SERVICE

MANUAL
MODELS
45 Jet • 50 • 55 • 60
45 Jet • 50 • 55 Marathon • 55 SeaPro • 60
60 Big Foot • 60 Marathon • 60 SeaPro
With Serial Numbers
United States . . . . . . . 0D000750 and Above
Belgium . . . . . . . . . . . 09671687 and Above

Printed in U.S.A. 1996, Mercury Marine 90-817643R1 DECEMBER 1996

 We could not possibly know of and advise the service trade
Notice of all conceivable procedures by which a service might be
Throughout this publication, “Dangers”, “Warnings” and performed and of the possible hazards and/or results of
“Cautions” (accompanied by the International HAZARD each method. We have not undertaken any such wide eval-
Symbol ! ) are used to alert the mechanic to special in- uation. Therefore, anyone who uses a service procedure
structions concerning a particular service or operation that and/or tool, which is not recommended by the manufactur-
may be hazardous if performed incorrectly or carelessly. er, first must completely satisfy himself that neither his nor
OBSERVE THEM CAREFULLY! the products safety will be endangered by the service pro-
cedure selected.
These “Safety Alerts” alone cannot eliminate the hazards
that they signal. Strict compliance to these special instruc- All information, illustrations and specifications contained in
tions when performing the service, plus “Common Sense” this manual are based on the latest product information
operation, are major accident prevention measures. available at the time of publication. As required, revisions
to this manual will be sent to all dealers contracted by us
! DANGER to sell and/or service these products.

DANGER - Immediate hazards which WILL result in se- It should be kept in mind, while working on the product, that
vere personal injury or death. the electrical system and ignition system are capable of vi-
olent and damaging short circuits or severe electrical
shocks. When performing any work where electrical termi-
! WARNING nals could possibly be grounded or touched by the me-
WARNING - Hazards or unsafe practices which COULD chanic, the battery cables should be disconnected at the
result in severe personal injury or death. battery.
Any time the intake or exhaust openings are exposed dur-
! CAUTION ing service they should be covered to protect against acci-
dental entrance of foreign material which could enter the
Hazards or unsafe practices which could result in mi-
cylinders and cause extensive internal damage when the
nor personal injury or product or property damage. engine is started.
It is important to note, during any maintenance procedure
replacement fasteners must have the same measure-
Notice to Users of This ments and strength as those removed. Numbers on the
heads of the metric bolts and on the surfaces of metric nuts
Manual indicate their strength. American bolts use radial lines for
This service manual has been written and published by the this purpose, while most American nuts do not have
Service Department of Mercury Marine to aid our dealers’ strength markings. Mismatched or incorrect fasteners can
mechanics and company service personnel when servic- result in damage or malfunction, or possibly personal inju-
ing the products described herein. ry. Therefore, fasteners removed should be saved for re-
use in the same locations whenever possible. Where the
It is assumed that these personnel are familiar with the fasteners are not satisfactory for re-use, care should be
servicing procedures of these products, or like or similar taken to select a replacement that matches the original.
products manufactured and marketed by Mercury Marine,
that they have been trained in the recommended servicing
procedures of these products which includes the use of
mechanics’ common hand tools and the special Mercury
Marine or recommended tools from other suppliers.

90-817643R1 DECEMBER 1996 i

Cleanliness and Care of Service Manual Outline
Outboard Motor Section 1 - General Information & Specifications

A marine power product is a combination of many ma- Section 2 - Electrical & Ignition
chined, honed, polished and lapped surfaces with toler- Part A - Ignition System
ances that are measured in the ten thousands of an
inch./mm When any product component is serviced, care Part B - Battery, Charging System &
and cleanliness are important. Throughout this manual, it Starting System
should be understood that proper cleaning, and protection Part C - Timing/Synchronizing &
of machined surfaces and friction areas is a part of the re- Adjusting
pair procedure. This is considered standard shop practice
even if not specifically stated. Part D - Wiring Diagrams

Whenever components are removed for service, they Section 3 - Fuel Systems
should be retained in order. At the time of installation, they Part A - Carburetion
should be installed in the same locations and with the same
mating surfaces as when removed. Part B - Fuel Pump

Before raising or removing and outboard engine from a Part C - Fuel Enrichment
boat, the following precautions should be adhered to: Part D - Oil Injection
(1) Check that flywheel is secured to end of crankshaft with Section 4 - Powerhead
a locknut and lifting eye is threaded into flywheel a mini-
mum of 5 turns. Section 5 - Mid-Section

(2) Connect a hoist of suitable strength to the lifting eye. Part A - Clamp/Swivel Brackets and
Driveshaft Housing
In addition, personnel should not work on or under an out-
board which is suspended. Outboards should be attached Part B - Power Trim (Design I)
to work stands, or lowered to ground as soon as possible. Part C - Power Trim (Design II)
We reserve the right to make changes to this manual with- Part D - Power Trim (Design III)
out prior notification.
Part E - Power Trim (Design IV)
Refer to dealer service bulletins for other pertinent informa-
tion concerning the products described in this manual. Part F - Manual Tilt (Design I, II, III)
Part G - Manual Tilt (Design IV)
Section 6 - Lower Unit
Part A - Standard Gear Housing
Part B - 60 Big Foot, 60 SeaPro &
Marathon Gear Housing
Part C - Jet Drive
Section 7 - Outboard Installation/
Attachments
Part A - Ride-Guide Steering -
Throttle/Shift Cables &
Electrical Connections
Part B - Tiller Handle and Co-Pilot
Part C - Rewind Starter

ii 90-817643R1 DECEMBER 1996

GENERAL INFORMATION
and SPECIFICATIONS 1

50557
Table of Contents
Page Page
Propeller Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Ride Guide Steering Cable and Pivot
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Point Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1-15
Master Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Gear Housing Lubrication . . . . . . . . . . . . . . . . . 1-16
Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Salt Water Corrosion - Gear Housing
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Bearing Carrier and Cover Nut . . . . . . . . . . 1-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Cowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Flushing Outboard Cooling System . . . . . . . . . . . 1-17
Filling Oil Injection System . . . . . . . . . . . . . . . . . . . . 1-5 Following Complete Submersion . . . . . . . . . . . . . 1-18
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Salt Water Submersion (Special
Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Trim “In” Angle Adjustment . . . . . . . . . . . . . . . . . . . 1-7 Submerged While Running (Special
Propeller Information Chart . . . . . . . . . . . . . . . . . . . 1-8 Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
50/55 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Submerged Engine (Fresh Water)
60 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 (Plus Special Instructions) . . . . . . . . . . . . . . 1-18
Propeller Information Chart . . . . . . . . . . . . . . . . . . . 1-9 Out-of-Season Outboard Storage . . . . . . . . . . . . . 1-19
60 Big foot, 60 SeaPro/Marathon . . . . . . . . . . . 1-9 Out-of-Season Battery Storage . . . . . . . . . . . . . . . 1-19
50-60 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 How Weather Affects Engine Performance . . . . . 1-20
Stainless Steel Race Propellers – Conditions Affecting Operation . . . . . . . . . . . . . . . 1-21
Available from Mercury Performance Detonation: Causes and Prevention . . . . . . . . . . 1-21
Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Compression Check . . . . . . . . . . . . . . . . . . . . . . . . 1-21
General Information: . . . . . . . . . . . . . . . . . . . . . . 1-9 Water Pressure Check . . . . . . . . . . . . . . . . . . . . . . 1-22
Power Trim System Serial Number Location . . . . . . . . . . . . . . . . . . . . . 1-22
(Models with Power Trim) . . . . . . . . . . . . . . . . . . . 1-10 Painting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
General Information . . . . . . . . . . . . . . . . . . . . . . 1-10 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Checking Trim System Fluid Level . . . . . . . . . 1-11
Trimming (Models with Power Trim) . . . . . . . . . . . 1-11
Trimming Outboard “Out” (“Up”) . . . . . . . . . . . 1-11
Trimming Outboard “In” (“Down”) . . . . . . . . . . 1-11
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Boat Performance . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Test Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-0 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

 Section Section Heading
Propeller Information
1 General Information and Specifications
For in-depth information on marine propellers and boat
2 Electrical & Ignition
performance – written by marine engineers – see your Au-
3 Fuel Systems
thorized Dealer for the illustrated “What You Should Know
4 Powerhead
About Quicksilver Propellers... and Boat Performance In-
5 Mid-Section
formation” (Part No. 90-86144).
6 Lower Unit
7 Outboard Installation/Attachments

How To Use This Manual

The manual is divided into SECTIONS (shown, right) which
represents major components and systems. Page Numbering
Some SECTIONS are further divided into PARTS. Each Two number groups appear at the bottom of each page.
PART has a title page. A “Table of Contents” for the particu- The example, below, is self-explanatory.
lar PART is printed on the back of the title page.
SECTIONS and PARTS are listed on the “Service Manual
Outline” sheet which immediately follows the cover of this
book.

EXAMPLE:

EXAMPLE:

90-817643R2 DECEMBER 1996 LOWER UNIT - 6A-7

Revision No. 2 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

Page Number

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-1

Master Specifications
Model 45 Jet/50/55 Marathon-Seapro/60/60 Marathon-Seapro/60 Bigfoot
HORSEPOWER Model 50 50 (37)
(KW) Model 55 55 (41)
Model 60 60 (45)
Model 45 Jet 60 (45)
OUTBOARD Electric Start (ELPTO) 217.0 lbs. (98.4kg)
WEIGHT (ELO) 213.0 lbs. (96.6kg)
Manual Start (ML) 213.0 lbs. (96.6kg)
CYLINDER Type Two-Stoke Cycle – Loop Charged
BLOCK Displacement 51.8 cu. in. (849cc)
STROKE Length 2.520 in. (64.008mm)
CYLINDER Diameter (Std) 2.955 in. (75.057mm)
BORE Taper/Out of Round Maximum 0.003 in. (0.076mm)
Bore Type Cast Iron
PISTON Piston Type Aluminum
Standard 2.950 in. (74.93 mm)
0.015 in. (0.381mm) Oversize 2.965 in. (75.31 mm)
0.030 in. (0.762) Oversize 2.980 in. (75.69 mm)
REEDS Reed Stand 0pen (Max.) 0.020 in. (0.50mm)
Reed Stop (Max.) Not Adjustable
Reed Thickness
– 45 Jet/50/60 0.008 in. (0.203mm)
– 55 0.010 in. (0.254mm)
GEAR 50/55/60
HOUSING Gear Ratio 1.64:1
Gearcase Capacity 11.5 fl. oz. (340ml)
Forward Gear - No. of Teeth 23
Pinion Gear - No. of Teeth 14
Pinion Height 0.025 in. (0.64mm)
Forward Gear Backlash 0.013 in. – 0.019 in.
(0.33mm – 0.48mm)
Water Pressure
– @ Idle 1 – 3 PSI
– @ WOT 7 – 12 PSI
60 SeaPro/Marathon, 60 Bigfoot
Gear Ratio 2.3:1
Gearcase Capacity 22.5 fl. oz. (655ml)
Forward Gear - No. of Teeth-Type 30
Pinion Gear - No. of Teeth-Type 13
Pinion Height 0.025 in. (0.64mm)
Forward Gear Backlash 0.012 in. to 0.019 in. (0.30mm to 0.48mm)
Water Pressure @ RPM 10 to 15 PSI (69 to 103 kPa) @ 5250 RPM
FUEL Fuel Pre-Mixed Gasoline and Oil
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil Quicksilver TC-W II or TC-W3 2 Cycle
Outboard Oil
Gasoline/Oil Ratio 50:1 (25:1 Break-In)
Fuel Pressure – @ Idle 3-1/2 PSI
– @ WOT 6 PSI

1-2 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

 Model 45 Jet/50/55 Marathon-Seapro/60/60 Marathon-Seapro/60 Bigfoot
STARTING Manual Start – All Models Recoil Starter
SYSTEM Electric Start – Optional – All Models
Starter Draw (Under Load) 125 Amperes
Battery Rating Min. Reserve Cap. Rating of 100 Min. and
CCA of 350 Amperes
IGNITION Type Capacitor Discharge
SYSTEM Spark Plug Type NGK BP8H-N-10
Spark Plug Gap 0.040 in. (1.0mm)
CHARGING Alternator Output
SYSTEM Electric Models 16 Amperes @ 3000 RPM
14 Amperes @ 300 RPM
Manual Models (Not Regulated) 9 Amperes @ 3000 RPM
C Idle RPM 675 ± 25
A
R Wide Open Throttle (WOT) RPM 5000 – 5500
B
U Idle Mixture Screw Adjustment
R (Preset - Turns Out)
E Model 50 1-1/8 ± 1/4
T All Other Models 1-1/2 ± 1/4
O
R Float Adjustment
Float Level 7/16 in. (11.2mm)

Main Jet
– Model 50 (WME – 43) .048 in.
– Model 55/60 Seapro-Marathon
(WME – 44) .060 in.
– Model 45 Jet/60 (WME – 45) .062 in.
Vent Jet
– Model 50 (WME – 43) .090 in.
– Model 55/60 Seapro-Marathon
(WME – 44) None
– Model 45 Jet/60 (WME – 45) .090 in.
OIL Recommended Oil Quicksilver TC-W II or TC-W 3
INJECTION
Oil Tank Capacity/Approx. Time 3.0 qts. (2.8L) 7 hrs.
Reserve Capacity/Approx. Time 14.5 fl. oz. (0.43L) 1/2 hr.

Output @ 1500 RPM for 10 Minutes

with Pump @ Full Open 10.0cc ± 3cc
T Idle 2° – 6° ATDC
I Maximum BTDC
M @ Cranking Speed
I – Model 50/60 24° BTDC
N – Model 55/60 Seapro-Marathon 18° BTDC
G @ 5000 RPM
– Model 50/60 22° BTDC
– Model 55/60 Seapro-Marathon 16° BTDC

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-3

Powerhead Reed Block
Reed Stop Opening (Max.) . . . . . . . 0.020 in.
(0.50 mm)
Specifications Crankshaft
Block Runout (Max.) . . . . . . . . . . 0.003 in. (0.08 mm)
Taper (Max.) . . . . . . . . . . . 0.003 in. (0.08 mm)
Type . . . . . . . . . . . . . . . . . . . 3 Cylinder, 2 Cycle
Displacement Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-2
50/55/60 Horsepower . 51.8 cu in. (849 cc)
Cylinder Bore
Special Tools
Dia. Standard . . . . . . . . . . . 2.955 in. (75.057 mm)
Dia. .015 in. Oversize . . . . 2.970 in. (75.438 mm) Description Part Number
Dia. .030 in. Oversize . . . . 2.985 in. (75.819 mm)
Out of Round (Max.) . . . . . 0.003 in. (0.076 mm) Flywheel Holder 91–52344
Taper (Max.) . . . . . . . . . . . . 0.003 in. (0.076 mm) Protector Cap 91-24161
Flywheel Puller 91-73687A1
Piston Lifting Eye 91-90455
Dia. Standard . . . . . . . . . . . 2.950 in. (74.93 mm) Piston Ring Expander 91-24697
Dia. .015 in. Oversize . . . . 2.965 in. (75.31 mm)
Dia. .030 in. Oversize . . . . 2.980 in. (75.69 mm) Piston Pin Tool 91-74607A2
IMPORTANT: Measure piston skirt at right angle (90°) Lock Ring Installation 91-77109A1
to piston pin center line, 0.50 in. (12.7mm) up from bot- Tool
tom edge of skirt. Powerhead Stand 91-25821A1
*Torque Wrench (0–200 91-32610
lb. ft.)
*Torque Wrench (0–150 91-66274
lb. in.)

0.50 in.
Compression Tester 91-29287
(12.7mm)
*May be Obtained Locally

PISTON PISTON SKIRT CYLINDER BORE

SIZE DIAMETER FINISH HONE
Standard 2.950 in. 2.955 in.
Piston (74.93 mm) (75.057mm)

0.015 in. 2.965 in. 2.970 in.

(0.381 mm) (75.31 mm) (75.438 mm)
Oversize
0.030 in. 2.980 in. 2.985 in.
(0.752 mm) (75.69 mm) (75.819 mm)
Oversize

1-4 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

Cowl Removal Filling Oil Injection System
Remove fill cap (a) from the oil tank and fill tank with oil. Re-
tighten the fill cap.

50553 50552

Use Quicksilver NMMA Certified TC-W3 or TC-WII 2-Cycle

Outboard Oil.
• Quicksilver Certified TC-W3 Outboard Oil is a higher
grade oil that provides increased lubrication and extra
resistance to carbon buildup when used with good or va-
rying grades of gasoline.
• Quicksilver Certified TC-WII Outboard Oil is an industry
leading oil that provides superior outboard lubrication
and resistance to carbon buildup when used with good
grades of gasoline.
Periodically consult with your dealer to get the latest gaso-
line and oil recommendations. If Quicksilver 2-Cycle Out-
board Oil is not available, substitute a 2-Cycle outboard
manufacturers oil that is NMMA Certified TC-W3 or TC-
WII, or another brand of 2-Cycle outboard oil that is NMMA
Certified TC-W3 or TC-WII. The use of an inferior 2-Cycle
outboard oil can reduce engine durability. Damage from
use of inferior oil may not be covered under the limited war-
ranty.

50554

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-5

Propeller Selection Propeller Installation
1. Select a propeller that will allow the engine to operate
at or near the top of the recommended full throttle RPM ! WARNING
range (listed in “Specifications,” preceding) with a nor- To avoid accidental starting, which could result in per-
mal load. Maximum engine speed (RPM) for propeller sonal injury, remove spark plug leads from spark
selection exists when boat speed is maximum and trim plugs before working near propeller. Place a block of
is minimum for that speed. (High RPM, caused by an wood between the anti-ventilation plate and propeller
excessive trim angle, should not be used in determin- to protect hands from propeller blades while tighten-
ing correct propeller.) Normally, there is a 150-350 ing propeller nut.
RPM change between propeller pitches.
2. If full throttle operation is below the recommended ! CAUTION
range, the propeller MUST BE changed to one with a
lower pitch to prevent loss of performance and possi- If the propeller moves forward-and-aft on the propeller
ble engine damage. shaft (is loose), retighten the propeller nut. Operation
with a loose propeller could cause damage to the
3. For better acceleration, such as is needed in water thrust hub and gear housing during acceleration, de-
skiing, changing to a different pitch to increase the celeration or when shifting gears.
engine speed to 500 RPM above the recommended
range is advised. Continuous operation above the rec- IMPORTANT: To assure that the propeller remains se-
ommended maximum RPM, however, is not permissi- cure on the shaft during the season, periodically
ble. check propeller shaft nut for tightness.

4. After initial propeller installation, the following common 1. To aid in future removal of the propeller, liberally coat
conditions may require that the propeller be changed the propeller shaft spline with one of the following
to a lower pitch: Quicksilver lubricants:
– Anti-Corrosion Grease
a. Warmer weather and great humidity will cause an – 2-4-C Marine Lubricant
RPM loss. – Special Lubricant 101
b. Operating in a higher elevation causes an RPM 2. Place forward thrust hub on propeller shaft.
loss.
c. Operating with a damaged propeller or a dirty boat
bottom or gear housing will cause an RPM loss.
d. Operation with an increased load (additional pas- a
sengers, equipment, pulling skiers, etc.). b

50551
a - Thrust Hub
b - Propeller Shaft

1-6 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

3. While aligning splines, place Quicksilver propeller and Water test the boat not using the trim adjustment pin. If un-
tab washer on propeller shaft in this order. desirable and/or unsafe steering conditions are experi-
enced (boat runs with nose down), install trim adjustment
4. To prevent propeller from rotating, place a flat block of
pin in proper hole to prevent unsafe handling characteris-
wood between the anti-ventilation plate and the
tics.
propeller.
5. Thread propeller nut on propeller shaft, tighten secure-
ly with wrench [minimum of 55 lb. ft. (74.5 N·m) of
torque] and bend on tab washer to secure propeller
nut.
6. After first use, bend the tab straight, retighten propeller
nut [minimum of 55 lb. ft. (74.5 N⋅m) of torque] and
again bend tab washer to secure nut. Check propeller
periodically for tightness.

c
d

51119
c - Tab Washer
d - Propeller Nut
Installing and Removing Propeller 50157

Trim “In” Angle Adjustment

! WARNING
Operating some boats with outboard trimmed to the
full “in” trim angle [not using trim adjustment bolt (a)]
at planing speed will cause undesirable and/or unsafe
steering conditions. Each boat must be water tested
for handling characteristics after outboard installation
and after any trim adjustments.
IMPORTANT: Some boat/outboard combinations, that
do not use the trim adjustment pin (a) and are trimmed
to the full “in” trim angle, will not experience any unde-
sirable and/or unsafe steering conditions during plan-
ing speed. Thus, not using trim adjustment pin may be
desired. However, some boats with outboard trimmed
to the full “in” trim angle at planing speeds will cause
undesirable and/or unsafe steering conditions. If
these steering conditions are experienced, under no
circumstances should the outboard be operated with-
out the trim adjustment pin and without the pin ad-
justed in the proper holes to prevent unsafe handling
characteristics.

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-7

 Propeller Information Chart
50/55 MODELS
Wide Open Throttle RPM: 5000-5500
Recommended Transom Height: Short Shaft 16-1/2 in. (41.9 cm), Long Shaft 21 in. (53.3 cm)
Right Hand Rotation
Gear Reduction: 1.64:1
Thrust Hub: 73345A 1
Approx. Approx. Speed
No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (Lbs.) Length (MPH) Part Number
10″ 19″ 3 Alum Up to 700 Up to 14′ 48-55 48-73146A400
10″ 17″ 3 Alum Up to 800 Up to 15′ 44-51 48-73144A400
10″ 16″ 3 Steel 700-900 Up to 15′ 41-48 48-91818A500
10″ 16″ 3 Alum 700-900 Up to 15′ 41-48 48-73142A400
10.13″ 15″ 3 Steel 800-1100 13′ to 15′ 38-45 48-76232A500
10.13″ 15″ 3 Alum 800-1100 13′ to 15′ 38-45 48-73140A400
10.38″ 14″ 3 Alum 900-1300 14′ to 16′ 35-41 48-816706A40
10-1/4″ 14″ 3 Steel 900-1300 14′ to 16′ 35-41 48-76230A500
10.38″ 13″ 3 Steel 1000-1500 14′ to 17′ 32-38 48-76228A500
10-1/2″ 13″ 3 Alum 1000-1500 14′ to 17′ 32-38 48-816704A40
10.63″ 12″ 3 Steel 1100-1700 15′ to 17′ 28-34 48-79792A500
10-3/4″ 12″ 3 Alum 1100-1700 15′ to 17′ 28-34 48-816702A40
10.88″ 11″ 3 Alum 1200-1900 16′ to 18′ 24-30 48-85632A400
12″ 10-1/2″ 3 Alum 1400-2100 16′ + 22-28 48-42740A100
11-1/4″ 10″ 3 Alum 1500-2300 17′ + 20-26 48-73132A400
12-1/4″ 9″ 3 Steel 1800 + 18′ + 14-22 48-97868A500
12-1/4″ 9″ 3 Alum 1800 + 18′ + 14-22 48-87818A100
12-1/2″ 8″ 3 Alum 2100 + 18′ + 01-18 48-42738A100

60 MODELS
Wide Open Throttle RPM: 5000-5500
Recommended Transom Height: Short Shaft 16-1/2 in. (41.9 cm), Long Shaft 20 in. (53.3 cm)
Right Hand Rotation
Gear Reduction: 1.64:1
Thrust Hub: 73345A 1
Approx. Approx. Speed
No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (Lbs.) Length (MPH) Part Number
10″ 19″ 3 Alum Up to 8000 Up to 14′ 48-55 48-73146A400
10″ 17″ 3 Alum Up to 1000 Up to 15′ 44-51 48-73144A400
10″ 16″ 3 Steel 700-1100 Up to 15′ 41-48 48-91818A500
10″ 16″ 3 Alum 700-1100 Up to 15′ 41-48 48-73142A400
10.13″ 15″ 3 Steel 800-1200 13′ to 15′ 38-45 48-76232A500
10.13″ 15″ 3 Alum 800-1200 13′ to 15′ 38-45 48-73140A400
10.38″ 14″ 3 Alum 900-1500 14′ to 16′ 35-41 48-816706A40
10-1/4″ 14″ 3 Steel 900-1500 14′ to 16′ 35-41 48-76230A500
10.38″ 13″ 3 Steel 1200-1800 15′ to 17′ 32-38 48-76228A500
10-1/2″ 13″ 3 Alum 1200-1800 15′ to 17′ 32-38 48-816704A40
10.63″ 12″ 3 Steel 1500-2100 16′ to 18′ 28-34 48-79792A500
10-3/4″ 12″ 3 Alum 1500-2100 16′ to 18′ 28-34 48-816702A40
10.88″ 11″ 3 Alum 1800-2400 16′ to 18′ 24-30 48-85632A400
12″ 10-1/2″ 3 Alum 2000-2600 17′ + 22-28 48-42740A100
11-1/4″ 10″ 3 Alum 2100-2600 17′ + 20-26 48-73132A400
12-1/4″ 9″ 3 Steel 2400 + 18′ + 14-22 48-97868A500
12-1/4″ 9″ 3 Alum 2400 + 18′ + 14-22 48-87818A100
12-1/2″ 8″ 3 Alum 2800 + 19′ + 01-18 48-42738A100

1-8 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

 Propeller Information Chart
60 BIG FOOT, 60 SEAPRO/MARATHON MODELS
Wide Open Throttle RPM: 5000-5500
Recommended Transom Height: Short Shaft 16-1/2 in. (41.9 cm), Long Shaft 21 in. (53.3 cm),
Extra Long Shaft 23-1/2 in. (59.7cm)
Right Hand Rotation, 4-1/4 in. Gear Case Torpedo
Gear Reduction: 2.3:1
Thrust Hub : 13191A1
Approx. Approx. Speed
No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (Lbs.) Length (MPH) Part Number
12-3/4″ 26″ 5 Steel Up to 800 Up to 15′ 48-55 48-815748A400
13-1/2″ 26″ 3 Steel Up to 800 Up to 15′ 48-54 48-16996A40 0
12-3/4″ 24″ 5 Steel Up to 1000 Up to 15′ 46-52 48-815746A400
13-1/2″ 24″ 3 Steel Up to 1000 Up to 15′ 46-52 48-16994A40 0
12-1/2″ 23″ 3 Alum 700-1100 Up to 15′ 45-51 48-77350A4000
12-3/4″ 22″ 5 Steel 700-1100 Up to 15′ 43-49 48-815744A400
13-1/2″ 22″ 3 Steel 700-1100 Up to 16′ 43-49 48-16992A40
12-3/4″ 21″ 3 Alum 800-1200 13′ to 16′ 40-47 48-77348A4000
12-3/4″ 20″ 5 Steel 800-1200 13′ to 16′ 38-45 48-816612A400
13-1/2″ 20″ 3 Steel 800-1200 13′ to 16′ 38-45 48-16990A40
13″ 19″ 3 Alum 1000-1500 14′ to 17′ 35-42 48-77346A40 0
13″ 18″ 3 Steel 1000-1500 14′ to 17′ 33-40 48-16988A 5
13-1/4″ 17″ 3 Alum 1300-1800 15′ to 18′ 31-38 48-77344A40 0
13-1/8″ 16″ 3 Steel 1300-1800 15′ to 18′ 29-36 48-16986A 5 0
13-3/4″ 15″ 3 Alum 1600-2200 16′ to 19′ 26-33 48-77342A40 0
13-3/8″ 14″ 3 Steel 1600-2200 16′ to 19′ 23-31 48-17314A 500
14″ 13″ 3 Alum 2000-2600 17′ + 20-28 48-77340A40 0
14″ 12″ 3 Steel 2000-2600 17′ + 17-26 48-17312A 5 0
14″ 11″ 3 Alum 2400 + 18′ + 1-22 48-77338A40 0
14″ 10″ 3 Steel 2800 + 19′ + 1-20 48-17310A 5

0
50-60 MODELS
Stainless Steel Race Propellers – Available from Mercury Performance Products
No. of Propeller
Diameter Pitch Blades Rotation Part Number
11″ 18″ 3 RH 48-66106
11″ 20″ 3 RH 48-66108
11″ 22″ 3 RH 48-66110

GENERAL INFORMATION:
Propeller-Drive Hub: 43676
Diffuser Rings: Alum Propellers – 32201

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-9

Power Trim System Trim System Design II

(Models with Power Trim)

GENERAL INFORMATION
NOTE: 50/60 models are not equipped with Trim System
Design I. See chart below. a

Model Design I Design II Design III b

40 (4cyl) X X X
50/60 X X

50158 50146

The power trim system is filled at the manufacturer and is Trim System Design III
ready for use.
Trim outboard through entire trailering range several times
to remove any air from the system.
The trim system is pressurized and is not externally vented.
The outboard can be raised or lowered manually by loos-
ening the manual release valve 2 to 3 turns counterclock-
wise. a
a
The trim “out” angle of this outboard is not adjustable. The
trim system has an internal valve which will automatically
stop the outward trim travel at 20° when engine RPM is ap-
proximately 2000 RPM or higher; outboard also has to be
in water and in gear.
52029 52028
The outboard can be operated beyond the 20° trim limit for a - Fill Screw (System is Pressurized, DO NOT Open Unless Outboard
operating outboard in shallow water if engine RPM is kept is Tilted to Full Up Position)
b - Manual Tilt Release Valve Location
below approximately 2000 RPM.

1-10 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

CHECKING TRIM SYSTEM FLUID LEVEL TRIMMING OUTBOARD “OUT” (“UP”) CHARACTER-
ISTICS
IMPORTANT: This trim system is pressurized. Remove
fill screw when outboard is trimmed to the full “up” po-
sition. Retighten fill screw securely. ! WARNING
1. Trim outboard to full “up” position. Engage tilt lock lever Excessive trim “out” also may reduce the stability of
(a). Trim system fluid can only be checked when out- some high speed hulls. To correct instability at high
board is in this position. speed, reduce the power GRADUALLY and trim the
outboard “in” slightly before resuming high speed op-
eration. (Rapid reduction in power will cause a sudden
change of steering torque and may cause additional
momentary boat instability.)
1. Will lift bow of boat, generally increasing top speed.
a 2. Transfers steering torque harder to left on standard or
slightly elevated transom installation (single out-
board).
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced water
supply can cause serious overheating.

TRIMMING OUTBOARD “IN” (“DOWN”)

CHARACTERISTICS

50157 ! WARNING
Excessive speed at minimum trim “in” may cause un-
2. Remove fill screw and check fluid level. Fluid level
should be to bottom of threads in fill hole (b). desirable and/or unsafe steering conditions. Each
boat should be tested for handling characteristics af-
3. If necessary, add Quicksilver Power Trim & Steering ter any adjustment is made to the trim angle (trim ad-
Fluid or; Automatic Transmission Fluid (ATF) Type F, justment pin relocation).
FA or Dexron II fluid to trim system.
1. Will help planing off, particularly with a heavy load.
4. Reinstall fill screw.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or right
Trimming (Models with Power Trim) (bow steer).
4. Transfers steering torque harder to right (or less to the
NOTE: Because varying hull designs react differently in
left) on single outboard installations.
various degrees of rough water, it is recommended to ex-
periment with trim positions to determine whether trimming 5. Improves planing speed acceleration.
up or down will improve the ride in rough water.
When trimming your outboard from a mid-trim position (trim
tab in neutral straight fore-and-aft position), you can expect
the following results:

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-11

Trim Tab Adjustment Boat Performance
1. Check trim tab position as follows: TEST INSTRUCTIONS
a. Operate boat at the speed at which it would nor-
mally be operated. ! WARNING
b. If the boat pulls to the right (starboard), the trailing A tight grip on the steering wheel/tiller handle is
edge of trim tab must be moved to the right. If the always advisable and is required when accelerating,
boat pulls to the left (port), the trailing edge of trim decelerating or when trimming the boat. On models
tab must be moved to the left. with Power Trim, upon reaching cruising speed, the
outboard should be trimmed to obtain a balanced
2. If necessary, adjust trim tab as follows: steering condition. While trimming, steering loads will
a. Shift outboard control into neutral and turn ignition vary and will pull in one direction until a balanced
key to “Off” position. condition has been attained. If the outboard is trimmed
past the balanced steering condition, the steering
b. Loosen bolt (c) and trim tab (b). wheel/tiller handle then will have a tendency to pull in
c. If boat pulls to the left, adjust trailing edge of trim the opposite direction. Excessive trimming past the
tab to the left. If boat pulls to the right, adjust trailing balanced steering position will result in increased
edge of trim tab to the right. steering loads and, in most boat applications, a
decrease in performance.
d. Tighten trim tab bolt securely.
e. Operate boat per “Check trim tab position as ! CAUTION
follows,” to check trim tab setting. If necessary
readjust trim tab. When trimming boat with dual outboards, both out-
boards should be at approximately the same tilt angle
and be tilted out (up) simultaneously (to prevent boat
from veering side-to-side) until desired boat attitude is
achieved. Outboards can then be trimmed individually
to precisely adjust boat trim angle and pitch.
a
1. With boat in water, trim the outboard(s) (trim button in
remote control handle) so that the decal on the side of
cowl is horizontal. This is a typical average setting that
should give reasonable acceleration and top speed.
2. Go for a short familiarization ride at various throttle and
trim settings BEFORE starting testing.
NOTE: Instruments should be read with eye directly in front
b to eliminate any error in reading the instruments.
3. When making either top speed or acceleration runs,
best accuracy will be obtained by running with or
c against any wind. Side winds require driving in a con-
stant turn to keep the boat moving straight-ahead. If
winds are 10 MPH (16 km/hr) or greater, it is suggested
that all acceleration runs be made downwind.
4. The top speed WOT (wide-open-throttle) test should
be done with the boat normally loaded (to duplicate
50553
actual running conditions). Operate boat in gear at
WOT and check RPM. Engine RPM must be within the
a - Anti-Ventilation Plate recommended full throttle RPM range (listed in the
b - Adjustable Trim Tab Operation and Maintenance Manual).
c - Bolt
NOTE: When performing an acceleration test, it is
recommended that a stop watch be used to improve testing
accuracy. A wrist watch with a second hand may also be
substituted.

1-12 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

 BOAT TEST CHART (Example)

Propeller Acceleration Propeller Break Loose Wind during Run

WOT WOT Water Air
Diameter Time
RPM MPH During Condition Temperature Comments
and in Seconds During
Pitch
* *
Acceleration Turns
Direction MPH (°F)

10 1/8 ” x 5450 35 7 slight no 5 3” 73

15 5700 34 6 no no 5 chop 73
10 1/4 ” x

*WOT is wide-open-throttle

5. An acceleration test can also be performed if desired. 7. It is suggested that all applicable data be recorded on
Start the test with boat motionless in the water and out- a chart (such as that illustrated, above) and retained
board in neutral. A stop watch should be started as the for future reference.
throttle is quickly pushed to WOT (wide-open-throttle).
8. After several propellers of different pitch and/or design
Stop the watch as the speedometer needle sweeps
have been tried, select one that best serves the gener-
past 20 MPH (32 km/hr). Several runs should be made
al purpose of the boat. The selected propeller should
to assure a good average.
enable the engine to operate within its recommended
6. Prop “break loose” (sudden higher RPM), if not exces- full throttle RPM range, without excessive propeller
sive, in some cases can be beneficial during accelera- “break loose” during acceleration or turns. A second
tion. If undesirable “break loose” occurs, it can be de- propeller that would make both a suitable spare or a
creased by trimming the outboard further under. If it special purpose alternate might also be desirable.
remains excessive with all similar propellers, the out-
NOTE: A higher pitch often gives best top speed, but the
board must be lowered.
next lower pitch gives adequate top speed with much better
acceleration.

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-13

Lubrication Points 1 1 1
Item Type of Fresh Water Salt Water
Description
No. Lubricant Frequency Frequency

Throttle/Shift
1 Linkage
Pivot Points
Upper
2 Shift Quicksilver
Shaft 2-4-C w/Te- Every Every
3 Swivel Pin flon 60 Days 30 Days
Marine 1
Ride Guide Lubricant
4 Steering
Cable
5 Tilt Tube 1
1 1
Steering SAE 30W
1
Every Every
6 Link Rod Motor Oil 60 Days 30 Days
Pivot Points
50554
1 - Throttle/Shift Linkage Pivot Point Lubrication
Quicksilver
-Anti-Corro-
7 Propeller sion Grease Once in Every
Shaft Season 60 Days

8 Starter Motor SAE 30W Once in Every

Pinion Gear Motor Oil Season 60 Days
Quicksilver After first 20
Gear
9 2-4-C w/Te- Hours, then
Housing
* Bearing flon once in
Carrier Marine season
Lubricant

Check and fill Check and fill

after first 10 after first 10
days, then days, then
every 30 days every 30 days
2

10 Gear Quicksilver Drain and re- Drain and re-

◊ Housing Gear Lube fill after 1st 25 fill after 1st 25
hours, then hours, then
after every after every 2
100 hours, or 100 hours, or 51122
once a year once a year 2 - Upper Shift Shaft Lubrication
before storing before storing

Engine Quicksilver
Crankshaft 2-4-C w/Te-
∆ Splines to flon
Once in
Season
Once in
Season
Drive Shaft Marine
Splines Lubricant

* Refer to lubrication instructions outlined in “Salt Water Corrosion -

Gear Housing Bearing Carrier and Cover Nut” of this section (see
“Table of Contents”).

◊ Refer to “Gear Housing Lubrication” of this section (see “Table of

Contents”).

∆ Refer to “Gear Housing Removal and Installation” (Section 5).

1-14 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

 7
3

50551
7 - Propeller Shaft Lubrication (a)

50157
8
3 - Swivel Pin Grease Fittings

RIDE GUIDE STEERING CABLE and PIVOT POINTS

LUBRICATION

! WARNING
Core of steering cable (transom end) must be fully
retracted into cable housing before lubricating cable.
If cable is lubricated while extended, hydraulic lock of
cable could occur.
With core of Ride Guide Steering cable (transom end) fully
retracted, lubricate transom end of steering cable thru 51118
grease fitting and exposed portion of cable end with Quick- 8 - Rotate Starter Motor Pinion Gear To Expose Shaft and Lubricate
silver 2-4-C Marine Lubricant. Lubricate all pivot points with
SAE 30W engine oil.

6
4

50334 10
4 - Ride Guide Steering Grease Fitting
5 - Tilt Tube Grease Fitting 9
6 - Steering Link Rod Pivot Point Lubrication 50558
Gear Housing Lubrication

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-15

GEAR HOUSING LUBRICATION 5. Note color of gear lubricant. White or cream color indi-
cates presence of water in lubricant. Gear lubricant
NOTE: Refer to “Specifications,” for gear housing lubricant
which has been drained from a gear housing recently
capacity.
in operation will have a yellowish color due to lubricant
agitation/aeration. This is normal and should not be
! WARNING confused with the presence of water.
If gear housing is installed on outboard, to avoid acci- 6. Presence of water in gear lubricant indicates the need
dental starting, disconnect (and isolate) spark plug for disassembly and inspection of oil seals, seal sur-
leads from spark plugs before working near the pro- faces, O-rings, water pump gaskets as well as gear
peller. housing components for damage.
IMPORTANT: Never add lubricant to gear housing
! CAUTION without first removing VENT plugs, as trapped air will
Do not use automotive grease in the gear housing. Use prevent housing from being filled. Fill gear housing
only Quicksilver Gear Lube or Quicksilver Super-Duty only when outboard is in operating position.
Lower Unit Lubricant. 7. With outboard in operating position, insert lubricant
1. Tilt outboard so that lubricant in gear housing will drain tube into fill hole.
toward front of housing, out fill hole and into clean con- 8. Fill gear housing until excess lubricant flows from for-
tainer. ward VENT hole.
IMPORTANT: Inspect FILL and VENT plug washers for 9. Install VENT plug and washer (a).
damage. Use new washer as needed.
10. Continue to fill gear housing until lubricant flows from
2. Remove lubricant fill plug and washer. Note amount of VENT hole.
metal particles on magnetic fill plug.
11. Install VENT plug and washer (c).
3. Remove VENT plugs and washers (a and c) and allow
all lubricant to drain. 12. Clean magnet on FILL plug and install FILL plug and
washer (b).

SALT WATER CORROSION - GEAR HOUSING

BEARING CARRIER and COVER NUT
Salt water corrosion buildup can be sufficient to split a gear
housing and destroy an entire lower unit. To protect against
such damage, therefore, it is recommended that the gear
housing bearing carrier be lubricated on a regular basis, as
follows:
c
a Service first at the 20-hour inspection, then on an annual
basis. Remove the entire bearing carrier to adequately
clean corrosive deposits and dried-up lubricant from both
ends of the bearing carrier, as well as the gear housing.
Apply a liberal amount of 2-4-C w/Teflon Marine Lubricant
to the 2 ends of the bearing carrier, then reassemble and
b torque to specifications. Refer to gear housing disassem-
bly and reassembly (Section 6A).

50558
a - Lubricant VENT Plug/Washer
b - Lubricant Fill Plug/Washer
c - Lubricant VENT Plug/Washer

4. Inspect gear lubricant for metal particles (lubricant will

have a “metal flake” appearance). Presence of fine
metal particles (resembling powder) on the FILL plug
bar magnet indicates normal wear. The presence of
metal chips on the drain plug bar magnet indicates the
need for gear housing disassembly and components
inspection.

1-16 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

Periodic Inspection Flushing Outboard Cooling System
Conduct a periodic, systematic inspection to uncover and
correct a failure before it can cause inconvenience or me- ! WARNING
chanical damage. Inspection interval is based on average When flushing, be certain that area in vicinity of pro-
operating conditions in recreation service. Under severe peller is clear and that no person is standing nearby –
conditions, the inspection interval should be shortened. In- to avoid possible injury. It is recommended to remove
spection includes: propeller as a precautionary measure.
1. Clean entire unit thoroughly, including all accessible 1. Install Quicksilver Flushing Attachment (73971A2) [or
powerhead parts. equivalent tool] on the gear housing from the FRONT
2. Check entire unit for loose, damaged or missing parts. side, positioning the rubber cups over the water intake
Tighten or replace as required. openings.
3. Lubricate gear housing.
4. Lubricate other points as indicated, previously.
5. Lubricate starter motor shaft with light film of SAE 10W
motor oil. Do not over-lubricate.
6. Service spark plugs. Inspect spark plug leads and
electrical leads for damage or deterioration, as ex-
plained in Section 2 “Electrical and Ignition”.
7. Inspect fuel lines for damage or deterioration and ser-
vice fuel filters as indicated in Section 3 “Fuel System
and Carburetion.” b
8. Remove propeller and inspect. Trim nicks and burrs
with a file, being careful not to remove more metal than
absolutely necessary. Inspect for cracks, damage or
bent condition. If condition is doubtful, refer to autho-
rized Quicksilver Propeller Repair Station facilities.
a
Before reinstalling propeller, coat propeller shaft with 50551
Quicksilver Special Lubricant 101, Anti-Corrosion a - Water Hose (1/2 in. [13mm] I.D. or Larger)
Grease or 2-4-C w/Teflon Marine Lubricant. b - Flushing Attachment (73971A2)
(Typical Gear Housing)
9. Inspect the outboard surface finish for damage or
corrosion. Thoroughly clean damaged or corroded 2. Connect hose (1/2 in. [13mm] I.D. or larger) between
areas and apply matching paint (Quicksilver Spray flushing attachment and water tap.
Paints). IMPORTANT: To prevent water pump damage, do not
10. Check trim tab and galvanic corrosion sacrificial anode start or run engine unless cooling water is flowing.
for damage or for deterioration from salt water 3. With the outboard in normal operating position (verti-
operation. cal), partially open water tap (IT MAY NOT BE NECES-
11. Check remote controls and steering. Be sure that all SARY to use full water pressure) and adjust water flow
connections and fittings are in good condition, properly so that there is a significant water loss around the rub-
secured and correctly adjusted. ber cups.

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-17

4. Start engine and idle in neutral. Then increase engine SUBMERGED ENGINE (FRESH WATER)
speed, not to exceed 2500 RPM. (PLUS SPECIAL INSTRUCTIONS)
5. Flush or service engine as required. Be sure adequate 1. Recover engine as quickly as possible.
cooling water is provided.
2. Remove cowling.
a. Water must be discharged thru “tell-tale outlet.”
3. Flush exterior of outboard with fresh water to remove
IMPORTANT: Prevent engine overheating. If water flow mud, weeds, etc. DO NOT attempt to start engine if
is insufficient, stop engine and determine cause be- sand has entered powerhead, as powerhead will be
fore continuing. severely damaged. Disassemble powerhead if neces-
sary to clean components.
b. Flush until discharged water is clear. In saltwater
areas, run outboard 3 to 5 minutes. 4. Remove spark plugs and get as much water as possi-
ble out of powerhead. Most water can be eliminated by
c. Stop engine before turning off water.
placing engine in a horizontal position (with spark plug
6. Stop engine, turn water off and remove flushing attach- holes down) and rotating flywheel.
ment from gear housing.
5. Pour alcohol into carburetor throat (alcohol will absorb
IMPORTANT: While and after flushing, keep outboard water). Again rotate flywheel.
in upright position until all water has drained from
6. Turn engine over and pour alcohol into spark plug
drive shaft housing to prevent water from entering the
openings and again rotate flywheel.
powerhead via drive shaft housing and exhaust ports.
7. Turn engine over (place spark plug openings down)
and pour engine oil into throats of carburetors while
Following Complete Submersion rotating flywheel to distribute oil throughout crankcase.
8. Again turn engine over and pour approximately one
Submerged engine treatment is divided into 3 distinct teaspoon of engine oil into each spark plug opening.
problem areas. The most critical is submersion in salt Again rotate flywheel to distribute oil in cylinders.
water; the second is submersion while running.
9. Remove and clean carburetors and fuel pump assem-
SALT WATER SUBMERSION (SPECIAL bly.
INSTRUCTIONS) 10. Reinstall spark plugs, carburetors and fuel pump.
Due to the corrosive effect of salt water on internal engine 11. Attempt to start engine, using a fresh fuel source. If
components, complete disassembly is necessary before engine starts, it should be run for at least one hour to
any attempt is made to start the engine. eliminate any water in engine.
12. If engine fails to start, determine cause (fuel, electrical
SUBMERGED WHILE RUNNING (SPECIAL
or mechanical). Engine should be run within 2 hours
INSTRUCTIONS)
after recovery of outboard from water, as serious inter-
When an engine is submerged while running, the possibil- nal damage may occur. If unable to start engine in this
ity of internal engine damage is greatly increased. If, after period, disassemble engine and clean all parts and
engine is recovered and with spark plugs removed, engine apply oil as soon as possible.
fails to rotate freely when turning flywheel, the possibility of
internal damage (bent connecting rod and/or bent crank-
shaft) exists. If this is the case, the powerhead must be
disassembled.

1-18 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

Out-of-Season Outboard Storage 10. If the water pickup is clogged, the speedometer will be
inoperative. Clean the pickup with a piece of wire or
blow out with compressed air. Before blowing out with
! WARNING air, disconnect the tubing from the speedometer.
As a safety precaution, when boat is in storage, 11. To prevent freeze damage, drain the speedometer
remove positive (+) battery cable. This will eliminate system of water completely before storage. Remove
possibility of accidental starting of engine and resul- tubing from speedometer fitting and blow thru the
tant overheating and damage to engine from lack of tubing to remove water.
water.
12. Store battery as outlined in “Out-of-Season Battery
In preparing an outboard for out-of-season storage, 2 pre- Storage,” following.
cautions must be considered: 1) The engine must be pro-
tected from physical damage and 2) the engine must be 13. For out-of-season storage information on Autoblend
protected from rust, corrosion and dirt. units, refer to Section 8 in this service manual.

1. Remove cowling from engine. IMPORTANT: When storing outboard for the winter, be
sure that all water drain holes in gear housing are open
2. Place outboard in water or install Quicksilver Flushing and free so that all water will drain out. If a speedome-
Attachment over water intake by following instructions ter is installed in the boat, disconnect the pickup tube
outlined in “Flushing Cooling System” (see “Table of and allow it to drain. Reconnect the tube after draining.
Contents”). Trapped water may freeze and expand, thus cracking
3. Start engine and allow to warm up. Disconnect fuel gear housing and/or water pump housing. Check and
line. When engine starts to stall quickly spray Quicksil- refill gear housing with Quicksilver Gear Lube before
ver Storage Seal into each carburetor throat. Continue storage to protect against possible water leakage into
to spray until engine dies from lack of fuel. gear housing which is caused by loose lubricant vent
plug or loose grease fill plug. Inspect gaskets under
4. Remove spark plugs and inject a 5 second spray of lubricant vent and fill plugs, replacing any damaged
Quicksilver Storage Seal around the inside of each cyl- gaskets, before reinstalling plugs.
inder. Manually turn engine over several times to dis-
tribute Storage Seal throughout cylinders. Reinstall
spark plugs.
Out-of-Season Battery Storage
5. If engine fuel filter appears to be contaminated, re-
move and replace. Refer to Section 3 “Fuel System 1. Remove battery as soon as possible and remove all
and Carburetion.” grease, sulfate and dirt from top surface.
6. Drain and refill lower unit with Quicksilver Gear Lube, 2. Cover PLATES with distilled water, but not over 3/16 in.
as explained in “Gear Housing Lubrication” (see “Table (5mm) above perforated baffles.
of Contents”). 3. Cover terminal bolts well with grease.
7. Clean outboard thoroughly, including all accessible 4. Store battery in a COOL, DRY place in a dry carton or
powerhead parts, and spray with Corrosion and Rust box.
Preventive.
5. Remove battery from storage every 60 days. Check
8. Refer to lubrication chart in this section (see “Table of water level and place on charge for 5 to 6 hours at 6
Contents”) and lubricate all lubrication points. amperes. DO NOT fast charge.
9. Remove propeller. Apply Quicksilver Special Lubricant
101, Anti-Corrosion Grease or 2-4-C w/Teflon Marine ! CAUTION
Lubricant to propeller shaft and reinstall propeller.
A discharged battery can be damaged by freezing.
Refer to “Propeller Installation” (see “Table of
Contents”).

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-19

How Weather Affects Engine Summer Conditions of high temperature, low barometric
pressure and high humidity all combine to reduce the
Performance engine power. This, in turn, is reflected in decreased boat
speeds--as much as 2 or 3 miles-per-hour (3 or 5 Km
per-hour) in some cases. (Refer to previous chart.) Nothing
will regain this speed for the boater, but the coming of cool,
dry weather.
In pointing out the practical consequences of weather
effects, an engine--running on a hot, humid summer
day--may encounter a loss of as much as 14% of the
horsepower it would produce on a dry, brisk spring or fall
day. The horsepower, that any internal combustion engine
produces, depends upon the density of the air that it
consumes and, in turn, this density is dependent upon the
temperature of the air, its barometric pressure and water
vapor (or humidity) content.
Accompanying this weather-inspired loss of power is a
second but more subtle loss. At rigging time in early spring,
the engine was equipped with a propeller that allowed the
engine to turn within its recommended RPM range at full
throttle. With the coming of the summer weather and the
consequent drop in available horsepower, this propeller
will, in effect, become too large. Consequently, the engine
operates at less than its recommended RPM.
Due to the horsepower/RPM characteristics of an engine,
this will result in further loss of horsepower at the propeller
with another decrease in boat speed. This secondary loss,
however, can be regained by switching to a smaller pitch
It is a known fact that weather conditions exert a profound propeller that allows the engine to again run at recom-
effect on power output of internal combustion engines. mended RPM.
Therefore, established horsepower ratings refer to the
For boaters to realize optimum engine performance under
power that the engine will produce at its rated RPM under
changing weather conditions, it is essential that the engine
a specific combination of weather conditions.
have the proper propeller to allow it to operate at or near
Corporations internationally have settled on adoption of the top end of the recommended maximum RPM range at
I.S.O. (International Standards Organization) engine test wide-open-throttle with a normal boat load.
standards, as set forth in I.S.O. 3046 standardizing the
Not only does this allow the engine to develop full power,
computation of horsepower from data obtained on the dy-
but equally important is the fact that the engine also will be
namometer, correcting all values to the power that the en-
operating in an RPM range that discourages damaging
gine will produce at sea level, at 30% relative humidity at
detonation. This, of course, enhances overall reliability and
77° F (25° C) temperature and a barometric pressure of
durability of the engine.
29.61 inches of mercury.

1-20 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

Conditions Affecting Operation Detonation generally is thought of as spontaneous ignition,
but it is best described as a noisy explosion in an unburned
1. Proper positioning of the weight inside the boat (per- portion of the fuel/air charge after the spark plug has fired.
sons and gear) has a significant effect on the boat’s Detonation creates severe, untimely, shock waves in the
performance, for example: engine, and these shock waves often find or create a weak-
ness: The dome of a piston, piston rings or piston ring
a. Shifting weight to the rear (stern)
lands, piston pin and roller bearings.
(1) Generally increases top speed.
While there are many causes for detonation in a 2-cycle
(2) If in excess, can cause the boat to porpoise. engine, emphasis is placed on those causes which are
most common in marine 2-cycle application. A few, which
(3) Can make the bow bounce excessively in
are not commonly understood, are:
choppy water.
1. Over-advanced ignition timing.
(4) Will increase the danger of the following -
wave splashing into the boat when coming off 2. Use of low octane gasoline.
plane.
3. Propeller pitch too high (engine RPM below rec-
b. Shifting weight to the front (bow) ommended maximum range).
(1) Improves ease of planing off. 4. Lean fuel mixture at or near wide-open-throttle.
(2) Generally improves rough water ride. 5. Spark plugs (heat range too hot - incorrect reach
- cross-firing).
(3) If excessive, can make the boat veer left and
right (bow steer). 6. Inadequate engine cooling (deteriorated cooling
system).
2. Boat Bottom: For maximum speed, a boat bottom
should be nearly a flat plane where it contacts the 7. Combustion chamber/piston deposits (result in
water and particularly straight and smooth in fore-and- higher compression ratio).
aft direction.
Detonation usually can be prevented, provided that 1) the
a. Hook: Exists when bottom is concave in fore-and- engine is correctly set up and 2) diligent maintenance is
aft direction when viewed from the side. When applied to combat the detonation causes, listed, preceding.
boat is planing, “hook” causes more lift on bottom
near transom and allows bow to drop, thus greatly
increasing wetted surface and reducing boat
speed. “Hook” frequently is caused by supporting
boat too far ahead of transom while hauling on a
trailer or during storage.
b. Rocker: The reverse of hook and much less com-
mon. “Rocker” exists if bottom is convex in fore-
and-aft direction when viewed from the side, and
boat has strong tendency to porpoise.
c. Surface Roughness: Moss, barnacles, etc., on
boat or corrosion of outboard’s gear housing in-
crease skin friction and cause speed loss. Clean
surfaces when necessary.
3. Gear Housing: If unit is left in the water, marine vege-
tation may accumulate over a period of time in certain
types of water. This growth must be removed from unit
before operation, as it may clog the water inlet holes in
the gear housing and cause the engine to overheat.
51115
Damaged Piston Resulting from Detonation
Detonation: Causes and Prevention
Detonation in a 2-cycle engine somewhat resembles the
“pinging” heard in an automobile engine. It can be other- Compression Check
wise described as a tin-link “rattling” or “pinging” sound.
1. Remove spark plugs.
2. Install compression gauge (a) in spark plug hole.
3. Hold throttle plates at W.O.T.

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-21

4. Crank engine thru at least 4 compression strokes to
obtain highest possible reading.
5. Check and record compression of each cylinder.
Variation of more than 15 psi. (103.5 kPa) between
cylinders indicates that lower compression cylinder is
in some way defective, such as worn or sticking piston
rings and/or scored piston and cylinder.
6. Compression check is important because an engine
with low or uneven compression cannot be tuned
successfully to give peak performance. It is essential,
therefore, that improper compression be corrected
before proceeding with an engine tuneup. a
7. Cylinder scoring: If powerhead shows any indication of
overheating, such as discolored or scorched paint,
visually inspect cylinders for scoring or other damage
as outlined in Section 4 “Powerhead.”

Water Pressure Check

51046
NOTE: To perform these checks, a Water Pressure Gauge a - Compression Gauge (P/N 91-29287)
Kit, P/N 91-79250A2 is recommended.
1. Water pressure at idle, in neutral, is 1-3 psi (7-21 kPa).
2. Water pressure should increase, then drop to 4-6 psi Serial Number Location
(21-35 kPa) prior to 2500 RPM (due to poppet valve The engine serial number is located on the starboard side
opening.) of the swivel bracket (as on all Mariner/Mercury models)
3. At 2500 RPM, water pressure should not exceed 12 psi and also on the cylinder head (a).
(83 kPa). Readings above 12 psi at 2500 RPM may in-
dicate a stuck poppet valve.
4. Static test (boat stationary - operate in forward gear
with a cut down “ smaller diameter” propeller) at 5000
RPM or above is 7-12 psi (48-83 kPa).

! CAUTION
A MODIFIED PROPELLER OR LOW PITCH PROPEL-
LER IS REQUIRED TO PERFORM THE ABOVE STATIC
TEST. STATIC TEST REQUIRES THE BOAT BE STA- a
TIONARY IN THE WATER SECURED TO A DOCK OR
TRAILER AND RUN IN FORWARD GEAR. DO NOT USE
A FLUSHING DEVICE FOR THIS TEST.

51139

1-22 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

Painting Procedures 3. Sand blistered area with 3M 180 grit sandpaper
or P180 Gold Film Disc to remove paint blisters
only. Feather edge all broken paint edges.
Cleaning & Painting Aluminum 4. Clean gear housing thoroughly with (DX-330)
Propellers & Gear Housings wax and grease remover.
5. Spot repair surfaces where bare metal is ex-
! WARNING posed with (DX-503) alodine treatment.
Avoid serious injury from flying debris. Avoid se- IMPORTANT: Do not use any type of aerosol
rious injury from airborne particles. Use eye and spray paints as the paint will not properly adhere
breathing protection with proper ventilation. to the surface nor will the coating be sufficiently
thick to resist future paint blistering.
PROPELLERS
6. Mix epoxy chromate primer (DP-40) with equal
1. Sand the entire area to be painted with 3M 120 part catalyst (DP-401) per manufacturers
Regalite Polycut or coarse Scotch-Brite, disc or instructions, allowing proper induction period for
belts. permeation of the epoxy primer and catalyst.
2. Feather edges of all broken paint edges. Try not 7. Allow a minimum of one hour drying time and no
to sand through the primer. more than one week before top coating assem-
blies.
3. Clean the surface to be painted using PPG
Industries DX330 Wax and Grease Remover or 8. Use Ditzler Urethane DU9000 for Mercury Black,
equivalent (Xylene or M.E.K.). DU34334 for Mariner Grey, and DU35466 for
Force Charcoal, and DU33414M for Sea Ray
4. If bare metal has been exposed, use Quicksil-
White. Catalyze all three colors with Ditzler DU5
ver’s Light Gray Primer.
catalyst mixed 1:1 ratio. Reduce with solvents
5. Allow a minimum of 1 hour dry time and no more per Ditzler label.
than 1 week before applying the finish coat.
! CAUTION
6. Apply the finish coat using Quicksilver’s EDP
Propeller Black. Be sure to comply with instructions on the label
for ventilation and respirators. Using a spray gun,
GEAR HOUSINGS apply one half to one mil even film thickness. Let
dry, flash off for five minutes and apply another
The following procedures should be used in refinish- even coat of one half to one mil film thickness.
ing gear housings. This procedure will provide the This urethane paint will dry to the touch in a mat-
most durable paint system available in the field. The ter of hours, but will remain sensitive to scratches
materials recommended are of high quality and and abrasions for a few days.
approximate marine requirements. The following
procedure will provide a repaint job that compares 9. The type of spray gun used will determine the
with a properly applied factory paint finish. It is rec- proper reduction ratio of the paint.
ommended that the listed materials be purchased IMPORTANT: Do not paint sacrificial zinc trim tab
from a local Ditzler Automotive Finish Supply Outlet. or zinc anode.
The minimum package quantity of each material
shown following is sufficient to refinish several gear 10. Cut out a cardboard “plug” for trim tab pocket to
housings. keep paint off of mating surface to maintain good
continuity circuitry between trim tab and gear
Procedure: housing.

1. Wash gear housing with a muriatic acid base

cleaner to remove any type of marine growth,
and rinse with water, if necessary.
2. Wash gear housing with soap and water, then
rinse.

90-817643R1 DECEMBER 1996 GENERAL INFORMATION and SPECIFICATIONS - 1-23

Decal Application DECAL APPLICATION
1. Mix 1/2 ounce (16 ml) of dish washing liquid in one
gallon (4 l) of cool water to use as wetting solution.
Decal Removal NOTE: Leave protective masking, if present, on the face of
1. Mark decal location before removal to assure decal until final steps of decal installation. This will ensure
that the vinyl decal keeps it’s shape during installation.
proper alignment of new decal.
2. Place the decal face down on a clean work sur-
2. Carefully soften decal and decal adhesive with a
face and remove the paper backing from “adhe-
heat gun or heat blower while removing old decal.
sive side” of decal.
3. Clean decal contact area with a 1:1 mixture of iso-
3. Using a spray bottle, flood the entire “adhesive
propyl alcohol and water.
side” of the decal with the pre-mixed wetting solu-
4. Thoroughly dry decal contact area and check for tion.
a completely cleaned surface.
4. Flood area where the decal will be positioned with
wetting solution.
Instructions for “Wet” Application 5. Position pre-wetted decal on wetted surface and
slide into position.
NOTE: The following decal installation instructions are pro-
vided for a “Wet” installation. All decals should be applied 6. Starting at the center of the decal, “lightly”
wet. squeegee out the air bubbles and wetting solution
with overlapping strokes to the outer edge of the
TOOLS REQUIRED decal. Continue going over the decal surface until
all wrinkles are gone and adhesive bonds to the
1. Plastic Squeegee*
cowl surface.
2. Stick Pin
7. Wipe decal surface with soft paper towel or cloth.
3. Dish Washing Liquid/Detergent without am-
8. Wait 10 - 15 minutes.
monia** “Joy” and “Drift” are known to be com-
patible for this process. 9. Starting at one corner, “carefully and slowly” pull
the masking off the decal surface at a 180° angle.
** Automotive Body Filler Squeegee
NOTE: To remove any remaining bubbles, pierce the decal
** Do not use a soap that contains petroleum based at one end of the bubble with stick pin and press out the en-
solvents. trapped air or wetting solution with your thumb (moving to-
SERVICE TIP: Placement of decals using the ward the puncture).
“Wet” application will allow time to position de-
cal. Read entire installation instructions on this
technique before proceeding.

TEMPERATURE
IMPORTANT: Installation of vinyl decals should
not be attempted while in direct sunlight. Air and
surface temperature should be between 60°F
(15°C) and 100°F (38°C) for best application.

SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum
based solvents to clean application surface.
Clean entire application surface with mild dish wash-
ing liquid and water. Rinse surface thoroughly with
clean water.

1-24 - GENERAL INFORMATION and SPECIFICATIONS 90-817643R1 DECEMBER 1996

ELECTRICAL and IGNITION

2
A

51123

IGNITION SYSTEM
 Page
Table of Contents Ignition Components
Page Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Direct Voltage Adapter (DVA) Tests . . . . . . . . . . . 2A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8
Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 BLACK and RED Stator . . . . . . . . . . . . . . . . . . . . . 2A-8
Ignition System Test Chart . . . . . . . . . . . . . . . . . . . 2A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8
Stator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 BLACK Stator Installation . . . . . . . . . . . . . . . . . 2A-9
Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 RED Stator Installation . . . . . . . . . . . . . . . . . . . 2A-9
Trigger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
ADI Ignition using a RED Stator with an Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
RED Stator with Adaptor and Ignition Coils . . . . . . . 2A-6 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11
RED Stator DVA Test . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11
Electric Start Engines . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Manual Start Engines . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Troubleshooting Procedures . . . . . . . . . . . . . . . . . 2A-6
Ignition (Key) Switch Test . . . . . . . . . . . . . . . . . . . . . . . 2A-7

2A-0 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Description Test Procedures
The outboard ignition system is alternator-driven with dis-
tributor-less capacitor discharge. Major components of the Direct Voltage Adapter (DVA) Tests
ignition system are the flywheel, stator, trigger, switch box,
ignition coils and spark plugs. ! WARNING
The stator assembly is mounted stationary below the fly- DANGER – HIGH VOLTAGE/SHOCK HAZARD! Do not
wheel and has 2 capacitor charging coils. The flywheel is touch ignition components and/or metal test probes
fitted with permanent magnets inside the outer rim. As the while engine is running and/or being “cranked”. STAY
flywheel rotates the permanent magnets pass the capaci- CLEAR OF SPARK PLUG LEADS. To assure personal
tor charging coils. This causes the capacitor charging coils safety, each individual spark plug lead should be
to produce AC voltage. The AC voltage then is conducted grounded to engine.
to the switch box where it is rectified and stored in a capaci-
tor. ! CAUTION
The trigger assembly (also mounted under the flywheel)
To protect against meter and/or component damage,
has 3 coils. The flywheel has a second set of permanent
observe the following precautions:
magnets (located around the center hub). As the flywheel
rotates the second set of magnets pass the trigger coils. – 400 VDC* test position (or higher) MUST BE used for
This causes the trigger coils to produce an AC voltage that all tests.
is conducted to an electric Silicon Controlled Rectifier – INSURE the Positive (+) lead/terminal of DVA is con-
(SCR) in the switch box. nected to the Positive (+) receptacle of meter
The switch discharges the capacitor voltage into the igni- – DO NOT CHANGE meter selector switch position
tion coil at the correct time and firing order sequence. while engine is running and/or being ”cranked”.
– Switch box MUST BE GROUNDED during tests.
Capacitor voltage is conducted to the primary side of the
Running or ”cranking” engine with switch box un-
ignition coil. The ignition coil multiplies this voltage high
grounded may damage switch box.
enough to jump the gap at the spark plug.
*If using a meter with a built–in DVA, the DVA/400 VDC test
The preceding sequence occurs once-per-engine-revolu- position should be used.
tion for each cylinder.
NOTE: Test leads are not supplied with the DVA. Use test
Spark timing is changed (advanced/retarded) by rotating leads supplied with meter.
the trigger assembly which changes each trigger coil posi-
tion in relation to the permanent magnets on the flywheel Test procedures and specifications are provided for check-
center hub. ing primary ignition voltage while the engine is running
and/or being ”cranked”.
IMPORTANT: If the engine misfires, runs rough or does
not start, the ignition system should be checked using TROUBLESHOOTING TIPS:
a Multi-Meter/DVA Tester (91-99750), or a voltmeter 1. Intermittent, weak, or no spark output at two spark
(capable of measuring 400 volts DC, or higher) and Di- plugs usually indicates a bad TRIGGER.
rect Voltage Adaptor (91-89045).
2. Intermittent, weak, or no spark output at all three spark
plugs usually indicates a bad STATOR or SWITCH
BOX.
3. Intermittent, weak, or no spark at any one spark plug
usually indicates a bad SPARK PLUG, COIL, or
SWITCH BOX.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2A-1

Test Sequence 2-B) Check ignition switch/wiring, as follows:

1-A) Check primary input voltage to coils (See Test ! CAUTION

Chart) To prevent engine from starting, remove spark plug
1. If voltage readings to coil(s) are BELOW specification, leads from ALL spark plugs and ground leads to en-
proceed with Step 2-A. gine.
2. If voltage readings to coil(s) are WITHIN specifica- 1. Disconnect ignition switch and stop switch leads
tions, proceed with Step 1-B. from switch box and isolate the leads.
1-B) Check coils for spark. [Connect Spark Gap Tester 2. Repeat check in Step 2-A.
(91–63998A1) between coil high voltage tower and a. If reading is still BELOW specification, proceed
spark plug.] with Step 3-A.
1. No spark or weak spark. COIL is bad.
2. Spark is OK, proceed with Step 1-C. b. If reading is WITHIN specification, either the igni-
tion switch, stop switch, or wiring is bad.
1-C) If Step 1-A and 1-B check OK, replace spark plugs.
3-A) Check stator low speed and high speed input to
If problem exists after replacing spark plugs, proceed with switch box. (see Test Chart).
Step 1-D.
1. If either the low speed or high speed reading to switch
1-D) If Steps 1-A, 1-B, and 1-C check OK, check igni- box is BELOW specification, Stator or Switch Box is
tion timing. bad (test stator as outlined in this service manual sec-
1. If ignition timing does not check to specification (or a tion; if stator checks to specification replace switch box
sudden or unexplained timing change occurs) check and repeat check).
trigger advance linkage for loose and/or broken parts 2. If both the low speed and high speed reading are
and check trigger magnet ring (on flywheel hub) for WITHIN specification, replace switch box and repeat
looseness and/or a shift in position. test.
2. If ignition checks to specification and engine does not
run or runs poorly, trouble exists with fuel system or
engine mechanical.
2-A) Check switch box ”stop” circuit. (See Test Chart).
1. If reading is BELOW specifications, proceed with Step
2-B.
2. If reading is ABOVE specifications, the Trigger or
Switch Box is bad (test trigger as outlined in this ser-
vice manual section; if trigger checks OK, replace
switch box and repeat check).
3. If reading is WITHIN specifications, proceed with Step
3-A.

2A-2 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Ignition System Test Chart
IMPORTANT: BEFORE attempting the ignition system checks, following, thoroughly read the preceding pages of
these instructions to become familiar with the proper Automatic Distributorless Ignition (ADI) test sequence and pro-
cedures (particularly any “Safety Warnings” and “Cautions”). ALL tests are performed with lead wires connected –
terminals exposed. SWITCH BOX MUST BE GROUNDED (CASE TO ENGINE BLOCK) FOR ALL TESTS – IF NOT,
SWITCH BOXES MAY BE DAMAGED.

55/60 MARATHON/SEAPRO – (398-9873A-5 printed on the stator)

USA S/N 0G277479 and BELOW
BELGIUM S/N (Not Available at Time of Printing)
45 JET, 50/60 ELECTRIC – (398-9710A22, 398-9710A23, or 398-9710A34 printed on the stator)
USA S/N 0G277605 and BELOW
BELGIUM S/N (Not Available at Time of Printing)
NOTE: When servicing a unit prior to the listed serial number and below, it is recommended that the flywheel be removed and
the stator part number verified to determine proper testing applications.

ADI Test Test Selector Sw. DVA Leads Voltage (1) Voltage
Seq
Seq. Position @300-1000
@300 1000 RPM @1000-4000
@1000 4000 RPM
Red Black
1–A Coil Primary 400 VDC* Coil (+) Coil (–) 150–250 180–280
Terminal Terminal
2–A Switch Box - 400VDC* Black/Yellow(3) Ground 200–360 200–360
Stop Circuit Sw. Box Terminal
3–A Stator - 400VDC* Blue Sw. Box Ground 200–300 200–330
4–A Low Speed Terminal
3–A Stator - 400VDC* Red Sw. Box Ter- Ground 20–90 130–300
4–A High Speed minal
5–A Switch Box - 20 VDC or Ground (1) White/Black Sw. 2–10 10–30
Bias 40 VDC Box Terminal (1)
(1) Using meter only, REVERSE LEAD POLARITY, connect leads as specified.
(*) If using a meter with built-in DVA, place selector switch in the DVA/400 VDC position.

55/60 MARATHON/SEAPRO – (398-9873A21 printed on the stator)

USA S/N 0G277480 and ABOVE
BELGIUM S/N (Not Available at Time of Printing)
45 JET, 50/60 ELECTRIC – (398-9873A24 printed on the stator)
USA S/N 0G277606 and ABOVE
BELGIUM S/N (Not Available at Time of Printing)

ADI Test Test Selector Sw. DVA Leads Voltage Voltage Voltage
Seq
Seq. Position @300 RPM @1000 RPM @4000 RPM
Red Black
1–A Coil Primary 400 VDC* Coil (+) Coil (–) 145–175 210–250 200–240
Terminal Terminal
2–A Switch Box - 400VDC* Black/Yellow(3) Ground 215–265 280–340 260–320
Stop Circuit Sw. Box Termi-
nal
3–A Stator - 400VDC* Blue Sw. Box Ground 215–265 280–340 260–320
4–A Low Speed Terminal
3–A Stator - 400VDC* Red Sw. Box Ground 10–15 45–55 205–255
4–A High Speed Terminal
5–A Switch Box - 20 VDC or Ground (1) White/Black Sw. 2–10 10–30 10–30
Bias 40 VDC Box Terminal (1)
(1) Using meter only, REVERSE LEAD POLARITY, connect leads as specified.
(*) If using a meter with built-in DVA, place selector switch in the DVA/400 VDC position.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2A-3

 55/60 MARATHON/SEAPRO – (398-9873A-5 printed
! WARNING on the stator)
When testing or servicing the ignition system, high USA S/N 0G277479 and BELOW
voltage is present, be extremely cautious! DO NOT BELGIUM S/N (Not Available at Time of Printing)
TOUCH OR DISCONNECT any ignition parts while en-
45 JET, 50/60 ELECTRIC – (398-9710A22,
gine is running, while key switch is on, or while battery
398-9710A23, or 398-9710A34 printed on the stator)
cables are connected.
USA S/N 0G277605 and BELOW
BELGIUM S/N (Not Available at Time of Printing)
! CAUTION
NOTE: When servicing a unit listed “Serial Number and
Failure to comply with the following items may result Below”, it is recommended that the flywheel be removed
in damage to the ignition system. and the stator part number verified to determine proper
testing applications.
1. DO NOT reverse battery cable connections. The
battery negative cable is (-) ground.
Test Leads Resistance Scale Reading
2. DO NOT “spark” battery terminals with battery (OHMS) (x_______)
cable connections to check polarity. Between Blue
3. DO NOT disconnect battery cables while engine is Stator Lead and 3600 – 4200 3.6 – 4.2
running. Red Stator Lead (90 – 140) (R x 1000)
(Low Speed)
4. DO NOT crank engine when switch box is not
Between Red
grounded to engine.
Stator Lead and 90 – 140 90 – 140
A process of elimination must be used when checking the Engine Ground* (R x 1)
ignition system without a Multi-Meter/DVA Tester (Hi-Speed)
(91-99750) or a voltmeter (capable of measuring 400 volts
DC, or higher) and Direct Voltage Adaptor (91-89045), as *If stator is mounted on engine, black stator lead must be
the switch box and ignition coils cannot be thoroughly grounded to powerhead when testing. Connect test lead to
checked with conventional test equipment. black stator lead if stator is removed from engine.

All other components can be tested with an ohmmeter. Be- 55/60 MARATHON/SEAPRO – (398-9873A21 printed
fore troubleshooting the ignition system, check the follow- on the stator)
ing: USA S/N 0G277480 and ABOVE
1. Make sure that electrical harness and ignition switch BELGIUM S/N (Not Available at Time of Printing)
are not the source of the problem.
45 JET, 50/60 ELECTRIC – (398-9873A24 printed on
2. Check that plug-in connectors are fully engaged and the stator)
terminals are free of corrosion. USA S/N 0G277606 and ABOVE
3. Make sure that wire connections are tight and free of BELGIUM S/N (Not Available at Time of Printing)
corrosion.
Test Leads Resistance Scale Reading
4. Check all electrical components, that are grounded di- (OHMS) (x_______)
rectly to engine, and all ground wires to see that they Between Blue
are grounded to engine. Stator Lead and 1100 – 1600 1.1 – 1.6
5. Check for disconnected wires, and short and open cir- Red Stator Lead (R x 1000)
cuits. (Low Speed)
Between Red
STATOR TEST Stator Lead and 30 – 35 30 – 35
Engine Ground* (R x 1)
NOTE: Stator can be tested without removing from engine. (Hi-Speed)
1. Disconnect stator leads from switch box.
*If stator is mounted on engine, black stator lead must be
2. Use an ohmmeter and perform the following tests. grounded to powerhead when testing. Connect test lead to
IMPORTANT: If stator is mounted on engine, black sta- black stator lead if stator is removed from engine.
tor lead must be grounded to powerhead when testing.
Connect test lead to black stator lead if stator is re-
moved from engine.
NOTE: Readings are for a cold engine (room temperature).
Resistance will increase slightly, if engine is warm.
3. If meter readings are other than specified, replace sta-
tor assembly.

2A-4 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

IGNITION COIL TEST
ADI Ignition using a RED
IMPORTANT: Ohmmeter tests can only detect certain
faults in the ignition coil. Replace ignition coil, if ohm- Stator with an Adapter
meter readings (listed in chart, following) are not as
specified. If coil tests OK, and coil is still suspected of Module
being faulty, use Multi-Meter/DVA Tester (91-99750) or Red stators require an adapter module that is con-
a voltmeter (capable of measuring 400 volts DC, or nected between the stator and switch box. Without the
higher) and Direct Voltage Adaptor (91-89045) to thor- adapter module, the voltage supplied by the stator
oughly check coil.
would exceed the voltage capability of the switch box.
1. Disconnect wires from coil terminals.
2. Pull spark plug lead out of coil tower.
3. Use an ohmmeter and perform the following tests.

Resistance Scale Reading

Test Leads (OHMS) (x_________)

Between (+) and (-) Coil .02-.04* .02-.04*

Terminals (R x 1)

Between Coil Tower and (-) 8-11**

800-1100**
Coil Terminal (R x 100)

* The primary DC resistance of these coils generally is less than one

(1) OHM. If a reading resembling a short is obtained, this would be
acceptable.
** Copper wire is an excellent conductor, but it will have a noticeable
difference in resistance from cold to hot temperatures. Reasonable
variations from these readings are acceptable.

4. If meter readings are not as specified, replace ignition

coil.

TRIGGER TEST
1. Disconnect all trigger leads from switch box.
2. Use an Ohmmeter and perform the following tests.

Resistance Scale Reading

Test Leads (OHMS) (x_________)

Between Brown Trigger Lead 11-14

1100-1400
and White/Black Trigger Lead (R x 100)

Between White Trigger Lead 11-14

1100-1400 (R x 100)
and White/Black Trigger Lead

Between Violet Trigger Lead 11-14

and White/Black Trigger Lead 1100-1400 (R x 100)

NOTE: Above readings are for a cold engine (room tem-

perature). Resistance will increase slightly, if engine is
warm.
3. If meter readings are not as specified, replace trigger.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2A-5

 NOTE: If using a meter with a built -in DVA, place selector
RED Stator with Adaptor and switch in the DVA/400 VDC position.
Ignition Coils NOTE: Red stators require an adapter module that is
connected between the stator and switch box. With-
out the adapter module, the voltage supplied by the
RED Stator DVA Test stator would exceed the voltage capability of the
switch box.
Test Selector RED DVA BLACK DVA Voltage @ 300 Voltage @ Voltage @
Switch Posi- Lead Lead RPM 1000 RPM 4000 RPM
tion
Coil Primary 400 VDC* Coil (+) Termi- Coil (–) Termi- 130 Volts Mini- 195 to 275 195 to 275
nal nal mum
Stop Circuit 400 VDC* Black/Yellow Ground 190 Volts Mini- 275 to 320 260 to 320
Sw. Box Termi- mum
nal
Blue Sw. Box 400 VDC* Blue Sw. Box Ground 190 Volts Mini- 275 to 320 260 to 320
Terminal Terminal mum
Blue/White Sw. 400 VDC* Blue/White Sw. Ground 190 Volts Mini- 275 to 320 260 to 320
Box Terminal Box Terminal mum
NOTE: The stator for manual start engines have a BLUE/ NOTE: Resistance varies greatly with temperature. Mea-
WHITE and a BLACK wire which provide power for the over- surements should be made within an ambient range of 65 to
heat horn and overspeed limiter module. 85 degrees F°

Electric Start Engines Troubleshooting Procedures

If the DVA reading is HIGH (particularly @ 1000 RPM)
Red Stator Resistance Test
(all wires disconnected) R x 1 Ohms the ADAPTER MODULE is defective.

Positive Meter Negative Scale If the DVA reading is LOW, the stator, adapter module
Lead (+) Meter Lead (–) or switch box may be defective. Refer to the particular
engine model procedure, following, to isolate the prob-
Connect to Connect to lem.
White/Green Green/White 660 – 710
stator lead stator lead • Disconnect the BLUE adapter lead from the
Connect to Yel- Connect to Yel- switch box.
low stator lead low stator lead 0.165 – 0.181 • Connect the DVA meter between the BLUE
adapter lead and ground.
• Crank the engine (manual or electric).
Manual Start Engines
• If the DVA is normal (190 to 260 volts), the switch
box is defective.
Red Stator Resistance Test
(all wires disconnected) R x 1 Ohms • If the DVA reading is still low, either the stator or
Positive Meter Negative Scale the adapter is defective.
Lead (+) Meter Lead (–) • Disconnect the GREEN/WHITE and WHITE/
Connect to Connect to GREEN stator leads from the adapter.
White/Green Green/White 660 – 710 • Measure the resistance between the GREEN/
stator lead stator lead WHITE and WHITE/GREEN stator leads.
Connect to Connect to 130 – 145
• If the resistance is normal (660 to 710 ohms), the
Blue/White Black
adapter is defective.
Connect to Yel- Connect to Yel-
low stator lead low stator lead 0.17 – 0.19 • If the resistance is incorrect, the stator is defec-
tive.

2A-6 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Ignition (Key) Switch Test Ignition Components
1. Disconnect remote control wiring harness and instru-
ment panel connector.
Removal and Installation
NOTE: Wiring diagram for control boxes is located in SEC- Flywheel
TION 2D.
2. Set ohmmeter on R x 1 scale for the following tests: REMOVAL
COMMANDER 2000 KEY SWITCH 1. Remove flywheel cover from engine.

! WARNING
Engine could possibly start when turning flywheel
during removal and installation; therefore, disconnect
(and isolate) spark plug leads from spark plugs to pre-
vent engine from starting.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with Flywheel Holder (a)
(91-52344), remove flywheel nut and washer.
23894
COMMANDER KEY SWITCH

(PUR)
A
M(BLK)
(BLK/YEL)M

(RED)B S (YEL/RED)
C
(YEL/BLK)

CONTINUITY SHOULD BE INDICATED

KEY AT THE FOLLOWING POINTS: a
POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK
51123
OFF • • 4. Install Crankshaft Protector Cap (91-24161) on the
RUN • • end of crankshaft, then install Flywheel Puller (a)
(91-73687A1) into flywheel (b).
• •
START • • 5. Remove flywheel.
• •
NOTE: Neither heat or hammer should be used on flywheel
• • to aid in removal as damage to flywheel or electrical com-
CHOKE* • • ponents under flywheel may result.
• •

*Key switch must be positioned to “RUN” or “START” and key pushed a

in to actuate choke, for this continuity test.

BLK•BLACK
PUR•PURPLE
RED•RED
YEL•YELLOW b
3. If meter readings are other than specified in the pre-
ceding test, verify that switch and not wiring is faulty.
If wiring checks OK, replace switch.

51124

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2A-7

INSTALLATION BLACK and RED Stator
! WARNING REMOVAL
Engine could possibly start when turning flywheel 1. Remove flywheel; refer to “Flywheel Removal”.
during installation; therefore, disconnect (and isolate)
spark plug leads from spark plugs to prevent engine 2. Remove screws (a).
from starting. a
1. Disconnect spark plug leads from spark plugs.
2. Place flywheel key (a) into slot in crankshaft.

51123

3. Disconnect stator leads as shown and remove stator.

51123
3. Align slot in flywheel center bore with flywheel key and
install flywheel onto crankshaft. c
4. Install washer and locknut.
5. Hold flywheel with Flywheel Holder (a) (91-52344);
torque locknut to 100 lb. ft. (136 N·m).

a
51123
6. Install flywheel cover.

51124
a - Stator Leads to Switch Box (2)
b - Yellow Leads to Rectifier (2)
c - Ground Lead (1)

2A-8 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

BLACK STATOR INSTALLATION RED STATOR INSTALLATION
1. Install stator as shown. IMPORTANT: The stator must be oriented as
a shown to obtain correct system voltage.
b 1. Position red stator so appropriate arrow on decal
points aft.
2. Secure stator with four (4) attaching screws re-
tained from disassembly. Apply Loctite 222 to
threads and torque to 60 lb. in. (7.0 N·m).
FORWARD

51124 b
a - Screws; apply Loctite 271 on Threads (unless Patch Screw b
used) and torque to 60 lbs. in. (7.0 N·m)
b - Stator
b
2. Connect stator leads; refer to wiring diagrams in Sec-
b
tion 2D.

a
c
a
c AFT 54067
a - Orient Appropriate Arrow of Decal Aft
b - Apply Loctite 222 (obtain locally) To Screws (4) and Torque
to 60 lb. in. (7.0 N·m)
c - Stator Harness
3. Route stator harness thru top of electrical plate
b grommet as shown. Secure to powerhead with
sta-strap.
4. Position stator adaptor in cavity of electrical plate
with blue lead toward top of engine.
5. Refer to electrical diagram and make electrical
connections as shown.
6. Bundle and secure stator adaptor, harnesses and
connections with sta-straps as shown.

51124
a - Stator Leads to Switch Box (2)
b - Yellow Leads to Rectifier (2)
c - Ground Lead (1)

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2A-9

 a b f c 3. Disconnect trigger leads (a) from switch box (b) and re-
move trigger.

a b
f d

f
e

54981

a - Electrical Plate Grommet

b - Blue Lead of Stator Adaptor
c - Stator Harness 51123
d - Black Ground Lead of Stator Adaptor
e - Stator Adaptor INSTALLATION
f - Sta-Straps
1. Install trigger (a) and connect link arm (b).

Trigger
a
REMOVAL
1. Remove flywheel and stator; refer to “Flywheel” and
“Stator” removal, preceding.
2. Disconnect link arm (a) and remove trigger(b).

b
19459

19459

2A-10 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

2. Connect trigger leads (a) to switch box (b); refer to wir- Switch Box
ing diagrams in Section 2D.
1. Refer to wiring diagrams in Section 2D when connect-
ing wires.
a b

g h

c d
f

51123
3. Install stator; refer to “Stator Installation”, preceding.
4. Install flywheel; refer to “Flywheel Installation”, preced-
ing.
a
Ignition Coils e

1. Refer to wiring diagrams in Section 2D when connect-

ing wires. b

a
b
51123
a - White/Black
b - Purple
c - Brown
d d - White
e e - Red
f - Blue
c g - Black
h - Grommet
c b

e a

c
d
e
a b
51124
a - Coils
b - Cover
c - Hex Nuts; coat with Quicksilver Liquid Neoprene
d - Bolts; torque to 20 lb. in. (2.5 N·m)
e - Coil Tower Boots; form a water tight seal between coil tower and
spark plug lead using Quicksilver Insulating Compound

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2A-11

ELECTRICAL

2
B

11669

BATTERY, CHARGING SYSTEM and

STARTING SYSTEM
Table of Contents
Page Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Starting System Components . . . . . . . . . . . . . . . 2B-12
Recommended Battery . . . . . . . . . . . . . . . . . . . . . . 2B-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Operating Engine Without Battery . . . . . . . . . . . . 2B-1 Troubleshooting the Starting Circuit . . . . . . . . . . 2B-12
Specific Gravity Readings . . . . . . . . . . . . . . . . . . . 2B-1 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Specific Gravity Cell Comparison Test . . . . . . 2B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Charging A Discharged Battery . . . . . . . . . . . . . . . 2B-2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 2B-16
Winter Storage of Batteries . . . . . . . . . . . . . . . . . . 2B-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Battery Charging System . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Armature Test for Shorts . . . . . . . . . . . . . . . . . 2B-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Armature Test For Ground . . . . . . . . . . . . . . . 2B-17
Battery Charging System Troubleshooting . . . . . 2B-4 Checking Positive Brushes and Terminals . 2B-17
Stator Ohms Test (Alternator Coils Only) . . . . . . 2B-4 Testing Negative Brushes For Ground . . . . . 2B-17
Alternator System Test . . . . . . . . . . . . . . . . . . . . . . 2B-5 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . 2B-18
Unregulated Systems . . . . . . . . . . . . . . . . . . . . 2B-5 Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Regulated Systems . . . . . . . . . . . . . . . . . . . . . . 2B-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
9 Ampere Battery Charging Wiring Diagram Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20
(Rectifier Models) . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
9 Ampere Battery Charging Wiring Diagram
(Regulator Models) . . . . . . . . . . . . . . . . . . . . . . 2B-8
9 Ampere Battery Charging Diagram
with Battery Isolator (Rectifier Models) . . . . . 2B-9
15/16 Ampere Battery Charging Diagram
with Battery Isolator . . . . . . . . . . . . . . . . . . . . 2B-10
Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11

2B-0 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Battery Specific Gravity Readings
Use a hydrometer (a) to measure specific gravity of electro-
Precautions lyte in each cell.
When charging batteries, an explosive gas mixture forms
in each cell. A portion of this gas escapes thru holes in vent
plugs and may form an explosive atmosphere around bat-
tery if ventilation is poor. This explosive gas may remain in
or around battery for several hours after it has been
charged. Sparks or flames can ignite this gas and cause an
internal explosion which may shatter the battery.
The following precautions should be observed to prevent
a
an explosion.
1. DO NOT smoke near batteries being charged or which
have been charged very recently.
2. DO NOT break live circuits at terminals of batteries be-
cause a spark usually occurs at the point where a live
circuit is broken. Always be careful when connecting or
disconnecting cable clamps on chargers. Poor con-
nections are a common cause of electrical arcs which
cause explosions.
3. DO NOT reverse polarity of battery cables on battery
terminals.

! 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 doctor.
22532

Hydrometer measures percentage of sulfuric acid in bat-

Recommended Battery tery electrolyte in terms of specific gravity. As a battery
drops from a charged to a discharged condition, acid
The 2-cycle Outboard type engine requires a 12 volt bat- leaves the solution and chemically combines with the
tery with a “Cold Cranking Amperage” rating for cranking plates, causing a decrease in specific gravity of electrolyte.
and a “Reserve Capacity” rating. The minimum should be An indication of concentration of electrolyte is obtained
a “Cold Cranking Amperage” of 350 amperes and a “Re- with a hydrometer.
serve Capacity” of 100 minutes for engines outlined in this
manual. When using a hydrometer, observe the following points:
1. Hydrometer must be clean (inside and out) to insure an
accurate reading.
Operating Engine Without Battery 2. Never take hydrometer readings immediately after wa-
If desired (or in an emergency), engines equipped with an ter has been added. Water must be thoroughly mixed
alternator can be started and operated without a battery with electrolyte by charging for at least 15 minutes at
(either disconnected or removed) if “Warning”, below, is fol- a rate high enough to cause vigorous gassing.
lowed. 3. If hydrometer has built-in thermometer, draw liquid in
several times to ensure correct temperature before
! WARNING taking reading.
Before operating engine with battery leads discon- 4. Hold hydrometer vertically and draw in just enough liq-
nected from battery, disconnect stator leads (yellow) uid from battery cell so that float is free-floating. Hold
from rectifier. Insulate (tape) stator lead ring terminals. hydrometer at eye level so that float is vertical and free
of outer tube, then take reading at surface of liquid. Dis-
regard curvature where liquid rises against float stem
due to capillary action.
5. Avoid dropping electrolyte on boat or clothing, as it is
extremely corrosive. Wash off immediately with baking
soda solution.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-1

Specific gravity of electrolyte varies not only with percent- Charging A Discharged Battery
age of acid in liquid but also with temperature.As tempera-
ture drops, electrolyte contracts, so that specific gravity in- The following basic rules apply to any battery charging situ-
creases. Unless these variations in specific gravity are ation:
taken into account, specific gravity obtained by hydrometer
1. Any battery may be charged at any rate (in amperes)
may not give a true indication of concentration of acid in
as long as spilling of electrolyte (from violent gassing)
electrolyte.
does not occur and as long as electrolyte temperature
A fully charged battery will have a specific gravity reading does not exceed 125° F (52° C). If spewing of electro-
of approximately 1.270 at an electrolyte temperature of 80° lyte occurs, or if electrolyte temperature exceeds 125°
F (27° C). If electrolyte temperature is above or below 80° F, charging rate (in amperes) must be reduced or tem-
F, additions or subtractions must be made in order to obtain porarily halted to avoid damage to the battery.
a hydrometer reading corrected to 80° F standard. For ev-
2. Battery is fully charged when, over a 2-hour period at
ery 10° F (3.3° C) above 80° F, add 4 specific gravity points
a low charging rate (in amperes), all cells are gassing
(.004) to hydrometer reading. Example: A hydrometer
freely (not spewing liquid electrolyte), and no change
reading of 1.260 at 110° F (43° C) would be 1.272 corrected
in specific gravity occurs. Full charge specific gravity
to 80° F, indicating a fully charged battery.
is 1.260-1.275, corrected for electrolyte temperature
For every 10° below 80° F, subtract 4 points (.004) from the with electrolyte level at 3/16” (4.8mm) over plate. For
reading. Example: A hydrometer reading of 1.272 at 0° F most satisfactory charging, lower charging rates in am-
(-18° C) would be 1.240 corrected to 80° F, indicating a par- peres are recommended.
tially charged battery.
3. If, after prolonged charging, specific gravity of at least
1.230 on all cells cannot be reached, battery is not in
SPECIFIC GRAVITY CELL COMPARISON TEST optimum condition and will not provide optimum per-
This test may be used when an instrumental tester is not formance; however, it may continue to provide addi-
available. To perform this test, measure specific gravity of tional service, if it has performed satisfactorily in the
each cell, regardless of state of charge, and interpret re- past.
sults as follows: If specific gravity readings show a differ- 4. To check battery voltage while cranking engine with
ence between highest and lowest cell of .050 (50 points) or electric starter motor, place red (+) lead of tester on
more, battery is defective and should be replaced. positive (+) battery terminal and black (-) lead of tester
on negative (-) battery terminal. If the voltage drops be-
low 9-1/2 volts while cranking, the battery is weak and
Electrolyte Level should be recharged or replaced.

Check electrolyte level in battery regularly. A battery in use

in hot weather should be checked more frequently because
of more rapid loss of water. If electrolyte level is found to be
low, then distilled water should be added to each cell until
liquid level rises approximately 3/16” (4.8mm) over plate.
DO NOT OVERFILL, because this will cause loss of elec-
trolyte and result in poor performance, short life and exces-
sive corrosion.

! CAUTION
During service, only distilled water should be added to
the battery, not electrolyte.

2B-2 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Winter Storage of Batteries Some models are equipped with either a voltage regulator
or a voltage regulator/rectifier. The voltage regulator
Battery companies are not responsible for battery damage, senses battery voltage and allows the correct amount of di-
either in winter storage or in dealer stock, if the following rect current to charge the battery.
instructions are not observed:
Models Equipped With Rectifier
1. Remove battery from its installation as soon as possi-
ble and remove all grease, sulfate and dirt from top sur-
face by running water over top of battery. Be sure, how-
ever, that vent caps are tight beforehand, and blow off a
all excess water thoroughly with compressed air.
Check water level, making sure that plates are cov-
ered.
2. When adding distilled water to battery, be extremely
careful not to fill more than 3/16” (4.8mm) over plate in- b
side battery. Battery solution or electrolyte expands
from heat caused by charging. Overfilling battery will
cause electrolyte to overflow (if filled beyond 3/16”
over plate).
3. Grease terminal bolts well with Quicksilver 2-4-C Ma-
rine Lubricant, and store battery in COOL-DRY place. c
Remove battery from storage every 30-45 days, check
water level (add water if necessary), and put on charge
for 5 or 6 hours at 6 amperes. DO NOT FAST
a - Stator
CHARGE. b - Rectifier
c - Battery
4. If specific gravity drops below 1.240, check battery for
reason, and then recharge. When gravity reaches Models Equipped With Regulator/Rectifier
1.260, discontinue charging. To check specific gravity,
use a hydrometer, which can be purchased locally.
a
5. Repeat preceding charging procedure every 30-45
days, as long as battery is in storage. When ready to
place battery back in service, remove excess grease
from terminals (a small amount is desirable on termi- b
nals at all times), recharge again as necessary and re-
install battery.

! WARNING
Hydrogen and oxygen gases are produced during nor-
mal battery operation or charging. Sparks or flame can
cause this mixture to ignite and explode, if they are
brought near the battery. Sulfuric acid in battery can c
cause serious burns, if spilled on skin or in eyes. Flush
or wash away immediately with clear water.

Battery Charging System a - Stator

b - Regulator/Rectifier
Description c - Battery

The charging system may be damaged by: 1) reversed bat-

The battery charging system components are the stator,
tery cables, 2) running the engine with battery cables dis-
rectifier or voltage regulator/rectifier and the battery. Alter-
connected and stator leads connected to rectifier, and 3)
nating current is generated in the stator alternator coils and
and open circuit, such as a broken wire or loose connec-
flows to the rectifier. The rectifier changes the alternating
tion.
current to direct current for charging the battery.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-3

Battery Charging System Stator Ohms Test
Troubleshooting (Alternator Coils Only)
A fault in the battery charging system usually will cause the NOTE: Stator can be tested without removing from engine.
battery to become undercharged. Check battery electro-
1. Disconnect both yellow (stator leads) from voltage reg-
lyte level, and charge battery. See “Electrolyte Level”, and
ulator/rectifier, or terminal block.
“Charging a Discharged Battery”.
2. Use an ohmmeter and perform the following test.
If battery will NOT accept a satisfactory charge, replace
battery. IMPORTANT: If stator is mounted on engine, black sta-
tor lead (if provided) must be grounded to powerhead
If battery accepts a satisfactory charge, determine the
when testing.
cause of the charging system problem as follows.
3. Replace stator if readings are outside ranges shown.
1. Check for correct battery polarity [red cable to positive
(+) battery terminal]. If polarity was incorrect, check for NOTE: When servicing a unit listed “Serial Number and
damaged rectifier. See “Rectifier Test”. Below”, it is recommended that the flywheel be removed
and the stator part number verified to determine proper
2. Check for loose or corroded battery connections.
testing applications.
3. Visually inspect wiring between stator and battery for
cuts, chafing; and disconnected, loose or corroded 55/60 MARATHON/SEAPRO – (398-9873A-5 or
connection. 398-9873A21 printed on the stator)
4. Excessive electrical load (from too many accessories)
will cause battery to run down. LIGHTING COIL STATOR - 7 AMPERE (96 WATTS)

If visual inspection determines that battery connections Test Leads Resistance Scale Reading
and wiring are OK, perform the following stator and rectifier (OHMS) (x_______)
tests. Between Yellow .12 – .23* .12 – .23*
Stator Leads (R x 1)
Between Either
Yellow Stator No Continuity No Continuity
Lead and Engine (R x 1000)
Ground**
Between Blue/
White and Black 100 – 140 10 – 14
Stator Leads (R x 10)

* DC Resistance of these windings generally is less than 1.5 OHMS.

If a reading (resembling a short) is obtained, this would be accept-
able.
** If stator is removed from engine, connect test lead to black stator
lead, if provided.

45 JET, 50/60 ELECTRIC – (398-9710A22,

398-9710A23, or 398-9710A34 printed on the stator)
USA S/N 0G277605 and BELOW
BELGIUM S/N (Not Available at Time of Printing)

9 AMPERE STATOR

Test Leads Resistance Scale Reading

(OHMS) (x_______)
Between Yellow .6 – 1.1* .6 – 1.1*
Stator Leads (R x 1)
Between Either
Yellow Stator No Continuity No Continuity
Lead and Engine (R x 1000)
Ground**

2B-4 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

16 AMPERE STATOR REGULATED SYSTEMS
1. Check battery voltage at battery with engine running.
Test Leads Resistance Scale Reading
(OHMS) (x_______) 2. If battery voltage is above 14.5 volts, replace voltage
Between Yellow .17 – .19* .17 – .19* regulator/rectifier. Check condition of battery as over-
Stator Leads (R x 1) charging may have damaged battery.
Between Either 3. If battery voltage is below 14.5 volts, charge battery;
Yellow Stator No Continuity No Continuity refer to “Charging a Discharged Battery”. If battery can
Lead and Engine (R x 1000) NOT be satisfactorily charged, replace battery.
Ground**
4. If battery accepts a satisfactory charge, check battery
* DC Resistance of these windings generally is less than 1.5 OHMS. voltage while cranking engine; refer to “Charging a
If a reading (resembling a short) is obtained, this would be accept- Discharged Battery”. If cranking voltage is not accept-
able. able, replace battery.
** If stator is removed from engine, connect test lead to black stator 5. If cranking voltage is acceptable, disconnect larger di-
lead, if provided.
ameter RED harness wire from starter solenoid termi-
45 JET, 50/60 ELECTRIC – (398-9873A24 printed on nal.
the stator) 6. Remove smaller diameter RED wire (sense lead) from
USA S/N 0G277606 and ABOVE starter solenoid terminal and connect to the positive (+)
BELGIUM S/N (Not Available at Time of Printing) terminal of a 9 volt transistor battery. Ground the nega-
tive (–) terminal of the 9 volt battery to the engine.
15 AMPERE STATOR
7. Connect RED (+) ammeter lead to larger diameter
Test Leads Resistance Scale Reading RED harness wire, and BLACK (–) ammeter lead to
(OHMS) (x_______) positive terminal on starter solenoid.
Between Yellow .20 – .25* .20 – .25* 8. Secure starter wires away from flywheel.
Stator Leads (R x 1)
9. With engine running at the indicated RPM’s, the am-
Between Either meter should indicate the following appropriate am-
Yellow Stator No Continuity No Continuity peres:
Lead and Engine (R x 1000)
Ground**
9 AMP
* DC Resistance of these windings generally is less than 1.5 OHMS. RPM AMPERES
If a reading (resembling a short) is obtained, this would be accept-
able. Idle 1
** If stator is removed from engine, connect test lead to black stator 1000 4
lead, if provided.
2000 8
3000 9
Alternator System Test
16 AMP
UNREGULATED SYSTEMS RPM AMPERES
IMPORTANT: Rectifier must be functioning properly Idle 2
for accurate test results to be obtained.
1000 10
1. If engine is equipped with a voltage regulator, discon-
2000 16
nect voltage regulator leads at rectifier; re-install hex
nut on rectifier terminal that has yellow stator lead. 3000 18
2. Remove red wire from (+) terminal of rectifier.
15 AMP
3. Connect red (+) ammeter lead to rectifier (+) terminal
and black (-) ammeter lead to red rectifier wire. RPM AMPERES
4. Run engine at 3000 RPM. Idle 3.5

5. Meter should read 7-9 amperes; if not, replace stator. 1000 8

2000 13
3000 14

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-5

10. A reading of 18 amperes (16 amp system) or 9 am-
peres (9 amp system) at 3000 RPM indicates the
charging system is functioning properly and the battery
being discharging current due to the amperage draw
on the system is greater than the amperage output of
the engine charging system.
11. If ammeter reads less than required amperes @ 3000
RPM, test the stator; refer to “Stator Ohm Test (Alterna-
tor Coils Only)”. If stator tests OK, replace voltage reg-
ulator.
d

51000

a - Voltage Regulator/Rectifier
b - Red Lead (2)
c - Yellow Lead (2)
d - Grey Lead

2B-6 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

9 Ampere Battery Charging Wiring
Diagram
(RECTIFIER MODELS)
a

BLK • Black
BLU • Blue
GRY • Gray
RED • Red
YEL • Yellow

RED SLEEVE
f

51249

IMPORTANT: After electrical connections are made,

a - Stator/Alternator Assembly
coat all terminal connections using Quicksilver Liquid
b - Rectifier Neoprene (92-25711), to avoid corrosion.
c - 20 Ampere Fuse (Remote Control Harness)
d - Starter Solenoid
e - GRAY Wire to Tachometer
f - To Battery (+) Positive Terminal

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-7

9 Ampere Battery Charging Wiring Diagram
IMPORTANT: After electrical connections are made,
coat all terminal connections using Quicksilver Liquid
Neoprene (92-25711), to avoid corrosion.

(REGULATOR MODELS)
a

BLK • Black
BLU • Blue
GRY • Gray
RED • Red
YEL • Yellow

d
e

RED SLEEVE

c f

a - Stator/Alternator Assembly
b - Regulator
c - 20 Amp Fuse (Remote Control Harness)
d - Starter Solenoid
e - Gray Wire to Tachometer
f - To Battery (+) Positive Terminal

51249

2B-8 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

9 Ampere Battery Charging Diagram IMPORTANT: After electrical connections are made,
coat all terminal connections using Quicksilver Liquid
with Battery Isolator Neoprene (92-25711), to avoid corrosion.
(RECTIFIER MODELS)

BLK • Black
BLU • Blue
GRY • Gray
RED • Red
YEL • Yellow

RED SLEEVE
c

a - Stator/Alternator Assembly
b - Rectifier
c - 20 Amp Fuse
d - Starter Solenoid
e - Gray Wire to Tachometer
f - Battery Isolation
51251
90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-9
15/16 Ampere Battery Charging IMPORTANT: After electrical connections are made,
coat all terminal connections using Quicksilver Liquid
Diagram with Battery Isolator Neoprene (92-25711), to avoid corrosion.

BLK • Black
BLU • Blue
GRY • Gray
RED • Red
YEL • Yellow b

c RED SLEEVE

a - Stator/Alternator Assembly
b - Voltage Regulator
c - 20 Amp Fuse
d - Starter Solenoid
e - Gray Wire to Tachometer
f - Battery Isolation 51250

2B-10 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Rectifier Test a
d c
! WARNING
Disconnect battery leads from battery before testing
rectifier.
b
NOTE: Rectifier can be tested without removing from en-
gine. f
1. Disconnect all wires from terminals on rectifier.
2. Use an ohmmeter (R x 1000 scale) and perform the fol-
e
lowing test. Refer to drawing for rectifier terminal iden-
tification.
NOTE: Due to differences in the manufacture of ohm me-
ters, the internal battery polarity may vary from manufac-
turer to manufacturer. As a result, the test readings may be
07300
a direct reversal of those listed. If so, reverse meter leads
and reperform test. a - Terminal
b - Terminal
c - Terminal
d - Stator Terminals
e - Positive Terminal
f - Ground

Rectifier Test (continued)

Connect red meter lead to ground, black lead alternately
to terminals “a” and “c”.

Continuity Indicated No Continuity Indicated

Connect black meter lead to ground, red lead Connect black meter lead to ground, red lead
alternately to terminals “a” and “c”. alternately to terminals “a” and “c”.

No Continuity Indicated Continuity Indicated.

Connect black meter lead to terminal “b”, red Replace Rectifier.
lead alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated

Replace Rectifier. Connect black meter lead to terminal “b”, red
lead alternately to terminals “a” and “c”.

Continuity Indicated No Continuity Indicated.

Connect red meter lead to terminal “b”, Replace Rectifier.
black lead alternately to terminals “a”
and “c”.

Continuity Indicated. No Continuity Indicated

Replace Rectifier. Connect red meter lead to terminal “b”,
black lead alternately to terminals “a”
and “c”.

No Continuity Indicated. Continuity Indicated. No Continuity Indicated. Continuity Indicated.

Rectifier tests O.K. Replace Rectifier. Replace Rectifier. Rectifier Tests O.K.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-11

 The neutral start switch opens the start circuit when the
Starting System shift control lever is not in neutral. This prevents accidental
starting when engine is in gear.
Starting System Components
The starting system consists of the following components. ! CAUTION
1. Battery The starter motor may be damaged if operated contin-
uously. DO NOT operate continuously for more than 30
2. Starter Solenoid
seconds. Allow a 2 minute cooling period between
3. Neutral Start Switch starting attempts.
4. Starter Motor
5. Ignition Switch Troubleshooting the Starting Circuit
Before beginning the starting circuit troubleshooting flow
Description chart, following, check first for the following conditions:
1. Make sure that battery is fully charged.
The function of the starting system is to crank the engine.
The battery supplies electrical energy to crank the starter 2. Check that control lever is in “neutral” position.
motor. When the ignition switch is turned to “Start” position,
3. Check terminals for corrosion and loose connections.
the starter solenoid is activated and completes the starting
circuit between the battery and starter. 4. Check cables and wiring for frayed and worn insula-
tion.
5. Check in-line fuse in red wire; see diagram.

2B-12 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

The following “Starting Circuit Troubleshooting Flow Chart” is designed as an aid to troubleshooting the starting circuit. This
flow chart will accurately locate any existing malfunction. Location of “Test Points” (called out in the chart) are numbered in
diagram below.

RED SLEEVE

RED SLEEVE

5 3
6

NEUTRAL START SWITCH

(LOCATED IN CONTROL
HOUSING IF ENGINE IS
EQUIPPED WITH REMOTE
CONTROL)
4

51208

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.

No continuity indicated; there is an open circuit in the black neg- Continuity Indicated
ative (-) battery cable between the negative (-) battery post and Proceed to TEST 2, on next page.
the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-13

 * Battery Voltage
TEST 2
a. Disconnect black ground wire(s) from Test Point 2.
b. Connect voltmeter between common engine ground and Test Point 2.
No voltage reading; c. Turn ignition key to “Start” position.
proceed to TEST 3.

TEST 3 12 Volt Reading*

a. Reconnect black ground wire(s). Check black ground wire for poor connection or
b. Connect voltmeter between common engine ground and Test Point 3. open circuit. Reconnect ground wire to starter
c. Turn ignition key to “Start” position. solenoid; proceed to TEST 7.

No voltage reading; 12 Volt Reading

proceed to TEST 4. Defective starter solenoid.

TEST 4
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 4. Neutral start switch is open, or yellow/red wire
No voltage reading; b. Turn ignition key to “Start” position. is open between Test Points 4 and 3.
proceed to TEST 5.

TEST 5
Connect voltmeter between common 12 Volt Reading*
No voltage reading; engine ground and Test Point 5. Defective ignition switch.
proceed to TEST 6.

TEST 6
Connect voltmeter between common engine ground and Test Point 6.

No voltage reading; check red wire between 12 Volt Reading*

battery (+) positive terminal and Test Point 6. Check fuse in red wire between test points 5 and 6.
Check for open red wire between test points 5 and 6.

TEST 7
a. Connect voltmeter between common engine ground and Test Point 1.
b. Turn ignition key to “Start” position.

No voltage reading; De- 12 Volt Reading*

fective starter solenoid. Should hear solenoid click; proceed to TEST 8.

TEST 8
a. Reconnect black (starter motor) cable to starter solenoid Test Point 1.
b. Connect voltmeter between common engine ground and Test Point 7
c. Turn ignition key to “Start” position.

No voltage reading; check black cable 12 Volt Reading*

for poor connection or open circuit. Check black ground cable at starter for loose
or corroded connection, or open circuit. If
cable is O.K., check starter motor.

2B-14 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Starter Motor Disassembly
1. Remove 2 thru bolts and commutator end cap, taking
Removal care not to lose brush springs.

! CAUTION a
c
Disconnect battery leads from battery before remov-
ing starter.
1. Disconnect battery leads from battery.
2. Disconnect black cable.
b c
3. Remove bolts and remove starter clamp. 11646
4. Remove starter. a - Thru Bolts
b - Commutator End Cap
5. Remove black cable. c - Brush Springs

2. Pull armature from starter frame.

3. Remove locknut.

b
b b

c
a

a
d

51209 11659
a - Black Cable a - Armature
b - Bolts (2) b - Locknut
c - Starter Clamp
d - Black Cable

6. Remove 2 rubber collars and 2 rubber bumpers

a
a

b
11645
a - Rubber Collars
b - Rubber Bumpers

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-15

4. Remove components from armature. b. Clean the commutator slots after undercutting.
d c. De-burr the commutator lightly with No. 00 sand-
f paper, then clean the commutator.
e
d. Check the armature on a growler for shorts. See
“Testing”, following.
9. Open-circuited armatures often can be saved where
and open circuit is obvious and repairable. The most
likely place for an open circuit is at the commutator
bars. Long cranking periods overheat the starter motor
so that solder in the connections melts. The poor con-
nections cause arcing and burning of the commutator
bars.
c
a 10. Repair bars, that are not too badly burned, by re-sold-
b
ering the leads in bars (using rosin flux solder) and
turning down the commutator in a lathe to remove
burned material, then undercut the mica.
11. Clean out the copper or brush dust from slots between
11658
the commutator bars.
a - Spacer
b - Spring 12. Check the armature for shorts and ground. See “Test-
c - Drive Assembly ing”.
d - Drive End Cap
e - Armature Shaft
f - Washer
Testing
Cleaning and Inspection ARMATURE TEST FOR SHORTS
1. Clean all motor parts. Check armature for short circuits by placing on growler and
2. Check pinion teeth for chips, cracks or excessive wear. holding hack saw blade over armature core while armature
is rotated. If saw blade vibrates, armature is shorted. Re-
3. Replace the drive clutch spring and/or collar, if tension check after cleaning between commutator bars. If saw
is not adequate, or if wear is excessive. blade still vibrates, replace armature.
4. Check that the brush holder is not damaged or is not
holding the brushes against the commutator.
5. Replace brushes that are pitted or worn to less than
1/4” (6.4mm) in length. Refer to “Brush Replacement”,
following.
6. Replace a damaged or excessively worn bushing in
the end cap.
7. Check the armature conductor (commutator bar junc-
tion) for a firm connection. A poor connection usually
results in a burned commutator bar.
8. Re-surface and undercut a rough commutator, as fol-
lows:

! CAUTION
11669
Do not turn down the commutator excessively.
a. Re-surface the commutator and undercut the in-
sulation between the commutator bars 1/32″
(0.8mm) to the full width of the insulation, make
sure that the undercut is flat.

2B-16 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

ARMATURE TEST FOR GROUND TESTING NEGATIVE BRUSHES FOR GROUND
1. Set ohmmeter to (R x 1 scale). Place one lead of ohm- Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter
meter on armature core (or shaft) and other lead on on the negative brush and the other lead on the end cap
commutator, as shown. (bare metal). If the meter indicates NO continuity, replace
the negative brush. Repeat this procedure on the other
2. If meter indicates continuity, armature is grounded and
negative brush.
must be replaced.

a b

11675
11674
CHECKING POSITIVE BRUSHES AND TERMINALS a - Negative (-) Brushes
b - End Cap
1. Connect ohmmeter (R x 1 scale) leads between posi-
tive brushes.
2. Ohmmeter must indicate full continuity (zero resis-
tance). If resistance is indicated, check lead to positive
terminal solder connection. If connection cannot be re-
paired, brushes must be replaced. Refer to “Brush Re-
placement”.

11673
a - Positive Brushes

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-17

STARTER SOLENOID TEST
Test starter solenoid as follows:
1. Disconnect all leads from solenoid terminals.
2. Use an ohmmeter, set to (R x 1 scale) and connect be-
tween solenoid terminals 1 and 2. c
3. Connect a 12-volt supply between solenoid terminals
3 and 4. Solenoid should click and meter should read
zero ohms.
4. If meter does not read zero ohms (full continuity), re- d
place solenoid.

b a
f
g

11660

a - Positive (+) Terminal

b - Long Brush Lead
c - Push Lead Into Slot
d - Insulating Washer
e - Flat Washer
f - Lock Washer
g - Nut

2. Install components.

c b
4 a
1

a b
d
3 2
d
14354
a - 12-Volt Supply
b - Ohmmeter Leads
b a

Brush Replacement 11656

a - Positive (+) Brushes
IMPORTANT: Replace brushes that are pitted or worn b - Negative (-) Brushes
c - Brush Holder
to less than 1/4” (6.4mm) in length. d - Bolts (Fasten Negative Brushes and Holder)
1. Install positive brushes into commutator end cap.

Reassembly
1. Lubricate helix threads and drive end cap bushing with
SAE 10W oil.
2. Install components onto armature shaft.

2B-18 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

 4. Construct a brush retainer tool as shown.
d
c b a

e
g
f

11658
a - Washer
b - Helix Threads
c - Armature Shaft
d - Drive End Cap
e - Drive Assembly
f - Spring
g - Spacer

3. Install locknut (a).

Brush Retainer Tool Layout (Full Size)

11659
18-Gauge Sheet Metal
METRIC
SCALE
3” = 76.2mm
2” = 50.8mm
1-3/4” = 44.5mm
1-11/16” = 42.9mm
3/4” = 19.1mm
1/2” = 12.7mm

Brush Retainer Tool Side View (Full Size)

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2B-19

5. Place springs and brushes into brush holder and hold Installation
in place with brush retainer tool.
1. Install 2 rubber collars and 2 rubber bumpers.
6. Lubricate bushing with one drop of SAE 10W oil. DO
NOT over-lubricate. a
a

b
b
11645
a - Rubber Collars
b - Rubber Bumpers

2. Install components as shown.

3. Connect battery leads to battery.

11661
a - Brush Retainer Tool
b - Bushing
c
7. Position armature into starter frame so that commuta-
tor end of armature is at end of starter frame where per- c
manent magnets are recessed 1” (25.4mm). Align
marks (a) as shown.
8. Install commutator end cap onto starter frame; align b
marks (b) as shown, and remove brush retainer tool. a
d
9. Install thru bolts (c) and torque to 70 lbs. in. (8 N·m).

c
c

a 51209
a - Starter
b - Clamp
c - Bolts (2)
d - Black Cable (from Battery)
e - Black Cable (from Solenoid)

11648

2B-20 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

ELECTRICAL and IGNITION

2
C

51046

TIMING/SYNCHRONIZING/ADJUSTING
Table of Contents
Page
Timing/Synchronizing/Adjusting . . . . . . . . . . . . . . . . . 2C-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Timing Pointer Adjustment . . . . . . . . . . . . . . . . . . . 2C-1
Carburetor Synchronization . . . . . . . . . . . . . . . . . . 2C-2
(Models With One Piece Throttle Link
Rod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
(Models With Adjustable Length
Throttle Link Rod) . . . . . . . . . . . . . . . . . . . . . . 2C-2
(Both One Piece and Adjustable Link
Rod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
Timing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Idle Timing Adjustment . . . . . . . . . . . . . . . . . . . 2C-3
Maximum Timing . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4
Throttle Cable Installation . . . . . . . . . . . . . . . . . . . 2C-4

2C-0 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Timing/Synchronizing/
Adjusting

Specifications

FULL THROTTLE RPM 5000 - 5500 RPM

IDLE TIMING 2 - 6° ATDC

IDLE RPM IN
650 - 750 RPM
(FORWARD GEAR)

MAXIMUM TIMING
@ 5000RPM 50/60-22° BTDC 55-16° BTDC
(@ Cranking Speed) 50/60-24° BTDC 55-18° BTDC

SPARK PLUG TYPE NGK BP8H-N-10 *

50/55/60 NGK BPZ8H-N-10**

FIRING ORDER 1-3-2

* 50/55/60 Models, Serial No. D000750 to D181999, came

standard with NGK BU8H spark plugs. NGK BP8H-N-10
can be used in these models. 91-58222A1
51046 51128
** Suppressor (Resistor) Spark Plug.

3. Turn flywheel clockwise until No. 1 (TOP) piston is at

Special Tools top dead center (TDC). Set dial indicator to “0” (zero).
4. Turn flywheel counterclockwise until dial indicator
Part Number Description
needle reads .550 in. (14.0 mm) BTDC, then turn fly-
*91-58222A1 Dial Indicator Gauge Kit wheel clockwise until needle reads .459 in. (11.7 mm)
BTDC exactly.
*91-59339 Service Tachometer
5. Flywheel cover timing pointer (a) should align exactly
*91-99379 Timing Light
with .459 (14.0 mm) timing mark (b) on flywheel. If not,
91-63998A1 Spark Gap Tool loosen two (2) timing pointer attaching screws (c) and
adjust pointer. After adjusting pointer, torque attaching
*May be obtained locally.
screws to 20 lb. in. (2.26 N·m).

Timing Pointer Adjustment

IMPORTANT: Models equipped with adjustable timing c c
pointer or .459 mark on flywheel require the following b
procedure before timing engine.

! WARNING
Remove all spark plugs from engine to prevent engine
from starting. a
1. Remove three (3) spark plugs. 51046

2. Install dial indicator into No. 1 (TOP) cylinder. 6. Remove dial indicator from No. 1 (TOP) cylinder.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2C-1

Carburetor Synchronization d. Look into throats of carburetors and verify all
throttle shutters are completely closed. Tighten
four (4) synchronizing screws (b).
(MODELS WITH ONE PIECE THROTTLE LINK ROD)
a. Remove four (4) attaching screws from sound box
cover and remove cover.
b. Loosen screw (a) of cam follower.
b
c. Loosen two (2) synchronizing screws (b) located
on throttle levers of top and bottom carburetors. a
d. Look into throats of carburetors and verify all
throttle shutters are completely closed. Tighten
synchronizing screws.

b
b

a 51045

(BOTH ONE PIECE AND ADJUSTABLE LINK ROD)

1. Recheck throttle shutters and make any necessary ad-
justments.
2. Hold throttle arm (c) so that idle stop screw (d) is
b against stop.
3. Place roller (e) of cam follower against throttle cam (f)
and adjust idle stop screw (d) to align raised mark (g)
of throttle cam with center of cam follower roller. Tight-
en locknut (h).
51045
7. f

(MODELS WITH 4 ADJUSTABLE LENGTH THROTTLE

LINK ROD) e
a. Remove four (4) attaching screws from sound box
cover and remove cover.
b. Loosen screw (a) of cam follower.
c. Loosen four (4) synchronizing screws (b) located
on link rod.
h

g c

51045

2C-2 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

4. Hold throttle arm at idle position. Adjust cam follower Timing Adjustments
so that a clearance of .005 in.-.040 in.(0.13 mm-1.02
mm) exists between roller (e) of cam follower and
throttle cam (f). Tighten screw (a) securing cam follow- ! CAUTION
er. Engine may be timed while cranking engine with start-
er motor. To prevent engine from starting when being
cranked, all spark plugs must be removed.

f 1. Insert Spark Gap Tool (91-63998A1) into each spark

plug boot and attach alligator clips to good engine
ground.
.005 in.
2. Disconnect remote fuel line from engine.
.040 in.
(0.13 mm 3. Connect remote control electric harness to engine wir-
1.02 mm) ing harness.
e 4. Remove throttle cable barrel from barrel retainer.

IDLE TIMING ADJUSTMENT

1. Connect timing light to No. 1 (TOP) spark plug lead.

! WARNING
While cranking engine, keep clear of propeller as it
may rotate.
a 2. Shift engine to neutral.
IMPORTANT: To time engine at cranking speed, a fully
51069 charged battery must be used.
5. Hold throttle arm (a) against full throttle stop screw (b).
3. Hold throttle arm at idle position, crank engine with
Adjust full throttle stop screw to allow throttle shutters
starter motor and adjust idle timing screw (a) to align
to open fully while providing approximately .015 in. (.38
2 degrees ATDC timing mark of flywheel with timing
mm) freeplay in throttle linkage to prevent carburetor
pointer. Tighten locknut (b).
throttle shutters from acting as throttle stops at wide
open throttle. Tighten locknut (c) on stop screw (b). NOTE: Timing will be 2° - 6° ATDC after adjusting idle RPM.

2° ATDC
10 0 10

20442

51045 51045
6. Reinstall sound box cover.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2C-3

MAXIMUM TIMING 3. Hold throttle arm at idle position (throttle cable barrel
removed from barrel retainer). Adjust idle timing screw
1. Hold control arm (a) so that maximum spark advance
(a) to attain an engine idle RPM of 650-750 RPM in
screw (b) is against stop. Crank engine with starter mo-
“FORWARD” gear. Tighten locknut (b) and turn off en-
tor and adjust maximum spark advance screw to align
gine.
the specified BTDC timing mark on flywheel with timing
pointer. Tighten locknut (c).
b

c
b
a

51045

Throttle Cable Installation

1. With end of throttle cable connected to throttle lever,
hold throttle lever against idle stop. Adjust throttle
cable barrel to slip into barrel retainer on cable anchor
51045
bracket with a very light preload of throttle lever against
NOTE: All timing adjustments made to engine under crank- idle stop. Lock barrel in place.
ing speed conditions should be verified with engine running
and adjustments made if necessary. This is due to advance IMPORTANT: Excessive preload on throttle cable will
characteristics of individual ignition systems. cause difficulty when shifting from forward to neutral.
(Re-adjust throttle cable barrel, if necessary.)
2. Check preload on throttle cable by placing a thin piece
Idle Adjustment of paper between idle stop screw and idle stop. Pre-
load is correct when paper can be removed without
1. With engine is water, connect electrical harness and tearing but has some drag on it. Re-adjust throttle
fuel line to engine. Start engine and allow to warm up. cable barrel, if necessary.
2. Properly adjust carburetor low speed mixture screws.
Initial setting is 1-1/4 turns off seat.

2C-4 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

ELECTRICAL AND IGNITION

2
D

51127

WIRING DIAGRAMS
 Page
Table of Contents
Key/Choke Switch Continuity Test
Page
(COMMANDER 2000 Side Mount Remote Control)
Model 45 Jet Electric Start Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 COMMANDER 2000 Side Mount Remote Control
Model 50/60 Electric Start (Power Trim/Tilt Electric Start with Warning Horn)
Wiring Diagram Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10
(Rectifier Models) . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 COMMANDER Side Mount Remote Control
Model 50/60 Electric Start (Power Tilt Electric Start with Warning Horn)
Wiring Diagram Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11
(Regulator Models) . . . . . . . . . . . . . . . . . . . . . . 2D-3 COMMANDER 2000 Side Mount Remote Control
Model 50/60 Electric Start Tiller Handle (Electric Start with Warning Horn)
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Model 55 Manual Start
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5
Model 50/60 Power Trim
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6
Model 50/60 Manual Start with RED Stator
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7
Model 50/60 Electric Start with RED Stator
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8

2D-0 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Model 45 Jet Electric Start
Wiring Diagram

BLK • BLACK
1
BLU • BLUE
BRN • BROWN
GRY • GREY 2
GRN • GREEN 5
PUR • PURPLE
RED • RED
TAN • TAN
3
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

4 (+)
18 (–)
7

13
17
12

16
14 11

15 8

10
4
3 5
1 - Stator 2 6
2 - Trigger
1 7
3 - Switch Box 8
4 - Voltage Regulator/Rectifier
5 - Starter
53471
6 - Starter Solenoid
7 - Battery
8 - Engine Harness
9 - RPM Limiter
10- Warning Module 9
11- Temperature Switch
12- Enrichment Valve
13- 20 Ampere Fuse
14- Low Oil Sensor
15- To Power Trim Motor
16- Ignition Coil #3 Cylinder
17- Ignition Coil #2 Cylinder
18- Ignition Coil #1 Cylinder

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2D-1

Model 50/60 Electric Start
Wiring Diagram a
(RECTIFIER MODELS)

a - Stator
b - Trigger
c - Switch Box
d - Ignition Coil Cylinder No. 1
e - Ignition Coil Cylinder No. 2 g
f - Ignition Coil Cylinder No. 3
g - Starter Motor
h - Starter Solenoid
b
i - Rectifier i
j - Fuse Holder (20 Amp Fuse) c h
k - Battery
l - Wiring Harness Connector
m- Enrichment Valve
n - Temperature Switch
o - Low Oil Warning Module
p - Low Oil Sensor

e
k

J
m

p n
l

o
BLK • BLACK
BLU • BLUE
BRN • BROWN
GRY • GREY
GRN • GREEN
PUR • PURPLE
RED • RED
TAN • TAN
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

2D-2 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Model 50/60 Electric Start
Wiring Diagram
(REGULATOR MODELS)
a

a - Stator
b - Trigger
c - Switch Box
d - Ignition Coil Cylinder No. 1
e - Ignition Coil Cylinder No. 2
f - Ignition Coil Cylinder No. 3
g - Starter Motor g
h - Starter Solenoid
i - Regulator
j - Fuse Holder (20 Amp Fuse)
k - Battery b
l - Wiring Harness Connector c
m- Enrichment Valve
n - Temperature Switch
o - Low Oil Warning Module
p - Low Oil Sensor

h
d

J
m
p n k

l
o

BLK • BLACK
BLU • BLUE
BRN • BROWN
GRY • GREY
GRN • GREEN
PUR • PURPLE
RED • RED
TAN • TAN
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2D-3

Model 50/60 Electric a

Start Tiller Handle g

Wiring Diagram b

c BLK • BLACK
BLU • BLUE
BRN • BROWN
GRY • GREY
GRN • GREEN
PUR • PURPLE
RED • RED
d i h TAN • TAN
WHT • WHITE
YEL • YELLOW
LIT • LIGHT
(+)
(–)
e

J
k
f
m

p 4
n 3 5
2 6
l 1 7
8
o

a - Stator
b - Trigger 4
5 3
c - Switch Box q
d - Ignition Coil Cylinder No. 1 6 2
e - Ignition Coil Cylinder No. 2 7 1
8
f - Ignition Coil Cylinder No. 3 w
g - Starter Motor
h - Starter Solenoid
i - Regulator
j - Fuse Holder (20 Amp Fuse)
k - Battery r
l - Engine Wiring Harness Connector
m- Enrichment Valve
n - Temperature Switch
o - Low Oil Warning Module
p - Low Oil Sensor
q - RPM Limiter
r - Stop Button t
s - Lanyard Stop Switch
t - Key Switch
u - Neutral Start Switch s
v - Warning Horn v
w- Tiller Handle Wiring Harness Connector u

2D-4 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Model 55 Manual Start a

Wiring Diagram
a - Stator
b - Trigger
c - Switch Box
d - Ignition Coil Cylinder No. 1
e - Ignition Coil Cylinder No. 2
f - Ignition Coil Cylinder No. 3
g - Temperature Switch
h - Overheat Warning Module
i - Warning Horn
j - Stop Button
b
k - Lanyard Stop Switch

BLK • BLACK c
BLU • BLUE
BRN • BROWN
GRY • GREY
GRN • GREEN
PUR • PURPLE
RED • RED
TAN • TAN
WHT • WHITE d
YEL • YELLOW
LIT • LIGHT

h
e

51126

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2D-5

55/60 Manual Start with RED
Stator Wiring Diagram
a - Stator a
b - Terminal Block
c - Adaptor
d - Ground
e - Switch Box
f - RPM Limiter
g - Audio Horn
h - Insulate Unused Red Lead and Secure with
Sta-Strap

d
BLK = Black
BLU = Blue b
BRN = Brown
GRY = Gray e
GRN = Green
ORN = Orange c
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LT = Light
DRK = Dark f

54488

2D-6 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

50/60 Electric Start with RED
Stator Wiring Diagram
a

a - 16 Amp Red Stator

b - Switch Box
c - Stator Adaptor
d - Ground Connection
e - Voltage Regulator
f - Insulate Unused Red Lead

b c d

f
e (+)
(–)

4
3 5
2 6
BLK = Black 1 7
BLU = Blue 8
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LT = Light
DRK = Dark

54982
90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2D-7
Model 50/60 Power Trim
Wiring Diagram
a - Power Trim
b - Power Trim Relay
c - Engine Starter Motor Solenoid
d - Rectifier
e - Cowl Mounted Trim Switch
f - Red (+) Battery Cable
g - Fuse Holder (20 Amp Fuse)
h - Engine Wiring Harness Connector
i - Remote Control Wiring Harness Connector

i
BLK • BLACK
BLU • BLUE
BRN • BROWN
GRY • GREY
a

GRN • GREEN
PUR • PURPLE
RED • RED
TAN • TAN

h
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

e
g
c

d
b

51125

2D-8 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

Key/Choke Switch Continuity
Test
(COMMANDER 2000 Side
Mount Remote Control)

23894

“OFF” BLK/YEL - BLK

“RUN” RED - PUR
“START” RED - PUR - YEL/RED
PUSH (CHOKE)* RED - YEL/BLK
*Key switch must be positioned to “RUN” or “START”
and key pushed in to actuate choke, for this continuity
test.

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2D-9

COMMANDER 2000 Side
Mount Remote Control
(Power Trim/Tilt Electric Start
with Warning Horn)
Wiring Diagram
a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness Connector g
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch

d f
e a

BLK • BLACK
BLU • BLUE
BRN • BROWN
GRY • GRAY
GRN • GREEN
PUR • PURPLE
RED • RED
TAN • TAN
WHT • WHITE
YEL • YELLOW

23891

2D-10 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

COMMANDER Side Mount
Remote Control (Power Tilt
Electric Start with Warning
Horn) Wiring Diagram
a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness

h
g
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch
h - Wire Retainer
i – Control Handle
j - Trim Harness Bushing
k - Trim Harness Connector
l - Lead to Trim Indicator Gauge

BLK • BLACK

i
BLU • BLUE
BRN • BROWN
GRY • GREY
GRN • GREEN
PUR • PURPLE
•

f
RED RED
TAN • TAN
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

J
d
a
e

c
k

24072

90-817643R1 DECEMBER 1996 ELECTRICAL and IGNITION - 2D-11

COMMANDER 2000 Side
Mount Remote Control (Elec-
tric Start with Warning Horn)
Wiring Diagram

d
e
f
a
b

a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness Connector c
e - Wiring Harness Connector
f - Warning Horn

BLK • BLACK
BLU • BLUE
BRN • BROWN
GRY • GREY
GRN • GREEN
PUR • PURPLE
RED • RED
TAN • TAN
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

2D-12 - ELECTRICAL and IGNITION 90-817643R1 DECEMBER 1996

FUEL SYSTEMS

3
A

51046

CARBURETION
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Attenuator Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
WME Carburetor Specifications . . . . . . . . . . . . . . . . . 3A-4
Reed Valve Specifications . . . . . . . . . . . . . . . . 3A-4
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Carburetion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8
Fuel System Troubleshooting . . . . . . . . . . . . . . . . 3A-8
Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . 3A-8
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . . 3A-11
Initial Starting Adjustment . . . . . . . . . . . . . . . . 3A-11
idle Speed Adjustment . . . . . . . . . . . . . . . . . . 3A-11
Idle Mixture Screw Adjustment . . . . . . . . . . . 3A-11
Carburetor Float Adjustment . . . . . . . . . . . . . 3A-11
Main (High Speed) Jet Adjustment . . . . . . . . 3A-11
WME Carburetor Specifications . . . . . . . . . . . . . . . . 3A-12
Rejetting Carburetors For High Altitude
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12
Jet Orifice Size/Part Number Chart . . . . . . . 3A-12
Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . . 3A-13
Carburetor Disassembly . . . . . . . . . . . . . . . . . . . . 3A-13
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 3A-15
Carburetor Reassembly . . . . . . . . . . . . . . . . . . . . 3A-15
Carburetor Installation . . . . . . . . . . . . . . . . . . . . . 3A-17

3A-0 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Specifications Special Tools

Idle RPM 650-700 Part No. Description

(in “Forward” Gear)
91-36392 Carburetor Scale
Float Level 9/16 in. (14.3mm)
Fuel Pump Pressure
(@ W.O.T.) 4-7 PSI (28-43 kPa)

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-1

Attenuator Plate

14
12

11 8
7

12
9
10

13
11
12 5
4

6 1

3A-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 Attenuator Plate
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SOUND ATTENUATOR
2 4 SCREW Drive Tight
3 1 CAP PLUG
4 3 SEAL
5 2 SOUND ATTENUATOR PLATE
6 6 SCREW 100 135.5
7 1 ARM
8 1 ROLLER
9 1 SCREW Drive Tight
10 1 WASHER
11 2 TUBING (4-1/4 IN.)
12 AR STA-STRAP
13 3 GASKET
14 1 THROTTLE LINK

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-3

WME Carburetor Specifications

Carburetor Number Stamped at TOP of Carburetor Mounting Flange

Carburetor Number Location Model H.P. Main Jet Bowl Vent Jet

WME 43-1 Top Carburetor

WME 43-2 Center Carburetor 50 .048 .090
WME 43-3 Bottom Carburetor

WME 45-1 Top Carburetor

WME 45-2 Center Carburetor 60 .062 .090
WME 45-3 Bottom Carburetor

WME 44-1 Top Carburetor

WME 44-2 Center Carburetor 55/60 .060 None
WME 44-3 Bottom Carburetor

REED VALVE SPECIFICATIONS

Reed Valve Opening (Maximum)

.020 in. (0.5 mm)

.020

3A-4 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Notes:

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-5

Carburetor

2
4

11
10

92
7
8
7 9

6
3

15 5
12
16
13
1

17
18
19
20
14

21

22

25
26
27
23

24

7 Loctite 271 (92-809820)

92 Loctite 7649 Primer (92-809824)

3A-6 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 Carburetor
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CARBURETOR (TOP)
1 1 CARBURETOR (CENTER) 50 - WME-43
1 1 CARBURETOR (BOTTOM)
1 1 CARBURETOR (TOP) 55/60 SeaPro/Marathon
1 1 CARBURETOR (CENTER)
1 1 CARBURETOR (BOTTOM) WME-44
1 1 CARBURETOR (TOP) 60 - WME-45
1 1 CARBURETOR (CENTER) BEACHING/PONTOON/BIG FOOT
1 1 CARBURETOR (BOTTOM) FORMULA/MAGNUM III
2 2 SCREW–throttle adjustment (UPPER/BOTTOM)
3 1 THROTTLE SHAFT (UPPER)
4 1 THROTTLE SHAFT (CENTER) 50/60
4 1 THROTTLE SHAFT (BOTTOM)
3 2 THROTTLE SHAFT (UPPER/BOTTOM)
4 1 THROTTLE SHAFT (CENTER) WME-44
5 3 SPRING–throttle return
6 3 VENT JET (.090 - 50/60)
7 3 IDLE NEEDLE
8 3 SPRING–idle needle
9 3 GASKET–cover plate
10 3 COVER PLATE
11 6 SCREW–cover plate 18 2.0
12 3 GASKET–flange
13 1 LEVER–oil pump (WME43/45 - Bottom)
14 1 SCREW–oil pump lever (WME43/45 - Bottom)
15 6 SCREW–throttle valve 6 0.7
16 3 THROTTLE VALVE
17 3 RETAINING RING
18 3 FLOAT SHAFT
19 3 GASKET–nozzle well
20 3 GASKET–fuel bowl
21 3 INLET NEEDLE VALVE
22 3 FLOAT
23 12 SCREW–fuel bowl 18 2.0
24 1 FUEL BOWL (UPPER)
24 2 FUEL BOWL (CENTER/BOTTOM)
25 3 PLUG KIT 25 3.0
26 3 SEAL–bowl drain
27 3 MAIN FUEL JET (.048 - 50) 14 1.5
27 3 MAIN JET (.060-55/60 SeaPro/Marathon/Pontoon) 14 1.5
27 3 MAIN FUEL JET (.062 - 60) 14 1.5

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-7

Carburetion Troubleshooting Charts

Fuel System Troubleshooting PROBLEM 1: ENGINE TURNS OVER BUT WILL

NOT START OR STARTS HARD
Troubles, that are caused by items 1-thru-5, listed below, WHEN COLD
may give the impression that a problem exists in the fuel
system: Possible Cause Corrective Action
1. Spark plugs Improper starting proce- Check procedure, as out-
dure lined in “Operation and
2. Ignition spark voltage Maintenance Manual.”
3. Cylinder compression Fuel tank empty; improp- Check fuel in fuel tank
4. Reed valves erly mixed fuel; con- and replace or add.
taminants (water, dirt,
5. Ignition timing etc.) in fuel.
Fuel tank air vent closed Air vent must be open
or restricted. and free from contami-
nants.
A pinched or restricted Check, and replace as
fuel line. needed.
Dirty or restricted fuel fil- Check, replace or clean.
ter
Enrichener Valve not op- Check enrichener sys-
erating. tem. (Refer to “Enri-
chener System”
following.)
An inlet needle (in carbu- Remove, clean, or re-
retor) that is stuck place.
open or closed. (A
needle stuck open, will
cause a flooding con-
dition. A needle stuck
closed, will prevent
fuel from entering car-
buretor.)

Anti-Siphon valve re- Refer to “Checking for

stricting fuel flow. Restricted Fuel Flow
caused by Anti-Siphon
Valves”, following.

See “Checking for Restricted Fuel Flow caused

by Anti-Siphon Valves, page 3A-13.

3A-8 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 PROBLEM: ENGINE FLOODS PROBLEM 1: ENGINE IDLES ROUGH AND
Possible Cause Corrective Action STALLS
PROBLEM 2: ENGINE RUNS UNEVEN OR
Dirt or foreign particles Flush out inlet seat and SURGES
are preventing inlet clean inlet needle. PROBLEM 3: ENGINE WILL NOT ACCELERATE
needle from seating.
Worn inlet needle. Replace. Possible Cause Corrective Action
Fuel tank air vent closed Check - Air vent must be
Punctured float. Replace. or restricted. open all-the-way and
Incorrect float setting. Reset float. free from restrictions.

A pinched, cut or re- Check all fuel lines and

stricted fuel line; also replace as needed.
PROBLEM: ENGINE RUNS TOO LEAN
loose fuel line connec- Check and tighten all
Possible Cause Corrective Action tion. fuel line connections.
Carburetor is loose. Air Tighten bolts securely. A dirty or restricted fuel Check, replace, or clean
leaks past mixing Tighten cover or re- filter. all fuel filters.
chamber cover. place gasket.
Restricted filter in fuel Clean by rinsing in clean
Fuel level too low. Reset float level. tank. lead-free gasoline or
Clogged high speed jet. Check and clean. kerosene.

Restricted fuel flow to Check fuel lines and fil- Improperly mixed fuel; Check fuel and replace,
carburetor. ter(s) for restricted contaminants (water, if necessary.
flow. dirt, etc,) in fuel.
An inlet needle (in carbu- Remove and replace
Incorrect high speed jet. Refer to main jet chart retor) that is either with new inlet needle.
and replace with prop- stuck open or closed.
er jet. (A needle, that is stuck
Idle mixture set too lean. Adjust to run richer. open, will cause a
flooding condition. A
needle, that is stuck
Air leakage into fuel sys- Check fuel line connec- closed, will prevent
tem. tions, hose clamps, fuel from entering car-
fuel pump, and fuel buretor.)
outlet tube (located in
fuel tank) for loose fit- Incorrect idle mixture ad- Re-adjust.
tings. justment.
Anti-Siphon valve re- Refer to “Checking for re- Damaged fuel pump dia- Replace.
stricting fuel flow. stricted fuel flow phragm.
caused by Anti-Siphon
valves.” Carburetor is loose. Tighten bolts securely.

Chamber cover leaking Tighten or replace gas-

air. ket.
PROBLEM: ENGINE RUNS TOO RICH
Off idle holes plugged. Blow out with com-
Possible Cause Corrective Action pressed air.
Fuel level too high. Reset float to correct Main nozzle or idle Blow out with com-
level. nozzle air bleed holes pressed air.
plugged.
Carburetor floods. See preceding “Engine
Floods” Improper main jet or re- Clean or replace with
stricted jet. proper jet (refer to
Idle nozzle air Blow out with com- “Main Jet Chart”).
holes plugged. pressed air.
Damaged reed(s). Inspect reeds as outlined
Restricted air flow. Check cowl air inlet and in Section 4A.
carburetor for obstruc- A crack in the fuel pick- Replace.
tions. up outlet tube (located
Main Fuel Jet loose. Retighten Jet. in fuel tank).

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-9

 CHECKING FOR RESTRICTED FUEL FLOW CAUSED
PROBLEM 1: ENGINE IDLES ROUGH AND BY ANTI-SIPHON VALVES
STALLS
While anti-siphon valves are helpful from a safety stand-
PROBLEM 2: ENGINE RUNS ENEVEN OR point, they clog, they may be too small, or they may have
SURGES too heavy a spring. The pressure drop across these valves
PROBLEM 3: ENGINE WILL NOT ACCELERATE. can, create operational problems and/or powerhead dam-
age by restricting fuel. Some symptoms of restricted (lean)
Possible Cause Corrective Action
fuel flow, are:
A crack in the fuel outlet Replace. 1 - Loss of fuel pump pressure
tube (located in fuel 2 - Loss of power
tank.) 3 - High speed surging
Anti-Siphon valve re- Refer to “Checking for 4 - Preignition/detonation (piston dome erosion)
stricting fuel flow. Restricted Fuel Flow 5 - Outboard cuts out or hesitates upon acceleration
Caused by Anti-Si- 6 - Outboard runs rough
phon Valves,” follow- 7 - Outboard quits and cannot be restarted
ing. 8 - Outboard will not start
9 - Vapor lock
Any type of anti-siphon device must be located between
PROBLEM : FUEL BLOW-BACK OUT OF CAR- the outboard fuel inlet and fuel tank outlet. A method of
BURETOR checking [if such a device (or bad fuel) is a problem source]
Possible Cause Corrective Action is to operate the outboard with a separate fuel supply which
is know to be good.
Chipped/Broken (reed- Replace Reeds.
block) Reeds If, it is found that the anti-siphon valve is the cause of the
problem, either 1) replace the anti-siphon valve or 2) re-
PROBLEM : ROUGH IDLE place it with a solenoid-operated fuel shutoff valve.
If related to reed-block, Replace Reeds.
indicates excessive
preload in reeds.

PROBLEM : CAN’T REDUCE ENGINE RPM TO

SLOW IDLE
Multiple chipped reeds Replace Reeds.

3A-10 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Carburetor Adjustments CARBURETOR FLOAT ADJUSTMENT
1. Remove carburetor as outlined in “Carburetor Remov-
al,” following.
INITIAL STARTING ADJUSTMENT
2. Remove fuel bowl and gasket and check float level us-
Turn idle mixture screw in (clockwise) until it seats LIGHT-
ing a carburetor scale.
LY--then back-off (each carburetor) 1-1/4 turns.
3. If necessary, adjust float level by bending metal tab (on
float) to which inlet needle is clipped.
IDLE SEED ADJUSTMENT
1. Adjust engine idle RPM as outlined in Section 2C 9/16″ (14.3mm)
“Timing/Synchronizing/Adjusting.”

IDLE MIXTURE SCREW ADJUSTMENT a

1. Start engine and allow to warm-up. Throttle back en-
gine to idle for about one minute.
2. With engine running at idle speed in “Forward” gear -- b
turn idle mixture screw IN (clockwise) until engine
starts to “bog” down and misfire. Back out 1/4 turn or
more.

a
51046
a - Metal Tab
b - Inlet Needle

MAIN (HIGH SPEED) JET ADJUSTMENT

The carburetor has a fixed high speed jet. Extreme
changes in weather (temperature and humidity) and/or ele-
vation may result in a too lean or rich fuel mixture at wide-
open-throttle, which may require a change in the high
speed jet. A smaller size main jet will lean the fuel mixture,
and a larger size jet will enrich the fuel mixture.

50555

a - Idle Mixture Screw (on each carburetor)

3. Check for too lean mixture on acceleration.

4. DO NOT adjust leaner than necessary to attain rea-
sonably smooth idling. When in doubt, stay on the
slightly rich side of the adjustment.
a

b
51118

a - High Speed Jet

b - Bowl Drain Plug
c - Bowl Vent Jet
d - Idle Mixture Screw

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-11

WME Carburetor
Specifications

Carburetor Number Stamped at TOP of carburetor mounting flange.

Model
Carburetor Number H.P. Main Jet Bowl Vent Jet
WME-23 50 .052 .092
WME-26 50 .048 .090
WME-27 55 .060 None
WME-22 A or B 60 .070 .090
WME-35 60 .068 None
WME-28 60 .062 .090
WME-43 50 .048 .090
WME-44 55/60 .060 None
WME-45 45/60 .062 .090

REJETTING CARBURETORS FOR HIGH ALTITUDE *Standard Jets listed are for operation of engine from 0 ft. – 2500 ft.
OPERATION (0–762 M) of elevation.

The carburetor jet installed at the manufacturer is for en-

gine operation at sea level through an elevation of 2500 JET ORIFICE SIZE/PART NUMBER CHART
feet (762m) above sea level. If the engine is to be operated NOTE: Thread size for jets is 10-32.
at an altitude higher than 2500 feet above sea level, it will
be necessary to rejet (remove the carburetor jets and in-
stall jets with a different orifice size) the carburetors. Each JET ORIFICE SIZE/PART NUMBER CHART
time the engine is to be operated at a different elevation Jet Jet
Orifice Part Orifice Part
from the previous time, refer to the “Carburetor Jet Charts” Size Number Size Number
following, and rejet the carburetors for elevation engine will (inch) (inch)
be operated at.
.040 19266040 .058 1395-7831
.042 1399-5315 .060 1395-6487
HIGH ALTITUDE JET CHART .044 1395-7394 .062 1399-4217
.046 1399-5317 .064 1399-4216
.048 1395-6246 .066 1399-4215
Engine Operation .050 1395-6028 .068 1395-6029
Elevation High Speed Jet Size .052 1395-6359 .070 1395-6030
(Above Sea Level) .054 1399-5225 .072 1395-6207
.056 1399-5213 .074 1399-3794
2500’-5000’ .002” smaller (than standard jet) .076 1399-3796 .094 1395-8423
(750-1500m) .078 1395-6680 .096 1399-6249
.080 1395-6201 .098 1395-7335
5000’-7500’ .004” smaller (than standard jet) .082 1399-3518
.084 1399-3517
(1500-2250m) .086 1395-5815
7500’ and Up .006” smaller (than standard jet) .088 1395-6202
.090 1395-6247
(2250m and Up) .092 1395-5733

3A-12 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Carburetor Removal Carburetor Disassembly
• Remove four screws and lift off attenuator. • Remove fuel bowl.
• Remove six screws and remove carburetors.
Disconnect linkages and fuel and primer lines.
a

a
51119
b

a - Fuel Bowl

• Remove float pin and remove float.

• Remove fuel bowl gasket.

50527

a - Attenuator Screw (4)

b - Carburetor Screw (6)

51115

a - Float Pin
b - Float
c - Gasket

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-13

• Remove fuel inlet needle. • Remove main jet plug and gasket.
• Remove stem gasket. • Remove main jet.

b
b

a
51116 51116

a - Fuel Inlet Needle a - Main Jet Plug and Gasket

b - Stem Gasket b - Main Jet

• Remove mixing chamber cover and gasket. NOTE: It is not necessary to disassemble carburetor be-
yond this point for cleaning. Examine throttle shaft for wear
• Remove idle mixture screw. and inspect for damaged throttle shutter plate.
• Remove bowl vent jet If removal of throttle shaft and/or throttle shutter plate is
necessary, remove 2 screws, which secure throttle shutter
a plate to throttle shaft. Remove retaining clip from end of
throttle shaft, then pull shaft out of carburetor.
b

a
c

c b

51116

a - Mixing Chamber Cover and Gasket

51117
b - Idle Mixture Screw
c - Bowl Vent Jet
a - Throttle Shaft
b - Screw (2)
c - Throttle Shaft Spring

3A-14 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Cleaning and Inspection • Spring tension on stud.

1. Carefully inspect carburetor body and fuel bowl for

cracks, stripped threads, plugged or restricted pas-
sages and passage plugs that show signs of leakage.
2. Thoroughly clean all carburetor parts with a mild clean- c
ing solution (that will not damage rubber or plastic) to
remove dirt, and varnish that may have accumulated.
3. After washing parts, blow parts dry with compressed
air. Be sure to blow air thru all passages, orifices and
nozzles.
4. Check float hinge in the float pin area for wear and d
check float for leaks. Replace parts as necessary.
5. Examine inlet needle for wear. If worn, replace with
new inlet needle. 51259

c - Spring
Carburetor Reassembly d - Stud

• Install mixing chamber cover and gasket as shown.

• If removed, install throttle shaft, throttle shutter plate, 2
screws (use Loctite Grade ‘A’), and throttle shaft spring • Install idle mixture screw.
as shown. Install retaining clip on other end of shaft. • Install bowl vent jet
d
a a
d b

c b

51117

a - Throttle Shaft 51116

b - Screws (2) (Torque 6 lb. in. (0.7 N·m)
c - Throttle Shaft Spring a - Mixing Chamber Cover and Gasket
b - Idle Mixture Screw
c - Bowl Vent Jet
d - Screw (2) Torque 18 lb. in. (2.1 N·m)

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-15

• Install main jet. • Attach Spring Clip on Inlet Needle to metal float tab and
place needle into its seat.
• Install main jet plug and gasket.

b
51116
b

a - Main Jet [Torque 14 lb. in (1.6 N·m)]

b - Main Jet Plug and Gasket [Torque 22 lb. in. (2.5 N·m)] 51115
• Install stem gasket. a - Spring Clip
• Install fuel bowl gasket. b - Float Tab

• Install float into carburetor with float pin.

b • Adjust float following “Carburetor Float Adjustment,”

a Page 3A-13.

51119

a - Stem Gasket
b - Fuel Bowl Gasket

NOTE: If Spring Clip on Inlet Needle was removed, or if b 51115

needle was replaced, be sure spring clip is reattached.
a - Float
b - Float Pin

3A-16 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

• Install float bowl. Carburetor Installation
• Install carburetors, attenuator plate, connect linkages,
and fuel and primer lines.
• Install sound attenuator.

b 51116
b
a
a - Fuel Bowl
b - Screw (4) Torque 18 lb in. (2.1 N·m)

50527

a - Attenuator Brackets (2)

b - Carburetor Screw (6) Torque 100 lb. in. (11.5 N·m)
c - Attenuator Screw (4)

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3A-17

FUEL SYSTEMS

3
B

FUEL PUMP
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1
Fuel Pump (50/60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2
Fuel Pump (55/60 Seapro/Marathon) . . . . . . . . . . . . 3B-4
Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
Fuel Pump Description/Operation . . . . . . . . . . 3B-6
Checking for Restricted Fuel Flow
Caused by Anti-siphon Valves . . . . . . . . . . . . . 3B-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
Troubleshooting Fuel Pump . . . . . . . . . . . . . . . . . . 3B-7
Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8
Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3B-8
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3B-8
Fuel Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 3B-9
Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 3B-9
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . 3B-9
Fuel Pump Exploded View . . . . . . . . . . . . . . . . . . . . . 3B-10
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 3B-10
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-11
Fuel Tank Components . . . . . . . . . . . . . . . . . . . . . . . 3B-11
Fuel Line and Primer Bulb Assembly . . . . . . . . . . . . 3B-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-13

3B-0 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Specifications

Fuel Pump Pressure

(@ W.O.T.) 4-7 PSI (28-43 kPa)

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-1

Fuel Pump (50/60)

28
A
20
21
29 19
21 21
30
29 21 18
29
33 7 21
21 6
31 1 3
4 5

5 12
32 11 4
3 2
19
9 14
17 21

10
15
13 8
22
24
B
21 16
C 22
22
21
26 23 27
15
21 21
25 22
21

19 Perfect Seal (92-34227-1)

A – To Carburetor
B – To Crankcase
C – To Oil Pump

3B-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 Fuel Pump (50/60)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL PUMP ASSEMBLY
2 1 DIAPHRAGM KIT
3 2 RUBBER CHECK VALVE
4 2 CHECK VALVE
5 2 RETAINER
6 1 SPRING
7 1 CAP
8 1 SPRING
9 1 CAP
10 1 DIAPHRAGM
11 1 GASKET
12 1 GASKET–boost
13 1 GASKET–pulse
14 1 PLATE
15 2 FITTING
16 2 SCREW–fuel pump 55 6.0
16 2 SCREW–fuel pump to crankcase 55 6.0
17 1 BASE
18 1 HOSE
19 1 FUEL FILTER
20 1 FUEL LINE
21 AR STA-STRAP
22 3 HOSE (1-1/4″)(1-1/4″)(14-1/4″)
23 1 TEE
24 1 CHECK VALVE
25 1 FUEL CONNECTOR
26 1 SCREW 80 9.0
27 1 HOSE (4-1/4″)
28 1 SOLENOID VALVE
29 3 HOSE (1-3/4″)(3-1/4″)(11-1/2″)
30 1 TEE FITTING
31 1 HOSE (16″)
32 1 CLAMP
33 1 SCREW 100 135.5

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-3

Fuel Pump (55/60 Seapro/Marathon)

26
27

26 A

20
26

7
6 1
3 4
25 5

5 12
4 3 2
26 11
9 14
19
17
10 19
8 15
13
18
B 16

19

19
21
15
19
29
19
28 24
19
23

22

19 Perfect Seal (92-34227-1)

A – To Carburetor
B – To Crankcase

3B-4 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 Fuel Pump (55/60 Seapro/Marathon)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL PUMP ASSEMBLY
2 1 DIAPHRAGM KIT
3 2 RUBBER CHECK VALVE
4 2 CHECK VALVE
5 2 RETAINER
6 1 SPRING
7 1 CAP
8 1 SPRING
9 1 CAP
10 1 DIAPHRAGM
11 1 GASKET
12 1 GASKET–boost
13 1 GASKET–pulse
14 1 PLATE
15 2 FITTING
16 2 SCREW–fuel pump 55 6.0
16 2 SCREW–fuel pump to crankcase 55 6.0
17 1 BASE
18 2 HOSE (10″)(14-1/4″)
19 AR STA-STRAP
20 1 HOSE
21 1 HOSE (4-1/4″)
22 1 FUEL FILTER
23 1 BRACKET
24 1 NUT Drive Tight
25 1 TEE FITTING
26 4 HOSE (1-1/2″)(5-1/2″)(9-1/2″)(9-1/2″)
27 1 PRIMER BULB
28 1 FUEL CONNECTOR
29 1 SCREW 80 9.0

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-5

 CHECKING FOR RESTRICTED FUEL FLOW CAUSED
! WARNING BY ANTI-SIPHON VALVES
FIRE AND EXPLOSION HAZARD. Observe fire preven- While anti-siphon valves are helpful from a safety stand-
tion rules, particularly NO SMOKING. Before servicing point, they clog, they may be too small, or they may have
any part of the fuel system, disconnect electrical sys- too heavy a spring. The pressure drop occures these
tem at the battery. Drain the fuel system completely. valves can create operational problems and/or powerhead
Use an approved container to collect and store fuel. damage by restricting flow of fuel. Some symptoms of re-
Wipe up any spillage immediately. Materials used to stricted (lean) fuel flow, are:
contain spillage must be disposed of in an approved 1 - Loss of fuel pump pressure
receptacle. Any fuel system service must be per- 2 - Loss of power
formed in a well ventilated area. 3 - High speed surging
4 - Preignition/detonation (piston dome erosion)
FUEL LEAKAGE FROM ANY PART OF THE FUEL SYS- 5 - Outboard hesitates upon acceleration
TEM CAN BE A FIRE AND EXPLOSION HAZARD 6 - Outboard runs rough
WHICH CAN CAUSE SERIOUS BODILY INJURY OR 7 - Outboard quits and cannot be restarted
DEATH. Careful periodic inspection of the entire fuel 8 - Outboard will not start
system is mandatory, particularly after engine storage. 9 - Vapor lock
All fuel components, including fuel tanks, whether Any type of anti-siphon device must be located between
plastic, metal, or fiberglass, fuel lines, primer bulbs, the outboard fuel inlet and fuel tank outlet. A method of
fittings, swelling, and must be inspected for corrosion. checking [if such a device (or bad fuel) is a problem source]
Any sign of leakage or deterioration necessitates re- is to operate the outboard with a separate fuel supply which
placement before further engine operation. is known to be good.
If it is found that the anti-siphon valve is the cause of the
problem, either 1) replace the anti-siphon valve, or 2) re-
Fuel Pumps place it with a solenoid-operated fuel shutoff valve.

General Information
Testing
FUEL PUMP DESCRIPTION/OPERATION
Install clear fuel hose(s) between fuel pump and carbure-
The fuel pump is a crankcase-pressure-operated, dia- tor(s). Run engine, and inspect hose(s) for air bubbles. If
phragm-type pump. Crankcase pulsating pressure is air bubbles are found, see “Air Bubbles in Fuel Line” . If air
transferred by way of a passage (hole) from the crankcase bubbles are NOT found, see “Lack of Fuel Pump Pres-
to the fuel pump. sure”.
When the piston travels upward, a vacuum is created in the
crankcase. This vacuum pulls in the fuel pump diaphragm,
the inlet check valve (in fuel pump) is opened and, and fuel
is drawn into fuel pump.
Downward motion of the piston forces out the fuel pump di-
aphragm, closes the inlet check valve (to keep fuel from re-
turning to fuel tank) and opens the outlet check valve, forc-
ing fuel to the carburetors.

3B-6 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Troubleshooting Fuel Pump PROBLEM: LACK of FUEL PUMP PRESSURE
Possible Cause Corrective Action
PROBLEM: AIR BUBBLES IN FUEL LINE
An anti-siphon valve Read “Checking for
Possible Cause Corrective Action
Restricted Fuel Flow
Low fuel in fuel tank. Fill tank Caused by Anti-Siphon
Valves” preceding.
Loose fuel line connection Check and tighten
connections. Air in fuel line “Air Bubbles in Fuel Line,”
preceding.
Fuel pump fitting loose. Tighten fitting.
A dirty or clogged fuel filter Clean or replace filter.
A hole or cut in fuel line. Check condition of fuel
lines and replace any The fuel pickup in fuel tank Clean or replace pickup.
found bad. clogged or dirty.
Fuel pump anchor Tighten all screws Worn out fuel pump Rebuild pump.
screw(s) loose. diaphragm.
Fuel pump gasket(s) Rebuild fuel pump. Defective (hole or crack) Rebuild pump.
worn out. check valve(s) in fuel
pump (unlikely).
Broken check valve Rebuild pump.
retainer.
Pulse hole plugged. Remove pump and clean
out hole.
Hole in pulse hose. Replace pulse hose

Loose pulse hose. Tighten connection.

Boost diaphragm gasket Check seal between mat-
distorted or out of place. ing surfaces where
“rib” divides pulse cham-
ber and gasket must align
with rib; check for dis-
torted gasket. Align or re-
place gasket if necessary.

IMPORTANT: Align diaphragm aligning tabs with fuel

pump aligning tabs during reassembly.

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-7

Fuel Pump Removal Fuel Pump Disassembly
1. Remove oil tank from outboard. Refer to Section 8A 1. Remove bolts (a) and chamber plate (b).
“Oil Injection System.”
a
2. Remove fuel “inlet” hose, (a) “outlet” hose, (b) and b
pulse hose (d).
3. Remove two bolts (f) securing fuel pump to power-
head.
f
e
b
d
a
e
a
e
e 51267
2. Disassemble fuel pump as shown in “Fuel Pump Ex-
a ploded View.”
e
c
e
f Cleaning and Inspection
1. Clean fuel pump housing, chamber plate and pump
base, then dry with compressed air.
2. Look at spring for signs of bad coils or other damage.
51267 3. Check pump body, chamber plate and pump base, for
cracks or rough gasket surfaces.
a - Inlet Fuel Hose
b - Outlet Fuel Hose 4. Check hoses for looseness or signs of leakage.
c - Oil Injection hose - From Oil Tank
d - Pulse Hose - From Crankcase 5. Look at check valve discs for cracks, tears, or other
e - Sta-Strap (6) damage.
f - Bolts (2)
6. Repair of fuel pump is limited to the replacement of
4. Remove gasket from backside and replace gasket as
those bad parts found during inspection.
necessary -- check gasket in port area.

b
a

51267
a - Gasket
b - Port Area

3B-8 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Fuel Pump Reassembly

Check Valve Assembly a

1. Insert retainer (a) thru plastic disc (b) and rubber check b
valve (c).

23601

a
a

c b

23601
2. Install check valves and retainers into fuel pump body.

23610

Fuel Pump Assembly

1. Assemble remaining components as shown in “Fuel
Pump Exploded View”.
2. Install bolts (a) and torque to 40 lb. in. (4.5 N·m).

51267

23601

3. With retainer installed in pump body, break retainer

rod (a) from retainer (b) by bending sideways.
4. Reinstall rod (a) into retainer cap (b) and, use a small
hammer or hammer and punch to tap rod down into re-
tainer until flush with top of retainer.

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-9

 NOTE: In fuel pump reassembly, remember that respec-
Fuel Pump Exploded View tive diaphragms go against the mating surfaces of the fuel
IMPORTANT: Align all gasket and diaphragm aligning pump body, and respective gaskets are between the dia-
tabs with fuel pump aligning tabs during reassembly. phragms and end caps. Gaskets should always be re-
placed on fuel pump during reassembly.

1- Fuel Pump Body

2- Rubber Disc (2)
3- Plastic Check Valve Disk (2)
4- Retainer (2)
5- Spring
6- Cap
7- Diaphragm
8- Boost Gasket
9- Spring
10- Cap
11 -Chamber Plate
12- Diaphragm
13- Pulse Gasket
14- Fuel Pump Base
15- Gasket
16- Bolt 40mm (2)
Bolt 50mm (2)
17- Pipe Plug
18- Fitting 90°

Torque Specifications
a 40 lb. in. (4.5 N·m) 50569

NOTE: Gaskets, items 8 and 13 were not used on early

production units, however they should be installed
when rebuilding a fuel pump.

3B-10 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Fuel Tank Fuel Tank Components
Maintenance 12
13
The inside of the fuel tank should be cleaned once each 4
season. Dirt or water may have entered the fuel tank during
refilling. Clean the tank by flushing with clean, lead-free 6
gasoline or kerosene. 5
If a fuel restriction problem is encountered, the fuel filter on 7
end of outlet tube may be obstructed. Remove cover and
inspect filter for varnish, dirt or deposits. Clean filter by rins- 8
ing in clean, lead-free gasoline or kerosene.
10
9
1 11
c
b 2

a 3

51046

a - Fuel Tank Filter REF.

b - Pick-Up Tube NO. DESCRIPTION QUAN.
c - Cover
d - Gasket 1 FUEL TANK ASSEMBLY (PLASTIC-6.6 GAL.) 1
2 FILLER CAP 1
3 GASKET, filler cap 1
4 PICK-UP BODY ASSEMBLY 1
5 ADAPTOR 1
6 WINDOW ASSEMBLY 1
7 GASKET, pick-up body 1
8 FUEL GAUGE ASSEMBLY 1
9 SCREW, fuel gauge 2
10 HOSE 1
11 FILTER 1
12 SCREW, pick-up body 6
13 WASHER, pick-up body screw 6

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-11

Fuel Line and Primer Bulb
Assembly

6
3 10
8
5
9 11
2
12
13
14
5 7
9

REF.
NO. DESCRIPTION
1 FUEL LINE ASSEMBLY
2 PRIMER BULB ASSEMBLY
3 CHECK VALVE, inlet
4 FITTING, outlet
5 CLAMP, primer bulb to check valve (LARGE)
6 CLAMP, fuel line to check valve (SMALL)
7 CONNECTOR, fuel tank (OUTLET)
8 CONNECTOR, engine (INLET)
9 CLAMP, fuel line to connector
10 BAYONET BODY ASS’Y
(FUEL TANK END)
11 STEM, bayonet body
12 “O” RING, bayonet body stem
13 SPRING, bayonet body stem
14 WASHER, CUPPED - body spring

3B-12 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Maintenance 2. To install fuel line clamps, grip hose clamp with pliers
and push down on hook with screwdriver until hooks in-
Periodically check fuel line and primer bulb for cracks, terlock.
breaks, restrictions or chafing. Check all fuel line connec-
Installing Fuel Line Clamps
tions for tightness. All fuel line connections must be
clamped securely.
Primer bulb assembly has 2 check valves: Fuel inlet (to-
ward tank) and a fuel outlet (toward engine).
The fuel inlet valve allows fuel to fill primer bulb but closes
to prevent fuel from returning to tank when bulb is
squeezed. The fuel outlet valve opens when primer bulb is
squeezed to allow fuel flow to carburetor, but closes as bulb
is released to prevent fuel from returning to primer bulb.

FUEL LINE CLAMP REMOVAL AND INSTALLATION

1. To remove fuel line clamps, grip clamp with pliers and
bend over, lapping hook backward.
Removing Fuel Line Clamps

51115

51115

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3B-13

FUEL SYSTEMS

3
C

ENRICHMENT
Table of Contents
Page
Enrichener System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
Enrichener Valve Test . . . . . . . . . . . . . . . . . . . . . . . 3C-2

3C-0 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Enrichener System
The enrichener system provides the engine with extra fuel
charge for ease of starting cold engine. The system con-
sists of an electrically operated enrichener valve which is
connected by a hose to the intake manifold.
Fuel is gravity fed to the valve from the float bowl of the top
carburetor via a hose. When the ignition key is turned to the
“on” position and pushed in (and held in) current is sent to
the valve causing it to open, which allows fuel to pass thru.
The fuel passes thru a hose and is supplied to the engine
via fitting located in the intake manifold of the middle carbu-
retor. When the key (or choke button) is released, the valve
will return to the closed position. The valve can be operated
manually by pressing and holding button located at bottom
of valve.

Connect to Fitting on Oil Pump Base

Connect to Fitting
on bowl of TOP
carburetor

51223

Enrichener Valve Manual Operation Button

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3C-1

 IMPORTANT: Use of enrichener if engine is warm
could result in engine flooding

ENRICHENER VALVE TEST

Push key (or choke button) in.
Valve should click

No Click Click
Check for battery voltage to YELLOW/BLACK wire at terminal Squeeze primer bulb until bulb is firm. Remove lower hose from fit-
block on engine when key (or choke button) is pushed in. ting on enrichener valve. Place a container under valve, then push
key (or choke button). Check for fuel flow from fitting.

Battery Voltage Indicated

Check for loose or corroded connection between YELLOW/BLACK
wire and black wire (under same screw at terminal block).
Check that other BLACK wire at terminal block is properly No Voltage Indicated
grounded.
Check for open in YELLOW/BLACK wire between
Repair connections(s) as necessary, then push key (or choke but- key switch (or choke button) and terminal block.
ton) in. If enrichener valve DOES NOT click, replace valve.

Fuel Flow from Fitting

Valve is O.K. Check hoses and fittings from valve to carburetors for
leaks or obstructions.

No Fuel Flow from Fitting

Remove upper hose from fitting on enrichener valve. If fuel flows
from hose, replace valve. If not, check hose and carburetor fittings for
leaks or obstructions.

3C-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

FUEL SYSTEMS

3
D

51203

OIL INJECTION
Table of Contents
Page Page
Operation of the Injection System . . . . . . . . . . . . . . . 3D-1 Outboard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-10
Oil Injection System . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 Check Operation of the Oil Injection
Oil Injection Flow System (Fixed Ratio Oil System (Engine Running) . . . . . . . . . . . . . . . . . 3D-10
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-2 Required Side Mount Remote Control or
Pump Drive Assembly (Fixed Ratio Oil Ignition Key Switch Assembly . . . . . . . . . . . . . 3D-10
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3 Oil Injection System
Pump Drive System (Fixed Ratio Oil Pump) . . . . 3D-3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
Oil Pump to Powerhead Assembly (Fixed Troubleshooting the Oil Injection System . . . . . 3D-11
Ratio Oil Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4 Installing Drive Gear (For Oil Injection
Oil Injection Flow System (Variable Ratio Pump) On to Crankshaft . . . . . . . . . . . . . . . . . . . . . 3D-12
Oil Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-5 Oil Warning Module . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-12
Pump Drive Assembly (Variable Ratio Oil Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 3D-12
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6 Engine Mounted Oil Reservoir . . . . . . . . . . . . . . . . . 3D-13
Pump Drive System (Variable Ratio Oil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-13
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-14
Oil Pump to Powerhead Assembly (Variable
Ratio Oil Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7
Set Up Instructions for Oil
Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
Carburetor/Oil Pump Synchronization
(Variable Ratio Oil Pump) . . . . . . . . . . . . . . . . . . 3D-8
Filling Oil Injection System with Oil . . . . . . . . . . . . 3D-8
Bleeding Air From Oil Injection
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
Bleeding Air From Oil Pump Inlet Hose . . . . . 3D-9
Bleeding Air From Oil Pump Outlet Hose . . . 3D-9

3D-0 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 2. Oil Injection Pump
Operation of the Injection The crankshaft driven oil pump is a constant ratio oil
System pump which provides an oil fuel mixture.

The oil injection system delivers a oil mixture thru a con- 3. Check Valve Vent
stant ratio oil pump. Provides air to oil reservoir for proper venting and also
prevents oil leaks when outboard is tilted forward.
The engine mounted oil reservoir holds 3 qts. (2.8 Liters)
which will provide 10.5 hours of running time at wide open 4. 2 PSI Check Valve
throttle. This valve prevents gasoline from being forced into oil
line.
A low oil warning horn will be activated when 14.5 fl. oz.
(435 ml) of oil remains in the reservoir. This will provide ap- 5. Low Oil Sensor
proximately 1.5 hours of wide open throttle running before When oil level in reservoir drops to approximately 14.5
oil is depleted. fl. oz. (435 ml), the sensor will signal warning module
to activate warning horn.
The crankshaft driven oil pump injects oil into the fuel be-
fore the fuel pump. 6. Warning Module
When ignition key is initially turned on, the warning
module will briefly provide a self test of its engine over-
heat warning system - a brief continuous BEEP tone,
Oil Injection System followed by a self test of its low oil warning system - a
1. Oil Reservoir brief intermittent BEEP-BEEP tone.
The oil reservoir gravity feeds oil to the oil pump. The If the oil in the reservoir drops to less than 14.5 fl. oz. (435
reservoir contains a low oil sensor which activates a ml), the low oil sensor in the reservoir will signal the warn-
warning horn when 14.5 fl. oz. (435 ml) of oil remains ing module to activate the warning horn. If the powerhead
in the reservoir. temperature should exceed 300° F (65° C), the overheat
temperature sensor in the water jacket cover will signal the
warning module to activate the warning horn.

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-1

Oil Injection Flow System (Fixed Ratio Oil Pump)

Warning Module

Fill Cap
Fuel Filter
Vent

Carburetor

Oil Fuel Pump

Level
Sight
Gauge

2 PSI
Check
Valve

Fuel Line Connector

Oil Pump

51202

3D-2 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Pump Drive Assembly (Fixed Ratio Pump Drive System (Fixed Ratio Oil
Oil Pump) Pump)

b
a

a
e

c
d
c
51203

a - O-Rings
d b - Driven Gear
c - Drive Gear
51203 d - Crankshaft
a - Bleed Screw e - Oil Pump
b - Oil Outlet
c - Oil Pump
d - Oil Inlet

b
d

51203
a - Oil Pump
b - Apply 2-4-C w/Teflon to Shaft
c - Driven Gear
d - Bushings
e - O-Rings

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-3

Oil Pump to Powerhead Assembly
(Fixed Ratio Oil Pump)

95

95

6 51203

a 5
1 4

95 2-4-C With Teflon (92-825407A12) TORQUE SPECIFICATIONS

a 60 lb. in. (7.0 N·m)

1 - Bolt
2 - Oil Pump
3 - O-Rings
4 - Bushing
5 - Bearing
6 - Bushing
7 - Driven Gear

3D-4 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Oil Injection Flow System (Variable Ratio Oil Pump)

a
b

f
k

g
j

52049

a - Fill Cap
b - Vent
c - Warning Module
d - Fuel Filter
e - Carburetors
f - Fuel Pump
g - 2 psi Check Valve
h - Oil Pump
i - Fuel Line Connector
j - Low Oil Sensor
k - Oil Level Sight Gauge

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-5

Pump Drive Assembly (Variable Ratio Pump Drive System (Variable Ratio
Oil Pump) Oil Pump)

a b
a

b
e
d
c
c 52044

52046
a - Oil Outlet a - O–Rings
b - Oil Pump b - Driven Gear
c - Oil Inlet c - Drive Gear
d - Bleed Screw d - Crankshaft
e - Oil Pump

e
d b

52044

a - Oil Pump
b - Apply 2-4-C w/Teflon to Shaft
c - Driven Gear
d - Bushings
e - O-Rings

3D-6 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Oil Pump to Powerhead Assembly
(Variable Ratio Oil Pump)

95

95

6 52046

a 5
1 4

95 2-4-C With Teflon (92-825407A12) TORQUE SPECIFICATIONS

a 60 lb. in. (7.0 N·m)

1 - Bolt
2 - Oil Pump
3 - O-Rings
4 - Bushing
5 - Bearing
6 - Bushing
7 - Driven Gear

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-7

Set Up Instructions for Oil Filling Oil Injection System with Oil
Injection System Quicksilver 2-Cycle Outboard Oil is recommended for this
oil injection system. In an emergency, whin Quicksilver oil
is not available, substitute a high quality 2-cycle outboard
! CAUTION oil that meets BIA ratings TC-W and TC-WII, shown on oil
During break-in, engine must be run on a 25:1 gasoli- container. BIA ratings, TC-W and TC-WII are the Boating
ne/oil ratio (50:1 mixed oil/fuel ratio in fuel tank plus Industry Association’s designation for approved 2-Cycle
50:1 ratio from oil pump) for the first 15 gallons of fuel. water-cooled outboard oils.
Refer to engine break-in procedure in the Operation
and Maintenance Manual.

! CAUTION
If using an electric fuel pump, fuel pressure must not
exceed 4 psi (27.4 kPa). If necessary, install a pressure
regulator between electrical fuel pump and engine. Set
at 4 psi maximum.

Carburetor/Oil Pump Synchronization

(Variable Ratio Oil Pump)
While holding throttle arm at idle position, adjust length of
link rod so that stamped mark of oil pump body aligns with
stamped mark of oil pump lever, and lever is in closed posi-
tion.

52047
a - Mark on Body
b - Mark on Lever
c - Link Rod

3D-8 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

Bleeding Air From Oil Injection Outboard Operation
System 1. Check oil level in oil tank.
2. A 50:1 gasoline/oil mixture must be used during break-
! CAUTION in or after extended storage.
If air exists in either oil pump hose (inlet or outlet), the 3. Check warning horn operation.
air MUST BE bled from hose(s) or engine damage may
occur. Turning the key from the “off” to “on” position (engine not
running) will momentarily trigger the warning horn. This
BLEEDING AIR FROM OIL PUMP INLET HOSE alerts you the warning system is functional. If the warning
horn does not sound or stays on when the key is in the “on”
With engine not running, place a shop towel below oil position, refer to oil injection system troubleshooting chart
pump. Loosen bleed screw three to four turns and allow air following to correct the problem.
bubbles to exit inlet hose. Torque bleed screw to 25 lb. in.
(3.0 N·m). This procedure also allows oil pump to fill with The oil injection warning sound is an intermittent “beep”,
oil. “beep”, “beep”, etc. The overheat warning sound is a con-
tinuous “beep” .
BLEEDING AIR FROM OIL PUMP OUTLET HOSE
1. Purge air from outlet hose by running engine (on 50:1 Check Operation of the Oil Injection
gasoline/oil mixture in fuel tank) at idle speed until no
air bubbles are present in outlet hose. System (Engine Running)
Fixed Ratio Oil Pump 1. Operate engine following the break-in procedure out-
lined in the Operation and Maintenance Manual.
If warning horn should sound and intermittent “beep”,
“beep”, “beep” during operation, a problem may be occur-
ring in the oil injection system. Refer to troubleshooting fol-
lowing.

51204

Variable Ratio Oil Pump

b
52047

a - Bleed Screw
b - Inlet Hose
c - Outlet Hose

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-9

Required Side Mount Remote Control Oil Injection System
or Ignition Key Switch Assembly
Troubleshooting Chart
Boats Equipped with a Side Mount Remote Control
A Quicksilver Commander Series Side Mount Remote
Control equipped with a warning horn, must be used with Troubleshooting the Oil Injection
this outboard. This warning horn is necessary for both the System
oil injection warning system and the engine overheat warn-
ing system. If a problem occurs with the oil injection system and the
warning horn sounds in a intermittent manner, stop engine
Boats Equipped with Panel or Console Mount Remote
and check if problem is caused by (1) low oil Level, or (2)
Controls
a faulty warning sensor of module.
A Quicksilver Ignition Key/Choke Assembly equipped with
a warning horn is necessary for both the oil injection warn-
ing system and the engine overheat warning system.
Troubleshooting Chart
Problem: Warning Horn Does Not Sound When Ignition Key is Turned to “ON” Position.

Possible Cause Corrective Action

Horn malfunction or open (tan/blue) wire between horn and Disconnect tan/blue warning module lead (engine over-
engine. heat sensor) located in cylinder head. Use a jumper wire
to ground tan/blue warning module lead to engine ground.
Warning horn should sound. If not, check tan/blue wiring
between engine and warning horn for open circuit. Check
horn.

Faulty Warning Module Check if all warning module leads are connected

Using incorrect side mount remote control or ignition/ See info above
choke assembly.

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. Turn ignition key to
“ON” position. If horn stops sounding, the engine overheat
sensor is faulty.
Faulty Warning Module Check connections-replace module.

Problem: Warning Horn Sounds (Intermittent Beep) When Engine is Running and Oil Tank is Full.

Possible Cause Corrective Action

Defective low oil sensor (located in bottom of oil tank). Disconnect both low oil sensor leads (blue) at bullet con-
nections. Connect an ohmmeter between sensor leads.
There should be no continuity through sensor. If continuity
exists, sensor is faulty

If all of the checks are positive, the Warning Module is faulty. Replace Module and re-test.

3D-10 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

1. Check oil level in oil tank. If oil level is approximately
14.5 fl. oz. (435 ml) or less, the problem is low oil level.
Installing Drive Gear (For Oil
Add oil to oil tank. Injection Pump) Onto
NOTE: There is a safety reserve of oil left in the oil tank af-
ter the low oil warning is sounded that allows enough oil for Crankshaft
approximately 1.5 hours of full throttle operation. 1. Refer to Section 4A (Powerhead) for proper disassem-
2. If there is more than approximately 14.5 fl. oz. (435 ml) bly of components.
of oil remaining in tank, then the problem may be a 2. Inspect gear teeth for damage. Replace gear if any of
faulty low oil warning sensor or a faulty warning mod- these problems exist:
ule. Refer to troubleshooting chart following.
*Excessive Wear
*Cracks in hub or rear (Do Not mistake plastic flow
lines for cracks)
*Distorted Teeth

51084

a - Oil Drive Gear

b - Key

3. Refer to Section 4 (POWERHEAD) for proper

reassembly of components.

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-11

 3. Connect PURPLE, TAN and both BLUE leads at
Oil Warning Module respective bullet connectors. Secure warning module
BLACK lead to switch box mounting bolt and install
Removal/Installation warning module.Tighten bolts securely.
1. Disconnect battery cables.
b

b 50430

c
51204
51084
a - Warning Module
b - Warning Module Leads
2. Disconnect warning module PURPLE, TAN and both c - Screws
d - Ground Wire (BLACK)
BLUE leads at bullet connectors. Remove warning
module from lower cowl. 4. Re-connect battery cables.

b 50430

c
51204 51084
a - Warning Module
b - Warning Module Leads
c - Screws
d - Ground Wire

3D-12 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

 3. Disconnect oil hose and low oil sensor wires (BLUE) at
Engine Mounted Oil bullet connectors. Remove oil reservoir.
Reservoir
b
Removal
1. Disconnect battery cables.

51203

a - Oil Tank Wires (BLUE)

b - Oil Hose

4. Remove oil level sensor from oil reservoir.

! CAUTION
Oil level sensor is FRAGILE. Handle with care.
51084

2. Remove starter/oil bracket.

a
b

51204

a - Screw
b - Oil Level Sensor

51080
a - Starter Bracket
b - Bolts

90-817643R1 DECEMBER 1996 FUEL SYSTEMS - 3D-13

Installation 3. Install starter/oil tank bracket.

1. Install oil level sensor and secure in place. b

a
b
a

51204

a - Oil Level Sensor

b - Screw (Tighten Securely) 51080

2. Connect sensor oil level wires (BLUE) at bullet connec- a - Starter/Oil Tank Bracket
tors. Re-connect oil hose and secure in place with stay b - Bolts
strap. Install reservoir to outboard. 4. Re-connect battery cables.

51203

a - Oil Level Sensor Wires

b - Oil Hose
51084

3D-14 - FUEL SYSTEMS 90-817643R1 DECEMBER 1996

POWERHEAD

51081
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Powerhead Reassembly and Installation . . . . . . . . . 4-26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Quicksilver Lubricants and Service Aids . . . . . . . . . . . 4-1 End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Cylinder Block and Crankcase . . . . . . . . . . . . . . . . . . . 4-2 Assembling Rod to Piston . . . . . . . . . . . . . . . . . . . 4-26
Induction Manifold and Reed Block . . . . . . . . . . . . . . . 4-6 Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . 4-28
Crankshaft, Pistons and Connecting Rods . . . . . . . . . 4-8 Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . 4-30
Throttle Lever and Linkage . . . . . . . . . . . . . . . . . . . . . 4-10 Installing Rods to Crankshaft . . . . . . . . . . . . . . . . . 4-31
Powerhead Torque Sequence . . . . . . . . . . . . . . . . . . . 4-12 Connecting Rod Cap Alignment . . . . . . . . . . . . . . 4-32
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Crankcase Cover to Block . . . . . . . . . . . . . . . . . . . 4-32
ELPTO Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Intake/Reed Block Manifold Installation . . . . . . . . 4-34
Powerhead Disassembly . . . . . . . . . . . . . . . . . . . . . . . 4-16 Thermostat Cover Installation . . . . . . . . . . . . . . . . 4-35
Removing Engine Components . . . . . . . . . . . . . . 4-16 Install Remaining Engine Components . . . . . . . . 4-35
Crankshaft Disassembly . . . . . . . . . . . . . . . . . . . . . 4-18 Powerhead Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Test Run Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Cylinder Block and Crankcase Cover . . . . . . . . . 4-21 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Honing Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-21
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . 4-22
Cleaning Piston Ring Grooves . . . . . . . . . . . . 4-23
Measuring Piston Skirt . . . . . . . . . . . . . . . . . . . 4-23
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Reed Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-0 - POWERHEAD 90-817643R1 DECEMBER 1996

Specifications Special Tools
General Part No. Description
Type Two-Stroke Cycle 91-52344 Flywheel Holder
91-24161 Protector Cap
Displacement 51.8 cu. in. (849 cc)
91-73687A1 Flywheel Puller
Cylinder Bore 91-90455 Lifting Eye
*91-24697 Piston Ring Expander
Diameter Standard 2.955 in. (75.057 mm)
91-74607A2 Piston Pin Tool
Diameter .015 Oversize 2.970 in. (75.438 mm) 91-77109A1 Lockring Installation Tool
*91-32610 Torque Wrench (0 – 200 lb. ft.)
Diameter .030 Oversize 2.985 in. (75.819 mm)
(0 – 27 N·m)
Out of Round (Max.) 0.003 in. (0.08 mm) *91-66274 Torque Wrench (0 – 150 lb. ft.)
(0 – 20 N·m)
Taper (Max.) 0.003 in. (0.08 mm)
91-25821A1 Powerhead Stand
Piston *May be obtained locally
Diameter Standard 2.950 in. (74.93 mm)
Diameter .015 Oversize 2.965 in. (75.31 mm)
Diameter .030 Oversize 2.980 in. (75.69 mm) Quicksilver Lubricants and
Piston Ring Service Aids
End Gap 0.010 in. – 0.018 in.
(.254 mm – .457 mm) Part No. Description
Crankshaft 92-32609-1 Loctite 271 Grade “A”
Runout (Max.) 0.002 in. (0.05 mm) 92-12564--1 Master Gasket Sealant
92-42649A1 Needle Bearing Assembly
Lubricant
92-13249A24 2 Cycle Outboard Oil
92-59327-1 Loctite Primer “T”
92-90018A12 2-4-C Marine Lubricant
92-34277-1 Perfect Seal
* Loctite 272
*May be obtained locally

90-817643R1 DECEMBER 1996 POWERHEAD - 4-1

Cylinder Block and Crankcase

44

43
45
20
38 21
37 16

26
9 24 25 7
23
22
36
35 29
28
34 27
17
32
33 1
31

30 37

29
9
13 6
15 14
8 7
5
12 18
11
19 9
12
10
41
95 39
42 3

4 2
40 9

7 Loctite 271 (92-809820)

9 Loctite PST Pipe Sealant (92-809822)
12 Loctite Master Gasket (92-12564-2)
95 2-4-C With Teflon (92-825407A12)

4-2 - POWERHEAD 90-817643R1 DECEMBER 1996

 Cylinder Block and Crankcase
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CYLINDER BLOCK
2 8 SCREW 220 18.5 25.0
3 6 SCREW 220 18.5 25.0
4 1 CHECK VALVE
5 1 HOSE (16″)
6 1 CHECK VALVE (PRESS-IN)
7 2 CARRIER ASSEMBLY
8 2 CHECK VALVE
9 1 ADJUSTING SCREW
10 1 JAM NUT
11 1 CAP
12 1 DOWEL PIN (LOCATING)
13 3 DOWEL PIN (BEARING RACE)
14 1 COVER
15 2 SCREW 220 18.5 25.0
16 1 GASKET
17 2 STUD
18 4 PIPE PLUG
19 6 SCREW 350 29.0 39.5
20 4 SCREW (25MM - Qty. of 3 on 55) 220 18.5 25.0
21 1 SCREW (55) Drive Tight
22 1 POPPET VALVE
23 1 DIAPHRAGM
24 1 WASHER
25 1 SCREW 50/60 Drive Tight
26 1 SPRING
26 1 SPRING (60 Pontoon/Big Foot)
27 1 THERMOSTAT (120
)
28 1 GASKET

90-817643R1 DECEMBER 1996 POWERHEAD - 4-3

Cylinder Block and Crankcase

44

43
45
20
38 21
37 16

26
9 24 25 7
23
22
36
35 29
28
34 27
17
32
33 1
31

30 37

29
9
13 6
15 14
8 7
5
12 18
11
19 9
12
10
41
95 39
42 3

4 2
40 9

7 Loctite 271 (92-809820)

9 Loctite PST Pipe Sealant (92-809822)
12 Loctite Master Gasket (92-12564-2)
95 2-4-C With Teflon (92-825407A12)

4-4 - POWERHEAD 90-817643R1 DECEMBER 1996

 Cylinder Block and Crankcase
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
29 1 PIPE PLUG Drive Tight
30 1 TEMPERATURE SENDER
31 1 RETAINER
32 1 SCREW Drive Tight
33 1 WASHER
34 2 WASHER
35 2 WASHER
36 2 WING NUT 50/60 Hand Tight
37 1 ELBOW
37 1 ELBOW (55)
38 1 COVER
39 1 FITTING (50/60)
40 1 COVER
41 1 O-RING 55
42 2 SCREW 60 7.0
43 1 LIFTING EYE
44 1 SCREW (55MM ) 220 18.5 25.0
45 1 NUT Drive Tight

90-817643R1 DECEMBER 1996 POWERHEAD - 4-5

Induction Manifold and Reed Block

25
24
23
30
29
26
27

95
28
22
20 21 19
18
17
15
1 11
13
10
9
7 8
14
5

4
3
2 12
6
14
16
19

14 2 Cycle Outboard Oil (92-13249A24)

19 Perfect Seal (92-34227-1)

4-6 - POWERHEAD 90-817643R1 DECEMBER 1996

 Induction Manifold and Reed Block
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 GASKET
2 1 LOWER END CAP ASSEMBLY
3 1 OIL SEAL
4 1 OIL SEAL
5 1 O-RING
6 3 SCREW 220 18.5 25.0
7 1 BRACKET ASSEMBLY
8 2 STUD
9 2 WASHER
10 2 WASHER 50/60
11 2 WING NUT Hand Tight
12 4 SCREW 220 18.5 25.0
13 1 INDUCTION MANIFOLD
14 1 ELBOW (Qty. of 2 on 55)
15 1 GASKET
16 10 SCREW 220 18.5 25.0
17 1 REED BLOCK ASSEMBLY
18 1 GASKET
19 3 REED SET (0.008 THICK)
19 3 REED SET (0.010 THICK)
20 3 TAB WASHER
21 3 RETAINER
22 3 SCREW 60 7.0
23 1 SHIFT RAIL
24 2 TAB WASHER
25 2 SCREW 165 14.0 18.5
26 1 SLIDE
27 1 NYLINER
28 1 NUT Drive Tight
29 1 WASHER
30 1 NUT Drive Tight

90-817643R1 DECEMBER 1996 POWERHEAD - 4-7

Crankshaft, Pistons and Connecting Rods

14 95

7 14
13
14 6
12 95
11
4
9
14

10 14
16 16
12
15

5
95

14
3

14 2 Cycle Outboard Oil (92-13249A24)

95 2-4-C With Teflon (92-825407A12)

4-8 - POWERHEAD 90-817643R1 DECEMBER 1996

 Crankshaft, Pistons and Connecting Rods
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CRANKSHAFT ASSEMBLY
2 1 BALL BEARING
3 1 RETAINING RING
4 2 KEY
5 1 DRIVER GEAR
6 1 ROLLER BEARING ASSEMBLY (TOP)
7 1 OIL SEAL
8 2 ROLLER BEARING ASSEMBLY (CENTER)
9 3 PISTON ASSEMBLY (STANDARD)
9 AR PISTON ASSEMBLY (.015 O.S.)
9 AR PISTON ASSEMBLY (.030 O.S.)
10 6 LOCK RING
11 1 PISTON RING (STANDARD)
11 AR PISTON RING (.015 O.S.)
11 AR PISTON RING (.030 O.S.)
12 3 CONNECTING ROD ASSEMBLY
13 6 WASHER
14 87 NEEDLE BEARING
15 6 SCREW 1st Torque – 15 lb. in.
(1.5 N·m)
2nd Torque –
1/4″ Bolt – 120 lb. in.
(13.5 N·m) + an addi-
tional 1/4 turn
5/16″ Bolt – 27 lb. ft.
(36.5 N·m)
16 3 ROLLER BEARING

90-817643R1 DECEMBER 1996 POWERHEAD - 4-9

Throttle Lever and Linkage

10
9
2
16
3 8
17
15 95

10
5 9
14

95

95 7
11
6
1
5

12
4
95

13
18

24
22 23

19
21 11
20

95 2-4-C With Teflon (92-825407A12)

4-10 - POWERHEAD 90-817643R1 DECEMBER 1996

 Throttle Lever and Linkage
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 THROTTLE LEVER
2 1 ADJUSTING SCREW
3 1 JAM NUT
4 1 PIN
5 2 ADJUSTING SCREW
6 1 WASHER
7 1 NUT Drive Tight then Back
Off 1/2 Turn
8 1 BUSHING
9 2 JAM NUT
10 2 CAP
11 2 SWIVEL BUSHING
12 1 SPRING
13 1 WASHER
14 1 SPARK ADVANCE LEVER
15 1 SPARK ADVANCE ROD
16 2 SWIVEL BASE
17 2 SWIVEL BALL
18 1 SCREW Drive Tight
19 1 THROTTLE ROD
20 1 STUD
21 1 SPRING
22 1 THROTTLE CAM
23 1 WASHER
24 1 NUT Drive Tight then Back
Off 1/2 Turn

90-817643R1 DECEMBER 1996 POWERHEAD - 4-11

Powerhead Torque Sequence
INTAKE MANIFOLD TORQUE SEQUENCE
Install bolts and torque to 18 lb. ft. (24.5 N·m) 5
6

11 12

1 2

9 10
3 4

13 14

8
7
PE-51085

CRANKCASE COVER AND LOWER END CAP COV-

ER TORQUE SEQUENCE
Torque bolts to 18 lb. ft. (24.5 N·m)

8 10 6 12 14
4 2

1
7 9 11 3
5 13 PE-51085

3
1

PE-51086

4-12 - POWERHEAD 90-817643R1 DECEMBER 1996

 2. Disconnect control/trim harness and fuel line.
General Information
Powerhead “Disassembly” and “Reassembly” instructions
are printed in a sequence that should be followed to assure
best results when removing or replacing powerhead com-
ponents. If complete disassembly is not necessary, start
reassembly at point disassembly was stopped. Refer to
“Table of Contents” preceding.
If major powerhead repairs are to be performed, remove
powerhead from drive shaft housing as an assembly. Re-
move external engine components referring to appropriate
section of service manual.

ELPTO MODEL
1. Remove battery cables.

PE-51082
3. Disconnect trim switch and trim relay wires.

a b

PE-51084

PE-51089
a - Blue/White
b - Green/White
c - Red/Black
d - Trim Switch

90-817643R1 DECEMBER 1996 POWERHEAD - 4-13

4. Remove control cables. 6. Remove electrical box cover.

b
a

PE-51088
a - Shift Cable
b - Throttle Cable

5. Remove bolt and rubber grommet.

PE-51089
c
7. Remove battery cables and starter bracket.
a

c
b
b

PE-51082
a - Bolt
a
b - Fuel Connector
c - Rubber Grommet

PE-51080

a - Positive Cable
b - Ground Cable
c - Bracket

4-14 - POWERHEAD 90-817643R1 DECEMBER 1996

8. Disconnect wires and remove oil tank. 10. Remove cover (a).

PE-51088
a - Oil Tank Wires (Blue)
b - Power Trim Wires (Blue/White) and (Green/White)
c - Oil Hose (From Tank)

9. Remove ground wire to powerhead. Disconnect wires

from trim relay module(s). Disconnect tel tale hose

a
PE-51083
11. Remove powerhead bolts.

a PE-51082
Design 1

a
54244

Design 2
a - Trim Relay Module(s)
b - Ground Lead
c - Tel Tale Hose PE-51088

90-817643R1 DECEMBER 1996 POWERHEAD - 4-15

12. Install lifting eye (p/n 91-90455) into flywheel a mini-
mum of five turns. Lift powerhead from drive shaft
Powerhead Disassembly
housing allowing shift linkage to slide off shift rail guide.
Removing Engine Components
Remove the following engine components:

Component/Assembly Section
Starter Motor 2B
Ignition Switch Box 2A*
Ignition Coil 2A*
Starter Solenoid 2B*
Voltage Regulator/Rectifier 2B*
Flywheel 2A
Stator Assembly 2A*
Trigger Assembly 2A*
Air Attenuator 3A
Carburetor and Linkage 3A
Fuel Pump 3B
Fuel Enrichment valve 3C
Shift Cable Latch Assembly 7A
Control Cable Anchor Bracket 7A
Warning Module 3D*
Oil Pump 3D

*NOTE: all ignition and electrical components can be re-

moved and installed as an assembly.
1. Place powerhead in repair stand or on bench.
NOTE: Powerhead stand p/n 91-25821A1 can be used.

PE-51081

PE-51227a

4-16 - POWERHEAD 90-817643R1 DECEMBER 1996

2. Remove thermostat components. 4. Remove check valves and holders.

a b c
d

f e
PE-51087

a - Bolts
b - Thermostat Cover
c - Thermostat Gasket
d - Thermostat
e - Poppet Valve
f - Spring a
3. Remove intake manifold and reed block manifold.

PE-51227c
a - Check Valve/Holders

5. Place engine on work bench and remove end cap

bolts.

PE-51085
a - Bolts

PE-51227a
a - Bolts (14)

90-817643R1 DECEMBER 1996 POWERHEAD - 4-17

6. Remove crankcase cover bolts. Crankshaft Disassembly
a
1. Remove roller bearing assemblies from crankshaft.

c
b PE-51085
a - Bolts (14)
b - Lower End Cap

7. Remove crankcase cover from cylinder block.

8. Remove end cap. a a

PE-51085
a - Roller Bearing Race
b - Roller Bearing
c - Retaining Ring

2. Remove 2 bolts from each rod cap. Keep components

with respective connecting rod.
IMPORTANT: DO NOT reuse connecting rod bolts.

a
PE-51087
Crankcase Cover Removed
9. Remove crankshaft assembly.

PE-51080
a - Bolts, use 5/16 in. – 12 point socket or 1/4 – 12 point socket

PE-51085
Crankshaft Assembly Removed

4-18 - POWERHEAD 90-817643R1 DECEMBER 1996

3. Remove connecting rod/piston assembly from crank- 6. Remove piston rings. Always install new piston rings.
shaft; re-attach caps to respective rod as each is re-
moved. CAPS MUST BE INSTALLED IN SAME DI-
RECTION ON SAME ROD, or mating surface will not a
seat properly.
4. Remove main bearing sealing rings.

PE-51081
a - Piston Ring Expander (p/n 91-24697)
b - Piston Rings

NOTE: Cylinders must be honed for rings to seat properly.

! CAUTION
Safety glasses should be worn when removing or in-
PE-51083 stalling locking rings.
7. Remove piston pin lock rings using awl. Always install
5. Scribe (with awl) identification number (cylinder 1, 2, new lock rings.
and 3) on inside of piston and connecting rod in order
to reassemble piston to same connecting rod.

1 PE-51083

PE-51081

90-817643R1 DECEMBER 1996 POWERHEAD - 4-19

8. Remove piston pin. 11. Press crankshaft bearing as shown.
b a

PE-51086
a - Piston Pin
b - Piston Pin Tool (91-74607A2)

9. Remove piston pin needle bearings (29 per piston pin)

and locating washers (“a” 2 per piston) as shown.

PE-51081

12. Remove oil drive gear if necessary.

a
PE-51088
a - Locating Washers

! CAUTION
Bearing removal will cause bearing damage and will
require replacement.
b
10. Inspect crankshaft bearing. Remove bearing (a) and
retaining ring (b) only if necessary.

PE-51084
a - Oil Drive Gear
b - Key

PE-51084

4-20 - POWERHEAD 90-817643R1 DECEMBER 1996

Cleaning and Inspection ! CAUTION
If crankcase cover and cylinder block is to be sub-
Cylinder Block and Crankcase Cover merged in a very strong cleaning solution, it will be
IMPORTANT: Crankcase cover and cylinder block are necessary to remove the crankcase cover/cylinder
matched, line-bored assembly should not be mis- block bleed system from cover/cylinder block to pre-
matched by using a different crankcase cover or cylin- vent damage to hoses and check valves.
der block.
CYLINDER BORE SIZE
PISTON SIZE CYL. BLOCK
FINISH HONE
Standard Diameter 2.955 in.
75.057 mm
.015 Oversize 2.970 in.
75.438 mm
.030 Oversize 2.985 in.
75.819 mm
• Inspect cylinder bores for scoring (a transfer of alumi-
num from piston to cylinder wall). Cylinder wall scor-
ing usually can be “cleaned up” by honing or rebor-
ing.

! CAUTION
When reboring cylinder block, remove hone frequent-
ly and check condition of cylinder walls. DO NOT hone
any more than absolutely necessary, as hone can re-
move cylinder wall material rapidly.
PE-51090
HONING PROCEDURE
• Inspect cylinder block and crankcase cover for cracks Follow hone manufacture’s recommendations for use of
or fractures. hone cleaning and lubrication during honing.
• Check gasket surfaces for nicks, deep grooves, IMPORTANT: After honing, bores should be thorough-
cracks and distortions that could cause compression ly cleaned with hot water and detergent. Scrub well
leakages. with stiff bristle brush and rinse with hot water. If any
abrasive material is allowed to remain in the cylinder
• Check that all water passages in cylinder block are
bore, it will cause a rapid wear of new piston rings and
not obstructed. Check locating pins in cylinder block
cylinder bore. After cleaning, bores should be
that they are tight.
swabbed several times with 2 cycle engine oil and a
• Check crankcase cover fuel/bleed passages that they clean cloth. Wipe excess oil with clean, dry cloth. Cyl-
are not obstructed. Verify that check valves in crank- inders should not be cleaned with kerosene or gaso-
case cover are not damaged. line. Clean remainder of cylinder block.
• Thoroughly clean cylinder block and crankcase cover. • Hone all cylinder walls just enough to de-glaze.
Verify that all sealant and old gaskets are removed
from matching surfaces. Clean all carbon deposits
from exhaust ports.
• Inspect spark plug holes for stripped or damaged
threads.

90-817643R1 DECEMBER 1996 POWERHEAD - 4-21

• Measure cylinder bore inside diameter (with an inside TO CHECK: Inspect check valves by looking through hole.
micrometer) of each cylinder, as shown below. Check If light can be seen the nylon ball is bad (probably melted);
for tapered, out-of-round (“egg-shaped”) and oversize REPLACE valve. If you see no light, insert fine wire into
bore. check valve hole to see if there is slight movement of nylon
ball. If ball moves, valve is O.K.. Replace valve if ball does
not move.
Install check valve into check valve holder as shown.
TOP
Air

CENTER b

BOTTOM

Air
PE-51080
a - Check Valve
b - Holder
• If a cylinder bore is tapered, out-of-round or worn
more than .003 in. (0.08 mm) from standard “Cylin-
der Block Finish Hone” diameter (refer to chart), it will
be necessary to rebore that cylinder(s) to designated
Piston and Piston Rings
oversize bore and install oversize piston(s) and pis- IMPORTANT: If engine was submerged while engine
ton rings during reassembly. was running, piston pin and connecting rod may be
NOTE: The weight of an oversize piston is approximately bent. If piston pin is bent, piston must be replaced. Pis-
the same as a standard size piston; therefore, it is not nec- ton pins are not sold separately because of matched
essary to rebore all cylinders in a block just because one fit into piston. If piston pin is bent, connecting rod
cylinder requires reboring. must be checked for straightness (refer to “Connect-
ing Rods” for checking straightness).
IMPORTANT: Ports must be deburred after honing.
• Inspect piston for scoring and excessive piston skirt
• After honing and thoroughly cleaning cylinder bores, wear.
apply 2 cycle outboard oil to cylinder walls to prevent
rusting. • Check tightness of piston ring locating pins. Locating
pins must be tight.
• Thoroughly clean pistons. Carefully remove carbon de-
Check Valves posits, with a soft wire brush or carbon remover solu-
tion. DO NOT burr or round off machined edges.
NOTE: Check valves can be replaced by removing intake
manifold when powerhead is attached to driveshaft hous- • Inspect piston grooves for wear and carbon accumula-
ing. tion. If necessary, scrape carbon from piston ring
grooves being careful not to scratch sides of grooves.
The check valves are a 3/16 in. (4.76 mm) diameter brass Refer to procedure for cleaning piston ring grooves.
casing containing a nylon ball-valve. These can be dam-
aged by hot combustion blow-by into crankcase (ie.: back-
fire, or a hole in top of piston, etc.).

4-22 - POWERHEAD 90-817643R1 DECEMBER 1996

CLEANING PISTON RING GROOVES
PISTON PISTON SKIRT CYL. BORE
IMPORTANT: The piston rings are half – keystone rings SIZE DIAMETER FINISH HONE
– (tapered on the top side) – follow cleaning and in-
spection carefully! Chromed ring is installed on top. Standard 2.950 in. 2.955 in.
Piston (74.93 mm) (75.057 mm)
.015 2.965 in. 2.970 in.
Oversize (75.31 mm) (75.438 mm)
.030 2.980 in. 2.985 in.
Oversize (75.69 mm) (75.819 mm)

Crankshaft
Enlarged View of
Piston Ring Grooves • Inspect crankshaft to drive shaft splines for wear. (Re-
place crankshaft, if necessary.)
• Check crankshaft for straightness. (Replace as neces-
sary.)
• Inspect crankshaft oil seal surfaces. Sealing surfaces
must not be grooved, pitted or scratched. (Replace as
necessary.)
• Check all crankshaft bearing surfaces for rust, water
! CAUTION marks, chatter marks, uneven wear and/or overheat-
Care must be taken not to scratch the side surfaces of ing. (Refer to “Connecting Rods”.)
ring groove. Scratching the side surfaces of the ring • If necessary, clean crankshaft surfaces with crocus
groove will cause damage to the ring groove. cloth as shown.
• Use a bristle brush and carbon remover solution to re-
move carbon from side surfaces.
• A tool can be made for cleaning the inner diameter of
the tapered ring grooves. The tool can be made from a
broken tapered piston ring with the side taper removed
to enable inside edge of the ring to reach the inside di-
ameter of the groove. Carefully scrape the carbon from
inner diameter of ring grooves. Care must be taken not
to damage the grooves by scratching the surfaces of
the grooves.

MEASURING PISTON SKIRT

Measure piston skirt at right angle (90°) to piston pin cent-
erline, 0.50 in. (12.7 mm) up from bottom edge of skirt.

.50 in.
(12.7 mm)
PE-51089

90-817643R1 DECEMBER 1996 POWERHEAD - 4-23

· Thoroughly clean (with solvent) and dry crankshaft and Thermostat
crankshaft ball bearings. Recheck surfaces of crank-
shaft. Replace crankshaft if surfaces cannot be proper- Wash thermostat with clean water. Using a thermostat tes-
ly “cleaned up”. If crankshaft will be reused, lubricate ter, similar to the one shown, test thermostat as follows:
surfaces of crankshaft with light oil to prevent rust. DO
· Open thermostat valve, then insert a thread between
NOT lubricate crankshaft ball bearings at this time.
valve and thermostat body. Allow valve to close against
thread.
! WARNING
· Suspend thermostat (from thread) and thermometer in-
DO NOT spin-dry crankshaft ball bearing with com- side tester so that neither touches the container. Bottom
pressed air. of thermometer must be even with bottom of thermostat
to obtain correct thermostat opening.
· Fill thermostat tester with water to cover thermostat.
Connecting Rods
· Plug tester into electrical outlet.
If necessary, clean connecting rod surfaces as follows:
· Observe temperature at which thermostat begins to
· Attach end caps to connecting rods. Following these di- open. Thermostat will drop off thread when it starts to
rections, tighten rod cap attaching bolts to specifica- open. Thermostat must begin to open when tempera-
tions. Recheck alignment. ture reaches 5°F (3°C) above designated stamping on
bottom of thermostat.
! CAUTION · Continue to heat water until thermostat is completely
Crocus cloth MUST BE USED to clean bearing surface open.
at crankshaft end of connecting rod. DO NOT use any · Unplug tester unit.
other type of abrasive cloth.
· Replace thermostat, if it fails to open at the specified
· Clean crankshaft end of connecting rod by using crocus temperature, or if it does not fully open.
cloth placed in a slotted 3/8 in. (9.5 mm) diameter shaft,
as shown. Insert shaft in a drill press and operate press
at full speed while keeping connecting rod at a 90°
angle to slotted shaft.
IMPORTANT: Clean connecting rod just enough to
clean bearing surfaces. DO NOT continue to clean af-
ter marks are removed from bearing surfaces.
· Clean piston pin end of connecting rod, using same
method as above. Use 320 grit carborundum cloth in-
stead of crocus cloth.
· Thoroughly wash connecting rods to remove abrasive
grit. Recheck bearing surfaces of connecting rods. Re-
place any connecting rod that cannot be properly pol-
ished. Lubricate bearing surfaces of connecting rods
which will be reused with 2 cycle engine oil to prevent
rust.

PE-51087

PE-51083

4-24 - POWERHEAD 90-817643R1 DECEMBER 1996

Reed Blocks If the opening exceeds .020 in. (0.5 mm), or if the reed is
chipped, cracked or otherwise damaged, replace.
NOTE: Do not disassemble reed block unless necessary.

b .020

PE-51089
PE-51089
a - Reed Block ! CAUTION
b - Reed (3 Sets)
c - Retaining Washer Replace locking tab-Washer. DO NOT REUSE.
d - Tab Washer
e - Bolt (With Loctite Grade “A”) If reed block was disassembled, reassemble by locating
reeds (a) on pins with (c) retaining washer (b). Use new
IMPORTANT: Do not “flop” (reverse) the reed petels for tab-washer. Insert bolt (d), and torque to 60 lb. in. (6.5
additional use – replace reed when necessary. N·m); then, if necessary, continue the torque to align flat on
Reed should lie flat. There should be no pre-load (pressure hex-head to locking tab (e). DO NOT exceed 100 lb. in.
between reed and reed-block), although a slight pre-load (11.5 N·m) of torque. Bend up lock tab to secure bolt posi-
is tolerable. tion.
The maximum allowable opening between reed and reed-
block is 0.020 in. (0.5mm). This must be checked with a flat
blade feeler gauge, as shown.
0.020 MAX.

90-817643R1 DECEMBER 1996 POWERHEAD - 4-25

Powerhead Reassembly and ! CAUTION
Installation Any GREASE used for bearings INSIDE the powerhead
MUST BE gasoline soluble. Use only Quicksilver
Needle Bearing Assembly Lubricant. DO NOT use
General Information 2-4-C Marine Lubricant, or other lubricants inside the
Before proceeding with powerhead reassembly, be sure powerhead, or damage may occur.
that all parts to be reused have been carefully cleaned and
thoroughly inspected, as outlined in “Cleaning and Inspec-
tion”. Parts, which have not been properly cleaned (or Assembling Rod to Piston
which are questionable), can severely damage an other-
wise perfectly good powerhead within a few minutes of op-
eration. All new powerhead gaskets must be installed dur- ! CAUTION
ing assembly. Never intermix new needle bearings with used needle
During reassembly, lubricate parts with Quicksilver bearings. It is required to replace needle bearings as
2-Cycle Outboard Oil whenever 2-cycle oil is specified, and a set. Never intermix needle bearings from one con-
Quicksilver 2-4-C Marine Lubricant whenever grease is necting rod with those of another connecting rod
specified. 1. Place clean needle bearings on a clean sheet of paper
A torque wrench is essential for correct reassembly of pow- and lubricate with Quicksilver Needle Bearing Lubri-
erhead. Do not attempt to reassemble powerhead without cant.
using a torque wrench.
Service Tip

End Cap
1. Clean thoroughly, including seal and O-ring seats; re-
move Perfect Seal residue and clean cap-to-head mat-
ing surface.
2. Using suitable mandrel, press oil seals into cap until
fully seated.
NOTE: Lip of smaller seal faces away from powerhead. Lip
of larger seal faces towards powerhead.
3. Lubricate oil seal lips with 2-cycle oil.
4. Lubricate O-ring seal with 2-cycle oil and install in
groove.
5. Apply Perfect Seal to flange of end cap.

Lip of Larger Seal

PE-51228
b
If the tip of an awl can be inserted between needle bear-
ings, one or more needles are missing and must be re-
placed.
Lip on Bottom of
Smaller Seal
PE-51088
a - 2-Cycle Oil
b - Perfect Seal

4-26 - POWERHEAD 90-817643R1 DECEMBER 1996

2. Install needle bearings. 4. Push sleeve from piston using piston pin tool.

b a b
a

PE-51081
a - Needle Bearings (29)
b - Sleeve [from Piston Pin Tool (91-74607A2)]

3. Place locating rings on connecting rod, carefully place

piston over end of rod. Refer to scribed identification
number for matching rod to piston and direction of as-
PE-51080
sembly (which side of rod is “UP”).
a - Sleeve
b - Piston Pin Tool (91-74607A2)

5. Place piston pin over tool, and tap into position (driving
tool out other side).

b 1 a

1 a

PE-51083
a - Scribed Identification Number
b - Locating Washer

PE-51086
a - Piston Pin
b - Piston Pin Tool

! WARNING
Eye protection must be worn while installing piston
pin lockrings.

90-817643R1 DECEMBER 1996 POWERHEAD - 4-27

6. Install new piston pin lockrings (each side of piston) us- Piston Ring Installation
ing Lockring Tool (p/n 91-77109A1).
IMPORTANT: Piston ring side with letter or mark must
7. Make sure lockrings are properly seated in piston
be facing up.
grooves.

! CAUTION
Do not re-use piston pin lockrings. Use only new lock-
rings and make sure they are properly seated in piston Piston Ring
grooves.
Piston rings are TAPERED top side, and flat (rectangular)
on the bottom side (half-keystone rings). Note that,top ring
b is chromed and bottom ring is steel.

Enlarged View of
Piston Ring Grooves

PE-51086
a - Lockring Installation Tool (91-77109A1)
b - Lockring (2)

! CAUTION
Care must be taken not to scratch the side surfaces of
ring groove. Scratching this area will damage the ring
groove.

PE-51086

NOTE: Shaft of Lockring Installation Tool 91-77109A1

must be modified (shortened) to 1.050 in. (26.7 mm).
1.050 in. (26.7 mm)

4-28 - POWERHEAD 90-817643R1 DECEMBER 1996

1. Install piston ring in appropriate groove on piston using 4. Remove connecting rod cap from connecting rod be-
Piston Ring Expander Tool. Spread rings just enough ing installed.
to slip over piston.
5. Install each piston with “UP” identification facing fly-
Top Groove – Chromed Ring wheel end. Pistons MUST be installed in this direction.
Bottom Groove – Steel Ring
2. Check piston rings to be sure they fit freely in groove. UP
Lubricate rings and cylinder wall with 2-cycle oil.

! CAUTION
PE-51081 Pistons must be installed very carefully into cylinders.
a - Piston Ring Expander Piston rings can not be inspected thru exhaust ports.
b - Piston Rings
6. Bottom end of cylinder bore has taper which permits
3. Align piston ring end gaps with ring locating pins as
the insertion of the piston into block without using a pis-
shown. Check locating pins making sure they are tight.
ton ring compressor. Place piston carefully into cylin-
der.
a

a b
PE-51228

b a

PE-51087
PE-51082

a - Locating Pin
b - Piston Rings

90-817643R1 DECEMBER 1996 POWERHEAD - 4-29

Crankshaft Installation ! CAUTION
1. If lower bearing and gear were removed from crank- Any grease used for bearings INSIDE the powerhead
shaft, slide gear in place (note keyway and key in gear MUST BE gasoline soluble. Use only Quicksilver
to crankshaft assembly). Install gear to crankshaft us- Needle Bearing Assembly Lubricant. DO NOT use
ing an arbor press and suitable mandrel. 2-4-C Marine Lubricant, or other lubricants inside pow-
2. Install main bearing retaining ring after pressing main erhead, or damage to engine may occur.
bearing tight against oil gear. 4. Grease crankshaft journal with Quicksilver Needle
Bearing Assembly Lubricant to hold bearing in place.
Position needle bearings on journal. There are 28
bearings per each center main.
b

a
PE-51084
b
PE-51081
a - Lower Bearing a - Crankshaft Journal
b - Gear b - Bearings (28)
c - Retaining Ring
IMPORTANT: Snap ring groove faces up towards fly-
! CAUTION wheel.

Safety glasses should be worn when removing or in- 5. Attach main bearing races with holes towards lower
stalling ring seals. gear end of crankshaft. Secure each main bearing
race with retaining ring. Lubricate top main bearing
3. Install ring seals (2) to crankshaft. with 2-cycle engine oil and install to crankshaft as
shown.
b a b
b c

PE-51083

a - Main Bearing Race

b - Retaining Ring (Groove Faces Flywheel)
c - Top Main Bearing (One Piece)
a

PE-51083
a - Ring Seal
b - Slot On Crankshaft

4-30 - POWERHEAD 90-817643R1 DECEMBER 1996

6. Position cylinder block and piston rods as shown. In- Installing Rods to Crankshaft
sert locating pins (a).
1. Oil rod and bearing cage with 2-cycle oil.

a a a 2. Pull rod into place and install bearing cages as shown.

PE-51080
PE-51088
NOTE: Clean rod bolt/rod cap bolt holes of oil and debris
Flywheel End Lower End before reassembly.
7. Place crankshaft into cylinder block; align and seat top IMPORTANT: The rod cap and rod must be aligned and
and center main bearings so that locating pins on block held together when threading oiled bolt. Check that
align with larger holes in each bearing race. mating surfaces are tight together after bolt enters
threads in piston rod.
3. Place rod cap over bearing cages. While holding cap
to rod, insert slightly oiled bolts and lightly tighten while
observing cap to rod alignment.

PE-51089
PE-51080

90-817643R1 DECEMBER 1996 POWERHEAD - 4-31

Connecting Rod Cap Alignment Crankcase Cover to Block
1. Check each connecting rod for correct alignment by 1. Install upper seal to crankshaft.
carefully running fingernails up and down edge of rod
cap. If not aligned, a ridge can be seen or felt at the
separating line. Correct any misalignment.
Front View Front View
Correct Incorrect

Side View Side View Side View

Correct Incorrect Incorrect PE-51243
a - Oil Seal (Lubricate Inside with 2-cycle oil)

2. Apply LOCTITE MASTER GASKET SEALANT to

Space Ridge clean block surface. Instructions in kit must be followed
exactly.
IMPORTANT: Extend sealer to edge on each center
main journal to prevent blow-by between cylinders.

PE-51224

2. When connecting rods are attached, and bolts drawn

down finger tight, torque rod-cap bolts to 15 lb. in. (1.7
N·m). Recheck alignment. Re-torque 1/4 in. bolts to
120 lb. in. (13.5 N·m) and then turn additional 1/4
turn or 5/16 in. bolts to 27 lb. ft. (36.5 N·m). Recheck
alignment.

PE-51087
Sealant “Bead Pattern” Indicated by Bold Line Above

4-32 - POWERHEAD 90-817643R1 DECEMBER 1996

3. Install end cap assembly (lubricate seals with 2-cycle 5. Insert clean bolts (note 2 sizes) and finger tighten.
engine oil) to block. Apply Perfect Seal to flange of end
6. Torque bolts to 18 lb. ft. (24.5 N·m) following sequence
cap (a).
shown below.

3
1
a
PE-51086

8 10 6 12 14
4 2
PE-51088
4. Place crankcase cover onto block.

1
b 7 9 11 3
5 13 PE-51085
a NOTE: Inspect all hoses on reinstallation. Replace if nec-
PE-51084 essary.
a - Crankcase Cover
b - End Cap

90-817643R1 DECEMBER 1996 POWERHEAD - 4-33

Intake/Reed Block Manifold Installa- 3. Install reed block manifold and intake manifold with
gasket to cylinder block.
tion
1. Place engine on repair stand or on bench.
NOTE: Powerhead repair stand p/n 91-25821A1 can be
used.

Can only be
installed one way.

PE-51225
4. Install bolts and torque to 18 lb. ft. (24.5 N·m) in se-
quence shown below.

5
6

11 12

1 2
PE-51227
2. Install check valve/holders.

9 10
3 4

13 14

PE-51080

8
7
PE-51085
a

PE-51227
a - Check Valve/Holders

4-34 - POWERHEAD 90-817643R1 DECEMBER 1996

Thermostat Cover Installation Powerhead Installation
1. Install thermostat components into cylinder block. 1. Install lifting eye (p/n 91-90455) into flywheel a mini-
Torque bolts to 18 lb. ft. (24.5 N·m). mum of 5 turns. Install powerhead to driveshaft hous-
ing. Slide shift slide on rail while lowering powerhead
50/60 Models on splines of drive shaft.

PE-51087

55 Model

PE-51087

Install Remaining Engine

Components
Component/Assembly Section
Starter Motor 2B
Ignition Switch Box 2A*
Ignition Coil 2A*
PE-51081
Starter Solenoid 2B*
Voltage Regulator/Rectifier 2B*
Flywheel 2A
Stator Assembly 2A*
Trigger Assembly 2A*
Air Silencer 3A
Carburetor and Linkage 3A
Fuel Pump 3B
Fuel Enrichment Valve 3C
Shift Cable Latch Assembly 7A
Control Cable Anchor Bracket 7A
Warning Module 3D*
Oil Pump 3D
* Note: All ignition and electrical components can be re-
moved and installed as an assembly.

90-817643R1 DECEMBER 1996 POWERHEAD - 4-35

2. Install Powerhead bolts. Torque to 28 lb.ft. (38.0 N·m). 4. Reattach ground wire to powerhead. Connect wires
from trim relay switch. Connect tel tale hose.
Design 1

b
c

a PE-51082

Design 2
b

PE-51088

3. Install cover. Torque bolts to 80 lb. in. (9.0 N·m).

c

a
54244
a - Module(s)
b - Ground Lead
c - Tel Tale Hose

5. Reconnect wires and oil hose. Secure in place with sta-

strap.

c
a

PE-51088
a - Oil Tank Wires
PE-51083 b - Power Trim Wires
c - Oil Hose (Connect to Tank)

4-36 - POWERHEAD 90-817643R1 DECEMBER 1996

6. Install oil tank. 9. Install bolt and rubber grommet.
7. Install battery cables and starter bracket.
c

c a

PE-51082
PE-51080
a - Bolt
a - Positive Cable b - Fuel Connector
b - Ground Cable c - Rubber Grommet
c - Bracket
10. Install control cables. Refer to cable adjustment in Sec-
8. Install electrical box cover. Note, bottom edge of cover tion 7A.
fits into groove of plate.

b
a PE-51088

a - Shift Cable
b - Throttle Cable

PE-51089

90-817643R1 DECEMBER 1996 POWERHEAD - 4-37

11. Reconnect trim switch.
Test Run Procedure
a ! CAUTION
b When engine is started, IMMEDIATELY check that wa-
ter pump is operating. Operation of water pump is indi-
cated by water discharging from “tell tale”.
1. While test running outboard, check powerhead as-
sembly for leaks and/or unusual noises. Make any re-
c pairs BEFORE placing outboard in service.

d Important Information
Proper break-in assures that all moving parts “wear-in”
evenly to ensure a longer engine life and optimum perform-
ance.
PE-51089 Operate your new outboard motor at varied throttle settings
a - Blue/White – not to exceed 1/2 throttle (2500-3500 RPM) during the
b - Green/White first hour or the first five gallons of break-in fuel. Refer to
c - Red/Black “Fuel Mixture and Gasoline/Oil Recommendations” –
d - Trim Switch
“Break-In Fuel Mixture” located in your operation and Main-
12. Connect control/trim harness and fuel line. tenance Manual.
During the second hour operation, or the second 5 gallons
(20 Litres) of break-in fuel, operate the Outboard at varied
throttle settings not to exceed 4500 RPM.
DO NOT OPERATE YOUR NEW OUTBOARD MOTOR
AT FULL THROTTLE UNTIL THE SECOND HOUR OF
BREAK-IN IS COMPLETED.This includes full throttle ac-
celeration, pulling waterskiers, or wide open throttle run-
ning.
After the first two hours of running, approximately 10 gal-
lons (40 Liters) of fuel, full throttle operation may be at-
tained, but not sustained, for the remaining break-in fuel
(approximately 5 gallons).
For the next five hours of operation, full throttle operation
may, again, be attained, but it is strongly not recommended
for sustained use. (Not more than 5 minutes of continuous
wide open throttle.)

! CAUTION
PE-51082 SEVERE DAMAGE to your engine can result by not
complying with the preceding break-in procedures.
13. Install battery cables.

PE-51084

4-38 - POWERHEAD 90-817643R1 DECEMBER 1996

MID-SECTION

5
50557

CLAMP/SWIVEL BRACKETS and

A
DRIVE SHAFT HOUSING
Table of Contents
Page
Mid-Section Components . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Swivel Bracket Components . . . . . . . . . . . . . . . . . 5A-1
Mid-Section Components . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Transom Bracket Components (55 Model) . . . . . 5A-2
Mid-Section Components . . . . . . . . . . . . . . . . . . . . . . . 5A-3
Transom Bracket Components (50/60
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
Mid-Section Components . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Drive Shaft Housing Components . . . . . . . . . . . . 5A-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
Tilt Lock Lever/Transom Bracket . . . . . . . . . . . . . 5A-5
Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-7

5A-0 - MID-SECTION 90-817643R1 DECEMBER 1996

Mid-Section Components

Swivel Bracket Components

17 a
1 - Swivel Bracket
2 - Bushing (2)
3 - Oil Seal
12 b
4 - Bushing 13
5 - Grease Fitting
10 11 18
6 - Washer (2)
7 - Yoke 16
8 - Retaining Ring
9 - Roll Pin
17
10 - Steering Arm
14 c
A
11 - Bracket 15 a
12 - Locking Plate
13 - Bolt (2)
14 - Steering Link
15 - Bolt
16 - Spacer 19 A
17 - Lock Nut
18 - Washer (2) 3 9 4
19 - Washer (2)
2
A

1
5

A
2
A 3
6

Lubrication/Sealant Application Torque Specifications

Points
a 20 lb. ft. (27.0 N·m)
A 2-4-C w/Teflon Marine Lubricant (92-90018A12)
b 40 lb. ft. (54.0 N·m)
c Torque until it seats, then back off 1/4 turn.

90-817643R1 DECEMBER 1996 MID-SECTION - 5A-1

Mid-Section Components

Transom Bracket Components (55 Model)

1 - Transom Bracket
2 - Grease Fitting
3 - Pin
4 - Transom Bracket A
5 - Lock Lever
6 - Spring
7 - Bushing
8 - Spring
9 - Lever 8
10 - Roll Pin
11 - Washer (2) b 9
29 34 7 10
12 - Bracket 33
13 - Anode
1
14 - Bolt (2)
15 - Washer (2)
28 5 21
16 - Bolt:
5 (30mm)
1 (35mm)
32
17 - Lockwasher (2) 30
2
18 - Lock Nut (2) 31 3 A
19 - Pin 4
20 - Tilt Tube
21 - Lock Nut (2)
22 - Bolt (4)
23 - Washer (4)
24 - Nut (4)
6
25
25 - Bolt (2) 11
26 - Washer (2) b
27 - Thumb Screw (2) A 16
28 - Rubber Grip 17 27
29 - Tilt Lever 26 D
30 - Bushing 20
31 - Washer 12 B
32 - Washer
33 - Bolt
34 - Link
35 - Bolt (4) b 18 15
36 - Washer (8)
37 - Bracket (2)
38 - Shim (4)
19
39 - Nut (4) 13 14
22 23 24 a
21
35 36
36
39
37
38

Lubrication/Sealant Application Torque Specifications

Points a 60 lb. in. (7.0 N·m)
A 2-4-C Marine w/Teflon Lubricant (92-90018A12) b 25 lb. ft. (34.0 N·m)
B Loctite 271 (92-823089--1)

D Special Lubricant 101 (92-13872A1)

5A-2 - MID-SECTION 90-817643R1 DECEMBER 1996

Mid-Section Components

Transom Bracket Components (50/60 Models)

A
1 -
Transom Bracket
2 -
Grease Fitting
3 -
Pin
4 -
Transom Bracket
5 -
Tilt Lock Lever
b
32 37
6 -
Spring A
7 -
Bushing A
8 -
Spring 9
8 10
9 -
Lever 36 7
10 -
Roll Pin
11 -
Washer (2) 35
12 -
Bracket 33 3
13 -
Anode Plate
14 -
Bolt (2) 34 31 21
15 -
Washer (2)
16 -
Bolt:
5 (30mm) 11
1 (35mm)
17 - Lockwasher (2) 4 2
18 - Lock Nut (2)
19 - Pin
20 - Tilt Tube
21 - Lock Nut (2) 5 6
A
22 - Spacer 25
23 - O-ring 16
24 - Cap 27 26 17
25 - Clamp A
26 - Washer
27 - Screw 22 20 12
28 - Bolt (4)
21 1
29 - Washer (4) 18
30 - Nut (4)
Non-Power Trim
24 b 13
31 - Link
32 - Tilt Lever 15
33 - Bushing 28 14 a
34 - Washer
35 - Wave Washer
36 - Knob
19 29
37 - Bolt 23
38 - Nut 30
39 - Bolt

39
38

Lubrication/Sealant Application Torque Specifications

Points
a 60 lb. in. (7.0 N·m)
A 2-4-C w/Teflon Marine Lubricant (92-90018A12)
b 25 lb. ft. (34.0 N·m)

90-817643R1 DECEMBER 1996 MID-SECTION - 5A-3

Mid-Section Components
e 9 f
12
Drive Shaft Housing Components 10 13 a
19
c 11 14
8
1 - Drive shaft Housing 20
2 - Seal
15
3 - Bolt (4)
7
4 - Exhaust Tube 22 21
5 - Gasket 23
6 - Pin
7 - Exhaust Plate 16
8 - Bolt 6
9 - Lock Nut (2)
10 - Washer (2)
11 - Washer (2)
12 - Bolt (4)
5 24
13 - Mount
14 - Bolt (2)
15 - Pin (4) A
16 - Bushing 4
17 - Coupling
18 - Spacer
19 - Lock Nut 25
20 - Washer c 3
21 - Wave Washer 26
22 - Shift Link
23 - Bushing
24 - Shift Shaft A
27 b
25 - Seal
26 - Clamp
27 - Bolt (2)
28 - Water Tube 2 28
29 - Seal
30 - Bolt (2)
31 - Ground Strap 29
32 - Bolt (4)
33 - Cover (2)
34 - Screw (4)
35 - Nut (4)
36 - Clamp (2) c 33
37 - Washer (2) A 32 34
38 - Nut (2)
31
39 - Connector
40 - Tube 30
1
41 - Fitting
42 - Washer (4)
43 - Bolt (4)
44 - Lock Nut 47 35
45 - Washer I
46 - Stud 36
47 - Mount (2) 37
46 38 e
40
39
45
Torque Specification 42
41
17
a No Torque Requirement - 44
Drive Unit Until Tight, 43 18
But Joint Must Be Free to
d
Pivot d
b 80 lb. in. (9.0 N·m)
Lubrication/Sealant Application
c 220 lb. in. (25.0 N·m)
Points
d 40 lb. ft. (54.0 N·m)
A 2-4-C w TeflonMarine Lubricant (92-90018A12)
e 50 lb.ft. (67.5 N·m)
I Loctite 35 (92-59328-1)
f 28 lb. ft. (38.0 N·m)

5A-4 - MID-SECTION 90-817643R1 DECEMBER 1996

Disassembly Reassembly
Remove shock system assembly (refer to Section 5C) from
non power trim models. Tilt Lock Lever/Transom Bracket
Remove power trim assembly (refer to Section 5B) from Apply Quicksilver 2-4-C Marine Lubricant to tilt lock lever
power trim models. shank, spacer and bushing prior to reassembly.
Servicing components such as steering arm, driveshaft b e
housing, exhaust assembly, swivel bracket assembly, etc. d
generally require powerhead and/or gear housing remov-
al. Refer to appropriate section in service manual. Compo-
nents such as transom bracket, lower mount bracket, tilt
tube and lower engine mounts can be serviced without
powerhead/gear housing removal; however, outboard c
must be supported (shown) before servicing components
not requiring powerhead/gear housing removal. a
f
! WARNING
Failure to support outboard as shown could result in
personal injury and/or damage to outboard or boat.
Typical Outboard Shown

b 51079
a - Spring
b - Tilt Lock Lever
c c - Bushing
d - Spring
e - Lever
f - Roll Pin

Install roll pin to tilt lock lever assembly using appropriate

punch.

51078
a - Hoist
b - Rope
c - Lifting Eye (P/N 91-90455)

Refer to parts views on pages 1, 2 and 3 and disassemble

mid-section components as required.
51078

! CAUTION
When reinstalling outboard tilt tube, longer threaded
end of tilt tube must extend approximately 3/4 in.
(19mm) toward steering cable nut side of boat.

90-817643R1 DECEMBER 1996 MID-SECTION - 5A-5

Lubricate outboard tilt tube using Quicksilver 2-4-C Marine Install and secure yoke and washer using snap ring.
Lubricant and install into swivel bracket.
Secure transom brackets into place using fiber washers
and lock nuts.

b c a

51078
b
a - Tilt Tube
b - Fiber Washer
c - Lock Nuts 51079

Apply Quicksilver 2-4-C Marine Lubricant to steering arm a - Washer

b - Yoke
shaft and install. c - Snap Ring

Install lower mounting bracket to transom brackets.

b
a

a
a
b

51079
b
a - Steering Arm
b - Washer

b 51079
a - Lower Mounting Bracket
b - Bolt

5A-6 - MID-SECTION 90-817643R1 DECEMBER 1996

 Install clamp.
Drive Shaft Housing
Secure transom bracket assembly to transom.
Install drive shaft housing to transom bracket assembly.
Secure using bolts and components as shown.

e e
g g
c c b

f a
51097
b
a - Clamp
b - Bolts [220 lb. in. (24 N·m)]

Install shift linkage assembly and new gasket to drive shaft

51097 housing.
a - Transom Bracket Assembly
b - Drive Shaft Housing Assembly b
a
c - Bolts [28 lb. in. (32 N·m)]
d - Lock Nuts [50 lb. ft. (69 N·m)]
e - Washer
f - Rubber Mount
g - Washer

Secure lower mount assembly to drive shaft housing. Se-

cure drive shaft housing to yoke.

d
c

e 51097
b
a - Shift Linkage Assembly
b - Gasket

Install powerhead and gearcase assemblies referring to

appropriate sections of service manual.
Powerhead Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A
Lower Unit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A

51097
a - Lower Mount
b - Bolt
c - Washer
d - Rubber Washer
e - Lock Nut [50 lb. ft. (68 N·m)

90-817643R1 DECEMBER 1996 MID-SECTION - 5A-7

MID-SECTION

5
50158

POWER TRIM (DESIGN 1)

B
Table of Contents
Page Page
Power Trim General Information . . . . . . . . . . . . 5B-1 Power Trim System Removal . . . . . . . . . . . . . 5B-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Power Trim System Disassembly . . . . . . . . . . 5B-22
Trimming Characteristics . . . . . . . . . . . . . . . 5B-1 Trim Rod Removal . . . . . . . . . . . . . . . . . . . . 5B-22
Trimming Outboard “Up” (“Out”) . . . . . . . 5B-1 Trim Rod Disassembly . . . . . . . . . . . . . . . . 5B-23
Trimming OUtboard “Down” (“In”) . . . . . 5B-1 Trim “Motor” Removal . . . . . . . . . . . . . . . . . 5B-25
Trailering Outboard . . . . . . . . . . . . . . . . . . . . 5B-2 Trim “Motor” Disassembly . . . . . . . . . . . . . . 5B-25
Tilting Outboard Up and Down Manually . . 5B-2 Reservoir Assembly Removal . . . . . . . . . . 5B-26
Trim “In” Angle Adjustment . . . . . . . . . . . . . . 5B-2 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . 5B-27
Power Trim System Components . . . . . . . . . . . 5B-3 Manifold Removal . . . . . . . . . . . . . . . . . . . . 5B-27
Torque Specifications . . . . . . . . . . . . . . . . . . 5B-3 Cleaning and Inspection of Trim Rod
Quicksilver Lubricants and Service Aids . . 5B-3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Power Trim Flow Diagrams Design 1 . . . . . . . 5B-4 Motor and Electrical Tests/Repair . . . . . . . . . . 5B-29
Determine if Problem is Electrical or Trim Pump Motor Test . . . . . . . . . . . . . . . . . 5B-29
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 Thermal Overload Switch Test . . . . . . . . . . 5B-29
Trouble Chart . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 Motor Assembled . . . . . . . . . . . . . . . . . . 5B-29
Hydraulic System Troubleshooting . . . . . . 5B-12 Motor Disassembled . . . . . . . . . . . . . . . . 5B-29
Preliminary Checks . . . . . . . . . . . . . . . . . . . 5B-12 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5B-30
Leak Down Check – Pump and Manifold Test for Shorts . . . . . . . . . . . . . . . . . . . . . 5B-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 Test for Ground . . . . . . . . . . . . . . . . . . . . 5B-30
Leak Down Check – Pilot Valve Checking and Cleaning Commutator . 5B-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-13 Power Trim System Reassembly . . . . . . . . . . 5B-30
Leak Down Check – Manual Release Manifold Installation . . . . . . . . . . . . . . . . . . . 5B-30
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-13 Oil Pump Installation . . . . . . . . . . . . . . . . . . 5B-31
Leakage Past Ball and Seat – Piston Trim Motor Reassembly . . . . . . . . . . . . . . . 5B-32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-13 Reservoir Installation . . . . . . . . . . . . . . . . . . 5B-33
Troubleshooting Flow Diagram . . . . . . . . . 5B-14 Trim Rod Re-assembly . . . . . . . . . . . . . . . . 5B-35
Troubleshooting Flow Diagram . . . . . . . . . 5B-15 Trim Rod Installation . . . . . . . . . . . . . . . . . . 5B-36
Electrical System Troubleshooting . . . . . . . . . 5B-16 Bleeding Power Trim Unit . . . . . . . . . . . . . . . . 5B-37
COMMANDER 2000 Side Mount Remote Power Trim Unit Installation . . . . . . . . . . . . 5B-37
Control (Power Trim/Tilt Electric Start with
Warning Horn) Wiring Diagram . . . . . . . 5B-16
Power Trim System Wiring Diagram . . . . . 5B-17
Troubleshooting the “Down” Circuit*
(When “Up” Circuit is OK) . . . . . . . . . . . . 5B-18
Troubleshooting the “Up” Circuit*
(When “Down” Circuit Is OK) . . . . . . . . . 5B-19
Troubleshooting the “Down” and “Up” Circuits
(All Circuits Inoperative)* . . . . . . . . . . . . 5B-20

5B-0 - MID-SECTION 90-817643R1 DECEMBER 1996

Power Trim General Make sure that water level is above gear housing
water intake holes whenever engine is running.
Information Operating “up” circuit will actuate the “up” solenoid
(located under engine cowl) and close the electric
motor circuit. The electric motor will drive the pump,
Description thus forcing automatic transmission fluid thru internal
The Power Trim system consists of an electric motor, passageways into the “up” side of the trim cylinder.
pressurized fluid reservoir, pump and trim cylinder. The trim cylinder/trim ram will position the engine at
The remote control (or trim panel) is equipped with a the desired trim angle within the 20° maximum trim
switch that is used for trimming the outboard “up” and range. The Power Trim system is designed so the en-
“down”, and for tilting the outboard for shallow water gine cannot be trimmed beyond the 20° maximum
operation (at slow speed) or for “trailering”. The out- trim angle as long as engine RPM is above approxi-
board can be trimmed “up” or “down” while engine is mately 2000 RPM.
under power or when engine is not running. The engine can be raised beyond the 20° maximum
trim angle for shallow water operation, etc., by keep-
ing the engine RPM below 2000 RPM. If engine RPM
Trimming Characteristics increases above 2000 RPM, the thrust created by the
propeller (if deep enough in the water) will cause the
NOTE: Because varying hull designs react differently
trim system to automatically lower the engine back to
in various degrees of rough water, it is recommended
the 20° maximum trim angle.
to experiment with trim positions to determine wheth-
er trimming “up” or “down” will improve the ride in
TRIMMING OUTBOARD “DOWN” (“IN”)
rough water.
When trimming your outboard from a mid-trim posi- WARNING
tion (trim tab in neutral, straight fore-and-aft, posi-
tion), you can expect the following results: Excessive speed at minimum trim “In” may cause
undesirable and/or unsafe steering conditions.
Each boat should be tested for handling charac-
TRIMMING OUTBOARD “UP” (“OUT”)
teristics after any adjustment is made to the tilt
angle (tilt pin relocation).
WARNING
Will help planing off, particularly with a heavy load.
Excessive trim “out” may reduce the stability of
some high speed hulls. To correct instability at Usually improves ride in choppy water.
high speed, reduce the power gradually and trim In excess, can cause boat to veer to the left or right
the motor “in” slightly before resuming high (bow steer).
speed operation. (Rapid reduction in power will
cause a sudden change of steering torque and Transfers steering torque harder to right (or less to
may cause additional momentary boat instabili- the left).
ty.) Improves planing speed acceleration (by moving tilt
Will lift bow of boat, generally increasing top speed. pin one hole closer to transom).
Transfers steering torque harder to left on installa- Operating “Down” circuit will actuate the “down” sole-
tions below 23” transom height. noid (located under engine cowl) and close the elec-
tric motor circuit (motor will run in opposite direction
Increases clearance over submerged objects. of the “Up” circuit). The electric motor will drive the
In excess, can cause porpoising and/or ventilation. pump, thus forcing automatic fluid thru internal pas-
sageways into the “down” side of the tilt ram. The tilt
In excess, can cause insufficient water supply to wa-
ram will move the engine downward to the desired
ter pump resulting in serious water pump and/or pow-
angle.
erhead overheating damage.

WARNING
Excessive engine trim angle will result in insuffi-
cient water supply to water pump causing water
pump and/or powerhead overheating damage.

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-1

Trailering Outboard Trim “In” Angle Adjustment

WARNING WARNING
Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to the
cient water supply to water pump causing water full “in” trim angle [not using trim adjustment pin
pump and/or powerhead overheating damage. (a)] at planing speed will cause undesirable and/
Make sure that water level is above gear housing or unsafe steering conditions. Each boat must be
water intake holes whenever engine is running. water tested for handling characteristics after en-
gine installation and after any trim adjustments.
While operating “up” circuit, tilt ram will continue to tilt
outboard to full up position for trailering. IMPORTANT: Some boat/motor combinations,
that doe not use the trim adjustment pin (a) and
are trimmed to the full “in” trim angle, will not ex-
Tilting Outboard Up and Down perience any undesirable and/or unsafe steering
Manually conditions during planing speed. Thus, not using
trim adjustment pin may be desired. However,
some boats with engine trimmed to the full “in”
WARNING trim angle at planing speeds will cause undesir-
Before loosening the manual release valve, make able and/or unsafe steering conditions. If these
sure all persons are clear of engine as engine will steering conditions are experienced, under no
drop to full “down” position when valve is loos- circumstances should the engine be operated
ened. without the trim adjustment pin and without the
pin adjusted in the proper holes to prevent unsafe
With power trim installed, the outboard can be raised
handling characteristics.
or lowered manually by opening the manual release
valve 3 to 4 turns (counterclockwise). Water test the boat not using the trim adjustment pin.
If undesirable and/or unsafe steering conditions are
experienced (boat runs with nose down), install trim
adjustment pin in proper hole to prevent unsafe han-
dling characteristics.

50146
a - Manual Release Valve

50157

5B-2 - MID-SECTION 90-817643R1 DECEMBER 1996

Power Trim System NOTE: It is recommended that “ALL” O-rings be re-
placed when servicing tilt system.
Components
1 - Trim Rod
2 - Dowel Pin (Upper) Torque Specifications
3 - Upper Pivot Pin
4 - Rod Wiper a 35 lb. in. (4.0 N·m)
5 - O-ring .671 in. I.D.
6 - Cylinder Cap b 100 lb. in. (11.2 N·m)
7 - O-ring 1.864 in. I.D.
8 - O-ring .614 in. I.D. c 70 lb. in. (7.9 N·m)
9 - Trim Rod Piston
10- Ball (5) d 90 lb. in. (10.2 N·m)
11- Spring Seat (5)
12- Spring (5) e 25 lb. in. (2.8 N·m)
13- Retaining Plate
14- Screw (5)
f 13 lb. in. (1.5 N·m)
15- O-ring 1.600 in I.D. (Rod Piston)
16- O-ring 1.600 in. I.D. (Memory Piston)
17- Memory Piston Quicksilver Lubricants and Service
18- Trim Rod Cylinder
19- Screw (2) Aids
20- O-ring .208 in I.D. (2)
21- Filter A Loctite Grade “A” (271)
22- O-ring .301 in. I.D.
23- Valve Seat B 2-4-C Marine Lubricant (92-90018A12)
24- O-ring .364 in. I.D.
25- Ball
26- Spring Guide
27- Spring
28- Dowel Pin (2)
29- Reservoir
30- Fill Screw
31- O-ring .583 in. I.D.
32- Screw (4)
33- Washer (4)
34- O-ring 2.364 in. I.D.
35- Screw
36- Drive Shaft
37- Pump
38- O-ring .176 in. I.D. (2)
39- Dowel Pin
40- Manifold
41- O-ring .114 in. I.D.
42- O-ring .208 in. I.D.
43- O-ring .239 in. I.D.
44- Relief Valve
45- “E” Clip
46- Wire Harness
47- Cap
48- Washer
49- Grommet
50- Screw (4)
51- Screw
52- Reservoir Cap
53- O-ring 2.364 in. I.D.
54- Disk Foam Pad
55- Nut (2)
56- End Cap
57- Washer (.030 in. Thick) (2)
58- Washer, Thrust
59- Armature
60- Washer (.010 in. Thick)
61- Housing
26153
62- O-ring
63- End Frame
64- O-ring .489 in. I.D.
65- Screw (2)

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-3

Power Trim Flow Diagrams
Design 1

51638

5B-4 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 1

51637

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-5

Design 1

51639

5B-6 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 1

51640

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-7

Design 1

51641

5B-8 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 1

51642

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-9

Design 1

51643

5B-10 - MID-SECTION 90-817643R1 DECEMBER 1996

Troubleshooting

Determine if Problem is Electrical or

Hydraulic
Refer to the following chart to determine which sys-
tem is at fault.

Trouble Chart

Outboard will not trim up or down.

Determine if Power Trim pump

Outboard trims up, will not trim motor operates when appro-
down. priate trim circuit is activated.

Outboard trims down, will not trim

up.

Pump motor operates. Pump motor does not operate.

Outboard will not return complete-
ly to “down” position or returns part
way with jerky motion.

Outboard thumps when shifted.

Outboard trails out when backing Refer to “Hydraulic System

off throttle at high speed. Troubleshooting”.

Outboard will not hold a trimmed

position or will not remain tilted for
any extended period.

Outboard will not hold trim position Refer to “Electrical System

when in reverse. Troubleshooting”.

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-11

Hydraulic System Troubleshooting Leak Down Check – Pump and
Support outboard with tilt lock lever when servicing Manifold Assembly
power trim system. NOTE: Scribe (d) pump housing halves before disas-
IMPORTANT: After debris or failed components sembly.
have been found (during troubleshooting proce- 1. Debris or chips between valve and seat (a). Usu-
dure) it is recommended that unit be disas- ally imbedded in rubber valve seat.
sembled completely and ALL O-rings be re-
placed. Check ball valve components and 2. Nicked or deteriorated O-ring (b).
castings must be cleaned using engine cleaner 3. Nicked, deteriorated or misplaced O-ring be-
and compressed air or replaced prior to reas- tween manifold and trim cylinder. Refer to “Man-
sembly. ifold Removal” for O-ring location.
IMPORTANT: Power trim system is pressurized.
Outboard must be in the full “UP” position (cylin-
der fully extended) prior to fill screw or manual re-
lease valve removal.
Refer to instructions following if disassembly is re-
quired.
Follow preliminary checks before proceeding to trou-
bleshooting flow diagrams (following).

Preliminary Checks
IMPORTANT: Operate Power Trim system after
each check to see if problem has been corrected.
If problem has not been corrected proceed to next
check.
1. Check that manual release valve is tightened to
full right (clockwise) position.
2. Check trim pump fluid level with outboard in full
“UP” position and fill if necessary. Refer to “Fill
and Purge the Power Trim System”.
3. Check for external leaks in Power Trim system.
Replace defective part(s) if leak is found.
4. Outboard not holding tilted position (falls to trim in
position) indicates debris or defective compo-
nents in trim valve assembly. Clean or replace
components as required.
5. Check manual release valve for broken stem and
one O-ring remaining in the release valve pas-
sage. (Separate the manifold assembly from the
cylinder to dislodge broken stem.) Install new re-
lease valve and test system.
6. Check for nicked, deteriorated or misplaced O-
51735
rings throughout trim system.
4. After reassembly, insert driveshaft and check
pump rotation resistance to turning – housing
halves can shift/turn during reassembly. Align
scribe marks (d) carefully.

5B-12 - MID-SECTION 90-817643R1 DECEMBER 1996

Leak Down Check – Pilot Valve Leakage Past Ball and Seat – Piston
Assembly Assembly
1. Debris or chips between check ball and seat (a), Unit will trim to full or near full DOWN position and
usually imbedded in rubber valve seat. then will begin to trim UP while trim switch is held in
“DOWN” mode.
2. Nicked or deteriorated O-ring (b).
If trim switch is released, outboard can be pushed (by
A leak path is created between the UP side of the cyl-
hand) DOWN to the point where trim UP started.
inder and the reservoir. The trim system will leak
DOWN until the trim port in cylinder is covered. 1. Inspect balls and seats in piston assembly for de-
bris or damage. Repair or replace balls/seats.

a - Check Ball and Seat

b - O-ring

Leak Down Check – Manual Release

Valve
1. Debris or chips under O-ring (a).
2. Flash from valve molding causing O-ring (a) to not 51143
a
seal.
a - Ball and Seat. Check for Debris or Damage
3. Nicked O-ring (a).

51560
a - O-ring

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-13

 Troubleshooting Flow Diagram

Outboard falls to full down position with manu-

al release valve closed.

Example a: Outboard lowers more than one

tilt pin hole in eight hours.

Example b: Outboard lowers during acceler-

ation.

Inspect Manual Release

Valve.
Result Result

Manual release valve and/or O- Manual release valve and O-rings

ring damage. appear to be OK. Replace O-
rings.

Replace defective valve and O-

rings. Inspect Memory Piston O-ring.

Result Result

O-rings appear to be OK. Cylinder O-ring, memory piston or cylinder

bore and memory piston are OK. bore defective.
Replace O-rings and proceed.

Inspect Oil Pump O-rings (located Replace defective O-rings or

below oil pump). components.

Result Result

O-ring failure (located below oil O-rings appear to be OK. Re-

pump). place O-rings.

Replace O-rings. Replace oil pump.

5B-14 - MID-SECTION 90-817643R1 DECEMBER 1996

 Troubleshooting Flow Diagram

Outboard will not hold tilted position in reverse

and/or trails out during high speed decelera-
tion.

Inspect Manual Release

Valve.
Result Result

Manual release valve and/or O- Manual release valve and O-rings

ring damage appear to be OK. Replace O-rings
and proceed.

Replace defective valve and O- Inspect Trim Rod Piston Check

rings. Valve.

Result Result

No debris or defective components Debris found in check valve com-

found. ponents.

Inspect Manifold Reverse Thrust Clean check valve components

Valve. using engine cleaner and com-
pressed air or replace.

CAUTION
DO NOT ADJUST OR REMOVE
REVERSE THRUST VALVE. THIS
VALVE IS PRESET AT FACTORY
FOR PRECISE REVERSE THRUST
PRESSURE AND DOES NOT RE-
QUIRE ADJUSTMENT. REVERSE
THRUST VALVE COMPONENTS
CAN ONLY BE CLEANED USING
ENGINE CLEANER AND COM-
PRESSED AIR (THROUGH MAN-
IFOLD PORTS) WHILE VALVE
COMPONENTS REMAIN IN MAN-
IFOLD.

Result Result

Debris found in manifold reverse No debris found in manifold re-

thrust valve components. verse thrust valve.

Clean manifold reverse thrust Replace Manifold as a Unit.

valve (without removing) compo-
nents using engine cleaner and
compressed air or replace.

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-15

Electrical System Troubleshooting
COMMANDER 2000 Side Mount
Remote Control (Power Trim/Tilt
Electric Start with Warning Horn)
Wiring Diagram

d 4
e f
a
5
b

BLK • Black
BLU • Blue
BRN • Brown c
GRY • Gray
GRN • Green
PUR • Purple
RED • Red
TAN • Tan
WHT • White
YEL • Yellow

a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness Connector 23891
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch

5B-16 - MID-SECTION 90-817643R1 DECEMBER 1996

Power Trim System Wiring Diagram

BLK • Black
BLU • Blue
GRN • Green
RED • Red
WHT • White

50285

a - To Power Trim Pump Motor

b - Relay Switch “UP”
c - Relay Switch “DOWN”
d - Engine Starter Motor Solenoid
e - Cowl Trim Switch
f - Fuse Holder (20 Amp Fuse)
g - Engine Wiring Harness Connector
h - Remote Control Wiring Harness

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-17

 Troubleshooting the “Down” Circuit*
(When “Up” Circuit is OK)
*Remote Control Not Equipped with Trailer Button

Connect Voltmeter red lead to

Point 1 and black lead to ground.
Depress the “Down” trim button.

Battery Voltage Indicated: No Voltage Indicated:

Connect Voltmeter red lead to Connect Voltmeter red lead to
Point 3. Point 4 and black lead to ground.
Depress “Down” trim button. If bat-
tery voltage is indicated, wire is
open between Points 4 and 1.

Battery Voltage Indicated: No Voltage Indicated:

• Connect Voltmeter red lead to There is an open circuit between
Point 2. Point 3 and positive (+) battery ter-
• Depress “Down” trim button. minal.
• Check for loose or corroded con-
nections.
• Check wires for open.

Battery Voltage Indicated: No Voltage Indicated:

• Pump motor wiring is defective. Relay Switch is defective.
• Pump motor is defective.

No Voltage Indicated:
Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
cated, trim switch is faulty. If no bat-
tery voltage, check for loose or cor-
roded connection at Point 5 or
open circuit in wire supplying cur-
rent to Point 5.

5B-18 - MID-SECTION 90-817643R1 DECEMBER 1996

 Troubleshooting the “Up” Circuit*
(When “Down” Circuit Is OK)
*Remote Control NOT Equipped with Trailer Button

Connect Voltmeter red lead to

Point 8 and black lead to ground.
Depress the “Up” trim button.

Battery Voltage Indicated: No Voltage Indicated:

Connect Voltmeter red lead to Connect Voltmeter red lead to
Point 3. Point 7 and black lead to ground.
Depress “Down” trim button. If bat-
tery voltage is indicated, wire is
open between Points 7 and 8.

Battery Voltage Indicated: No Voltage Indicated:

• Connect Voltmeter red lead to There is an open circuit between
Point 6. Point 3 and positive (+) battery ter-
• Depress “Up” trim button. minal.
• Check for loose or corroded con-
nections.
• Check wires for open circuit.

Battery Voltage Indicated: No Voltage Indicated:

• Pump motor wiring is defective. Relay Switch is defective.
• Pump motor is defective.

No Voltage Indicated:
Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
cated, trim switch is faulty. If no bat-
tery voltage, check for loose or cor-
roded connection at Point 5 or
open circuit in wire supplying cur-
rent to Point 5.

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-19

 Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)*
*Remote Control Not Equipped with Trailer Button

Check in-line fuse (under cowl) to

see if fuse is blown.

Blown Fuse: Fuse Not Blown:

• Correct problem that caused Connect Voltmeter red lead to
fuse to blow. Point 3 and black lead to ground.
• Replace fuse. Battery voltage should be indi-
cated.

No Voltage Indicated: Battery Voltage Indicated:

• Check battery leads for poor • Connect Voltmeter red lead to
connections or open circuits. Point 8 and black lead to ground.
• Check battery charge.
• Depress “Up” trim button and
check for battery voltage.

Battery Voltage Indicated:

• Check black ground wires for
No Voltage Indicated: poor connection or poor ground.
Connect red Voltmeter lead to • Pump motor is faulty. Refer to
Point 5, and black lead to ground. “Motor and Electrical Tests/Rep-
air”, following.

No Voltage Indicated: Battery Voltage Indicated:

Check that voltage is being Trim switch is faulty or there is an
supplied to control by performing open circuit in wires (green-white,
the following checks: blue-white) between trim buttons
• DO NOT start engine. and trim pump.
• Turn ignition switch to “Run” po- • Check trim switch.
sition. • Check all trim harness connec-
• Check for voltage at any instru- tors for loose or corroded con-
ment, using a Voltmeter. nections.
• Check for pinched or severed
wires.

No Voltage Indicated: Battery Voltage Indicated:

Red wire is open between Point 3 There is an open circuit in wire be-
and red terminal on back of the ig- tween Point 5 and Red terminal on
nition switch. the back of the ignition switch.
• Check for loose or corroded con-
nections.
• Check for open in wire.

5B-20 - MID-SECTION 90-817643R1 DECEMBER 1996

Power Trim System Removal 5. Use suitable punch to remove (DRIVE UP) lower
dowel pin. Retain dowel pin.
Support outboard with tilt lock lever when servicing
power trim system.
1. Disconnect power trim harness from outboard
wiring harness.
2. Remove screw and clip securing wiring harness
to clamp bracket.
3. Use suitable tool to remove (DRIVE DOWN) up-
per dowel pin. Retain dowel pin.

51144
a - Dowel Pin
6. Use suitable punch to drive out lower pivot pin.

51144
a - Dowel Pin
4. Use suitable punch to drive out upper pivot pin.

a a 51144
a - Pivot Pin

51144
a - Pivot Pin

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-21

7. Tilt power trim assembly (top first) out from clamp 9. Remove O-ring from fill cap.
bracket and remove assembly.

51194

Power Trim System

Disassembly
Trim Rod Removal
1. Secure power trim assembly in soft jawed vise.
2. Open manual release valve three or four turns
(counterclockwise) and position trim rod to full up
position.
2
3. Remove cylinder end cap assembly from cylinder
using spanner wrench (1/4 in. x 5/16 in. long
51195 pegs).
8. Remove fill cap and drain unit.

a
51194
51193
a - Manual Release Valve

5B-22 - MID-SECTION 90-817643R1 DECEMBER 1996

4. Remove trim rod assembly from cylinder. 6. Remove O-ring from memory piston.
a
b

51196
a - O-ring
b - Memory Piston
7. Remove trim system from vise and empty fluid
51196 into appropriate container.
5. Remove memory piston from cylinder using lock-
ring pliers (shown) or suitable tool.
Trim Rod Disassembly
1. Place trim rod assembly on clean work surface.
2. Remove screws securing plate to trim rod piston
and O-ring.
3. Remove check ball components from trim rod pis-
ton.

b c
51143
a - Screw
b - Plate
c - O-ring

CAUTION
51193 When removing Trim Rod piston, spanner
wrench must have 1/4 in. x 5/16 in. long pegs to
avoid damage to trim piston.

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-23

4. Place trim rod into soft jawed vise and apply heat
to shock piston using torch lamp (P/N 91-63209). CAUTION
5. Loosen trim rod piston using spanner wrench (1/4 Do not remove check ball components from trim
in. x 5/16 in. long pegs). rod piston. Removal and reinstallation of check
valve could result in improper operating pressure
6. Allow trim rod piston to cool, remove from trim rod. and possible power trim system damage. If check
valve is defective, replace trim rod piston.
7. Remove inner O-ring from piston.

a
c

b
51199
a - Check Ball Components
b - O-ring
c - Piston
8. Remove rod wiper, inner O-ring and outer O-ring.

51146

b
a

51147

c
b

51146
51145
a - Trim Rod Piston
b - Spanner Wrench a - Rod Wiper
b - Inner O-ring
c - Outer O-ring

5B-24 - MID-SECTION 90-817643R1 DECEMBER 1996

Trim “Motor” Removal 4. Remove motor and harness from reservoir.

1. Secure power trim assembly in soft jawed vise.

2. Remove cap, washer and grommet from reser-
voir assembly.
b
a
c

51196

Trim “Motor” Disassembly

51195 1. Remove end cap from motor housing. Note posi-
a - Cap tion of washers on armature.
b - Washer
c - Grommet
3. Remove screws securing reservoir cap to reser-
voir. c
a
a

d 51194
a - End Cap
a b - Motor Housing
c - Wave Washer (2)
d - Washer
51193
a - Screws

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-25

2. Remove O-ring from end frame. Reservoir Assembly Removal
3. Place scribe mark on motor housing and end
frame as reassembly reference, as shown. CAUTION
DO NOT ADJUST OR REMOVE REVERSE
a THRUST VALVE. THIS VALVE IS PRESET AT FAC-
TORY FOR PRECISE REVERSE THRUST PRES-
SURE AND DOES NOT REQUIRE ADJUSTMENT.
1. Remove manual release valve from manifold. DO
NOT remove or adjust reverse thrust valve.

51194
a - O-ring
c
b
b - Scribe Mark a
51194
4. Remove end frame and armature from housing. a - Manual Release Valve
b - Manifold
c - Reverse Thrust Valve
e
2. Remove “E” clip and O-rings from manual release
valve.

b
d

c
a
b c
51196
51194 a - “E” Clip
b - O-rings
a - End Frame
c - Manual Release Valve
b - Washer
c - Armature
d - Fiber Guard (Brush Wires)
e - Housing

5B-26 - MID-SECTION 90-817643R1 DECEMBER 1996

3. Remove four screws securing reservoir to man- Oil Pump Removal
ifold.
IMPORTANT: The oil pump is not rebuildable. If oil
pump is defective, replace as an assembly.
1. Remove screw, oil pump and O-rings from man-
ifold.

a a
51193
a - Screw
b
4. Remove reservoir from manifold.
5. Remove drive shaft from oil pump.
a
a
51007
a - O-ring
b - Oil Pump
c - Screw

a Manifold Removal
1. While holding trim cylinder to manifold, remove
screws.
b

b
a

51194
a - Drive Shaft
b - Oil Pump
c

51007
a - Trim Cylinder
b - Manifold
c - Screw

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-27

2. Slowly remove manifold from cylinder. Note posi- 3. Remove O-rings from cylinder.
tion of above trim check ball assembly and re-
4. Remove filter.
move.

a
b

54745

54743
a - O-rings
b - Filter

Cleaning and Inspection of

Trim Rod Components
IMPORTANT: Components must be dirt and lint
free. Slightest amount of debris in Power Trim
system could cause system to malfunction.

CAUTION
Do not remove check valve components from
trim rod piston. Removal and reinstallation of
check valve could result in improper operating
pressure and possible power trim system dam-
age.

51199
a - Check Ball Components
54744

a - Above Trim Check Ball Components

5B-28 - MID-SECTION 90-817643R1 DECEMBER 1996

Inspect check valve for debris; clean debris from MOTOR ASSEMBLED
check valve if found. If debris cannot be cleaned from
Connect Ohmmeter (R x 1 scale) leads as shown. If
check valve, replace trim rod piston as an assembly.
switch is good, full continuity (zero ohms) will be indi-
Clean trim rod and components with parts cleaner cated. If full continuity is not indicated, disassemble
and dry with compressed air. motor and recheck switch per instructions, following.
It is recommended that all O-rings in trim system be
replaced.
Inspect trim rod. If scraper (located in cap) has failed
to keep rod clean, replace scraper.
Lubricate all O-rings using Quicksilver Power Trim
and Steering Fluid or; (ATF) Type F, FA or Dexron II.

Motor and Electrical Tests/

Repair
Trim Pump Motor Test a

WARNING
Do not perform this test near flammables (or ex-
plosives), as a spark may occur when making
connections.
1. Disconnect orange (motor) wire and black (mo-
tor) wire from relay switch wiring harness.
2. Connect a 12 volt power supply to motor wires b
51196
(positive to orange; negative to black results in a - Motor Wire (Black)
motor up direction. Positive to black; negative to b - Motor Wire (Orange)
orange results in motor down direction). Motor
should run. MOTOR DISASSEMBLED
3. If motor does not run, disassemble motor and Connect Ohmmeter (R x 1 scale) leads as shown. If
check components. switch is good, full continuity (zero ohms) will be indi-
cated.

Thermal Overload Switch Test

IMPORTANT: If thermal overload switch has been
activated, pump motor cannot be tested for a
minimum of one minute. After this period switch
should close (reset itself) and pump motor may
be operated. Perform the following check(s) only
if switch does not reset itself.

51193
If full continuity is not indicated, clean switch contact
surfaces, using an ignition point file.
Recheck switch; if full continuity is not indicated, re-
place end frame.

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-29

Armature Tests Power Trim System
TEST FOR SHORTS Reassembly
Check armature on a Growler (follow Growler man-
ufacturer’s test instructions). Indication of a short re- Manifold Installation
quires replacement of armature.
IMPORTANT: Filter must be installed in trim cylin-
TEST FOR GROUND der with ridge of filter housing facing out.
Use an Ohmmeter (R x 1 scale). Place one lead of
Ohmmeter on armature shaft and other lead on com-
mutator, as shown. If continuity is indicated, armature
is grounded and must be replaced.

50447

1. Install lubricated O-rings and filter, with housing

ridge facing out, to trim cylinder.

51195
b
CHECKING AND CLEANING COMMUTATOR
If commutator (a) is worn it can be turned down on an
armature conditioner tool or on a lathe.
Clean commutator with “00” sandpaper.
a

54745

a - O-ring
b - Filter

5B-30 - MID-SECTION 90-817643R1 DECEMBER 1996

2. Install check ball components (a) into manifold. 4. Secure manifold to cylinder using screws, torque
to 100 lb. in. (11.2 N·m).

c
b

54746

a - Trim Cylinder
a b - Manifold
c - Screw

Oil Pump Installation

1. Secure power trim unit in soft jawed vise.
54744 2. Install lubricated O-rings to manifold.

3. Hold check ball components in place using 3. Install oil pump to manifold and secure using
screwdriver (as shown). Connect manifold to trim screw, torque to 90 lb. in. (10.2 N·m).
cylinder.
c

54747

a - O-ring
b - Oil Pump
c - Screw

54748

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-31

Trim Motor Reassembly 3. Align scribe mark on housing with mark on end
frame.
1. Apply Quicksilver Marine Lubricant (2-4-C) to ar-
mature shaft and insert into end frame. 4. Install lubricated O-ring to end frame.
a

b b
c

51195
a - Armature Shaft
b - Washer
c - End Frame 51194
a - O-ring
2. Guide armature and end frame into housing as b - Scribe Mark
shown.
5. Install washers to armature shaft as shown.
6. Install end cap to housing. Torque nuts to 25 lb. in.
(2.8 N·m).

c
a

d
51194
51196 a - End Cap
b - Motor Housing
c - Wave Washer
d - Washer

5B-32 - MID-SECTION 90-817643R1 DECEMBER 1996

IMPORTANT: When installing motor, wires (black, 3. Install end cap, O-ring and foam pad to cylinder.
orange) must rest in cavity of cylinder allowing
4. Torque screws to 13 lb. ft. (1.5 N·m).
motor to seat properly.
a
b
a c

51194
a - Manifold
b - Cavity

51195
Reservoir Installation a - End Cap
b - O-ring
1. Connect trim motor wires to harness. c - Foam Pad

2. Insert motor into reservoir. Motor must be seated 5. Install grommet, washer and screw cap to cylin-
properly prior to end cap installation. der end cap. Tighten screw securely.

b c
a

51195
a - Grommet
51196 b - Washer
c - Screw Cap

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-33

6. Place drive shaft into oil pump. 10. Install lubricated O-rings and “E” clip to manual
release valve.
7. Install lubricated O-ring to base of reservoir.
8. Carefully guide reservoir (with motor) down onto
drive shaft.

a
c
51196
b
a - “E” Clip
a b - O-ring
c - Manual Release Valve
11. Insert manual release valve into manifold and
tighten snuggly. Back release valve out 3 or 4
turns allowing trim rod installation.

b
a
51194
a - Drive Shaft
b - O-ring
9. Secure reservoir to manifold using four screws.
Torque screws to 70 lb. in. (7.9 N·m). c
51194
a - Manual Release Valve
b - Manifold
c - Reverse Thrust Valve

a a
51193
a - Screw

5B-34 - MID-SECTION 90-817643R1 DECEMBER 1996

Trim Rod Reassembly 4. Apply Loctite Grade A (271) to threads of trim rod
and install trim rod piston. Tighten piston securely
1. Install lubricated O-rings and rod wiper to end using spanner wrench (1/4 in. x 5/16 in. long peg).
cap.
b a

c
b

51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
2. Secure trim rod in soft jawed vise as shown.
3. Slide end cap onto trim rod. 51146
a - Trim Rod Piston
b - Spanner Wrench
a
5. Install lubricated O-ring to trim rod piston.
6. Install check ball components into its respective
bore.
7. Secure components in place using plate and
screws. Torque screws securely.

d
e
f
a

51146
a - End Cap
c
b
51147
a - Screw
b - Plate
c - O-ring
d - Ball
e - Seat, Spring
f - Spring

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-35

Trim Rod Installation 4. Install trim rod into cylinder.

1. Place trim cylinder in soft jawed vise.

2. Fill trim cylinder three inches (76.2mm) from top
of cylinder using Quicksilver Power Trim and
Steering Fluid or; (ATF) Type F, FA or Dexron II.
3. Install lubricated O-ring to memory piston and
place into cylinder. Push piston down to level of
oil.
b
a

51196

5. Tighten end cap assembly to cylinder securely

using spanner wrench (1/4 in. x 5/16 in. long
pegs).

51144
a - O-ring
b - Memory Piston
IMPORTANT: Memory piston must not come in
contact with trim rod end cap during end cap/trim
rod installation.

51145
6. Tighten manual release valve snuggly following
end cap installation.

5B-36 - MID-SECTION 90-817643R1 DECEMBER 1996

Bleeding Power Trim Unit Power Trim Unit Installation
IMPORTANT: Manual release valve must be in the 1. Apply Special Lubricant 101 (92-13872A1) to
closed position during power trim bleeding and lower pivot pin hole and pivot pin surface.
operation. 2. Start lower pivot pin into pivot pin bore and posi-
1. Secure power trim unit in soft jawed vise. tion lower dowel pin (RETAINED) in its respective
hole.
2. Remove fill screw. Add Quicksilver Power Trim
and Steering Fluid (92-90100A12) or Automatic
Transmission Fluid (ATF) Type F, FA or Dexron II
up to threads of reservoir.

51148
a - Lower Pivot Pin
b - Lower Dowel Pin
3. Position trim cylinder assembly (BOTTOM
FIRST) between clamp brackets and route trim
pump electrical harness through access hole in
starboard clamp bracket.

50241
2
3. Using a 12 volt power supply connect positive
lead to green wire, negative lead to blue wire and
drive trim rod to the down position. Connect posi- a
tive lead to blue wire and negative lead to green
wire and drive trim rod to the up position. Recheck
fluid level, add fluid if required and repeat cycle
until fluid level remains at lower portion of
threads.
4. Install fill plug.

1
51195
a - Trim Cylinder Assembly

90-817643R1 DECEMBER 1996 MID-SECTION - 5B-37

4. Using a suitable punch, drive lower pivot pin into 7. Using a suitable mallet, drive upper pivot pin into
clamp bracket and trim cylinder assembly until swivel bracket and through trim ram until pivot pin
pivot pin is flush with outside surface. is flushed with swivel bracket.

a
c
a

51147 51148
a - Lower Pivot Pin a - Pivot Pin
b - Swivel Bracket
5. Using a suitable punch, drive lower dowel pin into c - Trim Ram
its respective bore until seated. 8. Drive upper dowel pin (RETAINED) into its re-
spective hole until seated.

51148 51147
a - Dowel Pin
a - Lower Dowel Pin
9. Remove trim fluid fill screw. Fluid level should be
6. Apply 2-4-C Marine Lubricant (92-90018A12) to
to bottom of threads. Add Quicksilver Power Trim
surface of upper pivot pin, pivot pin bore and trim
and Steering Fluid (92-90100A12) or Automatic
ram bore.
Transmission Fluid (ATF) Type F, FA or Dexron II
to trim system, if necessary.
a 10. Reinstall fill screw.

c 11. Power trim may now be operated to lower out-

board to desired position. Trim system is self
bleeding.
12. Reconnect spark plug leads to spark plugs.
b 13. Reinstall top cowl.
14. Connect battery leads to battery terminals.

51148
a - Pivot Pin
b - Pivot Pin Bore
c - Trim Ram Bore

5B-38 - MID-SECTION 90-817643R1 DECEMBER 1996

MID-SECTION

5
50158

POWER TRIM (DESIGN II)

C
Table of Contents
Page Page
Power Trim General Information . . . . . . . . . . . . 5C-1 COMMANDER 2000 Side Mount Remote
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Control (Power Trim/Tilt Electric Start with
Trimming Characteristics . . . . . . . . . . . . . . . 5C-1 Warning Horn) Wiring Diagram . . . . . . . 5C-16
Trimming Outboard “Up” (“Out”) . . . . . . . 5C-1 Power Trim System Wiring Diagram . . . . . 5C-17
Trimming Outboard “Down” (“In”) . . . . . . 5C-1 Troubleshooting the “Down” Circuit*
Trailering Outboard . . . . . . . . . . . . . . . . . . . . 5C-2 (When “Up” Circuit is OK) . . . . . . . . . . . . 5C-18
Tilting Outboard Up and Down Manually . . 5C-2 Troubleshooting the “Up” Circuit*
Trim “In” Angle Adjustment . . . . . . . . . . . . . . 5C-2 (When “Down” Circuit Is OK) . . . . . . . . . 5C-19
Power Trim System Components . . . . . . . . . . . 5C-3 Troubleshooting the “Down” and “Up” Circuits
Torque Specifications . . . . . . . . . . . . . . . . . . 5C-3 (All Circuits Inoperative)* . . . . . . . . . . . . 5C-20
Quicksilver Lubricant/Sealant Application Power Trim System Removal . . . . . . . . . . . . . 5C-21
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Power Trim System Disassembly . . . . . . . . . . 5C-22
Power Trim Flow Diagrams Design II . . . . . . . 5C-4 Trim Rod Removal . . . . . . . . . . . . . . . . . . . . 5C-22
Design II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5 Trim Rod Disassembly . . . . . . . . . . . . . . . . 5C-23
Design II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Trim “Motor” Removal . . . . . . . . . . . . . . . . . 5C-25
Design II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7 Trim Motor Disassembly . . . . . . . . . . . . . . . 5C-25
Design II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-8 Reservoir Assembly Removal . . . . . . . . . . 5C-26
Design II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9 Oil Pump/Manifold Removal . . . . . . . . . . . . 5C-27
Design II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10 Cleaning and Inspection of Trim Rod
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5C-11 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-28
Determining if Problem is Electrical or Motor and Electrical Tests/Repair . . . . . . . . . . 5C-29
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-11 Trim Pump Motor Test . . . . . . . . . . . . . . . . . 5C-29
Trouble Chart . . . . . . . . . . . . . . . . . . . . . . . . 5C-11 Thermal Overload Switch Test . . . . . . . . . . 5C-29
Hydraulic System Troubleshooting . . . . . . 5C-12 Motor Assembled . . . . . . . . . . . . . . . . . . 5C-29
Preliminary Checks . . . . . . . . . . . . . . . . . . . 5C-12 Motor Disassembled . . . . . . . . . . . . . . . . 5C-29
Leak Down Check – Pump and Manifold Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5C-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-12 Test for Shorts . . . . . . . . . . . . . . . . . . . . . 5C-30
Leak Down Check – Pilot Valve Test for Ground . . . . . . . . . . . . . . . . . . . . 5C-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13 Checking and Cleaning Commutator . 5C-30
Leak Down Check – Manual Release Power Trim System Re-assembly . . . . . . . . . 5C-30
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13 Manifold/Oil Pump Installation . . . . . . . . . . 5C-30
Leakage Past Ball and Seat – Piston Trim Motor Re-assembly . . . . . . . . . . . . . . . 5C-31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13 Reservoir Installation . . . . . . . . . . . . . . . . . . 5C-33
Troubleshooting Flow Diagram . . . . . . . . . 5C-14 Trim Rod Re-assembly . . . . . . . . . . . . . . . . 5C-34
Troubleshooting Flow Diagram . . . . . . . . . 5C-15 Trim Rod Installation . . . . . . . . . . . . . . . . . . 5C-35
Electrical System Troubleshooting . . . . . . . . . 5C-16 Bleeding Power Trim Unit . . . . . . . . . . . . . . . . 5C-36
Power Trim Unit Installation . . . . . . . . . . . . 5C-37

5C-0 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Power Trim General WARNING
Information Excessive engine trim angle will result in insuffi-
cient water supply to water pump causing water
Description pump and/or powerhead overheating damage.
Make sure that water level is above gear housing
The Power Trim system consists of an electric motor, water intake holes whenever engine is running.
pressurized fluid reservoir, pump and trim cylinder.
Operating “Up” circuit will actuate the “up” solenoid
The remote control (or trim panel) is equipped with a (located under engine cowl) and close the electric
switch that is used for trimming the outboard “up” and motor circuit. The electric motor will drive the pump,
“down”, and for tilting the outboard for shallow water thus forcing automatic transmission fluid thru internal
operation (at slow speed) or for “trailering”. The out- passageways into the “up” side of the trim ram.
board can be trimmed “up” or “down” while engine is
under power or when engine is not running. The trim cylinder/trim ram will position the engine at
the desired trim angle within the 20° maximum trim
range. The Power Trim system is designed so the en-
gine cannot be trimmed beyond the 20° maximum
Trimming Characteristics trim angle as long as engine RPM is above approxi-
NOTE: Because varying hull designs react differently mately 2000 RPM.
in various degrees of rough water, it is recommended The engine can be raised beyond the 20° maximum
to experiment with trim positions to determine wheth- trim angle for shallow water operation, etc., by keep-
er trimming “up” or “down” will improve the ride in ing the engine RPM below 2000 RPM. If engine
rough water. speed increases above 2000 RPM, the thrust created
When trimming your outboard from a mid-trim posi- by the propeller (if deep enough in the water) should
tion (trim tab in neutral, straight fore-and-aft, posi- cause the trim system to automatically lower the en-
tion), you can expect the following results: gine back to the 20° maximum trim angle.

TRIMMING OUTBOARD “UP” (“OUT”) TRIMMING OUTBOARD “DOWN” (“IN”)

WARNING WARNING
Excessive trim “out” may reduce the stability of Excessive speed at minimum trim “In” may cause
some high speed hulls. To correct instability at undesirable and/or unsafe steering conditions.
high speed, reduce the power gradually and trim Each boat should be tested for handling charac-
the motor “In” slightly before resuming high teristics after any adjustment is made to the tilt
speed operation. (Rapid reduction in power will angle (tilt pin relocation).
cause a sudden change of steering torque and Will help planing off, particularly with a heavy load.
may cause additional momentary boat instabili-
ty.) Usually improves ride in choppy water.
Will lift bow of boat, generally increasing top speed. In excess, can cause boat to veer to the left or right
(bow steer).
Transfers steering torque harder to left on installa-
tions below 23 in. transom height. Transfers steering torque harder to right (or less to
the left).
Increases clearance over submerged objects.
Improves planing speed acceleration (by moving tilt
In excess, can cause porpoising and/or ventilation. pin one hole closer to transom).
In excess, can cause insufficient water supply to wa- Operating “Down” circuit will actuate the “down” sole-
ter pump resulting in serious water pump and/or pow- noid (located under engine cowl) and close the elec-
erhead overheating damage. tric motor circuit (motor will run in opposite direction
of the “Up” circuit). The electric motor will drive the
pump, thus forcing automatic transmission fluid thru
internal passageways into the “down” side of the tilt
ram. The tilt ram will move the engine downward to
the desired angle.

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-1

Trailering Outboard Trim “In” Angle Adjustment

WARNING WARNING
Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to the
cient water supply to water pump causing water full “in” trim angle [not using trim adjustment pin
pump and/or powerhead overheating damage. (a)] at planing speed will cause undesirable and/
Make sure that water level is above gear housing or unsafe steering conditions. Each boat must be
water intake holes whenever engine is running. water tested for handling characteristics after en-
gine installation and after any trim adjustments.
While operating “up” circuit, tilt ram will continue to tilt
outboard to full up position for trailering. IMPORTANT: Some boat/motor combinations,
that do not use the trim adjustment pin (a) and are
trimmed to the full “in” trim angle, will not experi-
Tilting Outboard Up and Down ence any undesirable and/or unsafe steering con-
Manually ditions during planing speed. Thus, not using
trim adjustment pin may be desired. However,
some boats with engine trimmed to the full “in”
WARNING trim angle at planing speed will cause undesir-
Before loosening the manual release valve, make able and/or unsafe steering conditions. If these
sure all persons are clear of engine as engine will steering conditions are experienced, under no
drop to full “down” position when valve is loos- circumstances should the engine be operated
ened. without the trim adjustment pin and without the
pin adjusted in the proper holes to prevent unsafe
With power trim installed, the outboard can be raised
handling characteristics.
or lowered manually by opening the manual release
valve 3 to 4 turns (counterclockwise). Water test the boat not using the trim adjustment pin.
If undesirable and/or unsafe steering conditions are
experienced (boat runs with nose down), install trim
adjustment pin (a) in proper hole to prevent unsafe
handling characteristics.

a
a

50146
a - Manual Release Valve
51057

5C-2 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Power Trim System NOTE: It is recommended that “ALL” O-rings be re-
placed when servicing tilt system.
Components
1 - Trim Rod
2 - Dowel Pin
2 46
3
3 - Pivot Pin 47
4 - Rod Wiper 48
5 - O-ring .671 in. I.D. 51
6 - Cylinder Cap 41 52 49
7 - O-ring 1.864 in. I.D.
8 - O-ring .614 in. I.D. 50
9 - Trim Rod Piston A f
10 - Ball (5)
1 c
11 - Seat Spring (5) 45 44 53
42 55
12 - Spring (5)
13 - Retainer Plate 56
14 - Screw (3)
5 54 e
43
15 - O-ring 1.600 in. I.D. (2) 4
16 - Memory Piston
17 - Trim Rod Cylinder
57
18 - Screw (2)
6 40 58
19 - O-ring .208 in. I.D. (2) b
20 - O-ring .114 in. I.D. 7 17 59 B
21 - Spool 18
8
22 - O-ring .301 in. I.D. (3) d 38
39
23 - Sleeve
24 - Spring
9 60
65
25 - Valve Seat 10
26 - Valve 11 2
27 - Spring (2) 12 61
28 - Ball 13 37
29 - Dowel Pin (2) 62
30 - Manifold a 14 36
31 - O-ring .114 in. I.D.
32 - O-ring .208 in. I.D. 15 19 22
33 - O-ring .239 in. I.D. 28
34 - Relief Valve
35 - “E” Clip 20
16 27
36 - Dowel Pin 3 21 64
37 - O-ring .176 in. I.D. (2) 23 63
38 - Bolt B 24
39 - Drive Shaft 30
26
40 - O-ring 2.364 in. I.D. 25 32
41 - Reservoir 35
42 - Bolt (4) 29
43 - Washer (4) 31
44 - O-ring .538 in. I.D. 33
45 - Fill Screw 34
51005
46 - Wire Harness
47 - Cap Torque Specifications
48 - Washer a 35 lb. in. (4.0 N·m)
49 - Grommet
50 - Screw (4) b 100 lb. in. (11.3 N·m)
51 - Screw c 70 lb. in. (7.9 N·m)
52 - Reservoir Cap
53 - O-ring 2.634 in. I.D. d 90 lb. in. (10.2 N·m)
54 - Nut (2)
55 - Disk Foam Pad
e 25 lb. in. (2.8 N·m)
56 - End Cap f 13 lb. in. (1.5 N·m)
57 - Washer (2; .030 in. Thick)
58 - Thrust Washer
59 - Armature
60 - Washer (.010 in. Thick) Quicksilver Lubricant/Sealant
61 - Housing Application Points
62 - End Frame
63 - O-ring .489 in. I.D. A Loctite Grade “A” (271)
64 - Bolt (2)
65 - Trim Pump B Special Lubricant 101

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-3

Power Trim Flow Diagrams
Design II

51644

5C-4 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Design II

51645

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-5

Design II

51646

5C-6 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Design II

51647

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-7

Design II

51648

5C-8 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Design II

51649

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-9

Design II

51650

5C-10 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Troubleshooting
Determining if Problem is Electrical
or Hydraulic
Refer to the following chart to determine which sys-
tem is at fault.

Trouble Chart

Outboard will not trim up or down.

Determine if Power Trim pump

Outboard trims up, will not trim motor operates when appro-
down. priate trim circuit is activated.

Outboard trims down, will not trim

up.

Pump motor operates. Pump motor does not operate.

Outboard will not return complete-
ly to “down” position or returns part
way with jerky motion.

Outboard thumps when shifted.

Refer to “Hydraulic System Refer to “Electrical System

Troubleshooting”. Troubleshooting”.
Outboard trails out when backing
off throttle at high speed.

Outboard will not hold a trimmed

position or will not remain tilted for
any extended period.

Outboard will not hold trim position

when in reverse.

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-11

Hydraulic System Troubleshooting Leak Down Check – Pump and Man-
Support outboard with tilt lock lever when servicing ifold Assembly
power trim system. NOTE: Scribe (d) pump housing halves before disas-
IMPORTANT: After debris or failed components sembly. Check pump for problems as follows:
have been found (during troubleshooting proce- 1. Debris or chips between valve and seat (a). Usu-
dure) it is recommended that unit be disas- ally imbedded in rubber valve seat.
sembled completely and ALL O-rings be re-
placed. Check ball valve components and 2. Nicked or deteriorated O-ring (b).
castings must be cleaned using engine cleaner 3. Nicked, deteriorated or misplaced O-ring be-
and compressed air or replaced prior to reas- tween manifold and trim cylinder. Refer to “Man-
sembly. ifold Removal” for O-ring location.
IMPORTANT: Power trim system is pressurized.
Outboard must be in the full “UP” position (trim
rod fully extended) prior to fill/drain plug, or man-
ual release valve removal.
Refer to instructions following if disassembly is re- d
quired when servicing.
Follow preliminary checks before proceeding to trou-
bleshooting flow diagrams (following).

Preliminary Checks
IMPORTANT: Operate Power Trim system after b
each check to see if problem has been corrected.
If problem has not been corrected proceed to next a
check.
51736
1. Check that manual release valve is tightened to
full right (clockwise) position.
2. Check trim pump fluid level with outboard in full
“UP” position and fill if necessary. Refer to “Bleed-
ing Power Trim Unit”.
b
3. Check for external leaks in Power Trim system.
Replace defective part(s) if leak is found.
4. Outboard not holding tilted position (falls down to d
trim position) indicates debris or defective com-
ponents in trim valve assembly. Clean or replace
components as required.
5. Check manual release valve for broken stem and
one O-ring remaining in the release valve pas-
sage. (Separate the manifold assembly from the
cylinder to dislodge broken stem.) Install new re-
lease valve and test system. 51735
6. Check for nicked, deteriorated or misplaced O-
rings throughout trim system.
4. After reassembly, insert drive shaft and check
pump rotation resistance to turning – housing
halves can shift/turn during reassembly. Align
scribe marks (d) carefully.

5C-12 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Leak Down Check – Pilot Valve As- Leakage Past Ball and Seat – Piston
sembly Assembly
1. Debris or chips between valve and seat (a), usu- Unit will trim to full or near full DOWN position and
ally imbedded in rubber valve seat. then will begin to trim UP while trim switch is held in
“DOWN” mode.
2. Pilot valve installed from non-chamfered end of
spool results in nicked or damaged O-ring (b). If trim switch is released, outboard can be pushed (by
hand) DOWN to the point where trim UP started.
3. Nicked or deteriorated O-ring (c).
1. Inspect balls and seats in piston assembly for de-
A leak path is created between the UP side of the cyl-
bris or damage. Repair or replace balls/seats.
inder and the reservoir. The trim system will leak
DOWN until the trim port in cylinder is covered.
c

b
a

51560
a - Valve and Seat
b - Pilot Valve O-ring 51143
c - O-ring a
a - Ball and Seat. Check for Debris or Damage

Leak Down Check – Manual Release

Valve
1. Debris or chips under O-ring (a).
2. Flash from valve molding causing O-ring (a) to not
seal.
3. Nicked O-ring (a).

51560
a - O-ring

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-13

 Troubleshooting Flow Diagram

Outboard falls to full down position with manu-

al release valve closed.

Example a: Outboard lowers more than one

tilt pin hole in eight hours.

Example b: Outboard lowers during acceler-

ation.

Inspect Manual Release

Valve.
Result Result

Manual release valve and/or O- Manual release valve and O-rings

ring damage. appear to be OK. Replace O-
rings.

Replace defective valve and O-

rings. Inspect Memory Piston O-ring.

Result Result

O-ring appear to be OK. Cylinder O-ring, memory piston or cylinder

bore and memory piston are OK. bore defective.
Replace O-rings and proceed.

Inspect Oil Pump O-rings (located Replace defective O-rings or

below oil pump). components.

Result Result

O-ring failure (located below oil O-rings appear to be OK. Re-

pump). place O-rings.

Replace O-rings. Replace oil pump.

5C-14 - MID-SECTION 90-8i7643R1 DECEMBER 1996

 Troubleshooting Flow Diagram

Outboard will not hold tilted position in reverse

and/or trails out during high speed decelera-
tion.

Inspect Manual Release

Valve.
Result Result

Manual release valve and/or O- Manual release valve and O-rings

ring damage appear to be OK. Replace O-rings
and proceed.

Replace defective valve and O- Inspect Trim Rod Piston Check

rings. Valve.

Result Result

No debris or defective components Debris found in check valve com-

found. ponents.

Inspect Manifold Reverse Thrust Clean check valve components

Valve. using engine cleaner and com-
pressed air or replace.

Result Result

Debris found in manifold reverse No debris found in manifold re-

thrust valve components. verse thrust valve.

Clean manifold reverse thrust Replace Manifold as a Unit.

valve without removing compo-
nents using engine or cleaner and
compressed air or replace.

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-15

Electrical System
Troubleshooting
COMMANDER 2000 Side Mount
Remote Control (Power Trim/Tilt
Electric Start with Warning Horn)
Wiring Diagram
g

d 4
e f
a
b 5

BLK • Black
BLU • Blue
BRN • Brown c
GRY • Gray
GRN • Green
PUR • Purple
RED • Red
TAN • Tan
WHT • White
YEL • Yellow

a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness Connector 23891
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch

5C-16 - MID-SECTION 90-8i7643R1 DECEMBER 1996

 REMOTE CONTROL

50436
Power Trim System Wiring Diagram

WIRES FROM
SIDE MOUNT

HARNESS
BLK • Black
BLU • Blue

8
GRN • Green
RED • Red

1
WHT • White

MOTOR
POWER
TRIM
6

BATTERY
SOLENOID
STARTER

TO

POWER
TRIM
MODULE

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-17

 Troubleshooting the “Down” Circuit*
(When “Up” Circuit is OK)

Connect Voltmeter red lead to

Point 1 and black lead to ground.
Depress the “Down” trim button.

Battery Voltage Indicated: No Voltage Indicated:

Connect Voltmeter red lead to Connect Voltmeter red lead to
Point 3. Point 4 and black lead to ground.
Depress “Down” trim button. If bat-
tery voltage is indicated, wire is
open between Points 4 and 1.

Battery Voltage Indicated: No Voltage Indicated:

• Connect Voltmeter red lead to There is an open circuit between
Point 2. Point 3 and positive (+) battery ter-
• Depress “Down” trim button. minal.
• Check for loose or corroded con-
nections.
• Check wires for open circuit.

Battery Voltage Indicated: No Voltage Indicated:

• Pump motor wiring is defective. Relay Switch is defective.
• Pump motor is defective.

No Voltage Indicated:
Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
cated, trim switch is faulty. If no bat-
tery voltage, check for loose or cor-
roded connection at Point 5 or
open circuit in wire supplying cur-
rent to Point 5.

5C-18 - MID-SECTION 90-8i7643R1 DECEMBER 1996

 Troubleshooting the “Up” Circuit*
(When “Down” Circuit Is OK)

Connect Voltmeter red lead to

Point 8 and black lead to ground.
Depress the “Up” trim button.

Battery Voltage Indicated: No Voltage Indicated:

Connect Voltmeter red lead to Connect Voltmeter red lead to
Point 3. Point 7 and black lead to ground.
Depress “Down” trim button. If bat-
tery voltage is indicated, wire is
open between Points 7 and 8.

Battery Voltage Indicated: No Voltage Indicated:

• Connect Voltmeter red lead to There is an open circuit between
Point 6. Point 3 and positive (+) battery ter-
• Depress “Up” trim button. minal.
• Check for loose or corroded con-
nections.
• Check wires for open circuit.

Battery Voltage Indicated: No Voltage Indicated:

• Pump motor wiring is defective. Relay Switch is defective.
• Pump motor is defective.

No Voltage Indicated:
Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
cated, trim switch is faulty. If no bat-
tery voltage, check for loose or cor-
roded connection at Point 5 or
open circuit in wire supplying cur-
rent to Point 5.

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-19

 Troubleshooting the “Down” and “Up” Circuits (All Circuits Inoperative)*

Check in-line fuse (under cowl) to

see if fuse is blown.

Blown Fuse: Fuse Not Blown:

• Correct problem that caused Connect Voltmeter red lead to
fuse to blow. Point 3 and black lead to ground.
• Replace fuse. Battery voltage should be indi-
cated.

No Voltage Indicated: Battery Voltage Indicated:

• Check battery leads for poor • Connect Voltmeter red lead to
connections or open circuits. Point 8 and black lead to ground.
• Check battery charge.
• Depress “Up” trim button and
check for battery voltage.

Battery Voltage Indicated:

• Check black ground wires for
No Voltage Indicated: poor connection or poor ground.
Connect red Voltmeter lead to • Pump motor is faulty. Refer to
Point 5, and black lead to ground. “Motor and Electrical Tests/Rep-
air”, following.

No Voltage Indicated: Battery Voltage Indicated:

Check that voltage is being Trim switch is faulty or there is an
supplied to control by performing open circuit in wires (green-white,
the following checks: blue-white) between trim buttons
• DO NOT start engine. and trim pump.
• Turn ignition switch to “Run” po- • Check trim switch.
sition. • Check all trim harness connec-
• Check for voltage at any instru- tors for loose or corroded con-
ment, using a Voltmeter. nections.
• Check for pinched or severed
wires.

No Voltage Indicated: Battery Voltage Indicated:

Red wire is open between Point 3 There is an open circuit in wire be-
and red terminal on back of the ig- tween Point 5 and Red terminal on
nition switch. the back of the ignition switch.
• Check for loose or corroded con-
nections.
• Check for open in wire.

5C-20 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Power Trim System Removal 5. Use suitable punch to remove (DRIVE UP) lower
dowel pin. Retain dowel pin.
Support outboard with tilt lock lever when servicing
power trim system.
1. Disconnect power trim harness form outboard
wiring harness.
2. Remove screw and clip securing wiring harness
to clamp bracket.
3. Use suitable tool to remove (DRIVE DOWN) up-
per dowel pin. Retain pin.

51144
a - Dowel Pin
6. Use suitable punch to drive out lower pivot pin.

51144
a - Dowel Pin
4. Use suitable punch to drive out upper pivot pin.

a a 51144
a - Pivot Pin

51144
a - Pivot Pin

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-21

7. Tilt power trim assembly (top first) out from clamp Power Trim System
bracket and remove assembly.
Disassembly
Trim Rod Removal

CAUTION
1 DO NOT ADJUST OR REMOVE REVERSE
THRUST VALVE. THIS VALVE IS PRESET AT FAC-
TORY FOR PRECISE REVERSE THRUST PRES-
SURE AND DOES NOT REQUIRE ADJUSTMENT.
1. Secure power trim assembly in soft jawed vise.
2. Open manual release valve three or four turns
(counterclockwise) and position trim rod to full up
position.
3. Remove cylinder end cap assembly from cylinder
using trim cylinder spanner wrench (1/4 in. x 5/16
in. long pegs).

a
2

51195 b
8. Remove fill cap and drain unit.

51194
a - Manual Release Valve
b - Manifold
c - Reverse Thrust Valve (Do Not Remove, or Adjust)

51193
9. Remove O-ring from fill cap.

51194

5C-22 - MID-SECTION 90-8i7643R1 DECEMBER 1996

4. Remove trim rod assembly from cylinder. 6. Remove O-ring from memory piston.
a
b

51196
a - O-ring
b - Memory Piston
7. Remove trim system from vise and empty fluid
51196 into appropriate container.
5. Remove memory piston from cylinder using lock-
ring pliers (Craftsman P/N 4735) or suitable tool.
Trim Rod Disassembly
1. Place trim rod assembly on clean work surface.
2. Remove screws securing plate to trim rod piston
and O-ring.
3. Remove check valve components from trim rod
piston.

d
b c
51143
a - Screw (3)
b - Plate
c - O-ring
d - Piston

CAUTION
51193
When removing Trim Rod piston, spanner
wrench must have 1/4 in. x 5/16 in. long pegs to
avoid damage to trim piston.

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-23

4. Place trim rod into soft jawed vise and apply heat
to loosen piston using torch lamp (P/N 91-63209). CAUTION
5. Loosen trim rod piston using trim spanner span- Do not remove check ball components from trim
ner wrench (1/4 in. x 5/16 in. long pegs). rod piston. Removal and re-installation of check
valve could result in improper operating pressure
6. Allow trim rod piston to cool, remove from trim rod. and possible power trim system damage. If check
valve is defective, replace trim rod piston.
7. Remove inner O-ring from piston.

a
c

b
51199
a - Check Ball Components
b - O-ring
c - Piston
8. Remove rod wiper, inner O-ring and outer O-ring.

51146

b
a

51147

c
b
51146
a - Trim Rod Piston
51145
b - Spanner Wrench
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring

5C-24 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Trim “Motor” Removal 4. Remove motor harness from reservoir.

1. Secure power trim assembly in soft jawed vise.

2. Remove cap, washer and grommet from reser-
voir assembly.
b
a
c

51196

Trim Motor Disassembly

51195 1. Remove end cap from motor housing. Note posi-
a - Cap tion of washers on armature.
b - Washer
c - Grommet
3. Remove screws securing reservoir cap to reser-
voir. c
a
a

d 51194
a - End Cap
a b - Motor Housing
c - Wave Washer (2)
d - Washer
51193
a - Screws (4)

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-25

2. Remove O-ring from end frame. Reservoir Assembly Removal
3. Place scribe mark on motor housing and end
frame as re-assembly reference, as shown. CAUTION
DO NOT ADJUST OR REMOVE REVERSE
a THRUST VALVE. THIS VALVE IS PRESET AT FAC-
TORY FOR PRECISE REVERSE THRUST PRES-
SURE AND DOES NOT REQUIRE ADJUSTMENT.
1. Remove manual release valve form manifold. DO
NOT remove or adjust reverse thrust valve.

51194
b
a - O-ring
a
b - Scribe Mark
51194
4. Remove end frame and armature from housing. a - Manual Release Valve
b - Manifold

e 2. Remove “E” clip and O-rings from manual release

valve.

a
b

c a
c
b 51196
a - “E” Clip
51194 b - O-rings
c - Manual Release Valve
a - End Frame
b - Washer
c - Armature
d - Fiber Guard (Liner)
e - Housing

5C-26 - MID-SECTION 90-8i7643R1 DECEMBER 1996

3. Remove four screws securing reservoir to man- Oil Pump/Manifold Removal
ifold.
1. Remove screw, oil pump, O-rings and check
valve components from manifold.
e
c
a

51006

a a b
51193
a - Screws (4)
4. Remove reservoir from manifold. a
5. Remove drive shaft from oil pump. a
51007
a - O-rings (3)
b - Oil Pump
c - Screw
d - Spring
e - Check Ball
2. Remove screws and manifold from cylinder.

b
a a

51194
a - Drive Shaft
b - Oil Pump 51007
a - Trim Cylinder
b - Manifold
c - Screw

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-27

IMPORTANT: Removal of O-ring (e) from manifold 4. Remove O-rings from cylinder.
will result in damage to O-ring. O-ring MUST be
replaced after removal.
3. Remove check valve components from manifold.

51008
a - O-rings

e
Cleaning and Inspection of
51736 Trim Rod Components
IMPORTANT: Components must be dirt and lint
a free. Slightest amount of debris in Power Trim
system could cause system to malfunction.

CAUTION
Do not remove check valve components (a) from
trim rod piston. Removal and re-installation of
check valve could result in improper operating
b pressure and possible power trim system dam-
age.
c

d a
e

51199
Inspect check valve for debris; clean debris form
h check valve if found. If debris cannot be cleaned from
51008
check valve, replace trim rod piston as an assembly.
a - Manifold
b - Spring Clean trim rod and components with parts cleaner
c - Check Valve and dry with compressed air.
d - Check Valve Seat
e - O-ring It is recommended that all O-rings in trim system be
f - Spring replaced.
g - Sleeve
h - Spool Inspect trim rod. If scraper (located in cap) has failed
to keep rod clean, replace scraper.
Lubricate all O-rings using Quicksilver Power Trim
and Steering Fluid or; (ATF) Type F, FA or Dexron II.

5C-28 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Motor and Electrical Tests/
Repair
Trim Pump Motor Test

WARNING
Do not perform this test near flammables (or ex-
plosives), as a spark may occur when making
connections.
1. Disconnect orange (motor) wire and black (mo-
tor) wire from relay switch wiring harness.
2. Connect a 12 volt power supply to motor wires a
(positive to orange; negative to black results in
motor up direction. Positive to black; negative to
orange results in motor down direction). Motor
should run.
3. If motor does not run, disassemble motor and
check components.

Thermal Overload Switch Test b

51196
a - Motor Wire (Black)
IMPORTANT: If thermal overload switch has been b - Motor Wire (Orange)
activated, pump motor cannot be tested for a
minimum of one minute. After this period switch MOTOR DISASSEMBLED
should close (reset itself) and pump motor may
be operated. Perform the following check(s) only Connect Ohmmeter (R x 1 scale) leads as shown. If
if switch does not reset itself. switch is good, full continuity (zero ohms) will be indi-
cated.
MOTOR ASSEMBLED
Connect Ohmmeter (R x 1 scale) leads as shown. If
switch is good, full continuity (zero ohms) will be indi-
cated. If full continuity is not indicated, disassemble
motor and recheck switch per instructions, following.

51193
If full continuity is not indicated, clean switch contact
surfaces, using an ignition point file.
Recheck switch; if full continuity is not indicated, re-
place end frame.

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-29

Armature Tests Power Trim System
TEST FOR SHORTS Reassembly
Check armature on a Growler (follow Growler man- Manifold/Oil Pump Installation
ufacturer’s test instructions). Indication of a short re-
quires replacement of armature. IMPORTANT: Install spring, check valve and O-
ring into manifold. Position components in place
TEST FOR GROUND using sleeve to seat in place.

Use an Ohmmeter (R x 1 scale). Place one lead on

Ohmmeter on armature shaft and other lead on com-
mutator, as shown. If continuity is indicated, armature
is grounded and must be replaced.

50999
1. Install check valve components into manifold.

51195
b
CHECKING AND CLEANING COMMUTATOR
c
If commutator (a) is worn it can be turned down on an
armature conditioner tool or on a lathe. d
Clean commutator with “00” sandpaper. e
a f

h
51008
a - Manifold
b - Spring
c - Check Valve
d - Check Valve Seat
e - O-ring
f - Spring
g - Sleeve
h - Spool

5C-30 - MID-SECTION 90-8i7643R1 DECEMBER 1996

2. Install O-rings on cylinder and secure manifold 4. Install check valve components and O-rings to
assembly to cylinder using screws. Torque manifold. Secure oil pump to manifold using bolt.
screws to 100 lb. in. (11.3 N·m). Torque bolt to 90 lb. in. (10.2 N·m).
e
c
a

d
a
51006

a
51008 a
51007
a - O-rings (3)
b - Oil Pump
c - Screw
d - Spring
e - Check Ball

Trim Motor Reassembly

b
1. Apply Quicksilver Marine Lubricant (2-4-C) to ar-
mature shaft and insert into end frame.

a
51007
a - O-ring
b - Screws [100 lb. in. (11.3 N·m)]
3. Secure power trim unit in soft jawed vise.

b
c

51195
a - Armature Shaft
b - Washer
c - End Frame

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-31

2. Guide armature and end frame into housing as 6. Install end cap to housing. Torque nuts to 25 lb. in.
shown. (2.8 N·m).

c
a

d
51194
a - End Cap
b - Motor Housing
c - Wave Washer
d - Washer
51196
IMPORTANT: When installing motor, wires (black,
3. Align scribe mark on housing to mark on end
orange) must rest in cavity of cylinder allowing
frame.
motor to seat properly.
4. Install lubricated O-ring to end frame.
a
a

b b

51194
51194 a - Manifold
a - O-ring b - Cavity
b - Scribe Mark
5. Install washers to armature shaft as shown.

5C-32 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Reservoir Installation 5. Install grommet, washer and screw cap to cylin-
der end cap. Tighten screw securely.
1. Connect trim motor wires to harness.
b a
2. Insert motor into reservoir. Motor must be seated c
properly prior to end cap installation.

51195
a - Screw Cap
b - Washer
c - Grommet
6. Place drive shaft into oil pump.
51196 7. Install lubricated O-ring to base of reservoir.
3. Install end cap, O-ring and foam pad to cylinder. 8. Carefully guide (cylinder/motor) down onto drive
4. Torque screws to 13 lb. in. (1.5 N·m). shaft.
a
b
c

b
a

51194
a - Drive Shaft
b - O-ring
51195
a - End Cap
b - O-ring
c - Foam Pad

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-33

9. Secure reservoir to manifold using four screws. Trim Rod Reassembly
Torque screws to 70 lb. in. (7.7 N·m).
1. Install lubricated O-rings and rod wiper to end
cap.

a c
a b
51193
a - Screw
10. Install “E” clip, lubricated O-rings and to manual
51145
release valve.
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
2. Secure trim rod in soft jawed vise as shown.

b 3. Slide end cap onto trim rod.

a
a
c
51196
a - “E” Clip
b - O-ring
c - Manual Release Valve
11. Insert manual release valve into manifold and
tighten snuggly. Back release valve out 3 or 4
turns allowing trim rod installation.

b
a

51146
a - End Cap

51194
a - Manual Release Valve
b - Manifold

5C-34 - MID-SECTION 90-8i7643R1 DECEMBER 1996

4. Apply Loctite Grade A (271) to threads of trim rod Trim Rod Installation
and install rod piston. Tighten piston securely us-
ing trim cylinder spanner wrench (1/4 in. x 5/16 in. 1. Place trim cylinder in soft jawed vise.
long peg). 2. Fill trim cylinder three inches (76.2mm) from top
of cylinder using Quicksilver Power Trim and
b a Steering Fluid or; (ATF) Type F, FA or Dexron II.
3. Install lubricated O-ring to memory piston and
place into cylinder. Push piston down to level of
oil.
b
a

51146
a - Trim Rod Piston
b - Spanner Wrench
5. Install lubricated O-ring to trim rod piston.
6. Install check valve components into their respec-
tive seats.
7. Secure components in place using plate and
screws. Torque screws to 35 lb. in. (4.0 N·m). 51144
a - O-ring
b - Memory Piston
IMPORTANT: Memory piston must not come in
contact with trim rod end cap during end cap/trim
rod installation.
d
e
f
a

c
b
51147
a - Screw (3)
b - Plate
c - O-ring
d - Ball (5)
e - Seat, Spring (5)
f - Spring (5)

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-35

4. Install trim rod into cylinder. Bleeding Power Trim Unit
IMPORTANT: Manual release valve must be in the
closed position during power trim bleeding and
operation.
1. Secure power trim unit in soft jawed vise.
2. Remove fill screw. Add Quicksilver Power Trim
and Steering Fluid (92-90100A12) or Automatic
Transmission Fluid (ATF) Type F, FA or Dexron II
up to threads of reservoir. Install cap.

51196
IMPORTANT: Memory piston must not come in
contact with trim rod end cap during end cap/trim
rod installation.
5. Tighten end cap assembly to cylinder securely
using trim cylinder spanner wrench (1/4 in. x 5/16
in. long pegs).

50241
3. Using a 12 volt power supply connect positive
lead to green wire, negative lead to blue wire and
drive trim rod to the down position. Connect posi-
tive lead to blue wire and negative lead to green
wire and drive trim rod to the up position. Recheck
fluid level, add fluid if required and repeat cycle
until fluid level remains at lower portion of
threads.

51145
6. Tighten manual release valve snuggly following
end cap installation.

5C-36 - MID-SECTION 90-8i7643R1 DECEMBER 1996

Power Trim Unit Installation 4. Using a suitable punch, drive lower pivot pin into
clamp bracket and trim cylinder assembly until
1. Apply Special Lubricant 101 (92-13872A1) to pivot pin is flush with outside surface.
lower pivot pin hole and pivot pin surface.
2. Start lower pivot pin into pivot pin bore and posi-
tion lower dowel pin (RETAINED) in its respective
hole.

51147
a - Lower Pivot Pin
a 5. Using a suitable punch, drive lower dowel pin into
its hole until seated.
51148
a - Lower Pivot Pin
b - Lower Dowel Pin
3. Position trim cylinder assembly (BOTTOM
FIRST) between clamp brackets and route trim
pump electrical harness through access hole in
starboard clamp bracket.
a

2
51148
a - Lower Dowel Pin
a

1
51195
a - Trim Cylinder Assembly

90-817643R1 DECEMBER 1996 MID-SECTION - 5C-37

6. Apply Special Lubricant 101 (92-13872A1) to sur- 8. Drive upper dowel pin (a) into its hole until seated.
face of upper pivot pin, pivot pin bore and trim ram
bore.

51147
9. Recheck fluid level.
10. Power trim may now be operated to lower out-
51148 board to desired position. Trim system is self
a - Pivot Pin bleeding.
b - Pivot Pin Bore
c - Trim Ram Bore 11. Re-connect spark plug leads to spark plugs.
7. Using a suitable mallet, drive upper pivot pin into 12. Re-install top cowl.
swivel bracket and through trim ram until pivot pin
13. Connect battery leads to battery terminals.
is flushed with swivel bracket.

a
c

51148
a - Pivot Pin
b - Swivel Bracket
c - Trim Ram

5C-38 - MID-SECTION 90-8i7643R1 DECEMBER 1996

MID-SECTION

POWER TRIM (DESIGN 3)

51486

D
Table of Contents
Page Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1 Power Trim System Removal . . . . . . . . . . . . . 5D-14
Power Trim - General Information . . . . . . . . . . 5D-1 Power Trim System Disassembly . . . . . . . . . . 5D-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1 Trim Rod Removal . . . . . . . . . . . . . . . . . . . . 5D-15
Trimming Characteristics . . . . . . . . . . . . . . . 5D-1 Trim Rod Disassembly . . . . . . . . . . . . . . . . 5D-16
Trimming Outboard “Up” (“Out”) . . . . . . . 5D-1 Trim “Motor” Removal . . . . . . . . . . . . . . . . . 5D-18
Trimming Outboard “Down” (“In”) . . . . . . 5D-1 Trim “Motor” Disassembly . . . . . . . . . . . . . . 5D-18
Trailering Outboard . . . . . . . . . . . . . . . . . . . . 5D-2 Reservoir Assembly Removal . . . . . . . . . . 5D-18
Tilting Outboard Up and Down Manually . . 5D-2 Manifold Removal . . . . . . . . . . . . . . . . . . . . 5D-19
Trim “In” Angle Adjustment . . . . . . . . . . . . . . 5D-2 Cleaning and Inspection of Trim Rod
Power Trim System Components . . . . . . . . . . . 5D-3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4 Motor and Electrical Tests/Repair . . . . . . . . . . 5D-20
Determining if Problem is Electrical or Trim Pump Motor Test . . . . . . . . . . . . . . . . . 5D-20
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5D-20
Hydraulic System Troubleshooting . . . . . . . 5D-5 Test for Shorts . . . . . . . . . . . . . . . . . . . . . 5D-20
Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5D-5 Test for Ground . . . . . . . . . . . . . . . . . . . . 5D-20
Leak Down Check - Pump and Manifold Checking and Cleaning Commutator . 5D-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-5 Power Trim System Reassembly . . . . . . . . . . 5D-21
Leak Down Check - Pilot Valve Manifold Installation . . . . . . . . . . . . . . . . . . . 5D-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-6 Trim Motor Reassembly . . . . . . . . . . . . . . . 5D-22
Leak Down Check - Manual Release Reservoir Installation . . . . . . . . . . . . . . . . . . 5D-23
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-6 Trim Rod Reassembly . . . . . . . . . . . . . . . . . 5D-24
Leaks Past Ball and Seat - Piston Trim Rod Installation . . . . . . . . . . . . . . . . . . 5D-25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-6 Purging Power Trim Unit . . . . . . . . . . . . . . . . . 5D-26
Troubleshooting Flow Diagram . . . . . . . . . . 5D-7 Power Trim Unit Installation . . . . . . . . . . . . 5D-26
Troubleshooting Flow Diagram . . . . . . . . . . 5D-8
Electrical System Troubleshooting . . . . . . . 5D-9
Commander 2000 Side Mount Remote
Control (Power Trim/Tilt Electric Start with
Warning Horn) Wiring Diagram . . . . . . . . 5D-9
Power Trim System Wiring Diagram . . . . . . 5D10
Troubleshooting the “Down” Circuit*
(When “Up” Circuit is OK) . . . . . . . . . . . . 5D-11
Troubleshooting the “Up” Circuit*
(When “Down” Circuit Is OK) . . . . . . . . . 5D-12
Troubleshooting the “Down” and “Up” Circuits
(All Circuits Inoperative)* . . . . . . . . . . . . 5D-13

5D-0 - MID-SECTION 90-817643R1 DECEMBER 1996

Special Tools Will lift bow of boat, usually increasing top speed.
Transfers steering torque harder to port (left) on in-
Description Part No. stallations below 23 in. transom height.
Torch Lamp 91-63209 Increases clearance over submerged objects.
Spanner Wrench 91-74951 In excess, can cause “porpoising” and/or ventilation.
Multi-Meter DVA Tester 91-99750 In excess, can cause insufficient water supply to wa-
ter pump resulting in serious water pump and/or pow-
erhead overheating damage.
Quicksilver Lubricants and
Service Aids WARNING
Excessive engine trim angle will result in insuffi-
Description Part No. cient water supply to water pump causing water
Power Trim and Steering Fluid 91-9010012 pump and/or powerhead overheating damage.
Make sure that water level is above gear housing
Loctite 271 91-32609-1
water intake holes whenever engine is running.
Liquid Neoprene 91-25711-1
Operating “Up” circuit will actuate the “up” relay (lo-
Anti-Corrosion Grease 91-78376A6 cated under engine cowl) and close the electric motor
circuit. The electric motor drives the pump, forcing
fluid thru internal passageways into the “up” side of
the trim cylinder.
Power Trim - General
The trim cylinder/trim ram will position the engine at
Information the desired trim angle within the 20° maximum trim
range. The Power Trim system is designed so the en-
Description gine cannot be trimmed beyond the 20° maximum
trim angle as long as engine RPM is above approxi-
The Power Trim system consists of an electric motor, mately 2000 RPM.
pressurized fluid reservoir, pump and trim cylinder.
The engine can be raised beyond the 20° maximum
The remote control (or trim panel) is equipped with a trim angle for shallow water operation, etc., by keep-
switch that is used for trimming the outboard “up” and ing the engine RPM below 2000 RPM. If engine RPM
“down”, and for tilting the outboard for shallow water increases above 2000 RPM, the thrust created by the
operation (at slow speed) or for “trailering”. The out- propeller (if deep enough in the water) will cause the
board can be trimmed “up” or “down” while engine is trim system to automatically lower the engine back to
under power or when engine is not running. the 20° maximum trim angle.

TRIMMING OUTBOARD “DOWN” (“IN”)

Trimming Characteristics
When trimming outboard from a mid-trim position WARNING
(trim tab in neutral, straight fore-and-aft position), you Excessive speed at minimum trim “In” may cause
can expect the following results: undesirable and/or unsafe steering conditions.
Each boat should be tested for handling charac-
TRIMMING OUTBOARD “UP” (“OUT”) teristics after any adjustment is made to the tilt
angle (tilt bolt relocation).
WARNING Will help planing off, particularly with a heavy load.
Excessive trim “out” may reduce the stability of
Usually improves ride in choppy water.
some high speed hulls. To correct instability at
high speed, reduce the power gradually and trim In excess, can cause boat to veer to the left or right
the motor “In” slightly before resuming high (bow steer).
speed operation. (Rapid reduction in power will Transfers steering torque harder to right (or less to
cause a sudden change of steering torque and the left).
may cause additional momentary boat instabili-
ty.) Improves planing speed acceleration (by moving tilt
bolt one hole closer to transom).

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-1

Operating “Down” circuit will actuate the “down” relay Trim “In” Angle Adjustment
(located under engine cowl) and close the electric
motor circuit (motor will run in opposite direction of the WARNING
“Up” circuit). The electric motor will drive the pump,
forcing fluid thru internal passageways into the Operating some boats with engine trimmed to the
“down” side of the tilt ram. The tilt ram will move the full “in” trim angle [not using trim adjustment bolt
engine down to the desired angle. (a)] at planing speed will cause undesirable and/
or unsafe steering conditions. Each boat must be
water tested for handling characteristics after en-
Trailering Outboard gine installation and after any trim adjustments.
IMPORTANT: Some boat/motor combinations,
WARNING that do not use the trim adjustment bolt (a) and
Excessive engine trim angle will result in insuffi- are trimmed to the full “in” trim angle, will not ex-
cient water supply to water pump causing water perience any undesirable and/or unsafe steering
pump and/or powerhead overheating damage. conditions during planing speed. Thus, not using
Make sure that water level is above gear housing trim adjustment bolt may be desired. However,
water intake holes whenever engine is running. some boats with engine trimmed to the full “in”
While operating “up” circuit, the ram will continue to trim angle at planing speed will cause undesir-
tilt outboard to full up position for trailering. able and/or unsafe steering conditions. If these
steering conditions are experienced, under no
circumstances should the engine be operated
Tilting Outboard Up and Down without the trim adjustment bolt and without the
Manually bolt adjusted in the proper holes to prevent un-
safe handling characteristics.
WARNING Water test the boat not using the trim adjustment bolt.
Before opening the manual release valve, make If undesirable and/or unsafe steering conditions are
sure all persons are clear of engine as engine will experienced (boat runs with nose down), install trim
drop to full “down” position when valve is adjustment bolt in proper hole to prevent unsafe han-
opened. dling characteristics.

With power trim installed, the outboard can be raised

or lowered manually by opening the manual release
valve 3 turns maximum (counterclockwise).

52029
a - Trim Adjustment Bolt

52028
a - Manual Release Valve

5D-2 - MID-SECTION 90-817643R1 DECEMBER 1996

Power Trim System
Components Q
1 - Tilt/Trim Cylinder 4
2 - Reservoir/Motor Housing 31
3 - Piston Rod
4 - Upper Pivot Shaft
5 - Cross Pin
6 - O-ring 5 26 32
7 - End Cap Seal 3
8 - End Cap Q
9 - O-ring
10- O-ring 6
11- Piston Assembly 23
12- O-ring 7 2
13- O-ring 8
14- Memory Piston 1
15- Lower Pivot Shaft 9 30
16- Cross Pin B
17- Screw (2) 25
18- Pump Assembly 17 24 29
19- Pilot Valve Assembly 10
20- O-ring 27
21- Driveshaft 22
22- Washer (4)
11 16
23- Screw (4)
20 28
24- Fill Screw
25- O-ring
26- Motor Frame 21 27
27- Thrust Washer (2) 12 36
28- Armature 38
13 37
29- Ring 44
30- Seal
35
19 36
31- Screw (2) Q 38
32- Screw (4)
33- Relay 15 18
34- Wiring Harness 14 43
35- Relay Mount (2) 42
36- Rubber Mount (2) 33
37- Screw (2) 39 37
38- Spacer (2)
39- Anode 34 35
40- Washer (2)
41- Screw (2) P
40
42- Manual Release Valve
43- O-ring 33
44- E-clip 41

51498
NOTE: Lubricate all
O-rings and seals with Q

Quicksilver Lubricants Torque Specifications

and Service Aids a - 100 lb. in (11.1 N·m)
B Loctite “271” (92-32609-1) b - 13 lb. ft. (1.5 N·m)
c - 70 lb. in. (7.7 N·m)
P Liquid Neoprene (92-25711-1)
d - 35 lb. in. (4.0 N·m)
Q Power Trim and Steering Fluid (92-90100A12)

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-3

Troubleshooting
Determining if Problem is Electrical
or Hydraulic
When a problem is encountered with the Power Trim
system, the first step is to determine whether the mal-
function is in the “electrical system” or the “hydraulic
system.” Refer to the following chart to determine
which system is at fault.

Problem Chart

Outboard will not trim up or

down.

Determine if Power Trim

Outboard trims up, will not trim pump motor operates when
down. appropriate trim circuit is
activated.

Outboard trims down, will not

trim up.

Outboard will not return com-

Pump motor operates. Pump motor does not operate
pletely to “down” position or re-
turns part way with jerky mo-
tion.

Outboard thumps when

shifted.
Refer to “Hydraulic System Refer to “Electrical System
Troubleshooting.” Troubleshooting.”
Outboard trails out when back-
ing off throttle at high speed.

Outboard will not hold a

trimmed position or will not re-
main tilted for any extended
period.

Outboard will not hold trim po-

sition when in reverse.

5D-4 - MID-SECTION 90-817643R1 DECEMBER 1996

Hydraulic System Troubleshooting Leak Down Check - Pump and
Support outboard with tilt lock lever when servicing Manifold Assembly
power trim system. NOTE: Scribe (d) pump housing and manifold before
After debris or failed components have been disassembly.
found (during troubleshooting procedures) dis- 1. Debris or chips between valve and seat (a), usu-
assemble unit completely and replace all O-rings. ally imbedded in rubber valve seat.
Check ball valve components and castings must
be cleaned using engine cleaner and com- 2. Nicked or deteriorated O-ring (b).
pressed air or replaced prior to reassembly. 3. Nicked, deteriorated, or misplaced O-ring (c).
Power trim system is pressurized. Outboard must a
be in the full ‘‘UP” position (cylinder fully ex-
tended) prior to fill screw or manual release valve
removal.
Refer to instructions following if disassembly is re-
quired.
Follow preliminary checks before proceeding to trou-
bleshooting flow diagrams (following). d

Preliminary Checks
Operate Power Trim System after each check to
see if problem is corrected. If not, proceed with
the next check. b
1. Check that manual release valve is tightened to
full right (clockwise) position.
2. Check trim pump fluid level with outboard in full c 51560
“UP” position and fill if necessary. Refer to “Fill
4. After reassembly, insert driveshaft and check
and Purge the Power Trim System.”
pump rotor resistance to turning - housing halves
3. Check for external leaks in Power Trim system. can shift/turn during reassembly. Align scribe
Replace defective part(s) if leak is found. marks (d) carefully.
4. Outboard not holding tilted position (falls to trim in
position) indicates debris or defective compo-
nents in trim valve assembly. Clean or replace
components as required.
5. Check manual release valve for broken stem and
one O-ring remaining in the release valve pas-
sage. (Separate the manifold assembly from the
cylinder to dislodge broken stem.) Install new re-
lease valve and test system.
6. Check for nicked, deteriorated, or misplaced
O-rings throughout trim system.

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-5

Leak Down Check - Pilot Valve Leaks Past Ball and Seat - Piston
Assembly Assembly
1. Debris or chips between valve and seat (a), usu- Unit will trim to full or near full down position and then
ally imbedded in rubber valve seat. will begin to trim up while trim switch is held in
‘‘DOWN” mode.
2. Pilot valve installed from non-chamfered end of
spool, results in nicked or damaged O-ring (b). If trim switch is released, outboard can be pushed (by
hand) down to the point where trim UP started.
3. Nicked or deteriorated O-ring (c).
1. Inspect balls and seats in piston assembly for de-
A leak path is created between the UP side of the cyl-
bris or damage. Repair or replace balls/seats.
inder and the reservoir. The trim system will leak
down until the trim port in cylinder is covered.

c
a

b
a

51143
51560
a - Ball and Seat. Check All For Debris or Damage.
a - Valve and Seat
b - Pilot Valve O-ring
c - O-ring

Leak Down Check - Manual Release

Valve
1. Debris or chips under O-ring (a).
2. Flash from valve molding causing O-ring (a) to not
seal.
3. Nicked O-ring (a).

51560
a - O-ring

5D-6 - MID-SECTION 90-817643R1 DECEMBER 1996

Troubleshooting Flow Diagram

Outboard falls to full down position with manu-

al release valve closed.

Example a: Outboard lowers more than one

tilt bolt hole in eight hours.

Example b: Outboard lowers during acceler-

ation.

Inspect Manual Release

Valve.
Result Result

Manual release valve and/or O- Manual release valve and O-rings

ring damage. appear to be OK. Replace O-
rings.

Replace defective valve and O-

rings.

Result

O-rings appear to be OK. Cylin-

der bore and memory piston are
OK. Replace O-rings and pro-
ceed.

Inspect O-rings on Pilot Relief

Valve (located in manifold assem-
bly).
Results Results

O-ring failure. O-rings appear to be OK. Re-

place O-rings.

Inspect Memory Piston

Replace O-rings. O-ring.

Results Results

All components appear to be OK. O-ring or Cylinder Bore Defective.

Replace Manifold and Pump Assembly. Replace O-ring or Components.

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-7

Troubleshooting Flow Diagram

Outboard will not hold tilted position in reverse

and/or trails out during high speed decelera-
tion.

Inspect Manual Release

Valve.

Results Results

Manual release valve and/or O- Manual release valve and O-rings

ring damage. appear to be OK. Replace O-rings
and proceed.

Replace defective valve and O- Inspect Trim Rod Piston Check

rings. Valve.

Results Results

No debris or defective components Debris found in check valve com-

found. ponents.

Inspect Manifold Reverse Thrust Clean check valve components

Valve. using engine cleaner and com-
pressed air or replace.

Replace Pump and Manifold Assembly.

5D-8 - MID-SECTION 90-817643R1 DECEMBER 1996

Electrical System Troubleshooting

COMMANDER 2000 Side Mount

Remote Control (Power Trim/Tilt
Electric Start with Warning Horn)
Wiring Diagram

g
UP
DOWN

d 4
e f
a
b 5

BLK • Black
BLU • Blue
BRN • Brown c
GRY • Gray
GRN • Green
PUR • Purple
RED • Red
TAN • Tan
WHT • White
YEL • Yellow

a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness Connector 23891
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-9

Power Trim System Wiring Diagram

BLK • Black Negative (–)

BLU • Blue Trim Motor (UP)
GRN • Green Trim Motor (DOWN) 8
RED • Red Positive (+)
BLU/WHT • Blue/White Trim Switch to UP Relay Wiring From
GRN/WHT • Green/White Trim Switch to DOWN Relay Side Mount
Remote
Control
Harness
1

Power
Trim
Motor Engine Harness

Fuse

Rectifier

Start Solenoid

To Battery

UP DOWN

Trim Relays

51507

5D-10 - MID-SECTION 90-817643R1 DECEMBER 1996

Troubleshooting the “Down” Circuit*
(When “Up” Circuit is OK)
*Remote Control Not Equipped with Trailer
Button

Connect Voltmeter red lead to

Point 1 and black lead to ground.
Depress the “Down” trim button.

Battery Voltage Indicated: No Voltage Indicated:

Down Relay is Defective. Replace and retest. Connect Voltmeter red lead to
Point 4 and black lead to ground.
Depress “Down” trim button. If bat-
tery voltage is indicated, wire is
open between Points 4 and 1.

No Voltage Indicated:
Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
cated, trim switch is faulty. If no bat-
tery voltage, check for loose or cor-
roded connection at Point 5 or
open circuit in wire supplying cur-
rent to Point 5.

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-11

Troubleshooting the “Up” Circuit*
(When “Down” Circuit Is OK)
*Remote Control NOT Equipped with Trailer
Button

Connect Voltmeter red lead to

Point 8 and black lead to ground.
Depress the “Up” trim button.

Battery Voltage Indicated: No Voltage Indicated:

UP Relay is defective. Replace and retest. Connect Voltmeter red lead to
Point 7 and black lead to ground.
Depress “Down” trim button. If bat-
tery voltage is indicated, wire is
open between Points 7 and 8.

No Voltage Indicated:
Connect Voltmeter red lead to
Point 5. If battery voltage is indi-
cated, trim switch is faulty. If no bat-
tery voltage, check for loose or cor-
roded connection at Point 5 or
open circuit in wire supplying cur-
rent to Point 5.

5D-12 - MID-SECTION 90-817643R1 DECEMBER 1996

Troubleshooting the “Down” and
“Up” Circuits (All Circuits Check in-line fuse (under cowl) to
Inoperative)* see if fuse is blown

*Remote Control NOT Equipped with Trailer

Button

Blown Fuse: Fuse Not Blown:

• Correct problem that caused Connect Voltmeter red lead to
fuse to blow. Point 3 and black lead to ground,
• Replace fuse. Battery voltage should be indi-
cated.

No Voltage Indicated: Battery Voltage Indicated:

• Check battery leads for poor • Connect Voltmeter red lead to
connections or open circuits. Point 8 and black lead to ground.
• Check battery charge.
• Depress “Up” trim button and
check for battery voltage.

Battery Voltage Indicated:

• Check black ground wires for
No Voltage Indicated: poor connection or poor ground.
Connect red Voltmeter lead to • Pump motor is faulty. Refer to
Point 5, and black lead to ground. “Motor and Electrical Tests/Rep-
air,” following.

No Voltage Indicated: Battery Voltage Indicated:

Check that voltage is being Trim switch is faulty or there is an
supplied to control by performing open circuit in wires (green-white,
the following checks: blue-white) between trim buttons
• DO NOT start engine. and trim pump.
• Turn ignition switch to “Run” po- • Check trim switch.
sition. • Check all trim harness connec-
• Check for voltage at any instru- tors for loose or corroded con-
ment using a Voltmeter. nections.
• Check for pinched or severed
wires.

No Voltage Indicated:
Battery Voltage Indicated:
Red wire is open between Point 3
and red terminal on back of the ig- There is an open circuit in wire be-
nition switch. tween Point 5 and Red terminal on
• Check for loose or corroded con- the back of the ignition switch.
nections.
• Check for open circuit in wire.

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-13

Power Trim System Removal Inspect cross pin hole and pivot pin hole for damage.

Support outboard with tilt lock lever when servicing 6. Use suitable punch to remove (DRIVE UP) lower
power trim system. dowel pin. Retain dowel pin.

1. Disconnect power trim harness from outboard

wiring harness.
2. Remove screw and clip securing wiring harness
to clamp bracket.
3. Remove trim gauge sender (if equipped).
4. Use suitable tool to remove upper headed cross
pin. Retain pin. Straight pin is hard to remove (see
item 5).

ab

51144
a - Cross Pin
7. Use suitable punch to drive out lower pivot pin.

51505

a - Cross Pin (Design 1 - Straight)

b - Cross Pin (Design 2 - Headed)
5. Drive out upper pivot pin. This will shear cross pin.
51144
a
a - Pivot Pin

50515
a - Upper Pivot Pin

5D-14 - MID-SECTION 90-817643R1 DECEMBER 1996

8. Tilt power trim assembly (top first) out from clamp Power Trim System
bracket and remove assembly.
Disassembly
Trim Rod Removal
1. Secure power trim assembly in soft jawed vise.
2. Open manual release valve three turns maxi-
mum (counterclockwise) and position trim rod to
full up position.
3. Remove cylinder end cap assembly from cylinder
using spanner wrench (1/4 in. x 5/16 in. long
pegs).

c b

51195
9. Remove fill screw and drain unit.

51194
a - Manual Release Valve
b - Manifold
c - Spanner Wrench (P/N 91-74951)
4. Remove trim rod assembly from cylinder.

51505
a - Fill Screw
10. Remove O-ring from fill cap.

51194

51196

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-15

5. Remove memory piston from cylinder using lock- Trim Rod Disassembly
ring pliers (Craftsman P/N 4735) or suitable tool.
1. Place trim rod assembly on clean work surface.
2. Remove screws securing plate to trim rod piston
and O-ring.
3. Remove check ball components from trim rod pis-
ton.

d
b c
51143
a - Screw (3)
b - Plate
LOCK-RING PLIERS c - O-ring
d - Piston

CAUTION
When removing Trim Rod piston, spanner
51193
wrench must have 1/4 in. x 5/16 in. long pegs to
6. Remove O-ring from memory piston. avoid damage to trim piston.
a
b

51196
a - O-ring
b - Memory Piston
7. Remove trim system from vise and empty fluid
into appropriate container.

5D-16 - MID-SECTION 90-817643R1 DECEMBER 1996

4. Place trim rod into soft jawed vise and apply heat
to shock piston using torch lamp (a) (P/N CAUTION
91-63209). Do not remove check ball components (a) from
5. Loosen trim rod piston using spanner wrench (1/4 trim rod piston. Removal and re-installation of
in. x 5/16 in. long pegs). check valve could result in improper operating
pressure and possible power trim system dam-
6. Allow trim rod piston to cool. Remove from trim age. If check valve is defective, replace trim rod
rod. piston.
7. Remove inner O-ring from piston.

a
a
c

51199
a - Check Ball Components
b - O-ring
c - Piston
8. Remove rod wiper, inner O-ring and outer O-ring.

51146
a - Torch Lamp

b
c

51147

c
b
51145

a - Rod Wiper
b - Inner O-Ring
51146 c - Outer O-Ring
b - Spanner Wrench
c - Trim Rod Piston

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-17

Trim “Motor” Removal Trim “Motor” Disassembly
1. Secure power trim assembly in soft jawed vise. 1. Remove armature from motor frame. Note posi-
tion of washers on armature.
2. Remove screws securing end cap to reservoir
and remove end cap. b

a a c
c

51486

a - Armature
b - Motor Frame
c - Washer (1 each end of armature)

Reservoir Assembly Removal

1. Remove manual release valve from manifold.
51486
a - Screws (4)
3. Remove motor from reservoir.

b
a - Manual Release Valve
b - Manifold
2. Remove “E” clip and O-rings from manual release
valve.

a
51484
c
51196
a - “E” Clip
b - O-rings
c - Manual Release Valve

5D-18 - MID-SECTION 90-817643R1 DECEMBER 1996

3. Remove four screws securing reservoir to man- Manifold Removal
ifold.
1. Remove screws and manifold from cylinder.

b
a

a a
51193
a - Screws (4)
4. Remove reservoir from manifold. 51007
a - Trim Cylinder
5. Remove drive shaft from oil pump. b - Manifold
c - Screw (2)
2. Remove check valve components from manifold.
a IMPORTANT: Sleeve (d) is chamfered on I.D. on
end opposite drilled cross hole. Install spool (b)
(with O-ring installed) from chamfered end of
sleeve to avoid possibility of damaging O-ring on
spool.
a b
c

b d
e
f
c g
h

51560
51486
a - O-ring (0.114 I.D.)
a - Reservoir b - Spool
b - Drive Shaft c - O-ring (0.301 I.D.) (3 each)
c - Oil Pump d - Sleeve
e - Spring
f - Valve Seat
g - Valve
h - Spring

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-19

3. Remove O-rings from cylinder. Motor and Electrical
Tests/Repair
Trim Pump Motor Test
a
WARNING
Do not perform this test near flammables (or ex-
plosives), as a spark may occur when making
connections.
1. Disconnect green (motor) wire and blue (motor)
wire from trim system wiring harness.
2. Connect a 12 volt power supply to motor wires
(positive to blue; negative to green results in mo-
51008 tor up direction. Positive to green; negative to
a - O-rings (2) blue results in motor down direction). Motor
should run.
Cleaning and Inspection of 3. If motor does not run, disassemble motor and
Trim Rod Components check components.

CAUTION
Armature Tests
Do not remove check ball components (a) from
trim rod piston. Removal and re-installation of
TEST FOR SHORTS
check valve could result in improper operating
pressure and possible power trim system dam- Check armature on a Growler (follow Growler man-
age. ufacturer’s test instructions). Indication of a short re-
quires replacement of armature.

TEST FOR GROUND

a Use an Ohmmeter (R x 1 scale). Place one lead on
Ohmmeter on armature shaft and other lead on com-
mutator, as shown. If continuity is indicated, armature
is grounded and must be replaced.

51199

Inspect check valve for debris; clean debris form

check valve if found. If debris cannot be cleaned from
check valve, replace trim rod piston as an assembly.
Clean trim rod and components with parts cleaner
and dry with compressed air.
It is recommended that all O-rings in trim system be
replaced.
Inspect trim rod. If scraper (located in cap) has failed
to keep rod clean, replace scraper.
Lubricate all O-rings using Quicksilver Power Trim 51195
and Steering Fluid or; (ATF) Type F, FA or Dexron II.

5D-20 - MID-SECTION 90-817643R1 DECEMBER 1996

CHECKING AND CLEANING COMMUTATOR 1. Install check valve components into manifold.
If commutator (a) is worn it can be turned down on an a b
armature conditioner tool or on a lathe. c
Clean commutator with “00” sandpaper.

d
e
f
g
h

51560
Power Trim System a - O-ring (0.114 I.D.)
Reassembly b
c
- Spool
- O-ring (0.301 I.D.) (3 each)
d - Sleeve
Manifold Installation e - Spring
f - Valve Seat
IMPORTANT: Install spring, check valve and O- g - Valve
ring into manifold. Position components in place h - Spring
using sleeve to seat in place. It is recommended IMPORTANT: Sleeve (d) is chamfered on I.D. on
that O-ring and valve seat be replaced when in- end opposite drilled cross hole. Install spool (e)
stalling Screw and Seal Kit 811226A1 in manifold. (with O-ring installed) from chamfered end of
sleeve to avoid possibility of damaging O-ring on
spool.
2. Install O-rings on cylinder and secure manifold
assembly to cylinder using screws. Torque
d screws to 100 lb. in. (11.0 N·m).

b
c

a 50999
a - Spring
b - O-ring
c - Sleeve
d - Valve Seat

51486
a - O-rings (2)

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-21

 b b

d
b
a
c

51007
b - Screws [100 lb. in. (11 N·m)] (2)
3. Secure power trim unit in soft jawed vise.
51484

a - End Cap Bushing. Lubricate with Quicksilver 2-4-C

Trim Motor Reassembly Lubricant
b - Brush (2)
1. Place brush tension springs on outer ends of c - Commutator
brush housings to release tension on brushes. d - Brush Tension Spring (2)
3. Guide armature and motor frame into reservoir
housing as shown.

a b

c
a

b c
a
51485

a - Brush Tension Spring (2)

d
b - Brush Housing (2)
c - Brush (2)
b
2. Lubricate end cap bushing with Quicksilver 2-4-C
Lubricant and install armature and motor frame 51485
into end cap. As brushes contact commutator, re-
lease brush tension spring from ends of brush a - End Cap
b - Motor Housing
housings (returning springs to apply brush pres- c - Armature and Motor Frame
sure to commutator). Install washer on each end d - Washer (One Each End of Armature)
of armature before installing armature into end
cap (see inset).

5D-22 - MID-SECTION 90-817643R1 DECEMBER 1996

Reservoir Installation 5. Secure reservoir to manifold using four screws.
Torque screws to 70 lb. in. (7.7 N·m).
1. Torque end cap screws to 13 lb. ft. (1.5 N·m).

a a
51193
a - Screws (4)
6. Install lubricated O-rings and “E” clip to manual
release valve.

51486
a - End Cap
b - O-ring b
c - Screws (4)
2. Place drive shaft into oil pump.
3. Install lubricated O-ring to base of reservoir. a
4. Carefully guide (with motor) down onto drive c
shaft. 51196
a - “E” Clip
b - O-ring
c - Manual Release Valve
7. Insert manual release valve into manifold and
tighten snuggly. Back release valve out 3 turns
maximum allowing trim rod installation.

b
a

b
a

51194
a - Manual Release Valve
b - Manifold

51486
a - Drive Shaft
b - O-ring

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-23

Trim Rod Reassembly 4. Apply Loctite Grade A (271) to threads of trim rod
and install rod piston. Tighten piston securely us-
1. Install lubricated O-rings and rod wiper to end ing spanner wrench (1/4 in. x 5/16 in. long peg).
cap.
b
a

c
b

51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
2. Secure trim rod in soft jawed vise as shown.
51146
3. Slide end cap onto trim rod.
a - Trim Rod Piston
b - Spanner Wrench
5. Install lubricated O-ring to trim rod piston.
a
6. Install check ball components into its respective
bore.
7. Secure components in place using plate and
screws. Torque screws to 35 lb. in. (4.0 N·m).

d
e
f
a

51146
a - End Cap
c
b
51147
a - Screw (3)
b - Plate
c - O-ring
d - Ball (5)
e - Seat, Spring (5)
f - Spring (5)

5D-24 - MID-SECTION 90-817643R1 DECEMBER 1996

Trim Rod Installation 4. Install trim rod into cylinder.

1. Place trim cylinder in soft jawed vise.

2. Fill trim cylinder three inches (76.2mm) from top
of cylinder using Quicksilver Power Trim and
Steering Fluid or; (ATF) Type F, FA or Dexron II.
3. Install lubricated O-ring to memory piston and
place into cylinder. Push piston down to level of
oil.
Memory piston must not contact end cap during
trim rod/end cap installation.
b
a

51196
5. Tighten end cap assembly to cylinder securely
using spanner wrench (1/4 in. x 5/16 in. long
pegs).

51144
a - O-ring
b - Memory Piston

51145
a - Spanner Wrench (P/N 91-74951)
6. Tighten manual release valve snuggly following
end cap installation.

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-25

Purging Power Trim Unit Power Trim Unit Installation
Manual release valve must be in full closed posi- 1. Apply Special Lubricant 101 (92-13872A1) to
tion during power trim purging and operation. lower pivot pin bore and pivot pin surface.
1. Secure power trim unit in soft jawed vise. 2. Start lower pivot pin into pivot pin bore and posi-
tion lower cross pin (RETAINED) in its respective
2. Remove fill cap (a). Add Quicksilver Power Trim
hole.
and Steering Fluid (92-90100A12) or Automatic
Transmission Fluid (ATF) Type F, FA or Dexron II
up to threads of reservoir. Install cap (a).

51148
a - Lower Pivot Pin
b - Lower Dowel Pin
a
3. Position trim cylinder assembly (BOTTOM
FIRST) between clamp brackets and route trim
pump electrical harness through access hole in
starboard clamp bracket.

52029
3. Using a 12 volt power supply connect positive
lead to green wire, negative lead to blue wire and
drive trim rod to the down position. Connect posi-
tive lead to blue wire and negative lead to green
wire and drive trim rod to the up position. Recheck
fluid level, add fluid as required and repeat cycle
until fluid level remains at lower portion of
threads.

51195
a - Trim Cylinder Assembly

5D-26 - MID-SECTION 90-817643R1 DECEMBER 1996

4. Using a suitable punch, drive lower pivot pin into 6. Apply Special Lubricant (92-13872A1) to surface
clamp bracket and trim cylinder assembly until of upper pivot pin, pivot pin bore and trim ram
pivot pin is flush with outside surface. bore.
NOTE: Install trim ram with cross hole located as
shown. If trim ram is installed reversed, the trim send-
er (if installed) will not operate.

a b b

51515

51147 Cross Hole

a - Lower Cross Pin
5. Using a suitable punch, drive lower pivot pin into
clamp bracket and trim cylinder assembly until Transom Side d
pivot pin is flush with outside surface.

Engine Side

a - Pivot Pin
b - Pivot Pin Bore
c - Trim Ram Bore
d - Install Trim Ram As Shown

51148
a - Lower Dowel Pin

90-817643R1 DECEMBER 1996 MID-SECTION - 5D-27

7. Using a suitable mallet, drive upper pivot pin into 8. Drive upper retaining pin (a) in until seated.
swivel bracket and through trim ram until pivot pin
is flush with swivel bracket.
a

c
b

51505
9. Recheck fluid level.
51515 10. Power trim may now be operated to lower out-
a - Pivot Pin board to desired position. Trim system is self
b - Swivel Bracket purging.
c - Trim Ram
11. Reconnect power trim leads to relays under igni-
tion cover.
12. Reinstall spark plug leads to spark plugs.
13. Reinstall cowls.
14. Connect battery leads to battery terminals.

5D-28 - MID-SECTION 90-817643R1 DECEMBER 1996

MID-SECTION

5
55331

POWER TRIM (DESIGN 4)

E
Table of Contents
Page Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-1 Power Trim System Removal . . . . . . . . . . . . . 5E-27
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . 5E-4 Power Trim Disassembly . . . . . . . . . . . . . . . . . 5E-28
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-4 Trim Motor Removal . . . . . . . . . . . . . . . . . . 5E-29
Trimming Characteristics . . . . . . . . . . . . . . . 5E-4 Pump and Components Removal . . . . . . . 5E-29
Trimming Outboard “Up” (“Out”) . . . . . . . 5E-4 Manifold Removal . . . . . . . . . . . . . . . . . . . . 5E-30
Trimming Outboard “Down” (“In”) . . . . . . 5E-4 Shock Rod Removal . . . . . . . . . . . . . . . . . . 5E-30
Trailering Outboard . . . . . . . . . . . . . . . . . . . . 5E-5 Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5E-31
Tilting Outboard Up and Down Memory Piston Removal . . . . . . . . . . . . . . . 5E-33
Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-5 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 5E-34
Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-7
Trim Motor Electrical Tests . . . . . . . . . . . . . 5E-34
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-35
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5E-11
Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-13 O-Ring and Seal Placement . . . . . . . . . . . . 5E-35
Shock Function Up . . . . . . . . . . . . . . . . . . . 5E-15 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-36
Shock Function Return . . . . . . . . . . . . . . . . 5E-17 O-ring Description and Sizes . . . . . . . . . . . . . . 5E-37
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-19
Power Trim Reassembly . . . . . . . . . . . . . . . . . 5E-38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5E-20
Shock Rod Reassembly . . . . . . . . . . . . . . . 5E-38
Preliminary Checks . . . . . . . . . . . . . . . . . . . 5E-20
Shock Rod Installation . . . . . . . . . . . . . . . . 5E-39
Hydraulic System Troubleshooting
Trim Limit Assembly Installation . . . . . . . . 5E-40
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-21
Manual Release Valve Installation . . . . . . 5E-40
Hydraulic System Troubleshooting
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-22 Manifold Installation . . . . . . . . . . . . . . . . . . . 5E-40
Hydraulic System Troubleshooting Oil Pump Installation . . . . . . . . . . . . . . . . . . 5E-41
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-23 Pressure Operated Assembly Installation 5E-42
Hydraulic System Troubleshooting Reservoir/Motor Installation . . . . . . . . . . . . 5E-42
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-24 Bleeding Power Trim Unit . . . . . . . . . . . . . . 5E-43
Troubleshooting the Power Trim Installation of Power Trim System . . . . . . . . . 5E-43
Electrical System (Wiring Diagram) . . . . . 5E-25
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . . 5E-26

5E-0 - MID SECTION 90-817643R1 DECEMBER 1996

Special Tools
1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Expanding Rod P/N CG 41-11

4. Collet P/N CG 41-14

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-1

POWER TRIM COMPONENTS

17 A
19 20

3 22

26 21
1
95 23
24
F 25

B
2
4
12

16
8 9 D
7
5
13
E
C
6 15
11 6 11
11 7

6 6 11
17 11 11
11 14

95
6

10
18 15 D
11
7 Loctite 271 (92-809820)
95 2-4-C With Teflon (92-825407A12)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.
NOTE: It is recommended that all o-rings be replaced when servicing tilt system.

5E-2 - MID SECTION 90-817643R1 DECEMBER 1996

 POWER TRIM COMPONENTS
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 POWER TRIM PUMP
1 1 SHOCK ROD KIT 45 61
2 1 MEMORY PISTON ASSEMBLY
3 1 O RING REBUILD KIT
4 2 O RING
5 1 CYLINDER ASSEMBLY
6 1 TRIM LIMIT VALVE KIT
7 1 PUMP ASSEMBLY
8 1 MOTOR KIT
9 1 RESERVOIR PLUG Drive Tight
10 1 MANUAL RELEASE ASSEMBLY Drive Tight
11 1 MANIFOLD KIT
12 1 SCREW KIT (MOTOR) 80 9.0
13 1 DRIVE SHAFT
14 1 FILTER KIT
15 1 P.O. CHECK ASSEMBLY KIT 120 13.5
16 1 CABLE
– 1 O RING KIT (COMPLETE TRIM)
17 2 GROOVE PIN
18 1 ANCHOR PIN
19 1 PIN
20 1 BRACKET
21 1 HARNESS-Trim
22 2 SCREW (M6 x 25)
23 2 RELAY
24 2 BRACKET
25 2 GROMMET
26 2 BUSHING
A – Torque cylinder cap to 45 lb. ft. (61 N·m)
B – Torque screws to 80 lb. in. (9.0 N·m)
C – Torque screws to 70 lb. in. (7.9 N·m)
D – Torque plugs to 120 lb. in. (13.5 N·m)
E – Torque screws to 100 lb. in. (11 N·m)
F – Torque shock piston to 90 lb. ft. (122 N·m)

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-3

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
The remote control (or trim panel) is equipped with a pump and/or powerhead overheating damage.
switch that is used for trimming the outboard “up” and Make sure that water level is above gear housing
“down”, and for tilting the outboard for shallow water water intake holes whenever engine is running.
operation (at slow speed), or for “trailering”. The out- Operating “Up” circuit will actuate the “up” relay (lo-
board can be trimmed “up” or “down” while engine is cated under engine cowl) and close the electric motor
under power or when engine is not running. circuit. The electric motor will drive the pump, thus
forcing automatic transmission fluid through internal
passageways into the “up” side of the trim cylinder.
Adjustments The trim cylinder/trim rod will position the engine at
the desired trim angle within the 20
maximum trim
range. The power trim system is designed so the en-
Trimming Characteristics gine cannot be trimmed beyond the 20
maximum
trim angle as long as engine RPM is above approxi-
NOTE: Because varying hull designs react differently mately 2000 RPM.
in various degrees of rough water, it is recommended
to experiment with trim positions to determine wheth- The engine can be raised beyond the 20
maximum
er trimming “up” or “down” will improve the ride in trim angle for shallow water operation, etc., by keep-
rough water. ing the engine RPM below 2000 RPM. If engine RPM
increases above 2000 RPM, the thrust created by the
When trimming your outboard from a mid-trim posi- propeller (if deep enough in the water) will cause the
tion (trim tab in neutral, straight fore-and-aft position), trim system to automatically lower the engine back to
you can expect the following results: the 20
maximum trim angle.
TRIMMING OUTBOARD “UP” (“OUT”) TRIMMING OUTBOARD “DOWN” (“IN”)

WARNING WARNING
Excessive trim “out” may reduce the stability of Excessive speed at minimum trim “In” may cause
some high speed hulls. To correct instability at undesirable and/or unsafe steering conditions.
high speed, reduce the power gradually and trim Each boat should be tested for handling charac-
the motor “In” slightly before resuming high teristics after any adjustment is made to the tilt
speed operation. (Rapid reduction in power will angle (tilt pin relocation).
cause a sudden change of steering torque and
may cause additional momentary boat instability. • Will help planing off, particularly with a heavy
load.
• Will lift bow of boat, generally increasing top
speed. • Usually improves ride in choppy water.
• Transfers steering torque harder to left on instal- • In excess, can cause boat to veer to the left or
lations below 23 in. transom height. right (bow steer).
• Increases clearance over submerged objects. • Transfers steering torque harder to right (or less
to the left).
• In excess, can cause porpoising and/or ventila-
tion. • Improves planing speed acceleration (by moving
tilt pin one hole closer to transom).
• In excess, can cause insufficient water supply to
water pump resulting in serious water pump and/ Operating “Down” circuit will actuate the “down” relay
or powerhead overheating damage. (located under engine cowl) and close the electric
motor circuit (motor will run in opposite direction of the
“Up” circuit). The electric motor will drive the pump,
thus forcing automatic transmission fluid through in-
ternal passageways into the “down” side of the trim
cylinder. The trim rod will move the engine downward
to the desired angle.

5E-4 - MID SECTION 90-817643R1 DECEMBER 1996

Trailering Outboard Tilting Outboard Up and Down
Manually
WARNING
Excessive engine trim angle will result in insuffi- WARNING
cient water supply to water pump causing water Before loosening the manual release valve, make
pump and/or powerhead overheating damage. sure all persons are clear of engine as engine will
Make sure that water level is above gear housing drop to full “down” position when valve is loos-
water intake holes whenever engine is running. ened.
While operating “up” circuit, the cylinder rod will con- With power trim installed, the outboard can be raised
tinue to tilt the outboard to a full “up” position for trail- or lowered manually by opening the manual release
ering. valve 3 to 4 turns (counterclockwise).

55170

a - Manual Release Valve

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-5

 POWER TRIM FLOW DIAGRAMS
a b
TRIM UP CIRCUIT

d
j l
i k

v e
u h
m n Reservoir Oil
g f g
t Filtered Feed Oil

Í Í
Í Í
Return Oil
o Oil Under Pressure
p
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)

Up Pressure s r
1625 (40-60)
2800 (75-125) Tilt Relief Pressure
min. 250-400 (40-60) q
540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-6 - MID SECTION 90-817643R1 DECEMBER 1996

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. Oil, under pressure, will slide
the shuttle valve (m) against the down circuit pres-
sure operated valve (f). The shuttle valve will me-
chanically open the down pressure operated valve,
allowing oil from the down cavity of the trim cylinder,
to flow into the oil pump. This returning oil, from the
down cavity, will supply most of the oil required for the
up circuit. Oil in the up circuit is blocked from returning
into the reservoir by the ball inside the down circuit
suction port (k). The pressure of the oil will force the
up circuit pressure operated valve (n) to open, allow-
ing the oil to enter the passages inside the manifold
(q) leading to the trim cylinder (w) up cavity. Oil is
blocked from all other passages by the closed manual
tilt valve (p). Oil under pressure will enter the trim cyl-
inder below the memory piston (t). With an increasing
amount of oil entering the cylinder, the memory piston
contacts the shock piston (u) and forces the piston
rod (a) up and out, raising the outboard motor. Oil on
the top of the shock piston exits through a passage
running down along the side of the cylinder and en-
ters the manifold passages. The oil is drawn back into
the pump (j) through the open down pressure oper-
ated valve (f) and enters the pump as supply for the
up circuit.

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-7

 TILT CIRCUIT
a b

u v
h d l
j
i k
t
e
Reservoir Oil
f
g m n
g Filtered Feed Oil

Í Í Return Oil

Í Í o
Oil Under Pressure
p
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)

Up Pressure s r
1625 (40-60)
Tilt Relief Pressure
2800 (75-125)
250-400 (40-60)
min. q
540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-8 - MID SECTION 90-817643R1 DECEMBER 1996

Tilt Up
In the “up” mode, as the piston rod (a) extends from
the cylinder (w), the memory piston (t) clears or un-
covers the pressure relief passage. Oil from the up
cavity will enter this passage and, if required, causes
the tilt relief piston (s) to open the tilt pressure relief
valve (r). This valve lowers the amount of pressure
available to lift the outboard motor. With the engine in
forward gear, and at high engine rpm, the oil pressure
available will not be able to overcome the propeller
thrust, limiting the trim range to below the pressure re-
lief orifice. When the engine rpm’s fall or if engine is
not in forward gear, the oil pressure is available to ex-
tend the piston rod (a) up into the tilt range.

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-9

 MAXIMUM TILT
a b
u v
h

t
c

d l
j
i k

e
Reservoir Oil
f m n
g g
Filtered Feed Oil

Í Í
Í Í
Return Oil

Oil Under Pressure

o
p
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)

Up Pressure s r
1625 (40-60)
Tilt Relief Pressure
2800 (75-125)
250-400 (40-60)
min. q
540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-10 - MID SECTION 90-817643R1 DECEMBER 1996

Maximum Tilt
With the piston rod at maximum travel, and due to no
rod movement, the pressure inside of the trim cylinder
(w) will increase to the pressure required to move the
tilt relief piston (s). The tilt relief piston’s “pin” opens
the tilt relief valve (r). Up pressure flows into the trim
relief passage, and returns back into the reservoir.

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-11

 DOWN CIRCUIT
a b

d
j l
i k

uv f m n Reservoir Oil
h g
g Filtered Feed Oil

Í Í
Í Í
t Return Oil
o
p Oil Under Pressure
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)
Up Pressure
1625 (40-60)
2800 (75-125) s r
min. Tilt Relief Pressure
250-400 (40-60) q
540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-12 - MID SECTION 90-817643R1 DECEMBER 1996

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). The pump forces
pressurized oil into the down passages, oil will slide
the shuttle valve (m) into the up circuit pressure oper-
ated valve (n). The shuttle valve will mechanically
open the up circuit pressure operated valve and allow
oil, from the up cavity of the trim cylinder (w), to return
into the oil pump. This returning oil, from the up cavity,
will supply the oil required for the down circuit. The oil
is blocked from returning into the reservoir by the ball
inside the up circuit suction port (i). Oil, under pres-
sure, opens the down pressure operated valve (f) and
enters the down passages inside of the manifold (q).
The manifold passage connects into the trim cylinder
passage leading to the top of the cylinder. The cavity,
inside the cylinder, above the shock piston (u) is the
down cavity. As the down cavity fills with oil, the piston
rod (a) retracts into the cylinder, lowering the out-
board motor. Oil from the up cavity exits in the cylinder
and is drawn back into the pump through the open up
pressure operated valve (n). When the piston rod
reaches full travel, the oil pressure inside the down
circuit will rise until the down pressure relief valve (e)
opens, bypassing oil back into the reservoir. When
the trim button is released, and the oil pump stops
supplying pressure, both of the pressure operated
valves (f & n) will close and; if open, the down pres-
sure regulating valve (e) will close. The closed valves
will lock the fluid on either side of the shock piston (u)
& memory piston (t), holding the outboard motor in
position.

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-13

 SHOCK FUNCTION UP
a b

v
u h

d l
j
t i k

f Reservoir Oil
m n
g
Return Oil
g

Í Í Oil Under Pressure

Í Í o
p
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)

Up Pressure s r
1625 (40-60)
Tilt Relief Pressure
2800 (75-125)
min.
250-400 (40-60) q
540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-14 - MID SECTION 90-817643R1 DECEMBER 1996

Shock Function Up
Oil inside the down cavity is locked in a static position
by the closed pressure operated valve (f), the manual
release valve (p) and the manifold reverse suction
valve (o). If the outboard strikes an underwater object
while in forward gear the piston rod (a) will try to rapid-
ly extend from the cylinder (w), the pressure in-
creases inside the trim cylinder down cavity and con-
necting passages. When the pressure increases to
the level required, the impact relief valves (v), located
inside the shock piston (u), will open and allow the
fluid to pass through the shock piston. As the fluid
passes through the piston, the piston rod (a) will ex-
tend from the trim cylinder. The memory piston (t) is
held in position by vacuum, created by the oil in the
up cavity being locked in a static position. Therefore;
oil passing through the shock piston is trapped be-
tween the memory piston (t) and shock piston (u).

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-15

 SHOCK FUNCTION RETURN
a b

v
u h

d j l
t i k

e
f Reservoir Oil
m n
g
Return Oil
g

Í Í
Í Í
Oil Under Pressure

o
p
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)

s r
Up Pressure
1625 (40-60) Tilt Relief Pressure
2800 (75-125) 250-400 (40-60) q
min. 540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-16 - MID SECTION 90-817643R1 DECEMBER 1996

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. If re-
quired, additional oil will enter the down cavity
through the manifold reverse suction valve (o). This
will return the engine back against the memory piston
(t) and into the original running position.

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-17

 MANUAL RELEASE
a b

Down
Pressure
525-880
PSI

v
u h
d j l
t i k

e
Reservoir Oil
f m n
g
Return Oil
g

Í Í Filtered Oil

Í Í o
p
Impact Relief Pressure #22
880-1110 (40-60)
1220-1420 (75-125)

Up Pressure s r
1625 (40-60)
Tilt Relief Pressure
2800 (75-125)
250-400 (40-60) q
min.
540-990 (75-125)

a - Piston Rod m- Shuttle Valve

b - End Cap n- Up Pressure Operated Valve
c - Electric Motor o- Manifold Reverse Suction Valve
d - Reservoir Oil p- Manual Release Valve
e - Down Pressure Regulating Valve q- Manifold
f - Down Pressure Operated Valve r - Tilt Relief Valve
g - Filter (2 shown for clarity) s - Tilt Relief Piston
h - Shock Return Valve t - Memory Piston
i - Up Circuit Suction Port u- Shock Piston
j - Oil Pump v - Impact Relief Valve
k - Down Circuit Suction Port w- Cylinder
l - Oil Fill Cap

5E-18 - MID SECTION 90-817643R1 DECEMBER 1996

Manual Tilt
To manually tilt the outboard engine, the owner will
need to back out the manual release valve (p) 3-4
turns. With the valve backed out, the internal pas-
sages inside the manifold are connected together.
These passages connect both the cylinder down and
up cavities together, along with the reservoir, allowing
the engine to be raised or lowered. Piston rod (a)
movement will continue until the manual release
valve (p) is closed, locking the fluid inside of the cylin-
der and manifold.

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-19

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.
IMPORTANT: Power trim system is pressurized.
Outboard must be in the full “UP” position (trim
rod fully extended) prior to fill/drain plug or manu-
al release valve removal.
Refer to instructions following if disassembly is re-
quired when servicing.
Follow preliminary checks before proceeding to trou-
bleshooting flow diagrams (following).

Preliminary Checks
IMPORTANT: Operate Power Trim system after
each check to see if problem has been corrected.
If problem has not been corrected, proceed to
next check.
1. Check that manual release valve is tightened to
full right (clockwise) position.
2. Check trim pump fluid level with outboard in full
“UP” position and fill if necessary. Refer to “Bleed-
ing Power Trim Unit”.
3. Check for external leaks in Power Trim system.
Replace defective part(s) if leak is found.
4. Outboard not holding tilted position (falls down to
trim position) indicates debris or defective com-
ponents in trim assembly. Clean or replace com-
ponents as required.

5E-20 - MID SECTION 90-817643R1 DECEMBER 1996

 Hydraulic System Troubleshooting Flow Chart

OUTBOARD WILL NOT HOLD TILTED POSITION

DURING REVERSE AND/OR TRAILS OUT
DURING HIGH SPEED DECELERATION

Manual release valve Manual release valve and

Inspect manual release valve O-rings appear to be O.K. -
and O-ring damaged
Clean and reinstall manual
release valve

Replace manual re- Trim will not hold

lease valve and O- reverse thrust Trim system holds
rings reverse thrust: Test-
ing complete

Trim system holds Remove and inspect pis-

reverse thrust: Test- ton rod assembly for de- Shock piston appears O.K.
ing complete bris and/or shock ball - Clean and reinstall piston
hang up rod assembly
Debris and/or shock
ball hang up identi-
fied
Trim will not hold
reverse thrust Trim system holds
reverse thrust: Test-
Replace piston ing complete
rod assembly
Remove PO check valve
assembly, inspect O-rings
and seals for damage
Trim system holds
reverse thrust: Test-
ing complete

Debris and/or dam- PO check valve appears

age identified O.K. - Clean and reinstall
PO check valve assembly

Replace PO check
valve assembly Trim system holds
reverse thrust: Test-
ing complete
Trim will not hold
Trim system holds reverse thrust
reverse thrust: Test-
ing complete
continued on next page

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-21

 Hydraulic System Troubleshooting Flow Chart
continued

Remove suction seat as-

sembly and inspect for
debris and/or damage

Suction seat assembly ap-

Debris and/or damage pears O.K. - Clean and rein-
identified stall suction seat assembly

Replace suction seat

assembly Trim will not hold
reverse thrust Trim system holds
reverse thrust: Test-
ing complete
Trim system holds
reverse thrust: Test-
ing complete
Replace trim system

5E-22 - MID SECTION 90-817643R1 DECEMBER 1996

 Hydraulic System Troubleshooting Flow Chart

TRIM SYSTEM LEAKS DOWN WITH

MANUAL RELEASE VALVE CLOSED

Manual release valve Inspect manual release valve Manual release valve and O-
and O-ring damaged rings appear to be O.K. - Clean
and reinstall manual release
valve

Replace manual re- Trim system leaks

lease valve and O- down
Trim system does
rings
not leak down: Test-
ing complete
Remove tilt relief valving
Trim system does and inspect O-rings and
not leak down: seals for debris and/or
Testing complete damage

Debris and/or dam- Tilt relief valving and O-rings

age identified appear to be O.K. - Clean and
reinstall tilt relief valving

Trim system leaks Trim system does

Replace tilt relief valving
down not leak down: Test-
ing complete

Trim system does Remove PO check valve

not leak down: Test- assembly, inspect O-rings
ing complete and seals for damage

Debris and/or dam- PO check valve appears

age identified O.K. - Clean and reinstall
PO check valve assembly

Replace PO check
valve assembly
Trim system leaks Trim system does
down not leak down: Test-
ing complete
Trim system does
continued on next page
not leak down: Test-
ing complete

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-23

 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-

ton and shock piston Trim leaks down
O-rings

Trim system does

not leak down: Test-
ing complete Replace trim system

5E-24 - MID SECTION 90-817643R1 DECEMBER 1996

Troubleshooting the Power Trim Electrical System

Trim Switch UP Trim Switch UP

(Remote Control DN (Panel Mounted) DN

Mounted)

BLU/WHT
Fuse Holder

GRN/WHT

BLU/WHT or PUR
GRN/WHT or GRN
RED
RED
RED
Fuse Holder

– + RED/PUR
B

RED
A

Battery

Solenoid GRN/WHT
BLU/WHT

Down Relay 3
GRN/WHT LT. GRN/WHT
GRN
14 BLK
RED LT. GRN/WHT
BLK

LT.BLU/WHT LT. BLU/WHT

BLUE
14 BLK
RED
BLK
LT. BLU/WHT
RED

Up Relay 4 RED/PUR
1
UP

DN
Cowl Switch
2

Trim Pump Motor

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-25

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” and Trim Switch. wire.
does operate. 2. Faulty Trim Switch. 2. Replace.

Cowl Switch “UP” is inopera- 1. Open wire between Wire Connection (2) 1. Check for an open connection or cut
tive, but the Trim Switch “UP” and Solenoid. wire.
does operate. 2. Faulty Cowl Switch. 2. Replace.

Trim Switch “UP” and Cowl 1. Open wire between Wire Connection (1) 1. Check for an open connection.
Switch “UP” are both inopera- and the Up Relay.
tive. 2. Open BLK wire between ground and UP 2. Check for an open connection.
Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
Up Relay.
4. Faulty Up Relay . 4. Replace.

Trim Switch “DOWN” is inop- 1. Open wire between Wire Connection (3) 1. Check for an open connection or cut
erative, but the Cowl Switch and Trim Switch. wire.
“DOWN” does operate. 2. Faulty Trim Switch. 2. Replace.

Cowl Switch “DOWN” is inop- 1. Open wire between Wire Connection (2) 1. Check for an open connection or cut
erative, but the Trim Switch and Solenoid. wire.
“DOWN” does operate. 2. Faulty Cowl Switch. 2. Replace.

Trim Switch “DOWN” and 1. Open wire between Wire Connection (3) 1. Check for an open connection.
Cowl Switch “DOWN” are both and the Up Relay.
inoperative. 2. Open BLK wire between ground and 2. Check for an open connection.
Down Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
Down Relay.
4. Faulty Down Relay 4. Replace.

Trim Switch “UP” and 1. 20 AMP Fuse blown. 1. Replace fuse. Locate the cause of the
“DOWN” are both inoperative, blown fuse. Check electrical wiring for a
but the Cowl Switch does op- shorted circuit.
erate. 2. Faulty trim switch. 2. Replace
3. Wire is open between fuse holder and 3. Check for an open connection or cut
solenoid. wire.
4. Wire is open between fuse holder and 4. Check for a loose or corroded connec-
trim switch. tion.

Trim Switch and Cowl Switch 1. One of the Trim Pump Motor wires is 1. Check wire connections (4) for loose
are both inoperative. open between the motor and the Relays. or corroded condition.
2. Faulty trim pump motor. 2. If voltage is present at connections (4)
when the appropriate trim button is
pressed, then motor is faulty. Replace
motor.

Trim system operates (motor 1. The Trim or Cowl switch is shorted. 1. Replace.
runs) without pressing the
switches.

5E-26 - MID SECTION 90-817643R1 DECEMBER 1996

Power Trim System Removal 3. Remove the trilobe pin.

1. Tilt outboard to the full up position and support 4. Drive out the upper pivot pin.
with tilt lock pin.

a
b

a - Trilobe Pin
55464
b - Upper Pivot Pin

a - Tilt Lock Pin

5. Remove the sacrificial anode.

2. Disconnect the power trim wire harness and re-

move clamp.

a 55331

a - Sacrificial Anode

55264

a - Power Trim Wire Harness Clamp

b - Harness

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-27

6. Use suitable punch to remove (Drive Up) lower Power Trim Disassembly
pin. Retain dowel pin.
IMPORTANT: Power trim system is pressurized.
Trim rod must be in the full “UP” position (fully ex-
tended) prior to fill/drain plug, or manual release
valve removal.
1. Remove reservoir cap.
2. Remove manual release valve assembly to drain
oil.

51144

a - Dowel Pin
7. Use suitable punch to drive out lower pivot pin. a

55263

a - Reservoir Cap
b - Manual Release Valve

a 51144

a - Lower Pivot Pin

5E-28 - MID SECTION 90-817643R1 DECEMBER 1996

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. Remove reservoir seal and coupler.
CG 41-14 with 5/16″ end to remove spool.
a

a
b b
c
d
c
e
d
d c
b
a
a - Plug (2)
b - Spring (2)
c - Check Valve/Poppet (2)
e d - Seat (2)
e - Spool
IMPORTANT: Inspect poppet assembly for debris
in the area shown. If debris is found on poppet, re-
a - Screw (4) place poppet.
b - Reservoir
c - Reservoir Seal a
d - Coupler
e - Manifold Assembly
b

a - Debris Under Valve Tip

b - Rubber Seat

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-29

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.
a

a
b b
c
c
d
d
51008

a - Spring
b - Poppet
c - Spool Housing
d - Trim Limit Spool

a - Screws (3) Shock Rod Removal

b - Filter Seal
c - Filter 1. Unscrew end cap assembly from cylinder using
d - Suction Seat Assembly spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm)
long pegs].

Manifold Removal
1. Remove two (2) screws to remove manifold from
cylinder.

2. Remove shock rod assembly from cylinder.

a
51146

a - Screw (2)

5E-30 - MID SECTION 90-817643R1 DECEMBER 1996

Shock Rod Disassembly 3. Remove check ball components from shock rod
piston.
NOTE: The only serviceable items on the shock rod
assembly are the O-rings and wiper ring. If shock rod 4. Remove o-ring from shock rod piston.
requires any other repair, replace shock rod assem-
bly.

c
c
b b
a
b

a d
a - End Cap
b - O-ring 51147
c - Wiper Ring

a - Spring (5)
b - Seat (5)
1. Place shock rod assembly on clean work surface. c - Ball (5)
2. Remove three (3) screws and remove plate from d - O-ring
shock rod piston.
a

b
c
51143

a - Screw (3)
b - Plate
c - Shock Rod Piston

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-31

 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).
6. Loosen shock rod piston using spanner wrench
[1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs].
7. Allow shock rod piston to cool. Remove from
b
shock rod.
a
51199

a - Shock Piston
b - O-ring

11. Remove cylinder end cap assembly from shock

rod.
12. Inspect shock. If wiper (located in cap) has failed
to keep rod clean, replace wiper.
13. Place end cap on clean work surface.
14. Remove rod wiper, inner o-ring, and outer o-ring.
51146

a b

a
c
b

51145

a - Rod Wiper
51146 b - Inner O-ring
a - Spanner Wrench c - Outer O-ring
b - Shock Rod Piston

8. Inspect check valve for debris; clean debris from

check valve if found. If debris cannot be cleaned
from check valve, replace shock piston as an as-
sembly.
9. Clean shock and components with compressed
air.

5E-32 - MID SECTION 90-817643R1 DECEMBER 1996

Memory Piston Removal 2. Remove o-ring from memory piston.

1. Remove memory piston from cylinder using one a

of two methods: b
a. Using lock ring pliers (Craftsman P/N 4735) or
suitable tool.

51144

a - O-Ring
b - Memory Piston

51144

b. Blowing compressed air into manual release

valve hole using adaptor (P/N 91-822778A3).

WARNING
Memory piston cup may be expelled at a high
velocity when air pressure is applied. Failure to
place cylinder as shown below could result in
personal injury.
NOTE: Point cylinder opening down and away. Use
a shop rag or towel to avoid damage to the memory
piston.

55466

a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-33

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. Use O-Ring Kit 25-827668A1.
Lubricate all o-rings with Quicksilver Power Trim
Fluid (92-90100A12). If not available, use automotive
(ATF) automatic transmission fluid.

Trim Motor Electrical Tests

1. Connect a 12 volt supply to motor leads. If motor
fails to run, replace pump motor.
IMPORTANT: Trim Motor is not serviceable. If mo-
tor fails to run, replace motor assembly.

5E-34 - MID SECTION 90-817643R1 DECEMBER 1996

Reassembly
O-Ring and Seal Placement
O-Rings and Seals are part of O-Ring Kit
25-809880A1

2
3

22

8
20 9
10
19

21 11
13
12
14
18 9

10
9
15
8 16
17

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-35

O-ring Sizes
1 2
9

4, 22

13

5
12, 17, 18
14

15, 20
6
16

19 Cutaway View of O-Ring

8

Width
10 21

11
O.D. I.D.

O-RINGS SHOWN ARE ACTUAL SIZE

5E-36 - MID SECTION 90-817643R1 DECEMBER 1996

O-ring Description and Sizes
O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width
1 Wiper Ring (412585)
2 Cyl. Cap, Inner12586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm)
3 Cyl. Cap8134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm)
4 Shock Piston2579) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
5 Piston Bolt05797) 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm)
6 Reservoir Plug01271) 0.549 in. (13.94 mm) 0.755 in. (19.17 mm) 0.103 in. (2.616 mm)
7 Motor Seal12599)
8 (2) P.O. Check Plug06484) 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm)
9 (3) Poppet Assy.74585)
10 (2) P.O. Check Seat07328) 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm)
11 (2) Pump Port 0.145 in. (3.683 mm) 0.285 in. (7.239 mm) 0.07 in. (1.78 mm)
12 Suction Seat 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm)
13 Filter Seal12607)
14 Filter12590)
15 Manual Release406483) 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
16 Manual Release06226) 0.176 in. (4.47 mm) 0.316 in. (8.026 mm) 0.07 in. (1.78 mm)
17 Manual Release09051) 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm)
18 Spool09051) 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm)
19 (3) Spool Housing09005) 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
20 Trim Limit Spool06483) 0.114 in. (2.895 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
21 (2) Manifold405387) 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm)
22 Memory Piston412579) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-37

Power Trim Reassembly 4. Clamp shock rod in soft jawed vise.

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

Shock Rod Reassembly

1. Install lubricated o-rings to end cap.
2. Install rod wiper.

51146

a CAUTION
c
b When installing shock rod piston, spanner
wrench must have1/4 in. x 5/16 in. (6.4mm x8mm)
long pegs to avoid damage to shock rod piston.

51145
6. Apply Loctite Grade “A” (271) to threads on shock
rod.
a - Rod Wiper
b - Inner O-ring 7. Install shock rod piston.
c - Outer O-ring
8. Tighten shock rod piston securely using spanner
wrench (1/4 in. x 5/16 in. long pegs). If a torquing
type spanner tool is used to tighten shock piston,
3. Install lubricated o-rings to shock piston. then torque to 90 lb. ft. (122 N⋅m).
b a

b c

a 51199

a - Shock Piston
b - O-ring
c - O-ring 51146

a - Shock Rod Piston - Torque to 90 lb. ft. (122 N⋅m)

b - Spanner Wrench

5E-38 - MID SECTION 90-817643R1 DECEMBER 1996

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. Push memory piston all the
35 lb. in. (4.0 Nm). way to bottom.
a
b

d e
a - Memory Piston
c b - O-ring

a
3. Fill cylinder three inches (76.2mm) from top of cyl-
inder using Quicksilver Power Trim and Steering
Fluid. If not available, use automotive (ATF) auto-
b 51147
matic transmission fluid.
4. Install shock rod into cylinder until power trim fluid
flows through oil blow off ball passage. Fill re-
a - Screws (3) Torque to 35 lb. in. (4.0 N⋅m)
maining cylinder to just below the cylinder
b - Plate threads.
c - Springs (5)
d - Seats (5)
e - Balls (5)

a - Oil Blow Off Ball Passage

CAUTION
End cap must not make contact with shock rod
piston when tightening. Shock rod piston must
be positioned in cylinder deep enough to avoid
contact.
5. 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 to 45 lb. ft. (61.0 N·m).

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-39

Trim Limit Assembly Installation Manifold Installation
1. Lubricate all O-rings. Install spring, poppet spool
housing and trim limit spool into manifold.
1. Install dowel pin and two (2) lubricated O-rings
NOTE: There are two different size springs used in into trim cylinder.
this manifold. The heavy spring is used on 75 to 125
HP engines. The light spring is used on 40 to 60 HP
engines.

a
or a

b
b
c
a - O-Rings (2)
b - Dowel Pin
d 51008

a - Spring 2. Align the trim cylinder and pump/reservoir as-

b - Poppet sembly together.
c - Spool Housing
d - Trim Limit Spool

Manual Release Valve Installation

1. Install “E” clip (if removed) and lubricate O-rings a
to manual release valve.
2. Install manual release valve assembly into man-
ifold.
a

a - Trim Cylinder Assembly

c b - Reservoir/Manifold Assembly

b
a - Manifold
b - Manual Release Valve
c - E Clip

5E-40 - MID SECTION 90-817643R1 DECEMBER 1996

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.
3. Install filter and filter seal under pump. Install
pump onto manifold. Torque screws to 70 lb. in.
(7.7 N⋅m).
a

a
51146

a - Screws (2) Torque to 100 lb. in. (11 N⋅m)

a - Screws (3) Torque to 70 lb. in. (7.7 N⋅m)

b - Suction Seat Assembly

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-41

Pressure Operated Assembly Reservoir/Motor Installation
Installation 3. Install coupler into top of pump. Make sure reser-
IMPORTANT: Inspect poppet assembly for debris voir seal is in the reservoir groove and place res-
in the area shown. If debris is found on poppet re- ervoir onto pump/manifold assembly. Install
place poppet. ground strap under screw shown Torque screws
to 80 lb. in. (9 N⋅m).
a a
b

c
a - Debris Under Valve Tip
b - Rubber Seat d

1. Lubricate o-rings.
2. Install spool, seat with O-ring, check valve/pop-
f
pet, spring and plug with O-ring into pump. Re-
peat for other side. Torque plugs to 120 lb. in.
(13.5 N⋅m). e

a - Screw (4) Torque to 80 lb. in. (9 N⋅m)

b - Reservoir
a c - Reservoir Seal
d - Coupler
b
c e - Manifold Assembly
d f - Ground Strap

e 4. Fill reservoir to bottom of fill hole using Quicksil-

d
c ver Power Trim Fluid (92-901000A12). If not
b available, use automotive (ATF) automatic trans-
a mission fluid.
a - Plugs (2) Torque to 120 lb. in. (13.5 N⋅m)
b - Springs (2)
c - Check Valve/Poppet (2)
d - Seats (2)
e - Spool

5E-42 - MID SECTION 90-817643R1 DECEMBER 1996

Bleeding Power Trim Unit Installation of Power Trim
1. Secure power trim unit in soft jawed vise. System
2. Add power trim fluid until even with the bottom of 1. Lubricate lower pivot pin, mounting holes with
the fill hole. Reinstall plug. 2-4-C Marine Lubricant.
3. Close the manual release valve. (Turn full clock- 2. Start lower pivot pin into pivot pin bore and posi-
wise). tion lower dowel pin (Retained) in its respective
hole.

b
a
55263
51148
a - Reservoir Plug/Fill Hole
b - Manual Release Valve a - Lower Pivot Pin
b - Lower Dowel Pin

4. Using a 12 volt power supply, connect the positive 3. Position trim cylinder assembly (Bottom First) be-
lead to (blue) trim motor wire and negative lead to tween clamp brackets.
(green) trim motor wire and drive shock rod to the
up position. Repeat for three times.
5. Connect the positive lead to the (green) trim mo-
tor wire, and the negative lead to the (blue) trim
motor wire and drive the shock rod to the down
position.
6. Recheck fluid level, add fluid if required and re-
peat cycle until fluid level stays even with the bot-
tom of the fill hole.

55467

a - Trim Cylinder Assembly

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-43

4. Apply 2-4-C Marine Lubricant ( 92-90018A12) to 6. Apply 2-4-C Marine Lubricant (92-90018A12) to
lower pivot pin. Using a suitable punch, drive low- surface of upper pivot pin, pivot pin bore and trim
er pivot pin into clamp bracket and trim cylinder ram bore.
assembly until pivot pin is flush with outside sur-
face.
a
c

a
51148
51147
a - Pivot Pin
b - Pivot Pin Bore
a - Lower Pivot Pin c - Trim Ram Bore

5. Using a suitable punch, drive lower dowel pin into 7. Using a suitable mallet, drive upper pivot pin into
its hole until seated. swivel bracket and through trim ram until pivot pin
is flush with swivel bracket.

51148 51148
a - Lower Dowel Pin a - Pivot Pin
b - Swivel Bracket
c - Trim Ram

5E-44 - MID SECTION 90-817643R1 DECEMBER 1996

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.
11. Secure trim harness with clamp as shown.

b
a
c 55465

a - Sacrificial Anode
b - Ground Strap
c - Bracket

a - Clamp

90-817643R1 DECEMBER 1996 MID-SECTION - 5E-45

MID-SECTION

MANUAL TILT SYSTEM

F
(DESIGN I, II, III)
Table of Contents
Page
Manual Tilt System Components (Design One
and Two) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Quicksilver Lubricant/Sealant Application
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Torque Specification . . . . . . . . . . . . . . . . . . . 5F-1
Manual Tilt System Components (Design
Three) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-2
Quicksilver Lubricant/Sealant Application
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-2
Torque Specification . . . . . . . . . . . . . . . . . . . 5F-2
Manual Tilt Flow Diagrams Design 1 . . . . . . . . 5F-3
Manual Tilt Flow Diagrams Design 2 . . . . . . . . 5F-8
Manual Tilt Flow Diagrams Design 3 . . . . . . . 5F-13
Hydraulic System Troubleshooting . . . . . . . . . 5F-18
Troubleshooting Flow Chart . . . . . . . . . . . . . . 5F-19
Manual Tilt System Removal . . . . . . . . . . . . . . 5F-21
Manual Tilt System Disassembly . . . . . . . . . . 5F-22
Accumulator Removal . . . . . . . . . . . . . . . . . 5F-22
Shock Rod Removal . . . . . . . . . . . . . . . . . . 5F-23
Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5F-24
Valve Block Removal . . . . . . . . . . . . . . . . . . 5F-26
Valve Block Disassembly . . . . . . . . . . . . . . . . . 5F-27
Manual Tilt System Cleaning and
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-28
Manual Tilt System Reassembly . . . . . . . . . . 5F-28
Valve Block Reassembly . . . . . . . . . . . . . . . 5F-28
Valve Block Installation . . . . . . . . . . . . . . . . 5F-30
Shock Rod Reassembly . . . . . . . . . . . . . . . 5F-30
Shock Rod Installation . . . . . . . . . . . . . . . . 5F-32
Instructions for Making Retaining Tool . . . . . . 5F-33
Bleeding Manual Tilt System . . . . . . . . . . . . . . 5F-34
Manual Tilt System Installation . . . . . . . . . . . . 5F-35

5F-0 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt System Components (Design One and Two)
1 - Shock Rod Cylinder
2 - Accumulator
Torque Specification
3 - Shock Rod
4 - Valve Block
a 35 lb. ft. (47 N·m)
5 - Dowel Pin
6 - Pivot Pin b 100 lb. in. (11.5 N·m)
7 - Rod Wiper
8 - O-ring .671 in. I.D. c 35 lb. in. (4.0 N·m)
9 - Cylinder Cap 6
10- O-ring 1.864 in I.D 5
11- O-ring .614 in. I.D. d 27 lb. in. (3.0 N·m)
12- Shock Rod Piston
13- Ball (5) e 75 lb. in. (8.5 N·m)
14- Spring Seat (5) 3
15- Spring (5)
16- Retaining Plate Bottom of Valve Block/Cylinder
17- Screw (3)
18- O-ring 1.600 in. I.D. (Shock Piston)
19- O-ring 1.600 in. I.D. (Memory Piston)
20- Memory Piston
21- Screw (2)
22- O-Ring .208 in. I.D. (2)
23- Pipe Plug
24- Spring (Large)
25- Spring (Small) 7 Check
Ball
26- Ball 8
27- Plunger DESIGN 1 DESIGN 2
28- Screw Plug (2)
29- Spring (2) 9 1
Side of Valve Block
30- O-ring (2)
31- Ball (2)
lower
32- Push Rod (2) 10 notch
33- Dowel Pin
34- Spool 11
35- Spring
21
36- O-ring .301 in I.D. 55
37- Screw Plug 12
38- O-ring .301 in. I.D.
39- Cam Shaft 13
40- Insulator 14 49 DESIGN 1 DESIGN 2
41- Retainer Plate 48
42- Screw 15
43- O-ring 2.114 in. I.D.
44- Push Rod 16
45- Ball
46- Flat Spring 17 22
47- Screw
Design One Only 18
48- O-ring 2
49- Filter 47
19 C 46
50- Valve Seat 23
51- O-ring .364 in. I.D. 24 45
52- Ball 26 50
53- Spring Guide
25 44
20 27 51 52 43
54- Spring
55- Hole in Cyliner
53 54
Quicksilver Lubricant/Sealant 42
Application Points 28
29 31
Lubricate ALL O-rings using Quicksilver Power Trim 30
32 38 39
and Steering Fluid or; (ATF) Type F, FA or Dexron II.
41 26153
33 4 40
A Loctite 271
34 37
35 36
B Loctite Pipe Sealant with Teflon (592)

C Special Lubricant 101

NOTE: It is recommended that ALL O-rings be re-
placed when servicing tilt system.

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-1

Manual Tilt System Components (Design Three)
1 - Shock Rod Cylinder
2 - Accumulator
Torque Specification
3 - Shock Rod
4 - Valve Block
a 35 lb. ft. (47 N·m)
5 - Dowel Pin
6 - Pivot Pin b 100 lb. in. (11.5 N·m)
7 - Rod Wiper
8 - O-ring .671 in. I.D. c 35 lb. in. (4.0 N·m)
9 - Cylinder Cap
10- O-ring 1.864 in I.D
11- O-ring .614 in. I.D. d 27 lb. in. (3.0 N·m)
12- Shock Rod Piston
13- Ball (5) e 75 lb. in. (8.5 N·m)
14- Spring Seat (5)
15- Spring (5)
16- Retaining Plate
17- Screw (3) stamped
18- O-ring 1.600 in. I.D. (Shock Piston)
upper
19- O-ring 1.600 in. I.D. (Memory Piston) notch “s”
20- Memory Piston
21- Screw (2) or
22- O-Ring .208 in. I.D. (2)
23- Plug s
24- Spring (Large)
25- Spring (Small)
26- Ball DESIGN 3
27- Plunger
28- Screw Plug (2)
29- Spring (2)
30- O-ring (2)
31- Ball (2)
32- Push Rod (2)
33- Dowel Pin
34- Spool
35- Spring
36- O-ring .301 in I.D.
37- Screw Plug
38- O-ring .301 in. I.D.
39- Cam Shaft
40- Insulator
41- Retainer Plate
42- Screw
43- O-ring 2.114 in. I.D.
44- Push Rod
45- Ball
46- Flat Spring
47- Screw

Quicksilver Lubricant/Sealant
Application Points
Lubricate ALL O-rings using Quicksilver Power Trim
and Steering Fluid or; (ATF) Type F, FA or Dexron II.
A Loctite Grade “A” (271) 26153

B Loctite Pipe Sealant with Teflon (592)

C Special Lubricant 101

NOTE: It is recommended that ALL O-rings be re-
placed when servicing tilt system.

5F-2 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt Flow Diagrams
Design 1

51651

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-3

Design 1

51652

5F-4 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 1

51653

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-5

Design 1

51654

5F-6 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 1

51655

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-7

Manual Tilt Flow Diagrams
Design 2

51656

5F-8 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 2

51657

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-9

Design 2

51658

5F-10 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 2

51659

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-11

Design 2

51660

5F-12 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt Flow Diagrams
Design 3

51661

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-13

Design 3

51662

5F-14 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 3

51663

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-15

Design 3

51664

5F-16 - MID-SECTION 90-817643R1 DECEMBER 1996

Design 3

51665

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-17

Hydraulic System 2. Check for external leaks in the manual tilt system.
Replace defective part(s) if leak is found.
Troubleshooting IMPORTANT: If cut or damaged O-rings are found,
Refer to disassembly/reassembly instructions (fol- inspect machined surfaces for scoring, burrs or
lowing) if disassembly is required when servicing. debris.
IMPORTANT: After debris or failed components 3. Check for discharged accumulator. 35 to 50 lb. ft.
have been found (during troubleshooting proce- (47-68 N·m) of pulling force must be attained
dure) it is recommended that unit be disas- when tilting outboard from full “down” to full “up”
sembled completely and ALL O-rings be re- position. If more than 50 lb. ft. (68 N·m) of force is
placed. Check ball components and castings required, replace accumulator.
must be cleaned using engine cleaner and com- a
pressed air or replaced prior to reassembly.
Support outboard with tilt lock lever when servicing
manual tilt system.
1. Check manual release cam adjustment. Cam
must open and close freely. Adjust cam link rod as
necessary.
b

a
b

50431

a - Weight Scale
b - Valve Lever (open position)

51143

a - Link Rod
b - Manual Release Lever
c - Accumulator

5F-18 - MID-SECTION 90-817643R1 DECEMBER 1996

Troubleshooting Flow Chart

Outboard falls to full down position with manual re-

lease valve lever in LOCK/RUN (up) position. Ex-
ample a: Outboard lowers more than one tilt pin
hole in eight hours, Example b: Outboard lowers
during acceleration.

CAUTION
Tilt ram must be in full “up” position and accu-
mulator removed before manual tilt system
disassembly.

Inspect memory piston O-ring.

Results Results

O-ring defect. O-ring appears to be o.k., cylinder bore and

memory piston are o.k. Replace O-rings and
proceed.

Replace defective O-ring.

Inspect Transfer Valve.

Results Results

No debris or defective components found. Debris or defective components found in

transfer valve.

Replace valve block.

Clean components using engine cleaner and
compressed air or replace as necessary.

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-19

Troubleshooting Flow Chart
(Continued)

Outboard will not hold tilted position in reverse and/or

trails out during high speed deceleration with manual
release valve lever in the lock/run (up) position.

CAUTION
Tilt ram must be in full “up” position and accumu-
lator removed before manual tilt system disas-
sembly.

Inspect shock rod piston check valve(s).

Results Results

Debris or defective components found in check No debris or defective components found in check
valve(s). valve(s).

Clean check valve(s) components using engine clean- Inspect transfer valve(s).
er and compressed air or replace.

Results Results

No debris or defective components found in Debris or defective components found in

transfer valve(s). transfer valve(s).

Inspect valve block. Clean transfer valve(s) components using

engine cleaner and compressed air or re-
place.

Results Results

No debris found in valve block passages. Debris found in valve block passages.

Replace defective valve block. Clean valve block using engine cleaner and
compressed air.

5F-20 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt System Removal 3. Use suitable punch to remove (DRIVE DOWN)
upper dowel pin. Retain dowel pin.
CAUTION
Remove cowling and remove all spark plug leads
from spark plugs to prevent accidental starting
while servicing outboard.

WARNING
Service or installation of the tilt system may re-
sult in loss of pressure in the shock cylinder. If the
outboard is not in the full down position, such
loss of pressure will cause the engine to fall to the
full down position with a potential for damaging a
engine or causing personal injury. To avoid such
injury support outboard in the up position using
51144
tilt lock lever.
a - Dowel Pin
WARNING 4. Use suitable punch to drive out upper pivot pin.
Manual tilt system is pressurized. Accumulator
must be removed when shock rod is in the full up
a
position, prior to servicing, otherwise oil
spray-back may occur.
1. Support outboard in the up position using tilt lock
lever.
2. Remove link rod.

51144
a

a - Pivot Pin
b 5. Use punch to remove (DRIVE UP) lower dowel
pin. Retain dowel pin.

a
51143
a - Link Rod 51144
b - Accumulator
a - Dowel Pin

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-21

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-
a 51144 lator only when shock rod is in full up position.

a - Pivot Pin
7. Tilt shock absorber assembly (TOP FIRST) out Accumulator Removal
from clamp bracket and remove assembly. 1. Place manual tilt system in soft jawed vise.
2. Position shock rod to full up position.
3. Remove accumulator

1
a
1
a

2
51144
b
a - Manual Tilt System

51143

a - Shock Rod
b - Accumulator

5F-22 - MID-SECTION 90-817643R1 DECEMBER 1996

4. If plunger can be compressed into accumulator Shock Rod Removal
by hand, accumulator is defective. Replace accu-
mulator. 1. Remove cylinder end cap assembly using span-
ner wrench [1/4 in. x 5/16 in. long pegs].

51145
2. Remove shock rod assembly.

51143

a - Plunger
5. Remove O-ring.

51143

51145

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-23

3. Remove memory piston from cylinder using lock Shock Rod Disassembly
ring pliers (Craftsman P/N 4735) or suitable tool.
1. Place shock rod assembly on clean work surface.
2. Remove plate and O-ring.
3. Remove check ball components from shock rod
piston.
c
a

b
d

51143
a - Screw (3)
51144 b - Plate
c - O-ring
4. Remove O-ring from memory piston. d - Shock Rod Piston

b CAUTION
a
When removing shock piston, spanner wrench
must have 1/4 in. x 5/16 in. long pegs to avoid
damage to shock piston.

51144

a - O-ring
b - Memory Piston
5. Remove tilt system from vise and empty fluid into
appropriate container.

5F-24 - MID-SECTION 90-817643R1 DECEMBER 1996

4. Place shock rod into soft jawed vise and apply
heat to loosen piston using torch lamp (P/N CAUTION
91-63209). Do not remove check ball components from
5. Loosen shock rod piston using spanner wrench shock rod piston. Removal and reinstallation of
[1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs]. check valve could result in improper operating
pressure and possible manual tilt system dam-
6. Allow shock rod piston to cool. Remove from age.
shock rod.
7. Inspect check valve for debris; clean debris from
check valve if found. If debris cannot be cleaned
from check valve, replace shock piston as an as-
sembly.
8. Clean shock and components with compressed
air.
9. Remove inner O-ring.

51146
a

b a b 51199

a - O-ring
b - Shock Piston
10. Remove cylinder end cap assembly from shock
rod.
11. Inspect shock. If wiper (located in cap) has failed
to keep rod clean, replace wiper.

51146
a - Shock Rod Piston
b - Spanner Wrench

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-25

12. Place end cap on clean work surface. Valve Block Removal
13. Remove rod wiper, inner O-ring, and outer O-ring. 1. Remove valve block from shock rod cylinder.

b
a

51147

c
51146
a - Screws (2)
b - Valve Block
c - Shock Rod Cylinder
a
2. Remove O-rings.

c
b
a

51145

a - Rod Wiper
b - Inner O-ring
c - Outer O-ring

51148

a - O-rings (2)

5F-26 - MID-SECTION 90-817643R1 DECEMBER 1996

Valve Block Disassembly 4. Remove reservoir assembly.

1. Remove slow trim valve assembly.

2. Remove hydraulic oil transfer valve components.

c b
51142
a - Screw
b - Flat Spring
c - Ball
b
5. Remove cam assembly.
51143

a - Transfer Valves (2)

b - Slow trim Valve Assembly (Plug or Screw Plug)

3. Remove surge valve assembly.

a
51145
a - Screw
a b - Cam Assembly

51145

a - Surge Valve

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-27

Manual Tilt System Cleaning
and Inspection
1. It is recommended that all O-rings exposed dur-
ing disassembly be replaced.
2. Clean components, filter, and check valve seats
using engine cleaner and compressed air. Do not
use cloth rags.
e
3. Inspect all machined surfaces for burrs or scoring
to assure O-ring longevity.
4. Inspect shock rod. If wiper (located in cap) has d
failed to keep rod clean, replace wiper.

Manual Tilt System c

Reassembly
IMPORTANT: Components must be dirt and lint b
free. Slightest amount of debris in tilt system
could cause system to malfunction.
a
Apply Quicksilver Power Trim and Steering Fluid or, 51142

(ATF) Type F, FA or Dexron II on all O-rings during a - Screw

reassembly. b - Retainer Plate
c - Insulator
NOTE: Refer to “Manual Tilt System Components” d - Cam Shaft
for proper O-ring sizes. e - O-ring
4. Install push rod, ball, flat spring and screw in valve
block.
Valve Block Reassembly
5. Torque screw to 27 lb. in. (3.0 N·m).
IMPORTANT: Cam shaft O-ring must be lubri-
cated using Special Lubricant 101 prior to instal-
lation.
1. Install lubricated O-ring to cam shaft.
2. Install cam shaft in valve block.
3. Secure cam shaft in place using insulator, retain-
er plate, and screw. Tighten screw securely.

b
51145
a - Screw
b - Flat Spring
c - Ball
d - Push Rod

5F-28 - MID-SECTION 90-817643R1 DECEMBER 1996

6. Install spool, spring, lubricated O-ring and screw
plug (surge valve assembly) into valve block.
7. Torque screw plug to 75 lb. in. (8.5 N·m).

b
c
a
d
e
b
f
51142
a - Plunger
b - Ball
c c - Spring (Small)
d - Spring (Large)
e - O - ring
d 51142 f - Plug (Design 3)

a - Spool 12. Torque screw plug to 75 lb. in. (8.5 N·m).

b - Spring
c - O-ring
d - Screw Plug
8. Install push rod, ball, spring, lubricated O-rings
and screw plug (transfer valve components) in
valve block.
9. Install plunger, ball, spring (small), spring (large)
in valve block (Slow Trim Valve Assembly).
10. Apply Loctite Pipe Sealant with Teflon 592 to
threads of pipe plug (design one and two style
valve block).
11. Install pipe plug or plug into valve block. Tighten a
pipe plug (if equipped) securely.
b

e
51142
a - Push Rod (2)
b - Ball (2)
c - Spring (2)
d - O-ring (2)
e - screw Plug (2)

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-29

Valve Block Installation 3. Install lubricated O-ring.

1. Install lubricated O-rings.

51148

a - O-rings (2)
2. Install valve block to shock rod cylinder. Torque 51145
screws to 100 lb. in. (11.5 N·m).
Shock Rod Reassembly
1. Install lubricated O-rings.
2. Install rod wiper.

b
a

c
c 51146 b

a - Screw (2) 51145

b - Valve Block
c - Shock Rod Cylinder a - Rod Wiper
b - Inner O-ring
c - Outer O-ring

5F-30 - MID-SECTION 90-817643R1 DECEMBER 1996

3. Install lubricated O-ring. 8. Tighten shock rod piston securely using spanner
wrench (1/4 in. x 5/16 in. long pegs).
b a

51199
b
a - O-ring
b - Shock Piston
4. Clamp shock rod in soft jawed vise.
51146
5. Position cylinder end cap onto rod as shown. a - Shock Rod Piston
b - Spanner Wrench
9. Remove shock rod assembly from vise.
10. Install lubricated O-ring to shock rod piston.
11. Install ball, seat, and spring (five sets) to shock
rod piston.
12. Secure components with plate. Torque screws to
35 lb. in. (4.0 N·m).

51146
d
e
CAUTION f
When installing shock rod piston, spanner a
wrench must have1/4 in. x 5/16 in. (6.4mm x8mm)
long pegs to avoid damage to shock rod piston.
6. Apply Loctite 271 to threads on shock rod. c
7. Install shock rod piston. b
51147

a - Screw (3)
b - Plate
c - O-ring
d - Ball (5)
e - Seat (5)
f - Spring (5)

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-31

Shock Rod Installation 6. Refill cylinder to top.

1. Place cylinder/manifold assembly into soft jawed CAUTION

vise.
End cap must not make contact with shock rod
2. Fill cylinder to top using Quicksilver Power Trim piston when tightening. Shock rod piston must
and Steering Fluid or; (ATF) Type F, FA of Dexron be positioned in cylinder deep enough to avoid
II. contact.
3. Place cam shaft lever in the open position (lever 7. Tighten end cap securely using spanner wrench
facing down). [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs].
4. Install lubricated O-ring to memory piston and in-
stall piston into cylinder three inches (76mm) from
top.

b
a

51145

51144

a - O-ring
b - Memory Piston
5. Refill cylinder to top and install shock rod assem-
bly into cylinder.

51143

5F-32 - MID-SECTION 90-817643R1 DECEMBER 1996

Instructions for Making
Retaining Tool

3/16 in. x 3 in.

(5 x 7.5 cm)
Steel Plate

3/8 in. x 13 in.

(10mm x 33cm)
Threaded Rod

4 in. x 1/4 in. min.

(10cm x 6.4mm) minimum
Channel Iron

10 in.
(25 cm)
1 in. 8 in.
(25mm (20 cm)
)

3 in.
(76mm
)

2 holes, 7/16 in. dia. (11 mm)

5 in. 1-1/4 in. dia.
(125mm) (30m)

20 in.
(508mm)

2 in.
(50mm)

4 in.
(100 mm)

6 in. 8 in. 3/8 in. dia. 2 holes

(152mm) (203mm)

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-33

Bleeding Manual Tilt System 3. Bleed unit by pushing rod down slowly (18-20 se-
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.
1. With shock rod in the full up position and manifold
cam lever open (facing down), secure tilt system
to retaining tool and container. (A No. 10 can or 3
lb. coffee can can be used).
2. Fill container to near full level using Quicksilver
Power Trim and Steering Fluid or; (ATF) Type F,
FA or Dexron II.
IMPORTANT: Fluid level must remain above accu-
mulator opening during bleeding process.

50432

e b 4. During up stroke, pull up on rod slowly 3 in.

(76mm) from base.
c 5. Wait until all air bubbles exit accumulator base.
a

50447
a - Retaining Tool
b - Tilt System
c - Container
d - Cam Lever
e - Accumulator Opening

50433

6. Slowly cycle unit 5-8 times (round trip per cycle)

using short strokes 3 in. (76mm) from base allow-
ing bubbles to disappear during each stroke.

5F-34 - MID-SECTION 90-817643R1 DECEMBER 1996

7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), re-
cycle unit 2-3 more times using short strokes. No move tilt assembly from oil and secure in soft
air bubbles should appear from accumulator port jawed vise. Torque accumulator to 35 lb. ft. (47
at this time. N·m).
8. With oil level well above accumulator port, slowly
pull rod to full up position.
9. Install accumulator making sure air bubbles do
not enter system.

50433

Manual Tilt System

50432
10. Tighten accumulator snugly at this time. Installation
1. Apply Special Lubricant 101 to lower pivot pin
hole and pivot pin surface.
2. Start lower pivot pin into pivot pin hole and posi-
tion lower dowel pin (retained) in its hole.

a
51148
a - Lower Pivot Pin
b - Lower Dowel Pin
50432

90-817643R1 DECEMBER 1996 MID-SECTION - 5F-35

3. Reinstall manual tilt system. Reconnect release 6. Apply 2-4-C w/Teflon Marine Lubricant
valve link rod. (92-90018A12) to surface of upper pivot pin, pivot
pin hole and shock rod hole.
2

a
a c
2

1
b

51148
a - Pivot Pin
1 b - Pivot Pin Bore
c - Shock Rod Bore
7. Using a mallet, drive upper pivot pin into swivel
51144 bracket and through shock rod until pivot pin is
flush with swivel bracket.
a - Manual Tilt System
4. Using a suitable punch, drive lower pivot pin into
clamp bracket and trim cylinder assembly until
pivot pin is flush with outside surface.
b

c
a

51148
a a - Pivot Pin
b - Swivel Bracket
c - Shock Rod
51147
a - Lower Pivot Pin 8. Drive upper dowel pin (a) into its hole until seated.
5. Using a punch, drive lower dowel pin in until
seated.

51147
a - Dowel Pin
a
9. Check manual release cam adjustment. Cam
51148 must open and close freely. Adjust link rod as nec-
a - Lower Dowel Pin
essary.

5F-36 - MID-SECTION 90-817643R1 DECEMBER 1996

MID-SECTION

MANUAL TILT SYSTEM

G
(DESIGN 4)
Table of Contents
Page Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-1 Manual Tilt System
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-5 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . 5G-27
Tilt Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-7 Manual Tilt System Reassembly . . . . . . . . . . . . . . 5G-27
Slow Tilt Down Cam Shaft Reassembly . . . . . . . . . . . . . . . . . . . 5G-27
Under High Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-9 Valve Body Check Reassembly . . . . . . . . . . . . 5G-27
Under Water Strike Velocity Valve Reassembly . . . . . . . . . . . . . . . . 5G-27
with Valves Open . . . . . . . . . . . . . . . . . . . . . . . . . . 5G11 Check Retainer Reassembly . . . . . . . . . . . . . . . 5G-28
Shock Function Valve Plug Reassembly . . . . . . . . . . . . . . . . . . . 5G-28
with Valves Closed . . . . . . . . . . . . . . . . . . . . . . . 5G-13 Valve Block Installation . . . . . . . . . . . . . . . . . . . . 5G-28
Shock Function Return . . . . . . . . . . . . . . . . . . . . 5G-15 Shock Rod Reassembly . . . . . . . . . . . . . . . . . . . 5G-29
Hydraulic System Troubleshooting . . . . . . . . . . . . . 5G-16 Shock Rod Installation and
Manual Tilt System Removal . . . . . . . . . . . . . . . . . . 5G-17 Fluid Filling Procedure . . . . . . . . . . . . . . . . . . . . 5G-30
Manual Tilt System Disassembly . . . . . . . . . . . . . . 5G-18 Instructions for Making
Accumulator Removal . . . . . . . . . . . . . . . . . . . . . 5G-18 Retaining Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-32
Shock Rod Removal . . . . . . . . . . . . . . . . . . . . . . 5G-19 Bleeding Manual Tilt System . . . . . . . . . . . . . . . . . . 5G-33
Shock Rod Disassembly . . . . . . . . . . . . . . . . . . . . . 5G-20 Manual Tilt System Installation . . . . . . . . . . . . . . . . 5G-35
Valve Block Removal . . . . . . . . . . . . . . . . . . . . . 5G-22 Manual Release Valve Adjustment . . . . . . . . . . . . . 5G-36
Memory Piston Removal . . . . . . . . . . . . . . . . . . 5G-22
Valve Block Disassembly . . . . . . . . . . . . . . . . . . . . . 5G-23
Actual O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-25
O-ring Description and Sizes . . . . . . . . . . . . . . . . . . 5G-26

5G-0 - MID-SECTION 90-817643R1 DECEMBER 1996

Special Tools
1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-1

MANUAL TILT COMPONENTS
13
A

1 12

F
95

2
4

7
B
E
6
8
11
7

D
5
11 8
13 6 11
8
11 8 9
11

12
9
95 10
8
C
7 Loctite 271 (92-809820)
95 2-4-C With Teflon (92-825407A12)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.
NOTE: It is recommended that all O-rings be replaced when servicing tilt system.

5G-2 - MID-SECTION 90-817643R1 DECEMBER 1996

 MANUAL TILT COMPONENTS
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 MANUAL TRIM ASSEMBLY
– 1 MANUAL TRIM BEACHING ASSEMBLY
1 SHOCK ROD ASSEMBLY 45 61
1
1 SHOCK ROD ASSEMBLY (BEACHING)
2 1 MEMORY PISTON ASSEMBLY
3 1 O RING REBUILD KIT-Cylinder
4 2 O RING
5 1 CYLINDER ASSEMBLY
6 1 SCREW AND SEAL KIT
7 1 ACCUMULATOR ASSEMBLY 35 47
8 1 VALVE BODY ASSEMBLY
9 1 CAM KIT
10 1 VELOCITY VALVE KIT 75 8.5
11 1 CHECK SYSTEM REPAIR KIT 75 8.5
– 1 O RING KIT
12 2 PIN
13 2 GROOVE PIN
A – Torque cylinder cap to 45 lb. ft. (61 N·m)
B – Torque Accumulator to 35 lb. ft. (47 N·m)
C – Torque Velocity Valve to 75 lb. in. (8.5 N·m)
D – Torque Transfer Valve Plug to 75 lb. in. (8.5 N·m)
E – Torque Screw to 100 lb. in. (11 N·m)
F – Torque Shock Piston to 90 lb. ft. (122 N·m)

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-3

 MANUAL TRIM FLOW DIAGRAMS
b Up Circuit
a

p
e
o

f
n
k
m

j i h g
l

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
g - Manifold o- Shock Return Valve
h - Down Fast Transfer Valve p- Impact Relief Valve

5G-4 - MID-SECTION 90-817643R1 DECEMBER 1996

Tilt Up
With the engine in the down position, the accumulator
piston (d) will be at the top of the accumulator (c) with
the gas at maximum pressure. To raise the engine,
the camshaft lever (f) is rotated all the way down. The
internal shaft connected to the camshaft lever will
move the push rods, opening the accumulator check
valve (e), both fast transfer valves (h & j) and the
down slow transfer valve (i). As the operator lifts the
engine; oil, under pressure inside the accumulator,
will flow around both the slow transfer valve (i) and the
down circuit fast transfer valve (h). Oil flows into the
bottom of the tilt cylinder forcing the memory piston
(m) into the shock piston (n) and then forcing the
shock rod (a) up and out. Oil above the shock piston
exits the cylinder (l) through an interconnecting pas-
sage along side of the cylinder and returns into the
manifold (g). Inside the manifold the oil flows past the
groove in the surge valve (k), through the transfer
valve (j) and mixes with the oil flowing from the accu-
mulator into the up cavity. With the engine in the cor-
rect position, the camshaft lever (f) is rotated up and
the push rods allow the check valves (e, h, i, & j) to
close. The closed check valves prevent the oil from
traveling between cavities and locks the engine into
position.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-5

 b
Down Circuit
a

p
e
o

f
n
k
m

j i g
h
l

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
g - Manifold o- Shock Return Valve
h - Down Fast Transfer Valve p- Impact Relief Valve

5G-6 - MID-SECTION 90-817643R1 DECEMBER 1996

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
& j) and the down slow transfer valve (i). The operator
will have to press down on the engine cowl to over-
come the pressure inside cylinder. Fluid will flow out
of the bottom of the cylinder, past both the down fast
transfer valve (h) and down slow transfer valve (i).
Fluid will flow past the up fast transfer valve (j), surge
valve (k) and through the interconnecting passage
into the top of the cylinder (l). Due to the shock rod (a),
the tilt cylinder cavities differ in volume, the extra fluid
from the up cavity [forced into the accumulator (c)] will
cause the internal accumulator piston (d) to com-
press the gas. With the engine in the correct position,
the camshaft lever is rotated up and the push rods al-
low the check valves (e, h, i, & j) to close.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-7

 Slow Tilt Down Under
b
a
High Thrust

p
e f

n
k
m

j i h g
l

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
g - Manifold o- Shock Return Valve
h - Down Fast Transfer Valve p- Impact Relief Valve

5G-8 - MID-SECTION 90-817643R1 DECEMBER 1996

Slow Tilt Down Under High Thrust
To tilt the engine down under high thrust conditions
[where the propeller thrust forces the shock rod down,
creating higher pressure below the memory piston
(m)] the camshaft lever (f) is rotated slightly down-
ward. The internal shaft connected to the lever will
open the down slow transfer valve (i) allowing oil un-
der pressure into the cavity around the shaft. The
higher oil pressure will open the up fast transfer valve
(j) allowing oil from the bottom of the cylinder to flow
above the shock piston (n) while lowering the engine.
Additional oil will flow into the accumulator (c) as the
internal pressure forces the accumulator check valve
(e) to open. Oil flowing into the accumulator moves
the accumulator piston (d) and compresses the gas.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-9

 Under Water Strike
b
a
(Valves Open)

f
n
k
m

j i h g
l

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
g - Manifold o- Shock Return Valve
h - Down Fast Transfer Valve p- Impact Relief Valve

5G-10 - MID-SECTION 90-817643R1 DECEMBER 1996

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). 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 down fast transfer valve (h). As the shock
rod extends outward, the pressure inside the up cav-
ity will reach sufficient pressure to open the shock
valve (p) which opens at 880-1110 psi. Oil will flow into
the cavity created as the shock rod & shock piston (a
& n) moves away from the memory piston (m).

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-11

 Shock Function
b
a (Valve Closed)

c
Accumulator
Gas Pressure
400 PSI
d

o
e

n
f

k
m

j i h g
l

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
g - Manifold o- Shock Return Valve
h - Down Fast Transfer Valve p- Impact Relief Valve

5G-12 - MID-SECTION 90-817643R1 DECEMBER 1996

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). Fluid will attempt to exit
the cylinder through the interconnecting passage
back into the accumulator (c). The closed up fast
transfer valve (j) will prevent the fluid return. As the
shock rod extends outward, the pressure inside the
up cavity will reach sufficient pressure to open the
shock valve (p) which opens at 880-1110 psi. Oil will
flow into the cavity created as the shock rod & shock
piston (a & n) moves away from the memory piston
(m).

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-13

 b
Shock Function Return
a

o
e

n
f

k
m

j i h g
l

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
g - Manifold o- Shock Return Valve
h - Down Fast Transfer Valve p- Impact Relief Valve

5G-14 - MID-SECTION 90-817643R1 DECEMBER 1996

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.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-15

Hydraulic System 3. Check for discharged accumulator. 35 to 50 lb. ft.
(47-68 N·m) of pulling force must be attained
Troubleshooting when tilting outboard from full “down” to full“up”
position. If more than 50 lb. ft. (68 N·m) of force is
Refer to disassembly/reassembly instructions (fol-
required, replace accumulator.
lowing) if disassembly is required when servicing.
IMPORTANT: After debris or failed components
a
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 components and castings
must be cleaned using engine cleaner and com-
pressed air or replaced prior to reassembly.
Support outboard with tilt lock lever when servicing
manual tilt system.
1. Check manual release cam adjustment. Cam
must open and close freely. Adjust cam link rod as b
necessary.

50431
c
a - Weight Scale
b - Valve Lever (open position)

51143

a - Link Rod
b - Manual Release Lever
c - Accumulator

2. Check for external leaks in the manual tilt system.

Replace defective part(s) if leak is found.
IMPORTANT: If cut or damaged O-rings are found,
inspect machined surfaces for scoring, burrs or
debris.

5G-16 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt System Removal 3. Position piece of wood under transom bracket
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.

WARNING
Service or installation of the tilt system may re-
sult in loss of pressure in the shock cylinder. If the
b
outboard is not in the full down position, such
loss of pressure will cause the engine to fall to the
full down position with a potential for damaging
engine or causing personal injury. To avoid such
injury support outboard in the up position using a
tilt lock lever.
51144

WARNING a - Dowel Pin

b - Wood
Manual tilt system is pressurized. Accumulator
must be removed when shock rod is in the full up
position, prior to servicing, otherwise oil
spray-back may occur. 4. Position tilt lock and remove piece of wood. Use
suitable punch to drive out upper pivot pin.
1. Support outboard in the up position using tilt lock
lever.
a
2. Remove link rod.

b
b 51144

a - Pivot Pin
b - Tilt Lock

5. Use punch to remove (DRIVE UP) lower dowel

pin. Retain dowel pin.

51143

a - Link Rod
b - Accumulator

51144

a - Dowel Pin

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-17

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
a lator only when shock rod is in full up position.

a - Pivot Pin
Accumulator Removal
7. Tilt shock absorber assembly (TOP FIRST) out 1. Place manual tilt system in soft jawed vise.
from clamp bracket and remove assembly. 2. Position shock rod to full up position.
3. Open cam shaft valve (Down Position).
4. Loosen surge valve enough to drip, wait until drip-
ping stops.
a 1 5. When fluid stops dripping, loosen and remove ac-
cumulator.

2
51144

a - Manual Tilt System

c
a - Accumulator 51143
b - Cam Lever
c - Velocity Plug

5G-18 - MID-SECTION 90-817643R1 DECEMBER 1996

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

51145

2. Remove shock rod assembly from cylinder.

51143

a - Plunger

7. Once accumulator is removed, remove O-ring,

conical spring, steel ball and plunger.

b
c

51145

a - Conical Spring
b - Steel Ball
c - Plunger
d - O-ring

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-19

Shock Rod Disassembly 3. Remove check ball components from shock rod
piston.
NOTE: The only serviceable items on the shock rod
assembly are the O-rings and wiper ring. If shock rod 4. Remove O-ring.
requires any other repair, replace shock rod assem-
bly.

c
c
b b
a
b

a d
a - End Cap
b - O-rings (2) 51147
c - Wiper Ring

a - Springs (5)
b - Seats (5)
1. Place shock rod assembly on clean work surface. c - Balls (5)
2. Remove three (3) screws and remove plate from d - O-ring
shock rod piston.
a

b
c
51143

a - Screw (3)
b - Plate
c - Shock Rod Piston

5G-20 - MID-SECTION 90-817643R1 DECEMBER 1996

 10. Remove inner O-ring.
CAUTION
When removing shock piston, spanner wrench
must have 1/4 in. x 5/16 in. long pegs to avoid
damage to shock piston.
5. Place shock rod in soft jawed vise and apply heat
to loosen piston using torch lamp (P/N 91-63209).
6. Loosen shock rod piston using spanner wrench
[1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs].
b
7. Allow shock rod piston to cool. Remove from a
51199
shock rod.
a - Shock Piston
b - O-ring

11. Remove cylinder end cap assembly from shock rod.

12. Inspect shock. If wiper (located in cap) has failed to
keep rod clean, replace wiper.
13. Place end cap on clean work surface.
14. Remove rod wiper, inner O-ring, and outer O-ring.

51146

a b

51147

a
c
51146
a - Spanner Wrench
b
b - Shock Rod Piston
51145
a - Rod Wiper
8. Inspect check valve for debris; clean debris from b - Inner O-ring
check valve if found. If debris cannot be cleaned c - Outer O-ring
from check valve, replace shock piston as an as-
sembly.
9. Clean shock and components with compressed
air.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-21

Valve Block Removal Memory Piston Removal
1. Remove two screws from the shock rod cylinder 1. Remove memory piston from cylinder using one
to separate the valve block. of two methods:
a. Using lock ring pliers (Craftsman P/N 4735) or
(Snap-on P/N SRP4).
b
a

c
51146

a - Screws (2)
b - Valve Block
c - Shock Rod Cylinder

51144
2. Remove O-rings and dowel pins.
b. Blowing compressed air into center O-ring
hole.
b
WARNING
Memory piston cup may be expelled at a high
velocity when air pressure is applied. Failure to
place cylinder as shown below could result in
personal injury.
a NOTE: Point cylinder opening down and away. Use
a shop rag or towel to avoid damage to the memory
piston. Fluid will blow out also.
51148

a - O-ring (2) a
b - Dowel Pin (2)

55466

a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag

5G-22 - MID-SECTION 90-817643R1 DECEMBER 1996

2. Remove O-ring from memory piston. 3. Remove surge valve assembly.
a
b

a
b
c
d
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.

2. Remove hydraulic oil transfer valve plugs and 4. Remove screw and remove cam assembly.
components. e
d

c
b
a

a - Spacer Retainer Clip

b - Retainer Clip
c - Screw
d - Shaft Seal
e - Cam

b
51142
a - Transfer Valve Plug Assembly (2)
b - Check Retainer Plug or Screw Assembly

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-23

REASSEMBLY - O-RING AND SEAL PLACEMENT

14

7
9
6
11 12

10

13
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.
NOTE: It is recommended that all O-rings be replaced when servicing tilt system.

5G-24 - MID-SECTION 90-817643R1 DECEMBER 1996

Actual O-ring Sizes
1

2 9

4, 14

5 10

6 (2) 11 & 13

Cutaway View of O-Ring

7 12
Width

8 (2)

O.D. I.D.

O-RINGS SHOWN ARE ACTUAL SIZE

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-25

O-ring Description and Sizes
O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width
1 Wiper Ring (412585)
2 Cyl. Cap, Inner (412586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm)
3 Cyl. Cap (408134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm)
4 Shock Piston (412782) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
5 Piston Bolt (405797) 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm)
6 (2) Manifold Split Line405387 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm)
7 Slow Valve (401627) 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
8 (2) Plug (404463) 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm)
9 Accumulator (412175) 2.114 in. (53.69 mm) 2.254 in. (57.25 mm) 0.07 in. (1.78 mm)
10 Lip Seal (412574)
11 Cam Shaft (402664) 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
12 Back Up Ring (412592)
13 Surge Valve (402664) 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
14 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)

5G-26 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt System Cleaning VALVE BODY CHECK REASSEMBLY
1. Install lubricated O-ring, plunger, steel ball and
and Inspection conical spring to valve block.
1. It is recommended that all O-rings exposed dur-
ing disassembly be replaced.
a

2. Clean components, filter, and check valve seats b

using engine cleaner and compressed air. Do not
use cloth rags. c
3. Inspect all machined surfaces for burrs or scoring
d
to assure O-ring longevity.
4. Inspect shock rod. If wiper (located in cap) has
failed to keep rod clean, replace wiper.

51145

Manual Tilt System

a - Conical Spring
Reassembly b - Steel Ball
IMPORTANT: Components must be dirt and lint c - Plunger
d - O-ring
free. Slightest amount of debris in tilt system
could cause system to malfunction.
Apply Quicksilver Power Trim and Steering Fluid to all VELOCITY VALVE REASSEMBLY
O-rings during reassembly. If not available, use auto- 1. Install spool, spring, lubricated O-ring and screw
motive (ATF) automatic transmission fluid. plug (surge valve assembly) into valve block.

CAM SHAFT REASSEMBLY 2. Torque screw plug to 75 lb. in. (8.5 N⋅m).

IMPORTANT: Cam shaft O-ring must be lubri-

cated using 2-4-C with Teflon (92-825407A12).

1. Install lubricated O-ring and back up seal to cam.

2. Install shaft seal in valve block with lips facing out.
3. Install cam shaft assembly in valve block.
a
4. Secure cam shaft in place using insulator, retain-
er plate, and screw. Tighten screw securely. b
g c
e f d
d

c
b a - Spool
a b - Spring
c - O-ring
d - Screw Plug - Torque to 75 lb. in. (8.5 N⋅m)

a - Spacer Retainer Clip

b - Retainer Clip
c - Screw
d - Shaft Seal
e - O-ring
f - Back up Seal
g - Cam

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-27

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.

b
1

a
51148
b
a - O-rings (2)
c b - Dowel Pins (2)
d
e 51142
2. Install valve block to shock rod cylinder. Insert
a - Plunger
screws to shock rod cylinder and torque to 100 lb.
b - Spring (Large) in. (11 N·m).
c - Ball
d - Spring (Small)
e - Plug
a
VALVE PLUG REASSEMBLY
b
1. Install plunger, steel ball, spring, lubricated O-ring
and screw plug. Torque screw plugs to 75 lb. in.
(8.5 N⋅m).

c
51146

a - Valve Block
b - Screws (2) Torque to 100 lb. in. (11 N⋅m)
c - Shock Rod Cylinder
a
b
c
d

e 51142

a - Plungers (2)
b - Steel Balls (2)
c - Springs (2)
d - O-rings (2)
e - Screw Plugs (2) Torque to 75 lb. in. (8.5 N⋅m)

5G-28 - MID-SECTION 90-817643R1 DECEMBER 1996

Shock Rod Reassembly 4. Clamp shock rod in soft jawed vise.

1. Install lubricated O-rings to end cap. 5. Position cylinder end cap onto rod as shown.

2. Install rod wiper.

a
c
b
51145 51146

a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
CAUTION
When installing shock rod piston, spanner
3. Install lubricated O-rings to shock piston. wrench must have1/4 in. x 5/16 in. (6.4mm x8mm)
long pegs to avoid damage to shock rod piston.
6. Apply Loctite Grade “A” (271) to threads on shock
rod.
7. Install shock rod piston.
8. Tighten shock rod piston 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
b tighten shock piston, then torque to 90 lb. ft. (122
N⋅m).
c
a b
51199
a

a - Shock Piston
b - O-ring
c - O-ring

51146

a - Spanner Wrench
b - Shock Rod Piston - Torque to 90 lb. ft. (122 N⋅m)

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-29

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
35 lb.in. (3.9 N⋅m). NOTE: There are two ways for the filling procedure.
The first is the easiest and less time consuming.
11. Remove shock rod assembly from vise.
Filling Procedure Option One
1. Place trim cylinder in soft jawed vice.
2. With manifold cam lever closed (Up Position), fill
cylinder and manifold to top with Quicksilver Pow-
er trim and steering fluid, or (ATF) automatic
transmission fluid. Let bubbles disperse.
e 3. Install lubricated O-ring to memory piston.
d
c 4. Using lock ring pliers (Craftsman P/N 4735) or
(Snap-on P/N SRP4) set memory piston in top of
a cylinder then open cam lever (Down Position) and
push memory piston down just below cylinder
treads. Close cam lever (Up Position).

b 51147

a - Screw (3) Torque to 35 lb. in. (3.9 N⋅m)

b - Plate
c - Spring (5)
d - Seat (5)
e - Ball (5)

51144

5. Fill top of cylinder again with fluid to top and install

shock rod assembly on top memory piston. Open
cam lever (Down Position) and push shock rod
assembly down to 1/8″ below cylinder threads.
Close cam lever (Up Position).

5G-30 - MID-SECTION 90-817643R1 DECEMBER 1996

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. ft. (61.0
N⋅m). Close cam lever (up Position).

51145

8. Open and close cam lever watching for bubbles

coming from accumulator check ball hole. When
bubbles stop, fill accumulator opening to top with
fluid. Grease threads on accumulator and open-
ing with 2-4-C with Teflon. Start accumulator in
threads and open cam lever (Down Position).
Torque accumulator to 35 lb. ft. (47 N⋅m).

a
b

51143

a - Accumulator
b - Cam Lever (Down Position)
NOTE: If filling procedure is done correctly, it should
be hard to turn cylinder rod assembly by hand.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-31

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.
(25 cm)
1 in. 8 in.
(25mm) (20 cm)

3 in.
(76mm)

2 holes, 7/16 in. dia. (11 mm)

5 in. 1 1/4 in. dia.

(125mm) (30m)

20 in.
(508mm)

2 in.
(50mm)

4 in.
(100 mm)

6 in. 8 in. 3/8 in. dia. 2 holes

(152mm) (203mm)

5G-32 - MID-SECTION 90-817643R1 DECEMBER 1996

Bleeding Manual Tilt System 3. Bleed unit by pushing rod down slowly (18-20 se-
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.
1. With shock rod in the full up position and manifold
cam lever open (facing down), secure tilt system
to retaining tool and container. (A No. 10 can or 3
lb. coffee can could be used).
2. Fill container to near full level using Quicksilver
Power Trim and Steering Fluid. If not available,
use automotive (ATF) automatic transmission
fluid.
IMPORTANT: Fluid level must remain above accu-
mulator opening during bleeding process.

50432

e
b
4. During up stroke, pull up on rod slowly 3 in.
c (76mm) from base.
a 5. Wait until all air bubbles exit accumulator base.

d
50447
a - Retaining Tool
b - Tilt System
c - Container
d - Cam Lever
e - Accumulator Opening

50433

6. Slowly cycle unit 5-8 times (round trip per cycle)

using short strokes 3 in. (76mm) from base allow-
ing bubbles to disappear during each stroke.

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-33

7. Allow unit to stand five minutes then proceed to 11. With cam lever remaining open (facing down), re-
cycle unit 2-3 more times using short strokes. No move tilt assembly from oil and secure in soft
air bubbles should appear from accumulator port jawed vise. Torque accumulator to 35 lb. ft. (47
at this time. N·m).
8. With oil level well above accumulator port, slowly
pull rod to full up position.
9. Install accumulator making sure air bubbles do
not enter system.

50433

50432

10. Tighten accumulator snugly at this time.

50432

5G-34 - MID-SECTION 90-817643R1 DECEMBER 1996

Manual Tilt System 4. Using a suitable punch, drive lower pivot pin into
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. Start lower pivot pin into pivot pin hole and posi-
tion lower dowel pin (retained) in its hole.

b a
51147

a - Lower Pivot Pin

a
51148 5. Using a punch, drive lower dowel pin in until
seated.
a - Lower Pivot Pin
b - Lower Dowel Pin

3. Reinstall manual tilt system, bottom first. Recon-

nect release valve link rod.

a
a

51148

a - Lower Dowel Pin

51144

a - Manual Tilt System

90-817643R1 DECEMBER 1996 MID-SECTION - 5G-35

6. Apply 2-4-C Marine Lubricant (92-90018A12) to 8. Drive upper dowel pin (a) into its hole until seated.
surface of upper pivot pin, pivot pin hole and
shock rod hole.

a
c

2
a

b
51147

a - Dowel Pin
51148

a - Pivot Pin
b - Pivot Pin Bore 9. Check manual release cam adjustment. Cam
c - Shock Rod Bore must open and close freely. Adjust link rod as nec-
essary.

7. Using a mallet, drive upper pivot pin into swivel

bracket and through shock rod until pivot pin is
flush with swivel bracket. Manual Release Valve Adjustment
1. With outboard in full up position, place tilt lock le-
ver forward.
2. Lift cam lever (with link rod) to full up position.
b
a

c
c
a

51148

a - Pivot Pin
b - Swivel Bracket
c - Shock Rod

b 51143

a - Tilt Lock Lever

b - Cam Lever
c - Link Rod

3. Link rod end must snap onto ball of tilt lock lever
without moving tilt lock lever or cam lever.

5G-36 - MID-SECTION 90-817643R1 DECEMBER 1996

LOWER UNIT

51114

STANDARD GEAR HOUSING

6
A
Table of Contents
Page Page
Drive Shaft and Water Pump Components . . . . . . . . 6A-1 Gear Housing Re-assembly . . . . . . . . . . . . . . . . . . . 6A-13
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13
Lubrication/Sealant Application Points . . . . . . . . . 6A-1 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14
Propeller Shaft Components . . . . . . . . . . . . . . . . . . . . 6A-2 Forward Gear Bearing Race . . . . . . . . . . . . . . . . 6A-15
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15
Lubrication/Sealant Application Points . . . . . . . . . 6A-2 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17
Quicksilver Lubricants and Service Aids . . . . . . . . . . 6A-3 Lower Driveshaft Bearing Installation . . . . . . . . 6A-17
New Tools Required for 50-60 Gear Housing . . . . . . 6A-3 Upper Driveshaft Bearing Installation . . . . . . . . 6A-18
Draining and Inspecting Gear Lubricant . . . . . . . . . . 6A-5 Forward Gear, Pinion Gear, Upper Driveshaft
Propeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6 Bearing Race, Retainer and Driveshaft
Gear Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Gear Housing Disassembly . . . . . . . . . . . . . . . . . . . . . 6A-7 Pinion Gear Location and Forward Gear
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Bearing Carrier and Propeller Shaft . . . . . . . . . . . 6A-8 Determining Pinion Gear Location . . . . . . . . 6A-19
Propeller Shaft Disassembly . . . . . . . . . . . . . . . . 6A-10 Determining Forward Gear Backlash . . . . . . 6A-20
Pinion Gear, Driveshaft and Forward Gear . . . . 6A-11 Bearing Carrier and Propeller Shaft
Upper Driveshaft Bearing . . . . . . . . . . . . . . . . . . . 6A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Lower Driveshaft Bearing . . . . . . . . . . . . . . . . . . . 6A-12 Water Pump Re-assembly and Installation . . . . 6A-22
Forward Gear Bearing Race . . . . . . . . . . . . . . . . 6A-12 Gear Housing Pressure Test . . . . . . . . . . . . . . . . . . . 6A-24
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12 Gear Housing Installation . . . . . . . . . . . . . . . . . . . . . . 6A-24
Filling Gear Housing with Lubricant . . . . . . . . . . 6A-24
Gear Housing Installation . . . . . . . . . . . . . . . . . . . 6A-25
Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-26
Trim Tab Adjustment and Replacement . . . . . . . 6A-27

6A-0 - LOWER UNIT 90-817643R1 DECEMBER 1996

Drive Shaft and Water Pump D
Components A 31 a C
1 - Gear Housing
2 - Drain Screw 30
3 - Screw 32
4 - Washer
5 - Dowel Pin (Hollow) 27
6 - Dowel Pin (Solid) 33 19 c
7 - Pipe Plug
8 - Roller Bearing
26 18
9 - Pinion Gear D
10- Nut
11- Shift Shaft 25 a
12- Retaining Ring 17
13- Bushing 31
14- O-ring
15- Oil Seal 29
16- Drive Shaft
17- Shim Set 32
18- Tapered Roller Bearing
19- Nut 34 16
20- Water Pump Base 24
21- O-ring
22- Oil Seal
23- Oil Sea
24- Face Plate
25- Impeller 28 A
26- Key
27- Water Pump
28- Gasket (Lower)
29- Gasket (Upper)
30- Seal
20
B
31- Screw
32- Washer 21 (O.D.)
33- Insulator (Design 1)
34- Insulator (Design 1)
35- Shift Cam
22
(I.D.)
36- Spacer A
37- Coupler 23 D
38- Plate 38 (O.D.)
39- Seal 37
A (I.D.) 39 8 36
6 7 A
15
Torque Specifications 1
13
a 60 lb. in. (6.8 N·m) 5
D 14
b 20 lb. in. (2.2 N·m) 4 12
c 75 lb. ft. (101.7 N·m) f 3
d 22 lb. ft. (29.8 N·m) 35
e 50 lb. ft. (67.8 N·m)
f 35-80 lb. in. (3.8-8.8 N·m) 9 11

e 10
Lubrication/Sealant Application 4
3
Points
A 2-4-C Marine Lubricant (P/N 92-90018A12) D
4
B Super Duty Marine Gear Lubricant (P/N 92-13135A12) 2 51113
f
C Special Lubricant 101 (P/N 92- 13872A1)
D Loctite Grade A (P/N 92-32609-1)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-1

Propeller Shaft Components

59

61
d 60

E
a
63 64

48
(O.D.)
D 47 46
44
45 1
c 43
58 42
41

57 40
62

56 55
53
F
(I.D.) 54
G 52
51 49

40- Shim Set 50 51114

41- Tapered Roller Bearing E
42- Forward Gear
43- Roller Bearing
44- Cam Follower
45- Guide
46- Spring
47- Clutch
48- Cross Pin Torque Specifications
49- Spring a 55 lb. ft. (75 N·m)
50- Propeller Shaft
51- Reverse Gear b 275 lb. in. (31.0 N·m)
52- Ball Bearing
53- Bearing Carrier
c 150 lb. in. (17.0 N·m)
54- O-ring d 22 lb. ft. (30.0 N·m)
55- Roller Bearing
56- Oil Seal
57- Oil Seal
58- Screw
Lubrication/Sealant Application
59- Trim Tab
60- Screw
Points
61- Washer
62- Thrust Hub D Loctite Grade A (P/N 92-32609-1)
63- Propeller Nut
E 2-4-C Marine Lubricant (P/N 92-90018A12)
64- Tab Washer
F Needle Bearing Assembly Lubricant
(P/N 92-42649A-1)
G Special Lubricant 101 (P/N 92- 13872A1)

6A-2 - LOWER UNIT 90-817643R1 DECEMBER 1996

Special Tools New Tools Required for 50-60
Part No. Description Gear Housing
91-14311A2 Bearing Preload Tool
91-817057A1 Backlash Indicator Tool
91-19660--1 Backlash Indicator Update Kit
91-24273 Mandrel
91-27780 Puller b a
91-37241 Universal Puller Plate
91-37312* Driver Head c c
91-37323* Driver Rod
91-43506 Bearing Retaining Tool
91-46068A1 Puller Jaws
91-58222A1 Dial Indicator
91-83155 Dial Indicator Adaptor Kit
91-87516 Puller Bolt
d
91-817005 Forward Gear Bearing Installer
91-817006 Water Pump Base Seal Installer
e
l
91-817007 Bearing Carrier Seal Installer
91-817008 Pinion Gear Location Tool
91-817009 Forward Gear Bearing Race
Driver Cup
91-817011 Needle Bearing Installer f
91-817058A1 Lower Driveshaft Bearing Driver
Assembly
91-817070 Driveshaft Holding Tool
*Tools included in Bearing Removal and Installation Kit (91-31229A5) g

h
Quicksilver Lubricants and
Service Aids i

Part No. Description

92-34227--1 Perfect Seal
92-42649A1 Needle Bearing Assembly Lubricant
92-13872A1 Special Lubricant 101 k
92-19007A12 Gear Lubricant J
92-32609 Loctite A (271) 51270
92-90018A12 2-4-C Marine Lubricant
Ref. Description Qty.
a Bushing - 3/4 in. (19mm) I.D. 1
b Bushing - 7/8 in. (22mm) I.D. 1
c Set Screw 2
d Nut 1
e Bolt 1
f Spring 1
g Washer 1
h Bearing 1
i Adaptor 1
j Plate 1
k Nut 1
l Stud 1
91-14311A-2 Bearing Preload Tool
NOTE: Bearing Preload Tool 91-14311A-1 may be up-
dated to a 91-14311A-2 tool, by ordering Update Kit
91-817057A-1.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-3

 19660-1
51043
91-19660--1 Backlash Indicator Tool 51043
91-817009 Driver Cup (Forward Gear Bearing Race)

51043
91-817005 Bearing Installer (Forward Gear Needle
Bearing)
51043
91-817011 Needle Bearing Installer (Bearing Carrier)

51043

51043
91-817006 Seal Installer (Water Pump Base) a
b

51270
51043
91-817007 Seal Installer (Bearing Carrier) Ref. Description Qty.
a Plate 1
b Nut 1
c Stud 1
d Sleeve 1

91-817057A-1 Update Kit (Converts 91-14311A-1 Bear-

ing Preload Kit Tool to a 91-14311A-2)

51043
91-817008A2 Pinion Gear Locating Tool

6A-4 - LOWER UNIT 90-817643R1 DECEMBER 1996

 Draining and Inspecting Gear
Lubricant
! WARNING
If gear housing is installed on outboard, disconnect
(and isolate) spark plug leads from spark plugs before
working near the propeller.
1. With gear housing in normal running position, place a
clean pan under housing and remove two vent plugs
and one fill/drain plug (with gaskets).

50558
a - Vent Plug
b - Fill/Drain Plug

2. Inspect gear lubricant for metal particles (lubricant will

have a “metal flake” appearance). Presence of fine
metal particles (resembling powder) on the drain plug
magnet indicates normal wear. Metal chips on the
51043
magnet indicate the need for gear housing disassem-
91-817058A-1 Bearing Driver Assy. (Lower Drive Shaft bly and component inspection.
Bearing) 3. Note color of gear lubricant. White or cream color indi-
cates presence of water. Gear lubricant drained from
a gearcase recently in operation will have a yellowish
color due to lubricant agitation/aeration. This is normal
and should not be confused with the presence of water.
4. Presence of water indicates the need for disassembly
and inspection of oil seals, o-rings, gaskets and com-
51043 ponents for damage.
91-817070 Drive Shaft Holding Tool

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-5

Propeller Removal Gear Housing Removal
! WARNING ! WARNING
If gear housing is not removed from outboard, before To prevent accidental engine starting, remove (and
attempting to remove or install the propeller, remove isolate) spark plug leads from spark plugs before re-
(and isolate) spark plug leads from spark plugs to pre- moving gear housing.
vent outboard from starting.
1. Remove (and isolate) spark plug leads from spark
1. Bend tabs of tab washer (a) away from nut (b). plugs.
2. Shift into forward gear.
3. Tilt engine to full “Up ” position.
4. Remove four bolts and washers (a), two from each
side.
5. Remove trim tab (b).
6. Remove locknut and washer (c) in trim tab recess.
a
7. Remove gear housing.

b
c

51119
2. Use a block of wood (a) to prevent propeller from rotat-
ing. Remove nut and pull components from shaft. b a

50555

50552

6A-6 - LOWER UNIT 90-817643R1 DECEMBER 1996

Gear Housing Disassembly
a
Water Pump
1. If water tube seal (a) stayed on water tube (inside of dri-
veshaft housing) when gear housing was removed,
then pull seal from water tube. Replace water tube seal
c
(a) if damaged.
b
2. Remove 6 bolts (b), washers (c) and isolators (d) (De-
sign 1). Remove cover (e).
NOTE: Isolators (d) from forward 2 screws are different
from the other isolators. Retain these for proper re-assem-
bly (Design 1).
51207
IMPORTANT: The circular groove formed by the impel-
ler sealing bead should be disregarded when inspect- 5. Remove plate (a) and gasket (b).
ing cover and plate as the depth of the groove will not 6. Replace plate if groove(s) (other than impeller sealing
affect water pump output. groove) in plate are more than .030 in. (.762mm) deep.
3. Replace cover if thickness of steel at the discharge
slots is .060 in. (1.524mm) or less, or if groove(s) (other a
than impeller sealing groove) in cover roof are more
than .030 in. (.762mm) deep.

a b

e
c
b
51206
b b
7. Remove water pump base (a) by lifting gently as
shown.

c c
d c d
51206

4. Lift impeller (a), drive key (b), and gasket (c). Replace
a
impeller if:
– Impeller blades are cracked, torn, or worn.
– Impeller is glazed or melted (caused by insufficient
water supply).
– Rubber portion of impeller is not bonded to impeller 51206
hub.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-7

8. Remove (and discard) seals (a), if damaged. Bearing Carrier and Propeller Shaft
1. Drain lubricant; refer to “Draining and Inspecting Gear
a Lubricant”.
2. Remove bolts (a).

51205
9. Remove seal and plate if damaged or worn.

a a

b
51117
3. With propeller shaft horizontal, pull carrier to break
seal with gear housing. Remove bearing carrier/pro-
peller shaft components. Do not leave cam follower in
end of propeller shaft. Remove propeller shaft from
51268
bearing carrier using bearing puller.
a - Seal
b - Plate

b
a
d
c

e
19180
a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Bolt (91-85716)
d - Thrust Hub
e - Propeller Shaft

6A-8 - LOWER UNIT 90-817643R1 DECEMBER 1996

4. Replace reverse gear if gear teeth or clutch teeth on re- 7. If bearing (c) is rusted or does not roll freely, replace
verse gear are chipped or worn. If reverse gear must bearing. Remove bearing and oil seals. Discard oil
be replaced, pinion and sliding clutch should also be in- seals.
spected for damage.
5. If reverse gear bearing is rusted or does not roll freely,
replace bearing. Remove bearing and reverse gear
using bearing puller (91-27780).

51264
a - Driver Rod (91-37323)
b - Driver Head (91-37312)
c - Propeller Shaft Needle Bearing
d - Oil Seals (2)

8. Remove seals (if not removed with bearing) and O-ring

51205 (a).
6. Remove ball bearing (a) from reverse gear (b) using
Universal Puller Plate (c) and mandrel (d).

d
51263

51289

a
b c
51269
a - Ball Bearing
b - Reverse Gear
c - Universal Puller Plate (91-37241)
d - Driver Head (91-37312)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-9

Propeller Shaft Disassembly e
a e
1. Remove spring (a). Push out cross pin (e). c

a b
d
51265
a - Cam Follower
51265 b - Guide Block
c - Spring
d - Sliding Clutch
e - Jaws

4. Check bearing surfaces of propeller shaft. If shaft is

d worn/pitted, replace shaft and corresponding bearing.
5. Replace propeller shaft if:
a. Splines are twisted or worn.
b
c b. Oil seal surface (b) is grooved in excess of 0.005
in. (0.12mm).
c. Shaft has a noticeable “wobble” or is bent more
than 0.006 in. (.152 mm). Check with a dial indica-
tor and V-blocks.

c b b
c
e
51268
a - Spring
b - Cam Follower
c - Apply Pressure as Shown
d - Punch
e - Cross Pin

2. Replace cam follower if worn or pitted on either end.

3. Replace sliding clutch if jaws are rounded or chipped. a
Rounded jaws indicate the following: 51139
a - “Vee” Blocks
a. Improper shift cable adjustment. b - Bearing Surfaces
c - Check with Dial Indicator Here
b. Engine idle speed too high while shifting.
c. Shifting too slowly.

6A-10 - LOWER UNIT 90-817643R1 DECEMBER 1996

Pinion Gear, Driveshaft and Forward 7. Replace forward gear tapered roller bearing (a) and
race if either bearing or race are rusted or damaged;
Gear or if bearing does not roll freely after cleaning in sol-
1. Hold driveshaft using Driveshaft Holding Tool (a) vent. Remove bearing from gear using Universal Pull-
(91-817070); remove (and discard) pinion nut (b). er Plate (b) (91-37241) and Mandrel (c). To remove
race, refer to “Forward Gear Bearing Race”, following.
2. Remove driveshaft (c), pinion gear (d), and forward
gear (f).
c
3. Replace pinion gear (d) if chipped or worn.
4. Replace bearing (e) if rusted or damaged; or does not a
roll freely. To remove, refer to “Lower Driveshaft Bear-
ing”, following.
5. Replace forward gear (f) if gear teeth are chipped or
worn.

b
51119
51043

Upper Driveshaft Bearing

c 1. Replace bearing (a) and race if either bearing or race
are rusted or damaged; or if bearing does not roll freely
after cleaning in solvent.

To
Remove
f a
b e

51263
6. Replace bearing if rusted or does not roll freely after
cleaning in solvent. Remove as shown.

19203

51271

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-11

Lower Driveshaft Bearing Shift Shaft
1. Remove lower driveshaft bearing using tool 1. Remove shift shaft coupler (a) and spacer (b).
(91-817058A1) with bushing installed.

b 51271
2. Remove shift shaft bushing (a) and shift shaft (b). Pro-
tect shift shaft to prevent spline damage.

c b
a

51205
51260
a - Bearing 3. Remove shift shaft cam (a); replace if worn.
b - Removal Tool (91-817058A1)
c - Bushing

Forward Gear Bearing Race

IMPORTANT: Retain shim(s) for re-assembly. a
1. Remove race (a) and shim(s) (b) using bearing puller
(c) (91-27780).

b
c
a
51265 51117
a - Race
b - Shim(s)
c - Bearing Puller (91-27780)

6A-12 - LOWER UNIT 90-817643R1 DECEMBER 1996

4. Remove shift shaft bushing (a) and clip (b) from shift
shaft (c). Replace shift shaft if splines are twisted or
damaged on either end of shaft. Remove (and discard) c
O-ring (d) if damaged.

a d b
c
a

51264
5. Remove (and discard) seal (a) if damaged. 51270
3. Assemble components.
d
c b
a

51264
a - Shift Shaft
b - “E” Clip
c - Bushing
51265
d - O-ring

4. Install shift cam (a) (numbers toward top of gear hous-

ing); align hole in shift cam with hole (b).
Gear Housing Reassembly
b
Shift Shaft
1. Apply Perfect Seal on O.D. of new seal (a). Install with
seal lip up as shown.
a
2. Press seal into shift shaft bushing (b) until seal bot-
toms. Use a suitable tool (c).
Apply Quicksilver Needle Bearing Assembly Lubricant on
O-ring and I.D. of seal.

51117

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-13

5. Install shift shaft assembly (a); insert splines into shift 2. Install cross pin.
cam.
c

b
a
51268
a - Cross Pin
b - Cam Follower
c - Apply Pressure in This Direction

3. Install spring.
NOTE: Spring windings must lay flat with no overlapping in
clutch groove after installation.

51268

Propeller Shaft
1. Install components.

d c a

51265
a - Spring

b
A

51265

A 2-4-C Quicksilver Marine Lubricant

a - Spring
b - Clutch (Align Hole with Slot in Propshaft; Long End of Clutch with 3
Teeth Towards Propshaft Shoulder)
c - Guide Block
d - Cam Follower (Hold in Place with Quicksilver 2-4-C Marine
Lubricant

6A-14 - LOWER UNIT 90-817643R1 DECEMBER 1996

Forward Gear Bearing Race 3. Install small diameter oil seal (a). Seal lip faces away
from shoulder on Installer Tool. Press seal in until In-
1. Place shim(s) retained from disassembly into housing. staller Tool bottoms.
If shim(s) were lost or damaged, or a new gearcase is
being assembled, start with a .010 in. (.254mm) shim.
2. Drive bearing race into housing. Use a lead hammer to
avoid damage to propshaft. b

a
A

51043

a
e c b
d
c
51043
51265
a - Shim(s)
b - Race (Apply Quicksilver Needle Bearing Assembly Lubricant 51206
on O.D.)
c - Driver Cup (91-817009) A Loctite Grade A (O.D. of Seal)
d - Propeller Shaft a - Small Diameter Seal
e - Assembled Bearing Carrier b - Installer Tool (91-817007)

4. Install large diameter seal (a) on Installer Tool. Seal lip

faces towards shoulder on Installer Tool. Press in until
Bearing Carrier Installer tool bottoms.
1. Lubricate O.D. of needle bearing (a) with Quicksilver
Needle Bearing Assembly Lubricant.
2. Install needle bearing.
Installation Note: Push against numbered end of bearing.
b

b a
a
51043

51043

51263

A Loctite Grade A (O.D. of Seal)

a - Large Diameter Seal
b - Installer Tool (91-817007)

51269
a - Needle Bearing
b - Installer (91-817011)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-15

Installation Note: If service tools are not available, the fol- Reverse Gear
lowing reference dimensions apply for installing bearing
and seals to proper depths. 1. Lubricate I.D. of bearing (a) with Quicksilver Needle
Bearing Assembly Lubricant. Use Installer Tool and
.82 in. (20mm) press onto gear until bearing bottoms.

a
a
51275
a - Bearing
.44 in. (11mm)
.04 in. (1mm)

b
a 51205
a - Bearing
b - Installer Tool (91-817007)

51275 2. Install reverse gear and bearing assembly (a). Lubri-

cate O.D. of bearing with Quicksilver Needle Bearing
a - Oil Seal (Install with Lip Down)
b - Oil Seal (Install with Lip Up) Assembly Lubricant before installation.
5. Lubricate O-ring with Special Lubricant 101. Install O-
ring (a).

a
a
c
51263

51264
a - Reverse Gear and Bearing Assembly
b - Installer Tool (91-817007)
c - Bearing Carrier

6A-16 - LOWER UNIT 90-817643R1 DECEMBER 1996

Forward Gear Lower Driveshaft Bearing Installation
Press new propshaft bearing into gear. Lubricate O.D. of 1. Lubricate O.D. of bearing race with Quicksilver Needle
bearing with Quicksilver Needle Bearing Assembly Lubri- Bearing Assembly Lubricant.
cant before installation. Press until Installer Tool bottoms.
2. Install bearing (a) into housing. Press until Installer
Installation Note: Push against numbered end of bearing. Tool bottoms.
Installation Note: Push against numbered end of bearing.

51043

7.05 in.
7.07 in. (
179.0mm
179.5mm) b

51291
a - Installer Tool (91-817005)
a
1. Press tapered roller bearing (a) onto gear. Lubricate Ref. Bear-
I.D. of bearing with Quicksilver Needle Bearing As- ing
sembly Lubricant before installation. Use Installer Tool Depth
(b). Press until bearing bottoms on gear.

b
51260
a
a - Needle Bearing (Lubricate O.D. Before Assembly)
b - Bearing Installer Tool (91-817058A1)

51272
a - Bearing (Lubricate I.D. Before Assembly)
b - Installer Tool (91-817007)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-17

Upper Driveshaft Bearing Installation Forward Gear, Pinion Gear, Upper
1. Press upper driveshaft bearing (a) onto driveshaft. Lu- Driveshaft Bearing Race, Retainer
bricate I.D. of bearing with Quicksilver Needle Bearing and Driveshaft Installation
Assembly Lubricant before pressing in place.
NOTE: If shim(s) were lost or are not reusable (damaged),
start with approximately .015 in. (0.361mm).
Install components in sequence shown.

d
c

51285

51043
a
a b
g

51263
a - Forward Gear/Bearing: Apply Quicksilver Gear Lube to Bearing
Rollers Before Installation
b - Pinion Gear
c - Upper Driveshaft Bearing Race and Shim(s)
d - Upper Driveshaft Bearing Retainer [Torque to 75 lb. ft. (101.7 N·m)]
Use Tool (91-43506)
e - Driveshaft
f - Driveshaft Holding Tool (91-817070)
g - Pinion Nut (New) (See Note at “Pinion Gear Depth”, Following.)
51268 Recess in Nut is Installed Toward Pinion Gear (See Inset).
a - Upper Driveshaft Bearing (Lubricate I.D. Before Assembly)

6A-18 - LOWER UNIT 90-817643R1 DECEMBER 1996

Pinion Gear Location and Forward 3. Measure distance (a).
Gear Backlash 4. Increase distance (a) by 1 in. (25.4mm).
5. Rotate driveshaft 10 revolutions. This properly seats
DETERMINING PINION GEAR LOCATION upper driveshaft tapered roller bearing.
NOTE: Read entire procedure before attempting any c
change in shim thickness.
IMPORTANT: Forward gear assembly must be in- a
stalled in gear housing when checking pinion gear
depth to obtain accurate shim measurements.
1. Clean the gear housing bearing carrier shoulder and
diameter.
2. Position gear housing upright (driveshaft vertical). In-
stall Bearing Preload Tool in sequence shown.
b
h
3/4 in. (19mm) I.D.

i i
19884
6. Insert Pinion Location Tool (a). Position access hole (b)
g as shown. Insert feeler gauge between gauging sur-
f face (c) and pinion gear (d).

a d
b c
e

b
51265
a - Pinion Location Tool (91-817008A2)
b - Access Hole
c - Gauging Surface
d - Pinion Gear

51270
a - Plate
b - Adaptor: Bearing surfaces clean and free of nicks
c - Thrust Bearing: Oiled and able to move freely
d - Thrust Washer: Clean and free of nicks and bends
e - Spring
f - Nut: Threaded all-the-way onto bolt
g - Bolt: Held snug against spring
h - Sleeve: Holes in sleeve must align with set screws
i - Set Screw (2): Tighten against drive shaft, bolt should not slide on
driveshaft

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-19

7. The correct clearance between the gauging surface DETERMINING FORWARD GEAR BACKLASH
(b) and the pinion gear (c) is .025 in. (0.64mm).
NOTE: Read entire procedure before attempting any
8. To obtain .025 in. (0.64mm), add or subtract shims be- change in shim thickness.
low the upper bearing race (b) to lower or raise the pin-
1. Obtain correct pinion gear location; refer to “Determin-
ion gear.
ing Pinion Gear Location”, preceding.
9. After final adjustment to pinion height, and forward
2. Install Bearing Preload Tool on driveshaft; refer to “De-
gear backlash has been established, apply Loctite
termining Pinion Gear Location”, preceding.
271 to threads and torque new pinion nut to 50 lb. ft. (67
N·m). 3. Install components.
d 4. Torque to 45 lb. in. (5 N·m)

51285

b c d b
a

c
51119
c a - Propeller Shaft*
b - Bearing Carrier* (Assembled)
c - Puller Jaws (91-46086A1)
d - Puller Bolt (91-58716) Torque to 45 lb. in. (5.1 N·m).
*Refer to “Bearing Carrier and Propeller Shaft Installation”, following.

51263 5. Rotate driveshaft 10 revolutions to properly seat for-

a - Bearing Race ward gear tapered roller bearing.
b - Shim(s)
c - Pinion Nut [Recessed Side (d) Toward Pinion] 6. Re-torque puller bolt to 45 lb. in. (5.1 N·m).
d - Recessed Side Toward Pinion

6A-20 - LOWER UNIT 90-817643R1 DECEMBER 1996

7. Install components. Bearing Carrier and Propeller Shaft
e d f Installation
1. Insert propeller shaft assembly into bearing carrier.
2. Lubricate O-ring (a) and areas (b) with Quicksilver
Special Lubricant 101 (P/N 92-13872A1).
3. Install bearing carrier and propeller shaft assembly
into gear housing. Use care not to displace cam follow-
er (c).
a b

c
b

c b a c 51271
51275
! CAUTION
a - Threaded Rod
b - Washers Use care not to damage O-ring (a) during installation
c - Nuts of bearing carrier assembly.
d - Dial Indicator Adaptor Kit (91-83155)
e - Dial Indicator (91-58222A1) 4. Install bolts (a). Apply Loctite 271 to threads and torque
f - Backlash Indicator Tool (91-19660--1) to 150 lb. in. (17 N·m).
8. Position Dial Indicator on line “3” on Backlash Indicator
Tool.
9. Turn driveshaft back-and-forth (check for no rotation at a
the propeller shaft).
10. Dial Indicator registers amount of backlash, which
must be between .013 in. (.33mm) and .019 in.
(.48mm).
11. If backlash is less than the minimum reading, remove
shim(s)* from in front of the forward gear bearing race.
12. If backlash is more than the maximum reading, add
shim(s) in front of the forward gear bearing race.
* By adding or subtracting .001 in. (0.025mm) shim, the backlash will
change .00125 in. (0.032mm).

NOTE: When final measurement has been made, apply

Loctite 271 to threads of pinion nut. Torque to 50 lb. ft. (67.8
N·m).

51117

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-21

Water Pump Re-assembly and 0.04 in. (1.02 mm)
a
Installation
1. Place seal (a) on longer shoulder side (b) of tool.
2. Press into water pump base until tool bottoms. b

Seal
Bottom

51285

a - Seal (Install with spring visible when installed.)

b - Seal (Install with spring visible when installed.)
A If installation tool is not available, press seals in as shown
51043 to depths indicated.
5. Install O-ring (a). Lubricate O-ring and gear housing
b bore with Quicksilver Special Lubricant 101.

a 6. Install water pump base (b) into gearcase (c).

a
51270
A Quicksilver Gear Lubricant
a - Seal (Install with spring visible when installed.)
b - Seal Installation Tool (91-817006)

3. Place seal (a) on shorter side (b) of tool (c).

4. Press into water pump base until tool bottoms.

c
c
51263

51043
b
a

51263
A Quicksilver Gear Lubricant

6A-22 - LOWER UNIT 90-817643R1 DECEMBER 1996

7. If removed previously, re-install seal (a) and plate (b). 10. Lubricate I.D. of cover with Quicksilver Needle Bearing
Assembly Lubricant (P/N 92-42649A1). Install gasket
(a) with bead (b) towards cover.

b
a

51290
11. Rotate driveshaft clockwise and push cover down. Se-
a cure cover.

a
d
c d
d d
51268
c
8. Install gasket (a) and face plate (b).
b
b
c c
b b
51275
a
a - Cover
b - Isolators, (Design 1) Note: 2 isolators for forward screws are
different from remaining 4 isolators
c - Washers (6)
d - Bolts (6); Apply Loctite on threads and torque to 60 lb. in.
(6.8 N·m).

NOTE: Torque cover screws as shown.

51293
IMPORTANT: If the old impeller is re-used, install in the
original (clockwise) direction of rotation.
1 3
9. Install drive key (a) and impeller (b).

b
6

4 2

a
51271

51292

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-23

12. If water tube seal (a) stayed on water tube (inside of 3. Rotate driveshaft, prop shaft and move shift rod while
driveshaft) pull seal from water tube. housing is pressurized to check for leaks.
13. Lubricate I.D. of water tube seal (a) with Quicksilver
2-4-C Marine Lubricant (P/N 92-90018A12) and in-
stall.

51206
a - Water Tube Seal
4. If pressure drop is noted immerse housing in water.
5. Re-pressurize to 10-12 p.s.i. and check for air bubbles.
Gear Housing Pressure Test 6. Replace leaking seals as necessary. Retest housing.
1. Remove vent plug and install pressure test gauge. NOTE: It should hold 10-12 p.s.i. for 5 minutes.
Tighten securely.
7. Remove tester from housing and install vent plug.

Gear Housing Installation

Filling Gear Housing with Lubricant
NOTE: Gear housing lubricant capacity is approximately
11.5 fl. oz. (340 ml).

! WARNING
If gear housing is installed on outboard, disconnect
(and isolate) spark plug leads from spark plugs before
working near the propeller.

! CAUTION
Do not use automotive grease in the gear housing. Use
only Quicksilver Gear Lube.
1. Remove any gasket material from “Fill” and “Vent”
2. Pressurize housing to 10-12 p.s.i. and observe gauge plugs and gear housing. Install new gaskets on “Fill”
for 5 minutes. and “Vent” plugs.
IMPORTANT: Never add lubricant without removing
“Vent” plugs. Gear housing cannot be filled because
of trapped air. Fill gear housing when driveshaft is in
a vertical position.
2. Remove “Fill” plug and gasket (a).

6A-24 - LOWER UNIT 90-817643R1 DECEMBER 1996

3. Insert lubricant tube in “Fill” hole, then remove “Vent” Gear Housing Installation
plugs and gaskets (b and c).
4. Fill until excess lubricant flows out of “Vent” hole (b). ! WARNING
5. Replace this “Vent” plug and gasket and continue to fill Disconnect (and isolate) spark plug leads before in-
until lubricant flows from second “Vent” hole (c). stalling gear housing onto driveshaft housing.
6. Replace this “Vent” plug and gasket (c). 1. Position shift block (a) in forward gear position.
7. Install “Fill” plug and gasket (a).

b a
c

51190
a - Shift Block

2. Tilt engine to full “Up” position. Engage tilt lock lever.

3. Shift gear housing into neutral. Propeller shaft will ro-
tate freely in either direction.
4. Install water tube seal (a), spacer (b) and shift shaft
coupler (c).
a
50558 A
a - “Fill” Plug
b - “Vent” Plug
c - “Vent” Plug a
Torque screws to 35-80 lb. in. (3.8-8.8 N·m)

51206
2-4-C Marine Lubricant (I.D. of seal,
A coupler splines)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-25

 11. Check shift operation.
! CAUTION
a. Gear housing should not engage when propeller
Do not lubricate top of driveshaft. Excess lubricant will shaft is turned clockwise when in forward gear.
not allow driveshaft to fully engage crankshaft. Tight-
ening the gear housing fasteners (if excess lubricant b. Propeller shaft will rotate freely in either direction
is on top of driveshaft) will load the driveshaft/crank- when gearcase is in neutral.
shaft and may damage either or both powerhead and c. Propeller shaft will not rotate in either direction
gear housing. Wipe the top of driveshaft free of lubri- when gearcase is in reverse.
cant.
IMPORTANT: If shift operation is not as described, re-
5. Lightly apply Quicksilver 2-4-C Marine Lubricant onto move the gear housing and correct the shift operation.
the driveshaft splines.
6. Shift gear housing into forward gear. Gear housing will
not engage when propeller shaft is turned clockwise. Propeller Installation
7. Position driveshaft into driveshaft housing. Move gear
housing towards driveshaft housing while aligning shift ! WARNING
shaft coupler, water tube seal and driveshaft splines.
Disconnect and isolate spark plug leads when working
NOTE: If the driveshaft splines will not align with the crank- near the propeller to prevent the outboard from start-
shaft splines, install a propeller and turn the propeller shaft ing.
counterclockwise while pushing gear housing onto drive-
shaft housing. It may also be necessary to move the shift 1. Apply a thin coat of lubricant to propeller shaft
block (on the powerhead) to align the shift shaft splines for splines with Quicksilver 2-4-C Marine Lubricant.
proper re-assembly. 2. Install components as shown.
8. Install 4 bolts and washers (a), (two each side). Apply
Flo-Torq I Drive Hub Propellers
Loctite A (271) on threads of bolts prior to installation.
9. Install locknut and washer (b). c b
10. Torque bolts and locknut to 40 lb. ft. (54 N·m).

a - Forward Thrust Hub

b - Propeller Nut Retainer
c - Propeller Nut
Flo-Torq II Drive Hub Propellers
c
a a e d

b a

a - Forward Thrust Hub

b - Replaceable Drive Sleeve
c - Rear Thrust Hub
d - Propeller Nut Retainer
50551 e - Propeller Nut

6A-26 - LOWER UNIT 90-817643R1 DECEMBER 1996

3. Tighten propeller nut to 55 lb.ft. (75 N·m). Bend 2. The trim tab will offset (balance) some of the “steering
tabs against nut. load” that is caused by “propeller torque” at higher
speeds. If at higher speeds the boat turns more easily
a to the left, loosen bolt, move the trim tab (trailing edge)
to the left (when viewed from behind); re-tighten bolt.
Turn trim tab (trailing edge) to the right if the boat turns
b
b more easily to the right.

a - Propeller Nut - Torque To 55 lb. ft. (75 N·n)

b - Bend Tabs Against Nut

a
! CAUTION
c
Do not misinterpret propeller shaft movement for pro-
peller movement, propeller and propeller shaft howev-
er may move fore-and-aft. However, the propeller itself
should not move fore-and-aft on the propeller shaft.
4. Re-check propeller nut for tightness after first use.
Check for tightness periodically, especially if a stain-
less propeller is used. b
5. Install and adjust trim tab as follows.

Trim Tab Adjustment and

Replacement
IMPORTANT: The trim tab is made of a special alloy to 50553
aid in protecting the drive shaft housing and gear
a - Trim Tab
housing from galvanic corrosion (corrosion and pit- b - Anti-Ventilation Plate
ting of metal surfaces). Do not paint or place protective c - Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft. (29.8 N·m)
coating on the trim tab, or trim tab corrosion protec-
tion function will be lost.
1. Replace trim tab if 50% (or more) consumed. Mark lo-
cation of old trim tab on anti-ventilation plate before re-
moval; install new trim tab in same location.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6A-27

LOWER UNIT

791-H

60 BIG FOOT,
60 SEAPRO/MARATHON
GEAR HOUSING
6
(4-1/4 inch Torpedo, 2.3:1 Gear Ratio)
B
Table of Contents
Page Page
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Propeller Shaft Reassembly . . . . . . . . . . . . 6B-22
Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . . 6B-2 Drive Shaft Wear Sleeve Installation . . . . 6B-22
Gear Housing (Propeller Shaft) . . . . . . . . . . . . 6B-6 Lower Drive Shaft Bearing Race
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8 Oil Sleeve Installation . . . . . . . . . . . . . . . . . 6B-24
Propeller Removal . . . . . . . . . . . . . . . . . . . . . 6B-8 Upper Drive Shaft Bearing Installation . . . 6B-24
Draining and Inspecting Gear Housing Forward Gear, Lower Drive Shaft Bearing,
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9 Pinion Gear, and Drive Shaft
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25
Bearing Carrier and Propeller Shaft . . . . . 6B-11 Pinion Gear Depth and Forward Gear
Pinion Gear, Drive Shaft, and Forward Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Determining Pinion Gear Depth . . . . . . 6B-25
Upper Drive Shaft Bearing . . . . . . . . . . . . . 6B-15 Determining Forward Gear Backlash . 6B-27
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16 Bearing Carrier and Propeller Shaft
Lower Drive Shaft Bearing Race . . . . . . . . 6B-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-28
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-17 Water Pump Reassembly and
Forward Gear Bearing Race . . . . . . . . . . . 6B-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-29
Trim Tab Adjustment and Replacement . . 6B-18 Gear Housing Pressure Test . . . . . . . . . . . 6B-31
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18 Filling Gear Housing With Lubricant . . . . . . . 6B-31
Forward Gear Bearing Race . . . . . . . . . . . 6B-18 Propeller Installation . . . . . . . . . . . . . . . . . . . . . 6B-32
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18 Gearcase Installation . . . . . . . . . . . . . . . . . . . . 6B-33
Bearing Carrier Reassembly . . . . . . . . . . . 6B-19 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . 6B-34
Forward Gear Reassembly . . . . . . . . . . . . 6B-21

6B-0 - LOWER UNIT 90-817643R1 DECEMBER 1996

Notes:

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-1

Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot)
30
31 7

28
95
21
33
7
32 95
27

29
34 20
23
95 95
22 39 40

25 7

95
26 37
24 38
7 7
95
11 36

14 35
12 19

18
87

9 3
10
7

12
1
13 8 2

17
15
16 6
4
7 Loctite 271 (92-809820) 6
92 4
87 Super Duty Gear Lubricant (92-13783A24) 6
7
92 Loctite 7649 Primer (92-809824) 5

95 2-4-C With Teflon (92-825407A12)

6B-2 - LOWER UNIT 90-817643R1 DECEMBER 1996

 Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (LONG)
1 1 GEAR HOUSING ASSEMBLY
2 1 DOWEL PIN (FRONT)
3 1 OILER TUBE
4 2 DRAIN SCREW 60 7.0
5 1 SCREW (MAGNETIC) 60 7.0
6 3 WASHER-Sealing
7 1 DOWEL PIN (REAR)
8 1 TRIM TAB
9 1 SCREW 22 30.0
10 1 WASHER
11 1 CARRIER
12 2 ANODE
13 1 NUT 60 7.0
14 1 SCREW
15 1 PINION GEAR
16 1 NUT 70 95.0
17 1 SHIFT CAM
18 1 TAPERED ROLLER BEARING

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-3

Gear Hsg. (Drive Shaft) (60 SeaPro/Marathon/Big Foot)
30
31 7

28
95
21
33
7
32 95
95
27

29
34 20
23
95
22 39 40

25 7

95 26 37
24 38
7 95
7
11 36

14 35
12 19

18
87

9 3
10
7

12
1
13 8 2

17
15
16 6
92
4
7 Loctite 271 (92-809820) 6
4
87 Super Duty Gear Lubricant (92-13783A24) 7 6
92 Loctite 7649 Primer (92-809824) 5

95 2-4-C With Teflon (92-825407A12)

6B-4 - LOWER UNIT 90-817643R1 DECEMBER 1996

 Gear Hsg. (Drive Shaft)(60 Seapro/Marathon/Big Foot)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING
1 1 GEAR HOUSING ASSEMBLY
19 1 SHIM ASSEMBLY
20 1 DRIVE SHAFT ASSEMBLY
21 1 WEAR SLEEVE ASSEMBLY
22 1 COVER ASSEMBLY
23 1 GASKET
24 1 GASKET
25 1 OIL SEAL (LOWER)
26 1 OIL SEAL (UPPER)
27 1 GASKET
28 1 WATER PUMP ASSEMBLY
29 1 FACE PLATE
30 4 SCREW (M6 x 1 x 30) 60 7.0
31 1 COUPLING
32 1 KEY
33 1 IMPELLER
34 6 SCREW 60 7.0
35 1 SHIFT SHAFT ASSEMBLY
36 1 E-RING
37 1 BUSHING ASSEMBLY
38 1 O-RING
39 1 OIL SEAL
40 2 SCREW (M6 x 1) 35 4.0

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-5

Gear Hsg. (Prop Shaft)(60 Seapro/Marathon/Big Foot)
95
1
46
44

42
45
43
41
63

53 87

95
94

51

65
50
66

49
48
7 47
7
61
60
62

95

87
64
56
55
54 87

52
57
95 58
95
59

7 Loctite 271 (92-809820)

87 Super Duty Gear Lubricant (92-13783A24)
94 Anti-Corrosion Grease (92-78376A6)
95 2-4-C With Teflon (92-825407A12)

6B-6 - LOWER UNIT 90-817643R1 DECEMBER 1996

 Gear Hsg. (Prop Shaft)(60 Seapro/Marathon/Big Foot)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING
1 1 GEAR HOUSING ASSEMBLY
41 1 TAPERED ROLLER BEARING ASSEMBLY
42 1 FORWARD GEAR
43 1 ROLLER BEARING
44 1 CAM FOLLOWER ASSEMBLY
45 3 BALL
46 1 SPRING
47 1 CLUTCH
48 1 CROSS PIN
49 1 SPRING
50 1 PROPELLER SHAFT
51 1 REVERSE GEAR
52 1 BEARING CARRIER ASSEMBLY
53 1◗ O-RING
54 1 ROLLER BEARING
55 1◗ OIL SEAL (INNER)
56 1◗ OIL SEAL (OUTER)
57 1 ROLLER BEARING
58 1 THRUST WASHER
59 1 THRUST BEARING
60 2 STUD
61 2 WASHER
62 2 NUT 260 21.5 29.5
63 1 SHIM ASSEMBLY
64 1 THRUST HUB ASSEMBLY
65 1 PROPELLER NUT ASSEMBLY 55 74.5
66 1 TAB WASHER

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-7

Special Tools 6. Remove gear housing.

Part No. Description

91-46086A1 Puller Jaws
91-85716 Puller Bolt
91-34569A1 Slide Hammer
91-36569 Mandrel* b a
91-15755 Mandrel*
91-37323 Driver Rod*
91-56775 Drive Shaft Holding Tool
91-37241 Universal Puller Plate
91-83165M Bearing Puller Assembly
91-31106 Mandrel
91-31108 Oil Seal Driver
91-37350 Mandrel
91-31229 Threaded Rod* 53992
11-24156 Nut*
a - Bolts (or Locknuts) and Washers
91-78473 Backlash Indicator Tool (3 Cyl)
b - Locknut and Washer
91-58222A1 Dial Indicator
91-83155 Dial Indicator Adaptor Kit Propeller Removal
91-12349A2 Pinion Gear Locating Tool
91-14308A1 Bearing Race Tool
91-14309A1 Bearing Installation Tool
WARNING
91-14310A1 Wear Sleeve Installation Tool If gear housing is not removed from drive shaft
91-14311A2 Bearing Preload Tool housing, before attempting to remove or install
91-13945 Bearing Installation Tool the propeller, remove (and isolate) spark plug
91-13949 Oil Seal Driver leads from spark plugs to prevent engine from
91-19660--1 Backlash Indicator Tool (4 Cyl) starting accidentally.
* From Bearing Removal and Installation Kit (91-31229A7) 1. Bend tabs of tab washer away from hub.
b
Removal a
WARNING
To prevent accidental engine starting, remove
(and isolate) spark plug leads from spark plugs
before removing gear housing.
1. Remove (and isolate) spark plug leads from spark
plugs.
2. Shift engine into forward gear.
3. Tilt engine to full “Up” position.
4. Remove 4 bolts (or locknuts on 1995 Models) and 51871
washers (two each side).
a - Tab Washer
5. Remove locknut and washer. b - Hub

6B-8 - LOWER UNIT 90-817643R1 DECEMBER 1996

2. Place a block of wood, as shown, to prevent pro-
peller from rotating and to protect hands during re-
moval of nut.
3. Remove nut and pull components from shaft.
c a

a
b

53922
a - Oil Level Screw
b - Fill/Drain Screw
c - Vent Screw

2. Inspect gear lubricant for metal particles (lubricant

will have a “metal flake” appearance). Presence of
fine metal particles (resembling powder) on the
drain plug bar magnet indicates normal wear. The
presence of metal chips on the drain plug bar mag-
net indicates the need for gear housing disassem-
53923
bly and component inspection.
a - Block of Wood
3. Note color of gear lubricant. White or cream color
MAY indicate presence of water in lubricant. Gear
Draining and Inspecting Gear Housing lubricant which has been drained from a gear case
Lubricant recently in operation will have a yellowish color
due to lubricant agitation/aeration. Gear lube
WARNING which is mixed with assembly lubricant (Special
Lube 101 or 2-4-C w/Teflon will also be creamy
If gear housing is installed on engine, to avoid
white in color. This is normal and should not be
accidental starting, disconnect (and isolate) spark
confused with the presence of water. If water is
plug leads from spark plugs before working near
suspected to be present in gearcase, a pressure
the propeller.
check of gearcase should be made (with no lubri-
1. With gear housing in normal running position, cant in gearcase). Gearcase should hold 10 to 12
place a clean pan under housing and remove the psi of pressure for 5 minutes without leaking down.
two vent screws and one fill/drain screw (with Pouring a portion of the gear lubricant into a glass
gaskets). jar and allowing the lubricant to settle will allow any
water in the lube to separate and settle to the bot-
tom of the jar.
4. Presence of water in gear lubricant indicates the
need for disassembly and inspection of oil seals,
seal surfaces, O-rings, water pump gaskets as
well as gear housing components for damage. If
gearcase is rebuilt, gearcase should be pressure
checked before filling with lubricant.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-9

Water Pump 7. Inspect impeller. Replace impeller if any of the
following conditions exist:
1. If water tube seal stayed on water tube (inside of
drive shaft housing) when gear housing was – Impeller blade(s) are cracked, torn, or worn.
removed, pull water tube seal from water tube. – Impeller is glazed or melted (caused by opera-
2. Replace water tube seal, if damaged. tion without sufficient water supply).

3. Remove 4 bolts, washers, and isolators. – Rubber portion of impeller is not bonded to
impeller hub.
4. Remove cover.
8. Remove plate and gasket.
9. Replace plate if groove(s) (other than impeller
a sealing bead groove) in plate are more than
0.030
(0.762mm) deep.
c
c
b a

b
19212
a - Water Tube Seal c - Cover
b - Bolts (4 each)

IMPORTANT: The circular groove formed by the

impeller sealing bead should be disregarded 19219
when inspecting cover (Step 5) and plate (Step 9),
a - Plate
as the depth of the groove will not affect water
b - Gasket
pump output.
c - Impeller Sealing Groove
5. Replace cover if thickness of steel at the discharge
10. Remove bolts and washers.
slots is 0.060
or less, or if groove(s) (other than
impeller sealing bead groove) in cover roof are
more than 0.030
(0.762mm) deep. a
6. Lift impeller, drive key, and gasket from drive shaft.

c b

19217
19220
a - Bolts and Washers (6 each)
a - Impeller
b - Drive Key
c - Gasket

6B-10 - LOWER UNIT 90-817643R1 DECEMBER 1996

11. Remove water pump base. Bearing Carrier and Propeller Shaft
1. Drain lubricant from gear housing; refer to “Drain-
a ing and Inspecting Gear Housing Lubricant.”
2. Remove bolts and washers or self locking nuts if
applicable.

19226
a - Water Pump Base

12. Remove (and discard) seals.

a
a
51117
a - Bolt and Washers or Locknuts

3. With propeller shaft horizontal, pull carrier to break

seal with gear housing. Remove bearing carrier/
propeller shaft components as an assembly, tak-
ing care not to lose cam follower or 3 metal balls
in end of propeller shaft.
4. Remove propeller shaft from bearing carrier.

19195
a - Seals

13. Remove gasket.

b
e

a c a

d 51116
a - Bearing Carrier
b - Puller Jaws (91-46086A1)
19218
c - Puller Bolt (91-85716)
a - Gasket d - Thrust Hub
e - Propeller Shaft

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-11

5. Lift reverse gear, thrust bearing and thrust washer 9. If bearing is rusted or does not roll freely, replace
from bearing carrier. bearing. Remove bearing and oil seals using
Mandrel* (91-36569) and Driver Rod* (91-37323).
6. Replace reverse gear if gear teeth or clutch teeth
Discard oil seals.
on reverse gear are chipped or worn. If reverse
gear must be replaced, pinion gear and sliding * From Bearing Removal and Installation Kit (91-31229A5).
clutch should be inspected for damage.
7. Replace thrust bearing and thrust washer if rusted
or damaged.

a c

b
a
c

b 51264
a - Bearing
19202 b - Mandrel (91-26569)
a - Reverse Gear c - Driver Rod (91-37323)
b - Thrust Bearing 10. Remove (if not removed with bearing in Step 9)
c - Thrust Washer propeller shaft seals and bearing carrier O-ring.
8. If bearing is rusted or does not roll freely, replace
bearing. Remove bearing using Slide Hammer
(91-34569A1).
a
a

51263
a - O-ring

19205
a - Bearing

6B-12 - LOWER UNIT 90-817643R1 DECEMBER 1996

11. Remove spring. 14. Replace cam follower if worn or pitted.
15. Replace sliding clutch if jaws are rounded or
chipped. Rounded jaws indicate one or more of
the following:
a. Improper shift cable adjustment.

a b. Engine idle speed too high while shifting.

c. Shifting from neutral to reverse (or forward) too
slowly.
a b c d e

f f 51265
51876
a - Spring a - Cam Follower
b - 3 Metal Balls
12. Apply constant pressure to cam follower to pre- c - Guide Block
vent cam follower assembly from ejecting from d - Spring
propeller shaft while pushing cross pin out of e - Sliding Clutch
clutch dog. f - Jaws

16. Check bearing surfaces of propeller shaft for pit-

ting or wear. If shaft is worn or pitted, replace shaft
and corresponding bearing.
17. Replace propeller shaft if any of the following
exist:
a. Splines are twisted or worn.
b b. Oil seal surface is grooved.
c. Shaft has a noticeable “wobble” or is bent more
than 0.009 in. (0.228mm). Prop shaft trueness
should be measured with a dial indicator with
prop shaft on V-blocks.
c b b

51800
a
a - Cross Pin
b - Cam Follower
a
13. Remove components from propeller shaft.
51877
a - V-Blocks
b - Bearing Surfaces
c - Measure with Dial Indicator at This Point.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-13

Pinion Gear, Drive Shaft, and Forward 6. Replace bearing if it is rusted or does not roll free-
ly; use a punch and hammer to remove bearing.
Gear
1. Hold drive shaft using Drive Shaft Holding Tool
(91-56775); remove (and discard) pinion nut.
2. Remove drive shaft, pinion gear, bearing and for-
ward gear .
3. Replace pinion gear if it is chipped or worn.
4. Replace bearing and race if either are rusted or
damaged; or if bearing does not roll freely. To re-
move race, refer to “Lower Drive Shaft Bearing
Race,” following.
5. Replace forward gear if gear teeth or clutch teeth
are chipped or worn.

a a 19203
c a - Bearing

7. Replace forward gear bearing and race if either

are rusted or damaged; or if bearing does not roll
freely. Remove bearing from gear
using Universal Puller Plate (91-37241) and man-
drel. To remove race, refer to “Forward Gear Bear-
ing Race,” following.

a c

d
b
b
51119
f a - Forward Gear Bearing
19175 b - Universal Puller Plate (91-37241)
c - Mandrel
a - Drive Shaft Holding Tool (91-817070)
b - Pinion Nut
c - Drive Shaft
d - Pinion Gear
e - Bearing
f - Forward Gear

6B-14 - LOWER UNIT 90-817643R1 DECEMBER 1996

8. Replace drive shaft if splines are worn or twisted. Upper Drive Shaft Bearing
9. If bearing surface is damaged, replace drive shaft 1. Replace upper drive shaft bearing and sleeve if ei-
and corresponding bearing. ther are rust stained, or if bearing will not roll freely.
IMPORTANT: Do not tighten vise against drive Remove bearing and then sleeve using Puller As-
shaft. sembly (91-83165M) with suitable jaws.
10. If wear sleeve is deeply grooved allowing water to
c
enter gear case, remove (and discard) sleeve us- OR
ing Universal Puller Plate (91-37241) and mallet.

d c

b b
19177
a
a - Upper Drive Shaft Bearing
19710 b - Sleeve
a - Splines c - Puller Assembly (91-83165M)
b - Bearing Surface
c - Wear Sleeve
d - Universal Puller Plate (91-37241)
e - Mallet
11. Remove (and discard) rubber ring.
a

19152
a - Rubber Ring

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-15

IMPORTANT: Upper drive shaft bearing/sleeve IMPORTANT: Upper drive shaft bearing/sleeve
must be removed prior to oil sleeve removal. Refer and oil sleeve do not have to be removed for lower
to “Upper Drive Shaft Bearing,” preceding. drive shaft bearing race removal.
Oil Sleeve Lower Drive Shaft Bearing Race
1. Remove oil sleeve (if necessary) using Puller As- IMPORTANT: Retain shim(s) for reassembly.
sembly (91-83165M) with suitable jaws.
1. Remove race and shim(s) using bearing race tool
b (91-14308A1).

a
19222
19171
a - Oil Sleeve
b - Puller Assembly (91-83165M) a - Race
b - Shim(s)
c - Bearing Race Tool (91-14308A1)

6B-16 - LOWER UNIT 90-817643R1 DECEMBER 1996

Shift Shaft 4. Remove shift cam from housing.

1. Remove shift shaft coupler and nylon 5. Replace shift cam if worn.
spacer.
a
b

a
53925
a - Shift Shaft Coupler
b - Spacer 51117

2. Remove bolts. a - Shift Cam

Note: If shift shaft splines are rough, shift shaft seal

a lips wil be cut during removal/installation.
6. Remove shift shaft bushing and clip from shift
shaft.
7. Replace shift shaft if splines are worn or shaft is
twisted.
8. Remove (and discard) O-ring.
a
53926
d c e d
a - Bolts b
Note: Gearcase should be in FORWARD for easiest
removal of shift shaft.
3. Remove shift shaft bushing and shift shaft.
53928
b
a a - Bushing d - Splines
b - Clip e - O-ring
c - Shift Shaft
9. Remove (and discard) seal.

53927 a
a - Bushing
53929
b - Shift Shaft
a - Seal

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-17

Forward Gear Bearing Race Reassembly
IMPORTANT: Retain shim(s) for reassembly. If
shims are damaged, replace with new shims of
Forward Gear Bearing Race
equal thickness. 1. Place shim(s) (retained from disassembly) into
1. Remove race and shim(s) using Slide housing. If shim(s) were lost, or a new gear hous-
Hammer (91-34569A1). ing is being assembled, start with 0.010

(0.254mm) shim(s).
2. Assemble components as shown; drive race into
a housing by striking propeller shaft end with lead
hammer.
e d
c

b
c 27653 a
a - Race c - Slide Hammer
b - Shim(s) (91-34569A1)

Trim Tab Adjustment and

Replacement
IMPORTANT: The trim tab is now painted and does
NOT aid in protecting the drive shaft housing and
gear housing from galvanic corrosion (corrosion b
19179
and pitting of metal surfaces). Side anodes now
provide protection. Do not paint or place protec- a - Shim(s) d - Disassembled Propeller
tive coating on the side anodes, or corrosion b - Race, Apply 2-4-Cw/Tefl- Shaft
protection function will be lost. on Lubricant on O.D. e - Assembled Bearing
c - Mandrel (91-31106) Carrier
1. Replace trim tab if damaged. Mark location of old
trim tab on anti-ventilation plate before removal; Shift Shaft
install new trim tab in same location.
1. Apply Loctite 271 on O.D. of new seal.
2. The trim tab provides a means to offset (balance)
some of the steering load that is caused by propel- 2. Press seal into shift shaft bushing until seal is
ler torque at higher operating speeds. If at higher seated against shoulder.
speeds the boat turns more easily to the left, loos- 3. Install new O-ring.
en bolt, move the trim tab (trailing edge) to the left
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
(when viewed from behind); retighten bolt. Turn
trim tab (trailing edge) to the right if the boat turns c a
more easily to the right.
c

b
d 53930
a - Seal
b a 53931 b - Bushing
c - Surface
a - Trim Tab
d - O-ring
b - Anti-Ventilation Plate
c - Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft.
(29.8 N
m)

6B-18 - LOWER UNIT 90-817643R1 DECEMBER 1996

5. Assemble components as shown. 8. Apply Loctite 271 on bottom half of threads of
bolts; install bolts and torque to 60 lb. in. (6.5 N·m).
a b
a

c 53928
a - Shift Shaft c - Shift Shaft Bushing
b - “E” Clip

6. Install shift cam (numbers toward top of gear hous-

ing); align hole in shift cam with hole. 53926
a - Bolts [Torque to 60 lb. in. (6.5 N·m)]

b Bearing Carrier Reassembly

1. Lubricate O.D. of bearingand bearing carrier bore
with Quicksilver 2-4-C w/Teflon.
2. Protect lip on forward side of bearing carrier, using
bearing installation tool (91-13945).
3. Press propeller shaft needle bearing (number side
toward mandrel) into carrier, until bearing bottoms
out.
a

51117
a - Shift Cam (Numbers UP)
b - Hole
c
7. Install shift shaft assembly; insert splines into shift
cam.

a
b

53932
21042
a - Shift Shaft Assembly a - Bearing Installation Tool (91-13945)
b - Splines b - Mandrel (91-37263)
c - Suitable Driver Rod

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-19

4. Place smaller diameter seal on longer shoulder of 8. Install O-ring.
Oil Seal Driver (91-31108) with seal lip away from
9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate
shoulder.
seal lips with 2-4-C w/Teflon (92-825407A12). Lu-
5. Protect lip on front side of bearing carrier using bricate outside diameter of bearing and bearing
Bearing Installation Tool (91-13945). Apply Loctite carrier bore with a light coating of 2-4-C w/Teflon.
271 on O.D. of seal. Press seal into carrier until 10. Press bearing into carrier until tool bottoms.
tool bottoms.

b
b a

21040

a - Seal
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945) 19163

6. Place larger diameter seal on shorter shoulder of a - O-ring

b - Bearing, Numbered Side Toward Tool
Oil Seal Driver (91-31108) with seal lip
c - Bearing Installation Tool (91-13945)
toward shoulder.
11. Install thrust washer. Coat thrust washer with
7. Protect lip on front side of bearing carrier using
Quicksilver Gear Lubricant (92-13783A24).
Bearing Installation Tool (91-13945). Apply Loctite
271 on O.D. of new seal. Press seal into carrier
until tool bottoms. a

b a

a
c

19167
21041
a - Thrust Washer
a - Seal
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945)

6B-20 - LOWER UNIT 90-817643R1 DECEMBER 1996

12. Install thrust bearing . Coat thrust bearing with Forward Gear Reassembly
Quicksilver Gear Lubricant (92-13783A24).
1. Press bearing onto gear (press only on inner race
a of bearing).

51869
a - Mandrel (91-37350)
b - Bearing; Lubricate I.D. with Quicksilver 2-4-C w/Teflon
19168 2. Apply 2-4-Cw/Teflon to bore in center of gear and
a - Thrust Bearing to O.D. of bearing.
13. Apply gear lubricant to bearing surface of reverse 3. Press bearing into gear until bearing bottoms out.
gear and install reverse gear. NOTE: Do not apply pressing force AFTER bearing
bottoms out as bearing damage could result.

a
b

28062

19202 a - Mandrel
b - Bearing, Numbered Side Toward Mandrel
a - Reverse Gear
b - Bearing Surface

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-21

Propeller Shaft Reassembly
Drive Shaft Wear Sleeve Installation
1. Install components into propeller shaft in
sequence shown. 1. Install new rubber ring.
d c b a 2. Apply a light coat of Loctite 271 on outside
diameter of rubber ring.
a
19154
a - Spring c - 3 Metal Balls*
b - Guide Block d - Cam Follower* 19152

*Hold in Place With Quicksilver 2-4-C w/Teflon a - Ring

2. Install cross pin. 3. Insert sleeve into holder*.

*Component of Wear Sleeve Installation Tool (91-14310A1).

b
a a
a

51800
b
a - Apply Pressure in This Direction
b - Cross Pin
3. Install spring. DO NOT overlap springs.

19169
a - Sleeve
b - Holder
a

51876
a - Spring

6B-22 - LOWER UNIT 90-817643R1 DECEMBER 1996

4. Press sleeve onto drive shaft using Wear Sleeve Lower Drive Shaft Bearing Race
Installation Tool (91-14310A1); continue pressing
until surface contacts surface.
Installation
IMPORTANT: Lower drive shaft bearing cup can
be installed with or without upper drive shaft bear-
b
ing/sleeve and oil sleeve installed.
1. Lubricate O.D. of bearing race with Quicksilver
2-4-C w/Teflon.
2. Install shim(s) and bearing race into housing.
NOTE: Verify shim(s) are not cocked when drawing up
race.

d f
d

c e e
a
c
f
b
d

19166
a - Drive Shaft
b - Wear Sleeve Installation Tool
c - Surface a
d - Surface
5. Remove excess Loctite from assembled shaft.
b

c 53933
a - Shim(s); Retained From Disassembly. If Shim(s) Were Lost
or a New Gear Housing is Being Assembled, Start With
0.025
(0.635mm) Shim(s)
b - Bearing Race
c - Mandrel*
d - Mandrel*
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)
**From Bearing Removal and Installation Kit (91-31229A5)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-23

Oil Sleeve Installation IMPORTANT: Oil sleeve must be installed prior to
upper drive bearing installation.
1. Install oil sleeve with tab positioned as shown.
IMPORTANT: Upper drive shaft bearing/sleeve
can be installed with or without lower drive shaft
bearing cup installed.
b
3. Install bearing/sleeve into housing.

a f

e
c
e
d f
c
a b

53934
a - Oil Sleeve
b - Tab
d
Upper Drive Shaft Bearing Installation
1. Lubricate I.D. of bearing holder and O.D. of
bearing with 2-4-C w/ Teflon. 53935

2. Press bearing into sleeve. a - Bearing/Sleeve

b - Tapered End
c - Mandrel*
d - Mandrel*
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)
**From Bearing Removal and Installation Kit (91-31229A5)
d
c
a

19164
a - Bearing Sleeve
b - Tapered End
c - Bearing; Numbered Side Toward Mandrel
d - Mandrel; From Bearing Installation Tool (91-14309A1)

6B-24 - LOWER UNIT 90-817643R1 DECEMBER 1996

Forward Gear, Lower Drive Shaft 2. With gear housing positioned up right (drive shaft
vertical), install Bearing Preload Tool (91-14311A1)
Bearing, Pinion Gear, and Drive Shaft over drive shaft in sequence shown.
Installation
g
1. Install components in sequence shown.

h h
e d

e c

f b
d
a
d

a - Adaptor: Bearing surfaces clean and free of nicks

b - Thrust Bearing: Oiled and able to move freely
b c - Thrust Washer: Clean and free of nicks and bends
d - Spring
e - Nut: Threaded all-the-way onto bolt
f - Bolt: Held snug against spring
g - Sleeve: Holes in sleeve must align with set screws
c h - Set Screw (2): Tightened against drive shaft, bolt should not
f slide on drive shaft.
a 3. Measure distance between top of nut and bottom
of bolt head.
19175
4. Increase distance by 1
(25.4mm).
a - Forward Gear/Bearing: Work Quicksilver gear lube into
bearing rollers.
5. Rotate drive shaft 5 to 10 revolutions. This should
b - Lower Drive Shaft Tapered Roller Bearing: Work Quicksilver
properly seat upper drive shaft tapered roller bear-
gear lube into bearing rollers. ing.
c - Pinion Gear
d - Drive Shaft
e - Drive Shaft Holding Tool (91-817070) a
f - Pinion Nut (New): Apply Loctite 271 to threads during final c
assembly (after pinion gear depth and forward gear
backlash have been set), torque to 70 lb. ft. (95 N·m).

Pinion Gear Depth and Forward Gear

Backlash b
DETERMINING PINION GEAR DEPTH
NOTE: Read entire procedure before attempting any
change in shim thickness.

IMPORTANT: Forward gear assembly must be

installed in gear housing when checking pinion
gear depth or an inaccurate measurement will be
obtained.
19884
1. Clean the gear housing bearing carrier shoulder
a - 1“ (25.4mm)
and diameter.
b - Nut
c - Bolt Head

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-25

6. Assemble Pinion Gear Locating Tool (91-12349A2) 10. Install the number “3” locating disc against bearing
as shown; do not tighten collar retaining bolt at this carrier shoulder in gear housing.
time. 11. Position access hole as shown.
b d e

c
b

a c f a

a - Arbor
b - Gauging Block; Install With Numbers Away From Split Collar
24643
c - Bolt; Gauging Block Retaining
d - Split Collar a - Locating Disc
e - Bolt; Collar Retaining b - Access Hole
f - Snap Ring
12. Determine pinion gear depth by inserting a feeler
7. Insert tool into forward gear assembly; position gauge thru access hole in locating disc.
gauging block under pinion gear as shown.
13. The correct clearance between gauging block and
pinion gear is 0.025
(0.64mm).
a
14. If clearance is correct, leave Bearing Preload Tool
on drive shaft and proceed to “Determining For-
ward Gear Backlash,” following.
15. If clearance is incorrect, add (or subtract) shims
from above bearing race to lower (or raise) pinion
gear. When reinstalling pinion nut, apply Loctite
271 on threads of nut.
22067
c
a - Gauging Block a
8. Remove tool, taking care not to change gauging
block position, and tighten collar retaining bolt. d
9. Insert tool into forward gear assembly; position
proper numbered flat (from chart) of gauging block
– under pinion gear. b

GEAR RATIO USE

(PINION GEAR TEETH/ FLAT 24643
MODEL REVERSE GEAR TEETH) NO.
a - Feeler Gauge
60 Big Foot, 60
SeaPro/Marathon 13/30 8 b - Gauging Block
c - Pinion Gear
75-thru-90
d - Bearing Race
(3 Cylinder) 13/30 8
100/115/125
(4 Cylinder) 14/29 2

6B-26 - LOWER UNIT 90-817643R1 DECEMBER 1996

DETERMINING FORWARD GEAR BACKLASH 5. Install components as shown.
NOTE: Read entire procedure before attempting any e f
change in shim thickness.
1. Obtain correct pinion gear depth; refer to “Deter-
mining Pinion Gear Depth,” preceding.
2. Install Bearing Preload Tool (91-14311A1) on
drive shaft; refer to “Determining Pinion Gear
Depth,” preceding. d c
3. Install components as shown.

a b
d

c 53936 c 51117
b
a - Propeller Shaft*
b - Bearing Carrier* (Assembled) a - Threaded Rod (Obtain Locally)
c - Puller Jaws (91-46086A1) b - Washers
d - Puller Bolt (91-85716); Torque to 45 lbs. in. c - Nuts
(5.0 N·m) d - Dial Indicator Adaptor Kit (91-83155)
e - Dial Indicator (91-58222A1)
*Refer to “Bearing Carrier and Propeller Shaft Installation,” fol- f - Backlash Indicator Tool
lowing.
6. Position Dial Indicator on appropriate line (from
4. Rotate drive shaft 5 to 10 revolutions. This should
chart) marked on Backlash Indicator Tool.
properly seat forward gear tapered roller bearing.
ALIGN POINTER OF
MODEL DIAL INDICATOR WITH MARK
60 Big Foot, 60
SeaPro/Marathon
Backlash 4
Indicator
Tool (91-78473)
75-thru-90
(3 Cylinder)
Backlash 4
Indicator
Tool (91-78473)
100/115/125
(4 Cylinder)
Backlash 1
Indicator
Tool (91-19660)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-27

7. Lightly turn drive shaft back-and-forth (no move- 3. Lubricate o-ring and mating surfaces with 2-4-C
ment should be noticed at propeller shaft). w/Teflon (92-825407A12).
8. Dial Indicator registers amount of backlash, which 4. Install bearing carrier and propeller shaft into
must be between specification shown in chart. housing with the word “TOP” located on flange to-
ward top of housing.
DIAL
INDICATOR READING
MODEL MINIMUM MAXIMUM
60 Big Foot, 0.012 in. 0.019 in.
60 SeaPro/Marathon (0.30mm) (.48mm)
75-thru-90 0.012 in. 0.019 in.
(3 Cylinder) (0.30mm) (.48mm) b
100/115/125 0.015 in. 0.022 in. c
(4 Cylinder) (0.38mm) (0.55mm)

9. If backlash is less than the minimum specification,

remove shim(s)* from in front of forward gear bear-
ing race to obtain correct backlash. When reinstal-
ling pinion nut, apply Loctite 271 on threads of nut.
10. If backlash is more than the maximum specifica-
tion, add shim(s)* in front of forward gear bearing
race to obtain correct backlash. When reinstalling
a
pinion nut, apply Loctite 271 on threads of nut.
* By adding or subtracting 0.001
(0.025mm) shim, the back-
lash will change approximately 0.001
(.025mm).
21044

Bearing Carrier and Propeller Shaft a - Apply 2-4-C w/Teflon

b - O-ring
Installation c - TOP
1. Insert propeller shaft assembly into bearing
5. Install components as shown.
carrier.
2. Before installing bearing carrier assembly into a
gear housing, obtain locally a 6
(152.4mm) long b
by 1-1/4
– 1-1/2
(31.7 – 38.1mm) diameter
piece of PVC pipe (c). Install the PVC pipe over the
prop shaft (a) and secure the pipe against the
bearing carrier assembly (b) with the propeller nut
(d) and tab washer (e). This will allow the reverse
gear to apply pressure to the reverse gear thrust
bearing to prevent the thrust bearing from being in-
advertently dislodged as the bearing carrier
assembly is installed in the gear housing.
b c
d
a

19147
a - Washers
b - Bolts; Apply Loctite 271 on Threads and Torque to 25 lb. ft.
(34.0 N·m)
NOTE: If nuts are used in place of bolts, torque nuts
to 25 lb. ft. (34.0 N·m).
e 21043

6B-28 - LOWER UNIT 90-817643R1 DECEMBER 1996

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.
Driver (91-13949) with seal lip away from
shoulder. 5. Lubricate lip of each seal with Quicksilver 2-4-C w/
Teflon (92-825407A12).
2. Apply Loctite 271 on O.D. of seal; press seal into
LIP FACES TOWARD
water pump base until tool bottoms. GEAR CASE
TEFLON COATED LIP - GLOSS BLACK
- FLAT BROWNISH COLOR
BLACK COLOR
- LIP FACES TOWARD a
POWER HEAD
a

SPRING - FACES
TOWARD
GEAR CASE
SPRING - FACES
TOWARD
POWER HEAD
b

a
51553
a - Seal
51553 b - Oil Seal Driver (91-13949)
a - Seal
6. Install gasket.
b - Oil Seal Driver (91-13949)

19218
a - Gasket

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-29

7. Install components as shown. 9. Install gasket, drive key and impeller.

a c
b

b
a

19220

a - Gasket
19217 b - Drive Key
c - Impeller
a - Water Pump Base
b - Bolts and Washers; Apply Loctite 271 on bottom 1/2 10. Lubricate I.D. of cover with Quicksilver 2-4–C w/
ofThreads and Torque to 60 lb. in. (6.5 N·m). Teflon (92-825407A12).
8. Install gasket and plate. 11. Rotate drive shaft clockwise and push cover down
over impeller.
b 12. Install cover.
13. 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.
a
14. Lubricate I.D. of water tube seal with Quicksilver
2-4-C w/Teflon (92-825407A12) and install as
shown.

b
19219
a - Gasket a
b - Plate c
IMPORTANT: If the old impeller will be re-used,
impeller must be installed in original (clockwise) c
direction of rotation. 19212
a - Cover
b - Seal
c - Bolts (4); Apply Loctite 271 on Threads and Torque to
60 lb. in. (6.5 N·m).

NOTE: It is recommended that the gearcase be pres-

sure tested for leaks after reassembly and BEFORE
gear lube is added. Gearcase should hold 10 to 12
psi for 5 minutes.

6B-30 - LOWER UNIT 90-817643R1 DECEMBER 1996

Gear Housing Pressure Test Filling Gear Housing With
1. Remove vent plug and install pressure test gauge Lubricant
NOTE: Gear housing lubricant capacity is 22.5 fl. oz.
(665.2ml).

WARNING
If gear housing is installed on engine, to avoid
accidental starting, disconnect (and isolate) spark
plug leads from spark plugs before working near
the propeller.

CAUTION
Do not use automotive grease in the gear housing.
Use only Quicksilver Gear Lube or Quicksilver
Super-Duty Lower Unit Lubricant.
1. Remove any gasket material from “Fill” and “Vent”
screws and gear housing.
2. Pressurized housing to 10 to 12 psi and observe
gauge for 5 minutes. 2. Install new gaskets on “Fill” and “Vent” screws.
3. Rotate drive shaft,prop shaft and move shift shaft IMPORTANT: Never apply lubricant to gear hous-
while housing is pressurized to check for leaks. ing without first removing “Vent” screws or gear
housing cannot be filled because of trapped air.
Fill gear housing only when housing is in a vertical
position.
3. Remove lubricant “Fill” screw and gasket from
gear housing.
4. Insert lubricant tube into “Fill” hole, then remove
“Vent” screws and gaskets.
5. Fill gear housing with lubricant until excess starts
to flow out of one (first) “Vent” screw hole.

4. If pressure drop is noted, immerse housing in wa-

ter.
5. Re-pressurize to 10 to 12 psi and check for air
bubbles.
6. Replace leaking seals as necessary. Retest hous-
ing.
NOTE: Gearcase should hold 10 to 12 psi for 5 min-
utes.
7. Remove tester from housing and install vent plug.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-31

6. Replace this lubricant “Vent” screw and gasket 2. Install components as shown.
only and continue filling until excess starts to flow
out of second lubricant “Vent” screw hole.

b
a

a
c

51801
a - Thrust Hub; Flat Surface Toward Propeller
b b - Propeller
3. Install tab washer and locknut.
53922
4. Thread locknut onto propeller shaft until locknut is
a - Vent Screw
recessed into tab washer.
b - Fill/Drain Screw
c - Oil Level Vent Screw 5. Torque locknut to 55 lbs. ft. (75 N·m).
7. Replace second lubricant “Vent” screw and gas- 6. Bend 3 tabs of tab washer down into grooves to
ket. secure locknut. If tab washer tabs do not align with
slots, continue to tighten locknut to obtain align-
IMPORTANT: Do not lose more than one fluid
ment.
ounce (30cc) of gear lubricant while reinstalling
“FILL” screw.
8. Remove lubricant tube from “Fill” hole; install “Fill” CAUTION
screw and gasket. Do not misinterpret propeller shaft movement
with propeller movement. If propeller and
Propeller Installation propeller shaft together move forward-and-aft,
this is normal; however, propeller should not
WARNING move forward-and-aft on propeller shaft.
If gear housing is not removed from drive shaft 7. After first use, retighten propeller nut and again se-
housing, before attempting to remove or install cure with tab washer. Propeller should be checked
the propeller, remove (and isolate) spark plug periodically for tightness, particularly if a stainless
leads from spark plugs to prevent engine from steel propeller is used.
starting accidentally. c
1. Apply a liberal coat of one of the following Quicksil- b
ver products on propeller shaft splines:
– Special Lubricant 101 (P/N 92-13872A1)
– 2-4-C w/Teflon (92-825407A12)
– Anti-Corrosion Grease (92-19007A24) a
51871
a - Tab Washer
b - Locknut
c - Grooves

6B-32 - LOWER UNIT 90-817643R1 DECEMBER 1996

Gearcase Installation CAUTION
WARNING Do not use lubricant on top of drive shaft. Excess
lubricant, that is trapped in clearance space, will
Disconnect (and isolate) spark plug leads from not allow drive shaft to fully engage with
spark plugs before installing gear housing onto crankshaft. Subsequently, tightening the gear
drive shaft housing. Failure to follow this warning housing fasteners (while lubricant is on top of
could result in accidental engine starting and drive shaft) will load the drive shaft/crankshaft
possible injury. and damage either or both the power head and
1. Position shift block in forward gear position, gear housing. Top of drive shaft is to be wiped free
as shown. of lubricant.

a 6. Apply a light coat of Quicksilver 2-4-C w/Teflon

b onto drive shaft splines.
7. Apply a light coat of Quicksilver 2-4-C w/Teflon on
gear case shift shaft splines and upper shift shaft
splines. Do not use lubricant on ends of shift
shafts.
8. Install components as shown in appropriate
19879 photo.
a - Shift Block; Front of Block MUST Extend 1/8
(3.2mm) Past
Front of Rail.
b - Rail
2. Tilt engine to full up position and engage tilt lock b
lever.
3. Shift gear housing into neutral position. Propeller
shaft will rotate freely in either direction.
4. Install water tube seal; lube I.D. of seal with Quick- a
silver 2-4-C w/Teflon (92-825407A12).
5. Apply a bead of RTV Sealer as shown.
a
53968
b a - Nylon Spacer
b - Shift Shaft Coupler; Used on Models Equipped with Power
Trim

53938
a - Water Tube Seal
b - RTV Sealer

90-817643R1 DECEMBER 1996 LOWER UNIT - 6B-33

 a b

b a

53922

a - Bolts and Washers (4)

b - Locknut and Washer
16. Check shift operation as follows:
53925
a. Place shift lever in forward gear. Gear housing
a - Nylon Spacer
should ratchet when propeller shaft is turned
b - Shift Shaft Coupler; Used on Models NOT Equipped with
Power Trim clockwise and resistance should be felt when
c - Flat; MUST BE Positioned Toward Front of Gear Housing. propeller shaft is turned counterclockwise.

9. Shift gear housing into forward gear position. In b. Place shift lever in neutral. Propeller shaft
forward gear the gear housing will ratchet when should rotate freely in either direction.
propeller shaft is turned clockwise and resistance c. While rotating propeller shaft, place shift lever in
will be felt when propeller shaft is rotated counter- reverse gear. Resistance should be felt when
clockwise. propeller shaft is rotated in either direction.
10. Apply Loctite Grade 271 on threads of gear hous- IMPORTANT: If shift operation is not as described,
ing retaining bolts. preceding, the gear housing must be removed and
NOTE: If, while performing Step 11, the drive shaft the cause corrected.
splines will not align with the crankshaft splines, place Trim Tab Adjustment
a propeller onto propeller shaft and turn it counter-
clockwise as the gear housing is being pushed toward 1. Check trim tab position as follows:
drive shaft housing. a. Operate boat at the speed at which it normally
NOTE: During installation of gear housing, it may be would be operated.
necessary to move the shift block (located under cowl) b. If the boat pulls to the right (STARBOARD), the
slightly to align upper shift shaft splines with shift shaft trailing edge of trim tab must be moved to the
coupler splines. right. If the boat pulls to the left (PORT), the trailing
11. Position gear housing so that the driveshaft is pro- edge of trim tab must be moved to the left.
truding into drive shaft housing. 2. If necessary, adjust trim tab as follows:
12. Move gear housing up toward drive shaft housing, a. Shift engine control into NEUTRAL and turn igni-
while aligning upper shift shaft splines with shift tion key to “OFF” position.
shaft coupler splines, water tube with water tube
seal, and crank shaft splines with drive shaft NOTE: Loosen trim tab bolt sufficiently to allow trim tab
splines. to disengage from locking ridges in gear case before at-
tempting to move tab. DO NOT strike trim tab with a hard
13. Install 4 bolts and washers (two each side). object to make adjustments.
14. Install locknut and washer. b. If boat pulls to the left, adjust trailing edge of trim
15. Torque bolts and locknut (or nuts only if applicable) tab to the left. If boat pulls to the right, adjust trail-
to 40 lbs. ft. (54 N·m). ing edge of trim tab to the right.
3. Tighten trim tab retaining bolt and washer to 22 lb.
ft. (30.0 N·m).
6B-34 - LOWER UNIT 90-817643R1 DECEMBER 1996
LOWER UNIT

JET DRIVE
6
C
Table of Contents
Page Page
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Worn (Dull) Impeller . . . . . . . . . . . . . . . . . . . . . 6C-11
Jet Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 6C-2 Flushing The Cooling System . . . . . . . . . . . . . 6C-12
Jet Components . . . . . . . . . . . . . . . . . . . . . . . . . 6C-4 Liner Replacement . . . . . . . . . . . . . . . . . . . . . . 6C-12
Selecting A Boat Best Suited For Jet Power . 6C-5 Jet Drive Removal . . . . . . . . . . . . . . . . . . . . . . . 6C-12
Engine Horsepower Selection . . . . . . . . . . . . . . 6C-5 Bearing Carrier Removal . . . . . . . . . . . . . . . . . 6C-13
Transom Height of the Boat . . . . . . . . . . . . . . . . 6C-6 Bearing Carrier Disassembly . . . . . . . . . . . . . . 6C-14
Locate Center line Of The Outboard . . . . . . . . 6C-6 Bearing Carrier Reassembly . . . . . . . . . . . . . . 6C-14
Outboard Mounting Height . . . . . . . . . . . . . . . . . 6C-6 Installing Lower Seals . . . . . . . . . . . . . . . . . 6C-14
Water Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-7 Installing Upper Seals . . . . . . . . . . . . . . . . . 6C-15
Checking for Cavitation . . . . . . . . . . . . . . . . . 6C-7 Installing Drive Shaft Ball Bearing . . . . . . . 6C-15
Shift Cable Installation . . . . . . . . . . . . . . . . . . . . 6C-8 Installing Drive Shaft . . . . . . . . . . . . . . . . . . 6C-15
Lubricating The Drive Shaft Bearing . . . . . . . . 6C-9 Installing Upper Seal Housing . . . . . . . . . . 6C-16
Impeller Removal and Installation . . . . . . . . . . 6C-9 Installing Jet Drive to Drive Shaft Housing . . 6C-17
Steering Pull Adjustment . . . . . . . . . . . . . . . . . 6C-11 Reassembling Water Pump to Jet Drive . 6C-17
Impeller Clearance Adjustment . . . . . . . . . . . . 6C-11 Installing Jet Drive to Drive Shaft Housing 6C-18
Jet Drive Tiller Handle Adaptor KIt . . . . . . . . . 6C-20
Installation Instructions . . . . . . . . . . . . . . . . 6C-20
Shift Cable Adjustement . . . . . . . . . . . . . . . 6C-23

6C-0 - LOWER UNIT 90-817643R1 DECEMBER 1996

Notes:

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-1

JET PUMP ASSEMBLY

15 16
14
17

22
18
18 23

21
2
20
19 95

9
10
11

5
6

6
13 12

95 2-4-C With Teflon (92-825407A12)

6C-2 - LOWER UNIT 90-817643R1 DECEMBER 1996

 JET PUMP ASSEMBLY
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 JET PUMP ASSEMBLY
1 1 HOUSING-Pump
2 1 HOSE-lube
3 1 IMPELLER
4 1 HOUSING-Intake
5 1 LINER
6 1 DRIVESHAFT
7 1 SLEEVE
8 1 NUT Drive Tight
9 1 KEY
10 8 SHIM
11 1 TAB WASHER
12 6 SCREW (1/4-20 x .875) 100 11.5
13 4 SCREW (1/4-20 x .875) 70 8.0
14 2 SCREW (1/4-20 x .625) 70 8.0
15 1 SCREW (.312-18 x 1.25) 13 17.5
16 1 BRACKET
17 1 NUT 13 17.5
18 2 PIN-Dowel
19 2 SCREW (M10 x 60) 25 34.0
20 1 SCREW (M10 x 90) 25 34.0
21 1 SCREW (M10 x 70) 25 34.0
22 1 SCREW (.375-16 x .75) 22.5 30.5
23 1 WASHER

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-3

JET COMPONENTS

7
11
13
25
9
25

7 5
2
95
10
1

12 4
3 6
7

7 Loctite 271 (92-809820)

25 Liquid Neoprene (92-25711--2)
95 2-4-C With Teflon (92-825407A12)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 REV LIMITER
2 1 HARNESS–Adaptor–Rev Limiter
3 1 BRACKET
4 2 SCREW (M6 x 16) 70 8.0
5 2 SCREW (M5 x 25) 70 8.0
6 1 GREASE KIT
7 1 IMPELLER
8 1 KEY
9 1 WATER PUMP
10 1 GASKET (UPPER)
11 1 SEAL
12 1 FACE PLATE
13 4 SCREW 60 7.0

6C-4 - LOWER UNIT 90-817643R1 DECEMBER 1996

Selecting A Boat That Is Best Engine Horsepower Selection
Suited For Jet Power A boat operating at slow speed requires considerably
more depth than one which is planing on the surface
Too obtain the best performance from the jet drive, the of the water. It is important therefore to use sufficient
boat should have the following features: horsepower and not to overload your boat beyond its
1. The boat should be as light as possible. ability to plane. See the following table.
2. The boat should have hull and transom that is de-
signed for use with a jet drive.
3. The boat should be at least 13 feet in length.

Engine Horsepower Selection

The following table is based on experience obtained with sled-
type boats using outboard jets. The gross weights shown in-
cludes the outboard, boat, people, and all the gear carried. For a
given horsepower loading beyond these weights will give less
than good performance.

220

200

180

160

140

120
HP
100

80

60

40

20

0
500 6 8 1000 12 14 16 18 2000 22 24 26 28 3000 32 34 36

Gross Weight - Lbs.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-5

Transom height of the boat SETTING OUTBOARD MOUNTING HEIGHT ON
BOATS WITH “V” BOTTOM HULLS
Outboards with jet drives will be mounted approxi-
mately 7 inches higher on the transom than propeller 1. Measure the width of the leading edge on the water
driven outboards. This requires outboards that have a intake housing. Make a horizontal line (a) on the
15 in. shaft length to be installed on boats having a 22 transom up from the “V” bottom the same length as
in. transom height and outboards that have a 20 in. the width of the water intake housing (b).
shaft length to be installed on boats having a 27 in.
transom height.
If the boat transom is of insufficient height, and the out-
board cannot be installed to the recommended height,
a
contact the boat manufacturer for recommended pro-
cedure to build up the boat transom.

b
Locate Center line Of The 2. Place (center) the outboard on the boat transom so
Outboard that the transom brackets are resting on top of the
transom. Temporally fasten the outboard to the
Locate (and mark with pencil) the vertical centerline (a)
transom using two C-clamps.
of boat transom.
3. Position the outboard in a vertical position.
4. Line-up a straight edge (c) along the bottom of the
boat with the horizontal line made in Step 1 and
A B measure the distance between the horizontal line
and top front edge of the water intake housing (d).
a
C D

a - Centerline of Transom

Outboard Mounting Height

The initial outboard mounting height setting will work
good for most applications, however, because of differ- c
ent boat/hulls designs, the setting should be re- d
checked by test-running the boat. Refer to Water Test- 5. Raise The outboard up on the transom the dis-
ing. tance measured in Step 4. Use a straight edge and
• Installing the outboard too high on the transom will recheck the mounting height. The top edge of the
allow the water intake to suck in air and cause ca- water intake housing should be lined-up with the
vitation. (cavitation will cause the engine to over- horizontal line made in Step 1.
speed in spurts and reduce thrust). This condition
should be avoided by proper height setting.
• Installing the outboard too low on the transom will
allow excessive drag.

6. Fasten outboard to the transom at this height.

6C-6 - LOWER UNIT 90-817643R1 DECEMBER 1996

SETTING OUTBOARD MOUNTING HEIGHT ON When operating the boat, the outboard drive shaft
BOATS WITH FLAT BOTTOM HULLS should be vertical when planing or tilted toward the
boat in order to provide a scooping angle on the water
1. Place (center) the outboard on the boat transom so
intake. Tilting the outboard out beyond a vertical posi-
that the transom brackets are resting on top of the
tion reduces the scoop angle and can cause impeller
transom. Temporally fasten the outboard to the
slippage and cavitation. If the angle of the boat tran-
transom using two C-clamps.
som does not allow the drive shaft to be positioned ver-
2. Position the outboard in a vertical position. tical a Wedge kit should be installed behind the tran-
3. Place a straight edge (a) along the bottom of the som brackets to increase the tilt-in angle.
boat as shown and measure the distance between
NOTE: Slight cavitation in sharp turns and rough water
the bottom of the boat and top front edge of the wa-
is acceptable but excessive cavitation is harmful to the
ter intake housing (b).
outboard and should be avoided.
Test run the boat. If cavitation occurs (air enters the
pump causing loss of thrust, engine over-speeds errat-
ically). the first thing to try is lowering the outboard
height 1/4 in. This can be accomplished by elongating
the drilled mounting holes in the boat transom by 1/4
in.
If cavitation still exists after lowering the outboard 1/4
in., it maybe helpful to seek advice from the boat
a manufacturer.
b A number of other options are available to further re-
a - Straight Edge duce cavitation.
b - Top Edge of Water Intake Housing
1. Water intake fin kit (a) – Available from the Special-
4. Raise The outboard up on the transom the dis- ty Mfg. Co. for jet models 30 thru 140. The purpose
tance measured in Step 3. Use a straight edge and of these fins is to ram more water into the intake
recheck the mounting height. The top edge of the and shield the forward sides of the intake from the
water intake housing should be in line with the bot- entrance of air. This kit will help reduce cavitation
tom of the boat as shown. when running with the wind in a chop.

a
a - Intake Fin Kit
5. Fasten outboard to the transom at this height.
Water Intake Fin Kit Part No.1186 for jet models 45
thru 140 and Part No. 1185 for jet model 30 is
available from.
Water testing Specialty Mfg. Co.
2035 Edison Ave.
Checking for Cavitation San Leandro, CA 94577
Making the initial outboard height setting should be Continued on next page
close to the optimum setting for the outboard. However
because of the hull design of some boats, obstructions
or imperfections in the hull ahead of the water intake
may require this setting to change in order to prevent
cavitation at running speeds.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-7

Water testing 4. Attach the brass barrel (c) to the bracket with bolt
and locknut. Tighten the bolt until it seats against
the barrel, then back-off the bolt 1/4 turn. Hold bolt
Checking for Cavitation (Continued) from turning, and tighten locknut on bolt. The barrel
must be free to pivot.
2. Rough Water Plate (b) – Using this type of plate
may be helpful in reducing cavitation when running
in windy rough water conditions where air is
sucked-in the water intake when jumping waves.
Install a 1/32 in. metal plate that extends from the
hull bottom to the top of the water intake housing.
This plate tends to reduce air intake as well as re-
duce spray.

c
b
a

d
a - Shift Cable
b - Shift Cam
c - Barrel
b - Rough Water Plate d - Roller
5. Recheck the shift cable adjustment in forward shift
position. The correct shift adjustment will position
Shift Cable Installation the cam far enough on the roller in order to lock the
the reverse gate into forward position. You should
WARNING not be able to forcibly push up the reverse gate to-
ward neutral. Pull on the reverse gate by hand to
The shift cable must be adjusted to lock the re- verify this.
verse gate against unexpected engagement IMPORTANT: The forward locking of the reverse
(caused by water pressure hitting the gate) while gate must be met. If not, readjust the shift cable.
operating the boat in forward. Activation of the re-
verse gate will cause sudden unexpected stopping
of the boat. Sudden stopping may cause occu-
pants to be thrown within the boat or even out of
the boat. This action may result in serious injury or
death.
1. Attach shift cable (a) to the shift cam (b) with flat
washer and locknut as shown. Tighten locknut
against the flat washer, then back-off the locknut
1/4 turn.
2. Place remote control handle into full forward posi-
tion.
3. Adjust the brass barrel (c) on the shift cable so that
roller (d) is at the full end of travel (bottom) in the
shift cam when the remote control is in full forward.

6C-8 - LOWER UNIT 90-817643R1 DECEMBER 1996

Lubricating The Drive Shaft Impeller Removal and
Bearing Installation
Recommended Lubrication - Use 2-4-C w/Teflon.
REMOVAL
IMPORTANT: It is important that you do not use a
general-all-purpose grease for this bearing. The 1. Shift outboard to NEUTRAL (N) position.
lubricant we recommend is a water resistant 2. Remove spark plug leads to prevent engine from
grease of the proper consistency for this applica- starting.
tion. If you use a substitute grease, be sure that it
3. Remove the water intake housing that is fastened
is water resistant and of the same consistency.
with six screws.
Frequency of lubrication - We recommend lubricat-
ing the drive shaft bearing after each day’s use and af-
ter every 10 hours of operation. After every 30 hours
of operation, pump in extra grease to purge out any
moisture.

4. Straighten the bent tabs (a) on the impeller nut re-

b c tainer and remove the impeller nut (b).
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 keyway
is directly above the flat on the shaft. This will free
a - Vent Hose the jammed key and allow removal.
b - Grease Gun
c - Grease Exiting Vent Hose
Lubricating Procedure - Pull vent hose (a) off the
grease fitting. Pump in grease through the grease fit-
ting (using the grease gun (b) provided) until excess
grease starts to exit the vent hose (c).
Reconnect the vent hose (a) onto the grease fitting af-
ter greasing.
After 30 hours of operation, pump in extra grease to
purge out any moisture. Visually inspecting the purged
grease at this time will give you an indication of condi- b
tions inside the bearing housing. A gradual increase in a
moisture content, indicates seal wear. If the grease be- a - Tab
gins to turn dark, dirty gray, the drive shaft bearing and b - Nut
seals should be inspected and replaced if necessary.
Some discoloration of the grease is normal during the
break-in period on a new set of seals.

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-9

INSTALLATION 3. After setting the impeller height, tighten the impel-
ler nut snug with a wrench. Secure impeller nut by
1. Grease the drive shaft, shear key, and impeller
bending tabs (a) against the flats on the impeller
bore. Place the plastic sleeve (a) inside the impel-
nut.
ler (b) and install impeller, shear key (c), shims (d)
nut retainer (e), and impeller nut (f). Turn the nut
tight on the shaft to remove any play between the
impeller and shaft. If the tabs on the retainer do not
line up with the flats on the nut, remove the nut and
turn the retainer over and re-tighten the nut again.

a
a
a - Tabs
4. Reinstall the water intake housing with six bolts.
b Check clearance around the impeller to make sure
the water intake housing is centered and not rub-
bing against the liner. Torque mounting bolts to 100
c lb. in. (11.2 N·m).
d NOTE: If the outboard is used in salt water, apply
e Quicksilver Anti-Corrosion Grease around the entire
f mounting flange on the water intake housing and also
a - Plastic Sleeve to the threads on the six mounting bolts.
b - Impeller
c - Shear Key
d - Shims
e - Nut Retainer
f - Impeller Nut
2. Temporarily reinstall the water intake housing in or-
der to check for impeller clearance. The clearance
between the impeller and liner should be 0.030 in.
(0.8 mm). Shim washers can be transferred to ei-
ther side of the impeller to raise or lower the impel-
ler to the correct clearance setting. The water in-
take housing can be shifted side ways a small
amount in order to center the liner.

6C-10 - LOWER UNIT 90-817643R1 DECEMBER 1996

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

Do Not sharpen or alter the

top side lifting angle

Enlarged
leading View
edge
a
Sharpen to a 1/32 in. (.8mm) radius by
a - Exhaust Fins removing material from bottom side only
The intake of gravel through the pump can round off
Impeller Clearance and wear the leading edges on the impeller. Some
Adjustment conditions you may experience from a worn impeller
are (1) a noticeable performance loss, especially on
1. The impeller should be adjusted so there is approx- acceleration, (2) difficultly getting the boat on plane, or
imately 0.03 in. (0.8mm) clearance between the (3) an increase in engine RPM at wide open throttle.
impeller edge and liner. Operating the jet drive in Check the impeller blades occasionally for damage.
waters that contain sand and gravel can cause Use a flat file to resharpen the leading edges as shown.
wear to the impeller blades, and the clearance will
start to exceed 0.03 in. (0.8mm). As the blades
wear, shims (a) located in the stack outside of the
impeller can be transferred behind the impeller.
This will move the impeller further down into the ta-
pered liner to reduce the clearance.
2. Check the impeller clearance by sliding a feeler
gauge through the intake grate and measure the
clearance between the impeller edge and liner. If
adjustment is required, refer to Impeller Removal
and Installation.

a - Shims

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-11

Flushing The Cooling System 2. Remove the liner. If the liner is tight, tap on the inner
edge of the liner with a long drift punch through the
Use Quicksilver accessory hose coupling Part Number intake grate.
24789A1.
NOTE: Apply grease to the liner mounting bolt threads
1. Remove plug and gasket (a) and thread-in hose before assembly.
coupling (b).
3. Position the liner into the water intake housing.
2. Attach a water hose to the hose coupling. Turn on Line up one of the liner bolts and lightly thread it in.
the water gently, start the engine, and run it at idle It may be necessary to tap or press the liner into the
speed only. water intake housing to locate the liner for installa-
3. Check for a steady stream of water flowing out of tion of the remaining bolts. Torque bolts to 100 lbs.
the water pump indicator hole. Continue flushing in. (11.2 N·m)
the outboard for 3 to 5 minutes; adjust water pres- 4. Grind off the ends of any bolts that may extend be-
sure if needed. yond the inner liner surface.
4. Stop the engine, turn off the water, and remove the
hose coupling. Reinstall the plug and gasket.
Jet Drive Removal
1. Shift outboard to NEUTRAL (N) position and dis-
connect the shift linkage.
2. Remove spark plug leads to prevent engine from
starting.
a 3. Remove the water intake housing that is fastened
with six screws.

b
a - Plug and Gasket
b - Hose Coupling

Liner Replacement

1. Mark the liner mounting bolts for reassembly into

the same holes. Remove the bolts.

6C-12 - LOWER UNIT 90-817643R1 DECEMBER 1996

4. Straighten the bent tabs (a) on the impeller nut re- Bearing Carrier Removal
tainer and remove the impeller nut (b).
NOTE: Water pump assembly must be removed be-
5. Pull impeller straight off the shaft. If the impeller is fore bearing carrier can be removed.
tight, use a hammer and block of wood to rotate the
impeller (clockwise) on the shaft until the keyway 1. Remove 4 bolts securing water pump assembly
is directly above the flat on the shaft. This will free and remove water pump.
the jammed key and allow removal.
a
b

d
e

f
b
a
a - Tabs g
b - Nut
6. Remove 5 bolts securing jet drive to drive shaft
housing and remove pump.

a
54258

a - Bolts (4)
b - Seal
c - Housing
54165 d - Key
e - Impeller
f - Gasket
b g - Plate

a - Bolts (4)
b - Bolt (1)

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-13

2. Remove 4 bolts securing bearing carrier to jet Bearing Carrier Reassembly
drive.
a Installing Lower Seals
Install seals into bearing carrier as follows:
1. Install O-ring seals (a) into the top seats of the three
passage holes.
2. Install spiral retaining ring (b) into the inner ring
groove.
3. Spread a film of grease around the inside bore of
the seal surface before pressing in the seals.
4. Press in the garter spring seal (c) against the inner
a retaining ring as shown. Fill the garter spring cavity
in the seal with grease.
54165
a - Bolts 5. Install spiral retaining ring (d) into the outer ring
groove. Align the notched ends of the retaining ring
to straddle the small vent hole drilled in the ring
groove.
Bearing Carrier Disassembly 6. Press in the outer seal (e) against the retaining ring
1. Remove the large beveled snap ring (a) from the as shown.
bearing carrier.
7. Grease all the seal lips.
2. Heat the bearing carrier (b) with a torch only until
you can barely touch it. a
3. Hold the drive shaft vertical and bump the impeller
end of the drive shaft against a wooden block caus-
ing the bearing carrier to slide down off the bearing.
4. Remove snap ring (e), press the ball bearing (c) off
the drive shaft. Leave the bearing thrust ring (f) (lo-
cated in the drive shaft groove) unless damaged.
5. Remove the seals and spiral retaining rings from
the bearing carrier and the upper seal housing (d).
6. Clean all parts thoroughly and remove any burrs.

d a a
e b
c

d e
c IMPORTANT: The
b notched ends of the
f retaining ring must
a - Snap Ring
b - Bearing Carrier
straddle this vent hole.
c - Ball Bearing
d - Upper Seal Housing a - O-rings
e - Snap Ring b - Retaining Ring
f - Thrust Ring c - Spring Seal
d - Retaining Ring
e - Outer Seal

6C-14 - LOWER UNIT 90-817643R1 DECEMBER 1996

Installing Upper Seals Installing Drive Shaft Ball Bearing
1. Install spiral retaining ring (a) into the inner ring 1. If removed, install the bearing thrust ring (a) into
groove of the upper seal housing. the groove on the drive shaft.
2. Spread a film of grease around the inside bore of 2. Install collar (b) onto the drive shaft. Press the new
the seal surface before pressing in the seals. ball bearing (c) onto the drive shaft, pressing
against the inner race only. Press collar (b) over
3. Press in the garter spring seal (b) against the inner
the thrust ring (a), locking it in its groove. Install
retaining ring as shown. Fill the garter spring cavity
snap ring (d) into drive shaft groove below the
in the seal with grease.
bearing.
4. Install spiral retaining ring (c) into the outer ring
groove. Align the notched ends of the retaining ring a
to straddle the small vent hole drilled in the ring
groove. b
b a
5. Press in the outer seal against the retaining ring as c
shown.
6. Grease all the seal lips.
7. Grease the two O-ring seals (e) and install then into
the outer ring grooves. d
c d

Installing Drive Shaft

1. Lubricate the seals and inside bore of the bearing
carrier (a).
2. Place the drive shaft (“b” impeller end facing up)
into a vise.
e 3. Heat the bearing carrier (a) until it feels warm to the
touch.
4. Place the bearing carrier (a) onto the drive shaft.
Square up the inner bore with the ball bearing and
push the bearing carrier down until it bottoms-out
c d against the bearing. It may be necessary to lightly
tap bearing carrier onto the bearing using a rubber
hammer.
NOTE: Only a light pressing force is needed to press
on the bearing carrier. It may be necessary to lightly tap
the bearing carrier onto the bearing using a rubber
hammer.
a b

IMPORTANT: The notched

ends of the retaining ring
a
must straddle this vent hole.
a - Retaining Ring
b - Spring Seal
c - Retaining Ring
d - Outer Seal b
e - O-rings

a - Bearing Carrier
b - Drive Shaft

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-15

 7. Install spacer (c), and the upper seal housing (b)
being careful not to damage the O-ring seals as
they pass the snap ring groove. Only finger pres-
5. Grease the upper seals and inside bore of the sure should be necessary to push in the housing.
bearing carrier to ease entry of the seal housing. 8. Install the beveled snap ring (a), beveled side fac-
6. Install the thrust washer (d) against the ball bear- ing up into the ring groove. Make sure the snap ring
ing. is fully seated into groove.

Bearing Carrier Installation

1. Install the bearing carrier into the jet drive. Secure
carrier in drive with 4 bolts. Torque bolts to 70 lb. in.
(7.9 N·m).
2. Fill carrier with grease, using the grease gun sup-
plied with the jet drive. If using a hand lever gun,
pump very slowly so as to not build up internal
grease pressure and damage the seals or housing.

a - Snap Ring
b - Upper Seal Housing
c - Spacer e
d - Thrust Washer
e - Bolts [Torque to 70 lb. in. (7.9 N·m)]

6C-16 - LOWER UNIT 90-817643R1 DECEMBER 1996

Installing Jet Drive to Drive 4. Apply Loctite 271 to retaining bolts (4) and torque
to 60 lb. in. (6.8 N·m).
Shaft Housing
a
b
Reassembling Water Pump to Jet
Drive c
NOTE: Replace cover if thickness of steel at discharge
95
slots is 0.060 in. (1.524mm) or less, or if groove(s) (oth- d
er than impeller sealing groove) in cover roof are more
than 0.030 in. (0.762mm) deep. e
NOTE: Replace impeller if:
a. Impeller blades are cracked, torn or worn. f
b. Impeller is glazed or melted (caused by insuffi-
cient water supply.)
g
c. Rubber portion of impeller is not bonded to im-
peller hub.
1. Install base plate, pump cover gasket (NEO-
PRENE STRIP FACES UP) and impeller key.
IMPORTANT: If impeller being installed has been
previously used and vanes have taken a “set,” DO
NOT INSTALL THE IMPELLER WITH THE VANES
REVERSED FROM THEIR PREVIOUS “SET” AS
VANE BREAKAGE WILL OCCUR SHORTLY AFTER
UNIT IS RETURNED TO SERVICE.
2. Install impeller.
54258
NOTE: Apply a light coat of 2-4-C w/Teflon to inside of 95 2-4-C With Teflon (92-825407A12)
pump cover to ease installation of cover over impeller.
a - Bolts (4) [Apply Loctite 271. Torque to 60 lb. in. (7.0 N·m)]
3. Install pump cover. Rotate drive shaft CLOCK- b - Seal
WISE while pressing cover down over impeller. c - Cover
d - Key
e - Impeller
f - Gasket
g - Plate

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-17

Installing Jet Drive to Drive Shaft a - Bolt and Washer [Torque to 22.5 N·m)]

Housing 5. Grease the drive shaft, shear key, and impeller

bore. Place the plastic sleeve (a) inside the impel-
1. Apply a light coat of 2-4-C w/Teflon to the drive ler (b) and install impeller, shear key (c), shims (d)
shaft splines. DO NOT APPLY GREASE TO THE nut retainer (e), and impeller nut (f). Turn the nut
TOP OF THE DRIVE SHAFT AS THE GREASE tight on the shaft to remove any play between the
WILL PREVENT THE DRIVE SHAFT FROM FUL- impeller and shaft. If the tabs on the retainer do not
LY ENGAGING THE CRANKSHAFT AND DAM- line up with the flats on the nut, remove the nut and
AGE TO THE POWERHEAD AND/OR GEAR turn the retainer over and re-tighten the nut again.
CASE WILL RESULT.
2. Carefully slide jet drive into drive shaft housing
while aligning drive shaft splines with crankshaft
and the water tube with the water pump cover seal.
3. Secure jet drive to drive shaft housing with 4 bolts.
Torque bolts to 25 lb. ft. (34.0 N·m)]. a

a
c
d
a e
f
a - Plastic Sleeve
b - Impeller
c - Shear Key
d - Shims
e - Nut Retainer
f - Impeller Nut
54165
6. Temporarily reinstall the water intake housing in or-
a - Bolts [Torque to 25 lb. ft. (33.9 N·m)]
der to check for impeller clearance. The clearance
4. Secure aft end of jet drive to drive shaft housing between the impeller and liner should be 0.030 in.
with bolt and washer. Torque bolt to 22.5 lb. ft. (30 (0.8 mm). Shim washers can be transferred to ei-
.5 N·m). ther side of the impeller to raise or lower the impel-
ler to the correct clearance setting. The water in-
take housing can be shifted side ways a small
amount in order to center the liner.
a

6C-18 - LOWER UNIT 90-817643R1 DECEMBER 1996

7. After setting the impeller height, tighten the impel- NOTE: If the outboard is used in salt water, apply
ler nut snug with a wrench. Secure impeller nut by Quicksilver Anti-Corrosion Grease around the entire
bending tabs (a) against the flats on the impeller mounting flange on the water intake housing and also
nut. to the threads on the six mounting bolts.

a - Tabs
8. Reinstall the water intake housing with six bolts.
Check clearance around the impeller to make sure 9. Refer to “SHIFT CABLE INSTALLATION” page 8
the water intake housing is centered and not rub- and reinstall shift cable to jet drive.
bing against the liner. Torque mounting bolts to 100
lbs. in. (11.5 N·m).

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-19

Jet Drive Tiller Handle 2. Check to see if the shift cable will slide through the
drilled hole. If necessary, use a file to remove any
Adaptor Kit extra metal from the hole.

Installation Instructions
NOTE: This kit must be used in conjunction with the
recommended Quicksilver tiller handle kit.
1. Drill hole in bottom cowl for cable routing as fol-
lows:
a. Locate the center lines for the hole following
the dimensions given in the illustration below.
Use a center punch to mark center of hole.
b. Drill a 1/4 in. pilot hole and then a 9/16 in. hole
angling up into the bottom cowl.

Side View Front View

5/8 in.
(16 mm)
3. Install the shift cable to the jet drive. Use the exist-
ing mounting hardware supplied with the outboard.
Adjust shift cable after kit is installed.

1/2 in.
(12 mm)

a - Shift Cable
b - Bolt
c - Locknut
d - Flat Washer

6C-20 - LOWER UNIT 90-817643R1 DECEMBER 1996

4. Lubricate the shift cable. Slide the cable boot onto 8. Drill the shift cable retainer mounting hole as fol-
the cable. lows:
a. Remove air box cover off the carburetors. Re-
a install after installation.
b. Lay a straight ruler above the corner radius and
b
across the flat side of the cable opening in the
bottom cowl.
c. locate the center of hole by measuring 1-1/4 in.
(31 mm) from the opening.
d. Drill a 9/32 in. hole through bottom cowl.

a - Cable Boot
b - Lubricant

5. Slide the shift cable through the drilled hole.

6. Position the cable boot 1/2 in. (12 mm) out of the
drilled hole.
7. Fasten shift cable to the starter motor mount with a
J-clip. 1-1/4 in.
(31 mm)
a - Straight Ruler

9. Rotate the shift cable retainer so that the set screw

is facing up and the slot is facing out.
10. Slide shift cable into retainer until brass tube ex-
tends out 2-1/4 in. (56 mm). Secure the retainer at
b this position by tightening the set screw until it is
snug, then add an additional 1/8 turn.
11. Install the Allen head screw and tighten securely.
1/2 in.
(12 mm) a 2-1/4 in.
(56 mm) b

a - Position Cable Boot 1/2 in. (12 mm) out of Drilled Hole a
b - J-Clip
d
c

a - Cable Retainer
b - Set Screw
c - Lock Washer
d - Allen Head Screw - Tighten Securely

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-21

12. Fasten the shift cable retainer to the bottom cowl 13. Attach the shift cable to the outer flange hole.
with the mounting hardware shown. Tighten lock-
IMPORTANT: Do not over-tighten. Shift Cable must
nut, then back-off the locknut 1/4 turn.
be free to pivot.
IMPORTANT: Do not over-tighten. Shift cable re-
tainer must be free to pivot.

a
b
a c
b d
c
d b
e e
f a - Bolt
b - 1/2 in. OD Flat Washer
a - 7/8 in. OD White Nylon Washer c - Shift Cable
b - 1.00 in. OD Flat Washer d - Nylon Bearing
c - Bottom Cowl e - Locknut - Tighten, Then Back-Off The Locknut 1/4 turn.
d - 5/8 in. OD Black Nylon Washer
e - 21/32 in. OD Flat WAsher
f - Locknut - Tighten, Then Back-Off The Locknut 1/4 turn. 14. Lubricate the new cable seal.
15. Slip the cable seal onto the throttle cable.
16. Place the cable seal along with the throttle cable
into the cowl opening. Spread the seal over the
shift cable.

a - Cable Seal
b - Lubricant

6C-22 - LOWER UNIT 90-817643R1 DECEMBER 1996

17. Install the throttle cable as follows: Shift Cable Adjustment
a. Rotate the throttle grip to the IDLE position.
! WARNING
b. loosen the set screw (a) in the cable barrel.
The shift cable must be adjusted to lock the re-
c. Position the throttle cable barrel (b) so the bar-
verse gate against unexpected engagement
rel will be able to slip into the retainer when the
(caused by water pressure hitting the gate) while
cable end is on the mounting stud and there is
operating the boat in forward. Activation of the re-
a slight pre-load against the throttle stop.
verse gate will cause sudden unexpected stopping
d. Apply a small amount of Loctite to threads on of the boat. Sudden stopping may cause occu-
set screw and tighten until snug, then add an pants to be thrown within the boat or even out of
additional 1/8 turn. the boat. This action may result in serious injury or
death.
a
1. Place shift lever into full forward position.
b
2. Adjust the brass barrel (c) on the shift cable so that
roller (d) is at the full end of travel (bottom) in the
shift cam when the shift lever is in forward.
3. Attach the brass barrel (c) to the bracket with bolt
and locknut. Tighten the bolt until it seats against
the barrel, then back-off the bolt 1/4 turn. Hold bolt
from turning, and tighten locknut on bolt. The barrel
must be free to pivot.

a - Set Screw
b - Cable Barrel

18. Place the cable barrel into retainer.

19. Fasten the cable end to mounting stud with nylon
washer (a) and locknut (b). Tighten locknut against
the nylon washer, then back-off the locknut 1/4
turn.
20. Secure the retainer in place with cable latch (c).

a - Shift Cable
b - Shift Cam
c - Barrel
d - Roller
4. Recheck the shift cable adjustment in forward shift
position. The correct shift adjustment will position
the cam far enough on the roller in order to lock the
the reverse gate into forward position. You should
c not be able to forcibly push up the reverse gate to-
a ward neutral. Pull on the reverse gate by hand to
b verify this.
IMPORTANT: The forward locking of the reverse
gate must be met. If not, readjust the shift cable.
a - Nylon Washer
b - Locknut - Tighten Locknut Against The Nylon Washer, Then
Back-Off The Locknut 1/4 turn.
c - Cable Latch

90-817643R1 DECEMBER 1996 LOWER UNIT - 6C-23

OUTBOARD
INSTALLATION/
ATTACHMENTS

50331

RIDE-GUIDE STEERING -
THROTTLE/SHIFT CABLES &
ELECTRICAL CONNECTIONS 7
A
Table of Contents
Page Page
Installing Outboard Motor on Transom . . . . . . . . . . . 7A-1 Transom Mounted Ride-Guide Attaching Kit
Determining Recommended Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-13
Outboard Mounting Height . . . . . . . . . . . . . . . . . . . 7A-1 Attaching Kit Installation . . . . . . . . . . . . . . . . . . . . 7A-13
Locate Centerline of Boat Transom . . . . . . . . . . . 7A-1 Clevis Attaching Kit Installation . . . . . . . . . . . . . . . . . 7A-14
Lifting Outboard (Electric Start Models) . . . . . . . . 7A-1 Installation Instructions . . . . . . . . . . . . . . . . . . . . . 7A-14
Lifting Outboard (Manual Start Models) . . . . . . . . 7A-2 Steering Cable Installation . . . . . . . . . . . . . . . . . . 7A-15
Drilling Outboard Mounting Holes Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7A-15
(Electric Start Models) . . . . . . . . . . . . . . . . . . 7A-2 Remote Control Installation . . . . . . . . . . . . . . . . . . . . 7A-16
Fastening Outboard on Boat Transom Shift Cable Installation and
(Manual Start Models) . . . . . . . . . . . . . . . . . . . . . 7A-2 Adjustment to Engine . . . . . . . . . . . . . . . . . . . . . . 7A-16
Securing Outboard to Boat Transom Throttle Cable Installation and Adjustment
(Electric Start Models) . . . . . . . . . . . . . . . . . . . . . 7A-5 to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
Steering Cable Installation . . . . . . . . . . . . . . . . . . . . . . 7A-5 Connecting Remote Control Wiring Harness
Dual Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-5 to Engine Wiring Harness (Electric Start
Cable Installation to Tilt Tube - Cable Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
Routed on Starboard Side of Boat . . . . . . . . . . 7A-6 Power Trim Wiring Connections (Models
Cable Installation to Tilt Tube - Cable Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-18
Routed on Port Side of Boat . . . . . . . . . . . . . . . . 7A-7 Battery Connections . . . . . . . . . . . . . . . . . . . . . . . 7A-18
Tilt Tube Reversal . . . . . . . . . . . . . . . . . . . . . . . 7A-7
Installing Steering Link Rod . . . . . . . . . . . . . . . . . . 7A-7
Models with One-Piece steering Arm . . . . . . . 7A-8
Models with One-Piece steering
Arm/Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 7A-9
Dual Steering Installation . . . . . . . . . . . . . . . . . . . . . . . 7A-9
Steering Coupler Assembly . . . . . . . . . . . . . . . . . . 7A-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-10
Models With Forged Two Hole Steering
Arm and One Piece Top Cowl . . . . . . . . . . 7A-10
Models With Two Hole Two Piece Steering
Arm/Bracket and One Piece Top Cowl . . . 7A-11
Ride-Guide Steering Attachment
Extension Couplers . . . . . . . . . . . . . . . . . . . . . . . . 7A-12
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7A-12
Dual Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 7A-12
Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7A-12

7A-0 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Installing Outboard Motor Locate Centerline of Boat Transom
on Transom Locate (and mark with a pencil) vertical centerline (a) of
boat transom, as shown.
Determining Recommended
Outboard Mounting Height
A B
It is recommended for best-all-around boating perform-
ance, the outboard should be mounted with the anti-venti-
lation plate parallel to and at the same level as the boat bot- a
tom.
On boats with a 20 in. (508mm) transom height, this will re- C D
quire that the outboard be mounted approximately 1 in.
(25.4mm) high on the transom as the outboard has a 21 in.
(533mm) shaft length. NOTE: Dimension “A” & “B” and “C” & “D” are Equal
Length.

Lifting Outboard (Electric Start

Models)

! WARNING
Make sure that lifting eye is threaded into flywheel a
minimum of 5 turns and that hoist has a minimum lift
capacity of at least 500 lbs. (227 kg) BEFORE lifting
outboard.
Remove cowling from outboard and plastic cap from center
of flywheel. Thread lifting eye (a) into flywheel hub a mini-
mum of 5 turns. Replace plastic cap after installation.
Connect hoist [minimum lift capacity of 500 lbs. (227 kg)]
to lifting eye or rings of lift harness and lift outboard onto
boat transom.

50563
If, with the outboard mounted so that the anti-ventilation
plate is level with the bottom of the boat, excessive propel- a
ler slippage/cavitation is experienced, it is recommended
that the outboard be lowered one position on the transom
to increase propeller “BITE” at a slight loss at top end
speed and increase spray.
NOTE: Raising or lowering the outboard by one mounting
hole will change outboard height by approximately 3/4 in.
(19mm).

50565A
a - Lifting Ring (P/N 91-75132)
b - Hoist

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-1

Lifting Outboard (Manual Start IMPORTANT: If using “Transom Drill Fixture”
(91-98234A2), use drill guide holes marked “A” when
Models) drilling outboard mounting holes.
Remove cowling from outboard. Use lifting eye on out-
board and lift outboard on boat transom.

51456
1. Secure (tape) “Outboard Mounting Template” (located
in center of Installation Manual) to outside of boat tran-
Drilling Outboard Mounting Holes som.
(Electric Start Models)
2. Align “Top of Boat Transom Line” of template with top
IMPORTANT: Before drilling any mounting holes, care- edge of (real) boat transom, not shim(s).
fully read “Determining Recommended Outboard Mo-
3. Align vertical centerline of template with centerline of
tor Mounting Height”, preceding. There is a 3/4 in.
transom.
(19mm) difference between outboard mounting holes
in transom bracket. 4. Use a 17/32 in. (13.5mm) diameter drill bit and drill 4
mounting holes perpendicular to and thru transom at
! WARNING marked hole centers on template.

DO NOT under any circumstances, allow upper out-

board mounting bolts to be closer than 1 in. (25.4mm)
from top of boat transom. Upper mounting bolts must
Fastening Outboard on Boat Transom
never be installed thru shims. (Manual Start Models)

! WARNING
Outboard must be fastened to boat transom with tran-
som clamp handles and transom clamp retainers or
mounting bolts as shown in installation A or B should
the outboard strike an underwater object or be steered
into a sharp turn. Failure to tighten transom clamp
handles along with installing transom clamp retainers
or mounting bolts could result in outboard ejecting
suddenly off boat transom causing serious injury or
death, boat damage or loss of outboard.

7A-2 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Outboard Mounting Hardware Installation B
Use for easy removal and installation of outboard.

e b c
51509
a - Mounting Bolts (4)
b - Flat Washers (4) d
c - Locknuts (4)
51462
d - Transom Clamp Retainers With Mounting Hardware
e - Shims - Transom Clamp Retainers (If Required) a - Tighten Transom Clamp Handels
b - Part Number 812433-C1
Fasten outboard to boat transom following installation A or c - Part Number 812432-C1
B shown below. d - Transom Clamp Retainers (Opitional)

Installation A Installation A

Use for permanent installation. Fastening outboard for permanent installation.

Drill four 1/2 in. (12.5mm) holes and fasten outboard to
boat transom.

a
c
b

d
b
51489
51462 a - Bolts (4)
a - Tighten Transom Clamp Handles b - Flat Washers (4)
b - Mounting Bolts (Supplied with Outboard c - Locknuts (4)
d - Marine Sealer

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-3

 Installation B Retainers installed.
Fastening outboard for easy removal and installation.
Mark hole location.

51394

51393 Outboard can be easily removed and installed.

Drill four 3/8 in. (9.5mm) holes and fasten transom clamp
retainers to transom.
Add shims (if necessary) to allow for a small amount of
clearance between transom clamps and retainers.

a
e

b
d
51395

f 51489
a - Bolts (4)
b - Flat Washers (4)
c - Locknuts (4)
d - Marine Sealer
e - Transom Clamp Retainers (2)
f - Shims (4)
g - Transom Clamp

7A-4 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Outboard installed. Installation must be water-tight, and outboard should
be checked for tightness on the transom during opera-
tion. Failure to bolt outboard to transom (using 4 bolts
and locknuts, as shown) may result in damage to boat
and/or loss of outboard and possible injury to occu-
a pants of boat.

c
51462
a - Tighten transom clamp, handles. Retighten every 1/2 hour.
b

50181
Securing Outboard to Boat Transom a - Mounting Bolt 4 in. Long (4 Req’d)
b - Flat Washer (4 Req’d)
(Electric Start Models) c - Locknut (4 Req’d)
IMPORTANT: If boat is equipped with thru tilt tube
steering, steering cable end must be installed into tilt
tube of outboard before securing outboard to tran-
som. Refer to “Steering Cable and Steering Link Rod
Installation”, following. Steering Cable Installation
Refer to “Determining Recommended Outboard Motor Refer to “Quicksilver Accessories Guide” to determine cor-
Mounting Height”, and position outboard on boat transom rect length of steering cable and remote control cables.
aligning mounting holes in transom bracket. IMPORTANT: Steering cable and remote control cables
must be the correct length. Cables which are too short
! CAUTION or too long will result in unwanted cable stress.
Marine sealer must be used on shanks of mounting Install steering mount and steering wheel in accor-
bolts to make a water-tight installation. dance with installation instructions that accompany
each.
IMPORTANT: In order to avoid transom damage DO
NOT use an impact driver when tightening transom
mounting bolts.
Dual Outboard
Apply marine sealer to shanks of mounting bolts (not
threads) secure outboard to transom with 4 bolts, flat wash- IMPORTANT: The distance from each outboard’s cent-
ers and locknuts, as shown. Be sure that installation is wa- erline to the side of transom opening or gunnel MUST
ter-tight. BE a minimum of 16 in. (406mm).
With a dual steering system installation, a minimum out-
! WARNING board centerline distance of 21 in. (533mm) must be at-
Before operating, outboards(s) MUST BE SECURED to tained to assure interference-free movement.
boat transom with four 1/2 in. diameter bolts and lock-
nuts, as follows: 2 bolts must be installed thru upper
mounting holes and 2 bolts thru lower mounting holes.

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-5

Ride-Guide steering cable can be routed on either side of 1. Lubricate inside of outboard tilt tube (a) and steering
boat. If steering cable is routed on starboard side of boat, cable end (b) with Quicksilver 2-4-C Marine Lubricant.
cable attaches to port outboard. If steering cable is routed
2. Insert steering cable end thru outboard tilt tube and se-
on port side of boat, cable attaches to starboard outboard.
cure with steering cable attaching nut (c). Torque to 35
lb. ft. (41 N·m).

Cable Installation to Tilt Tube - Cable

Routed on Starboard Side of Boat

c a b

50564B
3. Make pencil mark (a) on tilt tube 1/4 in. (6.4mm) from
port end of tube. Slide spacer (b), O-ring (c) and cap
(d) over steering cable end.

1/4 in. d
51130 (6.4mm) b c
Single Cable-Dual Single Cable-Single
Outboard Outboard
IMPORTANT: Before installing steering cable tilt tube,
lubricate entire cable end with Quicksilver 2-4-C Ma-
rine Lubricant.
NOTE: Ride-Guide Steering cable is lubricated at the fac-
tory and requires no additional lubrication at initial installa-
tion. a
50180
4. Thread cap (d) onto tilt tube, up to mark (a).

a
50180

7A-6 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Cable Installation to Tilt Tube - Cable 1. Lubricate inside of outboard tilt tube (a) and steering
cable end (b) with Quicksilver 2-4-C w/Teflon Marine
Routed on Port Side of Boat Lubricant.
2. Insert steering cable end thru outboard tilt tube and se-
TILT TUBE REVERSAL
cure with steering cable attaching nut (c). Torque to 35
lb. ft. (41 N·m).
! CAUTION
Outboard tilt tube MUST BE removed and re-installed
in the opposite direction. When re-assembled, longer
threaded end of tilt tube extends out port side of out-
board approximately 3/4 in. (19mm). Failure to reposi-
tion outboard tilt tube as described could interfere
with steering system operation.
b a c
Remove outboard tilt tube and re-install in the opposite di-
rection (turn end for end). When re-assembled, longer 50579
threaded end (a) of tilt tube extends out port side of out- 3. Make pencil mark (a) on tilt tube 1/4 in. (6.4mm) from
board approximately 3/4 in. (19mm). Refer to Section 5A starboard end of tube. Slide spacer (b), O-ring (c) and
“Midsection”. cap (d) over steering cable end.

a
c b
1/4 in.
50579
d (6.4mm) 50325
4. Thread cap (d) onto tilt tube, up to mark (a).

a 50325

Installing Steering Link Rod

51130
Single Cable-Dual Single Cable-Single
Outboard
! WARNING
Outboard
IMPORTANT: Before installing steering cable tilt tube, Steering link rod MUST BE secured between outboard
lubricate entire cable end with Quicksilver 2-4-C w/Te- steering arm/bracket and steering cable end using a
flon Marine Lubricant. special washer head bolt, spacer and nylon locknuts
as shown. Both special washer head bolt and locknuts
NOTE: Ride-Guide Steering cable is lubricated at the fac- MUST BE tightened as specified.
tory and requires no additional lubrication at initial installa-
tion.

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-7

Lubricate hole in end of cable with Quicksilver 2-4-C w/Te- MODELS WITH TWO-PIECE STEERING
flon Marine Lubricant. Assemble steering link rod to steer- ARM/BRACKET
ing cable end using 2 flat washers and nylon insert locknut. Starboard Cable Entry Into Tilt Tube
Tighten locknut until it seats [DO NOT exceed 120 lb. in.
(13.5 N·m) of torque], then back off 1/4 turn.
a

Lubricate ball joint in steering link rod with SAE 30W motor
oil. Secure link rod to outboard steering arm (inner hole) us-
ing special washer head bolt and nylon insert locknut as
shown. Torque bolt to 20 lb. ft. (27 N·m), then torque nut to f
20 lb. ft. (27 N·m). b
e
MODELS WITH ONE-PIECE STEERING ARM
Starboard Cable Entry Into Tilt Tube
c
e

f
d
g

Port Cable Entry Into Tilt Tube

f a
c a

50056 b a f
51103 b
Port Cable Entry Into Tilt Tube e
e
c
f
d

d
a - Two-Piece Steering Bracket, Mount Steering Link Rod in Back Hole
f b - Flat Washer (2)
c c - Nylon Insert Locknut - Torque until it seats [DO NOT Exceed
a 120 lb. in. (14 N·m) or Torque], Then back off 1/4 Turn
d - Special Washer Head Bolt, Torque to 20 lb. ft. (27 N·m)
a e - Spacer
b 51103 f - Nylon Insert Locknut, Torque to 20 lb. ft. (27 N·m)
50056 g - Steering Link Rod
a - Flat Washer (2)
b - Nylon Insert Locknut - Torque until it seats [DO NOT Exceed
120 lb. in. (13.5 N·m) or Torque], Then back off 1/4 Turn ! WARNING
c - Special Washer Head Bolt, Torque to 20 lb. ft. (27 N·m)
d - Spacer After installation is complete and before operating
e - Nylon Insert Locknut, Torque to 20 lb. ft. (27 N·m) outboard, check that boat will turn right when steering
f - Steering Link Rod wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering thru full
range (right and left) at all tilt angles to assure inter-
ference-free movement.

7A-8 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Maintenance Instructions c d e b a b d c
Maintenance is the owner’s responsibility and must be per-
formed at intervals specified.
Normal Service - Every 50 hours of operation or 60 days
(whichever comes first). a - Coupler
b - Rubber Sleeve
*Severe Service - Every 25 hours of operation or 30 days c - Steering Eye
(whichever comes first). d - Rubber Bushing
e - Jam Nut
*Operation in salt water is considered “Severe Service”.

1. Carefully check steering system components for wear. ! WARNING

Replace worn parts.
Both steering eyes must be threaded into coupler 3/4
2. Check steering system fasteners to be sure that they
in. (19mm) minimum. Thread length of steering eye is
are torqued to correct specifications.
3-1/2 in. (89mm), so exposed thread must not extend
NOTE: Ride-Guide Steering cable is lubricated at the fac- out of coupler more than 2-3/4 in. (70mm). Failure to
tory and requires no additional lubrication at initial installa- adhere to this requirement could result in steering sys-
tion. tem failure.
Assemble steering coupler between outboard steering
! WARNING arms/brackets, as shown on the following pages.
Core of steering cable (transom end) must be fully re- IMPORTANT: With assembled steering coupler in-
tracted into cable housing before lubricating cable. If stalled and before tightening special washer head
cable is lubricated while extended, hydraulic lock of bolts/locknuts, check outboard alignment. Distance
cable could occur. between hole centers of steering eye ball joints MUST
3. With core of Ride-Guide Steering cable (transom end) BE equal to distance between propeller shaft center
fully retracted, lubricate transom end of steering cable lines, for proper steering. If adjustment is necessary,
thru grease fitting and exposed portion of cable end temporarily remove special washer head bolt/locknut
with 2-4-C Marine Lubricant. Lubricate all pivot points from one steering eye and turn eye in or out to correct
with SAE 30W engine oil. alignment.

! WARNING
Both steering eyes MUST BE threaded into coupler 3/4
Dual Steering Installation in. (19mm) minimum, and jam nut must be tightened
against coupler to prevent coupler from turning.
Steering Coupler Assembly Torque “jam” nut to 20 lb. ft. (27 N·m).
Position outboards so that they are pointing straight ahead. Tighten “jam” nut against coupler. Torque “jam” nut to 20 lb.
(Distance between threaded hole centers of steering arm/ ft. (27 N·m).
brackets MUST BE equal to distance between propeller
shaft centerlines.) Spray Quicksilver Corrosion Guard on exposed threads of
steering eyes and position rubber bushings and rubber
Lubricate inside of rubber sleeves with 2-4-C w/Teflon Ma- sleeves to cover exposed threads of steering eyes.
rine Lubricant and slide sleeves on steering coupler.
Work rubber bushings onto threaded ends of steering ! WARNING
eyes. After installation is complete (and before operating
Thread jam nut on starboard steering eye. outboard(s), check that boat will turn right when steer-
ing wheel is turned right and that boat will turn left
Thread steering eyes equally into coupler, so that distance
when steering wheel is turned left. Check steering thru
between hole centers of steering eye ball joints is equal to
full range (left and right) at all tilt angles to assure inter-
distance between threaded hole centers of steering arms/
ference-free movement.
brackets. Exposed threads of steering eyes MUST BE of
equal length and threads MUST NOT extend out from cou- Adjust trim tabs of both outboards, as outlined in “Trim Tab
pler more than 2-3/4 in. (70mm). Adjustment”, following.

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-9

Installation IMPORTANT: Lubricate all moving parts with Quicksil-
ver 2-4-C w/Teflon Marine Lubricant.
MODELS WITH FORGED TWO HOLE STEERING IMPORTANT: All 50-60 models with one piece top cowl
ARM AND ONE PIECE TOP COWL require a minimum centerline distance of 21 in.
(533mm) during dual outboard installation to assure
interference-free movement.

a
b

50159

Steering Cable Routed on Starboard Side of Boat Con-

nected to Port Outboard
i n m i f i
f l l f
c
h
h d
h

J
g k J
g g
e
o d

Steering Cable Routed on Port Side of Boat Connected

to Starboard Outboard
i f i m f
f l n l i
c
h
h h
d

J
g k J
g g
e
d o
a -
Steering Link Connecting Hole i - Lock Nut P/N 11-34863, Torque to 20 lb. ft. (27 N·m)
b -
Coupler Assembly Connecting Hole j - Steering Eye
c -
Steering Link k - Rubber Sleeve
d -
Washer l - Rubber Bushing
e -
Ride-Guide Cable m- Jam Nut, Torque to 20 lb. ft. (27.1 N·m)
f -
Steering Bracket n - Dual Steering Coupler
g -
Special (Washer Head) Bolt (3/8” x 1-5/8”; P/N 10-90041), o - Lock Nut P/N 11-34863, Torque Until it Seats [Do Not Exceed 120
Torque to 20 lb. ft. (27.1 N·m) lb. in. (14 N·m) of Torque], Then Back Off 1/4 Turn
h - Special Washer (P/N 12-71970)

7A-10 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

MODELS WITH TWO HOLE TWO PIECE STEERING IMPORTANT: Lubricate all moving parts with Quicksil-
ARM/BRACKET AND ONE PIECE TOP COWL ver 2-4-C w/Teflon Marine Lubricant.

a IMPORTANT: All 50-60 models with one piece top cowl

require a minimum centerline distance of 21 in.
b (533mm) during dual outboard installation to assure
interference-free movement.

c
g

51011

Steering Cable Routed on Starboard Side of Boat Con-

nected to Port Outboard
n J
J m o m g J
g d
g i
i i
e
i i
f
k k
h l h
h
p e

Steering Cable Routed on Port Side of Boat Connected

to Starboard Outboard

J m n o m J
g J g
d i g
i
i
e
i i
f k k
h h l
h
e
p

a -
Steering Link Connecting Hole j - Lock Nut P/N 11-34863, Torque to 20 lb. ft. (27 N·m)
b -
Coupler Assembly Connecting Hole k - Steering Eye
c -
Steering Arm l - Rubber Sleeve
d -
Steering Link m- Rubber Bushing
e -
Washer n - Jam Nut, Torque to 20 lb. ft. (27.1 N·m)
f -
Ride-Guide Cable o - Dual Steering Coupler
g -
Steering Bracket p - Lock Nut P/N 11-34863, Torque Until it Seats [Do Not Exceed 120
h -
Special (Washer Head) Bolt (3/8” x 1-5/8”; P/N 10-90041), lb. in. (13.5 N·m) of Torque], Then Back Off 1/4 Turn
Torque to 20 lb. ft. (27 N·m)
i - Special Washer (P/N 12-71970)

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-11

Ride-Guide Steering Attachment 2. If necessary, adjust trim tab as follows:
Extension Couplers a. Shift outboard into neutral and make sure ignition
key is at “OFF” position.
Outboard Center Required Coupler(s) Between b. Remove plastic cap from rear of drive shaft hous-
Line Distance Steering Eyes (Shown Below) ing and loosen bolt and trim tab.
18 in. thru 22-1/2 in. 9 in. (229mm) Coupler IMPORTANT: Trim tabs MUST BE set in the same posi-
(457mm thru 572mm) (p/n 814951--1) tion on both outboards.
22-1/2 in. thru 24-1/2 in. 12 in. (305mm) Coupler
c. If boat pulls to the right, adjust trailing edges of
(572mm thru 622mm) (p/n 814951--2)
both trim tabs to the right. If boat pulls to the left,
23-1/2 in. thru 27-1/2 in. 15 in. (381mm) Coupler adjust trailing edges of both trim tabs to the left.
(597mm thru 699mm) (p/n 814951--3)
d. Tighten both trim tab bolts securely and replace
26-1/2 in. thru 30-1/2 in. 18 in. (457mm) Coupler plastic caps.
(673mm thru 755mm) (p/n 814951--4)
e. Operate boat following trim tab adjustment. Read-
just trim tab if necessary.

Maintenance Instructions
a
Maintenance inspection is owner’s responsibility and must
be performed at intervals specified, following:
Normal Service - Every 50 hrs. of operation or 60 days
b (whichever comes first)
*Severe Service - Every 25 hrs. of operation or 30 days
(whichever comes first)
*Operation in a salt water area is considered “Sever Service”.
c 1. Carefully check steering system components for wear.
Replace worn parts.
2. Check steering system fasteners to be sure that they
d are torqued to correct specifications.

a - 18 in. (457mm) Coupler (P/N 814951--4) NOTE: Ride-Guide Steering Cables are lubricated at the
b - 15 in. (381mm) Coupler (P/N 814951--3) factory and require no additional lubrication at initial instal-
c - 12 in. (305mm) Coupler (P/N 814951--2) lation.
d - 9 in. (229mm) Coupler (P/N 814951--1)

! WARNING
Trim Tab Adjustment Core of each steering cable (transom end) must be ful-
ly retracted into cable housing before lubricating
cable. If cable is lubricated while extended, hydraulic
DUAL OUTBOARD
lock of cable could occur.
1. Check trim tab position as follows:
3. With core of Ride-Guide Steering Cable (transom end)
IMPORTANT: Initial trim tab setting for both outboards fully retracted, lubricate transom end of steering
should be straight to rear of outboard, so that tabs are cables thru grease fittings with 2-4-C w/Teflon Marine
aligned with gear housing centerline. Refer to “If nec- Lubricant. Lubricate exposed portion of cable ends
essary, adjust trim tab as follows”. with 2-4-C w/Teflon Marine Lubricant.
a. Operate boat at normal cruise throttle setting and 4. Lubricate pivot points of steering link rods and ball
adjust trim to optimum setting. joints of link rods/steering coupler with Quicksilver
2-4-C w/Teflon Lubricant.
b. If boat pulls to the right (starboard), trailing edge of
trim tab must be moved to the right (when viewing 5. Inspection and lubrication of steering head assembly
outboard from behind). If boat pulls to the left (rotary or straight rack) should be performed once
(port), trailing edge of trim tab must be moved to each year (by your Authorized Dealer) or whenever
the left. steering mount and/or steering head are disas-
sembled, or if steering effort has increased. Lubricate
with 2-4-C w/Teflon Marine Lubricant.

7A-12 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

 3. Place Ride-Guide yoke on pivot block and secure with
Transom Mounted Ride- 7/16 in. x 1-3/4 in bolt and locknut, as shown in Figures
Guide Attaching Kit 1 and 2. Torque locknut to 10 lb.ft. (13.5 N·m), then
back off 1/4 turn.
Installation 4. Install one cable tube jam nut onto steering cable tube.
Place tab washer over Ride-Guide yoke, then insert
Attaching Kit Installation cable tube thru tab washer and yoke. Install second
cable tube jam nut onto cable tube but do not tighten
1. Lubricate both holes in pivot block (Figure 1) with
at this time. (Figure 3)
Quicksilver 2-4-C w/Teflon Marine Lubricant.
5. Position transom attaching kit on transom as follows:
2. Place pivot block on pivot spacer and secure to tran-
som bracket with 3/8 in. x 2-1/2 in. bolt, flat washer and a. Determine centerline of outboard, then measure
locknut, as shown in Figure 1. Torque locknut to 20 lb. 15 in. (38.1cm) over from this centerline and draw
ft (27 N·m). a vertical line on transom. (Figure 1)
a b h b. Position attaching kit on transom so that transom
bracket is centered on the 15 in. line (Figure 1)
i
at a height where the center of Ride-Guide yoke
is even with, or not more than 1/2 in. (12.8mm)
above, top edge of transom. (Figure 3)
f
c
k
d l g f

J e
51140
a
g
d
a b h
i

f b
k c c
g
d l

J e e
51140 50568

a - Ride-Guide Cable
a -
Transom Backing Plate
b - Ride-Guide Yoke
b -
Bolt (5/16 in. x 3-1/4 in.)
c - Pivot Block
c -
Locknut (Torque to 10 lb. ft.)
d - Pivot Spacer
d -
Ride-Guide Yoke Attaching Locknut (Torque to 10 lb. ft.
e - 15 in. (Centerline of Attaching Kit Pivot to Centerline of Outboard)
Then Back Off 1/4-Turn
f - Pivot Attaching Locknut [Torque to 20 lb. ft. (27.1 N·m)]
e - 2-3/8 in. Maximum Transom Thickness
g - Outboard Steering Arm or Steering Arm/Bracket
f - Bolt (7/16 in. x 1-3/4 in.)
h - “Clevis Kit”
g - Ride-Guide Yoke
i - Ride-Guide Cable Attaching Locknut [Torque to 10 lb. ft. (13,5 N·m)
j - Bolt (3/8 in. x 2-1/2 in.) Figure 2. Installing Attaching Kit
k - Flat Washer
l - Transom Bracket
Figure 1. Installing Attaching Kit

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-13

NOTE: When drilling thru transom, be sure that holes are
drilled perpendicular to transom.
Clevis Attaching Kit
6. With attaching kit positioned as outlined preceding, Installation
use 3 holes in transom bracket as a guide and drill NOTE: This kit is used to attach Ride-Guide cable to out-
three 11/32 in. (8.7mm) holes thru transom. board steering arm ONLY when “Transom Mounted Ride-
7. Use a marine-type sealer on three 5/16 in. x 3-1/4 in. Guide Attaching Kit” is being used. If Ride-Guide cable is
bolts. Secure attaching kit to transom, using transom installed thru outboard tilt tube, then “Steering Link Rod”
backing plate, 3 bolts (with sealer) and 3 locknuts, in- must be used.
stalled as shown in Figure 2. Torque locknuts to 10 lb.
ft. (13.5 N·m). Installation Instructions
h k
f a f J ! CAUTION
e e Models with two hole two piece steering arm require
i outer connection hole to be used when connecting
clevis to steering arm.
c
J

b i

d g
51140 a
b h
k
h
f a f g
e e

i
c c f
d
J e
50811
b
a -
Clevis
d g b -
Steering Cable
51140
c -
Bolt (3/8 in. x 1-3/8 in.)
a - Ride-Guide Yoke d -
Clevis to Steering Cable Locknut [Torque to 10 lb. ft. (13.5 N·m)]
b - 0 in. to 1/2 in. (12.7 mm) (Center of Ride-Guide Yoke to Top of e -
Bolt 3/8 in. x 1-1/4 in. [Torque to 20 lb. ft. (27.0 N·m)]
Transom) f -
Thin Washer [1/16 in. (1.6mm) Thick]
c - Top of Transom g -
Spacer
d - Transom Bracket h -
Thick Washer [1/8 in. (3.2mm) Thick]
e - Cable Tube Jam Nuts [Torque to 35 lb. ft. (47.5 N·m)] i -
Outboard Steering Arm (use Inner Hole on Models with One Piece
f - Tab Washer Steering Arm or Outer Hole on Models with Two Hole Two Piece
g - After Jam Nuts are Torqued to Specification, Bend Locking Tabs Steering Arm)
Against Nuts j - Clevis to Outboard Locknut [Torque to 20 lb. ft. (27.0 N·m)]
h - Cable Guide Tube
i - Ride-Guide Cable Attaching Nut [Torque to 35 lb. ft. (47.5 N·m)] 1. Lubricate shank of bolt (c) with 2-4-C w/Teflon Marine
j - “Clevis Kit” Lubricant, then secure clevis to steering cable with this
k - Clevis Attaching Locknut [Torque to 20 lb. ft. (27.1 N·m)
bolt and locknut. Torque locknut (d) to 10 lb. ft (13.5
Figure 3. Installing Attaching Kit N·m).
2. Lubricate spacer (supplied with kit) with 2-4-C w/Teflon
Marine Lubricant.
3. Attach clevis to steering arm bolt using thin washer,
spacer, thick washer (positioned between clevis and
steering arm) and locknut, as shown. Torque bolt (e) to
20 lb. ft (27.0 N·m), then torque locknut (j) to 20 lb. ft.
(27.0 N·m).

7A-14 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Steering Cable Installation NOTE: Some Ride-Guide steering cables may not be
equipped with locking sleeve and cotter pin. If cable being
1. Lubricate steering cable end with Quicksilver 2-4-C w/ installed does not have these parts, disregard instructions
Teflon Marine Lubricant. to install them.
2. Install steering cable thru steering cable tube and se-
cure to cable tube with cable attaching nut. (See be- ! WARNING
low.) Do not tighten cable attaching nut at this time. After installation is completed (and before operating
3. Attach ride-guide cable to outboard steering bracket outboard), check that boat will turn right when steer-
(middle hole) using clevis kit (P/N 70599A4). ing wheel is turned right and that boat will turn left
when steering wheel is turned left. Check steering thru
4. Adjust 2 large jam nuts on cable tube of attaching kit, full range (left and right) at all tilt angles to assure inter-
so that steering wheel is in normal straight-driving po- ference-free movement.
sition with outboard in straight- driving position. Torque
each jam nut to 35 lb. ft. (47.5 N·m), then bend a side 6. Lubricate outboard end of Ride-Guide steering cable
of tab washer against flat of each jam. (below) (thru grease fitting next to cable attaching nut) with
Quicksilver 2-4-C w/Teflon Marine Lubricant.
5. Torque Ride-Guide cable attaching nut (which secures
cable to guide tube) to 35 lb. ft. (47.5 N·m). (below) In- NOTE: Ride-Guide steering cable is lubricated at the facto-
stall locking sleeve over cable attaching nut and se- ry and requires no additional lubrication at initial installa-
cure with cotter pin. Spread ends of cotter pin. tion.
a h 7. Lubricate all steering system pivot points (and ex-
o n b n posed portion of steering cable core) with Quicksilver
m m i 2-4-C w/Teflon Marine Lubricant. Lubricate at intervals
specified preceding.
8. Carefully check steering system components for wear
f (at intervals specified, preceding). Replace worn parts.
c
k 9. Check steering system fasteners (at intervals speci-
d l g fied, preceding) to be sure that they are torqued to cor-
rect specifications. (Figures 1, 2 and 3)
J e
51140
Maintenance Instructions
a h Lubrication and maintenance inspection is owner’s re-
n b n sponsibility and must be performed at intervals as specified
o m m i following:
Normal Service - Every 50 hours of operation or 60 days
(whichever comes first).
f *Severe Service - Every 25 hours of operation or 30 days
k c (whichever comes first).
g
d l *Operation in salt water is considered “Severe Service”.

J e 1. Carefully check steering components for wear. Re-

51140 place as necessary.
a - Ride-Guide Cable 2. Check steering system fasteners to be sure that they
b - Ride-Guide Yoke
c - Pivot Block are torqued to correct specifications.
d - Pivot Spacer
e - 15” (Centerline of Attaching Kit Pivot to Centerline of Engine)
3. Lubricate clevis points with a drop of light oil.
f - Pivot Attaching Locknut; Torque to 20 lb. ft. (27 N·m) 4. Inspection and lubrication of steering system should
g - Engine Steering Arm
h - Clevis Kit be performed once each year or whenever steering
i - Ride-Guide Cable Attaching Locknut; Torque to 10 lb. ft. (13.5 N·m) components are disassembled, steering effort has in-
j - Bolt (3/8” x 2-1/2”) creased or steering seems loose.
k - Flat Washer
l - Transom Bracket
m- Cable Tube Jam Nut; Torque to 35 lb. ft. (47.5 N·m)
n - Tab Washers (Bend Over Flat of Jam Nuts)
o - Cable Attaching Nut

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-15

 1. Position remote control handle into neutral detent.
Remote Control Installation
2. Manually shift outboard into neutral (propeller will ro-
IMPORTANT: Connect control cables to remote control
tate freely).
and mount remote control BEFORE attaching control
cables to engine. 3. Route shift cable (a) thru control cable grommet (b).
Install throttle and shift cables to remote control and mount 4. Adjust cable barrel (c) to attain the same length be-
remote control as outlined in the installation instructions tween cable barrel and hole in end of cable as exists
which accompany the remote control. between barrel receptacle (d) and shift actuator stud
(e), keep a slight preload toward reverse.
NOTE: It will be necessary to lift control cable rubber grom-
met out of opening in bottom cowl. so that control cables 5. Place end of shift cable on actuator stud (e), then place
can be routed thru grommet and into bottom cowl. plastic washer (f) on stud and secure with locknut (g).
e

a g

d
b
c f

b a

c
50564C
50566 6. Check shift cable adjustment as follows:
a - Control Cable Rubber Grommet
b - Shift Cable Opening a. Shift remote control into forward gear. Now,
c - Throttle Cable Opening check prop shaft, the shaft should not be able to
turn counterclockwise. If it does, adjust cable bar-
rel closer to cable end guide.
Shift Cable Installation and b. Shift remote control into neutral. The prop shaft
Adjustment to Engine now should turn freely without drag. If not, adjust
cable barrel away from cable end guide. Repeat
NOTE: Attach shift cable to engine first. Shift cable is the steps a and b.
first cable to move when remote control handle is ad-
vanced from neutral position toward in-gear position. c. Shift remote control into reverse as the prop
shaft is rotated by hand. The prop shaft should
If remote control has a neutral lock release, secure the re- not be able to turn clockwise. If it does, adjust
lease in the depressed position using a piece of tape. Now cable barrel away from cable end guide. Repeat
the true neutral detent can be found. steps a thru c.
NOTE: Move remote control handle back and forth. You d. Shift remote control into neutral. The prop shaft
will feel three detent positions; center detent is neutral. should turn freely without drag. If not, adjust cable
barrel closer to cable end guide. Repeat steps a
thru d.

7A-16 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Throttle Cable Installation and Connecting Remote Control Wiring
Adjustment to Engine Harness to Engine Wiring Harness
1. Shift remote control into neutral. (Electric Start Models)
2. Route throttle cable (a) thru control cable grommet (b). Route remote control harness or key switch harness along
side of boat to engine, fastening harness to boat. Be sure
3. Install throttle cable end (a) onto stud (c) of throttle le- that harness does not rub, get pinched or come in contact
ver. Place nylon washer (d) over stud and install lock- with bilge water.
nut (e). Tighten locknut against throttle cable end to
snug cable end against throttle lever, then back locknut Plug remote control harness or key switch harness con-
off 1/4 turn. nector (a) into engine harness connector (b) and push con-
nection securely into retainer (c).
4. Holding engine throttle lever (f) against idle stop, ad-
just throttle cable barrel (g) to slip into upper hole of
barrel receptacle, with a very light preload of throttle le- a
ver against idle stop.

b d

c c
b
e
a
g
50565B
50564D
5. Lock barrels in place with barrel retainer (h).
6. Check preload on throttle cable by placing a thin piece
of paper between idle stop screw and idle stop. Pre-
load is correct when paper can be removed without
tearing, but has some drag on it. Re-adjust cable bar-
rel, if necessary.

h 51026

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7A-17

Route remote control harness or key switch harness (d) Power Trim Wiring Connections
along side oil tank (e) and out of bottom cowl thru opening
(f) in battery cable grommet. (Models So Equipped)
Make bullet connector wiring connection, between remote
control wiring harness/key switch wiring harness and en-
gine wiring.

e IMPORTANT: Tape back and isolate any unused wiring

harness leads.
d
b

f
50566
a - Lead From Trim Solenoid (Down Solenoid)
b - Lead From Trim Solenoid (Up Solenoid)
! CAUTION
Remote control wiring harness and key switch wiring
harness must be routed between control cable rubber Battery Connections
grommet and engine harness connector, so that har-
ness will not interfere with engine throttle and shift op-
eration. ! CAUTION
Failure to observe correct polarity when connecting
battery cables to battery will result in damage to the
charging system.
1. Connect battery cables (from engine) to battery. Con-
nect red battery cable to positive (+) battery terminal
and black battery cable to negative (-) battery terminal.

7A-18 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

OUTBOARD
INSTALLATION/
ATTACHMENTS

TILLER HANDLE and CO-PILOT

7
B
Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
Steering Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2
Tiller Handle Adaptor Kit (JET 45) . . . . . . . . . . . . . . . 7B-8
Tiller Arm/Shift Lever Removal . . . . . . . . . . . . . . . 7B-9
Tiller Handle Disassembly . . . . . . . . . . . . . . . . . . 7B-11
Tiller Arm Reassembly . . . . . . . . . . . . . . . . . . . . . 7B-14
Tiller Arm/Shift Lever Installation . . . . . . . . . . . . 7B-17
Shift Link Rod Installation and Adjustment
to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-19
Throttle Cable Installation and Adjustment . . . . 7B-20
Co-Pilot Installation . . . . . . . . . . . . . . . . . . . . . . . . 7B-21
Wiring Harness Connection . . . . . . . . . . . . . . . . . 7B-23

7B-0 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Notes:

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-1

Steering Handle Kit

20

25
24
26
27 21
28
2
95
95

23
19 22
23
16
17
2 6
18
14 1

10 S

30 95

95
12

29

3
11
95
5 15 8
4 29 13
7

9 8
6

95 2-4-C With Teflon (92-825407A12)

S 2-4-C Soapy Water Solution (Obtain Locally)

7B-2 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

 Steering Handle Kit
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 STEERING ARM
2 2 BUSHING
3 1 HOUSING
4 1 PLATE
5 1 GASKET
6 SCREW (1/2 IN.) Drive Tight
6
1 SCREW (3/5 IN.) Drive Tight
7 1 CLAMP
8 2 SCREW 40 4.5
9 1 WING NUT
10 1 THROTTLE HANDLE/STOP SWITCH KIT
11 1 STOP SWITCH
12 1 SCREW Drive Tight
13 1 GRIP
14 1 J-CLAMP
15 1 J-CLAMP
– 1 THROTTLE CABLE KIT
16 1 CONDUIT
17 1 GUIDE TUBE
18 1 BARREL
19 1 SET SCREW Drive Tight
20 1 CABLE
21 1 GUIDE
22 1 ANCHOR
23 2 SET SCREW Drive Tight
24 1 SCREW 40 54.0
25 1 CAP
26 1 WASHER
27 1 WASHER
28 1 SPACER
29 1 THROTTLE TUBE
30 1 NUT 40 54.0

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-3

Steering Handle Kit

33
7
32
40 27 28
20
26 30 31
23 29
95
24
2
42 45
1 46
24
41
25
3 22
48
4 47 21
8
12
7
43
5 13
15

6 9 14
10 44

11
16
34

19 18

38
37
37 39

17
36 35
37

7 Loctite 271 (92-809820)

95 2-4-C With Teflon (92-825407A12)

7B-4 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

 Steering Handle Kit
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 BRACKET
2 2 STUD
3 2 TAB WASHER
4 2 NUT 35 47.5
5 1 STOP HARNESS
6 1 CABLE
7 1 PLUG
8 1 GROMMET
9 1 COVER
10 4 SCREW Drive Tight
11 1 HORN
12 1 PLUG
13 1 STOP SWITCH
14 1 LANYARD
15 1 RETAINER
16 1 CABLE
17 1 STUD
18 1 NUT 75 8.5
19 1 WASHER
20 1 SHIFT LEVER
21 1 SCREW 70 8.0
22 1 TAB WASHER
23 1 BUSHING
1 WASHER (BELLEVILLE)
24
1 WASHER (PLASTIC)

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-5

Steering Handle Kit

33
7
32
40 27 28
20
26 30 31
95 23 29
24
2
42 45
1 46
24
41
25
3 22
48
4 47 21
8
12
7
43
5 13
15

6 9 14
10 44

11
16
34

19 18

38
37
37 39

17
36 35
37

7 Loctite 271 (92-809820)

95 2-4-C With Teflon (92-825407A12)

7B-6 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

 Steering Handle Kit
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
25 1 WASHER
26 1 SHIFT ROD
27 1 ROD END
28 1 BUSHING
29 1 WASHER
30 1 COTTER PIN
31 1 DETENT ASSEMBLY
32 1 STUD
33 1 KNOB
34 1 CO-PILOT LEVER
35 1 CO-PILOT DRIVER
36 1 WASHER
37 3 BRAKE DISC
38 1 ARM (TOP)
39 1 ARM (BOTTOM)
40 1 HARNESS ASSEMBLY
41 1 KEY SWITCH
42 1 NUT
43 1 TRIM SWITCH
44 2 NUT
45 1 SWITCH ASSEMBLY
46 2 SCREW Drive Tight
47 1 CLAMP
48 1 SCREW Drive Tight

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-7

Tiller Handle Adaptor Kit (JET 45)

1 13

14

16
6
2
7 B
12
15
8
3 17

7
9 18
10
4 19
9
20
5 11
21
7 Loctite 271 (92-809820) A
A – Drive tight and then back off 1/4 turn.
B – Tighten until snug and then tighten an additional 1/8 turn.
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 TILLER HANDLE ADAPTOR KIT
1 1 SHIFT CABLE
2 1 TAB WASHER
3 1 SHIFT LEVER
4 1 STUD
5 1 SHIFT KNOB
6 1 CABLE BOOT
7 1 J CLIP
8 1 SCREW (1/4-20 x 7/8)
9 2 WASHER
10 1 BUSHING
11 1 NUT
12 1 CABLE SEAL
13 1 SCREW (1/4-28 x 1-3/4)
14 1 LOCKWASHER
15 1 RETAINER
16 1 SET SCREW
17 1 WASHER
18 1 WASHER
19 1 WASHER
20 1 WASHER
21 1 NUT

7B-8 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Tiller Arm/Shift Lever Removal 4. Release latch and remove throttle cable with grommet
from bottom cowl.
1. Remove battery cables from battery.

51084
2. Remove outboard cowling. 51093
3. Remove nut securing throttle cable to engine.
a - Rubber Grommet
b - Throttle Cable

5. Remove cotter key from shift rod.

f g
b
d d
e
b e
f b
g Design 2
Design 1
c
a

51092
a - Throttle Cable
b - Throttle Lever
c - Washer b c
d - Locknut
a

54256
a - Tiller Handle
b - Shift Rod
c - Lower Cowl
d - Bushing
e - Shift Handle
f - Washer
g - Cotter Key

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-9

6. Remove cover. 8. Remove plug from tiller handle bracket.

b a
a

51608

a - Cover
b - Screw (4)
51608
7. Disconnect stop switch wire at bullet connector and
a - Plug
screw securing ground wire.
9. Remove bolt and nut from tiller handle bracket.

51608

a - Stop Switch Wire (Bullet Connector) b

51608
a - Bolt
b - Nut (Hidden)

7B-10 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

10. Remove tiller handle, 2 nylon bushings, stainless steel Tiller Handle Disassembly
spacer and 2 flat washers from bracket.
1. Using a flat tip screwdriver, carefully pry/push rubber
grip off tiller handle.

d
c d
e

b b

a 51606 a
b 51603
a - Tiller Handle
b - Nylon bushing (2) a - Grip
c - Stainless Steel Spacer b - Tiller Handle
d - Washer (2)
e - Bolt 2. Remove screw from twist grip.
11. Bend tab washer away form bolt securing shift lever
and remove bolt and lever from bracket.

c a

51603

a - Screw

a b

51606
a - Tab Washer
b - Bolt
c - Shift Lever
d - Bracket

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-11

3. Cut sta-strap securing stop switch harness and re- 5. Remove throttle cable anchor screws and remove
move screw from harness J-clip. cable guide.

b a

a
51602
51603
a - Sta-Strap a - Anchor Screws
b - Screw b - Throttle Cable Guide

4. Remove stop switch and twist grip from tiller handle. 6. Remove allen screw from brass barrel and remove
barrel.

51603
51602

a - Allen Screw
b - Brass Barrel

7B-12 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

7. Unscrew (counterclockwise) stainless conduit from til- 9. Remove cover plate and gasket from tiller handle.
ler handle.
10. Remove bolt from throttle friction assembly.

c a

d b
c

c c
a

51604

51603
a - Cover Plate
b - Gasket (below plate)
c - Screws
a - Conduit d - Throttle Friction Assembly
e - Bolt
8. Pull throttle cable from tiller handle.
11. Remove throttle arm, gear assembly and friction de-
vice from tiller handle. Slide gear cover and friction de-
vice off of the throttle arm.

d c a

a
b
51604
a - Throttle Arm
b - Gear Assembly
c - Friction Device
d - Gear Cover

51604

a - Throttle Cable

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-13

12. Drive out drift pin and remove throttle gear from throttle 3. Slide cover and friction device onto throttle arm.
arm.
d c a
b

b
51604
a
51602 a - Throttle Arm
a - Gear b - Gear
b - Drift Pin c - Throttle Friction Device
d - Cover

4. Install throttle arm assembly into tiller arm.

Tiller Arm Reassembly 5. Torque friction device attaching bolt to 40 lb. in. (4.5
N·m)
1. Reinstall throttle gear on throttle arm and secure gear
to arm with new drift pin.

a a
51602
a - Gear
b - Drift Pin
51604
2. Apply a light coat of Special Lubricant 101 to gear teeth
and inside of gear cover. a - Bolt [Torque to 40 lb. in. (4.5 N.m)]

7B-14 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

6. Install gasket and cover plate over gear assembly. DO 9. Retract throttle cable into gear assembly until approxi-
NOT OVERTIGHTEN attaching screws. mately 17 in. (43 cm) extends from the tiller arm.

c a

b
c

c c

51604
51604
a - Cover Plate a - Cable [Extends 17 in. (43 cm)]
b - Gasket (Below Cover)
c - Screws 10. Slide stainless steel conduit over throttle cable and
thread into tiller arm until lightly seated. Rotate conduit
7. Rotate throttle arm so that twist grip attaching screw COUNTERCLOCKWISE ONE FULL TURN from a
hole faces DOWN and gear drift pin faces UP. lightly seated position.
8. Insert throttle cable (CURVED END FACING UP) into
tiller handle gear assembly while rotating tiller arm
COUNTERCLOCKWISE.

51604
a - Stainless Steel Conduit

51604
a - Gear Drift Pin (FACES UP)

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-15

11. Slide brass barrel over throttle cable tube. Secure bar- 13. Position throttle arm slot to face stop harness exit hole
rel to tube with allen screw approximately 3.5 in. (89 in tiller handle. Route stop switch harness through twist
mm) from stainless conduit. DO NOT OVERTIGHTEN grip, into throttle arm, and out through side of tiller han-
screw as tubing may be crushed binding throttle cable. dle.
Position barrel to face towards tiller handle.

a
b d e

c
d
51602
b a - Slot
b - Exit Hole
c c - Harness
d - Twist Grip
e - Stop Switch

14. Secure twist grip to throttle arm with attaching screw.

a
a
51607
a - Brass Barrel
b - Tube
c - Allen Screw
d - Tiller Handle

12. Install throttle cable guide onto throttle cable. Secure

guide to cable with anchor and two screws. Guide hole
should face up.
51603
a a - Screw

51602
a - Cable Guide
b - Screws (2)
c - Hole (Faces Up)

7B-16 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

15. Sta-strap harness to throttle arm. Tiller Arm/Shift Lever Installation
! CAUTION 1. Install shift lever with detent assembly to bracket.

Allow enough slack in harness (rotate throttle grip in

both directions) before securing harness to handle as-
sembly with J-clip. g
16. Attach harness to tiller arm with J-clip allowing enough
slack in harness for full throttle rotation.
17. Attach sta-strap to end of harness sleeve.

d
c e
a
d
a b
51607
a - Bolt
b - Tab Washer
b c - Washer
d - Wave Washer (2)
e - Shift Lever
f - Bushing
g - Detent Assembly

2. Install tiller handle with bushings to bracket. Secure in

51603
place with washers and bolt with nut. Tighten bolt al-
a - Sta-strap
lowing tiller handle movement. Torque nut to 40 lb. ft.
b - J-clip
(54 N·m).
18. Install rubber twist grip by aligning ridges on plastic
twist grip with grooves inside of rubber grip.
NOTE: Applying a soapy water solution to rubber grip will
ease installation.

d
c d
e

b a b b
51603
a - Ridges
b - Grooves (Under Handle)
a 51606
a - Tiller Handle
b - Bushings (2)
c - Stainless Steel Bushing
d - Washers (2)
e - Bolt

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-17

3. Reinstall plug. 5. Install Cover.

a b

51608

a - Cover
51608 b - Screw (4)
a - Plug 6. Install cotter key and components to shift rod.
4. Connect stop switch wire at bullet connector and se- f g
cure ground wire to handle with screw. b
d d
e
e
f b
g Design 2
Design 1

b c
a

a
54256
51608
a - Tiller Handle
b - Shift Rod
c - Lower Cowl
a - Stop Switch Wire (Bullet Connector) d - Bushing
e - Shift Handle
f - Washer
g - Cotter Key

7B-18 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

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

b
d
51093

a - Rubber Grommet
b - Throttle Cable

8. Proceed to “Shift Link Rod Installation and Adjustment c

to Engine” and “Throttle Cable Installation and Adjust- a
ment.” 51092

a - Shift Link Rod End

b - Actuator Bolt
c - Washer
d - Locknut (Tighten until snug, then back off 1/4 turn)

4. Check shift link rod adjustment as follows:

a. Place shift lever in “F” (forward) position. Propeller
should rotate in a CLOCKWISE direction. If pro-
peller does not rotate CLOCKWISE, length of link
rod must be reduced and step “a” repeated.
b. Place shift lever in “N” (neutral) position. Propeller
should rotate freely without drag. If not, length of
link rod must be increased and steps “a” and “b”
must be increased.
c. While rotating propeller, place shift lever in “R” (re-
verse) position. If propeller can rotate in either di-
rection, length of link rod must be increased and
steps “a” thru “c” repeated.
d. Place engine shift lever in “N” (neutral) position.
Propeller should turn freely in both directions. If
not, length of link rod must be decreased and steps
“a” thru “d” must be repeated.

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-19

Throttle Cable Installation and 4. Holding throttle lever against idle stop, adjust throttle
cable to slip into upper hole of barrel receptacle with a
Adjustment very light preload of throttle lever against idle stop. Ap-
1. Rotate throttle twist grip fully clockwise to stop “IDLE” ply small amount of Loctite 271 to threads of set screw.
position. Tighten until snug, then an additional 1/8 turn.

2. Back out set screw from throttle cable barrel until two
or three threads are exposed.

b
a

a
b
51077

a - Set Screw c
b - Throttle Cable Barrel

3. Place end of throttle cable guide over peg of throttle le-

ver and secure with locknut and washer.
51092

a - Throttle Lever
b - Idle Stop
c - Barrel Receptacle

5. Secure barrel in place with barrel retainer.

b

c
a

d a

51092

a - Throttle Cable Guide

b - Throttle Lever
c - Washer
d - Locknut (Tighten until snug, then back off 1/4 turn)

! CAUTION
51091
DO NOT exceed 1/4 turn on set screw after it has
a - Barrel Retainer
bottomed-out.
6. Check preload on throttle cable by placing a thin piece
of paper between idle stop screw and idle stop. Pre-
load is correct when paper can be removed without
tearing and still have drag on it. Readjust cable barrel
if necessary.
7. Install Cowl.

7B-20 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Co-Pilot Installation 3. Install brake disk and brake.

NOTE: To install Co-Pilot kit, tiller handle must be removed

and battery cables disconnected.
1. Install brake disk on swivel bracket. Position “bottom
up” lever, brake disk and “top up” lever onto swivel c
bracket. Note location of pin (on steering arm) in rela- b
tion to top and bottom levers as shown.

a
e a

51094
51094
b
a - Brake Disk (3)
d b - Brake
c - Pin (Holds brake in place)

4. Lubricate driver with Never Seize Lubricant or Special

Lubricant 101 (P/N 92-13872A1). Install driver into
handle and adjust until driver (flat) is flush with handle.
c

b
a

51093
a - Swivel Bracket b
b - Brake Disk
c - Bottom Up Lever
a
d - Top Up Lever
e - Pin, Steering Arm
28063
2. Double nut co-pilot stud and apply Loctite No. 35 (P/N
a - Handle
92-59328-1) to swivel bracket end of stud and install b - Driver (Flush to slightly recessed)
until flush with bottom of swivel bracket. Stake stud in
place as shown. Drive dowel pin (c) from bottom of 5. Install components to stud. Align hex of driver with hex
swivel bracket until flush with bottom of bracket. in brake.

b
b c

a c
28063

a
51094

c a - Handle
b - Driver
c - Plastic Washer
51094
a - Stud
b - Stake Marks
c - Dowel Pin (Driven thru Bottom of Swivel Bracket)

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-21

6. Holding components in place (lever facing forward), in- 2. Install tiller handle to studs with shift rod positioned thru
stall lock nut and torque to 75 lb. in. (8 N·m). Secure cowl opening as shown.
knob to lever with bolt. g
b f
d d
e
e
f b
g Design 2
Design 1
a

c
b 51095 b c
a - Locknut [75 lb. in. (8 N·m)] a
b - Knob
c - Bolt [45 lb. in. (5 N·m)]
54256
a - Tiller Handle
Tiller Handle Installation b - Shift Rod
c - Cowl
1. Apply Loctite No. 35 (P/N 92-59328-1) to threads d - Bushing
e - Shift Handle
(steering arm end) of tiller handle studs. Install with f - Washer
stud installer. Tighten securely. g - Cotter Key

3. Secure tiller handle assembly in place.

a
51092
b b
a - Studs
b - Steering Arm
51091

a - Tiller Handle Assembly

b - Tab Washer (bend tabs against flats of locknuts)
c - Locknuts [Torque to 26 lb. ft. (35 N·m)]

7B-22 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

4. Install rubber grommet to throttle cable and install into 2. Route wiring harness thru rubber grommet. Note, light
bottom cowl. Note, a light lubricant on grommet will aid oil on rubber grommet will aid in wiring harness instal-
in installation over shift rod. lation.

b
b

c a

51093 51095

a - Rubber Grommet a - Wiring Harness

b - Throttle Cable b - Rubber Grommet
c - Shift Rod
3. Connect handle wiring harness at engine harness con-
5. Adjust shift link rod and throttle cable “Shift Link Rod nector.
Installation and Adjustment” and “Throttle Cable In-
stallation and Adjustment” as required.

Wiring Harness Connection

1. Remove battery cables from battery.

a
b

51091

a - Engine Harness Connector

b - Handle Harness Connector

51084

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7B-23

4. Reconnect battery cables. 5. Adjust co-pilot tension by moving handle to port (loos-
en) or starboard (tighten). Locknut on co-pilot stud may
have to be adjusted to attain desired tension on tiller
arm.

51084 MORE LESS

51095

7B-24 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

OUTBOARD
INSTALLATION/
ATTACHMENTS

REWIND STARTER

7
C
Table of Contents
Page
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Rewind Starter Components . . . . . . . . . . . . . . . . . . . . 7C-2
Rewind Starter Disassembly . . . . . . . . . . . . . . . . . . . . 7C-4
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . 7C-4
Rewind Starter Reassembly . . . . . . . . . . . . . . . . . . . . 7C-5
Adjusting Rewind Spring Tension . . . . . . . . . . . . . 7C-6
Starter Interlock Cable Adjustment . . . . . . . . . . . . 7C-7

7C-0 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

Notes:

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7C-1

Starter Assembly (MANUAL – 55)

14 2 Cycle Outboard Oil (92-13249A24)

95 2-4-C With Teflon (92-825407A12)

7C-2 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

 Starter Assembly (MANUAL – 55)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 HANDLE ASSEMBLY
2 1 REST
3 1 SEAL
4 2 SCREW 55 6.0
5 2 SPACER
6 4 BUSHING
7 8 GROMMET
8 8 WASHER
9 4 NUT 75 8.5
10 1 INTERLOCK CABLE
11 1 SCREW Drive Tight
12 1 WASHER
13 1 COTTER PIN
14 1 SCREW Drive Tight
15 1 COTTER PIN
16 1 WASHER
– 1 RECOIL STARTER
17 1 STARTER HOUSING
18 1 SPRING
19 1 INTERLOCK LEVER
20 1 CAM
21 1 RETAINER
22 3 SCREW
23 1 WASHER - SPRING
24 1 SPRING
25 1 STARTER SHEAVE
26 2 SPRING
27 2 CAM
28 2 RETAINING RING
29 1 STARTER ROPE
30 1 SPRING
31 1 CAM
32 1 SCREW
33 1 BUSHING
34 1 RETAINING RING

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7C-3

Rewind Starter Disassembly 6. Remove cam retainer.

! WARNING a b
When disassembling and reassembling rewind start-
er, SAFETY GLASSES must be worn in case rewind
spring uncoils out of the housing.
1. Remove retaining clip and attaching screw which se-
cures shift interlock cable to starter housing.
2. Remove bolts (4) securing rewind starter to engine.

b a

c c

28374

a - Screws (3)
b - Cam Retainer

7. Remove cam lever, cam lever spring, and interlock le-

c c
ver.

b
51606
c
a - Retaining Clip
b - Screw
c - Bolts (4)

3. Slowly pull the starter rope out from the handle rest
approximately 2 feet (60 cm) and tie an overhand knot
between the rewind housing and the handle rest.
4. Remove retainer from rope handle and untie the rope
handle knot.
5. Remove the rewind starter.

28375

a - Cam Lever
b - Cam Lever Spring
c - Interlock Lever

a - Overhand Knot
b - Retainer

7C-4 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

8. Remove starter sheave. Cleaning and Inspection
1. Clean components in solvent and dry with compressed
air.

a 2. Inspect rewind spring for kinks, burrs, corrosion of

breakage.
3. Inspect starter sheave, rope guide and starter housing
for nicks, grooves, cracks, wear or distortion, especial-
ly area of rope travel.
4. Inspect bushing, starter drive pawl and spring for wear
or damage.
5. Inspect starter rope for wear.
6. Replace components as necessary.

Rewind Starter Reassembly

b
! WARNING
When reassembling rewind starter, SAFETY GLASSES
51605
must be worn in case rewind spring uncoils out of the
a - Starter Sheave housing.
b - Screw
1. Install spring/cover assembly into sheave.
9. Spring is replaced as a spring/cover assembly.

a
a

51607
51607 a - Spring/Cover Assembly
a - Spring/Cover Assembly

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7C-5

2. Install starter sheave to housing and secure in place 4. Reinstall cam retainer and secure with screws (3).
with screw. Torque to 135 lb. in. (15.3 N·m).
a
a b

28374
b 51605
a - Screws (3)
a - Starter Sheave b - Cam Retainer
b - Screw

3. Install interlock lever, position cam spring into recess

of starter housing and reinstall cam lever. Adjusting Rewind Spring Tension
a 1. Rotate sheave counterclockwise until it stops (coil is
bound). Then back off one full turn, plus what is needed
to align rope end with hole in housing. Never back off
b sheave less than one full turn.
c 2. Route starter rope thru rope guide in housing. Tie a
overhand knot in rope approximately 12 in. (305 mm)
from end of rope.

28375

a - Cam Lever
b - Cam Lever Spring
c - Interlock Lever

a - Rotate Counterclockwise and Back Off at Laest One Full Turn

b - Tie Off Starter Rope 12 Inches (305 mm) from End with Overhand
Knot

7C-6 - OUTBOARD INSTALLATION/ATTACHMENTS 90-817643R1 DECEMBER 1996

NOTE: Check operation of rewind and rewind tension be- Starter Interlock Cable Adjustment
fore outboard installation.
IMPORTANT: Lubricate core wire of interlock cable
3. Place rewind starter on engine.
with light oil prior to making adjustments.
4. Pull starter rope thru bracket, handle, and starter rope
retainer. Secure starter rope to starter rope retainer 1. While rotating the propeller shaft, place the gear shift
with knot. lever into REVERSE.
2. Return the gear shift lever to NEUTRAL without going
a past neutral detent.
3. Place end of interlock cable over pin of cam lever and
secure with retaining pin.
4. Secure interlock cable to starter housing using adjust-
b
ing screw. Do not tighted screw at this time.
c
d 5. Adjust interlock cable to align raised mark of cam lever
with pointer of rewind housing.

c
a - Starter Rope
b - Bracket
c - Handle
d - Starter Rope Retainer

5. Secure rewind starter to engine bolts (4), torque to

90 lb. in. (10 N·m). Secure interlock lock cable with
a
retaining clip and screw.
b
d
b a
e

c c

28376

a - Interlock Cable
b - Retaining Pin
c - Adjustment Screw
d - Raised Mark of Cam Lever
e - Pointer of Rewind Housing

c c 6. Tighten cable adjustment screw and check adjustment

after 4 or 5 shift cycles.

d
51606

a - Retaining Clip
b - Screw
c - Bolts (4) Torque to 90 lb. in. (10 N·m)
d - Bracket

90-817643R1 DECEMBER 1996 OUTBOARD INSTALLATION/ATTACHMENTS - 7C-7