How to Install Mercury Throttle and Shift Cables

• Contents
• Table of Contents
• Troubleshooting
• Bookmarks

Quick Links

• 6

  Important 1 a

• 16

  Important 1 B

• 28

  Important 1 C

• 49

  Electrical 2

• 75

  Electrical 2

• 97

  Electrical 2

• 103

  Electrical 2

• 114

  Fuel System

• 127

  Fuel System

• 149

  Fuel System

• 163

  Table of Contents

• 170

  Powerhead

• 213

  MID-Section

• 225

  MID-Section

• 237

  MID Section

  • 238

    Special Tools

  • 239

    Power Trim Components

  • 241

    Adjustments

  • 241

    Theory of Operation

  • 257

    Troubleshooting

  • 264

    Power Trim System Removal

  • 265

    Disassembly

  • 266

    Shock Rod Disassembly

  • 272

    Cleaning/Inspection/Repair

  • 273

    Reassembly

  • 275

    Power Trim Reassembly

  • 280

    Power Trim System Installation

SERVICE

Printed in U.S.A.

MANUAL

United States

Belgium

1997, Mercury Marine

MODELS

40·50·55·60

With Serial Numbers

. .

0G531301 and ABOVE

. . . . . . .

09974454 and ABOVE

90-852572R1 JANUARY 1998

Chapters

• 6

  Important 1 a

• 16

  Important 1 B

• 28

  Important 1 C

• 49

  Electrical 2

• 75

  Electrical 2

• 97

  Electrical 2

• 103

  Electrical 2

• 114

  Fuel System

• 127

  Fuel System

• 149

  Fuel System

• 163

  Table of Contents

• 170

  Powerhead

• 213

  MID-Section

• 225

  MID-Section

• 237

  MID Section

  • 238

    Special Tools

  • 239

    Power Trim Components

  • 241

    Adjustments

  • 241

    Theory of Operation

  • 257

    Troubleshooting

  • 264

    Power Trim System Removal

  • 265

    Disassembly

  • 266

    Shock Rod Disassembly

  • 272

    Cleaning/Inspection/Repair

  • 273

    Reassembly

  • 275

    Power Trim Reassembly

  • 280

    Power Trim System Installation

Troubleshooting

  Also See for Mercury 40

  Related Manuals for Mercury 40

  Summary of Contents for Mercury 40

• Page 1 SERVICE MANUAL MODELS 40·50·55·60 With Serial Numbers United States 0G531301 and ABOVE Belgium ..09974454 and ABOVE 1997, Mercury Marine 90-852572R1 JANUARY 1998 Printed in U.S.A.
• Page 2 This service manual has been written and published the same locations whenever possible. Where the by the Service Department of Mercury Marine to aid fasteners are not satisfactory for re-use, care should our dealers' mechanics and company service per-...
• Page 3 In addition, personnel should not work on or under an Cleanliness and Care of outboard which is suspended. Outboards should be Outboard Motor attached to work stands, or lowered to ground as soon as possible. A marine power product is a combination of many We reserve the right to make changes to this manual machined, honed, polished and lapped surfaces with without prior notification.
• Page 4 D - Emissions Section 4 - Powerhead Section 5 - Mid-Section Mid-Section A - 40/50 Clamp/Swivel Brackets & Drive Shaft Housing B - 55/60 Clamp/Swivel Brackets & Drive Shaft Housing C - 40/50 Power Trim D - 55/60 Power Trim...
• Page 5 IMPORTANT INFORMATION SPECIFICATIONS...

• Page 6: Table Of Contents

  1A-1 Propeller Information Charts ... . . 1A-4 Mercury/Mariner 40 HP (3 Cyl.) ..1A-4 Mercury/Mariner 50 HP (3 Cyl.) ..

• Page 7: Specifications

  Specifications Models 40/50/55/60 Model 40 40 (29.8) HORSEPOWER Model 50 50 (37.3) (kW) Model 55 55 (41.0) Model 60 60 (44.7) Manual 40/50 ML 205 lbs. (93.0 kg) 55 ML 220 lbs. (99.8 kg) Electric OUTBOARD WEIGHT 40/50 ELPTO 204 lbs. (92.5 kg) 40/50 ELO 200 lbs.
• Page 8 40/50 Gear Ratio 1.83:1 Gearcase Capacity 14.9 fl. oz. (440 mL) Lubricant Type Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth 22 Spiral/Bevel Pinion Gear Number of Teeth 12 Spiral/Bevel Pinion Height 0.025 in. (0.64 mm) Forward Gear Backlash...
• Page 9 5000-5500 Idle Mixture Screw Adjustment Preset (Turns Out) Float Adjustment CARBURETOR Float Level in. (14 mm) Main Jet Model 40 (WME-53, 69) 0.044 in. Model 50 (WME-68) 0.052 in. Model 55 (WME-57) 0.058 in. Model 60 (WME-58) 0.060 in. Recommended Oil...

• Page 10: Propeller Information Charts

  Propeller Information Charts Mercury/Mariner 40 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15", 20" Right Hand Rotation Standard Gear Reduction : 1.83:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wgt.

• Page 11: Mercury/Mariner 50 Hp (3 Cyl.)

  Mercury/Mariner 50 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15", 20", 22-1/2" Right Hand Rotation Standard Gear Reduction : 1.83:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wgt. (lbs)

• Page 12: Mercury/Mariner 55 Hp (3 Cyl.)

  Mercury/Mariner 55 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 16-1/2", 21", 23-1/2" Right Hand Rotation Standard Gear Reduction : 2.3:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wgt. (lbs)

• Page 13: Mercury/Mariner 60 Hp (3 Cyl.)

  Mercury/Mariner 60 HP (3 Cyl.) Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15", 20" Right Hand Rotation Standard Gear Reduction : 1.64:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wgt. (lbs)

• Page 14: Mercury/Mariner 60 Hp (3 Cyl.) Bigfoot

  Mercury/Mariner 60 HP (3 Cyl.) Bigfoot Wide Open Throttle RPM: 5000-5500 Recommended Transom Heights : 15", 20", 22-1/2" Right Hand Rotation Standard Gear Reduction : 2.31:1 Approx. Approx. Speed No. of Gross Boat Boat Range Propeller Diameter Pitch Blades Material Wgt.
• Page 15 IMPORTANT INFORMATION MAINTENANCE...
• Page 16 ......1B-7 40/50 HP ......

• Page 17: Specifications

  2. Quicksilver Anti-Corrosion Grease Specifications P/N 92-78376A6 Gear Case Lubricant Capacity Gear Case Ratio Capacity 1.83:1 14.9 fl. oz. (440 mL) 1.64 :1 11.5 fl. oz. (340 mL) 2.3:1 22.5 fl. oz. (655 mL) Special Tools 1. Quicksilver Flushing Attachment (44357A2) 3.

• Page 18: Inspection And Maintenance Schedule

  Every 100 Hours of Use or Once Inspection and Maintenance Yearly, Whichever Occurs First Schedule 1. Lubricate all lubrication points. Lubricate more frequently when used in salt water. Before Each Use 2. Inspect and clean spark plugs. 1. Check that lanyard stop switch stops the engine. 3.

• Page 19: Flushing The Cooling System

  3. Start the engine and run it at idle speed in neutral Flushing The Cooling shift position. System 4. Adjust water flow (if necessary) so excess water Flush the internal water passages of the outboard continues leaking out from around the rubber cups to ensure the engine is receiving an ade- with fresh water after each use in salt, polluted, or quate supply of cooling water.

• Page 20: Corrosion Control Anode

  3. Place the outboard in water or connect flushing attachment for circulating cooling water. Run the engine for ten minutes to allow treated fuel to reach the carburetors. Corrosion Control Anode 1. Your outboard has two corrosion control anodes. One of the anodes is the trim tab installed on the gear case and the other is installed on the bottom of the transom bracket assembly.

• Page 21: Lubrication Points

  Lubrication Points ITEM TYPE OF FRESH WATER SALT WATER DESCRIPTION LUBRICANT FREQUENCY FREQUENCY Throttle/Shift linkage Pivot Points Shift Handle (Tiller Quicksilver 2-4-C Handle Models) Marine Lubricant Swivel Pin 100 Hours of Use or Once Per Season Ride Guide Steering Cable Tilt Tube/Co-Pilot Steering Link Rod SAE 30W Motor Oil...
• Page 22 5 - Tilt Tube/Co-Pilot 2 - Shift Handle (Tiller Handle Models) 6 - Steering Link Rod Pivot Points 3 - Swivel Pin 4 - Ride Guide Steering Cable 7 - Propellor Shaft 1B-6- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998...

• Page 23: Checking Power Trim Fluid

  Steering Fluid or; Automatic Transmission Fluid (ATF) Type F, FA or Dexron II fluid to trim system. 4. Reinstall fill screw. 40/50 HP 1. Tilt outboard to the full up position and engage the tilt support lock. 2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole.

• Page 24: Gear Case Lubrication

  Gear Case Lubrication When adding or changing gear case lubricant, visual- ly check for the presence of water in the lubricant. If water is present, it may have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored ap- pearance.

• Page 25: Checking Lubricant Level And Filling Gear Case

  Checking Lubricant Level and Filling Storage Preparations Gear Case The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and Never add lubricant to gear housing IMPORTANT: damage caused by freezing of trapped water. without first removing VENT plug, as trapped air will prevent housing from being filled.

• Page 26: Positioning Outboard For Storage

  Gear Case 1. Drain and refill the gear case lubricant (refer to maintenance procedure). Positioning Outboard for Storage 1. Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing tempera- ture, 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...
• Page 27 IMPORTANT INFORMATION GENERAL INFORMATION...
• Page 28 Table of Contents Page Serial Number Location ....1C-1 Conditions Affecting Performance ..1C-1 Weather ......1C-1 Boat .

• Page 29: Serial Number Location

  30% relative humidity at 77 F (25 C) tem- perature and a barometric pressure of 29.61 inches OGXXXXXX of mercury. 19XX XXXX Summer Conditions of high temperature, low baro- metric pressure and high humidity all combine to re- duce the engine power.

• Page 30: Boat

  Boat TRIM TRIMMING OUTBOARD "OUT" ("UP") WEIGHT DISTRIBUTION Proper positioning of the weight inside the boat WARNING (persons and gear) has a significant effect on the Excessive trim "out" also may reduce the stabil- boat's performance, for example: ity of some high speed hulls. To correct instabili- Shifting weight to the rear (stern) ty at high speed, reduce the power GRADUALLY and trim the outboard "in"...

• Page 31: Engine

  CAVITATION Detonation usually can be prevented if: Cavitation is caused by water vapor bubbles forming 1. The engine is correctly set up. either from a sharp edge or angle on the gear case 2. Diligent maintenance is applied to combat the or from an irregularity in the propeller blade itself.

• Page 32: Submerged Engine (Fresh Water) (Plus Special Instructions)

  Submerged Engine (Fresh Water) Propeller Selection (Plus Special Instructions) For in-depth information on marine propellers and boat performance - written by marine engineers - see 1. Recover engine as quickly as possible. your Authorized Dealer for the illustrated "What You 2.

• Page 33: Propeller Removal/Installation

  After initial propeller installation, the following common conditions may require that the propel- ler be changed to a lower pitch: Warmer weather and great humidity will cause an RPM loss. Operating in a higher elevation causes an RPM loss. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss.
• Page 34 1. To aid in future removal of the propeller, liberally 6. After first use, bend the tab straight, re-tighten coat the propeller shaft spline with one of the fol- propeller nut and again bend tab washer to se- lowing Quicksilver lubricants: cure nut.
• Page 35 IMPORTANT INFORMATION OUTBOARD MOTOR INSTALLATION...
• Page 36 ..... . 1D-1 Installing Outboard 40-50 HP ... . 1D-2 40-50 Hp – Non-Thumb Screw Models 1D-2 40-50 HP – Thumb Screw Models ..1D-3 Installing Outboard 55-60 HP .

• Page 37: Lifting Outboard

  Electric Start Models – Remove plastic cap from fly- 1. Install steering link rod per illustration. wheel hub. Thread lifting ring into flywheel a mini- 40-60 HP mum of 5 turns. Replace plastic cap after installation. 60 Hp 40-50 Hp a - Special Bolt (10-90041) Torque to 20 lb.
• Page 38 5. Drill four mounting holes using a 17/32 in. (13.5 Installing Outboard 40-50 HP mm) drill bit. 40-50 Hp – Non-Thumb Screw Models a - Non-Thumb Screw 6. Position outboard so the anti-ventilation plate is 2. Center outboard on the transom.
• Page 39 40-50 HP – Thumb Screw Models NOTE: Quicksilver Accessory Outboard Mounting Kit (P/N 812432A5) allows for quick removal and installation of outboard. Refer to installation instruc- tions supplied with the mounting kit before drilling any holes. Tighten retainer screws into lower mounting holes when using mounting kit.
• Page 40 9. Drill four mounting holes using a 17/32 in. (13.5 Installing Outboard 55-60 HP mm) drill bit. 55-60 HP - Non-Thumb Screw Models a - Non Thumb Screw 10. Position outboard so the anti-ventilation plate is 6. Center outboard on the transom. within 1 in.
• Page 41 55-60 HP – Thumb Screw Models NOTE: Quicksilver Accessory Outboard Mounting Kit (P/N 812432A4) allows for quick removal and installation of outboard. Refer to installation instruc- tions supplied with the mounting kit before drilling any holes. a - Thumb Screw WARNING Outboard must be fastened to boat transom one of two ways: 1.
• Page 42 This warning horn is used with the engine warning system. 1. Route wiring harness into bottom cowl. 40-50 HP (–) a - Red Sleeve (Positive) b - Black Sleeve (Negative)
• Page 43 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. 40-50 Hp – Shift Cable Installation 1. Position remote control and outboard into neu- tral.
• Page 44 40-50 Hp – Throttle Cable Installation 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to acti- 1. Position remote control into neutral. vate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse.
• Page 45 3. Push-in on the cable end until resistance is felt. Shift and Throttle Cable Adjust the cable barrel to attain the measured 60 HP Models distance taken in Step 2. Install cables into the remote control following the 4. Place cable barrel into the bottom hole in the bar- rel holder.
• Page 46 60 HP – Throttle Cable Installation 4. Check throttle cable adjustment as follows: a. Shift outboard into gear a few times to acti- 1. Position remote control into neutral. vate the throttle linkage. Make sure to rotate the propeller shaft while shifting into reverse. 2.
• Page 47 Trim Tab Adjustment The trim tab can be adjusted within limits to help to compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2.
• Page 48 ELECTRICAL 55042 IGNITION...
• Page 49 2A-2 Flywheel And Stator (Manual) ... . 2A-3 Electrical Components 40/50 ... . 2A-4 Electrical Components 55/60 ... .

• Page 50: Specifications

  @ Cranking Speed -Model 40/50/60 24 B.T.D.C. TIMING -Model 55/60 Seapro-Marathon 18 B.T.D.C. @ 5000 RPM – Model 40/50/60 22 B.T.D.C. – Model 55/60 Seapro-Marathon 16 B.T.D.C. *Suppressor (resistor) spark plug 4. Spark Gap Tester 91-63998A1 Special Tools 1. Flywheel Holder 91-52344 2.

• Page 51: Flywheel And Stator (Electric)

  Flywheel And Stator (Electric) Loctite 222 (92-809818) 2-4-C With Teflon (92-850736A1) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FLYWHEEL COVER 135.6 WASHER FLYWHEEL STATOR SCREW (M5 x 30) TRIGGER SWIVEL BALL SWIVEL BASE CABLE TIE 2A-2 - ELECTRICAL 90-852572R1 JANUARY 1998...

• Page 52: Flywheel And Stator (Manual)

  Flywheel And Stator (Manual) Loctite 222 (92-809818) 2-4-C With Teflon (92-850736A1) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m FLYWHEEL 135.6 WASHER STATOR SCREW (M5 x 30) TRIGGER SWIVEL BALL SWIVEL BASE CABLE TIE PLUG 90-852572R1 JANUARY 1998 ELECTRICAL - 2A-3...

• Page 53: Electrical Components 40/50

  Electrical Components 40/50 Liquid Neoprene (92-25711--2) 2A-4 - ELECTRICAL 90-852572R1 JANUARY 1998...

• Page 54: Electrical Components 40/50

  Electrical Components 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m PLATE–Electrical SCREW (M5 x 12) WASHER STA–STRAP REV LIMITER (MANUAL) REV LIMITER CLAMP SCREW (M5 x 12) SOLENOID ASSEMBLY BUSHING GROMMET SCREW (M6 x 25) ELECTRIC NUT (1/4-20)
• Page 55 Electrical Components 55/60 55 HP ONLY Dielectric Grease (92-823506--1) Liquid Neoprene (92-25711--2) 2A-6 - ELECTRICAL 90-852572R1 JANUARY 1998...
• Page 56 Electrical Components 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m PLATE–Electrical SCREW (M5 x 12) WASHER STA–STRAP REV LIMITER (MANUAL) REV LIMITER CLAMP SCREW (M5 x 12) SOLENOID ASSEMBLY BUSHING GROMMET SCREW (M6 x 25) NUT (1/4-20) ELECTRIC LOCKWASHER CABLE...

• Page 57: Theory Of Operation

  Capacitor Charging #1 CDM Theory of Operation The STATOR assembly is mounted to the block be- This outboard ignition system is alternator driven low the flywheel and has 3 CAPACITOR CHARGING (distributor-less) capacitor discharge system. Major COILS wound in series. The FLYWHEEL is fitted with components of the ignition system are the flywheel, 6 permanent magnets inside the outer rim.

• Page 58: Capacitor Charging #2 & #3 Cdm

  Capacitor Charging #2 & #3 CDM NOTE: #1 CDM stator voltage return path is through The flywheel rotates the permanent magnets past the capacitor charging coils causing the coils to pro- either CDM #2 or #3. The return path for CDM #2 and duce AC voltage (260–320 volts).

• Page 59: Cylinder Trigger Circuit

  #1 Cylinder Trigger Circuit coils to produce a voltage pulse which is sent to the respective capacitor discharge module (CDM). A The TRIGGER assembly (also mounted under the positive voltage pulse (N–S) will activate the elec- flywheel) has one coil for each cylinder. These coils tronic switch (SCR) inside the capacitor discharge are mounted adjacent to the flywheel center hub.

• Page 60: Ignition Coil Circuit

  This secondary volt- age can, if necessary, reach approximately 40,000 volts. To complete the secondary voltage path, the released voltage enters the ground circuit of CDM module.

• Page 61: Stop Circuit

  Stop Circuit To stop the engine, the stop switch is closed allowing the capacitor charge current from the stator to drain directly to ground. NOTE: The CDM contains a zener diode (not shown for clarity). This diode prevents overcharging of the capacitor (and possible failure) if the SCR does not receive a trigger pulse.

• Page 62: Rev Limiter Circuit

  Rev Limiter Circuit The rev limiter is activated through the purple wire when the key switch is rotated to the "on" position. The rev limiter uses a trigger signal (brown wire) to determine engine speed or rpm. If the engine speed exceeds the specified rpm, the rev limiter will ground out the CDM capacitor charge.

• Page 63: Ignition Component Description

  Stator Assembly Ignition Component Description Located under the flywheel in the stator assembly are 12 coils (6 for manual stator), 3 ignition charge coils and 9 auxiliary (3 for manual) power coils wound in series that provide voltage to the CDM's and battery/ Capacitor Discharge Module (CDM) auxiliary circuits respectively.

• Page 64: Cdm (P/N 827509) Trouble Shooting Flowchart

  CDM (P/N 827509) Trouble Shooting Flowchart Chart 1 Step Action Value Tools Verify High Tension Leads, Spark – Step 2 Replace High Tension Plug and Spark Boots are in good Failed Com- lead pin condition. Inspect wires for chafing. ponent 84-813706A56 Visual Inspection Step 2...

• Page 65: Cdm Stop Diode Trouble Shooting

  CDM Stop Diode Trouble Shooting 2 Cyl.: CDM #1 gets its charging ground path through CDM #2 CDM #2 gets its charging ground path through CDM #1 A shorted Stop Diode in either CDM would prevent the opposite one from sparking. 3 Cyl.: CDM #1 gets its charging ground path through CDM #2 or #3 CDM #2 and #3 get their charging ground path through CDM #1...

• Page 66: Cdm Trouble Shooting Flowchart

  CDM Trouble Shooting Flowchart Chart #2 (No Spark on any CDM) Step Action Value Tools With the key switch ON: NO continuity Step 2 Repair or DVA/Multimeter Verify continuity between BLK/YEL Replace Com- P/N 91-99750 harness wire and ground. ponent This Test Checks: Run Engine Verify Repair...

• Page 67: Cdm Trouble Shooting Flowchart

  CDM Trouble Shooting Flowchart Chart #3 (At least one CDM has spark) Step Action Value Tools Resistance Check ALL CDMs Refer to chart Step 3 Replace any DVA/Multimeter CDMs that P/N 91-99750 do not pass specifica- tions even if they fire Step 2 Test all CDMs at Cranking with 7/16 in.
• Page 68 CAPACITOR DISCHARGE MODULE IMPORTANT Spark plug wires are screwed into CDM. A B C D a - Ground b - Black/Yellow c - Trigger Connection d - Stator Connection A resistance check is required and can be performed on the CDM as follows: NOTE: This test can be performed using the test harness (P/N 84-825207A2).

• Page 69: Ignition Test Procedures

  Ignition Test Procedures Stator Output Test 400 DVA Scale Positive Meter Negative Direct Voltage Adaptor (DVA) Test Lead (+) Meter Lead (–) Reading Connect to Connect to CAUTION Green Test Black Test Har- 100 - 350 Harness Lead ness Lead DVA checks can be made while cranking engine with starter motor.

• Page 70: Resistance Tests

  NOTE: If voltage remains low after installing a new Resistance Tests trigger, replaced CDM. TRIGGER A resistance test is not used on the trigger. Test trigger as outlined under "Testing Voltage Output to CDM" - "Trigger Output Test". STATOR 1. Disconnect stator leads. NOTE: Resistance varies greatly with temperature.

• Page 71: Flywheel Removal And Installation

  6. Remove flywheel. Remove flywheel key. Flywheel Removal and 7. Carefully inspect flywheel for cracks or damage. Installation 8. Inspect crankshaft and flywheel tapers for worn or damaged key ways. REMOVAL 9. Check for loose or damaged flywheel magnets 1. Remove flywheel cover from engine. (outer rim and center hub).

• Page 72: Stator Removal And Installation

  INSTALLATION Stator Removal and 1. Set stator on bearing cage. Secure with screws. Installation Screws threads should be lightly coated with loc- tite 222 and torqued to 60 lb. in. (6.8 N·m). REMOVAL 1. Remove flywheel. See "Removing Flywheel" In This Section.

• Page 73: Cdm

  4. Disconnect link arm and remove trigger. REMOVAL WARNING Always disconnect battery and disconnect spark plug leads from spark plugs before working on motor. 1. Disconnect CDM wire harness plug. 2. Remove screws securing CDM to ignition plate. 19459 INSTALLATION a - Link Arm b - Trigger 1.
• Page 74 ELECTRICAL CHARGING AND STARTING SYSTEM...
• Page 75 Table of Contents Page Specifications ......2B-1 Special Tools ......2B-1 Starter Motor .

• Page 76: Specifications

  Specifications Manual Start Recoil Starter Electric Start Starter Draw (Under Load) 125 Amperes STARTING SYSTEM Recommended Battery Rating Minimum Reserve Capacity 100 Minutes Cold Cranking Amperage (CCA) 350 Amperes Alternator Output CHARGING SYSTEM Electric Models 16 Amperes @ 2000 RPM Manual Models 9 Amperes @ 3000 RPM Special Tools...

• Page 77: Starter Motor

  Starter Motor Liquid Neoprene (92-25711--2) 2B-2 - ELECTRICAL 90-852572R1 JANUARY 1998...
• Page 78 Starter Motor TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m STARTER MOTOR THRU BOLT DRIVE KIT DRIVE ASSEMBLY DRIVE CAP ARMATURE COMMUTATOR CAP BRUSH & SPRING KIT BRUSH HOLDER SCREW LOCKWASHER NUT (1/4-20) BATTERY CABLE (5/16) (POSITIVE) SCREW (M8 x 45) 16.5 22.3 DECAL–Warning...

• Page 79: Battery

  Battery Specific Gravity Readings Use a hydrometer to measure specific gravity of elec- Precautions trolyte in each cell. CAUTION If battery acid comes into contact with skin or eyes, wash skin immediately with a mild soap. Flush eyes with water immediately and see a doc- tor.

• Page 80: Specific Gravity Cell Comparison Test

  5. Avoid dropping electrolyte on boat or clothing, as Charging A Discharged it is extremely corrosive. Wash off immediately Battery with baking soda solution. Specific gravity of electrolyte varies not only with per- The following basic rules apply to any battery charg- centage of acid in liquid, but also with temperature.

• Page 81: Winter Storage Of Batteries

  Winter Storage of Batteries Battery Charging System Troubleshooting Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, Description if the following instructions are not observed: 1. Remove battery from its installation as soon as The battery charging system components are the possible and remove all grease, sulfate and dirt stator, voltage regulator/rectifier and the battery.
• Page 82 1. Check for correct battery polarity [red cable to STATOR OHMS TEST positive (+) battery terminal]. If polarity was incor- (ALTERNATOR COILS ONLY) rect, check for damaged rectifier. See "rectifier NOTE: Stator can be tested without removing from test", later in this section. engine.
• Page 83 ALTERNATOR SYSTEMS TEST Remove RED sense lead wire from starter sole- noid terminal and connect to the positive (+) ter- 9 Ampere Manual Stator minal of a 9 volt transistor battery. Ground the IMPORTANT: Rectifier (optional accessory) must negative (–) terminal of the 9 volt battery to the be functioning properly for accurate test results engine.
• Page 84 RECTIFIER TEST (OPTIONAL ACCESSORY FOR 9 AMP STATOR) WARNING Disconnect battery leads from battery before testing rectifier. Rectifier can be tested without removing from NOTE: engine. Disconnect all wires from terminals on rectifier. Use an ohmmeter (R x 1000 scale) and perform the following test.
• Page 85 Test. Then change Red (+) meter lead to the other YELLOW regulator lead for 2ND test reading. TEST RESULTS (1ST READING): 40,000 to 1 OHMS TEST RESULTS (2ND READING): 1 OHMS (No needle movement) 2B-10 - ELECTRICAL 90-852572R1 JANUARY 1998...

• Page 86: Starting System

  Troubleshooting the Starting Circuit Starting System Before beginning the starting circuit troubleshooting flow chart, following, check first for the following con- Starting System Components ditions: The starting system consists of the following compo- 1. Make sure that battery is fully charged. nents.

• Page 87: Starting Circuit Wiring Diagram

  Starting Circuit Wiring Diagram a - Key Switch b - Neutral Start Switch c - Starter d - Solenoid e - Battery f - 20 Amp Fuse 2B-12 - ELECTRICAL 90-852572R1 JANUARY 1998...

• Page 88: Starting Circuit Troubleshooting Flow Chart 2B-13

  Starting Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (starter motor) cable from starter solenoid test point 1 BEFORE making tests 1-thru-7 to prevent unexpected engine cranking. TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads be- tween NEGATIVE (-) battery post and common powerhead ground.
• Page 89 TEST 7 a. Connect voltmeter between common engine ground and Test Point 1. b. Turn ignition key to "Start" position. 12 Volt Reading* No voltage reading; De- fective starter solenoid. Should hear solenoid click; proceed to TEST 8. TEST 8 a.

• Page 90: Starter Motor

  Starter Motor Removal WARNING Always disconnect the battery and remove spark plug leads from spark plugs before working on motor. 1. Disconnect battery leads from battery. a - Thru Bolts 2. Disconnect BLACK cable (w/YELLOW sleeve). b - Commutator End Cap c - Brush/Springs 3.

• Page 91: Cleaning And Inspection

  4. Remove components from armature Clean the commutator slots after undercut- ting. De-burr the commutator lightly with No. 00 sandpaper, then clean the commutator. Check the armature on a growler for shorts. See "Testing", following. Open-circuited armatures are repairable. The most likely place for an open circuit is at the com- mutator bars.
• Page 92 ARMATURE TEST FOR GROUND TESTING NEGATIVE BRUSHES FOR GROUND Set ohmmeter to (R x 1 scale). Place one lead of Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core (or shaft) and other ohmmeter on the negative brush and the other lead lead on commutator, as shown.

• Page 93: Brush Replacement

  STARTER SOLENOID TEST Brush Replacement Test starter solenoid as follows: IMPORTANT: Replace brushes that are pitted or worn to less than 1/4 in. (6.4 mm) in length Disconnect all leads from solenoid terminals. Use an ohmmeter, set to (R x 1 scale) and con- nect between solenoid terminals 3 and 4.

• Page 94: Reassembly

  Reassembly Brush Retainer Tool Layout (Full Size) 1. Lubricate helix threads and drive end cap bush- ing with SAE 10W oil. 2. Install components onto armature shaft 11658 a - Washer b - Helix Threads c - Armature Shaft d - Drive End Cap e - Drive Assembly f - Spring g - Spacer...

• Page 95: Installation

  5. Place springs and brushes into brush holder and Installation hold in place with brush retainer tool. 1. Secure starter to block with 3 bolts. Torque bolts 6. Lubricate bushing with one drop of SAE 10W oil. to 16.6 lb. ft. (22.5 N·m). Secure NEGATIVE bat- DO NOT over-lubricate tery lead to block with bottom bolt.
• Page 96 ELECTRICAL TIMING/SYNCHRONIZING/ADJUSTING...
• Page 97 Table of Contents Page Specifications ......2C-1 Special Tools ......2C-1 Timing .
• Page 98 Specifications Idle T.D.C. Maximum Timing @ Cranking Speed -Model 40/50/60 24 B.T.D.C. -Model 55 18 B.T.D.C. @ 5000 RPM – Model 50/60 22 B.T.D.C. – Model 55/60 16 B.T.D.C. TIMING Idle RPM Wide Open Throttle (W.O.T.) RPM 5000-5500 Spark Plug Type...

• Page 99: Timing

  Maximum Timing Adjustment Timing 1. Hold control arm so that maximum spark ad- CAUTION vance screw is against stop. Crank engine with starter motor and adjust maximum spark ad- Engine may be timed while cranking engine with vance screw to align the specified BTDC timing starter motor.

• Page 100: Carburetor Synchronization

  7. Place roller of cam follower against throttle cam Carburetor Synchronization and adjust idle stop screw to align recessed mark 1. Remove attenuator cover (see section 3B,"Car- of throttle cam with center of cam follower roller. buretor Removal"). Tighten locknut. 2.

• Page 101: Adjustments

  9. Hold throttle arm against full throttle stop screw. Adjustments Adjust full throttle stop screw to allow throttle shutters to open fully while providing approxi- Idle mately .015 in. (.38 mm) free-play in throttle link- age to prevent carburetor throttle shutters from 1.
• Page 102 ELECTRICAL WIRING DIAGRAMS...
• Page 103 Table of Contents Page 40/55 MH Wiring Diagram ....2D-1 40/50/60 EO Wiring Diagram ... .

• Page 104: 40/55 Mh Wiring Diagram

  40/55 MH Wiring Diagram a - Trigger f - Lanyard Stop Switch b - Stator g - Rev. Limiter c - Temperature Switch h - CDM #3 d - Warning Horn i - CDM #2 e - Push-Button Stop Switch...

• Page 105: 40/50/60 Eo Wiring Diagram

  40/50/60 EO Wiring Diagram a - Trigger i - 12 V Battery b - Stator j - Start Solenoid c - Remote Control k - Voltage Regulator d - 20 Amp Fuse l - Rev. Limiter e - Starter m - CDM #3...

• Page 106: 40/50 Ehpto Wiring Diagram

  40/50 EHPTO Wiring Diagram a - Trigger m - Fuel Enrichment Solenoid b - Stator n - Trim Pump c - Key Switch o - Oil Level Switch d - Warning Horn p - Head Temperature Switch e - Push Button Stop Switch...

• Page 107: 40/50/60 Epto Wiring Diagram

  40/50/60 EPTO Wiring Diagram a - Trigger k - Oil Level Switch b - Stator l - Head Temp. Switch c - Remote Control m - 12V Battery d - 20 Amp Fuse n - Start Solenoid e - Cowl Mounted Trim Switch...

• Page 108: 60 Ehpto Wiring Diagram

  60 EHPTO Wiring Diagram a - Key Switch n - Oil Level Switch b - Warning Horn o - Head Temp. Switch c - Neutral Start Switch p - 12V Battery d - Tiller Handle Trim Switch q - Start Solenoid e - Push-Button Stop Switch r - Voltage Regulator f - Lanyard Stop Switch...

• Page 109: Commander 2000 Side Mount Remote Control Wiring Diagrams

  COMMANDER 2000 Side Mount Remote Control Wiring Diagrams Key/Choke Switch Continuity Test "OFF" BLK/YEL - BLK "RUN" RED - PUR "START" RED - PUR - YEL/RED PUSH (CHOKE)* RED - YEL/BLK *Key switch must be positioned to "RUN" or "START" and key pushed in to actuate choke, for this continuity test.

• Page 110: Power Trim/Tilt Electric Start With Warning Horn

  Power Trim/Tilt Electric Start with Warning Horn a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Wiring Harness Connector f - Warning Horn g - Trim/Tilt Switch BLACK BLUE BROWN GRAY...

• Page 111: Power Tilt Electric Start With Warning Horn

  Power Tilt Electric Start with Warning Horn a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness e - Wiring Harness Connector f - Warning Horn g - Trim/Tilt Switch h - Wire Retainer i –...

• Page 112: Electric Start With Warning Horn

  Electric Start with Warning Horn a - Ignition/Choke Switch b - Emergency Stop Switch c - Neutral Start Switch d - Tachometer/Accessories Harness Connector e - Wiring Harness Connector f - Warning Horn BLACK BLUE BROWN GREY GREEN PURPLE WHITE YELLOW LIGHT 90-852572R1 JANUARY 1998...
• Page 113 FUEL SYSTEM FUEL PUMP...
• Page 114 ......3A-1 Fuel Pump (Electric) 40/50/55/60 ..

• Page 115: Specifications

  Specifications Fuel Electric Start Models Straight Gasoline Manual Start Models Pre-mixed Gasoline and Oil Recommended Gasoline Unleaded-87 Octane Minimum Recommended Oil Quicksilver TC-WII or TC-W3 FUEL SYSTEM Two Cycle Outboard Oil Gasoline/Oil Ratio 50:1 (Including Break-In) Fuel Pressure @ Idle 3.5 PSI (24 kPa) @ W.O.T.

• Page 116: Fuel Pump (Electric) 40/50/55/60

  Fuel Pump (Electric) 40/50/55/60 Loctite PST Pipe Sealant (92-809822) A= To top carburetor B= to crankcase c= to oil pump fitting D= TO INTAKE MANIFOLD FITTING E= TO FITTING F = to oil pump outlet 3A-2 - FUEL SYSTEM 90-852572R1 JANUARY 1998...
• Page 117 RUBBER CHECK VALVE RETAINER SPRING SPRING DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump (M5 x 40) SCREW– pump to crankcase (M6 x 50) BASE HOSE FUEL FILTER FUEL LINE STA-STRAP HOSE (1-1/2 HOSE (1-1/2 WYE CONNECTOR HOSE (2 IN.)

• Page 118: Fuel Pump (Manual) 40/50

  Fuel Pump (Manual) 40/50 Loctite Pipe Sealant W/Teflon (92-809822) A= TO CARBURETOR B= TO CRANKCASE C = TO TOP CARB D= TO MANIFOLD TOP E= TO MANIFOLD BOTTOM 3A-4 - FUEL SYSTEM 90-852572R1 JANUARY 1998...

• Page 119: Fuel Pump (Manual) 40/50

  DIAPHRAGM KIT RUBBER CHECK VALVE RETAINER SPRING SPRING DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump (M5 x 40) SCREW–pump to crankcase (M6 x 50) BASE HOSE (22 STA-STRAP HOSE HOSE (4-1/4 IN.) FUEL FILTER HOSE TEE FITTING HOSE (9-1/2...
• Page 120 Fuel Pump (Manual) 55/60 Loctite PST Pipe Sealant (92-809822) A= TO CARBURETOR, B= TO CRANKCASE , C = TO TOP FLOAT BOWL, D = TO TOP INTAKE MANIFOLD, E = TO LOWER INTAKE MANIFOLD, 3A-6 - FUEL SYSTEM 90-852572R1 JANUARY 1998...
• Page 121 Fuel Pump (Manual) 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – FUEL PUMP ASSEMBLY FUEL PUMP ASSEMBLY DIAPHRAGM KIT DIAPHRAGM RUBBER CHECK VALVE RETAINER SPRING SPRING DIAPHRAGM GASKET GASKET–boost GASKET–pulse PLATE FITTING SCREW–fuel pump SCREW–fuel pump to crankcase BASE HOSE (10 IN.) HOSE (14-1/4 IN.)

• Page 122: Theory Of Operation

  Checking For Restricted Fuel Flow Theory of Operation Caused By Anti-Siphon Valves The fuel pump is a crankcase-pressure-operated, di- aphragm-type pump. Crankcase pulsating pressure While anti-siphon valves are helpful from a safety is transferred by way of a passage (hole) from the stand-point, they clog, they may be too small, or they crankcase to the fuel pump.

• Page 123: Testing

  Testing PROBLEM: LACK OF FUEL PUMP PRESSURE Possible Cause Corrective Action Install clear fuel hose(s) between fuel pump and car- buretor(s). Run engine, and inspect hose(s) for air Anti-siphon valve. Refer to "Checking for bubbles. If air bubbles are found, see "Air Bubbles in Restricted Fuel Flow Fuel Line"...

• Page 124: Fuel Pump Removal

  Fuel Pump Removal Fuel Pump Disassembly 1. Remove oil tank from outboard (if equipped) . Re- 1. Remove bolts and chamber plate. fer to Section 3C "Oil Injection System." 2. Remove fuel "inlet" hose, "outlet" hose, and pulse hose. 3. Remove two bolts securing fuel pump to power- head.

• Page 125: Reassembly

  3. With retainer installed in pump body, break re- Reassembly tainer rod from retainer by bending sideways. Check Valve Assembly 1. Insert retainer thru plastic disc and rubber check valve. 23601 a - Retainer Rod b - Retainer Cap 4. Reinstall rod into retainer cap. Use a small ham- 23601 mer or hammer and punch to tap rod down into retainer until flush with top of retainer.
• Page 126 FUEL SYSTEM CARBURETOR...
• Page 127 ..... . . 3B-4 Attenuator Plate 40/50 ....

• Page 128: Specifications

  CARBURETOR WME Carburetor Chart NOTE: Carburetor Number Stamped on Side of Carburetor Body. Model Year Carburetor Main Fuel Jet Preset Idle Screw Number Turns Open 40 Electric 1998 53-1,-2,-3 0.044 in. 1-1/4 40 Manual 1997-1/2/98 69-1,-2,-3 0.044 in. 1-1/4 50 Manual/Electric...

• Page 129: Carburetor 40/50

  Carburetor 40/50 Loctite "271" (92-809819) 3B-2 - FUEL SYSTEM 90-852572R1 JANUARY 1998...
• Page 130 Carburetor 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR (ELECTRIC 40 - WME-53) CARBURETOR (MANUAL 40 - WME-69) CARBURETOR (50 - WME-68) THROTTLE SHAFT (UPPER) THROTTLE SHAFT (CENTER) WME-53/68 THROTTLE SHAFT (BOTTOM) THROTTLE SHAFT (UPPER/BOTTOM) WME-69 THROTTLE SHAFT (CENTER) SCREW–throttle adjustment (UPPER/BOTTOM)
• Page 131 Carburetor 55/60 Loctite "271" (92-809819) 3B-4 - FUEL SYSTEM 90-852572R1 JANUARY 1998...

• Page 132: Carburetor 55/60

  Carburetor 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CARBURETOR (60 ELECTRIC - WME-58) CARBURETOR (55/60 MANUAL - WME-57) THROTTLE SHAFT (UPPER) THROTTLE SHAFT (CENTER) WME-58 THROTTLE SHAFT (BOTTOM) THROTTLE SHAFT (UPPER/BOTTOM) THROTTLE SHAFT (CENTER) WME-57 SCREW–throttle adjustment (UPPER/BOTTOM) SPRING–throttle return IDLE NEEDLE SPRING–idle needle...

• Page 133: Attenuator Plate 40/50

  Attenuator Plate 40/50 A = MANUAL B = ELECTRIC 3B-6 - FUEL SYSTEM 90-852572R1 JANUARY 1998...

• Page 134: Attenuator Plate 40/50

  Attenuator Plate 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SOUND ATTENUATOR SCREW (M6 x 16) Drive Tight WASHER CAP PLUG BRACKET SEAL BRACKET SCREW (M8 x 100) ROLLER SCREW (M5 x 6) Drive Tight WASHER TUBING (4-1/4...
• Page 135 Attenuator Plate 55/60 A= MANUAL HOSE ROUTING B = ELECTRIC HOSE ROUTING C = TO ENRICHENER VALVE 3B-8 - FUEL SYSTEM 90-852572R1 JANUARY 1998...
• Page 136 Attenuator Plate 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SOUND ATTENUATOR SCREW Drive Tight CAP PLUG SEAL SOUND ATTENUATOR PLATE SCREW (M8 x 100) DECAL-Warning (MANUAL) DECAL-Caution DECAL-Full Throttle Timing (ELECTRIC) ROLLER SCREW (M5 x 6) Drive Tight WASHER TUBING (4-1/4 IN.)(MANUAL)

• Page 137: Adjustments

  Idle Speed Adjustment Adjustments 1. Adjust engine idle RPM as outlined in Section 2C "Timing/Synchronizing/Adjusting." Idle Mixture Screw Adjustment Float Adjustment INITIAL STARTING ADJUSTMENT 1. Remove carburetor as outlined in "Carburetor Removal" in this section. Turn idle mixture screw in (clockwise) until it seats LIGHTLY--then back-off (each carburetor) the cor- 2.

• Page 138: Main (High Speed) Jet Adjustment

  Main (High Speed) Jet Adjustment Jet Orifice Size Chart The carburetor has a fixed high speed jet. Extreme NOTE: 10-32 Thread Size changes in weather (temperature and humidity) and/ or elevation may result in a too lean or rich fuel mix- Jet Orifice Part ture at wide-open-throttle, which may require a...

• Page 139: High Altitude Jet Chart

  High Altitude Jet Chart Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet (1524m) above sea level. Between 2000 feet (609.6m) and 5000 feet (1524m) the reduction of the main fuel jet(s) may result in improved performance and fuel economy. Above 5000 feet, however, it is recommended that main jet size be reduced as shown per 1000 feet (304.8m) in the following chart.

• Page 140: Fuel System Troubleshooting

  Fuel System Troubleshooting General Information Problems that are thought to be caused by the fuel system may, in reality, be something completely dif- ferent. Items, that are shown below, could give the impression that there is a problem in the fuel system. 1.

• Page 141: Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold

  Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold Possible Cause Corrective Action Improper starting procedure used. Review starting procedure as outlined in "Operation and Maintenance Manual". Fuel tank empty or too low. Improperly mixed fuel. Check fuel in tank and replace or add whichever is Contaminants (water, dirt, etc.) in fuel.

• Page 142: Problem: Engine Runs Too Lean

  Problem: Engine Runs Too Lean Possible Cause Corrective Action Carburetor is loose. Air leaks past mixing chamber Tighten bolts securely. Tighten cover or replace gas- cover. ket. Fuel level is too low. Reset float level. Clogged high speed jet. Inspect jet for varnish or debris and clean. Restricted fuel flow to carburetor.

• Page 143: Removal/Installation

  55/60 Removal/Installation Attenuator cover and screw. 40/50 Attenuator cover and screw. 55041 55148 a - Screws (4) a - Screw b - Attenuator Cover b - Attenuator Cover Carburetor mounting bolts. Carburetor mounting bolts. 55172 50527 a - Carburetor Bolts (6)
• Page 144 Inspection 5. Inspect inlet needle valve. Replace if end is worn or grooved. CAUTION Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and seriously af- fect performance. Use a petroleum based solvent for cleaning and blow out all passages with com- pressed air.

• Page 145: Enrichment System

  Enrichment System Electric Enrichener Valve The enrichener system provides the engine with an extra fuel charge for ease of cold engine starting. The system consists of an electrically operated enrichen- er valve which is connected by a hose to the intake manifold.
• Page 146 ENRICHENER VALVE TEST IMPORTANT: Use of enrichener if engine is warm could result in engine flooding Push Key (Or Choke Button) In, Valve Should Click. Click No Click Squeeze primer bulb until bulb is firm. Remove lower hose from Check for battery voltage to yellow/black wire at terminal block fitting on enrichener valve.

• Page 147: Manual Primer Button

  Manual Primer Button CAUTION The manual starting primer bulb is designed to pro- All safety precautions should be adhered to vide a rich fuel mixture to the engine during cold start when testing the primer bulb system. Fuel conditions. When the primer bulb is pressed in, fuel should be directed into suitable container and all is forced from the primer bulb into the intake manifold flammable materials extinguished and sources...
• Page 148 FUEL SYSTEM OIL INJECTION...
• Page 149 ......3C-1 Oil Injection Components 40/50 ... .
• Page 150 Reserve Capacity/Approx. Time 14.5 fl. oz. (0.43 L) / 0.5 hour INJECTION Oil Output With Engine RPM of 1500 and Oil Pump @ W.O.T.* Model 40 15.0 3.0 cc of oil in 10 minutes Model 50/60 22.0 3.0 cc of oil in 10 minutes *See "Checking Oil Pump Volume Flow"...

• Page 151: Oil Injection Components 40/50

  Oil Injection Components 40/50 Needle Bearing Assy. Lub. (92-825265A1) 3C-2 - FUEL SYSTEM 90-852572R1 JANUARY 1998...

• Page 152: Oil Injection Components 40/50

  Oil Injection Components 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m BUSHING–Flanged GROMMET SCREW (M6 x 25) OIL TANK ASSEMBLY CAP ASSEMBLY TETHER NUT–Push VENT ASSEMBLY VALVE SEAL STA–STRAP GROMMET SWITCH SCREW (.164-18 x .375) Drive Tight...
• Page 153 Oil Injection Components 55/60 Needle Bearing Assy. Lub. (92-825265A1) 3C-4 - FUEL SYSTEM 90-852572R1 JANUARY 1998...
• Page 154 Oil Injection Components 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m OIL TANK CAP ASSY. TETHER PUSH NUT SEAL VENT VALVE GROMMET BOOT BOOT SWITCH SCREW (.164-18 X .375) Drive Tight WASHER OIL INJECTION PUMP O-RING O-RING SCREW DRIVEN GEAR BEARING ASSEMBLY...

• Page 155: Theory Of Operation

  A link rod is connected between the throttle linkage Theory of Operation and oil pump lever. When the throttle position is The major components of the oil injection system are changed, the link rod rotates the oil pump valve, an oil tank, oil pump, and low oil warning system. which changes the fuel/oil ratio.

• Page 156: Adjustments

  BLEEDING AIR FROM OIL PUMP OUTLET HOSE Adjustments 1. Purge air from outlet hose by running engine (on 50:1 gasoline/oil mixture in fuel tank) at idle Carburetor/Oil Pump speed until no air bubbles are present in outlet Synchronization hose. 1. Set carburetor linkage at idle position. Adjust length of link rod so stamped mark of oil pump body aligns with stamped mark of oil pump lever.

• Page 157: Check Operation Of The Oil Injection System (Engine Running)

  - Link Rod c - Outlet Hose e - Pump Arm 40/50 H.P. Flow Specifications: 1. Check oil level in oil tank. If oil level is approxi- @ 1500 RPM with oil pump link arm DISCON- mately 14.5 fl. oz. (435 ml) or less, the problem NECTED and pump arm rotated FULL COUNTER- is low oil level.

• Page 158: Troubleshooting Chart

  Troubleshooting Chart Problem: Warning Horn Stays On When Ignition Key is Turned to "ON" Position (Engine Cold). Possible Cause Corrective Action Faulty Engine overheat sensor. If warning horn sounds a continuous "beep", the engine overheat sensor may be faulty. Disconnect tan/blue over- heat sensor lead at bullet connection.

• Page 159: Installing Drive Gear (For Oil Injection Pump) Onto Crankshaft

  2. Remove bolts securing oil tank. 2. Inspect gear teeth for damage. Replace gear if any of these problems exist: 40/50 HP MODEL *Excessive Wear a. Remove bolts (2). *Cracks in hub or rear (Do Not mistake plastic...

• Page 160: Installation

  3. Disconnect oil hose and low oil sensor wires Installation (BLUE) at bullet connectors. Remove oil reser- 1. Install oil level sensor and secure in place. voir. NOTE: 40/50 H.P. version shown. 51204 a - Oil Level Sensor b - Screw (Tighten Securely) 55320 2.
• Page 161 3. Install starter/oil tank bracket. 60 HP MODEL b. Install starter/oil bracket. Torque to 16.5 lb. ft. 40/50 HP MODEL (22.3 N·m). a. Install bolts (2). Torque to 60 lb. in. (6.8 N·m). 51080 a - Starter Bracket b - Bolt Torque to 16.5 lb. ft. (22.3 N·m) a - Bolts (2) Torque to 60 lb.
• Page 162 Refer to Owners Manual for required maintenance. Exhaust Emission Control Systems: Fuel/Oil Timing: Engine Lubricants: TC-Wll or Ratio: Not TC-W3 2 Cycle Outboard Oil Adjustable Spark Plug: NGK BP8H-N-10 Gap: 0.040 in. Controlled Family: xxxxxxx.xxxx FEL: 32.20 GM/KW-HR 40-60 2-Stroke JUNE JULY EMISSIONS...
• Page 163 Table of Contents Page Exhaust Emissions Standards ... 3D-1 What Are Emissions? ....3D-1 Hydrocarbons – HC .

• Page 164: Exhaust Emissions Standards

  is a harmless gas. Carbon often combines with insuf- Exhaust Emissions ficient oxygen (one carbon atom with one oxygen Standards atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion Through the Environmental Protection Agency and is a dangerous, potentially lethal gas. (EPA), the federal government has established ex- haust emissions standards for all new marine en- gines sold in the U.S..

• Page 165: Outboard Hydrocarbon Emissions Reductions

  As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion tempera- tures raise the NOx content of the exhaust. But, enri- chening the air/fuel ratio to decrease combustion temperatures to reduce NOx also increases HC and CO, as well as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to keep the air/fuel ratio as close to 14.7:1 as possible.

• Page 166: Stratified Vs Homogenized Charge

  STRATIFIED VS HOMOGENIZED CHARGE DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models use a homogenized charge. The difference between the two is: Homogenized Charge Stratified Charge A homogenized charge has the fuel/air particles A stratified charged engine pulls only air through the mixed evenly throughout the cylinder.

• Page 167: Emissions Information

  EPA Emission Regulations Emissions Information All new 1998 and later outboards manufactured by Mercury Marine are certified to the United States En- Manufacturer's Responsibility vironmental Protection Agency as conforming to the requirements of the regulations for the control of air Beginning with 1998 model year engines, manufac- pollution from new outboard motors.

• Page 168: Decal Location For 1998 Models

  - Month of Production (Boxing Month Will Be Punched) n - Engine Lubricants Recommended by the Manufacturer l - FEL: Represents (Mercury Marine) Statement of the Maxi- mum Emissions Output For the Engine Family Decal Location for 1998 Models: Model Production Part No.
• Page 169 POWERHEAD...
• Page 170 ......Cylinder Block And Crankcase 40/50 ..Cylinder Block And Crankcase 55/60 ..Induction Manifold And Reed Block 40/50 Induction Manifold And Reed Block 55/60 4-10 Crankshaft, Pistons And Connection Rods 4-12 Water Circulation .

• Page 171: Specifications

  Specifications Type 3 Cylinder-2 Cycle-Loop Charged CYLINDER BLOCK Displacement 59 cu. in. (967 cc) STROKE Length 2.796 in. (71 mm) Diameter 2.993 in. (76 mm) CYLINDER BORE Taper/Out of Round Maximum 0.003 in. (0.08 mm) Bore Type Cast Iron Type Aluminum Standard Diameter 2.988 in.

• Page 172: Special Tools

  8. Driver Head 91-55919 Special Tools 1. Lifting Eye 91-90455 9. Universal Puller Plate 91-37241 2. Flywheel Holder 91-52344 73790 10. Snap Ring Pliers 91-24283 3. Flywheel Puller 91-73687A2 4. Powerhead Stand 91-25821A1 11. Piston Lock Ring Installer 91-77109A3 12. Torque Wrench (0-200 lb. ft.) Obtain Locally 5.
• Page 173 Notes: 90-852572R1 JANUARY 1998 POWERHEAD - 4-3...
• Page 174 Cylinder Block And Crankcase 40/50 Needle Bearing Assy. Lub. (92-825265A1) Loctite PST Pipe Sealant (92-809822) Loctite "RCA/680" Retaining Compound (92-809833) Loctite 518 Master Gasket (92-12564-2) A = Torque Sequence 4-4 - POWERHEAD 90-852572R1 JANUARY 1998...

• Page 175: Cylinder Block And Crankcase 40/50

  Cylinder Block And Crankcase 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK SCREW (M8 x 80) 18.4 24.9 SCREW (M8 x 30) 18.4 24.9 CHECK VALVE HOSE (15 CHECK VALVE (PRESS-IN) CARRIER ASSEMBLY CHECK VALVE...

• Page 176: Cylinder Block And Crankcase 55/60

  Cylinder Block And Crankcase 55/60 Needle Bearing Assy. Lub. (92-825265A1) Loctite PST Pipe Sealant (92-809822) Loctite "RCA/680" Retaining Compound (92-809833) Loctite 518 Master Gasket (92-12564-2) A = TORQUE SEQUENCE 4-6 - POWERHEAD 90-852572R1 JANUARY 1998...
• Page 177 Cylinder Block And Crankcase 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CYLINDER BLOCK SCREW (M8 x 80) 18.4 24.9 SCREW (M8 x 30) 18.4 24.9 CHECK VALVE HOSE (15 CHECK VALVE (PRESS-IN) CARRIER ASSEMBLY CHECK VALVE ADJUSTING SCREW (M6 x 55) JAM NUT DOWEL PIN (LOCATING)

• Page 178: Induction Manifold And Reed Block 40/50

  Induction Manifold And Reed Block 40/50 2 Cycle Outboard Oil (92-831222A24) Perfect Seal (92-34227-1) Loctite 680 (92-809833) A= ELECTRIC B = MANUAL 4-8 - POWERHEAD 90-852572R1 JANUARY 1998...

• Page 179: Induction Manifold And Reed Block 40/50

  Induction Manifold And Reed Block 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GASKET LOWER END CAP ASSEMBLY OIL SEAL OIL SEAL O-RING SCREW (M8 x 20) 18.3 24.9 BRACKET ASSEMBLY STUD WASHER WASHER ELECTRIC WING NUT...
• Page 180 Induction Manifold And Reed Block 55/60 22 23 2 Cycle Outboard Oil (92-831222A24) Perfect Seal (92-34227-1) Loctite 680 (92-809833) A= ELECTRIC B = MANUAL C = TO REF #33 ON PAGE 22 4-10 - POWERHEAD 90-852572R1 JANUARY 1998...
• Page 181 Induction Manifold And Reed Block 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m GASKET LOWER END CAP ASSEMBLY OIL SEAL OIL SEAL O-RING SCREW (M8 x 20) 18.3 24.9 BRACKET ASSEMBLY STUD WASHER WASHER ELECTRIC WING NUT Hand Tight SCREW (M8 x 35) 18.3...

• Page 182: Crankshaft, Pistons And Connection Rods

  Crankshaft, Pistons And Connection Rods 2 Cycle Outboard Oil (92-831222A24) 2-4-C w/Teflon (92-850736A1) 4-12 - POWERHEAD 90-852572R1 JANUARY 1998...
• Page 183 Crankshaft, Pistons And Connecting Rods TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CRANKSHAFT ASSEMBLY DRIVER GEAR BALL BEARING RETAINING RING ROLLER BEARING (TOP) OIL SEAL RACE ROLLER RING–Seal PISTON ASSEMBLY LOCK RING PISTON RING PISTON RING (CHROME FACE) CONNECTING ROD ASSEMBLY WASHER NEEDLE BEARING...

• Page 184: Water Circulation

  Water Circulation 55334 4-14 - POWERHEAD 90-852572R1 JANUARY 1998...

• Page 185: Thermostat Test

  Thermostat Test Temperature Switch Test 190° F (88° C) Wash thermostat with clean water. Using a thermo- stat tester, similar to the one shown, test thermostat The 190° F (88° C) temperature switch is located in as follows: outer side of cylinder head as shown. ·...

• Page 186: General Information

  7. Disconnect blue oil warning module wires. General Information 8. Remove BLACK ground lead between power- Powerhead "Disassembly" and "Reassembly" in- head and engine tray. structions are printed in a sequence that should be followed to assure best results when removing or re- 9.
• Page 187 13. Thread lifting eye at least 5 turns into flywheel. WARNING DO NOT leave powerhead suspended from hoist. Powerhead should be installed on a suitable stand or lowered to floor upon removal from drive shaft housing to avoid personal injury or damage to product.

• Page 188: Powerhead Disassembly

  2. Thermostat Cover 827251-C Powerhead Disassembly Removing Engine Components NOTE: Refer to appropriate sections in service manual for removal of individual fuel and electrical sub-assemblies from powerhead. Component/Assembly Section Flywheel Stator Assembly Trigger Assembly Starter Motor Starter Solenoid Voltage Regulator/Rectifier Fuel Pump a - Bolts Carburetor and Linkage...
• Page 189 4. Remove intake manifold and reed block man- 5. Remove check valves and holders. ifold. 55323 55322 a - Check Valve/Holders a - Bolts (14) 6. Place engine on work bench and remove end cap bolts. 55324 a - Bolts 90-852572R1 JANUARY 1998 POWERHEAD - 4-19...

• Page 190: Crankshaft Disassembly

  7. Remove crankcase cover bolts. Crankshaft Disassembly 55323 1. Remove roller bearing assemblies from crank- shaft. a - Bolts (14) b - Lower End Cap 8. Remove crankcase cover from cylinder block. 9. Remove end cap. PE-51085 a - Roller Bearing Race b - Roller Bearing c - Retaining Ring 2.
• Page 191 3. Remove connecting rod/piston assembly from 6. Remove piston rings. Always install new piston crankshaft; re-attach caps to respective rod as rings. each is removed. CAPS MUST BE INSTALLED IN SAME DIRECTION ON SAME ROD, or mat- ing surface will not seat properly. 4.
• Page 192 8. Remove piston pin. 11. Press crankshaft bearing as shown. PE-51086 a - Piston Pin b - Piston Pin Tool (91-74607A3) 9. Remove piston pin needle bearings (29 per pis- ton pin) and locating washers (2 per piston) as shown. PE-51081 12.

• Page 193: Cleaning And Inspection

  Cleaning and Inspection CAUTION If crankcase cover and cylinder block is to be Cylinder Block and Crankcase Cover submerged in a very strong cleaning solution, it will be necessary to remove the crankcase cover/ IMPORTANT: Crankcase cover and cylinder cylinder block bleed system from cover/cylinder block are matched, line-bored assembly should block to prevent damage to hoses and check not be mismatched by using a different crank-...

• Page 194: Check Valves

  Measure cylinder bore inside diameter (with an TO CHECK: Inspect check valves by looking through inside micrometer) of each cylinder, as shown hole. If light can be seen the nylon ball is bad (prob- below. Check for tapered, out-of-round ("egg- ably melted);...

• Page 195: Crankshaft

  CLEANING PISTON RING GROOVES IMPORTANT: The piston rings are half – keystone rings – (tapered on the top side) – follow cleaning and inspection carefully! Chromed ring is in- stalled on top. .50 in. (12.7 mm) Enlarged View of Piston Ring Grooves PISTON PISTON SKIRT CYL.

• Page 196: Connecting Rods

  Connecting Rods If necessary, clean connecting rod surfaces as fol- lows: Attach end caps to connecting rods. Following these directions, tighten rod cap attaching bolts to specifications. Recheck alignment. CAUTION Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of connecting rod. DO NOT use any other type of abrasive cloth.

• Page 197: Reed Blocks

  The maximum allowable opening between reed and reed-block is .020 in. (0.5mm). This must be checked with a flat blade feeler gauge, as shown. 40 HP Shown PE-51089 a - Reed Block b - Reed (3 Sets)

• Page 198: Reassembly And Installation

  Specified reed stop opening is 0.090 in. (2.286 mm). If reed stop opening is not correct, carefully bend reed stop to achieve specified opening. 40 HP 55350 a - 0.090 in. (2.286 mm) 4-28 - POWERHEAD 90-852572R1 JANUARY 1998...

• Page 199: Assembling Rod To Piston

  2. Install needle bearings. CAUTION Any GREASE used for bearings INSIDE the pow- erhead MUST BE gasoline soluble. Use only Quicksilver Needle Bearing Assembly Lubricant. DO NOT use 2-4-C Marine Lubricant, or other lu- bricants inside the powerhead, or damage may occur.
• Page 200 4. Push sleeve from piston using piston pin tool. 6. Install new piston pin lock rings (each side of pis- ton) using Lockring Tool (p/n 91-77109A3). 7. Make sure lockrings are properly seated in piston grooves. CAUTION Do not re-use piston pin lockrings. Use only new lockrings and make sure they are properly seated in piston grooves.

• Page 201: Piston Ring Installation

  1. Install piston ring in appropriate groove on piston 1.050 in. (26.7 mm) using Piston Ring Expander Tool. Spread rings just enough to slip over piston. Top Groove – Chromed Ring Bottom Groove – Steel Ring 2. Check piston rings to be sure they fit freely in groove.

• Page 202: Crankshaft Installation

  4. Remove connecting rod cap from connecting rod Crankshaft Installation being installed. 1. If lower bearing and gear were removed from 5. Install each piston with "UP" identification facing crankshaft, slide gear in place (note keyway and flywheel end. Pistons MUST be installed in this key in gear to crankshaft assembly).
• Page 203 6. Position cylinder block and piston rods as shown. CAUTION Insert locating pins. Any grease used for bearings INSIDE the power- head MUST BE gasoline soluble. Use only Quick- silver Needle Bearing Assembly Lubricant. DO NOT use 2-4-C Marine Lubricant, or other lubri- cants inside powerhead, or damage to engine may occur.

• Page 204: Installing Rods To Crankshaft

  Installing Rods to Crankshaft Connecting Rod Cap Alignment 1. Oil rod and bearing cage with 2-cycle oil. 1. Check each connecting rod for correct alignment by carefully running fingernails up and down 2. Pull rod into place and install bearing cages as edge of rod cap.

• Page 205: Crankcase Cover To Block

  1. Install upper seal to crankshaft. 1. Clean thoroughly, including seal and O-ring seats; remove Perfect Seal residue and clean cap-to-head mating surface. 40/50 models - Lip of smaller seal faces away from powerhead. Lip of larger seal faces toward power- head. PE-51088...

• Page 206: Intake/Reed Block Manifold Installation

  5. Place crankcase cover onto block. Intake/Reed Block Manifold Installa- tion 1. Place engine on repair stand or on bench. NOTE: Powerhead repair stand p/n 91-25821A1 can be used. PE-51084 a - Crankcase Cover b - End Cap 6. Insert clean bolts (note 2 sizes) and finger tight- 7.

• Page 207: Thermostat Cover Installation

  3. Install reed block manifold and intake manifold Thermostat Cover Installation with gasket to cylinder block. 1. Thermostat cover 827251C-1. Torque bolts to 18 lb. ft. (24 N·m). PE-51225 a - Can Only Be Installed One way a - Bolts 4.

• Page 208: Install Remaining Engine Components

  Shift Cable Latch Assembly Control Cable Anchor Bracket 40/50/55/60 Models P/N 27-828553 * Note: All ignition and electrical components can be removed and installed as an assembly. 50/55/60 Models P/N 27-812865 DO NOT INSTALL ON 40/50/55/60 MODELS 4-38 - POWERHEAD 90-852572R1 JANUARY 1998...
• Page 209 1. Install lifting eye (P/N 91-90455) into flywheel a 3. Install cover. Torque bolts to 80 lb. in. (9 N·m). minimum of 5 turns. Install powerhead to drive- shaft housing. Slide shift slide on rail while lower- ing powerhead on splines of drive shaft. 55320 a - Bolts - Torque to 80 lb.
• Page 210 - Oil Tank Wires b - Power Trim Wires c - Oil Hose (Connect to Tank) PE-51082 10. Install battery cables. (–) PE-51084 a - Red Sleeve (Positive) b - Black Sleeve (Negative) 4-40 - POWERHEAD 90-852572R1 JANUARY 1998...

• Page 211: Test Run Procedure

  After the first two hours of running, approximately 10 gallons (40 Liters) of fuel, full throttle operation may be attained, but not sustained, for the remaining break-in fuel (approximately 5 gallons).
• Page 212 MID-SECTION 40/50 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING...
• Page 213 Table of Contents Page Clamp Bracket ......5A-2 Swivel Tube Components ....5A-4 Swivel Bracket Components .
• Page 214 Notes: 90-852572R1 JANUARY 1998 MID-SECTION - 5A-1...

• Page 215: Clamp Bracket

  Clamp Bracket Loctite "271" Adhesive Sealant (92-809819) 2-4-C w/Teflon (92-825407A12) 5A-2 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 216 WAVE WASHER ROLL PIN (1/8 x 3/4 IN.) LINK ANCHOR PIN (14MM) BUSHING BUSHING GAS ASSIST TRIM & WASHER POWER TRIM MOUNTING SCREW (M10 x 40) WASHER TILT LOCK PIN NON POWER TRIM SPRING 90-852572R1 JANUARY 1998 MID-SECTION - 5A-3...

• Page 217: Swivel Tube Components

  Swivel Tube Components Anti-Corrosion Grease (92-850735A1) 2-4-C With Teflon (92-850736A1) 5A-4 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 218 Swivel Tube Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SWIVEL TUBE HEAD (BLACK) SWIVEL TUBE HEAD (GRAY) BRACKET TAB WASHER NON HANDLE SCREW (M10 x 45 Hex head cap) 43.4 NUT (.375-24) LEVER–Co–pilot WASHER ROD (THREADED) BRAKE PLATE DISC–Brake PLATE–Swivel Head...

• Page 219: Swivel Bracket Components

  Swivel Bracket Components 2-4-C w/Teflon (92-850736A1) – Tighten nut until it seats and then back off 1/4 turn. – Tighten nut to 32 lb. ft. (43.4 N·m) and then back off 1/4 turn, – To screw on bottom yoke. 5A-6 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 220 Swivel Bracket Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m LINK ROD SCREW (1-1/2 IN.) 27.1 WASHER NON HANDLE VERSIONS WASHER NUT (.375-24) PUCK–Co-pilot SWIVEL BRACKET ASSEMBLY (BLACK) SWIVEL BRACKET ASSEMBLY (GRAY) BUSHING (UPPER) GREASE FITTING (Qty. of 4 on Handle Version) Drive Tight BUSHING (LOWER) SEAL DECAL...

• Page 221: Drive Shaft Housing/Exhaust Plate Components

  Drive Shaft Housing/Exhaust Plate Components TO PORT SIDE OF SWIVEL BRACKET 5A-8 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 222 COVER–Mount (BLACK) COVER–Mount (GRAY) SCREW (M8 x 1.25 x 35) 18.3 24.9 BOTTOM YOKE (BLACK) BOTTOM YOKE (GRAY) SCREW (M8 x 40) WASHER NUT (M8 x 1.25) SCREW (M12 x 125) NUT (M12 x 1.75) 67.8 90-852572R1 JANUARY 1998 MID-SECTION - 5A-9...

• Page 223: Drive Shaft Housing Disassembly/Reassembly

  Drive Shaft Housing WARNING Disassembly/Reassembly Failure to support outboard as shown could re- sult in personal injury and/or damage to out- Servicing components such as steering arm, drive board or boat. shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal.
• Page 224 MID-SECTION 55/60 CLAMP/SWIVEL BRACKETS AND DRIVE SHAFT HOUSING...
• Page 225 Table of Contents Page Clamp Bracket Components (Manual) ..5B-2 Transom Bracket Components (Electric) 5B-4 Swivel Bracket Components ... . . 5B-6 Drive Shaft Housing ....5B-8 Drive Shaft Housing Disassembly/Reassembly...
• Page 226 Notes: 90-852572R1 JANUARY 1998 MID-SECTION - 5B-1...

• Page 227: Clamp Bracket Components (Manual)

  Clamp Bracket Components (Manual) 2-4-C With Teflon (92-850736A1) 5B-2 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 228 Clamp Bracket Components (Manual) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m CLAMP BRACKET (BLACK) PORT CLAMP BRACKET (GRAY) GREASE FITTING GROOVE PIN CLAMP BRACKET (BLACK) STARBOARD CLAMP BRACKET (GRAY) TILT LOCK LEVER (BLACK) TILT LOCK LEVER (GRAY) SPRING NYLINER SPRING...

• Page 229: Transom Bracket Components (Electric)

  Transom Bracket Components (Electric) 2-4-C With Teflon (92-850736A1) 5B-4 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 230 Transom Bracket Components (Electric) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m TRANSOM BRACKET (BLACK) TRANSOM BRACKET (GRAY) PORT GREASE FITTING GROOVE PIN TRANSOM BRACKET (BLACK) TRANSOM BRACKET (GRAY) STARBOARD TILT LOCK LEVER (BLACK) TILT LOCK LEVER (GRAY) SPRING NYLINER SPRING...

• Page 231: Swivel Bracket Components

  Swivel Bracket Components 2-4-C With Teflon (92-850736A1) 5B-6 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 232 Swivel Bracket Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SWIVEL BRACKET (BLACK) SHORT SWIVEL BRACKET (GRAY) SWIVEL BRACKET (BLACK) SWIVEL BRACKET (GRAY) LONG BEARING OIL SEAL BEARING GREASE FITTING WASHER BOTTOM YOKE (BLACK) BOTTOM YOKE (GRAY) RETAINING RING SWIVEL PIN (BLACK) SHORT...

• Page 233: Drive Shaft Housing

  Drive Shaft Housing Loctite "680" (92-809833) 5B-8 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 234 Drive Shaft Housing TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m DRIVE SHAFT HOUSING (SHORT) DRIVE SHAFT HOUSING (LONG) DRIVE SHAFT HOUSING (JET 45) STUD (M10 x 60) (SHORT/LONG) STUD (M10 x 100) (60 BIG FOOT - LONG) STUD (M10 x 166) (60 BIG FOOT - LL) SCREW (M10 x 110) STUD (M10 x 124) (60 BIGFOOT - LL - FRONT)

• Page 235: Drive Shaft Housing Disassembly/Reassembly

  Drive Shaft Housing WARNING Disassembly/Reassembly Failure to support outboard as shown could re- sult in personal injury and/or damage to out- Servicing components such as steering arm, drive board or boat. shaft housing, exhaust assembly and swivel bracket will usually require powerhead and/or gear housing removal.
• Page 236 MID SECTION 40/50 POWER TRIM...
• Page 237 Trim Motor Reassembly ....5C-40 Flow Chart ......

• Page 238: Special Tools

  Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Expanding Rod P/N CG 41-11* 4. Collet P/N CG 41-14* 5. Heat Lamp P/N 91-63209 * = Snap-On 90-852572R1 JANUARY 1998 MID-SECTION - 5C-1...

• Page 239: Power Trim Components

  Power Trim Components Liquid Neoprene (92-25711--2) Power Trim and Steering Fluid (92-90100A12) 5C-2 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 240 Power Trim TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m POWER TRIM ASSEMBLY – O RING KIT SHOCK ROD ASSY. PILOT CHECK ASSEMBLY 13.6 TILT RELIEF VALVE ASSEMBLY 13.6 SUCTION SEAT ASSEMBLY 13.6 PUMP ASSEMBLY BALL/SPRING SCREW FILTER O RING MOTOR ASSEMBLY SCREW...

• Page 241: Theory Of Operation

  Theory Of Operation WARNING The Power Trim system consists of an electric motor, Excessive engine trim angle will result in insuffi- pressurized fluid reservoir, pump and trim cylinder. cient water supply to water pump causing water pump and/or powerhead overheating damage. The remote control (or trim panel) is equipped with a Make sure that water level is above gear housing switch that is used for trimming the outboard "up"...

• Page 242: Trailering Outboard

  Trailering Outboard Trim "In" Angle Adjustment WARNING WARNING Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to cient water supply to water pump causing water the full "in" trim angle at planing speed will cause pump and/or powerhead overheating damage.

• Page 243: Power Trim Flow Diagrams

  POWER TRIM FLOW DIAGRAMS TRIM UP Reservoir and Feed Oil Oil Under Pressure Return Oil Up Pressure 2530 PSI (min) a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve Check Ball c - Impact Relief Valve p - Shuttle Valve d - Shock Piston...
• Page 244 TRIM UP When the trim switch is activated in the up position, the electric motor (a) begins to rotate the pump gears, the oil pump (n) draws a small amount of oil through the filter, up circuit pick–up and past the feed valve check ball (o).

• Page 245: Tilt Up

  TILT UP Reservoir and Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 500–600 PSI a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...
• Page 246 TILT UP In the up mode, as the trim ram (b) extends from the cylinder, the memory piston (e) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and open the tilt pressure relief valve (k).

• Page 247: Maximum Tilt

  MAXIMUM TILT Reservoir and Feed Oil Oil Under Pressure Return Oil Tilt Relief Pressure 500–600 PSI a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...
• Page 248 MAXIMUM TILT With the cylinder at maximum travel, and due to no ram movement, the pressure inside of the trim cylin- der will increase to the pressure required to move the tilt relief actuator (i). The tilt relief actuator's "pin" opens the tilt relief valve (k).
• Page 249 TRIM DOWN Reservoir and Feed Oil Oil Under Pressure Return Oil Down Relief 500–800 PSI a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...

• Page 250: Down Mode

  DOWN MODE When the trim switch is activated in the down posi- tion, the electric motor (a) will rotate the pump (n) in the opposite direction. With the pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter, past the feed check valve (m), into the down circuit oil pick–up, and finally into the oil pump.
• Page 251 SHOCK FUNCTION UP Reservoir and Feed Oil Oil Under Pressure Return Oil 1550–1850 PSI a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston...
• Page 252 SHOCK FUNCTION UP Oil inside the down cavity is locked in a static position by the down pressure operated valve (h), the manual release valve (j) and the tilt relief valve (k). If the out- board strikes an underwater object while in forward gear the trim ram (b) will try to rapidly extend from the cylinder, the pressure increases inside the trim cylin- der down cavity and connecting passages.

• Page 253: Shock Function

  SHOCK FUNCTION RETURN Reservoir and Feed Oil Oil Under Pressure Return Oil a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston r - Check Ball...
• Page 254 SHOCK FUNCTION RETURN After the engine clears the under water object, the weight of the engine will increase the oil pressure be- tween the memory piston (e) and shock piston (d) to the level required to open the shock return valve (v), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity.

• Page 255: Manual Tilt

  MANUAL TILT Reservoir and Feed Oil Return Oil q r w a - Electric Motor n - Oil Pump b - Trim Ram o - Up Circuit Feed Valve c - Impact Relief Valve p - Shuttle Valve d - Shock Piston q - Down Pressure Regulating Valve e - Memory Piston r - Check Ball...
• Page 256 MANUAL TILT To manually tilt the outboard engine, the owner will need to back out the manual release valve (j). With the valve backed out, the internal passages inside the manifold are connected together. These pas- sages connect both the cylinder down and up cavities together, along with the reservoir (t), allowing the en- gine to be raised or lowered.

• Page 257: Troubleshooting

  Follow preliminary checks before proceeding to trou- Troubleshooting bleshooting flow diagrams (following). Support outboard with tilt lock pin when servicing power trim system. Preliminary Checks IMPORTANT: After debris or failed components have been found (during troubleshooting proce- IMPORTANT: Operate Power Trim system after dure) it is recommended that unit be disas- each check to see if problem has been corrected.

• Page 258: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Manual release valve and Manual release Inspect manual release valve. O-rings appear to be O.K. valve and O-ring Clean reinstall damaged.

• Page 259: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage. Suction seat assembly Debris and/or damage appears O.K. - Clean and identified. reinstall suction seat assembly. Replace suction seat Trim will not hold assembly.

• Page 260: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Manual release Inspect manual release valve. Manual release valve and O- valve and O-ring rings appear to be O.K. - Clean damaged. and reinstall manual release valve.

• Page 261: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore ap- Cylinder bore appears pears rough and/or smooth with no debris. debris found in cylin- der. Replace memory pis- Trim leaks down. ton and shock piston O-rings.

• Page 262: Troubleshooting The Power Trim Electrical System

  Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch (Remote Control (Panel Mounted) Mounted) BLU/WHT Fuse Holder GRN/WHT BLU/WHT or PUR GRN/WHT or GRN Remote Control Fuse Holder RED/PUR – RED/PUR Battery Starter Bolt GRN/WHT Solenoid BLU/WHT Down Relay LT.

• Page 263: Troubleshooting The Power Trim Electrical System

  Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch "UP" is inopera- 1. Open wire between Wire Connection (1) 1. Check for an open connection or cut tive, but the Cowl Switch "UP"...

• Page 264: Power Trim System Removal

  3. Remove the trilobe pin Power Trim System Removal 4. Drive out the upper pivot pin. 1. Tilt outboard to the full up position and support with tilt lock pin. a - Tilt Lock Pin 2. Disconnect the power trim wire harness and re- move clamps.

• Page 265: Disassembly

  6. Remove nuts and washers securing the lower Disassembly pivot pin. Remove lower pivot pin. Retain the piv- ot pin bushings from the clamp brackets and trim unit. Shock Rod Removal 7. Remove the trim unit. IMPORTANT: Power trim system is pressurized. Outboard must be in the full "UP"...

• Page 266: Shock Rod Disassembly

  4. Secure power trim assembly in a soft jaw vise. Shock Rod Disassembly 5. Unscrew end cap assembly from cylinder using NOTE: The only serviceable items on the shock rod spanner wrench 91-74951. assembly are the o-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
• Page 267 3. Remove check ball components from shock rod CAUTION piston. When removing shock piston, spanner wrench 4. Remove o-ring from shock rod piston. must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).

• Page 268: Memory Piston Removal

  10. Remove inner o-ring from shock rod piston. Memory Piston Removal 15. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (P/N 91-822778A3) or suitable tool. 51199 a - Shock Piston b - O-ring 11.

• Page 269: Trim Motor Removal

  16. Remove o-ring from memory piston. Trim Motor Removal 1. Secure power trim assembly in soft jawed vise. 2. Remove screws securing trim motor to manifold. 3. Remove motor assembly. a - O-ring a - Trim Motor b - Screw (4) 5C-32 - MID-SECTION 90-852572R1 JANUARY 1998...

• Page 270: Oil Pump Removal

  Oil Pump Removal Tilt Relief Valve Removal NOTE: The following procedures requires the use of 1. Remove oil filter and pump from manifold. a Snap-On blind hole removal tool #CG 41-11 with IMPORTANT: DO NOT disassemble the oil pump. 5/16" attachment #41-12. Or a removal tool can be The pump is not serviceable.

• Page 271: Suction Seat Removal

  1. Unscrew plug from manifold and remove spring Suction Seat Removal and poppet assembly. 1. Unscrew plug from manifold and remove ball. NOTE: Do not lose shim that may be lodged in the 2. Use a pin punch and knock the filter and suction plug.

• Page 272: Cleaning/Inspection/Repair

  3. Use the (.060 wire) removal tool (see previous Cleaning/Inspection/Repair page) and push out the spool and one seat. IMPORTANT: Components must be dirt and lint 4. From opposite side, use a punch and push out free. Slightest amount of debris in Power Trim the remaining seat.

• Page 273: Reassembly

  Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-827668A1 5C-36 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 274 0.145 in. (3.68 mm) 0.285 in. (7.24mm) 0.07 in. (1.78 mm) Pump Filter O-ring, Pump Filter - Square Cut Reservoir/Motor 2.614 in. (66.40 mm) 2.754 in. (70.0 mm) 0.07 in. (1.78 mm) Memory Piston 1.037 in. (26.34 mm) 1.457 in. (37.0 mm) 0.21 in.

• Page 275: Power Trim Reassembly

  Suction Seat Reassembly Power Trim Reassembly 1. Lubricate O-rings with power trim fluid. IMPORTANT: Lubricate all O-rings with Quicksil- ver Power Trim Fluid (92-90100A12). If not avail- 2. Install filter and suction seat using a 9/32" or 7 able, use automotive (ATF) automatic transmis- mm socket on OUTSIDE diameter of suction sion fluid.

• Page 276: Pilot Check Valve Reassembly

  Pilot Check Valve Reassembly Oil Pump Reassembly 1. Lubricate o-rings with power trim fluid. 1. Install the down relief ball and spring into man- ifold. 2. Install one of the seats into manifold. Push the seat into place using a 9/32" or 7 mm socket on 2.

• Page 277: Trim Motor Reassembly

  - O-ring a - Coupler b - O-ring c - Trim Pump Motor d - Ground Strap e - Lock Washer (1) f - Screws (4) - Torque to 80 lb. in (9.0 N m) 5C-40 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 278 4. Clamp shock rod in soft jawed vise. 9. Remove shock rod assembly from vise. 5. Position cylinder end cap onto rod as shown. 10. Install ball, seat, and spring (five sets) to shock rod piston. 51147 51146 CAUTION a - Spring (5) When installing shock rod piston, spanner b - Seat (5) c - Ball (5)

• Page 279: Shock Rod Installation

  Shock Rod Installation Manual Release Valve Installation 1. Place trim cylinder in soft jawed vice. 1. Install "E" clip (if removed) and lubricate o-rings with power trim fluid. 2. Install lubricated o-ring to memory piston and place into cylinder. Push memory piston all the 2.

• Page 280: Power Trim System Installation

  4. Install sacrificial anode to clamp brackets. Fasten Power Trim System ground strap between anode and clamp bracket. Installation 1. Lubricate lower pivot pin, mounting holes and bushings with 2-4-C Marine Lubricant. 2. Install lower pivot pin bushings into the clamp brackets and trim unit.
• Page 281 7. Secure upper pivot pin with trilobe pin. Press tri- 11. Secure wire harness with clamps as shown. lobe pin in until its fully seated. a - Trilobe Pin 8. Re-connect trim wire harness leads (see wiring diagram, Section 2D for proper connections). 9.
• Page 282 MID-SECTION 55331 55/60 POWER TRIM...
• Page 283 Trim Limit Assembly Installation ..5D-40 Flow Chart ......

• Page 284: Special Tools

  Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Expanding Rod P/N CG 41-11* 4. Collet P/N CG 41-14* 5. Heat Lamp P/N 91-63209 * = Snap-On 90-852572R1 JANUARY 1998 MID-SECTION - 5D-1...

• Page 285: Power Trim Components

  Power Trim Components Loctite 271 (92-809819) 2-4-C With Teflon (92-850736A1) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. 5D-2 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 286 Power Trim Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O-RING REBUILD KIT O-RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG Drive Tight MANUAL RELEASE ASSEMBLY Drive Tight MANIFOLD KIT...

• Page 287: Theory Of Operation

  Theory Of Operation WARNING The Power Trim system consists of an electric motor, Excessive engine trim angle will result in insuffi- pressurized fluid reservoir, pump and trim cylinder. cient water supply to water pump causing water pump and/or powerhead overheating damage. The remote control (or trim panel) is equipped with a Make sure that water level is above gear housing switch that is used for trimming the outboard "up"...

• Page 288: Trailering Outboard

  Trailering Outboard Tilting Outboard Up and Down Manually WARNING WARNING Excessive engine trim angle will result in insuffi- cient water supply to water pump causing water Before loosening the manual release valve, make pump and/or powerhead overheating damage. sure all persons are clear of engine, as engine Make sure that water level is above gear housing will drop to full "down"...
• Page 289 Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880–1110 (40–60 HP) 1220–1420 (75–125 HP) Up Pressure 1625 (40–60 HP) 2800 (75–125 HP) Tilt Relief Pressure min. 250–400 (40–60 HP) 540–990 (75–125 HP)

• Page 290: Trim Up

  TRIM UP When the trim switch is activated in the up position, the electric motor (c) begins to rotate the pump gears (j), the oil pump draws a small amount of oil through the filter (g) and through the up circuit suction port (i). The oil pump gear (j) rotation forces oil into the pas- sages for the up circuit.
• Page 291 Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880–1110 (40–60 HP) 1220–1420 (75–125 HP) Up Pressure 1625 (40–60 HP) Tilt Relief Pressure 2800 (75–125 HP) 250–400 (40–60 HP) min. 540–990 (75–125 HP)

• Page 292: Tilt Up

  TILT UP In the up mode, as the piston rod (a) extends from the cylinder (w), the memory piston (t) clears or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and, if required, causes the tilt re- lief piston (s) to open the tilt pressure relief valve (r).

• Page 293: Maximum Tilt

  Filtered Feed Oil Return Oil Í Í Í Í Oil Under Pressure Impact Relief Pressure #22 880–1110 (40–60 HP) 1220–1420 (75–125 HP) Up Pressure 1625 (40–60 HP) 2800 (75–125 HP) Tilt Relief Pressure min. 250–400 (40–60 HP) 540–990 (75–125 HP)
• Page 294 MAXIMUM TILT With the piston rod at maximum travel, and due to no rod movement, the pressure inside of the trim cylin- der (w) will increase to the pressure required to move the tilt relief piston (s). The tilt relief piston's "pin" opens the tilt relief valve (r).
• Page 295 Filtered Feed Oil Í Í Return Oil Í Í Oil Under Pressure Impact Relief Pressure #22 880–1110 (40–60 HP) Up Pressure 1220–1420 (75–125 HP) 1625 (40–60 HP) 2800 (75–125 HP) min. Tilt Relief Pressure 250–400 (40–60 HP) 540–990 (75–125 HP)

• Page 296: Down Mode

  DOWN MODE When the trim switch is activated in the down posi- tion, the electric motor (c) will rotate the pump (j) in the opposite direction. With the pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port (k) and into the oil pump (j).

• Page 297: Shock Function Up

  Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Í Í Impact Relief Pressure #22 880–1110 (40–60 HP) 1220–1420 (75–125 HP) Up Pressure 1625 (40–60 HP) 2800 (75–125 HP) min. Tilt Relief Pressure 250–400 (40–60 HP) 540–990 (75–125 HP)
• Page 298 SHOCK FUNCTION UP Oil inside the down cavity is locked in a static position by the down pressure operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o). If the outboard strikes an underwater object while in forward gear, the piston rod (a) will try to rap- idly extend from the cylinder (w), the pressure in- creases inside the trim cylinder down cavity and con-...

• Page 299: Shock Function Return

  SHOCK FUNCTION RETURN Reservoir Oil Return Oil Oil Under Pressure Í Í Í Í Impact Relief Pressure #22 880–1110 (40–60 HP) 1220–1420 (75–125 HP) Up Pressure 1625 (40–60 HP) 2800 (75–125 HP) min. Tilt Relief Pressure 250–400 (40–60 HP) 540–990 (75–125 HP)
• Page 300 SHOCK FUNCTION RETURN After the engine clears the under water object, the weight of the engine will increase the oil pressure be- tween the memory piston (t) and shock piston (u) to the level required to open the shock return valve (h), inside the shock piston, allowing the oil to bleed back through the shock piston into the down cavity.
• Page 301 525–880 Reservoir Oil Return Oil Filtered Oil Í Í Í Í Impact Relief Pressure #22 880–1110 (40–60 HP) 1220–1420 (75–125 HP) Up Pressure 1625 (40–60 HP) 2800 (75–125 HP) min. Tilt Relief Pressure 250–400 (40–60 HP) 540–990 (75–125 HP) a - Piston Rod...

• Page 302: Manual Tilt

  MANUAL TILT To manually tilt the outboard engine, the owner will need to back out the manual release valve (p) 3–4 turns. With the valve backed out, the internal pas- sages inside the manifold are connected together. These passages connect both the cylinder down and up cavities together, along with the reservoir, allow- ing the engine to be raised or lowered.

• Page 303: Troubleshooting

  Troubleshooting Support outboard with tilt lock pin when servicing power trim system. IMPORTANT: After debris or failed components have been found (during troubleshooting proce- dure), it is recommended that unit be disas- sembled completely and ALL O-rings be re- placed. Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re-as- sembly.

• Page 304: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND/OR TRAILS OUT DURING HIGH SPEED DECELERATION. Manual release valve and Manual release Inspect manual release valve. O-rings appear to be O.K. - valve and O-ring Clean and reinstall manual damaged.

• Page 305: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as- sembly and inspect for debris and/or damage. Suction seat assembly Debris and/or damage appears O.K. - Clean and identified. reinstall suction seat assembly. Replace suction seat Trim will not hold assembly.

• Page 306: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED. Manual release valve Inspect manual release valve. Manual release valve and O- and O-ring damaged. rings appear to be O.K. - Clean and reinstall manual release valve.

• Page 307: Hydraulic System Troubleshooting Flow Chart

  Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis- ton O-ring and cylinder bore. Cylinder bore appears Cylinder bore appears rough and/or debris smooth with no debris. found in cylinder. Replace memory pis- Trim leaks down. ton and shock piston O-rings.

• Page 308: Troubleshooting The Power Trim Electrical System

  Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch (Remote Control (Panel Mounted) Mounted) BLU/WHT Fuse Holder GRN/WHT BLU/WHT or PUR GRN/WHT or GRN Remote Control Fuse Holder RED/PUR – RED/PUR Battery Starter Bolt GRN/WHT Solenoid BLU/WHT Down Relay LT.

• Page 309: Troubleshooting The Power Trim Electrical System

  Troubleshooting the Power Trim Electrical System Refer to wiring diagram on preceding page for location of wire connections. Problem Possible Cause Remedy Trim Switch "UP" is inopera- 1. Open wire between Wire Connection (1) 1. Check for an open connection or cut tive, but the Cowl Switch "UP"...

• Page 310: Power Trim System Removal

  3. Remove the trilobe pin. Power Trim System Removal 4. Drive out the upper pivot pin. 1. Tilt outboard to the full up position and support with tilt lock pin. a - Trilobe Pin 55464 b - Upper Pivot Pin a - Tilt Lock Pin 5.

• Page 311: Power Trim Disassembly

  6. Use suitable punch to remove (Drive Up) lower Power Trim Disassembly pin. Retain dowel pin. IMPORTANT: Power trim system is pressurized. Trim rod must be in the full "UP" position (fully extended prior to fill/drain plug, or manual re- lease valve removal.

• Page 312: Trim Motor Removal

  Trim Motor Removal Pump and Components Removal 1. Secure power trim assembly in a soft jaw vise. 1. Remove pressure operated plugs on pump. Re- move spring and check valve/poppet (both 2. Remove four (4) screws to remove motor/reser- sides). Use special tool CG 41-11 and special tool voir.

• Page 313: Manifold Removal

  2. Remove three (3) screws to remove pump. Re- 2. Remove tilt relief components. move filter and filter seal under pump. Remove suction seat assembly. 51008 a - Spring b - Poppet c - Spool Housing d - Trim Limit Spool Shock Rod Removal a - Screws (3) b - Filter Seal...

• Page 314: Shock Rod Disassembly

  3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove o-ring from shock rod piston. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
• Page 315 10. Remove inner o-ring from shock rod piston. CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).

• Page 316: Memory Piston Removal

  Memory Piston Removal 2. Remove o-ring from memory piston. 1. Remove memory piston from cylinder using one of two methods: a. Using lock ring pliers (P/N 91-822778A3) or suitable tool. 51144 a - O-Ring b - Memory Piston 51144 b. Blowing compressed air into manual release valve hole using air nozzle.

• Page 317: Cleaning/Inspection/Repair

  Cleaning/Inspection/Repair IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in Power Trim system could cause system to malfunction. Clean shock rod and components with parts cleaner and dry with compressed air. It is recommended that all O-rings in trim system be replaced.

• Page 318: Reassembly

  Reassembly O-Ring and Seal Placement O-Rings and Seals are part of O-Ring Kit 25-809880A1 90-852572R1 JANUARY 1998 MID-SECTION - 5D-35...

• Page 319: O-Ring Sizes

  O-ring Sizes 4, 22 12, 17, 18 15, 20 Cutaway View of O-Ring Width O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 5D-36 - MID-SECTION 90-852572R1 JANUARY 1998...

• Page 320: O-Ring Description And Sizes

  Cyl. Cap8134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) Shock Piston2579) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) Piston Bolt05797) 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm)

• Page 321: Power Trim Reassembly

  4. Clamp shock rod in soft jawed vise. Power Trim Reassembly 5. Position cylinder end cap onto rod as shown. IMPORTANT: Lubricate all o-rings with Quicksil- ver Power Trim Fluid (92-90100A12). If not avail- able, use automotive (ATF) automatic transmis- sion fluid.

• Page 322: Shock Rod Installation

  9. Remove shock rod assembly from vise. Shock Rod Installation 10. Install ball, seat, and spring (five sets) to shock 1. Place trim cylinder in soft jawed vice. rod piston. 2. Install lubricated o-ring to memory piston and 11. Secure components with plate. Torque screws to place into cylinder.

• Page 323: Trim Limit Assembly Installation

  NOTE: There are two different size springs used in this manifold. The heavy spring is used on 75 to 125 HP engines. The light spring is used on 40 to 60 HP engines. a - O-Ring (2) b - Dowel Pin 2.

• Page 324: Oil Pump Installation

  3. Install the two (2) long screws and torque to 100 Oil Pump Installation lb. in. (11 N m). 1. Install spring, ball, lubricated o-ring and plastic seat to manifold. 2. Check to see that o-rings are placed on bottom of pump.

• Page 325: Reservoir/Motor Installation

  Pressure Operated Assembly Reservoir/Motor Installation Installation 3. Install coupler into top of pump. Make sure reser- voir seal is in the reservoir groove and place res- IMPORTANT: Inspect poppet assembly for debris ervoir onto pump/manifold assembly. Install in the area shown. If debris is found on poppet, ground strap under screw shown Torque screws replace poppet.

• Page 326: Bleeding Power Trim Unit

  Bleeding Power Trim Unit Installation of Power Trim System 1. Secure power trim unit in soft jawed vise. 2. Add power trim fluid until it's even with the bottom 1. Lubricate lower pivot pin, mounting holes with of the fill hole. Reinstall plug. 2-4-C Marine Lubricant.
• Page 327 4. Apply 2-4-C Marine Lubricant to lower pivot pin. 6. Apply 2-4-C Marine Lubricant to surface of upper Using a suitable punch, drive lower pivot pin into pivot pin, pivot pin bore and trim ram bore. clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface.
• Page 328 8. Drive trilobe pin (a) into its hole until seated. 10. Route trim harness through clamp bracket and cowling. 55464 a - Trilobe Pin 55264 a - Trim Harness 9. Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode, as shown.
• Page 329 MID-SECTION 40/50 MANUAL TILT ASSIST...
• Page 330 Table of Contents Page Clamp Bracket ......5E-2 Hydraulic Assist Adjustments ... . 5E-4 Manual Trim System Removal .
• Page 331 Notes: 90-852572R1 JANUARY 1998 MID-SECTION - 5E-1...

• Page 332: Clamp Bracket

  Clamp Bracket Loctite "271" Adhesive Sealant (92-809819) 2-4-C w/Teflon (92-825407A12) 5E-2 - MID-SECTION 90-852572R1 JANUARY 1998...
• Page 333 WAVE WASHER ROLL PIN (1/8 x 3/4 IN.) LINK ANCHOR PIN (14MM) BUSHING BUSHING GAS ASSIST TRIM & WASHER POWER TRIM MOUNTING SCREW (M10 x 40) WASHER TILT LOCK PIN NON POWER TRIM SPRING 90-852572R1 JANUARY 1998 MID-SECTION - 5E-3...

• Page 334: Hydraulic Assist Adjustments

  Hydraulic Assist Manual Trim System Adjustments Removal 1. Tilt outboard to the full up position and support WARNING with tilt stop pin. This hydraulic assist system's contents are un- der pressure. Do not puncture, disassemble or apply heat or flame. IMPORTANT: If debris or leaking is found, unit must be replaced.

• Page 335: Manual Trim System Installation

  4. Disconnect link rod from cam lever. Manual Trim System 5. Remove tilt lock pin. Remove nuts and washers Installation securing the lower pivot pin. Remove anode bolt to remove ground strap. Remove lower anchor 1. Apply 2-4-C Marine Lubricant to surface of lower pin.
• Page 336 3. Apply 2-4-C Marine Lubricant to surface of upper 6. Check manual release cam adjustment. Cam pivot pin, pivot hole and shock rod hole. must open and close freely. Adjust cam link rod as necessary. 4. Position trim into position and drive pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket.
• Page 337 MID-SECTION 55/60 MANUAL TILT SYSTEM...
• Page 338 Table of Contents Page Special Tools ......5F-1 Manual Tilt Components ....5F-2 Manual Tilt Components .

• Page 339: Special Tools

  Special Tools 1. Spanner Wrench P/N 91-74951 2. Lock-Ring Pliers P/N 91-822778A3 3. Heat Lamp P/N 91-63209 90-852572R1 JANUARY 1998 MID-SECTION - 5F-1...

• Page 340: Manual Tilt Components

  Manual Tilt Components Loctite 271 (92-809819) 2-4-C With Teflon (92-850736A1) NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. 5F-2 - MID-SECTION 90-852572R1 JANUARY 1998...

• Page 341: Manual Tilt Components

  Manual Tilt Components TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SHOCK ROD ASSEMBLY SHOCK ROD ASSEMBLY (BEACHING) MEMORY PISTON ASSEMBLY O RING REBUILD KIT-Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY CAM KIT VELOCITY VALVE KIT CHECK SYSTEM REPAIR KIT...
• Page 342 MANUAL TRIM FLOW DIAGRAMS Up Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...

• Page 343: Tilt Up

  TILT UP With the engine in the down position, the accumula- tor piston (d) will be at the top of the accumulator (c) with the gas at maximum pressure. To raise the en- gine, the camshaft lever (f) is rotated all the way down.
• Page 344 Down Circuit a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...

• Page 345: Tilt Down

  TILT DOWN With the engine tilted up, the piston inside the accu- mulator piston (d) will be at the bottom of the accumu- lator (c) and the gas pressure is low. To lower the en- gine, the camshaft lever (f) is rotated down, the internal cam will cause the push rods to open the ac- cumulator check valve (e), both fast transfer valves (h &...

• Page 346: Slow Tilt Down Under High Thrust

  Slow Tilt Down Under High Thrust a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever...
• Page 347 SLOW TILT DOWN UNDER HIGH THRUST To tilt the engine down under high thrust conditions [where the propeller thrust forces the shock rod down, creating higher pressure below the memory piston (m)], the camshaft lever (f) is rotated slightly downward. The internal shaft connected to the lever will open the down slow transfer valve (i) allowing oil under pressure into the cavity around the shaft.
• Page 348 Under Water Strike (Valves Open) a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...

• Page 349: Under Water Strike With Valves Open

  UNDER WATER STRIKE WITH VALVES OPEN Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the interconnecting passage. The rapid fluid flow will increase the pressure below the surge valve (k), causing the valve to move, closing the oil return passage back into the accumulator (c).
• Page 350 Shock Function (Valve Closed) Accumulator Gas Pressure 400 PSI a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston...

• Page 351: Shock Function With Valves Closed

  SHOCK FUNCTION WITH VALVES CLOSED Should the drive unit strike a submerged object while in forward motion, the shock rod (a) will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the closed up fast transfer valve (j), the closed down slow transfer valve (i) and closed down fast transfer valve (h).
• Page 352 Shock Function Return a - Shock Rod i - Down Slow Transfer Valve b - End Cap j - Up Fast Transfer Valve c - Accumulator k - Surge Valve d - Accumulator Piston l - Cylinder e - Accumulator Check Valve m - Memory Piston f - Camshaft Lever n - Shock Piston...

• Page 353: Shock Function Return

  SHOCK FUNCTION RETURN After the drive clears the object, the shock return valve (o) will allow the oil to flow from between the shock piston (n) and memory piston (m) onto the down cavity as the drive returns to its original running position.

• Page 354: Hydraulic System Troubleshooting

  3. Check for discharged accumulator. 35 to 50 lb. ft. Hydraulic System (47-68 N·m) of pulling force must be attained Troubleshooting when tilting outboard from full "down" to full "up" position. If more than 50 lb. ft. (68 N·m) of force Refer to disassembly/reassembly instructions (fol- is required, replace accumulator.

• Page 355: Manual Tilt System Removal

  3. Position piece of wood under transom bracket Manual Tilt System Removal instead of tilt lock for access of removing pin. Use suitable punch to remove (DRIVE DOWN) upper CAUTION dowel pin. Retain dowel pin. Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard.

• Page 356: Manual Tilt System Disassembly

  6. Use suitable punch to drive out lower pivot pin. Manual Tilt System Disassembly NOTE: Accumulator contains a high pressure nitro- gen charge and is NOT SERVICEABLE. Replace if necessary. WARNING This tilt system is pressurized. Remove accumu- 51144 lator only when shock rod is in full up position. a - Pivot Pin Accumulator Removal 1.

• Page 357: Shock Rod Removal

  6. If plunger can be compressed into accumulator Shock Rod Removal by hand, accumulator is defective. Replace accu- 1. Unscrew cylinder end cap assembly using span- mulator. ner wrench [1/4 in. x 5/16 in. long pegs]. 51145 2. Remove shock rod assembly from cylinder. 51143 a - Plunger 7.

• Page 358: Shock Rod Disassembly

  3. Remove check ball components from shock rod Shock Rod Disassembly piston. NOTE: The only serviceable items on the shock rod 4. Remove o-ring. assembly are the O-rings and wiper ring. If shock rod requires any other repair, replace shock rod assem- bly.
• Page 359 Remove inner O-ring. CAUTION When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs to avoid damage to shock piston. 5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp (P/N 91-63209).

• Page 360: Valve Block Removal

  Valve Block Removal Memory Piston Removal 1. Remove two screws from the shock rod cylinder 1. Remove memory piston from cylinder using one to separate the valve block. of two methods: a. Using lock ring pliers. a a a 51146 a - Screw b - Valve Block c - Shock Rod Cylinder...

• Page 361: Valve Block Disassembly

  2. Remove O-ring from memory piston. 3. Remove surge valve assembly. 51144 a - O-Ring b - Memory Piston a - Spool b - Spring c - O-ring Valve Block Disassembly d - Screw Plug 1. Remove check retainer plug and components. 4.
• Page 362 Reassembly - O-Ring and Seal Placement NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. NOTE: It is recommended that all o-rings be replaced when servicing tilt system. 5F-24 - MID-SECTION 90-852572R1 JANUARY 1998...

• Page 363: Actual O-Ring Sizes

  Actual O-Ring Sizes 4, 14 6 (2) 11 & 13 Cutaway View of O-Ring Width 8 (2) O.D. I.D. O-RINGS SHOWN ARE ACTUAL SIZE 90-852572R1 JANUARY 1998 MID-SECTION - 5F-25...

• Page 364: O-Ring Description And Sizes

  Cyl. Cap (408134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm) Shock Piston (412782) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm) Piston Bolt (405797) 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in.

• Page 365: Manual Tilt System Reassembly

  VALVE BODY CHECK REASSEMBLY Manual Tilt System Cleaning 1. Install lubricated o-ring, plunger, steel ball and and Inspection conical spring to valve block. 1. It is recommended that all o-rings exposed during disassembly be replaced. 2. Clean components, filter, and check valve seats using engine cleaner and compressed air.

• Page 366: Valve Block Installation

  CHECK RETAINER REASSEMBLY Valve Block Installation 1. Install plunger, spring (large), ball, spring (small), 1. Install lubricated O-rings and dowel pins. and plug into valve block. 51148 a - O-ring (2) b - Dowel Pin (2) 51142 2. Install valve block to shock rod cylinder. Insert screws to shock rod cylinder and torque to 100 lb.

• Page 367: Shock Rod Reassembly

  Shock Rod Reassembly 4. Clamp shock rod in soft jawed vise. 5. Position cylinder end cap onto rod, as shown. 1. Install lubricated o-rings to end cap. 2. Install rod wiper. 51146 51145 a - Rod Wiper b - Inner O-ring c - Outer O-ring CAUTION hen installing shock rod piston, spanner...

• Page 368: Shock Rod Installation And Fluid Filling Procedure

  9. Install ball, seat, and spring (five sets) to shock Shock Rod Installation and Fluid Fill- rod piston. ing Procedure 10. Secure components with plate. Torque screws to NOTE: There are two ways for the filling procedure. 35 lb.in. (3.9 N m). The first is the easiest and less time consuming.
• Page 369 6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Position) and screw cylinder cap down. 7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap to 45 lb.

• Page 370: Filling Procedure Option Two Instructions For Making Retaining Tool

  Filling Procedure Option Two Instructions for Making Retaining Tool 3/16 in x 3 in. (5 x 7.5 cm) Steel Plate 3/8 in. x 13 in. (10mm x 33cm) Threaded Rod 4in. x 1/4 in. min. (10cm x 6.4mm) minimum Channel Iron 10 in.

• Page 371: Bleeding Manual Tilt System

  3. Bleed unit by pushing rod down slowly (18-20 se- Bleeding Manual Tilt System conds per stroke) until stopped at base. Wait until IMPORTANT: While bleeding tilt system, time all air bubbles exit accumulator base. must be allowed between each stroke to allow air bubbles to dissipate.
• Page 372 7. Allow unit to stand five minutes, then proceed to 11. With cam lever remaining open (facing down), cycle unit 2-3 more times using short strokes. No remove tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise.

• Page 373: Manual Tilt System Installation

  4. Using a suitable punch, drive lower pivot pin into Manual Tilt System clamp bracket and trim cylinder assembly until Installation pivot pin is flush with outside surface. 1. Apply 2-4-C Marine Lubricant to lower pivot pin hole and pivot pin surface. 2.

• Page 374: Manual Release Valve Adjustment

  6. Apply 2-4-C Marine Lubricant to surface of upper 8. Drive upper dowel pin (a) into its hole until seated. pivot pin, pivot pin hole and shock rod hole. 51147 a - Dowel Pin 51148 2-4-C w/Teflon (92-850736A1) 9. Check manual release cam adjustment. Cam a - Pivot Pin must open and close freely.
• Page 375 LOWER UNIT 40/50 LOWER UNIT...
• Page 376 Special Tools ......6A-2 Gear Housing (Drive Shaft)(40/50) ..6A-4 Gear Housing (Propeller Shaft)(40/50) .

• Page 377: Specifications

  Specifications Gear Ratio 1.83:1 Gearcase Capacity 14.9 fl. oz. (440 mL) Lubricant Type Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth 22 Spiral/Bevel Pinion Gear Number of Teeth 12 Spiral/Bevel Pinion Height No Adjustment Forward Gear Backlash No Adjustment GEAR HOUSING Reverse Gear Backlash No Adjustment...

• Page 378: Special Tools

  5. Mandrel 91-36571 Special Tools 1. Bearing 31-85560 54978 6. Universal Puller Plate 91-37241 2. Driver 91-13779 3. Bearing Puller & Installation Tool 91-31229A7 a. Nut 11-24156 b. Washer (2) 12-34961 7. Driver Head 91-37312 c. Plate 91-29310 d. Shaft 91-31229 8.
• Page 379 10. Drive Shaft Holding Tool 91-825196 16. Driver 91-826872 11. Mandrel 91-825197 17. Leakage Tester FT8950 12. Driver 91-817007 51043 13. Mandrel 91-825198 14. Pilot 91-825199 15. Spring Hook 91-825200A1 90-852572R1 JANUARY 1998 LOWER UNIT - 6A-3...

• Page 380: Gear Housing (Drive Shaft)(40/50

  Gear Housing (Drive Shaft)(40/50) Loctite "271" Adhesive Sealant (92-809819) Loctite "405" (Purchase Locally) Super Duty Gear Lubricant (92-13783A24) 2-4-C w/Teflon (92-825407A12) 6A-4 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 381 Gear Housing (Drive Shaft)(40/50) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING (BLACK) SHORT – GEAR HOUSING (GRAY) – GEAR HOUSING (BLACK) LONG – GEAR HOUSING (GRAY) GEAR HOUSING (BASIC-BLACK) GEAR HOUSING (BASIC-GRAY) SEAL/PLATE KIT PLATE SCREW (.375-16 x .25)

• Page 382: Gear Housing (Propeller Shaft)(40/50

  Gear Housing (Propeller Shaft)(40/50) Loctite "271" (92-809819) Super Duty Gear Lubricant (92-850737A1) Anti-Corrosion Grease (92-850735A1) 2-4-C w/Teflon (92-825407A12) 6A-6 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 383 Gear Housing (Propeller Shaft)(40/50) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING (BLACK) SHORT – GEAR HOUSING (GRAY) – GEAR HOUSING (BLACK) LONG – GEAR HOUSING (GRAY) GEAR HOUSING (BASIC-BLACK) GEAR HOUSING (BASIC-GRAY) DOWEL PIN...

• Page 384: General Service Recommendations

  Roller bearing condition is determined by inspecting General Service the surface of the shaft that the roller bearing sup- Recommendations ports. Check shaft surface for pitting scoring, groov- ing, imbedded particles, uneven wear and/or discol- There may be more than one way to "disassemble" oration from overheating.

• Page 385: Draining And Inspecting Gear Lubricant

  Draining and Inspecting Propeller Removal Gear Lubricant WARNING WARNING If gear housing is not removed from outboard, before attempting to remove or install the propel- If gear housing is installed on outboard, discon- ler, remove (and isolate) spark plug leads from nect (and isolate) spark plug leads from spark spark plugs to prevent outboard from starting.

• Page 386: Gear Housing Removal

  2. Shift into NEUTRAL. 3. Loosen jam nut. Unscrew attaching nut to sepa- rate shift shaft. 30/40, 40/50, FORCE 40/50 52835 a - Bolt and Washer b - Scribe Line 5. Remove nut and washer in trim tab cavity.

• Page 387: Disassembly

  6. Remove 4 bolts securing gear case to drive shaft 2. Remove cover, washer (above impeller), impel- housing. ler, key and washer (below impeller). 3. Remove cover gasket, base plate and base gas- ket. 52836 a - Bolt (4) Disassembly Water Pump NOTE: If water tube seal remained in drive shaft housing, remove seal from housing and reinstall on...
• Page 388 Discard tab washers. Model Drive Shaft Holding Tool 25, 45/50 (4-Stroke) 91-83180M Force 40/50 91-825196 30/40, 40/50 91-825196 8. Remove pinion nut and discard. 51043 a - Bolts and Tab Washers or Flat Washers b - Tab Washers Style 2 6.
• Page 389 10. Remove forward gear. 12. Insert pinion bearing race puller (91-825200A1) through gear case and position inside of pinion bearing race. Insert driver (91-13779) into puller through drive shaft cavity and drive out race. 52870 a - Forward Gear 52844 11.

• Page 390: Water Pump Seals

  Water Pump Seals 3. With lip of ribbed neoprene O.D. seal facing to- wards small shoulder of Mandrel (91-825197), NOTE: All gaskets, seals and o-rings should be re- press seal into carrier until mandrel bottoms on placed as a normal repair procedure during gear carrier.

• Page 391: Inspection

  Pinion Gear Bearing Inspection 1. Inspect bearing for rust, roughness or discolor- ation from lack of lubricant. Upper Drive Shaft Bearing 2. If bearing is damaged, bearing and race must be 1. Inspect bearing for rust, roughness or discolor- replaced as an assembly. ation from lack of lubricant.

• Page 392: Forward Gear

  Forward Gear 4. Use a suitable mandrel to press needle bearing out of forward gear. 1. Inspect forward gear teeth for rust, chipping, ex- cessive wear (teeth are sharped edged), or bro- ken teeth. 2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following: a.

• Page 393: Shift Shaft

  6. Inspect forward gear tapered bearing and race Shift Shaft for rust, roughness or excessive wear (loose- 1. Inspect shift cam for wear or galling. Replace ness). cam if necessary. 7. If bearing is in serviceable condition, DO NOT re- 2.

• Page 394: Propeller Shaft Disassembly

  Propeller Shaft Disassembly Propeller Shaft and Carrier Inspection 1. Remove propeller shaft from carrier and disas- semble shaft. Clutch 1. Inspect clutch jaws for chips or rounding off. 2. If wear is present, inspect corresponding forward or reverse gear matching jaws for similar wear. Replace appropriate components as required.

• Page 395: Reverse Gear

  Reverse Gear 4. Install new bearing using a suitable mandrel. PRESS ONLY ON INNER RACE when installing 1. Inspect reverse gear teeth for rust, chipping ex- bearing. cessive wear (teeth are sharped edged) or bro- ken teeth. 2. Inspect reverse gear clutch jaws for wear. Rounded jaws indicate the following: a.

• Page 396: Bearing Carrier

  Bearing Carrier 4. Apply a light coat of Special Lubricant 101 to O.D. of bearing. NEEDLE BEARING 5. Install bearing using Mandrel 91-817011. 1. The condition of the carrier needle bearing can 6. Press bearing into carrier until mandrel bottoms be determined by inspecting its running surface on carrier.

• Page 397: Gear Housing Reassembly

  .82 in. (20mm) Gear Housing Reassembly IMPORTANT: The 30/40 gear case assembly does not have have any shims for the gear assemblies. Backlash cannot be adjusted. The mechanic must verify that all bearing races are firmly...

• Page 398: Shift Shaft Assembly

  Shift Shaft Assembly Pinion Bearing Race 1. Apply 2-4-C w/Teflon to new o-rings and install o- 1. Apply Super Duty Gear Lubricant to O.D. of race. rings on shift shaft and carrier. 2. Position race in gear housing (NUMBERS UP - 2.

• Page 399: Forward Gear

  4. Install new pinion nut, with rounded corners FAC- ING pinion gear, onto drive shaft. Model Drive Shaft Holding Tool 25, 45/50 (4-Stroke) 91-83180M Force 40/50 91-825196 30/40, 40/50 91-825196 5. Using Drive Shaft Holding Tool to hold drive shaft, 52843 torque pinion nut to 50 lb.

• Page 400: Propeller Shaft

  Propeller Shaft 6. Install cam follower. 1. Slide clutch (short shoulder faces forward gear) over propeller shaft aligning cross pin hole with slot in propeller shaft. 2. Insert cam follower spring into propeller shaft. 3. Using a 3/16 in. allen wrench or similar device, compress the follower spring enough to insert the cross pin partially through clutch.

• Page 401: Bearing Carrier

  40/50 (3 Cylinder - 2 Stroke) 0G650699 and below Belgium ..Force 40/50 (2 Cylinder - 2 Stroke) 51117 0E323508 and below Loctite "271" (92-809819) a - Torque Bolts to 225 lb. in./18.8 lb. ft. (25.4 N m)

• Page 402: Water Pump

  Water Pump 4. Install impeller and nylon washer. 1. Install water pump seal carrier. 2. Install exhaust deflector plate, if removed. 52832 a - Seal Carrier b - Exhaust Deflector 52869 3. Install base gasket, face plate, pump cover gas- a - Impeller ket (NEOPRENE STRIP FACES UP), nylon b - Nylon Washer...

• Page 403: Gear Housing Pressure Test

  Gear Housing Pressure Test Gear Housing Installation 1. Remove vent plug and install pressure test Filling Gear Housing with Lubricant gauge. Tighten securely. NOTE: Gear housing lubricant capacity is approxi- mately 14.9 fl. oz. (440 ml). WARNING If gear housing is installed on outboard, discon- nect (and isolate) spark plug leads from spark plugs before working near the propeller.

• Page 404: Installing Gear Housing To Drive Shaft Housing

  7. Connect shift shaft by sliding retainer to the right and snapping into upper "locked" position. 25 (4 STROKE), 45/50 (4 STROKE) 52836 a - Bolt and Washers (2 each side) [Torque Bolt to 40 lb. ft. (54.2 N·m)] 53859 a - Retainer...

• Page 405: Trim Tab Adjustment And Replacement

  52833 a - Locknut and Washer [Torque Nut to 40 lb. ft. (54.2 N·m)] 2. If necessary, adjust trim tab as follows: Shift engine control into NEUTRAL and turn ignition key to "OFF"...

• Page 406: Propeller Installation

  Propeller Installation CAUTION Do not misinterpret propeller shaft movement for WARNING propeller movement. Propeller and propeller Disconnect and isolate spark plug leads when shaft may move fore-and-aft. However, the pro- working near the propeller to prevent the out- peller itself should not move fore-and-aft on the board from starting.
• Page 407 LOWER UNIT 55/60 LOWER UNIT...
• Page 408 Table of Contents Page Specifications ......6B-1 Special Tools ......6B-2 Gear Housing (Drive Shaft) (55/60) .
• Page 409 Specifications Gear Ratio 1.64:1 Gearcase Capacity 11.5 fl. oz. (340mL) Lubricant Type Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth Pinion Gear Number of Teeth Pinion Height 0.025 in. (0.64 mm) Pinion Gear Locating Tool GEAR HOUSING (91-817008A2) Forward Gear Backlash 0.013–0.019 in.
• Page 410 2. Backlash Indicator Tool 91-19660--1. Special Tools 1. Bearing Preload Tool 91-14311A-2. 19660-1 51043 3. Puller 91-27780. 4. Universal Puller Plate 91-37241. 51270 Ref. Description Qty. Bushing - 3/4 in. (19 mm) I.D. 5. Driver Head 91-37312. Bushing - 7/8 in. (22 mm) I.D. Set Screw Bolt Spring...
• Page 411 7. Bearing Retaining Tool 91-43506. 11. Forward Gear Bearing Installer 91-817005. 51043 12. Water Pump Base Seal Installer 91-817006. 73600 51043 8. Puller Jaws 91-46068A1 and Puller Bolt 91-85716. 13. Bearing Carrier Seal Installer 91-817007. 73599 9. Dial Indicator 91-58222A1. 51043 14.
• Page 412 15. Forward Gear Bearing Race Driver Cup 18. Lower Driveshaft Bearing Driver Assembly 91-817009. 91-817058A1. 51043 16. Needle Bearing Installer 91-817011. 51043 51043 17. Backlash Indicator Tool 91-817057A1. 19. Driveshaft Holding Tool 91-817070. 51043 51043 51270 Ref. Description Qty. Plate Stud Sleeve 91-817057A-1 Update Kit (Converts 91-14311A-1 Bear-...
• Page 413 Notes: 90-852572R1 JANUARY 1998 LOWER UNIT - 6B-5...

• Page 414: Gear Housing (Drive Shaft) (55/60

  Gear Housing (Drive Shaft) (55/60) Loctite "271" Adhesive Sealant (92-809819) Loctite "405" (Purchase Locally) Super Duty Gear Lubricant (92-13783A24) 2-4-C w/Teflon (92-825407A12) 6B-6 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 415 Gear Housing (Drive Shaft)(55/60) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING (BLACK) SHORT – GEAR HOUSING (GRAY) – GEAR HOUSING (BLACK) LONG – GEAR HOUSING (GRAY) – GEAR HOUSING (BLACK) X-LONG – GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) GEAR HOUSING (GRAY) DRAIN SCREW...

• Page 416: Gear Housing (Propeller Shaft)(55/60

  Gear Housing (Propeller Shaft)(55/60) Loctite "271" Adhesive Sealant (92-809819) Anti-Corrosion Grease (92-78376A6) 2-4-C w/Teflon (92-825407A12) 6B-8 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 417 Gear Housing (Propeller Shaft)(55/60) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING (BLACK) SHORT – GEAR HOUSING (GRAY) – GEAR HOUSING (BLACK) LONG – GEAR HOUSING (GRAY) – GEAR HOUSING (BLACK) X-LONG – GEAR HOUSING (GRAY) GEAR HOUSING (BLACK) GEAR HOUSING (GRAY) SHIM SET...

• Page 418: General Service Recommendations

  Roller bearing condition is determined by inspecting General Service the surface of the shaft that the roller bearing sup- Recommendations ports. Check shaft surface for pitting scoring, groov- ing, imbedded particles, uneven wear and/or discol- There may be more than one way to "disassemble" oration from overheating.

• Page 419: Draining And Inspecting Gear Lubricant

  Draining and Inspecting Propeller Removal Gear Lubricant WARNING WARNING If gear housing is not removed from outboard, before attempting to remove or install the propel- If gear housing is installed on outboard, discon- ler, remove (and isolate) spark plug leads from nect (and isolate) spark plug leads from spark spark plugs to prevent outboard from starting.

• Page 420: Gear Housing Removal

  Gear Housing Removal Gear Housing Disassembly Water Pump WARNING To prevent accidental engine starting, remove 1. If water tube seal stayed on water tube (inside of (and isolate) spark plug leads from spark plugs driveshaft housing) when gear housing was re- before removing gear housing.
• Page 421 4. Lift impeller, drive key, and gasket. Replace im- New Style Base peller if: 8. Remove water pump base by lifting gently as – Impeller blades are cracked, torn, or worn. shown. Inspect carefully for cracks. – Impeller is glazed or melted (caused by insuffi- cient water supply).

• Page 422: Bearing Carrier And Propeller Shaft

  Bearing Carrier and Propeller Shaft 4. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. If reverse 1. Drain lubricant; refer to "Draining and Inspecting gear must be replaced, pinion and sliding clutch Gear Lubricant".

• Page 423: Propeller Shaft Disassembly

  6. Remove ball bearing from reverse gear using 8. Remove seals (if not removed with bearing) and Universal Puller Plate and mandrel. O-ring. 51263 a - O-ring 51289 Propeller Shaft Disassembly 1. Remove spring. Push out cross pin. 51269 a - Ball Bearing b - Reverse Gear c - Universal Puller Plate (91-37241) d - Driver Head (91-37312)

• Page 424: Pinion Gear, Driveshaft And Forward Gear

  2. Replace cam follower if worn or pitted on either Pinion Gear, Driveshaft and Forward end. Gear 3. Replace sliding clutch if jaws are rounded or 1. Hold driveshaft using Driveshaft Holding Tool chipped. Rounded jaws indicate the following: (91-817070); remove (and discard) pinion nut. a.

• Page 425: Upper Driveshaft Bearing

  7. Replace forward gear tapered roller bearing and Lower Driveshaft Bearing race if either bearing or race are rusted or dam- 1. Remove lower driveshaft bearing using tool aged; or if bearing does not roll freely after clean- (91-817058A1) with bushing installed. ing in solvent.

• Page 426: Shift Shaft

  Shift Shaft 4. Remove shift shaft bushing and "E" clip from shift shaft. Replace shift shaft if splines are twisted or 1. Remove shift shaft coupler and spacer. damaged on either end of shaft. Remove (and discard) O-ring if damaged. 51271 a - Coupler 51264...

• Page 427: Gear Housing Reassembly

  5. Install shift cam (numbers toward top of gear Gear Housing Reassembly housing); align hole in shift cam with hole. Shift Shaft 1. Apply Perfect Seal on O.D. of new seal. Install with seal lip up, as shown. 2. Press seal into shift shaft bushing until seal bot- toms.

• Page 428: Propeller Shaft

  Propeller Shaft Forward Gear Bearing Race 1. Install components. 1. Place shim(s), retained from disassembly, into housing. If shim(s) were lost or damaged, or a new gearcase is being assembled, start with a .010 in. (.254mm) shim. 2. Drive bearing race into housing. Use a lead ham- mer to avoid damage to propshaft.

• Page 429: Bearing Carrier

  Bearing Carrier 4. Install large diameter seal on installer tool. Seal lip faces towards shoulder on installer tool. Press 1. Lubricate O.D. of needle bearing with Quicksilver in until Installer tool bottoms. Needle Bearing Assembly Lubricant. 2. Install needle bearing. Installation Note: Push against numbered end of bearing.

• Page 430: Reverse Gear

  5. Lubricate O-ring with Special Lubricant 101. In- 2. Install reverse gear and bearing assembly. Lubri- stall O-ring. cate O.D. of bearing with Quicksilver Needle Bearing Assembly. Lubricant before installation. 51263 2-4-C w/Teflon (92-850736A1) a - O-ring Reverse Gear 1. Lubricate I.D. of bearing with Quicksilver Needle Bearing Assembly Lubricant.

• Page 431: Lower Driveshaft Bearing Installation

  2. Press tapered roller bearing onto gear. Lubricate Lower Driveshaft Bearing Installation I.D. of bearing with Quicksilver Needle Bearing 1. Lubricate O.D. of bearing race with Quicksilver Assembly Lubricant before installation. Use In- Needle Bearing Assembly Lubricant. staller Tool. Press until bearing bottoms on gear. 2.

• Page 432: Upper Driveshaft Bearing Installation

  Upper Driveshaft Bearing Installation Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer 1. Press upper driveshaft bearing onto driveshaft. and Driveshaft Installation Lubricate I.D. of bearing with Quicksilver Needle Bearing Assembly Lubricant before pressing in NOTE: If shim(s) were lost or are not reusable (dam- place.

• Page 433: Pinion Gear Location And Forward Gear Backlash

  Pinion Gear Location and Forward 3. Measure distance. Gear Backlash 4. Increase distance by 1 in. (25.4mm). 5. Rotate driveshaft 10 revolutions. This properly DETERMINING PINION GEAR LOCATION seats upper driveshaft tapered roller bearing. NOTE: Read entire procedure before attempting any change in shim thickness.

• Page 434: Determining Forward Gear Backlash

  7. The correct clearance between the gauging sur- Determining Forward Gear Backlash face and the pinion gear is .025 in. (0.64mm). NOTE: Read entire procedure before attempting any 8. To obtain .025 in. (0.64mm), add or subtract change in shim thickness. shims below the upper bearing race to lower or 1.

• Page 435: Bearing Carrier And Propeller Shaft Installation

  7. Install components. Bearing Carrier and Propeller Shaft Installation 1. Insert propeller shaft assembly into bearing carri- 2. Lubricate O-ring and areas shown with Quicksil- ver 2-4-C w/Teflon. 3. Install bearing carrier and propeller shaft assem- bly into gear housing. Use care not to displace cam follower.

• Page 436: Bearing Carrier

  Bearing Carrier 4. Torque bolts to 225 lb. in./18.8 lb ft. (25.4 N m) 1. Install carrier into gear case. 2. Discard the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long bolts on models listed. Install thicker flat washers and longer bolts.

• Page 437: Water Pump Re-Assembly And Installation

  Water Pump Re-assembly and NOTE: If installation tool is not available, press seals in as shown to depths indicated. Installation 0.04 in. (1.02 mm) 1. Place seal on longer shoulder side of tool. 2. Press into water pump base until tool bottoms. 55878 a - Seal (Install with spring visible when installed.) b - Seal (Install with spring visible when installed.)
• Page 438 7. If removed previously, re-install seal and plate. 10. Lubricate I.D. of cover with Quicksilver Needle Bearing Assembly Lubricant. Install gasket with bead toward cover. 51290 Needle Bearing Assy. Lub. (92-825265A1) a - Gasket b - Bead Toward Cover 11. Rotate driveshaft clockwise and push cover down.

• Page 439: Gear Housing Pressure Test

  12. If water tube seal stayed on water tube (inside of 3. Rotate driveshaft, prop shaft and move shift rod driveshaft), pull seal from water tube. while housing is pressurized to check for leaks. 13. Lubricate I.D. of water tube seal with Quicksilver 2-4-C Marine Lubricant and install.

• Page 440: Gear Housing Installation

  Gear Housing Installation Filling Gear Housing with Lubricant NOTE: Gear housing lubricant capacity is approxi- mately 11.5 fl. oz. (340 ml). WARNING If gear housing is installed on outboard, discon- nect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear hous- ing.

• Page 441: Gear Housing Installation

  9. Install locknut and washer. 4. Install water tube seal, spacer and shift shaft cou- pler. 10. Torque bolts and locknut to 40 lb. ft. (54 N·m). 51206 Loctite "405" (Purchase Locally) 2-4-C w/Teflon (92-850736A1)

• Page 442: Propeller Installation

  11. Check shift operation. CAUTION a. Gear housing should not engage when pro- Do not misinterpret propeller shaft movement for peller shaft is turned clockwise when in for- propeller movement, propeller and propeller ward gear. shaft however may move fore-and-aft. However, b.
• Page 443 LOWER UNIT 791-H BIGFOOT GEAR HOUSING 4-1/4 IN. (108 MM) DIAMETER GEAR CASE...
• Page 444 Table of Contents Page Page Specifications ......6C-1 Reassembly ......6C-18 Special Tools .

• Page 445: Specifications

  Specifications Gear Ratio 2.3:1 Gearcase Capacity 22.5 fl. oz. (655 mL) Lubricant Type Quicksilver Gear Lube-Premium Blend Forward Gear Number of Teeth 30 Spiral/Bevel Pinion Gear Number of Teeth 13 Spiral/Bevel Pinion Height 0.025 in. (0.64 mm) Pinion Gear Locating Tool 1998 AND NEWER (91-12349A2) GEAR HOUSING...

• Page 446: Special Tools

  6. Wear Sleeve Installation Tool (91-14310A1) Special Tools 1. Pinion Gear Locating Tool (91-12349A2) 7. Bearing Preload Tool (91-14311A2) 55079 8. Mandrel (91-15755)* 2. Bearing Installation Tool (91-13945) 73815 9. Backlash Indicator Tool (91-19660--1) (4 cyl.) 3. Oil Seal Driver (91-13949) 19660-1 10.
• Page 447 12. Treaded Rod (91-31229) and Nut (91-24156)* 19. Driver Shaft Holding Tool (91-56775) 13. Slide Hammer (91-34569A1) 20. Dial Indicator (91-58222A1) 14. Mandrel (91-36569)* 21. Backlash Indicator Tool (91-78473) (3 cyl.) 15. Universal Puller Plate (91-37241) 22. Puller Bolt (91-85716) 23.

• Page 448: Gear Housing (Drive Shaft)(60 Bigfoot)

  Gear Housing (Drive Shaft)(60 Bigfoot) Loctite "271" Adhesive Sealant (92-809819) Super Duty Gear Lubricant (92-13783A24) 2-4-C w/Teflon (92-825407A12) 41 42 6C-4 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 449 TRIM TAB SCREW (.437-14 x 1.25) 29.8 WASHER CARRIER NEEDLE BEARING ANODE SCREW (M6 x 40) PINION GEAR (Also part of 43-850033A2)(13 TEETH) SHIFT CAM TAPERED ROLLER BEARING SHIM ASSEMBLY DRIVE SHAFT ASSEMBLY (LONG) DRIVE SHAFT ASSEMBLY (LL) WEAR SLEEVE ASSEMBLY...

• Page 450: Gear Housing (Prop Shaft)(60 Bigfoot)

  Gear Housing (Prop Shaft)(60 Bigfoot) Loctite "271" Adhesive Sealant (92-809819) 2-4-C w/Teflon (92-825407A12) 6C-6 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 451 Gear Housing (Prop Shaft)(60 Bigfoot) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – GEAR HOUSING (LONG) BLACK – GEAR HOUSING (LL) – GEAR HOUSING (LONG) GRAY – GEAR HOUSING (LL) GEAR HOUSING ASSEMBLY (BLACK) GEAR HOUSING ASSEMBLY (GRAY) TAPERED ROLLER BEARING ASSEMBLY FORWARD GEAR (30 TEETH) ROLLER BEARING...

• Page 452: Gear Case Identification

  Gear Case Identification Removal CAUTION WARNING Identify gear case design to ensure correct To prevent accidental engine starting, remove components are being installed. Design I - "3 Jaw (and isolate) spark plug leads from spark plugs Reverse Clutch" (a) gear case identified with before removing gear housing.

• Page 453: Water Pump

  Water Pump 1. If water tube seal stayed on water tube (inside of drive shaft housing) when gear housing was re- moved, pull water tube seal from water tube. 2. Replace water tube seal, if damaged. 3. Remove 4 bolts, washers, and isolators. 4.
• Page 454 7. Inspect impeller. Replace impeller if any of the 11. Remove water pump base. following conditions exist: Impeller blade(s) are cracked, torn, or worn. Impeller is glazed or melted (caused by operation without sufficient water supply). Rubber portion of impeller is not bonded to impel- ler hub.

• Page 455: Bearing Carrier And Propeller Shaft

  Bearing Carrier and Propeller Shaft 4. Lift reverse gear, thrust bearing and thrust wash- er from bearing carrier. 1. Remove fasteners. 5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage.
• Page 456 8. If bearing is rusted or does not roll freely, replace 10. Remove spring. bearing. Remove bearing and oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals. * From Bearing Removal and Installation Kit (91-31229A7) 51876 a - Spring 11.

• Page 457: Pinion Gear, Drive Shaft, And Forward Gear

  13. Replace cam follower if worn or pitted. Pinion Gear, Drive Shaft, and Forward Gear 14. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or more of the following: Model Drive Shaft Holding Tool a. Improper shift cable adjustment. 50 Bigfoot (4-Stroke) 91-56775 b.
• Page 458 6. Replace bearing if it is rusted or does not roll free- 8. Replace drive shaft if splines are worn or twisted. ly; use a punch and hammer to remove bearing. 9. If bearing surface is damaged, replace drive shaft and corresponding bearing.

• Page 459: Upper Drive Shaft Bearing

  Upper Drive Shaft Bearing Oil Sleeve 1. Replace upper drive shaft bearing and sleeve if 1. Remove oil sleeve (if necessary) using Puller As- either are rust stained, or if bearing will not roll sembly (91-83165M) with suitable jaws. freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with suitable jaws.

• Page 460: Lower Drive Shaft Bearing Race

  Lower Drive Shaft Bearing Race Shift Shaft IMPORTANT: Retain shim(s) for reassembly. 1. Remove shift shaft coupler and nylon spacer. 1. Remove race and shim(s) using bearing race tool (91-14308A1). 53925 a - Shift Shaft Coupler b - Spacer 2. Remove bolts. 53926 a - Bolts 19171...

• Page 461: Forward Gear Bearing Race

  4. Remove shift cam from housing. Forward Gear Bearing Race 5. Replace shift cam if worn. IMPORTANT: Retain shim(s) for reassembly. If shims are damaged, replace with new shims of equal thickness. 1. Remove race and shim(s) using Slide Hammer (91-34569A1).

• Page 462: Reassembly

  5. Assemble components as shown. Reassembly Forward Gear Bearing Race 1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new gear hous- ing is being assembled, start with 0.010 in. (0.254mm) shim(s). 53928 2. Assemble components as shown; drive race into a - Shift Shaft housing by striking propeller shaft end with lead b - "E"...

• Page 463: Bearing Carrier Reassembly

  50 Bigfoot (4-Stroke) 8. Apply Loctite 271 on bottom half of threads of bolts; install bolts and torque to 35 lb. in. (4.0 N·m). 850307 Loctite 271 (92-809820) 53926 a - Bolts [Torque to 35 lb. in. (4.0 N·m)] 51117 Bearing Carrier Reassembly a - Shift Cam (Numbers Down) b - Hole...
• Page 464 4. Place smaller diameter seal on longer shoulder 8. Install O-ring. of Oil Seal Driver (91-31108) with seal lip away 9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate from shoulder. seal lips with 2-4-C w/Teflon. Lubricate outside 5. Protect lip on front side of bearing carrier using diameter of bearing and bearing carrier bore with Bearing Installation Tool (91-13945).

• Page 465: Forward Gear Reassembly

  12. Install thrust bearing. Coat thrust bearing with Forward Gear Reassembly Quicksilver Gear Lubricant. 1. Press tapered bearing onto gear (press only on inner race of bearing). Quicksilver Gear Lubricant (92-19007A24) 51869 19168 a - Mandrel (91-37350) Quicksilver Gear Lubricant (92-19007A24) b - Bearing;...

• Page 466: Propeller Shaft Reassembly

  6 Jaw Reverse Clutch Propeller Shaft Reassembly 1. Install components into propeller shaft in se- quence shown. 19154 a - Spring b - Guide Block c - 3 Metal Balls* 56784 d - Cam Follower* a - Stamped "6" b - Numbered end of Needle Bearing * Hold in Place With Quicksilver 2-4-C w/Teflon c - 6 Jaw Reverse Clutch 3.

• Page 467: Drive Shaft Wear Sleeve Installation

  Drive Shaft Wear Sleeve Installation 4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); continue press- 1. Install new rubber ring. ing until surface contacts surface. 2. Apply a light coat of Loctite 271 on outside diame- ter of rubber ring.

• Page 468: Lower Drive Shaft Bearing Race Installation

  Lower Drive Shaft Bearing Race Oil Sleeve Installation Installation 1. Install oil sleeve with tab positioned as shown. IMPORTANT: Lower drive shaft bearing cup can be installed with or without upper drive shaft bearing/sleeve and oil sleeve installed. 1. Lubricate O.D. of bearing race with Quicksilver 2-4-C w/Teflon.

• Page 469: Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, And Drive Shaft Installation

  IMPORTANT: Oil sleeve must be installed prior to Forward Gear, Lower Drive Shaft upper drive bearing installation. Bearing, Pinion Gear, and Drive Shaft IMPORTANT: Upper drive shaft bearing/sleeve Installation can be installed with or without lower drive shaft bearing cup installed. Model Drive Shaft Holding Tool 3.

• Page 470: Pinion Gear Depth And Forward Gear Backlash

  Pinion Gear Depth and Forward Gear 3. Measure distance between top of nut and bottom of bolt head. Backlash 4. Increase distance by 1 in. (25.4mm). DETERMINING PINION GEAR DEPTH 5. Rotate drive shaft 5 to 10 revolutions. This should properly seat upper drive shaft tapered roller NOTE: Read entire procedure before attempting any bearing.
• Page 471 6. Assemble Pinion Gear Locating Tool (91-12349A2) 9. Insert tool into forward gear assembly; position as shown; do not tighten collar retaining bolt at proper numbered flat (from chart) of gauging this time. block – under pinion gear. GEAR RATIO (PINION GEAR TEETH/ FLAT REVERSE GEAR TEETH)

• Page 472: Determining Forward Gear Backlash

  12. Determine pinion gear depth by inserting a feeler Determining Forward Gear Backlash gauge thru access hole in locating disc. NOTE: Read entire procedure before attempting any 13. The correct clearance between gauging block change in shim thickness. and pinion gear is 0.025 in. (0.64mm). 1.
• Page 473 5. Install components as shown. 7. Lightly turn drive shaft back and forth (no move- ment should be noticed at propeller shaft). 8. Dial Indicator registers amount of backlash, which must be between specification shown in chart. DIAL INDICATOR READING MINIMUM MODEL MAXIMUM...

• Page 474: Bearing Carrier And Propeller Shaft Installation

  Bearing Carrier and Propeller Shaft 4. Install bearing carrier and propeller shaft into housing with the word "TOP" located on flange to- Installation ward top of housing. 1. Insert propeller shaft assembly into bearing carrier. 2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in.

• Page 475: Water Pump Reassembly And Installation

  Water Pump Reassembly and 3. Place seal on shorter shoulder side of Oil Seal Driver (91-13949) with seal lip toward shoulder. Installation 4. Apply Loctite 271 on O.D. of seal; press seal into 1. Place seal on longer shoulder side of Oil Seal water pump base until tool bottoms.
• Page 476 7. Install components as shown. 9. Install gasket, drive key and impeller. 19220 a - Gasket b - Drive Key Loctite 271 (92-809820) 19217 c - Impeller a - Water Pump Base b - Bolts and Washers; Apply Loctite 271 on bottom 1/2 of 10.

• Page 477: Gear Housing Pressure Test

  Gear Housing Pressure Test Filling Gear Housing With Lubricant 1. Remove vent plug and install pressure test gauge. NOTE: Gear housing lubricant capacity is 22.5 fl. oz. (665.2ml). WARNING If gear housing is installed on engine, to avoid ac- cidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller.

• Page 478: Gearcase Installation

  1. Position outboard shift linkage into forward gear position. Models 40/45/50 Bigfoot (4-Stroke) 53922 a - Vent Screw (Torque to 60 lb. in. (6.8 N·m) b - Fill/Drain Screw (Torque to 60 lb. in. (6.8 N·m) c - Oil Level Vent Screw (Torque to 60 lb.
• Page 479 - Nylon Spacer b - Shift Shaft Coupler; Used on Models Equipped with 2-4-C With Teflon (92-825407A12) Power Trim c - Bushing 40/45/50 Bigfoot (4-Stroke) Only a - Water Tube Seal b - RTV Sealer NON-POWER TRIM MODELS CAUTION Do not use lubricant on top of drive shaft.

• Page 480: Trim Tab Adjustment

  15. Torque bolts and locknut (or nuts only if applica- ble) to 40 lbs. ft. (54.0 N·m). b. If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, ad- just trailing edge of trim tab to the right.
• Page 481 LOWER UNIT JET DRIVE...
• Page 482 Table of Contents Page Jet 30 Pump Assembly ....6D-2 Jet 30 Water Pump Components ..6D-4 Notes: .
• Page 483 Notes: 90-852572R1 JANUARY 1998 LOWER UNIT - 6D-1...

• Page 484: Jet 30 Pump Assembly

  Jet 30 Pump Assembly 2-4-C With Teflon (92-850736A1) 6D-2 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 485 Jet 30 Pump Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – JET PUMP ASSEMBLY (BLACK) HOUSING-Pump HOSE-lube IMPELLER HOUSING-Intake LINER DRIVESHAFT SLEEVE Drive Tight SHIM TAB WASHER SCREW (1/4-20 X 3/4) SCREW (1/4-20 x .875) WASHER SCREW (1/4-20 x .625) WASHER SCREW (.312-18 x 1.25)

• Page 486: Jet 30 Water Pump Components

  Jet 30 Water Pump Components Loctite 271 (92-809819) Loctite 405 2-4-C w/Teflon (92-850736A1) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m SCREW (M6 x 16) WATER PUMP ASSEMBLY SEAL–Water Tube WASHER WASHER GASKET FACE PLATE IMPELLER WATER TUBE EXTENSION GASKET 6D-4 - LOWER UNIT 90-852572R1 JANUARY 1998...

• Page 487: Notes

  Notes: 90-852572R1 JANUARY 1998 LOWER UNIT - 6D-5...

• Page 488: Jet 45 Pump Assembly

  Jet 45 Pump Assembly 6D-6 - LOWER UNIT 90-852572R1 JANUARY 1998...
• Page 489 Jet 45 Pump Assembly TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m – JET PUMP ASSEMBLY (BLACK) HOUSING-Pump HOSE-lube IMPELLER HOUSING-Intake LINER DRIVESHAFT SLEEVE SHIM TAB WASHER STUD (.312-18 x 1.81) SCREW (.312-18 x .1) 17.6 SCREW (1/4-20 x .625) SCREW (.312-18 x 1.25) 17.6 BRACKET...

• Page 490: Jet 45 Water Pump Components

  Jet 45 Water Pump Components 2-4-C With Teflon (92-850736A1) TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m IMPELLER WATER PUMP GASKET (UPPER) SEAL FACE PLATE SCREW 6D-8 - LOWER UNIT 90-852572R1 JANUARY 1998...

• Page 491: Selecting A Boat That Is Best Suited For Jet Power

  Selecting A Boat That Is Engine Horsepower Best Suited For Jet Power Selection To obtain the best performance from the jet drive, the A boat operating at slow speed requires considerably boat should have the following features: more depth than one which is planing on the surface of the water.

• Page 492: Transom Height Of The Boat

  SETTING OUTBOARD MOUNTING HEIGHT ON Transom Height of the Boat BOATS WITH "V" BOTTOM HULLS Outboards with jet drives will be mounted approxi- 1. Measure the width of the leading edge on the wa- mately 7 inches higher on the transom than propeller ter intake housing.

• Page 493: Setting Outboard Mounting Height On Boats With Flat Bottom Hulls

  Setting Outboard Mounting Height When operating the boat, the outboard drive shaft should be vertical when planing or tilted toward the on Boats with Flat Bottom Hulls boat in order to provide a scooping angle on the water intake. Tilting the outboard out beyond a vertical 1.

• Page 494: Shift Cable Installation

  4. Attach the brass barrel to the bracket with bolt Water testing and locknut. Tighten the bolt until it seats against the barrel, then back off the bolt 1/4 turn. Hold bolt Checking for Cavitation (Continued) from turning, and tighten locknut on bolt. The bar- rel must be free to pivot.

• Page 495: Lubricating The Drive Shaft Bearing

  Lubricating The Drive Shaft Impeller Removal and Bearing Installation Recommended Lubrication - Use Quicksilver REMOVAL 2-4-C w/Teflon, or Lubricant 630-AA Grease. 1. Shift outboard to NEUTRAL (N) position. IMPORTANT: It is important that you do not use a general-all-purpose grease for this bearing. 2.
• Page 496 INSTALLATION 3. After setting the impeller height, tighten the im- peller nut snug with a wrench. Secure impeller 1. Grease the drive shaft, shear key, and impeller nut by bending tabs against the flats on the impel- bore. Place the plastic sleeve inside the impeller ler nut.

• Page 497: Steering Pull Adjustment

  Steering Pull Adjustment Worn (Dull) Impeller The steering on some boats will have the tendency to pull towards starboard. This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1/16 in. (1.5mm) toward the star- board side of the outboard.

• Page 498: Flushing The Cooling System

  2. Remove the liner. If the liner is tight, tap on the in- Flushing The Cooling ner edge of the liner with a long drift punch System through the intake grate. NOTE: Apply grease to the liner mounting bolt Use Quicksilver accessory hose coupling Part Num- threads before assembly.
• Page 499 4. Straighten the bent tabs on the impeller nut re- tainer and remove the impeller nut. 5. Pull impeller straight off the shaft. If the impeller is tight, use a hammer and block of wood to rotate the impeller (clockwise) on the shaft until the key- way is directly above the flat on the shaft.

• Page 500: Water Pump Removal And Installation

  b. Impeller is glazed or melted (caused by insuf- Water Pump Removal and ficient water supply.) Installation c. Rubber portion of impeller is not bonded to impeller hub. 1. Install face plate, gasket(s) and impeller key. Removal IMPORTANT: If impeller being installed has been 1.

• Page 501: Bearing Carrier Removal

  Bearing Carrier Removal Bearing Carrier Reassembly 1. Remove 4 bolts securing bearing carrier to jet Installing Lower Seals drive. Install seals into bearing carrier as follows: 1. Install O-ring seals into the top seats of the three passage holes. 2. Install spiral retaining ring into the inner ring groove.

• Page 502: Installing Upper Seals

  Installing Upper Seals Installing Drive Shaft Ball Bearing 1. Install spiral retaining ring into the inner ring 1. If removed, install the bearing thrust ring into the groove of the upper seal housing. groove on the drive shaft. 2. Spread a film of grease around the inside bore of 2.
• Page 503 5. Grease the upper seals and inside bore of the Bearing Carrier Installation bearing carrier to ease entry of the seal housing. 1. Install the bearing carrier into the jet drive. Se- 6. Install the thrust washer against the ball bearing. cure carrier in drive with 4 bolts.

• Page 504: Installing Jet Drive To Drive Shaft Housing

  Installing Jet Drive to Drive Shaft 5. Grease the drive shaft, shear key, and impeller bore. Place the plastic sleeve inside the impeller Housing and install impeller, shear key, shims nut retainer, and impeller nut. Turn the nut tight on the shaft to 1.
• Page 505 7. After setting the impeller height, tighten the im- NOTE: If the outboard is used in salt water, apply peller nut snug with a wrench. Secure impeller Quicksilver Anti-Corrosion Grease around the entire nut by bending tabs against the flats on the impel- mounting flange on the water intake housing and also to the threads on the six mounting bolts.
• Page 506 ATTACHMENTS/CONTROL LINKAGE THROTTLE/SHIFT LINKAGE...
• Page 507 Table of Contents Page Throttle Lever And Linkage 40/50 ..7A-2 Throttle Lever And Linkage 55/60 ..7A-4 7A-0 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...
• Page 508 Notes: 90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7A-1...
• Page 509 Throttle Lever And Linkage 40/50 Loctite "680" (92-809833) 2-4-C w/Teflon (92-850736A1) A = ELECTRIC B = HANDLE VERSIONS 7A-2 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...
• Page 510 Throttle Lever And Linkage 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m THROTTLE LEVER ADJUSTING SCREW JAM NUT WASHER Drive Tight ADJUSTING SCREW (M6 x 55) JAM NUT BUSHING INSERT SCREW (M10 x 45) Drive Tight but Joint...
• Page 511 Throttle Lever And Linkage 55/60 Loctite "680" (92-809833) 2-4-C w/Teflon (92-850736A1) 7A-4 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...
• Page 512 Throttle Lever And Linkage 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m THROTTLE LEVER ADJUSTING SCREW (M5 x 35) JAM NUT WASHER Drive Tight ADJUSTING SCREW (M6 x 55) JAM NUT BUSHING INSERT SCREW (M10 x 45) Drive Tight but Joint must move freely SWIVEL BUSHING...
• Page 513 ATTACHMENTS/CONTROL LINKAGE TILLER HANDLE...
• Page 514 Table of Contents Page Tiller Handle 40/50 ..... 7B-2 Tiller Handle 40/50 .....
• Page 515 Notes: 90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-1...

• Page 516: Tiller Handle 40/50

  Tiller Handle 40/50 2-4-C w/Teflon (92-850736A1) 7B-2 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...

• Page 517: Tiller Handle 40/50

  Tiller Handle 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m COVER KIT PULLEY CASE SCREW (10-16 x 1/2 IN. Self Tap) CABLE–Throttle CABLE–Throttle SLEEVE–Insulation SCREW (M8 x 1.25 Hex flange head) 16.5 22.4 COVER–Side BUSHING ARM–Steering Handle (BLACK) ARM–Steering Handle (GRAY)

• Page 518: Steering Handle Kit 55/60

  Steering Handle Kit 55/60 INSIDE Soap (Purchase Locally) 2-4-C With Teflon (92-850736A1) 7B-4 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...

• Page 519: Steering Handle Kit 55/60

  HOUSING PLATE GASKET SCREW (10-16 x 1/2 IN.) Drive Tight SCREW (10-16 x 3/5 IN.) Drive Tight CLAMP SCREW (M5 x 40) WING NUT THROTTLE HANDLE/STOP SWITCH KIT STOP SWITCH DECAL-Throttle SCREW (10-16 x 3/8 IN.) Drive Tight GRIP J-CLAMP J-CLAMP –...

• Page 520: Steering Handle Kit 55/60

  Steering Handle Kit 55/60 Loctite "271" (92-809819) Special Lubricant 101 (92-13872A1) 2-4-C With Teflon (92-850736A1) Loctite "RCA/680" Retaining Compound (92-809833) 7B-6 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...
• Page 521 Steering Handle Kit 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m BRACKET (BLACK) BRACKET (GRAY) DECAL-Shift STUD (M10 x 58) TAB WASHER 47.5 STOP HARNESS CABLE MANUAL PLUG GROMMET COVER SCREW (10-16 x 1/2 IN.) Drive Tight HORN PLUG (MANUAL) STOP SWITCH...
• Page 522 Steering Handle Kit 55/60 Loctite "271" (92-809819) Special Lubricant 101 (92-13872A1) 2-4-C With Teflon (92-850736A1) Loctite 680 7B-8 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998...
• Page 523 Steering Handle Kit 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m WASHER SHIFT ROD ROD END BUSHING WASHER COTTER PIN DETENT ASSEMBLY SPRING STUD KNOB CO-PILOT LEVER BRAKE CO-PILOT DRIVER WASHER BRAKE DISC ARM (TOP) ARM (BOTTOM) HARNESS ASSEMBLY KEY SWITCH (See below for Keys) DECAL-Trim...

• Page 524: Tiller Arm/Shift Lever Removal

  4. Release latch and remove throttle cable with Tiller Arm/Shift Lever grommet from bottom cowl. Removal 1. Remove battery cables from battery. 51093 a - Rubber Grommet b - Throttle Cable 51084 5. Remove cotter key from shift rod. 2. Remove outboard cowling. 3.
• Page 525 7. Disconnect stop switch wire at bullet connector 9. Remove bolt and nut from tiller handle bracket. and screw securing ground wire. 55336 55339 a - Bolt a - Stop Switch Wire (Bullet Connector) b - Nut (Hidden) 8. Remove plug from tiller handle bracket 10.

• Page 526: Tiller Handle Disassembly

  11. Bend tab washer away form bolt securing shift le- 3. Cut sta-strap securing stop switch harness and ver and remove bolt and lever from bracket. remove screw from harness J-clip. 51603 a - Sta-Strap 51606 b - Screw a - Tab Washer b - Bolt c - Shift Lever 4.
• Page 527 6. Remove allen screw from brass barrel and re- 9. Remove cover plate and gasket from tiller han- move barrel. dle. 10. Remove bolt from throttle friction assembly. 51602 a - Allen Screw b - Brass Barrel 51604 7. Unscrew (counterclockwise) stainless steel con- a - Cover Plate duit from tiller handle.

• Page 528: Tiller Arm Reassembly

  - Gear c - Throttle Friction Device d - Cover 4. Install throttle arm assembly into tiller arm. 5. Torque friction device attaching bolt to 40 lb. in. 51604 (4.5 N·m) a - Gear Drift Pin (FACES UP) 51604 a - Bolt [Torque to 40 lb.
• Page 529 9. Retract throttle cable into gear assembly until ap- 11. Slide brass barrel over throttle cable tube. Se- proximately 17 in. (43 cm) extends from the tiller cure barrel to tube with allen screw approximate- arm. ly 3.5 in. (89 mm) from stainless conduit. DO NOT OVERTIGHTEN screw, as tubing may be crushed, binding throttle cable.
• Page 530 13. Position throttle arm slot to face stop harness exit 15. Sta-strap harness to throttle arm. hole in tiller handle. Route stop switch harness CAUTION through twist grip, into throttle arm, and out through side of tiller handle. Allow enough slack in harness (rotate throttle grip in both directions) before securing harness to handle assembly with J-clip.

• Page 531: Tiller Arm/Shift Lever Installation

  2. Install tiller handle with bushings to bracket. Se- cure in place with washers and bolt with nut. Tighten bolt, allowing tiller handle movement. Torque nut to 40 lb. ft. (54 N·m). 55339 a - Stop Switch Wire (Bullet Connector)

• Page 532: Shift Link Rod Installation And Adjustment To Engine

  5. Install Cover. Shift Link Rod Installation and Adjustment to Engine 1. Position shift handle to neutral. 2. Manually shift outboard (shift actuator lever) to neutral. Propeller turns freely in both directions. 3. Adjust shift link rod end to slip over shift actuator bolt with slight preload toward reverse.

• Page 533: Throttle Cable Installation And Adjustment

  Throttle Cable Installation and 4. Holding throttle lever against idle stop, adjust throttle cable to slip into upper hole of barrel re- Adjustment ceptacle with a very light preload of throttle lever against idle stop. Apply small amount of Loctite 1.

• Page 534: Co-Pilot Installation

  3. Install brake disk and brake. Co-Pilot Installation NOTE: To install Co-Pilot kit, tiller handle must be re- moved and battery cables disconnected. 1. Install brake disk on swivel bracket. Position "bot- tom up" lever, brake disk and "top up" lever onto swivel bracket.

• Page 535: Tiller Handle Installation

  6. Holding components in place (lever facing for- 2. Install tiller handle to studs with shift rod posi- ward), install lock nut and torque to 75 lb. in. (8 tioned thru cowl opening as shown. N·m). 55347 a - Tiller Handle b - Shift Rod c - Cowl a - Locknut [75 lb.

• Page 536: Wiring Harness Connection

  4. Install rubber grommet to throttle cable and install 3. Connect handle wiring harness at engine har- into bottom cowl. Note, a light lubricant on grom- ness connector. met will aid in installation over shift rod. 4. Reconnect battery cables. (–) 51093 51084...
• Page 537 MANUAL STARTER...
• Page 538 Table of Contents Page Starter Assembly (Manual) 40/50 ..Starter Assembly (Manual) 55/60 ..Rewind Starter Disassembly ....
• Page 539 Notes: 90-852572R1 JANUARY 1998 MANUAL STARTER - 8-1...

• Page 540: Starter Assembly (Manual) 40/50

  Starter Assembly (Manual) 40/50 2-4-C w/Teflon (92-825407A12) 8-2 - MANUAL STARTER 90-852572R1 JANUARY 1998...

• Page 541: Starter Assembly (Manual) 40/50

  Starter Assembly (Manual) 40/50 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m HANDLE RETAINER REST--Starter Handle REST SEAL SCREW (M6 x 30) SPACER BUSHING GROMMET WASHER TIMING DECAL INTERLOCK CABLE SCREW (10 -16 x .625) Drive Tight...
• Page 542 Starter Assembly (Manual) 55/60 Cyanacrylate Adhesive (Purchase Locally) 2-4-C w/Teflon (92-825407A12) 8-4 - MANUAL STARTER 90-852572R1 JANUARY 1998...
• Page 543 Starter Assembly (Manual) 55/60 TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N· m HANDLE ASSEMBLY RETAINER REST SEAL SCREW (M6 x 75) SPACER BUSHING GROMMET WASHER INTERLOCK CABLE SCREW Drive Tight WASHER COTTER PIN SCREW Drive Tight COTTER PIN WASHER RECOIL STARTER STARTER HOUSING...

• Page 544: Rewind Starter Disassembly

  Rewind Starter Disassembly 6. Remove cam retainer. WARNING When disassembling and reassembling rewind starter, SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing. 1. Remove retaining clip and attaching screw which secures shift interlock cable to starter housing. 2.

• Page 545: Cleaning And Inspection

  Cleaning and Inspection 8. Remove starter sheave. 1. Clean components in solvent and dry with com- pressed air. 2. Inspect rewind spring for kinks, burrs, corrosion of breakage. 3. Inspect starter sheave, rope guide and starter housing for nicks, grooves, cracks, wear or dis- tortion, especially area of rope travel.

• Page 546: Adjusting Rewind Spring Tension

  2. Install starter sheave to housing and secure in 4. Reinstall cam retainer and secure with screws place with screw. Torque to 135 lb. in. (15.3 N· m). (3). 28374 51605 a - Screws (3) b - Cam Retainer a - Starter Sheave b - Screw Adjusting Rewind Spring Tension...

• Page 547: Starter Interlock Cable Adjustment

  Starter Interlock Cable NOTE: Check operation of rewind and rewind ten- sion before outboard installation. Adjustment 3. Place rewind starter on engine. IMPORTANT: Lubricate core wire of interlock 4. Pull starter rope thru bracket, handle, and starter cable with light oil prior to making adjustments. rope retainer.

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