gear bearing adaptor.
c. Insert the forward gear installation tool into the forward gear and remove the for-
ward gear, thrust bearing and thrust race.
d. Remove the propeller shaft.
e. Remove the spacer shim.
f. “Drive Shaft - Bearing Preload Tool”, ‘Removal’ section.
g. “Drive Shaft Assembly”, ‘Removal’ section.
h. Remove the reverse gear.
90-884294 OCTOBER 2001 Page 6B-79


Component Reassembly
a REVERSE
FORWARD
3.75″ (9.5cm) 4″ (10.2cm)

50885
a - Shorter Hub
1. Assemble the sliding clutch on the propeller shaft, being sure to align cross pin holes
in the clutch with the slot in the propeller shaft. Make sure that the sliding clutch is
placed on the propeller shaft with the grooved end of the clutch facing the propeller
end of the shaft.
2. Assemble the reverse gear onto the propeller shaft.
3. Assemble the shift spool assembly to the propeller shaft being sure to align the cross
pin hole of the shift spool shaft with the clutch slot.
b d
c
58018
a - Propeller Shaft
b - Sliding Clutch
c - Reverse Gear
d - Shift Spool Assembly
Page 6B-80 90-884294 OCTOBER 2001

4. Assemble the cross pin through the sliding clutch, through the propeller shaft and
through the shift spool shaft hole.
5. Install detent pin in third hole in clutch.
c d
a
b
58012
a - Propeller Shaft
b - Sliding Clutch
c - Cross Pin
d - Reverse Gear
e - Shift Spool Assembly
f - Detent Pin
6. Assemble the cross pin retaining spring over the propeller shaft and wind it around
the clutch over the cross pin hole. Be careful not to distort the spring while assembling
it. Make sure that the spring is wound on so that it does not cross over on itself
and that it lies flat against the clutch once it is assembled. If it does not lie flat
against the clutch a new spring must be installed.
b a 58015
a - Sliding Clutch
b - Propeller Shaft
c - Cross Pin Retaining Spring
90-884294 OCTOBER 2001 Page 6B-81


Installation
1. Lubricate the large thrust bearing with Premium Gear Lubricant and position first the
thrust race then the bearing into the gear housing onto the reverse gear bearing adap-
tor.
87

a - Thrust Bearing
b - Thrust Race
c - Reverse Gear Bearing Adaptor
2. Rotate the shift crank toward the aft end of the gear housing until it touches against
the bearing adaptor and hold it in this position.
b
50885
a - Shift Crank
b - Bearing Adaptor
IMPORTANT: Be careful when inserting the propeller shaft assembly into the gear
housing as the needle bearings in the reverse gear bearing adaptor can become
dislodged. If it is suspected that a needle has become dislodged, remove the pro-
peller shaft assembly and inspect the needle bearing cages for damage. If the
cages have not been damaged and a needle bearing is mispositioned, it can be
snapped back into place.
Page 6B-82 90-884294 OCTOBER 2001

3. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end
of the propeller shaft assembly to the left (port) side of gear housing and begin to lower
it into the gear housing.
b
50888
a - Shift Actuating Spool
b - Shift Crank
c - Propeller Shaft Assembly
4. With the propeller shaft assembly tilted to the port side of the gear housing, continue
to lower the assembly until the reverse gear hub comes into contact with the reverse
gear bearing adaptor and the propeller shaft is fully inserted into the reverse gear.
50888
a - Propeller Shaft
b - Reverse Gear Hub
c - Bearing Adaptor
90-884294 OCTOBER 2001 Page 6B-83

5. Slowly move the propeller shaft to the center of the housing and lower the reverse
gear into the bearing adaptor. The shift spool should engage with the shift crank as
the propeller shaft centers itself.
d
c
50885
a - Reverse Gear
b - Bearing Adaptor
c - Shift Spool
d - Shift Crank
6. Operate the shift shaft to ensure that it has been properly installed. The sliding clutch
should move forward when the shift shaft is turned clockwise, and should move aft
when the shift shaft is turned counterclockwise.
7. Make sure that the O-rings are present and positioned correctly. Install the screws that
secure the shift shaft bushing and torque them to 60 lb. in. (7 Nm).
8. Slide the rubber sleeve at top end of shift shaft down so that it just touches the oil seal
in the bushing.
57933
a - Screws [Torque to 60 lb. in. (7 Nm)]
b - Shift Shaft Bushing
c - Rubber Sleeve
d - Shift Shaft
Page 6B-84 90-884294 OCTOBER 2001


Final Installation
NOTE: Verify upper and lower driveshaft bearing shims are installed
1. Place the shim(s) into the drive shaft housing bore at the location shown.
70620
a - Shims
2. Install lower tapered bearing cup.

3. Apply Loctite Type 271 to the threads of the NEW pinion gear NUT and assemble the
pinion gear nut into the MR slot of the pinion nut adaptor.
4. Place the pinion gear (with the washer glued to it) into the gear housing.
6. Install upper tapered bearing cup and the retainer
7. Insert the pinion nut adaptor (with the nut assembled to it) into the gear housing. It may
be necessary to raise the drive shaft slightly to clear the tool.
is snug.
d
c
a
b
7 Loctite 271
c - Tapered Roller Bearing Cups
d - Retainer
90-884294 OCTOBER 2001 Page 6B-85

10. Torque the pinion nut by turning the drive shaft using the drive shaft nut wrench and
torque wrench with the appropriate socket to 70 lb. ft. (95 Nm).
b
57950
a - Pinion Nut Adaptor (91-61067A2)
11. Remove the bearing carrier, pinion nut adaptor and drive shaft nut wrench.
12. Torque the retainer to 100 lb. ft. (135 Nm).
57935
13. Remove the retainer wrench.
Page 6B-86 90-884294 OCTOBER 2001


Final Installation
1. Install appropriate spacer shim into the gear housing.
50782
a - Shim
2. Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust
race onto forward gear bearing adaptor.
87 c

a - Bearing Adaptor
b - Thrust Washer
c - Thrust Bearing
90-884294 OCTOBER 2001 Page 6B-87

3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor
assembly.
55221
b - Forward Gear/Bearing Adaptor Assembly
4. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying
downward pressure to bearing adaptor, remove installation tool from assembly.
55202
Page 6B-88 90-884294 OCTOBER 2001

5. Ensure that the top of the bearing adaptor is clean and install the small thrust race on
top of the bearing adaptor.
50880
a - Thrust Race
c - Forward Gear
6. Lubricate the small thrust bearing with Premium Gear Lubricant and install it on top
of the thrust race.
87
a
b

a - Small Thrust Bearing
90-884294 OCTOBER 2001 Page 6B-89

7. Assemble the thrust collar with its STEPPED SIDE DOWN toward the small thrust
bearing.
50784
a - Thrust Collar
b - Small Thrust Bearing
8. Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the
keepers. Assemble the two keepers into the groove and lower the propeller shaft.
50826
a - Propeller Shaft (slightly lifted)
b - Keepers (2)
c - Thrust Collar
Page 6B-90 90-884294 OCTOBER 2001

a b
50778
a - Thrust Collar
b - Keepers
9. Install the second thrust collar with its STEPPED SIDE UP.
50787
a - Propeller Shaft
b - Thrust Collar
90-884294 OCTOBER 2001 Page 6B-91

10. Lubricate the second thrust bearing with Premium Gear Lubricant and install it to the
top of the thrust collar.
87

a - Thrust Bearing
b - Thrust Collar
11. Lubricate the second small thrust bearing race with Premium Gear Lubricant. Assemble
it to the surface inside of the bearing carrier as shown.
a
87

a - Thrust Race
b - Bearing Carrier
Page 6B-92 90-884294 OCTOBER 2001

12. Lubricate the large O-ring with 2-4-C Marine Lubricant with Teflon and assemble into
the gear housing as shown following.
95

a - O-ring
13. Prepare the bearing carrier for installation as follows:

a. Lubricate the outer diameter of the bearing carrier with 2-4-C Marine Lubricant
with Teflon.
b. Fill the space between the carrier oil seals with 2-4-C Marine Lubricant with Teflon.
c. Lubricate the needle bearing with Premium Gear Lubricant.
14. Install the bearing carrier assembly into the gear housing.
95
87 95

90-884294 OCTOBER 2001 Page 6B-93

housing.
a
c
70713
a - Gear Case Alignment Hole
16. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.
70714
a - Tab Washer
b - “V” Tab
Page 6B-94 90-884294 OCTOBER 2001

17. Fill the bearing carrier retainer nut threads and corresponding gear housing threads
(360°) with 2-4-C Marine Lubricant with Teflon. Start the retainer into the gear housing
threads and screw it down fully by hand.
95

IMPORTANT: Before torquing bearing carrier retainer, gear case must be bolted to
drive shaft housing or securely fastened in a gear case holding fixture to avoid pos-
sible damage to gear housing.
18. Torque the bearing carrier retainer to 210 lb. ft. (284.7 N·m). If one tab does not align
up in space between two of the notches, continue to tighten retainer until alignment
is achieved. DO NOT loosen retainer to achieve alignment.
23355
90-884294 OCTOBER 2001 Page 6B-95

19. Bend one tab aft (outward) into a space between two of the notches of the retainer.
Bend all the remaining tabs forward (inward).
c
b
70490
a - Bearing Carrier
b - Tab
c - Retainer Notches
d - Alignment Tabs (Bend Inward)

Installation
NOTE: Apply hand pressure only to install the oil seal carrier into position. Do not hammer
it into position.
1. Lubricate the oil seal carrier, oil seal lips, space between seals and O-ring with 2-4-C
Marine Lubricant with Teflon and install the oil seal carrier over the drive shaft and into
the gear case.
a b
c
70501
b - Oil Seal Lips
c - O-ring
Page 6B-96 90-884294 OCTOBER 2001

Water Pump Assembly

Installation
NOTE: The gaskets/face plate hole pattern is not symmetrical. If the holes of the gaskets/
face plate do not align with the screw holes of the gear case and/or each other, one or
more of the parts is upside down. Determine which part(s) is (are) upside down and turn
the appropriate part(s) over.
1. Install the small hole gasket then the face plate followed by the large hole gasket onto
the gear case.
58011
a - Small Hole gasket
b - Face Plate
c - Large Hole Gasket (GRAY sealing ring faces up)
2. Place a small amount of 2-4-C Marine Lubricant with Teflon on the flat surface of the
impeller key and install the key onto the drive shaft keyway.
IMPORTANT: When using an impeller whose blades have taken a set, face the curl
of the blades in a counterclockwise direction. Do not install the impeller with its
blades oriented in a reversed direction from original rotation, or premature impeller
failure will occur.
3. Assemble the water pump impeller onto the drive shaft and down over the key.
b
95

a - Water Pump Impeller
b - Water Pump Impeller Key
90-884294 OCTOBER 2001 Page 6B-97
4. Install the 2 water pump locating pins through the gaskets and face plate.
5. Apply a light coat of 2-4-C Marine Lubricant with Teflon to the inside of the pump cover.
Position the water pump body over the drive shaft and water pump locating pins. Ro-
tate the drive shaft in a clockwise direction, while pushing down on the water pump
body to ease the water pump over the impeller blades.
c
b
95

a - Water Pump Body
b - Water Pump Alignment Pins (91-821571A1)
c - Drive Shaft (turn clockwise while installing water pump body)
6. Hand start two (2) fasteners into the water pump assembly and remove the water
pump locating pins. Install the remaining 2 fasteners. Run all fasteners down and
torque to 60 lb. in. (7 Nm).
7. Lightly lubricate the O-rings in the water tube coupling with 2-4-C Marine Lubricant
with Teflon.
8. Install the water tube coupling assembly to the water pump ensuring that the O-rings
are not damaged during assembly.
IMPORTANT: If seal installed above pump housing is not at the proper height, air
will be drawn into the pump resulting in overheating of the engine.
Page 6B-98 90-884294 OCTOBER 2001

9. Using tool provided in seal kit (26-816575A2) or water pump kit (817275A3), press
seal down over drive shaft (DO NOT GREASE DRIVE SHAFT) until tool seats against
pump housing.
57945
a - Tool
b - Seal
If tool is not available, lightly press seal against housing until a height of 0.350 in. ± 0.030
in. (8.9mm ± 0.76mm) is obtained.
0.350 in. ± 0.030 in.
57946
90-884294 OCTOBER 2001 Page 6B-99

Gear Lubricant Filling Instructions

1. Inspect “Fill” and “Vent” sealing washers for cuts or abrasions. Replace washers if
necessary.
2. Clean any metal debris from magnet on “Fill” plug.
IMPORTANT: Never apply lubricant to gear housing without first removing Vent
screw, or gear housing cannot be filled because of trapped air. Fill gear housing
ONLY when housing is in a vertical position.
3. Slowly fill housing thru Fill hole with Premium Gear Lubricant until lubricant flows out
of “Vent” hole and no air bubbles are visible.
4. Install Vent screw into Vent hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling Fill screw.
5. Remove grease tube (or hose) from Fill hole and quickly install Fill screw into Fill hole.
Installing Gear Housing to Driveshaft Housing

WARNING
engine before installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt lock lever.
2. Apply a light coat of 2-4-C Marine Lubricant with Teflon onto driveshaft splines.
CAUTION
DO NOT allow lubricant on top of driveshaft. Excess lubricant, that is trapped in
clearance space, will not allow driveshaft to fully engage with crankshaft. Subse-
quently, tightening the gear housing nuts (while excess lubricant is on top of dri-
veshaft) will load the driveshaft/crankshaft and damage either or both the power-
head and gear housing. Top of driveshaft is to be wiped free of lubricant.
3. Apply a light coat of 2-4-C Marine Lubricant with Teflon onto shift shaft splines. (DO
NOT allow lubricant on top of shift shaft.)
4. Apply a thin bead of G.E. Silicone Sealer against the top of divider block.
5. Insert trim tab bolt into hole in rear of gear housing to driveshaft housing machined
surface.
Page 6B-100 90-884294 OCTOBER 2001

6. Shift gear housing into NEUTRAL and place guide block anchor pin into NEUTRAL
position
Left Hand Rotation Outboard
a - Guide Block Anchor Pin
7. Position gear housing so that the driveshaft is protruding into driveshaft housing.
NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft
splines, place a propeller onto propeller shaft. Shift gearcase into FORWARD and turn
propeller counterclockwise as the gear housing is being pushed toward driveshaft hous-
ing.
8. Move gear housing up toward driveshaft housing while aligning shift shaft splines and
water tube with water tube guide (in water pump cover).
9. Place flat washers onto studs (located on either side of driveshaft housing). Start a
nut on these studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab recess. DO NOT tighten bolt at this
time.
11. Recheck shift shaft spline engagement and correct if necessary.
NOTE: Guide block anchor pin should be in FORWARD when gearcase is in FORWARD.
IMPORTANT: Do not force gear case up into place with attaching nuts.
12. Evenly tighten 2 nuts which were started in Step 9. Torque to 55 lb. ft. (75 Nm).
13. After 2 nuts (located on either side of driveshaft housing) are tightened, check shift
operation as follows:
a. Place guide block anchor pin into forward gear position while turning prop shaft.
Rotate flywheel clockwise (viewed from top). Propeller shaft should rotate coun-
terclockwise.
b. Place guide block anchor pin into NEUTRAL position. Propeller shaft should ro-
tate freely clockwise/counterclockwise.
c. Place guide block anchor pin into REVERSE gear position. Rotate flywheel clock-
wise (viewed from top). Propeller shaft should rotate clockwise.
IMPORTANT: If shifting operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
14. Install remaining washers and nuts onto drive shaft studs. Torque to 55 lb. ft. (75 Nm).
15. Torque bolt (started in Step 10) to 45 lb. ft. (61 Nm).
16. Position trim tab or anodic plate in gear housing. Align grooves of trim tab with ribs
in trim tab pocket. Adjust to position in which it had previously been installed, and while
holding trim tab, torque bolt to 40 lb. ft. (54 Nm)
17. Install plastic cap into trim tab bolt opening at rear edge of driveshaft housing.
90-884294 OCTOBER 2001 Page 6B-101

Propeller Installation
WARNING
When installing or removing propeller, because of the engine’s ease in starting,
VERIFY that the remote control is in NEUTRAL position and that the key switch
is “OFF.” Place a block of wood between the anti-cavitation plate and propeller
to prevent accidental starting and to protect hands from propeller blades while
removing or installing nut.
1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with
one of the following Quicksilver products:
-- Anti-Corrosion Grease
-- Special Lubricant 101
-- 2-4-C Marine Lubricant with Teflon
-- Perfect Seal
2. Place forward thrust hub over propeller shaft with shoulder side toward propeller.
3. Place propeller on propeller shaft and slide it up against thrust hub.
4. Place continuity washer (if equipped) onto shoulder of rear thrust hub.
5. Place rear thrust hub, tab washer and propeller nut on propeller shaft.
6. Thread propeller nut onto propeller shaft until nut is recessed into tab washer.
7. After propeller nut is recessed into tab washer, tighten nut securely [minimum of 55
Ib. ft. (74.5 Nm) torque].
8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller
nut. (If tab washer tabs do not align with slots, continue to tighten propeller nut to ob-
tain alignment. DO NOT loosen nut to align tabs.)
c
aa
e d
bb f
d 51916
a - Forward Thrust Hub
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut
CAUTION
DO NOT misinterpret propeller shaft movement with propeller movement. If pro-
peller and propeller shaft together move forward-and-aft, this is normal; however,
propeller should not move forward-and-aft on propeller shaft.
9. After first use, retighten propeller nut and again secure with tab washer (Steps 7 and
8, preceding). Propeller should be checked periodically for tightness, particularly if a
stainless steel propeller is used.
Page 6B-102 90-884294 OCTOBER 2001

Speedometer Tube Installation

1. Route speedometer tube from gearcase around lower yoke and push into junction.
Junction should be secured to yoke with sta-strap.
2. Route speedometer tube from swivel tube around lower yoke and push into junction.
After insertion of speedometer tubes into junction, pull on each tube to verify that they
are locked into junction. If tube pulls out, reinsert into junction.
a
c
d
57736 d 57735
a - Speedometer Tube from Gearcase
b - Junction
c - Sta-strap
d - Speedometer Tube from Swivel Tube
90-884294 OCTOBER 2001 Page 6B-103

ATTACHMENTS / CONTROL LINKAGE

Section 7
Table of Contents
Ride Guide Steering Cable/Attaching Kit Installation Installation Requirements . . . . . . . . . . . . . . . . . . . 7-10
(92876A10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Parallel Routed Steering Cables and Attaching
Single Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 7-2 Opposite Side Routed Steering Cables and
Ride Guide Steering Cable/Attaching Kit Installation Attaching Kit Installation . . . . . . . . . . . . . . . . . . . . 7-18
(92876A8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7-25
Dual Cable - Single Outboard . . . . . . . . . . . . . . . . 7-3 Ride Guide Steering Attachment Extension
Super Ride-Guide Steering Kit Installation . . . . . 7-4 Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Steering Cable Mounting Tube Installation . . . . . 7-5 Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7-26
Installing Steering Cables . . . . . . . . . . . . . . . . . . . 7-6 Transom Mounted Ride Guide Attaching Kit
Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Installation (73770A1) . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Installing Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Attaching Kit Installation . . . . . . . . . . . . . . . . . . . . 7-28
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 7-9 Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7-31
Ride Guide Steering Cable/Attaching Kit Installation Clevis Attaching Kit Installation (A-70599A5) . . . . . 7-32
(92876A9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Installation Instructions . . . . . . . . . . . . . . . . . . . . . 7-32
Dual Cable - Dual Outboard . . . . . . . . . . . . . . . . 7-10 Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7-32
Ride Guide Steering Cable/Attaching Kit Installation

(92876A10)
Single Cable
Refer to “Quicksilver Accessories Guide” to determine correct length of steering
7
cable and remote control cables.
IMPORTANT: Steering cable and remote control cables must be the correct length,
sharp bends on too-short cables result in “kinks”; too-long cables require unnec-
essary bends and/or loops. Both conditions place extra stress on the cables and
will reduce the performance of the steering system.
INSTALLING RIDE GUIDE CABLE TO OUTBOARD TILT TUBE
IMPORTANT: Before installing steering cable in tilt tube, lubricate entire cable end
with 2-4-C Marine Lubricant with Teflon.
NOTE: Ride Guide steering cable is lubricated at the factory and requires no additional
lubrication at initial installation.
1. Lubricate seal (a) inside of outboard tilt tube and entire cable end (b) with 2-4-C Ma-
rine Lubricant with Teflon.
2. Insert steering cable end through outboard tilt tube and secure steering cable to tilt
tube with steering cable attaching nut (c), as shown. Torque nut to 35 lb. ft. (47.5 N·m).
aa
c
b
28160
57833
90-884294 OCTOBER 2001 Page 7-1

STEERING LINK ROD INSTALLATION

IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” - Part Number 10-849838) and
self locking nuts (“b” & “c” - Part Number 11-826709113). These locknuts must nev-
er be replaced with common nuts (non locking) as they will work loose and vibrate
off freeing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown
overboard exposing them to serious injury or death.
3. Assemble steering link rod to steering cable with two flat washers (d) and nylon insert
locknut (“b” - Part Number 11-826709113). Tighten locknut (b) until it seats, then back
nut off 1/4 turn.
4. Production Outboards - Assemble steering link rod to engine with special washer
head bolt (“a” - Part Number 10-849838) and nylon insert locknut (“c” - Part Number
11-826709113). First torque bolt (a) to 20 lb. ft. (27 Nm), then torque locknut (c) to 20
lb. ft. (27 N·m).
High Performance Outboards - An access hole is provided through the bottom cowl
to ease installation of the link rod connecting bolt. Remove the BACK plug for installa-
tion and reinstall after installation.
aa
bb
c
57834
WARNING
After installation is complete (and before operating outboard), check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) and
at all tilt angles to assure interference-free movement.
Maintenance Instructions
Maintenance inspection is owner’s responsibility and must be performed at intervals spe-
cified, following:
Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)
*Severe Service - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered “Severe Service.”
1. Carefully check steering system components for wear. Replace worn parts.
2. Check steering system fasteners to be sure that they are torqued to correct specifica-
tions.
Page 7-2 90-884294 OCTOBER 2001

NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock
of cable could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate transom
end of steering cables through grease fittings (a) with 2-4-C Marine Lubricant with Te-
flon. Lubricate exposed portion of cable end (b) with 2-4-C Marine Lubricant with Teflon.
4. Lubricate pivot point (c) of steering link rod and ball joint (d) of link rod with SAE 30
Weight Oil (obtain locally).
5. Inspection and lubrication of steering head assembly (rotary or straight rack) should
be performed once each year (by your Authorized Dealer) or whenever steering
mount and/or steering head are disassembled, or if steering effort has increased. Lu-
bricate with 2-4-C Marine Lubricant with Teflon.
a b
a c
57834

(92876A8)
Dual Cable - Single Outboard
WARNING
Quicksilver Super Ride-Guide Steering (dual cables) MUST BE USED with this at-
taching kit. Failure to adhere to this requirement could result in steering system
failure.
Refer to “Quicksilver Accessories Guide” to determine correct length of steering
cables and remote control cables.
IMPORTANT: Steering cables and remote control cables MUST BE THE CORRECT
LENGTH, sharp bends on too-short cables result in “kinks”; too-long cables re-
quire unnecessary bends and/or loops. Both conditions place extra stress on the
cables and will reduce the performance of the steering system.
CAUTION
With this kit installed, the upper (outboard) mounting bolts MUST BE installed so
that hex head end of bolts is on the inside of boat transom, as illustrated. Failure
to install upper mounting bolts, as shown in illustration, could result in interfer-
ence between steering cable nut and ends of mounting bolts when outboard is
tilted up.
90-884294 OCTOBER 2001 Page 7-3

CAUTION
Marine sealer must be used on shanks of bolts to make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when tightening transom bolts.
Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard to
transom with 4 bolts, flat washers and locknuts, as shown. Be sure that installation is wa-
ter-tight.
Install upper bolts so that hex head end of bolts is on the inside of boat transom.
Super Ride-Guide Steering Kit Installation

IMPORTANT: Both gear racks or rotary steering heads must be installed so that
both steering cables will be routed together on the same side of the boat and will
push-and-pull together.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with
Super Ride-Guide Kit.
2. Make sure that both gear racks or rotary steering heads are installed so that both
steering cables are routed together down starboard side of boat and will
push-and-pull together.
a
bb b cc
a - Gear Rack
b - Steering Cables
c - Rotary Steering Heads
Page 7-4 90-884294 OCTOBER 2001

Steering Cable Mounting Tube Installation

IMPORTANT: Spacers must be installed between outboard swivel bracket and
mounting bracket for steering cable mounting tube to provide proper spacing be-
tween steering cables.
Secure mounting bracket for steering cable mounting tube on to swivel bracket of out-
board.
b
a
c
c 28163
a - Mounting Bracket for Steering Cable Mounting Tube
b - Spacer (2)
c - Locking Retainer (2)
d - Bolts (4) - 7/8 in. (22 mm) Long - Torque to 100 lb. in. (11.5 Nm), then Bend
Corner Tabs of Locking Retainers Up and Against Flats on Each Bolt
WARNING
Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube to outboard swivel
bracket to prevent bolts from turning out.
Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2
locking tab washers. Verify longer threaded end of tube is toward starboard side of boat.
Temporarily adjust tube so that longer threaded end of tube extends out the same dis-
tance as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d
b
c a
51891
a - Steering Cable Mounting Tube (End of Tube with Longer Threads Toward
Starboard Side of Boat)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab Washer)
90-884294 OCTOBER 2001 Page 7-5

Installing Steering Cables

IMPORTANT: Lubricate inside of outboard tilt tube, inside of steering cable mount-
ing tube and rubber O-ring seal (located in outboard tilt tube) with 2-4-C Marine Lu-
bricant with Teflon before installing steering cables.
Lubricate inside of outboard tilt tube and inside of steering cable mounting tube with 2-4-C
Marine Lubricant with Teflon. Verify rubber O-ring seal (a) (located in outboard tilt tube)
is lubricated.
51890
Insert steering cable ends (a) through outboard tilt tube (b) and cable mounting tube (c).
Thread steering cable attaching nuts (d) on to tubes hand tight.
NOTE: Torque steering cable attaching nuts only after final steering adjustments have
been made.
b
d a
c
51891
Place a mark (a) on steering cable mounting tube (b) 5/8 in. (16 mm) from end of mounting
tube. Slide plastic spacer (c), O-ring (d) and cap (e) over steering cable.
5/8″(16 mm)
a c d e
51890
Thread cap (e) onto steering cable mounting tube, up to mark (a).
a e 51890
Page 7-6 90-884294 OCTOBER 2001

Coupler Installation
WARNING
Locknuts must be used with bolts to secure steering cables to coupler. Failure
to adhere to this requirement could result in steering system failure.
Slide coupler (a) onto steering cable ends and secure each steering cable to coupler with
bolt (b) and locknut (c) as shown. Tighten to a torque of 20 Ib. ft. (27 Nm).
b c
a b
51888
Installing Link Rod
WARNING
Steering link rod MUST BE secured between outboard steering arm and steering
coupler, using special washer head bolt (10-849838) and two nylon insert lock-
nuts (11-826709113), as shown. Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
Lubricate hole in steering coupler, with 2-4-C Marine Lubricant with Teflon. Assemble
steering link rod to steering coupler, using 2 flat washers (one each side of coupler) and
nylon insert locknut. Tighten locknut until it seats [DO NOT exceed 120 Ib. in. (13.5 Nm)
of torque], then back nut off 1/4 turn.
Lubricate ball joint in steering link rod with SAE 30W Motor Oil (obtain locally). Secure link
rod to outboard steering arm, using special washer head bolt (10-849838) provided and
nylon insert locknut as shown. Torque special bolt to 20 Ib. ft. (27 Nm), then torque locknut
to 20 Ib. ft. (27 Nm).
e
b
f
a d 28172
a - Steering Coupler
b - Steering Link Rod
c - Flat Washer (2)
d - Nylon Insert Locknut - Torque until it seats [DO NOT exceed 120 lb. in. (13.5
Nm) of torque], then back nut off 1/4 turn
e - Special Washer Head Bolt (10-849838) - Torque to 20 lb. ft. (27 Nm)
f - Nylon Insert Locknut - Torque to 20 lb. ft. (27 Nm)
90-884294 OCTOBER 2001 Page 7-7

STEERING SYSTEM TENSION ADJUSTMENT

IMPORTANT: After this dual steering cable attachment kit is installed, there must
be proper tension in forward mounted steering cable tor this attachment kit to oper-
ate properly. Not enough tension will cause slack (or play) in steering system. Too
much tension will cause steering cables to bind. Perform the following steps to ad-
just for correct tension.
Loosen adjustment nuts and pull steering cable mounting tube (by hand) away from end
of steering cable (to remove slack in steering system). Tighten adjustment nuts against
mounting bracket and check system for slack (play.) If steering system is too tight, read-
just tube toward end of steering cable or, if too much slack (play) exists in system, readjust
tube away from end of steering cable. Tighten nuts against mounting bracket and read-
just, if necessary.
b
c a d
51887
a - Steering Cable Mounting Tube

b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steering System
d - Adjust Tube in This Direction to Reduce Tension from Steering System
After steering system tension is adjusted correctly, tighten adjustment nuts against
mounting bracket, to a torque of 35 Ib. ft. (47.5 Nm) and bend a tab lock washer against
flat on each adjustment nut.
c 51887
c a
b - Adjustment Nuts; Torque to 35 lb. ft. (47.5 Nm)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment Nut)
Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib. ft. (47.5
Nm).
a 51889
a - Cable Attaching Nut

b - “V” Groove
NOTE: Cable attaching nuts with a “V” groove around the outer circumference of the nut
are self locking and do not require locking sleeves.
Page 7-8 90-884294 OCTOBER 2001

WARNING
After installation is complete [and before operating outboard(s)], check that boat
steering wheel is turned left. Check steering through full range (left and right) at
all tilt angles to assure interference-free movement.
cified, following:

tions.
WARNING
could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate transom
end of steering cables through grease fittings with 2-4-C Marine Lubricant with Teflon.
Lubricate exposed portion of cable ends with 2-4-C Marine Lubricant with Teflon.
4. Lubricate pivot point of steering link rod and ball joint of link rod/steering coupler with
SAE 30W Motor Oil (obtain locally).
d
b
c
a a
28170
a - Grease Fittings
b - Cable Ends
c - Pivot Point
d - Ball Joint
90-884294 OCTOBER 2001 Page 7-9


(92876A9)
Dual Cable - Dual Outboard
WARNING
Quicksilver Super Ride-Guide Steering (dual cables) MUST BE USED with this at-
taching kit. Failure to adhere to this requirement could result in steering system
failure.
Refer to “Quicksilver Accessories Guide” to determine correct length of steering cable
and remote control cables.
IMPORTANT: Steering cable and remote control cables MUST BE THE CORRECT
LENGTH, sharp bends on too-short cables result in “kinks”; too-long cables re-
quire unnecessary bends and/or loops. Both conditions place extra stress on the
cables and reduce the performance of the steering system.
Installation Requirements
IMPORTANT: The distance from each outboard’s centerline to the side of transom
opening MUST BE a minimum of 16 in. (406 mm).
This kit contains all necessary parts to connect both outboards to Ride-Guide Steering
Cables for 23-1/2 in. thru 27-1/2 in. (597 mm thru 699 mm) outboard centerline spacing.
If outboard centerline distance is other then specified, refer to end of this instruction man-
ual for optional extension couplers.
DETERMINE ROUTING OF STEERING CABLES
Use “1” or “2”, following, to route steering cables:
1. Parallel cable routing: Cables routed together down starboard side of boat Refer to
“Parallel Routed Steering Cables and Attaching Kit Installation,” immediately
following.
2. Opposite side cable routing: One cable routed down starboard side of boat and one
cable routed down port side of boat. Refer to “Opposite Side Routed Steering
Cables and Attaching Kit Installation,” located on page 18 of this instruction manu-
al.
CAUTION
With this kit installed, the upper (outboard) mounting bolts MUST BE installed so
that hex head end of bolts is on the inside of boat transom, as illustrated. Failure
to install upper mounting bolts, as shown in illustration, could result in interfer-
ence between steering cable nut and ends of mounting bolts when outboard is
tilted up.
Install upper bolts so that hex head end of bolts is on the inside of boat transom.
Page 7-10 90-884294 OCTOBER 2001

Parallel Routed Steering Cables and Attaching Kit Installation

(Both Steering Cables Routed Together Down Starboard Side of Boat)
SUPER RIDE-GUIDE STEERING KIT INSTALLATION
IMPORTANT: Steering cable must be installed into tilt tube of port outboard before
outboard is mounted on boat transom.
Both gear racks or rotary steering heads must be installed so that both steering
cables will be routed together on the same side of the boat and will push-and-pull
together.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with
Super Ride-Guide Kit.
2. Make sure that both gear racks or rotary steering heads are installed so that both
steering cables are routed together and will push-and-pull together.
a
b b a
a - Straight Rack (Left); Rotary Steering (Right)
b - Steering Cables (Install so that Both Cables Will Push and Pull Together)
STEERING CABLE INSTALLATION STARBOARD OUTBOARD
IMPORTANT: Mounting bracket for steering cable mounting tube MUST BE secured
to outboard swivel bracket, using 5/8 in. (16 mm) long bolts supplied with this dual
cable - dual outboard attaching kit.
Secure mounting bracket for steering cable mounting tube, onto swivel bracket of star-
board outboard.
c
c
b
a 28164
b - Locking Retainers (2)
c - Bolts (4) - 5/8 in. (16 mm ) Long - Torque to 100 lb. in. (11.5 Nm), then Bend
Corner Tabs of Locking Retainers Up and Against Flats on Each Bolt
WARNING
secures mounting bracket for steering cable mounting tube to outboard swivel
bracket, to prevent bolts from turning out.
90-884294 OCTOBER 2001 Page 7-11

Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2
locking tab washers. Be sure longer threaded end of tube is toward starboard side of boat.
Temporarily adjust tube, so that longer threaded end of tube extends out the same dis-
d
b
a 51891
c
Starboard Side of Boat)
IMPORTANT: Lubricate inside of steering cable mounting tube with 2-4-C Marine
Lubricant with Teflon before installing steering cable.
Lubricate inside of steering cable mounting tube (starboard outboard) with 2-4-C Marine
Insert steering cable end through cable mounting tube and thread steering cable attach-
ing nut onto tube hand tight.
NOTE: Torque steering cable attaching nut only after final steering adjustments have
been made.
a
c b 51887
a - Steering Cable End
b - Cable Mounting Tube
c - Steering Cable Attaching Nut
Page 7-12 90-884294 OCTOBER 2001

Place a mark (a) on steering cable mounting tube (b) 5/8 in. (16 mm) from end of mounting
5/8 in. (16 mm)
a c d e 51890
a e 51890
STEERING CABLE INSTALLATION - PORT OUTBOARD

IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-
cated inside tilt tube with 2-4-C Marine Lubricant with Teflon, before installing
steering cable.
Lubricate inside of port outboard’s tilt tube and rubber O-ring seal (a) with 2-4-C Marine
51890
Insert steering cable end (b) through tilt tube (c) of port outboard and thread steering cable
attaching nut (d) onto tilt tube hand tight.
NOTE: Torque steering cable attaching nuts only after final steering adjustments have
been made.
b
d
d c
51887
90-884294 OCTOBER 2001 Page 7-13

WARNING
Steering link rods MUST BE secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
e c
f a
d 50061
a
b
c c
e e
a a
b b
d f d f
28166
a - Flat Washer (2 Each Link Rod)

b - Nylon Insert Locknut - Torque Until it Seats [DO NOT Exceed 120 lb. in. (13.5
Nm) of Torque], Then Back Off 1/4 Turn
c - Special Washer Head Bolt (10-849838) - Torque to 20 lb. ft. (27 Nm)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27 Nm)
e - Steering Link Rod
f - Steering Cable End
Lubricate holes in ends of steering cables, with 2-4-C Marine Lubricant with Teflon. As-
semble steering link rods to steering cable ends of each outboard, using flat washers and
nylon insert locknuts. Tighten locknuts until they seat [DO NOT exceed 120 Ib. in. (13.5
Nm) of torque], then back nut off 1/4 turn.
Lubricate ball joints in steering link rods with SAE 30W Motor Oil (obtain locally). Secure
link rods to outboard steering arms, using special washer head bolts (10-849838) pro-
vided and nylon insert locknuts as shown. Torque special bolts to 20 Ib. ft. (27 Nm) then
torque locknuts to 20 Ib. ft. (27 Nm).
Page 7-14 90-884294 OCTOBER 2001

STEERING ARM EXTENSION BRACKET INSTALLATION

Secure a steering arm extension bracket to each outboard’s steering arm.
b
d
d
c c
51889
a - Steering Arm (Port Outboard Shown)
b - Extension Bracket
c - Locking Retainer (2 Each Bracket)
d - Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to 23 lb. ft. (31 Nm),
Then Bend Corner Tabs of Locking Retainers Up Against Flats on Each Bolt
WARNING
Locking retainer corner tabs MUST BE bent up and against flats on each bolt that
secures extension bracket to outboard steering arm to prevent bolts from turning
out.
STEERING COUPLER ASSEMBLY AND INSTALLATION
Position outboards so that they are facing straight forward. (Distance between threaded
hole centers of steering arm extensions MUST BE equal to distance between propeller
shaft centerlines.)
Lubricate inside of rubber sleeves with 2-4-C Marine Lubricant with Teflon and slide
sleeves on steering coupler.
Work rubber bushings onto threaded ends of steering eyes.
Thread jam nut on starboard steering eye.
Thread steering eyes equally into coupler, so that distance between hole centers of steer-
ing eye ball joints is equal to distance between threaded hole centers of steering arm ex-
tensions. Exposed threads of steering eyes MUST BE of equal length and threads MUST
NOT extend out from coupler more than 2-3/4 in. (70 mm).
c d e b a b d c
50061
a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut
WARNING
Both steering eyes must be threaded into coupler 3/4 in. (19 mm) minimum.
Thread length of steering eye is 3-1/2 in. (89 mm), so exposed thread must not
extend out of coupler more than 2-3/4 in. (70 mm). Failure to adhere to this re-
quirement could result in steering system failure.
90-884294 OCTOBER 2001 Page 7-15

Lubricate ball joint in steering eyes, with SAE 30W Motor Oil (obtain locally).
Assemble steering coupler between outboard steering arm extension brackets, using
special washer head bolts (10-849838) provided and nylon insert locknuts as shown.
IMPORTANT: With assembled steering coupler installed and before tightening spe-
cial washer head bolts/locknuts, check outboard alignment. Distance between
centers of special washer head bolts MUST BE equal to distance between propeller
shaft center lines, for proper steering. It adjustment is necessary, temporarily re-
move special washer head bolt/locknut from one steering eye and turn eye in or out
to correct alignment.
Torque special washer head bolts to 20 Ib. ft. (27 Nm), then torque locknuts to 20 Ib. ft.
(27 Nm).
WARNING
Both steering eyes MUST BE threaded into coupler 3/4 in. (19 mm) minimum, and
jam nut must be tightened against coupler to prevent coupler from turning.
Torque “jam” nut to 20 Ib. ft. (27 N·m).
Tighten “jam” nut against coupler. Torque “jam” nut to 20 Ib. ft. (27 Nm).
Spray Corrosion Guard on exposed threads of steering eyes and position rubber bush-
ings and rubber sleeves to cover exposed threads of steering eyes.
f a f
g g 28167
f
c
g h
d b d
c
h h
f
f c e a 50061
a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut - Torque (Against Coupler) to 20 lb. ft. (27 Nm)
f - Special Washer Head Bolt (10-849838) - Torque to 20 lb. ft. (27 Nm)
g - Nylon Insert Locknut - Torque to 20 lb. ft. (27 Nm)
h - Steering Arm Extension Bracket
Page 7-16 90-884294 OCTOBER 2001

STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES)

IMPORTANT: For proper operation of this dual cable - dual outboard steering instal-
lation, there MUST BE proper tension in the steering system. NOT ENOUGH ten-
sion will cause slack (play) in steering system. TOO MUCH tension will cause steer-
ing cables to bind. Perform the following steps to correctly adjust tension.
mounting bracket and check system for slack (play). If steering system is too tight, read-
just, if necessary.
a b
c d
51887
b - Adjustment Nuts
mounting bracket, to a torque of 35 Ib. ft. (47.5 Nm) and bend a tab lock washer against
a flat on each nut.
bb
51887
c c a
b - Adjustment Nuts Torque to 35 lb. ft. (47.5 Nm)
Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib. ft. (47.5
Nm).
a
51887
a - Cable Attaching Nut
90-884294 OCTOBER 2001 Page 7-17

WARNING
After installation is complete (and before operating outboard(s)), check that boat
steering wheel is turned left. Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement.
Adjust trim tabs of both outboards, as outlined in “Trim Tab Adjustment”, following.
Opposite Side Routed Steering Cables and Attaching Kit Installation
(One Cable Routed down Starboard Side of Boat and One Cable Routed down Port
Side of Boat)
SUPER RIDE-GUIDE STEERING KIT INSTALLATION
IMPORTANT: Steering cable must be installed into tilt tube of port outboard before
outboard is mounted on boat transom.
Install Super Ride-Guide Steering Kit in accordance with instructions included with Super
Ride-Guide Kit.
STEERING CABLE INSTALLATION - STARBOARD OUTBOARD
IMPORTANT: Mounting bracket for steering cable mounting tube MUST BE secured
to outboard swivel bracket, using 5/8 in. (16 mm) long bolts supplied with this dual
cable - dual outboard attaching kit.
Secure mounting bracket for steering cable mounting tube, onto swivel bracket of star-
board outboard.
d d
c
28164
b a
b - “J” Clip - Supplied with Outboard
c - Locking Retainers (2)
d - Bolts (4) - 5/8 in. (16 mm) Long - Torque to 100 lb. in. (11.5 Nm), Then Bend
Corner Tabs of Locking Retainers Up and Against Flats on Each Bolt.
WARNING
Locking retainer corner tabs MUST BE bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube, to prevent bolts
from turning out.
Install Steering Cable mounting tube into mounting bracket with 2 adjusting nuts and 2
locking tab washers. Verify longer threaded end of tube is toward center of boat transom.
Page 7-18 90-884294 OCTOBER 2001

Temporarily adjust tube, so that longer threaded end of tube extends out the same dis-
b d
51891
a
c
Center of Boat Transom)
IMPORTANT: Lubricate inside of steering mounting tube with 2-4-C Marine Lubri-
cant with Teflon before installing steering cable.
Lubricate inside of steering cable mounting tube (starboard outboard) with 2-4-C Marine
Insert steering cable end (a) (steering cable routed down port side of boat) through cable
mounting tube (b) and thread steering cable attaching nut (c) onto tube hand tight.
been made.
a
b c
51887
Place a mark (a) on steering cable mounting tube (b) 5/8 in (16 mm) from end of mounting
5/8″(16 mm)
e d c b
51890
90-884294 OCTOBER 2001 Page 7-19

a
51888
STEERING CABLE INSTALLATION - PORT OUTBOARD
IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-
cated inside tilt tube with 2-4-C Marine Lubricant with Teflon, before installing
steering cable.
Lubricate inside of port outboard’s tilt tube and rubber O-ring seal (a) with 2-4-C Marine
51890
Insert steering cable end (b) (steering cable routed down starboard side of boat) through
tilt tube (c) of port outboard and thread steering cable attaching nut (d) onto tilt tube hand
tight.
been made.
d b
c
51887
WARNING
Steering link rods MUST BE secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
Page 7-20 90-884294 OCTOBER 2001

Lubricate holes in ends of steering cables, with 2-4-C Marine Lubricant with Teflon. As-
semble steering link rods to steering cable ends of each outboard, using flat washers and
nylon insert locknuts. Tighten locknuts until they seat [DO NOT exceed 120 lb. in. (13.5
Nm) of torque], then back nut off 1/4 turn.
Lubricate ball joints in steering link rods with SAE 30W Motor Oil (obtain locally). Secure
link rods to outboard steering arms, using special washer head bolts (10-849838) pro-
vided and nylon insert locknuts as shown. Torque special bolts to 20 lb. ft. (27 Nm) then
torque locknuts to 20 Ib. ft. (27 Nm).
e c
e
f a
d 50061
a
b
e c c
a e
a
d d
f f b
b
28165
a - Flat Washer (2 Each Link Rod)
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT Exceed 120 lb. in. (13.5
Nm) of Torque], Then Back Off 1/4 Turn
c - Special Washer Head Bolt (10-849838) - Torque to 20 lb.ft. (27 Nm)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27 Nm)
e - Steering Link Rod
f - Steering Cable End
90-884294 OCTOBER 2001 Page 7-21

STEERING ARM EXTENSION BRACKET INSTALLATION

Secure a steering arm extension bracket to each outboard’s steering arm.
b
d d
c c
51889
a - Steering Arm (Port Outboard Shown)
b - Extension Bracket
c - Locking Retainer (2 Each Bracket)
d - Bolts (2 Each Bracket) 1-1/4 in. (31.8 mm) Long - Torque to 23 lb. ft. (31 Nm),
Then Bend Corner Tabs of Locking Retainers Up Against Flats on Each Bolt
WARNING
secures extension bracket to outboard steering arm, to prevent bolts from turn-
ing out.
STEERING COUPLER ASSEMBLY AND INSTALLATION
Position outboards so that they are facing straight forward. (Distance between threaded
hole centers of steering arm extensions MUST BE equal to distance between propeller
shaft centerlines.)
Lubricate inside of rubber sleeves with 2-4-C Marine Lubricant with Teflon and slide
sleeves on steering coupler.
Work rubber bushings onto threaded ends of steering eyes.
Thread jam nut on starboard steering eye.
Thread steering eyes equally into coupler, so that distance between hole centers of steer-
ing eye ball joints is equal to distance between threaded hole centers of steering arm ex-
tensions. Exposed threads of steering eyes MUST BE of equal length and threads MUST
NOT extend out from coupler more than 2-3/4 in. (70 mm).
c d e b a b d c
50061
a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut
WARNING
Both steering eyes must be threaded into coupler 3/4 in. (19 mm) minimum.
Thread length of steering eye is 3-1/2 in. (89 mm), so exposed thread must not
extend out of coupler more than 2-3/4 in. (70 mm). Failure to adhere to this re-
quirement could result in steering system failure.
Page 7-22 90-884294 OCTOBER 2001

Lubricate ball joint in steering eyes with SAE 30W Motor Oil (obtain locally).
Assemble steering coupler between outboard steering arm extension brackets, using
special washer head bolts (10-849838) provided and nylon insert locknuts, as shown.
IMPORTANT: With assembled steering coupler installed and before tightening spe-
cial washer head bolts/locknuts, check outboard alignment. Distance between
centers of special washer head bolts MUST BE equal to distance between propeller
shaft center lines, for proper steering. If adjustment is necessary, temporarily re-
move special washer head bolt/locknut from one steering eye and turn eye in or out
to correct alignment.
Torque special washer head bolts to 20 Ib. ft. (27 Nm), then torque locknuts to 20 Ib. ft.
(27 Nm).
WARNING
Both steering eyes MUST BE threaded into coupler 3/4 in. (19 mm) minimum, and
jam nut must be tightened against coupler to prevent coupler from turning.
Torque “jam” nut to 20 Ib. ft. (27 Nm).
Tighten “jam” nut against coupler. Torque “jam” nut to 20 Ib. ft. (27 Nm).
Spray Corrosion Guard on exposed threads of steering eyes and position rubber bush-
ings and rubber sleeves to cover exposed threads of steering eyes.
f f
a
g g 28174
ff
cc
g h 50061
d b d
c
h h
f
f
c e a 50061
a - Coupler f - Special Washer Head Bolt

b - Rubber Sleeve (10-849838) - Torque to 20 lb.ft.
c - Steering Eye (27 Nm)
d - Rubber Bushing g - Nylon Insert Locknut - Torque to
e - Jam Nut - Torque 20 lb. ft. (27 Nm)
(Against Coupler) to 20 h - Steering Arm Extension Bracket
lb. ft. (27 Nm)
90-884294 OCTOBER 2001 Page 7-23

STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES)

IMPORTANT: For proper operation of this dual cable - dual outboard steering instal-
lation, there MUST BE proper tension in the steering system. NOT ENOUGH ten-
sion will cause slack (play) in steering system. TOO MUCH tension will cause steer-
ing cables to bind. Perform the following steps to correctly adjust tension.
mounting bracket and check system for slack (play). If steering system is too tight, read-
just, if necessary.
a
b
d c 51887
b - Adjustment Nuts
mounting bracket to a torque of 35 Ib. ft. (47.5 Nm) and bend a tab lock washer against
a flat on each nut.
c c a 51887

b - Adjustment Nuts; Torque to 35 lb. ft. (47.5 Nm)
Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib. ft.
(47.5 Nm).
NOTE: Cable attaching nuts with a “V” groove around outer circumference are self locking
and do not require locking sleeves.
WARNING
After installation is complete [and before operating outboard(s)], check that boat
steering wheel is turned left. Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement.
Adjust trim tabs of both outboards, as outlined in “Trim Tab Adjustment,” following.
Page 7-24 90-884294 OCTOBER 2001

Trim Tab Adjustment

DUAL OUTBOARD - COUNTER ROTATION
INSTALLATION
1. Shift outboard into neutral and make sure ignition key is at “OFF” position.
2. Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab.
3. Position trim tabs of both outboards straight to rear of outboard, so that tabs are
aligned with gear housing centerline.
4. Tighten both trim tab bolts securely and replace plastic caps. No further adjustment
will be required.
DUAL OUTBOARD - NON COUNTER ROTATION INSTALLATION
1. Check trim tab position as follows:
IMPORTANT: Initial trim tab setting for both outboards should be straight to rear
of outboard, so that tabs are aligned with gear housing center line. Refer to “If nec-
essary, adjust trim tab as follows,” following.
a. Operate boat at normal cruise throttle setting and adjust trim to optimum setting.
b. If boat pulls to the right (starboard), trailing edge of trim tab must be moved to the
right (when viewing outboard from behind). If boat pulls to the left (port), trailing
edge of trim tab must be moved to the left.
2. If necessary, adjust trim tab as follows:
a. Shift outboard into NEUTRAL and make sure ignition key is at “OFF” position.
b. Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab.
IMPORTANT: Trim tabs MUST BE set in the same position on both outboards.
c. If boat pulls to the right, adjust trailing edges of both trim tabs to the right. If boat
pulls to the left, adjust trailing edges of both trim tabs to the left.
d. Tighten both trim tab bolts securely and replace plastic caps.
e. Operate boat per “Check trim tab position as follows,” preceding, to check trim
tab setting. Readjust trim tabs, if necessary.
Ride Guide Steering Attachment Extension Couplers
Listed below are typical couplers available. Refer to the current Quicksilver Accessory
Guide for specific coupler lengths and part numbers.
Outboard Center Line Distance Required Coupler(s) Between Steering Eyes
22-1/2 in. through 24-1/2 in. 12″ (305 mm) Coupler
(572 mm through 622 mm)
23-1/2 in. through 27-1/2 in. 15″ (381 mm) Coupler (Supplied with this kit)
26-1/2 in. through 30-1/2 in. 18″ (457 mm) Coupler
30 in. through 34 in. 9″ (229 mm) Coupler and 12″ (305 mm) Coupler
(763 mm through 864 mm) (Connected together with coupler link rod)
33 in. through 37 in. 12″ (305 mm) Coupler and 12″ (305 mm) Coupler
(838 mm through 940 mm) (Connected together with coupler link rod)
90-884294 OCTOBER 2001 Page 7-25

WARNING
When 2 couplers are connected together with coupler link rod, a lock washer
must be used on each side of coupler link rod, and link rod must be torqued to
20 Ib. ft. (27 Nm) into end of each coupler.
a b a
51890
c
a - Couplers Connected Together
b - Lock washers
c - Coupler Link Rod [Torque to 20 lb. ft. (27 Nm) into End of Each Coupler]
cified, following:
tions.
WARNING
of cable could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate tran-
som end of steering cables through grease fittings (a) with 2-4-C Marine Lubricant
with Teflon. Lubricate exposed portion of cable ends (b) with 2-4-C Marine Lubricant
with Teflon.
4. Lubricate pivot points (c) of steering link rods and ball joints (d) of link rods/steering
coupler with SAE 30W Motor Oil (obtain locally).
Page 7-26 90-884294 OCTOBER 2001

d d
a c c
a b
a b a
28168
Lubrication Points for Parallel Cable Routing Installations
d d
c
c
b a a a a b
28175
Lubrication Points for Opposite Side Cable Routing Installations

a - Grease Fittings
b - Cable Ends
c - Pivot Points
d - Ball Joints
90-884294 OCTOBER 2001 Page 7-27

Transom Mounted Ride Guide Attaching Kit Installation

(73770A1)
Attaching Kit Installation
1. Lubricate both holes in pivot block (Figure 1) with 2-4-C Marine Lubricant with Teflon.
2. Place pivot block on pivot spacer and secure to transom bracket with 3/8 in. x 2-1/2
in. (9.5 mm x 63.5 mm) bolt, flat washer and locknut, as shown in Figure 1. Torque
locknut to 20 Ib. ft. (27 Nm).
a b h
i
f
k c g
d
l
j e
Figure 1
a - Ride-Guide Cable
b - Ride-Guide Yoke
c - Pivot Block
d - Pivot Spacer
e - 15 in. (381 mm) (Centerline of Attaching Kit Pivot to Centerline of Outboard)
f - Pivot Attaching Locknut [Torque to 20 lb. ft. (27 Nm)]
g - Outboard Steering Arm
h - “Clevis Kit”
i - Ride-Guide Cable Attaching Locknut [Torque to 10 lb. ft. (13.5 Nm)]
j - Bolt [3/8 in. x 2-1/2 in. (9.5 mm x 63.5 mm)]
k - Flat Washer
l - Transom Bracket
Page 7-28 90-884294 OCTOBER 2001

3. Place Ride-Guide yoke on pivot block and secure with 7/16 in. x 1-3/4 in.
(11.1 mm x 44.5 mm) bolt and locknut, as shown in Figures 1 and 2. Torque
locknut to 10 Ib. ft. (13.5 Nm), then back off 1/4-turn.
g ff
bb
cc
ee
Figure 2
a - Transom Backing Plate
b - Bolt [5/16 in. x 3-1/4 in. (7.9 mm x 82.5 mm)]
c - Locknut [Torque to 10 lb. ft. (13.5 Nm)]
d - Ride-Guide Yoke Attaching Locknut [Torque to 10 lb. ft. (13.5 Nm)] Then
Back Off 1/4-Turn
e - 2-3/8 in. (60.3 mm) Maximum Transom Thickness
f - Bolt [7/16 in. x 1-3/4 in. (11.1 mm x 44.5 mm)]
g - Ride-Guide Yoke
4. Install one cable tube jam nut onto steering cable tube. Place tab washer over
Ride-Guide yoke, then insert cable tube through tab washer and yoke. Install second
cable tube jam nut onto cable tube but do not tighten at this time. (Figure 3)
5. Position transom attaching kit on transom as shown:
a. Determine centerline of outboard, then measure 15 in. (38.1 cm) over from this
centerline and draw a vertical line on transom. (Figure 1)
90-884294 OCTOBER 2001 Page 7-29

b. Position attaching kit on transom so that transom bracket is centered on the 15

in. (38.1 mm) (Figure 1) at a height where the center of Ride-Guide yoke is even
with, or not more than 1/2 in. (12.7 mm) above top edge of transom. (Figure 3)
f h j
aa e
e
f
i
k
c
g
b
dd
Figure 3
a - Ride-Guide Yoke
b - 0 in. to 1/2 in. (0 mm to 12.8 mm) (Center of Ride-Guide Yoke to Top of Tran-
som
c - Top of Transom
d - Transom Bracket
e - Cable Tube Jam Nuts [ Torque to 35 lb. ft. (47.5 Nm)]
f - Tab Washer
g - After Jam Nuts Are Torqued to Specification, Bend Locking Tabs against Nuts
h - Cable Guide Tube
i - Ride-Guide Cable Attaching Nut [Torque to 35 lb. ft. (47.5 Nm)]
j - “Clevis Kit”
k - Clevis Attaching Locknut [Torque to 20 lb. ft. (27 Nm)]
NOTE: When drilling through transom, be sure that holes are drilled perpendicular to tran-
som.
6. With attaching kit positioned as outlined preceding, use 3 holes in transom bracket
as a guide and drill three 11/32 in. (8.7 mm) holes thru transom.
7. Use a marine-type sealer on three 5/16 in. x 3-1/4in. (7.9mm x 82.6mm) bolts. Secure
attaching kit to transom, using transom backing plate, 3 bolts (with sealer) and 3 lock-
nuts, installed as shown in Figure 2. Torque lock nuts to 10 Ib. ft. (13.5 Nm).
STEERING CABLE INSTALLATION
1. Lubricate steering cable end with 2-4-C Marine Lubricant with Teflon.
2. Install steering cable through steering cable tube and secure to cable tube with cable
attaching nut. (Figure 3) Do not tighten cable attaching nut at this time.
3. Attach Ride-Guide cable to outboard steering arm, using the proper “Clevis Kit.” In-
stallation instructions for clevis are with “Clevis Kit.”
4. Adjust 2 large jam nuts on cable tube of attaching kit, so that steering wheel is in nor-
mal straight-driving position with outboard in straight-running position. Torque each
jam nut to 35 Ib. ft. (47.5 Nm), then bend a side of tab washer against flat of each jam
nut. (Figure 3)
5. Torque Ride-Guide cable attaching nut (which secures cable to guide tube) to 35 Ib.
ft. (47.5 Nm). (Figure 3)
Page 7-30 90-884294 OCTOBER 2001

WARNING
After installation is completed (and before operating outboard), check that boat
steering wheel is turned left. Check steering through full range (left and right) at
all tilt angles to assure interference-free movement.
Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, following:
CAUTION
Core of steering cable must be fully retracted into cable housing when lubricating
cable. If cable is lubricated while extended, hydraulic lock of cable could occur.
1. Lubricate outboard end of Ride-Guide steering cable (through grease fitting - if
equipped - next to cable attaching nut) with 2-4-C Marine Lubricant with Teflon.
NOTE: Ride-Guide steering cable is lubricated at the factory and requires no additional
2. Lubricate all steering system pivot points (and exposed portion of steering cable core)
with 2-4-C Marine Lubricant with Teflon. Lubricate at intervals specified preceding.
3. Carefully check steering system components for wear (at intervals specified, preced-
ing). Replace worn parts.
4. Check steering system fasteners (at intervals specified, preceding) to be sure that
they are torqued to correct specifications. (Figures 1, 2 and 3)
90-884294 OCTOBER 2001 Page 7-31

Clevis Attaching Kit Installation (A-70599A5)

NOTE: This kit is used to attach Ride-Guide cable to outboard steering arm ONLY when
“Transom Mounted Ride-Guide Attaching Kit” is being used. If Ride-Guide cable is
installed through outboard tilt tube, then “Steering Link Rod” must be used.
Installation Instructions
1. Install clevis to steering cable as shown.
2. Lubricate 3/8 in. x 1-3/8 in. (9.5 mm x 34.9 mm) bolt (area without threads) with 2-4-C
Marine Lubricant with Teflon, then secure clevis to steering cable with this bolt and
a locknut. Torque locknut (item “d”) to 10 Ib. ft. (13.5 Nm).
a e
b
f
g
h
i
j
c d
a - Clevis
b - Steering Cable
c - Bolt [3/8 in. x 1-3/8 in. (9.5 mm x 34.9 mm)]
d - Clevis to Steering Cable Locknut [Torque to 10 lb. ft. (13.5 Nm)]
e - Bolt [3/8 in. x 1-1/4 in. (9.5 mm x 31.8 mm)] [Torque to 20 lb. ft. (27 Nm)]
f - Thin Washer [1/16 in. (1.6 mm) Thick]
g - Spacer
h - Thick Washer [1/8 in. (3.2 mm) Thick]
i - Engine Steering Arm
j - Clevis to Engine Locknut [Torque to 20 lb. ft. (27 Nm)]
3. Lubricate spacer (supplied with this kit) with 2-4-C Marine Lubricant with Teflon.
4. Attach clevis to top of outboard steering arm with a 3/8 in. x 1-1/4 in. (9.5 mm x 31.8
mm) bolt, thin washer, spacer, thick washer (thick washer must be installed between
clevis and steering arm) and locknut, as shown. Torque bolt (item “e”) to 20 Ib. ft. (27
Nm), then torque locknut (item “j”) to 20 Ib. ft. (27 Nm).
Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, following:
1. Carefully check steering system components (at intervals specified, preceding) for
wear. Replace worn parts.
2. Check steering system fasteners (at intervals specified, preceding) to be sure that
they are torqued to correct specifications.
3. Lubricate clevis pivot points with a drop of light oil. Lubricate at intervals specified, pre-
ceding.
Page 7-32 90-884294 OCTOBER 2001

COLOR DIAGRAMS
COLOR DIAGRAMS
Table of Contents
225/250/3.0 Litre Work EFI 2002 Model Year Typical SmartCraft Dual Outboard Installation
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-3 2002 Model Year . . . . . . . . . . . . . . . . . . . . . . . Page 8-9
Typical SmartCraft System Tachometer & System 225/250/3.0 Litre Work EFI 2002 Model Year
Speedometer Installation with System Link Gauges Oil & Fuel Flow Diagram . . . . . . . . . . . . . . . . Page 8-11
2002 Model Year . . . . . . . . . . . . . . . . . . . . . . . Page 8-5 225/250/3.0 Litre Work EFI 2002 Model Year
Typical SmartCraft System Monitor/Tachometer Water Flow Diagram . . . . . . . . . . . . . . . . . . . . Page 8-13
Installation with System Link Gauges
2002 Model Year . . . . . . . . . . . . . . . . . . . . . . . Page 8-7
90-884294 OCTOBER 2001 Page 8-1

COLOR DIAGRAMS
Notes:
Page 8-2 90-884294 OCTOBER 2001

COLOR DIAGRAMS
225/250/3.0 LITRE WORK EFI

WIRING DIAGRAM
2002 MODEL YEAR
90-884294 OCTOBER 2001 Page 8-3

225/250/3.0 Litre Work EFI 2002 Model Year
1. ECM 35. Cowl Mounted Trim Switch
2. Top ECM Connector 36. To Remote Control Trim Switch
3. Middle ECM Connector 37. 12 Volt Accessory Power
4. Bottom ECM Connector 38. To Analog Temperature Gauge
5. Ignition Coils 39. Detonation Sensor - Port Head
6. Ignition Coil Harness Connection 40. Detonation Sensor - Starboard Head
7. Fuel Injectors 41. Engine Harness
8. Analog Head Temperature Sender - Port Head 42. 10-Pin SmartCraft Harness (Gauges)
9. Oil Pump 43. DDT Data Port
10. MAP Sensor 44. 8-Pin SmartCraft Harness (Boat Sensors)
11. Block Pressure Sensor
12. Water Sensor
13. Shift Switch
14. Digital Air Temperature Sensor
15. Digital Temperature Sensor - Starboard Head
16. Digital Temperature Sensor - Port Head
17. Yellow Identifier - 2.5 Liter Only
18. Throttle Position Sensor (TPS)
19. Crank Position Sensor (CPS)
20. Accessories 15 Ampere Fuse
21. Fuel System & Oil Pump 20 Ampere Fuse
22. Main Power Relay, Remote Control Harness &
Power Trim Circuit 20 Ampere Fuse
23. Ignition Coils 20 Ampere Fuse
24. Low Oil Switch
25. Starter Solenoid
26. Centrifugal Bendix Starter Motor (Early 2002
Models)
27. Solenoid Driven Bendix Starter Motor (Late
2002 Models)
28. 60 Ampere Alternator
29. Main Power Relay
30. Electric Fuel Pump
31. Trim Down Relay
32. Trim Up Relay
33. To Trim Pump
34. To 12 Volt Battery
19
27 31 32
26 25
6
9 14 15 16 28
5 7 24
11
12 13 20 22 29
1 2 25
10 18
21 23
3 4
3
1
2
5 6 8
30
6 33
1 9 17 1
2
3
4
1 5
34
6
7
8 17
9
10
11
2
12
13
35
14
15
16
17
18
19
20 37 36
21
22
23 38
8 16 24 24
1 9 17 1
2
3
4
5
6
7
39
8
9
10
3 11
12
13
14
15
40
16
17
18
19
20
21
22 4
3 5
8 16 24
23
24
2 6 41
8
1 7
1
2
1 12 22 3
4
5
6
7
8
9 42
10
11
12
13
14
15
16
4 17
18 43
19
20
21
22
23
24
25
26
27
28 44
29
30
11 21 32 31
32
59138
COLOR DIAGRAMS
TYPICAL SMARTCRAFT
SYSTEM TACHOMETER &
SYSTEM SPEEDOMETER
INSTALLATION
WITH SYSTEM LINK GAUGES
2002 MODEL YEAR
90-884294 OCTOBER 2001 Page 8-5

Typical SmartCraft System Tachometer & System Speedometer
with System Link Gauges 2002 Model Year
1. 8-Pin Digital Sensor Harness Extension, Connect 27. Analog Tachometer Harness (Not Used on CAN
to 8-Pin SmartCraft Harness on Engine Installation)
2. Digital Speedometer Sensor 28. Warning Horn
3. Digital Trim Sender 29. Analog Temperature Gauge Connection
4. 10-Pin Control Area Network (CAN) Harness Con- 30. Paddle Wheel/Lake/Sea Water Temperature
nects to Data Buss 10-Pin CAN Harness on En- Sender
gine
31. 4-Pin Digital Sensor Harness Connection to
5. Yellow Identifier Marking Resistor End of CAN Paddle Wheel
Harness
32. Digital Connections to Oil Sender
6. Resistors within CAN Harness (120Ω 1/4W 5%)
33. Digital Connections to Fuel Sender
7. Weather Proof Cap on Un-Used Junction Box Ter-
34. Connection for Analog Trim Sender
minals
35. Connection to Trim Relays
8. Resistor Cap in Junction Box Terminal
36. Connection for Analog Temperature Sender
9. 10-Pin Control Area Network (CAN) Harness Con-
nects to Junction Box 37. Remote Control Harness Connects to Engine Har-
ness
nection to Junction Box and System Speedometer 38. 6-pin Digital Sensor Harness
nection to Junction Box and System Tachometer
12. Ambient Air Temperature Sensor
13. System Speedometer
14. Connections for GPS
15. System Tachometer
16. Connections for Auxiliary Warning Horn for Depth
Sensor
17. System Link Series Connection
18. 2-1/4 in. System Link Gauges (Fuel, Temperature,
Trim etc.)
Trim etc.)
21. Plugged Series Connection for Additional System
Link Gauges
22. 4000 Series Mechanical Panel Control (MPC
4000)
23. Connections for Lanyard Stop Switch
24. Connection for Power Trim Switch
25. Connections for Neutral Start Safety Switch
26. Ignition Key Switch
18 20
19
13 16 21
12
15 22
14 17
7 7
10
8
5 9 25
24
6 2
4 3 11 23
26
37
34
35
36 29 C B
38 27
D E A
31
1 28
30 59265
33 32
COLOR DIAGRAMS
TYPICAL SMARTCRAFT
SYSTEM MONITOR/TACHOMETER
INSTALLATION
WITH SYSTEM LINK GAUGES
2002 MODEL YEAR
90-884294 OCTOBER 2001 Page 8-7

Typical SmartCraft System Monitor/Tachometer with System
Link Gauges 2002 Model Year
1. 8-Pin Digital Sensor Harness Extension, Connect 27. 4-Pin Digital Sensor Harness Connection to
to 8-Pin SmartCraft Harness on Engine Paddle Wheel
2. Digital Speedometer Sensor 28. Digital Connections to Oil Sender
3. Digital Trim Sender 29. Digital Connections to Fuel Sender
4. 6-pin Digital Sensor Harness
5. Connection for Analog Temperature Sender
6. Connection to Trim Relays
7. Connection for Analog Trim Sender
8. Remote Control Harness Connects to Engine Har-
ness
nects to Data Buss 10-Pin CAN Harness on En-
gine
10. Resistors within CAN Harness (120Ω 1/4W 5%)
11. Connections for Auxiliary Warning Horn for Depth
Sensor
12. Yellow Identifiers Marking Resistor End of CAN
Harness
13. Either System Monitor or System Tachometer is
Used. If System Tachometer is Used, Tachometer
Link Gauge is not Used
15. 3-1/4 in. System Link Gauges (Tachometer and
Speedometer)
Trim etc.)
17. Plugged Series Connection for Additional System
Link Gauges
18. 4000 Series Mechanical Panel Control (MPC
4000)
19. Connections for Lanyard Stop Switch
20. Connection for Power Trim Switch
21. Connections for Neutral Start Safety Switch
22. Ignition Key Switch
23. Analog Tachometer Harness (Not Used on CAN
Installation)
24. Warning Horn
25. Analog Temperature Gauge Connection
26. Paddle Wheel/Lake/Sea Water Temperature
Sender
13
17
14 14 14
16 16
15 15
18
14
12
10
11 21
12
20
2 9
3 19
10 22
8
7
6
5 C B
25 23
D E A
4 27
1 26 24
59266
29 28
COLOR DIAGRAMS
TYPICAL SMARTCRAFT
DUAL OUTBOARD
INSTALLATION
2002 MODEL YEAR
90-884294 OCTOBER 2001 Page 8-9

Typical SmartCraft Dual Outboard Installation 2002 MY
1. 8-Pin Harness from Port Outboard 28. 10-Pin Control Area Network (CAN) Connection
from System Tachometer Starboard Outboard to
2. Digital Sensor Harness Extension Port Outboard
Junction Box
3. Digital Speedometer Sensor Port Outboard
29. 10-Pin Control Area Network (CAN) Junction Box
4. Digital Trim Sender Port Outboard
30. 10-Pin Control Area Network (CAN) Connection
5. Digital Sensor Harness Extension Port Outboard from Junction Box to Port Outboard 10-Pin Data
to 6-pin Digital Sensor Harness Buss CAN Harness
6. 6-pin Digital Sensor Harness Port Outboard (Only 31. 10-Pin Control Area Network (CAN) Connection
if Duel Fuel and Oil Tanks are Used) from Junction Box to Starboard Outboard 10-Pin
7. Digital Connections for Fuel Sender Data Buss CAN Harness
8. Digital connections for Oil Sender 32. Resistor in Port CAN Harness (120Ω 1/4W 5%)
9. Weather Proof Cap for 6-Pin Harness 33. Yellow Resistor Identifier on Harness End
10. Weather Proof Cap for System Link Gauges 34. 10-Pin Control Area Network (CAN) Connection
from Junction Box to Port Outboard 10-Pin Data
11. 2-1/4 in. System Link Gauges (Fuel, Temp, Trim, Buss CAN Harness
etc.) Port Outboard
35. 10-Pin Data Buss CAN Harness Port Outboard
12. System Tachometer Port Outboard
36. 3-Pin Data Buss CAN Connection for Power
13. System Speedometer
37. Resistor in Port CAN Harness (120Ω 1/4W 5%)
14. System Tachometer Starboard Outboard
38. Yellow Resistor Identifier on Harness End
15. System Link Series Connections Port Outboard
39. 10-Pin Control Area Network (CAN) Connection
16. 10-Pin Control Area Network (CAN) Connection to from Junction Box to Starboard Outboard 10-Pin
System Tachometer Port Outboard Data Buss CAN Harness
17. Connections for Auxiliary Warning Horn for Depth 40. 10-Pin Data Buss CAN Harness Starboard Out-
Sensor board
18. Ambient Air Temperature Sensor 41. 3-Pin Data Buss CAN Connection for Power, Must
19. 10-Pin Control Area Network (CAN) Connection to be Disconnected and Capped on Dual Installation
System Speedometer 42. Digital Trim Sender Starboard Outboard
20. Connections for GPS 43. Digital Speedometer Sensor Starboard Outboard
21. Connections for Auxiliary Warning Horn for Depth 44. 8-Pin Harness from Starboard Outboard
Sensor
45. Digital Sensor Harness Extension Starboard Out-
22. 10-Pin Control Area Network (CAN) Connection to board
System Tachometer Starboard Outboard
46. Digital Sensor Harness Extension Starboard Out-
23. System Link Series Connections Starboard Out- board to 6-pin Digital Sensor Harness
board
47. 6-pin Digital Sensor Harness Starboard Outboard
24. 2-1/4 in. System Link Gauges (Fuel, Temp, Trim,
etc.) Starboard Outboard 48. Digital Connections for Fuel Sender
25. Weather Proof Cap for System Link Gauges 49. Digital connections for Oil Sender
26. 10-Pin Control Area Network (CAN) Connection 50. 4-Pin Digital Sensor Harness Connection to
from System Tachometer Port Outboard to Junc- Paddle Wheel
tion Box 51. Paddle Wheel/Lake/Sea Water Temperature
27. 10-Pin Control Area Network (CAN) Connection Sender
from System Speedometer to Junction Box 52. Weather Proof Cap for Junction Box Terminal
15 23
10 25
12
13 14
11 24
18
7 8
1 2
5 6 17 21
15 23
20
16 19 22
9
35 34
30
26
32 27
36 33
52
31
28
41
40 38 37
39
29
42
43
50 51
46 47
44 45 49
48 59276
COLOR DIAGRAMS

OIL & FUEL FLOW DIAGRAM
2002 MODEL YEAR
90-884294 OCTOBER 2001 Page 8-11

225/250/3.0 Litre Work EFI Oil & Fuel Flow 2002 Model Year
1. Fuel inlet from primer bulb
2. Engine Pulse Fuel Pump
3. Fuel line to Water Separating Fuel Filter - 2-8 psi (14-55 kPa)
4. Water Separating Fuel Filter in Vapor Separator Tank (VST) Assembly
5. Fuel outlet from Needle and Seat
6. Fuel Level Float in VST
7. Pulse Pressure from Cylinder Block
8. On-Board Oil Tank
9. Check Valve in Outlet Hose from Oil Tank
10. Outboard Oil Tank
11. Oil Inlet Hose to Electronic Oil Pump
12. Electronic Oil Pump
13. Oil Outlet Hose from Oil Pump to VST
14. Oil is Mixed with Gas in VST
15. Gas/Oil Mixture is Drawn into High Pressure Fuel Pump
16. Fuel Drain
17. High Pressure Fuel Pump
18. Schrader Valve
19. Fuel Passage to Fuel Regulator
20. Fuel Regulator
21. Ambient Air Pressure
22. Fuel Blow-Off from Fuel Regulator to VST
23. In-Line Fuel Filter
24. High Pressure Fuel Line to Reed Valve Plate Assembly
25. Reed Valve Plate Assembly
26. Fuel Rail Assembly
27. Fuel Injectors
21
20
19
24
22
23
3
18
10 14
2
12 17 27
5 26
4
6
16
28
15
1
25
13 11
58847
COLOR DIAGRAMS

WATER FLOW DIAGRAM
2002 MODEL YEAR
90-884294 OCTOBER 2001 Page 8-13

225/250/3.0 Litre Work EFI Water Flow 2002 Model Year
1. Water Inlet
2. Water Pump
3. Wall of Water - If water level height is insufficient, water pump may draw in air resulting in an overheated
engine
4. Strainer - Exhaust cooling water
5. Main Water Feed to Powerhead from Water Tube
6. Rubber Water Dams - If missing may result in uneven cooling of cylinders and scuffed pistons
7. Cylinder Head Cover - Removed from head for illustration, normally part of head casting
8. Thermostats (2) 143° F (61.7° C) - If stuck closed, engine will overheat at low speed. If stuck open,
engine will not warm up at idle speed.
9. Poppet Valve - Controls water flow at high RPM. If poppet valve is stuck open at low RPM, the engine
will not reach proper operating temperature (run cold) and will run rough at idle
10. Primary water discharge into driveshaft housing.
11. Water discharge into exhaust relief passage
12. Water Pressure Sensor
13. Check Valve for powerhead flush
14. Water passing through thermostats dump into adaptor plate, then discharges down the exhaust.
15. Tell-Tale Outlet
16. Excess water from wall of of water around exhaust bucket exits around anodes.
17. Water Exits with Exhaust Discharge
8
11
1 17
6 9
2
3
4 10
11
14
1
16
17
5
16
1
14
59162
12 15
7
13

225/250 3.0 Litre Work: Electronic Fuel Injection

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Srvc Man-ME 3.

OL Work 225/250 10/16/01 2:38 PM Page 1

3.0 Litre Work 225/250 EFI

90-884294 OCTOBER 2001

Notice to Users of This Manual

90-884294 OCTOBER 2001 Page i

Cleanliness and Care of Outboard Motor

90-878079R1 OCTOBER 2000 LOWER UNIT - 6A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

90-884294 OCTOBER 2001 Page iii

Model 3 Liter Work/225 EFI/250 EFI

90-884294 OCTOBER 2001 Page 1A-1

REEDS Model 3 Liter Work/225 EFI/ 250 EFI

Battery Rating Min. 630 Marine Cranking Amps

Page 1A-2 90-884294 OCTOBER 2001

GEAR Gear Ratio

Oil Pump Output

90-884294 OCTOBER 2001 Page 1A-3

Mercury/Quicksilver Lubricants and Sealants

Description Mercury Part Number Quicksilver Part Number

Needle Bearing Assy. Lubricant

Loctite 271 – Thread Locker

Loctite 567 PST Pipe Sealant

Loctite Master Gasket Kit 92-12564-2 92-12564-2

2 Cycle Premium Outboard Oil

Cyanacrylate Adhesive Obtain Locally Obtain Locally

Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining Compound

Loctite 222 Thread Locker

3M Permabond #3M08155 Obtain Locally Obtain Locally

Loctite 242 Thread Locker

Loctite 609 Obtain Locally Obtain Locally

Loctite 405 Obtain Locally Obtain Locally

SAE 30W Oil Obtain Locally Obtain Locally

Page 1A-4 90-884294 OCTOBER 2001

Description Mercury Part Number Quicksilver Part Number

RTV 587 Silicone Sealer

Loctite 262 Obtain Locally Obtain Locally

Premium Gear Lubricant

Loctite 7649 Primer

2-4-C with Teflon

Loctite Quick Tite Obtain Locally Obtain Locally

Isopropyl Alcohol Obtain Locally Obtain Locally

Hot Glue Obtain Locally Obtain Locally

Special Lubricant 101

4 Stroke 10W30 Outboard Oil

4 Cycle 25W40 Engine Oil

Power Trim & Steering Fluid

Engine Coupler Spline Grease

Fuel System Treatment & Stabilizer

90-884294 OCTOBER 2001 Page 1A-5

90-884294 OCTOBER 2001 Page 1B-1

2. Flushing Attachment 44357A2

Mercury/Quicksilver Lubricants and Sealants

Page 1B-2 90-884294 OCTOBER 2001

Inspection and Maintenance Schedule

90-884294 OCTOBER 2001 Page 1B-3

Page 1B-4 90-884294 OCTOBER 2001

Remove and replace filter as follows:

90-884294 OCTOBER 2001 Page 1B-5

Corrosion Control Anode