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225/250 3.0 Litre Work: Electronic Fuel Injection
225/250 3.0 Litre Work: Electronic Fuel Injection
225/250
©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.
Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explana-
tory.
EXAMPLE:
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
IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Sealants and
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Specifications
Dielectric Grease
92-823506-1 92-823506-1
[8 oz. (226.8 grams)] can
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
Anti-Corrosion Grease
92-802867A1 92-802867Q1
[8 oz. (226.8 grams)] tube
Corrosion Guard
92-802878-55 92-802878Q55
[11 oz. (325 ml)] Spray Can
IMPORTANT INFORMATION 1
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)
Special Tools
1. Grease Gun 91-37299A1
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.
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
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.
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.
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.
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
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
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
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.
2 1
a
c
d
1-5 b
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).
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.
IMPORTANT INFORMATION 1
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
e
d
XX
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
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.
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.
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.
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.
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.
16
3
15
14 4
5
7
13
12
8
11 9
10
59029
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
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
20
4
19
5
18
6
7
15
8
14
17
12
16
10
13 11 59024
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
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.
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.
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.
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).
IMPORTANT INFORMATION 1
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
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
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)
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)
d
b
Steering Cable
STARBOARD SIDE ROUTED CABLE
1. Lubricate O-ring seal and entire cable end.
95
57832
57833
b 57834
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.
57841
BLU/WHT BLU/WHT
GRN/WHT GRN/WHT a
TAN TAN b
BRN/WHT BRN/WHT
c
59027
Battery Cables
SINGLE OUTBOARD
(+)
b
c
(–)
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
h c
d e
f
g
i
j
l k b a
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
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
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.
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
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
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
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.
2. Remove cap and fill engine oil reservoir with oil. Reinstall the fill cap.
b
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.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part. No. 91-880118A2.
b a
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.
a - Fill Cap
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
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
Specifications
IGNITION Type Digital Inductive
SYSTEM Spark Plug Type NGK BPZ8HS-10
Spark Plug Gap 0.040 in. (1.0 mm)
58903
58904
Special Tools
1. DMT 2000 Digital Tachometer Multimeter 91-854009A1
55117
55117
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.
a c
b d
59035
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.
59026
a - Electronic Control Module (ECM)
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
59031
a - Throttle Position Sensor (TPS) c - Roller
b - Throttle Stop Screw d - Pocket
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
59025
a - Manifold Absolute Pressure (MAP) Sensor
Power Supply:
Clean and inspect remote control
male and female harness connec-
tors.
58903
58904
a
a
59034
59071
a - Flywheel Holder (91-52344)
b - 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)
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)
59036
59026
a - Harness Connectors c - Control Module
b - Bolts (3)
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
ANALOG TEMPERATURE SENSOR
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.
DIGITAL TEMPERATURE SENSOR
1. Install sensors into cylinder heads. Torque sensors to 14 lb. in. (1.6 Nm).
2. Reconnect sensor harness connectors.
59025
a - Air Temperature Sensor
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.
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).
2. Reconnect sensor harness.
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
Specifications
Special Tools
1. Volt/Ohm Meter 91-99750A1 or DMT 2000 Digital Tachometer Multimeter 91-854009A1
a b
54964
4. Protector Cap 91-24161 (Used with Puller 91-73687A1)
a - Puller 91-73687A1
b - Puller 91-849154T1
Î
Î 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.
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.
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.
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
a - Flywheel Holder (91-25344)
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
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.
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
Notes:
Flywheel/Alternator
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
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.
59069
a - Terminal B
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)
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
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.
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
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
59067
a - Top Bolt [Torque to 40 lb-ft (54 Nm)]
b - Harnesses
59024
a - Belt Tensioner Assembly
Starter System
NOTE: Early production engines will be equipped with centrifugal bendix type starter mo-
tors. Later production engines will be equipped with solenoid driven bendix type starter
motors.
Starter Motor Amperes Draw
STARTING Electric Start – All Models
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
Starter Draw (Under Load) 175 Amperes
Starter Load (No Load) 60 Amperes
Minimum Brush Length 0.25 in. (25.4 mm)
Battery Rating Min. 630 Marine Cranking Amps
(MCA) or 490 Cold Cranking Amps
(CCA)
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.
25
25
95
25
25 Liquid Neoprene
95 2-4-C Marine Lubricant With Teflon
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
TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (-) battery post and common pow-
erhead ground.
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 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.
*Battery Voltage
TEST 7
a. Connect voltmeter between common engine and Test Point 1.
b. Turn ignition key to “Start” position.
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
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
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.
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)
a b c d 11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer
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”).
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
11673
a - Positive (+) Brushes
11674
a - Negative (–) Brushes
b - End Cap
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
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.
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:
7. Lubricate bushing (located in commutator end cap) with one drop of SAE 10W Oil (ob-
tain locally). DO NOT over lubricate.
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)]
b
1 3
a
a
b
2
51809
a - 12 Volt Supply
b - VOA Leads
5
4
12 14
13
9
10
11
23 15
24
16 18
24
25
17
21 19
20
21
22
22 58430
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
58431
Solenoid Driven Bendix Starter Circuit
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
TEST 2
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.
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 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.
TEST 8
a. Connect voltmeter between common engine ground and Test Point 2.
b. Turn ignition key to “Start” position.
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
b a
59038
a - Starter Solenoid
b - Mounting Bolts
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
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
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]
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
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
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
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
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)]
OFF
RUN
START
CHOKE*
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
Wide Open Throttle (WOT) RPM
– All Models 5000 – 5800
Float Adjustment (Vapor Separator)
Float Level Preset @ Factory
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
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
*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).
Special Tools
1. Digital Diagnostic Terminal (DDT) 91-823686A2
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
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
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
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
a
59025
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
cc
bb
aa
dd
m
m
ll
ee
ff
gg
kk
hh
j i
aa bb
c
58912
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
< F R >
RED
PURPLE
GREEN
aa
RED
PURPLE
GREEN
aa
d
RED/PURPLE
BLUE/WHITE
GREEN/WHITE aa
58629
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.
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.)
Notes:
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
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
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
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
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
a - Connect to +12 Volt
b - Position Light Bulb to the Unswitched Position
c - Connect to NEGATIVE (–) Ground
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
a - Connect to +12 Volt
b - Position Light Bulb to the Unswitched Position
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
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
51109
a - +12 Volt Light Switch Wire
b - Position Light Bulb to the Switched Position
51112
a - Position Light Bulb to the Unswitched Position
b - Sender
SENDER WIRING
a
51108
a - Connect to +12 Volt
b - Connect to NEGATIVE (–) Ground
SEND
51105
a - +12 Volt Light Switch Wire
b - Position Light Bulb to the Unswitched Position
51106
a - Position Light Bulb to the Switched Position
b - Sender
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
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.
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.
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.
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
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.
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)
Hrs
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.
Gal/h
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
Psi
Volt
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
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.
NOTE: The throttle will have to be returned to idle to reset the system.
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.
If no water is coming out of the water pump indicator hole, or flow is intermittent, stop engine
and check cooling water intake holes for obstruction. If no obstruction is found, this may indicate
a blockage in the cooling system or a water pump problem. Have the outboard checked by
your dealer. 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.
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.
A)
B)
C)
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.
NOTE: NOT ALL SCREENS MAY APPLY TO YOUR ENGINE TYPE.
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.
Trim
Trim
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
C
F
Bar
Psi
Gal Ltr M
Ft
Range
Miles
Miles NMiles
Km
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
Miles
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.
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 50% – The “50 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 75% setting.
Gal
Calibration 75% – The “75 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 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.
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.
Speedometer
1
30
40
50 6
2 20 60
10 70
7
0
3 80
8
4
9
5
Troll Control
BASIC OPERATION
Tachometer Speedometer
3 4
2 5
1 6
0 7
0 80
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.
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
• Alarms Warnings – When a problem is detected, the warning horn sounds and the
name of the offending alarm appears on the display.
If problem can cause immediate engine damage – the horn will sound continuously and
the Engine Guardian System will respond to the problem by limiting engine power. Im-
mediately reduce throttle speed to idle and refer to the warning messages on the fol-
lowing pages that tell what to do.
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
OVERHEAT
The overheat alarm message appears and the warning horn begins sounding continuously.
The Engine Guardian System will start limiting engine power.
If the engine overheats, immediately reduce throttle speed to idle. Shift engine into neu-
tral. Check for an obstruction covering the water intake holes on the engine.
NOTE: The throttle will have to be returned to idle to reset the system.
3 4
2 5
1 6 a
0 7
3 4
2 5
1 6
a
0 7
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)
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 limit-
ing the engine power.
NOTE: The throttle will have to be returned to idle to reset the system.
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
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.
NOTE: The throttle will have to be returned to idle to reset the system.
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
a no starboard
engine
3 4
2 5
0 7
c OIL TEMP
d OIL PRESSURE
MASTER RESET
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.
2. Press MODE to advance through the calibration selections.
TRIM POPUP?
Do you want power trim display screen to pop up momentarily
when you trim the engine?
[NO] [SAVE] [YES]
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 UP
THEN PRESS PLUS (+) BUTTON
[DFLT] [SKIP] [SAVE]
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]
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]
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]
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.
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]
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.
[DFLT] [SKIP] [SAVE]
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.
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.
2. Press MODE to advance through the calibration selections.
TIME
Allows you to set the time.
[NO] [SKIP] [EDIT]
TIME FORMAT
Choose between a 12 hour and 24 hour format.
[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]
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]
AIR TEMP?
Are you using a air temp. sensor?
[NO] [SAVE] [YES]
GPS?
Do you have a GPS sensor installed?
[NO] [SAVE] [YES]
WATER TEMPERATURE
ADJUST Adjust water temp. transducer to match actual sea water tem-
perature.
[DOWN] [SAVE] [UP]
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-
played before the ignition was turned off.
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.
When the ignition is turned on, the tachometer will display 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
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
Troll Control
Tachometer Speedometer
a TR
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.
• Alarms Warnings – When a problem is detected, the warning horn sounds and the
name of the offending alarm appears on the display.
If problem can cause immediate engine damage – the horn will sound 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.
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
OVERHEAT
NOTE: If you are in a stranded situation, stopping the engine and allowing it to cool back
down will usually allow some additional low speed (idle) running time before the engine
starts to overheat again.
The overheat problem must be corrected before you can resume normal operation.
PRESSURE
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.
NOTE: The throttle will have to be returned to idle to reset the system.
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.
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.
2. Press MODE to advance through the calibration selections.
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.
4. Press MODE to advance through the calibration selections.
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 Do you want the same contrast level for all SmartCraft
CONTRAST gauges? Press + for yes. Press MODE for no.
SET ALL INSTRUMENTS?
[ NO ] [ YES ]
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]
CALIBRATING FULL
FILL TANK TO FULL
THEN PRESS PLUS (+) BUTTON
[DFLT] [SKIP] [SAVE]
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
[DFLT] [SKIP] [SAVE]
2. Fill tank to 1/4 full, Press + to save.
3. Fill tank to 1/2 full, Press + to save
CALIBRATING 1/4 VALUE
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
CALIBRATING FULL
FILL TANK TO FULL
THEN PRESS PLUS (+) BUTTON
[DFLT] [SKIP] [SAVE]
CALIBRATION
PADDLE WHEEL SENSOR
MULTIPLIER 1.00
[DOWN] [SAVE] [UP]
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.
THEN PRESS PLUS (+) BUTTON
[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
THEN PRESS PLUS (+) BUTTON
[DFLT] [SKIP] [SAVE]
CALIBRATION
TRIM FULL UP
THEN PRESS PLUS (+) BUTTON
[DFLT] [SKIP] [SAVE]
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.
2. Press MODE to advance through the calibration selections.
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.
4. Press MODE to advance through the calibration selections.
Press – or + to adjust level. Press MODE to save setting
CALIBRATION
BRIGHTNESS
[SKIP] [EDIT]
CALIBRATION
UTC ZONE Press – or + to set the hour
UTC CORRECTION = X H Press MODE to save.
[DOWN] [SAVE] [UP]
CALIBRATION HOUR
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]
CALIBRATION Do you want to exit the calibration mode? Press + for yes.
Press MODE for no.
EXIT ? [ YES ]
[ NO ]
b
a
57738
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
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
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
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
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
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
59157
Notes:
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
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
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.
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
59042
a - Fuel Inlet
b - Fuel hose from fuel pump to Fuel/Water Separator
c - Pulse hose
d - Mounting screws
59040
a - Reverse View of Pump Body
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.
23601
a - Retainer
b - Plastic Check Valve
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
5. Place boost spring into pump body and place cap onto boost spring.
50161
a - Boost Spring
b - Pump Body
c - Cap
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.
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
Specifications
FUEL Idle RPM
INJECTION – All Models 650 ± 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
Special Tools
1. Fuel Pressure Gauge 91-852087A3 (a) or Fuel Pressure Gauge 91-881834A1 (b).
55294 58879
55117
10. Strap Wrench 91-24937A1
58685
Notes:
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.
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.
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.
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.
b
a
p
q
o n
m d
k
j
i
h
f e
g
58901
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.
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.
Results Results
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.
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
Results Results
Results Results
Results Results
Results Results
Fuel Injector has audible click. Fuel Injector does not have audible click.
Results Results
Results Results
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
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.
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
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.
1. Place emergency stop switch in OFF position to prevent engine from starting.
2. Remove vapor separator drain plug and place a clean container under drain.
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.
3. Remove vapor separator drain plug and place a clean container under drain.
59052
Results: If fuel flow is low or not present, remove, disassemble and inspect float assembly. See vapor separa-
tor disassembly.
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
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
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
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.
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
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
a
b
b
59025
59037
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.
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
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).
1. Place outboard in water, connect Digital Diagnostic Terminal (DDT) to engine.
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.
Problem Diagnosis
Condition Possible Source Action
Engine Down On Power Or RPM – Failed Ignition Coil Refer to Section 2 Electrical and
Ignition Tests.
*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)
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
b a
91-881834A1
59052
a - Drain Plug
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
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
7. Disconnect the following hoses and connectors:
b
a
59058
a - Air Temperature Sensor
b - MAP Sensor
c - Fuel Injector Harness Con-
nector
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)
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
a b a a
d
e
c
59048
a a a
58792
a - Fuel Injector Attaching Screws
b - Fuel Inlet Pipe Attaching Screw
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
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)]
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).
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).
2. Reconnect sensor harness.
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).
2. Reconnect sensor harness.
a
a
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.
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
b 58787 58783
a
c
d
b
58786
a - Harness
b - Filter
c - Seal
d - Fuel Pump
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)]
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
91-24937A1
b 59047
a - Water Separator
b - Water Sensor Lead
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).
2. Reconnect sensor harness.
3. Reconnect sensor link rod.
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.
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
58789
a - O-Rings
b - Filter
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.
CAUTION
Be careful not to get dirt or other contamination in tanks, hoses or other compo-
nents of the oil injection system during installation.
Notes:
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)
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.
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.
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.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
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.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part. No. 91-880118--1.
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.
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
59039
a - Oil Hose Without Blue Stripe
a - Fill Cap
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
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
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08
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.
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
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
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
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)
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)
2002 Merc/Mar 3.0 L V6 (225 H.P.) 37-804670-02 Starboard side of Air Handler
Assembly
(EFI)
2002 Merc/Mar 3.0 L V6 (250 H.P.) 37-804670-02 Starboard side of Air Handler
Assembly
(EFI)
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
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)
Dimension “A”
at Right Angle
(90°) to Piston
Pin
1/2 in.
(12.7mm)
Dimension “B” ( in
line with Piston Pin)
Special Tools
1. Lifting Eye 91-90455
91–52344
54964
3. Protector Cap 91-24161
55117
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
Notes:
A = TO BLOCK
9
95
28 95
9
27 9
41
21
95
95
62
14
2 7
2 1 3
7
2
7
6
4
4
2 5
1 7
8
2 5
3
12
1
8
9
6 5
1 10
11
8
5
1
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)
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
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.
a a
57841
a - Screws b - Retainer
59075
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
d
c
b
59030
a - Oil Supply Hose
b - Shift Lever Bracket Assembly
c - Water Pressure Hose (GREY)
d - Starboard Thermostat Discharge Hose
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
d - Starboard Thermostat Discharge Hose
a
a
a - Throttle Cable
b - Shift Cable
10. Disconnect input fuel line, water pressure hose and speedometer hose.
b c
a
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
59053
a - Fuel Pressure Gauge 91-881834A1
b - Fuel Pressure Test Port
c - Drain Plug
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
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
1. Disconnect the following hoses and connectors:
b
a
59058
a - Air Temperature Sensor
b - MAP Sensor
c - Fuel Injector Harness Con-
nector
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)
a c
d
b
f
f
e
g
f f
h
Starter Motor
Disconnect and/or remove the following:
c a b
g
e c
d
d
f 59044
59038
b
59078
a - Crank Position Sensor Connector
b - Trim Motor Bullet Connectors
c - ECM Screws (3)
d - Solenoid Plate Screws (3)
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
Powerhead Disassembly
1. Place powerhead in repair stand or on a bench.
2. Remove thermostat covers and washers.
a - Cover
b - Washer
b
a
52214
a - Cylinder Head
b - Engine Block
a
a
52325
a - Crankcase Attaching End Cap Bolts
55977
a - Crankcase Cover
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
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
CAUTION
Each connecting rod and end cap are a matched machined set and must never be
mismatched.
55967
55966
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
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
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
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
c
55983
a - Crankshaft Ball Bearing
b - Pliers
c - Retaining Ring
aa
bb
c
dd
51081
a - Press
b - Powerhead Stand (91-812549A1)
c - Crankshaft Ball Bearing
d - Universal Puller Plate (91-37241)
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)]
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.
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.
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 .
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
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)
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.
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.
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
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
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.
51087
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
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
14 2 Cycle Outboard Oil
95 2-4-C Marine Lubricant with Teflon
95
95
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.
55992
a - Dowel Pins
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
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
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
aa bb
55964
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.
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
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).
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
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
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)
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)
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
20 18
16 14
12 10
1 3
7 5
6 8
4 2
9 11
13 15
17 19
52132
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.
Notes:
95
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)
a
a
a
a a
52373
a - Locknuts and Washers – Torque nuts to 20 lb. ft. (27 N m)
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
d
c
b
59030
a - Oil Supply Hose
b - Shift Lever Bracket Assembly
c - Water Pressure Hose (GREY)
d - Starboard Thermostat Discharge Hose
d
a
59028
a - Water Pressure Sensor Hose (GREY)(for Digital Gauges)
b - Engine Flush Hose
c - Tell-Tale Hose
d - Starboard Thermostat Discharge Hose
59075
13. Reconnect input fuel line, water pressure hose and speedometer hose.
b c
a
Shift Cable
Install cables into the remote control following the instructions provided with the remote con-
trol.
NOTE : Install the shift cable to the engine first. The shift cable is the first cable to move when
the remote control handle is moved out of neutral.
COUNTER ROTATION OUTBOARDS
Counter rotating (left hand) gear cases can be identified by a “L” 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
Forward Gear Reverse Gear
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
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.
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
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
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 - Neoprene Wrap
b - Screws
CAUTION
Severe damage to the engine can result by not complying with the Engine Break-In
Procedure.
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
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
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
Special Tools
1. DMT 2000 Digital Tachometer Multimeter P/N 91-854009A1
56725
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.
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.
Notes:
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.
WARNING
Shut off engine and refer to troubleshooting chart if water pressure is not within
specification. DO NOT exceed 3000 RPM in neutral.
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.
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
•Severe internal leak
•Defective poppet valve seal
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
•Severe internal leak
•Defective poppet valve seal
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
•Severe internal leak
•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
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
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
95 2-4-C Marine Lubricant with Teflon
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
Transom Brackets
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
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
7 Loctite 271 22
19 Perfect Seal
33 Loctite 680
95 2-4-C Marine Lubricant with Teflon
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
d
e
b
a
c
58005
a c
d
b
c
b d
58004
a - Upper Mount Nuts
a
a
58003
a - Bolts
b - Adaptor Plate
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
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)
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.
d
c
95
a
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
a
a
58003
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
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)
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)]
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
Special Tools
1. Alignment Tool 91-11230
17238
51337
51337
73835
54458
51337
a b
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
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
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.
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.
58450
a - Manual Release Valve
a 58450
a - Trim Angle Adjustment Bolt
c
b
aa
27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut. Torque to 80 lb. in. (9 Nm)
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
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
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.
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.
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
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.
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
6 - Up Circuit Suction
Check Valve
7 - Electric Motor
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.
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
5 - Up Circuit Suction
Check Valve
6 - Shuttle Spool
7 - Up Circuit Pressure
Operated Valve
8 - Trim Cylinders
9 - Tilt Cylinder
10 - Down Circuit Pressure
Operated Valve
11 - Pivot Pin
12 - Shock Piston
13 - Trim Ram
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.
2 1
ÄÄ ÄÄ
Á ÁÁ Á
ÁÁ Á
7
8
6
3
a - High Pressure
1 - Up Circuit Pressure
Operated Valve
2 - Down Circuit Pressure
Operated Valve
3 - Manual Tilt Valve
4 - Tilt Cylinder
5 - Shock Piston
6 - Memory Piston
7 - Impact Relief & Trail
over Valves
8 - Return Valve
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.
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
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
ÄÄ Á
ÁÄ
ÁÁÁÁ Á
3
7 4
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.
7
4
3
9
8 6
53794
UP Relay DOWN Relay
BLK = Black
BLU = Blue
10 GRN = Green
RED = Red
WHT = White
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.
No Voltage Indicated:
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.
No Voltage Indicated:
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.
No Voltage Indicated:
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-
•Check for loose or corroded
minal on the back of the ignition
connections.
switch.
•Check for open in wire.
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
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.
58444 58454
a - Filler Cap
b - Retaining Nut
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.
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)
c b
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.
ee d c
c bb
ff aa 54457
54458
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)
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)
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.
a 54457
f e d c b
a - Test Adaptor (91-822778A3)
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
54458
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
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)
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
51343
a - Seal (remove as shown)
4. Install new seal with seal lip up.
a
a
58450
a - Trim Rods
b - Cylinder End Caps
c - Rod End Rollers (lubricate with Anti-Corrosion Grease or
Special Lubricant 101)
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
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
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
aa
51376
a - End Cap
SRP-4 (Snap-On)
51144
a - Memory Piston
b - O-Ring
c - Snap-On Pliers SRP-4
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.
bb
aa
cc
b
a - Cap
b - O-ring (2)
c - Scraper Seal
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
d
bb
aa
51376
cc
b
b
a - End Cap
b - O-ring (2)
c - Scraper seal
d - End Cap
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.
b
a
a - Alignment Tool (91-11230)
b - 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]
aa
51356
a - Pin (Drive Against Knurled End)
58604
a - Reservoir Cap
b - Manual Release Valve
a a
58606
a - Screws (4)
b - Reservoir Cover
4. Inspect reservoir cover O-ring for cuts or abraisions. Replace O-ring as required.
58605
a - O-Ring
58611 58610
a - Screws and Washers
b - O-Ring (YELLOW)
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
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
53774
Motor Disassembly
1. Remove 2 screws.
a a
53774
a - Screw (2)
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
53775
a - Commutator
FIELD TESTS
IMPORTANT: Commutator end of armature must be installed in brushes when per-
forming the following tests.
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.
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.
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
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)
aa
aa
53783
53784
a - O-rings
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)
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).
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)]
1
1
aa
22908
a - Trim sender
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
58451
a - Digital Trim Sender
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:
If voltage is not as indicated or voltage rise and fall is erratic, trim sender is defective.
aa bb c
22908
a - Trim Indicator
b - Remote Control
c - Trim Sender
d - Engine Ground
e - To Engine
f - Ignition Switch
g - Power Trim Harness
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
Gearcase without Oil Gearcase should hold 15 psi for 5 minutes without leakage
Special Tools
1. Gear Housing Cover Nut Tool 91-61069
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
8. Mandrel 91-38628
16. Backlash Indicator Rod 91-53459 for (1.75:1 ratio) and 91-78473 for (1.87:1 ratio)
7
6
4
3
2
TORPEDO DIA.
34
35
95
7 Loctite 271 36
32
92 Loctite 7649 Primer
31
95 2-4-C Marine Lubricant With Teflon
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
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
i
d g
f
a h
b
e
c
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.
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.
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
3. Remove the impeller, impeller key, the face plate and gaskets. Discard the gaskets.
b
d
70605
b 70613
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.
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.
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
a
57940
70501
a - O-ring
b - Oil Seals (2)
c
b
70610
95
a
95 2-4-C Marine Lubricant with Teflon
70490
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
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
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.”)
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.
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
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
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
23140
a - Oil Seals
b - Pry Bar
87
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
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
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
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)
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)
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.
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).
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.
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
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
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
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
a
52727
a - Check Movement with Dial Indicator (91-58222A1) Here
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)
23351
a - Forward Gear Teeth
b - Clutch Jaws
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.
a c
91-37241
b
51119
a - Forward Gear Bearing
b - Universal Puller Plate (91-37241)
c - Mandrel
57905 b
19203
a - Retaining RIng
b - Bearing
a
87
b
91-877321A1
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
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.
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.
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)
57934
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
e
b
d 57954
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
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
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)
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)
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
4. Install the bearing by screwing down the nut until the bearing is fully seated against
the bore shoulder.
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.
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
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
a - Shift Shaft Assembly
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
95 2-4-C Marine Lubricant With Teflon
a - Rollers (18)
b - Roller Bearing Outer Race
b
a
58016
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
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.
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
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
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)
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
3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom
nut away from top nut.
57937
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
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).
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.
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).
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
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
b
70719
a - Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
b. Torque the puller bolt to 45 lb. in. (5 Nm). Rotate drive shaft three full turns clock-
wise and retorque the bolt to 45 lb. 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)
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).
Reverse Gear Backlash
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
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
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).
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 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.
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
95
3. 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
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
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)
a b
c
70501
a - Oil Seal Carrier
b - Oil Seal Lips
c - O-ring
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
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
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.
57946
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
Forward Gear Reverse Gear
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
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.
a
c
d
57736 d 57735
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
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
Special Tools
1. Propeller Shaft 44-93003 and Load Washer 12-37429
7
6
4
3
2
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.
TORPEDO DIA. 34
7 Loctite 271 35
92
36
Loctite 7649 Primer
32
95 2-4-C Marine Lubricant with Teflon 95
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
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
95 2-4-C Marine Lubricant with Teflon
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
g
d
f h
a
c
b
e
c
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
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.)
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.
a
52377
a - Fill Screw
b - Vent Screw
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
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
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)
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.
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.
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
a
57940
a - Oil Seal Carrier
b - Screwdrivers
70501
a - O-ring
b - Oil Seals (2)
c
b
70610
a - Oil Seal Carrier
b - Oil Seals
c - Screwdriver
95
a
95 2-4-C Marine Lubricant with Teflon
a - Bottom Seal (lip faces down)
b - Top Seal (lip faces up)
70490
a - Tab on Tab Washer
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
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
a - Puller Jaws (91-46086A1)
b - Puller Bolt (91-85716)
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
50786
a - Thrust Bearing
50787
a - Thrust Collar
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)
50784
a - Thrust Collar
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
50783
a - Forward Gear Installation Tool (91-815850)
b - Thrust Race
c - Forward Gear
d - Shim
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
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.
c
a
b
23140
a - Needle Bearing
b - Oil Seals
c - Driver Head (91-36569)
d - Bearing Driver Rod (91-37323)
23140
a - Oil Seals
b - Pry Bar
87
a
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
95 2-4-C Marine Lubricant with Teflon 50788
a - Driver
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.
b
c
c
d
50874
a - Forward Gear Bearing Adaptor
b - Bearing Removal Tool (91-816245)
c - Pins
d - Universal Puller Plate
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)
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)
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.
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
5. Remove lower drive shaft bearing cup and shims using slide hammer puller
(34569A1) (retain shims for re-installation).
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.
c
d
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
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
d c
58015
a - Spring
b - Shift Spool Assembly
c - Reverse Gear Assembly
d - Sliding Clutch
58012
e d
c
58018
a - Detent Pin
b - Cross Pin
c - Reverse Gear Assembly
d - Spool
e - Clutch
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
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.
23351
a - Reverse Gear Teeth
b - Clutch Jaws
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
50778
a - Reverse Gear Needle Bearing
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
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
a b c
55694
a - Shift Spool Shaft
b - Shift Spool
c - Castle Nut
d - Cotter Pin
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.
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)
b
95
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
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
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
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)
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)
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
4. Install the bearing by screwing down the nut until the bearing is fully seated against
the bore shoulder.
95
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
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
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
a - Shift Shaft Assembly
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
95 2-4-C Marine Lubricant with Teflon
a - Rollers (18)
b - Roller Bearing Outer Race
87
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
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.
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 (with the washer glued to it) into the gear housing.
4. 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.
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.
7. Start the pinion nut onto the drive shaft threads by rotating the drive shaft until the nut
is snug.
c
57952
a - Pinion Gear (with the washer glued to it)
b - Pinion Nut Adaptor (91-61067A2)
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
9. Install the bearing carrier into the gear housing backwards to hold the propeller shaft
and the pinion nut adaptor in position.
10. Torque the pinion nut to 70 lb. ft. (95 Nm) by turning the drive shaft using the drive shaft
nut wrench and torque wrench.
57950
a - Pinion Nut Adapter (91-61067A2)
b - Drive Shaft Nut Wrench (91-56775)
c - Bearing Carrier (installed backwards)
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
a - Drive Shaft Bearing Retainer Wrench (91-43506)
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
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)]
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
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
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).
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.
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).
a
b
70973
a - Torque Wrench (91-66274)
b - Driver Bolt
c - Bearing Adaptor Installation Tool (91-18605A1)
d - Reverse Gear
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 ratio)
Backlash Indicator Rod (91-78473) (for 1.87:1 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).
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 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).
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.
(subtract) middle
of .050 in. (1.27 mm)
specification:
You get: .020 in. (0.50 mm)
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.
55428
a - Shim
2. Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust
race onto forward gear bearing adaptor.
87
c
3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor
assembly.
55221
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear/Bearing Adaptor Assembly
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
a - Forward Gear Bearing Adaptor
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
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)
b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer
7. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.
70714
a - Tab Washer
b - “V” Tab
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
a - Bearing Carrier Retainer Wrench (91-61069)
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.
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)
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.
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 4 above and take and record another reading. Repeat step 4 until a
total of 4 backlash readings have been taken.
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.
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.
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
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
87
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.
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
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
70620
a - Shims
d
c
a
b
7 Loctite 271
a - Pinion Gear (with the washer glued to it)
b - Pinion Nut Adaptor (91-61067A3)
c - Tapered Roller Bearing Cups
d - Retainer
9. Install the bearing carrier into the gear housing backwards to hold the propeller shaft
and the pinion nut adaptor in position.
10. Torque the pinion nut by turning the drive shaft using the drive shaft nut wrench and
torque wrench with the appropriate socket to 70 lb. ft. (95 Nm).
b
57950
a - Pinion Nut Adaptor (91-61067A2)
b - Drive Shaft Nut Wrench (91-56775)
c - Bearing Carrier (installed backwards)
11. Remove the bearing carrier, pinion nut adaptor and drive shaft nut wrench.
12. Torque the retainer to 100 lb. ft. (135 Nm).
57935
a - Drive Shaft Bearing Retainer Wrench (91-43506)
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
3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor
assembly.
55221
a - Forward Gear Installation Tool (91-815850)
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
a - Forward Gear Bearing Adaptor
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
b - Forward Gear Bearing Adaptor
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
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
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
10. Lubricate the second thrust bearing with Premium Gear Lubricant and install it to the
top of the thrust collar.
87
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
12. Lubricate the large O-ring with 2-4-C Marine Lubricant with Teflon and assemble into
the gear housing as shown following.
95
95
87 95
15. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing
and then install the tab washer with the external tab inserted into the hole in the gear
housing.
a
c
70713
a - Gear Case Alignment Hole
b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer
16. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.
70714
a - Tab Washer
b - “V” Tab
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
a - Bearing Carrier Retainer Wrench (91-61069)
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)
a b
c
70501
a - Oil Seal Carrier
b - Oil Seal Lips
c - O-ring
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
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
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.
57946
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
Left Hand Rotation Outboard
Reverse Gear Forward Gear
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.
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.
a
c
d
57736 d 57735
a - Speedometer Tube from Gearcase
b - Junction
c - Sta-strap
d - Speedometer Tube from Swivel Tube
aa
c
b
28160
57833
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.
NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
lubrication at initial installation.
WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock
of cable could occur.
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
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.
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.
a
bb b cc
a - Gear Rack
b - Steering Cables
c - Rotary Steering Heads
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)
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
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)
c a d
51887
c 51887
c a
a - Steering Cable Mounting Tube
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
WARNING
After installation is complete [and before operating outboard(s)], check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) at
all tilt angles to assure interference-free movement.
Maintenance Instructions
Maintenance inspection is owner’s responsibility and must be performed at intervals spe-
cified, following:
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
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).
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.
d
b
c
a a
28170
a - Grease Fittings
b - Cable Ends
c - Pivot Point
d - Ball Joint
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.
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
a - Mounting Bracket for Steering Cable Mounting Tube
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
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. Be sure longer threaded end of tube is toward starboard side of boat.
Temporarily adjust tube, so that longer threaded end of tube extends out the same dis-
tance as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d
b
a 51891
c
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)
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
Lubricant with Teflon.
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
Place a mark (a) on steering cable mounting tube (b) 5/8 in. (16 mm) from end of mounting
tube. Slide plastic spacer (c), O-ring (d) and cap (e) over steering cable.
5/8 in. (16 mm)
a c d e 51890
Thread cap (e) onto steering cable mounting tube, up to mark (a).
a e 51890
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
WARNING
Steering link rods MUST BE secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
nuts (11-826709113), as shown. Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
e c
f a
d 50061
a
b
c c
e e
a a
b b
d f d f
28166
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).
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.
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
c 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
a flat on each nut.
bb
51887
c c a
a - Steering Cable Mounting Tube
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
51887
WARNING
After installation is complete (and before operating outboard(s)), check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement.
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
a - Mounting Bracket for Steering Cable Mounting Tube
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.
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.
b d
51891
a
c
a - Steering Cable Mounting Tube (End of Tube with Longer Threads Toward
Center of Boat Transom)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab Washer)
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
Lubricant with Teflon.
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.
NOTE: Torque steering cable attaching nut only after final steering adjustments have
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
tube. Slide plastic spacer (c), O-ring (d) and cap (e) over steering cable.
5/8″(16 mm)
e d c b
51890
Thread cap (e) onto steering cable mounting tube, up to mark (a).
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
Lubricant with Teflon.
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.
NOTE: Torque steering cable attaching nut only after final steering adjustments have
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-
nuts (11-826709113), as shown. Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
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
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 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.
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
b
d c 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
a flat on each nut.
c c a 51887
WARNING
After installation is complete [and before operating outboard(s)], check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement.
Adjust trim tabs of both outboards, as outlined in “Trim Tab Adjustment,” following.
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]
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.
NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
lubrication at initial installation.
WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock
of cable could occur.
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).
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.
d d
a c c
a b
a b a
28168
d d
c
c
b a a a a b
28175
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
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)
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)
WARNING
After installation is completed (and before operating outboard), check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) at
all tilt angles to assure interference-free movement.
Maintenance Instructions
Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, 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.”
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
lubrication at initial installation.
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)
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
Notes:
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
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
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
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
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
11
1 17
6 9
2
3
4 10
11
14
1
16
17
5
16
1
14
59162
12 15
7
13