SERVICE

MANUAL
MODELS
40·50·55·60

With Serial Numbers

United States . . 0G531301 and ABOVE
Belgium . . . . . . . 09974454 and ABOVE

Printed in U.S.A. 1997, Mercury Marine 90-852572R1 JANUARY 1998

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 Notice who uses a service procedure and/or tool, which is
not recommended by the manufacturer, first must
Throughout this publication, “Dangers”, “Warnings” completely satisfy himself that neither his nor the
and “Cautions” (accompanied by the International products safety will be endangered by the service
HAZARD Symbol ) are used to alert the mechanic procedure selected.
to special instructions concerning a particular service
All information, illustrations and specifications con-
or operation that may be hazardous if performed in-
tained in this manual are based on the latest product
correctly or carelessly. OBSERVE THEM CARE-
FULLY! information available at the time of publication. As re-
quired, revisions to this manual will be sent to all deal-
These “Safety Alerts” alone cannot eliminate the haz- ers contracted by us to sell and/or service these prod-
ards that they signal. Strict compliance to these spe- ucts.
cial instructions when performing the service, plus
It should be kept in mind, while working on the prod-
“Common Sense” operation, are major accident pre-
vention measures. uct, that the electrical system and ignition system are
capable of violent and damaging short circuits or se-
vere electrical shocks. When performing any work
DANGER where electrical terminals could possibly be
DANGER - Immediate hazards which WILL result grounded or touched by the mechanic, the battery
in severe personal injury or death. cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed
WARNING during service they should be covered to protect
WARNING - Hazards or unsafe practices which against accidental entrance of foreign material which
COULD result in severe personal injury or death. could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
CAUTION It is important to note, during any maintenance proce-
Hazards or unsafe practices which could result dure replacement fasteners must have the same
in minor personal injury or product or property measurements and strength as those removed.
damage. Numbers on the heads of the metric bolts and on the
surfaces of metric nuts indicate their strength. Ameri-
can bolts use radial lines for this purpose, while most
American nuts do not have strength markings. Mis-
Notice to Users of This matched or incorrect fasteners can result in damage
or malfunction, or possibly personal injury. There-
Manual fore, fasteners removed should be saved for reuse in
This service manual has been written and published the same locations whenever possible. Where the
by the Service Department of Mercury Marine to aid fasteners are not satisfactory for re-use, care should
our dealers’ mechanics and company service per- be taken to select a replacement that matches the
sonnel when servicing the products described here- original.
in.
It is assumed that these personnel are familiar with
the servicing procedures of these products, or like or
similar products manufactured and marketed by
Mercury Marine, that they have been trained in the
recommended servicing procedures of these prod-
ucts which includes the use of mechanics’ common
hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone

90-852572R1 JANUARY 1998 i

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 Cleanliness and Care of In addition, personnel should not work on or under an
outboard which is suspended. Outboards should be
Outboard Motor attached to work stands, or lowered to ground as
soon as possible.
A marine power product is a combination of many
machined, honed, polished and lapped surfaces with We reserve the right to make changes to this manual
tolerances that are measured in the ten thousands of without prior notification.
an inch./mm. When any product component is serv- Refer to dealer service bulletins for other pertinent in-
iced, care and cleanliness are important. Throughout formation concerning the products described in this
this manual, it should be understood that proper manual.
cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is
considered standard shop practice even if not specif-
ically stated.
Whenever components are removed for service,
Page Numbering
they should be retained in order. At the time of instal- Two number groups appear at the bottom of each
lation, they should be installed in the same locations page. The example below is self-explanatory.
and with the same mating surfaces as when re-
moved.
Before raising or removing and outboard engine from
a boat, the following precautions should be adhered
to:
1. Check that flywheel is secured to end of crank-
shaft with a locknut and lifting eye is threaded into
flywheel a minimum of 5 turns.
2. Connect a hoist of suitable strength to the lifting
eye.

EXAMPLE:

90-826148R1 JANUARY 1997 LOWER UNIT - 6A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

Page Number
ii 90-852572R1 JANUARY 1998
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 Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
Fuel System
3
B - Carburetor
C - Oil Injection
D - Emissions
Section 4 - Powerhead
Powerhead
4
Section 5 - Mid-Section
A - 40/50 Clamp/Swivel Brackets & Drive Shaft Housing
B - 55/60 Clamp/Swivel Brackets & Drive Shaft Housing
C - 40/50 Power Trim
Mid-Section
5
D - 55/60 Power Trim
E - 40/50 Manual Tilt
F - 55/60 Manual Tilt
Section 6 - Lower Unit
Lower Unit
6
A - 40/50 Lower Unit
B - 55/60 Lower Unit
C - 60 Bigfoot
D - Jet Drive
Attachments/
Control Linkage
7
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter
Manual Starter
8

90-852572R1 JANUARY 1998 iii

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 IMPORTANT 1
INFORMATION
A

SPECIFICATIONS

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Propeller Information Charts . . . . . . . . . . . . . 1A-4
Mercury/Mariner 40 HP (3 Cyl.) . . . . . . . . . 1A-4
Mercury/Mariner 50 HP (3 Cyl.) . . . . . . . . . 1A-5
Mercury/Mariner 55 HP (3 Cyl.) . . . . . . . . . 1A-6
Mercury/Mariner 60 HP (3 Cyl.) . . . . . . . . . 1A-7
Mercury/Mariner 60 HP (3 Cyl.) Bigfoot . . 1A-8

1A-0 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Specifications
Models 40/50/55/60
Model 40 40 (29.8)
HORSEPOWER Model 50 50 (37.3)
(kW) Model 55 55 (41.0)
Model 60 60 (44.7)
Manual
40/50 ML 205 lbs. (93.0 kg)
55 ML 220 lbs. (99.8 kg)
Electric
OUTBOARD WEIGHT
40/50 ELPTO 204 lbs. (92.5 kg)
40/50 ELO 200 lbs. (90.7 kg)
60 ELPTO 219 lbs. (99.3 kg)
60 ELO 215 lbs. (97.5 kg)
Type 3 Cylinder-2 Cycle-Loop Charged
CYLINDER BLOCK
Displacement 59 cu. in. (967 cc)
STROKE Length 2.796 in. (71 mm)
Diameter 2.993 in. (76 mm)
CYLINDER BORE Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Type Aluminum
Standard Diameter 2.988 in. (75.895 mm)
PISTON
0.015 in. (0.381 mm) Oversize 3.003 in. (76.276 mm)
0.030 in. (0.762 mm) Oversize 3.018 in. (76.657 mm)
Reed Stand Open (Max.) 0.020 in. (0.50 mm)
Reed Stop (Max.)
REEDS 40 0.090 in. (2.286 mm)
50/55/60 Not Adjustable
Reed Thickness 0.010 in. (0.254 mm)
Recommended Gasoline Unleaded-87 Octane Minimum
Recommended Oil Quicksilver TC-WII or TC-W3
2 Cycle Outboard Oil
Break-in Gasoline/Oil Ratio
Manual Start Models Pre-mixed Gasoline and Oil 25:1
Electric Start Models 50:1 (In Fuel Tank)
FUEL SYSTEM
After Break-in Gasoline/Oil Ratio
Manual Start Models Pre-mixed Gasoline and Oil 50:1
Electric Start Models Straight Gasoline
Fuel Pressure
@ Idle 3.5 PSI (24 kPa)
@ W.O.T. 6.0 PSI (41 kPa)

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-1

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 40/50
Gear Ratio 1.83:1
Gearcase Capacity 14.9 fl. oz. (440 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 22 Spiral/Bevel
Pinion Gear
Number of Teeth 12 Spiral/Bevel
Pinion Height 0.025 in. (0.64 mm)
Forward Gear Backlash No Adjustment
Water Pressure
@ Idle 0.5-1.5 PSI (3-10 kPa)
@ W.O.T. 5.0–7.0 PSI (35-48 kPa)
Pressure Test 10-12 PSI (69-83 kPa)
for 5 Minutes
55/60
Gear Ratio 1.64:1
Gearcase Capacity 11.5 fl. oz. (340 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 23
Pinion Gear
Number of Teeth 14
GEAR HOUSING Pinion Height 0.025 in. (0.64 mm)
Pinion Gear Locating Tool
(91-817008A2)
Forward Gear Backlash 0.013-0.019 in. (0.33-0.48 mm)
Water Pressure
@ Idle 1–3 PSI (7-20 kPa)
@ W.O.T. 7–12 PSI (48-83 kPa)
Pressure Test 10-12 PSI (69-83 kPa)
for 5 Minutes
60 Bigfoot
Gear Ratio 2.3:1
Gearcase Capacity 22.5 fl. oz. (655 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 30
Pinion Gear
Number of Teeth 13
Pinion Height 0.025 in. (0.64 mm)
Forward Gear Backlash 0.012 in.-0.019 in. (0.30 mm-0.48 mm)
Water Pressure 10-15 PSI (69-103 kPa) @ 5250 RPM
@ Idle 2-7 PSI (14–48 kPa)
@ W.O.T. 10-15 PSI (69-104 kPa)
Pressure Test 10-12 PSI (69-83 kPa)
for 5 Minutes

1A-2 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Manual Start Recoil Starter
Electric Start
STARTING SYSTEM Starter Draw (Under Load) 125 Amperes
Battery Rating Min. Reserve Cap. Rating of 100
Min. and CCA of 350 Amperes
Type Capacitor Discharge
Spark Plug Type NGK BP8H-N-10
IGNITION SYSTEM *NGK BPZ8H-N-10
Spark Plug Gap 0.040 in. (1.0mm)
Firing Order 1-2-3
Alternator Output Single Phase (12 Pole)
Electric Models 16 Amperes @ 3000 RPM
CHARGING SYSTEM
9 Amperes @ 3000 RPM
Manual Models (Not Regulated) 7 Amperes @ 3000 RPM
Idle RPM 675 ± 25
Wide Open Throttle (W.O.T.) RPM 5000-5500
Idle Mixture Screw Adjustment
Preset (Turns Out) 11/4 ± 1/4
Float Adjustment
CARBURETOR Float Level 9/ in. (14 mm)
16
Main Jet
Model 40 (WME-53, 69) 0.044 in.
Model 50 (WME-68) 0.052 in.
Model 55 (WME-57) 0.058 in.
Model 60 (WME-58) 0.060 in.
Recommended Oil Quicksilver TC-WII or TC-W3
2 Cycle Outboard Oil
Oil Tank Capacity/Approx. Time 3.0 qts. (2.8 L) 7 hours
Reserve Capacity/Approx. Time 14.5 fl. oz. (0.43 L) 1/2 hour
OIL
INJECTION
Oil Output With Engine RPM of 1500
and Oil Pump @ W.O.T.
Model 40 15.0 ± 3.0 cc of oil in 10 minutes
Model 50/60 22.0 ± 3.0 cc of oil in 10 minutes
Idle T.D.C. ± 2°
Maximum Timing
@ Cranking Speed
-Model 40/50/60 24° B.T.D.C.
TIMING
-Model 55/60 Seapro-Marathon 18° B.T.D.C.
@ 5000 RPM
– Model 40/50/60 22° B.T.D.C.
– Model 55/60 Seapro-Marathon 16° B.T.D.C.
Temperature
TEMPERATURE Normal Open - No Continuity
SWITCH 190°F ± 8° (88°C ± 4°C) Closed - Full Continuity
170°F ± 8° (77°C ± 4°C) Open - No Continuity
*Suppressor (resistor) spark plug

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1A-3

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 Propeller Information Charts

Mercury/Mariner 40 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 1.83:1
Approx. Approx. Speed
No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
10” 19” 3 Alum Up to 900 Up to 14’ 41-49 48-73146A40
10” 17” 3 Alum Up to 900 Up to 14’ 35-43 48-73144A40
10” 16” 3 SS Up to 1200 Up to 15’ 32-40 48-91818A5
10” 16” 3 Alum Up to 1200 Up to 15’ 32-40 48-73142A40
10-1/8” 15” 3 SS 1000-1500 13-15’ 28-37 48-855862A5
10-1/8” 15” 3 Alum 1000-1500 13-15’ 28-37 48-73140A40
10-3/8” 14” 3 Alum 1100-1700 14-16’ 25-34 48-816706A40
10-1/4” 14” 3 SS 1100-1700 14-16’ 25-34 48-855860A5
10-1/4” 14” 3 Alum 1100-1700 14-16’ 25-34 48-73138A40
10-1/2” 13” 3 Alum 1300-2100 14-17’ 21-31 48-816704A40
10-3/8” 13” 3 SS 1300-2100 14-17’ 21-31 48-855858A5
10-3/8” 13” 3 Alum 1300-2100 14-17’ 21-31 48-73136A40
10-3/4” 12” 3 Alum 1500-2500 15-19’ 18-27 48-816702A40
10-5/8” 12” 3 SS 1500-2500 15-19’ 18-27 48-855856A5
10-5/8” 12” 3 Alum 1500-2500 15-19’ 18-27 48-73134A40
10-7/8” 11” 3 Alum 1800-3500 16-21’ 14-24 48-85632A40
11-1/4” 10” 3 Alum 2000+ 17’+ 11-21 48-73132A40
11-5/8” 11” 3 SS 1800-3500 16-21’ 14-24 48-823478A5
11-5/8” 10-1/2” 3 Alum 2000+ 17’+ 13-23 48-827312A10
12-1/4” 9” 3 Alum 2500+ 18’+ 8-17 48-87818A10
12-1/4” 9” 3 SS 2500+ 18’+ 8-17 48-97868A10
12-1/2” 8” 3 Alum 3000+ 20’+ 1-14 48-42738A10

1A-4 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Mercury/Mariner 50 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction : 1.83:1
Approx. Approx. Speed
No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
10” 19” 3 Alum Up to 1100 Up to 14’ 41-49 48-73146A40
10” 17” 3 Alum Up to 1400 Up to 14’ 35-43 48-73144A40
10” 16” 3 SS 1200-1500 Up to 15’ 32-40 48-91818A5
10” 16” 3 Alum 1200-1500 Up to 15’ 32-40 48-73142A40
10-1/8” 15” 3 SS 1300-1800 13-15’ 28-37 48-855862A5
10-1/8” 15” 3 Alum 1300-1800 13-15’ 28-37 48-73140A40
10-3/8” 14” 3 Alum 1400-2100 14-16’ 25-34 48-816706A40
10-1/4” 14” 3 SS 1400-2100 14-16’ 25-34 48-855860A5
10-1/4” 14” 3 Alum 1400-2100 14-16’ 25-34 48-73138A40
10-1/2” 13” 3 Alum 1600-2600 14-17’ 21-31 48-816704A40
10-3/8” 13” 3 SS 1600-2600 14-17’ 21-31 48-855858A5
10-3/8” 13” 3 Alum 1600-2600 14-17’ 21-31 48-73136A40
10-3/4” 12” 3 Alum 1900-3200 15-19’ 18-27 48-816702A40
10-5/8” 12” 3 SS 1900-3200 15-19’ 18-27 48-855856A5
10-5/8” 12” 3 Alum 1900-3200 15-19’ 18-27 48-73134A40
10-7/8” 11” 3 Alum 2200-4300 16-21’ 14-24 48-85632A40
11-1/4” 10” 3 Alum 2500+ 17’+ 11-21 48-73132A40
11-5/8” 11” 3 SS 2200-4300 16-21’ 14-24 48-823478A5
11-5/8” 10-1/2” 3 Alum 2200+ 17’+ 13-23 48-827312A10
12-1/4” 9” 3 Alum 3000+ 18’+ 8-17 48-87818A10
12-1/4” 9” 3 SS 3000+ 18’+ 8-17 48-97868A10
12-1/2” 8” 3 Alum 3500+ 20’+ 1-14 48-42738A10

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 Mercury/Mariner 55 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 16-1/2”, 21”, 23-1/2”
Right Hand Rotation Standard
Gear Reduction : 2.3:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
12-3/4” 26” 5 SS Up to 800 Up to 15’ 48-54 48-815748A45
13-1/2” 26” 3 SS Up to 800 Up to 15’ 48-54 48-16996A30
12-3/4” 24” 5 SS Up to1000 Up to 15’ 46-52 48-815746A45
13-1/2” 24” 3 SS Up to 1000 Up to 15’ 46-52 48-16994A30
12-1/2” 23” 3 Alum 700-1100 Up to 15’ 45-51 48-77350A45
12-3/4” 22” 5 SS 700-1100 Up to 15’ 43-49 48-815744A45
13-1/2” 22” 3 SS 700-1100 Up to 15’ 43-59 48-16992A30
12-3/4” 21” 3 Alum 800-1200 13-16’ 40-47 48-77348A45
12-3/4” 20” 5 SS 800-1200 13-16’ 38-45 48-816612A45
13-1/2” 20” 3 SS 800-1200 13-17’ 38-45 48-16990A30
13” 19” 3 Alum 1000-1400 14-17’ 35-42 48-77346A45
13” 18” 3 SS 1000-1400 14-17’ 33-40 48-16988A30
13-1/4” 17” 3 Alum 1200-1700 15-18’ 31-38 48-77344A45
13-1/8” 16” 3 SS 1200-1700 15-18’ 29-36 48-16986A30
13-3/4” 15” 3 Alum 1500-2100 16-19’ 26-33 48-77342A45
13-3/8” 14” 3 SS 1500-2100 16-19’ 23-31 48-17314A30
14” 13” 3 Alum 1900-2500 17’+ 20-28 48-77340A45
14” 12” 3 SS 1900-2500 17’+ 17-26 48-17312A30
14” 11” 3 Alum 2200+ 18’+ 1-22 48-77338A45
14” 10” 3 SS 2400+ 19’+ 1-20 48-17310A30

1A-6 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Mercury/Mariner 60 HP (3 Cyl.)
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 1.64:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
10” 19” 3 Alum Up to 800 Up to 14’ 48-55 48-73146A40
10” 17” 3 Alum Up to 1000 Up to 15’ 44-51 48-73144A40
10” 16” 3 SS 700-1100 Up to 15’ 41-48 48-91818A5
10” 16” 3 Alum 700-1100 Up to 15’ 41-48 48-73142A40
10-1/8” 15” 3 SS 800-1200 13-15’ 38-45 48-855862A5
10-1/8” 15” 3 Alum 800-1200 13-15’ 38-45 48-73140A40
10-1/4” 14” 3 SS 900-1500 14-16’ 35-41 48-816706A40
10-3/8” 14” 3 Alum 900-1500 14-16’ 35-41 48-855860A5
10-3/8” 13” 3 SS 1200-1800 15-17’ 32-38 48-73138A40
10-1/2” 13” 3 Alum 1200-1800 15-17’ 32-38 48-816704A40
10-5/8” 12” 3 SS 1500-2100 16-18’ 28-34 48-855858A5
10-3/4” 12” 3 Alum 1500-2100 16-18’ 28-34 48-73136A40
10-7/8” 11” 3 Alum 1800-2400 16-18’ 24-30 48-816702A40
11-5/8” 11” 3 SS Workboat 16’+ 24-30 48-855856A5
12” 10-1/2” 3 Alum 2000-2600 17’+ 22-28 48-73134A40
11-5/8” 10-1/2” 3 Alum 2000-2600 17’+ 22-28 48-85632A40
11-1/4” 10” 3 Alum 2100-2600 17’+ 20-26 48-73132A40
12-1/4” 9” 3 SS 2400+ 18’+ 14-22 48-823478A5
12-1/4” 9” 3 Alum 2400+ 18’+ 14-22 48-827312A10
12-1/2” 8” 3 Alum 2800+ 19’+ 1-18 48-87818A10

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 Mercury/Mariner 60 HP (3 Cyl.) Bigfoot
Wide Open Throttle RPM: 5000-5500
Recommended Transom Heights : 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction : 2.31:1
Approx. Approx. Speed
No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13” 18” 3 SS Up to 1100 Up to 14’ 41-49 48-16988A45
13-1/4” 17” 3 Alum Up to 1400 Up to 14’ 35-43 48-77344A45
13-1/8” 16” 3 SS 1200-1500 Up to 15’ 32-40 48-16986A45
13-3/4” 15” 3 Alum 1200-1500 Up to 15’ 32-40 48-77342A45
13-3/8” 14” 3 SS 1300-1800 13-15’ 28-37 48-17314A45
14” 13” 3 Alum 1300-1800 13-15’ 28-37 48-77340A45
14” 12” 3 SS 1400-2100 14-16’ 25-34 48-17312A45
14” 11” 3 Alum 1400-2100 14-16’ 25-34 48-77338A45
14” 10” 3 Alum 1400-2100 14-16’ 25-34 48-854342A45
14” 9” 3 Alum 1600-2600 14-17’ 21-31 48-854340A45

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 IMPORTANT 1
INFORMATION
B

MAINTENANCE

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
1B-1
Gear Case Lubricant Capacity . . . . . . . . . 1B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .1B-1
Quicksilver Lubricant/Sealant . . . . . . . . . . . . 1B-1
Inspection and Maintenance Schedule . . . . 1B-2
Before Each Use . . . . . . . . . . . . . . . . . . . . 1B-2
After Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-2
Every 100 Hours of Use or Once Yearly,
Whichever Occurs First . . . . . . . . . . . . . . . 1B-2
Every 300 Hours of Use or Three Years 1B-2
Before Periods of Storage . . . . . . . . . . . . 1B-2
Flushing The Cooling System . . . . . . . . . . . . 1B-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3
Corrosion Control Anode . . . . . . . . . . . . . . . . 1B-4
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . 1B-5
Checking Power Trim Fluid . . . . . . . . . . . . . . 1B-7
60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
40/50 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Gear Case Lubrication . . . . . . . . . . . . . . . . . . 1B-8
Draining Gear Case . . . . . . . . . . . . . . . . . . 1B-8
Checking Lubricant Level and Filling
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Storage Preparations . . . . . . . . . . . . . . . . . . . 1B-9
Protecting External Outboard
Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Protecting Internal Engine Components 1B-9
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Positioning Outboard for Storage . . . . . . 1B-10
Battery Storage . . . . . . . . . . . . . . . . . . . . . 1B-10

1B-0- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Specifications 2. Quicksilver Anti-Corrosion Grease
P/N 92-78376A6

Gear Case Lubricant Capacity

Gear Case Ratio Capacity
1.83:1 14.9 fl. oz. (440 mL)
1.64 :1 11.5 fl. oz. (340 mL)
2.3:1 22.5 fl. oz. (655 mL)

Special Tools
1. Quicksilver Flushing Attachment (44357A2) 3. 2-4-C Marine Lubricant with Teflon
P/N 92-825407A12

4. SAE 30W Motor Oil - Obtain Locally

50551

Quicksilver
Lubricant/Sealant 30W

1. Gear Lube-Premium Blend P/N 92-19007A24

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-1

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 Inspection and Maintenance Every 100 Hours of Use or Once
Yearly, Whichever Occurs First
Schedule
1. Lubricate all lubrication points. Lubricate more
frequently when used in salt water.
Before Each Use 2. Inspect and clean spark plugs.
1. Check that lanyard stop switch stops the engine. 3. Check engine fuel filter for contaminants.
2. Visually inspect the fuel system for deterioration 4. Adjust carburetor(s) (if required).∗
or leaks.
3. Check outboard for tightness on transom. 5. Check engine timing setup.∗

4. Check steering system for binding or loose com- 6. Check corrosion control anodes. Check more fre-
ponents. quently when used in salt water.

5. Remote Control Models – Visually check steering 7. Drain and replace gear case lubricant.
link rod fasteners for proper tightness. 8. Lubricate splines on the drive shaft.
6. Check propeller blades for damage. 9. Check power trim fluid.
10. Inspect battery.
After Each Use 11. Check control cable adjustments. ∗
1. Flush out the outboard cooling system if operat- 12. Remove engine deposits with Quicksilver Power
ing in salt or polluted water. Tune Engine Cleaner.
2. Wash off all salt deposits and flush out the ex- 13. Check tightness of bolts, nuts, and other fasten-
haust outlet of the propeller and gear case with ers.
fresh water if operating in salt water.
* These items should be serviced by an authorized
dealer.

Every 300 Hours of Use or Three

Years
1. Replace water pump impeller (more often if over-
heating occurs or reduced water pressure is
noted).

Before Periods of Storage

Refer to Storage Procedure.

1B-2- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Flushing The Cooling 3. Start the engine and run it at idle speed in neutral
shift position.
System 4. Adjust water flow (if necessary) so excess water
Flush the internal water passages of the outboard continues leaking out from around the rubber
with fresh water after each use in salt, polluted, or cups to ensure the engine is receiving an ade-
muddy water. This will help prevent a buildup of de- quate supply of cooling water.
posits from clogging the internal water passages. 5. Check for a steady stream of water flowing out of
Use a Quicksilver accessory (or equivalent) flushing the water pump indicator hole. Continue flushing
attachment. the outboard for 3 to 5 minutes, carefully monitor-
ing water supply at all times.
WARNING
To avoid possible injury when flushing, remove
the propeller. Refer to Propeller Replacement.
1. Remove propeller (refer to Propeller Replace-
ment). Install the flushing attachment so the rub-
ber cups fit tightly over the cooling water intake
holes.

6. Stop the engine, turn off the water, and remove

the flushing attachment. Reinstall the propeller.

Fuel System
IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid
2. Attach a water hose to the flushing attachment. during storage and can damage the fuel system.
Turn on the water and adjust the flow so water is If the gasoline being used contains alcohol, it is
leaking around the rubber cups to ensure the en- advisable to drain as much of the remaining gas-
gine receives an adequate supply of cooling wa- oline as possible from the fuel tank, remote fuel
ter. line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, and car-
buretors) with treated (stabilized) fuel to help prevent
formation of varnish and gum. Proceed with following
instructions.
1. Portable Fuel Tank – Pour the required amount of
Quicksilver Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank
back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Quicksilver Gasoline Stabilizer
(follow instructions on container) into a separate
container and mix with approximately one quart
(one liter) of gasoline. Pour this mixture into fuel
tank.

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-3

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 3. Place the outboard in water or connect flushing
attachment for circulating cooling water. Run the
engine for ten minutes to allow treated fuel to
reach the carburetors.

Corrosion Control Anode

1. Your outboard has two corrosion control anodes.
One of the anodes is the trim tab installed on the
gear case and the other is installed on the bottom
of the transom bracket assembly. An anode helps
protect the outboard against galvanic corrosion
by sacrificing its metal to be slowly eroded in-
stead of the outboard metals.

b
a - Trim Tab Anode
b - Transom Bracket Anode

NOTE: Each anode requires periodic inspection es-

pecially in salt water which will accelerate the ero-
sion. To maintain this corrosion protection, always re-
place the anode before it is completely eroded. Never
paint or apply a protective coating on the anode as
this will reduce effectiveness of the anode.

1B-4- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Lubrication Points
ITEM TYPE OF FRESH WATER SALT WATER
DESCRIPTION
NO. LUBRICANT FREQUENCY FREQUENCY
Throttle/Shift linkage
1
Pivot Points
Shift Handle (Tiller Quicksilver 2-4-C
2
Handle Models) Marine Lubricant
3 Swivel Pin 100 Hours of Use or
Ride Guide Steering Once Per Season
4
Cable
5 Tilt Tube/Co-Pilot
Steering Link Rod
6 SAE 30W Motor Oil 100 Hours of Use or Once Per Season
Pivot Points
Quicksilver Anti-Cor-
7 Propellor Shaft rosion Grease or
2-4-C W/Teflon
Starter Motor Pinion
8 SAE 30W Motor Oil
Gear
9 Gear Housing Bear- Quicksilver Special
* ing Carrier Lubricant 101
10 Quicksilver Gear
Gear Housing
◊ Lube
Engine Crankshaft
Quicksilver 2-4-C
∆ Splines to Drive Shaft Once Per Season
Marine Lubricant
Splines
* Refer to lubrication instructions outlined in “Salt Water Cor- ◊ Refer to “Gear Housing Lubrication” of this section (see
rosion - Gear Housing Bearing Carrier and Cover Nut” “Table of Contents”).
of this section (see “Table of Contents”).
∆ Refer to “Gear Housing Removal and Installation”.

1 - Throttle/Shift Linkage Pivot Points

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-5

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 2
2

5
5
5

5 - Tilt Tube/Co-Pilot

2 - Shift Handle (Tiller Handle Models)

6
6 - Steering Link Rod Pivot Points

3 - Swivel Pin

4 4

4 - Ride Guide Steering Cable 7

7 - Propellor Shaft

1B-6- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 8 a

50157

51118 a - Tilt Lock Lever

8 - Starter Motor Pinion Gear

2. Remove fill screw and check fluid level. Fluid lev-
el should be to bottom of threads in fill hole.
3. If necessary, add Quicksilver Power Trim &
Steering Fluid or; Automatic Transmission Fluid
(ATF) Type F, FA or Dexron II fluid to trim system.
4. Reinstall fill screw.

40/50 HP
1. Tilt outboard to the full up position and engage
the tilt support lock.
2. Remove fill cap and check fluid level. The fluid
level should be even with the bottom of the fill
hole. Add Quicksilver Power Trim & Steering
Fluid. If not available, use automotive (ATF) auto-
10
matic transmission fluid.
9 50558

9 - Gear Housing Bearing Carrier

10- Gear Housing

a
Checking Power Trim Fluid
IMPORTANT: This trim system is pressurized. Remove
fill screw when outboard is trimmed to the full “up” po-
sition. Retighten fill screw securely.
b

60 HP
1. Trim outboard to full “up” position. Engage tilt lock
lever. Trim system fluid can only be checked
when outboard is in this position.

a - Tilt Support Lock

b - Fill Cap

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-7

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 Gear Case Lubrication
When adding or changing gear case lubricant, visual-
ly check for the presence of water in the lubricant. If
water is present, it may have settled to the bottom
and will drain out prior to the lubricant, or it may be
mixed with the lubricant, giving it a milky colored ap-
pearance. If water is noticed, have the gear case a
checked by your dealer.Water in the lubricant may re-
sult in premature bearing failure or, in freezing tem-
peratures, will turn to ice and damage the gear case.
Whenever you remove the fill/drain plug, examine
the magnetic end for metal particles. A small amount
of metal filings or fine metal particles indicates nor- b
mal gear wear. An excessive amount of metal filings
or larger particles (chips) may indicate abnormal
gear wear and should be checked by an authorized
dealer.
a - Lubricant Vent Plug/Washer
WARNING b - Lubricant Fill Plug/Washer
If gear housing is installed on outboard, to avoid 4. Inspect gear lubricant for metal particles (lubri-
accidental starting, disconnect (and isolate) cant will have a “metal flake” appearance). Pres-
spark plug leads from spark plugs before work- ence of fine metal particles (resembling powder)
ing near the propeller. on the magnetic fill plug indicates normal wear.
The presence of metal chips on the magnetic fill
CAUTION plug indicates the need for gear housing disas-
Do not use automotive grease in the gear hous- sembly and components inspection.
ing. Use only Quicksilver Gear Lube or Quicksil- 5. Note color of gear lubricant. White or cream color
ver Super-Duty Lower Unit Lubricant. indicates presence of water in lubricant. Gear lu-
bricant which has been drained from a gear hous-
ing recently in operation, will have a yellowish col-
Draining Gear Case or due to lubricant agitation/aeration. This is
normal and should not be confused with the pres-
1. Tilt outboard so that lubricant in gear housing will
ence of water.
drain toward front of housing, out fill hole and into
clean container. 6. Presence of water in gear lubricant indicates the
need for disassembly and inspection of oil seals,
IMPORTANT: Inspect FILL and VENT plug washers
seal surfaces, o-rings, water pump gaskets, as
for damage. Use new washers as needed.
well as, gear housing components for damage.
2. Remove lubricant Fill plug and washer. Note
amount of metal particles on magnetic Fill plug.
Remove all magnetic particles from Fill plug.
3. Remove Vent plug and washer and allow all lubri-
cant to drain.

1B-8- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Checking Lubricant Level and Filling Storage Preparations
Gear Case The major consideration in preparing your outboard
IMPORTANT: Never add lubricant to gear housing for storage is to protect it from rust, corrosion, and
without first removing VENT plug, as trapped air damage caused by freezing of trapped water.
will prevent housing from being filled. Fill gear The following storage procedures should be followed
housing only when outboard is in operating posi- to prepare your outboard for out-of-season storage
tion. or prolonged storage (two months or longer).
NOTE: Refer to “Specifications,” for gear housing
lubricant capacity. CAUTION
1. With outboard in operating position, insert lubri- Never start or run your outboard (even momen-
cant tube into fill hole. tarily) without water circulating through all the
cooling water intake holes in the gear case to pre-
2. Fill gear housing until excess lubricant flows from
vent damage to the water pump (running dry) or
VENT hole.
overheating of the engine.

b
Protecting External Outboard
Components
1. Lubricate all outboard components listed in the
Inspection and Maintenance Schedule.
2. Touch up any paint nicks. See your dealer for
touch-up paint.
a 3. Spray Quicksilver Corrosion Guard on engine ex-
terior, electrical components, and other metal
surfaces (except corrosion control anodes).

a - Lubricant/Fill Hole Protecting Internal Engine

b - Vent Hole Components
NOTE: Before performing the following steps, make
3. Install VENT plug and washer. sure the fuel system has been prepared for storage.
4. Install FILL plug and washer. Refer to Fuel System.
1. Place the outboard in water or connect flushing
attachment for circulating cooling water. Start the
engine and let it run in neutral to warm up.
2. With engine running at fast idle, stop the fuel flow
by disconnecting the remote fuel line. When en-
gine begins to stall, quickly spray Quicksilver
Storage Seal into carburetor until engine stops
from lack of fuel.
3. Remove the spark plugs and inject a five second
spray of Quicksilver Storage Seal around the in-
side of each cylinder.
4. Rotate the flywheel manually several times to
distribute the storage seal in the cylinders. Rein-
stall spark plugs.
a - Vent Plug/Washer
b - Fill Plug/Washer

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-9

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 Gear Case
1. Drain and refill the gear case lubricant (refer to
maintenance procedure).

Positioning Outboard for Storage

1. Store outboard in an upright (vertical) position to
allow water to drain out of outboard.

CAUTION
If outboard is stored tilted up in freezing tempera-
ture, trapped cooling water or rain water that may
have entered the propeller exhaust outlet in the
gear case could freeze and cause damage to the
outboard.

Battery Storage
1. Follow the battery manufacturers instructions for
storage and recharging.
2. Remove the battery from the boat and check wa-
ter level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge
the battery during storage.

1B-10- IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 IMPORTANT 1
INFORMATION
C

GENERAL INFORMATION

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 Table of Contents
Page
Serial Number Location . . . . . . . . . . . . . . . . . 1C-1
Conditions Affecting Performance . . . . . . . . 1C-1
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3
Following Complete Submersion . . . . . . . . . 1C-3
Salt Water Submersion
(Special Instructions) . . . . . . . . . . . . . . . . . . 1C-3
Submerged While Running
(Special Instructions) . . . . . . . . . . . . . . . . . . 1C-3
Submerged Engine (Fresh Water)
(Plus Special Instructions) . . . . . . . . . . . . . 1C-4
Propeller Selection . . . . . . . . . . . . . . . . . . . . . 1C-4
Propeller Removal/Installation . . . . . . . . . . . 1C-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5

1C-0 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Serial Number Location Corporations internationally have settled on adop-
tion of I.S.O. (International Standards Organization)
The Outboard serial number is located on the lower engine test standards, as set forth in I.S.O. 3046
starboard side of the engine block. A serial number standardizing the computation of horsepower from
is also located on the starboard side of the swivel data obtained on the dynamometer, correcting all val-
bracket. ues to the power that the engine will produce at sea
a level, at 30% relative humidity at 77° F (25° C) tem-
OGXXXXXX perature and a barometric pressure of 29.61 inches
19XX
b of mercury.
XXXX
c
Summer Conditions of high temperature, low baro-
metric pressure and high humidity all combine to re-
duce the engine power. This, in turn, is reflected in
e decreased boat speeds, as much as 2 or 3 miles-per-
d
XX hour (3 or 5 km per-hour) in some cases. (Refer to
a - Serial Number previous chart.) Nothing will regain this speed for the
b - Model Year boater, but the coming of cool, dry weather.
c - Model Description
d - Year Manufactured
In pointing out the practical consequences of weath-
e - Certified Europe Insignia er 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 combus-
Conditions Affecting tion engine produces, depends upon the density of
Performance the air that it consumes and, in turn, this density is de-
pendent upon the temperature of the air, its baromet-
ric pressure and water vapor (or humidity) content.
Weather 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 avail-
able 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 en-
gine, 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 propeller that allows the
engine to again run at recommended RPM.
For boaters to realize optimum engine performance
under changing weather conditions, it is essential
that the engine have the proper propeller to allow it
to operate at or near the top end of the recommended
maximum RPM range at wide-open-throttle with a
normal boat load.
Not only does this allow the engine to develop full
power, but equally important is the fact that the en-
It is a known fact that weather conditions exert a pro- gine also will be operating in an RPM range that dis-
found effect on power output of internal combustion courages damaging detonation. This, of course, en-
engines. Therefore, established horsepower ratings hances overall reliability and durability of the engine.
refer to the power that the engine will produce at its
rated RPM under a specific combination of weather
conditions.

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 Boat TRIM

WEIGHT DISTRIBUTION TRIMMING OUTBOARD “OUT” (“UP”)

1. Proper positioning of the weight inside the boat WARNING

(persons and gear) has a significant effect on the
boat’s performance, for example: Excessive trim “out” also may reduce the stabil-
ity of some high speed hulls. To correct instabili-
a. Shifting weight to the rear (stern) ty at high speed, reduce the power GRADUALLY
(1.) Generally increases top speed. and trim the outboard “in” slightly before resum-
ing high speed operation. (Rapid reduction in
(2.) If in excess, can cause the boat to por-
power will cause a sudden change of steering
poise.
torque and may cause additional momentary
(3.) Can make the bow bounce excessively in boat instability.)
choppy water.
1. Will lift bow of boat, generally increasing top
(4.) Will increase the danger of waves splash- speed.
ing into the boat when coming off plane.
2. Transfers steering torque harder to left on single
b. Shifting weight to the front (bow) outboard installations below 23 in. (584mm) tran-
(1.) Improves ease of planing off. som height.

(2.) Generally improves rough water ride. 3. Increases clearance over submerged objects.

(3.) If excessive, can make the boat veer left 4. In excess, can cause porpoising and/or ventila-
and right (bow steer). tion.
5. If trimmed out beyond the water pickup, reduced
BOTTOM water supply can cause overheating resulting in
For maximum speed, a boat bottom should be engine damage.
nearly a flat plane where it contacts the water and
particularly straight and smooth in fore-and-aft di- TRIMMING OUTBOARD “IN” (“DOWN”)
rection.
1. Hook: Exists when bottom is concave in fore- WARNING
and-aft direction when viewed from the side. Excessive speed at minimum trim “in” may
When boat is planing, “hook” causes more lift on cause undesirable and/or unsafe steering condi-
bottom near transom and allows bow to drop, tions. Each boat should be tested for handling
thus greatly increasing wetted surface and re- characteristics after any adjustment is made to
ducing boat speed. “Hook” frequently is caused the angle (trim adjustment bolt relocation.)
by supporting boat too far ahead of transom while
1. Will help planing off, particularly with a heavy
hauling on a trailer or during storage.
load.
2. Rocker: The reverse of hook and much less
2. Usually improves ride in choppy water.
common. “Rocker” exists if bottom is convex in
fore-and-aft direction when viewed from the side, 3. In excess, can cause boat to veer to the left or
and boat has strong tendency to porpoise. right (bow steer).
3. Surface Roughness: Moss, barnacles, etc., on 4. Transfers steering torque harder to right (or less
boat or corrosion of outboard’s gear housing in- to the left) on single outboard installations.
crease skin friction and causes speed loss. Clean 5. Improves planing speed acceleration (by moving
surfaces when necessary. trim adjustment bolt one hole closer to transom).

WATER ABSORPTION
It is imperative that all through hull fasteners be
coated with a quality marine sealer at time of installa-
tion. Water intrusion into the transom core and/or in-
ner hull will result in additional boat weight (reduced
boat performance), hull decay and eventual structur-
al failure.

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 CAVITATION Detonation usually can be prevented if:
Cavitation is caused by water vapor bubbles forming 1. The engine is correctly set up.
either from a sharp edge or angle on the gear case
2. Diligent maintenance is applied to combat the
or from an irregularity in the propeller blade itself.
detonation causes.
These vapor bubbles flow back and collapse when
striking the surface of the propeller blade resulting in
the erosion of the propeller blade surface. If allowed
to continue, eventual blade failure (breakage) will
occur.

Engine

DETONATION
Detonation in a 2-cycle engine resembles the “ping-
ing” heard in an automobile engine. It can be other-
wise described as a tin-like “rattling” or “plinking”
sound.
Detonation is an explosion of an unburned portion of 51115
the fuel/air charge after the spark plug has fired. Det-
onation creates severe shock waves in the engine, Damaged Piston Resulting from Detonation
and these shock waves often find or create a weak-
ness; The dome of a piston, cylinder head/gasket,
piston rings or piston ring lands, piston pin and roller
bearings. Following Complete
A few of the most common causes of detonation in a Submersion
marine 2-cycle application are as follows:
• Over-advanced ignition timing.
Salt Water Submersion (Special
• Use of low octane gasoline. Instructions)
• Propeller pitch too high (engine RPM below rec-
Due to the corrosive effect of salt water on internal
ommended maximum range).
engine components, complete disassembly is nec-
• Lean fuel mixture at or near wide-open-throttle. essary before any attempt is made to start the en-
• Spark plugs (heat range too hot - incorrect reach gine.
- cross-firing).
• Inadequate engine cooling (deteriorated cooling Submerged While Running (Special
system).
Instructions)
• Combustion chamber/piston deposits (result in
higher compression ratio). When an engine is submerged while running, the
possibility of internal engine damage is greatly in-
creased. If, after engine is recovered and with spark
plugs removed, engine fails to turn over freely when
turning flywheel, the possibility of internal damage
(bent connecting rod and/or bent crankshaft) exists.
If this is the case, the powerhead must be disas-
sembled.

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 Submerged Engine (Fresh Water) Propeller Selection
(Plus Special Instructions) For in-depth information on marine propellers and
1. Recover engine as quickly as possible. boat performance - written by marine engineers - see
your Authorized Dealer for the illustrated “What You
2. Remove cowling. Should Know About Quicksilver Propellers... and
3. Flush exterior of outboard with fresh water to re- Boat Performance Information” (Part No.
move mud, weeds, etc. DO NOT attempt to start 90-86144-92).
engine if sand has entered powerhead, as pow- For best all around performance from your outboard/
erhead will be severely damaged. Disassemble boat combination, select a propeller that allows the
powerhead if necessary to clean components. engine to operate in the upper half of the recom-
4. Remove spark plugs and get as much water as mended full throttle RPM range with the boat normal-
possible out of powerhead. Most water can be ly loaded (refer to Specifications). This RPM range
eliminated by placing engine in a horizontal posi- allows for better acceleration while maintaining maxi-
tion (with spark plug holes down) and rotating fly- mum boat speed.
wheel. If changing conditions cause the RPM to drop below
5. Pour alcohol into carburetor throats (alcohol will the recommended range (such as warmer, more hu-
absorbed water). Again rotate flywheel. mid weather, operation at higher elevations, in-
creased boat load or a dirty boat bottom/gear case)
6. Turn engine over and pour alcohol into spark plug a propeller change or cleaning may be required to
openings and rotate flywheel. maintain performance and ensure the outboard’s du-
7. Turn engine over (place spark plug openings rability.
down) and pour engine oil into throat of carbure- Check full-throttle RPM using an accurate tachome-
tors while rotating flywheel to distribute oil ter with the engine trimmed out to a balanced-steer-
throughout crankcase. ing condition (steering effort equal in both directions)
8. Again turn engine over and pour approximately without causing the propeller to “break loose”.
one teaspoon of engine oil into each spark plug Refer to “Quicksilver Accessory Guide” for a com-
opening. Again rotate flywheel to distribute oil in plete list of available propellers.
cylinders.
1. Select a propeller that will allow the engine to op-
9. Remove and clean carburetors and fuel pump erate at or near the top of the recommended full
assembly. throttle RPM range (listed in “Specifications,”
10. Dry all wiring and electrical components using preceding) with a normal load. Maximum engine
compressed air. speed (RPM) for propeller selection exists when
boat speed is maximum and trim is minimum for
11. Disassemble the engine starter motor and dry the that speed. (High RPM, caused by an excessive
brush contacts, armature and other corrodible trim angle, should not be used in determining cor-
parts. rect propeller.) Normally, there is a 150-350 RPM
12. Reinstall spark plugs, carburetors and fuel pump. change between propeller pitches.
13. Attempt to start engine, using a fresh fuel source. 2. If full throttle operation is below the recom-
If engine starts, it should be run for at least one mended range, the propeller MUST BE changed
hour to eliminate any water in engine. to one with a lower pitch to prevent loss of per-
formance and possible engine damage.
14. If engine fails to start, determine cause (fuel,
electrical or mechanical). Engine should be run
within 2 hours after recovery of outboard from
water, or serious internal damage may occur. If
unable to start engine in this period, disassemble
engine and clean all parts. Apply oil as soon as
possible.

1C-4 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 3. After initial propeller installation, the following
common conditions may require that the propel-
ler be changed to a lower pitch:
a. Warmer weather and great humidity will
cause an RPM loss.
b. Operating in a higher elevation causes an
RPM 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
passengers, equipment, pulling skiers, etc.).
5. Pull propeller straight off shaft. If propeller is
seized to the shaft and cannot be removed, have
Propeller the propeller removed by an authorized dealer.

Removal/Installation
Installation
Removal WARNING
1. Shift outboard to neutral (N) position. If the propeller shaft is rotated while the engine
2. Remove the spark plug leads to prevent engine is in gear, there is the possibility that the engine
from starting. will crank over and start. To prevent this type of
accidental engine starting and possible serious
3. Straighten the bent tabs on the propeller nut re- injury caused from being struck by a rotating pro-
tainer. peller, always shift outboard to neutral position
and remove spark plug leads when you are serv-
icing the propeller.

CAUTION
If the propeller moves forward-and-aft on the pro-
peller shaft (is loose), re-tighten the propeller
nut. Operation with a loose propeller could cause
damage to the thrust hub and gear housing dur-
ing acceleration, deceleration or when shifting
gears.
IMPORTANT: To assure that the propeller remains
secure on the shaft during the season, periodi-
cally check propeller shaft nut for tightness.
4. Place a block of wood between gear case and
propeller to hold propeller and remove propeller
nut.

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-5

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 1. To aid in future removal of the propeller, liberally 6. After first use, bend the tab straight, re-tighten
coat the propeller shaft spline with one of the fol- propeller nut and again bend tab washer to se-
lowing Quicksilver lubricants: cure nut. Check propeller periodically for tight-
ness.
• Anti-Corrosion Grease
• 2-4-C Marine Lubricant
2. Place forward thrust hub on propeller shaft.
3. Flo-Torque I Drive Hub Propellers – Install for-
ward thrust hub, propeller, propeller nut retainer
and propeller nut onto the shaft.

d c

b a

a - Forward Thrust Hub

b - Propeller
c - Propeller Nut Retainer
d - Propeller Nut

4. Flo-Torque II Drive Hub Propellers – Install for-

ward thrust hub, propeller, replaceable drive
sleeve, rear thrust hub, propeller nut retainer and
propeller nut onto the shaft.

f e d

c b a

a - Forward Thrust Hub

b - Propeller
c - Replaceable Drive Sleeve
d - Rear Thrust Hub
e - Propeller Nut Retainer
f - Propeller Nut

5. Place propeller nut retainer over pins. Place a

block of wood between gear case and propeller
and tighten propeller nut to 55 lb.ft. (75 N·m),
aligning flat sides of the propeller nut with tabs on
the propeller nut retainer.
a b

a
b
a - Pins
b - Tabs

1C-6 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 IMPORTANT 1
INFORMATION
D

OUTBOARD MOTOR INSTALLATION

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 Table of Contents
Page
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . .
1D-1
Steering Link Rod . . . . . . . . . . . . . . . . . . . . . .
1D-1
Installing Outboard 40-50 HP . . . . . . . . . . . . 1D-2
40-50 Hp – Non-Thumb Screw Models . 1D-2
40-50 HP – Thumb Screw Models . . . . . 1D-3
Installing Outboard 55-60 HP . . . . . . . . . . . . 1D-4
55-60 HP - Non-Thumb Screw Models . 1D-4
55-60 HP – Thumb Screw Models . . . . . 1D-5
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . .
1D-6
Battery Cable Connections . . . . . . . . . . . . . . 1D-6
Shift and Throttle Cable
40 and 50 Hp Models . . . . . . . . . . . . . . . . . . . 1D-7
40-50 Hp – Shift Cable Installation . . . . . 1D-7
40-50 Hp – Throttle Cable Installation . . 1D-8
Shift and Throttle Cable
60 HP Models . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9
60 HP – Shift Cable Installation . . . . . . . . 1D-9
60 HP – Throttle Cable Installation . . . . . 1D-10
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 1D-11

1D-0 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Lifting Outboard Steering Link Rod
Electric Start Models – Remove plastic cap from fly- 1. Install steering link rod per illustration.
wheel hub. Thread lifting ring into flywheel a mini- 40-60 HP
mum of 5 turns. Replace plastic cap after installation.
60 Hp
f 40-50 Hp

b d
e
c

a
a - Special Bolt (10-90041) Torque to
20 lb. ft.(27.1 N·m)
b - Nylon Insert Locknut (11-34863) Torque to
Manual Start Models – Use lifting eye. 20 lb. ft.(27.1 N·m)
c - Spacer (12-71970)
d - Flat Washer (2)
e Nylon Insert Locknut (11-34863) Tighten Locknut Until it
Seats, Then Back Nut Off 1/4 Turn
f - Use Correct Hole
IMPORTANT: The steering link rod that connects
the steering cable to the engine must be fastened
using special bolt (“a” - Part Number 10-90041)
and self locking nuts (“b” & “e” Part Number
11-34863). These locknuts must never be re-
placed with common nuts (non-locking) as they
will work loose and vibrate off, freeing the link
rod to disengage.

WARNING
Disengagement of a steering link rod can result
in the boat taking a full, sudden, sharp turn. This
potentially violent action can cause occupants to
be thrown overboard exposing them to serious
injury or death.

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-1

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 Installing Outboard 40-50 HP 5. Drill four mounting holes using a 17/32 in. (13.5
mm) drill bit.

40-50 Hp – Non-Thumb Screw Models

a - Non-Thumb Screw 6. Position outboard so the anti-ventilation plate is

2. Center outboard on the transom. within 1 in. (25.4 mm) of the boat bottom.

0 - 1 in.
(0 - 25.4mm)

3. Secure outboard to the transom temporarily us-

a - Anti-Ventilation Plate
ing C-clamps.
7. Fasten outboard with provided mounting hard-
ware shown. Apply RTV Silicon Sealer to shanks
of bolts (not threads).

85

4. Mark location for four mounting holes.

c
a
NOTE: Normally the 4 upper mounting holes marked b
are to be drilled. This allows the outboard to be raised
without re-drilling. Use other holes if necessary to 85 RTV Silicone Sealer (92-91601-1)
avoid obstructions.
a - 1/2 in. (12.7 mm) Diameter Bolt (4)
b - Flat Washer (4)
a c - Locknut (4)
a
WARNING
Before operation, the outboard must be correctly
a a installed with four mounting bolts shown. Failure
to correctly fasten outboard could result in out-
board ejecting off boat transom causing serious
a - Upper Mounting Holes
injury, death, or property damage.

1D-2 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 40-50 HP – Thumb Screw Models NOTE: Quicksilver Accessory Outboard Mounting
Kit (P/N 812432A5) allows for quick removal and
installation of outboard. Refer to installation instruc-
tions supplied with the mounting kit before drilling any
a holes. Tighten retainer screws into lower mounting
holes when using mounting kit.

a - Thumb Screw

WARNING a

Outboard must be fastened to boat transom one

of two ways: 1. permanently fastened to transom b
with thumb screws and mounting bolts (pro-
vided), or 2. secured to the transom using the op-
tional outboard mounting kit (P/N 812432A5). a - Accessory Outboard Mounting KIt
Should the outboard strike an underwater object b - Retaining Screws
or be steered into a sharp turn, failure to fasten
outboard correctly to the boat transom with
mounting bolts or optional mounting kit could re- 3. Type 1 Bracket – Drill two 1/2 in. (12.7 mm) holes
sult in outboard ejecting suddenly off boat tran- through a lower set of mounting holes.
som causing serious injury, death, boat damage, 4. Type 2 Bracket – Drill two 3/8 in. (9.5 mm) holes
or loss of outboard. through the lower mounting holes.
1. Center outboard on the transom. 5. Fasten outboard with provided mounting hard-
ware shown. Apply RTV Silicon Sealer to shanks
of bolts (not threads).
Type 1 Bracket Type 2 Bracket

e e

d c
85

b
d
c a
2. Position outboard so the anti-ventilation plate is
within 1 in. (25.4 mm) of the boat bottom. 85
85 RTV Silicone Sealer (92-91601-1)

a - 1/2 in.(12.7 mm) Diameter Bolt (2)

b - 3/8 in. (9.5 mm) Diameter Bolt (2)
a c - Flat Washer (2)
d - Locknut (2)
e - Thumb Screws, Tighten Securely

0 - 1 in.
(0 - 25.4 mm) WARNING
DO NOT, under any circumstances, allow the
cupped washers on the ends of the thumb
screws to be closer than 1 in. (25.4 mm) from top
a - Anti-Ventilation Plate
of the boat transom, not shims.
90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-3
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 Installing Outboard 55-60 HP 9. Drill four mounting holes using a 17/32 in. (13.5
mm) drill bit.

55-60 HP - Non-Thumb Screw Models

a - Non Thumb Screw

6. Center outboard on the transom. 10. Position outboard so the anti-ventilation plate is
within 1 in. (25.4 mm) of the boat bottom.

0 - 1 in.
(0 - 25.4 mm)

7. Secure outboard to the transom temporarily us-

ing C-clamps. a - Anti-Ventilation Plate
11. Fasten outboard with provided mounting hard-
ware shown. Apply RTV Silicon Sealer to shank
of bolts (not threads).

8. Mark location for four mounting holes.

NOTE: Normally the 4 upper mounting holes marked c 85

(a) are to be drilled. This allows the outboard to be

raised without re-drilling. Use other holes if neces- b a
sary to avoid obstructions.
85 RTV Silicone Sealer (92-91601-1)

a - 1/2 in. Diameter Bolts (4)

a b - Flat Washer (4)
a c - Locknut (4)

WARNING
a a Before operation, the outboard must be correctly
installed with four mounting bolts shown. Failure
to correctly fasten outboard could result in out-
board ejecting off boat transom causing serious
a - Upper Mounting Holes injury, death, or property damage.

1D-4 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 55-60 HP – Thumb Screw Models NOTE: Quicksilver Accessory Outboard Mounting
Kit (P/N 812432A4) allows for quick removal and
installation of outboard. Refer to installation instruc-
tions supplied with the mounting kit before drilling any
a holes.

a - Thumb Screw

WARNING
Outboard must be fastened to boat transom one a
of two ways: 1. permanently fastened to transom
with thumb screws, and mounting bolts (pro-
vided), or 2. secured to the transom using the op- a - Accessory Outboard Mounting Kit
tional outboard mounting kit (P/N 812432A4). 3. Drill four 1/2 in. (12.7 mm) mounting holes.
Should the outboard strike an underwater object 4. Fasten outboard with provided mounting hard-
or be steered into a sharp turn, failure to fasten ware shown. Apply RTV Silicon Sealer to shank
outboard correctly to the boat transom with of bolt (not thread).
mounting bolts or optional mounting kit could re-
sult in outboard ejecting suddenly off boat tran-
som causing serious injury, death, boat damage,
or loss of outboard.
1. Center outboard on the transom. d

85

c
b
a
85 RTV Silicone Sealer (92-91601-1)

a - 1/2 in.(12.7 mm) Diameter Bolt (4)

b - Flat Washer (4)
2. Position outboard so the anti-ventilation plate is c - Locknut (4)
within 1 in. (25.4 mm) of the boat bottom. d - Thumb Screws, Tighten Securely

WARNING
a
DO NOT, under any circumstances, allow the
cupped washers on the ends of the thumb
screws to be closer than 1 inch (25.4 mm) from
0 - 1 in. top of the boat transom, not shims.
(0 - 25.4 mm)

a - Anti-Ventilation Plate

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-5

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 Wiring Harness Battery Cable Connections
IMPORTANT: Warning Horn Requirement – The
remote control or key switch assembly must be SINGLE OUTBOARD
wired with a warning horn. This warning horn is
used with the engine warning system. a
1. Route wiring harness into bottom cowl.
(+)
40-50 HP

(–) c
a
a - Red Sleeve (Positive)
b - Black Sleeve (Negative)
c - Starting Battery

60 HP
DUAL OUTBOARD
1. Connect a common ground cable (wire size
same as main battery cable) between negative
a (–) terminals on starting batteries.

a - Route wiring harness into bottom cowl

2. Connect wiring. Place harness into the holder.

(–)

40-50-60 HP

(–)

a - Ground Cable (Same Wire Size As Main Battery Cable –

Connect Between Negative (–) Terminals

BLU/WHT BLU/WHT
GRN/WHT GRN/WHT a
TAN
BRN/WHT

a - Power Trim Connections

1D-6 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Shift and Throttle Cable 3. Push-in on the cable end until resistance is felt.
Adjust the cable barrel to attain the measured
40 and 50 Hp Models distance taken in Step 2.
Install cables into the remote control following the 4. Place cable barrel into the bottom hole in the bar-
instructions provided with the remote control. rel holder. Fasten cable to pin with retainer.
NOTE: Install the shift cable to the engine first. The
shift cable is the first cable to move when the remote
control handle is moved out of neutral. a

40-50 Hp – Shift Cable Installation

1. Position remote control and outboard into neu- b
tral.
N

2. Measure distance between mounting pin and

middle of the barrel holder.

a
c d

a - Move Cable Barrel to Attain the Measured Distance Taken

in Step 2
b - Cable Barrel
c - Barrel Holder, Place Barrel into Bottom Hole
d - Retainer

5. Check shift cable adjustments as follows:

c a. Shift remote control into forward. The propel-

ler shaft should be locked in gear. If not, ad-
b just the barrel closer to the cable end.

a - Distance Between Pin and Middle of Barrel Holder

b. Shift remote control into neutral. The propel-
b - Mounting Pin ler shaft should turn freely without drag. If not,
c - Barrel Holder adjust the barrel away from the cable end.
Repeat steps a and b.
c. Shift remote control into reverse while turning
propeller. The propeller shaft should be
locked in gear. If not, adjust the barrel away
from the cable end . Repeat steps a thru c.
d. Shift remote control back to neutral. The pro-
peller shaft should turn freely without drag. If
not, adjust the barrel closer to the cable end.
Repeat steps a thru d.

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-7

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 40-50 Hp – Throttle Cable Installation 4. Check throttle cable adjustment as follows:

1. Position remote control into neutral. a. Shift outboard into gear a few times to acti-
vate the throttle linkage. Make sure to rotate
N the propeller shaft while shifting into reverse.

F N R

2. Install cable to the throttle lever. Tighten locknut,

then back-off the locknut 1/4 turn. b. Return remote control to neutral. Place a thin
piece of paper between idle adjustment
screw and idle stop. Adjustment is correct
when the paper can be removed without tear-
ing, but has some drag on it. Readjust cable
barrel if necessary.
a
b
c b

a - Throttle Cable
b - Nylon Washer
c - Locknut, Tighten Locknut, Then Back Off the Locknut 1/4 a
Turn

3. Adjust the cable barrel so that the installed

throttle cable will hold the idle adjustment screw a - Idle Adjustment Screw
against the stop. b - Idle Stop

5. Lock the barrel holder in place with the cable

latch.

a
a

c a - Cable Latch
b

a - Cable Barrel, Adjust to Hold Idle Adjustment Screw Against

Stop
b - Idle Adjustment Screw
c - Barrel Holder, Place Barrel Into Top Hole

1D-8 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Shift and Throttle Cable 3. Push-in on the cable end until resistance is felt.
Adjust the cable barrel to attain the measured
60 HP Models distance taken in Step 2.
Install cables into the remote control following the 4. Place cable barrel into the bottom hole in the bar-
instructions provided with the remote control. rel holder. Fasten cable to pin with locknut.
NOTE: Install the shift cable to the engine first. The
shift cable is the first cable to move when the remote a
control handle is moved out of neutral.

60 HP – Shift Cable Installation

b
1. Position remote control and outboard into neu-
tral.
N

d
2. Measure distance between mounting pin and
middle of the barrel holder. e

a - Move Cable Barrel to Attain the Measured Distance Taken

a in Step 2
b - Cable Barrel
c - Barrel Holder, Place Barrel Into Bottom Hole
c d - Nylon Washer
b e - Locknut, Tighten Locknut, Then Back-Off the Locknut 1/4
Turn

5. Check shift cable adjustments as follows:

a. Shift remote control into forward. The propel-
ler shaft should be locked in gear. If not, ad-
just the barrel closer to the cable end.
a - Distance Between Pin and Middle of Barrel Holder b. Shift remote control into neutral. The propel-
b - Mounting Pin
c - Barrel Holder
ler shaft should turn freely without drag. If not,
adjust the barrel away from the cable end.
Repeat steps a and b.
c. Shift remote control into reverse while turning
propeller. The propeller shaft should be
locked in gear. If not, adjust the barrel away
from the cable end . Repeat steps a thru c.
d. Shift remote control back to neutral. The pro-
peller shaft should turn freely without drag. If
not, adjust the barrel closer to the cable end.
Repeat steps a thru d.

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-9

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 60 HP – Throttle Cable Installation 4. Check throttle cable adjustment as follows:

1. Position remote control into neutral. a. Shift outboard into gear a few times to acti-
vate the throttle linkage. Make sure to rotate
N the propeller shaft while shifting into reverse.

F N R

2. Install cable to the throttle lever. Tighten locknut,

then back-off the locknut 1/4 turn. b. Return remote control to neutral. Place a thin
piece of paper between idle adjustment
screw and idle stop. Adjustment is correct
when the paper can be removed without tear-
ing, but has some drag on it. Readjust cable
barrel if necessary.
a
b
c b
a - Throttle Cable
b - Nylon Washer
c - Locknut, Tighten Locknut, Then Back-Off the Locknut 1/4 a
Turn

3. Adjust the cable barrel so that the installed

throttle cable will hold the idle adjustment screw a - Idle Adjustment Screw
against the stop. b - Idle Stop

5. Lock the barrel holder in place with the cable

latch.

a
a - Cable Latch

a - Cable Barrel – Adjust To Hold Idle Adjustment Screw

Against Stop
b - Idle Adjustment Screw
c - Barrel Holder – Place Barrel Into Top Hole

1D-10 - IMPORTANT INFORMATION 90-852572R1 JANUARY 1998

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 Trim Tab Adjustment
The trim tab can be adjusted within limits to help to
compensate for steering torque.
Adjust trim tab as follows:
1. If boat tends to pull to the right, move the rear
edge of the trim tab to the right.
2. If boat tends to pull to the left, move the rear edge
of the trim tab to the left.

a - Trim Tab
NOTE: Trim tab adjustment will have little effect re-
ducing steering torque if the the anti-ventilation plate
is raised 2 inches (50.8 mm) or more above the boat
bottom.

90-852572R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-11

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 ELECTRICAL

2
A

55042

IGNITION

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Flywheel And Stator (Electric) . . . . . . . . . . . . 2A-2
Flywheel And Stator (Manual) . . . . . . . . . . . . 2A-3
Electrical Components 40/50 . . . . . . . . . . . . 2A-4
Electrical Components 55/60 . . . . . . . . . . . . 2A-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . 2A-8
Capacitor Charging #1 CDM . . . . . . . . . . 2A-8
Capacitor Charging #2 & #3 CDM . . . . . . 2A-9
#1 Cylinder Trigger Circuit . . . . . . . . . . . . 2A-10
Ignition Coil Circuit . . . . . . . . . . . . . . . . . . . 2A-11
Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Rev Limiter Circuit . . . . . . . . . . . . . . . . . . . 2A-13
Ignition Component Description . . . . . . . . . . 2A-14
Capacitor Discharge Module (CDM) . . . . 2A-14
Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Stator Assembly . . . . . . . . . . . . . . . . . . . . . 2A-14
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
CDM (P/N 827509) Trouble Shooting
Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15
CDM (P/N 827509) . . . . . . . . . . . . . . . . . . 2A-15
Spark Gap Tester P/N 91-850439 . . . . . . 2A-15
CDM Test Harness 84-825207A2 . . . . . . 2A-15
CDM Stop Diode Trouble Shooting . . . . . . . 2A-16
CDM Trouble Shooting Flowchart . . . . . . . . 2A-17
CDM Trouble Shooting Flowchart . . . . . . . . 2A-18
Ignition Test Procedures . . . . . . . . . . . . . . . . . 2A-20
Direct Voltage Adaptor (DVA) Test . . . . . 2A-20
Resistance Tests . . . . . . . . . . . . . . . . . . . . 2A-21
Flywheel Removal and Installation . . . . . . . . 2A-22
Stator Removal and Installation . . . . . . . . . . 2A-23
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23
CDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-24

2A-0 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Specifications
Type Capacitor Discharge
Spark Plug Type NGK BP8H-N-10
*NGK BPZ8H-N-10
IGNITION SYSTEM NGK BUZ8H
NGK BP8HS-10
Spark Plug Gap 0.040 in. (1.0mm)
Firing Order 1-2-3
Idle T.D.C. ± 2°
Maximum Timing
@ Cranking Speed
-Model 40/50/60 24° B.T.D.C.
TIMING
-Model 55/60 Seapro-Marathon 18° B.T.D.C.
@ 5000 RPM
– Model 40/50/60 22° B.T.D.C.
– Model 55/60 Seapro-Marathon 16° B.T.D.C.
*Suppressor (resistor) spark plug

4. Spark Gap Tester 91-63998A1

Special Tools
1. Flywheel Holder 91-52344

2. Flywheel Puller 91-73687A2

5. TPI/CDM Test Harness 84-825207A2

3. Volt/Ohm/DVA Meter 91-99750A1

6. Spark Gap Tester 91-850439

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-1

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 Flywheel And Stator (Electric)

6
51

5
7

51 Loctite 222 (92-809818) 10 10

8 95
95 2-4-C With Teflon (92-850736A1) 9

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FLYWHEEL COVER
2 1 NUT 100 135.6
3 1 WASHER
4 1 FLYWHEEL
5 1 STATOR
6 4 SCREW (M5 x 30) 60 5 6.8
7 1 TRIGGER
8 1 SWIVEL BALL
9 1 SWIVEL BASE
10 2 CABLE TIE

2A-2 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Flywheel And Stator (Manual)

51
5

6
9

10

7 95
8 9

51 Loctite 222 (92-809818)

95 2-4-C With Teflon (92-850736A1)

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FLYWHEEL
2 1 NUT 100 135.6
3 1 WASHER
4 1 STATOR
5 4 SCREW (M5 x 30) 60 5 6.8
6 1 TRIGGER
7 1 SWIVEL BALL
8 1 SWIVEL BASE
9 2 CABLE TIE
10 2 PLUG

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-3

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 Electrical Components 40/50

41
21
43 20

25 4

37 1 3
39 2

23
42 25

38 26

36
19 25
40
24
5
22
18
27

7
28
25
18
17
6 16
8 15
25
25

35 13
12
25
10 14
13

32 12
9 22
31 33
34 23
11
7 30

29

25 Liquid Neoprene (92-25711--2)

2A-4 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Electrical Components 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 PLATE–Electrical
2 1 SCREW (M5 x 12) 40 3.3 4.5
3 1 WASHER
4 1 STA–STRAP
1 REV LIMITER (MANUAL)
5
1 REV LIMITER
6 1 CLAMP
7 3 SCREW (M5 x 12) 40 3.3 4.5
8 1 SOLENOID ASSEMBLY
9 2 BUSHING
10 2 GROMMET
11 2 SCREW (M6 x 25) ELECTRIC 60 5 6.8
12 2 NUT (1/4-20) 30 2.5 3.4
13 2 LOCKWASHER
14 1 CABLE
15 1 CABLE
16 2 NUT 20 2.3
17 1 VOLTAGE REGULATOR
18 2 SCREW (M6 x 35) 60 5 6.8
19 1 J CLAMP
20 1 BOOT
21 1 BATTERY CABLE (NEGATIVE)
22 1 WASHER (QTY. OF 3 ON ELECTRIC)
23 AR STA–STRAP
24 2 SCREW (M6 x 25) 40 3.3 4.5
25 1 CABLE
26 1 SCREW (M8 x 20)(MANUAL) 30 2.5 3.4
27 1 SCREW (M6 x 10)(MANUAL) 60 5 6.8
28 2 J CLAMP (QTY. OF 3 ON ELECTRIC)
29 1 HARNESS ASSEMBLY–Engine (ELECTRIC)
30 1 FUSE
31 3 GROMMET
32 3 BUSHING
33 3 WASHER
34 3 SCREW (M6 x 25) 100 8.3 11.3
35 1 HARNESS-Ignition
2 CDM ASSEMBLY (5 IN. LEADS)
36
1 CDM ASSEMBLY (8 IN. LEADS)
37 3 HI-TENSION CABLE
38 3 BOOT
3 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
39 3 SPARK PLUG (NGK#BPZ–8H–N–10) 240 20 27.1
3 SPARK PLUG (NGK#BUZ8H) 240 20 27.1
40 6 SCREW (M6 x 14) 60 5 6.8
41 1 HARNESS-Power (MANUAL)
42 1 HARNESS
1 HARNESS ASSY. -Adaptor (MANUAL)
43
1 HARNESS ASSY. -Adaptor (ELECTRIC)

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-5

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 Electrical Components 55/60

21

42

20
55 HP ONLY
25 4
6

38 3
40 1 2
43
25 23

39 26

37
19 25
41
24
5
22
18
27

7
28
25
18
17
6 16
8 15
25
25
13
36 12
25
10 14
13
12
33 9
32 34 22
35 11 23
7
30

29

6 Dielectric Grease (92-823506--1) 31

25 Liquid Neoprene (92-25711--2)

2A-6 - ELECTRICAL 90-852572R1 JANUARY 1998

Downloaded from www.Manualslib.com manuals search engine
 Electrical Components 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 PLATE–Electrical
2 1 SCREW (M5 x 12) 40 3.3 4.5
3 1 WASHER
4 1 STA–STRAP
1 REV LIMITER (MANUAL)
5
1 REV LIMITER
6 1 CLAMP
7 3 SCREW (M5 x 12) 40 3.3 4.5
8 1 SOLENOID ASSEMBLY
9 2 BUSHING
10 2 GROMMET
11 2 SCREW (M6 x 25) 60 5 6.8
12 2 NUT (1/4-20) ELECTRIC 30 2.5 3.4
13 2 LOCKWASHER
14 1 CABLE
15 1 CABLE
16 2 NUT 20 2.3
17 1 VOLTAGE REGULATOR
18 2 SCREW (M6 x 35) 60 5 6.8
19 1 J CLAMP
20 1 BOOT
21 1 BATTERY CABLE (NEGATIVE)
22 2 WASHER
23 AR STA–STRAP
24 2 SCREW (M6 x 25) 40 3.3 4.5
25 1 CABLE
26 1 SCREW (M8 x 20)(MANUAL) 30 2.5 3.4
27 1 SCREW (M6 x 10)(MANUAL) 60 5 6.8
28 3 J CLAMP (Qty. of 2 required on Manual)
29 1 HARNESS ASSEMBLY–Engine
30 1 FUSE ELECTRIC
31 1 PLUG
32 3 GROMMET
33 3 BUSHING
34 3 WASHER
35 3 SCREW (M6 x 25) 100 8.3 11.3
36 1 HARNESS-Ignition
37 3 CDM ASSEMBLY
38 3 HI-TENSION CABLE
39 3 BOOT
3 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
3 SPARK PLUG (NGK#BPZ–8H–N–10) 240 20 27.1
40
3 SPARK PLUG (NGK#BUZ8H) 240 20 27.1
3 SPARK PLUG (NGK#BP8HS-10) 240 20 27.1
41 6 SCREW (M6 x 14) 60 5 6.8
42 1 HARNESS-Power MANUAL
43 1 HARNESS

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-7

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 Theory of Operation Capacitor Charging #1 CDM
This outboard ignition system is alternator driven The STATOR assembly is mounted to the block be-
(distributor-less) capacitor discharge system. Major low the flywheel and has 3 CAPACITOR CHARGING
components of the ignition system are the flywheel, COILS wound in series. The FLYWHEEL is fitted with
stator, trigger, capacitor discharge modules (CDM’s) 6 permanent magnets inside the outer rim. The fly-
and spark plugs. Each capacitor discharge module wheel rotates the permanent magnets past the ca-
functions as a combination switchbox and secondary pacitor charging coils causing the coils to produce
ignition coil. AC voltage (260–320 volts). The AC voltage is then
conducted to the CAPACITOR DISCHARGE MOD-
ULES (CDM), where it is rectified (DC) and stored in
a capacitor. The stator voltage return path is through
the ground wire of the other CDM and back through
that CDM’s charging coil wire to the capacitor charg-
ing coils.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _
BLK/YEL

N WHT/GRN

S
PPL

S
BLK

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

2A-8 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Capacitor Charging #2 & #3 CDM
The flywheel rotates the permanent magnets past NOTE: #1 CDM stator voltage return path is through
the capacitor charging coils causing the coils to pro- either CDM #2 or #3. The return path for CDM #2 and
duce AC voltage (260–320 volts). The opposite volt- #3 is through CDM #1, if #1 stator wire is discon-
age pulse is then conducted to the CAPACITOR DIS- nected the engine will die (the stator circuit is incom-
CHARGE MODULES (CDM), where it is rectified plete and the capacitors cannot be charged).
(DC) and stored in a capacitor. The stator voltage re-
turn path is through the ground wire of the other CDM
and back through that CDM’s charging coil wire to the
capacitor charging coils.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-9

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 #1 Cylinder Trigger Circuit coils to produce a voltage pulse which is sent to the
respective capacitor discharge module (CDM). A
The TRIGGER assembly (also mounted under the positive voltage pulse (N–S) will activate the elec-
flywheel) has one coil for each cylinder. These coils tronic switch (SCR) inside the capacitor discharge
are mounted adjacent to the flywheel center hub. module (CDM). The switch discharges the capacitor
The center hub of the flywheel contains a permanent voltage through the coil primary windings. The return
magnet with two north–south transitions. voltage pulse exits the CDM through the ground wire
As the flywheel rotates, the magnet north–south tran- and returns through the trigger ground.
sitions pass the trigger coils. This causes the trigger

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

2A-10 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Ignition Coil Circuit
As the capacitor voltage flows through the primary
windings of the ignition coil, a voltage is induced into
the ignition coil secondary windings. This secondary
voltage rises to the level required to jump the spark
plug gap and return to ground. This secondary volt-
age can, if necessary, reach approximately 40,000
volts. To complete the secondary voltage path, the
released voltage enters the ground circuit of CDM
module.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-11

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

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

2A-12 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Rev Limiter Circuit
The rev limiter is activated through the purple wire
when the key switch is rotated to the “on” position.
The rev limiter uses a trigger signal (brown wire) to
determine engine speed or rpm. If the engine speed
exceeds the specified rpm, the rev limiter will ground
out the CDM capacitor charge. The capacitor voltage
flows through the black/yellow wires into the rev limit-
er and to engine ground through the black wire.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN

Source Voltage
BLK

Trigger Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-13

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 Ignition Component Stator Assembly
Description Located under the flywheel in the stator assembly are
12 coils (6 for manual stator), 3 ignition charge coils
and 9 auxiliary (3 for manual) power coils wound in
Capacitor Discharge Module (CDM) series that provide voltage to the CDM’s and battery/
auxiliary circuits respectively.
Each module contains an ignition coil and amplifier
circuitry which produces approximately 45,000 volts
at the spark plugs.

Flywheel
Contains 6 magnets (12 pole) around circumference.
Trigger Coil Has one magnet on inner hub for trigger. Outer mag-
Located under flywheel. Is charged by single magnet nets are for battery charge coils and ignition charge
on flywheel hub. Trigger pulses are sent to CDM. coils.

NOTE: Electric start model flywheel shown.

2A-14 - ELECTRICAL 90-852572R1 JANUARY 1998

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 CDM (P/N 827509) Trouble Shooting Flowchart
Chart 1
Step Action Value Yes No Tools
1 Verify High Tension Leads, Spark – Step 2 Replace High Tension
Plug and Spark Boots are in good Failed Com- lead pin
condition. Inspect wires for chafing. ponent P/N
Visual Inspection Step 2 84-813706A56
2 Verify 4 Pin Connector Integrity – Step 3 Repair/Re- –
place Con-
Visual Inspection nector Com-
ponents
Step 3
3 Verify Ground from CDM connector 0.2 Ohms Step 4 Correct DVA/Multimeter
to block and below Ground Path P/N 91-99750
Step 4 Test Harness
P/N
84-825207A2
4 Test all CDMs at Cranking with 7/16 in. If at least Continue Spark Gap Tes-
Spark Gap Tester (11.11 mm) one CDM with Chart #2 ter
gap has spark, P/N 91-850439
Spark on All CDMs? continue with
Will spark jump a 7/16 in. Chart #3
(11.11 mm) gap?
CDM (P/N 827509)

A B C D

a - Ground
b - Black/Yellow
c - Trigger Connection
d - Stator Connection

Spark Gap Tester P/N 91-850439 CDM Test Harness 84-825207A2

55117

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-15

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

1 2

3 Cyl.:
CDM #1 gets its charging ground path through CDM #2 or #3
CDM #2 and #3 get their charging ground path through CDM #1
A shorted Stop Diode in CDM #1 would prevent CDMs #2 and #3 from sparking.
A shorted Stop Diode in CDM #2 or #3 would prevent CDM #1 from sparking.

1 2 3

4 Cyl.:
CDM #1 and #2 get their charging ground path through CDM #3 or #4
CDM #3 and #4 get their charging ground path through CDM #1 or #2
A shorted Stop Diode in CDM #1 or #2 would prevent CDMs #3 and #4 from sparking.
A shorted Stop Diode in CDM #3 or #4 would prevent CDM #1 and #2 from sparking.

1 2 3 4

6 Cyl.:
All CDMs get their charging ground path independently through the stator’s white leads.
A shorted Stop Diode in any one CDM will prevent at least 2 other CDMs from sparking

1 3 5 2 4 6

2A-16 - ELECTRICAL 90-852572R1 JANUARY 1998

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 CDM Trouble Shooting Flowchart
Chart #2 (No Spark on any CDM)

Step Action Value Yes No Tools

1 With the key switch ON: NO continuity Step 2 Repair or DVA/Multimeter
Verify continuity between BLK/YEL Replace Com- P/N 91-99750
harness wire and ground. ponent
This Test Checks: Run Engine
Lanyard Switch Verify Repair
Key Switch Step 6
Rev Limiter (external)
Chafed BLK/YEL wire
CDM Stop Circuit
2 Check Stator 660-710 Step 3 Replace DVA/Multimeter
Resistance between GRN/WHT Ohms Stator P/N 91-99750
and WHT/GRN 2, 3 & 4 Cyl. Run Engine
Models Verify Repair
Open circuit voltage at cranking
should be no less than 100 Volts 990 - 1210 Step 6
on the DVA Ohms 6 Cyl.
3 Check Trigger/Crank Shaft Posi- 1 Volt and Step 5 2, 3, & 4 Cyl DVA/Multimeter
tion Sensor Output: above - CDM Replace Trig- P/N 91-99750
disconnected. ger TPI/CDM Test
Cranking with CDM disconnected. 0.2 - 5 Volts- Run Engine Harness
CDM Verify Repair 84-825207A2
Cranking with CDM connected. connected. Step 6
6 Cyl. - Step 4
4 V-6 Models 900 - 1300 Step 5 Replace DVA/Multimeter
Ohms Crank Posi- P/N 91-99750
Resistance Check Crank Position tion Sensor
Sensor Run Engine
Verify Repair
Step 6
5 Test all CDMs at Cranking with 7/16 in. Step 6 Verify All Pre- Spark Gap Tes-
Spark Gap Tester (11.11 mm) ceding Steps ter P/N
gap 91-850439
Spark on All CDMs?
Will spark jump a 7/16 in.
(11.11 mm) gap?
6 If mis-firing is in a repeatable Stator: Run Engine Refer to *Note DVA/Multimeter
range: 200 Volts and Verify Repair Below P/N 91-99750
Perform DVA readings on stator above TPI/CDM Test
and trigger at all running speeds.* END Harness
Trigger: 84-825207A2
2 Volts and
above
* Note: Stator tests will only isolate problem down to
a charging pair. Further testing is necessary to deter-
mine faulty CDM. Disconnecting one CDM of the
charging pair is recommended.

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-17

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 CDM Trouble Shooting Flowchart
Chart #3 (At least one CDM has spark)
Step Action Value Yes No Tools
1 Resistance Check ALL CDMs Refer to chart Step 3 Replace any DVA/Multimeter
CDMs that P/N 91-99750
do not pass
specifica-
tions even if
they fire
Step 2
2 Test all CDMs at Cranking with 7/16 in. Run Engine Step 3 Spark Gap Tes-
Spark Gap Tester (11.11 mm) Verify Repair ter
gap Step 6 P/N 91-850439
Spark on All CDMs
Will spark jump a 7/16 in.
(11.11 mm) gap?
3 Check Trigger Output: 1 Volt and Step 5 2, 3, & 4 Cyl DVA/Multimeter
above - CDM - Replace P/N 91-99750
Cranking with CDM disconnected. disconnected. Trigger TPI/CDM Test
0.2 - 5 Volts - Run Engine Harness
Cranking with CDM connected. CDM Verify Repair 84-825207A2
connected. Step 6
6 Cyl–Step 4
4 V6 Models 900 - 1300 Step 5 Replace DVA/Multimeter
Ohms Crank Posi- P/N 91-99750
Resistance Check Crank Position tion Sensor
Sensor Run Engine
Verify Repair
Step 6
5 Test all CDMs at Cranking with 7/16 in. Run Engine Replace any Spark Gap Tes-
Spark Gap Tester (11.11 mm) Verify Repair non-firing ter
gap Step 6 CDMs P/N 91-850439
Spark on All CDMs? Step 6
Will spark jump a 7/16 in.
(11.11 mm) gap?
6 If mis-firing is in a repeatable Stator: Run Engine Refer to DVA/Multimeter
range: 200 Volts and Verify Repair *Note Below. P/N 91-99750
Perform DVA readings on stator above END TPI/CDM Test
and trigger at all running speeds.* Harness
Trigger: 84-825207A2
2 Volts and
above
* Note: Stator tests will only isolate problem down to
a charging pair. Further testing is necessary to deter-
mine faulty CDM. Disconnecting one CDM of the
charging pair is recommended.

2A-18 - ELECTRICAL 90-852572R1 JANUARY 1998

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 CAPACITOR DISCHARGE MODULE
IMPORTANT Spark plug wires are screwed into CDM.

A B C D

a - Ground
b - Black/Yellow
c - Trigger Connection
d - Stator Connection

A resistance check is required and can be performed on the CDM as follows:

NOTE: This test can be performed using the test harness (P/N 84-825207A2). Do Not connect the test harness
plug to the stator/trigger engine wire harness.

CAPACITOR DISCHARGE MODULE

Connect Negative Connect Positive
Ohms
Circuit Test (–) (+) Results:
Scale
Meter Lead To: Meter Lead To:
Green (D)/ or Black/Yellow (B)/ or
Stop Diode R x 100
Green test harness Black/Yellow test Continuity
Forward Bias Diode Reading*
lead harness lead
Black/Yellow (B)/ or Green (D)/ or
Stop Diode R x 100
Black/Yellow test Green test harness No Continuity
Reverse Bias Diode Reading*
harness lead lead
Return Ground Green (D)/ or Ground Pin (A) or
R x 100
Path Diode, Green test harness Black test harness No Continuity
Diode Reading*
Reverse Bias lead lead
Return Ground Ground Pin (A)/ or Green (D)/ or
R x 100
Path Diode, Black test harness Green test harness Continuity
Diode Reading*
Forward Bias lead lead
Ground Pin (A)/ or
CDM Trigger Input White (C)/ or White 1000 - 1250
Black test harness R x 100
Resistance test harness lead Ohms
lead
Spark Plug
Ground Pin (A) or Terminal
Coil Secondary
Black test harness R x 100 900 - 1200 Ohms
Impedance (At Spark Plug
lead Boot)

*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such
a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measure-
ments above will be opposite if using a Fluke equivalent multimeter.

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-19

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 Ignition Test Procedures Stator Output Test 400 DVA
Scale
Positive Meter Negative DVA
Direct Voltage Adaptor (DVA) Test Lead (+) Meter Lead (–) Reading
Connect to Connect to
CAUTION Green Test Black Test Har- 100 - 350
Harness Lead ness Lead
DVA checks can be made while cranking engine
with starter motor. To prevent engine from start- If only one CDM stator reading is below specifications,
ing while being cranked, all spark plugs must be replace that CDM. If all CDM stator voltage readings
removed. are low, go to “Testing Stator Resistance”.

CAUTION
To protect against meter and/or component dam-
age, observe the following precautions:
• INSURE that the Positive (+) meter lead is
connected to the DVA receptacle on the me-
ter.
• DO NOT CHANGE meter selector switch posi-
tion while engine is running and/or being
“cranked”.
NOTE: Each CDM is grounded through the engine
wiring harness via the connector plug. It is not neces-
sary to have the CDM mounted on the ignition plate
for testing.
1. Remove all spark plugs.
2. Insert spark gap tool (P/N 91-63998A1) into each
spark plug boot and attach alligator clips to a
good engine ground.
Test each CDM.
3. Disconnect remote fuel line from engine.
4. Make sure all CDMs are plugged in. Trigger Output Test 2 DVA Scale

5. Test Stator and Trigger voltage to CDM: Positive Meter Negative DVA
Lead (+) Meter Lead (–) Reading
a. Install test harness (84-825207A2) between White Test Black Test Har-
ignition harness and CDM. Harness Lead ness Lead 0.2 - 2.0

If reading is below specifications, replace trigger. If

reading is above specifications, check CDM.

a - Stator/Trigger Harness
b - Test Harness (84-825207A2)
c - Capacitor Discharge Module
b. Test each CDM.

2A-20 - ELECTRICAL 90-852572R1 JANUARY 1998

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 NOTE: If voltage remains low after installing a new Resistance Tests
trigger, replaced CDM.
TRIGGER
A resistance test is not used on the trigger. Test trigger
as outlined under “Testing Voltage Output to CDM” -
“Trigger Output Test”.

STATOR
1. Disconnect stator leads.
NOTE: Resistance varies greatly with temperature.
Measurements should be taken with an ambient tem-
perature range of 65° to 85° F.

Stator Resistance Test

R x 1 Ohms
Positive Meter Negative Scale
Lead (+) Meter Lead (–)
ENGINE RUNNING AT IDLE
Connect to Connect to
It is not necessary to perform this test if the voltage out- White/Green Green/White 660-710
put was tested in the previous step. stator lead stator lead
Connect to Connect to en-
Stator Output Test 400 DVA White/Green gine ground No continuity
Scale stator lead
Positive Meter Negative DVA Connect to Connect to en-
Lead (+) Meter Lead (–) Reading Green/White gine ground No continuity
Connect to Connect to stator lead
Green Test Black Test Har- 200 - 350
Harness Lead ness Lead IMPORTANT If all CDM stator output voltage is
low and stator resistance tests are within specifi-
If stator output is low, go to “Testing Stator Resis- cations, then each CDM (one at a time) must be
tance”. replaced with a CDM known to be good until sta-
tor output voltage returns to proper levels. This
Trigger Output Test 20 DVA Scale process of elimination will reveal a defective
Positive Meter Negative DVA CDM.
Lead (+) Meter Lead (–) Reading
White Test Black Test Har-
Harness Lead ness Lead 2 - 8 Volts

If reading is below specifications, replace trigger. If

reading is above specifications, check CDM.
NOTE: If voltage remains low after installing a new
trigger, replace CDM.

RX1

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-21

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

Engine could possibly start when turning fly- INSTALLATION

wheel during removal and installation; therefore,
disconnect (and isolate) spark plug leads from 1. Install flywheel key in crankshaft slot with outer
spark plugs to prevent engine from starting. edge of key parallel to center line of crankshaft.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with flywheel holder
(91-52344), remove flywheel nut and washer.

a - Flywheel Key

2. Align slot in flywheel center bore with flywheel

key and install flywheel onto crankshaft.

a - Flywheel Holder
3. Install washer and nut.
4. Hold flywheel with Flywheel Holder (91-52344);
torque nut to 125 lb. ft. (169.5 N·m).
4. Install a crankshaft Protector Cap (91-24161) on
end of crankshaft, then install Flywheel Puller
(91-73687A2) into flywheel.
5. Hold flywheel tool with wrench while tightening
bolt down on protector cap. Tighten bolt until fly-
wheel comes free.

a - Flywheel Holder

55333

a - Flywheel Puller
NOTE: Neither heat nor hammer should be used on
flywheel to aid in removal as damage to flywheel or
electrical components under flywheel may result.

2A-22 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Stator Removal and INSTALLATION
1. Set stator on bearing cage. Secure with screws.
Installation Screws threads should be lightly coated with loc-
tite 222 and torqued to 60 lb. in. (6.8 N·m).
REMOVAL
1. Remove flywheel. See “Removing Flywheel” In
This Section.
2. Remove yellow stator leads from rectifier/regula-
tor leads.
3. Disconnect all stator leads from CDM wire har-
ness.
NOTE: Removal of ignition plate may be necessary a
to gain access to stator leads.
4. Remove screws and lift stator off bearing cage.
a

55330

a - Screws

2. Connect yellow stator leads to yellow voltage

regulator leads (electric models).
a 3. Connect all stator leads to corresponding CDM
wire harness.
a 4. Install flywheel. See “Installing Flywheel” in this
section.
55330

a - Screws
Trigger
REMOVAL
1. Remove flywheel. See “Removing Flywheel” in
this section.
2. Remove stator. See “Removing Stator” in this
section.
3. Disconnect trigger leads from CDM wire harness.

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-23

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 4. Disconnect link arm and remove trigger. CDM

REMOVAL

WARNING
Always disconnect battery and disconnect spark
plug leads from spark plugs before working on
a b motor.
1. Disconnect CDM wire harness plug.
19459 2. Remove screws securing CDM to ignition plate.

a - Link Arm INSTALLATION

b - Trigger 1. Position CDM on ignition plate. Install screws,
torque to 60 lb. in. (6.8 N·m).
5. Lift trigger off bearing cage.
2. Connect CDM wire harness plug to CDM.
55042
INSTALLATION
1. Install trigger and connect link arm.

b a

a b

19459
a - Wire Harness Plug
b - Screws
a - Link Arm
b - Trigger

2. Place trigger on bearing cage.

3. Route lead wires under ignition plate and down to
the CDM wire harness.
4. Connect corresponding trigger leads to CDM
wire harness.
5. Install stator. See “Installing Stator” in this sec-
tion.
6. Install flywheel. See “Installing Flywheel” in this
section.
7. Check engine timing. See “Engine Timing” in
Section 2C.

2A-24 - ELECTRICAL 90-852572R1 JANUARY 1998

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 ELECTRICAL

2
B

CHARGING AND STARTING SYSTEM

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Operating Engine Without Battery . . . . . . . . 2B-4
Specific Gravity Readings . . . . . . . . . . . . . . . 2B-4
Specific Gravity Cell Comparison Test . . 2B-5
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Charging A Discharged Battery . . . . . . . . . . 2B-5
Winter Storage of Batteries . . . . . . . . . . . . . . 2B-6
Battery Charging System Troubleshooting . 2B-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Starting System . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Starting System Components . . . . . . . . . 2B-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Troubleshooting the Starting Circuit . . . . 2B-11
Starting Circuit Wiring Diagram . . . . . . . . . . . 2B-12
Starting Circuit Troubleshooting Flow Chart 2B-13
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2B-15
Cleaning and Inspection . . . . . . . . . . . . . . 2B-16
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Brush Replacement . . . . . . . . . . . . . . . . . . 2B-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-20

2B-0 - ELECTRICAL 90-852572R1 JANUARY 1998

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

Special Tools
1. Volt/Ohm Meter 91-99750A1.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-1

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 Starter Motor

2 4
5

10
14

8
9
6 7

16 15

12 11 8
14
13

25

25 Liquid Neoprene (92-25711--2)

2B-2 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Starter Motor
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 STARTER MOTOR
2 1 THRU BOLT 70 5.8 7.9
3 1 DRIVE KIT
4 1 DRIVE ASSEMBLY
5 1 DRIVE CAP
6 1 ARMATURE
7 1 COMMUTATOR CAP
8 1 BRUSH & SPRING KIT
9 1 BRUSH HOLDER
10 2 SCREW
11 1 LOCKWASHER
12 1 NUT (1/4-20) 60 5 6.8
13 1 BATTERY CABLE (5/16) (POSITIVE)
14 3 SCREW (M8 x 45) 198 16.5 22.3
15 1 DECAL–Warning
16 1 BRACKET-Oil Tank

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-3

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 Battery Specific Gravity Readings
Use a hydrometer to measure specific gravity of elec-
Precautions trolyte in each cell.

CAUTION
If battery acid comes into contact with skin or
eyes, wash skin immediately with a mild soap.
Flush eyes with water immediately and see a doc- a
tor.
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 atmo-
sphere around battery if ventilation is poor. This ex-
plosive gas may remain in or around battery for sev-
eral hours after it has been charged. Sparks or
flames can ignite this gas and cause an internal ex-
plosion which may shatter the battery.
The following precautions should be observed to pre-
vent an explosion.
1. DO NOT smoke near batteries being charged or 22532
which have been charged very recently. a - Hydrometer
2. DO NOT break live circuits at terminals of batter-
ies because a spark usually occurs at the point Hydrometer measures percentage of sulfuric acid in
where a live circuit is broken. Always be careful battery electrolyte in terms of specific gravity. As a
when connecting or disconnecting cable clamps battery drops from a charged to a discharged condi-
on chargers. Poor connections are a common tion, acid leaves the solution and chemically com-
cause of electrical arcs which cause explosions. bines with the plates, causing a decrease in specific
gravity of electrolyte. An indication of concentration
3. DO NOT reverse polarity of battery cables on bat-
of electrolyte is obtained with a hydrometer.
tery terminals.
When using a hydrometer, observe the following
points:
Operating Engine Without 1. Hydrometer must be clean (inside and out) to in-
sure an accurate reading.
Battery 2. Never take hydrometer readings immediately af-
If desired (or in an emergency), engines equipped ter water has been added. Water must be thor-
with an alternator can be started and operated with- oughly mixed with electrolyte by charging for at
out a battery (either disconnected or removed) if least 15 minutes at a rate high enough to cause
“Warning”, below, is followed. vigorous gassing.
3. If hydrometer has built-in thermometer, draw liq-
WARNING uid in several times to ensure correct tempera-
Before operating engine with battery leads dis- ture before taking reading.
connected from battery, disconnect stator leads
4. Hold hydrometer vertically and draw in just
(yellow) from voltage regulator. Insulate (electri-
enough liquid from battery cell so that float is free-
cal tape) stator lead terminals.
floating. Hold hydrometer at eye level so that float
is vertical and free of outer tube, then take read-
ing at surface of liquid. Disregard curvature
where liquid rises against float stem due to capil-
lary action.

2B-4 - ELECTRICAL 90-852572R1 JANUARY 1998

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 5. Avoid dropping electrolyte on boat or clothing, as Charging A Discharged
it is extremely corrosive. Wash off immediately
with baking soda solution. Battery
Specific gravity of electrolyte varies not only with per- The following basic rules apply to any battery charg-
centage of acid in liquid, but also with temperature. ing situation:
As temperature drops, electrolyte contracts, so that
1. Any battery may be charged at any rate, (in am-
specific gravity increases. Unless these variations in
peres) as long as spilling of electrolyte (from vio-
specific gravity are taken into account, specific grav-
lent gassing) does not occur, and as long as elec-
ity obtained by hydrometer may not give a true indica-
trolyte temperature does not exceed 125° F (52°
tion of concentration of acid in electrolyte.
C). If spewing of electrolyte occurs, or if electro-
A fully charged battery will have a specific gravity lyte temperature exceeds 125° F, charging rate
reading of approximately 1.270 at an electrolyte tem- (in amperes) must be reduced or temporarily
perature of 80° F (27° C). If electrolyte temperature halted to avoid damage to the battery.
is above or below 80° F, additions or subtractions
2. Battery is fully charged when, over a 2-hour peri-
must be made in order to obtain a hydrometer read-
od at a low charging rate (in amperes), all cells
ing corrected to 80° F standard. For every 10° F (3.3°
are gassing freely (not spewing liquid electro-
C) above 80° F, add 4 specific gravity points (.004) to
lyte), and no change in specific gravity occurs.
hydrometer reading. Example: A hydrometer reading
Full charge specific gravity is 1.260-1.275, cor-
of 1.260 at 110° F (43° C) would be 1.272 corrected
rected for electrolyte temperature with electrolyte
to 80° F, indicating a fully charged battery.
level at 3/16” (4.8 mm) over plate. For most satis-
For every 10° below 80° F, subtract 4 points (.004) factory charging, lower charging rates in am-
from the reading. Example: A hydrometer reading of peres are recommended.
1.272 at 0° F (-18° C) would be 1.240 corrected to 80°
3. If, after prolonged charging, specific gravity of at
F, indicating a partially charged battery.
least 1.230 on all cells cannot be reached, battery
is not in optimum condition and will not provide
optimum performance; however, it may continue
Specific Gravity Cell Comparison to provide additional service, if it has performed
Test satisfactorily in the past.
This test may be used when an instrumental tester is 4. To check battery voltage while cranking engine
not available. To perform this test, measure specific with electric starter motor, place red (+) lead of
gravity of each cell, regardless of state of charge, and tester on positive (+) battery terminal and black
interpret results as follows: If specific gravity read- (-) lead of tester on negative (-) battery terminal.
ings show a difference between highest and lowest If the voltage drops below 9-1/2 volts while crank-
cell of .050 (50 points) or more, battery is defective ing, the battery is weak and should be recharged
and should be replaced. or replaced.

Electrolyte Level
Check electrolyte level in battery regularly. A battery
in use in hot weather should be checked more fre-
quently because of more rapid loss of water. If elec-
trolyte level is found to be low, then distilled water
should be added to each cell until liquid level rises ap-
proximately 3/16” (4.8mm) over plate. DO NOT
OVERFILL, because this will cause loss of electro-
lyte and result in poor performance, short life and ex-
cessive corrosion.

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

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-5

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 Winter Storage of Batteries Battery Charging System
Battery companies are not responsible for battery Troubleshooting
damage, either in winter storage or in dealer stock,
if the following instructions are not observed: Description
1. Remove battery from its installation as soon as The battery charging system components are the
possible and remove all grease, sulfate and dirt stator, voltage regulator/rectifier and the battery.
from top surface by running water over top of bat- Alternating current is generated in the stator alterna-
tery. Be sure, however, that vent caps are tight tor coils and flows to the regulator/rectifier. The recti-
beforehand, and blow off all excess water thor- fier changes the alternating current to direct current
oughly with compressed air. Check water level, for charging the battery and the regulator senses bat-
making sure that plates are covered. tery voltage and allows the correct amount of direct
2. When adding distilled water to battery, be ex- current to charge the battery.
tremely careful not to fill more than 3/16” (4.8mm) The charging system may be damaged by:
over plate inside battery. Battery solution or elec-
trolyte expands from heat caused by charging. a. Reversed battery cables.
Overfilling battery will cause electrolyte to over- b. Running the engine with battery cables dis-
flow (if filled beyond 3/16” (4.8 mm) over plate). connected and stator leads connected to reg-
3. Grease terminal bolts well with Quicksilver 2-4-C ulator/rectifier.
Marine Lubricant, and store battery in COOL- c. Open circuit, such as a broken wire or loose
DRY place. Remove battery from storage every connection.
30-45 days, check water level (add water if nec-
essary), and put on charge for 5 or 6 hours at 6
amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check bat-
tery for reason, and then recharge. When gravity
reaches 1.260, discontinue charging. To check a
specific gravity, use a hydrometer, which can be
purchased locally.
5. Repeat preceding charging procedure every
30-45 days, as long as battery is in storage.
When ready to place battery back in service, re- b d
move excess grease from terminals (a small
amount is desirable on terminals at all times), re-
charge again as necessary and re-install battery.

WARNING c
Hydrogen and oxygen gases are produced dur-
ing normal battery operation or charging. Sparks a - Stator
b - Voltage Regulator/Rectifier
or flame can cause this mixture to ignite and ex-
c - Start Solenoid
plode if they are brought near the battery. Sulfu- d - 12V Battery
ric acid in battery can cause serious burns, if
spilled on skin or in eyes. Flush or wash away im- A fault in the battery charging system usually will
mediately with clear water. cause the battery to become undercharged. Check
battery electrolyte level, and charge battery. See
“Electrolyte Level”, and “Charging a Discharged Bat-
tery”.
If battery will not accept a satisfactory charge, re-
place battery.
If battery accepts a satisfactory charge, determine
the cause of the charging system problem as follows.

2B-6 - ELECTRICAL 90-852572R1 JANUARY 1998

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 1. Check for correct battery polarity [red cable to STATOR OHMS TEST
positive (+) battery terminal]. If polarity was incor- (ALTERNATOR COILS ONLY)
rect, check for damaged rectifier. See “rectifier
NOTE: Stator can be tested without removing from
test”, later in this section.
engine.
2. Check for loose or corroded battery connections.
1. Disconnect both yellow (stator leads) from volt-
3. Visually inspect wiring between stator and bat- age regulator/rectifier, or terminal block.
tery for cuts, chafing, and disconnected, loose or
2. Use an ohmmeter and perform the following test.
corroded connection.
IMPORTANT: If stator is mounted on engine, black
4. Excessive electrical load (from too many acces-
stator lead (if provided) must be grounded to power-
sories) will cause battery to run down.
head when testing.
If visual inspection determines that battery connec-
3. Replace stator if readings are outside ranges
tions and wiring are OK, perform the following stator
shown.
and alternator systems tests.
NOTE: Resistance varies greatly with temperature.
Measurements should be taken with an ambient tem-
perature range of 65° to 85° F.

9 Ampere Manual Stator

Resistance Scale
Test Leads
(Ohms) Reading
Between Yellow
0.16 - 0.19* Rx1
Stator Leads
Between Either
Yellow Stator Lead
No Continuity R x 1000
and Engine
Ground
* DC Resistance of these windings generally is less than
1.5 Ohms. If a reading resembling a short is obtained, this
would be acceptable.

16 Ampere Stator
Resistance Scale
Test Leads
(Ohms) Reading
Between Yellow
0.16 - 0.19* Rx1
Stator Leads
Between Either
Yellow Stator Lead
No Continuity R x 1000
and Engine
Ground
* DC Resistance of these windings generally is less than
1.5 Ohms. If a reading resembling a short is obtained, this
would be acceptable.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-7

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 ALTERNATOR SYSTEMS TEST 6. Remove RED sense lead wire from starter sole-
noid terminal and connect to the positive (+) ter-
9 Ampere Manual Stator
minal of a 9 volt transistor battery. Ground the
IMPORTANT: Rectifier (optional accessory) must negative (–) terminal of the 9 volt battery to the
be functioning properly for accurate test results engine.
to be obtained.
1. Remove RED lead from (+) terminal of rectifier.
2. Connect RED (+) ammeter lead to rectifier (+) ter-
a
minal and BLACK (–) ammeter lead to RED recti-
fier lead.
3. With engine running at the indicated RPM, the
ammeter should indicate the following approxi-
mate amperes: a - Red Sense Lead (Female Connector)

RPM AMPERES
Idle 0 7. Connect RED (+) ammeter lead to larger diame-
9 Ampere ter RED harness wire, and BLACK (–) ammeter
Manual Stator 1000 0.6
lead to POSITIVE terminal on starter solenoid.
2000 8.0
8. Secure starter wires away from flywheel.
3000 9.0
9. With engine running at the indicated RPM’s, the
4. If proper ampere readings are not obtained, re- ammeter should indicate the following approxi-
place stator. mate amperes:
RPM AMPERES
16 Ampere Idle 2.8
16 Ampere Stator
S
Stator 1000 9.3
1. Check battery voltage at battery with engine run-
ning. 2000 16
2. If battery voltage is above 14.5 volts, replace volt- 10. A reading of 16 amperes at 2000 RPM indicates
age regulator/rectifier. Check condition of battery the charging system is functioning properly. The
as overcharging may damage battery. battery is being discharged because of the
3. If battery voltage is below 14.5 volts, charge bat- excessive amperage draw on the system (the
tery; refer to “Charging a Discharged Battery”, draw is greater than the amperage output of the
preceding. If battery can not be satisfactorily engine charging system).
charged, replace battery. 11. If ammeter reads less than required amperes @
4. If battery accepts a satisfactory charge, check 3000 RPM, test the stator; refer to “Stator Ohm
battery voltage while cranking engine; refer to Test (Alternator Coils Only)”. If stator tests OK,
“Charging a Discharged Battery”, preceding. If replace voltage regulator.
cranking voltage is not acceptable, replace battery.
5. If cranking voltage is acceptable, disconnect
larger diameter RED harness wire from starter
solenoid terminal.

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 RECTIFIER TEST (OPTIONAL ACCESSORY
FOR 9 AMP STATOR) d
a c
WARNING
Disconnect battery leads from battery before
testing rectifier.
b
NOTE: Rectifier can be tested without removing from
engine. f
1. Disconnect all wires from terminals on rectifier.
2. Use an ohmmeter (R x 1000 scale) and perform
the following test. Refer to drawing for rectifier e
terminal identification.

07300
a - Terminal
b - Terminal
c - Terminal
d - Stator Terminals
e - Positive Terminal
f - Ground

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.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-9

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 VOLTAGE REGULATOR/RECTIFIER TEST SCR TEST:
NOTE: Voltage regulator/rectifier specifications are 1. Set Ohm meter to R X 1k scale.
given for informational purposes only, use the
2. Connect Red (+) meter lead to regulator case.
appropriate troubleshooting techniques previously
mentioned to find the faulty component in the charg- 3. Connect Black (–) meter lead to one YELLOW
ing system. regulator lead. Test. Connect Black (–) meter
lead to the other YELLOW lead.
TEST RESULTS (BOTH TESTS):
15,000 -  OHMS (15k - )

TACHOMETER CIRCUIT TEST:

1. Set Ohm meter to R X 1k scale.
2. Connect Red (+) meter lead to GREY regulator
lead.
DIODE TEST:
3. Connect Black (–) meter lead to regulator case.
1. Set Ohm meter to R X 10 scale.
TEST RESULTS:
2. Connect Red (+) meter lead to RED regulator 10,000 - 50,000 OHMS (10k - 50k)
lead.
3. Connect Black (–) meter lead to YELLOW regula-
tor lead.
TEST RESULTS:
100 - 400 OHMS

DIODE TEST:
1. Set Ohm meter to R X 1k scale.
2. Connect Black (–) meter lead to RED regulator
lead.
3. Connect Red (+) meter lead to YELLOW regula-
tor lead. Test. Then change Red (+) meter lead to
the other YELLOW regulator lead for 2ND test
reading.
TEST RESULTS (1ST READING):
40,000 to  OHMS
TEST RESULTS (2ND READING):
 OHMS (No needle movement)

2B-10 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Starting System Troubleshooting the Starting Circuit
Before beginning the starting circuit troubleshooting
flow chart, following, check first for the following con-
Starting System Components ditions:
The starting system consists of the following compo- 1. Make sure that battery is fully charged.
nents.
2. Check that control lever is in “NEUTRAL” posi-
1. Battery tion.
2. Starter Solenoid 3. Check bullet connectors for corrosion and loose
3. Neutral Start Switch connections.

4. Starter Motor 4. Check cables and wiring for frayed and worn in-
sulation.
5. Ignition Switch
5. Check in-line fuse in RED wire; see diagram.

Description
The function of the starting system is to crank the en-
gine. The battery supplies electrical energy to crank
the starter motor. When the ignition switch is turned
to “START” position, the starter solenoid is activated
and completes the starting circuit between the bat-
tery and starter.
The neutral start switch opens the start circuit when
the shift control lever is not in neutral. This prevents
accidental starting when engine is in gear.

CAUTION
The starter motor may be damaged if operated
continuously. DO NOT operate continuously for
more than 30 seconds. Allow a 2 minute cooling
period between starting attempts.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-11

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 Starting Circuit Wiring Diagram

b
a 4
5

f c

2
3 d

6
1
a - Key Switch
b - Neutral Start Switch
c - Starter
d - Solenoid
e - Battery
f - 20 Amp Fuse

2B-12 - ELECTRICAL 90-852572R1 JANUARY 1998

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 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 Continuity Indicated

NEGATIVE (-) battery cable between the NEGATIVE (-) battery Proceed to TEST 2
post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open circuit.
* 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
b. Connect voltmeter between common engine ground and Test Point 3. or 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
No voltage reading; b. Turn ignition key to “Start” position. wire 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.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-13

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 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 90-852572R1 JANUARY 1998

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 a
Starter Motor c

Removal

WARNING
Always disconnect the battery and remove spark
plug leads from spark plugs before working on
motor. a c
b
1. Disconnect battery leads from battery.
a - Thru Bolts
2. Disconnect BLACK cable (w/YELLOW sleeve). b - Commutator End Cap
c - Brush/Springs
3. Remove 3 bolts.
4. Remove starter.
2. Pull armature from starter frame.
3. Remove locknut.

b
b

a a
b
55329

a - Black Cable (w/YELLOW sleeve)

b - Bolts (3)
a - Armature
b - Locknut
Disassembly
1. Remove 2 thru bolts and commutator end cap,
taking care not to lose brush springs.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-15

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 4. Remove components from armature. b. Clean the commutator slots after undercut-
ting.
d
c. De-burr the commutator lightly with No. 00
e f sandpaper, then clean the commutator.
d. Check the armature on a growler for shorts.
See “Testing”, following.
9. Open-circuited armatures are repairable. The
most likely place for an open circuit is at the com-
mutator bars. Long cranking periods overheat
the starter motor so that solder in the connections
melts. The poor connections cause arcing and
a c burning of the commutator bars.
b
10. Repair bars, that are not too badly burned, by re-
soldering the leads in bars (using rosin flux sol-
der) and turning down the commutator in a lathe
to remove burned material, then undercut the
a - Spacer mica.
b - Spring
11. Clean out the copper or brush dust from slots be-
c - Drive Assembly
d - Drive End Cap tween the commutator bars.
e - Armature Shaft 12. Check the armature for shorts and ground. See
f - Washer “Testing”, following.

Cleaning and Inspection

Testing
1. Clean all motor parts.
2. Check pinion teeth for chips, cracks or excessive ARMATURE TEST FOR SHORTS
wear. Check armature for short circuits by placing on growl-
3. Replace the drive clutch spring and/or collar, if er and holding hack saw blade over armature core
tension is not adequate, or if wear is excessive. while armature is rotated. If saw blade vibrates, ar-
mature is shorted. Re-check after cleaning between
4. Check that the brush holder is not damaged or is commutator bars. If saw blade still vibrates, replace
not holding the brushes against the commutator. armature.
5. Replace brushes that are pitted or worn to less
than 1/4 in. (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
junction) for a firm connection. A poor connection
usually results in a burned commutator bar.
8. Re-surface and undercut a rough commutator, as
follows:

CAUTION
Do not turn down the commutator excessively.
a. Re-surface the commutator and undercut the
insulation between the commutator bars 1/3
in. (8.5 mm) to the full width of the insulation,
make sure that the undercut is flat.

2B-16 - ELECTRICAL 90-852572R1 JANUARY 1998

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

a b

11675

CHECKING POSITIVE BRUSHES AND TERMI-

NALS
1. Connect ohmmeter (R x 1 scale) leads between
positive brushes. a - Negative (-) Brushes
b - End Cap
2. Ohmmeter must indicate full continuity (zero re-
sistance). If resistance is indicated, check lead to
positive terminal solder connection. If connection
cannot be repaired, brushes must be replaced.
Refer to “BRUSH REPLACEMENT”.

11673

a - Positive Brushes

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-17

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 STARTER SOLENOID TEST Brush Replacement
Test starter solenoid as follows: IMPORTANT: Replace brushes that are pitted or
1. Disconnect all leads from solenoid terminals. worn to less than 1/4 in. (6.4 mm) in length.
2. Use an ohmmeter, set to (R x 1 scale) and con-
nect between solenoid terminals 3 and 4.
3. Connect a 12-volt supply between solenoid ter-
minals 1 and 2. Solenoid should click and meter
should read zero ohms. c
4. If meter does not read zero ohms (full continuity),
replace solenoid.

e 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
4 1
a b
c

a
b

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

b a

11656

a - Positive (+) Brushes

b - Negative (–) Brushes
c - Brush Holder
d - Bolts (Fasten Negative Brushes and Holder)

2B-18 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Reassembly Brush Retainer Tool Layout (Full Size)

1. Lubricate helix threads and drive end cap bush-

ing with SAE 10W oil.
2. Install components onto armature shaft.

b a
c

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 Side View (Full Size)

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
51711 1/2” = 12.7mm

4. Construct a brush retainer tool as shown.

90-852572R1 JANUARY 1998 ELECTRICAL - 2B-19

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 5. Place springs and brushes into brush holder and Installation
hold in place with brush retainer tool.
1. Secure starter to block with 3 bolts. Torque bolts
6. Lubricate bushing with one drop of SAE 10W oil. to 16.6 lb. ft. (22.5 N·m). Secure NEGATIVE bat-
DO NOT over-lubricate. tery lead to block with bottom bolt.
2. Connect battery lead (BLACK w/YELLOW
a sleeve) to starter. Torque attaching nut to 60 lb.
in.(6.8 N·m).

11661
a - Brush Retainer Tool
b - Bushing

7. Position armature into starter frame so that com-

mutator end of armature is at end of starter frame a
b
where permanent magnets are recessed 1 in.
(25.4 mm). Align marks as shown. 55329
8. Install commutator end cap onto starter frame;
align marks as shown, and remove brush retainer a - Black Cable (w/YELLOW sleeve)
tool. b - Bolts (3)

9. Install thru bolts and torque to 70 lb. in. (7.9 N·m).

c c

52659
a - Alignment Marks
b - End Cap Alignment Marks
c - Bolts

2B-20 - ELECTRICAL 90-852572R1 JANUARY 1998

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 ELECTRICAL

2
C

TIMING/SYNCHRONIZING/ADJUSTING

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
Idle Timing Adjustment . . . . . . . . . . . . . . . . 2C-2
Maximum Timing Adjustment . . . . . . . . . . . 2C-2
Carburetor Synchronization . . . . . . . . . . . . . . 2C-3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4

2C-0 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Specifications
Idle T.D.C. ± 2°
Maximum Timing
@ Cranking Speed
-Model 40/50/60 24° B.T.D.C.
-Model 55 18° B.T.D.C.
@ 5000 RPM
– Model 50/60 22° B.T.D.C.
– Model 55/60 16° B.T.D.C.
TIMING
Idle RPM 675 ± 25
Wide Open Throttle (W.O.T.) RPM 5000-5500
Spark Plug Type NGK BP8H-N-10
*NGK BPZ8H-N-10
NGK BUZ8H
NGK BP8HS-10
Spark Plug Gap 0.040 in. (1.0mm)
Firing Order 1-2-3
*Suppressor (resistor) spark plug

Special Tools
3. Spark Gap Tool P/N 91-63998A1
1. Service Tachometer P/N 91-854009A1

*May be obtained locally.

2. Timing Light P/N *91-99379

*May be obtained locally.

90-852572R1 JANUARY 1998 ELECTRICAL - 2C-1

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 Timing Maximum Timing Adjustment
1. Hold control arm so that maximum spark ad-
CAUTION vance screw is against stop. Crank engine with
Engine may be timed while cranking engine with starter motor and adjust maximum spark ad-
starter motor. To prevent engine from starting vance screw to align the specified BTDC timing
when being cranked, all spark plugs must be re- mark on flywheel with timing pointer. Tighten
moved. locknut.
1. Insert Spark Gap Tool (91-63998A1) into each
spark plug boot and attach alligator clips to good
engine ground. b
2. Disconnect remote fuel line from engine.
3. Connect remote control electric harness to en-
gine wiring harness.
4. Remove throttle cable barrel from barrel retainer. c
a
Idle Timing Adjustment
5. Connect timing light to No. 1 (TOP) spark plug
lead.

WARNING
While cranking engine, keep clear of propeller as
it may rotate.
51045
6. Shift engine to neutral.
IMPORTANT: To time engine at cranking speed, a a - Control Arm
b - Spark Advance Screw
fully charged battery must be used. c - Locknut
7. Hold throttle arm at idle position as shown below,
crank engine with starter motor and adjust idle NOTE: All timing adjustments made to engine under
timing screw to align T.D.C. timing mark of fly- cranking speed conditions should be verified with en-
wheel with timing pointer. Tighten locknut. gine running and adjustments made if necessary.
NOTE: Timing will be T.D.C. ± 2° after adjusting idle This is due to advance characteristics of individual ig-
RPM. nition systems.

55039

TDC
10 0 10

a - Idle Timing Screw

b - Locknut

2C-2 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Carburetor Synchronization 7. Place roller of cam follower against throttle cam
and adjust idle stop screw to align recessed mark
1. Remove attenuator cover (see section 3B,“Car- of throttle cam with center of cam follower roller.
buretor Removal”). Tighten locknut.
2. Loosen screw of cam follower. 55039

3. Loosen two (2) synchronizing screws located on

throttle levers of top and bottom carburetors.
c
4. Look into throats of carburetors and verify all
throttle shutters are completely closed. Tighten d
synchronizing screws.

b 55039
f
a

b
a
e
a - Throttle Arm
b - Idle Stop Screw
c - Throttle Cam
d - Raised Mark
e - Locknut
f - Cam Roller

b
8. Hold throttle arm at idle position. Adjust cam fol-
a - Screw-Cam Follower lower so that a clearance of .005-.040 in.(0.13
b - Screws-Synchronizing mm-1.02 mm) exists between roller of cam fol-
lower and throttle cam. Tighten screw securing
cam follower.
5. Recheck throttle shutters and make any neces-
sary adjustments.
6. Hold throttle arm so that idle stop screw is against
stop. d

c .005-.040 in.

a
55039

a - Cam Follower
b - Screw
c - Roller
d - Throttle Cam

90-852572R1 JANUARY 1998 ELECTRICAL - 2C-3

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 9. Hold throttle arm against full throttle stop screw. Adjustments
Adjust full throttle stop screw to allow throttle
shutters to open fully while providing approxi-
mately .015 in. (.38 mm) free-play in throttle link- Idle
age to prevent carburetor throttle shutters from
1. With engine in water, connect electrical harness
acting as throttle stops at wide open throttle.
(if equipped) and fuel line to engine. Start engine
Tighten locknut on stop screw.
and allow to warm up.
2. Properly adjust carburetor low speed mixture
screws. Initial setting is 1-1/4 turns off seat.
3. Hold throttle arm at idle position (throttle cable
barrel removed from barrel retainer). Adjust idle
timing screw to attain an engine idle RPM of
a 650-700 RPM in “FORWARD” gear. Tighten lock-
nut and turn off engine.

55039

b
a

c
51045 b
a - Throttle Arm
b - Stop Screw
c - Locknut (Hidden)

10. Reinstall attenuator cover.

a - Idle Timing Screw

b - Locknut

2C-4 - ELECTRICAL 90-852572R1 JANUARY 1998

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 ELECTRICAL

2
D

WIRING DIAGRAMS

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 Table of Contents
Page
40/55 MH Wiring Diagram . . . . . . . . . . . . . . . 2D-1
40/50/60 EO Wiring Diagram . . . . . . . . . . . . 2D-2
40/50 EHPTO Wiring Diagram . . . . . . . . . . . 2D-3
40/50/60 EPTO Wiring Diagram . . . . . . . . . . 2D-4
60 EHPTO Wiring Diagram . . . . . . . . . . . . . . 2D-5
COMMANDER 2000 Side Mount Remote
Control Wiring Diagrams . . . . . . . . . . . . . . . . 2D-6
Key/Choke Switch Continuity Test . . . . . . 2D-6
Power Trim/Tilt Electric Start with
Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7
Power Tilt Electric Start with
Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8
Electric Start with Warning Horn . . . . . . . . . . 2D-9

2D-0 - ELECTRICAL 90-852572R1 JANUARY 1998

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 40/55 MH Wiring Diagram

c
i

g f

a - Trigger f - Lanyard Stop Switch

b - Stator g - Rev. Limiter
c - Temperature Switch h - CDM #3
d - Warning Horn i - CDM #2
e - Push-Button Stop Switch j - CDM #1

90-852572R1 JANUARY 1998 ELECTRICAL - 2D-1

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 40/50/60 EO Wiring Diagram
b

a c
d

o
f

n
g

m h

k j

a - Trigger i - 12 V Battery
b - Stator j - Start Solenoid
c - Remote Control k - Voltage Regulator
d - 20 Amp Fuse l - Rev. Limiter
e - Starter m- CDM #3
f - Fuel Enrichment Solenoid n- CDM #2
g - Oil Level Switch o- CDM #1
h - Head Temp. Switch

2D-2 - ELECTRICAL 90-852572R1 JANUARY 1998

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 40/50 EHPTO Wiring Diagram

d e

f
c l
j k
b g
h i

m n
x
o

q
u
r

t s
a - Trigger m- Fuel Enrichment Solenoid
b - Stator n- Trim Pump
c - Key Switch o- Oil Level Switch
d - Warning Horn p- Head Temperature Switch
e - Push Button Stop Switch q- 12 Volt Battery
f - Lanyard Switch r - Neutral Start Switch
g - Remote Control s - Start Solenoid
h - 20 Amp Fuse t - Voltage Regulator
i - Cowl Mounted Trim Switch u- Rev. Limiter
j - Trim-Down Relay v - CDM 3
k - Trim-Up Relay w- CDM 2
l - Starter x - CDM 1

90-852572R1 JANUARY 1998 ELECTRICAL - 2D-3

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 40/50/60 EPTO Wiring Diagram

b h
f g
a
c d e

s
i
r j
k

q
l

a - Trigger k - Oil Level Switch

b - Stator l - Head Temp. Switch
c - Remote Control m- 12V Battery
d - 20 Amp Fuse n- Start Solenoid
e - Cowl Mounted Trim Switch o- Voltage Regulator
f - Trim-Down Relay Switch p- Rev. Limiter
g - Trim-Up Relay Switch q- CDM #3
h - Starter r - CDM #2
i - Trim Pump s - CDM #1
j - Fuel Enrichment Solenoid

2D-4 - ELECTRICAL 90-852572R1 JANUARY 1998

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 60 EHPTO Wiring Diagram
c
a d
e
x f g

i h
b
w
k j

l
v m
n

u
o

s p

r q

a- Key Switch n- Oil Level Switch

b- Warning Horn o- Head Temp. Switch
c - Neutral Start Switch p- 12V Battery
d- Tiller Handle Trim Switch q- Start Solenoid
e- Push-Button Stop Switch r - Voltage Regulator
f - Lanyard Stop Switch s - Rev. Limiter
g- Starter t - CDM #3
h- Trim-Up Relay u- CDM #2
i - Trim-Down Relay v - CDM #1
j - Cowl Mounted Trim Switch w- Trigger
k - 20 Amp Fuse x - Stator
l - Trim Pump y - Remote Control
m- Fuel Enrichment Solenoid

90-852572R1 JANUARY 1998 ELECTRICAL - 2D-5

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 COMMANDER 2000 Side Mount Remote
Control Wiring Diagrams

Key/Choke Switch Continuity Test

“OFF” BLK/YEL - BLK

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

2D-6 - ELECTRICAL 90-852572R1 JANUARY 1998

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

a f
d
e
b

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

23891

90-852572R1 JANUARY 1998 ELECTRICAL - 2D-7

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 Power Tilt Electric Start with Warning Horn
a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch
d - Tachometer/Accessories Harness
e - Wiring Harness Connector
f - Warning Horn
g - Trim/Tilt Switch
h - Wire Retainer
i – Control Handle
j - Trim Harness Bushing
k - Trim Harness Connector
l - Lead to Trim Indicator Gauge

h
BLK • BLACK
g

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

i
TAN • TAN
WHT • WHITE
YEL • YELLOW
LIT • LIGHT

j
d
a
e

b
k

c
l

24072

2D-8 - ELECTRICAL 90-852572R1 JANUARY 1998

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 Electric Start with Warning Horn

e d f
a

a - Ignition/Choke Switch
b - Emergency Stop Switch
c - Neutral Start Switch c
d - Tachometer/Accessories Harness Connector
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

90-852572R1 JANUARY 1998 ELECTRICAL - 2D-9

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 FUEL SYSTEM

3
A

FUEL PUMP

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Fuel Pump (Electric) 40/50/55/60 . . . . . . . . . 3A-2
Fuel Pump (Manual) 40/50 . . . . . . . . . . . . . . 3A-4
Fuel Pump (Manual) 55/60 . . . . . . . . . . . . . . 3A-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . 3A-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 3A-8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9
Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . 3A-10
Fuel Pump Disassembly . . . . . . . . . . . . . . . . 3A-10
Cleaning and Inspection . . . . . . . . . . . . . . . . . 3A-10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-11
Check Valve Assembly . . . . . . . . . . . . . . . 3A-11
Fuel Pump Assembly . . . . . . . . . . . . . . . . 3A-11

3A-0 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Specifications
Fuel
Electric Start Models Straight Gasoline
Manual Start Models Pre-mixed Gasoline and Oil
Recommended Gasoline Unleaded-87 Octane Minimum
Recommended Oil Quicksilver TC-WII or TC-W3
FUEL SYSTEM
Two Cycle Outboard Oil
Gasoline/Oil Ratio 50:1 (Including Break-In)
Fuel Pressure
@ Idle 3.5 PSI (24 kPa)
@ W.O.T. 6.0 PSI (41 kPa)

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3A-1

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 Fuel Pump (Electric) 40/50/55/60

9 Loctite PST Pipe Sealant (92-809822)

A= To top carburetor B= to crankcase c= to oil pump fitting
D= TO INTAKE MANIFOLD FITTING E= TO FITTING
F = to oil pump outlet

3A-2 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Fuel Pump (Electric) 40/50/55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 FUEL PUMP ASSEMBLY
1 1 FUEL PUMP
2 2 DIAPHRAGM KIT
3 1 DIAPHRAGM
4 2 RUBBER 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
2 SCREW–fuel pump (M5 x 40) 55 4.6 6.2
16 2 SCREW– pump to crankcase (M6 x 50) 55 4.6 6.2
17 1 BASE
18 1 HOSE
19 1 FUEL FILTER
20 1 FUEL LINE
21 AR STA-STRAP
22 1 HOSE (1-1/2 IN.)
23 1 HOSE (1-1/2 IN.) 40
24 1 WYE CONNECTOR
25 1 HOSE (2 IN.)
22 1 HOSE (1-1/4 IN.)
23 1 HOSE (1-1/4 IN.) 50
24 1 TEE CONNECTOR
25 1 HOSE (1-1/2 IN.)
26 1 HOSE (22 IN.)
27 1 CHECK VALVE
28 1 FUEL CONNECTOR
29 1 SCREW (M6 x 35) 80 6.7 9.0
30 1 HOSE (4-1/4 IN.)
1 CLAMP (NO STAMPING)
31 1 CLAMP (STAMPED ’3’)
32 1 SOLENOID VALVE (USE WITH NO STAMPING CLAMP
33 1 SOLENOID VALVE (USE WITH STAMPED ’3’ CLAMP
1 HOSE (9-1/2 IN.) (MANUAL BUTTON MOUNTED DOWN)
34 1 HOSE (8 IN.) (MANUAL BUTTON MOUNTED UP)
1 HOSE (3-1/4 IN.) (MANUAL BUTTON MOUNTED DOWN)
35 1 HOSE (4 IN.) (MANUAL BUTTON MOUNTED UP)
1 HOSE (16 IN.) (MANUAL BUTTON MOUNTED DOWN)
36 1 HOSE (14 IN.) (MANUAL BUTTON MOUNTED UP)
37 1 TEE FITTING
38 1 HOSE (2 IN.)
39 1 SCREW (M6 x 16) 100 8.3 11

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3A-3

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 Fuel Pump (Manual) 40/50

9 Loctite Pipe Sealant W/Teflon (92-809822)

A= TO CARBURETOR B= TO CRANKCASE C = TO TOP CARB

D= TO MANIFOLD TOP E= TO MANIFOLD BOTTOM

3A-4 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Fuel Pump (Manual) 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 FUEL PUMP ASSEMBLY
1 1 FUEL PUMP
2 2 CHECK VALVE
3 1 DIAPHRAGM KIT
4 2 RUBBER 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
2 SCREW–fuel pump (M5 x 40) 55 4.6 6.2
16
2 SCREW–pump to crankcase (M6 x 50) 55 4.6 6.2
17 1 BASE
18 1 HOSE (22 IN.)
19 AR STA-STRAP
20 1 HOSE
21 1 HOSE (4-1/4 IN.)
22 1 FUEL FILTER
23 1 HOSE
24 1 TEE FITTING
25 2 HOSE (9-1/2 IN.)
26 1 PRIMER BULB
27 1 FUEL CONNECTOR
28 1 SCREW (M6 x 35) 80 6.7 9.0
29 1 HOSE (5-1/2 IN.)
30 1 HOSE (1-1/2 IN.)

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3A-5

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 Fuel Pump (Manual) 55/60

30 27

D C
27 A

21
29

7 20
6 1
4
2
26 5

5 12
2 4 3
11
28 14
9

17
10 20
8 15
9
E 13
19
B 16

20

20
15 22
20
32
20
31 18 25

20
24

9 Loctite PST Pipe Sealant (92-809822)

23

A= TO CARBURETOR, B= TO CRANKCASE , C = TO TOP FLOAT BOWL,

D = TO TOP INTAKE MANIFOLD, E = TO LOWER INTAKE MANIFOLD,

3A-6 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Fuel Pump (Manual) 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 FUEL PUMP ASSEMBLY
1 1 FUEL PUMP ASSEMBLY
2 2 DIAPHRAGM KIT
3 1 DIAPHRAGM
4 2 RUBBER 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
2 SCREW–fuel pump 55 4.6 6.2
16
2 SCREW–fuel pump to crankcase 55 4.6 6.2
17 1 BASE
18 1 HOSE (10 IN.)
19 1 HOSE (14-1/4 IN.)
20 AR STA-STRAP
21 1 HOSE
22 1 HOSE (4-1/4 IN.)
23 1 FUEL FILTER
24 1 BRACKET
25 1 NUT Drive Tight
26 1 TEE FITTING
27 2 HOSE (9-1/2 IN.)
28 1 HOSE (5-1/2 IN.)
29 1 HOSE (1-1/2 IN.)
30 1 PRIMER BULB
31 1 FUEL CONNECTOR
32 1 SCREW 80 6.7 9.0

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3A-7

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 Theory of Operation Checking For Restricted Fuel Flow
The fuel pump is a crankcase-pressure-operated, di- Caused By Anti-Siphon Valves
aphragm-type pump. Crankcase pulsating pressure While anti-siphon valves are helpful from a safety
is transferred by way of a passage (hole) from the stand-point, they clog, they may be too small, or they
crankcase to the fuel pump. may have too heavy a spring. The pressure drop that
When the piston travels upward, a vacuum is created occurs with these valves can create operational
in the crankcase. This vacuum pulls in the fuel pump problems and/or powerhead damage by restricting
diaphragm, the inlet check valve (in fuel pump) is flow of fuel. Some symptoms of restricted (lean) fuel
opened, and fuel is drawn into fuel pump. flow, are:

Loss of fuel pump pressure
Downward motion of the piston forces out the fuel
Loss of power
pump diaphragm, closes the inlet check valve (to
High speed surging
keep fuel from returning to fuel tank) and opens the
Preignition/detonation (piston dome erosion)
outlet check valve, forcing fuel to the carburetors.
Outboard hesitates upon acceleration

Outboard runs rough

Outboard quits and cannot be restarted
Troubleshooting
Outboard will not start

Vapor lock
WARNING Any type of anti-siphon device must be located be-
FIRE AND EXPLOSION HAZARD. Observe fire tween the outboard fuel inlet and fuel tank outlet. A
prevention rules, particularly NO SMOKING. Be- method of checking [if such a device (or bad fuel) is
fore servicing any part of the fuel system, discon- a problem source] is to operate the outboard with a
nect electrical system at the battery. Drain the separate fuel supply which is known to be good.
fuel system completely. Use an approved con- If it is found that the anti-siphon valve is the cause of
tainer to collect and store fuel. Wipe up any spil- the problem, either 1) replace the anti-siphon valve,
lage immediately. Materials used to contain spil- or 2) replace it with a solenoid-operated fuel shutoff
lage must be disposed of in an approved valve.
receptacle. Any fuel system service must be per-
formed in a well ventilated area.

FUEL LEAKAGE FROM ANY PART OF THE FUEL

SYSTEM CAN BE A FIRE AND EXPLOSION HAZ-
ARD WHICH CAN CAUSE SERIOUS BODILY IN-
JURY OR DEATH. Careful periodic inspection of
the entire fuel system is mandatory, particularly
after engine storage. All fuel components, in-
cluding fuel tanks, whether plastic, metal, fiber-
glass, fuel lines, primer bulbs, and fittings, must
be inspected for corrosion. Any sign of leakage
or deterioration necessitates replacement before
further engine operation.

3A-8 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Testing PROBLEM: LACK OF FUEL PUMP PRESSURE
Install clear fuel hose(s) between fuel pump and car- Possible Cause Corrective Action
buretor(s). Run engine, and inspect hose(s) for air Anti-siphon valve. Refer to “Checking for
bubbles. If air bubbles are found, see “Air Bubbles in Restricted Fuel Flow
Fuel Line” . If air bubbles are not found, see “Lack of Caused by Anti-siphon
Fuel Pump Pressure”. Valves” preceding.
Air in fuel line. “Air Bubbles in Fuel
PROBLEM: AIR BUBBLES IN FUEL LINE
Line,” preceding.
Possible Cause Corrective Action
Dirty or clogged fuel fil- Clean or replace filter.
Low fuel in tank. Fill tank. ter.
Loose fuel line connec- Inspect and tighten con- Dirty or clogged fuel Clean or replace pickup.
tion. nections. pickup in fuel tank.
Fuel pump fitting loose. Tighten fitting. Worn out fuel pump dia- Rebuild pump.
A hole or cut in fuel line. Inspect condition of fuel phragm.
lines and replace any Defective check valves Rebuild pump.
found bad. in fuel pump.
Fuel pump anchor Inspect and tighten all Broken check valve re- Rebuild pump.
screws loose. screws. tainer.
Fuel pump gaskets worn Rebuild fuel pump. Pulse hole plugged. Remove pump and
out. clean out hole.
Hole in pulse hose. Replace pulse hose.
Loose pulse hose. Tighten connection.
Boost diaphragm gasket Check seal between
distorted or out of place. mating surfaces where
“rib” divides pulse
chamber. Gasket must
align with rib. Align or re-
place gasket as neces-
sary.

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3A-9

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

51267
a
a
a - Bolt (2)
b - Chamber Plate
e
2. Disassemble fuel pump as shown in “Fuel Pump
e
Exploded View.”

d
51267
Cleaning and Inspection
1. Clean fuel pump housing, chamber plate and
pump base. Dry with compressed air.
a - Inlet Fuel Hose
b - Outlet Fuel Hose
2. Look at spring for signs of bad coils or other dam-
c - Pulse Hose - From Crankcase age.
d - Bolt (2) 3. Check pump body, chamber plate and pump
e - Sta-strap
base for cracks or rough gasket surfaces.
4. Check hoses for looseness or signs of leakage.
4. Remove gasket from backside and replace gas- 5. Look at check valve discs for cracks, tears, or oth-
ket as necessary -- check gasket in port area. er damage.
6. Repair of fuel pump is limited to the replacement
of those bad parts found during inspection.

b
a

51267

a - Gasket
b - Port Area

3A-10 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Reassembly 3. With retainer installed in pump body, break re-
tainer rod from retainer by bending sideways.

Check Valve Assembly

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

23601

a a - Retainer Rod
b - Retainer Cap

c
4. Reinstall rod into retainer cap. Use a small ham-
23601 mer or hammer and punch to tap rod down into
a - Retainer retainer until flush with top of retainer.
b - Plastic Disc
c - Rubber Check Valve a

2. Install check valves and retainers into fuel pump b

body.

23610

a - Retainer Rod
b - Retainer Cap

Fuel Pump Assembly

a
1. Assemble remaining components as shown in
the fuel pump exploded view.
2. Install bolts and torque to 55 lb. in. (6.2 N·m).

a
a
51267

23601
a - Bolt (2)

a - Check Valve/Retainer

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3A-11

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 FUEL SYSTEM

3
B

CARBURETOR

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1
WME Carburetor Chart . . . . . . . . . . . . . . . . . . 3B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1
Carburetor 40/50 . . . . . . . . . . . . . . . . . . . . . . . 3B-2
Carburetor 55/60 . . . . . . . . . . . . . . . . . . . . . . . 3B-4
Attenuator Plate 40/50 . . . . . . . . . . . . . . . . . . 3B-6
Attenuator Plate 55/60 . . . . . . . . . . . . . . . . . . 3B-8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10
Idle Mixture Screw Adjustment . . . . . . . . 3B-10
Idle Speed Adjustment . . . . . . . . . . . . . . . 3B-10
Float Adjustment . . . . . . . . . . . . . . . . . . . . 3B-10
Main (High Speed) Jet Adjustment . . . . . 3B-11
Jet Orifice Size Chart . . . . . . . . . . . . . . . . 3B-11
High Altitude Jet Chart . . . . . . . . . . . . . . . 3B-12
Fuel System Troubleshooting . . . . . . . . . . . . 3B-13
General Information . . . . . . . . . . . . . . . . . . 3B-13
Problem: Engine Floods . . . . . . . . . . . . . . 3B-13
Problem: Engine Runs Too Rich . . . . . . . 3B-13
Problem: Fuel Blow Back Out Of
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-13
Problem: Rough Idle . . . . . . . . . . . . . . . . . 3B-13
Problem: Engine Turns Over But Will
Not Start Or Starts Hard When Cold . . . . 3B-14
Problem: Unable to Reduce Engine
RPM to Slow Idle . . . . . . . . . . . . . . . . . . . . 3B-14
Problem: Engine Runs Too Lean . . . . . . . 3B-15
Problems: Engine Idles Rough And Stalls
Engine Runs Uneven Or Surges
Engine Will Not Accelerate . . . . . . . . . . . . 3B-15
Removal/Installation . . . . . . . . . . . . . . . . . . . . 3B-16
40/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-16
55/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-17
Enrichment System . . . . . . . . . . . . . . . . . . . . . 3B-18
Electric Enrichener Valve . . . . . . . . . . . . . 3B-18
Manual Primer Button . . . . . . . . . . . . . . . . 3B-20

3B-0 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Specifications
Idle RPM (In Forward Gear) 675 ± 25
Wide Open Throttle (W.O.T.) RPM 5000-5500
Float Height 9/16 in. (14.29 mm)
CARBURETOR

WME Carburetor Chart

NOTE: Carburetor Number Stamped on Side of Carburetor Body.

Model Year Carburetor Main Fuel Jet Preset Idle Screw

Number Turns Open
40 Electric 1998 53-1,-2,-3 0.044 in. 1-1/4
40 Manual 1997-1/2/98 69-1,-2,-3 0.044 in. 1-1/4
50 Manual/Electric 1998 68-1,-2,-3 0.052 in. 1-1/4
55/60 Manual 1998 57-1,-2,-3 0.058 in. 1-1/4
60 Electric 1998 58-1,-2,-3 0.060 in. 1-1/8

Special Tools

P/N 91-36392 Carburetor Scale

73656

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-1

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 Carburetor 40/50

5
3
11
10
7
8 4
7 9

15 6
12
16
1
13
17
18
19
20
14

21

22

25
26
27
23

24

7 Loctite “271” (92-809819)

3B-2 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Carburetor 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 CARBURETOR (ELECTRIC 40 - WME-53)
1 1 CARBURETOR (MANUAL 40 - WME-69)
1 CARBURETOR (50 - WME-68)
2 1 THROTTLE SHAFT (UPPER)
3 1 THROTTLE SHAFT (CENTER) WME-53/68
4 1 THROTTLE SHAFT (BOTTOM)
2 2 THROTTLE SHAFT (UPPER/BOTTOM) WME-69
3 1 THROTTLE SHAFT (CENTER)
5 2 SCREW–throttle adjustment (UPPER/BOTTOM)
6 3 SPRING–throttle return
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 THROTTLE LEVER Bottom - WME-53/68
14 1 SCREW–oil pump lever
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
3 FUEL BOWL (WME-53/68)
24 1 FUEL BOWL (UPPER) WME-69
2 FUEL BOWL (CENTER/BOTTOM)
25 3 PLUG KIT
26 3 SEAL–bowl drain
3 MAIN FUEL JET (.044 - WME-53/WME-69) 14 1.6
27
3 MAIN JET (.052 - WME-68) 14 1.6

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-3

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 Carburetor 55/60

3
5
2

11
10
7
8
7 9

15 6
12
16
13
1

17
18
19
20
14

21

22

24
26
27
23

24

7 Loctite “271” (92-809819)

3B-4 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Carburetor 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 CARBURETOR (60 ELECTRIC - WME-58)
1
1 CARBURETOR (55/60 MANUAL - WME-57)
2 1 THROTTLE SHAFT (UPPER)
3 1 THROTTLE SHAFT (CENTER) WME-58
4 1 THROTTLE SHAFT (BOTTOM)
2 2 THROTTLE SHAFT (UPPER/BOTTOM)
3 1 THROTTLE SHAFT (CENTER) WME-57
5 2 SCREW–throttle adjustment (UPPER/BOTTOM)
6 3 SPRING–throttle return
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 THROTTLE LEVER WME-58 - Bottom
14 1 SCREW–oil pump lever
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
1 FUEL BOWL (UPPER) WME-57
24 2 FUEL BOWL (CENTER/BOTTOM)
3 FUEL BOWL (WME-58)
25 3 PLUG KIT 25 2.8
26 3 SEAL–bowl drain
3 MAIN FUEL JET (.058 - WME-57) 14 1.6
27
3 MAIN JET (.060 - WME-58) 14 1.6

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-5

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 Attenuator Plate 40/50

A B
19
17
17 19
13 16
10
9 17
15 10
9
17
17
14
11
12
12 11
17
18
13
17

13
17

1
8

20
6
3
2

21

4
5
22

A = MANUAL B = ELECTRIC

3B-6 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Attenuator Plate 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SOUND ATTENUATOR
2 1 SCREW (M6 x 16) Drive Tight
3 1 WASHER
4 1 CAP PLUG
5 1 BRACKET
6 3 SEAL
7 1 BRACKET
8 6 SCREW (M8 x 100) 100 8.3 11
9 1 ARM
10 1 ROLLER
11 1 SCREW (M5 x 6) Drive Tight
12 1 WASHER
2 TUBING (4-1/4 IN.)(MANUAL)
13
1 TUBING (4-1/4 IN.)
14 1 TUBING (3 IN.) ELECTRIC
15 1 FITTING–Tee
16 1 TUBING (1 IN.)
17 AR STA-STRAP
18 3 GASKET
19 1 THROTTLE LINK
20 1 DECAL–Warning (MANUAL)
21 1 DECAL–Caution
22 1 DECAL-Caution in gear idle (ELECTRIC)

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-7

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 Attenuator Plate 55/60

A B

18 19
18

17
14
11 18 C
10
16
18
18
20
15
13 12 11
10

18
19
14
18 13 12

14
18

5
4

6 1

9
3

7
2
21
A= MANUAL HOSE ROUTING B = ELECTRIC HOSE ROUTING C = TO ENRICHENER VALVE

3B-8 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Attenuator Plate 55/60
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 (M8 x 100) 100 8.3 11
7 1 DECAL-Warning (MANUAL)
8 1 DECAL-Caution
9 1 DECAL-Full Throttle Timing (ELECTRIC)
10 1 ARM
11 1 ROLLER
12 1 SCREW (M5 x 6) Drive Tight
13 1 WASHER
2 TUBING (4-1/4 IN.)(MANUAL)
14
1 TUBING (4-1/4 IN.)
15 1 TUBING (3 IN.) ELECTRIC
16 1 FITTING-Tee
17 1 TUBING (1 IN.)
18 AR STA-STRAP
19 3 GASKET
20 1 THROTTLE LINK
21 1 DECAL-Caution In Gear Idle

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-9

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 Adjustments Idle Speed Adjustment
1. Adjust engine idle RPM as outlined in Section 2C
“Timing/Synchronizing/Adjusting.”
Idle Mixture Screw Adjustment
Float Adjustment
INITIAL STARTING ADJUSTMENT 1. Remove carburetor as outlined in “Carburetor
Turn idle mixture screw in (clockwise) until it seats Removal” in this section.
LIGHTLY--then back-off (each carburetor) the cor- 2. Remove fuel bowl and gasket and check float lev-
rect number of turns (See Specifications). el using a carburetor scale (gasket removed).

RUNNING QUALITY ADJUSTMENT

1. Position outboard at level trim. With gear case
submerged, start outboard and allow to warm up.
Throttle outboard back to idle for about one min-
ute.
2. Shift outboard into forward gear. Turn low speed
mixture “in” (clockwise) until outboard starts to
bog down and misfire. Turn mixture screw out 1/4
turn or more.

52372

9/16 in. (14.29 mm)

a
3. Attach Spring Clip on Inlet Needle to metal float
tab and place needle into its seat.
b

a
b
c

55883
a - Metal Float Tab
b - Spring Clip

4. If necessary, adjust float level by bending metal

tab (on float) to which inlet needle is clipped.
a - Top Idle Mixture Screw
b - Middle Idle Mixture Screw
c - Bottom Idle Mixture Screw

3. Check for too lean mixture on acceleration.

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

a - Bend Tab Here for Float Level Adjustment

3B-10 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Main (High Speed) Jet Adjustment Jet Orifice Size Chart
The carburetor has a fixed high speed jet. Extreme
changes in weather (temperature and humidity) and/ NOTE: 10-32 Thread Size
or elevation may result in a too lean or rich fuel mix-
ture at wide-open-throttle, which may require a Jet Orifice Part
change in the high speed jet. A smaller size main jet Size-inches Number
will lean the fuel mixture, and a larger size jet will en- 0.034 19266034
rich the fuel mixture.
0.036 19266036
0.038 19266038
c
0.040 19266040
0.042 1399-5315
0.044 1395-7394
0.046 1399-5317
0.048 1395-6246
0.050 1395-6028
0.052 1395-6359
0.054 1399-5225
0.056 1399-5213
0.058 1395-7831
0.060 1395-6487
0.062 1399-4217
a
b 0.064 1399-4216
0.066 1399-4215
a - High Speed Jet
b - Bowl Drain Plug
0.068 1395-6029
c - Idle Mixture Screw 0.070 1395-6030
0.072 1395-6207
0.074 1399-3794
0.076 1399-3796
0.078 1395-6680
0.080 1395-6201
0.082 1399-3518
0.084 1399-3517
0.086 1395-5815
0.088 1395-6202
0.090 1395-6247
0.092 1395-5733
0.094 1395-8423
0.096 1399-6249
0.098 1395-7335

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-11

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 High Altitude Jet Chart
Factory installed main fuel jets are normally adequate for proper performance up to approximately 5000 feet
(1524m) above sea level. Between 2000 feet (609.6m) and 5000 feet (1524m) the reduction of the main fuel jet(s)
may result in improved performance and fuel economy. Above 5000 feet, however, it is recommended that main
jet size be reduced as shown per 1000 feet (304.8m) in the following chart. RETURN TO LOWER ELEVATION.
Carburetor jet changes must be reversed to avoid a lean fuel condition when used at low elevation.

Feet 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Meter 304.8 609.6 914.4 1219.2 1524 1828.8 2133.6 2438.4 2743.2 3048 3352.8 3657.6
Jet Size
0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032 0.032 0.030 0.030 0.030 0.030
0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032
0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034
0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.034
0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036
0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038
0.046 0.046 0.046 0.044 0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040
0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044 0.042 0.042 0.042
0.050 0.050 0.050 0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044
0.052 0.052 0.050 0.050 0.050 0.050 0.048 0.048 0.048 0.048 0.046 0.046 0.046
0.054 0.054 0.052 0.052 0.052 0.052 0.050 0.050 0.050 0.048 0.048 0.048 0.048
0.056 0.056 0.054 0.054 0.054 0.054 0.052 0.052 0.052 0.050 0.050 0.050 0.048
0.058 0.058 0.056 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052 0.052 0.050
0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052
0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054
0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056
0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058
0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.060 0.060 0.060
0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062
0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.062
0.074 0.074 0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064
0.076 0.076 0.074 0.074 0.072 0.072 0.072 0.070 0.070 0.068 0.068 0.068 0.066
0.078 0.078 0.076 0.076 0.074 0.074 0.074 0.072 0.072 0.070 0.070 0.068 0.068
0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072 0.070 0.070
0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072
0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074
0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.074
0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076
0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078
0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080
0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082
0.096 0.096 0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.086 0.086 0.084 0.084
0.098 0.098 0.096 0.096 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086

3B-12 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Fuel System Troubleshooting
General Information
Problems that are thought to be caused by the fuel
system may, in reality, be something completely dif-
ferent. Items, that are shown below, could give the
impression that there is a problem in the fuel system.
1. Propeller
2. Spark Plugs
3. Ignition Timing
4. Ignition Spark Voltage
5. Cylinder Compression
6. Reed Valves
Typical symptoms and solutions in troubleshooting a
fuel system are shown below.

Problem: Engine Floods

Possible Cause Corrective Action
Dirt or debris are preventing inlet needle from seat- Flush out inlet seat and clean inlet needle
ing
Worn inlet needle Replace
Punctured float Replace
Incorrect float setting Reset float

Problem: Engine Runs Too Rich

Possible Cause Corrective Action
Fuel level too high Reset float to correct level
Carburetor floods See preceding “Engine Floods”
Idle nozzle air holes plugged Blow out with compressed air
Restricted air flow Inspect cowl air inlet and carburetor for obstructions
Main fuel jet loose Re-tighten jet

Problem: Fuel Blow Back Out Of Carburetor

Possible Cause Corrective Action
Chipped or broken reeds on reed block Replace reeds

Problem: Rough Idle

Possible Cause Corrective Action
Excessive pre-load on reeds Replace reeds

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-13

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 Problem: Engine Turns Over But Will Not Start Or Starts Hard When Cold
Possible Cause Corrective Action
Improper starting procedure used. Review starting procedure as outlined in “Operation
and Maintenance Manual”.
Fuel tank empty or too low. Improperly mixed fuel. Check fuel in tank and replace or add whichever is
Contaminants (water, dirt, etc.) in fuel. necessary.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all the way and free from any contaminants.
Pinched, cut, restricted fuel line or loose fuel line Inspect all fuel lines and replace as needed. Tighten
connection. fuel line connections.
Dirty or restricted fuel filter. Inspect and replace or clean all fuel filters.
Choke solenoid or enrichment valve not operating. Inspect solenoid or valve and wiring. Replace as re-
quired.
Needle and seat in carburetor that is either stuck Refer to carburetor disassembly in this section.
open (flooding) or closed (no fuel).
Improper carburetor jet, restricted jet or idle mixture Refer to carburetor adjustments in this section.
screw out of adjustment.
Improper float level. Refer to carburetor adjustments in this section.
Low fuel pump pressure. Refer to Section 3A “Fuel Pump”.
Defective anti-siphon valve. Refer to Section 3A “Fuel Pump”.
Needle and seat in carburetor that is either stuck Refer to carburetor adjustments in this section.
open or closed.
Improper float level. Refer to carburetor adjustments in this section.
Carburetor loose on intake manifold. Check tightness of carburetor nuts.
Using a pressure oil can, apply 2-cycle oil around
reed block housing/crankcase housing matching
Reed block loose or gasket defective. surfaces and carburetor base. If engine RPM
changes, tighten bolts/nuts or replace gaskets as
required.
Improperly routed or restricted bleed hose(s). Refer to bleed hose routing in Section 4A “Power-
head”.
Damaged fuel pump diaphragm. Refer to Section 3A “Fuel Pump”.
Carburetor mixing chamber cover leaking air. Tighten screws or replace gasket.
Off idle holes plugged. Blow with compressed air.
Main nozzle or idle nozzle air bleed holes plugged. Blow with compressed air.
Damaged reeds. Refer to Section 4A “Powerhead” for reed inspec-
tion.
Fuel pick-up outlet tube in fuel tank cracked. Replace.

Problem: Unable to Reduce Engine RPM to Slow Idle

Possible Cause Corrective Action
Chipped or broken reeds on reed block. Replace reeds.

3B-14 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Problem: Engine Runs Too Lean
Possible Cause Corrective Action
Carburetor is loose. Air leaks past mixing chamber Tighten bolts securely. Tighten cover or replace gas-
cover. ket.
Fuel level is too low. Reset float level.
Clogged high speed jet. Inspect jet for varnish or debris and clean.
Restricted fuel flow to carburetor. Check fuel lines and filter(s) for restricted flow.
Incorrect high speed jet. Refer to main jet chart and replace with proper jet.
Idle mixture set too lean. Adjust to run richer (turn idle mix screw counter-
clockwise).
Air leakage into fuel system. Inspect fuel line connections, hose clamps, fuel
pump and fuel outlet tube (located in fuel tank) for
loose fittings.
Anti-siphon valve restricting fuel flow. Refer to Section 3A for checking for restriction of
fuel flow caused by anti-siphon valve.

Problems:
-Engine Idles Rough And Stalls
-Engine Runs Uneven Or Surges
-Engine Will Not Accelerate
Possible Cause Corrective Action
Fuel tank air vent closed or restricted. Air vent must be open all the way and free from re-
strictions.
A pinched, cut or restricted fuel line; also loose fuel Check all fuel lines and replace as needed. Check
line connection. and tighten all fuel line connections.
A dirty or restricted fuel filter. Check, replace, or clean all fuel filters.
Restricted filter in fuel tank. Clean by rinsing in clean lead-free gasoline or kero-
sene.
Improperly mixed fuel; contaminants (water, dirt, Check fuel and replace,
etc,) in fuel. if necessary.
An inlet needle (in carburetor) that is either stuck Remove and replace with new inlet needle.
open or closed. (A needle, that is stuck open, will
cause a flooding condition. A needle, that is stuck
closed, will prevent fuel from entering carburetor.)
Incorrect idle mixture adjustment. Re-adjust.
Carburetor is loose. Tighten bolts securely.
Chamber cover leaking air. Tighten or replace gasket.
Off idle holes plugged. Blow out with compressed air.
Main nozzle or idle nozzle air bleed holes plugged. Blow out with compressed air.
Improper main jet or restricted jet. Clean or replace with proper jet (refer to “Main Jet
Chart”).
Damaged reed(s). Inspect reeds as outlined in Section 4A.
A crack in the fuel pick-up outlet tube (located in fuel Replace.
tank).

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-15

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 Removal/Installation 55/60
Attenuator cover and screw.
40/50
Attenuator cover and screw.
55041
b

55148

a
a a
b

a - Screws (4)
a - Screw
b - Attenuator Cover
b - Attenuator Cover

Carburetor mounting bolts. Carburetor mounting bolts.

55172

50527

a a
a a

a - Carburetor Bolts (6)

a - Carburetor Bolts (6)

3B-16 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Inspection 5. Inspect inlet needle valve. Replace if end is worn
or grooved.
CAUTION
Do not use steel wire for cleaning the jets as this
may enlarge the jet diameters and seriously af-
fect performance. Use a petroleum based solvent
for cleaning and blow out all passages with com-
pressed air.
28375
1. Inspect carburetor body. Replace if cracked or
damaged.

2. Inspect float. Replace if cracked or damaged.

55883

3. Inspect idle mixture screw. Replace if bent or

damaged.

53673

4. Inspect main jet. Clean if contaminated.

53672

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-17

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 Enrichment System
Electric Enrichener Valve
The enrichener system provides the engine with an
extra fuel charge for ease of cold engine starting. The
system consists of an electrically operated enrichen-
er valve which is connected by a hose to the intake
manifold.
Fuel is pressure 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 carburetor. When
the key (or choke button) is released, the valve will re-
turn to the closed position. The valve can be operated
manually by pressing and holding the button located
at the bottom of the valve.

ENRICHENER VALVE FUEL FLOW DIAGRAM

b
c

a - Carburetor
b - Enrichment Valve
c - Intake Manifold

3B-18 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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

Push Key (Or Choke Button)

In, Valve Should Click.

No Click Click
Check for battery voltage to yellow/black wire at terminal block Squeeze primer bulb until bulb is firm. Remove lower hose from
on engine when key (or choke button) is pushed in. fitting 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 circuit, yellow/black wire be-
Repair connections(s) as necessary, then push key (or choke tween key switch (or choke button) and terminal
button) in. If enrichener valve DOES NOT click, replace valve. block.

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.

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3B-19

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 Manual Primer Button CAUTION
The manual starting primer bulb is designed to pro- All safety precautions should be adhered to
vide a rich fuel mixture to the engine during cold start when testing the primer bulb system. Fuel
conditions. When the primer bulb is pressed in, fuel should be directed into suitable container and all
is forced from the primer bulb into the intake manifold flammable materials extinguished and sources
via hose and fitting on the side of the manifold. When of spark turned off.
the primer bulb is released, a suction is created in the
bulb and fuel is drawn into the bulb through a hose PRIMER BUTTON TEST
from the carburetor float bowl.
Removing the primer hose from the intake manifold
and pressing the primer bulb will determine if the
primer is working properly as fuel should be expelled
from the hose whenever the primer bulb is pressed.

PRIMER BUTTON FUEL FLOW DIAGRAM

b d
a
c

a - Primer Cover
b - Primer Check Valve
c - Primer Button
d - Starter Handle Rest
e - Carburetor (3)
f - Intake Manifold

3B-20 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 FUEL SYSTEM

3
C

OIL INJECTION

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
Oil Injection Components 40/50 . . . . . . . . . . . . 3C-2
Oil Injection Components 60 . . . . . . . . . . . . . . . 3C-4
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 3C-6
Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . 3C-6
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Carburetor/Oil Pump Synchronization . . . . 3C-7
Bleeding Air From Oil Injection System . . . 3C-7
Bleeding Air From
Oil Pump Inlet Hose . . . . . . . . . . . . . . . . . 3C-7
Bleeding Air From
Oil Pump Outlet Hose . . . . . . . . . . . . . . . 3C-7
Check Operation of the Oil Injection
System (Engine Running) . . . . . . . . . . . . . . . 3C-8
Oil Pump Volume (Flow) Test . . . . . . . . . 3C-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-8
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 3C-9
Installing Drive Gear (For Oil Injection Pump)
Onto Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-10
Engine Mounted Oil Reservoir . . . . . . . . . . . . 3C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-11

3C-0 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Specifications
Recommended Oil Quicksilver TC-W II or TC-W3
2 Cycle Outboard Oil
Oil Tank Capacity/Approx. Time 3.0 qts. (2.8 L) / 7.0 hours
Reserve Capacity/Approx. Time 14.5 fl. oz. (0.43 L) / 0.5 hour
OIL
INJECTION
Oil Output With Engine RPM of
1500 and Oil Pump @ W.O.T.*
Model 40 15.0 ± 3.0 cc of oil in 10 minutes
Model 50/60 22.0 ± 3.0 cc of oil in 10 minutes
*See “Checking Oil Pump Volume Flow” in this sec-
tion for proper procedures for checking volume flow.

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3C-1

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 Oil Injection Components 40/50

22 18 25
23
24
26

20
21
5

6
7

27
3
8
9
1

19 2

10

17

13

15 11
14 12

16

4 Needle Bearing Assy. Lub. (92-825265A1)

3C-2 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Oil Injection Components 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 2 BUSHING–Flanged
2 2 GROMMET
3 2 SCREW (M6 x 25) 60 5 6.8
4 1 OIL TANK ASSEMBLY
5 1 CAP ASSEMBLY
6 1 TETHER
7 1 NUT–Push
8 1 VENT ASSEMBLY
9 1 VALVE
10 1 SEAL
11 2 STA–STRAP
12 1 GROMMET
13 1 SWITCH
14 1 SCREW (.164-18 x .375) Drive Tight
15 1 WASHER
16 1 SPACER
17 1 TUBING (12 IN.)
18 1 OIL INJECTION PUMP (40)
19 1 OIL INJECTION PUMP (50)
20 1 O RING
21 1 O RING
22 2 SCREW (M5 x 20) 60 5 6.8
23 1 DRIVEN GEAR
24 1 BEARING ASSEMBLY
25 1 BUSHING (FLANGED)
26 1 BUSHING
27 1 LINK

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3C-3

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 Oil Injection Components 55/60

20
17 18
19
21

16
2
15

3
14 4

23

6
9 5
7

1
8

11

22

10

13
12

4 Needle Bearing Assy. Lub. (92-825265A1)

3C-4 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Oil Injection Components 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 OIL TANK
2 1 CAP ASSY.
3 1 TETHER
4 1 PUSH NUT
5 1 SEAL
6 1 VENT
7 1 VALVE
8 1 GROMMET
9 1 BOOT
10 1 BOOT
11 1 SWITCH
12 1 SCREW (.164-18 X .375) Drive Tight
13 1 WASHER
14 1 OIL INJECTION PUMP
15 1 O-RING
16 1 O-RING
17 2 SCREW 60 5 6.8
18 1 DRIVEN GEAR
19 1 BEARING ASSEMBLY
20 1 BUSHING (FLANGED)
21 1 BUSHING
22 1 HOSE (6 IN.)
23 1 LINK

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3C-5

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 Theory of Operation A link rod is connected between the throttle linkage
and oil pump lever. When the throttle position is
The major components of the oil injection system are changed, the link rod rotates the oil pump valve,
an oil tank, oil pump, and low oil warning system. which changes the fuel/oil ratio.
The oil tank is attached to the powerhead and holds The oil tank is equipped with a low oil sensor and a
oil for delivery to the oil pump. Oil is gravity fed to the magnetic float. When oil level in oil tank drops to
oil pump via a hose. The oil pump injects oil into the approximately 14.5 fl. oz. (435 mL), the magnetized
fuel line prior to the fuel pump and is driven by the float will complete the circuit between the low oil sen-
crankshaft. sor leads, causing the warning horn to sound.

Oil Flow Diagram

b

f
g

a - Oil Reservoir g - 2 PSI Check Valve

b - Fill Cap h - Oil Pump Relief Fitting
c - Oil Level Sight Gauge i - Oil Pump
d - Carburetor j - Inlet Fuel Connector
e - Fuel Filter
f - Fuel Pump

3C-6 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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

d b
52047

a - Bleed Screw
b - Inlet Hose
c - Outlet Hose
a
a - Link Rod
b - Oil Pump Body Stamped Mark
c - Oil Pump Lever Stamped Mark
d - Bleed Screw

Bleeding Air From Oil Injection

System

CAUTION
If air exists in either oil pump hose (inlet or outlet), the
air MUST BE bled from hose(s) or engine damage may
occur.

BLEEDING AIR FROM OIL PUMP INLET HOSE

With engine not running, place a shop towel below oil
pump. Loosen bleed screw three to four turns and al-
low air bubbles to exit inlet hose. Torque bleed screw
to 25 lb. in. (2.8 N·m). This procedure also allows oil
pump to fill with oil.

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3C-7

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 Check Operation of the Oil Injection Troubleshooting
System (Engine Running) 1. Fill tank with recommended oil.

OIL PUMP VOLUME (FLOW) TEST 2. Inspect the oil pump inlet hose for air bubbles. If
air exists, place a shop towel below the oil pump
and loosen bleed screw four turns. Allow oil to
WARNING
flow out of the bleed hole until air is removed from
The input fuel line TEE fitting from which the oil the hose.
line was removed MUST BE CAPPED OFF to pre-
3. Inspect the oil pump outlet oil hose for air
vent fuel leakage while the engine is running.
bubbles. If air exists, disconnect link rod from oil
NOTE: The following specifications are determined pump. Start engine and run at 1000 to 1500 RPM.
with the outboard running off a remote fuel supply Rotate (and hold) the pump arm full counter-
with pre-mix fuel. The oil pump output hose (clear) clockwise until the air is purged out of the hose.
must be disconnected from the input fuel line TEE fit-
ting and directed into a graduated container. The in- b
put fuel line TEE fitting from which the oil line was re-
moved MUST BE CAPPED OFF to prevent fuel
leakage while the engine is running.
c

a
a

b e
52047 d
a - Inlet Hose
a - Bleed Screw b - Outlet Hose
b - Inlet Hose c - Bleed Screw
c - Outlet Hose d - Link Rod
e - Pump Arm

40/50 H.P. Flow Specifications:

@ 1500 RPM with oil pump link arm DISCON- 1. Check oil level in oil tank. If oil level is approxi-
NECTED and pump arm rotated FULL COUNTER- mately 14.5 fl. oz. (435 ml) or less, the problem
CLOCKWISE and HELD AGAINST PUMP CAST- is low oil level. Add oil to oil tank.
ING NOTE: There is a safety reserve of oil left in the oil
15.0cc ± 3.0 cc of oil in 10 minutes. tank after the low oil warning is sounded that allows
60 H.P. Model Flow Specifications: enough oil for approximately 0.5 hours of full throttle
operation.
@ 1500 RPM with oil pump link arm DISCON-
NECTED and pump arm rotated FULL COUNTER- 2. If there is more than approximately 14.5 fl. oz.
CLOCKWISE and HELD AGAINST PUMP CAST- (435 ml) of oil remaining in tank, then the problem
ING may be a faulty low oil warning sensor. Refer to
22.0cc ± 3.0 cc of oil in 10 minutes. troubleshooting chart following.

3C-8 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 Troubleshooting Chart

Problem: Warning Horn Stays On When Ignition Key is Turned to “ON” Position (Engine Cold).

Possible Cause Corrective Action

Faulty Engine overheat sensor. If warning horn sounds a continuous “beep”, the engine
overheat sensor may be faulty. Disconnect tan/blue over-
heat sensor lead at bullet connection. Turn ignition key to
“ON” position. If horn stops sounding, the engine overheat
sensor is faulty.

Problem: Warning Horn Sounds (Continuous 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.

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3C-9

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 Installing Drive Gear (For Oil Engine Mounted Oil
Injection Pump) Onto Reservoir
Crankshaft Removal
1. Refer to Section 4A (Powerhead) for proper dis-
1. Disconnect battery cables.
assembly of components.
2. Remove bolts securing oil tank.
2. Inspect gear teeth for damage. Replace gear if
any of these problems exist:
40/50 HP MODEL
*Excessive Wear a. Remove bolts (2).
*Cracks in hub or rear (Do Not mistake plastic
flow lines for cracks)
*Distorted Teeth

a
a

a - Bolts (2)

a
51084 60 HP MODEL
b. Remove starter/oil bracket.
b a
a - Oil Drive Gear
b - Key

3. Refer to section 4A (Powerhead) for proper

re-assembly of components.

51080

a - Starter Bracket
b - Bolt

3C-10 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 3. Disconnect oil hose and low oil sensor wires Installation
(BLUE) at bullet connectors. Remove oil reser-
voir. 1. Install oil level sensor and secure in place.
NOTE: 40/50 H.P. version shown.

b
a

51204

a - Oil Level Sensor

55320 b - Screw (Tighten Securely)

b
2. Connect sensor oil level wires (Light Blue/Black)
a at bullet connectors. Re-connect oil hose and se-
cure in place with sta-strap. Install reservoir to
outboard.
a - Oil Tank Wires (Light Blue/Black)
b - Oil Hose NOTE: 40/50 H.P. version shown.

4. Remove oil level sensor from oil reservoir.

CAUTION
Oil level sensor is FRAGILE. Handle with care.

55320
a
b b
a

51204

a - Screw a - Oil Level Sensor Wires

b - Oil Level Sensor b - Oil Hose

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3C-11

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 3. Install starter/oil tank bracket. 60 HP MODEL
b. Install starter/oil bracket. Torque to 16.5 lb. ft.
40/50 HP MODEL (22.3 N·m).
a. Install bolts (2). Torque to 60 lb. in. (6.8 N·m). b a

a 51080
a
a - Starter Bracket
b - Bolt Torque to 16.5 lb. ft. (22.3 N·m)
a - Bolts (2) Torque to 60 lb. in. (6.8 N·m)

4. Re-connect battery cables.

3C-12 - FUEL SYSTEM 90-852572R1 JANUARY 1998

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 FUEL SYSTEM

3
Emission Control 967
D
1998
Information cc PART # 37–XXXXX XX
This engine conforms to 1998 Model Year This engine is certified to operate on regular 87
U.S. EPA regulations for marine SI engines. octane unleaded fuel (R+M)/2
Refer to Owners Manual for required maintenance. Idle Speed (in gear): XXX RPM
Exhaust Emission Control Systems:
Engine Lubricants: TC-Wll or Fuel/Oil Timing:
TC-W3 2 Cycle Outboard Oil Ratio: Not
Adjustable
ECM Spark Plug: NGK BP8H-N-10 Gap: 0.040 in.
Family: xxxxxxx.xxxx Controlled
FEL: 32.20 GM/KW-HR
40-60
2-Stroke
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC

EMISSIONS

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 Table of Contents
Page
Exhaust Emissions Standards . . . . . . . . . . . 3D-1
What Are Emissions? . . . . . . . . . . . . . . . . 3D-1
Hydrocarbons – HC . . . . . . . . . . . . . . . . . . 3D-1
Carbon Monoxide – CO . . . . . . . . . . . . . . 3D-1
Oxides of Nitrogen - NOx . . . . . . . . . . . . . 3D-1
Controlling Emissions . . . . . . . . . . . . . . . . 3D-1
Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3D-1
Outboard Hydrocarbon
Emissions Reductions . . . . . . . . . . . . . . . . . . 3D-2
Stratified Vs Homogenized Charge . . . . . . . 3D-3
Homogenized Charge . . . . . . . . . . . . . . . . 3D-3
Stratified Charge . . . . . . . . . . . . . . . . . . . . 3D-3
Emissions Information . . . . . . . . . . . . . . . . . . 3D-4
Manufacturer’s Responsibility . . . . . . . . . 3D-4
Dealer Responsibility . . . . . . . . . . . . . . . . . 3D-4
Owner Responsibility . . . . . . . . . . . . . . . . . 3D-4
EPA Emission Regulations . . . . . . . . . . . . 3D-4
Decal Location for 1998 Models . . . . . . . 3D-6

FUEL SYSTEM - 3D-0 90-852572R1 JANUARY 1998

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 Exhaust Emissions is a harmless gas. Carbon often combines with insuf-
ficient oxygen (one carbon atom with one oxygen
Standards atom). This forms carbon monoxide, CO. Carbon
monoxide is the product of incomplete combustion
Through the Environmental Protection Agency
and is a dangerous, potentially lethal gas.
(EPA), the federal government has established ex-
haust emissions standards for all new marine en-
gines sold in the U.S..
Oxides of Nitrogen - NOx
NOx is a slightly different byproduct of combustion.
What Are Emissions? Nitrogen is one of the elements that makes up the air
going into the engine. Under extremely high temper-
Emissions are what comes out of the exhaust system
atures, it combines with oxygen to form oxides of ni-
in the exhaust gas when the engine is running. They
trogen (NOx). This happens in the engine’s combus-
are formed as a result of the process of combustion
tion chambers when temperatures are too high. NOx
or incomplete combustion. To understand exhaust
itself is not harmful, but when exposed to sunlight it
gas emissions, remember that both air and fuel are
combines with unburned hydrocarbons to create the
made of several elements. Air contains oxygen and
visible air pollutant known as smog. Smog is a seri-
nitrogen among other elements; gasoline contains
ous problem in California as well as many other
mainly hydrogen and carbon. These four elements
heavily populated areas of the United States.
combine chemically during combustion. If combus-
tion were complete, the mixture of air and gasoline
would result in these emissions: water, carbon diox-
ide and nitrogen, which are not harmful to the envi- Controlling Emissions
ronment. However combustion is not usually com- There are two principle methods of reducing emis-
plete. Also, potentially harmful gases can be formed sions from a two-stroke-cycle marine engine. The
during and after combustion. first method is to control the air/fuel ratio that goes
All marine engines must reduce the emission of cer- into the combustion chamber. The second is to con-
tain pollutants, or potentially harmful gases, in the ex- trol the time when this air/fuel mixture enters the com-
haust to conform with levels legislated by the EPA. bustion chamber. Timing is important, to prevent any
Emissions standards become more stringent each unburned mixture from escaping out of the exhaust
year. Standards are set primarily with regard to three port.
emissions: hydrocarbons (HC), carbon monoxide
(CO) and oxides of nitrogen (NOx).
Stoichiometric (14.7:1) Air/Fuel Ratio
In the search to control pollutants and reduce ex-
Hydrocarbons – HC haust emissions, engineers have discovered that
Gasoline is a hydrocarbon fuel. The two elements of they can be reduced effectively if a gasoline engine
hydrogen and carbon are burned during combustion operates at an air/fuel ratio of 14.7:1. The technical
in combination with oxygen. But they are not totally term for this ideal ratio is stoichiometric. An air/fuel
consumed. Some pass through the combustion ratio of 14.7:1 provides the best control of all three
chamber and exit the exhaust system as unburned elements in the exhaust under almost all conditions.
gases known as hydrocarbons. The HC and CO content of the exhaust gas is in-
fluenced significantly by the air/fuel ratio. At an air/
fuel ratio leaner than 14.7:1, HC and CO levels are
Carbon Monoxide – CO low, but with a ratio richer than 14.7:1, they rise rapid-
ly. It would seem that controlling HC and CO by them-
Carbon is one of the elements that make up the fuel selves might not be such a difficult task; the air/fuel
burned in the engine along with oxygen during the ratio only needs to be kept leaner than 14.7:1. How-
combustion process. If the carbon in the gasoline ever, there is also NOx to consider.
could combine with enough oxygen (one carbon
atom with two oxygen atoms), it would come out of
the engine in the form of carbon dioxide (CO2). CO2

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3D-1

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

OUTBOARD HYDROCARBON
EMISSIONS REDUCTIONS
8 1/3%
PER YEAR OVER 9 MODEL YEARS

120

100

80

60

40

20

0
96 97 98 99 2000 01 02 03 04 05 06 07 08

FUEL SYSTEM - 3D-2 90-852572R1 JANUARY 1998

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 STRATIFIED VS HOMOGENIZED CHARGE
DFI engines use a stratified charge inside the combustion chamber to aid in reducing emissions. All other models
use a homogenized charge. The difference between the two is:
Homogenized Charge Stratified Charge
A homogenized charge has the fuel/air particles A stratified charged engine pulls only air through the
mixed evenly throughout the cylinder. This mixing oc- transfer system. The fuel required for combustion is
curs inside the carburetor venturi, reed blocks and forced into the cylinder through an injector placed in
crankcase. Additional mixing occurs as the fuel is the top of the cylinder (head). The injector sprays a
forced through the transfer system into the cylinder. fuel/air mixture in the form of a bubble into the cylin-
der. Surrounding this bubble is air supplied by the
The homogenized charge is easy to ignite when the
transfer system. As the bubble is ignited and burns,
air/fuel ratio is approximately 14.7:1.
the surrounding air provides almost complete com-
bustion before the exhaust port opens.
A stratified charge is hard to ignite, the fuel/air bubble
is not evenly mixed at 14.7:1 and not easily ignited.

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3D-3

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 Emissions Information EPA Emission Regulations
All new 1998 and later outboards manufactured by
Mercury Marine are certified to the United States En-
Manufacturer’s Responsibility vironmental Protection Agency as conforming to the
Beginning with 1998 model year engines, manufac- requirements of the regulations for the control of air
turers of all marine propulsion engines must deter- pollution from new outboard motors. This certifica-
mine the exhaust emission levels for each engine tion is contingent on certain adjustments being set to
horsepower family and certify these engines with the factory standards. For this reason, the factory proce-
United States Environmental Protection Agency dure for servicing the product must be strictly fol-
(EPA). A certification decal/emissions control in- lowed and, whenever practicable, returned to the
formation label, showing emission levels and engine original intent of the design.
specifications directly related to emissions, must be The responsibilities listed above are general and in
placed on each engine at the time of manufacture. no way a complete listing of the rules and regulations
pertaining to the EPA laws on exhaust emissions for
marine products. For more detailed information on
Dealer Responsibility this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
When performing service on all 1998 and later out- Office of Mobile Sources
boards that carry a certification decal, attention must Engine Programs and Compliance Division
be given to any adjustments that are made that effect Engine Compliance Programs Group (6403J)
emission levels. 401 M St. NW
Adjustments must be kept within published factory Washington, DC 20460
specifications.
Replacement or repair of any emission related com- VIA EXPRESS or COURIER MAIL:
ponent must be executed in a manner that maintains Office of Mobile Sources
emission levels within the prescribed certification Engine Programs and Compliance Division
standards. Engine Compliance Programs Group (6403J)
Dealers are not to modify the engine in any manner 501 3rd St. NW
that would alter the horsepower or allow emission Washington, DC 20001
levels to exceed their predetermined factory specifi- EPA INTERNET WEB SITE:
cations. http:/www.epa.gov/omswww
Exceptions include manufacturers prescribed
changes, such as that for altitude adjustments.

Owner Responsibility
The owner/operator is required to have engine main-
tenance performed to maintain emission levels within
prescribed certification standards.
The owner/operator is not to modify the engine in any
manner that would alter the horsepower or allow
emissions levels to exceed their predetermined fac-
tory specifications.
Single engine exceptions may be allowed with per-
mission from the EPA for racing and testing.

FUEL SYSTEM - 3D-4 90-852572R1 JANUARY 1998

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 CERTIFICATION LABEL:
The certification label must be placed on each engine
at the time of manufacture and must be replaced in
the same location if damaged or removed. Shown
below is a typical certification label and is not repre-
sentative of any one model.
h
a

Emission Control 967 1998 b

Information cc
This engine conforms to 1998 Model Year This engine is certified to operate on regular 87
U.S. EPA regulations for marine SI engines. octane unleaded fuel (R+M)/2 c
Refer to Owners Manual for required maintenance. Idle Speed (in gear): XXX RPM
Exhaust Emission Control Systems:
Fuel/Oil Timing:
d
Engine Lubricants: TC-Wll or
n TC-W3 2 Cycle Outboard Oil Ratio: Not
Adjustable e
ECM Spark Plug: NGK BP8H-N-10 Gap: 0.040 in.
m Family: WM9XM.323220 Controlled
FEL: 32.20 GM/KW-HR
l f
40-60
2-Stroke g
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC

k j
i

a -
Spark Ignition (SI) m - Family Example:
b -
Model Year of Engine and Production Decal Part Number W M9X M 03.0 2 2 0
c -
Type and Octane of fuel (Recommended Fuel)
d -
Timing Specifications When Adjustable
e -
Spark Plug Gap
f -
Recommended Spark Plug For Best Engine Performance Model Year Regulation Application Unspecified
g -
Engine Horsepower Rating W=1998 M=Marine 1=PWC
h -
Engine Displacement X=1999 2=OB
i -
Valve Clearance (Four Stoke Engines Only) Manufacturer Displacement Technology type
j -
Recommended Oil/Fuel Ratio For Best Engine Perfor- Mercury Marine Liter 1=Existing
mance and Minimal Emissions Cubic Inch 2=New
k - Month of Production (Boxing Month Will Be Punched)
l - FEL: Represents (Mercury Marine) Statement of the Maxi- n - Engine Lubricants Recommended by the Manufacturer
mum Emissions Output For the Engine Family

Decal Location for 1998 Models:

Model Production Part No. Service Part No. Location on Engine
Merc/Mar 13 965cc,
37-855211 8 37-855577 8 Top Cowl Inlet Duct
2-Stroke (40-60 H.P.)

90-852572R1 JANUARY 1998 FUEL SYSTEM - 3D-5

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 POWERHEAD

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cylinder Block And Crankcase 40/50 . . . . . 4-4
Cylinder Block And Crankcase 55/60 . . . . . 4-6
Induction Manifold And Reed Block 40/50 . 4-8
Induction Manifold And Reed Block 55/60 . 4-10
Crankshaft, Pistons And Connection Rods . 4-12
Water Circulation . . . . . . . . . . . . . . . . . . . . . . . 4-14
Thermostat Test . . . . . . . . . . . . . . . . . . . . . 4-15
Temperature Switch Test . . . . . . . . . . . . . 4-15
General Information . . . . . . . . . . . . . . . . . . . . 4-16
Powerhead Removal . . . . . . . . . . . . . . . . . . . 4-16
Powerhead Disassembly . . . . . . . . . . . . . . . . 4-18
Removing Engine Components . . . . . . . . 4-18
Crankshaft Disassembly . . . . . . . . . . . . . . 4-20
Cleaning and Inspection . . . . . . . . . . . . . . . . . 4-23
Cylinder Block and Crankcase Cover . . . 4-23
Check Valves . . . . . . . . . . . . . . . . . . . . . . . 4-24
Piston and Piston Rings . . . . . . . . . . . . . . 4-24
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Connecting Rods . . . . . . . . . . . . . . . . . . . . 4-26
Reed Blocks . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Reassembly and Installation . . . . . . . . . . . . . 4-28
General Information . . . . . . . . . . . . . . . . . . 4-28
Assembling Rod to Piston . . . . . . . . . . . . 4-29
Piston Ring Installation . . . . . . . . . . . . . . . 4-31
Crankshaft Installation . . . . . . . . . . . . . . . . 4-32
Installing Rods to Crankshaft . . . . . . . . . . 4-34
Connecting Rod Cap Alignment . . . . . . . 4-34
Crankcase Cover to Block . . . . . . . . . . . . 4-35
Lower End Cap . . . . . . . . . . . . . . . . . . . . . . 4-35
Intake/Reed Block Manifold Installation . 4-36
Thermostat Cover Installation . . . . . . . . . 4-37
Install Remaining Engine Components . 4-38
Powerhead Installation . . . . . . . . . . . . . . . . . . 4-38
Test Run Procedure . . . . . . . . . . . . . . . . . . . . 4-41
Important Information . . . . . . . . . . . . . . . . . . . 4-41

4-0 - POWERHEAD 90-852572R1 JANUARY 1998

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 Specifications
Type 3 Cylinder-2 Cycle-Loop Charged
CYLINDER BLOCK
Displacement 59 cu. in. (967 cc)
STROKE Length 2.796 in. (71 mm)
Diameter 2.993 in. (76 mm)
CYLINDER BORE Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Type Aluminum
Standard Diameter 2.988 in. (75.895 mm)
PISTON
0.015 in. (0.381 mm) Oversize 3.003 in. (76.276 mm)
0.030 in. (0.762 mm) Oversize 3.018 in. (76.657 mm)
Reed Stand Open (Max.) 0.020 in. (0.50 mm)
Reed Stop (Max.)
REEDS 40 0.090 in. (2.286 mm)
50/55/60 Not Adjustable
Reed Thickness 0.010 in. (0.254 mm)
Temperature
TEMPERATURE Normal Open - No Continuity
SWITCH 190°F ± 8° (88°C ± 4°C) Closed - Full Continuity
170°F ± 8° (77°C ± 4°C) Open - No Continuity

90-852572R1 JANUARY 1998 POWERHEAD - 4-1

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 Special Tools 8. Driver Head 91-55919

1. Lifting Eye 91-90455

9. Universal Puller Plate 91-37241

2. Flywheel Holder 91-52344

73790

3. Flywheel Puller 91-73687A2 10. Snap Ring Pliers 91-24283

4. Powerhead Stand 91-25821A1

11. Piston Lock Ring Installer 91-77109A3

12. Torque Wrench (0-200 lb. ft.) Obtain Locally

5. Piston Ring Expander 91-24697

13. Torque Wrench (0-150 lb. in.) 91-66274

6. Lock-ring Removal Tool 91-52952A1

14. Compression Tester 91-29287

7. Piston Pin Tool 91-74607A3

54965

4-2 - POWERHEAD 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 POWERHEAD - 4-3

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 Cylinder Block And Crankcase 40/50

33 23 24
9

36
17 20
35 27 14
34 26
15 28
31 25
1
32
30
21 33
29

9
22

9 6
13
19 9
17 8
19 7 5
18
11
16
18 9
9 12
75
10
2
39
41 37 3
40 4

4
9
38 1
13

2
14 3

4
11
12

A 5
6
4 Needle Bearing Assy. Lub. (92-825265A1)
9 Loctite PST Pipe Sealant (92-809822) 10
33 Loctite “RCA/680” Retaining Compound (92-809833)
75 Loctite 518 Master Gasket (92-12564-2) 9
8

A = Torque Sequence

4-4 - POWERHEAD 90-852572R1 JANUARY 1998

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 Cylinder Block And Crankcase 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CYLINDER BLOCK
2 8 SCREW (M8 x 80) 220 18.4 24.9
3 6 SCREW (M8 x 30) 220 18.4 24.9
4 1 CHECK VALVE
5 1 HOSE (15 IN.)
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 GASKET
15 2 STUD
16 1 PIPE PLUG (3/8-18)
17 2 PIPE PLUG
18 2 ELBOW
19 2 CHECK VALVE
1 COVER (S/N- 0G662183 & UP)
20
1 COVER (S/N-OG662182 & BELOW)
21 1 LIFTING EYE MANUAL
22 1 SCREW (M8 x 25) 220 18.4 24.9
23 1 SERIAL NUMBER PLUG
24 4 SCREW (M8 x 25) 220 18.4 24.9
25 1 CARRIER
26 1 THERMOSTAT (110 Degrees)
27 1 SEAL (S/N- 0G662183 & UP)
28 1 O RING (S/N-0G662182 & BELOW)
29 1 TEMPERATURE SENDER
30 1 RETAINER
31 1 SCREW Drive Tight
32 1 WASHER
33 1 ELBOW
34 2 WASHER
35 2 WASHER
36 2 WING NUT ELECTRIC Hand Tight
37 1 FITTING
38 1 COVER
39 1 O-RING MANUAL
40 2 SCREW (M5 x 20) 60 5 6.8
41 2 HOSE (5-1/2 IN.)

90-852572R1 JANUARY 1998 POWERHEAD - 4-5

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 Cylinder Block And Crankcase 55/60
39
33 23 24
9

36
17 20
35
34 26 14
27
15 25
31
32 1
30
21 18
33 45
29
9

22

9
13 6
19
19 8 5
19 7
11
18 16 9
9 12
75
10
2
39
18 37 3
40 4
41
4
9
38 1
13

2
14 3

4
11
12

A 5
6
4 Needle Bearing Assy. Lub. (92-825265A1)
10
9 Loctite PST Pipe Sealant (92-809822)
33 Loctite “RCA/680” Retaining Compound (92-809833)
75 Loctite 518 Master Gasket (92-12564-2) 9
8

7
A = TORQUE SEQUENCE

4-6 - POWERHEAD 90-852572R1 JANUARY 1998

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 Cylinder Block And Crankcase 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CYLINDER BLOCK
2 8 SCREW (M8 x 80) 220 18.4 24.9
3 6 SCREW (M8 x 30) 220 18.4 24.9
4 1 CHECK VALVE
5 1 HOSE (15 IN.)
6 1 CHECK VALVE (PRESS-IN)
7 2 CARRIER ASSEMBLY
8 2 CHECK VALVE
9 1 ADJUSTING SCREW (M6 x 55)
10 1 JAM NUT
11 1 CAP
12 1 DOWEL PIN (LOCATING)
13 3 DOWEL PIN (BEARING RACE)
14 1 GASKET
15 2 STUD
16 1 PIPE PLUG (3/8-18)
17 1 PIPE PLUG (ELECTRIC)
18 1 PIPE PLUG (MANUAL)
19 1 PIPE PLUG
20 2 ELBOW
21 2 CHECK VALVE
1 COVER (S/N-& UP)
22
1 COVER (S/N-& BELOW)
23 1 LIFTING EYE MANUAL
24 1 SCREW (M8 x 25) 220 18.4 24.9
25 1 SERIAL NUMBER PLUG
26 4 SCREW (M8 x 25) 220 18.4 24.9
27 1 CARRIER ELECTRIC
28 1 THERMOSTAT (110 Degrees)
29 1 O RING (S/N-& BELOW)
30 1 SEAL (S/N-& UP)
31 1 TEMPERATURE SENDER
32 1 RETAINER
33 1 SCREW Drive Tight
34 1 WASHER
35 2 WASHER
36 2 WASHER
37 2 WING NUT ELECTRIC Hand Tight
38 1 ELBOW
39 1 ELBOW (MANUAL)
40 1 FITTING (ELECTRIC)
41 1 COVER
42 1 O-RING MANUAL
43 2 SCREW (M5 x 20) 60 5 6.8
44 2 HOSE (5-1/2 IN.)
45 1 DECAL-Caution-Start (ELECTRIC-NON-HANDLE)

90-852572R1 JANUARY 1998 POWERHEAD - 4-7

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 Induction Manifold And Reed Block 40/50

14 2 Cycle Outboard Oil (92-831222A24)

19 Perfect Seal (92-34227-1)

33 Loctite 680 (92-809833)

A= ELECTRIC B = MANUAL

4-8 - POWERHEAD 90-852572R1 JANUARY 1998

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 Induction Manifold And Reed Block 40/50
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 (M8 x 20) 220 18.3 24.9
7 1 BRACKET ASSEMBLY
8 2 STUD
9 2 WASHER
10 2 WASHER ELECTRIC
11 2 WING NUT Hand Tight
12 4 SCREW (M8 x 35) 220 18.3 24.9
13 1 WASHER (Bottom Left Only)
1 INDUCTION MANIFOLD (ELECTRIC)
14
1 INDUCTION MANIFOLD (MANUAL)
15 1 ELBOW (ELECTRIC)
16 3 ELBOW (MANUAL)
17 1 CAP
18 1 STA STRAP
19 1 GASKET
20 10 SCREW (M8 x 30) 220 18.3 24.9
21 1 REED BLOCK ASSEMBLY
22 1 GASKET
23 6 DOWEL PIN
24 3 REED SET
25 3 TAB WASHER
26 3 RETAINER (50)
27 3 REED STOP (40)
28 3 SCREW (M6 x 16) 60 5 6.8

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 Induction Manifold And Reed Block 55/60

27
26
25 13
32 C
31
28
29
14
30
24
22 23 21
17
20
19 33
18
16
A 11
1
10
9
7 8
5

4
3
2
B
12
6
14 13

19

15

14 2 Cycle Outboard Oil (92-831222A24)

19 Perfect Seal (92-34227-1) 17

33 Loctite 680 (92-809833)

A= ELECTRIC B = MANUAL C = TO REF #33 ON PAGE 22

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 Induction Manifold And Reed Block 55/60
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 (M8 x 20) 220 18.3 24.9
7 1 BRACKET ASSEMBLY
8 2 STUD
9 2 WASHER
10 2 WASHER ELECTRIC
11 2 WING NUT Hand Tight
12 4 SCREW (M8 x 35) 220 18.3 24.9
1 INDUCTION MANIFOLD (ELECTRIC)
13
1 INDUCTION MANIFOLD (MANUAL)
14 1 ELBOW (ELECTRIC)
15 2 ELBOW (MANUAL)
16 1 GASKET
17 10 SCREW (M8 x 30) 220 18.3 24.9
18 1 REED BLOCK ASSEMBLY
19 1 GASKET
20 6 DOWEL PIN
21 3 REED SET
22 3 TAB WASHER
23 3 RETAINER
24 3 SCREW (M6 x 16) 60 5 6.8
25 1 SHIFT RAIL
26 2 TAB WASHER
27 2 SCREW (M8 x 25) 165 13.8 18.6
28 1 SLIDE
29 1 NYLINER
30 1 NUT Drive Tight
31 1 WASHER
32 1 NUT Drive Tight

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 Crankshaft, Pistons And Connection Rods

14
14

12

7 14
16
17 6
14
13 15 95

11 14 14

19
12 19
14 15
18

1
8

2
95

3 9
14
4

10

14 2 Cycle Outboard Oil (92-831222A24)

95 2-4-C w/Teflon (92-850736A1)

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 Crankshaft, Pistons And Connecting Rods
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 CRANKSHAFT ASSEMBLY
2 1 DRIVER GEAR
3 1 BALL BEARING
4 1 RETAINING RING
5 2 KEY
6 1 ROLLER BEARING (TOP)
7 1 OIL SEAL
8 2 RACE
9 56 ROLLER
10 2 RING–Seal
11 3 PISTON ASSEMBLY
12 6 LOCK RING
13 3 PISTON RING
14 3 PISTON RING (CHROME FACE)
15 3 CONNECTING ROD ASSEMBLY
16 6 WASHER
17 87 NEEDLE BEARING
18 6 SCREW (1/4-28) 120 + 1/4 Turn
19 6 ROLLER BEARING

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 Water Circulation

55334

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 Thermostat Test Temperature Switch Test
Wash thermostat with clean water. Using a thermo- 190°F (88°C)
stat tester, similar to the one shown, test thermostat The 190°F (88°C) temperature switch is located in
as follows: outer side of cylinder head as shown.
· Open thermostat valve, then insert a thread be-
tween valve and thermostat body. Allow valve to
close against thread.
· Suspend thermostat (from thread) and thermom-
eter inside tester so that neither touches the con-
tainer. Bottom of thermometer must be even with
bottom of thermostat to obtain correct thermostat a
opening.
· Fill thermostat tester with water to cover thermo-
stat.
· Plug tester into electrical outlet.
· Observe temperature at which thermostat begins
to open. Thermostat will drop off thread when it
starts to open. Thermostat must begin to open
when temperature reaches 5°F (3°C) above des-
56671
ignated stamping on bottom of thermostat.
a - Temperature Switch
· Continue to heat water until thermostat is com-
pletely open.
During normal engine operating temperature, the
· Unplug tester unit. switch electrical circuit is open. The switch will close
· Replace thermostat, if it fails to open at the speci- when the temperature reaches 190°F ±8°F (88°C ±
fied temperature, or if it does not fully open. 4°C). Reset of the switch to open circuit occurs at
170°F ± 8°F (77°C ±4°C).
To test, place switch end into water with thermometer
and heat to 190°F ±8°F (88°C ±4°C). Take out and
perform ohms test. Compare to specifications. If
switch does not fall within specifications, replace
switch.

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 General Information 7. Disconnect blue oil warning module wires.

Powerhead “Disassembly” and “Reassembly” in- 8. Remove BLACK ground lead between power-
structions are printed in a sequence that should be head and engine tray.
followed to assure best results when removing or re- 9. Remove tell-tale hose from powerhead.
placing powerhead components. If complete disas-
10. Remove anti-start in gear cable on manual start
sembly is not necessary, start reassembly at point
models and disconnect neutral switch bullet con-
disassembly was stopped. Refer to “Table of Con-
nectors on all models.
tents” preceding.
11. Remove primer hoses from carb and manifold on
If major powerhead repairs are to be performed, re-
manual start models and remove recoil starter.
move powerhead from drive shaft housing as an as-
sembly. Remove external engine components refer- 12. Remove bolt, nut and flat washer securing upper
ring to appropriate section of service manual. drive shaft housing cover and remove cover.

Powerhead Removal
1. Disconnect battery leads from battery (if applica-
ble).
2. Remove spark plug leads from spark plugs.
3. Disconnect remote control harness from engine
(if applicable) - or lanyard and stop button/horn
wiring on manual models.
4. Disconnect trim switch and trim relay wires.
5. Disconnect fuel connector from engine. Fuel line
must also be removed at either engine tray or fuel
filter.
b
6. Remove throttle and shift cables.
a

a - Nut
b - Drive Shaft Housing Cover

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 13. Thread lifting eye at least 5 turns into flywheel.
WARNING
DO NOT leave powerhead suspended from hoist.
Powerhead should be installed on a suitable
stand or lowered to floor upon removal from
drive shaft housing to avoid personal injury or
a damage to product.
15. Using suitable hoist, remove powerhead from
drive shaft housing.

55320

a - Lifting Eye (91-90455)

14. Remove 6 bolts securing powerhead to drive

shaft housing.

a a

55319
a - Bolts (6)

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 Powerhead Disassembly 2. Thermostat Cover 827251-C

Removing Engine Components

NOTE: Refer to appropriate sections in service
manual for removal of individual fuel and electrical
sub-assemblies from powerhead.

Component/Assembly Section
b c
CDM 2A
Flywheel 2A
Stator Assembly 2A
Trigger Assembly 2A
Starter Motor 2B
Starter Solenoid 2B d e f
a
Voltage Regulator/Rectifier 2B
Fuel Pump 3A
a - Bolts
Carburetor and Linkage 3B b - Thermostat Cover - 827251-C
Air Silencer 3B c - Thermostat Cover Gasket
d - Thermostat
Fuel Enrichment Valve 3B e - O-ring
Oil Pump 3C f - Carrier

Shift Cable Latch Assembly 7A

Control Cable Anchor Bracket 7A 3. Thermostat Cover 827251C-1

*NOTE: All ignition and electrical components can be

removed and installed as an assembly.
1. Place powerhead in repair stand or on bench.

b c
f

a d

a - Bolts
b - Thermostat Cover - 827251C-1
c - Thermostat Cover Gasket
d - Thermostat
a e - Seal
f - Carrier
55322

a - Powerhead Stand (91-25821A1).

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 4. Remove intake manifold and reed block man- 5. Remove check valves and holders.
ifold.
a

55323

55322 a - Check Valve/Holders

a - Bolts (14)

6. Place engine on work bench and remove end cap

bolts.

55324

a
a - Bolts

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 7. Remove crankcase cover bolts. Crankshaft Disassembly
a 55323
1. Remove roller bearing assemblies from crank-
shaft.

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

8. Remove crankcase cover from cylinder block.

a a
9. Remove end cap.

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

2. Remove 2 bolts from each rod cap. Keep compo-

nents with respective connecting rod.
55325
IMPORTANT: Always use new rod bolts.

a
Crankcase Cover Removed

10. Remove crankshaft assembly.

PE-51080

a - Bolts, use 1/4 – 12 point socket

Crankshaft Assembly Removed

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

PE-51081
a - Piston Ring Expander (91-24697)
b - Piston Rings
NOTE: Cylinders must be honed for rings to seat
properly.

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

PE-51081 PE-51083

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

PE-51086
a - Piston Pin
b - Piston Pin Tool (91-74607A3)
9. Remove piston pin needle bearings (29 per pis-
ton pin) and locating washers (2 per piston) as
shown.

PE-51081

12. 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 and

retaining ring only if necessary.

a
b

PE-51084
a - Oil Drive Gear
b - Key

PE-51084
a - Bearing
b - Retaining Ring

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

CYLINDER BORE SIZE

PISTON SIZE CYL. BLOCK

FINISH HONE
Standard Diameter 2.988 in.
75.895 mm
.015 Oversize 3.003 in.
76.276 mm
.030 Oversize 3.018 in.
76.657 mm

• Inspect cylinder bores for scoring (a transfer of

aluminum from piston to cylinder wall). Cylinder
wall scoring usually can be “cleaned up” by hon-
ing or re-boring.

CAUTION
When re-boring cylinder block, remove hone fre-
quently and check condition of cylinder walls.
DO NOT hone any more than absolutely neces-
sary, as hone can remove cylinder wall material
• Inspect cylinder block and crankcase cover for rapidly.
cracks or fractures.
• Check gasket surfaces for nicks, deep grooves, HONING PROCEDURE
cracks and distortions that could cause com-
Follow hone manufacture’s recommendations for
pression leakages.
use of hone cleaning and lubrication during honing.
• Check that all water passages in cylinder block
IMPORTANT: After honing, bores should be thor-
are not obstructed. Check locating pins in cylin-
oughly cleaned with hot water and detergent.
der block that they are tight.
Scrub well with stiff bristle brush and rinse with
• Check crankcase cover fuel/bleed passages hot water. If any abrasive material is allowed to
that they are not obstructed. Verify that check remain in the cylinder bore, it will cause a rapid
valves (2) in crankcase cover and block are not wear of new piston rings and cylinder bore. After
damaged. cleaning, bores should be swabbed several
• Thoroughly clean cylinder block and crankcase times with 2 cycle engine oil and a clean cloth.
cover. Verify that all sealant and old gaskets are Wipe excess oil with clean, dry cloth. Cylinders
removed from matching surfaces. Clean all car- should not be cleaned with kerosene or gasoline.
bon deposits from exhaust ports. Clean remainder of cylinder block.

• Inspect spark plug holes for stripped or dam- • Hone all cylinder walls just enough to de-glaze.
aged threads.

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 • Measure cylinder bore inside diameter (with an TO CHECK: Inspect check valves by looking through
inside micrometer) of each cylinder, as shown hole. If light can be seen the nylon ball is bad (prob-
below. Check for tapered, out-of-round (“egg- ably melted); replace valve. If you see no light, insert
shaped”) and oversize bore. fine wire into 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.

TOP Install check valve into check valve holder as shown.

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 stan-
dard “Cylinder Block Finish Hone” diameter (re-
fer to chart), it will be necessary to re-bore that Piston and Piston Rings
cylinder(s) to designated oversize bore and in- IMPORTANT: If engine was submerged while en-
stall oversize piston(s) and piston rings during gine was running, piston pin and connecting rod
reassembly. may be bent. If piston pin is bent, piston must be
NOTE: The weight of an oversize piston is approxi- replaced. Piston pins are not sold separately be-
mately the same as a standard size piston; therefore, cause of matched fit into piston. If piston pin is
it is not necessary to re-bore all cylinders in a block bent, connecting rod must be checked for
just because one cylinder requires re-boring. straightness (refer to “Connecting Rods” for
checking straightness).
IMPORTANT: Ports must be de-burred after hon-
ing. • Inspect piston for scoring and excessive piston
skirt wear.
• After honing and thoroughly cleaning cylinder
bores, apply 2 cycle outboard oil to cylinder • Check tightness of piston ring locating pins. Lo-
walls to prevent rusting. cating pins must be tight.
• Thoroughly clean pistons. Carefully remove car-
bon deposits, with a soft wire brush or carbon re-
Check Valves mover solution. DO NOT burr or round off ma-
chined edges.
NOTE: Check valves can be replaced by removing
intake manifold when powerhead is attached to dri- • Inspect piston grooves for wear and carbon accu-
veshaft housing. mulation. If necessary, scrape carbon from piston
ring grooves being careful not to scratch sides of
The check valves are a 3/16 in. (4.76 mm) diameter
grooves. Refer to procedure for cleaning piston
brass casing containing a nylon ball-valve. These
ring grooves.
can be damaged by hot combustion blow-by into
crankcase (ie.: backfire, or a hole in top of piston,
etc.).

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 CLEANING PISTON RING GROOVES
IMPORTANT: The piston rings are half – keystone
rings – (tapered on the top side) – follow cleaning
and inspection carefully! Chromed ring is in-
stalled on top.

.50 in.
(12.7 mm)

Enlarged View of
Piston Ring Grooves
PISTON PISTON SKIRT CYL. BORE
SIZE DIAMETER FINISH HONE
Standard 2.950 in. 2.988 in.
Piston (74.93 mm) (75.895 mm)
.015 2.965 in. 3.003 in.
Oversize (75.31 mm) (76.276 mm)
.030 2.980 in. 3.018 in.
Oversize (75.69 mm) (76.657 mm)
CAUTION
Care must be taken not to scratch the side sur-
faces of ring groove. Scratching the side sur-
faces of the ring groove will cause damage to the Crankshaft
ring groove.
• Inspect crankshaft to drive shaft splines for wear.
• Use a bristle brush and carbon remover solution (Replace crankshaft, if necessary.)
to remove carbon from side surfaces.
• Check crankshaft for straightness. (Replace as
• A tool can be made for cleaning the inner diameter necessary.)
of the tapered ring grooves. The tool can be made
from a broken tapered piston ring with the side ta- • Inspect crankshaft oil seal surfaces. Sealing sur-
per removed to enable inside edge of the ring to faces must not be grooved, pitted or scratched.
reach the inside diameter of the groove. Carefully (Replace as necessary.)
scrape the carbon from inner diameter of ring • Check all crankshaft bearing surfaces for rust, wa-
grooves. Care must be taken not to damage the ter marks, chatter marks, uneven wear and/or
grooves by scratching the surfaces of the overheating. (Refer to “Connecting Rods”.)
grooves.
• If necessary, clean crankshaft surfaces with cro-
cus cloth as shown.
MEASURING PISTON SKIRT
Measure piston skirt at right angle (90°) to piston pin
centerline, 0.50 in. (12.7 mm) up from bottom edge
of skirt.

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 Connecting Rods
If necessary, clean connecting rod surfaces as fol-
lows:
• Attach end caps to connecting rods. Following
these directions, tighten rod cap attaching bolts to
specifications. Recheck alignment.

CAUTION
Crocus cloth MUST BE USED to clean bearing
surface at crankshaft end of connecting rod. DO
NOT use any other type of abrasive cloth.
• Clean crankshaft end of connecting rod by using
crocus cloth placed in a slotted 3/8 in. (9.5 mm) di-
ameter shaft, as shown. Insert shaft in a drill press
and operate press at full speed while keeping con-
necting rod at a 90° angle to slotted shaft.
IMPORTANT: Clean connecting rod just enough
to clean bearing surfaces. DO NOT continue to
clean after marks are removed from bearing sur-
faces.
• Clean piston pin end of connecting rod, using
PE-51089 same method as above. Use 320 grit carborun-
• Thoroughly clean (with solvent) and dry crank- dum cloth instead of crocus cloth.
shaft and crankshaft ball bearings. Recheck sur-
• Thoroughly wash connecting rods to remove
faces of crankshaft. Replace crankshaft if sur-
abrasive grit. Recheck bearing surfaces of con-
faces cannot be properly “cleaned up”. If
necting rods. Replace any connecting rod that
crankshaft will be reused, lubricate surfaces of
cannot be properly polished. Lubricate bearing
crankshaft with light oil to prevent rust. DO NOT
surfaces of connecting rods which will be reused
lubricate crankshaft ball bearings at this time.
with 2 cycle engine oil to prevent rust.
WARNING
DO NOT spin-dry crankshaft ball bearing with
compressed air.

PE-51083

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 Reed Blocks IMPORTANT: Do not “flop” (reverse) the reed pet-
als for additional use – replace reed when neces-
NOTE: Do not disassemble reed block unless neces- sary.
sary.
Reed should lie flat. There should be no pre-load
50/55/60 (pressure between reed and reed-block), although a
slight pre-load is tolerable.
e
The maximum allowable opening between reed and
d reed-block is .020 in. (0.5mm). This must be checked
with a flat blade feeler gauge, as shown.
40 HP Shown
a

PE-51089
a - Reed Block
b - Reed (3 Sets)
c - Retaining Washer 55350
d - Tab Washer
e - Bolt (With Loctite 271)
a - 0.020 in. (0.50 mm) Maximum

40
55349
d

c
a
b e

a - Reed Block
b - Reed (3 Sets)
c - Tab Washer
d - Bolt (With Loctite 271)
e - Reed Stop

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 If the opening exceeds .020 in. (0.5 mm), or if the Reassembly and Installation
reed is chipped, cracked or otherwise damaged, re-
place.
General Information
Before proceeding with powerhead reassembly, be
sure that all parts to be reused have been carefully
cleaned and thoroughly inspected, as outlined in
“Cleaning and Inspection”. Parts which have not
been properly cleaned (or which are questionable),
can severely damage an otherwise perfectly good
powerhead within a few minutes of operation. All new
powerhead gaskets must be installed during assem-
bly.
During reassembly, lubricate parts with Quicksilver
2-Cycle Outboard Oil whenever 2-cycle oil is speci-
fied, and Quicksilver 2-4-C Marine Lubricant when-
ever grease is specified.
A torque wrench is essential for correct reassembly
.020 of powerhead. Do not attempt to reassemble power-
head without using a torque wrench.

PE-51089

CAUTION
Replace locking tab-Washer. DO NOT REUSE.
If reed block was disassembled, reassemble by lo-
cating reeds on pins with retaining washer. Use new
tab-washer. Insert bolt, and torque to 60 lb. in. (6.8
N·m); then, if necessary, continue the torque to align
flat on hex-head to locking tab. DO NOT exceed 100
lb. in. (11.3 N·m) of torque. Bend up lock tab to secure
bolt position.
Specified reed stop opening is 0.090 in. (2.286 mm).
If reed stop opening is not correct, carefully bend
reed stop to achieve specified opening.
40 HP

55350

a - 0.090 in. (2.286 mm)

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 2. Install needle bearings.
CAUTION
b
Any GREASE used for bearings INSIDE the pow- a
erhead MUST BE gasoline soluble. Use only
Quicksilver Needle Bearing Assembly Lubricant.
DO NOT use 2-4-C Marine Lubricant, or other lu-
bricants inside the powerhead, or damage may
occur.

Assembling Rod to Piston

PE-51081
CAUTION a - Needle Bearings (29)
b - Sleeve [from Piston Pin Tool (91-74607A3)]
Never intermix new needle bearings with used
needle bearings. It is required to replace needle
bearings as a set. Never intermix needle bearings
from one connecting rod with those of another 3. Place locating rings on connecting rod, carefully
connecting rod place piston over end of rod. Refer to scribed
1. Place clean needle bearings on a clean sheet of identification number for matching rod to piston
paper and lubricate with Quicksilver Needle and direction of assembly (which side of rod is
Bearing Lubricant. “UP”).

Service Tip

b 1

1
a
PE-51083
a - Scribed Identification Number
b - Thrust Washer

PE-51228
If the tip of an awl can be inserted between needle
bearings, one or more needles are missing and must
be replaced.

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 4. Push sleeve from piston using piston pin tool. 6. Install new piston pin lock rings (each side of pis-
ton) using Lockring Tool (p/n 91-77109A3).
a b
7. Make sure lockrings are properly seated in piston
grooves.

CAUTION
Do not re-use piston pin lockrings. Use only new
lockrings and make sure they are properly seated
in piston grooves.

PE-51080

a - Sleeve a
b - Piston Pin Tool (91-74607A3)

5. Place piston pin over tool, and tap into position

(driving tool out other side).

a
PE-51086
a - Lockring Installation Tool (91-77109A3)
b - Lockring (2)
b

PE-51086
a - Piston Pin
b - Piston Pin Tool (91-74607A3)

WARNING
Eye protection must be worn while installing pis-
ton pin lock-rings.

PE-51086
NOTE: Shaft of previous Lock ring Installation Tool
91-77109A3 must be modified (shortened) to 1.050
in. (26.7 mm).

4-30 - POWERHEAD 90-852572R1 JANUARY 1998

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 1.050 in. (26.7 mm) 1. Install piston ring in appropriate groove on piston
using Piston Ring Expander Tool. Spread rings
just enough to slip over piston.
Top Groove – Chromed Ring
Bottom Groove – Steel Ring
2. Check piston rings to be sure they fit freely in
groove. Lubricate rings and cylinder wall with
Piston Ring Installation 2-cycle oil.
IMPORTANT: Piston ring side with mark must be
facing up.
a

Piston Ring

Piston rings are tapered on the top side, and flat (rect-
angular) on the bottom side (half-keystone rings).
b
Note that top ring is chromed and bottom ring is steel.

PE-51081
a - Piston Ring Expander (91-24697)
b - Piston Rings
3. Align piston ring end gaps with ring locating pins
as shown. Check locating pins making sure they
Enlarged View of are tight.
Piston Ring Grooves

a
b
PE-51228
CAUTION
Care must be taken not to scratch the side sur-
faces of ring groove. Scratching this area will
damage the ring groove.

b a

PE-51082

a - Locating Pin
b - Piston Rings

90-852572R1 JANUARY 1998 POWERHEAD - 4-31

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 4. Remove connecting rod cap from connecting rod Crankshaft Installation
being installed.
1. If lower bearing and gear were removed from
5. Install each piston with “UP” identification facing crankshaft, slide gear in place (note keyway and
flywheel end. Pistons MUST be installed in this key in gear to crankshaft assembly). Install gear
direction. to crankshaft using an arbor press and suitable
mandrel.
UP
2. Install main bearing retaining ring after pressing
main bearing tight against oil gear.

CAUTION
Pistons must be installed very carefully into cyl-
inders. Piston rings can not be inspected thru ex-
haust ports.
6. Bottom end of cylinder bore has taper which per-
mits the insertion of the piston into block without
using a piston ring compressor. Place piston
carefully into cylinder.
PE-51084
a - Lower Bearing
b - Gear
c - Retaining Ring

CAUTION
Safety glasses should be worn when removing or
installing ring seals.
3. Install ring seals (2) to crankshaft.
b

PE-51087
a
PE-51083
a - Ring Seal
b - Slot On Crankshaft

4-32 - POWERHEAD 90-852572R1 JANUARY 1998

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 6. Position cylinder block and piston rods as shown.
CAUTION Insert locating pins.
Any grease used for bearings INSIDE the power-
head MUST BE gasoline soluble. Use only Quick- a a a
silver Needle Bearing Assembly Lubricant. DO
NOT use 2-4-C Marine Lubricant, or other lubri-
cants inside powerhead, or damage to engine
may occur.
4. Grease crankshaft journal with Quicksilver
Needle Bearing Assembly Lubricant to hold bear-
ing in place. Position needle bearings on journal.
There are 28 bearings per each center main.

PE-51088
a - Locating Pins
Flywheel End Lower End

7. Place crankshaft into cylinder block; align and

seat top and center main bearings so that locat-
ing pins on block align with larger holes in each
bearing race.

a
b PE-51081
a - Crankshaft Journal
b - Bearings (28)
IMPORTANT: Snap ring groove faces up towards
flywheel.
5. Attach main bearing races with holes towards
lower gear end of crankshaft. Secure each main
bearing race with retaining ring. Lubricate top
main bearing with 2-cycle engine oil and install to
crankshaft as shown.
c b a b

PE-51080

PE-5108
a - Main Bearing Race
b - Retaining Ring (Groove Faces Flywheel)
c - Top Main Bearing (One Piece)

90-852572R1 JANUARY 1998 POWERHEAD - 4-33

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 Installing Rods to Crankshaft Connecting Rod Cap Alignment
1. Oil rod and bearing cage with 2-cycle oil. 1. Check each connecting rod for correct alignment
by carefully running fingernails up and down
2. Pull rod into place and install bearing cages as
edge of rod cap. If not aligned, a ridge can be
shown.
seen or felt at the separating line. Correct any
misalignment.

a b

PE-51080
NOTE: Clean rod bolt/rod cap bolt holes of oil and de-
bris before reassembly. d f
c
IMPORTANT: Always use new rod bolts. The rod
cap and rod must be aligned and held together
when threading oiled bolt. Check that mating sur-
e g
faces 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-51224
a - Front View Correct
b - Front View Incorrect
c - Side View Correct
d - Side View Incorrect
e - Space
f - Side View Incorrect
g - Ridge

2. When connecting rods are attached, and bolts

PE-51089 drawn down finger tight, torque rod-cap bolts to
15 lb. in. (1.7 N·m). Recheck alignment. Re-tor-
que to 120 lb. in. + 1/4 Turn. Recheck top and
center main alignment with dowel pins.

4-34 - POWERHEAD 90-852572R1 JANUARY 1998

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

a
a 14

b PE-51088

14 2 Cycle Outboard Oil (92-831222A24)

PE-51243
a - Lip of Larger Seal
a - Oil Seal (Lubricate Inside with 2-cycle oil)
b - Lip of Smaller Seal
c - End Cap/Perfect Seal

2. Apply LOCTITE MASTER GASKET SEALANT 55/60 models - Lip of smaller seal faces away from
to clean block surface. Instructions in kit must be powerhead. Lip of larger seal faces away power-
followed exactly. head.
IMPORTANT: Extend sealer to edge on each cen- 2. Install end cap assembly (lubricate seals with
ter main journal to prevent blow-by between cyl- 2-cycle engine oil) to block. Apply Perfect Seal
inders. to flange of end cap.

14

b
PE-51088
PE-51087 14 2 Cycle Outboard Oil (92-831222A24)
Sealant “Bead Pattern” Indicated by Bold Line
Above a - Lip of Larger Seal
b - Lip of Smaller Seal
c - End Cap/Perfect Seal

3. Using suitable mandrel, press oil seals into cap

until fully seated.
4. Install end cap assembly (lubricate seals with
2-cycle engine oil) to block. Apply Perfect Seal to
flange of end cap.

90-852572R1 JANUARY 1998 POWERHEAD - 4-35

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 5. Place crankcase cover onto block. Intake/Reed Block Manifold Installa-
tion
1. Place engine on repair stand or on bench.
NOTE: Powerhead repair stand p/n 91-25821A1 can
be used.

a PE-51084
a - Crankcase Cover
b - End Cap

6. Insert clean bolts (note 2 sizes) and finger tight-

en.
7. Torque bolts to 18 lb. ft. (24 N·m) following se-
quence shown below.

7 13 3 9 11
1 5

55323

2. Install check valve/holders.

6
8 14 2
4 10 12 PE-51085

2 PE-51080

3
1

PE-51086
NOTE: Inspect all hoses on reinstallation. Replace if
necessary.
a - Check Valve/Holders

4-36 - POWERHEAD 90-852572R1 JANUARY 1998

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 3. Install reed block manifold and intake manifold Thermostat Cover Installation
with gasket to cylinder block.
1. Thermostat cover 827251C-1. Torque bolts to 18
lb. ft. (24 N·m).

b c
f

e
PE-51225
a - Can Only Be Installed One way
a d

4. Install bolts and torque to 18 lb. ft. (24 N·m) in se- a - Bolts
quence shown below. b - Thermostat Cover - 827251C-1
c - Thermostat Cover Gasket
5 d - Thermostat
6 e - Seal
f - Carrier

11 12
2. Thermostat cover 827251-C. Torque bolts to 18
lb. ft. (24 N·m).

1 2

9 10
3 4
b c

13 14

8 f
PE-51085 a d e
7

a - Bolts
b - Thermostat Cover - 827251-C
c - Thermostat Cover Gasket
d - Thermostat
e - O-ring
f - Carrier

90-852572R1 JANUARY 1998 POWERHEAD - 4-37

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 Install Remaining Engine Powerhead Installation
Components
CAUTION
Component/Assembly Section
There are two different gasket styles. Newer style
CDM 2A replaces old. Note tab on outer edge and also dif-
Flywheel 2A ferent configuration as shown on new style.
Replace with same style or new style gasket.
Stator Assembly 2A
Engine damage could result with 50/55/60 gasket
Trigger Assembly 2A installed on 40/50/55/60 models.
Starter Motor 2B
Starter Solenoid 2B
Voltage Regulator/Rectifier 2B
Fuel Pump 3A
Carburetor and Linkage 3B
Air Silencer 3B
40/50/55/60
Fuel Enrichment Valve 3B
Oil Pump 3C
Shift Cable Latch Assembly 7A
Control Cable Anchor Bracket 7A
40/50/55/60 Models P/N 27-828553
* Note: All ignition and electrical components can be
removed and installed as an assembly.

50/55/60 Models P/N 27-812865

DO NOT INSTALL ON 40/50/55/60 MODELS

4-38 - POWERHEAD 90-852572R1 JANUARY 1998

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 1. Install lifting eye (P/N 91-90455) into flywheel a 3. Install cover. Torque bolts to 80 lb. in. (9 N·m).
minimum of 5 turns. Install powerhead to drive-
shaft housing. Slide shift slide on rail while lower-
ing powerhead on splines of drive shaft.
55320

b
a

a - Bolts - Torque to 80 lb. in. (9 N⋅m)

b - Cover

2. Install Powerhead bolts. Torque to 28 lb.ft.

(38 N·m).
4. Reattach ground wire to powerhead. Connect
wires from trim relay switch. Connect tell tale
hose.

a
a

55014
a - Ground Lead

55319
a - Bolts

90-852572R1 JANUARY 1998 POWERHEAD - 4-39

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 5. Install oil tank. 7. Install control cables. Refer to cable adjustment
in Section 7A.
6. Reconnect wires and oil hose. Secure in place
with sta-strap. 8. Reconnect trim switch. See section 2D Wiring
Diagrams.
9. Connect control/trim harness and fuel line.

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

PE-51082

10. Install battery cables.

a (–)
(+)

PE-51084
a - Red Sleeve (Positive)
b - Black Sleeve (Negative)

4-40 - POWERHEAD 90-852572R1 JANUARY 1998

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 Test Run Procedure
CAUTION
When engine is started, IMMEDIATELY check
that water pump is operating. Operation of water
pump is indicated by water discharging from “tell
tale”.
1. While test running outboard, check powerhead
assembly for leaks and/or unusual noises. Make
any repairs before placing outboard in service.

Important Information
Proper break-in assures that all moving parts “wear-
in” evenly to ensure a longer engine life and optimum
performance.
Operate your new outboard motor at varied throttle
settings – not to exceed 1/2 throttle (2500-3500
RPM) during the first hour or the first five gallons of
break-in fuel. Refer to “Fuel Mixture and Gasoline/Oil
Recommendations” – “Break-In Fuel Mixture” lo-
cated in your operation and Maintenance Manual.
During the second hour operation, or the second 5
gallons (20 Liters) of break-in fuel, operate the Out-
board at varied throttle settings not to exceed 4500
RPM.
DO NOT OPERATE YOUR NEW OUTBOARD MO-
TOR AT FULL THROTTLE UNTIL THE SECOND
HOUR OF BREAK-IN IS COMPLETED.This in-
cludes full throttle acceleration, pulling water skiers,
or wide open throttle running.
After the first two hours of running, approximately 10
gallons (40 Liters) of fuel, full throttle operation may
be attained, but not sustained, for the remaining
break-in fuel (approximately 5 gallons).
For the next five hours of operation, full throttle oper-
ation may, again, be attained, but it is strongly not
recommended for sustained use. (Not more than 5
minutes of continuous wide open throttle.)

CAUTION
SEVERE DAMAGE to your engine can result by
not complying with the preceding break-in pro-
cedures.

90-852572R1 JANUARY 1998 POWERHEAD - 4-41

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 MID-SECTION

5
A

40/50 CLAMP/SWIVEL BRACKETS AND

DRIVE SHAFT HOUSING

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 Table of Contents
Page
Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . .
5A-2
Swivel Tube Components . . . . . . . . . . . . . . . 5A-4
Swivel Bracket Components . . . . . . . . . . . . . 5A-6
Drive Shaft Housing/Exhaust Plate
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8
Drive Shaft Housing
Disassembly/Reassembly . . . . . . . . . . . . . . . 5A-10

5A-0 - MID-SECTION 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 MID-SECTION - 5A-1

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 Clamp Bracket

7 Loctite “271” Adhesive Sealant (92-809819)

95 2-4-C w/Teflon (92-825407A12)

5A-2 - MID-SECTION 90-852572R1 JANUARY 1998

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 Clamp Bracket
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 CLAMP BRACKET (BLACK) PORT
1
1 CLAMP BRACKET (GRAY)
1 CLAMP BRACKET (BLACK) STARBOARD
2
1 CLAMP BRACKET (GRAY)
3 2 THUMB SCREW ASSEMBLY
4 2 HANDLE
5 2 RIVET MANUAL
6 2 WASHER
7 2 SCREW (Hex shoulder) 60 5 6.8
8 1 ANODE
9 2 WASHER
10 2 SCREW (M6 x 25) 60 5 6.8
11 2 NUT (.500-20) Drive Tight
12 2 WASHER
13 2 SCREW (.500-20 x 4 IN.)
14 1 DECAL-Tilt Lock
15 1 DECAL-Warning
16 1 CAP–Tilt Stop Pin
17 1 ROLL PIN
18 1 BUSHING
19 1 PIN–Tilt Stop
20 1 TRIM, Hydraulic assist
21 1 CABLE
22 1 TILT LEVER
23 1 TILT KNOB GAS ASSIST TRIM
24 1 LEVER ARM
25 1 WAVE WASHER
26 1 ROLL PIN (1/8 x 3/4 IN.)
27 1 LINK
28 1 NUT
29 1 ANCHOR PIN (14MM)
30 2 BUSHING
31 2 BUSHING GAS ASSIST TRIM &
32 2 WASHER POWER TRIM MOUNTING
33 2 NUT
34 2 SCREW (M10 x 40)
35 2 WASHER
36 2 NUT
37 1 TILT LOCK PIN NON POWER TRIM
38 1 SPRING

90-852572R1 JANUARY 1998 MID-SECTION - 5A-3

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 Swivel Tube Components

14

95
3

5
4

95

6
7

8
94

10

11

13 12

94 Anti-Corrosion Grease (92-850735A1)

95 2-4-C With Teflon (92-850736A1)

5A-4 - MID-SECTION 90-852572R1 JANUARY 1998

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 Swivel Tube Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 SWIVEL TUBE HEAD (BLACK)
1
1 SWIVEL TUBE HEAD (GRAY)
2 1 BRACKET
3 1 TAB WASHER NON HANDLE
4 2 SCREW (M10 x 45 Hex head cap) 32 43.4
5 1 NUT (.375-24)
6 1 LEVER–Co–pilot
7 1 WASHER
8 1 ROD (THREADED)
9 1 BRAKE PLATE
10 1 DISC–Brake
11 1 PLATE–Swivel Head
12 1 DISC–Brake
13 2 SCREW (HEX SHOULDER) 70 5.8 7.9
14 1 BUMPER

90-852572R1 JANUARY 1998 MID-SECTION - 5A-5

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 Swivel Bracket Components

95 2-4-C w/Teflon (92-850736A1)

A – Tighten nut until it seats and then back off 1/4 turn.
B – Tighten nut to 32 lb. ft. (43.4 N·m) and then back off 1/4 turn,
C – To screw on bottom yoke.

5A-6 - MID-SECTION 90-852572R1 JANUARY 1998

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 Swivel Bracket Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 LINK ROD
2 1 SCREW (1-1/2 IN.) 240 20 27.1
3 1 WASHER NON HANDLE VERSIONS
4 2 WASHER
5 2 NUT (.375-24) A
6 1 PUCK–Co-pilot
1 SWIVEL BRACKET ASSEMBLY (BLACK)
7
1 SWIVEL BRACKET ASSEMBLY (GRAY)
8 1 BUSHING (UPPER)
9 3 GREASE FITTING (Qty. of 4 on Handle Version) Drive Tight
10 1 BUSHING (LOWER)
11 1 SEAL
12 1 DECAL
13 1 CABLE ASSEMBLY
14 1 WASHER
1 SCREW (M8 x 10) (HANDLE VERSIONS) 200 17 23
15
1 SCREW (M8 x 1.25 x 25)(NON-HANDLE VERSIONS)
16 1 SEAL-Co-Pilot
17 1 SEAL KIT NON-HANDLE VERSIONS
18 1 O RING
19 1 SPACER
20 1 WASHER
21 1 TILT TUBE
22 2 NUT (.875-14) 32 43
23 1 DECAL–Co-pilot
24 1 PIN (TRILOBE)
25 2 BUSHING
26 1 PIVOT PIN (UPPER)
27 1 SCREW (10-16 x 3/8 IN.) Drive Tight

90-852572R1 JANUARY 1998 MID-SECTION - 5A-7

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 Drive Shaft Housing/Exhaust Plate Components

A = TO PORT SIDE OF SWIVEL BRACKET

5A-8 - MID-SECTION 90-852572R1 JANUARY 1998
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 Drive Shaft Housing/Exhaust Plate Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 2 SCREW (M8 x 55) 80 16.5 22.4
2 1 GROMMET–Water Tube
3 1 CLAMP–Water Tube
4 1 SEAL–Water Tube
1 WATER TUBE (SHORT)
5 1 WATER TUBE (LONG)
6 1 EXHAUST TUBE
7 4 SCREW (M8 x 45) 220 16.5 22.4
8 1 GASKET–Drive Shaft Housing
1 ADAPTOR PLATE (BLACK)
9 1 ADAPTOR PLATE (GRAY)
10 4 DOWEL PIN
11 1 SCREW (M10 x .75) 220 16.5 22.4
12 1 SEAL–Bottom Cowl
13 1 COUPLER
14 1 GROMMET–Shift Shaft
15 1 SHIFT SHAFT (UPPER)
16 1 WASHER
17 1 PIN–Shift Link
18 1 COTTER PIN
19 2 SCREW (M12 x 1.75 x 162)
20 1 MOUNT
21 4 SCREW (M8 x 45) 220 18.3 24.0
22 1 CABLE ASSEMBLY
23 2 WASHER
24 2 WASHER
25 2 NUT (M12 x 1.75) 50 67.8
1 TRIM COVER (BLACK)
26 1 TRIM COVER (GRAY)
27 1 BUMPER
28 1 SCREW (M5 x .8 x 60)
29 1 WASHER
30 1 NUT (M5 x .8) Drive Tight
31 1 BUMPER–Trim Cover
32 1 SEAL–Exhaust Tube
33 1 SEAL–Idle Relief
34 6 SCREW (M10 x 110) 29 39.3
1 DRIVESHAFT HOUSING (BLACK) (LONG)
1 DRIVESHAFT HOUSING (GRAY)
35 1 DRIVESHAFT HOUSING (BLACK) (SHORT)
1 DRIVESHAFT HOUSING (GRAY)
36 1 STUD (M10 x 1.5 x 50)
37 1 WASHER
38 1 NUT (M10) 220 18.3 24.9
39 2 MOUNT (LOWER)
2 COVER–Mount (BLACK)
40 2 COVER–Mount (GRAY)
41 4 SCREW (M8 x 1.25 x 35) 220 18.3 24.9
2 BOTTOM YOKE (BLACK)
42 2 BOTTOM YOKE (GRAY)
43 3 SCREW (M8 x 40)
44 3 WASHER
45 3 NUT (M8 x 1.25) 100 8.3 11
46 2 SCREW (M12 x 125)
47 2 NUT (M12 x 1.75) 50 67.8

90-852572R1 JANUARY 1998 MID-SECTION - 5A-9

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 Drive Shaft Housing WARNING
Disassembly/Reassembly Failure to support outboard as shown could re-
Servicing components such as steering arm, drive sult in personal injury and/or damage to out-
shaft housing, exhaust assembly and swivel bracket board or boat.
will usually require powerhead and/or gear housing a
removal.
Refer to SECTION 4 for powerhead removal and b
SECTION 6A for gear housing removal.
The transom bracket, lower mount bracket, tilt tube
and lower engine mounts can be serviced without c
powerhead/gear housing removal. However, OUT-
BOARD MUST BE SUPPORTED BEFORE SERV-
ICING COMPONENTS.

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

IMPORTANT: All gaskets should be replaced

when removing powerhead and/or disassem-
bling drive shaft housing. Corresponding gasket
mating surfaces should be cleaned of any gasket
material before installing new gaskets.

5A-10 - MID-SECTION 90-852572R1 JANUARY 1998

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 MID-SECTION

5
B

55/60 CLAMP/SWIVEL BRACKETS AND

DRIVE SHAFT HOUSING

Downloaded from www.Manualslib.com manuals search engine

 Table of Contents
Page
Clamp Bracket Components (Manual) . . . . 5B-2
Transom Bracket Components (Electric) . . 5B-4
Swivel Bracket Components . . . . . . . . . . . . . 5B-6
Drive Shaft Housing . . . . . . . . . . . . . . . . . . . .
5B-8
Drive Shaft Housing
Disassembly/Reassembly . . . . . . . . . . . . . . . 5B-10

5B-0 - MID-SECTION 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 MID-SECTION - 5B-1

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 Clamp Bracket Components (Manual)

32 9
8
36 95 7 10

39
31 22
37
35
38 34 33 2
4
3

95 5 6
11
16 95
17 25 23
21 24
22
12
1
18
20 13 23
15
28
14
19 29
27
30 26

95 2-4-C With Teflon (92-850736A1)

5B-2 - MID-SECTION 90-852572R1 JANUARY 1998

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 Clamp Bracket Components (Manual)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 CLAMP BRACKET (BLACK) PORT
1
1 CLAMP BRACKET (GRAY)
2 1 GREASE FITTING
3 1 GROOVE PIN
1 CLAMP BRACKET (BLACK) STARBOARD
4
1 CLAMP BRACKET (GRAY)
1 TILT LOCK LEVER (BLACK)
5
1 TILT LOCK LEVER (GRAY)
6 1 SPRING
7 1 NYLINER
8 1 SPRING
1 KNOB (BLACK)
9
1 KNOB (GRAY)
10 1 GROOVE PIN
11 2 WASHER
1 ANCHOR BRACKET (BLACK)
12
1 ANCHOR BRACKET (GRAY)
13 1 ANODE ASSEMBLY
14 2 SCREW 60 5 6.8
15 2 WASHER
5 SCREW (30 MM)
16
1 SCREW (35 MM)
17 4 LOCKWASHER
18 2 NUT
19 1 TILT PIN ASSEMBLY
20 1 SPRING
21 1 TILT TUBE
22 2 NUT 264 22 29.8
23 2 THUMB SCREW ASSEMBLY
24 2 WASHER
25 2 SCREW 60 5 6.8
26 1 HANDLE
27 1 RIVET
28 4 SCREW Drive Tight
29 4 WASHER
30 4 NUT Drive Tight
31 1 LINK
32 1 TILT LEVER
33 1 BUSHING
34 1 WASHER
35 1 WAVE WASHER
36 1 TILT KNOB
37 1 SCREW (.375-16 x .62) 220 18.3 24.9
38 1 DECAL, Tilt Lock
39 1 DECAL, Warning

90-852572R1 JANUARY 1998 MID-SECTION - 5B-3

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 Transom Bracket Components (Electric)

9
34 8
7 10
38 95

23
33
39
19 37
36 35 11
4
2
3

5 6
27
28
29 16 95
17
95

22
23 12
1
18

25 21 13
15
30
14
26
20 31
24
32

95 2-4-C With Teflon (92-850736A1)

5B-4 - MID-SECTION 90-852572R1 JANUARY 1998

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 Transom Bracket Components (Electric)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 TRANSOM BRACKET (BLACK)
1
1 TRANSOM BRACKET (GRAY) PORT
2 1 GREASE FITTING
3 1 GROOVE PIN
1 TRANSOM BRACKET (BLACK)
4
1 TRANSOM BRACKET (GRAY) STARBOARD
1 TILT LOCK LEVER (BLACK)
5
1 TILT LOCK LEVER (GRAY)
6 1 SPRING
7 1 NYLINER
8 1 SPRING
1 KNOB (BLACK)
9
1 KNOB (GRAY)
10 1 GROOVE PIN
11 2 WASHER
1 ANCHOR BRACKET (BLACK)
12
1 ANCHOR BRACKET (GRAY)
13 1 ANODE ASSEMBLY
14 2 SCREW (M6 x 25) 60 5 6.8
15 2 WASHER
5 SCREW (30 MM)
16
1 SCREW (35 MM)
17 4 LOCKWASHER
18 2 NUT
19 1 DECAL, Tilt Lock
20 1 TILT PIN ASSEMBLY NON POWER TRIM
21 1 SPRING
22 1 TILT TUBE
Tighten nut to 32 lb.
23 2 NUT ft. and then back off
1/4 turn
24 1 SEAL KIT
25 1 O RING
26 1 SPACER
27 1 CLIP
28 1 C-WASHER POWER TRIM
29 1 SCREW Drive Tight
30 4 SCREW Drive Tight
31 4 WASHER Drive Tight
32 4 NUT
33 1 LINK
34 1 TILT LEVER
35 1 BUSHING NON POWER TRIM
36 1 WASHER
37 1 WAVE WASHER
38 1 TILT KNOB
39 1 SCREW (.375-16 x .62) 220 18.3 24.9

90-852572R1 JANUARY 1998 MID-SECTION - 5B-5

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 Swivel Bracket Components

10 9
17

12
13
11 18
16 19
95
14
15

95

20
95

3
21 4
2

24 95

1
5

23

2 95

3
6

7
22

95 2-4-C With Teflon (92-850736A1)

5B-6 - MID-SECTION 90-852572R1 JANUARY 1998

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 Swivel Bracket Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 SWIVEL BRACKET (BLACK) SHORT
1 SWIVEL BRACKET (GRAY)
1
1 SWIVEL BRACKET (BLACK)
1 SWIVEL BRACKET (GRAY) LONG
2 2 BEARING
3 2 OIL SEAL
4 2 BEARING
5 3 GREASE FITTING 38 3.2 4.3
6 1 WASHER
1 BOTTOM YOKE (BLACK)
7
1 BOTTOM YOKE (GRAY)
8 1 RETAINING RING
1 SWIVEL PIN (BLACK) SHORT
1 SWIVEL PIN (GRAY)
9
1 SWIVEL PIN (BLACK)
1 SWIVEL PIN (GRAY) LONG
10 1 PIN–Co–Pilot
11 1 BRACKET
12 1 STRAP
13 2 SCREW (M10 x 30) 220 18.3 24.9
1 LINK ROD (STARBOARD) 50/60
14
1 LINK ROD (PORT)
15 1 SCREW (1-1/2 IN.) 288 20 27.1
16 1 WASHER
17 1 NUT 288 20 27.1
18 2 WASHER
Tighten nut until it
19 1 NUT seats and then back
off 1/4 turn
20 1 WASHER
21 1 ROLL PIN (HANDLE)
22 1 CABLE
23 1 SCREW (1/4-20x .50) Drive Tight
24 1 DECAL (Serial Over laminate)

90-852572R1 JANUARY 1998 MID-SECTION - 5B-7

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 Drive Shaft Housing

3
20
17 21
1 15

12

13 19
18
14
33

2
9
6

7
14
8 11
10 16
4 23
22
5
7
8

33

33 Loctite “680” (92-809833)

5B-8 - MID-SECTION 90-852572R1 JANUARY 1998

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 Drive Shaft Housing
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 DRIVE SHAFT HOUSING (SHORT)
1 1 DRIVE SHAFT HOUSING (LONG)
1 DRIVE SHAFT HOUSING (JET 45)
1 STUD (M10 x 60) (SHORT/LONG)
2 1 STUD (M10 x 100) (60 BIG FOOT - LONG)
1 STUD (M10 x 166) (60 BIG FOOT - LL)
3 6 SCREW (M10 x 110) 30 40
4 STUD (M10 x 124) (60 BIGFOOT - LL - FRONT)
4
5 STUD (M10 x 120) (55 LL - FRONT)
5 4 SCREW (SHORT/LONG)(NON JET MODELS) 40 54.2
6 4 WASHER
7 1 WASHER NON BIGFOOT MODELS
8 1 NUT 40 54.2
6 4 WASHER
7 5 WASHER BIGFOOT MODELS
8 5 NUT 40 54.2
9 1 SPEEDOMETER PICK-UP ASSEMBLY
10 1 CONNECTOR (STRAIGHT)
11 1 FITTING
12 2 BOLT (M12 x 154) 220 18.3 24.9
13 2 LOWER MOUNT
14 4 WASHER
15 1 GROUND WIRE
16 2 NUT 50 67.8
17 4 SCREW (M8 x 25) 220 18.3 24.9
18 2 CLAMP
19 4 NUT
20 2 COVER
21 4 SCREW Drive Tight
1 SPACER
22
1 SPACER (LL)
23 1 COUPLING
MODEL VERSION LENGTH DESIGNATION:
SHORT = 15 IN. LONG = 20 IN. LL = 22-1/2 IN.

90-852572R1 JANUARY 1998 MID-SECTION - 5B-9

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 Drive Shaft Housing WARNING
Disassembly/Reassembly Failure to support outboard as shown could re-
Servicing components such as steering arm, drive sult in personal injury and/or damage to out-
shaft housing, exhaust assembly and swivel bracket board or boat.
will usually require powerhead and/or gear housing
a
removal.
Refer to SECTION 4 for powerhead removal and
SECTION 6B for gear housing removal. b
The transom bracket, lower mount bracket, tilt tube
and lower engine mounts can be serviced without c
powerhead/gear housing removal. However, OUT-
BOARD MUST BE SUPPORTED BEFORE SERV-
ICING COMPONENTS.

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

IMPORTANT: All gaskets should be replaced

when removing powerhead and/or disassem-
bling drive shaft housing. Corresponding gasket
mating surfaces should be cleaned of any gasket
material before installing new gaskets.

5B-10 - MID-SECTION 90-852572R1 JANUARY 1998

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 MID SECTION

5
C

40/50 POWER TRIM

Downloaded from www.Manualslib.com manuals search engine

 Table of Contents
Page Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Power Trim System Removal . . . . . . . . . . . . 5C-27
Power Trim Components . . . . . . . . . . . . . . . . 5C-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-28
Theory Of Operation . . . . . . . . . . . . . . . . . . . . 5C-4 Shock Rod Removal . . . . . . . . . . . . . . . . . 5C-28
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Shock Rod Disassembly . . . . . . . . . . . . . . . . 5C-29
Trimming Characteristics . . . . . . . . . . . . . 5C-4 Memory Piston Removal . . . . . . . . . . . . . . 5C-31
Trailering Outboard . . . . . . . . . . . . . . . . . . 5C-5 Trim Motor Removal . . . . . . . . . . . . . . . . . 5C-32
Tilting Outboard Up and Down Oil Pump Removal . . . . . . . . . . . . . . . . . . . 5C-33
Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5 Tilt Relief Valve Removal . . . . . . . . . . . . . 5C-33
Trim “In” Angle Adjustment . . . . . . . . . . . . 5C-5 Suction Seat Removal . . . . . . . . . . . . . . . . 5C-34
Power Trim Flow Diagrams . . . . . . . . . . . 5C-6 Pilot Check Valve Assembly Removal . . 5C-34
Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-7 Cleaning/Inspection/Repair . . . . . . . . . . . . . . 5C-35
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9 Trim Motor Electrical Tests . . . . . . . . . . . . 5C-35
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . 5C-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-36
Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5C-13 O-Ring and Seal Placement . . . . . . . . . . . 5C-36
Shock Function Up . . . . . . . . . . . . . . . . . . 5C-15 Power Trim Reassembly . . . . . . . . . . . . . . . . 5C-38
Shock Function Return . . . . . . . . . . . . . . . 5C-17 Tilt Relief Valve Reassembly . . . . . . . . . . 5C-38
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-19 Suction Seat Reassembly . . . . . . . . . . . . 5C-38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5C-20 Pilot Check Valve Reassembly . . . . . . . . 5C-39
Preliminary Checks . . . . . . . . . . . . . . . . . . 5C-20 Oil Pump Reassembly . . . . . . . . . . . . . . . . 5C-39
Hydraulic System Troubleshooting Trim Motor Reassembly . . . . . . . . . . . . . . 5C-40
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-21 Shock Rod Reassembly . . . . . . . . . . . . . . 5C-40
Hydraulic System Troubleshooting Shock Rod Installation . . . . . . . . . . . . . . . 5C-42
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-22 Manual Release Valve Installation . . . . . 5C-42
Hydraulic System Troubleshooting Bleeding Power Trim Unit . . . . . . . . . . . . . 5C-42
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-23 Power Trim System Installation . . . . . . . . . . 5C-43
Hydraulic System Troubleshooting
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-24
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . 5C-25
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . 5C-26

5C-0 - MID-SECTION 90-852572R1 JANUARY 1998

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 Special Tools
1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Expanding Rod P/N CG 41-11*

4. Collet P/N CG 41-14*

5. Heat Lamp P/N 91-63209

* = Snap-On

90-852572R1 JANUARY 1998 MID-SECTION - 5C-1

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 Power Trim Components

27

28
29

11 B
A 12
13

14 25

20
2
G

15
110 16 110
8
17 22 21
C
6 26
110 23
24
10 25

9 D
1 7
3

4
19

E
5
18

25 Liquid Neoprene (92-25711--2)

D
F 110 Power Trim and Steering Fluid (92-90100A12)

5C-2 - MID-SECTION 90-852572R1 JANUARY 1998

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 Power Trim
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 POWER TRIM ASSEMBLY
– 1 O RING KIT
2 1 SHOCK ROD ASSY. 45 61
3 1 PILOT CHECK ASSEMBLY 120 10 13.6
4 1 TILT RELIEF VALVE ASSEMBLY 120 10 13.6
5 1 SUCTION SEAT ASSEMBLY 120 10 13.6
6 1 PUMP ASSEMBLY
7 1 BALL/SPRING
8 1 SCREW 70 5.8 7.9
9 1 FILTER
10 1 O RING
11 1 MOTOR ASSEMBLY
12 4 SCREW 80 6.7 9.0
13 4 WASHER
14 1 CABLE
15 1 O RING
16 1 COUPLER
17 1 MEMORY PISTON
18 1 MANUAL RELEASE VALVE ASSEMBLY Drive Tight
19 1 RESERVOIR PLUG Drive Tight
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
27 1 SCREW (10-16 x 1/2 IN.)
28 1 C WASHER
29 2 CLIP
A - Torque cylinder cap to 45 lb. ft. (61 N⋅m)
B - Torque screw to 80 lb. in. (9.0 N⋅m)
C - Torque screw to 70 lb. in. (7.9 N⋅m)
D - Torque pilot check plug to 120 lb. in. (13.6 N⋅m)
E - Torque tilt relief plug to 120 lb. in. (13.6 N⋅m)
F - Torque suction seat plug to 120 lb. in. (13.6 N⋅m)
G - Torque shock piston to 45 lb. ft. (61 N⋅m)

90-852572R1 JANUARY 1998 MID-SECTION - 5C-3

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 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, posi- trim system to automatically lower the engine back to
tion), 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
some high speed hulls. To correct instability at cause undesirable and/or unsafe steering condi-
high speed, reduce the power gradually and trim tions. Each boat should be tested for handling
the motor “In” slightly before resuming high characteristics after any adjustment is made to
speed operation. (Rapid reduction in power will the tilt angle (tilt pin relocation).
cause a sudden change of steering torque and
may cause additional momentary boat instabili- • Will help planing off, particularly with a heavy
ty. load.
• Will lift bow of boat, general 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 internal passageways into the “down” side of
the trim cylinder. The trim rod will move the engine
downward to the desired angle.

5C-4 - MID-SECTION 90-852572R1 JANUARY 1998

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 Trailering Outboard Trim “In” Angle Adjustment

WARNING WARNING
Excessive engine trim angle will result in insuffi- Operating some boats with engine trimmed to
cient water supply to water pump causing water the full “in” trim angle at planing speed will cause
pump and/or powerhead overheating damage. undesirable and/or unsafe steering conditions.
Make sure that water level is above gear housing Each boat must be water tested for handling
water intake holes whenever engine is running. characteristics after engine installation and after
any trim adjustments.
While operating “up” circuit, the cylinder rod will con-
tinue to tilt the outboard to a full up position for trailer- IMPORTANT: Some boat/motor combinations
ing. that are trimmed to the full “in” trim angle, will not
experience any undesirable and/or unsafe steer-
ing conditions during planing speed. However,
Tilting Outboard Up and Down some boats with engine trimmed to the full “in”
Manually trim angle at planing speed will cause undesir-
able and/or unsafe steering conditions. If these
steering conditions are experienced, adjust the
WARNING left and right tilt stop pins to prevent unsafe han-
Before loosening the manual release valve, make dling characteristics.
sure all persons are clear of engine as engine will Water test the boat. If undesirable and/or unsafe
drop to full “down” position when valve is loos- steering conditions are experienced (boat runs with
ened. nose down), adjust the left and right tilt stop pins in
With power trim installed, the outboard can be raised proper hole to prevent unsafe handling characteris-
or lowered manually by opening the manual release tics.
valve 3 to 4 turns (counterclockwise).

a b

a - Left Tilt Stop Pin

a - Manual Release Valve b - Right Tilt Stop Pin
IMPORTANT: In order to remove the right tilt stop
pin it may be necessary to remove the upper piv-
ot pin and pivot the tilt/trim assembly out of the
clamp brackets. See “Power Trim System Re-
moval” to remove the upper pivot pin.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-5

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 POWER TRIM FLOW DIAGRAMS

TRIM UP
Reservoir and Feed Oil
Oil Under Pressure
Return Oil b
a

u t
s

n c
o w v d
w q r
p e

m
Á Á Á
Á Á
Up Pressure
2530 PSI
l (min)

h
k
i g

j
f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve Check Ball
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-6 - MID-SECTION 90-852572R1 JANUARY 1998

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 TRIM UP
When the trim switch is activated in the up position,
the electric motor (a) begins to rotate the pump
gears, the oil pump (n) draws a small amount of oil
through the filter, up circuit pick–up and past the feed
valve check ball (o). The oil pump gear (n) rotation
forces oil into the passages for the up circuit. Oil, un-
der pressure, will slide the shuttle valve (p) against
the down circuit pressure operated valve (h). The
shuttle valve will mechanically open the down pres-
sure operated valve, allowing oil from the down cavity
of the trim cylinder, to flow into the oil pump. This re-
turning 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 (t) by the
ball inside the down circuit feed valve (m). The pres-
sure of the oil will force the up circuit pressure oper-
ated valve (l) to open, allowing the oil to enter the pas-
sages inside the manifold (f) leading to the trim
cylinder up cavity. Oil is blocked from all other pas-
sages by the closed manual relief valve (j) and closed
tilt relief valve (k). Oil under pressure will enter the
trim cylinder below the memory piston (e). With an in-
creasing amount of oil entering the cylinder, the
memory piston contacts the shock piston (d) and
forces the trim ram (b) up and out, raising the out-
board motor. Oil on the top of the shock piston exits
through a passage running down along the side of
the cylinder and enters the manifold passages. In-
side the manifold the oil seats the ball (r) inside the
suction seat (g), closing the passage into the reser-
voir. The oil is drawn back into the pump (n) through
the open pressure operated valve (h) and enters the
pump as supply for the up circuit.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-7

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 TILT UP
Reservoir and Feed Oil
Oil Under Pressure
Return Oil b
a

u t c
s v d
e
n o w
w
q r
p

Á ÁÁ Á
Tilt Relief
m Pressure

l
ÁÁ Á 500–600 PSI

h
k
i
g

j
f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-8 - MID-SECTION 90-852572R1 JANUARY 1998

Downloaded from www.Manualslib.com manuals search engine
 TILT UP
In the up mode, as the trim ram (b) extends from the
cylinder, the memory piston (e) clears or uncovers
the pressure relief passage. Oil from the up cavity will
enter this passage and open the tilt pressure relief
valve (k). 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 pres-
sure available will not be able to overcome the pro-
peller thrust, limiting the trim range to below the pres-
sure relief orifice. When the engine rpm’s fall, or if
engine is not in forward gear, the oil pressure is avail-
able to extend the trim ram (b) up into the tilt range.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-9

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 MAXIMUM TILT
Reservoir and Feed Oil
Oil Under Pressure b
Return Oil
a
v cd

Tilt Relief
t Pressure
u s 500–600 PSI

n o w
w q r
p

m
Á ÁÁ Á
ÁÁ Á
l

h
k
i g

j
f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-10 - MID-SECTION 90-852572R1 JANUARY 1998

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 MAXIMUM TILT
With the cylinder at maximum travel, and due to no
ram movement, the pressure inside of the trim cylin-
der will increase to the pressure required to move the
tilt relief actuator (i). The tilt relief actuator’s ”pin”
opens the tilt relief valve (k). Up pressure flows into
the trim relief passage, and return back into the reser-
voir (t).

90-852572R1 JANUARY 1998 MID-SECTION - 5C-11

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 TRIM DOWN
Reservoir and Feed Oil
Oil Under Pressure
Return Oil b
a

Down Relief
500–800 PSI

u t
s

n o
o w cd
v
w q r
p e
m
m
l Á ÁÁ ÁÁ
ÁÁ
l

k h
k
i g

j
f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-12 - MID-SECTION 90-852572R1 JANUARY 1998

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 DOWN MODE
When the trim switch is activated in the down posi-
tion, the electric motor (a) will rotate the pump (n) in
the opposite direction. With the pump gears rotating
backwards, the flow of oil is reversed. Oil is drawn
through the filter, past the feed check valve (m), into
the down circuit oil pick–up, and finally into the oil
pump. The pump feeds pressurized oil into the down
passages, oil will slide the shuttle valve (p) into the up
circuit pressure operated valve (l). The shuttle valve
will mechanically open the pressure operated valve
and allow oil, from the up cavity of the manifold (f), 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 shuttle valve (p) inside the up circuit feed valve.
Oil, under pressure, opens the pressure operated
valve (h) and enters the down passages inside of the
manifold (f). The manifold passage connects into the
trim cylinder passage leading to the top of the cylin-
der. The cavity, inside the cylinder, above the shock
piston (d) is the down cavity. As the down cavity fills
with oil, the trim ram (b) retracts into the cylinder, low-
ering the outboard motor. Oil from the up cavity exits
the cylinder and is drawn back into the pump through
the up pressure operated valve (l). When the trim ram
reaches full travel, the oil pressure inside the down
circuit will rise until the down pressure regulation
valve (q) opens, bypassing oil back into the reser-
voir(t). When the trim button is released, and the oil
pump stops supplying pressure, both of the pressure
operated valves (h & l) will close and; if open, the
down pressure regulating valve (q) will close. The
closed valves will lock the fluid on either side of the
shock piston (d), holding the outboard motor in posi-
tion.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-13

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 SHOCK FUNCTION UP
Reservoir and Feed Oil
Oil Under Pressure
Return Oil b
a

u t s
cd

n o
w w v 1550–1850 PSI
q r
p e

m
Á ÁÁ ÁÁ
l

h
k
i g

j
f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-14 - MID-SECTION 90-852572R1 JANUARY 1998

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 SHOCK FUNCTION UP
Oil inside the down cavity is locked in a static position
by the down pressure operated valve (h), the manual
release valve (j) and the tilt relief valve (k). If the out-
board strikes an underwater object while in forward
gear the trim ram (b) will try to rapidly extend from the
cylinder, the pressure increases inside the trim cylin-
der down cavity and connecting passages. The rise
in pressure will seat the check ball (r) inside the suc-
tion seat (g), preventing fluid from returning into the
reservoir. When the pressure increases to the level
required, the impact relief valve (c), located inside the
shock piston (d), will open and allow the fluid to pass
through the shock piston. As the fluid passes through
the piston, the trim ram (b) will extend from the trim
cylinder. The memory piston (e) 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 trim ram piston is trapped between the
memory piston (e) and shock piston (d).

90-852572R1 JANUARY 1998 MID-SECTION - 5C-15

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 SHOCK FUNCTION
RETURN
Reservoir and Feed Oil
Oil Under Pressure b
Return Oil

u t
s cd
v
n o
w
w q r
p e

Á Á ÁÁ
m
Á Á ÁÁ
ÁÁ
l h

k
i
g

j
f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-16 - MID-SECTION 90-852572R1 JANUARY 1998

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 SHOCK FUNCTION RETURN
After the engine clears the under water object, the
weight of the engine will increase the oil pressure be-
tween the memory piston (e) and shock piston (d) to
the level required to open the shock return valve (v),
inside the shock piston, allowing the oil to bleed back
through the shock piston into the down cavity. If re-
quired, additional oil will enter the down cavity
through the suction seat (g). This will return the en-
gine back against the memory piston (e) into the orig-
inal running position.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-17

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 MANUAL TILT
Reservoir and Feed Oil
Return Oil b
a

u t s

n
o
cd
w q r w v
p e

Á ÁÁ Á
m

Á
l h

k
i g

j f

a- Electric Motor n- Oil Pump

b- Trim Ram o- Up Circuit Feed Valve
c - Impact Relief Valve p- Shuttle Valve
d- Shock Piston q- Down Pressure Regulating Valve
e- Memory Piston r - Check Ball
f - Manifold s - Reservoir Oil
g- Suction Seat t - Oil Reservoir
h- Down Pressure Operated Valve u- Oil Fill Cap
i - Tilt Relief Actuator v - Shock Return Valve
j - Manual Release Valve w- Filter
k - Tilt Relief Valve
l - Up Pressure Operated Valve
m- Down Circuit Feed Valve

5C-18 - MID-SECTION 90-852572R1 JANUARY 1998

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 MANUAL TILT
To manually tilt the outboard engine, the owner will
need to back out the manual release valve (j). With
the valve backed out, the internal passages inside
the manifold are connected together. These pas-
sages connect both the cylinder down and up cavities
together, along with the reservoir (t), allowing the en-
gine to be raised or lowered. Trim ram (b) movement
will continue until the manual release valve is closed,
locking the fluid inside of the cylinder and manifold.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-19

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 Troubleshooting Follow preliminary checks before proceeding to trou-
bleshooting flow diagrams (following).
Support outboard with tilt lock pin when servicing
power trim system.
IMPORTANT: After debris or failed components Preliminary Checks
have been found (during troubleshooting proce- IMPORTANT: Operate Power Trim system after
dure) it is recommended that unit be disas- each check to see if problem has been corrected.
sembled completely and ALL O-rings be re- If problem has not been corrected, proceed to
placed. Check ball valve components and next check.
castings must be cleaned using engine cleaner
and compressed air or replaced prior to re-as- 1. Check that manual release valve is tightened to
sembly. full right (clockwise) position.
IMPORTANT: Power trim system is pressurized. 2. Check trim pump fluid level with outboard in full
Outboard must be in the full “UP” position (trim “UP” position and fill if necessary. Refer to
rod fully extended) prior to fill/drain plug, or man- “Bleeding Power Trim Unit”.
ual release valve removal. 3. Check for external leaks in Power Trim system.
Refer to instructions following if disassembly is re- Replace defective part(s) if leak is found.
quired when servicing. 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.

5C-20 - MID-SECTION 90-852572R1 JANUARY 1998

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 Hydraulic System Troubleshooting Flow Chart

OUTBOARD WILL NOT HOLD TILTED POSITION

DURING REVERSE AND/OR TRAILS OUT
DURING HIGH SPEED DECELERATION.

Manual release Manual release valve and

Inspect manual release valve. O-rings appear to be O.K.
valve and O-ring
damaged. - Clean and reinstall
manual release valve.

Trim will not hold

Replace manual release reverse thrust.
valve and O-rings. Trim system holds
reverse thrust.
Testing complete.

Trim system holds Remove and inspect pis-

reverse thrust. ton rod assembly for de- Shock piston appears
Testing complete. bris and/or shock ball O.K. - Clean and reinstall
hang up. piston rod assembly.
Debris and/or shock
ball hang up identi-
fied.
Trim will not hold
reverse thrust. Trim system holds
reverse thrust.
Testing complete.
Replace piston
rod assembly.
Remove PO check valve
assembly, inspect O-
rings and seals for dam-
age.
Trim system holds
reverse thrust.
Testing complete.

Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.

Replace PO check
valve assembly. Trim system holds
reverse thrust.
Testing complete.
Trim will not hold
Trim system holds reverse thrust.
reverse thrust.
Testing complete.
continued on next page

90-852572R1 JANUARY 1998 MID-SECTION - 5C-21

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 Hydraulic System Troubleshooting Flow Chart
continued

Remove suction seat as-

sembly and inspect for
debris and/or damage.

Suction seat assembly

Debris and/or damage appears O.K. - Clean and
identified. reinstall suction seat
assembly.

Replace suction seat

assembly. Trim will not hold
reverse thrust. Trim system holds
reverse thrust.
Testing complete.
Trim system holds
reverse thrust.
Testing complete.
Replace trim system.

5C-22 - MID-SECTION 90-852572R1 JANUARY 1998

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 Hydraulic System Troubleshooting Flow Chart

TRIM SYSTEM LEAKS DOWN WITH

MANUAL RELEASE VALVE CLOSED.

Manual release Inspect manual release valve. Manual release valve and O-
valve and O-ring rings appear to be O.K. - Clean
damaged. and reinstall manual release
valve.

Replace manual re- Trim system leaks

lease valve and down.
Trim system does
O-rings.
not leak down.
Testing 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.
Testing complete.

Trim system does Remove PO check valve

not leak down. assembly, inspect O-
Testing complete. rings and seals for dam-
age.

Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly.
Trim system leaks Trim system does
down. not leak down.
Testing complete.
Trim system does
continued on next page
not leak down.
Testing complete.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-23

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 Hydraulic System Troubleshooting Flow Chart
continued

Inspect memory pis-

ton O-ring and cylinder
bore.
Cylinder bore ap-
Cylinder bore appears pears rough and/or
smooth with no debris. debris found in cylin-
der.

Replace memory pis-

ton and shock piston Trim leaks down.
O-rings.

Trim system does

not leak down.
Testing complete. Replace trim system.

5C-24 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

Remote Control
RED
Fuse Holder
2 RED/PUR
– + RED/PUR
B

RED
A

Battery
Starter Bolt
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

Up Relay 4 1
UP

DN
Cowl Switch

Trim Pump Motor

90-852572R1 JANUARY 1998 MID-SECTION - 5C-25

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 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 2. Check for an open connection.
“UP” 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 and the “Up” Relay.
both 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
“DOWN” are both inoperative, 2. Faulty trim switch. the blown fuse. Check electrical wiring
but the Cowl Switch does op- 3. Wire is open between fuse holder and for a shorted circuit.
erate. solenoid. 2. Replace.
4. Wire is open between fuse holder and 3. Check for an open connection or cut
trim switch. wire.
4. Check for a loose or corroded con-
nection.

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, than motor is faulty. Replace
motor.

Trim system operates (motor 1. The Trim or Cowl switch is shorted. 1. Replace.
runs) without pressing the
switches.

5C-26 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 - Tilt Lock Pin

2. Disconnect the power trim wire harness and re-

a
move clamps.

a - Trilobe Pin
b - Upper Pivot Pin

5. Remove the sacrificial anode.

a - Power Trim Wire Harness Clamps

a
a - Sacrificial Anode

90-852572R1 JANUARY 1998 MID-SECTION - 5C-27

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 6. Remove nuts and washers securing the lower Disassembly
pivot pin. Remove lower pivot pin. Retain the piv-
ot pin bushings from the clamp brackets and trim
unit.
Shock Rod Removal
7. Remove the trim unit.
IMPORTANT: Power trim system is pressurized.
Outboard must be in the full “UP” position (trim
rod fully extended) prior to fill/drain plug, or man-
ual release valve removal.
1. Remove reservoir cap.
2. Remove manual release valve assembly.

a - Reservoir Cap
b - Manual Release Valve

3. Drain power trim fluid as shown.

5C-28 - MID-SECTION 90-852572R1 JANUARY 1998

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 4. Secure power trim assembly in a soft jaw vise. Shock Rod Disassembly
5. Unscrew end cap assembly from cylinder using NOTE: The only serviceable items on the shock rod
spanner wrench 91-74951. assembly are the o-rings and wiper ring. If shock rod
requires any other repair, replace shock rod assem-
bly.

6. Remove shock rod assembly from cylinder. c

b
a

a - End Cap
b - Shock Piston
c - O-ring
d - Wiper Ring

1. Place shock rod assembly on clean work surface.

2. Remove bolt from end of shock rod.

a - Bolt

90-852572R1 JANUARY 1998 MID-SECTION - 5C-29

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 3. Remove check ball components from shock rod
piston. CAUTION
When removing shock piston, spanner wrench
4. Remove o-ring from shock rod piston.
must have 1/4 in. x 5/16 in. long pegs to avoid
damage to shock piston.
5. Place shock rod into soft jawed vise and apply
heat to loosen piston using torch lamp (P/N
91-63209).
6. Loosen shock rod piston using spanner wrench
c [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs].
b
7. Allow shock rod piston to cool. Remove from
a shock rod.

51147

a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring

51146

a b

51146

a - Spanner Wrench
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.

5C-30 - MID-SECTION 90-852572R1 JANUARY 1998

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

b
a
51199

a - Shock Piston
b - O-ring

11. Remove cylinder end cap assembly from shock

rod. b. Blowing compressed air into manual release
12. Inspect shock. If wiper (located in cap) has failed valve hole using air nozzle.
to keep rod clean, replace wiper.
13. Place end cap on clean work surface.
WARNING
Memory piston cup may be expelled at a high
14. Remove rod wiper, inner o-ring, and outer o-ring.
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.

a
a
c
b

51145 b
a - Rod Wiper
b - Inner O-ring d
c - Outer O-ring

a - Adaptor
b - Air Hose
c - Memory Piston Exit
d - Shop Rag

90-852572R1 JANUARY 1998 MID-SECTION - 5C-31

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 16. Remove o-ring from memory piston. Trim Motor Removal
1. Secure power trim assembly in soft jawed vise.
2. Remove screws securing trim motor to manifold.
3. Remove motor assembly.

b
a - O-ring

a - Trim Motor
b - Screw (4)

5C-32 - MID-SECTION 90-852572R1 JANUARY 1998

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

3 1/4”
b
1/4”

e
4 1/2”

d
a
c
f
a - Removal Tool made from .060 Stainless Steel Rod

a - Screw (2)
b - Oil Pump
c - Spring
d - Filter
e - O-Ring
f - Down Relief Ball

90-852572R1 JANUARY 1998 MID-SECTION - 5C-33

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 1. Unscrew plug from manifold and remove spring Suction Seat Removal
and poppet assembly.
1. Unscrew plug from manifold and remove ball.
NOTE: Do not lose shim that may be lodged in the
plug. 2. Use a pin punch and knock the filter and suction
seat out from the inside of the manifold cavity.
2. Use the removal tool and pull out the pilot valve.
CAUTION
DO NOT use any tool on the suction seat as any
damage to the surface will not allow the ball to
seat.

a
a

b
c
b b d
b
b

c
d a - Filter
e b - Suction Seat
f g c - Ball
h
d - Plug
a - Tilt Relief Valve Assembly
b - O-Rings
c - Actuator Pin
d - Pilot Valve
Pilot Check Valve Assembly Removal
e - Poppet Assembly 1. Unscrew both plugs.
f - Spring
g - Shim 2. Remove both springs and poppets.
h - Plug
IMPORTANT: Inspect poppet assembly for debris
in the area shown. If debris is found on poppet,
replace poppet.

a - Debris Under Valve Tip

b - Rubber Seat

5C-34 - MID-SECTION 90-852572R1 JANUARY 1998

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

a
b
c
d
e
d
a b c

a - Plug (2)
b - Spring (2)
c - Poppet Assembly (2)
d - Seat (2)
e - Spool (1)

IMPORTANT: Inspect poppet assemblies for de-

bris in the area shown. If debris is found on pop-
pets, replace poppets.

a - Debris Under Valve Tip

b - Rubber Seat

90-852572R1 JANUARY 1998 MID-SECTION - 5C-35

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 Reassembly
O-Ring and Seal Placement
O-Rings and Seals are part of O-Ring Kit 25-827668A1

r
p

o
l

n
m

i
w
h

v a
b c
w d

h
g
w
i u
e t s

5C-36 - MID-SECTION 90-852572R1 JANUARY 1998

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 O-Ring and Seal Placement
O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width
a Actuator Pin 0.07 in. (1.78 mm) 0.21 in. (5.33 mm) 0.07 in. (1.78 mm)
b Tilt Relief Cartridge 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm)
c Tilt Relief Cartridge 0.301 in. (7.65 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
d Tilt Relief Plug 0.359 in. (9.12 mm) 0.565 in. (14.35 mm) 0.139 in. (3.53
mm)
e Suction Seat 0.301 in. (7.65 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
f Suction Seat Plug 0.487 in. (12.37 mm) 0.693 in. (17.60 mm) 0.103 in. (2.62
mm)
g Spool 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm)
h P. O. Check Seat 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm)
i P. O. Check Plug 0.489 in. (12.42 mm) 0.629 in. (15.98 mm) 0.07 in. (1.78 mm)
j Pump Ports 0.145 in. (3.68 mm) 0.285 in. (7.24mm) 0.07 in. (1.78 mm)
k Pump Filter O-ring, Pump Filter - Square Cut
l Reservoir/Motor 2.614 in. (66.40 mm) 2.754 in. (70.0 mm) 0.07 in. (1.78 mm)
m Memory Piston 1.037 in. (26.34 mm) 1.457 in. (37.0 mm) 0.21 in. (5.33 mm)
n Piston Bolt 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm)
o Shock Piston 1.171 in. (29.74 mm) 1.449 in. (36.80 mm) 0.139 in. (3.53
mm)
p Cylinder Cap 1.364 in. (34.65 mm) 1.50 in. (38.10 mm) 0.07 in. (1.78 mm)
q Wiper Ring
r Cylinder Cap - Inner 0.546 in. (13.87 mm) 0.752 in. (19.10 mm) 0.139 in. (3.53
mm)
s Manual Release Valve 0.239 in. (6.07 mm) 0.379 in. (9.63 mm) 0.07 in. (1.78 mm)
t Manual Release Valve 0.176 in. (4.47 mm) 0.316 in. (8.03 mm) 0.07 in. (1.78 mm)
u Manual Release Valve 0.114 in. (2.90 mm) 0.254 in. (6.45 mm) 0.07 in. (1.78 mm)
v Reservoir Plug 0.426 in. (10.82 mm) 0.566 in. (14.38 mm) 0.07 in. (1.78 mm)
w Check Valve

Cutaway Veiw Of O-Ring

Width

O.D. I.D.

90-852572R1 JANUARY 1998 MID-SECTION - 5C-37

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 Power Trim Reassembly Suction Seat Reassembly
IMPORTANT: Lubricate all O-rings with Quicksil- 1. Lubricate O-rings with power trim fluid.
ver Power Trim Fluid (92-90100A12). If not avail- 2. Install filter and suction seat using a 9/32” or 7
able, use automotive (ATF) automatic transmis- mm socket on OUTSIDE diameter of suction
sion fluid. seat.
3. Install ball and plug. Torque plug to 120 lb. in.
Tilt Relief Valve Reassembly (13.5 N·m).

1. Lubricate O-rings with power trim fluid.

2. Place actuator pin into pilot valve.
3. Install and seat the pilot valve into manifold. Seat a
the pilot valve using a 9/32″ or 7 mm socket on
OUTSIDE diameter of the pilot valve.
IMPORTANT: The pilot valve must be seated us- b
ing a suitable mandrel on the OUTSIDE diameter.
4. Install poppet, spring, shim (if used) and plug. c
Torque plug to 120 lb. in. (13.5 N·m).

a - Filter
b - Suction Seat
c - Ball
a d - Plug - Torque to 120 lb. in (13.5 N⋅m)
b
b b
b
c
d
e f g h
a - Tilt Relief Valve Assembly
b - O-Rings
c - Actuator Pin
d - Pilot Valve
e - Poppet Assembly
f - Spring
g - Shim
h - Plug - Torque to 120 lb. in (13.5 N⋅m)

5C-38 - MID-SECTION 90-852572R1 JANUARY 1998

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 Pilot Check Valve Reassembly Oil Pump Reassembly
1. Lubricate o-rings with power trim fluid. 1. Install the down relief ball and spring into man-
ifold.
2. Install one of the seats into manifold. Push the
seat into place using a 9/32” or 7 mm socket on 2. Check to see that O-Rings are placed on bottom
the OUTSIDE diameter of the seat. of pump.
3. Install corresponding poppet, spring and plug. 3. Place O-Ring (square cut) on filter.
4. From the opposite side of the manifold, install 4. Place filter over the oil pump.
spool and the other seat. Push the seat into place
5. Install oil pump with two (2) screws. Torque
using a 9/32” or 7 mm socket on OUTSIDE diam-
screws to 70 lb. in. (7.9 N·m).
eter of seat.
5. Install remaining poppet, spring and plug. Torque
plugs to 120 lb. in. (13.5 N·m).

a
g
b

a
b c

d d

e e
f
d
c
b
a

a - Plug (2) - Torque to 120 lb. in (13.5 N⋅m)

b - Spring (2)
c - Poppet (2)
d - Seat (2)
e - Spool
a - Screws (2) - Torque to 70 lb. in (7.9 N⋅m)
b - Oil Pump
c - O-ring
d - Filter
e - Spring
f - Down Relief Ball
g - Pump O-Ring (2)

90-852572R1 JANUARY 1998 MID-SECTION - 5C-39

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 Trim Motor Reassembly Shock Rod Reassembly
1. Align coupler between oil pump and motor. 1. Install lubricated o-rings to end cap.
2. Install trim motor and secure with four (4) screws. 2. Install rod wiper.
Torque screws to 80 lb. in. (9.0 N·m).

a
c
f
b
c

e
51145

a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
d

3. Install lubricated o-rings to shock piston.

b c

a 51199

a - Shock Piston
b - O-ring
c - O-ring

a - Coupler
b - O-ring
c - Trim Pump Motor
d - Ground Strap
e - Lock Washer (1)
f - Screws (4) - Torque to 80 lb. in (9.0 N⋅m)

5C-40 - MID-SECTION 90-852572R1 JANUARY 1998

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 4. Clamp shock rod in soft jawed vise. 9. Remove shock rod assembly from vise.
5. Position cylinder end cap onto rod as shown. 10. Install ball, seat, and spring (five sets) to shock
rod piston.

b c
a

51147
51146

CAUTION a - Spring (5)

When installing shock rod piston, spanner b - Seat (5)
wrench must have1/4 in. x 5/16 in. (6.4mm x8mm) c - Ball (5)
long pegs to avoid damage to shock rod piston.
6. Apply Loctite Grade “A” (271) to threads on shock
11. Secure components with shock piston bolt.
rod.
Torque bolt to 45 lb.in. (61 Nm).
7. Install shock rod piston.
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,
then torque to 90 lb. ft. (122 N⋅m).
a
b a

a - Bolt - Torque to 45 lb. in (61 N⋅m)

51146

a - Shock Rod Piston - Torque to 90 lb. ft (122 N⋅m)

b - Spanner Wrench

90-852572R1 JANUARY 1998 MID-SECTION - 5C-41

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 Shock Rod Installation Manual Release Valve Installation
1. Place trim cylinder in soft jawed vice. 1. Install “E” clip (if removed) and lubricate o-rings
with power trim fluid.
2. Install lubricated o-ring to memory piston and
place into cylinder. Push memory piston all the 2. Insert manual release valve into manifold and
way to bottom. tighten securely.
a
b

a - Memory Piston
b - O-ring

3. Fill cylinder three inches (76.2mm) from top of Bleeding Power Trim Unit
cylinder using Quicksilver Power Trim and Steer- 1. Secure power trim unit in soft jawed vise.
ing Fluid. If not available, use automotive (ATF)
automatic transmission fluid. 2. Remove reservoir plug. Add power trim fluid until
its even with the bottom of the fill hole. Reinstall
4. Install shock rod into cylinder until power trim fluid plug.
flows through oil blow off ball passage. Fill re-
maining cylinder to just below the cylinder 3. Close the manual release valve. (Turn full clock-
threads. wise).

a - Oil Blow Off Ball Passage

CAUTION
a - Reservoir Plug
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. 4. Using a 12 volt power supply connect the positive
lead to (blue) trim motor wire and negative lead
5. Tighten end cap securely using spanner wrench to (green) trim motor wire and drive shock rod to
[3/16 in. x 5/16 in. (4.8mm x 8mm) long pegs]. If the up position.
a torquing type spanner tool is used to tighten end
cap, then torque to 45 lb. ft. (61.0 N·m). 5. Using a 12 volt power supply, connect the posi-
tive lead to the (green) trim motor wire, and the
negative lead to the (blue) trim motor wire and
drive the shock rod to the down position.
6. Recheck fluid level with rod fully extended, add
fluid if required and repeat cycle until fluid level
stays even with the bottom of the fill hole.

5C-42 - MID-SECTION 90-852572R1 JANUARY 1998

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 Power Trim System 4. Install sacrificial anode to clamp brackets. Fasten
ground strap between anode and clamp bracket.
Installation
1. Lubricate lower pivot pin, mounting holes and
bushings with 2-4-C Marine Lubricant.
2. Install lower pivot pin bushings into the clamp
brackets and trim unit.

a - Ground Wire
b - Sacrificial Anode

a
5. Lubricate the upper pivot pin and mounting holes
with 2-4-C Marine Lubricant.
6. Fasten shock rod with the upper pivot pin.
NOTE: Pivot pin should be installed with grooved end
b 95 inserted first.
95 2-4-C w/Teflon (92-850736A1)

a - Bushing (2) Install into each Clamp Bracket

b - Bushing (2) Install into each side of Trim Unit

3. Install lower pivot pin. Secure with flat washers

and nuts. Torque nuts to 18 lb. ft. (24.4 N·m).

95

95 2-4-C w/Teflon (92-850736A1)

b
a - Nuts - Torque to 18 lb. ft. (24.4 N⋅m)
b - Washers (Not Shown)

90-852572R1 JANUARY 1998 MID-SECTION - 5C-43

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 7. Secure upper pivot pin with trilobe pin. Press tri- 11. Secure wire harness with clamps as shown.
lobe pin in until its fully seated.

a - Trilobe Pin

8. Re-connect trim wire harness leads (see wiring

diagram, Section 2D for proper connections).
9. Recheck fluid level (tilt/trim rod fully extended).
10. Route wire harness through clamp bracket and
cowling.

a - Wire Harness

5C-44 - MID-SECTION 90-852572R1 JANUARY 1998

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 MID-SECTION

5
D

55331

55/60 POWER TRIM

Downloaded from www.Manualslib.com manuals search engine

 Table of Contents
Page Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1 Power Trim System Removal . . . . . . . . . . . . 5D-27
Power Trim Components . . . . . . . . . . . . . . . . 5D-2 Power Trim Disassembly . . . . . . . . . . . . . . . . 5D-28
Theory Of Operation . . . . . . . . . . . . . . . . . . . . 5D-4 Trim Motor Removal . . . . . . . . . . . . . . . . . 5D-29
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4 Pump and Components Removal . . . . . . 5D-29
Trimming Characteristics . . . . . . . . . . . . . 5D-4 Manifold Removal . . . . . . . . . . . . . . . . . . . 5D-30
Trailering Outboard . . . . . . . . . . . . . . . . . . 5D-5 Shock Rod Removal . . . . . . . . . . . . . . . . . 5D-30
Tilting Outboard Up and Down Shock Rod Disassembly . . . . . . . . . . . . . . . . 5D-31
Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-5 Memory Piston Removal . . . . . . . . . . . . . . 5D-33
Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-7 Cleaning/Inspection/Repair . . . . . . . . . . . . . . 5D-34
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-9 Trim Motor Electrical Tests . . . . . . . . . . . . 5D-34
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . 5D-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-35
Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5D-13 O-Ring and Seal Placement . . . . . . . . . . . 5D-35
Shock Function Up . . . . . . . . . . . . . . . . . . 5D-15 O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-36
Shock Function Return . . . . . . . . . . . . . . . 5D-17 O-Ring Description and Sizes . . . . . . . . . . . . 5D-37
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-19 Power Trim Reassembly . . . . . . . . . . . . . . . . 5D-38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5D-20 Shock Rod Reassembly . . . . . . . . . . . . . . 5D-38
Preliminary Checks . . . . . . . . . . . . . . . . . . 5D-20 Shock Rod Installation . . . . . . . . . . . . . . . 5D-39
Hydraulic System Troubleshooting Trim Limit Assembly Installation . . . . . . . 5D-40
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-21 Manual Release Valve Installation . . . . . 5D-40
Hydraulic System Troubleshooting Manifold Installation . . . . . . . . . . . . . . . . . . 5D-40
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-22 Oil Pump Installation . . . . . . . . . . . . . . . . . 5D-41
Hydraulic System Troubleshooting Pressure Operated Assembly Installation 5D-42
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-23 Reservoir/Motor Installation . . . . . . . . . . . 5D-42
Hydraulic System Troubleshooting Bleeding Power Trim Unit . . . . . . . . . . . . . 5D-43
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-24 Installation of Power Trim System . . . . . . . . 5D-43
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . 5D-25
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . 5D-26

5D-0 - MID-SECTION 90-852572R1 JANUARY 1998

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 Special Tools
1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Expanding Rod P/N CG 41-11*

4. Collet P/N CG 41-14*

5. Heat Lamp P/N 91-63209

* = Snap-On

90-852572R1 JANUARY 1998 MID-SECTION - 5D-1

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 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 (92-809819)
95 2-4-C With Teflon (92-850736A1)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive
(ATF) automatic transmission fluid.
NOTE: It is recommended that all o-rings be replaced when servicing tilt system.

5D-2 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 6.7 9.0
13 1 DRIVE SHAFT
14 1 FILTER KIT
15 1 P.O. CHECK ASSEMBLY KIT 120 10 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)

90-852572R1 JANUARY 1998 MID-SECTION - 5D-3

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 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, posi- trim system to automatically lower the engine back to
tion), 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
some high speed hulls. To correct instability at cause undesirable and/or unsafe steering condi-
high speed, reduce the power gradually and trim tions. Each boat should be tested for handling
the motor “In” slightly before resuming high characteristics after any adjustment is made to
speed operation. (Rapid reduction in power will the tilt angle (tilt pin relocation).
cause a sudden change of steering torque and
may cause additional momentary boat instabili- • Will help planing off, particularly with a heavy
ty.) load.
• Will lift bow of boat, generally increasing top • Usually improves ride in choppy water.
speed. • In excess, can cause boat to veer to the left or
• Transfers steering torque harder to left on instal- right (bow steer).
lations below 23 in. transom height. • Transfers steering torque harder to right (or less
• Increases clearance over submerged objects. to the left).
• In excess, can cause porpoising and/or ventila- • Improves planing speed acceleration (by moving
tion. tilt pin one hole closer to transom).
• In excess, can cause insufficient water supply to Operating “Down” circuit will actuate the “down” relay
water pump resulting in serious water pump and/ (located under engine cowl) and close the electric
or powerhead overheating damage. 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 internal passageways into the “down” side of
the trim cylinder. The trim rod will move the engine
downward to the desired angle.

5D-4 - MID-SECTION 90-852572R1 JANUARY 1998

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 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
Make sure that water level is above gear housing will drop to full “down” position when valve is
water intake holes whenever engine is running. loosened.
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 trailer- or lowered manually by opening the manual release
ing. valve 3 to 4 turns (counterclockwise).

55170

a - Manual Release Valve

90-852572R1 JANUARY 1998 MID-SECTION - 5D-5

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 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 HP)
1220–1420 (75–125 HP)

Up Pressure s r
1625 (40–60 HP)
2800 (75–125 HP) Tilt Relief Pressure
min. 250–400 (40–60 HP) q
540–990 (75–125 HP)

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

5D-6 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 return-
ing into the reservoir by the ball inside the down cir-
cuit suction port (k). The pressure of the oil will force
the up circuit pressure operated valve (n) to open, al-
lowing the oil to enter the passages inside the man-
ifold (q) leading to the trim cylinder (w) up cavity. Oil
is blocked from all other passages by the closed
manual release valve (p). Oil under pressure will en-
ter the trim cylinder 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 out-
board motor. Oil on the top of the shock piston exits
through a passage running down along the side of
the cylinder and enters the manifold passages. The
oil is drawn back into the pump (j) through the open
down pressure operated valve (f) and enters the
pump as supply for the up circuit.

90-852572R1 JANUARY 1998 MID-SECTION - 5D-7

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 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 HP)
1220–1420 (75–125 HP)

Up Pressure s r
1625 (40–60 HP)
2800 (75–125 HP) Tilt Relief Pressure
min. 250–400 (40–60 HP) q
540–990 (75–125 HP)

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

5D-8 - MID-SECTION 90-852572R1 JANUARY 1998

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 TILT UP
In the up mode, as the piston rod (a) extends from the
cylinder (w), the memory piston (t) clears or uncovers
the pressure relief passage. Oil from the up cavity will
enter this passage and, if required, causes the tilt re-
lief piston (s) to open the tilt pressure relief valve (r).
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 avail-
able will not be able to overcome the propeller thrust,
limiting the trim range to below the pressure relief ori-
fice. When the engine rpm’s fall or if engine is not in
forward gear, the oil pressure is available to extend
the piston rod (a) up into the tilt range.

90-852572R1 JANUARY 1998 MID-SECTION - 5D-9

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 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 HP)
1220–1420 (75–125 HP)
Up Pressure
1625 (40–60 HP)
2800 (75–125 HP) s r
min. Tilt Relief Pressure
250–400 (40–60 HP)
540–990 (75–125 HP) q

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

5D-10 - MID-SECTION 90-852572R1 JANUARY 1998

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 MAXIMUM TILT
With the piston rod at maximum travel, and due to no
rod movement, the pressure inside of the trim cylin-
der (w) will increase to the pressure required to move
the tilt relief piston (s). The tilt relief piston’s “pin”
opens the tilt relief valve (r). Up pressure flows into
the trim relief passage, and returns back into the res-
ervoir.

90-852572R1 JANUARY 1998 MID-SECTION - 5D-11

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 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 HP)
Up Pressure 1220–1420 (75–125 HP)
1625 (40–60 HP)
2800 (75–125 HP)
min. s r
Tilt Relief Pressure
250–400 (40–60 HP) q
540–990 (75–125 HP)

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

5D-12 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 cav-
ity, will supply the oil required for the down circuit. The
oil is blocked from returning into the reservoir by the
ball (i) inside the up circuit suction port. Oil, under
pressure, opens the down pressure operated valve
(f) and enters the down passages inside of the man-
ifold (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 pis-
ton (u) is the down cavity. As the down cavity fills with
oil, the piston rod (a) retracts into the cylinder, lower-
ing the outboard motor. Oil from the up cavity exits
the cylinder and is drawn back into the pump through
the open up pressure operated valve (n). When the
piston rod reached full travel, the oil pressure inside
the down circuit will rise until the down pressure regu-
lating valve (e) opens, bypassing oil back into the res-
ervoir. 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 pressure 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 out-
board motor in position.

90-852572R1 JANUARY 1998 MID-SECTION - 5D-13

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 SHOCK FUNCTION UP
a b

v
u h

d l
j
t i k

f Reservoir Oil
m n
g
Return Oil
g

Í ÍÍ Oil Under Pressure

Í ÍÍ o
p
Impact Relief Pressure #22
880–1110 (40–60 HP)
1220–1420 (75–125 HP)
Up Pressure
1625 (40–60 HP)
2800 (75–125 HP) s r
min. Tilt Relief Pressure
250–400 (40–60 HP) q
540–990 (75–125 HP)

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

5D-14 - MID-SECTION 90-852572R1 JANUARY 1998

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 SHOCK FUNCTION UP
Oil inside the down cavity is locked in a static position
by the down pressure operated valve (f), the manual
release valve (p) and the manifold reverse suction
valve (o). If the outboard strikes an underwater object
while in forward gear, the piston rod (a) will try to rap-
idly extend from the cylinder (w), the pressure in-
creases inside the trim cylinder down cavity and con-
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).

90-852572R1 JANUARY 1998 MID-SECTION - 5D-15

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 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 HP)
1220–1420 (75–125 HP)
Up Pressure
1625 (40–60 HP)
2800 (75–125 HP)
s r
min. Tilt Relief Pressure
250–400 (40–60 HP) q
540–990 (75–125 HP)

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

5D-16 - MID-SECTION 90-852572R1 JANUARY 1998

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 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.

90-852572R1 JANUARY 1998 MID-SECTION - 5D-17

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 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 HP)
1220–1420 (75–125 HP)
Up Pressure
1625 (40–60 HP)
2800 (75–125 HP) s r
min. Tilt Relief Pressure
250–400 (40–60 HP) q
540–990 (75–125 HP)

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

5D-18 - MID-SECTION 90-852572R1 JANUARY 1998

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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-19

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 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 man-
ual 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
“Bleeding 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.

5D-20 - MID-SECTION 90-852572R1 JANUARY 1998

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 Hydraulic System Troubleshooting Flow Chart

OUTBOARD WILL NOT HOLD TILTED POSITION

DURING REVERSE AND/OR TRAILS OUT
DURING HIGH SPEED DECELERATION.

Manual release Manual release valve and

Inspect manual release valve.
valve and O-ring O-rings appear to be O.K. -
damaged. Clean and reinstall manual
release valve.

Trim will not hold

Replace manual re- reverse thrust. Trim system holds re-
lease valve and O-rings. verse thrust. Testing
complete.

Trim system holds re- Remove and inspect pis-

verse thrust. Testing ton rod assembly for de- Shock piston appears
complete. bris and/or shock ball O.K. - Clean and reinstall
hang up. piston rod assembly.
Debris and/or shock
ball hang up identi-
fied.
Trim will not hold
reverse thrust. Trim system holds re-
verse thrust. Testing
complete.
Replace piston
rod assembly.
Remove PO check valve
assembly, inspect O-rings
and seals for damage.
Trim system holds re-
verse thrust. Testing
complete.

Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.

Replace PO check
valve assembly. Trim system holds
reverse thrust. Test-
ing complete.
Trim will not hold
Trim system holds re- reverse thrust.
verse thrust. Testing
complete.
continued on next page

90-852572R1 JANUARY 1998 MID-SECTION - 5D-21

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 Hydraulic System Troubleshooting Flow Chart
continued

Remove suction seat as-

sembly and inspect for
debris and/or damage.

Suction seat assembly

Debris and/or damage appears O.K. - Clean and
identified. reinstall suction seat
assembly.

Replace suction seat

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.

5D-22 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 down.
Trim system does
O-rings.
not leak down. Test-
ing complete.
Remove tilt relief valving
Trim system does and inspect O-rings and
not leak down. Test- seals for debris and/or
ing 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-
ing complete. rings and seals for dam-
age.

Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly.
Trim system leaks down. Trim system does
not leak down.
Testing complete.
Trim system does
continued on next page
not leak down. Test-
ing complete.

90-852572R1 JANUARY 1998 MID-SECTION - 5D-23

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 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.

5D-24 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

Remote Control
RED
Fuse Holder
2 RED/PUR
– + RED/PUR
B

RED
A

Battery
Starter Bolt
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

Up Relay 4 1
UP

DN
Cowl Switch

Trim Pump Motor

90-852572R1 JANUARY 1998 MID-SECTION - 5D-25

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 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 2. Check for an open connection.
“UP” 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 a 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 and the “UP” Relay.
both 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
“DOWN” are both inoperative, the blown fuse. Check electrical wiring
but the Cowl Switch does op- for a shorted circuit.
erate. 2. Faulty trim switch. 2. Replace.
3. Wire is open between fuse holder and 3. Check for a open connection or cut
solenoid. wire.
4. Wire is open between fuse holder and 4. Check for a loose or corroded con-
trim switch. nection.

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.

5D-26 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-27

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

51144

a - Dowel Pin
a

7. Use suitable punch to drive out lower pivot pin.

55263

a - Reservoir Cap
b - Manual Release Valve

a 51144

a - Lower Pivot Pin

5D-28 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

a - Screw (4) in the area shown. If debris is found on poppet re-
b - Reservoir
c - Reservoir Seal
place poppet.
d - Coupler
e - Manifold Assembly a

a - Debris Under Valve Tip

b - Rubber Seat

90-852572R1 JANUARY 1998 MID-SECTION - 5D-29

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 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)

5D-30 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 (2) 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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-31

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 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
b - Inner O-ring
51146 c - Outer O-ring

a - Spanner Wrench
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.

5D-32 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 (P/N 91-822778A3) or
suitable tool.

51144

a - O-Ring
b - Memory Piston

51144

b. Blowing compressed air into manual release

valve hole using air nozzle.

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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-33

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 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 25-8809880A1.
Lubricate all o-rings with Quicksilver Power Trim
Fluid (92-90100A12). If not available, use automo-
tive (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.

5D-34 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-35

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 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

5D-36 - MID-SECTION 90-852572R1 JANUARY 1998

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 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)

90-852572R1 JANUARY 1998 MID-SECTION - 5D-37

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 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

5D-38 - MID-SECTION 90-852572R1 JANUARY 1998

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 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
cylinder using Quicksilver Power Trim and Steer-
ing Fluid. If not available, use automotive (ATF)
b 51147
automatic transmission fluid.
4. Install shock rod into cylinder until power trim fluid
flows through oil blow off ball passage. Fill re-
a - Screw (3) Torque to 35 lb. in. (4.0 N⋅m)
maining cylinder to just below the cylinder
b - Plate threads.
c - Spring (5)
d - Seat (5)
e - Ball (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).

90-852572R1 JANUARY 1998 MID-SECTION - 5D-39

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 Trim Limit Assembly Installation Manifold Installation
1. Lubricate all O-rings. Install spring, poppet, spool 1. Install dowel pin and two (2) lubricated o-rings
housing and trim limit spool into manifold. into trim cylinder.
NOTE: There are two different size springs used in
this manifold. The heavy spring is used on 75 to 125
HP engines. The light spring is used on 40 to 60 HP
engines.

or a

b b

c a - O-Ring (2)
b - Dowel Pin

2. Align the trim cylinder and pump/reservoir as-

d 51008 sembly together.

a - Spring
b - Poppet
c - Spool Housing
d - Trim Limit Spool
a
Manual Release Valve Installation
1. Install “E” clip (if removed) and lubricate o-rings
to manual release valve.
2. Install manual release valve assembly into man-
ifold.
a b

a - Trim Cylinder Assembly

b - Reservoir/Manifold Assembly

b
a - Manifold
b - Manual Release Valve
c - E Clip

5D-40 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 - Screw (2) Torque to 100 lb. in. (11 N⋅m)

a - Screw (3) Torque to 70 lb. in. (7.7 N⋅m)

b - Suction Seat Assembly

90-852572R1 JANUARY 1998 MID-SECTION - 5D-41

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 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, ervoir onto pump/manifold assembly. Install
replace 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-
pet, spring and plug with o-ring into pump. Re-
peat for other side. Torque plugs to 120 lb. in. f
(13.5 N⋅m).
e

a - Screw (4) Torque to 80 lb. in. (9 N⋅m)

a b - Reservoir
b c - Reservoir Seal
c d - Coupler
d e - Manifold Assembly
f - Ground Strap
e
d 4. Fill reservoir to bottom of fill hole using Quicksil-
c ver Power Trim Fluid (92-901000A12). If not
b
a available, use automotive (ATF) automatic trans-
mission fluid.
a - Plug (2) Torque to 120 lb. in. (13.5 N⋅m)
b - Spring (2)
c - Check Valve/Poppet (2)
d - Seat (2)
e - Spool

5D-42 - MID-SECTION 90-852572R1 JANUARY 1998

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 Bleeding Power Trim Unit Installation of Power Trim
1. Secure power trim unit in soft jawed vise. System
2. Add power trim fluid until it’s even with the bottom 1. Lubricate lower pivot pin, mounting holes with
of the fill hole. Reinstall plug. 2-4-C Marine Lubricant.
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
95
a
55263
51148
a - Reservoir Plug/Fill Hole 95 2-4-C w/Teflon (92-850736A1)
b - Manual Release Valve
a - Lower Pivot Pin
4. Using a 12 volt power supply, connect the posi- b - Lower Dowel Pin
tive lead to (blue) trim motor wire and negative
lead to (green) trim motor wire and drive shock 3. Position trim cylinder assembly (bottom first) be-
rod to the up position. Repeat three times. tween clamp brackets.
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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-43

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 4. Apply 2-4-C Marine Lubricant to lower pivot pin. 6. Apply 2-4-C Marine Lubricant to surface of upper
Using a suitable punch, drive lower pivot pin into pivot pin, pivot pin bore and trim ram bore.
clamp bracket and trim cylinder assembly until
pivot pin is flush with outside surface.
a
c

95

a 95
51148
51147
95 2-4-C w/Teflon (92-850736A1)
95 2-4-C w/Teflon (92-850736A1) 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

5D-44 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

90-852572R1 JANUARY 1998 MID-SECTION - 5D-45

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 MID-SECTION

5
E

40/50 MANUAL TILT ASSIST

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 Table of Contents
Page
Clamp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . 5E-2
Hydraulic Assist Adjustments . . . . . . . . . . . . 5E-4
Manual Trim System Removal . . . . . . . . . . . 5E-4
Manual Trim System Installation . . . . . . . . . . 5E-5

5E-0 - MID-SECTION 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 MID-SECTION - 5E-1

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 Clamp Bracket

38
15
37 1
20
95
36
35
26 27
95 3
24
28

7 6
18
23 34 7
17
19
16 3
14
25
22
2 5
9 4

8 10 33
12
11
13 32
31
30
21

30

29

31
32
33
7 Loctite “271” Adhesive Sealant (92-809819)
95 2-4-C w/Teflon (92-825407A12)

5E-2 - MID-SECTION 90-852572R1 JANUARY 1998

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 Clamp Bracket
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 CLAMP BRACKET (BLACK) PORT
1
1 CLAMP BRACKET (GRAY)
1 CLAMP BRACKET (BLACK) STARBOARD
2
1 CLAMP BRACKET (GRAY)
3 2 THUMB SCREW ASSEMBLY
4 2 HANDLE
5 2 RIVET MANUAL
6 2 WASHER
7 2 SCREW (Hex shoulder) 60 5 6.8
8 1 ANODE
9 2 WASHER
10 2 SCREW (M6 x 25) 60 5 6.8
11 2 NUT (.500-20) Drive Tight
12 2 WASHER
13 2 SCREW (.500-20 x 4 IN.)
14 1 DECAL-Tilt Lock
15 1 DECAL-Warning
16 1 CAP–Tilt Stop Pin
17 1 ROLL PIN
18 1 BUSHING
19 1 PIN–Tilt Stop
20 1 TRIM, Hydraulic assist
21 1 CABLE
22 1 TILT LEVER
23 1 TILT KNOB GAS ASSIST TRIM
24 1 LEVER ARM
25 1 WAVE WASHER
26 1 ROLL PIN (1/8 x 3/4 IN.)
27 1 LINK
28 1 NUT
29 1 ANCHOR PIN (14MM)
30 2 BUSHING
31 2 BUSHING GAS ASSIST TRIM &
32 2 WASHER POWER TRIM MOUNTING
33 2 NUT
34 2 SCREW (M10 x 40)
35 2 WASHER
36 2 NUT
37 1 TILT LOCK PIN NON POWER TRIM
38 1 SPRING

90-852572R1 JANUARY 1998 MID-SECTION - 5E-3

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 Hydraulic Assist Manual Trim System
Adjustments Removal
1. Tilt outboard to the full up position and support
WARNING with tilt stop pin.
This hydraulic assist system’s contents are un-
der pressure. Do not puncture, disassemble or
apply heat or flame.
IMPORTANT: If debris or leaking is found, unit
must be replaced. This hydraulic assist system is
NOT SERVICEABLE. Replace if necessary.
1. Check manual release cam adjustment. Cam a
must open and close freely. Adjust cam link rod
as necessary.

a - Tilt Stop Pin

b

a 2. Remove the trilobe pin.

3. Drive out the upper pivot pin.

a - Link Rod
b - Manual Release Lever

2. Check for external leaks in the manual tilt system. a

Replace unit if leak is found.

a - Trilobe Pin
b - Upper Pivot Pin

5E-4 - MID-SECTION 90-852572R1 JANUARY 1998

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 4. Disconnect link rod from cam lever. Manual Trim System
5. Remove tilt lock pin. Remove nuts and washers
securing the lower pivot pin. Remove anode bolt Installation
to remove ground strap. Remove lower anchor 1. Apply 2-4-C Marine Lubricant to surface of lower
pin. Retain the anchor pin bushings from the anchor pin and anchor pin hole. Place trim into
clamp brackets and trim unit. proper position. Install anchor pin and bushings
6. Remove trim unit. into anchor pin hole and clamp brackets. Install
nuts and washers to anchor pin and tighten se-
curely. Install ground strap and anode bolt.
2. Install tilt lock pin.

c
a

d
f 95
e b
a - Tilt Lock Pin d
b - Link Rod c
c - Cam Lever
d - Nut (2) 95 2-4-C w/Teflon (92-850736A1)
e - Anode Bolt/Ground Strap
f - Pivot Pin
a - Tilt Lock Pin
b - Nut (2)
c - Anode Bolt/Ground Strap
d - Pivot Pin

90-852572R1 JANUARY 1998 MID-SECTION - 5E-5

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 3. Apply 2-4-C Marine Lubricant to surface of upper 6. Check manual release cam adjustment. Cam
pivot pin, pivot hole and shock rod hole. must open and close freely. Adjust cam link rod
as necessary.
4. Position trim into position and drive pivot pin into
swivel bracket and through shock rod until pivot
pin is flush with swivel bracket. Drive trilobe pin
into its hole until seated.
b

95

a
a - Link Rod
95 b - Manual Release Lever
2-4-C w/Teflon (92-850736A1)

a - Trilobe Pin
b - Upper Pivot Pin

5. Connect link rod onto cam lever.

a - Link Rod
b - Cam Lever

5E-6 - MID-SECTION 90-852572R1 JANUARY 1998

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 MID-SECTION

5
F

55/60 MANUAL TILT SYSTEM

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 Table of Contents
Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Manual Tilt Components . . . . . . . . . . . . . . . . 5F-2
Manual Tilt Components . . . . . . . . . . . . . . . . 5F-3
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-5
Tilt Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-7
Slow Tilt Down Under High Thrust . . . . . 5F-9
Under Water Strike With Valves Open . . 5F-11
Shock Function With Valves Closed . . . . 5F-13
Shock Function Return . . . . . . . . . . . . . . . 5F-15
Hydraulic System Troubleshooting . . . . . . . . 5F-16
Manual Tilt System Removal . . . . . . . . . . . . . 5F-17
Manual Tilt System Disassembly . . . . . . . . . 5F-18
Accumulator Removal . . . . . . . . . . . . . . . . 5F-18
Shock Rod Removal . . . . . . . . . . . . . . . . . 5F-19
Shock Rod Disassembly . . . . . . . . . . . . . . . . 5F-20
Valve Block Removal . . . . . . . . . . . . . . . . . 5F-22
Memory Piston Removal . . . . . . . . . . . . . . 5F-22
Valve Block Disassembly . . . . . . . . . . . . . . . . 5F-23
Reassembly - O-Ring and Seal Placement 5F-24
Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . 5F-25
O-ring Description and Sizes . . . . . . . . . . . . . 5F-26
Manual Tilt System Cleaning and Inspection 5F-27
Manual Tilt System Reassembly . . . . . . . . . 5F-27
Valve Block Installation . . . . . . . . . . . . . . . 5F-28
Shock Rod Reassembly . . . . . . . . . . . . . . 5F-29
Shock Rod Installation and Fluid
Filling Procedure . . . . . . . . . . . . . . . . . . . . 5F-30
Filling Procedure Option Two Instructions
for Making Retaining Tool . . . . . . . . . . . . . . . 5F-32
Bleeding Manual Tilt System . . . . . . . . . . . . . 5F-33
Manual Tilt System Installation . . . . . . . . . . . 5F-35
Manual Release Valve Adjustment . . . . . 5F-36

5F-0 - MID-SECTION 90-852572R1 JANUARY 1998

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 Special Tools
1. Spanner Wrench P/N 91-74951

2. Lock-Ring Pliers P/N 91-822778A3

3. Heat Lamp P/N 91-63209

90-852572R1 JANUARY 1998 MID-SECTION - 5F-1

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 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 (92-809819)
95 2-4-C With Teflon (92-850736A1)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not available, use automotive
(ATF) automatic transmission fluid.
NOTE: It is recommended that all o-rings be replaced when servicing tilt system.

5F-2 - MID-SECTION 90-852572R1 JANUARY 1998

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 Manual Tilt Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 6.2 8.5
11 1 CHECK SYSTEM REPAIR KIT 75 6.2 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)

90-852572R1 JANUARY 1998 MID-SECTION - 5F-3

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 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

5F-4 - MID-SECTION 90-852572R1 JANUARY 1998

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 TILT UP
With the engine in the down position, the accumula-
tor piston (d) will be at the top of the accumulator (c)
with the gas at maximum pressure. To raise the en-
gine, the camshaft lever (f) is rotated all the way
down. The internal shaft connected to the camshaft
lever will move the push rods, opening the accumula-
tor 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 accu-
mulator, 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 up and out. Oil above the shock
piston exits the cylinder (l) through an interconnect-
ing passage 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 accumulator into the up cavity. With the engine in
the correct 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.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-5

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 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

5F-6 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 oper-
ator will have to press down on the engine cowl to
overcome 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 pas-
sage 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 accumu-
lator (c)] will cause the internal accumulator piston (d)
to compress the gas. With the engine in the correct
position, the camshaft lever is rotated up and the
push rods allow the check valves (e, h, i, & j) to close.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-7

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 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

5F-8 - MID-SECTION 90-852572R1 JANUARY 1998

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 SLOW TILT DOWN UNDER HIGH
THRUST
To tilt the engine down under high thrust conditions
[where the propeller thrust forces the shock rod
down, creating higher pressure below the memory
piston (m)], the camshaft lever (f) is rotated slightly
downward. The internal shaft connected to the lever
will open the down slow transfer valve (i) allowing oil
under pressure into the cavity around the shaft. 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.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-9

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 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

5F-10 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 trans-
fer valve (i) and down fast transfer valve (h). 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).

90-852572R1 JANUARY 1998 MID-SECTION - 5F-11

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 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

5F-12 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 (n) moves away from the memory piston (m).

90-852572R1 JANUARY 1998 MID-SECTION - 5F-13

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 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

5F-14 - MID-SECTION 90-852572R1 JANUARY 1998

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 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.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-15

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 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
Refer to disassembly/reassembly instructions (fol-
is 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 replaced.
Check ball components and castings must be
cleaned using engine cleaner and compressed
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 b
as 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 sys-

tem. 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.

5F-16 - MID-SECTION 90-852572R1 JANUARY 1998

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 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
b
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 damag-
ing engine or causing personal injury. To avoid
such injury support outboard in the up position a
using 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

90-852572R1 JANUARY 1998 MID-SECTION - 5F-17

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 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
dripping stops.
a 1 5. When fluid stops dripping, loosen and remove
accumulator.

2
51144

a - Manual Tilt System

c
a - Accumulator 51143
b - Cam Lever
c - Velocity Plug

5F-18 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

90-852572R1 JANUARY 1998 MID-SECTION - 5F-19

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 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-ring (2) 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

5F-20 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 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]. b
a
51199
7. Allow shock rod piston to cool. Remove from
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
b

a - Spanner Wrench 51145

b - Shock Rod Piston
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
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.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-21

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 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.

b
a

c
51146

a - Screw
b - Valve Block
c - Shock Rod Cylinder 51144

b. Blowing compressed air into center o-ring

2. Remove o-rings and dowel pins. hole.

WARNING
b 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
a piston. Fluid will blow out also.

a
51148

a - O-ring (2)
b - Dowel Pin (2)

55466

a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag

5F-22 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

90-852572R1 JANUARY 1998 MID-SECTION - 5F-23

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 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.

5F-24 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

90-852572R1 JANUARY 1998 MID-SECTION - 5F-25

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 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)

5F-26 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 during
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 scraper (located in cap) has
failed to keep rod clean, replace scraper.

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 VELOCITY VALVE REASSEMBLY
all o-rings during reassembly. If not available, use au- 1. Install spool, spring, lubricated o-ring and screw
tomotive (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.

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 95 b - Spring
c - O-ring
d - Screw Plug - Torque to 75 lb. in. (8.5 N⋅m)

95 2-4-C w/Teflon (92-850736A1)

a - Spacer Retainer Clip

b - Retainer Clip
c - Screw
d - Shaft Seal
e - O-ring
f - Back up Seal
g - Cam

90-852572R1 JANUARY 1998 MID-SECTION - 5F-27

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 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

51148

a - O-ring (2)
b - Dowel Pin (2)

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 - Screw (2) Torque to 100 lb. in. (11 N⋅m)
c - Shock Rod Cylinder
a
b
c
d

e 51142

a - Plunger (2)
b - Steel Ball (2)
c - Spring (2)
d - O-ring (2)
e - Screw Plug (2) Torque to 75 lb. in. (8.5 N⋅m)

5F-28 - MID-SECTION 90-852572R1 JANUARY 1998

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 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

7 Loctite “271” (92-809819)

a - Spanner Wrench
b - Shock Rod Piston - Torque to 90 lb. ft. (122 N⋅m)

90-852572R1 JANUARY 1998 MID-SECTION - 5F-29

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 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
Power 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 (P/N 91-822778A3). Set
memory piston in top of cylinder then open cam
a 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).

5F-30 - MID-SECTION 90-852572R1 JANUARY 1998

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 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.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-31

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 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)

5F-32 - MID-SECTION 90-852572R1 JANUARY 1998

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 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 ac-
cumulator 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 to 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.

90-852572R1 JANUARY 1998 MID-SECTION - 5F-33

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 7. Allow unit to stand five minutes, then proceed to 11. With cam lever remaining open (facing down),
cycle unit 2-3 more times using short strokes. No remove tilt assembly from oil and secure in soft
air bubbles should appear from accumulator port jawed vise. 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

5F-34 - MID-SECTION 90-852572R1 JANUARY 1998

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 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
95
51148 5. Using a punch, drive lower dowel pin in until
seated.
95 2-4-C w/Teflon (92-850736A1)

a - Lower Pivot Pin

b - Lower Dowel Pin

3. Reinstall manual tilt system, bottom first. Recon-

nect release valve link rod.

2
a

a
51148

a - Lower Dowel Pin

51144

a - Manual Tilt System

90-852572R1 JANUARY 1998 MID-SECTION - 5F-35

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 6. Apply 2-4-C Marine Lubricant to surface of upper 8. Drive upper dowel pin (a) into its hole until seated.
pivot pin, pivot pin hole and shock rod hole.

a
c

a
b

51147
95
51148 a - Dowel Pin

95 2-4-C w/Teflon (92-850736A1)

a - Pivot Pin
9. Check manual release cam adjustment. Cam
b - Pivot Pin Bore must open and close freely. Adjust link rod as
c - Shock Rod Bore necessary.

7. Using a mallet, drive upper pivot pin into swivel

bracket and through shock rod until pivot pin is Manual Release Valve Adjustment
flush with swivel bracket.
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

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.

5F-36 - MID-SECTION 90-852572R1 JANUARY 1998

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 LOWER UNIT

6
A

40/50 LOWER UNIT

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-2
Gear Housing (Drive Shaft)(40/50) . . . . . . . 6A-4
Gear Housing (Propeller Shaft)(40/50) . . . . 6A-6
General Service Recommendations . . . . . . 6A-8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-8
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-8
Draining and Inspecting Gear Lubricant . . . 6A-9
Propeller Removal . . . . . . . . . . . . . . . . . . . . . .6A-9
Gear Housing Removal . . . . . . . . . . . . . . . . . 6A-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-11
Water Pump . . . . . . . . . . . . . . . . . . . . . . . .
6A-11
Water Pump Seals . . . . . . . . . . . . . . . . . . . 6A-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-15
Upper Drive Shaft Bearing . . . . . . . . . . . . 6A-15
Pinion Gear Bearing . . . . . . . . . . . . . . . . . 6A-15
Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . .
6A-15
Forward Gear . . . . . . . . . . . . . . . . . . . . . . .
6A-16
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-17
Propeller Shaft Disassembly . . . . . . . . . . 6A-18
Propeller Shaft and Carrier Inspection . . . . 6A-18
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-18
Cam Follower . . . . . . . . . . . . . . . . . . . . . . .
6A-18
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . .
6A-19
Reverse Gear Bearing . . . . . . . . . . . . . . . 6A-19
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . .
6A-20
Gear Housing Reassembly . . . . . . . . . . . . . . 6A-21
Shift Shaft Assembly . . . . . . . . . . . . . . . . . 6A-22
Pinion Bearing Race . . . . . . . . . . . . . . . . . 6A-22
Forward Gear . . . . . . . . . . . . . . . . . . . . . . .
6A-23
Pinion Gear/Drive Shaft Assembly . . . . . 6A-23
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . .
6A-24
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . .
6A-25
Water Pump . . . . . . . . . . . . . . . . . . . . . . . .
6A-26
Gear Housing Pressure Test . . . . . . . . . . . . . 6A-27
Gear Housing Installation . . . . . . . . . . . . . . . . 6A-27
Filling Gear Housing with Lubricant . . . . 6A-27
Installing Gear Housing to Drive
Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . 6A-28
Trim Tab Adjustment and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29
Propeller Installation . . . . . . . . . . . . . . . . . . . . 6A-30

6A-0 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Specifications
Gear Ratio 1.83:1
Gearcase Capacity 14.9 fl. oz. (440 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 22 Spiral/Bevel
Pinion Gear
Number of Teeth 12 Spiral/Bevel
Pinion Height No Adjustment
Forward Gear Backlash No Adjustment
GEAR HOUSING Reverse Gear Backlash No Adjustment
Water Pressure
With Thermostat
@ Idle 0.5-1.5 PSI (3-10 kPa) @ 750 RPM
@ W.O.T. 5-7 PSI (34-48 kPa) @ 5000 RPM
W/O Thermostat
@ Idle 0-1 PSI (0-6 kPa) @ 750 RPM
@ W.O.T. 5-7 PSI (34-48 kPa) @ 5000 RPM
Pressure Test 10-12 PSI (68-83 kPa)
for 5 Minutes
NOTE: Before filling gear case, apply 10-12 PSI of air
pressure at the vent hole. Pressure should not drop
for 5 minutes while alternately applying a 2-3 pound
force to the top of the shift shaft in the fore and aft
direction.

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-1

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 Special Tools 5. Mandrel 91-36571

1. Bearing 31-85560
54978

6. Universal Puller Plate 91-37241

2. Driver 91-13779

3. Bearing Puller & Installation Tool 91-31229A7

a. Nut 11-24156

b. Washer (2) 12-34961 7. Driver Head 91-37312

c. Plate 91-29310

d. Shaft 91-31229
8. Driver 91-817011

51043

4. Bearing Puller Tool 91-27780

9. Driver Rod 91-37323

6A-2 - LOWER UNIT 90-852572R1 JANUARY 1998

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 10. Drive Shaft Holding Tool 91-825196 16. Driver 91-826872

11. Mandrel 91-825197 17. Leakage Tester FT8950

12. Driver 91-817007

51043

13. Mandrel 91-825198

14. Pilot 91-825199

15. Spring Hook 91-825200A1

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-3

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 Gear Housing (Drive Shaft)(40/50)

95

23
24
22
7 28
29
25 95
14
74 26 87 30
12
7
13 95 31 95

95 15
95 32
21 27
33
34
16 2 36
17
35
18

3 37

20 38

39
19

11
5
10 4
87
9
7
8 7 6
7 Loctite “271” Adhesive Sealant (92-809819)
74 Loctite “405” (Purchase Locally)
87 Super Duty Gear Lubricant (92-13783A24)
95 2-4-C w/Teflon (92-825407A12)

6A-4 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing (Drive Shaft)(40/50)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (BLACK) SHORT
– 1 GEAR HOUSING (GRAY)
– 1 GEAR HOUSING (BLACK) LONG
– 1 GEAR HOUSING (GRAY)
1 GEAR HOUSING (BASIC-BLACK)
1
1 GEAR HOUSING (BASIC-GRAY)
2 1 SEAL/PLATE KIT
3 1 PLATE
4 1 SCREW (.375-16 x .25) 55 4.8 6.2
5 1 WASHER–Sealing
6 1 DRAIN SCREW (MAGNETIC) 55 4.8 6.2
7 1 WASHER–Sealing
8 1 NUT 50 67.8
9 1 PINION GEAR (12 TEETH)
10 1 BEARING ASSEMBLY–Roller
11 1 CUP
12 4 SCREW (M6 x 16) 60 5 6.8
13 1 WATER PUMP ASSEMBLY
14 1 SEAL–Water Tube
15 1 WASHER
16 1 KEY
17 1 WASHER
18 1 GASKET
19 1 GASKET (LOWER)
20 1 FACE PLATE
21 1 IMPELLER
22 1 WATER PUMP BASE ASSEMBLY
23 1 SEAL–Oil
24 1 SEAL–Oil
25 1 O RING
26 1 BALL BEARING
1 DRIVESHAFT (SHORT)
27
1 DRIVESHAFT (LONG)
28 1 NUT (INCLUDED WITH REF #35)
29 1 CABLE TIE
30 1 BOOT–Shift Shaft
31 1 RETAINER–Shift Shaft
32 1 O RING
33 1 O RING
34 1 WASHER
1 SHIFT SHAFT (SHORT)
35
1 SHIFT SHAFT (LONG)
36 1 WASHER
37 1 ROLL PIN
38 1 CAM–Shift
39 1 PIN

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-5

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 Gear Housing (Propeller Shaft)(40/50)

43

45
42

47
44
46 41 40
68
56
55 54

1
40
53
70 52
71 95
48 51

50
69 66
64 87 49
65
67 73
60
7 72
63 61
62
59

87
58
7

95
57

87
95

94
7 Loctite “271” (92-809819)

87 Super Duty Gear Lubricant (92-850737A1)

94 Anti-Corrosion Grease (92-850735A1)

95 2-4-C w/Teflon (92-825407A12)

6A-6 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing (Propeller Shaft)(40/50)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (BLACK) SHORT
– 1 GEAR HOUSING (GRAY)
– 1 GEAR HOUSING (BLACK) LONG
– 1 GEAR HOUSING (GRAY)
1 GEAR HOUSING (BASIC-BLACK)
1
1 GEAR HOUSING (BASIC-GRAY)
40 2 DOWEL PIN
41 1 GASKET Water Tube
42 1 TUBE
43 1 PLUG–RUBBER
44 1 SCREEN–Water Inlet
45 1 TRIM TAB
46 1 SCREW (M8 x 20) 186 15.5 20.1
47 1 WASHER
48 1 FORWARD GEAR ASSEMBLY (22 TEETH)
49 1 ROLLER BEARING ASSEMBLY
50 1 CUP
51 1 ROLLER BEARING
52 1 FOLLOWER–Cam
53 1 SPRING
54 1 PIN–Cross
55 1 CLUTCH
56 1 SPRING
57 1 PROPELLER SHAFT
58 1 REVERSE GEAR (22 TEETH)
59 1 BALL BEARING
60 1 BEARING CARRIER
61 1 O RING
62 1 NEEDLE BEARING
63 1 OIL SEAL
64 1 OIL SEAL
2 WASHER
65
2 WASHER (USE WITH THREADED INSERT)
2 SCREW (M8 x 25 – Cap Screw) 198 16.5 22.4
66
2 SCREW (M8 x 30) (Use With Threaded Insert) 225 18.8 25.4
67 2 THREADED INSERT
68 1 DECAL 1.83:1 (12 x 22)
69 1 THRUST HUB
70 1 PROP NUT 55 74.6
71 1 TAB WASHER
72 4 SCREW 40 54.2
73 4 WASHER

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-7

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 General Service Roller bearing condition is determined by inspecting
the surface of the shaft that the roller bearing sup-
Recommendations ports. Check shaft surface for pitting scoring, groov-
ing, imbedded particles, uneven wear and/or discol-
There may be more than one way to “disassemble”
oration from overheating. The shaft and bearing
or “reassemble” a particular part(s), therefore, it is
must be replaced if such a condition exists.
recommended that the entire procedure be read prior
to repair.
IMPORTANT: Read the following before attempt- Seals
ing any repairs.
As a normal procedure, all O-rings and oil seals
In many cases, disassembly of a sub-assembly may should be replaced without regard to appearance. To
not be necessary until cleaning and inspection re- prevent leakage around seals, apply Loctite 271 to
veals that disassembly is required for replacement of outer diameter of all metal case seals. When using
one or more components. Loctite on seals or threads, surfaces must be clean
Service procedure order in this section is a normal and dry. Apply 2-4-C w/Teflon on all O-rings and on
disassembly-reassembly sequence. I.D. of oil seals. Apply 2-4-C w/Teflon to external sur-
faces of bearing carrier.
Threaded parts are right hand (RH), unless other-
wise indicated.
When holding, pressing or driving is required, use
soft metal vise jaw protectors or wood for protection
of parts. Use a suitable mandrel (one that will contact
only the bearing race) when pressing or driving bear-
ings.
Whenever compressed air is used to dry a part, verify
that no water is present in air line.

Bearings
All bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air.
Air should be directed at the bearing so that it passes
through the bearing. DO NOT spin bearing with com-
pressed air, as this may cause bearing to score from
lack of lubrication. After cleaning, lubricate bearings
with Quicksilver Gear Lubricant. DO NOT lubricate
tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bear-
ing race side wear. Work inner bearing race in-and-
out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condi-
tion of rollers and inner bearing race by inspecting
bearing cup for pitting, scoring, grooves, uneven
wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and
race as a set.
Inspect gear housing for bearing races that have
spun in their respective bores. If race(s) have spun,
gear housing must be replaced.

6A-8 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Draining and Inspecting Propeller Removal
Gear Lubricant WARNING
WARNING If gear housing is not removed from outboard,
before attempting to remove or install the propel-
If gear housing is installed on outboard, discon- ler, remove (and isolate) spark plug leads from
nect (and isolate) spark plug leads from spark spark plugs to prevent outboard from starting.
plugs before working near the propeller.
1. Bend tabs of tab washer away from nut.
1. With gear housing in normal running position,
place a clean pan under housing and remove
vent plug and fill/drain plug (with gaskets).

51119

a - Tab Washer
b - Nut
a - Vent Plug/Washer
b - Fill/Drain Plug/Washer
2. Use a block of wood to prevent propeller from ro-
tating. Remove nut and pull components from
2. Inspect gear lubricant for metal particles (lubri- shaft.
cant will have a “metal flake” appearance). Pres-
ence of fine metal particles (resembling powder)
on the drain plug magnet indicates normal wear.
Metal chips on the magnet indicate the need for a
gear housing disassembly and component in-
spection.
3. Note color of gear lubricant. White or cream color
indicates presence of water. Gear lubricant
drained from a gear case assembled with Special
Lubricant 101 or a gear case recently in operation
will have a yellowish color due to lubricant agita-
tion/aeration. This is normal and should not be
confused with the presence of water.
4. Presence of water indicates the need for disas-
sembly and inspection of oil seals, o-rings, gas-
kets and components for damage. 50552
a - Block of Wood

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-9

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 Gear Housing Removal 4. Make a scribe line showing alignment of trim tab
to gear case and remove trim tab bolt and wash-
er.
WARNING
To prevent accidental engine starting, remove b
(and isolate) spark plug leads from spark plugs
before removing gear housing.
1. Remove (and isolate) spark plug leads from
spark plugs.
2. Shift into NEUTRAL. a
3. Loosen jam nut. Unscrew attaching nut to sepa-
rate shift shaft.

30/40, 40/50, FORCE 40/50

52835
a - Bolt and Washer
b b - Scribe Line
a
5. Remove nut and washer in trim tab cavity.

52832

a - Jam Nut
b - Attaching Nut
a
25 (4 STROKE), 45/50 (4 STROKE)

52835
a - Nut and Washer
b

a - Retainer
b - Lower Clip

6A-10 - LOWER UNIT 90-852572R1 JANUARY 1998

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 6. Remove 4 bolts securing gear case to drive shaft 2. Remove cover, washer (above impeller), impel-
housing. ler, key and washer (below impeller).
3. Remove cover gasket, base plate and base gas-
ket.

52836 c
a - Bolt (4)

d
Disassembly e
Water Pump
NOTE: If water tube seal remained in drive shaft f
housing, remove seal from housing and reinstall on
water pump cover. Secure seal to cover with Loctite
405.
1. Remove 4 bolts securing pump cover.
g

a
b
h

52692
a - Cover
b - Washer (above impeller)
c - Impeller
d - Key
e - Washer (below impeller)
f - Cover Gasket
g - Face Plate
52830 h - Base Gasket
a - Seal NOTE: Replace impeller if:
b - Bolt (4) – Impeller blades are cracked, torn or worn.
– Impeller is glazed or melted
NOTE: Replace cover if thickness of steel at dis- – Rubber portion of impeller is not bonded to
charge slots is 0.060 in. (1.524mm) or less, or if impeller hub.
groove(s)(other than impeller sealing groove) in cov-
er roof are more than 0.030 in. (0.762mm) deep.

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-11

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 4. Remove and/or replace exhaust deflector plate if NOTE: When removing propeller shaft assembly,
damaged. cam follower may dislodge. Retrieve follower from
gear housing.
7. Remove propeller shaft assembly.
a

52832
a - Deflector Plate a
52864
5. Remove bearing carrier attaching bolts and lock-
a - Propeller Shaft
ing tab washers or flat washers. Discard tab
washers.

Model Drive Shaft Holding Tool

b
25, 45/50 (4-Stroke) 91-83180M
Force 40/50 91-825196
30/40, 40/50 91-825196

8. Remove pinion nut and discard.

51043

a - Bolts and Tab Washers or Flat Washers a

b - Tab Washers Style 2
b
6. Using Puller (91-27780), remove carrier assem-
bly from gear case.

a 52864

a - Drive Shaft Holding Tool

b - Pinion Gear

9. Remove drive shaft assembly and pinion gear.

52829
a - Puller (91-27780)

6A-12 - LOWER UNIT 90-852572R1 JANUARY 1998

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 10. Remove forward gear. 12. Insert pinion bearing race puller (91-825200A1)
through gear case and position inside of pinion
bearing race. Insert driver (91-13779) into puller
through drive shaft cavity and drive out race.

b
a

52870
a - Forward Gear

52844
11. Remove shift shaft assembly a - Puller (91-825200A1)
b - Driver (91-13779)

13. Remove forward bearing race with puller

(91-27780).

b a

52841
a - Shift Shaft Assembly

53838
a - Race
b - Puller (91-27780)

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-13

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 Water Pump Seals 3. With lip of ribbed neoprene O.D. seal facing to-
wards small shoulder of Mandrel (91-825197),
NOTE: All gaskets, seals and o-rings should be re- press seal into carrier until mandrel bottoms on
placed as a normal repair procedure during gear carrier.
case disassembly.
NOTE: DO NOT use a screwdriver to remove seals
from carrier, as carrier may be damaged.
1. Using a suitable mandrel, press both seals from
carrier.

a b a
7

d
52692 52853
a - Neoprene Ribbed Seal a - Seal (Ribbed Neoprene) Lip Facing Up
b - Metal Cased Seal b - Mandrel (91-825197)
c - Carrier
d - O-ring
NOTE: Apply a light coat of 2-4-C w/Teflon
7 Loctite “271” (92-809819) (92-850736A1) to the lips of both seals after installa-
tion in carrier.

2. Apply Loctite 271 to the O.D. of the metal cased

seal. With seal lip facing away from the large 4. Apply a light coat of 2-4-C w/Teflon to the new o-
shoulder of mandrel (91-825197), press seal into ring and install on carrier.
carrier until mandrel bottoms on carrier.

95

52825
a
95 2-4-C w/Teflon (92-850736A1)
b a - O-ring

52850
a - Seal (Metal Cased) Lip Facing Down
b - Mandrel (91-825197)

6A-14 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Inspection Pinion Gear Bearing
1. Inspect bearing for rust, roughness or discolor-
ation from lack of lubricant.
Upper Drive Shaft Bearing
2. If bearing is damaged, bearing and race must be
1. Inspect bearing for rust, roughness or discolor- replaced as an assembly.
ation from lack of lubricant.
3. If race appears to have spun in drive shaft bore,
2. DO NOT remove bearing from drive shaft unless gear case housing must be replaced.
bearing must be replaced, as removal process
will damage bearing.
a
3. If bearing must be replaced, position drive shaft
assembly in vise (jaws of vise supporting only
bearing) and while holding drive shaft, strike top
of drive shaft with lead hammer and drive bearing b
off.
52823
a - Bearing
b - Race

Pinion Gear
a 1. Inspect pinion gear teeth for rust, chipping, ex-
cessive wear (teeth are sharp edged) or broken.
2. If pinion gear teeth are damaged, also inspect
forward and reverse gear teeth for damage.
3. Replace gears as required.

a - Bearing

4. To install new bearing, thread old pinion nut 3/4

way onto drive shaft. Position Universal Puller
Plate (91-37241) under bearing and press on pin-
ion nut while holding drive shaft until bearing
seats against shoulder. 52839

b
c

52387
a - Old Pinion Nut (Nut Should be Above Drive Shaft)
b - Bearing
c - Universal Puller Plate (91-37241)

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-15

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 Forward Gear 4. Use a suitable mandrel to press needle bearing
out of forward gear.
1. Inspect forward gear teeth for rust, chipping, ex-
cessive wear (teeth are sharped edged), or bro-
ken teeth.
2. Inspect forward gear clutch jaws for wear.
Rounded jaws indicate the following:
a b
a. Improper shift cable adjustment.
b. Engine idle speed too high.
c. Shifting too slowly.

52873
a - Mandrel (14 mm Socket)
b - Bearing

5. Use Driver 91-826872 to press new needle bear-

ing into forward gear. Press on numbered side of
bearing.

52874

a
3. Inspect propeller shaft forward gear bearing sur-
face to determine condition of forward gear 87 b
needle bearing. If bearing surface is discolored
(from lack of lubricant), pitted or worn, propeller
shaft and bearing should be replaced.

52847

87 Super Duty Gear Lubricant (92-850737A1)

52874
a a - Driver (91-826872)
b b - Bearing

52846

a - Bearing Surface
b - Bearing

6A-16 - LOWER UNIT 90-852572R1 JANUARY 1998

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 6. Inspect forward gear tapered bearing and race Shift Shaft
for rust, roughness or excessive wear (loose-
ness). 1. Inspect shift cam for wear or galling. Replace
cam if necessary.
7. If bearing is in serviceable condition, DO NOT re-
move bearing from gear, as removal process will 2. If cam is worn, inspect cam follower in end of pro-
damage bearing. peller shaft for wear.
8. If bearing must be replaced, remove bearing from
gear using Universal Puller Plate (91-37241) and
suitable mandrel.
9. Replace bearing and race as a set. Use suitable
b
mandrel to press bearing onto gear. PRESS
ONLY ON INNER RACE when installing bearing.

b
a
52845
a a - Cam Follower
b - Shift Cam

3. Inspect shift shaft boot for deterioration.

4. Inspect shift shaft carrier o-ring for cuts or abra-
sions. It is a good service procedure to replace all
o-rings, seals and gaskets regardless of appear-
ance.

51119

REMOVAL a
a - Universal Puller Plate (91-37241)
b - Mandrel (15/16 in. socket)

52828
a - Boot
b - O-ring

INSTALLATION
a - Mandrel (1-1/8 in. socket)

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-17

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 Propeller Shaft Disassembly Propeller Shaft and Carrier
1. Remove propeller shaft from carrier and disas- Inspection
semble shaft.

a d Clutch
b
c 1. Inspect clutch jaws for chips or rounding off.
2. If wear is present, inspect corresponding forward
f or reverse gear matching jaws for similar wear.
e Replace appropriate components as required.

a - Prop Shaft
b - Retaining Spring
c - Clutch Dog
d - Cross Pin
e - Cam Follower Spring
f - Cam Follower

2. Remove reverse gear and bearing from carrier

with Puller (91-27780).

52824

a
Cam Follower
1. Inspect cam follower for wear or galling.
2. If wear is present, inspect corresponding shift
cam for wear. Replace if worn.

52840
a - Reverse Gear and Bearing 52822
b - Puller (91-27780)

6A-18 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Reverse Gear 4. Install new bearing using a suitable mandrel.
PRESS ONLY ON INNER RACE when installing
1. Inspect reverse gear teeth for rust, chipping ex- bearing.
cessive wear (teeth are sharped edged) or bro-
ken teeth.
2. Inspect reverse gear clutch jaws for wear.
Rounded jaws indicate the following:
a. Improper shift cable adjustment.
b. Engine idle speed too high.
d
c. Shifting too slowly.

51289

b c
REMOVAL 51269
a - Bearing
b - Reverse Gear
c - Universal Puller Plate (91-37241)
d - Driver (91-37312)

52875

Reverse Gear Bearing a

1. Inspect bearing for rust, roughness or excessive
wear (looseness).
2. If bearing is in serviceable condition, DO NOT re- b
87
move bearing from gear as removal will damage
bearing.
3. If bearing must be replaced, remove bearing from
gear using Universal Puller Plate (91-37241) and
Driver (91-37312).

INSTALLATION 52867
a - Mandrel (1-1/4 in. socket)
b - Bearing

87 Super Duty Gear Lubricant (92-850737A1)

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-19

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 Bearing Carrier 4. Apply a light coat of Special Lubricant 101 to O.D.
of bearing.
NEEDLE BEARING 5. Install bearing using Mandrel 91-817011.
1. The condition of the carrier needle bearing can 6. Press bearing into carrier until mandrel bottoms
be determined by inspecting its running surface on carrier.
on the propeller shaft.
2. If the shaft is discolored (from lack of oil) or pitted,
replace bearing and shaft. b
3. Bearing can be removed by using Driver Rod
(91-37323) and Driver (91-37312). Removing
bearing will also remove both propeller shaft
seals.
108 a

52861
b 108 Special Lubricant 101 (92-13872A1)
a - Bearing
b - Mandrel (91-817011)
c
7. Apply Loctite 271 to O.D. of small diameter seal.
8. With seal lip facing away from large shoulder of
Mandrel 91-817007, press seal into carrier until
mandrel bottoms on carrier.
d

b
51264
a - Driver Rod (91-37323)
b - Driver (91-37312)
c - Needle Bearing
d - Seals

52862
7 Loctite “271” (92-809819)
a - Seal
b - Mandrel (91-817007)

6A-20 - LOWER UNIT 90-852572R1 JANUARY 1998

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 9. Apply Loctite 271 to O.D. of large diameter seal. 11. Bearing carrier o-ring should be inspected for
cuts and abrasions.
10. With seal lip FACING TOWARDS SMALL
SHOULDER of Mandrel 91-817007, press seal NOTE: It is a good repair procedure to replace all o-
into carrier until mandrel bottoms on carrier. rings and seals regardless of appearance.
12. Apply 2-4-C w/Teflon to o-ring and install on carri-
er.
b 13. Using suitable mandrel, press reverse gear as-
sembly into carrier.

b
c
a 95 a
7

52863
7 Loctite “271” (92-809819)
a - Seal 52827
b - Mandrel (91-817007)
95 2-4-C w/Teflon (92-850736A1)
Installation Note: If service tools are not available, a - O-ring
the following reference dimensions apply for install- b - Mandrel (3/4 in. Socket)
ing bearing and seals to proper depths. c - Reverse Gear Assembly

.82 in. (20mm)

Gear Housing Reassembly

IMPORTANT: The 30/40 gear case assembly does
not have have any shims for the gear assemblies.
Backlash cannot be adjusted. The mechanic
must verify that all bearing races are firmly
seated in the gear case during reassembly and
that all gear case components are in serviceable
a 51275
condition. Prior to installing the seal carrier and
a - Bearing water pump assembly on the drive shaft, the
.44 in. (11mm) FORWARD gear should be held stationary (with
.04 in. (1mm) a screw driver or similar tool). While pulling up on
the drive shaft, lightly turn the shaft back and
forth. A light “clicking” sound should be heard
indicating the presence of backlash between
FORWARD and PINION gears. If this backlash is
not present, the pinion gear race and/or forward
b gear race are not fully seated. Races should be
a removed and inspected for debris. Reinstall
races and check backlash. If backlash is still not
51275
present, replace gear housing.

a - Oil Seal (Install with Lip Down)

b - Oil Seal (Install with Lip Up)

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-21

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 Shift Shaft Assembly Pinion Bearing Race
1. Apply 2-4-C w/Teflon to new o-rings and install o- 1. Apply Super Duty Gear Lubricant to O.D. of race.
rings on shift shaft and carrier.
2. Position race in gear housing (NUMBERS UP -
2. Install carrier on shift shaft. TAPERED SIDE FACING DOWN).
IMPORTANT: When installing shift shaft assem- 3. Draw race up into housing until seated.
bly into gear housing, DO NOT BOTTOM OUT a f
SHAFT IN HOUSING. Pull up on shift shaft until
shift boot is not deformed. If shaft is bottomed d b
out, cross pin in clutch dog will be bent by cam c
follower when tightening carrier bolts.
3. Install shift shaft/carrier assembly into gear hous-
ing.
4. Secure boot to carrier with sta-strap.
5. Position shift shaft so ramp faces towards propel- e
ler shaft.

d c

a g
95
b

87

52842
e
87 Super Duty Gear Lubricant (92-850737A1)
a - Threaded Rod (91-31229)
52841 b - Washer (2) (12-34961)
95 c - Bearing (31-85560)
2-4-C w/Teflon (92-850736A1)
d - Plate (91-29310)
a - O-rings e - Pilot (91-825199)
b - Carrier f - Nut (11-24156)
c - Boot g - Mandrel (91-825198)
d - Sta-strap
e - Ramp

6A-22 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Forward Gear Pinion Gear/Drive Shaft Assembly
1. Apply Super Duty Gear Lubricant to O.D. of race. 1. Clean pinion nut and pinion nut threads of drive
Install forward gear bearing race into housing us- shaft with Loctite Primer T.
ing Mandrel 91-36571 and propeller shaft. Use a
2. Position pinion bearing into race while installing
lead hammer on prop shaft to prevent damage to
drive shaft and pinion gear into housing.
threads. Bearing carrier should be installed to
keep prop shaft centered while seating race. 3. Apply Loctite 271 to pinion nut threads.
4. Install new pinion nut, with rounded corners FAC-
ING pinion gear, onto drive shaft.

b
Model Drive Shaft Holding Tool
25, 45/50 (4-Stroke) 91-83180M
Force 40/50 91-825196
30/40, 40/50 91-825196
87

a 52843 5. Using Drive Shaft Holding Tool to hold drive shaft,

torque pinion nut to 50 lb. ft. (67.8 N·m).
87 Super Duty Gear Lubricant (92-850737A1)
a - Race
b - Mandrel (91-36571)
NOTE: Remove drain plug/magnet assembly from
gear case (if installed) to prevent possible breakage
of magnet if struck by forward gear. 51043

c
1. Install forward gear and bearing assembly into
forward gear race. d

b
7
a

52864
7 Loctite “271” (92-809819)
a a - Pinion Nut [Torque to 50 lb. ft. (67.8 N·m)]
b - Pinion Gear
c - Pinion Bearing
d - Drive Shaft Holding Tool

52870
a - Forward Gear Assembly

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-23

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 Propeller Shaft 6. Install cam follower.

1. Slide clutch (short shoulder faces forward gear)

over propeller shaft aligning cross pin hole with
slot in propeller shaft.
2. Insert cam follower spring into propeller shaft.
3. Using a 3/16 in. allen wrench or similar device,
compress the follower spring enough to insert the
cross pin partially through clutch.
a
4. Remove wrench and press cross pin through
clutch and propeller shaft until flush.
c a

95
52826
95 2-4-C w/Teflon (92-850736A1)
a - Cam Follower
b
52851
a - Short Shoulder
7. Install propeller shaft assembly into gear case.
b - Allen Wrench
c - Cross Pin

5. Reinstall retaining spring. position spring so as

spring coils lay flat in clutch groove.
a

52854 52864
a - Spring a - Propeller Shaft Assembly

NOTE: Applying 2-4-C w/Teflon to cam follower will

aid in retention of follower in propeller shaft during
installation of propeller shaft assembly into gear
case.

6A-24 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Bearing Carrier 4. Torque bolts to 225 lb. in./18.8 lb ft. (25.4 N⋅m)

1. Install carrier into gear case.

2. Discard the original tab washers or the thin 0.063 7
in. (1.60 mm) flat washers and the 25 mm long
bolts on models listed. Install thicker flat washers a
and longer bolts.
25 (2 Cylinder - 4 Stroke)
USA 0G621670 and below
45/50 (4 Cylinder - 4 Stroke) Non Big Foot
USA 0G621709 and below
30/40 (2 Cylinder - 2 Stroke)
USA 0G650736 and below
Belgium . . . . . NA
40/50 (3 Cylinder - 2 Stroke)
USA 0G650699 and below
Belgium . . . . . NA a
Force 40/50 (2 Cylinder - 2 Stroke) 51117
7
USA 0E323508 and below
a 7 Loctite “271” (92-809819)
b c
a - Torque Bolts to 225 lb. in./18.8 lb. ft. (25.4 N⋅m)

a - Bolt 25 mm Long - Discard

b - Tab Washer - Discard
c - Thin Flat Washer 0.063 in. (1.60 mm) thick - Discard

3. Install thicker flat washers and longer bolts.

a b

a - Bolt (10-855940-30) 1.18 in. (30 mm) Long

b - Washer (12-855941) 0.090 in. (2.29 mm) Thick

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-25

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 Water Pump 4. Install impeller and nylon washer.

1. Install water pump seal carrier.

b
2. Install exhaust deflector plate, if removed. a

b a

52832
a - Seal Carrier
b - Exhaust Deflector
52869
3. Install base gasket, face plate, pump cover gas- a - Impeller
ket (NEOPRENE STRIP FACES UP), nylon b - Nylon Washer
washer and impeller key.

d NOTE: Apply a light coat of 2-4-C w/Teflon to inside

of pump cover to ease installation of cover over im-
c peller.
5. Install pump cover. Rotate drive shaft CLOCK-
f WISE while pressing cover down over impeller.
e 6. Apply Loctite 271 to retaining bolts and torque
bolts to 60 lb. in. (6.8 N·m).
b

b
7

a
52868
a - Base Gasket
b - Base Plate a
c - Cover Gasket
d - Neoprene Strip
e - Nylon Washer 7 Loctite “271” (92-809819)
f - Key
52830
IMPORTANT: If impeller being installed has been a - Cover
previously used and vanes have taken a “set,” b - Bolts [Torque to 60 lb. in. (6.8 N·m)]
DO NOT INSTALL THE IMPELLER WITH THE
VANES REVERSED FROM THEIR PREVIOUS
“SET” AS VANE BREAKAGE WILL OCCUR
SHORTLY AFTER UNIT IS RETURNED TO SER-
VICE.

6A-26 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing Pressure Test Gear Housing Installation
1. Remove vent plug and install pressure test
gauge. Tighten securely. Filling Gear Housing with Lubricant
NOTE: Gear housing lubricant capacity is approxi-
mately 14.9 fl. oz. (440 ml).

WARNING
If gear housing is installed on outboard, discon-
nect (and isolate) spark plug leads from spark
plugs before working near the propeller.

CAUTION
Do not use automotive grease in the gear hous-
ing. Use only Quicksilver Gear Lube.
1. Remove any gasket material from “Fill” and
“Vent” plugs and gear housing. Install new gas-
kets on “Fill” and “Vent” plugs.
IMPORTANT: Never add lubricant without remov-
ing “Vent” plug. Gear housing cannot be filled
because of trapped air. Fill gear housing when
driveshaft is in a vertical position.
2. Pressurize housing to 10-12 PSI (69-83 kPa) and 2. Remove “Fill” plug and gasket.
observe gauge for 5 minutes.
3. Insert lubricant tube in “Fill” hole, then remove
3. Rotate drive shaft, prop shaft and move shift rod “Vent” plug and gasket.
while housing is pressurized to check for leaks.
4. Fill until excess lubricant flows out of “Vent” hole.
5. Replace this “Vent” plug and gasket.
6. Install “Fill” plug and gasket.

4. If pressure drop is noted immerse housing in wa- a

ter.
5. Re-pressurize to 10-12 PSI (69-83 kPa) and
check for air bubbles.
6. Replace leaking seals as necessary. Retest
housing.
a - “Vent” Plug
NOTE: It should hold 10-12 PSI (69-83 kPa) for 5
minutes.
7. Torque “Fill” and “Vent” screws to 55 lb. in. (6.2
7. Remove tester from housing and install vent
N·m).
plug.

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-27

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 Installing Gear Housing to Drive 6. Reconnect shift shaft with coupler nut and jam
nut. Tighten jam nut against coupler nut.
Shaft Housing
NOTE: After reconnecting shift shaft, bottom of jam
WARNING nut should be approximately flush with top of spray
plate.
Disconnect (and isolate) spark plug leads before
installing gear housing onto drive shaft housing. 30/40, 40/50, FORCE 40/50
1. Position shift lever in NEUTRAL gear position.
2. Tilt engine to full “Up” position. Engage tilt lock le-
ver.
3. Shift gear housing into NEUTRAL. Propeller
shaft will rotate freely in either direction.
IMPORTANT: Liberally apply 2-4-C Marine Lubri-
cant w/Teflon to drive shaft splines.
4. Position drive shaft into drive shaft housing.
Move gear housing upwards in drive shaft hous- c a
ing while aligning both shift shafts, water tube
seal and drive shaft splines.
NOTE: If the drive shaft splines will not align with the
crankshaft splines, rotate flywheel slightly while
pushing gear housing into drive shaft housing. b

5. Install 4 bolts and washers, (two each side).

Torque bolts to 40 lb. ft. (54.2 N·m). 52834

a - Coupler Nut
b - Jam Nut
c - Spray Plate

7. Connect shift shaft by sliding retainer to the right

a and snapping into upper “locked” position.

25 (4 STROKE), 45/50 (4 STROKE)

52836
a - Bolt and Washers (2 each side) [Torque Bolt to 40 lb. ft.
(54.2 N·m)]

53859

a - Retainer
b - Lower Clip

6A-28 - LOWER UNIT 90-852572R1 JANUARY 1998

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 8. Install locknut and washer. Torque nut to 40 lb. ft. Trim Tab Adjustment and
(54.2 N·m).
Replacement
IMPORTANT: The trim tab is made of a special
alloy to aid in protecting the drive shaft housing
and gear housing from galvanic corrosion (cor-
rosion and pitting of metal surfaces). Do not
paint or place protective coating on the trim tab,
a or trim tab corrosion protection function will be
lost.
Replace trim tab if 50% (or more) corroded. Mark lo-
cation of old trim tab on anti-ventilation plate before
removal; install new trim tab in same location.
1. Check trim tab position as follows:
a. Operate boat at the speed at which it would
normally be operated.
b. If the boat pulls to the right (starboard), the
trailing edge of trim tab must be moved to the
right. If the boat pulls to the left (port), the trail-
52833 ing edge of trim tab must be moved to the left.
a - Locknut and Washer [Torque Nut to 40 lb. ft. (54.2 N·m)]
2. If necessary, adjust trim tab as follows:
a. Shift engine control into NEUTRAL and turn
ignition key to “OFF” position.
9. Check shift operation.
NOTE: Loosen trim tab bolt sufficiently to allow trim
a. In NEUTRAL, propeller shaft should turn
tab to disengage from locking ridges in gear case be-
freely in either direction.
fore attempting to move tab. DO NOT strike trim tab
b. In FORWARD, propeller shaft SHOULD NOT with a hard object to make adjustments.
TURN COUNTERCLOCKWISE.
b. If boat pulls to the left, adjust trailing edge of
c. In REVERSE, propeller shaft SHOULD NOT trim tab to the left. If boat pulls to the right, ad-
TURN IN EITHER DIRECTION. just trailing edge of trim tab to the right.
IMPORTANT: If shift operation is not as de- a
scribed, remove the gear housing and correct the
shift operation.

b
c

52835
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Bolt and Washer; Torque Bolt to 15.8 lb. ft. (21.4
N·m)

90-852572R1 JANUARY 1998 LOWER UNIT - 6A-29

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 Propeller Installation CAUTION
WARNING Do not misinterpret propeller shaft movement for
propeller movement. Propeller and propeller
Disconnect and isolate spark plug leads when shaft may move fore-and-aft. However, the pro-
working near the propeller to prevent the out- peller itself should not move fore-and-aft on the
board from starting. propeller shaft.
1. Apply one of the following Quicksilver products 4. Re-check propeller nut for tightness after first
on propeller shaft splines. use. Check for tightness periodically, especially
a. Anti-Corrosion Grease if a stainless propeller is used.

b. 2-4-C Marine Lubricant w/Teflon

2. Install components.
a. Flo-Torque I Drive Hub Propellers – Install
forward thrust hub, propeller, propeller nut re-
tainer and propeller nut onto the shaft.
c
d

a 94
b
94 Anti-Corrosion Grease (92-850735A1)

a - Forward Thrust Hub

b - Propeller
c - Propeller Nut Retainer
d - Propeller Nut - Torque to 55 lb. ft. (74.6 N⋅m)
b. Flo-Torque II Drive Hub Propellers – Install
forward thrust hub, propeller, replaceable
drive sleeve, rear thrust hub retainer and pro-
peller nut onto the shaft.

f e d

c b a 94

94 Anti-Corrosion Grease (92-850735A1)

a - Forward Thrust Hub

b - Propeller
c - Drive Sleeve
d - Rear Thrust Hub
e - Retainer
f - Propeller Nut - Torque to 55 lb. ft. (74.6 N⋅m)

3. Re-check propeller nut for tightness after first

use. Check for tightness periodically, especially
if a stainless propeller is used.

6A-30 - LOWER UNIT 90-852572R1 JANUARY 1998

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 LOWER UNIT

6
B

55/60 LOWER UNIT

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 Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2
Gear Housing (Drive Shaft) (55/60) . . . . . . . 6B-6
Gear Housing (Propeller Shaft)(55/60) . . . . 6B-8
General Service Recommendations . . . . . . 6B-10
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Draining and Inspecting Gear Lubricant . . . 6B-11
Propeller Removal . . . . . . . . . . . . . . . . . . . 6B-11
Gear Housing Removal . . . . . . . . . . . . . . . 6B-12
Gear Housing Disassembly . . . . . . . . . . . 6B-12
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . 6B-12
Bearing Carrier and Propeller Shaft . . . . 6B-14
Propeller Shaft Disassembly . . . . . . . . . . . . . 6B-15
Pinion Gear, Driveshaft and Forward Gear . 6B-16
Upper Driveshaft Bearing . . . . . . . . . . . . . . . . 6B-17
Lower Driveshaft Bearing . . . . . . . . . . . . . 6B-17
Forward Gear Bearing Race . . . . . . . . . . 6B-17
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-18
Gear Housing Reassembly . . . . . . . . . . . . . . 6B-19
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . 6B-20
Forward Gear Bearing Race . . . . . . . . . . 6B-20
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . 6B-21
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . 6B-22
Lower Driveshaft Bearing Installation . . . 6B-23
Upper Driveshaft Bearing Installation . . . 6B-24
Forward Gear, Pinion Gear, Upper
Driveshaft Bearing Race, Retainer
and Driveshaft Installation . . . . . . . . . . . . 6B-24
Pinion Gear Location and Forward
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . 6B-25
Determining Forward Gear Backlash . . . 6B-26
Bearing Carrier and Propeller Shaft
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-27
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . 6B-28
Water Pump Re-assembly and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-29
Gear Housing Pressure Test . . . . . . . . . . . . . 6B-31
Gear Housing Installation . . . . . . . . . . . . . . . . 6B-32
Filling Gear Housing with Lubricant . . . . 6B-32
Gear Housing Installation . . . . . . . . . . . . . 6B-33
Propeller Installation . . . . . . . . . . . . . . . . . 6B-34
Trim Tab Adjustment and Replacement . 6B-34

6B-0 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Specifications
Gear Ratio 1.64:1
Gearcase Capacity 11.5 fl. oz. (340mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 23
Pinion Gear
Number of Teeth 14
Pinion Height 0.025 in. (0.64 mm)
Pinion Gear Locating Tool
GEAR HOUSING
(91-817008A2)
Forward Gear Backlash 0.013–0.019 in. (0.33–0.48 mm)
Backlash Indicator Tool (91-19660--1)
Mark #3
Water Pressure
@ Idle 1–3 PSI (7-21 kPa)
@ W.O.T. 7–12 PSI (48-83 kPa)
Pressure Test 10-12 PSI (69-83 kPa)
for 5 Minutes

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-1

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 Special Tools 2. Backlash Indicator Tool 91-19660--1.

1. Bearing Preload Tool 91-14311A-2.

b
a 19660-1
51043
c c

3. Puller 91-27780.
d

e
l

g
4. Universal Puller Plate 91-37241.
h

j
k
51270

Ref. Description Qty.

a Bushing - 3/4 in. (19 mm) I.D. 1
5. Driver Head 91-37312.
b Bushing - 7/8 in. (22 mm) 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 6. Driver Rod 91-37323.
j Plate 1
k Nut 1
l Stud 1
74184
NOTE: Bearing Preload Tool 91-14311A-1 may be
updated to a 91-14311A-2 tool, by ordering Update
Kit 91-817057A-1.

6B-2 - LOWER UNIT 90-852572R1 JANUARY 1998

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 7. Bearing Retaining Tool 91-43506. 11. Forward Gear Bearing Installer 91-817005.

51043

12. Water Pump Base Seal Installer 91-817006.

73600

51043
8. Puller Jaws 91-46068A1 and Puller Bolt
91-85716.

13. Bearing Carrier Seal Installer 91-817007.

73599

9. Dial Indicator 91-58222A1.

51043

14. Pinion Gear Location Tool 91-817008A2.

73429

10. Dial Indicator Adaptor Kit 91-83155.

51043

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-3

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 15. Forward Gear Bearing Race Driver Cup 18. Lower Driveshaft Bearing Driver Assembly
91-817009. 91-817058A1.

51043

16. Needle Bearing Installer 91-817011.

51043

51043
17. Backlash Indicator Tool 91-817057A1.

19. Driveshaft Holding Tool 91-817070.

d
c
51043

a
b 51043

51270

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)

6B-4 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-5

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 Gear Housing (Drive Shaft) (55/60)
7

32
74 34

29 22

28 21 95

27 20
19
31
34
95
33
7 Loctite “271” Adhesive Sealant (92-809819)
74 Loctite “405” (Purchase Locally)
30 87 Super Duty Gear Lubricant (92-13783A24)
7
95 2-4-C w/Teflon (92-825407A12)
23
95 18
24

26 87

25

95 10
95
6
7
8 87
17
7 9
15
5 16

1 14 95
4
3
35
13
11
12

3 4

7
4
2

6B-6 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing (Drive Shaft)(55/60)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (BLACK) SHORT
– 1 GEAR HOUSING (GRAY)
– 1 GEAR HOUSING (BLACK) LONG
– 1 GEAR HOUSING (GRAY)
– 1 GEAR HOUSING (BLACK) X-LONG
– 1 GEAR HOUSING (GRAY)
1 GEAR HOUSING (BLACK)
1
1 GEAR HOUSING (GRAY)
2 1 DRAIN SCREW 58 4.8 6.5
3 2 SCREW 58 4.8 6.5
4 3 WASHER-sealing
5 1 DOWEL PIN
6 1 DOWEL PIN
7 1 PIPE PLUG
8 1 ROLLER BEARING
9 1 SEAL KIT
10 1 FILLER PLATE
11 1 PINION GEAR (14 TEETH)
12 1 NUT 50 67.8
1 SHIFT SHAFT ASSEMBLY (SHORT/LONG)
13
1 SHIFT SHAFT (X-LONG)
14 1 RETAINING RING
15 1 BUSHING ASSEMBLY
16 1 O-RING
17 1 OIL SEAL
1 DRIVE SHAFT (SHORT)
1 DRIVE SHAFT (LONG) 60 ELECTRIC
18
1 DRIVE SHAFT (X-LONG)
1 DRIVE SHAFT (55 MANUAL)
19 AR SHIM SET
20 1 TAPERED ROLLER BEARING
21 1 CUP
22 1 NUT 75 101.7
23 1 WATER PUMP BASE
24 1 O-RING
25 1 OIL SEAL
26 1 OIL SEAL
27 1 IMPELLER
28 1 KEY
29 1 WATER PUMP
1 GASKET (LOWER)
30 GASKET
1
(EXPORT - HIGH SULFUR LEADED FUELS/ WARM WATER)
31 1 GASKET (UPPER)
32 1 SEAL (SHORT/LONG)
33 1 FACE PLATE
34 6 SCREW 60 5 6.8
35 1 SHIFT CAM

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-7

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 Gear Housing (Propeller Shaft)(55/60)

58

60
59

1
95

63 45
44
64 46
42
41
61
7 39
40
55 37
56 38
57 36

62
54
53
95 52
50

95 51
49
48

94 47

95 43

7 Loctite “271” Adhesive Sealant (92-809819)

94 Anti-Corrosion Grease (92-78376A6)

95 2-4-C w/Teflon (92-825407A12)

6B-8 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing (Propeller Shaft)(55/60)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (BLACK) SHORT
– 1 GEAR HOUSING (GRAY)
– 1 GEAR HOUSING (BLACK) LONG
– 1 GEAR HOUSING (GRAY)
– 1 GEAR HOUSING (BLACK) X-LONG
– 1 GEAR HOUSING (GRAY)
1 GEAR HOUSING (BLACK)
1
1 GEAR HOUSING (GRAY)
36 AR SHIM SET
37 1 TAPERED ROLLER BEARING
38 1 CUP
39 1 FORWARD GEAR (23 TEETH)
40 1 ROLLER BEARING
41 1 CAM FOLLOWER
42 1 SLIDE
43 1 SPRING
44 1 CLUTCH
45 1 CROSS PIN
46 1 SPRING
47 1 PROPELLER SHAFT
48 1 REVERSE GEAR (23 TEETH)
49 1 BALL BEARING
50 1 BEARING CARRIER ASSEMBLY
51 1 O-RING
52 1 ROLLER BEARING
53 1 OIL SEAL
54 1 OIL SEAL
2 SCREW (M8 x 25) 198 16.5 22.4
55 SCREW (M8 x 25)
2 225 18.8 25.4
(Use W/Threaded Insert)
2 WASHER
56
2 WASHER (Use W/Threaded Insert)
57 2 THREADED INSERT
58 1 TRIM TAB
59 1 SCREW 186 15.5 20.1
60 1 WASHER
61 1 PROPELLER KIT (55 BEACHING)
62 1 THRUST HUB
63 1 PROPELLER NUT 55 74.6
64 1 TAB WASHER

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-9

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 General Service Roller bearing condition is determined by inspecting
the surface of the shaft that the roller bearing sup-
Recommendations ports. Check shaft surface for pitting scoring, groov-
ing, imbedded particles, uneven wear and/or discol-
There may be more than one way to “disassemble”
oration from overheating. The shaft and bearing
or “reassemble” a particular part(s), therefore, it is
must be replaced if such a condition exists.
recommended that the entire procedure be read prior
to repair.
IMPORTANT: Read the following before attempt- Seals
ing any repairs.
As a normal procedure, all O-rings and oil seals
In many cases, disassembly of a sub-assembly may should be replaced without regard to appearance. To
not be necessary until cleaning and inspection re- prevent leakage around seals, apply Loctite 271 to
veals that disassembly is required for replacement of outer diameter of all metal case seals. When using
one or more components. Loctite on seals or threads, surfaces must be clean
Service procedure order in this section is a normal and dry. Apply 2-4-C w/Teflon on all O-rings and on
disassembly-reassembly sequence. I.D. of oil seals. Apply 2-4-C w/Teflon to external sur-
faces of bearing carrier.
Threaded parts are right hand (RH), unless other-
wise indicated.
When holding, pressing or driving is required, use
soft metal vise jaw protectors or wood for protection
of parts. Use a suitable mandrel (one that will contact
only the bearing race) when pressing or driving bear-
ings.
Whenever compressed air is used to dry a part, verify
that no water is present in air line.

Bearings
All bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air.
Air should be directed at the bearing so that it passes
through the bearing. DO NOT spin bearing with com-
pressed air, as this may cause bearing to score from
lack of lubrication. After cleaning, lubricate bearings
with Quicksilver Gear Lubricant. DO NOT lubricate
tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bear-
ing race side wear. Work inner bearing race in-and-
out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condi-
tion of rollers and inner bearing race by inspecting
bearing cup for pitting, scoring, grooves, uneven
wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and
race as a set.
Inspect gear housing for bearing races that have
spun in their respective bores. If race(s) have spun,
gear housing must be replaced.

6B-10 - LOWER UNIT 90-852572R1 JANUARY 1998

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

1. With gear housing in normal running position, 1. Bend tabs of tab washer away from nut.
place a clean pan under housing and remove two
vent plugs and one fill/drain plug (with gaskets).

a
a

51119
a - Tab Washer
b b - Nut

50558
a - Vent Plug 2. Use a block of wood to prevent propeller from ro-
b - Fill/Drain Plug tating. Remove nut and pull components from
shaft.

2. Inspect gear lubricant for metal particles (lubri-

cant will have a “metal flake” appearance). Pres-
ence of fine metal particles (resembling powder)
on the drain plug magnet indicates normal wear.
Metal chips on the magnet indicate the need for
gear housing disassembly and component in- a
spection.
3. Note color of gear lubricant. White or cream color
indicates 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 con-
fused with the presence of water.
4. Presence of water indicates the need for disas-
sembly and inspection of oil seals, o-rings, gas-
kets and components for damage.

50552
a - Block of Wood

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-11

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 Gear Housing Removal Gear Housing Disassembly
WARNING Water Pump
To prevent accidental engine starting, remove 1. If water tube seal stayed on water tube (inside of
(and isolate) spark plug leads from spark plugs driveshaft housing) when gear housing was re-
before removing gear housing. moved, then pull seal from water tube. Replace
1. Remove (and isolate) spark plug leads from water tube seal if damaged.
spark plugs. 2. Remove 6 bolts, washers and isolators (Design
2. Shift into forward gear. 1). Remove cover.

3. Tilt engine to full “Up ” position. NOTE: Isolators from forward 2 screws are different
from the other isolators. Retain these for proper re-
4. Remove four bolts and washers, two from each assembly (Design 1).
side.
IMPORTANT: The circular groove formed by the
5. Remove trim tab. impeller sealing bead should be disregarded
6. Remove locknut and washer in trim tab recess. when inspecting cover and plate as the depth of
the groove will not affect water pump output.
7. Remove gear housing.
3. Replace cover if thickness of steel at the dis-
charge slots is .060 in. (1.524mm) or less, or if
groove(s) (other than impeller sealing groove) in
cover roof are more than .030 in. (.762mm) deep.
a
c

c b
b
b a b
c

c
d d
51206
a - Water Tube Seal
b - Bolts (6)
c - Washers (6)
d - Isolators (6)
50555 e - Cover
a - Bolts and Washers (4)
b - Trim Tab
c - Locknut and Washer

6B-12 - LOWER UNIT 90-852572R1 JANUARY 1998

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 4. Lift impeller, drive key, and gasket. Replace im- New Style Base
peller if:
8. Remove water pump base by lifting gently as
– Impeller blades are cracked, torn, or worn. shown. Inspect carefully for cracks.
– Impeller is glazed or melted (caused by insuffi-
cient water supply). a
– Rubber portion of impeller is not bonded to im-
peller hub.

c
b

55874
51207
a - Water Pump Base
a - Impeller
b - Drive Key
c - Gasket 9. Remove (and discard) seals, if damaged.
5. Remove plate and gasket.
a
6. Replace plate if groove(s) (other than impeller
sealing groove) in plate are more than .030 in.
(.762mm) deep.
a

51205
51206 a - Seals

a - Plate 10. Remove seal and plate if damaged or worn.

b - Gasket

Old Style Base

7. Remove water pump base by lifting gently as
shown. Inspect carefully for cracks.

a b

51206
51268
a - Seal
a - Water Pump Base b - Plate

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-13

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 Bearing Carrier and Propeller Shaft 4. Replace reverse gear if gear teeth or clutch teeth
on reverse gear are chipped or worn. If reverse
1. Drain lubricant; refer to “Draining and Inspecting gear must be replaced, pinion and sliding clutch
Gear Lubricant”. should also be inspected for damage.
2. Remove bolts. 5. If reverse gear bearing is rusted or does not roll
freely, replace bearing. Remove bearing and re-
verse gear using bearing puller (91-27780).

51117
a - Bolts (2)

3. With propeller shaft horizontal, pull carrier to

break seal with gear housing. Remove bearing
carrier/propeller shaft components. Do not leave 51205
cam follower in end of propeller shaft. Remove a - Bearing Puller (91-27780)
propeller shaft from bearing carrier using bearing
puller.

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

6B-14 - LOWER UNIT 90-852572R1 JANUARY 1998

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 6. Remove ball bearing from reverse gear using 8. Remove seals (if not removed with bearing) and
Universal Puller Plate and mandrel. O-ring.

a
d

51263
a - O-ring
51289

Propeller Shaft Disassembly

1. Remove spring. Push out cross pin.

a
b c
51269
a - Ball Bearing
b - Reverse Gear
c - Universal Puller Plate (91-37241) a
d - Driver Head (91-37312)

51265
7. If bearing is rusted or does not roll freely, replace
bearing. Remove bearing and oil seals. Discard
oil seals.
d

b
a c

c e
51268
a - Spring
b - Cam Follower
c - Apply Pressure as Shown
d - Punch
d e - Cross Pin

51264
a - Driver Rod (91-37323)
b - Driver Head (91-37312)
c - Propeller Shaft Needle Bearing
d - Oil Seals (2)

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-15

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 2. Replace cam follower if worn or pitted on either Pinion Gear, Driveshaft and Forward
end.
Gear
3. Replace sliding clutch if jaws are rounded or 1. Hold driveshaft using Driveshaft Holding Tool
chipped. Rounded jaws indicate the following: (91-817070); remove (and discard) pinion nut.
a. Improper shift cable adjustment. 2. Remove driveshaft, pinion gear, and forward
b. Engine idle speed too high while shifting. gear.
c. Shifting too slowly. 3. Replace pinion gear if chipped or worn.
e e 4. Replace bearing if rusted or damaged; or does
a c not roll freely. To remove, refer to “Lower Drive-
shaft Bearing”, following.
5. Replace forward gear if gear teeth are chipped or
worn.
a

d b 51265

a - Cam Follower 51043

b - Guide Block
c - Spring
d - Sliding Clutch
e - Jaws c

4. Check bearing surfaces of propeller shaft. If shaft

is worn/pitted, replace shaft and corresponding d
bearing.
5. Replace propeller shaft if:
a. Splines are twisted or worn. f
b. Oil seal surface is grooved in excess of 0.005 b e
in. (0.12mm).
51263
c. Shaft has a noticeable “wobble” or is bent a - Driveshaft Holding Tool (91-817070)
more than 0.006 in. (.152 mm). Check with a b - Pinion Nut
dial indicator and V-blocks. c - Driveshaft
d - Pinion Gear
b b e - Bearing
f - Forward Gear
c

6. Replace bearing if rusted or does not roll freely af-

ter cleaning in solvent. Remove as shown.

a 51139
a - V-Blocks
b - Bearing Surfaces
c - Check with Dial Indicator Here

19203

6B-16 - LOWER UNIT 90-852572R1 JANUARY 1998

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 7. Replace forward gear tapered roller bearing and Lower Driveshaft Bearing
race if either bearing or race are rusted or dam-
aged; or if bearing does not roll freely after clean- 1. Remove lower driveshaft bearing using tool
ing in solvent. Remove bearing from gear using (91-817058A1) with bushing installed.
Universal Puller Plate (91-37241) and Mandrel.
To remove race, refer to “Forward Gear Bearing
Race”, following.

c
a

b 51119
c
a - Bearing/Race
b - Puller Plate (91-37241) a
c - Mandrel

Upper Driveshaft Bearing

1. Replace bearing and race if either bearing or race
are rusted or damaged; or if bearing does not roll
freely after cleaning in solvent.

51260
a - Bearing
b - Removal Tool (91-817058A1)
c - Bushing

a
Forward Gear Bearing Race
IMPORTANT: Retain shim(s) for re-assembly.
1. Remove race and shim(s) using bearing puller
(91-27780).

b
c a 51265
51271 a - Race
a - Bearing b - Shim(s)
c - Bearing Puller (91-27780)

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-17

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 Shift Shaft 4. Remove shift shaft bushing and “E” clip from shift
shaft. Replace shift shaft if splines are twisted or
1. Remove shift shaft coupler and spacer. damaged on either end of shaft. Remove (and
discard) O-ring if damaged.
a
a d b c

51271

a - Coupler 51264
b - Spacer a - Shift Shaft Bushing
b - “E” Clip
c - Shift Shaft
2. Remove shift shaft bushing and shift shaft. Pro- d - O-ring
tect shift shaft to prevent spline damage.

b 5. Remove (and discard) seal if damaged.

51205
a - Shift Shaft Bushing
b - Shift Shaft

51265
3. Remove shift shaft cam, replace if worn. a - Seal

51117
a - Shift Shaft Cam

6B-18 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing Reassembly 5. Install shift cam (numbers toward top of gear
housing); align hole in shift cam with hole.
Shift Shaft b
1. Apply Perfect Seal on O.D. of new seal. Install
with seal lip up, as shown.
2. Press seal into shift shaft bushing until seal bot- a
toms. Use a suitable tool.
3. Apply Quicksilver Needle Bearing Assembly Lu-
bricant on O-ring and I.D. of seal.

4
a
19
51117

b a - Shift Cam
b - Hole

51270 6. Install shift shaft assembly; insert splines into

4 Needle Bearing Assy. Lub. (92-825265A1) shift cam.
19 Perfect Seal (92-34227-1)
a - Seal - Lips Facing Up
b - Shift Shaft Bushing
c - Tool a

4. Assemble components.
d
c b
a

51264
a - Shift Shaft 51268
b - “E” Clip a - Shift Shaft Assembly
c - Bushing
d - O-ring

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-19

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

95
b

95 2-4-C w/Teflon (92-850736A1)

51265
a - Spring
b - Clutch (Align Hole with Slot in Prop Shaft, Long End of
Clutch with 3 Teeth Towards Prop Shaft Shoulder)
c - Guide Block
d - Cam Follower (Hold in Place with Quicksilver 2-4-C Marine a
Lubricant) d
c 4

2. Install cross pin.

51043 b
51265
c
4 Needle Bearing Assy. Lub. (92-825265A1)
a - Shim(s)
b - Driver Cup (91-817009)
c - Propeller Shaft
d - Assembled Bearing Carrier

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 overlap-
ping in clutch groove after installation.
a

51265
a - Spring

6B-20 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Bearing Carrier 4. Install large diameter seal on installer tool. Seal
lip faces towards shoulder on installer tool. Press
1. Lubricate O.D. of needle bearing with Quicksilver in until Installer tool bottoms.
Needle Bearing Assembly Lubricant.
2. Install needle bearing.
Installation Note: Push against numbered end of
bearing.
b
b a
a
51043

51043

7
4 51263
7 Loctite “271” (92-809819)
a - Large Diameter Seal
b - Installer Tool (91-817007)

51269 Installation Note: If service tools are not available, the

4 Needle Bearing Assy. Lub. (92-825265A1) following reference dimensions apply for installing
bearing and seals to proper depths.
a - Needle Bearing
b - Installer (91-817011) .82 in. (20mm)

3. Install small diameter oil seal. Seal lip faces away

from shoulder on Installer Tool. Press seal in until
Installer Tool bottoms.

b
a
51275
a
a - Bearing
.44 in. (11mm)
7
.04 in. (1mm)
51043

b
a
51206

7 Loctite “271” (92-809819) 51275

a - Small Diameter Seal a - Oil Seal (Install with Lip Down)
b - Installer Tool (91-817007) b - Oil Seal (Install with Lip Up)

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-21

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 5. Lubricate O-ring with Special Lubricant 101. In- 2. Install reverse gear and bearing assembly. Lubri-
stall O-ring. cate O.D. of bearing with Quicksilver Needle
Bearing Assembly. Lubricant before installation.

a b
95

51263 a c
95 2-4-C w/Teflon (92-850736A1)
a - O-ring
4

Reverse Gear
1. Lubricate I.D. of bearing with Quicksilver Needle
Bearing Assembly Lubricant. Use Installer Tool
and press onto gear until bearing bottoms.

51264
4 Needle Bearing Assy. Lub. (92-825265A1)
a - Reverse Gear and Bearing Assembly
b - Installer Tool (91-817007)
c - Bearing Carrier

b
a Forward Gear
1. Press new propshaft bearing into gear. Lubricate
O.D. of bearing with Quicksilver Needle Bearing
Assembly Lubricant before installation. Press un-
til Installer Tool bottoms.
4 Installation Note: Push against numbered end of
bearing.

51205
51043
4 Needle Bearing Assy. Lub. (92-825265A1)
a - Bearing 4
a
b - Installer Tool (91-817007)

51291
4 Needle Bearing Assy. Lub. (92-825265A1)
a - Installer Tool (91-817005)

6B-22 - LOWER UNIT 90-852572R1 JANUARY 1998

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 2. Press tapered roller bearing onto gear. Lubricate Lower Driveshaft Bearing Installation
I.D. of bearing with Quicksilver Needle Bearing
Assembly Lubricant before installation. Use In- 1. Lubricate O.D. of bearing race with Quicksilver
staller Tool. Press until bearing bottoms on gear. Needle Bearing Assembly Lubricant.
2. Install bearing into housing. Press until Installer
Tool bottoms.
Installation Note: Push against numbered end of
bearing.

b
a
4

7.05 in.
7.07 in. ( )
179.0mm
179.5mm b

51272
4 Needle Bearing Assy. Lub. (92-825265A1) c
a - Bearing (Lubricate I.D. Before Assembly)
b - Installer Tool (91-817007)

51260
4 Needle Bearing Assy. Lub. (92-825265A1)
a - Needle Bearing (Lubricate O.D. Before Assembly)
b - Bearing Installer Tool (91-817058A1)
c - Reference (Bearing Depth)

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-23

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 Upper Driveshaft Bearing Installation Forward Gear, Pinion Gear, Upper
1. Press upper driveshaft bearing onto driveshaft. Driveshaft Bearing Race, Retainer
Lubricate I.D. of bearing with Quicksilver Needle and Driveshaft Installation
Bearing Assembly Lubricant before pressing in
NOTE: If shim(s) were lost or are not reusable (dam-
place.
aged), start with approximately .015 in. (0.361mm).
Install components in sequence shown.

d
c

51285

e
g

51043
a
4 b
a
g
f

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”, Fol-
51268 lowing.) Recess in Nut is Installed Toward Pinion Gear
(See Inset).
4 Needle Bearing Assy. Lub. (92-825265A1)
a - Upper Driveshaft Bearing (Lubricate I.D. Before Assembly)

6B-24 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Pinion Gear Location and Forward 3. Measure distance.
Gear Backlash 4. Increase distance by 1 in. (25.4mm).
5. Rotate driveshaft 10 revolutions. This properly
DETERMINING PINION GEAR LOCATION seats upper driveshaft tapered roller bearing.
NOTE: Read entire procedure before attempting any c
change in shim thickness.
IMPORTANT: Forward gear assembly must be in-
stalled in gear housing when checking pinion
gear depth to obtain accurate shim measure- a
ments.
1. Clean the gear housing bearing carrier shoulder
and diameter.
2. Position gear housing upright (driveshaft verti-
b
cal). Install Bearing Preload Tool in sequence
shown.

h
3/4 in. (19mm) I.D.

19884
i i a - Distance, 1 in. (25.4 mm)
b - Bolt
c - Nut
g
f
6. Insert Pinion Location Tool. Position access hole
as shown. Insert feeler gauge between gauging
e surface and pinion gear.

a c d
b
d

a 51265

51270
a - Pinion Location Tool (91-817008A2)
b - Access Hole
a - Plate c - Gauging Surface
b - Adaptor: Bearing surfaces clean and free of nicks d - Pinion Gear
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

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-25

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 7. The correct clearance between the gauging sur- Determining Forward Gear Backlash
face and the pinion gear is .025 in. (0.64mm).
NOTE: Read entire procedure before attempting any
8. To obtain .025 in. (0.64mm), add or subtract change in shim thickness.
shims below the upper bearing race to lower or
raise the pinion gear. 1. Obtain correct pinion gear location; refer to “De-
termining Pinion Gear Location”, preceding.
9. After final adjustment to pinion height, and for-
ward gear backlash has been established, ap- 2. Install Bearing Preload Tool on driveshaft; refer to
ply Loctite 271 to threads and torque new pinion “Determining Pinion Gear Location”, preceding.
nut to 50 lb. ft. (67 N·m). 3. Install components.
c 4. Torque to 45 lb. in. (5 N·m)

51285
d
b b
a
7

c
c 51119
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”,
51263 following.
7 Loctite “271” (92-809819)
a - Bearing Race
b - Shim(s)
c - Pinion Nut (Recessed Side Toward Pinion) 5. Rotate driveshaft 10 revolutions to properly seat
forward gear tapered roller bearing.
6. Re-torque puller bolt to 45 lb. in. (5.1 N·m).

6B-26 - LOWER UNIT 90-852572R1 JANUARY 1998

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

c
b

c
95
51275 b a c 51271

a - Threaded Rod 95 2-4-C w/Teflon (92-850736A1)

b - Washers
c - Nuts a - O-ring
d - Dial Indicator Adaptor Kit (91-83155) b - Area to be Lubricated
e - Dial Indicator (91-58222A1) c - Cam Follower
f - Backlash Indicator Tool (91-19660--1)

8. Position Dial Indicator on line “3” on Backlash In-

dicator Tool.
9. Turn driveshaft back-and-forth (check for no rota-
tion at 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, re-
move 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 0.0125 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).

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-27

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 Bearing Carrier 4. Torque bolts to 225 lb. in./18.8 lb ft. (25.4 N⋅m)

1. Install carrier into gear case.

7
2. Discard the thin 0.063 in. (1.60 mm) flat washers
and the 25 mm long bolts on models listed. Install
thicker flat washers and longer bolts. a
55/60 (3 Cylinder - 2 Stroke) Non Big Foot
USA 0G662097 and below
Belgium NA
a b

a - Bolt 25 mm Long - Discard a

b - Thin Flat Washer 0.063 in. (1.60 mm) thick - Discard
51117
7

3. Install thicker flat washers and longer bolts. 7 Loctite “271” (92-809819)

a b a - Torque Bolts to 225 lb. in./18.8 lb. in (25.4 N⋅m)

a - Bolt (10-855940-30) 1.18 in. (30 mm) Long

b - Washer (12-855941) 0.090 in. (2.29 mm)

6B-28 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Water Pump Re-assembly and NOTE: If installation tool is not available, press seals
in as shown to depths indicated.
Installation
0.04 in. (1.02 mm) a
1. Place seal on longer shoulder side of tool.
2. Press into water pump base until tool bottoms.
b

b
87

55878

a - Seal (Install with spring visible when installed.)

a b - Seal (Install with spring visible when installed.)
c - Seal Bottom

5. Install O-ring. Lubricate O-ring and gear housing

bore with Quicksilver Special Lubricant 101.
55876
6. Install water pump base into gear case.
87 Super Duty Gear Lubricant (92-850737A1)

a - Seal (Install with spring visible when installed.)

b - Seal Installation Tool (91-817006)

3. Place seal on shorter side of tool.

4. Press into water pump base until tool bottoms. b

95

c
87 c

b
a
55879
95 2-4-C w/Teflon (92-850736A1)

a - O-ring
b - Water Pump Base
55877
c - Gear Case

87 Super Duty Gear Lubricant (92-850737A1)

a - Seal
b - Shorter Side of Tool
c - Seal Installation Tool (91-817006)

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-29

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 7. If removed previously, re-install seal and plate. 10. Lubricate I.D. of cover with Quicksilver Needle
Bearing Assembly Lubricant. Install gasket with
bead toward cover.
b a
4

51290

4 Needle Bearing Assy. Lub. (92-825265A1)

a
a - Gasket
b - Bead Toward Cover

11. Rotate driveshaft clockwise and push cover

51268 down. Secure cover.
a - Seal
b - Plate a
c d
8. Install gasket and face plate.
b d
c d
c

a b b b c

51275

a - Cover
b - Isolators, (Design 1) Note: 2 isolators for forward screws
are different from remaining 4 isolators
c - Washers (6)
51293
d - Bolts (6); Apply Loctite on threads and torque to 60 lb. in.
a - Gasket (6.8 N·m).
b - Face Plate

IMPORTANT: If the old impeller is re-used, install NOTE: Torque cover screws as shown.
in the original (clockwise) direction of rotation.
9. Install drive key and impeller.

1 3
b
5

a 4 2

51271

51292
a - Drive Key
b - Impeller

6B-30 - LOWER UNIT 90-852572R1 JANUARY 1998

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

51206
a - Water Tube Seal

4. If pressure drop is noted, immerse housing in wa-

ter.
Gear Housing Pressure Test
5. Re-pressurize to 10-12 PSI (69-83 kPa) and
1. Remove vent plug and install pressure test check for air bubbles.
gauge. Tighten securely.
6. Replace leaking seals as necessary. Retest
housing.
NOTE: It should hold 10-12 PSI (69-83 kPa) for 5
minutes.
7. Remove tester from housing and install vent
plug.

2. Pressurize housing to 10-12 PSI (69-83 kPa) and

observe gauge for 5 minutes.

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-31

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 Gear Housing Installation
Filling Gear Housing with Lubricant
NOTE: Gear housing lubricant capacity is approxi-
mately 11.5 fl. oz. (340 ml).

WARNING
If gear housing is installed on outboard, discon-
nect (and isolate) spark plug leads from spark
plugs before working near the propeller.

CAUTION
b c
Do not use automotive grease in the gear hous-
ing. Use only Quicksilver Gear Lube.
1. Remove any gasket material from “Fill” and
“Vent” plugs and gear housing. Install new gas-
kets on “Fill” and “Vent” plugs.
IMPORTANT: Never add lubricant without remov-
ing “Vent” plugs. Gear housing cannot be filled
because of trapped air. Fill gear housing when
driveshaft is in a vertical position. a
2. Remove “Fill” plug and gasket. 50558
a - “Fill” Plug
3. Insert lubricant tube in “Fill” hole, then remove b - “Vent” Plug
“Vent” plugs and gaskets. c - “Vent” Plug
4. Fill until excess lubricant flows out of left “Vent” 8. Torque screws to 35-80 lb. in. (3.8-8.8 N·m)
hole.
5. Replace left “Vent” plug and gasket and continue
to fill until lubricant flows from right “Vent” hole.
6. Replace right “Vent” plug and gasket.
7. Install “Fill” plug and gasket.

6B-32 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing Installation CAUTION
WARNING Do not lubricate top of driveshaft. Excess lubri-
cant will not allow driveshaft to fully engage
Disconnect (and isolate) spark plug leads before crankshaft. Tightening the gear housing fasten-
installing gear housing onto driveshaft housing. ers (if excess lubricant is on top of driveshaft) will
1. Position shift block in forward gear position. load the driveshaft/crankshaft and may damage
either or both powerhead and gear housing. Wipe
the top of driveshaft free of lubricant.
5. Lightly apply Quicksilver 2-4-C Marine Lubricant
onto the driveshaft splines.
6. Shift gear housing into forward gear. Gear hous-
ing will not engage when propeller shaft is turned
clockwise.
7. Position driveshaft into driveshaft housing. Move
gear housing towards driveshaft housing while
aligning shift shaft coupler, water tube seal and
driveshaft splines.
NOTE: If the driveshaft splines will not align with the
crankshaft splines, install a propeller and turn the
a propeller shaft counterclockwise while pushing gear
51190 housing onto driveshaft housing. It may also be nec-
a - Shift Block essary to move the shift block (on the powerhead) to
2. Tilt engine to full “Up” position. Engage tilt lock le- align the shift shaft splines for proper re-assembly.
ver. 8. Install 4 bolts and washers, (two each side). Ap-
3. Shift gear housing into neutral. Propeller shaft ply Loctite 271 on threads of bolts prior to installa-
will rotate freely in either direction. tion.
4. Install water tube seal, spacer and shift shaft cou- 9. Install locknut and washer.
pler. 10. Torque bolts and locknut to 40 lb. ft. (54 N·m).
95

a 74

b
7
a
b

51206

74 Loctite “405” (Purchase Locally)

95 2-4-C w/Teflon (92-850736A1)
50551
a - Water Tube Seal
b - Spacer
7 Loctite “271” (92-809819)
c - Shift Shaft Coupler a - Bolts and Washers
b - Locknut and Washer

90-852572R1 JANUARY 1998 LOWER UNIT - 6B-33

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 11. Check shift operation.
CAUTION
a. Gear housing should not engage when pro-
peller shaft is turned clockwise when in for- Do not misinterpret propeller shaft movement for
ward gear. propeller movement, propeller and propeller
shaft however may move fore-and-aft. However,
b. Propeller shaft will rotate freely in either direc- the propeller itself should not move fore-and-aft
tion when gearcase is in neutral. on the propeller shaft.
c. Propeller shaft will not rotate in either direc- 3. Re-check propeller nut for tightness after first
tion when gearcase is in reverse. use. Check for tightness periodically, especially
IMPORTANT: If shift operation is not as de- if a stainless propeller is used.
scribed, remove the gear housing and correct the 4. Install and adjust trim tab as follows.
shift operation.
Trim Tab Adjustment and
Replacement
Propeller Installation
IMPORTANT: The trim tab is made of a special
WARNING alloy to aid in protecting the drive shaft housing
and gear housing from galvanic corrosion (cor-
Disconnect and isolate spark plug leads when rosion and pitting of metal surfaces). Do not
working near the propeller to prevent the out- paint or place protective coating on the trim tab,
board from starting. or trim tab corrosion protection function will be
1. Apply one of the following Quicksilver products lost.
on propeller shaft splines. 1. Replace trim tab if 50% (or more) corroded. Mark
– Anti-Corrosion Grease location of old trim tab on anti-ventilation plate
before removal; install new trim tab in same loca-
– 2-4-C Marine Lubricant tion.
2. Install components. 2. The trim tab will offset (balance) some of the
“steering load” that is caused by “propeller
torque” at higher speeds. If at higher speeds the
boat turns more easily to the left, loosen bolt,
move the trim tab (trailing edge) to the left (when
viewed from behind); re-tighten bolt. Turn trim tab
(trailing edge) to the right if the boat turns more
easily to the right.

c a a
c

d 94
b
50551
94 Anti-Corrosion Grease (92-850735A1)
50553
a - Thrust Hub; Flat Surface Towards Propeller a - Trim Tab
b - Propeller b - Anti-Ventilation Plate
c - Tab Washer; Bend Tabs Down Against Nut Flats c - Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft.
d - Locknut; Torque to 55 lb. ft. (75 N·m) (29.8 N·m)

6B-34 - LOWER UNIT 90-852572R1 JANUARY 1998

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 LOWER UNIT

6
791-H C
BIGFOOT GEAR HOUSING
4-1/4 IN. (108 MM) DIAMETER GEAR CASE

Downloaded from www.Manualslib.com manuals search engine

 Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Forward Gear Bearing Race . . . . . . . . . . 6C-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Gear Housing (Drive Shaft)(60 Bigfoot) . . . 6C-4 Bearing Carrier Reassembly . . . . . . . . . . 6C-19
Gear Housing (Prop Shaft)(60 Bigfoot) . . . . 6C-6 Forward Gear Reassembly . . . . . . . . . . . 6C-21
Gear Case Identification . . . . . . . . . . . . . . . . . 6C-8 Propeller Shaft Reassembly . . . . . . . . . . . 6C-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-8 Drive Shaft Wear Sleeve Installation . . . 6C-23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-8 Lower Drive Shaft Bearing Race
Draining and Inspecting Gear Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-24
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-8 Oil Sleeve Installation . . . . . . . . . . . . . . . . 6C-24
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . 6C-9 Upper Drive Shaft Bearing Installation . . 6C-24
Bearing Carrier and Propeller Shaft . . . . 6C-11 Forward Gear, Lower Drive Shaft
Pinion Gear, Drive Shaft, and Bearing, Pinion Gear, and Drive
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . 6C-13 Shaft Installation . . . . . . . . . . . . . . . . . . . . . 6C-25
Upper Drive Shaft Bearing . . . . . . . . . . . . 6C-15 Pinion Gear Depth and Forward Gear
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-15 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-26
Lower Drive Shaft Bearing Race . . . . . . . 6C-16 Determining Forward Gear Backlash . . . 6C-28
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-16 Bearing Carrier and Propeller Shaft
Forward Gear Bearing Race . . . . . . . . . . 6C-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-30
Trim Tab Adjustment and Replacement . 6C-17 Water Pump Reassembly and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-31
Gear Housing Pressure Test . . . . . . . . . . 6C-33
Filling Gear Housing With Lubricant . . . . . . 6C-33
Gearcase Installation . . . . . . . . . . . . . . . . . . . 6C-34
Trim Tab Adjustment . . . . . . . . . . . . . . . . . 6C-36

6C-0 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Specifications
Gear Ratio 2.3:1
Gearcase Capacity 22.5 fl. oz. (655 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 30 Spiral/Bevel
Pinion Gear
Number of Teeth 13 Spiral/Bevel
Pinion Height 0.025 in. (0.64 mm)
Pinion Gear Locating Tool
1998 AND NEWER
(91-12349A2)
GEAR HOUSING
Flat #8
(2.3:1)
Disc #3
Forward Gear Backlash 0.012-0.019 in. (0.30-0.48 mm)
Backlash Indicator Tool (91-78473)
Mark #4
Water Pressure
@ 750 rpm (Idle) 2.0-4.0 PSI (14-28 kPa)
@ 6000 rpm (W.O.T.) 10.0-15.0 PSI (69-103 kPa)
Pressure Test 10.0-12.0 PSI (69-83 kPa)
for 5 Minutes

Special Tools
Part No. Description
91-15755 Mandrel*
91-12349A2 Pinion Gear Locating Tool
91-14308A1 Bearing Race Tool
91-14309A1 Bearing Installation Tool
91-14310A1 Wear Sleeve Installation Tool
91-14311A2 Bearing Preload Tool
91-13945 Bearing Installation Tool
91-13949 Oil Seal Driver
91-19660--1 Backlash Indicator Tool
91-31106 Mandrel
91-31108 Oil Seal Driver
91-37350 Mandrel
91-31229 Threaded Rod*
91-34569A1 Slide Hammer
91-36569 Mandrel*
91-37323 Driver Rod*
91-37241 Universal Puller Plate
91-46086A1 Puller Jaws
91-56775 Drive Shaft Holding Tool
91-58222A1 Dial Indicator
91-85716 Puller Bolt
91-83165M Bearing Puller Assembly
11-24156 Nut*
91-78473 Backlash Indicator Tool
91-83155 Dial Indicator Adaptor Kit
* From Bearing Removal and Installation Kit (91-31229A7)

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-1

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 Special Tools 6. Wear Sleeve Installation Tool (91-14310A1)

1. Pinion Gear Locating Tool (91-12349A2)

7. Bearing Preload Tool (91-14311A2)

55079

2. Bearing Installation Tool (91-13945) 8. Mandrel (91-15755)*

73815

9. Backlash Indicator Tool (91-19660--1) (4 cyl.)

3. Oil Seal Driver (91-13949)

19660-1

10. Mandrel (91-31106)

4. Bearing Race Tool (91-14308A1)

11. Oil Seal Driver (91-31108)

5. Bearing Installation (91-14309A1)

6C-2 - LOWER UNIT 90-852572R1 JANUARY 1998

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 12. Treaded Rod (91-31229) and Nut (91-24156)* 19. Driver Shaft Holding Tool (91-56775)

13. Slide Hammer (91-34569A1)

20. Dial Indicator (91-58222A1)

14. Mandrel (91-36569)*

21. Backlash Indicator Tool (91-78473) (3 cyl.)

15. Universal Puller Plate (91-37241)

22. Puller Bolt (91-85716)

23. Dial Indicator Adaptor Kit (91-83155)

73652

16. Driver Rod (91-37323)*

74184 24. Bearing Puller Assembly (91-83165M)

17. Mandrel (91-37350)

25. Bearing Installation Tool (91-855875)

18. Puller Jaws (91-46086A1)

56783
* From Bearing Removal and Installation Kit
(91-31229A7)

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-3

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 Gear Housing (Drive Shaft)(60 Bigfoot)
32
33 7

30
22
95
23 7
35
95
34
7 Loctite “271” Adhesive Sealant (92-809819)
29
87 Super Duty Gear Lubricant (92-13783A24)
31 95 2-4-C w/Teflon (92-825407A12)
36 21
25
7

24
7 41 42

27
28 39
26 95 40
95
12 7

11 38

15 37
13 20

19
87

9 3
10
7

13
1
14 8 2

18
16
17 6
4
6
4
7
6
5

6C-4 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing (Drive Shaft)(60 Bigfoot)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (LONG) BLACK
– 1 GEAR HOUSING (LL)
– 1 GEAR HOUSING (LONG) GRAY
– 1 GEAR HOUSING (LL)
1 GEAR HOUSING ASSEMBLY (BLACK)
1
1 GEAR HOUSING ASSEMBLY (GRAY)
2 1 DOWEL PIN (FRONT)
3 1 OILER TUBE
4 2 DRAIN SCREW 60 5 6.8
5 1 SCREW (MAGNETIC) 60 5 6.8
6 3 WASHER-Sealing
7 1 DOWEL PIN (REAR)
8 1 TRIM TAB
9 1 SCREW (.437-14 x 1.25) 264 22 29.8
10 1 WASHER
11 1 CARRIER
12 1 NEEDLE BEARING
13 2 ANODE
14 1 NUT
15 1 SCREW (M6 x 40) 60 5 6.8
16 1 PINION GEAR (Also part of 43-850033A2)(13 TEETH)
17 1 NUT
18 1 SHIFT CAM
19 1 TAPERED ROLLER BEARING
20 AR SHIM ASSEMBLY
1 DRIVE SHAFT ASSEMBLY (LONG)
21
1 DRIVE SHAFT ASSEMBLY (LL)
22 1 WEAR SLEEVE ASSEMBLY
23 1 RING SEAL
24 1 COVER ASSEMBLY
25 1 GASKET
26 1 GASKET
27 1 OIL SEAL (LOWER)
28 1 OIL SEAL (UPPER)
29 1 GASKET
30 1 WATER PUMP ASSEMBLY
31 1 FACE PLATE
32 4 SCREW (M6 x 1 x 30) 60 5 6.8
1 COUPLING (LONG)
33
1 COUPLING (LL)
34 1 KEY
35 1 IMPELLER
36 6 SCREW 60 5 6.8
1 SHIFT SHAFT ASSEMBLY (LONG)
37
1 SHIFT SHAFT ASSEMBLY (LL)
38 1 E-RING
39 1 BUSHING ASSEMBLY
40 1 O-RING
41 1 OIL SEAL
42 2 SCREW (M6 x 1) 60 5 6.8
MODEL VERSION LENGTH DESIGNATION LONG = 20 IN. LL = 22-1/2 IN.

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-5

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 Gear Housing (Prop Shaft)(60 Bigfoot)

95

1 69
50

45
48
46
49 47
43
44 67 68

57 68

95
95

55

71
54
72

53
52
7 51

65
66
64

95

70
60
59
58
95
95 56
61
62
63
7 Loctite “271” Adhesive Sealant (92-809819)
95 2-4-C w/Teflon (92-825407A12)

6C-6 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing (Prop Shaft)(60 Bigfoot)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 GEAR HOUSING (LONG) BLACK
– 1 GEAR HOUSING (LL)
– 1 GEAR HOUSING (LONG) GRAY
– 1 GEAR HOUSING (LL)
1 GEAR HOUSING ASSEMBLY (BLACK)
1
1 GEAR HOUSING ASSEMBLY (GRAY)
43 1 TAPERED ROLLER BEARING ASSEMBLY
44 1 CUP
45 1 FORWARD GEAR (30 TEETH)
46 1 ROLLER BEARING
47 1 CAM FOLLOWER ASSEMBLY
48 3 BALL
49 1 SLIDE
50 1 SPRING
51 1 CLUTCH
52 1 CROSS PIN
53 1 SPRING
54 1 PROPELLER SHAFT
55 1 REVERSE GEAR (30 TEETH)
56 1 BEARING CARRIER ASSEMBLY
57 1 O-RING
58 1 ROLLER BEARING
59 1 OIL SEAL (INNER)
60 1 OIL SEAL (OUTER)
61 1 ROLLER BEARING
62 1 THRUST WASHER
63 1 THRUST BEARING
64 2 STUD 100 135
65 2 WASHER
66 2 NUT 300 25 33.9
67 1 SHIM ASSEMBLY
68 2 THREAD INSERT
69 1 DECAL
70 1 THRUST HUB ASSEMBLY
71 1 PROPELLER NUT ASSEMBLY
72 1 TAB WASHER

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-7

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 Gear Case Identification Removal
CAUTION WARNING
Identify gear case design to ensure correct To prevent accidental engine starting, remove
components are being installed. Design I - “3 Jaw (and isolate) spark plug leads from spark plugs
Reverse Clutch” (a) gear case identified with before removing gear housing.
straight machined edge for trim tab screw
1. Remove (and isolate) spark plug leads from
mounting surface. Design II - “6 Jaw Reverse
spark plugs.
Clutch” (b) gear case identified with angled
machined edge for trim tab screw mounting 2. Shift engine into forward gear.
surface. 3. Tilt engine to full “Up” position.
4. Remove fasteners.
a 5. Remove locknut and washer.
b
6. Remove gear housing.

b a

53992
a - Fasteners (2 each side)
1987 – 1997 1998 and Newer b - Locknut and Washer
“3 Jaw Reverse Clutch” “6 Jaw Reverse Clutch”
a - Design I - “3 Jaw Reverse Clutch” Gear Case Identifier
b - Design II - “6 Jaw Reverse Clutch” Gear Case Identifier
Disassembly

Draining and Inspecting Gear

Housing Lubricant

WARNING
If gear housing is installed on engine, to avoid ac-
cidental starting, disconnect (and isolate) spark
plug leads from spark plugs before working near
the propeller.
1. With gear housing in normal running position,
place a clean pan under housing and remove the
two vent screws and one fill/drain screw (with
gaskets).

6C-8 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Water Pump
1. If water tube seal stayed on water tube (inside of
drive shaft housing) when gear housing was re-
moved, pull water tube seal from water tube.
c a 2. Replace water tube seal, if damaged.
3. Remove 4 bolts, washers, and isolators.
4. Remove cover.

b c

b
53922
a - Oil Level Screw b
b - Fill/Drain Screw
c - Vent Screw

2. Inspect gear lubricant for metal particles (lubri-

cant will have a “metal flake” appearance). Pres- 19212
ence of fine metal particles (resembling powder) a - Water Tube Seal
on the drain plug bar magnet indicates normal b - Bolts (4 each)
wear. The presence of metal chips on the drain c - Cover
plug bar magnet indicates the need for gear
housing disassembly and component inspection. IMPORTANT: The circular groove formed by the
impeller sealing bead should be disregarded
3. Note color of gear lubricant. White or cream color when inspecting cover (Step 5) and plate (Step 9),
MAY indicate presence of water in lubricant. Gear as the depth of the groove will not affect water
lubricant which has been drained from a gear pump output.
case recently in operation will have a yellowish
color due to lubricant agitation/aeration. Gear 5. Replace cover if thickness of steel at the dis-
lube which is mixed with assembly lubricant charge slots is 0.060 in. (1.52mm) or less, or if
(Special Lube 101 or 2-4-C w/Teflon will also be groove(s) (other than impeller sealing bead
creamy white in color. This is normal and should groove) in cover roof are more than 0.030 in.
not be confused with the presence of water. If wa- (0.76mm) deep.
ter is suspected to be present in gearcase, a 6. Lift impeller, drive key, and gasket from drive
pressure check of gearcase should be made shaft.
(with no lubricant in gearcase). Gearcase should
hold 10 to 12 psi (68 – 82 kPa) of pressure for 5
minutes without leaking down. Pouring a portion a
of the gear lubricant into a glass jar and allowing
the lubricant to settle will allow any water in the
lube to separate and settle to the bottom of the jar.
4. Presence of water in gear lubricant indicates the c b
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.
19220
a - Impeller
b - Drive Key
c - Gasket

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-9

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 7. Inspect impeller. Replace impeller if any of the 11. Remove water pump base.
following conditions exist:
• Impeller blade(s) are cracked, torn, or worn. a
• Impeller is glazed or melted (caused by operation
without sufficient water supply).
• Rubber portion of impeller is not bonded to impel-
ler hub.
8. Remove plate and gasket.
9. Replace plate if groove(s) (other than impeller
sealing bead groove) in plate are more than
19226
0.030 in. (0.76mm) deep.
a - Water Pump Base
c
a 12. Remove (and discard) seals.

19219
a - Plate
b - Gasket
c - Impeller Sealing Groove
19195

10. Remove bolts and washers. a - Seals

13. Remove gasket.

a

19217 19218

a - Bolts and Washers (6 each) a - Gasket

6C-10 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Bearing Carrier and Propeller Shaft 4. Lift reverse gear, thrust bearing and thrust wash-
er from bearing carrier.
1. Remove fasteners.
5. Replace reverse gear if gear teeth or clutch teeth
on reverse gear are chipped or worn. If reverse
a gear must be replaced, pinion gear and sliding
clutch should be inspected for damage.
6. Replace thrust bearing and thrust washer if
rusted or damaged.

a c
a - Fasteners

2. With propeller shaft horizontal, pull carrier to

break seal with gear housing. Remove bearing
carrier/propeller shaft components as an assem-
bly, taking care not to lose cam follower or 3 metal
balls in end of propeller shaft.
3. Remove propeller shaft from bearing carrier.

a - Reverse Gear
b b - Thrust Bearing
e
c - Thrust Washer
c a 7. If bearing is rusted or does not roll freely, replace
bearing. Remove bearing using Slide Hammer
(91-34569A1).
a

d
51116
a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Bolt (91-85716)
d - Thrust Hub
e - Propeller Shaft

19205
a - Bearing

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-11

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 8. If bearing is rusted or does not roll freely, replace 10. Remove spring.
bearing. Remove bearing and oil seals using
Mandrel* (91-36569) and Driver Rod* (91-37323).
Discard oil seals.
* From Bearing Removal and Installation Kit (91-31229A7)

a
51876
a - Spring

11. Apply constant pressure to cam follower to pre-

vent cam follower assembly from ejecting from
propeller shaft while pushing cross pin out of
clutch dog.

b 51264
a - Bearing
b - Mandrel (91-26569)
c - Driver Rod (91-37323) b

9. Remove (if not removed with bearing in Step 8)

propeller shaft seals and bearing carrier O-ring.

a
51800
a - Cross Pin
b - Cam Follower
51263
a - O-ring 12. Remove components from propeller shaft.

6C-12 - LOWER UNIT 90-852572R1 JANUARY 1998

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 13. Replace cam follower if worn or pitted. Pinion Gear, Drive Shaft, and
14. Replace sliding clutch if jaws are rounded or Forward Gear
chipped. Rounded jaws indicate one or more of
the following: Model Drive Shaft Holding Tool
a. Improper shift cable adjustment. 50 Bigfoot (4-Stroke) 91-56775
b. Engine idle speed too high while shifting. 60 Bigfoot 91-817070
c. Shifting from neutral to reverse (or forward) 75/90/100/115/125 91-56775
too slowly.
1. Hold drive shaft using Drive Shaft Holding Tool
a b c d e (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.
f f 4. Replace bearing and race if either are rusted or
51265
damaged; or if bearing does not roll freely. To re-
a - Cam Follower move race, refer to “Lower Drive Shaft Bearing
b - 3 Metal Balls Race,” following.
c - Guide Block
d - Spring 5. Replace forward gear if gear teeth or clutch teeth
e - Sliding Clutch are chipped or worn.
f - Jaws
a
15. Check bearing surfaces of propeller shaft for pit- c
ting or wear. If shaft is worn or pitted, replace
shaft and corresponding bearing.
16. Replace propeller shaft if any of the following ex-
ist:
a. Splines are twisted or worn.
b. Oil seal surface is grooved.
c. Shaft has a noticeable “wobble” or is bent
more than 0.009 in. (0.23mm). Prop shaft
trueness should be measured with a dial indi-
cator with prop shaft on V-blocks. e

b b
c
d
b

f
a
19175
a - Drive Shaft Holding Tool (91-56775)
51877
b - Pinion Nut
a - V-Blocks c - Drive Shaft
b - Bearing Surfaces d - Pinion Gear
c - Measure with Dial Indicator at This Point e - Bearing
f - Forward Gear

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-13

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 6. Replace bearing if it is rusted or does not roll free- 8. Replace drive shaft if splines are worn or twisted.
ly; use a punch and hammer to remove bearing.
9. If bearing surface is damaged, replace drive shaft
and corresponding bearing.
IMPORTANT: Do not tighten vise against drive
shaft.
10. If wear sleeve is deeply grooved; allowing water
to enter gear case, remove (and discard) sleeve
using Universal Puller Plate (91-37241) and
mallet.

a 19203

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 Univer-
sal Puller Plate (91-37241) and mandrel. To re-
move race, refer to “Forward Gear Bearing
Race,” following.

a c
d c

b
a
19710

a - Splines
b b - Bearing Surface
c - Wear Sleeve
51119
d - Universal Puller Plate (91-37241)
a - Forward Gear Bearing e - Mallet
b - Universal Puller Plate (91-37241)
c - Mandrel 11. Remove (and discard) rubber ring.
a

19152
a - Rubber Ring

6C-14 - LOWER UNIT 90-852572R1 JANUARY 1998

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

c
OR
a

19222
b a - Oil Sleeve
19177
b - Puller Assembly (91-83165M)
a - Upper Drive Shaft Bearing
b - Sleeve IMPORTANT: Upper drive shaft bearing/sleeve
c - Puller Assembly (91-83165M) and oil sleeve do not have to be removed for low-
er drive shaft bearing race removal.
IMPORTANT: Upper drive shaft bearing/sleeve
must be removed prior to oil sleeve removal. Re-
fer to “Upper Drive Shaft Bearing,” preceding.

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-15

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

53925
a - Shift Shaft Coupler
b - Spacer

2. Remove bolts.

a
b

a
53926
a - Bolts
19171
a - Race NOTE: Gearcase should be in FORWARD for easi-
b - Shim(s) est removal of shift shaft.
c - Bearing Race Tool (91-14308A1)
3. Remove shift shaft bushing and shift shaft.

b
a

53927
a - Bushing
b - Shift Shaft

6C-16 - LOWER UNIT 90-852572R1 JANUARY 1998

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

a
b
c 27653
51117 a - Race
b - Shim(s)
a - Shift Cam
c - Slide Hammer (91-34569A1)

NOTE: If shift shaft splines are rough, shift shaft seal

lips will be cut during removal/installation. Trim Tab Adjustment and
6. Remove shift shaft bushing and clip from shift Replacement
shaft.
IMPORTANT: The trim tab is now painted and
7. Replace shift shaft if splines are worn or shaft is does NOT aid in protecting the drive shaft hous-
twisted. ing and gear housing from galvanic corrosion
8. Remove (and discard) O-ring. (corrosion and pitting of metal surfaces). Side
anodes now provide protection. Do not paint or
a
e place protective coating on the side anodes, or
d c d corrosion protection function will be lost.
b
1. Replace trim tab if damaged. Mark location of old
trim tab on anti-ventilation plate before removal;
install new trim tab in same location.
2. The trim tab provides a means to offset (balance)
53928 some of the steering load that is caused by pro-
a - Bushing peller torque at higher operating speeds. If at
b - Clip higher speeds the boat turns more easily to the
c - Shift Shaft left, loosen bolt, move the trim tab (trailing edge)
d - Splines to the left (when viewed from behind); retighten
e - O-ring
bolt. Turn trim tab (trailing edge) to the right if the
boat turns more easily to the right.
9. Remove (and discard) seal.
c

b a 53931
a
a - Trim Tab
53929 b - Anti-Ventilation Plate
c - Retaining Bolt and Washer; Torque Bolt to 22 lbs. ft.
a - Seal (29.8 N
m)

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-17

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

e d
c 6. Install shift cam (numbers toward top of gear
housing); align hole in shift cam with hole.
60 Bigfoot 75/90/100/115/125

a
b

95
b
95 2-4-C With Teflon (92-825407A12) 19179 a
a - Shim(s)
b - Race, Apply 2-4-C w/Teflon Lubricant on O.D.
c - Mandrel (91-31106)
d - Disassembled Propeller Shaft 51117
e - Assembled Bearing Carrier
a - Shift Cam (marked with “UP” and part number)
b - Gear Housing Hole
60 Bigfoot 75/90/100/115/125
Shift Shaft
1. Apply Loctite 271 on O.D. of new seal. b
2. Press seal into shift shaft bushing until seal is
seated against shoulder.
3. Install new O-ring. 850307
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
c a
a

d b
56791
7 Loctite 271 (92-809820) 53930
a - Seal (Lip faces UP) a - Shift Cam (marked with part number only)
b - Bushing b - Gear Housing Hole
c - Surface
d - O-ring

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 50 Bigfoot (4-Stroke) 8. Apply Loctite 271 on bottom half of threads
of bolts; install bolts and torque to 35 lb. in.
(4.0 N·m).
b a

850307 7 Loctite 271 (92-809820) 53926

a - Bolts [Torque to 35 lb. in. (4.0 N·m)]
51117
a - Shift Cam (Numbers Down) Bearing Carrier Reassembly
b - Hole
1. Lubricate O.D. of bearing and bearing carrier
7. Install shift shaft assembly; insert splines into bore with Quicksilver 2-4-C w/Teflon.
shift cam. 2. Protect lip on forward side of bearing carrier, us-
ing Bearing Installation Tool (91-13945).
a 3. Press propeller shaft needle bearing (number
side toward mandrel) into carrier, until bearing
bottoms out.

c
95
b

53932 b
a - Shift Shaft Assembly
b - Splines
a

95 2-4-C With Teflon (92-825407A12) 21042

a - Bearing Installation Tool (91-13945)
b - Mandrel (91-15755)
c - Suitable Driver Rod

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-19

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 4. Place smaller diameter seal on longer shoulder 8. Install O-ring.
of Oil Seal Driver (91-31108) with seal lip away
9. Lubricate O-ring with 2-4-C w/Teflon. Lubricate
from shoulder.
seal lips with 2-4-C w/Teflon. Lubricate outside
5. Protect lip on front side of bearing carrier using diameter of bearing and bearing carrier bore with
Bearing Installation Tool (91-13945). Apply Loc- a light coating of 2-4-C w/Teflon.
tite 271 on O.D. of seal. Press seal into carrier un-
10. Press bearing into carrier until tool bottoms.
til tool bottoms.

b a b
95

7 Loctite 271 (92-809820) 21040

a - Seal 19163
95 2-4-C With Teflon (92-825407A12)
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945)
a - O-ring
b - Bearing, Numbered Side Toward Tool
6. Place larger diameter seal on shorter shoulder of c - Bearing Installation Tool (91-13945)
Oil Seal Driver (91-31108) with seal lip toward
shoulder. 11. Install thrust washer. Coat thrust washer with
7. Protect lip on front side of bearing carrier using Quicksilver Gear Lubricant.
Bearing Installation Tool (91-13945). Apply Loc-
tite 271 on O.D. of new seal. Press seal into carri- a
er until tool bottoms.

87
b a
7

a
c

19167
87 Quicksilver Gear Lubricant (92-19007A24)
7 Loctite 271 (92-809820) 21041
a - Thrust Washer
a - Seal
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945)

6C-20 - LOWER UNIT 90-852572R1 JANUARY 1998

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 12. Install thrust bearing. Coat thrust bearing with Forward Gear Reassembly
Quicksilver Gear Lubricant.
1. Press tapered bearing onto gear (press only on
a inner race of bearing).
87

87
a

87 Quicksilver Gear Lubricant (92-19007A24)

51869

19168 a - Mandrel (91-37350)

87 Quicksilver Gear Lubricant (92-19007A24) b - Bearing; Lubricate I.D. with Quicksilver Gear Lubricant

a - Thrust Bearing
2. Inspect reverse gear end of clutch to determine
the number of jaws. Refer to chart, following, for
13. Apply gear lubricant to bearing surface of reverse tool end selection.
gear and install reverse gear.
Model Installation End Bearing
Tool Stamped Position
3 Jaw Re- 91-856875 3 0.155 in.
verse (3.94mm)
Clutch below sur-
b face
87
6 Jaw Re- 91-856875 6 Flush with
verse surface
a Clutch
3 Jaw Reverse Clutch

b 56783
c
19202
87 Quicksilver Gear Lubricant (92-19007A24) a - Stamped “3”
b - Numbered end of Needle Bearing
a - Reverse Gear c - 3 Jaw Reverse Clutch
b - Bearing Surface

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-21

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 6 Jaw Reverse Clutch Propeller Shaft Reassembly
1. Install components into propeller shaft in se-
a quence shown.
d c b a

19154
b a - Spring
c b - Guide Block
56784 c - 3 Metal Balls*
a - Stamped “6” d - Cam Follower*
b - Numbered end of Needle Bearing
c - 6 Jaw Reverse Clutch * Hold in Place With Quicksilver 2-4-C w/Teflon

3. Apply Quicksilver gear lubricant to I.D. of forward

gear. Press bearing into forward gear until tool 2. Install cross pin.
contacts gear. b
a

87

51800
a - Apply Pressure in This Direction
b - Cross Pin

3. Install spring. DO NOT overlap springs.

56785
a
87 Quicksilver Gear Lubricant (92-19007A24)

a - Forward Gear Bearing Installer (91-856875)

b - Needle Bearing, Numbered Side Toward Installer Tool

51876
a - Spring

6C-22 - LOWER UNIT 90-852572R1 JANUARY 1998

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

7 Loctite 271 (92-809820) 19152

a - Ring
d
3. Insert sleeve into holder*.
* Component of Wear Sleeve Installation Tool (91-14310A1).
c
a a
a
b

19166
a - Drive Shaft
b - Wear Sleeve Installation Tool
c - Surface
d - Surface
b
5. Remove excess Loctite from assembled shaft.

19169
a - Sleeve
b - Holder

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-23

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 Lower Drive Shaft Bearing Race Oil Sleeve Installation
Installation 1. Install oil sleeve with tab positioned as shown.
IMPORTANT: Lower drive shaft bearing cup can
be installed with or without upper drive shaft
bearing/sleeve and oil sleeve installed. b
1. Lubricate O.D. of bearing race with Quicksilver
2-4-C w/Teflon. a
2. Install shim(s) and bearing race into housing.
NOTE: Verify shim(s) are not cocked when drawing
up race.

f
d
e e
53934
c
f a - Oil Sleeve
b - Tab
d

Upper Drive Shaft Bearing Installation

1. Lubricate I.D. of bearing holder and O.D. of bear-
ing with 2-4-C w/Teflon.
a 2. Press bearing into sleeve.

c 95

95 53933
2-4-C With Teflon (92-825407A12)
d
a - Shim(s); Retained From Disassembly. If Shim(s) Were Lost
or a New Gear Housing is Being Assembled, Start With 95
c
0.025 in. (0.635mm) Shim(s)
b - Bearing Race a
c - Mandrel* (91-13780)
d - Mandrel* (91-13781) b
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)

* From Bearing Installation Tool (91-14309A1)

** From Bearing Removal and Installation Kit (91-31229A7)

95 2-4-C With Teflon (92-825407A12) 19164

a - Bearing Sleeve
b - Tapered End
c - Bearing; Numbered Side Toward Mandrel
d - Mandrel (91-13781); From Bearing Installation Tool
(91-14309A1)

6C-24 - LOWER UNIT 90-852572R1 JANUARY 1998

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 IMPORTANT: Oil sleeve must be installed prior to Forward Gear, Lower Drive Shaft
upper drive bearing installation.
Bearing, Pinion Gear, and Drive Shaft
IMPORTANT: Upper drive shaft bearing/sleeve Installation
can be installed with or without lower drive shaft
bearing cup installed. Model Drive Shaft Holding Tool
3. Install bearing/sleeve into housing. 50 Bigfoot (4-Stroke) 91-56775
f 60 Bigfoot 91-817070
75/90/100/115/125 91-56775
e
c 1. Install components in sequence shown.
e
d f e
c d
a b

53935 b
a - Bearing/Sleeve
b - Tapered End
c - Mandrel* (91-13781)
d - Mandrel* (91-13780)
e - Threaded Rod** (91-31229) c
f - Nut** (11-24156) f
* From Bearing Installation Tool (91-14309A1) 7 a
** From Bearing Removal and Installation Kit (91-31229A7)

7 Loctite 271 (92-809820) 19175

a - Forward Gear/Bearing: Work Quicksilver gear lube into

bearing rollers.
b - Lower Drive Shaft Tapered Roller Bearing: Work Quicksil-
ver gear lube into bearing rollers.
c - Pinion Gear
d - Drive Shaft
e - Drive Shaft Holding Tool
f - Pinion Nut (New): Apply Loctite 271 to threads during final
assembly (after pinion gear depth and forward gear back-
lash have been set), torque to 70 lb. ft. (95 N·m)

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-25

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 Pinion Gear Depth and Forward Gear 3. Measure distance between top of nut and bottom
of bolt head.
Backlash
4. Increase distance by 1 in. (25.4mm).
DETERMINING PINION GEAR DEPTH 5. Rotate drive shaft 5 to 10 revolutions. This should
NOTE: Read entire procedure before attempting any properly seat upper drive shaft tapered roller
change in shim thickness. bearing.
IMPORTANT: Forward gear assembly must be
installed in gear housing when checking pinion a
gear depth or an inaccurate measurement will be c
obtained.
1. Clean the gear housing bearing carrier shoulder
and diameter.
2. With gear housing positioned up right (drive shaft b
vertical), install Bearing Preload Tool (91-14311A2)
over drive shaft in sequence shown.
g

h h

e c
19884
f b
a - 1 in. (25.4mm)
b - Nut
a c - Bolt Head
d

a - Adaptor: Bearing surfaces clean and free of nicks

b - Thrust Bearing: Oiled and able to move freely
c - Thrust Washer: Clean and free of nicks and bends
d - Spring
e - Nut: Threaded all the way onto bolt
f - Bolt: Held snug against spring
g - Sleeve: Holes in sleeve must align with set screws
h - Set Screw (2): Tightened against drive shaft, bolt should
not slide on drive shaft.

6C-26 - LOWER UNIT 90-852572R1 JANUARY 1998

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 6. Assemble Pinion Gear Locating Tool (91-12349A2) 9. Insert tool into forward gear assembly; position
as shown; do not tighten collar retaining bolt at proper numbered flat (from chart) of gauging
this time. block – under pinion gear.
b d e GEAR RATIO USE
(PINION GEAR TEETH/ FLAT
MODEL REVERSE GEAR TEETH) NO.
50 Bigfoot (4-stroke) 13/30 8
60 Bigfoot/60 Sea-
pro/60 Marathon 13/30 8
c 75-thru-90
(3 Cylinder) 13/30 8
100/115/125
(4 Cylinder) 14/29 2

10. Install the number “3” locating disc against bear-

a c f ing carrier shoulder in gear housing.
11. Position access hole as shown.

a - Arbor
b - Gauging Block; Install With Numbers Away From Split
Collar
c - Bolt; Gauging Block Retaining
d - Split Collar
e - Bolt; Collar Retaining
f - Snap Ring
b
7. Insert tool into forward gear assembly; position
gauging block under pinion gear as shown.

a a

24643
a - Locating Disc
b - Access Hole

22067
a - Gauging Block

8. Remove tool, taking care not to change gauging

block position, and tighten collar retaining bolt.

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-27

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 12. Determine pinion gear depth by inserting a feeler Determining Forward Gear Backlash
gauge thru access hole in locating disc.
NOTE: Read entire procedure before attempting any
13. The correct clearance between gauging block change in shim thickness.
and pinion gear is 0.025 in. (0.64mm).
1. Obtain correct pinion gear depth; refer to “Deter-
14. If clearance is correct, leave Bearing Preload mining Pinion Gear Depth,” preceding.
Tool on drive shaft and proceed to “Determining
Forward Gear Backlash,” following. 2. Install Bearing Preload Tool (91-14311A2) on
drive shaft; refer to “Determining Pinion Gear
15. If clearance is incorrect, add (or subtract) shims Depth,” preceding.
from above bearing race to lower (or raise) pinion
gear. When reinstalling pinion nut, apply Loctite 3. Install components as shown.
271 on threads of nut.
c
a
d

a b
d
7
b

c
7 Loctite 271 (92-809820) 24643 53936

a - Feeler Gauge a - Propeller Shaft*

b - Gauging Block b - Bearing Carrier* (Assembled)
c - Pinion Gear c - Puller Jaws (91-46086A1)
d - Puller Bolt (91-85716); Torque to 45 lbs. in. (5.1 N·m)
d - Bearing Race

* Refer to “Bearing Carrier and Propeller Shaft Installation,”

following.

4. Rotate drive shaft 5 to 10 revolutions. This should

properly seat forward gear tapered roller bearing.

6C-28 - LOWER UNIT 90-852572R1 JANUARY 1998

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 5. Install components as shown. 7. Lightly turn drive shaft back and forth (no move-
ment should be noticed at propeller shaft).
e f
8. Dial Indicator registers amount of backlash,
which must be between specification shown in
chart.
DIAL
INDICATOR READING
MODEL MINIMUM MAXIMUM
d c 0.012 in. 0.019 in.
50 Bigfoot
(4-Stroke) (0.30mm) (.48mm)
0.012 in. 0.019 in.
60 Bigfoot
(0.30mm) (.48mm)
a
75-thru-90 0.012 in. 0.019 in.
(3 Cylinder) (0.30mm) (.48mm)
100/115/125 0.015 in. 0.022 in.
(4 Cylinder) (0.38mm) (0.55mm)

9. If backlash is less than the minimum specifica-

tion, remove shim(s) from in front of forward gear
bearing race to obtain correct backlash. When re-
installing pinion nut, apply Loctite 271 on threads
of nut.
10. If backlash is more than the maximum specifica-
c tion, add shim(s)* in front of forward gear bearing
b 51117 race to obtain correct backlash. When reinstal-
a - Threaded Rod (Obtain Locally) ling pinion nut, apply Loctite 271 on threads of
b - Washers nut.
c - Nuts
NOTE: By adding or subtracting 0.001 in. (0.03mm)
d - Dial Indicator Adaptor Kit (91-83155)
e - Dial Indicator (91-58222A1) shim, the backlash will change approximately 0.001
f - Backlash Indicator Tool in. (.03mm).

6. Position Dial Indicator on appropriate line (from

chart) marked on Backlash Indicator Tool.

ALIGN POINTER OF
MODEL DIAL INDICATOR WITH MARK
50 Bigfoot (4-stroke)
Backlash
4
Indicator
Tool (91-78473)
60 Seapro/60 Mara-
thon/60 Bigfoot
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--1)

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-29

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 Bearing Carrier and Propeller Shaft 4. Install bearing carrier and propeller shaft into
housing with the word “TOP” located on flange to-
Installation
ward top of housing.
1. Insert propeller shaft assembly into bearing
carrier.
2. Before installing bearing carrier assembly into
gear housing, obtain locally a 6 in. (152.4mm)
long by 1-1/4 in. – 1-1/2 in. (31.7mm – 38.1mm) b
diameter piece of PVC pipe. Install the PVC pipe c
over the prop shaft and secure the pipe against
the bearing carrier assembly with the propeller
nut and tab washer. This will allow the reverse
gear to apply pressure to the reverse gear thrust
bearing to prevent the thrust bearing from being
inadvertently dislodged as the bearing carrier as-
sembly is installed in the gear housing.
a
a b
c d 95
95
21044
95 2-4-C With Teflon (92-825407A12)
a - Apply 2-4-C w/Teflon
b - O-ring
c - TOP
e 21043

a - Bearing Carrier Assembly 5. Install components as shown.

b - PVC Pipe NOTE: Use thick 0.090 in. (2.29mm) washers
c - Tab Washer
d - Prop Shaft
(12-855941) under fasteners if not previously
e - Propeller Nut installed.
3. Lubricate O-ring and mating surfaces with 2-4-C
Washer Thickness Fastener Torque
w/Teflon.
0.090 in. (2.29mm) 22 lb. ft. (29.8 N·m)
0.060 in. (1.53mm) 25 lb. ft. (33.9 N·m)

b
a

a - Washers
b - Fasteners; (If using Bolts – Apply Loctite 271 on Threads)

6C-30 - LOWER UNIT 90-852572R1 JANUARY 1998

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 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 shoul-
der. 5. Lubricate lip of each seal with Quicksilver 2-4-C
w/Teflon.
2. Apply Loctite 271 on O.D. of seal; press seal into
water pump base until tool bottoms. Lubricate
seal lip with Quicksilver 2-4-C w/Teflon. 95 a 7

95 a 7

c
c

51553
7 Loctite 271 (92-809820)
95 2-4-C With Teflon (92-825407A12)

7 Loctite 271 (92-809820) 51553 a - Seal (Gloss Black Color – Lip faces toward Gear Case)
b - Spring Faces Toward Gear Case
95 2-4-C With Teflon (92-825407A12) c - Oil Seal Driver (91-13949)

a - Seal – Teflon Coated Lip (Flat Brownish Color – Lip faces

toward Power Head) 6. Install gasket.
b - Spring Faces Toward Power Head
c - Oil Seal Driver (91-13949)
a

19218
a - Gasket

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-31

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 7. Install components as shown. 9. Install gasket, drive key and impeller.

a 7 c
b

b
a

19220
a - Gasket
b - Drive Key
7 Loctite 271 (92-809820) 19217 c - Impeller
a - Water Pump Base
b - Bolts and Washers; Apply Loctite 271 on bottom 1/2 of 10. Lubricate I.D. of cover with Quicksilver 2-4-C w/
Threads and Torque to 60 lb. in. (6.8 N·m) Teflon.

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 and install as shown.

95
19219
a - Gasket b
b - Plate
7
IMPORTANT: If the old impeller will be re-used, 95 a
c
impeller must be installed in original (clockwise)
direction of rotation.

7 Loctite 271 (92-809820) 19212

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

a - Cover
b - Seal
c - Bolts (4); Apply Loctite 271 on Threads and Torque to
60 lb. in. (6.8 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(68-82kPa) for 5 minutes.
52869

6C-32 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Gear Housing Pressure Test Filling Gear Housing With
1. Remove vent plug and install pressure test Lubricant
gauge.
NOTE: Gear housing lubricant capacity is 22.5 fl. oz.
(665.2ml).

WARNING
If gear housing is installed on engine, to avoid ac-
cidental starting, disconnect (and isolate) spark
plug leads from spark plugs before working near
the propeller.

CAUTION
Do not use automotive grease in the gear hous-
ing. Use only Quicksilver Gear Lube or Quicksil-
ver Super-Duty Lower Unit Lubricant.
1. Remove any gasket material from “Fill” and
“Vent” screws and gear housing.
2. Install new gaskets on “Fill” and “Vent” screws.
2. Pressurized housing to 10 to 12 psi (69-82 kPa) IMPORTANT: Never apply lubricant to gear hous-
and observe gauge for 5 minutes. ing without first removing “Vent” screws or gear
3. Rotate drive shaft, prop shaft and move shift housing cannot be filled because of trapped air.
shaft while housing is pressurized to check for Fill gear housing only when housing is in a verti-
leaks. cal position.
3. Insert lubricant tube into “Fill” hole.
4. 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

water.
5. Re-pressurize to 10 to 12 psi (69-82 kPa) and
check for air bubbles.
6. Replace leaking seals as necessary. Retest
housing.
NOTE: Gearcase should hold 10 to 12 psi (69-82
kPa) for 5 minutes.
7. Remove tester from housing and install vent
plug. Torque vent screw to 60 lb. in. (6.8 N·m).

90-852572R1 JANUARY 1998 LOWER UNIT - 6C-33

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 5. Replace this lubricant “Vent” screw and gasket Gearcase Installation
only and continue filling until excess starts to flow
out of second lubricant “Vent” screw hole.
WARNING
Disconnect (and isolate) spark plug leads from
spark plugs before installing gear housing onto
drive shaft housing. Failure to follow this warn-
ing could result in accidental engine starting and
possible injury.
a
c 1. Position outboard shift linkage into forward gear
position.
Models 40/45/50 Bigfoot (4-Stroke)

53922

a - Vent Screw (Torque to 60 lb. in. (6.8 N·m)

b - Fill/Drain Screw (Torque to 60 lb. in. (6.8 N·m)
c - Oil Level Vent Screw (Torque to 60 lb. in. (6.8 N·m) a
6. Replace second lubricant “Vent” screw and Remote Control Model Shown
gasket. a - Shift Lever
Models 60 Bigfoot
IMPORTANT: Do not lose more than one fluid
ounce (30cc) of gear lubricant while reinstalling
“FILL” screw.
7. Remove lubricant tube from “Fill” hole; install
“Fill” screw and gasket. Torque “Fill” screw to 60
lb. in. (6.8 N·m).

a - Shift Block
Models 75/90/100/115/125

a b

19879

a - Shift Block; Front of Block MUST Extend 1/8 in. (3.2mm)

Past Front of Rail.
b - Rail

2. Tilt engine to full “UP” position and engage tilt

6C-34 - LOWER UNIT 90-852572R1 JANUARY 1998

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 lock lever. 8. Install components as shown in appropriate
photo.
3. Shift gear housing into neutral position. Propeller
shaft will rotate freely in either direction. POWER TRIM MODELS
4. Install water tube seal; lube I.D. of seal with
Quicksilver 2-4-C w/Teflon (92-825407A12).
5. Apply a bead of RTV Sealer as shown. c

95
b
a
78

a
b

53938 53968

78 G. E. RTV Sealant (92-90113--2) a - Nylon Spacer

b - Shift Shaft Coupler; Used on Models Equipped with
95 2-4-C With Teflon (92-825407A12) Power Trim
c - Bushing 40/45/50 Bigfoot (4-Stroke) Only
a - Water Tube Seal
b - RTV Sealer
NON-POWER TRIM MODELS

CAUTION a b
Do not use lubricant on top of drive shaft. Excess
lubricant, that is trapped in clearance space, will c
not allow drive shaft to fully engage with crank-
shaft. Subsequently, tightening the gear housing
fasteners (while lubricant is on top of drive shaft)
will load the drive shaft/crankshaft and damage
either or both the power head and gear housing.
Top of drive shaft is to be wiped free of lubricant.
6. Apply a light coat of Quicksilver 2-4-C w/Teflon
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.

53925

a - Nylon Spacer
b - Shift Shaft Coupler; Used on Models NOT Equipped with
Power Trim
c - Flat; MUST BE Positioned Toward Front of Gear Housing

9. Shift gear housing into forward gear position. In

forward gear the gear housing will ratchet when
propeller shaft is turned clockwise and resistance
will be felt when propeller shaft is rotated counter-
clockwise.

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 10. Apply Loctite Grade 271 on threads of gear hous- IMPORTANT: If shift operation is not as de-
ing retaining bolts. scribed, preceding, the gear housing must be re-
moved and the cause corrected.
NOTE: If, while performing Step 11, the drive shaft
splines will not align with the crankshaft splines,
place a propeller onto propeller shaft and turn it coun-
terclockwise as the gear housing is being pushed to- Trim Tab Adjustment
ward drive shaft housing. 1. Check trim tab position as follows:
NOTE: During installation of gear housing, it may be a. Operate boat at the speed at which it normally
necessary to move the shift block (located under would be operated.
cowl) slightly to align upper shift shaft splines with
shift shaft coupler splines. b. If the boat pulls to the right (STARBOARD),
the trailing edge of trim tab must be moved to
11. Position gear housing so that the drive shaft is the right. If the boat pulls to the left (PORT),
protruding into drive shaft housing. the trailing edge of trim tab must be moved to
12. Move gear housing up toward drive shaft hous- the left.
ing, while aligning upper shift shaft splines with 2. If necessary, adjust trim tab as follows:
shift shaft coupler splines, water tube with water
tube seal, and crank shaft splines with drive shaft a. Shift engine control into NEUTRAL and turn
splines. ignition key to “OFF” position.

13. Install 4 bolts and washers (two each side). NOTE: Loosen trim tab bolt sufficiently to allow trim
tab to disengage from locking ridges in gear case be-
14. Install locknut and washer. fore attempting to move tab. DO NOT strike trim tab
15. Torque bolts and locknut (or nuts only if applica- with a hard object to make adjustments.
ble) to 40 lbs. ft. (54.0 N·m). b. If boat pulls to the left, adjust trailing edge of
trim tab to the left. If boat pulls to the right, ad-
just trailing edge of trim tab to the right.
3. Tighten trim tab retaining bolt and washer to
22 lb. ft. (30.0 N·m).
b a

53922
a - Bolts and Washers (4)
b - Locknut and Washer

16. Check shift operation as follows:

a. Place shift lever in forward gear. Gear hous-
ing should ratchet when propeller shaft is
turned clockwise and resistance should be
felt when propeller shaft is turned counter-
clockwise.
b. Place shift lever in neutral. Propeller shaft
should rotate freely in either direction.
c. While rotating propeller shaft, place shift
lever in reverse gear. Resistance should be
felt when propeller shaft is rotated in either
direction.

6C-36 - LOWER UNIT 90-852572R1 JANUARY 1998

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 LOWER UNIT

6
D

JET DRIVE

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 Table of Contents
Page
Jet 30 Pump Assembly . . . . . . . . . . . . . . . . . . 6D-2
Jet 30 Water Pump Components . . . . . . . . . 6D-4
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-5
Jet 45 Pump Assembly . . . . . . . . . . . . . . . . . . 6D-6
Jet 45 Water Pump Components . . . . . . . . . 6D-8
Selecting A Boat That Is Best Suited For
Jet Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-9
Engine Horsepower Selection . . . . . . . . . . . . 6D-9
Transom Height Of The Boat . . . . . . . . . . . . 6D-10
Locate Center line Of The Outboard . . . . . . 6D-10
Outboard Mounting Height . . . . . . . . . . . . . . . 6D-10
Setting Outboard Mounting Height On
Boats With Flat Bottom Hulls . . . . . . . . . . 6D-11
Water Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-11
Checking for Cavitation . . . . . . . . . . . . . . . 6D-11
Shift Cable Installation . . . . . . . . . . . . . . . . . . 6D-12
Lubricating The Drive Shaft Bearing . . . . . . 6D-13
Impeller Removal and Installation . . . . . . . . 6D-13
Steering Pull Adjustment . . . . . . . . . . . . . . . . 6D-15
Impeller Clearance Adjustment . . . . . . . . . . . 6D-15
Worn (Dull) Impeller . . . . . . . . . . . . . . . . . . . . 6D-15
Flushing The Cooling System . . . . . . . . . . . . 6D-16
Liner Replacement . . . . . . . . . . . . . . . . . . . . . 6D-16
Jet Drive Removal . . . . . . . . . . . . . . . . . . . . . . 6D-16
Water Pump Removal and Installation . . . . 6D-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-18
Reassembling Water Pump to Jet Drive 6D-18
Bearing Carrier Removal . . . . . . . . . . . . . . . . 6D-19
Bearing Carrier Disassembly . . . . . . . . . . . . . 6D-19
Bearing Carrier Reassembly . . . . . . . . . . . . . 6D-19
Installing Lower Seals . . . . . . . . . . . . . . . . 6D-19
Installing Upper Seals . . . . . . . . . . . . . . . . 6D-20
Installing Drive Shaft Ball Bearing . . . . . . 6D-20
Installing Drive Shaft . . . . . . . . . . . . . . . . . 6D-20
Installing Upper Seal Housing
(Continued) . . . . . . . . . . . . . . . . . . . . . . . . . 6D-21
Installing Jet Drive to Drive Shaft
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-22

6D-0 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 LOWER UNIT - 6D-1

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 Jet 30 Pump Assembly

23
26
28
28
17 18 24
15 19 26
25
26
16 27
20
20

22
21 2
95
3

9
10
11

5
6

6
14 12

13

95 2-4-C With Teflon (92-850736A1)

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 Jet 30 Pump Assembly
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 JET PUMP ASSEMBLY (BLACK)
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 3/4) 70 6 8.0
13 4 SCREW (1/4-20 x .875) 70 6 8.0
14 4 WASHER
15 2 SCREW (1/4-20 x .625) 70 6 8.0
16 2 WASHER
17 1 SCREW (.312-18 x 1.25) 155 13 17.6
18 1 BRACKET
19 1 NUT 155 13 17.6
20 2 PIN-Dowel
2 SCREW (.312-18 x 2-1/2 IN.) 155 13 17.6
21
2 SCREW (.312-18 x 2-3/4 IN.) 155 13 17.6
22 4 WASHER
23 1 SCREW (.375-16 x 1-1/4 IN.) 220 18.4 24.9
24 1 ADAPTOR
25 1 SCREW (M10 x 30) 301 25 34
26 6 WASHER
27 4 SCREW 301 25 34
28 2 DOWEL PIN

90-852572R1 JANUARY 1998 LOWER UNIT - 6D-3

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 Jet 30 Water Pump Components

10

3
74
1
7
2

95
4
9

5
6

7 Loctite 271 (92-809819)

74 Loctite 405 11
95 2-4-C w/Teflon (92-850736A1)

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 4 SCREW (M6 x 16) 60 5 6.8
2 1 WATER PUMP ASSEMBLY
3 1 SEAL–Water Tube
4 1 WASHER
5 1 KEY
6 1 WASHER
7 1 GASKET
8 1 FACE PLATE
9 1 IMPELLER
10 1 WATER TUBE EXTENSION
11 1 GASKET

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 Notes:

90-852572R1 JANUARY 1998 LOWER UNIT - 6D-5

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 Jet 45 Pump Assembly

16 17
15
18

23 19
19 24

22
2
21

20

9
10
11

5
6

12
6 13
14

6D-6 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Jet 45 Pump Assembly
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 JET PUMP ASSEMBLY (BLACK)
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
9 1 KEY
10 8 SHIM
11 1 TAB WASHER
12 6 STUD (.312-18 x 1.81)
13 6 NUT
14 4 SCREW (.312-18 x .1) 156 13 17.6
15 2 SCREW (1/4-20 x .625) 97 8 11
16 1 SCREW (.312-18 x 1.25) 156 13 17.6
17 1 BRACKET
18 1 NUT
19 2 PIN-Dowel
20 2 SCREW (M10 x 60) 301 25 34
21 1 SCREW (M10 x 90) 301 25 34
22 1 SCREW (M10 x 70) 301 25 34
23 1 SCREW (.375-16 x .3-1/4) 266 22 30
24 1 WASHER

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 Jet 45 Water Pump Components

5
7

1
95
4
7

95 2-4-C With Teflon (92-850736A1)

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 IMPELLER
2 1 KEY
3 1 WATER PUMP
4 1 GASKET (UPPER)
5 1 SEAL
6 1 FACE PLATE
7 6 SCREW 60 5 6.7

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 Selecting A Boat That Is Engine Horsepower
Best Suited For Jet Power Selection
To obtain the best performance from the jet drive, the A boat operating at slow speed requires considerably
boat should have the following features: more depth than one which is planing on the surface
of the water. It is important, therefore, to use sufficient
1. The boat should be as light as possible.
horsepower and not to overload your boat beyond its
2. The boat should have hull and transom that is de- ability to plane. See the following table.
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.

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 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 wa-
driven outboards. This requires outboards that have ter intake housing. Make a horizontal line on the
a 15 in. shaft length to be installed on boats having transom up from the “V” bottom the same length
a 22 in. transom height and outboards that have a 20 as the width of the water intake housing.
in. shaft length to be installed on boats having a 27
in. transom height.
If the boat transom is of insufficient height, and the a
outboard cannot be installed to the recommended
height, contact the boat manufacturer for recom-
mended procedure to build up the boat transom.
b
a - Horizontal Line
Locate Center Line of the b - Water Intake Housing
2. Place (center) the outboard on the boat transom
Outboard so that the transom brackets are resting on top of
Locate (and mark with pencil) the vertical centerline the transom. Temporally fasten the outboard to
of boat transom. the transom using two C-clamps.
3. Position the outboard in a vertical position.
4. Line-up a straight edge along the bottom of the
boat with the horizontal line made in Step 1 and
A B measure the distance between the horizontal line
a and top front edge of the water intake housing.

C D

a - Centerline of Transom

Outboard Mounting Height

The initial outboard mounting height setting will work a
good for most applications, however, because of dif- b
ferent boat/hulls designs, the setting should be re- a - Straight Edge
checked by test-running the boat. Refer to “Water b - Water Intake Housing
Testing”. 5. Raise the outboard up on the transom the dis-
• Installing the outboard too high on the transom will tance measured in Step 4. Use a straight edge
allow the water intake to suck in air and cause ca- and recheck the mounting height. The top edge
vitation. (cavitation will cause the engine to over- of the water intake housing should be lined up
speed in spurts and reduce thrust). This condition with the horizontal line made in Step 1.
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.

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 Setting Outboard Mounting Height When operating the boat, the outboard drive shaft
should be vertical when planing or tilted toward the
on Boats with Flat Bottom Hulls
boat in order to provide a scooping angle on the water
1. Place (center) the outboard on the boat transom intake. Tilting the outboard out beyond a vertical
so that the transom brackets are resting on top of position reduces the scoop angle and can cause im-
the transom. Temporarily fasten the outboard to peller slippage and cavitation. If the angle of the boat
the transom using two C-clamps. transom does not allow the drive shaft to be posi-
2. Position the outboard in a vertical position. tioned vertical a Wedge kit should be installed behind
the transom brackets to increase the tilt-in angle.
3. Place a straight edge along the bottom of the boat
as shown and measure the distance between the NOTE: Slight cavitation in sharp turns and rough wa-
bottom of the boat and top front edge of the water ter is acceptable but excessive cavitation is harmful
intake housing. to the outboard and should be avoided.
Test run the boat. If cavitation occurs (air enters the
pump causing loss of thrust, engine over-speeds er-
ratically). the first thing to try is lowering the outboard
height 1/4 in. This can be accomplished by elongat-
ing 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
manufacturer.
a
A number of other options are available to further re-
b
duce cavitation.
a - Straight Edge
b - Top Edge of Water Intake Housing 1. Water intake fin kit – Available from the Specialty
Mfg. Co. for jet models 30 thru 140. The purpose
4. Raise the outboard up on the transom the dis-
of these fins is to ram more water into the intake
tance measured in Step 3. Use a straight edge
and shield the forward sides of the intake from the
and recheck the mounting height. The top edge
entrance of air. This kit will help reduce cavitation
of the water intake housing should be in line with
when running with the wind in a chop.
the bottom of the boat as shown.

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.
San Leandro, CA 94577
Checking for Cavitation
Making the initial outboard height setting should be
close to the optimum setting for the outboard. How-
ever because of the hull design of some boats, ob-
structions or imperfections in the hull ahead of the
water intake may require this setting to change in or-
der to prevent cavitation at running speeds.

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 Water testing 4. Attach the brass barrel 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 bar-
rel must be free to pivot.
2. Rough Water Plate – 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,
reduce spray.

b
a

d
a - Shift Cable
b - Shift Cam
c - Barrel
a - Rough Water Plate d - Roller

Shift Cable Installation 5. Recheck the shift cable adjustment in forward

shift position. The correct shift adjustment will
WARNING position the cam far enough on the roller in order
to lock the reverse gate into forward position. You
The shift cable must be adjusted to lock the re-
should not be able to forcibly push up the reverse
verse gate against unexpected engagement gate toward neutral. Pull on the reverse gate by
(caused by water pressure hitting the gate) while hand to verify this.
operating the boat in forward. Activation of the
reverse gate will cause sudden unexpected stop- IMPORTANT: The forward locking of the reverse
ping of the boat. Sudden stopping may cause oc- gate must be met. If not, readjust the shift cable.
cupants to be thrown within the boat or even out
of the boat. This action may result in serious inju-
ry or death.
1. Attach shift cable to the shift cam 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
position.
3. Adjust the brass barrel on the shift cable so that
roller is at the full end of travel (bottom) in the shift
cam when the remote control is in full forward.

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 Lubricating The Drive Shaft Impeller Removal and
Bearing Installation
Recommended Lubrication - Use Quicksilver
2-4-C w/Teflon, or Lubricant 630-AA Grease. REMOVAL

IMPORTANT: It is important that you do not use 1. Shift outboard to NEUTRAL (N) position.
a general-all-purpose grease for this bearing. 2. Remove spark plug leads to prevent engine from
The lubricant we recommend is a water resistant starting.
grease of the proper consistency for this applica-
3. Remove the water intake housing that is fastened
tion. If you use a substitute grease, be sure that
with six screws.
it is water resistant and of the same consistency.
Frequency of Lubrication - We recommend lubri-
cating the drive shaft bearing after each day’s use
and after 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 on the impeller nut re-

tainer and remove the impeller nut.
b c 5. Pull impeller straight off the shaft. If the impeller
is tight, use a hammer and block of wood to rotate
the impeller (clockwise) on the shaft until the key-
way is directly above the flat on the shaft. This will
free the jammed key and allow removal.
a - Vent Hose
b - Grease Gun
c - Grease Exiting Vent Hose
Lubricating Procedure - Pull vent hose off the
grease fitting. Pump in grease through the grease fit-
ting (using the grease gun provided) until excess
grease starts to exit the vent hose.
Reconnect the vent hose (a) onto the grease fitting
after 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 b
of conditions inside the bearing housing. A gradual a
increase in moisture content, indicates seal wear. If
the grease begins to turn dark, dirty gray, the drive a - Tab
shaft bearing and seals should be inspected and re- b - Nut
placed if necessary. Some discoloration of the
grease is normal during the break-in period on a new
set of seals.

90-852572R1 JANUARY 1998 LOWER UNIT - 6D-13

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 INSTALLATION 3. After setting the impeller height, tighten the im-
peller nut snug with a wrench. Secure impeller
1. Grease the drive shaft, shear key, and impeller
nut by bending tabs against the flats on the impel-
bore. Place the plastic sleeve inside the impeller
ler nut.
and install impeller, shear key, shims nut retainer,
and impeller nut. 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 re-
tainer over and re-tighten the nut again.

a
a
a - Tabs

b 4. Reinstall the water intake housing with six bolts.

Check clearance around the impeller to make
sure the water intake housing is centered and not
c rubbing against the liner. Torque mounting bolts
d to 100 lb. in. (11.2 N·m).
e
NOTE: If the outboard is used in salt water, apply
f Quicksilver Anti-Corrosion Grease around the entire
a - Plastic Sleeve
mounting flange on the water intake housing and also
b - Impeller
c - Shear Key to the threads on the six mounting bolts.
d - Shims
e - Nut Retainer
f - Impeller Nut

2. Temporarily reinstall the water intake housing in

order to check for impeller clearance. The clear-
ance between the impeller and liner should be
0.030 in. (0.8 mm). Shim washers can be trans-
ferred to either side of the impeller to raise or low-
er the impeller to the correct clearance setting.
The water intake housing can be shifted side
ways a small amount in order to center the liner.

6D-14 - LOWER UNIT 90-852572R1 JANUARY 1998

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

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 acceleration, (2) difficulty getting the boat on plane,
approximately 0.03 in. (0.8mm) clearance be- or (3) an increase in engine RPM at wide open
tween the impeller edge and liner. Operating the throttle. Check the impeller blades occasionally for
jet drive in waters that contain sand and gravel damage. Use a flat file to resharpen the leading
can cause wear to the impeller blades, and the edges as shown.
clearance will start to exceed 0.03 in. (0.8mm).
As the blades wear, shims located in the stack
outside of the impeller can be transferred behind
the impeller. This will move the impeller further
down into the tapered liner to reduce the clear-
ance.
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 Remov-
al and Installation”.

a - Shims

90-852572R1 JANUARY 1998 LOWER UNIT - 6D-15

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 Flushing The Cooling 2. Remove the liner. If the liner is tight, tap on the in-
ner edge of the liner with a long drift punch
System through the intake grate.
Use Quicksilver accessory hose coupling Part Num- NOTE: Apply grease to the liner mounting bolt
ber 24789A1. threads before assembly.
1. Remove plug and gasket and thread-in hose cou- 3. Position the liner into the water intake housing.
pling. Line up one of the liner bolts and lightly thread it
in. It may be necessary to tap or press the liner
2. Attach a water hose to the hose coupling. Turn on
into the water intake housing to locate the liner for
the water gently, start the engine, and run it at idle
installation of the remaining bolts. Torque bolts to
speed only.
100 lbs. in. (11.2 N·m)
3. Check for a steady stream of water flowing out of
4. Grind off the ends of any bolts that may extend
the water pump indicator hole. Continue flushing
beyond the inner liner surface.
the outboard for 3 to 5 minutes; adjust water pres-
sure if needed.
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.
3. Remove the water intake housing that is fastened
with six screws.
a

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.

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 4. Straighten the bent tabs on the impeller nut re-
tainer and remove the impeller nut.
5. Pull impeller straight off the shaft. If the impeller
is tight, use a hammer and block of wood to rotate
the impeller (clockwise) on the shaft until the key-
way is directly above the flat on the shaft. This will
free the jammed key and allow removal.

b
a

a - Tabs
b - Nut
6. Remove 5 bolts securing jet drive to drive shaft
housing and remove pump.

54165

a - Bolts (4)
b - Bolt (1)

90-852572R1 JANUARY 1998 LOWER UNIT - 6D-17

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 Water Pump Removal and b. Impeller is glazed or melted (caused by insuf-
ficient water supply.)
Installation c. Rubber portion of impeller is not bonded to
impeller hub.
Removal 1. Install face plate, gasket(s) and impeller key.
1. Remove water pump assembly as shown IMPORTANT: If impeller being installed has been
according to model size. previously used and vanes have taken a “set,”
DO NOT INSTALL THE IMPELLER WITH THE
VANES REVERSED FROM THEIR PREVIOUS
Reassembling Water Pump to Jet “SET” AS VANE BREAKAGE WILL OCCUR
SHORTLY AFTER UNIT IS RETURNED TO SER-
Drive VICE.
NOTE: Replace water pump cover if thickness of 2. Install impeller.
steel at discharge slots is 0.060 in. (1.524mm) or
less, or if groove(s) (other than impeller sealing NOTE: Apply a light coat of 2-4-C w/Teflon to inside
groove) in cover roof are more than 0.030 in. of pump cover to ease installation of cover over im-
(0.762mm) deep. peller.
NOTE: Replace impeller if: 3. Install pump cover. Rotate drive shaft CLOCK-
WISE while pressing cover down over impeller.
a. Impeller blades are cracked, torn or worn.
4. Apply Loctite 271 to retaining screws (4) and
torque to 60 lb. in. (6.8 N·m).

j 45 Hp e g
30 Hp
c
c
74 a 95
b
7
b a
95 d
i d

e
f f

k
54258

a - Screw a - Impeller
b - Water Pump Cover Assembly b - Key
c - Seal c - Water Pump Cover Assembly
d - Washer d - Gasket
e - Key e - Seal
f - Washer f - Face Plate
g - Gasket g - Screw
h - Face Plate
7 Loctite “271” (92-809819)
i - Impeller
j - Water Tube Extension 74 Loctite “405” (Purchase Locally)
k - Gasket
95 2-4-C w/Teflon (92-850736A1)

6D-18 - LOWER UNIT 90-852572R1 JANUARY 1998

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 Bearing Carrier Removal Bearing Carrier Reassembly
1. Remove 4 bolts securing bearing carrier to jet
drive. Installing Lower Seals
a Install seals into bearing carrier as follows:
1. Install O-ring seals into the top seats of the three
passage holes.
2. Install spiral retaining ring into the inner ring
groove.
3. Spread a film of grease around the inside bore of
the seal surface before pressing in the seals.
a 54165 4. Press in the garter spring seal against the inner
retaining ring as shown. Fill the garter spring cav-
a - Bolts ity in the seal with grease.
5. Install spiral retaining ring into the outer ring
groove. Align the notched ends of the retaining
Bearing Carrier Disassembly ring to straddle the small vent hole drilled in the
ring groove.
1. Remove the large beveled snap ring from the
bearing carrier. 6. Press in the outer seal against the retaining ring
as shown.
2. Heat the bearing carrier with a torch only until you
can barely touch it. 7. Grease all the seal lips.
3. Hold the drive shaft vertical and bump the impel- a
ler end of the drive shaft against a wooden block
causing the bearing carrier to slide down off the
bearing.
4. Remove snap ring, press the ball bearing off the
drive shaft. Leave the bearing thrust ring (located
in the drive shaft groove) unless damaged.
5. Remove the seals and spiral retaining rings from
the bearing carrier and the upper seal housing.
6. Clean all parts thoroughly and remove any burrs.

d a
a
e b
c

d e
c f
b a - O-rings
f
a - Snap Ring b - Retaining Ring
b - Bearing Carrier c - Spring Seal
c - Ball Bearing d - Retaining Ring
d - Upper Seal Housing e - Outer Seal
e - Snap Ring f - The Notched ends of the Retaining Ring Must Straddle this
f - Thrust Ring Vent Hole

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 Installing Upper Seals Installing Drive Shaft Ball Bearing
1. Install spiral retaining ring into the inner ring 1. If removed, install the bearing thrust ring into the
groove of the upper seal housing. groove on the drive shaft.
2. Spread a film of grease around the inside bore of 2. Install collar onto the drive shaft. Press the new
the seal surface before pressing in the seals. ball bearing onto the drive shaft, pressing
against the inner race only. Press collar over
3. Press in the garter spring seal against the inner
the thrust ring, locking it in its groove. Install snap
retaining ring as shown. Fill the garter spring cav-
ring into drive shaft groove below the bearing.
ity in the seal with grease.
4. Install spiral retaining ring into the outer ring a
groove. Align the notched ends of the retaining b
ring to straddle the small vent hole drilled in the a
c b
ring groove.
5. Press in the outer seal against the retaining ring
as shown.
6. Grease all the seal lips. d
7. Grease the two O-ring seals and install them into c d
the outer ring grooves. a - Bearing Thrust Ring
b - Collar
c - Ball Bearing
d - Snap Ring
Installing Drive Shaft
1. Lubricate the seals and inside bore of the bearing
carrier.
2. Place the drive shaft (impeller end facing up) into
e a vise.
3. Heat the bearing carrier until it feels warm to the
touch.
4. Place the bearing carrier onto the drive shaft.
Square up the inner bore with the ball bearing and
c d push the bearing carrier down until it bottoms-out
against the bearing. It may be necessary to lightly
tap bearing carrier onto the bearing using a rub-
ber 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 rub-
b ber hammer.
a
f

a
a - Retaining Ring
b - Spring Seal
c - Retaining Ring
d - Outer Seal
e - O-rings
f - The Notched ends of the Retaining Ring Must Straddle this b
Vent Hole

a - Bearing Carrier
b - Drive Shaft

6D-20 - LOWER UNIT 90-852572R1 JANUARY 1998

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 5. Grease the upper seals and inside bore of the Bearing Carrier Installation
bearing carrier to ease entry of the seal housing.
1. Install the bearing carrier into the jet drive. Se-
6. Install the thrust washer against the ball bearing. cure carrier in drive with 4 bolts. Torque bolts to
7. Install spacer, and the upper seal housing being 70 lb. in. (7.9 N·m).
careful not to damage the O-ring seals as they 2. Fill carrier with grease, using the grease gun sup-
pass the snap ring groove. Only finger pressure plied with the jet drive. If using a hand lever gun,
should be necessary to push in the housing. pump very slowly so as to not build up internal
8. Install the beveled snap ring, beveled side facing grease pressure and damage the seals or hous-
up into the ring groove. Make sure the snap ring ing.
is fully seated into groove.

a - Snap Ring
b - Upper Seal Housing
c - Spacer e
d - Thrust Washer
e - Bolts [Torque to 70 lb. in. (7.9 N·m)]

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 Installing Jet Drive to Drive Shaft 5. Grease the drive shaft, shear key, and impeller
bore. Place the plastic sleeve inside the impeller
Housing
and install impeller, shear key, shims nut retainer,
1. Apply a light coat of 2-4-C w/Teflon to the drive and impeller nut. Turn the nut tight on the shaft to
shaft splines. DO NOT APPLY GREASE TO THE remove any play between the impeller and shaft.
TOP OF THE DRIVE SHAFT AS THE GREASE If the tabs on the retainer do not line up with the
WILL PREVENT THE DRIVE SHAFT FROM flats on the nut, remove the nut and turn the re-
FULLY ENGAGING THE CRANKSHAFT AND tainer over and re-tighten the nut again.
DAMAGE TO THE POWERHEAD AND/OR
GEAR 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.
a
3. Secure jet drive to drive shaft housing with 4
bolts. Torque bolts to 25 lb. ft. (34.0 N·m)].

c
a d
e
f
a 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

order to check for impeller clearance. The clear-
a - Bolts [Torque to 25 lb. ft. (33.9 N·m)]
ance between the impeller and liner should be
4. Secure aft end of jet drive to drive shaft housing 0.030 in. (0.8 mm). Shim washers can be trans-
with bolt and washer. Torque bolt to 22.5 lb. ft. (30 ferred to either side of the impeller to raise or low-
.5 N·m). er the impeller to the correct clearance setting.
The water intake housing can be shifted side
ways a small amount in order to center the liner.

a - Bolt and Washer [Torque to 22.5 N·m)]

.03 in. (.8mm)

6D-22 - LOWER UNIT 90-852572R1 JANUARY 1998

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 7. After setting the impeller height, tighten the im- NOTE: If the outboard is used in salt water, apply
peller nut snug with a wrench. Secure impeller Quicksilver Anti-Corrosion Grease around the entire
nut by bending tabs against the flats on the impel- mounting flange on the water intake housing and also
ler 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 9. Refer to “SHIFT CABLE INSTALLATION” page
sure the water intake housing is centered and not 12 and reinstall shift cable to jet drive.
rubbing against the liner. Torque mounting bolts
to 100 lbs. in. (11.5 N·m).

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 ATTACHMENTS/CONTROL
LINKAGE

7
A
THROTTLE/SHIFT LINKAGE

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 Table of Contents
Page
Throttle Lever And Linkage 40/50 . . . . . . . . 7A-2
Throttle Lever And Linkage 55/60 . . . . . . . . 7A-4

7A-0 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7A-1

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 Throttle Lever And Linkage 40/50

21
20
16 2 12
18
22 3
10
95 11
9
19 8

17
95

95
13 6
5
1
7

14
4

15

33 Loctite “680” (92-809833)

95 2-4-C w/Teflon (92-850736A1)

A = ELECTRIC B = HANDLE VERSIONS

7A-2 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Throttle Lever And Linkage 40/50
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 1 WASHER
6 1 NUT Drive Tight
7 1 ADJUSTING SCREW (M6 x 55)
8 1 JAM NUT
9 1 CAP
10 1 BUSHING
11 1 INSERT
12 1 SCREW (M10 x 45) Drive Tight but Joint
must move freely
13 1 SWIVEL BUSHING
14 1 SPRING
15 1 WASHER
16 1 SPARK ADVANCE LEVER
17 1 SPARK ADVANCE ROD
18 1 SWIVEL BASE
19 1 ADJUSTING SCREW (M6 x 55)
20 1 JAM NUT
21 1 CAP
22 1 SWIVEL BALL
23 1 STUD
24 1 SPRING (ELECTRIC)
25 1 THROTTLE CAM
26 1 SWIVEL BUSHING
27 1 THROTTLE ROD
28 1 WASHER
29 1 NUT Drive Tight but joint
must move freely
30 1 WASHER (ELECTRIC)
31 1 BRACKET-Throttle cable HANDLE VERSIONS
32 1 SCREW (M6 x 16) 80 6.6 9.0

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 Throttle Lever And Linkage 55/60
21
20
2 12
18 16
3
22
95
10
11
9
19 8

17
95

95

13 6
5
1
7

14
4

15

33 Loctite “680” (92-809833)

95 2-4-C w/Teflon (92-850736A1)

7A-4 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Throttle Lever And Linkage 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 THROTTLE LEVER
2 1 ADJUSTING SCREW (M5 x 35)
3 1 JAM NUT
4 1 PIN
5 1 WASHER
6 1 NUT Drive Tight
7 1 ADJUSTING SCREW (M6 x 55)
8 1 JAM NUT
9 1 CAP
10 1 BUSHING
11 1 INSERT
12 1 SCREW (M10 x 45) Drive Tight but Joint
must move freely
13 2 SWIVEL BUSHING
14 1 SPRING
15 1 WASHER
– 1 SPARK ADVANCE LEVER ASSEMBLY
16 1 SPARK ADVANCE LEVER
17 1 SPARK ADVANCE ROD
18 1 SWIVEL BASE
19 1 ADJUSTING SCREW (M6 x 55)
20 1 JAM NUT
21 1 CAP
22 1 SWIVEL BALL
23 1 STUD
24 1 SPRING
25 1 THROTTLE CAM
26 1 THROTTLE ROD
27 1 WASHER
28 1 NUT Drive Tight but joint
must move freely
29 1 WASHER

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7A-5

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 ATTACHMENTS/CONTROL
LINKAGE

7
B
TILLER HANDLE

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 Table of Contents
Page
Tiller Handle 40/50 . . . . . . . . . . . . . . . . . . . . . 7B-2
Tiller Handle 40/50 . . . . . . . . . . . . . . . . . . . . . 7B-3
Steering Handle Kit 55/60 . . . . . . . . . . . . . . . 7B-4
Steering Handle Kit 55/60 . . . . . . . . . . . . . . . 7B-6
Steering Handle Kit 55/60 . . . . . . . . . . . . . . . 7B-8
Tiller Arm/Shift Lever Removal . . . . . . . . . . . 7B-10
Tiller Handle Disassembly . . . . . . . . . . . . . . . 7B-12
Tiller Arm Reassembly . . . . . . . . . . . . . . . . . . 7B-14
Tiller Arm/Shift Lever Installation . . . . . . . . . 7B-17
Shift Link Rod Installation and
Adjustment to Engine . . . . . . . . . . . . . . . . 7B-18
Throttle Cable Installation and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7B-19
Co-Pilot Installation . . . . . . . . . . . . . . . . . . . . . 7B-20
Tiller Handle Installation . . . . . . . . . . . . . . . . . 7B-21
Wiring Harness Connection . . . . . . . . . . . . . . 7B-22

7B-0 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-1

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 Tiller Handle 40/50
1

5 2

3
4 8
6

95
7 9
95
10
95
95

95
26 11
27
30
29 12
32
28 13
14
15
16
33 17

31
24 25

23 19
18

20

22

21

95 2-4-C w/Teflon (92-850736A1)

7B-2 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Tiller Handle 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 COVER KIT
2 1 PULLEY
3 1 CASE
4 1 SCREW (10-16 x 1/2 IN. Self Tap) 20 1.6 2.3
5 1 CABLE–Throttle
6 1 CABLE–Throttle
7 1 SLEEVE–Insulation
8 2 SCREW (M8 x 1.25 Hex flange head) 198 16.5 22.4
9 1 COVER–Side
10 1 BUSHING
1 ARM–Steering Handle (BLACK)
11
1 ARM–Steering Handle (GRAY)
12 1 RETAINER
13 1 SCREW (M5 x 16 Hex Washer Head) 35 2.9 4.0
14 1 SCREW (M6 x 1 x 25 Hex Head Cap)
15 1 LOCK–Throttle
16 1 SPRING
17 1 KNOBS–Throttle
18 1 TILLER TUBE
19 1 DECAL (TURTLE/RABBIT)
20 1 HANDLE–Throttle
21 1 GRIP–Throttle Handle
22 1 SWITCH–Stop
23 2 SCREW (M10 x 110 Hex Head Cap) 420 35 47.5
24 1 TAB WASHER
25 1 CLIP–Cable Retainer
26 1 SPACER
27 1 BRACKET–Tiller
28 1 WAVE WASHER
29 1 BUSHING
30 1 WASHER
31 1 STOP SWITCH
32 1 RETAINER
33 1 LANYARD STOP SWITCH

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-3

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 Steering Handle Kit 55/60

95

22

27
26
28
29 23
30
2

25
21 24
25
18
3
19
2 7
20
16 1
13

11

36

14
32
35
33 23
INSIDE

34
4
12
95
6 17 9
5 31 15
8

10 9
7

23 Soap (Purchase Locally)

95 2-4-C With Teflon (92-850736A1)

7B-4 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Steering Handle Kit 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 STEERING ARM (BLACK)
1
1 STEERING ARM (GRAY)
2 2 BUSHING
3 1 GREASE FITTING Drive Tight
4 1 HOUSING
5 1 PLATE
6 1 GASKET
6 SCREW (10-16 x 1/2 IN.) Drive Tight
7
1 SCREW (10-16 x 3/5 IN.) Drive Tight
8 1 CLAMP
9 2 SCREW (M5 x 40) 40 3.3 4.5
10 1 WING NUT
11 1 THROTTLE HANDLE/STOP SWITCH KIT
12 1 STOP SWITCH
13 1 DECAL-Throttle
14 1 SCREW (10-16 x 3/8 IN.) Drive Tight
15 1 GRIP
16 1 J-CLAMP
17 1 J-CLAMP
– 1 THROTTLE CABLE KIT
18 1 CONDUIT
19 1 GUIDE TUBE
20 1 BARREL
21 1 SET SCREW (10-32) Drive Tight
22 1 CABLE
23 1 GUIDE
24 1 ANCHOR
25 2 SET SCREW (8-32) Drive Tight
26 1 SCREW (M10 x 105) 480 40 54.2
27 1 CAP
28 1 WASHER
29 1 WASHER
30 1 SPACER
31 1 THROTTLE TUBE
32 1 ROLL PIN
33 1 DRIVE WHEEL
34 1 INSULATOR
35 2 CABLE TIE
36 1 NUT 480 40 54.2

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-5

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 Steering Handle Kit 55/60

30
29
37
7
36
45 31
21
28 33
32 34

33
24
3
47 51
2 1 52
35
26
46 95
25
4 27
54
5 53 23
9 48
13 22

8
49
6 14
16

7 10 15
11 50

12
17
38
108

20 19
39
43
42
42 44
33

41 40
42
7 Loctite “271” (92-809819)
18
108 Special Lubricant 101 (92-13872A1)
95 2-4-C With Teflon (92-850736A1)
33 Loctite “RCA/680” Retaining Compound (92-809833)

7B-6 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Steering Handle Kit 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 BRACKET (BLACK)
1
1 BRACKET (GRAY)
2 1 DECAL-Shift
3 2 STUD (M10 x 58)
4 2 TAB WASHER
5 2 NUT 420 35 47.5
6 1 STOP HARNESS
7 1 CABLE MANUAL
8 1 PLUG
9 1 GROMMET
10 1 COVER
11 4 SCREW (10-16 x 1/2 IN.) Drive Tight
12 1 HORN
13 1 PLUG (MANUAL)
14 1 STOP SWITCH POWER TRIM
15 1 LANYARD
16 1 RETAINER
17 1 CABLE
18 1 STUD (M10 x 2.12)
19 1 NUT 75 6.2 8.5
20 1 WASHER
1 SHIFT LEVER (BLACK)
21
1 SHIFT LEVER (GRAY)
22 1 SCREW (M8 x 45) 70 5.8 7.9
23 1 TAB WASHER
24 1 BUSHING
25 1 WASHER (PLASTIC)
26 1 WASHER (BELLEVILLE)

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-7

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 Steering Handle Kit 55/60

30
29
37
7
36
45 31
21
28 33
32 34

33
24
3
47 51
2 1 52
35
26
46 95
25
4 27
54
5 53 23
9 48
13 22

8
49
6 14
16

7 10 15
11 50

12
17
38
108

20 19
39
43
42
42 44
33

41 40
42
7 Loctite “271” (92-809819)
18
108 Special Lubricant 101 (92-13872A1)
95 2-4-C With Teflon (92-850736A1)

33 Loctite 680

7B-8 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Steering Handle Kit 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
27 1 WASHER
28 1 SHIFT ROD
29 1 NUT
30 1 ROD END
31 1 BUSHING
32 1 WASHER
33 1 COTTER PIN
34 1 DETENT ASSEMBLY
35 1 SPRING
36 1 STUD
37 1 KNOB
38 1 CO-PILOT LEVER
39 1 BRAKE
40 1 CO-PILOT DRIVER
41 1 WASHER
42 3 BRAKE DISC
43 1 ARM (TOP)
44 1 ARM (BOTTOM)
45 1 HARNESS ASSEMBLY
46 1 KEY SWITCH (See below for Keys)
47 1 NUT
48 1 DECAL-Trim
49 1 TRIM SWITCH POWER TRIM
50 2 NUT
51 1 SWITCH ASSEMBLY
52 2 SCREW Drive Tight
53 1 CLAMP
54 1 SCREW Drive Tight

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-9

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 Tiller Arm/Shift Lever 4. Release latch and remove throttle cable with
grommet from bottom cowl.
Removal
1. Remove battery cables from battery.
b

51093
a - Rubber Grommet
b - Throttle Cable

51084
5. Remove cotter key from shift rod.

2. Remove outboard cowling.

3. Remove nut securing throttle cable to engine.

a b 55347
a - Tiller Handle
b - Shift Rod
c - Lower Cowl

6. Remove cover.

55342
a - Throttle Cable
b - Throttle Lever
c - Washer
d - Locknut

a
b 55340
a - Cover
b - Screw (4)

7B-10 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 7. Disconnect stop switch wire at bullet connector 9. Remove bolt and nut from tiller handle bracket.
and screw securing ground wire.

a
55339 55336
a - Bolt
a - Stop Switch Wire (Bullet Connector) b - Nut (Hidden)

8. Remove plug from tiller handle bracket 10. Remove tiller handle, two (2) nylon bushings,
stainless steel spacer and two (2) flat washers
from bracket.

d
c

b
55338
a - Plug

a 51606

a - Tiller Handle
b - Nylon bushing (2)
c - Stainless Steel Spacer
d - Washer (2)
e - Bolt

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-11

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 11. Bend tab washer away form bolt securing shift le- 3. Cut sta-strap securing stop switch harness and
ver and remove bolt and lever from bracket. remove screw from harness J-clip.

c a

a b 51603

51606 a - Sta-Strap
b - Screw
a - Tab Washer
b - Bolt
c - Shift Lever
d - Bracket 4. Remove stop switch and twist grip from tiller han-
dle.

Tiller Handle Disassembly

1. Using a flat tip screwdriver, carefully pry/push
rubber grip off tiller handle.

b a

51603
a - Stop Switch
51603 b - Twist Grip
b a
a - Grip
b - Tiller Handle
5. Remove throttle cable anchor screws and re-
move cable guide.

2. Remove screw from twist grip.

a a
51603
a - Screw

51602
a
a - Anchor Screws
b - Throttle Cable Guide

7B-12 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 6. Remove allen screw from brass barrel and re- 9. Remove cover plate and gasket from tiller han-
move barrel. dle.
10. Remove bolt from throttle friction assembly.
a c

e a
d b

b 51602

a - Allen Screw
b - Brass Barrel c
51604

7. Unscrew (counterclockwise) stainless steel con- a - Cover Plate

duit from tiller handle. b - Gasket (below plate)
c - Screw (4)
d - Throttle Friction Assembly
e - Bolt

11. Remove throttle arm, gear assembly and friction

device from tiller handle. Slide gear cover and
friction device off of the throttle arm.
d c a

51603

b 51604
a - Conduit
a - Throttle Arm
b - Gear Assembly
8. Pull throttle cable from tiller handle. c - Friction Device
d - Gear Cover

12. Drive out drift pin and remove throttle gear from
throttle arm.

51604 a
51602
a - Gear
a - Throttle Cable b - Drift Pin

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-13

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 Tiller Arm Reassembly 6. Install gasket and cover plate over gear assem-
bly. DO NOT OVERTIGHTEN attaching screws.
1. Reinstall throttle gear on throttle arm and secure c
gear to arm with new drift pin.
a
b
b

a c
51602
51604
a - Gear
b - Drift Pin a - Cover Plate
b - Gasket (Below Cover)
c - Screw (4)

2. Apply a light coat of Special Lubricant 101 to gear

teeth and inside of gear cover.
7. Rotate throttle arm so that twist grip attaching
3. Slide cover and friction device onto throttle arm. screw hole faces DOWN and gear drift pin faces
UP.
d c a
108
8. Insert throttle cable (CURVED END FACING UP)
into tiller handle gear assembly while rotating til-
ler arm counterclockwise.

b 51604

108 Special Lubricant 101 (92-13872A1)

a - Throttle Arm
b - Gear
c - Throttle Friction Device
d - Cover

4. Install throttle arm assembly into tiller arm.

5. Torque friction device attaching bolt to 40 lb. in. 51604
(4.5 N·m)
a - Gear Drift Pin (FACES UP)

51604
a
a - Bolt [Torque to 40 lb. in. (4.5 N.m)]

7B-14 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 9. Retract throttle cable into gear assembly until ap- 11. Slide brass barrel over throttle cable tube. Se-
proximately 17 in. (43 cm) extends from the tiller cure barrel to tube with allen screw approximate-
arm. ly 3.5 in. (89 mm) from stainless conduit. DO NOT
OVERTIGHTEN screw, as tubing may be
crushed, binding throttle cable. Position barrel to
face towards tiller handle.

a
d
b
c
51604
a - Cable [Extends 17 in. (43 cm)]

10. Slide stainless steel conduit over throttle cable a

and thread into tiller arm until lightly seated. Ro-
51607
tate conduit counterclockwise one full turn from a - Brass Barrel
a lightly seated position. b - Tube
c - Allen Screw
d - Tiller Handle

12. Install throttle cable guide onto throttle cable. Se-

cure guide to cable with anchor and two screws.
Guide hole should face up.
a
b
a

c 51602

51604 a - Cable Guide

a - Stainless Steel Conduit b - Screws (2)
c - Hole (Faces Up)

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-15

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 13. Position throttle arm slot to face stop harness exit 15. Sta-strap harness to throttle arm.
hole in tiller handle. Route stop switch harness
through twist grip, into throttle arm, and out CAUTION
through side of tiller handle.
Allow enough slack in harness (rotate throttle
grip in both directions) before securing harness
to handle assembly with J-clip.
16. Attach harness to tiller arm with J-clip allowing
enough slack in harness for full throttle rotation.

a 17. Attach sta-strap to end of harness sleeve.

b e
d
c

51602 a
a - Slot
b - Exit Hole
c - Harness
d - Twist Grip
e - Stop Switch

b
14. Secure twist grip to throttle arm with attaching
screw.
51603
a
a - Sta-strap
b - J-clip

18. Install rubber twist grip by aligning ridges on plas-

tic twist grip with grooves inside of rubber grip.
51603
a - Screw
NOTE: Applying a soapy water solution to rubber grip
will ease installation.

b a
51603
a - Ridges
b - Grooves (Under Handle)

7B-16 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Tiller Arm/Shift Lever 3. Reinstall plug.

Installation
1. Install shift lever with detent assembly to bracket.

d
c e
d 55338
a a - Plug
b 55337

a - Bolt
b - Tab Washer
c - Washer 4. Connect stop switch wire at bullet connector and
d - Wave Washer (2) secure ground wire to handle with screw.
e - Shift Lever
f - Bushing
g - Detent Assembly

2. Install tiller handle with bushings to bracket. Se-

cure in place with washers and bolt with nut.
Tighten bolt, allowing tiller handle movement.
Torque nut to 40 lb. ft. (54 N·m).

a
c d 55339

e a - Stop Switch Wire (Bullet Connector)

a 51606

a - Tiller Handle
b - Bushings (2)
c - Stainless Steel Bushing
d - Washers (2)
e - Bolt

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-17

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

b a
55340
a - Cover
b - Screw (4)

6. Install cotter key and components to shift rod.

c 55342
b a - Shift Cable End
a b - Actuator Stud
55347
c - Washer
a - Tiller Handle d - Locknut (Tighten until snug, then back off 1/4 turn)
b - Shift Rod
c - Lower Cowl

7. Install throttle cable with grommet. 4. Check shift link rod adjustment as follows:
a. Place shift lever in “F” (forward) position. Pro-
peller should rotate in a CLOCKWISE direc-
b tion. If propeller does not rotate CLOCK-
WISE, length of link rod must be reduced and
step “a” repeated.
b. Place shift lever in “N” (neutral) position. Pro-
peller should rotate freely without drag. If not,
length of link rod must be increased and steps
“a” and “b” must be repeated.
c. While rotating propeller, place shift lever in
“R” (reverse) position. If propeller can rotate
a in either direction, length of link rod must be
increased and steps “a” thru “c” repeated.
51093 d. Place engine shift lever in “N” (neutral) posi-
a - Rubber Grommet tion. Propeller should turn freely in both direc-
b - Throttle Cable
tions. If not, length of link rod must be de-
creased and steps “a” thru “d” must be
8. Proceed to “Shift Link Rod Installation and Ad- repeated.
justment to Engine” and “Throttle Cable Installa-
tion and Adjustment.”

7B-18 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 Throttle Cable Installation and 4. Holding throttle lever against idle stop, adjust
throttle cable to slip into upper hole of barrel re-
Adjustment
ceptacle with a very light preload of throttle lever
1. Rotate throttle twist grip fully clockwise to stop against idle stop. Apply small amount of Loctite
“IDLE” position. Grade “A” to threads of set screw. 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.

a
b 51077

a - Set Screw
b - Throttle Cable Barrel
c

3. Place end of throttle cable guide over peg of

throttle lever and secure with locknut and washer.

55342
a - Throttle Lever
b - Idle Stop
c - Barrel Receptacle

5. Secure barrel in place with barrel retainer.

55342
a - Throttle Cable End
b - Throttle Lever
c - Washer
d - Locknut (Tighten until snug, then back off 1/4 turn)

CAUTION
a
DO NOT exceed 1/4 turn on set screw after it has 51091
bottomed-out.
a - Barrel Retainer

6. Check preload on throttle cable by placing a thin

piece of paper between idle stop screw and idle
stop. Preload is correct when paper can be re-
moved without tearing and still have drag on it.
Readjust cable barrel if necessary.
7. Install Cowl.

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-19

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 Co-Pilot Installation 3. Install brake disk and brake.

NOTE: To install Co-Pilot kit, tiller handle must be re-

moved and battery cables disconnected. c
b
1. Install brake disk on swivel bracket. Position “bot-
tom up” lever, brake disk and “top up” lever onto
swivel bracket. Note location of pin (on steering
arm) in relation to top and bottom levers as
shown.

c a
b 51094 51094
d
a - Brake Disk (3)
b - Brake
c - Pin (Holds brake in place)

4. Lubricate driver surface with Special Lubricant

a 101. Install driver into handle and adjust until driv-
er (flat) is flush with handle.
b 55343
51093

a - Swivel Bracket b
b - Brake Disk
c - Bottom Up Lever
d - Top Up Lever
e - Pin, Steering Arm 108

a
2. Double nut co-pilot stud and apply Loctite No. 35 108 Special Lubricant 101 (92-13872A1)
to swivel bracket end of stud. Install until flush
a - Handle
with bottom of swivel bracket. Stake stud in place b - Driver (Flush to slightly recessed)
as shown. Drive dowel pin from bottom of swivel
bracket until flush with bottom of bracket.
Remove nuts. 5. Install components to stud. Align hex of driver
with hex in brake.
17
b

a
c
28063

55344
c 5109
a - Handle
17 Loctite 35 (92-59328-1) b - Driver
c - Plastic Washer
a - Stud
b - Stake Marks
c - Dowel Pin (Driven thru Bottom of Swivel Bracket)

7B-20 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 6. Holding components in place (lever facing for- 2. Install tiller handle to studs with shift rod posi-
ward), install lock nut and torque to 75 lb. in. (8 tioned thru cowl opening as shown.
N·m).

a b 55347
a - Tiller Handle
b - Shift Rod
c - Cowl
a - Locknut [75 lb. in. (8 N·m)]

3. Secure tiller handle assembly in place.

Tiller Handle Installation
1. Apply Loctite No. 35 to threads (steering arm
end) of tiller handle studs. Install with stud install-
er. Tighten securely.
c
b

a
b b

55348
17 55346 a - Tiller Handle Assembly
a b - Tab Washer (bend tabs against flats of locknuts)
17 Loctite 35 (92-59328-1) c - Locknuts [Torque to 26 lb. ft. (35 N·m)]
a - Studs
b - Steering Arm

90-852572R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7B-21

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 4. Install rubber grommet to throttle cable and install 3. Connect handle wiring harness at engine har-
into bottom cowl. Note, a light lubricant on grom- ness connector.
met will aid in installation over shift rod.
4. Reconnect battery cables.

b
b
a

(–)

(+)
c

51093
51084
a - Rubber Grommet
b - Throttle Cable
c - Shift Rod a - Red Sleeve (Positive)
b - Black Sleeve (Negative)

5. Adjust shift link rod and throttle cable “Shift Link 5. Adjust co-pilot tension by moving handle to port
Rod Installation and Adjustment” and “Throttle (loosen) or starboard (tighten). Locknut on co-pi-
Cable Installation and Adjustment” as required. lot stud may have to be adjusted to attain desired
tension on tiller arm.

Wiring Harness Connection

1. Remove battery cables from battery.
2. Route wiring harness thru rubber grommet. Note,
light oil on rubber grommet will aid in wiring har-
ness installation.
55335
b

MORE LESS

55348

a - Wiring Harness
b - Rubber Grommet

7B-22 - ATTACHMENTS/CONTROL LINKAGE 90-852572R1 JANUARY 1998

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 MANUAL STARTER

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 Table of Contents
Page
Starter Assembly (Manual) 40/50 . . . . . . . . . . 8-2
Starter Assembly (Manual) 55/60 . . . . . . . . . . 8-4
Rewind Starter Disassembly . . . . . . . . . . . . . . 8-6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 8-7
Rewind Starter Reassembly . . . . . . . . . . . . . . 8-7
Adjusting Rewind Spring Tension . . . . . . . . . . 8-8
Starter Interlock Cable Adjustment . . . . . . . . . 8-9

8-0 - MANUAL STARTER 90-852572R1 JANUARY 1998

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 Notes:

90-852572R1 JANUARY 1998 MANUAL STARTER - 8-1

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 Starter Assembly (Manual) 40/50

18 6

36 3
13
4
11 1
34 2
15
35
14 10
9
16 8

17
7
12
9 8 24
19

20
25
21 95

95
22

23 26

27
30
31
28
32
29

95 33

95 2-4-C w/Teflon (92-825407A12)

8-2 - MANUAL STARTER 90-852572R1 JANUARY 1998

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 Starter Assembly (Manual) 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 HANDLE
2 1 RETAINER
-- 1 REST--Starter Handle
3 1 REST
4 1 SEAL
5 2 SCREW (M6 x 30) 55 4.6 6.2
6 2 SPACER
7 4 BUSHING
8 8 GROMMET
9 8 WASHER
10 4 NUT 75 6.2 8.5
11 1 TIMING DECAL
12 1 INTERLOCK CABLE
13 1 SCREW (10 -16 x .625) Drive Tight
14 1 WASHER
15 1 COTTER PIN
16 1 SCREW Drive Tight
17 1 COTTER PIN
-- 1 RECOIL STARTER
18 1 STARTER HOUSING
19 1 SPRING
20 1 INTERLOCK LEVER
21 1 CAM
22 1 RETAINER
23 3 SCREW Drive Tight
24 1 WASHER - SPRING
25 1 SPRING
26 1 STARTER SHEAVE
27 2 SPRING
28 2 CAM
29 2 RETAINING RING
30 1 STARTER ROPE
31 1 SPRING
32 1 CAM
33 1 SCREW 135 11.2 15.3
34 1 BUSHING
35 1 RETAINING RING
36 1 DECAL-Caution in gear idle

90-852572R1 JANUARY 1998 MANUAL STARTER - 8-3

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 Starter Assembly (Manual) 55/60

26

18 6

3
13
4 36 1
2
34
15 35
14 10
9
16
8
7
17
12 11
9 8 24
19

20
25 95
21
95

22

23 26

26 Cyanacrylate Adhesive (Purchase Locally)

27
95 2-4-C w/Teflon (92-825407A12) 30
31
28
32
29

33
95

8-4 - MANUAL STARTER 90-852572R1 JANUARY 1998

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 Starter Assembly (Manual) 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 HANDLE ASSEMBLY
2 1 RETAINER
3 1 REST
4 1 SEAL
5 2 SCREW (M6 x 75) 55 4.6 6.2
6 2 SPACER
7 4 BUSHING
8 8 GROMMET
9 8 WASHER
10 4 NUT 75 6.2 8.5
11 1 INTERLOCK CABLE
12 1 SCREW Drive Tight
13 1 WASHER
14 1 COTTER PIN
15 1 SCREW Drive Tight
16 1 COTTER PIN
17 1 WASHER
-- 1 RECOIL STARTER
18 1 STARTER HOUSING
19 1 SPRING
20 1 INTERLOCK LEVER
21 1 CAM
22 1 RETAINER
23 3 SCREW
24 1 WASHER - SPRING
25 1 SPRING
26 1 STARTER SHEAVE
27 2 SPRING
28 2 CAM
29 2 RETAINING RING
30 1 STARTER ROPE
31 1 SPRING
32 1 CAM
33 1 SCREW 135 11.2 15.3
34 1 BUSHING
35 1 RETAINING RING
36 1 DECAL-Full throttle timing

90-852572R1 JANUARY 1998 MANUAL STARTER - 8-5

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 Rewind Starter Disassembly 6. Remove cam retainer.

a b
WARNING
When disassembling and reassembling rewind
starter, SAFETY GLASSES must be worn in case
rewind spring uncoils out of the housing.
1. Remove retaining clip and attaching screw which
secures shift interlock cable to starter housing.
2. Remove bolts (4) securing rewind starter to en-
gine.
a
b

c
c 28374

a - Screws (3)
b - Cam Retainer

7. Remove cam lever, cam lever spring, and inter-

lock lever.
c c
a

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 over-
hand 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.
a
28375

a - Cam Lever
b - Cam Lever Spring
c - Interlock Lever

a - Overhand Knot
b - Retainer

8-6 - MANUAL STARTER 90-852572R1 JANUARY 1998

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 8. Remove starter sheave. Cleaning and Inspection
a
1. Clean components in solvent and dry with com-
pressed air.
2. Inspect rewind spring for kinks, burrs, corrosion
of breakage.
3. Inspect starter sheave, rope guide and starter
housing for nicks, grooves, cracks, wear or dis-
tortion, especially area of rope travel.
4. Inspect bushing, starter drive pawl and spring for
wear or damage.
5. Inspect starter rope for wear.
b 6. Replace components as necessary.
51605

a - Starter Sheave
b - Screw
Rewind Starter Reassembly
9. Spring is replaced as a spring/cover assembly. WARNING
When reassembling rewind starter, SAFETY
GLASSES must be worn in case rewind spring
a uncoils out of the housing.
1. Install spring/cover assembly into sheave.

51607
a - Spring/Cover Assembly

51607
a - Spring/Cover Assembly

90-852572R1 JANUARY 1998 MANUAL STARTER - 8-7

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 2. Install starter sheave to housing and secure in 4. Reinstall cam retainer and secure with screws
place with screw. Torque to 135 lb. in. (15.3 N·m). (3).

a
a
b

28374
b 51605 a - Screws (3)
b - Cam Retainer
a - Starter Sheave
b - Screw

Adjusting Rewind Spring

3. Install interlock lever, position cam spring into re-
cess of starter housing and reinstall cam lever.
Tension
1. Rotate sheave counterclockwise until it stops
a (coil is bound). Then back off one full turn, plus
what is needed to align rope end with hole in
housing. Never back off sheave less than one full
b
turn.
c 2. Route starter rope thru rope guide in housing. Tie
an 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 Least One Full

Turn
b - Tie Off Starter Rope 12 in. (305 mm) from End with Over-
hand Knot

8-8 - MANUAL STARTER 90-852572R1 JANUARY 1998

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 NOTE: Check operation of rewind and rewind ten-
sion before outboard installation.
Starter Interlock Cable
3. Place rewind starter on engine. Adjustment
4. Pull starter rope thru bracket, handle, and starter IMPORTANT: Lubricate core wire of interlock
rope retainer. Secure starter rope to starter rope cable with light oil prior to making adjustments.
retainer with knot. 1. While rotating the propeller shaft, place the gear
shift lever into REVERSE.
2. Return the gear shift lever to NEUTRAL without
a going past neutral detent.
3. Place end of interlock cable over pin of cam lever
and secure with retaining pin.
b
4. Secure interlock cable to starter housing using
c adjusting screw. Do not tighten screw at this time.
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 a

to 90 lb. in. (10 N·m). Secure interlock lock cable
with retaining clip and screw. b
d
e
b a

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 ad-

justment 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

90-852572R1 JANUARY 1998 MANUAL STARTER - 8-9

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