200/225 OptiMax Manual 12/16/02 2:36 PM Page 1

200/225 OptiMax
200/225
OptiMax
Direct Fuel Injection

Starting Model Year 1997 Thru 1999

S/N OG386496 Thru 0G960499 Starting Model Year 1997 Thru 1999
Serial Number 0G386496 Thru 0G960499
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com
Frankston Road P.O. Box 1939 (Parc Industriel de Petit-Rechain)
P.O. Box 80 Fond du Lac, WI 54936-1939 USA B-4822 Verviers/Belgium
Dandenong, Victoria 3175 Australia
U.S. Version 90-855348R02
©August 2002, Mercury Marine. All rights reserved. Printed in U.S.A. International Version 90-889764R02
Service Manual Outline
Section 1 - General Information & Specifications
General Information
& Specifications 1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Electrical
2
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Fuel System
3
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Direct Fuel Injection
Powerhead
4
C - Oil Injection
D - Emissions
Section 4 - Powerhead
A - Cylinder Block Assembly
Mid-Section
5
B - Cooling System
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
Gear Housing
6
B - Power Trim
Section 6 - Gear Housing
A - Right Hand Rotation
B - Left Hand Rotation
Attachment/Control Linkage
7
Section 7 - Attachments/Control Linkage

90-855348R02 NOVEMBER 2002 Page iii

Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.

DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal in-
jury or death.

CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.

Notice to Users of This Manual

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

90-855348R02 NOVEMBER 2002 Page i

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

Cleanliness and Care of Outboard Motor

A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manu-
al, it should be understood that proper cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
Personnel should not work on or under an outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.

Page Numbering
Two number groups appear at the bottom of each page. The example below is
self-explanatory.

EXAMPLE:

90-855348R02 SEPTEMBER 2002 Page - 6A-7

Revision No. 2 Page

Month of Printing Section Number

Year of Printing Part of Section Letter

Page Number
Page ii 90-855348R02 NOVEMBER 2002
 SPECIFICATIONS

IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Master Specifications . . . . . . . . . . . . . . . . . . . . 1A-1 Optimax 225 . . . . . . . . . . . . . . . . . . . . . . . . . 1A-7
Propeller Information Charts . . . . . . . . . . . . . . 1A-6 Mercury/Quicksilver Lubricants and Sealants 1A-9
Optimax 200 . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6

Master Specifications

Model 200/225 DFI

HORSE- Model 200 200 (149.2)
POWER (KW) Model 225 225 (167.8)
OUTBOARD Model 200/225
WEIGHT – 20 in. (50.8cm) Shaft 507.0 lbs. (230.0kg)
– 25 in. (63.5cm) Shaft 512.0 lbs. (232.0kg)
CYLINDER Type V–6 Cylinder, Two Cycle, Loop Charged
BLOCK Displacement 185 cu. in. (3032cc)
Thermostat 120°F (48.9°C)
STROKE Length (All Models) 3.00 in. (76.2mm)
CYLINDER Diameter (Standard) 3.6265 in. (92.1131mm)
BORE Taper/Out of Round/Wear Maximum 0.003 in. (0.076mm)
Bore Type Cast Iron
PISTON Piston Type Aluminum
Standard 3.6205 in. ± .0005 in. (91.9607mm ±
0.0127mm)
REEDS Reed Stand Open (Maximum.) 0.020 in. (0.50mm)
MID Power Trim (Total Tilt Range) 75°
SECTION Power Trim (Tilt Range) 20°
Steering Pivot Range 60°
Tilt Pin Adjustment Positions 5
Allowable Transom Thickness 2-3/8 in. (6.03cm)

90-855348R02 NOVEMBER 2002 Page 1A-1

SPECIFICATIONS

Model 200/225 DFI

GEAR Gear Ratio
HOUSING Standard Ratio All Models 1.75:1 12/21 Teeth
Optional High Altitude Ratio 1.87:1 15/28 Teeth

Gearcase Capacity 28.0 fl. oz. (828.0ml)

Pinion Height 0.025 in. (0.635mm)

Forward Gear Backlash

– 1.75:1/1.87:1 0.017 in. – 0.028 in. (0.431mm –
0.711mm)
Reverse Gear Backlash
– Standard Rotation 0.028 in. – 0.052 in. (0.71mm – 1.32mm)
– Counter Rotation 0.040 in. – 0.060 in. (1.0mm – 1.52mm)

Water Pressure @ RPM 8 – 10 PSI Minimum @ 5000 RPM

FUEL Fuel Gasoline with Oil Injection
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil TC-W3 Premium Plus 2 Cycle Outboard
Oil
Gasoline/Oil Ratio
– @ Idle 300 – 400:1
– @ WOT 60:1
Fuel Pressure
Crankcase Pump
– @ Idle 2 PSI (13.8kPa)
– @ WOT 8 PSI (55.2 kPa)

Electric High Pressure Pump – at all

RPM 89 ± 2 PSI (613.7 ± 13.8kPa)
Normal Amperage Draw – 6 to 9 Amps

Electric Low Pressure Pump – at all

RPM 8 – 10 PSI (55.2kPa – 68.9kPa)
Normal Amperage Draw 1 to 2 Amps
STARTING Electric Start – All Models
SYSTEM Starter Draw (Under Load) 210 Amperes
Starter Draw (No Load) 30 Amperes
Minimum Brush Length 0.25 in. (65.4mm)

Battery Rating 1000 (Minimum) Marine Cranking Amps

(MCA)
750 (Minimum) Cold Cranking Amps
(CCA)

Page 1A-2 90-855348R02 NOVEMBER 2002

 SPECIFICATIONS

Model 200/225 DFI (Continued)

IGNITION Type Digital Inductive
SYSTEM
Spark Plug Type NGK PZFR5F-11 (1998 Heavy Duty)
NGK ZFR5F-11 (1998 Light Duty)
Champion RC10-ECC (1997)

Spark Plug Gap 0.040 in. (1.0mm)

CHARGING Alternator Output (Regulated) 30 Amperes @ 750 RPM
SYSTEM 60 Amperes @ 2000 RPM
Brush Length Std. Exposed Length: 0.413 in.
(10.5mm)
Voltage Output Min. Exposed Length: 0.059 in. (1.5mm)
Regulator Current Draw 13.5 to 15.1 Volts
0.15 m A (Ign. Switch Off)
30.0 m A (Ign. Switch On)
TIMING Note: Timing is controlled by the ECM
and is not adjustable
Injectors
– Quantity 6
– Injectors are Crank Angle Driven by
ECM
– #2 Cylinder WHT/RED + RED/WHT Leads
DIRECT – #4 Cylinder WHT/YEL + YEL/WHT Leads
INJECTION – #6 Cylinder WHT/PPL + PPL/WHT Leads
– #1 Cylinder WHT/BRN + BRN/WHT Leads
– #3 Cylinder WHT/ORG + ORG/WHT Leads
– #5 Cylinder WHT/DRK BLU + DRK BLU/WHT Leads

Line Pressure @ Injectors 89 ± 2 PSI (613.7kPa ± 13.8kPa)

90-855348R02 NOVEMBER 2002 Page 1A-3

SPECIFICATIONS

Model 200/225 DFI (Continued)

Idle RPM (Not Adjustable – Con-
trolled by ECM) 650 ± 25 (1997 Models)
550 ± 25 (1998 Models)

Wide Open Throttle (WOT) RPM 5000 – 5750

Float Adjustment (Vapor Separator)

FUEL Float Level Preset @ Factory
INJECTION Injectors
– Quantity 6
– Injectors are Crank Angle Driven by
ECM
– #2 Cylinder RED/PNK + PNK/RED Leads
– #4 Cylinder YEL/PNK + PNK/YEL Leads
– #6 Cylinder PPL/PNK + PNK/PPL Leads
– #1 Cylinder BRN/PNK + PNK/BRN Leads
– #3 Cylinder ORG/PNK + PNK/ORG Leads
– #5 Cylinder DRK BLU/PNK + PNK/DRK BLU Leads

Line Pressure @ Injectors 89 ± 2 PSI (613.5 ± 13.8kPa)

PISTON DIA. 3.6205 in. ± .0005 in.
(91.973 mm ± .0127 mm)
Using a micrometer, measure dimension
“A” at location shown. Dimension “A”
Dimension should be 3.6205 in. ± .0005 for a
“A” at Right STANDARD size piston (new) Dimension
Angle (90°) “A” will be 0.001 – 0.0015 less if coating is
to Piston
Pin
worn off piston (used)
1 in.
(25.4mm)

Page 1A-4 90-855348R02 NOVEMBER 2002

 SPECIFICATIONS

Air Compressor Specifications (Model 200/225 DFI)

Air Compressor Type Reciprocating Piston
(1 to 1 ratio with engine RPM)
Compressor Output @ Idle – 80 psi
@ W.O.T. – 110 psi
Cylinder Block Displacement 7.07 cu. in. (116cc)
Cylinder Bore Diameter (Standard) 2.5591 in. (65.0mm)
Taper/Out-of-Round/Wear Maxi-
mum 0.001 in. (0.025mm)
Bore Type Cast Iron
Stroke Length 1.374 in. (34.9mm)
Piston Piston Type Aluminum
Piston Diameter 2.5578 ± .0004 in.
(64.97 ± 0.010mm)
Dimension
“A” at
Right
Angle
(90°) to
Piston Pin
0.500 in.

Piston Ring End Gap

Top Ring 0.0059 - 0.0098 in.
(0.15 - 0.25mm)
Middle Ring 0.0059 - 0.0098 in.
(0.15 - 0.25mm)
Bottom Ring 0.0039 - 0.014 in.
(0.10 - 0.35mm)
Reeds Reed Stand Open 0.010 in. (0.25mm)

90-855348R02 NOVEMBER 2002 Page 1A-5

SPECIFICATIONS

Propeller Information Charts

Optimax 200
• Wide Open Throttle RPM: 5000-5750 • Gear Reduction: 1.75:1
No. of Gross Boat Boat Speed RH Propeller LH Propeller
Diameter Pitch Blades Model Wgt. (lbs) Length (mph) Part Number Part Number
14.62″ 27 3 Tempest+ Up to 2300 Up to 19′ 67-80 48-825868A47
13.75″ 26 4 Trophy+ Up to 2400 Up to 20′ 65-77 48-825944A47
14.62″ 26 3 Tempest+ Up to 2400 Up to 20′ 65-77 48-825874A47
13.75″ 25 3 Laser II 2100 – 2600 18 – 21′ 62-73 48-16550A46 48-16549A46
13.75″ 25 4 Trophy+ 2100 – 2600 18 – 21′ 62-73 48-825942A47
14.62″ 25 3 Tempest+ 2100 – 2600 18 – 21′ 62-73 48-825866A47
13.25″ 25 5 Hi-Five 2100 – 2600 18 – 21′ 62-73 48-816374A46
13.38″ 25 3 Aluminum 2100 – 2600 18 – 21′ 62-73 48-78126A45
13.75″ 24 4 Trophy+ 2200 – 2700 19 – 21′ 60-70 48-825940A47
14.62″ 24 3 Tempest+ 2200 – 2700 19 – 21′ 60-70 48-825872A47
13.75″ 23 3 Laser II 2300 – 2900 19 – 22′ 57-67 48-16548A46 48-16547A46
13.75″ 23 4 Trophy+ 2300 – 2900 19 – 22′ 57-67 48-825938A47
14.62″ 23 3 Tempest+ 2300 – 2900 19 – 22′ 57-67 48-825864A47
14.63″ 23 3 Mirage+ 2300 – 2900 19 – 22′ 57-67 48-13704A46 48-13705A46
13.25″ 23 5 Hi-Five 2300 – 2900 19 – 22′ 57-67 48-815762A46
13.5″ 23 3 Vengeance 2300 – 2900 19 – 22′ 57-67 48-16320A46 48-16321A46
14″ 23 3 Aluminum 2300 – 2900 19 – 22′ 57-67 48-832834A45
13.88″ 21 3 Laser II 2600 – 3100 19 – 23′ 52-61 48-16546A46 48-16319A46
13.75″ 21 4 Trophy+ 2600 – 3100 19 – 23′ 52-61 48-825934A47
14.62″ 21 3 Tempest+ 2600 – 3100 19 – 23′ 52-61 48-825862A47
14.75″ 21 3 Mirage+ 2600 – 3100 19 – 23′ 52-61 48-13702A46 48-13703A46
13.25″ 21 5 Hi-Five 2600 – 3100 19 – 23′ 52-61 48-815760A46
13.75″ 21 3 Vengeance 2600 – 3100 19 – 23′ 52-61 48-16318A46 48-16319A46
14.25″ 21 3 Aluminum 2600 – 3100 19 – 23′ 52-61 48-832832A45
14″ 19 3 Laser II 2900 – 3600 20 – 24′ 46-55 48-16544A46 48-16543A46
14.62″ 19 3 Tempest+ 2900 – 3600 20 – 24′ 46-55 48-825860A47
15.25″ 19 3 Mirage + 2900 – 3600 20 – 24′ 46-55 48-13700A46 48-13701A46
13.25″ 19 5 Hi-Five 2900 – 3600 20 – 24′ 46-55 48-815758A46
14″ 19 3 Vengeance 2900 – 3600 20 – 24′ 46-55 48-16316A46 48-16317A46
14.5″ 19 3 Aluminum 2900 – 3600 20 – 24′ 46-55 48-832830A45
15.5″ 17 3 Mirage + 3300 – 4300 21 – 25′ 39-49 48-18278A46 48-90159A46
13.5″ 17 5 Hi-Five 3300 – 4300 21 – 25′ 39-49 48-821154A46
14.5″ 17 3 Vengeance 3300 – 4300 21 – 25′ 39-49 48-16314A46 48-16315A46
15″ 17 3 Aluminum 3300 – 4300 21 – 25′ 39-49 48-832828A45
16″ 16 3 Aluminum 3600 – 4700 22 – 26 36-46 48-16440A45
15.75″ 15 3 Mirage + 3900 – 5400 23 – 26′ 32-43 48-19838A46 48-19841A46
14.5″ 15 3 Vengeance 3900 – 5400 23 – 26′ 32-43 48-16312A46
15.25″ 15 3 Aluminum 3900 – 5400 23 – 26′ 32-43 48-78116A45
16″ 14 3 Aluminum 4300 – 6000 24 – 27′ 29-39 48-16438A45

Page 1A-6 90-855348R02 NOVEMBER 2002

 SPECIFICATIONS

Optimax 200 continued

• Wide Open Throttle RPM: 5000-5750 • Gear Reduction: 1.75:1
16″ 13 3 Mirage + 5000 + 25 – 30′ 25-36 48-826072A46
16″ 13 3 Aluminum 5000+ Pontoon 25-36 48-78114A45
16″ 12 3 Aluminum 7000+ Pontoon/Work 21-33 48-16436A45
16″ 11 3 Aluminum 8500 + House/Work 1-29 48-78112A45

Optimax 225
• Wide Open Throttle RPM: 5000-5750 • Gear Reduction: 1.75:1
No. of Gross Boat Boat Speed RH Propeller LH Propeller
Diameter Pitch Blades Model Wgt. (lbs) Length (mph) Part Number Part Number
14.62″ 27 3 Tempest+ Up to 2600 Up to 20′ 67-80 48-825868A47
13.75″ 26 4 Trophy+ Up to 2700 Up to 21′ 65-77 48-825944A47
14.62″ 26 3 Tempest+ Up to 2700 Up to 21′ 65-77 48-825874A47
13.75″ 25 3 Laser II 2400 – 2900 19 – 22′ 62-73 48-16550A46 48-16549A46
13.75″ 25 4 Trophy+ 2400 – 2900 19 – 22′ 62-73 48-825942A47
14.62″ 25 3 Tempest+ 2400 – 2900 19 – 22′ 62-73 48-825866A47
13.25″ 25 5 Hi-Five 2400 – 2900 19 – 22′ 62-73 48-816374A46
13.38″ 25 3 Aluminum 2400 – 2900 19 – 22′ 62-73 48-78126A45
13.75″ 24 4 Trophy+ 2500 – 3000 20 – 23′ 60-70 48-825940A47
14.62″ 24 3 Tempest+ 2500 – 3000 20 – 23′ 60-70 48-825872A47
13.75″ 23 3 Laser II 2600 – 3200 20 – 23′ 57-67 48-16548A46 48-16547A46
13.75″ 23 4 Trophy+ 2600 – 3200 20 – 23′ 57-67 48-825938A47
14.62″ 23 3 Tempest+ 2600 – 3200 20 – 23′ 57-67 48-825864A47
14.63″ 23 3 Mirage+ 2600 – 3200 20 – 23′ 57-67 48-13704A46 48-13705A46
13.25″ 23 5 Hi-Five 2600 – 3200 20 – 23′ 57-67 48-815762A46
13.5″ 23 3 Vengeance 2600 – 3200 20 – 23′ 57-67 48-16320A46 48-16321A46
14″ 23 3 Aluminum 2600 – 3200 20 – 23′ 57-67 48-832834A45
13.88″ 21 3 Laser II 2900 – 3500 21 – 24′ 52-61 48-16546A46 48-16319A46
13.75″ 21 4 Trophy+ 2900 – 3500 21 – 24′ 52-61 48-825934A47
14.62″ 21 3 Tempest+ 2900 – 3500 21 – 24′ 52-61 48-825862A47
14.75″ 21 3 Mirage+ 2900 – 3500 21 – 24′ 52-61 48-13702A46 48-13703A46
13.25″ 21 5 Hi-Five 2900 – 3500 21 – 24′ 52-61 48-815760A46
13.75″ 21 3 Vengeance 2900 – 3500 21 – 24′ 52-61 48-16318A46 48-16319A46
14.25″ 21 3 Aluminum 2900 – 3500 21 – 24′ 52-61 48-832832A45
14″ 19 3 Laser II 3300 – 4000 21 – 25′ 46-55 48-16544A46 48-16543A46
14.62″ 19 3 Tempest+ 3300 – 4000 21 – 25′ 46-55 48-825860A47
15.25″ 19 3 Mirage + 3300 – 4000 21 – 25′ 46-55 48-13700A46 48-13701A46
13.25″ 19 5 Hi-Five 3300 – 4000 21 – 25′ 46-55 48-815758A46
14″ 19 3 Vengeance 3300 – 4000 21 – 25′ 46-55 48-16316A46 48-16317A46
14.5″ 19 3 Aluminum 3300 – 4000 21 – 25′ 46-55 48-832830A45
15.5″ 17 3 Mirage + 3700 – 4800 22 – 26′ 39-49 48-18278A46 48-90159A46
13.5″ 17 5 Hi-Five 3700 – 4800 22 – 26′ 39-49 48-821154A46
14.5″ 17 3 Vengeance 3700 – 4800 22 – 26′ 39-49 48-16314A46 48-16315A46
15″ 17 3 Aluminum 3700 – 4800 22 – 26′ 39-49 48-832828A45

90-855348R02 NOVEMBER 2002 Page 1A-7

SPECIFICATIONS

Optimax 225 continued

• Wide Open Throttle RPM: 5000-5750 • Gear Reduction: 1.75:1
16″ 16 3 Aluminum 4000 – 5300 23 – 26 36-46 48-16440A45
15.75″ 15 3 Mirage + 4300 – 6100 23 – 27′ 32-43 48-19838A46 48-19841A46
14.5″ 15 3 Vengeance 4300 – 6100 23 – 27′ 32-43 48-16312A46
15.25″ 15 3 Aluminum 4300 – 6100 23 – 27′ 32-43 48-78116A45
16″ 14 3 Aluminum 4800 – 6800 24 – 29′ 29-39 48-16438A45
16″ 13 3 Mirage + 6000 + 25 – 30′ 25-36 48-826072A46
16″ 13 3 Aluminum 6000+ Pontoon 25-36 48-78114A45
16″ 12 3 Aluminum 8000+ Pontoon/Work 21-33 48-16436A45
16″ 11 3 Aluminum 9500 + House/Work 1-29 48-78112A45

Page 1A-8 90-855348R02 NOVEMBER 2002

 SPECIFICATIONS

Mercury/Quicksilver Lubricants and Sealants

Tube Mercury Part Num- Quicksilver Part
Description
Ref. No. ber Number
Needle Bearing As-
4 92-802868A1 N/A
sembly Lubricant
Dielectric Grease
6 92-823506-1 92-823506-1

Loctite 271 – Thread

7 92-809819 92-809819
Locker
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2 Cycle Premium Out-
14 92-802813A1 92-802813Q1
board Oil
19 Perfect Seal 92-34227-1 92-34227-1

25 Liquid Neoprene 92-25711-3 92-25711-3

27 Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining
33 92-809833 92-809833
Compound
34 Special Lubricant 101 92-802865A1 92-802865Q1
U-Joint and Gimbal 92-802870A1 92-802870Q1
42
Bearing Grease
Loctite 222 Thread
51 92-809818 92-809818
Locker
Loctite 242 Thread
66 92-809821 92-809821
Locker
4 Cycle 25W40 Engine
79 92-802837A1 92-802837Q1
Oil
Premium Gear Lubri-
82 92-802846A1 92-802846Q1
cant
High Performance 92-802854A1 92-802854Q1
87
Gear Lube
Engine Coupler Spline
91 92-802869A1 92-802869Q1
Grease
94 Anti-Corrosion Grease 92-802867A1 92-802867Q1
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30 Out-
110 92-802833A1 92-802833Q1
board Oil
Power Trim & Steering
114 92-802880A1 92-802880Q1
Fluid

90-855348R02 NOVEMBER 2002 Page 1A-9

SPECIFICATIONS

Tube Mercury Part Num- Quicksilver Part

Description
Ref. # ber Number
Premium Plus 2 Cycle
115
TC-W3 Outboard Oil 92-802824A1 92-802824Q1
RTV 587 Silicone
116 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust In- 92-802878-56 92-802878Q56
119
hibitor
120 Corrosion Guard 92-802878 55 92-802878Q55

121
15W40 4-cycle Diesel 92-877695K1 92-877695Q1
Engine Oil
Extended Life Anti- 92-877770K1 92-877770K1
122
freeze/Coolant
123 Marine Engine Coolant NA 92-813054A2
Fuel System Treat-
124 ment and Stabilizer 92-802876A1 92-802876Q1
Concentrate
Heat Transfer Com- 92-805701 1
125
pound
126 Liquid Gasket 92-808137 NA

127 T442 Sealant 92-862258 NA

Loctite 5900 Ultra 92-809826 NA
128 Black RTV Silicone
Sealant
Loctite Gasket Remov- 92-809828 1 NA
129
er
Sealer Kit, Two Part NA 92-65150 1
130
Epoxy
131 Anti-seize Compound 92-881091K1
132 Torco MTF Gear Oil 92–849864–1
Optimol Longtime PD 92–848767
133
2
Dexron III Automatic Obtain Locally Obtain Locally
134
Transmission Fluid
135 Loctite 592 Obtain Locally Obtain Locally
136 Loctite Quick Tite Obtain Locally Obtain Locally
137 Isopropyl Alcohol Obtain Locally Obtain Locally
138 Hot Glue Obtain Locally Obtain Locally
139 Loctite 609 Obtain Locally Obtain Locally
1
140 Loctite 405 Obtain Locally Obtain Locally

Page 1A-10 90-855348R02 NOVEMBER 2002

 SPECIFICATIONS

Tube Mercury Part Num- Quicksilver Part

Description
Ref. # ber Number
Cyanacrylate Adhe-
1
141 Obtain Locally Obtain Locally
sive
3M Permabond
142 Obtain Locally Obtain Locally
#3M08155
143 Loctite 262 Obtain Locally Obtain Locally
144 Loctite 290 Obtain Locally Obtain Locally
Loctite 598 RTV Seal- Obtain Locally Obtain Locally
145
ant
146 Insulating Compound 92–41669–1

90-855348R02 NOVEMBER 2002 Page 1A-11

 MAINTENANCE

IMPORTANT INFORMATION 1
Section 1B - Maintenance B
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Fuel Line Filter . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Gear Case Lubricant Capacity . . . . . . . . . 1B-2 Water Separating Fuel Filter . . . . . . . . . . . 1B-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . . 1B-6
Mercury/Quicksilver Lubricants Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-6
and Sealants . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . 1B-7
Inspection and Maintenance Schedule . . . . . 1B-3 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-3 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . 1B-8
After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Every 100 Hours of Use or Once Yearly, Checking Power Trim Fluid . . . . . . . . . . . . . . . 1B-10
Whichever Occurs First . . . . . . . . . . . . . . . 1B-3 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . 1B-11
Every 300 Hours of Use or Every Gear Case Lubricant Capacity . . . . . . . . . 1B-11
Three Years, Whichever Occurs First . . . 1B-3 Draining Gear Case . . . . . . . . . . . . . . . . . . 1B-11
Before Periods of Storage . . . . . . . . . . . . . 1B-4 Checking Lubricant Level
Flushing Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 and Refilling Gear Case . . . . . . . . . . . . . . 1B-12
Flushing Cooling System with Engine NOT Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Running (Using Cowl Flush Plug) . . . . . . 1B-4 Compressor Air Intake Filter . . . . . . . . . . . . . . 1B-14
Flushing Cooling System with Engine 1997 Model Compressor Air Intake Filter . 1B-14
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 1998/1999 Model Compressor
(Using Flushing Attachment 44357A2) . . 1B-4 Air intake Filter . . . . . . . . . . . . . . . . . . . . . . 1B-14
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Cleaning the Cooling Water Strainer . . . . . . . 1B-15

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Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.75:1 28.0 fl. oz. (828.0ml)
1.87:1 28.0 fl. oz. (828.0ml)

Special Tools
1. Flushing Attachment 44357A2

2. Grease Gun 91-37299A1

Mercury/Quicksilver Lubricants and Sealants

NOTE: Refer to Section 1A for lubricants and sealants chart.

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Inspection and Maintenance Schedule

Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case
with fresh water if operating in salt water.

Every 100 Hours of Use or Once Yearly, Whichever Occurs First

1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Replace water separating fuel filter.
4. Replace compressor air intake filter.
5. Check corrosion control anodes. Check more frequently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft and shift shaft.∗
8. Check power trim fluid.
9. Inspect battery.
10. Check control cable adjustments.∗
11. Check tightness of bolts, nuts, and other fasteners.

Every 300 Hours of Use or Every Three Years, Whichever Occurs First
Replace water pump impeller (more often if overheating occurs or reduced water pressure
is noted).∗
∗ These items should be serviced by an authorized dealer.

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Before Periods of Storage

FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, carburetors and fuel injection systems) with
treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with follow-
ing:
1. Portable Fuel Tank – Pour the required amount of Gasoline Stabilizer (follow instructions
on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of 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.
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 fill the fuel system.
∗ These items should be serviced by an authorized dealer.

Flushing Engine
Flushing Cooling System with Engine NOT Running (Using Cowl Flush Plug)
Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted or muddy water. This will help prevent a buildup of deposits from clogging the inter-
nal water passages.
1. Remove the plug from fitting in the bottom cowl.

2. Attach a water hose to the fitting. Turn water on and flush for 3 to 5 minutes.
NOTE: Engine can be stopped or running at idle speed when flushing the cooling system.
Do not flush engine using a water system that exceeds 45psi.
Flushing Cooling System with Engine Running
(Using Flushing Attachment 44357A2)
WARNING
When flushing, verify that area in vicinity of propeller is clear and that no person
is standing nearby – to avoid possible injury. It is recommended to remove propeller
as a precautionary measure.

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1. Install Flushing Attachment 44357A2 (or equivalent tool) on the gear housing from the
FRONT side, positioning the rubber cups over the water intake openings.
2. Connect hose [1/2 in.(12.7mm) I.D. or larger] between flushing attachment and water
tap.
IMPORTANT: To prevent water pump damage, do not start or run engine unless cool-
ing water is flowing.
3. With the outboard in the normal operating position (vertical), partially open water tap (IT
IS NOT NECESSARY to use full water pressure) and adjust water flow so that there is
a significant water loss around the rubber cups.
4. Start engine and idle in NEUTRAL. Increase engine speed, not to exceed 2500 RPM.
5. Flush or service engine as required. Verify adequate cooling water is provided.
a. Water must be discharged through tell tale.
IMPORTANT: Prevent engine overheating. If water flow is insufficient, stop engine
and determine cause before continuing.
b. Flush until discharge water is clear. In salt-water areas, run outboard 3 to 5 minutes.
c. Stop engine before turning off water.
6. Stop engine, turn water off and remove flushing attachment from gear housing.
IMPORTANT: While and after flushing, keep outboard in upright position until all wa-
ter has drained from drive shaft housing to prevent water from entering the power-
head via drive shaft housing and exhaust ports.

Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or al-
low open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area. In-
spect any completed service work for sign of fuel leakage.
Fuel Line Filter

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Water Separating Fuel Filter

NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
This filter removes moisture and also debris from the fuel. If the filter becomes filled with
water, the water can be removed. If the filter becomes plugged with debris, the filter must
be replaced with a new filter.
Remove and replace filter as follows:
a. Turn ignition key switch to “OFF” position.
b. Disconnect wire at bottom of filter.
c. Remove filter by turning the filter in the direction of the arrow (clockwise). Tip the filter
to drain fluid in a suitable container.
d. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten
securely by hand. Reconnect the wire to the filter.
IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer
bulb until firm, forcing fuel into the filter.

Fuel Line Inspection

Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of deterioration or damage. If any of these conditions is found, the fuel line or primer
bulb must be replaced.

Corrosion Control Anode

The gear case has two corrosion control anodes. Another anode is installed on the bottom
of the transom bracket assembly. An anode helps protect the outboard against galvanic cor-
rosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
a

a - Gear Case Anodes (2)

b - Transom Bracket Anode

Each anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is com-
pletely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.

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Spark Plug Inspection

Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect
spark plug boots and replace if cracked.

2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough,cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart in General Information Section.

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

Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capa-
bility.
IMPORTANT: Read the safety and maintenance instructions which accompany your
battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.

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Fuse Replacement
The electric starting circuit is protected from overload by an 20 AMP fuse. If the fuse is blown,
the electric starter motor will not operate. Try to locate and correct the cause of the overload.
If the cause is not found, the fuse may blow again. Replace the fuse with a fuse of the same
rating.

a
b
c
d

The electrical wiring circuits on the outboard are protected from overload by fuses in the wir-
ing. If a fuse is blown, try to locate and correct the cause of the overload. If the cause is not
found, the fuse may blow again.
Open the fuse holder and look at the silver colored band inside the fuse. If band is broken,
replace the fuse. Replace fuse with a new fuse with the same rating.
The fuses and circuits are identified as follows:
a - Electric Fuel Pump Circuits – 20 AMP Fuse.
b - Fuel/Air Injector Circuits – 20 AMP Fuse.
c - Starting Circuit – 20 AMP Fuse.
d - Ignition Coil/Oil Pump Circuit – 20 AMP Fuse.

Lubrication Points
Lubricate Point 1 with Special Lubricant 101.
1. Trim Rod Ball Ends – Turn the ball ends to work the lubricant into the ball sockets.

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Lubricate Point 2 with Anti-Corrosion Grease or 2-4-C with Teflon.

2. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the
propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from
corroding and seizing to the shaft.
2

Lubricate Points 3 through 5 with 2-4-C with Teflon or Special Lubricant 101.
3. Swivel Bracket – Lubricate through fitting.
4. Tilt Support Lever – Lubricate through fitting.

4
5. Tilt Tube – Lubricate through fitting.

WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube be-
fore adding lubricant. Adding lubricant to steering cable when fully extended could
cause steering cable to become hydraulically locked. An hydraulically locked steer-
ing cable will cause loss of steering control, possibly resulting in serious injury or
death.

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Lubricate Point 6 with 2-4-C with Teflon or Special Lubricant 101 and Point 7 With Light Weight Oil.
6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the
steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b).
7. Steering Link Rod Pivot Points – Lubricate pivot points.
6-b 6-a

7
Checking Power Trim Fluid
1. Tilt outboard to the full up position and engage the tilt support lock.

a - 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 Power Trim & Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.

a - Fill Cap

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Gear Case Lubrication

Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.75:1 28.0 fl. oz. (828.0ml)
1.87:1 28.0 fl. oz. (828.0ml)

Draining Gear Case

WARNING
If gear housing is installed on outboard, to avoid accidental starting, disconnect
(and isolate) spark plug leads from spark plugs before working near the propeller.

CAUTION
Do not use automotive grease in gear housing. Use only Premium Gear Lubricant.
1. Tilt outboard so that lubricant in gear housing will drain toward front of housing.
IMPORTANT: Inspect FILL and VENT screw sealing washers for damage. Use new
washers as needed.
2. Remove lubricant FILL screw and sealing washer. Note amount of metal particles on
magnetic fill screw.
3. Remove VENT screw with sealing washer and allow sufficient time for lubricant to drain.

a
b

a - Vent Screw with Sealing Washer

b - Fill Screw with Sealing Washer

4. Inspect gear lubricant for metal particles (lubricant will have a metal flake appearance).
Presence of a small amount of fine metal particles (resembling powder) on fill screw bar
magnet indicates normal gear wear. An excessive amount of metal filings or larger
particles (chips) may indicate abnormal wear and requires gear housing disassembly
and component inspection.
5. Note color of gear lubricant. White or cream color indicates presence of water in
lubricant. Gear lubricant which has been drained from a gear case recently in operation
will have a yellowish color due to lubricant agitation/aeration. This is normal and should
not be confused with the presence of water.
6. Presence of water in gear lubricant indicates the need for disassembly and inspection
of oil seals, seal surfaces, O-rings, and water pump gaskets as well as gear housing
components for damage.

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Checking Lubricant Level and Refilling Gear Case

IMPORTANT: Never add lubricant to gear housing without first removing VENT
screw, as trapped air will prevent housing from being filled. Fill gear housing only
when outboard is in operating position.
1. With outboard in vertical position, insert lubricant tube into fill hole.
2. Slowly fill housing through “FILL” hole with Premium Gear Lubricant until lubricant flows
out of “VENT” hole and no air bubbles are visible.
3. Install vent screw into “VENT” hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling “FILL” screw.
4. Remove grease tube (or hose) from fill hole and quickly install fill screw into “FILL” hole.

b
a - Vent Screw
b - Fill Screw

Storage

FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, It is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
1. Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated
(stabilized) fuel to help prevent formation of varnish and gum. Proceed with following
instructions.
a. Portable Fuel Tank – Pour the required amount of Gasoline Stabilizer (follow
instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer
with the fuel.
b. Permanently Installed Fuel Tank – Pour the required amount of 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.
c. Place the outboard in water or connect flushing attachment for circulating cooling
water. Run the engine for ten minutes to allow treated fuel to fill the fuel system.

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PROTECTING INTERNAL ENGINE COMPONENTS

NOTE: Before performing make sure the fuel system has been prepared for storage.
1. Remove spark plugs and add approximately one ounce (30 ml) of engine oil into each
spark plug hole.
2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.
3. Remove the water separating fuel filter and empty contents in a suitable container.
Replace fuel filter annually or every 100 hours of operation or if a large amount of fuel
contamination is present.

PROTECTING EXTERNAL OUTBOARD COMPONENTS

1. Lubricate all outboard components listed in the Inspection and Maintenance
Schedule, preceding.
2. Touch up any paint nicks.
3. Spray Corrosion Guard on engine exterior (except corrosion control anodes).

GEAR CASE
1. Drain and refill the gear case lubricant.

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 temperature, trapped cooling water or rain
water that may have entered the propeller exhaust outlet in the gear case could
freeze and cause damage to the outboard.

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

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Compressor Air Intake Filter

1997 Model Compressor Air Intake Filter
The air filter keeps dust and dirt out of the air compressor. The filter is a layered type filter
that contains 4 separate filter elements. The filter is not cleanable. The pores in the filter ele-
ments clog permanently, requiring filter replacement. We recommend changing the filter ev-
ery 100 hours of operation, or once a season. Never run the engine without the air filter.

ÄÄÄÄ
ÄÄÄÄ

REMOVAL
Remove the filter through the top opening in the flywheel cover.
INSTALLATION
Tuck the filter into the filter pocket. White side of the filter facing out. Spread out the filter
so that it fits into the channel that surrounds the pocket.
1998/1999 Model Compressor Air intake Filter
The filter should be changed every 100 hours of operation, or once a season. Never run the
engine without the air filter.
REMOVAL
1. Remove flywheel cover from the engine. Remove cover and the filter.

7
a

7 Loctite 271
a - Cover
b - Filter
INSTALLATION
2. Install filter into cover. Apply Loctite 271 to screw threads, and fasten cover with four
screws.

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Cleaning the Cooling Water Strainer

The cooling water strainer filters the cooling water flowing to the fuel cooler and air compres-
sor. We recommend cleaning this strainer every 100 hours of operation, or once a season.

a - Cooling Water Strainer

1. Remove the bottom cowl. Disconnect the water hose from the strainer plug.
2. Remove and clean the strainer.
3. Apply Loctite PST Pipe Sealant to strainer threads and reinstall strainer. Reconnect
water hose and secure with sta-strap.
NOTE: On later models the water strainer filters water going to the air compressor and is
located at the top of the cylinder block.

TIMING ADJUSTMENT FOR HIGH ALTITUDE OPERATION

Timing is not adjustable and is controlled automatically by the Electronic Control Unit.

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 GENERAL INFORMATION

IMPORTANT INFORMATION 1
Section 1C - General Information C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Conditions Affecting Performance . . . . . . . . . 1C-2 Instructions for Wet Application . . . . . . . . . 1C-11
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 1997 Model Powerhead Starboard View . . . . 1C-13
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 1997 Model 200 Powerhead Port View . . . . . 1C-14
Engine Compression . . . . . . . . . . . . . . . . . . 1C-4 1997 Model 200 Powerhead Top View . . . . . 1C-15
Water Pressure Check . . . . . . . . . . . . . . . . 1C-4 1997 Model 200 Powerhead Aft View . . . . . . 1C-16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 1998/1999 Model 200/225 Powerhead
Following Complete Submersion . . . . . . . . . . 1C-6 Starboard View . . . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-6 1998/1999 Model 200/225 Powerhead
Submerged While Running . . . . . . . . . . . . 1C-6 Port View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Propeller Replacement . . . . . . . . . . . . . . . . . . . 1C-8 1998/1999 Model 200/225 Powerhead
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8 Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 1998/1999 Model 200/225 Powerhead
Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-10 Aft View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Cleaning & Painting Aluminum Propellers 1998 Model 200/225 Powerhead Front
& Gear Housings . . . . . . . . . . . . . . . . . . . . 1C-10 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-11

Serial Number Location

The engine serial number is located on the lower starboard side of the engine block. A
serial number is also located on the starboard side of the swivel bracket.

a
OGXXXXXX
b
19XX
XXXX c

e
d
XX

a - Serial Number
b - Model Year
c - Model designation
d - Year Manufactured
e - Certified Europe Insignia

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GENERAL INFORMATION

Conditions Affecting Performance

Weather

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

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Boat
WEIGHT DISTRIBUTION
Proper positioning of the weight inside the boat (persons and gear) has a significant effect
on the boat’s performance, for example:
1. Shifting weight to the rear (stern)
a. Generally increases top speed.
b. If in excess, can cause the boat to porpoise.
c. Can make the bow bounce excessively in choppy water.
d. Increases the danger of the following wave splashing into boat when coming off plane.
2. Shifting weight to the front (bow)
a. Improves ease of planing off.
b. Generally improves rough water ride.
c. If excessive, can make the boat veer back-and-forth (bow steer).
BOTTOM
Boat Bottom: For maximum speed, a boat bottom should be nearly a flat plane where it
contacts the water and particularly straight and smooth in fore-and-aft direction.
1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the
side. When boat is planing, hook causes more lift on bottom near transom and allows
bow to drop, thus greatly increasing wetted surface and reducing boat speed. Hook fre-
quently is caused by supporting boat too far ahead of transom while hauling on a trailer
or during storage.
2. Rocker: The reverse of hook and much less common. Rocker exists if bottom is convex
in fore-and-aft direction when viewed from the side, and boat has strong tendency to
porpoise.
3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of motor’s gear hous-
ing increase skin friction and cause speed loss. Clean surfaces when necessary.
4. Gear Housing: If unit is left in the water, marine vegetation may accumulate over a peri-
od of time. This growth MUST be removed from unit before operation, as it may clog the
water inlet holes in the gear housing and cause the engine to overheat.

TRIMMING OUTBOARD “OUT” (UP)

WARNING
Excessive trim out also may reduce stability of some high speed hulls. To correct
instability at high speed, reduce the power GRADUALLY and trim the outboard in
slightly before resuming high speed operation. (Rapid reduction in power will
cause a sudden change of steering torque and may cause additional momentary
boat instability.)
1. Will lift bow of boat, generally increasing top speed.
2. Transfers steering torque harder to left on single outboard installations below 23 in.
(584mm) transom height.
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced water supply can cause overheating
resulting in engine damage.

90-855348R02 NOVEMBER 2002 Page 1C-3

GENERAL INFORMATION

TRIMMING OUTBOARD “IN” (DOWN)

WARNING
Excessive speed at minimum trim in may cause undesirable and/or unsafe steering
conditions. Each boat should be tested for handling characteristics after any ad-
justment is made to the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or right (bow steer).
4. Transfers steering torque harder to right (or less to left) on single outboard installations.
5. Improves planing speed acceleration (by moving trim adjustment bolt one hole closer
to transom).
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in additional
boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on
the gearcase or from an irregularity in the propeller blade itself. These vapor bubbles flow
back and collapse when striking the surface of the propeller blade resulting in erosion of the
propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur.
VENTILATION
Ventilation occurs when air is drawn from the water’s surface (excessive trim out angle) or
from the engine exhaust flow (wrong propeller/propeller hardware installed or gear case lab-
yrinth seal worn) into the propeller blades. These air bubbles strike the propeller blade sur-
face and cause erosion of the blade surface. If allowed to continue, eventual blade failure
(breakage) will occur.
Engine Compression
Engine compression should be checked with engine block warm, throttle shutter wide open,
all spark plugs removed and using a fully charged battery. Normal compression for all cylin-
ders should be 90 to 110 psi (616.3 – 753.3 kPa). Cylinders should not vary more than 15
psi (103.4 kPa) between one another. A variance of more than 15 psi would indicate the
need for a power head inspection/disassembly.
Water Pressure Check
NOTE: To perform these checks, a Water Pressure Gauge Kit (91-79250A2) is recom-
mended.
1. Water pressure at idle, in NEUTRAL, is 1-1/2 - 4-1/2 psi. (10.3 - 30.8 kPa).
2. Water pressure should increase, then drop to 4-6 psi. (27. - 41 kPa) prior to 2500 RPM
(due to poppet valve opening at 2500 RPM).
3. At 2500 RPM, water should not exceed 12 psi (82.7 kPa).
4. Static test (boat stationary - operate in forward gear with a cut down propeller) at 5000
RPM or above is 8 - 10 psi. (54.8 - 68.5 kPa).

CAUTION
A modified propeller or low pitch propeller is required to perform the above static
test. Static test requires the boat be stationary in the water secured to a dock or trail-
er and run in forward gear. DO NOT use a flush device for this test.

Page 1C-4 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

Engine
DETONATION
Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine. It
can be otherwise described as a tin-like “rattling” or “plinking” sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug
has fired. Detonation creates severe shock waves in the engine, and these shock waves
often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings
or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 2-cycle application are as fol-
lows:
1. Over-advanced ignition timing.
2. Use of low octane gasoline.
3. Propeller pitch too high (engine RPM below recommended maximum range).
4. Lean fuel mixture at or near wide-open-throttle.
5. Spark plugs (heat range too hot – incorrect reach – cross-firing).
6. Inadequate engine cooling (deteriorated cooling system).
7. Combustion chamber/piston deposits (result in higher compression ratio).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.

51115
Damaged Piston Resulting from Detonation

90-855348R02 NOVEMBER 2002 Page 1C-5

GENERAL INFORMATION

Following Complete Submersion

Salt Water Submersion
Due to the corrosive effect of salt water on internal engine components, complete disassem-
bly is necessary before any attempt is made to start the engine.
Submerged While Running
When an engine is submerged while running, the possibility of internal engine damage is
greatly increased. If, after engine is recovered and with spark plugs removed, engine fails
to turn over freely when turning flywheel, the possibility of internal damage (bent connecting
rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled.
SUBMERGED ENGINE (FRESH WATER)
IMPORTANT: Engine should be run within 2 hours after recovery, 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.
NOTE: If sand has entered the air intake on the engine, do not attempt to the start the en-
gine. Sand will cause internal engine damage. Disassembly is required to clean all internal
engine components of sand.
1. Recover engine from water as quickly as possible.
2. Remove cowling.
3. Clean the exterior of the outboard with fresh water.
4. Dry all wiring and electrical components using compressed air.
5. Drain water from fuel system as follows:
a. Disconnect remote fuel hose from engine.
b. Remove drain plug from vapor separator and drain fuel/water. Reinstall plug after
draining.
c. Remove the fuel hose from bottom of port side fuel rail and drain fuel/water. Reinstall
hose.
d. Remove the water separating fuel filter and empty contents.
6. Drain water from air compressor system as follows:
a. Dry or replace the air filter for the compressor.
b. Remove air outlet hose for the air compressor and drain water from compressor and
hose. Reinstall hose.
c. Remove the air hose from bottom of port side fuel rail and drain water. Reinstall
hose.
7. Drain water from engine as follows:
a. Remove air sensor from front of the air plenum. Tilt up the outboard and drain water
out of the air plenum through the air sensor mounting hole. Reinstall Sensor.
b. Remove spark plugs from engine.
c. Rotate flywheel manually to blow out any water from the cylinders.
d. Add approximately one ounce (30ml) of engine oil into each spark plug hole. Rotate
the flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.

Page 1C-6 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

8. Drain water from the oil injection system as follows:

a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard
side of engine.
b. Drain any water from hose and reconnect.
c. If water was present in hose, check for water in the remote oil tank. Drain tank if water
is present.
9. Disassemble the engine starter motor and dry components.
10. Prime the oil injection pump as follows:
a. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it fells firm.
b. Turn the ignition key switch to the “ON” position.

c. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F

NOTE: Audible click from the oil pump will tell you the pump is priming. It may take a few
minutes for the pump to complete the priming process.
11. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
12. If engine fails to start, determine cause (fuel, electrical or mechanical).

90-855348R02 NOVEMBER 2002 Page 1C-7

GENERAL INFORMATION

Propeller Replacement
Removal
WARNING
When removing or installing propeller, verify remote control is in NEUTRAL posi-
tion and that key switch is “OFF.” Place a block of wood between the anti-ventilation
plate and propeller to prevent accidental engine starting and to protect hands from
propeller blades while removing propeller nut.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.
2. Shift engine into neutral position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller
locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propeller
shaft.

b
51866

d
f

d e

51871
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut

Page 1C-8 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

Installation
1. To aid in future removal of the propeller, coat the propeller shaft splines with one of the
following lubricants:
– Anti-Corrosion Grease
– 2-4-C with Teflon
– Special Lubricant 101
2. Place forward thrust hub onto propeller shaft.
3. Align splines and slide propeller onto shaft.

a 22750

a - Forward Thrust Hub

b - Propeller Shaft
4. Place locking tab washer on propeller shaft, then thread propeller nut on shaft.
5. Place propeller nut into recess in locking tab washer and torque propeller nut to 55 lb.
ft. (74.6 Nm). Verify nut is recessed into tab washer while applying torque.
6. Bend 3 tabs from locking tab washer down into grooves of propeller hub to secure pro-
peller nut.
7. After first use, bend three tabs straight and retorque propeller nut [55 lb. ft. (74.6 Nm)].
Bend tabs down into propeller hub grooves (check periodically for tightness.)

CAUTION
If propeller moves fore-and-aft on the propeller shaft, retighten the propeller nut.
Operation with a loose propeller could cause damage to the thrust hub and gear
housing during acceleration, deceleration or when shifting gears.

e
c

c - Locking Tab Washer (Bend Tabs into Thrust Hub Grooves)

d - Propeller Nut
e - Rear Thrust Hub

90-855348R02 NOVEMBER 2002 Page 1C-9

GENERAL INFORMATION

Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne par-
ticles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite,
disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover
or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black.
GEAR HOUSINGS
The following procedures should be used in refinishing gear housings. This procedure will
provide the most durable paint system available in the field. The materials recommended
are of high quality and approximate marine requirements. The following procedure will pro-
vide a repaint job that compares with a properly applied factory paint finish. It is recom-
mended that the listed materials be purchased from a local Ditzler Automotive Finish Supply
Outlet. The minimum package quantity of each material shown following is sufficient to
refinish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint
blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly
adhere to the surface nor will the coating be sufficiently thick to resist future paint
blistering.

CAUTION
Be sure to comply with instructions on the label for ventilation and respirators. Us-
ing a spray gun, apply one half to one mil even film thickness. Let dry, flash off for
five minutes and apply another even coat of one half to one mil film thickness. This
urethane paint will dry to the touch in a matter of hours, but will remain sensitive
to scratches and abrasions for a few days.

Page 1C-10 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

6. Mix epoxy chromate primer (DP-90LF) with equal part catalyst (DP-402LF) per
manufacturers instructions, allowing proper induction period for permeation of the
epoxy primer and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coating
assemblies.
8. Use Ditzler Urethane DU9300 for Mercury Phantom Black and DU34334 for Mariner
Light Grey. Catalyze colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with sol-
vents per Ditzler label instructions.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode.
10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to main-
tain good continuity circuitry between trim tab and gear housing.
Decal Application
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing
old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for Wet Application
NOTE: The following decal installation instructions are provided for a Wet installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia. Do not use a soap that contains
petroleum based solvents.
** Automotive Body Filler Squeegee
SERVICE TIP: Placement of decals using the Wet application will allow time to posi-
tion decal. Read entire installation instructions on this technique before proceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun-
light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C)
for best application.

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

90-855348R02 NOVEMBER 2002 Page 1C-11

GENERAL INFORMATION

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

Page 1C-12 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

1997 Model Powerhead Starboard View


23


22

 
15

14 1

13

21 
12

11 2

17


10

5

9 8 
7 6 3
4


20

 

1 - Starter Motor 13 - ECM Fuse (20 Ampere)

2 - Water Separating 14 - Electric Fuel Pump
Fuel Filter Fuse (20 Ampere)
3 - Air Temperature Sensor 15 - ECM
4 - Throttle Position 16 - Temperature Sensor
Sensors (2) 17 - Starboard Direct
(Not Adjustable) Injectors
5 - Oil Pump 18 - Serial Number
6 - Diagnostic Port 19 - Air Hose
7 - Main Power Relay 20 - Fuel Hose
8 - Trim DOWN Relay 21 - Starboard Fuel Rail
9 - Trim UP Relay 22 - Fuel Pressure
10 - Starter Solenoid Test Valve
11 - Oil Pump Fuse 23 - Air Hose
(20 Ampere)
12 - Harness Fuse
(20 Ampere)

90-855348R02 NOVEMBER 2002 Page 1C-13

GENERAL INFORMATION

1997 Model 200 Powerhead Port View


21 5

1 2


20 
4
3
6

7




19


14

18
8

13



17

 
16 

10 9
1 - Bleed Oil Inlet Hose to 11 - Shift Interrupt Switch
Air Compressor 12 - Fuel Return to Vapor
2 - Oil Inlet Hose to Separator
Air Compressor 13 - Fuel Cooler
3 - Excess Oil Return to 14 - Oil Reservoir
Throttle Plate Body 15 - Pulse Fuel Pump
4 - Water (IN) to Air 16 - Oil Hose to Oil Pump
Compressor 17 - Electric Fuel Pump
5 - Air Compressor 18 - Vapor Separator
6 - Fuel Return to Fuel 19 - MAP Sensor
Cooler
20 - Fuel Hose to Fuel Rail
7 - Port Fuel Rail
21 - To Air Filter Box
8 - Direct Injectors
9 - Air Exit to Exhaust
Adaptor Plate
10 - Water from Exhaust
Adaptor Plate

Page 1C-14 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

1997 Model 200 Powerhead Top View


1

17 2 3

16
4

5
6

7

14

13




12


11 9



1 - Compressed Air (IN) 9 - Vapor Separator

2 - Fuel Pressure 10 - Electric Fuel Pump
Regulator 11 - Water Separating
3 - Port Fuel Rail Fuel Filter
4 - Fuel Return Hose to 12 - Starter Motor
Fuel Cooler 13 - Air Compressor
5 - Fuel (IN) Hose 14 - Alternator
6 - Knock Sensor 15 - Crank Position Sensor
7 - Oil Reservoir 16 - Starboard Fuel Rail
8 - MAP Sensor 17 - Tracker Diaphragm

90-855348R02 NOVEMBER 2002 Page 1C-15

GENERAL INFORMATION

1997 Model 200 Powerhead Aft View


27 1 2
3

26
 
24

4

5

6

23  
7

22

17
8

15


18

14

21


19


13
20

9


10

 

1 - Air Compressor Cooling 15 - #2 Ignition Coil

Water (OUT) to Tell-Tale 16 - Exhaust Pressure
2 - Alternator Sensor Connector
3 - Compressed Air (IN) 17 - #1 Ignition Coil
4 - Air Fitting Screen 18 - #3 Ignition Coil
5 - Fuel Pressure 19 - #5 Ignition Coil
Test Valve 20 - Air Pressure Regulator
6 - Fuel Injector 21 - Fuel Pressure
7 - Tracker Diaphragm Regulator
8 - Starboard Fuel Rail 22 - Port Fuel Rail
9 - Air Hose 23 - Air Pressure Test Valve
10 - Fuel Hose 24 - Fuel Return Hose to
11 - Not Used Fuel Cooler
12 - Water Pressure Plug 25 - Fuel (IN) Hose
13 - #6 Ignition Coil 26 - Air Compressor
14 - #4 Ignition Coil 27 - Air Inlet for Air Com-
pressor

Page 1C-16 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

1998/1999 Model 200/225 Powerhead Starboard View


 











  








 56822

1 - Fuel Pressure 12 - Electric Fuel Pump

Test Valve Fuse (20 Ampere)
2 - Air Hose 13 - ECM Fuse (20 Ampere)
3 - Electronic Control 14 - Harness Fuse
Module (20 Ampere)
4 - Starter Motor 15 - Oil Pump Fuse
5 - Throttle Plate/Air (20 Ampere)
Plenum Assembly 16 - Trim UP Relay
6 - Air Temperature Sensor 17 - Trim DOWN Relay
7 - Oil Hose to Air Com- 18 - Poppet Valve Assembly
pressor 19 - Air Hose
8 - Oil Hose from Oil Tank 20 - Fuel Hose
to Oil Pump 21 - Fuel Injector
9 - Oil Pump 22 - Starboard Fuel Rail
10 - Main Power Relay 23 - Direct Injector
11 - Starter Solenoid

90-855348R02 NOVEMBER 2002 Page 1C-17

GENERAL INFORMATION

1998/1999 Model 200/225 Powerhead Port View

4 6 7
3
5 8
9
2


10

11
1

27



12


28

21

26 
25 
24 
13



14


23

15



17

19 
18 56032

1 - High Pressure 15 - Air Hose

Fuel Pump 16 - Fuel Hose
2 - Fuel Outlet Hose 17 - Air Exit to Exhaust
3 - Vapor Separator Adaptor Plate
Vent Hose 18 - Fuel Cooler Water
4 - Throttle Position Sensor Inlet Hose
(2 Each) 19 - Oil Hose to Oil Pump
5 - Oil Hose to Air 20 - 2 PSI Check Valve
Compressor 21 - Oil Reservoir
6 - Air Compressor 22 - Pulse Fuel Pump
7 - Air Inlet Hose to Air 23 - Water Sensor
Compressor 24 - Low Pressure Fuel
8 - Tell-Tale Hose Pump
9 - Temperature Sensor 25 - Fuel/Water Separator
10 - Air Pressure Valve Filter
11 - Fuel Injector 26 - Vapor Separator
12 - Fuel Cooler 27 - Fuel Cooler Water
13 - Port Fuel Rail Outlet Hose
14 - Fuel Return Hose to 28 - Fuel Inlet Hose to Fuel
Vapor Separator Cooler

Page 1C-18 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

1998/1999 Model 200/225 Powerhead Top View

 1

14
2


13
3

12
4

5

7


11



10

56824

1 - Water Outlet (Tell-Tale) 9 - Throttle Plate Assembly

Hose 10 - Oil Return Hose from
2 - Air Inlet Nozzle for Air Air Compressor
Compressor 11 - Starter Motor
3 - Water Inlet Hose to 12 - Crank Position Sensor
Fuel Cooler Harness
4 - Air Compressor 13 - Belt Tensioner
5 - Fuel Cooler 14 - Air Hose (80 PSI) to
6 - Oil Reservoir Fuel Rail
7 - Throttle Position 15 - 60 Ampere Alternator
Sensors (TPS) (2 each)
8 - Manifold Absolute
Pressure (MAP) Sensor
Hose

90-855348R02 NOVEMBER 2002 Page 1C-19

GENERAL INFORMATION

1998/1999 Model 200/225 Powerhead Aft View

 









 

  

 




 

55990
1 - 60 Ampere Alternator 13 - #2 Ignition Coil
2 - Compressed Air (IN) 14 - #4 Ignition Coil
3 - Fuel Pressure 15 - #6 Ignition Coil
Test Valve 16 - Air Regulator
4 - Fuel Injector 17 - Port Fuel Rail
5 - Tracker Valve 18 - Fuel Regulator
6 - Starboard Fuel Rail 19 - Fuel (IN) Hose
7 - Air Hose 20 - Air Pressure Test Valve
8 - Fuel Hose 21 - Air Compressor
9 - Water Pressure Sensor 22 - Air Inlet Hose to Air
Hose Compressor
10 - #5 Ignition Coil 23 - Water Pressure Sensor
11 - #3 Ignition Coil 24 - Manifold Absolute
12 - #1 Ignition Coil Pressure Sensor

Page 1C-20 90-855348R02 NOVEMBER 2002

 GENERAL INFORMATION

1998 Model 200/225 Powerhead Front View

1
2

3


13


11


12

4
5


10

6

7

9 8
56825
1 - Air Compressor 8 - Inlet Fuel Hose to Low
2 - Fuel Outlet Hose to Pressure Electric
Fuel Rails Fuel Pump
3 - Vapor Separator 9 - Inlet Oil Hose to Oil
Vent Filter Pump from Oil
4 - Fuel/Water Separator Reservoir
5 - Vapor Separator 10 - Air Temperature Sensor
6 - Internal Electric Fuel 11 - Outlet Fuel Hose from
Pump Low Pressure Electric
7 - Inlet Fuel Hose to Pulse Fuel Pump
Fuel Pump 12 - Electric Oil Pump
13 - Starter Motor

90-855348R02 NOVEMBER 2002 Page 1C-21

 OUTBOARD MOTOR INSTALLATION

IMPORTANT INFORMATION 1
Section 1D - Outboard Motor Installation D
Table of Contents
Notice to Installer and Owner . . . . . . . . . . . . . 1D-1 Boats Equipped with Panel
Boat Horsepower Capacity . . . . . . . . . . . . . . . 1D-2 or Console Mount Remote Control . . . . . 1D-10
Outboard Remote Control . . . . . . . . . . . . . . . . 1D-2 Shift and Throttle Cable Installation
Selecting Accessories For The Outboard . . . 1D-2 to the Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-11
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . 1D-2 Shift Cable Installation . . . . . . . . . . . . . . . . 1D-11
Selecting Steering Cables Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
and Remote Control Cables . . . . . . . . . . . . . . 1D-2 Remote Wiring Connections . . . . . . . . . . . . . . 1D-15
Determining Recommended Outboard Routing Location for Wiring and Hoses
Mounting Height . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 through Clamp in Bottom Cowl . . . . . . . . . . . 1D-16
Locating Centerline of Boat Transom . . . . . . 1D-4 Installation Note . . . . . . . . . . . . . . . . . . . . . . 1D-16
Installation Specifications . . . . . . . . . . . . . . . . . 1D-4 Warning Gauge Harness . . . . . . . . . . . . . . 1D-18
Drilling Outboard Mounting Holes . . . . . . . . . 1D-4 Battery Connections . . . . . . . . . . . . . . . . . . . . . 1D-19
Applying Counter Rotation Decals . . . . . . 1D-5 Front Clamp and Cowl Reassembly . . . . . 1D-20
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . 1D-21
Installing Outboard To Boat Transom . . . . . . 1D-6 Portable Fuel Tank . . . . . . . . . . . . . . . . . . . 1D-21
Single Steering Cable and Steering Permanent Fuel Tank . . . . . . . . . . . . . . . . . 1D-21
Link Rod Installation . . . . . . . . . . . . . . . . . . . . 1D-7 Fuel Hose Size . . . . . . . . . . . . . . . . . . . . . . . 1D-21
Installing Ride Guide Cable to Fuel Hose Connection . . . . . . . . . . . . . . . . 1D-21
Outboard Tilt Tube . . . . . . . . . . . . . . . . . . . 1D-8 Set Up Instructions for Oil Injection System . . . 1D-21
Steering Link Rod Installation . . . . . . . . . . 1D-8 Filling Fuel System . . . . . . . . . . . . . . . . . . . . . . 1D-25
Remote Control Installation . . . . . . . . . . . . . . . 1D-9 Oil Injection System . . . . . . . . . . . . . . . . . . . . . 1D-25
Counter (Left Hand) Rotation Outboards . . . 1D-10 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Required Side Mount Remote Control Priming the Oil Injection Pump . . . . . . . . . 1D-26
or Ignition Key Switch Assembly . . . . . . . . . . 1D-10 Purging Air From the Engine Oil Tank . . . 1D-27
Boats Equipped with Side Mount Trim “In” Angle Adjustment . . . . . . . . . . . . . . . 1D-27
Remote Control . . . . . . . . . . . . . . . . . . . . . . 1D-10 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-28

Notice to Installer and Owner

This manual as well as safety labels posted on the outboard use the following safety
alerts to draw your attention to special safety instructions that should be followed.

WARNING
WARNING – Hazards or unsafe practices which COULD result in severe person-
al injury or death.

CAUTION
CAUTION – Hazards or unsafe practices which could result in minor injury or
product or property damage.

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OUTBOARD MOTOR INSTALLATION

Boat Horsepower Capacity

U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX

Do not overpower. Most boats carry a required capacity plate, indicating the maximum ac-
ceptable power and load (as determined by the manufacturer) following certain federal
guidelines. If in doubt, contact the boat manufacturer.

WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can 1)
cause loss of boat control, 2) place too much weight at the transom altering the
designed flotation characteristics of the boat, or 3) cause the boat to break apart
particularly around the transom area. Overpowering a boat can result in serious
injury, death or boat damage.

Outboard Remote Control

The remote control connected to the outboard must be equipped with a start in gear protection
device. This prevents the engine from starting when the outboard is in gear.

WARNING
Avoid serious injury or death from a sudden unexpected acceleration when starting
the engine. The design of this outboard requires that remote control used with it
must have a built in start in gear protection device.

Selecting Accessories For The Outboard

Some accessories not manufactured or sold by Mercury Marine are not designed to be safely
used with these outboards or outboard operating system. Acquire and read the installation,
operation and maintenance manuals for all selected accessories.
Electric Fuel Pump
If an external mounted electric fuel pump is used, fuel pressure must not exceed 4 psi at
the engine. If necessary, install a pressure regulator to regulate the pressure.

WARNING
The misuse of acceptable accessories or the use of unacceptable accessories can
result in serious injury, death or product failure.

Selecting Steering Cables and Remote Control Cables

Refer to the Mercury/Quicksilver Accessories Guide to determine correct length of steering
cables and remote control cables.
IMPORTANT: Steering cables and remote control cables must be the correct length.
Sharp bends on too-short cables result in kinks; too-long cables require unneces-
sary bends and/or loops. Both conditions place extra stress on the cables.
Page 1D-2 90-855348R02 NOVEMBER 2002
 OUTBOARD MOTOR INSTALLATION

Determining Recommended Outboard Mounting Height

WARNING
Boat instability can occur at high speeds by installing engine at the wrong transom
height. Contact the boat manufacturer for their recommendations for a specific en-
gine installation.

26 in.
(660mm)
25 in.
(635mm)

24 in.
(609mm)
b
23 in.
(584mm)
c
Outboard
Mounting 22 in.
(560mm)
Height (See
e
NOTE below)
21 in.
(533mm)
a
20 in. d
(508mm)

19 in.
(482mm)

10 20 30 40 50 60 70 80

NOTE: Add 5 in. (127mm) for XL models and 10 in. (254mm) for XXL models to listed out-
board mounting height.
a. This solid line is recommended to determine the outboard mounting height.
IMPORTANT: Increasing outboard height will generally provide the following: 1) Less
steering torque, 2) more top speed, 3) greater boat stability, but 4) will cause more prop
break loose which may be particularly noticeable when planing off or with heavy load.
b. These broken lines represent the extremes of known successful outboard mounting
height dimensions.
c. This line may be preferred to determine outboard mounting height dimension, if
maximum speed is the only objective.
d. This line may be preferred to determine outboard mounting height dimension for
dual outboard installation.
e. Outboard mounting height (height of outboard transom brackets from bottom of boat
transom). For heights over 22 in. (560mm), a propeller, that is specifically designed
for surfacing operation, such as the “Laser” and “Mirage” series, usually are preferred.
f. Maximum boat speed anticipated.

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OUTBOARD MOTOR INSTALLATION

Locating Centerline of Boat Transom

Locate (and mark with pencil) vertical centerline (a) of boat transom.

A B

a
C D

a - Centerline of Transom

NOTE: Dimensions “A” & “B” and “C” & “D” are equal length.

Installation Specifications
a
a
b

a – Transom Opening – Minimum

Single Engine – 33-3/8 in. (848 mm)
Dual Engines – 59-3/4in. (1518 mm)
b – Engine Center Line For Dual Engine
26 in. (660mm) Minimum

Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read Determining Recom-
mended Outboard Mounting Height, preceding. There is a 3/4 in. (19 mm) difference
between outboard mounting holes in transom brackets.

WARNING
DO NOT, under any circumstances, allow upper outboard mounting bolts to be clos-
er than 1 in. (25.4 mm) from top of boat transom. Upper mounting bolts must never
be installed through shims.
NOTE: When drilling into a fiberglass boat, place masking tape directly onto boat where
mounting holes will be drilled to help prevent fiberglass from chipping.
Use a 17/32 inch (13.5mm) diameter drill bit and drill 4 mounting holes perpendicular to and
through the transom.

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 OUTBOARD MOTOR INSTALLATION

IMPORTANT: If using Transom Drilling Fixture, use drill guide holes marked “A” when
drilling outboard mounting holes.

a
a - Centerline of Transom
b - Transom Drilling Fixture (91-98234A2)

IMPORTANT: During installation of dual or multiple V-6 product, the following is rec-
ommended. A minimum of 26 inches (660mm) centerline to centerline width is recom-
mended. This is required to alleviate cowling interference during lock to lock turns
if one outboard would be in the full tilt position, while the other outboards are in the
vertical running position.
Applying Counter Rotation Decals
IMPORTANT: For dual outboard counter rotation installations, the left-hand rotation
outboard is generally placed on the port side of boat transom.
Apply “COUNTER ROTATION” decal (supplied with left-hand rotation outboard) onto bot-
tom cowl (rear) of right-hand rotation outboard. Match decal placement with left-hand rota-
tion outboard.
a b

a - Counter Rotation Decal (Left-Hand Rotation Outboard)

b - Counter Rotation Decal (Right-Hand Rotation Outboard)

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OUTBOARD MOTOR INSTALLATION

Lifting Outboard
WARNING
Verify lifting ring is threaded on crankshaft a minimum of 5 turns and that hoist has
a maximum lift capacity over 500 lbs. (227 kg) BEFORE lifting outboard.
Remove cowling from outboard. Remove plastic cap from center of flywheel. Thread lifting
eye into flywheel hub a minimum of 5 turns. Replace plastic cap after installation. Connect
hoist [minimum lift capacity of 500 Ibs. (227 kg)] to lifting eye. Lift outboard and place on boat
transom.

a - Lifting Eye (91-75132)

b - Hoist

Installing Outboard To Boat Transom

IMPORTANT: If boat is equipped with through tilt tube steering, steering cable end
must be installed into tilt tube of outboard (port outboard only for dual outboard in-
stallations) before securing outboard to transom. Refer to Steering Cable and Steer-
ing Link Rod Installation, following.
Refer to Determining Recommended Outboard Motor Mounting Height, preceding and po-
sition outboard on boat transom, to align mounting holes in transom bracket that will place
the outboard nearest to the recommended mounting height.

CAUTION
Marine sealer must be used on shanks bolts to make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when tightening transom bolts.
Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard to tran-
som with 4 bolts, flat washers and locknuts, as shown. Be sure that installation is water-tight.

Page 1D-6 90-855348R02 NOVEMBER 2002

 OUTBOARD MOTOR INSTALLATION

WARNING
Before operating, outboards MUST BE SECURED to boat transom with four 1/2 in.
diameter bolts and locknuts, as follows: 2 bolts must be installed through upper
mounting holes and 2 bolts through lower mounting holes. The installation must
be water-tight and outboard should be checked for tightness on the transom during
operation. Failure to bolt outboard to transom (using 4 bolts and locknuts, as
shown) may result in damage to boat and/or loss of outboard and possible injury
to occupants of boat.

b
c
b

c
a
a - 1/2 in. Diameter Bolts
b - Flat Washers
c - Locknuts

Single Steering Cable and Steering Link Rod Installation

NOTE: These instructions are for single cable-single outboard installations. Instructions for
mounting dual engines are included with the applicable dual engine attaching kit. Refer to
the Mercury/Quicksilver Accessories Guide to determine correct kit.
Refer to the Mercury/Quicksilver Accessories Guide to determine correct length of steering
cable.
IMPORTANT: Steering cable must be correct length. Sharp bends on too-short of a
cable result in kinks; too-long of a cable require unnecessary bends and/or loops.
Both conditions place extra stress on the cable.
Install steering mount and steering wheel in accordance with installation instructions that
accompany each.

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OUTBOARD MOTOR INSTALLATION

Installing Ride Guide Cable to Outboard Tilt Tube

IMPORTANT: Before installing steering cable in tilt tube, lubricate outside of cable
end with 2-4-C with Teflon.
NOTE: The Ride Guide steering cable is internally lubricated at the factory and requires no
additional lubrication at initial installation.
1. Lubricate seal inside of outboard tilt tube and entire cable end with 2-4-C with Teflon.
2. Insert steering cable end through outboard tilt tube and secure cable to tilt tube with
steering cable attaching nut, as shown. Torque nut to 35 lb. ft. (41.0 Nm).

95 95

c b

95

28160
95 2-4-C With Teflon
a - Seal
b - Cable End
c - Steering Cable Attaching Nut

Steering Link Rod Installation

IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” – Part Number 10-849838) and
self locking nuts (“b” & “c” – Part Number 11-826709113). These locknuts must never
be replaced with common nuts (non-locking) as they will work loose and vibrate off
freeing the link rod to disengage.

WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown over-
board exposing them to serious injury or death.
1. Assemble steering link rod to steering cable with two flat washers and nylon insert lock-
nut “b”. Tighten locknut until it seats, then back nut off 1/4 turn.

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 OUTBOARD MOTOR INSTALLATION

2. Assemble steering link rod to engine with special washer head bolt “a” and nylon insert lock-
nut “c”. First torque bolt to 20 lb. ft. (27.0 Nm), then torque locknut to 20 lb. ft. (27.0 Nm).

c
a - Special Washer Head Bolt (91-849838) [Torque to 20 lb. ft. (27 Nm)]
b - Nylon Insert Locknut (91-826709113) (Tighten until seats then back off 1/4 turn)
c - Nylon Insert Locknut (91-826709113) [Torque to 20 lb. ft. (27 Nm)]
d - Flat Washers (2)

WARNING
After installation is complete (and before operating outboard), check that the boat
will turn right when steering wheel is turned right, and that the boat will turn left
when the steering wheel is turned left. Check steering through full range (left and
right) and at all tilt angles to assure interference-free movement.

Remote Control Installation

Refer to the Mercury/Quicksilver Accessories Guide to determine correct length of remote
control cables.
IMPORTANT: Remote control cables must be the correct length. Sharp bends on too
short cables result in kinks; too-long cables require unnecessary bends and/or
loops. Both conditions place extra stress on the cables.
IMPORTANT: Install control cables to remote control. Mount remote control BEFORE
attaching control cables to engine. Refer to installation instructions included with the
remote control.

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OUTBOARD MOTOR INSTALLATION

Counter (Left Hand) Rotation Outboards

IMPORTANT: Counter rotating (left hand) gearcases can be identified by a “L”
stamped into the end of the propeller shaft.
On counter (left hand) rotation outboards, the shift guide block moves aft for FORWARD and
towards the bow for REVERSE. This is opposite motion compared to a standard (right hand)
rotation outboard.
The Commander Series Dual Engine Console Mount Control (88688A22), is required to
shift the counter rotation outboard. The installation instructions shipped with the control ex-
plain the procedure required to connect this control to a counter rotation outboard.
IMPORTANT: If a counter rotation outboard is rigged similar to a standard rotation
outboard OR if a standard rotation outboard is rigged similar to a counter rotation
outboard, the reverse gear and bearing in the gearcase must function as forward
gear. The reverse gear/bearing are not designed to carry the sustained loads that are
generated when running under constant high RPM and thrust conditions.

Required Side Mount Remote Control or Ignition Key Switch

Assembly
Boats Equipped with Side Mount Remote Control
A Commander 2000 series Side Mount Remote Control equipped with a warning horn must
be used with this outboard. This warning horn is necessary for the engine warning system.

a
a - Warning Horn

Boats Equipped with Panel or Console Mount Remote Control

A Ignition Key/Choke Assembly equipped with a warning horn must be used with this en-
gine. This warning horn is necessary for the engine warning system.
a

a - Warning Horn

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 OUTBOARD MOTOR INSTALLATION

Shift and Throttle Cable Installation to the Outboard

Shift Cable Installation
Install cables into the remote control following the instructions provided with the remote con-
trol.
NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when
the remote control handle is moved out of neutral.

COUNTER ROTATION OUTBOARDS

Counter rotating (left hand) gearcases can be identified by a “L” stamped into the end of the
propeller shaft.
The Dual Engine Console Mount Control, P/N 88688A22 or 88688A52, is required to shift
the counter rotation outboard. The installation instructions shipped with the control explain
the procedure required to connect this control to a counter rotation outboard.
IMPORTANT: If the counter rotation outboard is rigged similar to a standard rotation
outboard OR if a standard rotation outboard is rigged similar to a counter rotation
outboard, the reverse gear and bearing in the gearcase must function as forward
gear. THE REVERSE GEAR/BEARING ARE NOT DESIGNED TO CARRY THE SUS-
TAINED LOADS THAT ARE GENERATED WHEN RUNNING UNDER CONSTANT HIGH
RPM AND THRUST CONDITIONS.

OUTBOARD SHIFTING DIRECTION

On counter rotation outboards, the shift linkage moves in the opposite direction compared
to a standard rotation outboard.

STANDARD ROTATION GEAR OUTBOARDS

Forward Gear Reverse Gear

COUNTER ROTATION OUTBOARDS

Reverse Gear Forward Gear

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OUTBOARD MOTOR INSTALLATION

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

Standard Rotation Outboards

a

Counter Rotation Outboards

2. Position remote control and outboard into NEUTRAL (“N”).
N

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 OUTBOARD MOTOR INSTALLATION

3. Slide the shift cable retainer forward until resistance is felt, then slide cable anchor to-
ward rear until resistance is felt. Center the anchor pin between resistance points.

a b

a - Shift Cable Retainer

b - Anchor Pin

4. Align the shift cable end guide with the center mark as instructed in Step 1.

5. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder.
6. Install cable to anchor pin. Tighten locknut, then back-off the locknut 1/4 turn.
c
a
b

a - Cable Barrel
b - Nylon Washer
c - Locknut – Tighten Locknut, Then Back-Off The Locknut 1/4 Turn

7. Check shift cable adjustments as follows:

a. With remote control in forward, the propshaft should lock solidly in gear. If it does not,
adjust cable barrel closer to cable end guide.
b. Shift remote control into neutral. The propshaft should turn freely without drag. If not,
adjust barrel away from cable end guide. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propshaft should lock
solidly in gear. If not, adjust barrel away from cable end guide. Repeat steps a
through c.
d. Return remote control handle to neutral. The propeller should turn freely without
drag. If not, adjust barrel closer to cable end guide. Repeat steps a through d.

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OUTBOARD MOTOR INSTALLATION

Throttle Cable
INSTALLATION
1. Position remote control into NEUTRAL (”N”).
N

2. Attach throttle cable to the throttle lever. Secure with latch.

a
b
a - Nylon Washer
b - Locknut – Tighten Locknut, Then Back-off The Locknut 1/4 Turn

3. Adjust the cable barrel so that the installed throttle cable will hold the idle stop screw
against the stop.
b
a

a - Cable Barrel – Adjust To Hold Idle Adjustment Screw Against Stop

b - Idle Stop Screw

4. Check throttle cable adjustment as follows:

a. Shift outboard into gear a few times to activate the throttle linkage. Make sure to ro-
tate the propeller shaft while shifting into REVERSE (“R”).
F N R

b. Return remote control to NEUTRAL (”N”). Place a thin piece of paper between idle
adjustment screw and idle stop. Adjustment is correct when the paper can be re-
moved without tearing, but has some drag on it. Readjust cable barrel if necessary.

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 OUTBOARD MOTOR INSTALLATION

IMPORTANT: The idle stop screw must be touching the stop.

a - Idle Adjustment Screw

b - Idle Stop

5. Lock the barrel holder in place with the cable latch.

Remote Wiring Connections

Connect wiring. Place harness into the holder.

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

a - Main Engine Harness

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OUTBOARD MOTOR INSTALLATION

Routing Location for Wiring and Hoses through Clamp in

Bottom Cowl
IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables,
fuel hose, and oil hoses routed between clamp and engine attachment point, to
relieve stress and prevent hoses from being kinked or pinched.
IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly
must be wired with a warning horn. This warning horn is used with the engine warning
system.
Installation Note
NOTE: For ease of installation, remove front clamp and separate front end of bottom cowl.
1. Remove the front clamp.

a - Front Clamp

2. Separate the front end of the bottom cowl as follows:

a. Remove the 2 front screws.
b. Loosen the rear 2 screws.
b

b
a - Front Screws
b - Rear Screws - Remove Rubber Plug for Access to Lower Screw

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 OUTBOARD MOTOR INSTALLATION

3. Separate the bottom cowl.

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OUTBOARD MOTOR INSTALLATION

Warning Gauge Harness

1. Connect the harness extension to gauge and engine.

1 6

2 3 45

a
b
c
d e

a
b
c
d

a - TAN/BLACK
b - TAN/WHITE
c - PINK/LT. BLUE to PINK/LT. BLUE
d - ORANGE
e - Connect PURPLE to 12 Volt Source or Adjacent Gauge

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 OUTBOARD MOTOR INSTALLATION

Battery Connections
Single Outboard

(+)

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

Dual Outboard
Connect a common ground cable (wire size same as engine battery cables) between nega-
tive (–) terminals on starting batteries.

(–)

(–)

d - Ground Cable (Same Wire Size As Engine Battery Cable – Connect Between
Negative (–) Terminals

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OUTBOARD MOTOR INSTALLATION

Front Clamp and Cowl Reassembly

Fasten the clamp over the wiring, hoses, and cables as shown.

ÇÇÇb c

ÇÇ ÇÇ
ÇÇÇÇÇ
ÉÉ
ÇÇ
a
ÇÇÇ
ÉÉÉÉÉ
ÇÇ
d

ÉÉÉ e
g f

a - Battery Cables
b - Remote Wiring Harness
c - Warning Gauge Wiring Harness
d - Control Cables
e - Oil Hose with Blue Stripe
f - Fuel Hose
g - Oil Hose

Page 1D-20 90-855348R02 NOVEMBER 2002

 OUTBOARD MOTOR INSTALLATION

Fuel Connections
Portable Fuel Tank
Select a suitable location in boat within engine fuel line length limitations and secure tank
in place.
Permanent Fuel Tank
These should be installed in accordance with industry and federal safety standards which
include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.
Fuel Hose Size
Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate fuel line/fuel tank
pickup for each engine.
Fuel Hose Connection
Connect fuel hose to fitting with hose clamp.

a
a - Hose Clamp

Set Up Instructions for Oil Injection System

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

CAUTION
If an electric fuel pump is to be used on engines with oil injection, the fuel pressure
at the engine must not exceed 4 psi. If necessary, install a pressure regulator be-
tween electrical fuel pump and engine and set at 4 psi maximum.

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OUTBOARD MOTOR INSTALLATION

MOUNTING OIL TANK

1. Mount the remote oil tank in the boat. The tank should be restrained from moving. Use
the oil tank hold down kit provided.
2. Arrange the hoses so they will not get pinched, kinked, or stretched during operation.
NOTE: An oil hose extension kit (41729A3) is available.

CONNECTING OIL HOSE WITH BLUE STRIPE

3. Remove shipping cap from fitting and connect oil hose. Fasten hose with sta-strap.

a - Oil Hose with Blue Stripe

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 OUTBOARD MOTOR INSTALLATION

CONNECTING OIL HOSE WITHOUT BLUE STRIPE

4. Remove shipping cap from fitting and connect hose. Fasten hose with sta-strap.

a
a - Oil Hose Without Blue Stripe

5. Slide the clamp up and into the bottom cowl.

6. Tighten the clamp screws at this time.

a - Clamp Screws (2)

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OUTBOARD MOTOR INSTALLATION

7. Fasten bottom cowl together.

NOTE: Lift up the clamp to gain access to front screw.

8. Fasten clamp into cowl with two bolts.

a

a - Bolts

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 OUTBOARD MOTOR INSTALLATION

Filling Fuel System

NOTE: For initial start of a new engine or for an engine that ran out of fuel, or was drained
of fuel, the fuel system should be filled as follows.

• Squeeze the fuel line primer bulb until it feels firm.

• Turn the ignition key switch to the “ON” position for three seconds. This operates the
electric fuel pump.
• Turn the ignition key switch back to the “OFF” position, and squeeze the primer bulb
again until it feels firm. Turn the ignition key switch to the “ON” position again for
three seconds. Continue this procedure until the fuel line primer bulb stays firm.

Oil Injection System

Filling
1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance
Manual. Tighten fill cap.

a - Fill Cap

2. Remove cap and fill engine oil tank with oil. Reinstall the fill cap.
b

a - Engine Oil Tank

b - Fill Cap

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OUTBOARD MOTOR INSTALLATION

Priming the Oil Injection Pump

Before starting engine for the first time, prime the oil injection pump. Priming will remove
any air that may be in the pump, oil supply hose, or internal passages.

a b
a - Oil Injection Pump
b - Oil Supply Hose

CAUTION
To prevent damage to the fuel pumps, fill the engine fuel system with fuel. Other-
wise the fuel pumps will run without fuel during the priming process.
Prime the oil injection pump as follows:
1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it feels firm.
2. Turn the ignition key switch to the “ON” position.

3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from NEUTRAL (”N”) into FORWARD (”F”) gear 3 to 5 times. This will au-
tomatically start the priming process.

N
F

NOTE: It may take a few minutes for the pump to complete the priming process.

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Purging Air From the Engine Oil Tank

1. Loosen the fill cap on the engine oil tank.
2. Start the engine. Run the engine until the all the air has been vented out of the tank and
oil starts to flow out of the tank. Re-tighten fill cap.

a - Fill Cap

Trim “In” Angle Adjustment

Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further “in” or “under”. This great-
er trim “under” capability is desirable to improve acceleration, reduce the angle and time
spend in a bow high boat, and in some cases, may be necessary to plane off a boat with
aft live wells.
However, once on plane, the engine should be trimmed to a more intermediate position to
a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering”
or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a
turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may re-
sult.
In rare circumstances, the owner may decide to limit the trim under. This can be accom-
plished by purchasing a stainless steel tilt pin (P/N 17–49930A1) and inserting it through
whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this
application other than on a temporary basis.

WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim po-
sition as soon as boat is on plane to avoid possible ejection due to boat spin-out.
Do not attempt to turn boat when engine is trimmed extremely under or in.

a - Tilt Pin

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OUTBOARD MOTOR INSTALLATION

Trim Tab Adjustment

Propeller steering torque may cause your boat to pull in one direction. This steering torque
results from your outboard not being trimmed so the propeller shaft is parallel to the water
surface. The trim tab can help compensate for this steering torque and can be adjusted with-
in limits to reduce any unequal steering effort.

MODELS WITHOUT POWER STEERING

Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left
and right and note the direction the boat turns more easily.
If adjustment is necessary, loosen trim tab bolt until trim tab moves freely (does not rub
against locking ridges). DO NOT strike tab to make adjustments. Make small adjustments
at a time. If the boat turns more easily to the left, move the trailing edge of trim tab to the
left. If the boat turns more easily to the right move the trailing edge of trim tab to the right.
Position trim tab in one of the locating grooves BEFORE tightening bolt to prevent damage
to holding mechanism. Torque bolt to 40 lb. ft. (54.0 Nm) and retest.

MODELS WITH POWER STEERING

Trim tab adjustment is not required. The trailing edge of the trim tab should be set straight
back.

Page 1D-28 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

ELECTRICAL
Section 2A - Ignition System
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Troubleshooting with the Digital A
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Diagnostic Terminal . . . . . . . . . . . . . . . . . . . . . 2A-10
Electrical Components . . . . . . . . . . . . . . . . . . . 2A-4 Troubleshooting Without Digital
Flywheel/Alternator . . . . . . . . . . . . . . . . . . . . . . 2A-6 Diagnostic Terminal . . . . . . . . . . . . . . . . . . . . . 2A-11
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 1997 DFI Troubleshooting without the DDT . . 2A-12
Theory of Operation . . . . . . . . . . . . . . . . . . 2A-8 1998/1999 DFI Troubleshooting without DDT . . 2A-15
Electronic Control Module (ECM) . . . . . . . 2A-8 Flywheel Removal and Installation . . . . . . . . . 2A-19
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 1997 Models: . . . . . . . . . . . . . . . . . . . . . . . . 2A-19
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 1998/1999 Models: . . . . . . . . . . . . . . . . . . . 2A-19
Crank Position Sensor . . . . . . . . . . . . . . . . 2A-9 Flywheel Removal . . . . . . . . . . . . . . . . . . . . 2A-20
Throttle Position Sensor (TPS) . . . . . . . . . 2A-9 Flywheel Installation . . . . . . . . . . . . . . . . . . 2A-21
Charging System Alternator . . . . . . . . . . . . 2A-9 Electronic Control Module (ECM)
Manifold Absolute Pressure Removal and Installation . . . . . . . . . . . . . . . . . 2A-22
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Ignition Module Removal and Installation . . . 2A-23
Air Temperature Sensor . . . . . . . . . . . . . . . 2A-9 1997 Model – Ignition Module (Coil) . . . . 2A-23
Direct Injectors . . . . . . . . . . . . . . . . . . . . . . . 2A-9 1998/1999 Model – Ignition Module (Coil) . . 2A-24
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Crank Position Sensor Removal
Disconnecting Harness Connectors and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
from Ignition Coils and/or Injectors . . . . . 2A-10 Throttle Position Sensors (TPS)
1998 EPA Certified . . . . . . . . . . . . . . . . . . . 2A-10 Removal and Installation . . . . . . . . . . . . . . . . . 2A-26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-10

Specifications

IGNITION Type Digital Inductive

SYSTEM
Spark Plug Type NGK PZFR5F-11 (1998 Heavy Duty)
NGK ZFR5F-11 (1998 Light Duty)
Champion RC10-ECC (1997)

Spark Plug Gap 0.040 in. (1.0mm)

CHARGING Alternator Output (Regulated) 30 Amperes @ 750 RPM
SYSTEM 60 Amperes @ 2000 RPM
Brush Length Std. Exposed Length: 0.413 in.
(10.5mm)
Min. Exposed Length: 0.059 in.
(1.5mm)

90-855348R02 NOVEMBER 2002 Page 2A-1

IGNITION SYSTEM

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

2. Digital Diagnostic Terminal 91-823686A2

3. Cartridge 91-822608-4 or 91-822608-5

Page 2A-2 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

4. Adapter Harness 84-822560A5

5. Service Tachometer DMT-2000 91-854009A1

6. Flywheel Holder 91-52344

91–52344

54964
7. Protector Cap 91-24161

8. Flywheel Puller 91-849154T1

90-855348R02 NOVEMBER 2002 Page 2A-3

IGNITION SYSTEM

Electrical Components
16 17
A
14 18
15

19
13
9
27 21
11 12
8
B 20
25
7 22 23
6
10 24 34
26 35
36
35
2
3 33
4 31
28 37
1
5
38

39 TO
BLOCK

54
42
30

45
48 43
47
32 46
41
40
29
 44
 53
49
56 55
6 Dielectric Grease
25 Liquid Neoprene

NOTE: Coat all eyelet wiring terminals with #25 GACO N700
NOTE: Coat all Multi-Pin electrical connections (Except power trim Relay connectors) with
#6 DC-4
A = TO AIR HANDLER B = TO BLOCK

Page 2A-4 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

Electrical Components
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 ELECTRICAL MOUNTING PLATE
2 6 IGNITION COIL
3 1 HI-TENSION CABLE
4 6 BOOT
6 SPARK PLUG (HEAVY DUTY) 20 27.1
5 OPT SPARK PLUG (LIGHT DUTY) 20 27.1
6 12 SCREW (M6 x 30)
7 1 SENSOR
8 1 CONNECTOR
9 1 RETAINER
10 1 ADAPTOR HARNESS
11 1 STA-STRAP
12 1 TUBING (15 IN.)
13 1 MAP SENSOR
14 2 SCREW (M6 x 14) 35 3.9
15 1 TUBING (28-1/2 IN.)
16 4 SCREW (.312-18 x 1-1/4 IN.) 235 20 26.5
17 4 WASHER
18 4 GROMMET
19 4 BUSHING
20 2 SCREW-engine harness ground (M6 x 14) 35 3.9
21 1 TRIM HARNESS
22 3 RELAY
23 3 DECAL-Trim Relay
24 3 BRACKET
25 3 BUSHING
26 3 GROMMET
27 3 SCREW (M6 x 25) 35 3.9
28 1 STA STRAP
29 1 ENGINE HARNESS
30 4 FUSE
31 1 BRACKET-Fuse Holder
32 2 SCREW (M4 x .7)
1 ECU (225)
33 1 ECU (200)
34 3 SCREW (M6 x 25) 70 7.9
35 6 BUSHING
36 3 GROMMET
37 2 SCREW (M6 x 12) 100 11.3
38 1 PAD
39 1 CLIP
40 1 SOLENOID MOUNTING PLATE
41 3 SCREW (M6 x 12) 150 16.9
42 1 BATTERY CABLE (NEGATIVE)
43 2 SCREW (M6 x 14) 35 3.9
44 1 STARTER SOLENOID
45 2 GROMMET
46 2 SCREW (M6 x 25) 35 3.9
47 1 CABLE (BLACK)
48 2 BUSHING
49 1 BATTERY CABLE (POSITIVE)
50 2 LOCKWASHER
51 2 NUT (5/16-18) 50 5.6
52 2 NUT (10-32) 8 0.9
53 1 CAP NUT
54 1 SCREW (M8 x 12) 190 16 21.5
55 1 INSULATOR
56 1 NUT (10-32)(BRASS)

90-855348R02 NOVEMBER 2002 Page 2A-5

IGNITION SYSTEM

Flywheel/Alternator









10

14

15

14

Page 2A-6 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

Flywheel/Alternator
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 ALTERNATOR
2 1 SPRING
3 1 BEARING
4 1 BELT TENSIONER
5 1 BUSHING
6 1 SCREW (M10 x 45) 16.6 22.6
7 1 PULLEY
8 1 SCREW (M10 x 35) 25 33.9
9 1 BELT
10 1 FLYWHEEL
11 1 NUT (.625-18) 125 169
12 1 WASHER
13 1 PLUG
14 2 WASHER
15 1 CABLE

90-855348R02 NOVEMBER 2002 Page 2A-7

IGNITION SYSTEM

Ignition System
Theory of Operation
When the ignition key is turned to the RUN position, battery voltage is applied to the main
relay through the PURPLE wire. The main relay is then closed and D.C. current from the
battery or charging system is transferred through the main relay 20 Amp fuse to the positive
terminal of all 6 ignition coil primary windings. The negative terminal of the coil primary is
connected to engine ground through the Electronic Control Module (ECM). When this circuit
is closed, a magnetic field is allowed to be built up in the ignition coil. The Crank Position
Sensor senses the location of the 24 teeth on the flywheel and supplies a trigger signal to
the ECM. When the ECM receives this signal, the ECM will then open the ground circuit of
the coil primary. The magnetic field in the ignition coil primary will then collapse cutting
across the coil secondary winding creating a high voltage charge (50,000 volts) that is sent
to the spark plug.
Electronic Control Module (ECM)
The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop
running.
The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal
91-823686A2 using adaptor harness 84-822560A5.
The ECM performs the following functions:
• Calculates the precise fuel and ignition timing requirements based on engine speed,
throttle position, manifold pressure and coolant temperature.
• Controls fuel injectors for each cylinder, direct injectors for each cylinder and ignition
for each cylinder.
• Controls all alarm horn and warning lamp functions.
• Supplies tachometer signal to gauge.
• Controls RPM limit function.
• Monitors shift interrupt switch.
Flywheel
24 teeth under the flywheel ring gear provide engine rpm and crankshaft position informa-
tion to the ECM through the crank position sensor.
Ignition Coils
Inductive type ignition coils are used on the DFI engines.
Ignition Coil Ohm Test
1997 Models

Connect meter leads between each coil

0.67 ± 0.1

terminal pin.

1998/1999 Models

Connect meter leads between primary terminal (GRN/Striped)

0.38 - 0.78

and ground (Black) terminal pin.
Connect meter leads between spark plug wire/high voltage tower
8.1 - 8.9 k

and ground terminal pin.

Page 2A-8 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

Crank Position Sensor

Senses 24 teeth located on flywheel under ring gear. Supplies the ECM with crank position
information and engine speed. If sensor should fail, the engine will stop running.
Throttle Position Sensor (TPS)
Two (2) Throttle Position Sensors are used in conjunction with one another. If one sensor
should fail, the dash mounted CHECK ENGINE light will light and the warning horn will
sound.
On 1997 Model – RPM will not be limited.
On 1998/1999 Model – RPM will be limited to 3000 rpm. If both TPS’s should fail, on 1997,
1998 and 1999 model engines, rpm will be reduced to idle by the ECM. TPS settings are
not adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal through
the ECM.
Charging System Alternator
Battery charging system is contained within the belt driven alternator, including the regula-
tor. At cranking speeds, electrical power for the engine is provided by the boat battery – mini-
mum recommended size is 750, or 1,000 MCA, cold cranking amperes. Above 650 RPM
for 1997 Models (550 RPM on 1998/1999 Models), all electrical power is provided by the
alternator. Should engine rpm drop below 650 (550 RPM on 1998/1999 Models), the alter-
nator is not capable of providing sufficient output and the battery becomes the primary
source of electrical power. Once the engine is running and rpm is 650 or higher, the engine
will continue to run should the battery become shorted or disconnected. Alternator output
(when hot) to the battery @ 2000 RPM is approximately 33 - 38 amperes.
Manifold Absolute Pressure (MAP)
Sensor
The map sensor is mounted between the cylinder heads. A vacuum hose connects the map
sensor to the intake manifold. The ECM regulates fuel flow, in part, based on manifold abso-
lute pressure. Drawing a vacuum on the MAP sensor hose will create a lean fuel condition.
Air Temperature Sensor
The air temperature sensor is mounted on the intake manifold. The ECM regulates fuel flow,
in part, based on manifold air temperature. As air temperature increases, the ECM de-
creases fuel flow.
Direct Injectors
6 direct injectors (1 per cylinder) are used to inject a fuel/air mix into cylinders. Injectors are
mounted between fuel rails and cylinder heads.

Direct Injector Ohm Test

(Injector Lead Disconnected)
Connect meter leads between each injec-
1 - 1.6

tor terminal pin.
Fuel Injectors
6 fuel injectors (1 per cylinder) are used to provide fuel from the fuel rail to the direct injectors.
The fuel injectors are mounted in the fuel rail.

Fuel Injector Ohm Test

(Injector Lead Disconnected)
Connect meter leads between each injec-
1.7 - 1.9

tor terminal pin.

90-855348R02 NOVEMBER 2002 Page 2A-9

IGNITION SYSTEM

Disconnecting Harness Connectors from Ignition Coils and/or Injectors

54871

a - Wire Clip (push center down to remove)

1998 EPA Certified
All new outboards manufactured by Mercury Marine are certified with the United States En-
vironmental Protection Agency, as conforming to the requirements of the regulations for the
control of air pollution from new outboard motors.
Troubleshooting
The ECM is designed such that if a sensor fails, the ECM will compensate so that the engine
doesn not go into an over-rich condition. The Digital Diagnostic Terminal must be used to
thoroughly check ECM system components.
NOTE: Disconnecting a sensor for troubleshooting purposes may have no noticeable effect.

Troubleshooting with the Digital Diagnostic Terminal

b
a

a - Digital Diagnostic Terminal (91-823686A2)

b - Software Cartridge (91-822608--4) (91-822608--5)
c - DDT Reference Manual (90-825159-2)
d - Adapter Harness (84-822560A--5)

Page 2A-10 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

The Digital Diagnostic Terminal (DDT) has been developed specifically to help technicians
diagnose and repair Mercury Marine 2 and 4 cycle engines.
Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car-
tridge. You will be able to monitor sensors and ECM data values including status switches.
The ECM program can help diagnose intermittent engine problems. It will record the state
of the engine sensors and switches for a period of time and then can be played back to re-
view the recorded information.
Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic proce-
dures.

Troubleshooting Without Digital Diagnostic Terminal

Troubleshooting without the DDT is limited to checking resistance on some of the sensors.
Typical failures usually do not involve the ECM. Connectors, set-up, and mechanical wear
are most likely at fault.
• Verify spark plug wires are securely installed (pushed in) into the coil tower.
• The engine may not run or may not run above idle with the wrong spark plugs
installed.
• Swap ignition coils to see if the problem follows the coil or stays with the particular
cylinder.
NOTE: 1998/1999 Model ECMs are capable of performing a cylinder misfire test to isolate
problem cylinders. Once a suspect cylinder is located, an output load test on the ignition coil,
fuel injector and direct injector may be initiated through use of the DDT.
• Any sensor or connection can be disconnected and reconnected while the engine is
operating without damaging the ECM. Disconnecting the crank position sensor will
stop the engine.
IMPORTANT: Any sensor that is disconnected while the engine is running will be re-
corded as a Fault in the ECM Fault History. Use the DDT to view and clear the fault
history when troubleshooting/repair is completed.
• If all cylinders exhibit similar symptoms, the problem is with a sensor or harness in-
put to the ECM.
• If problem is speed related or intermittent, it is probably connector or contact related.
Inspect connectors for corrosion, loose wires or loose pins. Secure connector seat-
ing; use Dielectric Compound.
• Inspect the harness for obvious damage: pinched wires, chaffing.
• Secure grounds and all connections involving ring terminals (coat with Liquid Neo-
prene).
• Check fuel pump terminals.
• Check fuel pump pressure.
• Check air compressor pressure.

90-855348R02 NOVEMBER 2002 Page 2A-11

IGNITION SYSTEM

1997 DFI Troubleshooting without the DDT

1997 DFI Troubleshooting Guide
Symptom Cause Action
1. Engine cranks but won’t start 1.1 Weak battery or bad starter Replace/charge battery.
motor, battery voltage drops Inspect condition of starter motor.
below 8 volts while cranking Check condition of battery terminals
(ECM cuts out below 8 volts) and cables.
(Fuel pump requires 9 volts).
1.2 Low air pressure in rail (less Inspect air system for leaks.
than 70 psi at cranking) Inspect air filter for plugging (air
pressure measured on port rail).
Inspect air compressor reed valves if
necessary.
1.3 ECM not functioning Injection System:
Listen for injector “ticking” when
cranking or connect spare injector to
each respective harness. Ticking
should start after 2 cranking revolu-
tions.

Ignition System:
–Check for proper operation by us-
ing Inductive Timing Light
91-99379.
–Check battery voltage (RED/YEL
Lead) @ ignition coils.
– Check for blown fuse.
– Check battery voltage to fuse
from key switch (PURPLE Lead).
–Check for shorted stop wire (BLK/
YEL).
–Check crank position sensor set-
ting [0.015 in. – 0.040 in.
(0.38mm – 1.01mm)] from fly-
wheel or for defective crank posi-
tion sensor.
–Defective ECM. Power Supply:
Clean and inspect remote control
male and female harness con-
nectors.
1.4 No fuel Check that primer bulb is firm. Key-
on engine to verify that fuel pump
runs for 2 seconds and then turn off.
Measure fuel pressure (valve on
starboard rail). Fuel pressure should
be 10 ± 1 psi greater than the air
pressure.
1.5 Sheared Flywheel Key Remove flywheel and inspect key.

Page 2A-12 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

1997 DFI Troubleshooting Guide (continued)

Symptom Cause Action
1. Engine cranks but will not 1.6 Low fuel pressure Check for fuel leaks. If fuel pressure
start (continued) leaks down faster than air pressure,
seals on fuel pump may be leaking.
Check air system pressure, see 1.2.
1.7 Blown fuse Replace fuse. Inspect engine har-
ness and electrical components.
2. Engine cranks, starts and stalls 2.1 Low air pressure in rail See 1.2
2.2 Low fuel pressure in rail See 1.4 and 1.5
2.3 Abnormally high friction in en- Check for scuffed piston or other
gine. sources of high friction.
2.4 Air in fuel system/lines See 1.4. Crank and start engine sev-
eral times to purge.
2.5 TPS malfunction Check motion of throttle arm. Stop
nuts should contact block at idle and
WOT. Check TPS set-up. TPS read-
ing should be in “idle” mode when
remote control is in neutral. Must
connect DDT with adapter harness
(84-822560A5) to ECM to verify
this).
2.6 Remote control to engine har- Clean and inspect male and female
ness connection is poor. connectors.
2.7 Loose connectors or improp- Inspect all connectors and harness
erly attached spark leads leads for proper termination. Inspect
spark plug wires. Inspect ground
wires.
3. Engine idle is rough 3.1 Low air pressure in rail (less See 1.2
than 79 ± 2 psi while running).
3.2 Fouled spark plug Replace spark plug:
–If carbon bridges electrode gap
or if it is completely black.
–If it is not firing and is wet with
fuel.
Note: If spark plug is gray with alu-
minum specs, this indicates internal
mechanical damage requiring im-
mediate attention before returning
engine to service.
3.3 Flywheel key sheared Remove flywheel and inspect key.

90-855348R02 NOVEMBER 2002 Page 2A-13

IGNITION SYSTEM

1997 DFI Troubleshooting Guide (continued)

Symptom Cause Action
4. Engine idles fast (RPM >700) 4.1 TPS sensor malfunction See 2.5
or surges
4.2 Broken fuel pressure regulator Measure fuel pressure. Remove and
or tracker diaphragm. inspect diaphragms.
4.3 Fuel leak Check for fuel entering induction
manifold or air compressor inlet.
Fuel pump diaphragm leaking.
5. Engine runs rough below 5.1 Fouled spark plug See 3.2
3000 rpm
5.2 Low air pressure in rail See 1.2
5.3 Throttles misadjusted Check throttle cam setup on induc-
tion manifold. Inspect linkage and
roller.
If throttle plate stop screws have
been tampered with, contact Mercu-
ry Marine Service Department for
correct adjustment procedures.
5.4 TPS sensor malfunction See 2.5
6. Engine runs rough above 6.1 Fouled spark plug See 3.2
3000 rpm
6.2 Low air pressure in rails See 1.2
6.3 TPS sensor malfunction See 2.5
6.4 Crank Position Sensor misad- Gap between sensor and flywheel
justed should be 0.015 in. – 0.040 in.
(0.38mm – 1.01mm).

6.5 Loose connectors or improp- Inspect all connectors and harness

erly attached spark leads leads for proper termination. Inspect
spark plug wires. Inspect ground
wires.
7. Engine RPM limited to 7.1 ECM Reset Turn ignition off and restart engine
approximately 3000 RPM after correcting RPM limiting fault –
low oil, overheat, etc.

Page 2A-14 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

1998/1999 DFI Troubleshooting without DDT

1998/1999 DFI Troubleshooting Guide
Symptom Cause Action
1. Engine cranks but won’t start 1.1 Weak battery or bad starter Replace/charge battery.
motor, battery voltage drops Inspect condition of starter motor.
below 8 volts while cranking Check condition of battery termi-
(ECM cuts out below 8 volts) nals and cables.
(Fuel pump requires 9 volts).
1.2 Low air pressure in rail (less Inspect air system for leaks.
than 70 psi at cranking) Inspect air filter for plugging (air
pressure measured on port rail).
Inspect air compressor reed valves
if necessary.
1.3 No fuel Check that primer bulb is firm.
Key-on engine to verify that fuel
pump runs for 2 seconds and then
turn off. Measure fuel pressure
(valve on starboard rail). Fuel pres-
sure should be 10 ± 1 psi greater
than the air pressure.
1.4 Low fuel pressure Check for fuel leaks. If fuel pres-
sure leaks down faster than air
pressure, seals on fuel pump may
be leaking. Check air system pres-
sure, see 1.2.
1.5 Sheared Flywheel Key Remove flywheel and inspect key.
1.6 Blown fuse Replace fuse. Inspect engine har-
ness and electrical components.
1.7 Main Power Relay not Check lanyard switch.
functioning Listen for relay to “click” when the
key switch is turned on.

90-855348R02 NOVEMBER 2002 Page 2A-15

IGNITION SYSTEM

1998/1999 DFI Troubleshooting Guide (continued)

Symptom Cause Action
1. Engine cranks but will not 1.8 ECM not functioning Injection System:
start (continued) Listen for injector “ticking” when
cranking or connect spare injector
to each respective harness. Tick-
ing should start after 2 cranking
revolutions.

Ignition System:
– Check for proper operation by
using Inductive Timing Light
91-99379.
– Check battery voltage
(RED/YEL Lead) @ ignition
coils.
– Check for blown fuse.
– Check battery voltage to fuse
from key switch
(PURPLE Lead).
– Check for shorted stop wire
(BLK/YEL).
– Check crank position sensor
setting [0.015 in. – 0.040 in.
(0.38mm – 1.01mm)] from
flywheel or for defective crank
position sensor.
– Defective ECM.

Power Supply:
Clean and inspect remote control
male and female harness connec-
tors.
2. Engine cranks, starts and 2.1 Low air pressure in rail See 1.2
stalls
2.2 Low fuel pressure in rail See 1.3 and 1.4
2.3 Abnormally high friction in Check for scuffed piston or other
engine sources of high friction.
2.4 Air in fuel system/lines See 1.3 Crank and start engine
several times to purge.
2.5 TPS malfunction Check motion of throttle arm. Stop
nuts should contact block at idle
and WOT. Check TPS set-up. Must
connect DDT with adapter harness
(84-822560A5) to ECM.
2.6 Remote control to engine Clean and inspect male and fe-
harness connection is poor male connectors.

Page 2A-16 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

1998/1999 DFI Troubleshooting Guide (continued)

Symptom Cause Action
3. Engine idle is rough 3.1 Low air pressure in rail (less See 1.2
than 79 ± 2 psi while running)

3.2 Fouled spark plug Replace spark plug:

–If carbon bridges electrode gap
or if it is completely black.
–If it is not firing and is wet with
fuel.
Note: If spark plug is grey or com-
pletely black with aluminum specs,
this indicates a scuffed piston.

3.3 Flywheel key sheared Remove flywheel and inspect key.

4. Engine idles fast (RPM 4.1 Broken fuel pressure regulator Measure fuel pressure. Remove
>700) or surges or tracker diaphragm and inspect diaphragms (a special
tool is required for assembly).

4.2 Fuel leak Check for fuel entering induction

manifold or air compressor inlet.
Fuel pump diaphragm leaking.

4.3 Improper set-up Check throttle cable & cam roller

adjustment.

5. Engine runs rough below 5.1 Fouled spark plug See 3.2
3000 rpm

5.2 Low air pressure in rail See 1.2

5.3 Throttle misadjusted Check throttle cam setup on induc-

tion manifold. Inspect linkage and
roller.
If throttle plate stop screws have
been tampered with, contact Mer-
cury Marine Service Department
for correct adjustment procedures.

5.4 TPS malfunction See 2.5

90-855348R02 NOVEMBER 2002 Page 2A-17

IGNITION SYSTEM

1998/1999 DFI Troubleshooting Guide (continued)

Symptom Cause Action
6. Engine runs rough above 6.1 Fouled spark plug See 3.2
3000 rpm

6.2 Speed Reduction See 7

6.3 Low air pressure in rails See 1.2

6.4 TPS malfunction See 2.5

6.5 Crank Position Sensor Gap between sensor and flywheel

mis-adjusted should be 0.015 in. – 0.040 in.
(0.38mm – 1.01mm)

7. Speed Reduction (RPM re- 7.1 Low battery voltage Check battery and/or alternator.
duced or limited to 3,000) ECM requires 8 volts minimum Check electrical connections.
Fuel Pump requires 9 volts
7.2 Overheat condition (engine Check water pump impeller/cooling
and/or air compressor) system.

7.3 No oil or oil pump failure Check oil. Check electrical connec-
tion.

7.4 TPS failure Check electrical connections.

If one (1) TPS fails rpm is
reduced to 3,000. If both TPSs
fail, rpm is reduced to idle

8. Engine RPM reduced to idle 8.1 Both TPSs failed See 2.5
only 8.2 Battery voltage below 9.5 volts Use DDT or volt meter to check
battery voltage.

Page 2A-18 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

Flywheel Removal and Installation

1997 Models:
REMOVAL
Remove flywheel cover by lifting off. Disconnect vent hose.
INSTALLATION
Reconnect vent hose to fitting in flywheel cover. Install the flywheel cover by inserting the
two front pins into the front mounting holes, and then pushing the cover down onto the rear
pin and air intake tube for the air compressor.

a - Vent Hose
b - Air Intake Tube

1998/1999 Models:
REMOVAL
Remove flywheel cover by lifting off.
INSTALLATION
Install the flywheel cover by inserting the front pin and air tube into the rubber grommets,
and then pushing the cover down onto the rear pin and air intake tube for the air compressor.

a - Rubber Grommets
b - Air Intake Tube

90-855348R02 NOVEMBER 2002 Page 2A-19

IGNITION SYSTEM

Flywheel Removal
1. Remove alternator/air compressor belt from flywheel by using breaker bar to release
belt tensioner.

c
a

56829
a - Belt
b - Tensioner
c - Breaker Bar

2. Remove flywheel nut.

56828
a - Flywheel Holding Tool (91-52344)

Page 2A-20 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

3. Remove flywheel.

56827
a - Puller (91-849154T1)
b - Protector Cap (91-24161) (HIDDEN)
Flywheel Installation
IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry.
1. Reinstall flywheel with nut and washer.
2. Torque flywheel nut to 125 lb. ft. (169.5 Nm)
3. Use breaker bar to relieve belt tensioner and reinstall alternator/air compressor belt.
4. Reinstall flywheel cover.
5. Reinstall top cowling.

90-855348R02 NOVEMBER 2002 Page 2A-21

IGNITION SYSTEM

Electronic Control Module (ECM) Removal and Installation

REMOVAL
1. Remove top cowling.
2. Disconnect ECM harness connectors.
3. Remove 3 bolts securing ECM.
a

55941
a

a
a - Bolts

INSTALLATION
1. Secure ECM to powerhead with 3 bolts. Torque bolts to 80 lb. in. (9.0 Nm).
2. Verify ECM ground lead is secured with attaching bolt.
3. Reconnect harness connectors.
4. Reinstall top cowling.

Page 2A-22 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

Ignition Module Removal and Installation

1997 Model – Ignition Module (Coil)
REMOVAL
1. Remove top cowling.
2. Disconnect module harness.
3. Remove spark plug lead from spark plug.
4. Remove module attaching bolts.

a
a

a - Ignition Modules (6)

INSTALLATION
1. Secure module to ignition plate with bolt. Torque bolt to 80 lb. in. (9.0 Nm).
2. Reconnect harness.
3. Reconnect spark plug lead.
4. Reinstall top cowling.

90-855348R02 NOVEMBER 2002 Page 2A-23

IGNITION SYSTEM

1998/1999 Model – Ignition Module (Coil)

REMOVAL
1. Remove top cowling.
2. Disconnect module harness.
3. Remove spark plug lead from spark plug.
4. Remove module attaching bolts.

55990
a - Ignition Modules (6)

INSTALLATION
CAUTION
If spark plug high tension lead boot is removed from the ignition module tower, the
boot must be glued to the coil tower using Loctite 454.
1. Secure module to ignition plate with bolts Torque bolts to 80 lb. in. (9.0 Nm).
2. Reconnect harness.
3. Reconnect spark plug lead.
4. Reinstall top cowling.

Page 2A-24 90-855348R02 NOVEMBER 2002

 IGNITION SYSTEM

Crank Position Sensor Removal and Installation

REMOVAL
1. Remove top cowling.
2. Remove sta-strap securing sensor harness and disconnect harness.
3. Remove two bolts securing sensor bracket.
4. Remove bolt securing sensor to bracket.
c

a
51627
a - Sta-strap
b - Harness
c - Bracket Bolts
d - Sensor Bolt

INSTALLATION
1. Secure sensor to bracket with bolt. Torque bolt to 50 lb. in. (5.6 Nm).
2. Secure bracket to powerhead with 2 bolts.
NOTE: Position bracket/sensor assembly to allow a 0.015 – 0.040 .in (0.38mm ± 1.01mm)
air gap between sensor and flywheel teeth.
3. Torque bracket bolts to 100 lb. in. (11.3 Nm).
4. Reconnect sensor harness.
5. Secure harness with sta-strap.
6. Reinstall top cowling.

90-855348R02 NOVEMBER 2002 Page 2A-25

IGNITION SYSTEM

Throttle Position Sensors (TPS) Removal and Installation

REMOVAL
1. Remove top cowling.
2. Disconnect sensor harness.
3. Remove screws securing sensors to bracket.
1997 Models

1998/1999 Models
a

a - Throttle Sensors

INSTALLATION
1. Secure sensors to bracket with screws. Torque screws to 20 lb. in. (2.3 Nm).
2. Reconnect harness.
3. Reinstall top cowling.

Page 2A-26 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

ELECTRICAL
Section 2B – Battery Charging System
and Starting System
Table of Contents 2
B
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Voltage Output . . . . . . . . . . . . . . . . . . . . . . . 2B-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Current Output . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Alternator Torque Specifications . . . . . . . . . . . 2B-2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Disassembly and Test . . . . . . . . . . . . . . . . . 2B-13
Battery Cable Size . . . . . . . . . . . . . . . . . . . . . . 2B-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 2B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Alternator Belt Tension Adjustment . . . . . . . . 2B-23
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23
Charging a Discharged Battery . . . . . . . . . . . . 2B-4 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-24
Winter Storage of Batteries . . . . . . . . . . . . . . . 2B-5 Troubleshooting the Starter Circuit . . . . . . 2B-25
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Starter Circuit Troubleshooting Flow Chart . 2B-26
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 2B-7 Starter Removal and Installation . . . . . . . . 2B-28
System Components . . . . . . . . . . . . . . . . . . . . 2B-7 Starter Cleaning, Inspection and Testing . . . 2B-31
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-31
Alternator Description . . . . . . . . . . . . . . . . . . . . 2B-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-32
Diagnosis of Alternator System on Engine . . 2B-8 Starter Reassembly . . . . . . . . . . . . . . . . . . . 2B-34
Alternator System Circuitry Test . . . . . . . . . . . 2B-9 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-38
Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Commander 2000 Key Switch Test . . . . . . . . 2B-39
Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . 2B-9

Specifications

CHARGING Alternator Output (Regulated) 30 Amperes @ 750 RPM

SYSTEM 60 Amperes @ 2000 RPM
Brush Length Std. Exposed Length: 0.413 in.
(10.5mm)
Voltage Output Min. Exposed Length: 0.059 in.
Regulator Current Draw (1.5mm)
13.5 to 15.1 Volts
0.15 m A (Ign. Switch Off)
30.0 m A (Ign. Switch On)
STARTING Electric Start – All Models
SYSTEM Starter Draw (Under Load) 210 Amperes
Starter Draw (No Load) 30 Amperes
Minimum Brush Length 0.25 in. (65.4mm)

Battery Rating 1000 (Minimum) Marine Cranking

Amps (MCA)
750 (Minimum) Cold Cranking Amps
(CCA)

90-855348R02 NOVEMBER 2002 Page 2B-1

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Alternator Torque Specifications

Fastener Torque
End Frame Bolts and Nuts 39.5 lb. in. (4.5 Nm)
Pulley Nut 50 lb. ft. (67.8 Nm)
Regulator Screws 17 lb. in. (1.9 Nm)
Rectifier Screws 17 lb. in. (1.9 Nm)
End Cover Screws 23 lb. in. (2.6 Nm)
Terminal Insulator Nut 36 lb. in. (4.1 Nm)

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

2. Ammeter (Obtain Locally)

Page 2B-2 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Battery Cable Size

If standard (original) battery cables are replaced with longer cables, the wire gauge size
must increase. See chart below for correct wire gauge size.

ÎÎ
ÎÎ Wire Gage Size

Battery Cable Length

Battery Cable Wire Gage Size

Mercury/Mariner Outboards
Battery Cable Length
8 ft. 9 ft. 10ft. 11ft. 12ft. 13ft. 14ft. 15ft. 16ft. 17ft. 18ft. 19ft. 20ft. 21ft. 22ft. 23ft. 24ft.
2.4m 2.7m 3.0m 3.4m 3.7m 4.0m 4.3m 4.6m 4.9m 5.2m 5.5m 5.8m 6.1m 6.4m 6.7m 7.0m 7.3m

Models Wire Gage Size No. SAE

6-25 Hp #8* #8 #6 #6 #6 #6 #4 #4 #4 #4 #4 #4 #4 #4 #2 #2 #2
30-115 #6* #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Hp
125-250 #6* #6 #4 #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2
Hp (ex-
cept
DFI)
DFI #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Models

* = Standard (original) Cable Length and wire gage size.

Replacement Parts
WARNING
Electrical, ignition and fuel system components on your Mercury/Mariner outboard
are designed and manufactured to comply with U. S. Coast Guard Rules and Regu-
lations to minimize risks of fire and explosions. Use of replacement electrical, igni-
tion or fuel system components, which do not comply with these rules and regula-
tions, could result in a fire or explosion hazard and should be avoided.

Battery
A 12 volt marine battery with a minimum Cold Cranking amperage rating of 490 amperes
or 630 (minimum) Marine Cranking amperes should be used.

CAUTION
Deep-cycle batteries are not suitable for use as engine starting batteries or for use
as accessory batteries that are connected to high output engine charging systems.
Deep-cycle battery life may be shortened by high output engine charging systems.
Refer to individual battery maker instructions for specific battery charging proce-
dures and applications.

90-855348R02 NOVEMBER 2002 Page 2B-3

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

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

Charging a Discharged Battery

WARNING
Hydrogen and oxygen gases are produced during normal battery operation or
charging. Sparks or flame can cause this mixture to ignite and explode, if they are
brought near the vent openings. Sulphuric acid in battery can cause serious burns,
if spilled on skin or in eyes. Flush or wash away immediately with clear water.

The following basic rule applies to any battery charging situation:

1. Any battery may be charged at any rate (in amperes) or as long as spewing of electrolyte
(from violent gassing) does not occur and for as long as electrolyte temperature does
not exceed 125° F (52° C). If spewing of electrolyte occurs, or if electrolyte temperature
exceeds 125° F, charging rate (in amperes) must be reduced or temporarily halted to
avoid damage to the battery.
2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes),
all cells are gassing freely (not spewing liquid electrolyte), and no change in specific
gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte tem-
perature with electrolyte level at 3/16 in. (4.8 mm) over plate, unless electrolyte loss has
occurred (from age or over-filling) in which case specific gravity reading will be lower.
For most satisfactory charging, lower charging rates in amperes are recommended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be
reached, battery is not in optimum condition and will not provide optimum performance;
however, it may continue to provide additional service, if it has performed satisfactorily
in the past.
4. To check battery voltage while cranking engine with electric starting motor, place RED
(+) lead of tester on POSITIVE (+) battery terminal and BLACK (–) lead of tester on NEG-
ATIVE (–) battery terminal. If the voltage drops below 9-1/2 volts while cranking, the bat-
tery is weak and should be recharged or replaced.

Page 2B-4 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Winter Storage of Batteries

Battery companies are not responsible for battery damage either in winter storage or in deal-
er stock if the following instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sulfate
and dirt from top surface by running water over top of battery. Be sure, however, that vent
caps are tight beforehand, and blow off all excess water thoroughly with compressed
air. Check water level, making sure that plates are covered.
2. When adding distilled water to battery, be extremely careful not to fill more than 3/16 in.
(4.8 mm) above perforated baffles inside battery. Battery solution or electrolyte expands
from heat caused by charging. Overfilling battery will cause electrolyte to overflow (if
filled beyond 3/16 in. above baffles).
3. Grease terminal bolts well with 2-4-C with Teflon and store battery in a COOL-DRY
place. Remove battery from storage every 30-45 days, check water level and put on
charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check battery for reason and recharge. When grav-
ity reaches 1.260, discontinue charging. To check 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,
for best possible maintenance during inactive periods to ensure a good serviceable bat-
tery in spring. When ready to place battery back in service, remove excess grease from
terminals (a small amount is desirable on terminals at all times), recharge again as nec-
essary and reinstall battery.

90-855348R02 NOVEMBER 2002 Page 2B-5

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter

4
3
5

1
2

79
10

7
16 6 8
9
11

16 14 7
17 13 12 15
79 4 Cycle 25W40 Engine Oil A

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 STARTER MOTOR
2 1 DRIVE CAP
3 2 THRU-BOLT 70 7.9
4 1 DRIVE KIT
5 1 PINION
6 1 ARMATURE
7 1 BRUSH/SPRING KIT
8 1 BRUSH HOLDER
9 1 COMMUTATOR CAP
10 2 SCREW Drive Tight
11 1 DECAL-Warning-High voltage
12 1 LOCKWASHER
13 2 NUT (1/4-20) 60 6.8
14 2 LOCKWASHER
15 1 NUT (1/4-20) 60 6.8
16 3 SCREW (M8 x 40) 23 31.2
17 1 SPACER
NOTE: A – Torque bottom starter bolt to 21.0 lb. ft. (28.5 Nm)

Page 2B-6 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Replacement Parts
WARNING
Electrical, ignition and fuel system components on your Mercury/Mariner outboard
are designed and manufactured to comply with U. S. Coast Guard Rules and Regula-
tions to minimize risks of fire and explosions. Use of replacement electrical, ignition
or fuel system components, which do not comply with these rules and regulations,
could result in a fire or explosion hazard and should be avoided.

System Components
The battery charging system consists of the alternator, battery, ignition switch, starter sole-
noid and the wiring which connects these components.

b
To
51708
a - Alternator c - 20 Ampere Fuse
b - Battery d - Starter Solenoid

Precautions
The following precautions must be observed when working on the alternator system. Failure
to observe these precautions may result in serious damage to the alternator system.
1. Do not attempt to polarize the alternator.
2. Do not short across or ground any terminals on the alternator, unless specifically instructed.
3. Never disconnect the alternator output lead, regulator harness or battery cables when
the alternator is being driven by the engine.
4. Always remove NEGATIVE (–) battery cable from battery before working on alternator
system.
5. When installing battery, be sure to connect the NEGATIVE (–) (grounded) battery cable
to NEGATIVE (–) battery terminal and the POSITIVE (+) battery cable to POSITIVE (+)
battery terminal.
6. When using a charger or booster battery, connect it in parallel with existing battery
(POSITIVE to POSITIVE; NEGATIVE to NEGATIVE).

90-855348R02 NOVEMBER 2002 Page 2B-7

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Alternator Description
The alternator employs a rotor, which is supported in 2 end frames by ball bearings, and is
driven at 2.5 times engine speed. The rotor contains a field winding enclosed between 2
multiple-finger pole pieces. The ends of the field winding are connected to 2 brushes which
make continuous sliding contact with the slip rings. The current (flowing through the field
winding) creates a magnetic field that causes the adjacent fingers of the pole pieces to be-
come alternate north and south magnetic poles.
A 3-phase stator is mounted directly over the rotor pole pieces and between the 2 end
frames. It consists of 3 windings wound 120° electrically out-of-phase on the inside of a lami-
nated core. The windings are connected together on one end, while the other ends are con-
nected to a full-wave rectifier bridge.
The rectifier bridge contains 8 diodes which allows current to flow from ground, through the
stator and to the output terminal, but not in the opposite direction.
When current is supplied to the rotor field winding, and the rotor is turned, the movement
of the magnetic fields created induces an alternating current into the stator windings. The
rectifier bridge changes this alternating current to direct current which appears at the output
terminal. A diode trio is connected to the stator windings to supply current to the regulator
and the rotor field during operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that senses
the voltage at the battery and regulates the field current to maintain alternator voltage for
properly charging the battery. Current output of the alternator does not require regulation,
as maximum current output is self-limited by the design of the alternator. As long as the volt-
age is regulated within the prescribed limits, the alternator cannot produce excessive cur-
rent. A cutout relay in the voltage regulator also is not required, as the rectifier diodes pre-
vent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor field
to initially start the alternator charging. Once the alternator begins to produce output, field
current is supplied solely by the diode trio.
The alternator is equipped with 2 fans which induce air flow through the alternator to remove
heat created by the rectifier and stator.

Diagnosis of Alternator System on Engine

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

Page 2B-8 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Alternator System Circuitry Test

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

OHMS 4030 2015 10

10060 5
200
20 0
10 10 1530
5 40
0
VOLTS 4 6 20
0 2 8
DC AMPS0 10

DCV ACV

DVA

56025
a - Terminal B

Sensing Circuit
1. Unplug RED and PURPLE lead connector from alternator.
2. Connect POSITIVE (+) voltmeter lead to RED lead and NEGATIVE (–) voltmeter lead
to ground.

90-855348R02 NOVEMBER 2002 Page 2B-9

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

3. Voltmeter should indicate battery voltage. If correct voltage is not present, check sens-
ing circuit (RED lead) for loose or dirty connections or damaged wiring.
a

4030 201510
10060
OHMS 5
200 0
20 30
10 10 15
5 40
00 4 6 8 20
VOLTS 2 10
0
DC AMPS

DCV ACV

DVA

56024
a - Sense Lead (RED)

Voltage Output
1. Using a 0-20 volt DC voltmeter, connect POSITIVE (+) lead of voltmeter to TERMINAL
B of alternator and NEGATIVE (–) lead of voltmeter to engine ground.
a

OHMS 4030 2015 10

10060 5
200
20 0
10 10 15 30
5 40
0 20
VOLTS
0 2 4 6 8
DC AMPS0 10

DCV ACV

DVA

56025
a - Terminal B

Page 2B-10 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

2. Start engine and allow to warm up. Increase engine RPM from idle to 2000. Normal volt-
age output should be 13.5 – 15.1 volts. If voltage reading is greater than normal, replace
voltage regulator.
3. If voltage reading is less than normal, fabricate a tool from a piece of stiff wire to the fol-
lowing specifications:

0.060 in. (1.52mm)

13/16 in. (20.6mm)

8 in. (203mm)
4. Insert bent end of tool through end cover and ground TERMINAL F.

51683

OHMS 4030 2015 10

10060 5
200
20 0
10 10 30
5 15 40
0 20
VOLTS
0 2 4 6 8
0
DC AMPS 10

DCV ACV

20

DVA

c a
56027
b
a - Terminal F
b - Tool
c - Jumper Wire to Engine Ground (Attach to end of Tool)

5. With TERMINAL F grounded, voltage should rise to within the normal range
(13.5 – 15.1). If voltage rises, replace the regulator.
6. If the voltage DOES NOT rise to within the normal range with TERMINAL F grounded,
perform CURRENT OUTPUT test.

90-855348R02 NOVEMBER 2002 Page 2B-11

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Current Output
1. With engine shut off, install ammeter (capable of reading 60+ amperes) in series be-
tween TERMINAL B on alternator and POSITIVE (+) terminal of battery.
2. Start engine and allow to warm up. Advance RPM to 2000.
3. Insert tool, previously fabricated for VOLTAGE OUTPUT, through end cover and ground
TERMINAL F.
e

b d

56026
c
a - Terminal F
b - Tool
c - Jumper Wire to Engine Ground
d - Terminal B
e - Ammeter

4. Normal output is 60 amperes @ 2000 RPM. If output is normal, replace regulator. If out-
put is low, a disassembly of the alternator is necessary to inspect and test individual
components.
Repair
REMOVAL
1. Remove top cowling.
2. Disconnect battery cables from battery.
3. Disconnect wiring harness from alternator.
4. Use a breaker bar to release belt tensioner and remove alternator belt.

Page 2B-12 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

5. Remove attaching bolts and remove alternator.

d

c
a

56829
a - Belt
b - Tensioner
c - Breaker Bar
d - Attaching Bolts

Disassembly and Test

1. Remove 3 screws and nut securing end cover and remove insulator and cover.
c

a
51683
a - Cover
b - Screws
c - Nut
d - Insulator

90-855348R02 NOVEMBER 2002 Page 2B-13

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

2. Remove 5 screws securing regulator and brush assembly.

c c

51680
a - Regulator
b - Brush Assembly
c - Screws

NOTE: Proper regulator operation can be determined by VOLTAGE OUTPUT and CUR-
RENT OUTPUT, previous. If regulator does not meet specifications, replace regulator.
Torque regulator screws to 17 lb. in. (1.9 Nm).
NOTE: Brushes are replaced as an assembly. Inspect assembly for stuck brushes or exces-
sive brush wear. Normal exposed brush length is 0.156 in. (4.0mm). Minimum exposed
brush length is 0.059 in. (1.5mm).
3. Remove 4 screws securing rectifier (diode assembly) to alternator.

b 51684
a - Screws
b - Rectifier (Diode Assembly)

Page 2B-14 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

NOTE: To test rectifier assembly, touch POSITIVE (+) lead from ohmmeter to POSITIVE
stud and NEGATIVE (–) lead from ohmmeter to each diode terminal. The ohmmeter should
indicate continuity.

c b
51679
a - Positive Stud
b - Positive Ohm Lead
c - Negative Ohm Lead

4. Reverse leads – NEGATIVE lead on POSITIVE stud and POSITIVE lead on each diode
assembly. NO CONTINUITY should be observed. If continuity is observed in both tests,
or NO CONTINUITY is observed in both tests, the rectifier assembly is defective and
must be replaced. Torque rectifier screws to 17 lb. in. (1.9 Nm).

b c
a 51679
a - Positive Stud
b - Negative Ohm Lead
c - Positive Ohm Lead

IMPORTANT: Depending on the polarity of the ohmmeter, reversed readings may be

obtained – I.E. – CONTINUITY is observed when the NEGATIVE lead touches the POS-
ITIVE stud and NO CONTINUITY is observed when the POSITIVE lead touches the
POSITIVE stud.

90-855348R02 NOVEMBER 2002 Page 2B-15

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

IMPORTANT: The regulator, rectifier and brush assembly are the only components
individually replaceable on this alternator. If the rotor or stator is defective, the entire
rotor, stator and housing must be replaced as an assembly.
IMPORTANT: Clean anti-corrosion paint from electrical connections prior to reas-
sembly. Coat all electrical connections with Liquid Neoprene.

ROTOR TEST
1. Inspect slip ring surface for roughness, abnormal wear and/or burning. If such condi-
tions exist, rotor is not considered serviceable and alternator should be replaced.

51684
a - Slip Rings

2. Measure the outer diameter of the slip rings using vernier calipers. STANDARD DIAME-
TER: 0.567 in. (14.4mm); MINIMUM DIAMETER: 0.551 in. (14.0mm). If slip ring diame-
ter is less than minimum, rotor is not considered serviceable and alternator should be
replaced.

51680

Page 2B-16 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

3. Inspect rotor for an open circuit. Using an ohmmeter, check for continuity between slip
rings. Resistance should not exceed 3 ohms. If no continuity exists, rotor is defective.

51682
a - Slip Rings

4. Check rotor for short to ground. NO CONTINUITY should exist between slip rings and
rotor shaft. If CONTINUITY exists, rotor is defective.

51683
a - Slip Rings
b - Rotor Shaft

90-855348R02 NOVEMBER 2002 Page 2B-17

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

STATOR TEST
1. With rectifier removed, use an ohmmeter to check for a short circuit between each stator
lead and the stator frame. If CONTINUITY exists, stator is defective.

a
b

51682
a - Stator Leads
b - Frame

2. Inspect stator for open circuit. Using an ohmmeter, check for an open circuit between
each of the stator leads. If no continuity exists, stator is defective.

51682
a - Stator Leads

Page 2B-18 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Reassembly
1. Position rectifier assembly over stator leads.
b

51683
a - Rectifier Assembly
b - Stator Leads

2. Form stator leads in a clockwise loop and secure leads to rectifier with 4 screws. Torque
screws to 17 lb. in. (1.9 Nm).

a
b
a

b 51684
a - Stator Leads
b - Screws [Torque to 17 lb. in. (1.9 Nm)]

90-855348R02 NOVEMBER 2002 Page 2B-19

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

3. Secure regulator to alternator with 2 screws [1 in. (25.4mm) long]; 1 screw [0.25 in.
(6.4mm) long] and lockwashers. DO NOT tighten screws at this time.

a
b 51684
a - Regulator
b - Screws [1 in. (25.4mm)]
c - Screw [0.25 in. (6.4mm)]

4. Secure brush assembly with 2 screws – [0.25 in. (6.4mm) long] and [0.312 in. (8.0mm)
long].

51680
a - Brush Assembly
b - Screw [0.25 in. (6.4mm)]
c - Screw [0.312 in.(8.0mm)]

Page 2B-20 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

5. Install end cover. Secure cover with 3 screws. Torque screws to 23 lb. in. (2.6 Nm). Install
terminal insulator. Torque nut to 36 lb. in. (4.1 Nm).
d

51683
a - Cover
b - Screw [Torque to 23 lb. in. (2.6 Nm)]
c - Terminal Insulator
d - Nut [Torque to 36 lb. in. (4.1 Nm)]

PULLEY
1. While holding rotor shaft, remove pulley nut.
a

51679
a - Pulley
b - Rotor Shaft
c - Nut

90-855348R02 NOVEMBER 2002 Page 2B-21

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

2. Before reinstalling pulley, verify spacer is installed on rotor shaft.

51683
a - Spacer

3. Torque pulley nut to 50 lb. ft. (67.8 Nm).

Installation
1. Secure alternator to engine block with 2 attaching bolts. Torque bolts to 40 lb. ft.
(54.2 Nm).
2. Install alternator belt in groove of flywheel, alternator and compressor pulley.
3. Reconnect electrical harness to alternator.
d

c
a

56829
a - Belt
b - Tensioner
c - Breaker Bar
d - Attaching Bolts

Page 2B-22 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Alternator Belt Tension Adjustment

Correct alternator belt tension is maintained by a belt tensioner assembly.
a

55936
a - Belt Tensioner Assembly

Starter System

STARTER MOTOR AMPERES DRAW

STARTER MOTOR PART NO. NO LOAD AMP. DRAW NORMAL AMP. DRAW
50-833153-1 30 AMPS 210 AMPS

STARTER SYSTEM COMPONENTS

1. Battery
2. Starter Solenoid
3. Neutral Start Switch
4. Starter Motor
5. Ignition Switch

DESCRIPTION
The battery supplies electricity to activate the starter motor. When the ignition is turned to
the “START” position, the starter solenoid is energized and completes the starter circuit be-
tween the battery and starter.
The neutral start switch opens the starter circuit when the shift control lever is not in neutral
thus preventing accidental starting when the engine is in gear.

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

90-855348R02 NOVEMBER 2002 Page 2B-23

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Notes:

Page 2B-24 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Troubleshooting the Starter Circuit

Before beginning the troubleshooting flow chart, verify the following conditions:
1. Confirm that battery is fully charged.
2. Check that control lever is in “NEUTRAL” position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 20 amp fuse.
Location of “Test Points” (called out in flow chart) are numbered below.

STARTER
TO ALTERNATOR

BATTERY

7
2
1

20 AMP FUSE 6
3
STARTER
SOLENOID
4

NEUTRAL START SWITCH

IGNITION SWITCH (LOCATED IN CONTROL HOUSING)

Starter Circuit

90-855348R02 NOVEMBER 2002 Page 2B-25

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Circuit Troubleshooting Flow Chart

Starter Motor Does Not Turn

SAFETY WARNING: Disconnect yellow (starter motor)

cable from starter solenoid test point 1 BEFORE making
tests 1–thru–7 to prevent unexpected engine cranking.

TEST 1
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.

No Continuity Indicated – There is an open circuit in the Continuity Indicated

BLACK NEGATIVE (–) battery cable between the NEGATIVE (–) Proceed to TEST 2
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.

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

TEST 3 12 Volt Reading*

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

No voltage reading: 12 Volt Reading

proceed to Step 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 with
No voltage reading: RED wire is open between Test Points 4 and 3.
proceed to Test 5 b. Turn ignition key to “Start” position.

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
Check for voltage between common engine ground and Test Point 6.

No voltage reading: 12 Volt Reading*

Check RED wire between battery(+) Check fuse in RED wire between Test
POSITIVE terminal and Test Point 6. Points 5 and 6.
Check for open RED wire between Test
Points 5 and 6.

*Battery Voltage

Page 2B-26 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

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

No voltage reading: 12 Volt Reading*

Defective starter solenoid Should hear solenoid click: proceed to TEST 8

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

No voltage reading:
Check BLACK cable (with YELLOW
12 Volt Reading*
sleeve) for poor connection or open circuit. If starter motor does not turn, check starter motor.

*Battery Voltage

90-855348R02 NOVEMBER 2002 Page 2B-27

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Removal and Installation

REMOVAL

CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect BLACK cable (with YELLOW sleeve) from starter.
2. Remove 2 upper bolts and 1 lower bolt securing starter and remove starter.
b

a
c

52135

a - BLACK (with YELLOW sleeve) POSITIVE (+) 12-Volt Cable

b - Upper Mounting Bolts
c - Lower Mounting Bolt

INSTALLATION
1. Secure starter to engine with 3 bolts. Torque top attaching bolts to 23 lb. ft. (31.2 Nm).
Torque bottom attaching bolt to 21 lb. ft. (28.5 Nm).
2. Secure BLACK cable (with YELLOW sleeve) to POSITIVE (+) terminal on starter.
Torque nut to 60 lb. in. (6.8 Nm).
a

c
b
52135

a - Top Bolts [Torque to 23 lb. ft. (31.2 Nm)]

b - Bottom Bolt [Torque to 21 lb. ft. (28.5 Nm)]
c - BLACK Cable (with YELLOW sleeve)
d - Nut [Torque to 60 lb. in. (6.8 Nm)]

Page 2B-28 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

DISASSEMBLY

1. Remove starter as outlined in Starter Removal and Installation, preceding.

2. Remove 2 thru-bolts from starter.
3. Tap commutator end cap to loosen and remove from frame. Do not loose brush springs.
a

b
11646
a - Thru-Bolts
b - Commutator End Cap

4. Brush replacement is recommended if brushes are pitted, chipped or worn to less than
0.25 in. (6.4 mm). If necessary, remove brushes as follows:
a. Remove hex nut and washers from POSITIVE (+) terminal and remove POSITIVE
brushes and terminal as an assembly.
b. Remove 2 bolts securing NEGATIVE (–) brushes and brush holder to end cap.
a c
b

c d b 11656
a - Brush Holder
b - Positive Brushes
c - Negative Brushes
d - Positive Terminal

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

90-855348R02 NOVEMBER 2002 Page 2B-29

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

6. Remove locknut and remove drive assembly from armature shaft.

51711
a - Hold Armature Shaft with Wrench on Hex Portion of Drive Assembly
e g
f

a b c

11658

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

Page 2B-30 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Cleaning, Inspection and Testing

Cleaning and Inspection
1. Clean all starter motor parts.
2. Check pinion teeth for chips, cracks or excessive wear.
3. Replace drive clutch spring and/or collar if tension is not adequate or if wear is excessive.
4. Inspect brush holder for damage or for failure to hold brushes against commutator.
5. Replace brushes that are pitted or worn to less than 1/4 in. (6.4mm) in length.
6. Inspect the armature conductor (commutator bar junction) for a tight connection. A loose
connection (excessive heat from prolonged cranking melts solder joints) results in a
burned commutator bar.
7. Resurface and undercut a rough commutator as follows:

CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the insulation between the commutator
bars 1/32 in. (0.8mm) to the full width of the insulation and so that undercut is flat.
b. Clean the commutator slots after undercutting.
c. Sand the commutator lightly with No. 00 sandpaper to remove burrs, then clean the
commutator.
d. Recheck the armature on a growler for shorts as specified in Testing.
8. Open-circuited armatures often can be repaired. The most likely place for an open circuit
is at the commutator bars, as a result of long cranking periods. Long cranking periods
overheat the starter motor so that solder in the connections melts and is thrown out. The
resulting poor connections then cause arcing and burning of the commutator bars.
9. Repair bars, that are not excessively burned, by resoldering the leads in bars (using ros-
in flux solder) and turning down the commutator in a lathe to remove burned material,
then undercut the mica.
10. Clean out the copper or brush dust from slots between the commutator bars.
11. Check the armature for ground. See Testing, following.

90-855348R02 NOVEMBER 2002 Page 2B-31

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Testing
Armature Test for Shorts
1. Check armature for short circuits by placing on growler and holding hack saw blade over
armature core while armature is rotated. If saw blade vibrates, armature is shorted. Re-
check after cleaning between commutator bars. If saw blade still vibrates, replace arma-
ture.

11669
Armature Test for Ground
1. Set ohmmeter to (R x 1 scale). Place one lead of ohmmeter on armature core or shaft
and other lead on commutator.
2. If meter indicates continuity, armature is grounded and must be replaced.

51711

Page 2B-32 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

CHECKING POSITIVE BRUSHES AND TERMINAL

Set ohmmeter to (R x 1 scale). Connect meter leads between POSITIVE brushes. Meter
must indicate full continuity or zero resistance. If resistance is indicated, inspect lead to
brush and lead to POSITIVE terminal solder connection. If connection cannot be repaired,
brushes must be replaced.

51711
a - POSITIVE (+) Brushes
Testing Negative Brushes for Ground
Set ohmmeter to (R x1 scale). Place one lead of the ohmmeter on the NEGATIVE brush and
the other lead on the end cap (bare metal). If the meter indicates NO continuity, replace the
NEGATIVE brush. Repeat this procedure on the other NEGATIVE brush.

a
51711
a - NEGATIVE (–) Brushes
b - End Cap

90-855348R02 NOVEMBER 2002 Page 2B-33

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Reassembly
1. If brushes were removed, replace as follows:
a. Install POSITIVE brushes (along with POSITIVE terminal) into commutator end cap.

a
b

e
f 52131

a - End Cap d - Insulating Block

b - POSITIVE Brushes e - Insulating Washer
c - POSITIVE Terminal f - Hex Nut

a 51713

a - POSITIVE (+) Terminal

b - Long Brush Lead
c - Push Lead into Slot

Page 2B-34 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

b. Install NEGATIVE brushes (along with brush holder).

b
a c

b
a
11656
a - POSITIVE (+)Brushes
b - NEGATIVE (–) Brushes
c - Brush Holder
d - Bolts (Fasten NEGATIVE Brushes and Holder)
2. If removed, reinstall parts on armature shaft. Use a new locknut and tighten securely on
end of shaft.
e f g

a b c

11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
g - Washer
3. Lubricate helix threads on armature shaft with a drop of SAE 10W oil.
4. Lubricate bushing in drive end plate with a drop of SAE 10W oil.
5. Position armature into starter frame.

90-855348R02 NOVEMBER 2002 Page 2B-35

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

6. Lubricate bushing (located in commutator end cap) with one drop of SAE 10W oil. DO
NOT overlubricate.

a - Bushing (DO NOT overlubricate)

7. To prevent damage to brushes and springs when installing commutator end cap, it is
recommended that a brush retaining tool be made as shown:

2-1/6″

5″ 9/16″

1-3/4″

Page 2B-36 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

8. Place springs and brushes into brush holder and hold in place with brush retainer tool.

51713
a - Brush Retainer Tool
9. Install commutator end cap onto starter frame. Align marks on frame with alignment
marks on end caps. Remove brush retainer tool. Install through bolts and torque to 70
lb. in. (8.0 Nm).

52130
a - Alignment Marks

90-855348R02 NOVEMBER 2002 Page 2B-37

BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Starter Solenoid Test

1. Disconnect all wires from solenoid.
2. Connect ohmmeter (R x1 scale) between terminals 1 and 2.
3. Connect a 12-volt power supply between terminals 3 and 4. Solenoid should click and
meter should read 0 ohms (full continuity).
4. If meter does not read 0 ohms (full continuity), replace solenoid.

DCV ACV

DVA

3 1

b 4
2

a - 12-VOLT Supply
b - VOA Leads

Page 2B-38 90-855348R02 NOVEMBER 2002

 BATTERY CHARGING SYSTEM AND STARTING SYSTEM

Commander 2000 Key Switch Test

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

23894

KEY CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:

POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK

OFF

RUN

START

CHOKE*

90-855348R02 NOVEMBER 2002 Page 2B-39

 TIMING, SYNCHRONIZING AND ADJUSTING

ELECTRICAL
Section 2C - Timing, Synchronizing and Adjusting
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Maximum Throttle . . . . . . . . . . . . . . . . . . . . 2C-8
C
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Throttle Plate Screw . . . . . . . . . . . . . . . . . . 2C-9
Crank Position Sensor Adjustment Throttle Position Sensor (TPS) Adjustment
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-9
Throttle Cam Adjustment (1997 Models) . . . 2C-4 Idle Speed (All Models) . . . . . . . . . . . . . . . . . . 2C-9
Maximum Throttle . . . . . . . . . . . . . . . . . . . . 2C-5 Alternator Belt Tension Adjustment
Throttle Plate Stop Screws . . . . . . . . . . . . 2C-6 (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-9
Throttle Cam Adjustment
(1998/1999 Models) . . . . . . . . . . . . . . . . . . . . . 2C-7

Specifications
1997, 1998 & 1999 MODELS

FULL THROTTLE RPM RANGE 5000 - 5750

IDLE RPM (IN FORWARD GEAR)

1997 MODELS 650
1998 MODELS 550
MAXIMUM TIMING: Not Adjustable
@ WIDE OPEN Controlled by ECM
IDLE TIMING Not Adjustable
Controlled by ECM
SPARK PLUG
1997 MODEL 200 Champion RC10-ECC

1998 MODEL 200/225 NGK PZFR5F-11 or

Champion RC12MC4
FIRING ORDER 1-2-3-4-5-6
THROTTLE POSITION SENSOR 1
(INNER TPS)
@ IDLE 3.70 – 4.90 VDC
@ W.O.T. 0.30 – 1.80 VDC
THROTTLE POSITION SENSOR 2
(OUTER TPS)
@ IDLE 0.10 – 1.50 VDC
@ W.O.T. 3.20 – 4.99 VDC
 Light Duty Use

90-855348R02 NOVEMBER 2002 Page 2C-1

TIMING, SYNCHRONIZING AND ADJUSTING

Special Tools
1. Service Tachometer DMT-2000 91-854009A1

2. Digital Diagnostic Terminal 91-823686A2

3. Cable [10 ft. (3.05m)]* 84-825003A1

Page 2C-2 90-855348R02 NOVEMBER 2002

 TIMING, SYNCHRONIZING AND ADJUSTING

4. ECM Harness 84-822560A5

5. Cartridge 91-822608-4 or 91-822608--5

Crank Position Sensor Adjustment (All Models)

1. Remove flywheel cover.
2. Using a feeler gauge, measure the air gap between the crank position sensor and a tooth
on the flywheel. It should be 0.040 in. ± 0.020 in. [1.02 mm ± 0.51 mm)]. If not, loosen
bracket screws, set gap to specification, and retighten screws to 105 lb. in. (11.9 N·m).
d b

57796_1
a c
a - Air Gap [0.025 in. – 0.040 in.(0.635 mm – 1.02 mm)]
b - Crank Position Sensor
c - Flywheel Tooth
d - Bracket Screws [Torque to 105 lb. in. (12 Nm)]
IMPORTANT: Crank Position Sensor must be perpendicular to flywheel tooth.

90-855348R02 NOVEMBER 2002 Page 2C-3

TIMING, SYNCHRONIZING AND ADJUSTING

3. Reinstall flywheel cover.

IMPORTANT: A new replacement crank position sensor will have a felt pad on the end
of the sensor. Install the new sensor with the pad touching the flywheel; this will re-
sult in a gap of 0.030 (0.762mm)

a
a - Felt Pad on a New Crank Position Sensor

Throttle Cam Adjustment (1997 Models)

1. Loosen throttle cam roller screw so the roller moves freely. Allow the roller to rest on
the throttle cam. Adjust the idle stop screw on the throttle arm and align mark on cam
with center of roller.

c
d

b e

54452
a - Throttle Cam Roller Screw
b - Throttle Cam
c - Idle Stop Screw
d - Alignment Mark
e - Roller

Page 2C-4 90-855348R02 NOVEMBER 2002

 TIMING, SYNCHRONIZING AND ADJUSTING

2. Hold throttle arm against idle stop. Tighten throttle cam roller screw so that roller just
touches throttle cam.

c
d

a - Throttle Arm
b - Idle Stop
c - Throttle Cam Roller Screw
d - 0.000 in. (0.0mm) Clearance

Maximum Throttle
Hold throttle arm against full throttle stop. Adjust full throttle stop screw until alignment mark
on cam is centered with roller.

a
b
e

a - Throttle Arm
b - Full Throttle Stop
c - Full Throttle Stop Screw
d - Alignment Mark on Cam
e - Roller

90-855348R02 NOVEMBER 2002 Page 2C-5

TIMING, SYNCHRONIZING AND ADJUSTING

Throttle Plate Stop Screws

IMPORTANT: DO NOT adjust throttle plate stop screws from factory setting. The top
throttle plate clearance is set @ 0.038 in. (0.965mm) (#62 drill) and the bottom throttle
plate is set @ 0.011 in. (0.279mm) (#80 drill). Contact the Mercury Marine Technical
Service Department for proper adjustment procedure.

a - Screws (DO NOT Adjust from Factory Setting)

Page 2C-6 90-855348R02 NOVEMBER 2002

 TIMING, SYNCHRONIZING AND ADJUSTING

Throttle Cam Adjustment

(1998/1999 Models)
1. Loosen cam follower screw allowing cam follower to move freely.
2. Allow roller to rest on throttle cam. Adjust idle stop screw on throttle arm to align cam
roller in the pocket of the throttle cam.
3. Tighten roller arm screw to provide clearance of 0.005 in. ± 0.005 in. (0.127 mm ± 0.127
mm) between roller and cam.

e 55967
a - Roller Arm Screw
b - Roller
c - Throttle Cam
d - Wide Open Throttle Stop Screw
e - Idle Stop Screw

90-855348R02 NOVEMBER 2002 Page 2C-7

TIMING, SYNCHRONIZING AND ADJUSTING

Maximum Throttle
1. Hold throttle arm against full throttle stop.
2. Adjust full throttle stop screw to allow full throttle valve opening while maintaining a 0.010
in. (0.254 mm) clearance between arm of throttle shaft and stop on attenuator box.
3. Tighten jam nut on full throttle stop screw.
4. Check for free play (roller lifts from cam) between roller and cam at full throttle to prevent
linkage from binding. Readjust full throttle stop screw, if necessary.

d c

b
55982

a - Throttle Arm
b - Full Throttle Stop Screw
c - Throttle Shaft Arm
d - 0.010 in. (0.254mm) Clearance
e - Stop on Attenuator Box

Page 2C-8 90-855348R02 NOVEMBER 2002

 TIMING, SYNCHRONIZING AND ADJUSTING

Throttle Plate Screw

IMPORTANT: DO NOT adjust throttle plate stop screw from factory setting. The
throttle plate clearance is set @ 0.092 in. (02.34mm) (#42 drill). Contact the Mercury
Marine Technical Service Department for proper adjustment procedure.
a

a - Throttle Plate Stop Screw

Throttle Position Sensor (TPS) Adjustment (All Models)

The Throttle Position Sensors are not adjustable. TPS settings can be monitored with the
Digital Diagnostic Terminal through the ECM. If TPS settings are not within specifications,
replace Throttle Position Sensors as required.

Idle Speed (All Models)

Engine idle speed is not adjustable. The parameters affecting idle speed can be checked
and monitored by the DDT. Refer to the DDT Reference Manual for complete details.

Alternator Belt Tension Adjustment (All Models)

Correct alternator belt tension is maintained by a belt tensioner assembly.
a

55936
a - Belt Tensioner Assembly

90-855348R02 NOVEMBER 2002 Page 2C-9

 WIRING

ELECTRICAL
Section 2D - Wiring
Table of Contents
2
Power Trim Wiring Diagram . . . . . . . . . . . . . . 2D-2 Oil Level Gauge Wiring . . . . . . . . . . . . . . . . 2D-14 D
........................................ 2D-3 Engine Synchronizer Wiring Diagram . . . 2D-16
Commander 3000 Classic Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-18
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 Multi-Function Gauge . . . . . . . . . . . . . . . . . . . . 2D-18
Commander 3000 Panel Remote Control . . . 2D-5 Dip Switch Setting/Testing . . . . . . . . . . . . . 2D-18
Commander 3000/3000 Classic Components . 2D-6 Outboard Multi-Function Gauge Setting . . . 2D-19
Instrument/Lanyard Stop Switch Warning System . . . . . . . . . . . . . . . . . . . . . . . . 2D-20
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8 Warning System Signals . . . . . . . . . . . . . . 2D-21
Oil Level Gauge Wiring Diagram . . . . . . . . . . 2D-9 Warning System Operation . . . . . . . . . . . . 2D-22
Instrument/Lanyard Stop Switch Panel Mount Remote Contro
Wiring Diagram l Wiring Installation . . . . . . . . . . . . . . . . . . . . . . 2D-25
(Dual Outboard) . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10 ........................................ 2D-25
........................................ 2D-11 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-26
QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . 2D-12 1997 Model 200 DFI Wiring Diagram . . . . . . 2D-27
Tachometer Wiring Diagram . . . . . . . . . . . 2D-12 1998/1999 Model 200/225 DFI
Water Temperature Gauge . . . . . . . . . . . . 2D-13 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-28

90-855348R02 NOVEMBER 2002 Page 2D-1

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Power Trim Wiring Diagram

c
b
a

l
e

f
g

h
j i

a - Tachometer Connector h - Trim Pump and Motor

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

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Instrument Wiring Connections

Speedometer Tachometer

Temperature/Oil Volt Meter

Figure 1 Warning Panel

Without Light Switch

a b
c

TAN/WHT
TAN/BLK
51820
NOTE: ANY INSTRUMENT WIRING HARNESS
LEADS NOT USED MUST BE TAPED BACK TO d
THE HARNESS.
Speedometer Tachometer

Temperature/Oil Volt Meter

Figure 2 To 12V Warning Panel
With Light Switch
e

a b
c

TAN/WHT
TAN/BLK 51819
a - Tachometer Receptacle - From
Control Box or Ignition/Choke Switch
b - Tachometer Wiring Harness d
c - Lead to Optional Visual Warning Kit Wire Color Where To
(Taped Back to Harness)
BLK = BLACK GROUND
d - Cable Extension TAN/WHT = TAN/WHITE OIL LIGHT
(For Two Function Warning Panel) TAN/BLK = TAN/BLACK TEMPERATURE LIGHT
TAN = TAN TEMPERATURE GAUGE
e - Light Switch PUR = PURPLE IGNITION 12 VOLT
GRY = GRAY TACHOMETER
BRN/WHT = BROWN/WHITE TRIM GAUGE
TAN/BLU = TAN/BLUE VISUAL WARNING KIT (OPT.)

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Commander 3000 Classic Panel Remote Control

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

< F R >

RED

PUR

GRN
a

a - Neutral Interlock Switch

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Commander 3000 Panel Remote Control

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

RED

PUR

GRN
a

a - Neutral Interlock Switch

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Commander 3000/3000 Classic Components

1 3
2 95

13
9
12 10 95
11 95

8 21
5 95
18

16
6
19
95
95

95 20 24

15 22
17 23
28 14

95

7
17
7 23

25

7
27
26

7 Loctite 271
95 2-4-C With Teflon

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Commander 3000/3000 Classic Components

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 HOUSING-Control (Panel Mount)
1 1 HOUSING-Control (Console Mount)
2 1 BOLT-Locking (Special) 150 16.9
3 5 SPRING
4 1 ROLLER
5 1 BUSHING
6 1 SWITCH ASSEMBLY-Neutral Start (2 Ring Terminals)
6 1 SWITCH ASSEMBLY-Neutral Start (No Terminals)
7 2 GROMMET
8 2 BALL-Steel
9 1 RING-Retaining
10 1 GEAR-Shift
11 1 SPRING
12 1 SHAFT-Throttle Only
13 1 PIN-Shift Gear
14 2 SCREW (#10-32 x 1/4″)
15 2 NUT (10-32)
16 1 ARM ASSEMBLY-Shift
17 2 SCREW (#8-32 x 3/8″) 25 2.8
18 1 SUPPORT ASSEMBLY-Shaft
19 4 SCREW (#10-32 x 5/8″) 35 4.0
20 1 ARM ASSEMBLY-Throttle
21 1 SHAFT KIT-Handle
22 1 ROLLER-Throttle Plate
23 2 BOLT-Shoulder (Special) 35 4.0
24 1 PLATE
25 1 BACK PLATE
26 3 SCREW (#10-32 x 5/8″) 10 1.1
27 1 WASHER
28 2 INSULATOR (2″)

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Instrument/Lanyard Stop Switch Wiring Diagram

g
f

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

c a
b

j
k
h
i

52204

a - Ignition/Choke Switch i - Power Trim Harness

b - Lanyard Stop Switch Connector
c - Lead Not Used on j - Connect Wires Together
Outboard Installations with Screw and Nut
d - Retainer (2 Places); Apply Liquid
e - Tachometer Neoprene to
Connections and Slide
f - Trim Indicator Gauge
Rubber Sleeve over
(Optional)
each Connection.
g - Temperature Gauge
k - Lead to Optional
h - Remote Control Visual Warning Kit
IMPORTANT: On installations where gauge options will not be used, tape back any
unused wiring harness leads.

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Oil Level Gauge Wiring Diagram

d f

c
g

q
r
p s h

o t

m
l
k i

a - To 12 Volt Source i - Screw (10-16 x 5/8 in.)

b - PURPLE Wire (Connect j - Spring
to Trim Indicator Gauge k - Oil Clip Connector
“I” [or POSITIVE (+) 12 l - Housing
Volt Source that is m - Screw (10-16 x 1/4 in.)
Turned “ON” and “OFF”
n - Spring
with Ignition Switch])
o - Screw (10-16 x 5/8 in.)
c - Oil Level Gauge
p - BLACK Wire
d - BLACK Wire (Connects
to NEGATIVE Ground) q - Oil Level Sender Unit
e - To Ground r - Oil Pick-Up Tube
f - BLACK Wire s - WHITE Lead
(From Gauge to Oil Clip (from Oil Level Sender)
Connector) t - Screw (10-16 x 5/8 in.)
g - LIGHT BLUE Sender
Lead to Gauge
h - Wiring Harness
(LT. BLUE and BLACK)

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Instrument/Lanyard Stop Switch Wiring Diagram

(Dual Outboard)

d k d

c b
g
l
BATT GND
BLK=BLACK
d
BLU=BLUE
SENDER
BRN=BROWN
GRN=GREEN
GRY=GRAY e
PUR=PURPLE a
RED=RED
TAN=TAN
WHT=WHITE
YEL=YELLOW

o
n
h

PORT INSTALLATION
52205

a - Ignition/Choke Switch f - Trim Indicator Gauge

b - Lanyard Stop Switch g - Temperature Gauge
c - Lead not used on h - Remote Control
Outboard Installations i - Synchronizer Gauge
d - Retainer j - Synchronizer Module
e - Tachometer k - Lanyard Switch
(Isolation) Diode

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IMPORTANT: On installations where gauge options will not be used, tape back and
isolate unused wiring harness leads.
g

BATT GND

i
SENDER

a
e

j
f

STARBOARD INSTALLATION 52206

l - Y Harness
m - Power Trim Harness Connector
n - Connect Wires together with Screw and Nut (4 Places); Apply Liquid Neoprene
to Connections and slide Rubber Sleeve over each Connection.
o - Lead to Visual Warning Kit

90-855348R02 NOVEMBER 2002 Page 2D-11

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QSI Gauge Wiring Diagrams

Tachometer Wiring Diagram
Tachometer dial on back side of case must be set to position number 4.

WIRING DIAGRAM A
Use this wiring diagram when using a separate light switch for instrument lighting.
b
c

a
d

51106
a - Connect to + 12 Volt
b - +12 Volt Light Switch Wire
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground

WIRING DIAGRAM B
Use this wiring diagram when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key switch is turned on.)

a
c

51106

a - Connect to +12 Volt

b - Position Light Bulb to the Unswitched Position
c - Connect to NEGATIVE (–) Ground

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Water Temperature Gauge

WIRING DIAGRAM A
Use this wiring diagram when using a separate light switch for instrument lighting.
b c

d
a

SEND

e
a - Connect to + 12 Volt
b - +12 Volt Light Switch Wire
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground
e - Connect to TAN Lead located at the Tachometer Receptacle on Commander
Side Mount Remote Control or TAN Lead coming from Accessory Ignition/
Choke Assembly.

WIRING DIAGRAM B
Use this wiring diagram when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key is turned on.)
b

c
a

SEND

d 51105
a - Connect to +12 Volt
b - Position Light Bulb to the Unswitched Position
c - Connect to NEGATIVE (–) Ground
d - Connect to TAN Lead located at the Tachometer Receptacle on Commander
Side Mount Remote Control or TAN Lead coming from Accessory Ignition/
Choke Assembly

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Route TAN lead on starboard side of engine to engine/remote control harness. Connect as
shown.
IMPORTANT: Tape back and isolate any unused wiring harness leads.

28086
a - Lead from Temperature Sender
b - Engine/Remote Control Harness

Oil Level Gauge Wiring

LIGHT BULB POSITION A
Use this position when using a separate light switch for instrument lighting.
b

51109
a - +12 Volt Light Switch Wire
b - Position Light Bulb to the Switched Position

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LIGHT BULB POSITION B

Use this position when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key switch is turned on.)
a

51112
a - Position Light Bulb to the Unswitched Position
b - Sender

SENDER WIRING
a

51108
a - Connect to +12 Volt
b - Connect to NEGATIVE (–) Ground

90-855348R02 NOVEMBER 2002 Page 2D-15

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Engine Synchronizer Wiring Diagram

LIGHT BULB POSITION A
Use this position when using a separate light switch for instrument lighting.

SEND

51105

a - +12 Volt Light Switch Wire

b - Position Light Bulb to the Unswitched Position

LIGHT BULB POSITION B

Use this position when instrument lighting is wired directly to the ignition key switch. (Instru-
ment lights are on when ignition key switch is turned on.)
a

51106
a - Position Light Bulb to the Switched Position
b - Sender

Synchronizer wiring can be accomplished two different ways as an option to the user.

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Wiring Diagram – Gauge needle to point toward slow running engine

a c
b

GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE
51107

a - Tachometer Starboard Engine

b - Synchronizer Gauge
c - Tachometer Port Engine
d - Synchronizer Module

Wiring Diagram – Gauge needle to point toward fast running engine

a c
b

GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE 51107

a - Tachometer Starboard Engine

b - Synchronizer Gauge
c - Tachometer Port Engine
d - Synchronizer Module

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Maintenance
Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with
a soft cloth moistened with water. The gauge may be scored or damaged if wiped with abra-
sive material (sand, saline or detergent compounds, etc.) or washed with solvents such as
trichloroethylene, turpentine, etc.

Multi-Function Gauge
Dip Switch Setting/Testing
NOTE: The multi-function gauge Dip Switch must be set on the back of gauge prior to opera-
tion. Turn the ignition switch to the “OFF” position before setting dip switch. The gauge will
reset to selected settings when the ignition is turned “ON”.
IMPORTANT: Test the gauge and related wiring BEFORE making final Dip Switch set-
tings and BEFORE securing the gauge to dashboard of boat.
1. With the ignition switch in the “Off” position, set the multi-function gauge Dip Switch in
(test) position as shown. (Black dot indicates switch position).

1 2 3 4

Open
52095

a - “Dip Switch” (shown in test position)

b - Black Dot - Switch in “Open” Position

2. Turn ignition switch to the “Run” position. The multi-function gauge now is in the display
test mode. The gauge Temperature, Battery, Oil, and Fuel red warning lights should be
alternately flashing ON and OFF, and the Black L.C.D. bar graphs should be cycling.
(This indicates that all gauge functions are operational.)

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3. Turn ignition switch to the “Off” position. Reset the gauge Dip Switch to the correct oper-
ating position for the outboard application.

a - Gauge Lights (Red)

b - Gauge L.C.D. Bar Graph (Black)

Outboard Multi-Function Gauge Setting

Model Dip Switch Setting
Test Display (All)
1 2 3 4

Open
275 hp (3.4 Litre) Outboards
1 2 3 4
(single engine)

Open
135-250 hp Outboards
1 2 3 4
(single engine)

Open
“Note” On Dual Engine/Single Fuel Tank
1 2 3 4
Applications: Position Dip Switch 4 “Open” *

Open

* Dip Switch (4) in “Open Position” For Dual Engine Single Fuel Tank Applications. Switches 1,2,3 Must Be In Specified
Model Position.

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Warning System
The outboard warning system incorporates warning light gauge (a) and warning horn (b).
The warning horn is located inside the remote control or is part of the ignition key switch wir-
ing harness.

b
b
a
a - Warning Light Gauge
b - Warning Horn

When the key switch is turned to the ON position, the warning lights and horn will turn on
for a moment as a test to tell you the system is working.

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Warning System Signals

NOTE: The warning system signals which includes audible and visual indicator involving
the horn and lights will identify the potential problems listed in the chart.

Problem Horn Check Low Oil Over Water In Engine Speed Re-
Engine Light Heat Fuel duction Activated
Light Light Light (@ 3000 RPM)
Power Up/System Check Single Yes Yes Yes Yes No
Beep
Low Oil 4 Beep... 2 Yes No
Minutes Off
No Oil Flow Continuous Yes Yes Yes (Limits to
(1997 Models Only) Beep 3000 RPM)
Over Heat Continuous Yes Yes (Limits to
Beep 3000 RPM)
Water In Fuel 4 Beep... 2 Yes
Minutes Off
Over Speed Continuous Yes (activated at
Beep 5800 RPM)
Coolant Sensor Failure No Yes
MAP Sensor Failure No Yes
Air Temperature Sensor No Yes
Failure
Ignition Coil Failure No Yes
Injector Failure No Yes
Oil Pump Electrical Failure Yes Yes Yes (Limits to
3000 RPM)
Block Water Pressure Yes Yes Yes Yes (Limits to
1200 RPM)
Horn Failure N/A Yes No
Battery Voltage too high No Yes Yes – If battery
(16V) or too low (11V) or voltage is less
very low (9.5V) than 10.4 V, RPM
is reduced to
3000. If voltage is
9.5V or less, RPM
is reduced to idle.
Over Heat Cylinder Head/ Continuous Yes Yes
Compressor Beep
Throttle Sensor Failure Continuous Yes 1997 Model –
Intermittant Speed does not
Beeping reduce if only 1
sensor fails. 1998
Model – Speed
does reduce if 1
sensor fails. On
1997 and 1998
Models RPM is
reduced to Idle
speed if both sen-
sors fail.

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Warning System Operation

LOW OIL LEVEL

a - Oil Light

The system is activated when the oil in the engine mounted oil reservoir tank drops below 50
fl. oz. (1.5 liters) You still have an oil reserve remaining for 50 minutes of full speed operation.
NOTE: The engine mounted oil reservoir tank (located beneath the top cowl) along with the
remote oil tank will have to be refilled.
The oil light will come on and the warning horn sounds a series of four short tones. If you
continue to operate the outboard, the light will stay on and the horn will sound four short
tones every two minutes. The engine has to be shut off to reset the warning system.

OIL PUMP NOT FUNCTIONING ELECTRICALLY

b
a - Oil Light
b - Check Engine Light

The system is activated if the oil pump stops functioning electrically. No lubricating oil is be-
ing supplied to the engine. Stop the engine as soon as possible. Continuing to operate the
engine can result in severe engine damage.
The oil light and check engine light will come on and the warning horn will begin sounding.
The warning system will automatically reduce and limit the engine speed to 3000 RPM. The
engine has to be shut off to reset the warning system.

ENGINE OVERHEAT

a - Temperature Light
The system is activated when the engine temperature is too hot.
The temperature light will come on and the warning horn will begin sounding. The warning
system will automatically limit the engine speed to 3000 RPM.

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IGNITION COIL, SENSOR, INJECTOR OR WARNING HORN NOT FUNCTIONING

a - Check Engine Light

The system is activated if an ignition coil, sensor, injector or warning horn is not functioning
correctly.
The check engine light will turn on.

THROTTLE SENSOR NOT FUNCTIONING

a
a - Check Engine Light

The system is activated if the throttle sensors are not functioning correctly.
The check engine light will turn on and the warning horn will begin sounding.

WATER SEPARATING FUEL FILTER IS FULL OF WATER

a

a - Water Detection Light

The water level detection warning is activated when water in the water separating fuel filter
reaches the full level. The water can be removed from the filter.
The water detection light will come on and the warning horn will begin sounding a series of
four beeps. If you continue to operate the outboard, the light will stay on and the horn will
sound every two minutes.

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ENGINE OVER-SPEED PROTECTION SYSTEM

a - Warning Horn

The system is activated when the engine speed exceeds the maximum allowable RPM.
Anytime the engine over-speed system is activated, the warning horn begins to sound contin-
uously. The system will automatically reduce the engine speed to within the allowable limit.
NOTE: Engine speed should never reach the maximum limit to activate the system unless
the propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty.

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Panel Mount Remote Control Wiring Installation

a b
BLK = Black
GRY = Gray
r BLU = Blue
PUR = Purple
f TAN = Tan
25 WHT = White
e LIT = Light
d g h
c
i
u

s
k l
j o
n
p
m
t
q

25 Liquid Neoprene
a - (+) 12 Volt Terminal j - Multi-Function Gauge
b - (–) Ground Terminal k - Multi-Function Adapter
c - Speedometer Harness
d - Tachometer l - To Fuel Sender
e - Tachometer Signal (Optional)
Terminal m - To Oil Sender (Optional)
f - Connect Wires Together n - Two Wire Harness
with Screw and Hex Nut o - Ignition/Choke Switch
(3 Places); Apply Liquid p - Low Oil Sender Lead
Neoprene to Connec- q - Over Temperature
tions and Slide Rubber Switch Lead
Sleeve Over Each Con- r - Panel Mount Remote
nection. Control
g - Power Trim Connector s - To Engine
h - Horn t - To Engine
i - 8 Pin Harness u - Neutral Safety Switch
Connector Lead

90-855348R02 NOVEMBER 2002 Page 2D-25

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Notes:

Page 2D-26 90-855348R02 NOVEMBER 2002

 1997 Model 200 DFI Wiring Diagra

1 2 3 10
4 5 6 7 8 9
1 - Fuel Injector #1
2 - Fuel Injector #2
3 - Fuel Injector #3
4 - Direct Injector #1
5 - Direct Injector #2
6 - Direct Injector #3
7 - Direct Injector #4
8 - Direct Injector #5
9 - Direct Injector #6
10- Oil Pump
11- EAP Sensor
12- MAP Sensor
13- T.P.S. Sensor (Inner)
14- T.P.S. Sensor (Outer)
15- Crank Position Sensor
16- Water Sensor
17- Air Temperature Sensor
18- Shift Switch
19- Low-Oil Switch
20- Cylinder Head Temperature Sensor
21-Knock Sensor
22- Fuel Pump (In Vapor Separator)
23- 60 Ampere Alternator
24- Fuel Pump Circuit 20 Ampere Fuse
25- Ignition Coils and Oil Pump 20 Ampere
Fuse
26- Starting Circuit 20 Ampere Fuse
27- Fuel/Air Injector Circuits 20 Ampere Fuse
28- Main Power Relay
44
29- Remote Control Connector
30- 12 Volt Battery
31- Starter Solenoid
32- Temperature Gauge
33- Low Oil Light
34- Over-Heat Light
35- Water In Fuel Light
36- Check Engine Light
37- Digital Diagnostic Terminal
Connector
38- Starter 42 41 40
39- To Remote Trim Switch
40- Cowl Mounted Trim Switch 53 52 51
41- Trim-Down Relay 50 49 48 47 46 45
42- Trim-Up Relay 38
43- Trim Pump
44- Electronic Control Module
45- Coil #6
46- Coil #5
 1998/1999 Model 200/225 DFI Wiring Di
1 - Fuel Injector #1 1 2 3 4 5 6 8 9
7 10
2 - Fuel Injector #2
3 - Fuel Injector #3
4 - Direct Injector #1
5 - Direct Injector #2
6 - Direct Injector #3
7 - Direct Injector #4 B A B A B A
8 - Direct Injector #5 B A B A B A B A B A B A A B C D

PNK/ORG
ORG/PNK
PNK/BRN

PNK/RED
BRN/PNK

RED/PNK
9 - Direct Injector #6

WHT/BRN
BRN/WHT

WHT/YEL

WHT/DK.BLU
DK.BLU/WHT
ORG/WHT
WHT/RED
RED/WHT

WHT/ORG

YEL/WHT

WHT/PPL
PPL/WHT

RED/YEL
BLK
LT.BLU/GRN
LT.BLU/BLK
10- Oil Pump
11- MAP Sensor
12- T.P.S. #1 (Inner)
13- T.P.S. #2 (Outer)
14- Crank Position Sensor
15- Air Temperature Sensor
16- Water Sensor
17- Shift Switch
18- Low-Oil Switch
19- a – Cylinder Head Temperature Switch (Starboard Side)
19- b – Cylinder Head Temperature Switch (Port Side)
20- Digital Diagnostic Terminal Connector BLK/TAN

21- Compressor Temperature Sensor BLK

BLK
22- Fuel Pump Circuit 20 Ampere Fuse

WHT/DK.BLU

LT.BLU/GRN

LT.BLU/RED
23- Fuel/Air Injector Circuit 20 Ampere Fuse

WHT/ORG
ORG/WHT

BRN/WHT
WHT/BRN

ORG/PNK

BLK/ORG

PNK/BRN
BRN/PNK

PPL/YEL
24- Starting Circuit 20 Ampere Fuse GRN/PPL 1

BLK
BLK
PPL/WHT 2
25- Ignition Coils and Oil Pump Circuits 20 Ampere Fuse PNK/PPL 3
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
26- Fuel Pump #2 (Outside Vapor Separator) YEL/WHT 4
PNK/YEL 5
27- Fuel Pump #1 (Inside Vapor Separator) RED/WHT 6
28- 12 Volt Battery PNK/RED 7
DK.BLU/WHT 8
29- Starter Solenoid WHT/PPL 9
30- To Remote Control Trim Switch PPL/PNK 10
11
31- Remote Control WHT/YEL
YEL/PNK 12 12345678 12345678 12345678910 1
910
11
1121
3141
56 910
11
1123
14 16 12
15 11
34115161
7182
920
32- Auxilliary WHT/RED 13 1719
182202
122 34 1719
1822
02 34 22
122 22
3245
2262
78230
9331

33- Check Engine Light RED/PNK

PNK/DK.BLU
14
15
34- Water In Fuel Light DK.BLU/PNK 16

35- Over-Heat Light GRN/YEL

GRN/RED
17
18
38
36- Low Oil Light BLK 19
37- Temperature Gauge BLK/TAN 20
BLK

BLK/TAN 21
38- Electronic Control Module GRN/BLU 22
39- Main Power Relay GRN/ORG
GRN/BRN
23
24
3
40- Trim Down Relay 41 40 39
41- Trim Up Relay
42- Cowl Mounted Trim Switch
PNK/DK.BLU
DK.BLU/PNK

43- Trim Pump

42
GRN/ORG
GRN/BRN

GRN/RED

GRN/BLU

GRN/PPL
GRN/YEL
RED/YEL

RED/YEL
RED/YEL

RED/YEL
RED/YEL

RED/YEL
PNK/PPL
PPL/PNK

PNK/YEL
YEL/PNK

44- 60 Ampere Alternator

BLK

BLK

BLK
BLK

BLK

BLK
45- Starter
46- Ignition Coil #6 B A B A B A A B C A B C A B C A B C A B C A B C

47- Ignition Coil #5

UP
48- Ignition Coil #4 DN
49- Ignition Coil #3

87a

87a

87a
30
85

87
30
85

87

30

86

86
85

87
86
50- Ignition Coil #2

GRN/WHT

GRN/WHT
RED

GRN

BLK
BLK

BLK

BLK
RED
BLU
RED/PPL

RED

RED/WHT
YEL/PPL
LT.BLU/WHT

LT.BLU/WHT

PPL
51- Ignition Coil #1
52- Fuel Injector #4
53- Fuel Injector #5 54 53 52
54- Fuel Injector #6 51 50 49 47 46
48
 FUEL PUMP

FUEL SYSTEM
Section 3A - Fuel Pump
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Checking for Restricted Fuel Flow
Fuel Pump Pressure @ W.O.T. . . . . . . . . . 3A-1 Caused by Anti-Siphon Valves . . . . . . . . . 3A-4
Fuel Pump Pressure @ Idle . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-1
3A-1
Checking Fuel Pump Lift (Vacuum) . . . . . . . .
Vacuum Test Troubleshooting . . . . . . . . . .
3A-5
3A-5 3
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-2
3A-3
Fuel Pump Removal/Disassembly . . . . . . . . .
Cleaning/Inspection . . . . . . . . . . . . . . . . . . . . .
3A-7
3A-8
A
Fuel Pump Description/Operation . . . . . . . . . 3A-4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8
Fuel Pump Specifications . . . . . . . . . . . . . . 3A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10

Specifications
Fuel Pump Pressure @ W.O.T.
Maximum – 10 psi (68.5kPa)
Normal – 6-8 psi (41.0 – 54.8kPa)
Minimum – 4 psi (27.4kPa)
Fuel Pump Pressure @ Idle
Normal – 2-3 psi (13.7 – 20.5kPa)
Minimum – 1 psi (6.8kPa)
NOTE: Electric fuel pump pressure, if used in conjunction with engine mechanical fuel
pump, must be limited to no more than 4 psi. (27.4kPa)

Special Tools
Fuel Pressure Gauge 91-16850

90-855348R02 NOVEMBER 2002 Page 3A-1

FUEL PUMP

Fuel Pump



A
 




 

  


 

 


 B






A = TO VAPOR SEPARATOR FUEL INLET FITTING B = TO CYL. BLOCK

Page 3A-2 90-855348R02 NOVEMBER 2002

 FUEL PUMP

Fuel Pump
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
– 1 FUEL PUMP ASSEMBLY
1 1 FUEL PUMP
2 2 CHECK VALVE
3 1 DIAPHRAGM KIT
4 2 RETAINER
5 1 SPRING
6 1 CAP
7 1 SPRING
8 1 CAP
9 1 DIAPHRAGM
10 1 GASKET–boost
11 1 GASKET–pulse
12 1 GASKET
13 1 PLATE
14 1 FITTING
2 SCREW–fuel pump (M5 x 40) 55 6.2
15
2 SCREW–pump to crankcase (M6 x 50) 55 6.2
16 1 BASE
17 2 SPRING CLAMP
18 1 HOSE
19 1 SLEEVE-Insulating (10-1/2 IN.)
20 1 HOSE
21 2 CLAMP (15.3)
22 1 CONNECTOR

90-855348R02 NOVEMBER 2002 Page 3A-3

FUEL PUMP

Fuel Pump Description/Operation

The fuel pump is a crankcase-pressure-operated, diaphragm-type pump. Crankcase pul-
sating pressure (created by the up-and-down movement of piston) is transferred to fuel
pump by way of a passage (hole) between crankcase and fuel pump.
When piston is in an upward motion, a vacuum is created in the crankcase, thus pulling in
a fuel/air mixture (from carburetor) into crankcase. This vacuum also pulls in on the fuel
pump diaphragm, thus the inlet check valve (in fuel pump) is opened and fuel (from fuel tank)
is drawn into fuel pump.
Downward motion of the piston forces the fuel/air mixture out of the crankcase into the cylin-
der. This motion also forces out on the fuel pump diaphragm, which closes the inlet check
valve (to keep fuel from returning to fuel tank) and opens the outlet check valve, thus forcing
fuel to the carburetors.
Fuel Pump Specifications
NOTE: Fuel pressure should be measured between in-line fuel filter and carburetors.
Fuel Pump Pressure at Wide Open Throttle:
Maximum: 10 PSI
Normal: 6 - 8 PSI
Minimum: 4 PSI (With Water Separating Fuel Filter)
Fuel Pump Pressure at Idle:
Normal : 2 - 3 PSI
Minimum: 1 PSI
Electric Fuel Pump Pressure, if used, must be limited to no more than 4 PSI.
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
While anti-siphon valves may be helpful from a safety stand-point, they clog with debris, they
may be too small, or they may have too heavy a spring. The pressure drop across these
valves can create operational problems and/or powerhead damage by restricting fuel flow
to the fuel pump and carburetors. Some symptoms of restricted (lean) fuel flow which could
be caused by use of an anti-siphon valve are:
1. Loss of fuel pump pressure
2. Loss of power
3. High speed surging
4. Pre-ignition/detonation (piston dome erosion)
5. Outboards cuts out or hesitates upon acceleration
6. Outboards runs rough
7. Outboard quits and cannot be restarted
8. Outboard will not start
9. Vapor lock
Since any type of anti-siphon device must be located between the outboard fuel inlet and
fuel tank outlet, a simple method of checking if such a device (or bad fuel) is a problem
source, is to operate the outboard with a separate fuel supply which is known to be good,
such as a remote fuel tank.
If it is found that the anti-siphon valve is the cause of the problem, either 1) remove the anti-
siphon valve or 2) replace it with a solenoid-operated fuel shut off valve.

Page 3A-4 90-855348R02 NOVEMBER 2002

 FUEL PUMP

Checking Fuel Pump Lift (Vacuum)

The square fuel pump is designed to lift fuel (vertically) about 60 in. (1524 mm) if there are
no other restrictions in the system using a fuel hose that is 5/16 in. (7.9 mm) minimum diame-
ter. As restrictions are added, such as filters, fittings, valves etc., the amount of fuel pump
lift decreases.
Fuel pump vacuum and air bubbles in the fuel supply can be checked with a vacuum gauge,
a t-fitting and a clear piece of fuel hose. Connect the clear hose between the inlet fitting on
the pulse driven fuel pump and the vacuum gauge t-fitting keeping the t-fitting as close as
possible to the pump. Connect the fuel line from the fuel tank to the remaining connection
on the t-fitting.

a
57721_1

a - Clear Hose
b - T-fitting
c - Vacuum Gauge
Vacuum Test Troubleshooting
PUMP CAPABILITY TEST
Before proceeding with the system vacuum test, confirm that the pulse fuel pump is capable
of supplying the required vacuum. To do this, start the engine and run at idle speed. Pinch
off/restrict the fuel supply hose between the vacuum gauge and fuel tank, using tubing
clamp.

Normal Reading 2.5 in. of vacuum (mercury) or higher, pro-

ceed to fuel system leak test.

Reading below 2.5 in. vacuum (mercu- • Pump check valves defective, replace
ry) valves
• Pump diaphragm defective, replace
diaphragms
• Air leak in pump, rebuild pump with new
gasket, check fitting for leaks
• Low crankcase pressure, check for
crankcase leaks or plugged pulse pump
pressure/vacuum passageways.

90-855348R02 NOVEMBER 2002 Page 3A-5

FUEL PUMP

FUEL SYSTEM LEAK TEST

This test is done with the engine running and the tubing clamp removed. The clear hose that
was installed previously is used to view the fuel flow to the pulse pump.

No air bubbles seen in clear hose No air leaks, perform vacuum test (follow-
ing)

Air bubbles seen in clear hose Air leak on intake side of fuel system
• Pick up tube in fuel tank leaking
• Outlet fitting at fuel tank leaking
• Fuel inlet hose not properly clamped at
fitting
• Leaking fuel tank valve
• Fuel line from kicker engine connected
into fuel line of main engine.

SYSTEM VACUUM TEST

The system vacuum test is normally performed at idle speed. As engine RPM increases,
there will be a slight increase in vacuum. This increase should not exceed normal readings
at any RPM.

Normal Reading Below 2.5 in. of Vacuum (mercury)

Reading above 2.5 in. of vacuum (mer- Restriction within the fuel system
cury) • Restricted anti-siphon valve
• Restricted or malfunctioning primer bulb
• Kinked or collapsed fuel hose
• Plugged water separating fuel filter (in the
boat)
• Restriction in fuel line thru-hull fitting
• Restriction in fuel tank switching valves
• Plugged fuel tank pick-up screen

Page 3A-6 90-855348R02 NOVEMBER 2002

 FUEL PUMP

Fuel Pump Removal/Disassembly

IMPORTANT: Fuel pump diaphragm and gaskets should not be re-used once fuel
pump is disassembled.
1. Disconnect fuel hoses from fuel pump.
2. Disconnect pulse hose.
3. Remove two mounting screws.
4. Remove fuel pump from engine.

c
b

d
e
d
a

53643

a - Fuel hose from tank to fuel pump

b - Fuel hose from fuel pump to carburetors/EFI water separator
c - Pulse hose
d - Mounting screws
e - Fuel pump

5. Disassemble fuel pump.

Reverse View of Pump Body

52362_2

90-855348R02 NOVEMBER 2002 Page 3A-7

FUEL PUMP

Cleaning/Inspection
1. Clean fuel pump housing, check valves, pulse chamber and pump base in solvent and
dry all but check valves with compressed air.
2. Inspect each check valve for splits or chips.
3. Inspect boost springs for weakness or breakage.
4. Inspect fuel pump housing, pulse chamber and base for cracks or rough gasket surface
and replace if any are found.
5. Inspect fitting on fuel pump housing for loosening or any signs of fuel or air leaks. Re-
place or tighten fitting if a leak is found.

Reassembly
1. Insert retainer through plastic disc and rubber check valve.

23601_2
a - Retainer
b - Plastic Disc

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

50161_3

Page 3A-8 90-855348R02 NOVEMBER 2002

 FUEL PUMP

3. With retainer installed in pump body, break retainer rod from retainer by bending side-
ways.

23601_4
a - Rod
b - Retainer Cap

4. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap
rod down into retainer until flush with top of retainer.

23601_5
a - Rod
b - Retainer Cap

5. Place boost spring into pump body and place cap onto boost spring.

50161
a - Boost Spring
b - Pump Body
c - Cap

90-855348R02 NOVEMBER 2002 Page 3A-9

FUEL PUMP

6. Assemble remainder of components as shown and install retaining screws through to

align.

Reverse View of Pump Body

52362_2

Installation
1. Install pump onto engine. Torque to 55 Ib. in. (6.2 Nm).
2. Install hoses onto proper fittings and secure with sta-straps.
3. Run engine and check for leaks.

Page 3A-10 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

FUEL SYSTEM
Section 3B - Direct Fuel Injection
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Reed Block Assembly Removal . . . . . . . . 3B-32
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Reed Block Assembly Installation . . . . . . . 3B-33
1997 Model 200 DFI Fuel/Air
Management System . . . . . . . . . . . . . . . . . . . . 3B-4
Air Temperature Sensor Removal . . . . . .
Air Temperature Sensor Installation . . . . .
3B-33
3B-33 3
1997 Model 200 DFI Reed Block/Flywheel
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6
Throttle Plate Assembly Removal . . . . . . .
Throttle Plate Assembly Installation . . . . .
3B-34
3B-34
B
1997 Model 200 DFI Vapor Separator . . . . . . 3B-8 Vapor Separator Disassembly . . . . . . . . . . 3B-34
1997 Model 200 DFI Fuel Rails . . . . . . . . . . . 3B-10 Vapor Separator Reassembly . . . . . . . . . . 3B-37
1998/1999 Model 200/225 DFI Fuel/Air Air Plenum Installation . . . . . . . . . . . . . . . . 3B-39
Management . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Vapor Separator Installation . . . . . . . . . . . 3B-40
1998/1999 Model 200/225 DFI Air Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . 3B-42
Handler Components . . . . . . . . . . . . . . . . . . . . 3B-14 Fuel Rail Disassembly . . . . . . . . . . . . . . . . 3B-46
1998/1999 Model 200/225 DFI Fuel Pressure Regulator . . . . . . . . . . . . . . 3B-51
Vapor Separator . . . . . . . . . . . . . . . . . . . . . . . . 3B-16 Air Pressure Regulator . . . . . . . . . . . . . . . . 3B-55
1998/1999 Model 200/225 DFI Fuel Rails . . 3B-18 Tracker Valve . . . . . . . . . . . . . . . . . . . . . . . . 3B-59
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . 3B-20 Fuel Rail Cleaning . . . . . . . . . . . . . . . . . . . . 3B-62
DFI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-22 Direct Injector Removal . . . . . . . . . . . . . . . 3B-64
Installation and Removal of High Fuel Rail and Direct Injector Installation . 3B-67
Pressure Fuel and Air Hoses . . . . . . . . . . . . . 3B-25 Air Compressor . . . . . . . . . . . . . . . . . . . . . . 3B-68
High Pressure Hose Removal . . . . . . . . . . 3B-25 Air Compressor Disassembly/Reassembly . 3B-71
High Pressure Hose Installation . . . . . . . . 3B-26 Air Compressor Flow Diagram . . . . . . . . . 3B-72
Fuel Management Assembly Removal . . . . . 3B-27 Air Compressor Pressure Test . . . . . . . . . 3B-73

Specifications
Fuel Pressure 89 ± 2 psi (613.5 ± 13.8 kPa)
Air Pressure 79 ± 2 psi (544.0 ± 13.8 kPa)
Fuel/Air Differential 10 psi (68.5 kPa)
Electric Fuel Pump Amperage Draw 6-9 Amps
Fuel Injector Ohm Resistance 1.8 ± 0.1Ω
Direct Injector Ohm Resistance 1.3 ± 0.3Ω

90-855348R02 NOVEMBER 2002 Page 3B-1

DIRECT FUEL INJECTION

Special Tools
1. Single Fuel/Air Pressure Gauge 160 PSI – 91-16850A2
NOTE: Note: To convert 100 psi gauge 91-16850A1 to 160 psi gauge, order upgrade
91-16850--1.

2. Dual Fuel/Air Pressure Gauge 160 PSI – 91-852087A1

55295
3. Adaptors to convert pressure gauge 91-852087A1/A2 to an A3
NOTE: 2 Adaptors 91-803804A2 are required to convert a pressure gauge set.

a b c d e
a - 1/2 in. to 1/4 in. Adapter – if required
b - Female quick disconnect
c - Male quick disconnect
d - Screw on Schrader
e - O-ring (25-803803)

Page 3B-2 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

4. Screw (5mm x 25mm) (2 each) – 10-40073 25

5. Flat Washer (2 each)

6. Seal/Teflon Ring Installation Tool – 91-851980

56015
7. Seal/Teflon Ring Sizing Tool – 91-851980–1

8. Volt/Ohm Meter – 91-99750A1

9. Clamp Tool – 91-803146T

10. Regulator Installation Tool (91-889431)

90-855348R02 NOVEMBER 2002 Page 3B-3

DIRECT FUEL INJECTION

1997 Model 200 DFI Fuel/Air Management System

7
8

3
4 6
3
9
10
11
2

20
14

19
18
13 15
12 2 5 17
16

Page 3B-4 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1997 Model 200 DFI Fuel/Air Management System

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 AIR MANAGEMENT
2 2 THROTTLE POSITION INDICATOR
3 8 BUSHING
4 4 GROMMET
5 1 PLATE
6 1 HOUSING
7 2 SCREW
8 2 LOCKWASHER
9 4 WASHER
10 4 LOCKWASHER
11 4 SCREW (M6 x 25) 45 5.1
12 4 SCREW (M5 x 30) 30 3.4
13 4 WASHER
14 4 LOCKWASHER
15 1 TEMPERATURE SENSOR
16 3 SCREW (M4 x 10) Drive Tight
17 3 LOCKWASHER
18 1 O RING
19 12 SCREW 18 24.4
20 12 WASHER

90-855348R02 NOVEMBER 2002 Page 3B-5

DIRECT FUEL INJECTION

1997 Model 200 DFI Reed Block/Flywheel Cover

5
C

3
96

12
C

4
D 2
96
7
11
14
10 6

15 9

18
18

19
16 13
26

20 21 9
22
23
24 25 A
9
9 Loctite 567 PST Pipe Sealant B
17
136 Loctite Quick Tite

Page 3B-6 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1997 Model 200 DFI Reed Block/Flywheel Cover

REF. TORQUE
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 FLYWHEEL COVER
2 3 GROMMET
3 1 GROMMET
4 1 RESTRICTOR (8MM)
5 1 FILTER, Air
6 2 CLAMP
7 2 SCREW (M6 x 12) 100 11.3
8 3 GASKET
9 1 ADAPTOR PLATE
10 1 GASKET
11 1 BACKING PLATE
12 1 GASKET
13 12 SCREW (M6 x 25) 100 11.3
14 6 REED BLOCK (1-Piece)
15 12 SCREW (M6 x 1 x 25) 90 10.2
16 1 OIL PUMP
17 1 GASKET
2 SCREW (M8 x 35) 17.0 23.0
18
1 SCREW (M8 x 133.35)
19 1 WASHER
20 1 BRACKET-Oil Pump
21 2 SCREW (M8 x 45)
22 1 ELBOW
23 1 STA–STRAP
24 1 TUBING (23 IN.)
25 1 FITTING
26 1 TUBING (31 IN.)
– 1 GASKET SET
– 1 POWERHEAD
A - To Compressor
B - To Oil Tank
C - Apply Loctite Quick Tite to outer diameter of flywheel cover grommets. Apply a light coat of 2-4-C with Teflon
to the flywheel cover posts which pass through the grommets.
D - Air Restrictor Valve - Located inside of air filter outlet tube. This valve should be removed if outboard is oper-
ated above 5000 ft. (1524 m) sea level.

90-855348R02 NOVEMBER 2002 Page 3B-7

DIRECT FUEL INJECTION

1997 Model 200 DFI Vapor Separator

21

24
15 24

14 20
21

4
20
16 21

17 21
11
12
13
10
19 20
11

11 18

A
22

23

2
4
21
1

5
6
7
8

9
A = TO FLYWHEEL COVER

Page 3B-8 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1997 Model 200 DFI Vapor Separator

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 VAPOR SEPARATOR BODY KIT
2 1 O RING
3 1 DRAIN SCREW KIT Drive Tight
4 1 COVER KIT
5 3 BOLT 45 5.1
6 3 WASHER
7 3 WASHER
8 3 GROMMET
9 3 COLLAR
10 1 TUBING (2-3/4 IN.)
11 AR STA-STRAP
12 1 CHECK VALVE
13 1 TUBING (2-1/2 IN.)
14 1 MAP SENSOR
15 2 SCREW (M6 x 12) 100 11.3
16 5 SCREW 30 3.4
17 4 SCREW 30 3.4
18 1 FLOAT KIT
19 1 FLOAT VALVE KIT 10 1.1
20 1 FUEL PUMP
21 1 COVER KIT-Fuel Pump
22 1 PLATE
23 1 FUEL STRAINER
1 NUT (M5) 8 0.9
24
1 NUT (M4) 6 0.7

90-855348R02 NOVEMBER 2002 Page 3B-9

DIRECT FUEL INJECTION

1997 Model 200 DFI Fuel Rails

3
14
6
5 A
10 8 27
21 23

22
16
1 22
16
2 14
4

6 24
7 22
20 25
B
3 19
12 17
9
26
22
28
18 16

16
22
C
D
15

11 14
12

14

14
13

28
30
14 2 Cycle Premium Outboard Oil 29
30
27

A = TO COMPRESSOR B = TO FUEL PUMP (OUT) C = WATER IN D = FUEL RETURN

Page 3B-10 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1997 Model 200 DFI Fuel Rails

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 3 SCREW 100 11.3
2 1 PULLEY
3 1 AIR COMPRESSOR
4 1 REED PLATE KIT
5 4 SCREW (M8 x 35) 12 27.1
6 2 O-RING
7 1 O-RING
8 1 SEAL
9 4 SCREW 19 25.8
10 1 HOSE
11 1 FUEL RAIL (STARBOARD) (Includes tracker valve)
12 6 INJECTOR (DIRECT)
– 1 SEAL KIT
13 1 HOSE
14 1 HOSE
15 1 TUBING (8 IN.)
16 AR STA-STRAP
17 1 FUEL RAIL (PORT)(Includes regulators)
18 1 TUBING (11 IN.)
19 1 CHECK VALVE
20 1 TUBING (2-1/2 IN.)
21 1 TUBING (8 IN.)
22 AR CLAMP
23 1 HOSE
24 1 HOSE
25 1 FUEL COOLER
26 1 HOSE
27 1 TUBING (8 IN.)
28 1 TUBING (19 IN.)
29 1 CHECK VALVE CHECK VALVE DESIGN
30 2 CLAMP

90-855348R02 NOVEMBER 2002 Page 3B-11

DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Fuel/Air Management

4 3 4

2
7
B
6 32

31
30 33
27 21
34

32
8 35

29 32
A 25
13 12
28 14 22 36

13 41 32
25
15
11 37
26
25 10
42
24

25
17
16 9

39
20
18
40 38 23
13 Mercop_2
13 19
A = TO AIR ATTENUATOR B = TO FUEL COOLER

Page 3B-12 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Fuel/Air Management

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 COVER
2 1 GROMMET
3 1 GROMMET
4 2 GROMMET
5 1 AIR FILTER
6 1 COVER
7 4 SCREW (M5 x 13)
8 1 AIR HANDLER ASSEMBLY
9 1 DECAL-Caution-Start in Gear
10 1 BRACKET
11 1 FUEL PUMP
12 1 ELBOW
13 4 CLAMP
14 1 TUBING (18 IN.)
15 1 INSULATING SLEEVE
16 1 FITTING ASSEMBLY
17 1 O RING
18 1 TUBE FITTING
19 1 TUBING (5-1/2 IN.)
20 1 DECAL-EPA Label Information
21 1 SCREW (M6 x 50) 120 13.6
22 1 CLAMP-(STARBOARD)
23 11 SCREW (M6 x 45) 120 13.6
24 1 TUBING (1-1/4 IN.)
25 4 STA STRAP
26 1 CANISTER-Vent
27 1 AIR ATTENUATOR
28 1 TUBING (15 IN.)
29 1 FITTING-Straight
30 1 CLIP
31 1 SCREW (10-16 x 3/4 IN.)
32 4 CLAMP
33 1 HOSE
34 1 INSULATING SLEEVE (9-1/2 IN.)
35 1 CHECK VALVE
36 1 TUBING (17 IN.)
37 1 INSULATING SLEEVE (17 IN.)
38 1 CABLE
39 1 WASHER
40 1 WASHER
41 1 CABLE TIE (14 IN.)
42 4 SCREW (M6 X 16) 100 11.5

90-855348R02 NOVEMBER 2002 Page 3B-13

DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Air Handler Components

4
2
5
35
22
36
B
28

27 30
32 29
31 26
33 24 6
29 36
37 27
8
29
A 7
25

19 21

13 12
20

11
3
9
10
1 18 7 8

34
14
23
15 17 16

A = TO OIL TANK B = TO AIR COMPRESSOR

Page 3B-14 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Air Handler Components

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
– 1 AIR HANDLER
1 1 ADAPTOR PLATE KIT
2 1 GASKET
3 1 GASKET
4 6 REED BLOCK
5 12 SCREW (M6 x 1)
6 1 DISTRIBUTOR
7 6 BUSHING
8 6 GROMMET
9 3 SCREW (M8 x 35)
10 3 WASHER
11 1 AIR PLENUM KIT
12 1 FITTING
13 1 ELBOW
14 1 GASKET
15 1 TEMPERATURE SENSOR
16 3 SCREW
17 3 LOCKWASHER
18 2 SCREW (M4 x 10)
19 1 THROTTLE BODY KIT
20 1 O-RING
21 4 SCREW
22 1 PLATE
23 3 SCREW 17 22.4
24 1 BRACKET
25 3 SCREW 17 22.4
26 6 TUBING (6 IN.)
27 13 STA-STRAP
28 1 TUBING (36 IN.)
29 3 STA-STRAP
30 2 SCREW (M8 x 40) 28 38.0
31 1 BRACKET
32 1 FITTING
33 1 FITTING
34 1 RETAINER
35 1 OIL PUMP
36 2 GASKET
37 1 TUBING (25 IN.)
– 1 GASKET SET

= COMPONENT OF ENGINE GASKET SET (27-832934A98)

90-855348R02 NOVEMBER 2002 Page 3B-15

DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Vapor Separator

2

4
5

18

7
10
8
9 3
19 13

11
8 12

15

14

16
17

Page 3B-16 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Vapor Separator

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 COVER KIT
2 1 ELBOW
3 1 SEAL
4 1 FITTING KIT-Pump Outlet
5 1 O RING
6 7 SCREW 30 3.4
7 1 GASKET
8 1 FLOAT KIT
9 1 FLOAT PIN
10 1 NEEDLE VALVE
11 1 SCREW 10 1.1
12 1 FUEL PUMP KIT
13 1 SLEEVE
14 1 BOWL KIT
15 1 SEAL
16 1 PLUG KIT
17 2 ELBOW
18 1 FUEL FILTER ASSEMBLY
19 1 PROBE

90-855348R02 NOVEMBER 2002 Page 3B-17

DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Fuel Rails

2 3 
13 15
28
15 12
 14
15
15
24 4
29

30
28

31 28
22
28 32 11

28
28
 16
21

7 6
32 28


8
28

23 17
54 28 18
19 27 27
5

9
20
26 90°

27 9

25 27
 10
26

110 4-Stroke Outboard Oil

A = TO TELL TALE B = TO VAPOR SEPARATOR C = TO FUEL COOLER D = TO TEE FITTING ON BLEED
SYSTEM E = TO ADAPTOR PLATE F = TO STRAINER IN TOP OF BLOCK

Page 3B-18 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1998/1999 Model 200/225 DFI Fuel Rails

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
AIR COMPRESSOR
1 1
(See breakdown on Air Compressor Components)
2 5 SCREW (M6 x 12) 190 21.5
3 1 PULLEY
4 4 SCREW (M8 x 50) 20 27.1
5 1 FUEL RAIL (PORT)
6 6 INJECTOR
7 6 CUPPED WASHER
8 1 STA-STRAP
9 2 HOSE - Fuel/Air Balance
10 1 INSULATING SLEEVE (27 IN.)
11 1 FUEL RAIL (STARBOARD)
12 1 TUBING (2-1/2 IN.)
13 1 CHECK VALVE
14 1 TUBING (9 IN.)
15 4 STA-STRAP
16 1 TUBING
17 4 SCREW (M5 x 10) 100 11.3
18 4 CLAMP
19 4 STUD (M10 x 91)
20 4 NUT 33 45.1
21 1 HOSE - Fuel Supply
22 1 INSULATING SLEEVE (27 IN.)
23 1 HOSE (2 IN.) - Fuel Return
24 1 HOSE
25 1 TUBING - Air Dump
26 2 CLAMP (14.0)
27 4 CLAMP
28 9 CLAMP (15.3)
29 1 HOSE-Air Supply
30 1 INSULATING SLEEVE (16 IN.)
31 1 FITTING
32 4 SCREW (M5 X 8) 70 8

90-855348R02 NOVEMBER 2002 Page 3B-19

DIRECT FUEL INJECTION

Air Compressor

1 9

8
17

7
9

ÇÇÇ
ÇÇÇ
ÇÇÇ
19
20

18
8 ÇÇÇ
11
15
12
10 20 22
21
23
11
13
26
25

14

16
24

Page 3B-20 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Air Compressor
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 AIR COMPRESSOR
2 1 END CAP
3 1 SNAP RING
4 4 SCREW (M6 x 20) 100 11.3
5 1 O-RING
6 1 O-RING
7 1 CONNECTING ROD
8 1 PISTON ASSEMBLY
9 2 LOCK RING
10 1 REED PLATE ASSEMBLY
11 2 O-RING
12 1 O-RING
13 1 SEAL
14 1 COMPRESSOR HEAD
15 1 FITTING-Straight
16 4 SCREW (M8 x 35) 20 27.1
17 1 ELBOW
18 1 ELBOW
19 1 ELBOW
20 2 PIPE PLUG
21 1 CONNECTOR
22 1 FITTING
23 1 O-RING
24 1 TEMPERATURE SENSOR
25 1 RETAINER
26 1 SCREW (M8 x 12) 20 27.1

90-855348R02 NOVEMBER 2002 Page 3B-21

DIRECT FUEL INJECTION

DFI Operation

 
 

  







 



 



  










1 - Fuel Tank 18 - Plenum Assembly

2 - Fuel Pressure Regulator 19 - Oil Pump
3 - Tracker Diaphragm 20 - Oil Storage Tank
4 - Air/Fuel Rails 21 - Standard Remote Oil
5 - Air Pressure Regulator Reservoir
6 - Orifice 22 - Vapor Separator
7 - Ignition Coils 23 - Water Separating Fuel
8 - Engine Control Module Filter
(ECM) 24 - Return Fuel Line
9 - Hose 25 - Fuel Pump
10 - Serpentine Belt 26 - Primer Bulb
11 - Filter 27 - Fuel Injector
12 - Compressor 28 - Direct Injector
13 - Throttle Position Sen- 29 - Spark Plug
sors (TPS) 30 - Engine Temperature
14 - MAP Sensor Sensor
15 - Reed Valves 31 - Crank Position Sensor
16 - Crankshaft 32 - Crankcase
17 - Shutters

Page 3B-22 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

AIR INDUCTION THROUGH CRANKCASE

Combustion air enters the cowl through holes located in top aft end of cowl. The cowl liner
directs air to bottom of powerhead. This limits exposure of salt air to components inside en-
gine cowl.
Once inside the cowl the air enters the plenum through the throttle shutters (located in plenum
assembly). The air then continues through reed valves and into crankcase. The throttle shut-
ters are actuated by the throttle shaft. Mounted onto a separate shaft are two throttle position
sensors (TPS). These sensors tell the engine control unit (ECM) the position of the throttle.
Two TPS’s are installed on DFI engines for safety redundancy. If one TPS should fail, the dash
mounted CHECK ENGINE light will flash and warning horn will sound. The 1997 Model en-
gine will continue to perform normally; the 1998 Model engine speed will be reduced to 3000
RPM. If both TPS’s should fail, engine speed will be reduced to idle. DFI engines require large
amounts of air into cylinders at idle speed. To accomplish this, the throttle shutters are partially
open at low engine speeds. The dual TPS system reads shaft movement in both directions,
one reads movement up (increasing resistance), the other reads the same movement down
(decreasing resistance). The ECM reads both and calculates the throttle shutter position.

AIR COMPRESSOR SYSTEM

Air from inside engine cowl is drawn into compressor through the flywheel cover. This cover
acts like a muffler to quiet compressor noise and contains a filter to prevent ingestion of debris
into the compressor. A restrictor is located between the filter and compressor. The restrictor
design lowers compressor intake noise and should be removed at altitudes above 5000 feet.
The compressor is driven by a serpentine belt from a pulley mounted on the crankshaft, and
is automatically self‘-adjusted using a single idler pulley. This air compressor is a single cylin-
der unit containing a connecting rod, piston, rings, bearings, reed valves, and a crankshaft.
It is water cooled to lower the temperature of the air charge and is lubricated by oil from the
engine oil pump assembly. As the compressor piston moves downward inside the cylinder,
air is pulled through the filter, reed valves and into the cylinder. After the compressor piston
changes direction, the intake reeds close and exhaust reeds open allowing compressed air
into the hose leading to air/fuel rails. An orifice is installed in the line between the compressor
and air rail to smooth pulses transmitted from the compressor to the air rail.
Air/fuel rails contain two passages; one for fuel, the other for air. The air passage is common
between all cylinders included in the rail. A hose connects the starboard rail air passage to
the air compressor. Another hose connects the starboard rail air passage to the port air rail
passage. An air pressure regulator limits the amount of pressure developed inside air pas-
sages to approximately 10 psi below pressure of fuel inside fuel passages (i.e. 80 psi air vs
90 psi fuel). Air exiting the pressure regulator is returned to the exhaust adaptor and exits
through the propeller.
FUEL
Engine fuel is stored in a typical fuel tank. A primer bulb is installed into the fuel line to allow
priming of fuel system. A crankcase mounted pulse driven diaphragm fuel pump draws fuel
through fuel line, primer bulb, fuel pump assembly and then pushes fuel through a water
separating fuel filter. This removes any contaminates and water before fuel reaches the va-
por separator. Fuel vapors are bled into the air compressor inlet in front of flywheel cover.
This prevents vapor lock of the electric fuel pump assembly (mounted in vapor separator).
The electric fuel pump is different than the fuel pump that is utilized on standard EFI engines
(non DFI), and is capable of developing fuel pressures in excess of 90 psi. Fuel inside the
rail must remain pressurized at exactly 10 psi over air rail pressure or ECM (map) calibra-
tions will be incorrect. Fuel from the vapor separator is supplied to the top of one fuel rail.
A fuel line connects the bottom of the first rail to the opposite fuel rail. Fuel is stored inside
the rail until an injector opens.

90-855348R02 NOVEMBER 2002 Page 3B-23

DIRECT FUEL INJECTION

A fuel pressure regulator controls pressure in the fuel rails, and allows excess fuel to return
into the vapor separator. The fuel regulator not only regulates fuel pressure but also regu-
lates it at approximately 10 p.s.i. higher than whatever air rail pressure is. The fuel regulator
diaphragm is held closed with a spring that requires 10 p.s.i. to force the diaphragm off the
diaphragm seat. The back side of the diaphragm is exposed to air rail pressure. As air rail
pressure increases, fuel pressure needed to open the regulator will equally increase. Exam-
ple: If there is 50 p.s.i. of air pressure on air rail side of the diaphragm, 60 p.s.i. of fuel pres-
sure is required to open the regulator. The return fuel line to the vapor separator is water
cooled. This design is used to prevent cold fuel from the fuel tank hitting hot fuel returning
from the fuel rail and flashing off the light ends (boiling over).
To equalize pulses developed by the pumps (both air and fuel) a tracker diaphragm is installed
in the starboard rail. The tracker diaphragm is positioned between fuel and air passages. It
is a rubber diaphragm which expands and retracts depending upon which side of the dia-
phragm senses the pressure increase (pulse).

OIL
Oil in this engine is not mixed with fuel before entering the combustion chamber. Oil is stored
inside a standard remote oil reservoir. Crankcase pressure will force oil from the remote oil
reservoir into the oil storage tank on the side of the powerhead. Oil will flow from the oil storage
tank into the oil pump. The oil pump is a solenoid design. It is activated by the ECM and in-
cludes 7 pistons with corresponding discharge ports. The oil pump is mounted directly onto
the powerhead. Each cylinder is lubricated by one of the discharge ports. The oil is discharged
into the crankcase in front of the reed blocks. The seventh passage connects to the hose that
leads to the air compressor for lubrication. Excess oil from the compressor returns into the
plenum and is ingested through the crankcase.
The ECM will change the discharge rate of the oil pump, depending upon engine demand.
The ECM will also pulse the pump on initial start-up to fill oil passages, eliminating the need
to bleed the oil system. The ECM provides additional oil for break in, as determined by its
internal clock. The oil ratio ranges from 300 - 400:1 at idle to 60:1 at WOT. A DFI engine will
use less oil than a non-DFI engine.

ELECTRICAL
The electrical system consists of the ECM, crank position sensor (flywheel speed & crank-
shaft position), throttle position sensor (TPS), MAP sensor, engine temperature sensor,
ignition coils and injectors (fuel & direct). The engine requires a battery to start (i.e. the igni-
tion and injection will not occur if the battery is dead). The system will run off of the alternator.

OPERATION
The operation of the system happens in milliseconds (ms); exact timing is critical for engine
performance. As crankshaft rotates, air is drawn into crankcase through throttle shutters,
into plenum, and through reed valves. As piston nears bottom-dead-center, air from the
crankcase is forced through the transfer system into the cylinder. As crankshaft continues
to rotate, the exhaust and intake ports close. With these ports closed, fuel can be injected
into the cylinder. The ECM will receive a signal from the TPS, engine temperature sensor
and crank position sensor (flywheel speed and position sensor). With this information the
ECM refers to the fuel calibration (maps) to determine when to activate (open and close)
injectors and fire ignition coils. With piston in the correct position, the ECM opens the fuel
injector, 90 psi fuel is discharged into a machined cavity inside air chamber of the air/fuel
rail. This mixes fuel with the air charge. Next the direct injector will open, discharging the
air/fuel mixture into the combustion chamber. The direct injector directs the mixture at the
bowl located in top of the piston. The piston’s bowl directs the air/fuel mixture into the center
of the combustion chamber. This air fuel mixture is then ignited by the spark plug.

Page 3B-24 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Compressor Notes: To aid in starting when air rail pressure is low, and before compressor has
time to build pressure, the direct injector is held open by the ECM. This allows compression from
inside the cylinders to pressurize air rail faster (1 or 2 strokes, or 60° of crankshaft rotation).
Idle Notes: Idle quality is controlled by fuel volume and fuel timing. Throttle shutters will be open
at idle speeds. The shift cut-out switch will interrupt fuel to 3 of the cylinders to assist in shifting.
The TPS signals the ECM to change the fuel and spark without movement of the throttle
shutters. The throttle cam is manufactured to allow the TPS sensor shaft to move before
opening the throttle shutters.
The crankshaft position sensor is different from the standard 3.0 litre sensor. The crank posi-
tion sensor is a hall effect sensor and serves two functions (flywheel speed and position).

Installation and Removal of High Pressure Fuel and Air

Hoses
CAUTION
To prevent failure of high pressure fuel and air hoses, proper tools must be used
when removing or reinstalling high pressure hoses. Sharp side cutter or end cutter
should be used to remove hose clamps. Clamp Tool 91-803146T must be used to
install new hose clamps. Do not use screw-type clamps to secure hoses as damage
to hose may result.

High Pressure Hose Removal

Use a sharp side cutter or end cutter to peel back end of clamp.

CAUTION
Do not cut through clamp. Hose damage may occur.

56962

56963

CAUTION
Do not use sharp side cutter or end cutter to crimp clamps. Damage to clamp may
occur resulting in hose leakage.

90-855348R02 NOVEMBER 2002 Page 3B-25

DIRECT FUEL INJECTION

High Pressure Hose Installation

1. Use Clamp Tool to install new hose clamps.

56959

56963

56960
a - Hose Clamp
b - Clamp Tool 91-803146T

2. Do not over crimp hose clamps. Over tight clamps may damage hose. Too loose clamps
may allow fuel or air to leak pass end of hose.
a b c

56961
a - Too Loose
b - Too Tight – Roll Crimp Touching
c - Correct Tightness – Small Air Gap Between Roll Crimp

Page 3B-26 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Fuel Management Assembly Removal

CAUTION
Fuel system must be bled off prior to removal of fuel system components.
1. De-pressurize fuel system by wrapping a clean cloth around fuel pressure port valve
(STARBOARD fuel rail) and depressing valve core.

b
a

55923
a - Starboard Fuel Rail
b - Fuel Pressure Port

2. Place suitable container underneath vapor separator drain plug and remove plug.

a
55933
a - Drain Plug

90-855348R02 NOVEMBER 2002 Page 3B-27

DIRECT FUEL INJECTION

3. Disconnect water separator sensor lead.

4. Disconnect external electric fuel pump harness connector.

55937
a - Sensor Lead
b - External Electric Fuel Pump Harness Connector

5. Disconnect internal electric fuel pump harness connector.

6. Remove sta-strap securing air temperature sensor harness to fuel hose.
7. Remove vapor separator vent hose to air plenum.
NOTE: Upper fuel hose goes to electric pump beside fuel/water separator. Lower fuel hose
goes to fuel cooler.

c
a

c 55933
a - Internal Electric Fuel Pump Harness Connector
b - Sta-Strap
c - Fuel Hoses

Page 3B-28 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

8. Remove the fuel inlet hose from the pulse fuel pump.
9. Remove the fuel outlet hose and fuel return hose from the vapor separator.
10. Remove 3 mounting bolts and remove separator.
NOTE: Front fuel hose goes to top of port fuel rail. Rear fuel hose goes to side of port fuel
rail.

55937
a - Fuel Inlet Hose
b - Fuel Outlet Hose
c - Fuel Return Hose

11. Disconnect throttle cam link rod and the Throttle Position Sensor link rod.

a - Throttle Cam Link Rod

b - Throttle Position Sensor Link Rod

90-855348R02 NOVEMBER 2002 Page 3B-29

DIRECT FUEL INJECTION

12. Disconnect MAP Sensor hose and compressor oil return hose from air management as-
sembly.

55936

a - MAP Sensor Hose

b - Oil Return Hose

13. Disconnect oil hoses from oil pump adaptor plate.

14. Remove and plug oil inlet hose to oil pump.
1997 Model

a
55194

a - Oil Inlet Hose

Page 3B-30 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1998 Model

b
55989

a - Oil Hoses
b - Oil Inlet Hose

15. Remove 12 allen screws securing fuel management assembly to powerhead and re-
move assembly.
1997 Model

53645

a - Allen Screws

90-855348R02 NOVEMBER 2002 Page 3B-31

DIRECT FUEL INJECTION

16. Remove 12 bolts securing air management assembly to crankcase and remove assembly.
1998 Model

55971
a - Air Management Assembly
b - Bolts (12 each)

Reed Block Assembly Removal

1. Remove 2 screws securing air plenum to reed plate assembly.
2. Remove 3 bolts securing oil pump adaptor plate to air plenum assembly.

55971
a - Screws (2 each)
b - Bolts (3 each)

Page 3B-32 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Reed Block Assembly Installation

1. Secure oil pump adaptor plate to air plenum with 3 bolts. Torque bolts to 16 lb. ft. (21.7 Nm).
2. Secure air plenum to reed plate with 2 screws. Drive screws tight.

Air Temperature Sensor Removal

1. Remove 3 screws securing sensor and remove sensor.

55971

a - Sensor

Air Temperature Sensor Installation

1. Secure sensor in air plenum with 3 screws. Drive screws tight.

90-855348R02 NOVEMBER 2002 Page 3B-33

DIRECT FUEL INJECTION

Throttle Plate Assembly Removal

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

55936
a - Bolts
b - Throttle Plate Assembly

Throttle Plate Assembly Installation

1. Secure throttle plate assembly to air plenum with 4 bolts. Torque bolts to 100 lb. in.
(11.3 Nm).

Vapor Separator Disassembly

1. Remove 7 screws securing separator cover and remove cover.
a a a

a
a a

56055
a - Screws (7 each)

Page 3B-34 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

2. Inspect seal in fuel pump chamber of separator tank for cuts and abraisions. Replace
seal if necessary. If seal is serviceable, apply 2-4-C with Teflon to seal lips.

56056
a - Seal (Seal shoulder faces UP/OUT)

3. Fuel pump may be removed from cover by wiggling slightly while pulling outward.
IMPORTANT: DO NOT twist pump during removal as wire harness may be damaged.
4. Disconnect harness from pump to separate pump from cover. Inspect filter screen for
debris. Screen may be pried out of pump and cleaned as required.

b
c a
56057
a - Filter Screen
b - Harness Connector
c - Pump

90-855348R02 NOVEMBER 2002 Page 3B-35

DIRECT FUEL INJECTION

5. Inspect seal above fuel pump for cuts or abrasions. Replace seal if necessary. Apply
2-4-C with Teflon to seal lips.
a

56058
a - Seal (Seal shoulder faces out)

6. Loosen screw securing float assembly and remove float. Inspect float for deterioration
or fuel retention. Replace float as required.

b
a
56058
a - Screw
b - Float

7. Remove phenolic sealing plate and inspect imbedded neoprene seal on both sides of
plate for cuts or abraisions. Replace plate/seal assembly as required.
a

56059
a - Plate
b - Seal

Page 3B-36 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Vapor Separator Reassembly

1. Reinstall phenolic sealing plate onto vapor separator cover.
2. Secure float, needle and pivot pin assembly to separator cover with screw. Torque screw
to 10 lb. in. (1.1 Nm).
a

c
d

b
e
56058
a - Sealing Plate
b - Float
c - Needle
d - Pivot Pin
e - Screw [Torque to 10 lb. in. (1.1 Nm)]

3. Apply 2-4-C with Teflon to lips of seal in separator cover.

56058
a - Seal (Seal shoulder faces out)

90-855348R02 NOVEMBER 2002 Page 3B-37

DIRECT FUEL INJECTION

4. Connect electrical harness to fuel pump. Inspect fuel pump filter screen for debris. Re-
move screen and clean as required.
5. Seat fuel pump and harness into separator cover being careful not to pinch harness.

a
c b 56057
a - Harness
b - Filter
c - Fuel Pump

6. Apply 2-4-C with Teflon to lips of seal in separator tank.

a
56056
a - Seal (Seal shoulder faces up/out)

Page 3B-38 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

7. Install separator cover with pump onto separator tank.

8. Secure cover to tank with 7 screws. Torque screws to 30 lb. in. (3.4 Nm).
a a a

a
a a 56055
a - Screws [Torque to 30 lb. in. (3.4 Nm)]

Air Plenum Installation

1. Secure plenum to crankcase with 12 bolts. Torque bolts to 100 lb. in. (11.3 Nm).

55971

a - Air Plenum
b - Bolts [Torque to 100 lb. in. (11.3 Nm)]

90-855348R02 NOVEMBER 2002 Page 3B-39

DIRECT FUEL INJECTION

Vapor Separator Installation

1. Secure vapor separator to air plenum with 3 bolts. Torque bolts to 45 lb. in. (5.1 Nm).
2. Connect fuel inlet hose from pulse pump.
3. Connect fuel outlet hose and fuel return hose to vapor separator.

55937
a - Mounting Bolts (3) – Torque to 45 lb. in. (5.1 Nm)
b - Fuel Inlet Hose
c - Fuel Outlet Hose
d - Fuel Return Hose

4. Connect water separator sensor lead to water separator.

Page 3B-40 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

5. Connect external electric fuel pump harness.

55937
a - Sensor Lead
b - Harness Connector

6. Connect internal electric fuel pump harness.

7. Secure air temperature sensor leads to fuel hose with sta-strap.

c
55933

a - Electric Fuel Pump Harness Connector

b - Sta-Strap
c - Fuel Return Hose

90-855348R02 NOVEMBER 2002 Page 3B-41

DIRECT FUEL INJECTION

Fuel Rail Removal

CAUTION
Fuel system must be bled off prior to removal of fuel system components.
1. De-pressurize fuel system by wrapping a clean cloth around fuel pressure port valve
(STARBOARD fuel rail) and depressing valve core.
1997 Model

b
a

55923
a - Starboard Fuel Rail
b - Fuel Pressure Port

1998/1999 Model

56119
a - Starboard Fuel Rail
b - Fuel Pressure Port

Page 3B-42 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

2. Remove fuel injector harness from each injector by compressing spring clip with flat tip
screwdriver while pulling on connector.

b
c

55922
a - Spring Clip
b - Fuel Injector
c - Harness Connector

3. Remove fuel inlet hose, fuel outlet hose and air hose from fuel rail.
1997 Model

c b 55931
a - Air Hose
b - Air Outlet Hose
c - Fuel Hose

90-855348R02 NOVEMBER 2002 Page 3B-43

DIRECT FUEL INJECTION

1998/1999 Model
IMPORTANT: If air inlet or outlet hose clamps are removed, it is recommended that
the respective air inlet and outlet hose be replaced to avoid the possibility of future
air leaks.

a
c
d

b
c

e d

56140
a - Air Hose
b - Retainer
c - Allen Screws (remove)
d - Air Hose Clamp
e - Fuel Hose

NOTE: On 1997 Models only, there is a filter in the air line adaptor on the starboard fuel rail.
Inspect filter for debris and clean as required.

55924

a - Filter

Page 3B-44 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

NOTE: It is recommended that direct injectors remain in the cylinder head (if they are not
to be replaced) while removing the fuel rail. The direct injectors have a teflon seal which may
expand if the injector is removed from the head. This expansion may cause reinstallation
difficulty or require the replacement of the seal.
4. Remove 2 nuts securing fuel rail.
5. As fuel rail is removed, use a flat tip screwdriver to hold direct injectors in cylinder head.

b 55926
a - Fuel Rail
b - Direct Injectors

90-855348R02 NOVEMBER 2002 Page 3B-45

DIRECT FUEL INJECTION

Fuel Rail Disassembly

The starboard fuel rail contains 3 fuel injectors and a tracker valve.
The port fuel rail contains 3 fuel injectors, 1 fuel fuel regulator and 1 air regulator.
NOTE: Each fuel/air inlet or outlet hose adaptor has an O-ring seal. This O-ring should be
inspected for cuts or abraisions and replaced as required when fuel rail is disassembled for
cleaning.
1997 Model

a a
b
c

a
a

a
a

e
e

56007
a - Fuel Injector d - Air Regulator
b - Tracker Valve e - Hose Adaptor
c - Fuel Regulator (contains O-ring seal)

1998/1999 Model
a a
a
b d

a
c

a a

56122

a - Fuel Injector c - Air Regulator

b - Fuel Regulator d - Tracker Valve

Page 3B-46 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

FUEL INJECTOR REMOVAL

1. Remove 2 screws securing injector.
1997 Model 1998/1999 Model

56006 56125
a - Screws

2. Gently pry up on injector to loosen O-ring adhesion and remove injector.

1997 Model

56005
1998/1999 Model

56125

90-855348R02 NOVEMBER 2002 Page 3B-47

DIRECT FUEL INJECTION

3. 1997 Models Only – Remove fuel nozzle from fuel rail.

NOTE: Move nozzle with small tip screwdriver, then tap fuel rail on hard surface to dislodge
nozzle. On 1998 models, the fuel injector is positioned differently on the fuel rail and sepa-
rate fuel nozzles are not required.

56004
a - Nozzle

4. Inspect fuel injector and fuel nozzle orifices for foreign debris; o-rings for cuts or abrai-
sions and plastic components for heat damage. Replace components as required.
1997 Model

c
b
c
56016
c

a - Fuel Injector
b - Fuel Nozzle (1997 Model Only)
c - O-Rings

1998/1999 Model

56124
a - Fuel Injector
b - O-Rings

Page 3B-48 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

5. An ohm test of the fuel injector may be made by connecting test leads to injector termi-
nals. Ohm reading should be 1.8 ± 0.1 ohm.
OHMS 60 40 30 20 15 10
100 5
200
20 0
10 10 30
5 15
0 40
VOLTS0 4 6 8 20
2
DC AMPS 0 10

DCV ACV

X1
DVA

56002

FUEL INJECTOR INSTALLATION

1. Insert fuel nozzle with orifice facing direct injector opening.
1997 Model

b
a
56001
56004
a - Fuel Nozzle (1997 Model Only)
b - Direct Injector Opening
c - Nozzle Installed (1997 Model Only)

90-855348R02 NOVEMBER 2002 Page 3B-49

DIRECT FUEL INJECTION

NOTE: Apply anti-seize grease (obtain locally) or 2-4-C with Teflon to fuel injector attaching
screw threads.
2. Insert fuel injector into fuel rail with connector pins facing towards bottom of fuel rail.
NOTE: Turn injector back-and-forth slightly to seat injector O-rings in fuel rail, while securing
injector with retainer and 2 screws. Torque screws to 70 lb. in. (7.9 Nm).
1997 Model

a
b
c

56006
a - Injector
b - Retainer
c - Screws [Torque to 70 lb. in. (7.9 Nm)]
1998/1999 Model

56125

a - Screws [Torque to 70 lb. in. (7.9 Nm)]

Page 3B-50 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Fuel Pressure Regulator

Regulator Closed Regulator Open

1 1
2 2
3 3
4 4
13 13
5 5

12 ÇÇ ÇÇ 7
6 12
ÇÇ ÇÇ 7
6

11 11
8 8
10 10

9 9

1 - Top Cover 10 - Fuel Return Passage

2 - Expansion Plug (to Vapor Separator)
3 - O-ring 11 - Fuel Inlet Passage
4 - Spring Retainer (from Electric Fuel
5 - Spring Pump)
6 - O-ring 12 - Diagram Assembly
7 - Diaphragm Seat 13 - Calibration Screw (Do
Not Turn)
8 - Air Rail
9 - Air Passage (from Air
Compressor)

The fuel pump is capable of delivering more fuel than the engine can consume. Excess fuel
flows through the fuel pressure regulator, interconnecting passages/hoses, fuel cooler, and back
to the vapor separator tank. This constant flow of fuel means the fuel system is always supplied
with cool fuel; preventing formation of fuel vapor bubbles and minimizing chances of vapor lock.
The fuel pressure regulator is calibrated to raise fuel pressure to 10 psi above air pressure.
The fuel regulator is mounted on the port fuel rail near the top. This regulator relies on both air
and spring pressure to control fuel pressure. Inside the regulator assembly is a 10 lb. spring,
which holds the diaphragm against the diaphragm seat. Contact between the diaphragm and
diaphragm seat closes the passage between the incoming fuel (from electric fuel pump) and
the fuel return passage.
When engine is not running (no air pressure on spring side of diaphragm), fuel pressure required
to move the diaphragm is 10 psi. When engine is running, air pressure from the air compressor
(80 psi) is routed through air passages, to spring side of fuel pressure regulator diaphragm.
Air pressure (80 psi) and spring pressure (10 psi) combine to regulate system fuel pressure
to 90 psi - or 10 psi higher than air pressure in the DFI system fuel/air rails.

90-855348R02 NOVEMBER 2002 Page 3B-51

DIRECT FUEL INJECTION

FUEL REGULATOR REMOVAL

1. Remove 4 screws securing regulator and remove regulator.
1997 Model

b 55999

a - Screws
b - Fuel Regulator

1998/1999 Model

b
56126

a - Screws
b - Fuel Regulator

2. Inspect regulator diaphragm for cuts or tears.

3. Inspect regulator housing O-ring for cuts and abrasions. Replace components as re-
quired.

c b d
a

56127
a - Diaphragm
b - Spring
c - Cup
d - O-Ring

Page 3B-52 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

FUEL REGULATOR INSTALLATION

NOTE: Apply a light coat of 2-4-C with Teflon to diaphragm and o-ring groove area on the
fuel rail to aid in the retention of diaphragm and O-ring on fuel rail during reassembly.
1. Position diaphragm on fuel rail.

00207

RAIL SIDE SPRING SIDE

a - Diaphragm

2. Position O-ring on fuel rail.

00208

a - O-Ring

3. Position spring and cup onto diaphragm.

00206

a - Spring
b - Cup

90-855348R02 NOVEMBER 2002 Page 3B-53

DIRECT FUEL INJECTION

4. Place cover over spring/cup/diaphragm assembly. Place the alinement pins from the
special tool (91-889431) through two of the regulator cover mounting holes and thread
them into the corresponding threaded holes in the fuel rail.

a
a

00205
a - Alignment Pins

5. Push the regulator cover against the fuel rail. While holding the cover down install two
cover retaining screws through the open holes in the cover. Thread the two screws down
until the head of the screw makes contact with the cover. Do not torque screws at this
time.

00204

a - Screw

6. Remove the alignment pins and install the two remaining screws. Torque in two stages,
First torque to 50 lb in. (5.6 Nm) then to 70 lb in. (8 Nm).

 

a a



56126
a - Screws

Page 3B-54 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Air Pressure Regulator

Regulator Closed Regulator Open

1 2 1 2

3 3
12 12
4 4

5 5

11 ÇÇÇ ÇÇ 6
11 ÇÇ ÇÇ 6

10 10
7 7
9 9

8 8

1 - Top Cover
2 - Expansion Plug
3 - Spring Retainer
4 - Vent
5 - Spring
6 - Diaphragm Seat
7 - Air Rail
8 - Air Passage (from Air Compressor)
9 - Excess Air Passage (to Exhaust Adaptor)
10 - Fuel Inlet Passage (from Electric Fuel Pump)
11 - Diagram Assembly
12 - Calibration Screw (Do Not Turn)

The air pressure regulator is designed to limit the air pressure inside the rails to approxi-
mately 80 psi.
The air regulator uses a spring (pressure) to control air pressure. This spring (80 psi) holds
the diaphragm against the diaphragm seat. The contact area blocks (closes) the air inlet
passage from excess air passage. As air pressure rises (below diaphragm), it must reach
a pressure equal to or greater than the spring pressure holding the diaphragm closed. Once
this pressure is achieved, the spring compresses, allowing the diaphragm to move. The dia-
phragm moves away from the diaphragm seat, allowing air to exit through the diaphragm
seat, into the excess air passage leading to the exhaust adaptor plate.

90-855348R02 NOVEMBER 2002 Page 3B-55

DIRECT FUEL INJECTION

AIR REGULATOR REMOVAL

1. Remove 4 screws securing regulator and remove regulator.
1997 Model
a

a
56000
a - Screws
b - Air Regulator

1998/1999 Model
a

a
56129
a - Screws
b - Air Regulator

2. Inspect regulator diaphragm for cuts or tears. Replace as required.

56130
a - Diaphragm
b - Spring
c - Cup

Page 3B-56 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

AIR REGULATOR INSTALLATION

NOTE: Apply a light coat of 2-4-C with Teflon to diaphragm groove area on the fuel rail to
aid in the retention of diaphragm and o-ring on fuel rail during reassembly.
NOTE: Apply anti-seize grease (obtain locally) or 2-4-C with Teflon to regulator attaching
screw threads.
NOTE: Due to the stiffness of the regulator spring, it is recommended that Regulator Instal-
lation Tool 91-889431 be utilized when installing the air regulator cover.
1. Position diaphragm, spring and cup onto fuel rail.
c b

56131

RAIL SIDE SPRING SIDE

a - Diaphragm
b - Spring
c - Cup

2. Position cover over diaphragm spring and install Regulator Installation Tool.

59356
a - Regulator installation tool (91-889431)

90-855348R02 NOVEMBER 2002 Page 3B-57

DIRECT FUEL INJECTION

3. Gently apply pressure to cover with installation tool until cover is seated against fuel rail.

59357

4. Install two retaining screws. Remove installation tool. Install remaining two screws and
torque four screws in two stages first torque to 50 lb in. (5.6 Nm) then to 70 lb in. (8 Nm).

a
a

59360

a - Screws – torque to 8 Nm (70 lb. in.)

Page 3B-58 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Tracker Valve
Engine Off (No Pressure) Engine at Operating Pressures
1 1
2 3 2
3

4 9 4
9
5 5

8 8
6 6

7 7

1 - Top Cover 6 - Air Rail

2 - Spring Retainer (not 7 - Air Passage (from Air
shown) Compressor)
3 - Spring 8 - Fuel Inlet Passage
4 - O-ring (from Electric Fuel
5 - Diaphragm (at rest) Pump)
Seat 9 - Diagram Assembly

The tracker is located on the starboard fuel/air rail assembly. The DFI system must maintain
a constant 10 psi pressure difference between the fuel pressure and air pressure in the rails,
at all times. The tracker is designed to maintain the 10 psi differential when the air or fuel
pressure suddenly raises (i.e. pulses generated by the compressor’s piston or by the fuel
injectors opening and closing). The tracker contains a spring on the air side of the dia-
phragm. This spring positions the diaphragm against the diaphragm’s seat (when the en-
gine is not running).
After the engine starts, and the fuel and air pressure reach normal operating range, the fuel
pressure will compress the spring and the diaphragm will move slightly away from the seat
(to a neutral position). At this point the pressure on both sides of the tracker diaphragm is
equal (10 psi spring pressure + 80 psi air pressure = 90 psi fuel pressure).
Any air or fuel pressure spikes on one side of the diaphragm will transfer this pressure rise
to the other system (air or fuel) on the other side of the diaphragm. Both systems will have
a momentary increase in pressure so that the 10 psi difference between air and fuel system
pressures can be maintained.
NOTE: To prevent excessive wear in the seat, the tracker is calibrated to allow the dia-
phragm to be slightly away from the seat during normal operation.

90-855348R02 NOVEMBER 2002 Page 3B-59

DIRECT FUEL INJECTION

TRACKER VALVE REMOVAL

1. Remove 4 screws securing tracker valve and remove tracker assembly.
1997 Model 1998/1999 Model
a a

a 56012 a 56135
a - Screws

2. Inspect tracker diaphragm for cuts tear.

3. Inspect tracker cover O-ring for cuts and abraisions. Replace components as required.
1997 Model

a
c
b

56013

a - Diaphragm
b - Spring
c - O-Ring

1998/1999 Model

56136
a - Diaphragm
b - Spring
c - O-Ring

Page 3B-60 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

TRACKER VALVE INSTALLATION

NOTE: Apply a light coat of 2-4-C with Teflon to tracker diaphragm and cover o-ring to aid
in their retention on fuel rail while reinstalling tracker valve to fuel rail.
NOTE: Apply anti-seize grease or 2-4-C with Teflon to tracker valve attaching screw threads.
1. Position diaphragm, spring and o-ring onto fuel rail.
1997 Model
c a b

56011
a - Diaphragm
b - Spring
c - O-Ring

1998/1999 Model
c
b

a
a - Diaphragm
b - Spring
c - O-Ring

2. Place cover over diaphragm/spring/o-ring assembly and secure with 4 screws. Torque
screws to 70 lb. in. (7.9 Nm).
1997 Model 1998/1999 Models
b b

b 56012
a b 56135
a - Cover
b - Screws [Torque to 70 lb. in. (7.9 Nm)]

90-855348R02 NOVEMBER 2002 Page 3B-61

DIRECT FUEL INJECTION

Fuel Rail Cleaning

After all fuel injectors, air regulator, tracker valve, fuel regulator, inlet hoses and outlet hoses
have been removed, the fuel rails may be flushed out with a suitable parts cleaning solvent.
Used compressed air to remove any remaining solvent.
Torque 1/2″ (12.7mm) hose fittings on fuel rails to 28 lb. ft. (38.0 Nm).
Torque 9/16″ (14.3mm) hose fittings on fuel rails to 35 lb. ft. (47.5 Nm).
1997 Model Top View

b
55995
a - 1/2″ (12.7mm) Fitting
b - 9/16″ (14.3mm) Fitting

Bottom View

b
55996
a - 1/2″ (12.7mm) Fitting
b - 9/16″ (14.3mm) Fitting

Page 3B-62 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

1998/1999 Model

a
c

a - Air Hose
b - Retainer
c - Allen Screws [Torque to 60 lb. in. (6.8 Nm)

1998/1999 Model

56140

a - Air Hose
b - Fuel Hose
c - Allen Screws [Torque to 60 lb. in. (6.8 Nm)]

90-855348R02 NOVEMBER 2002 Page 3B-63

DIRECT FUEL INJECTION

Direct Injector Removal

1. Remove harness connectors from direct injectors.
2. Remove direct injector from cylinder head.

55928
a - Direct Injector (3 each cylinder head)
b - Harness Connector

3. Inspect injector teflon sealing ring (white) for signs of combustion blowby (teflon ring will
be streaked brownish black). If blowby is present, replace teflon sealing ring. If blowby
is not present, sealing ring may be reused.
4. Inspect O-rings and cork gasket for cuts or abraisions. Replace components as required.

ÄÄ
ÄÄ
c a

b
a - Teflon Sealing Ring
b - Cork Gasket
c - O-Rings

Page 3B-64 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

5. If teflon seal requires replacement, use teflon ring installation tool to slide new seal onto
injector. Following installation of teflon ring, the teflon ring sizing tool (91-851980-1) can
be used to compress the teflon seal to aid in the installation of the injector into the cylin-
der head.
1997 Model

Ä
Ä
Ä
Ä
Ä
Ä
a e
b d
c
a - Teflon Seal
b - Teflon Ring Installation Tool (91-851980)
c - Cork Gasket
d - O-Ring
e - O-Ring

1998/1999 Model

a b c c

a - Teflon Seal
b - Teflon Ring Installation Tool (91-851980)
c - O-Ring

90-855348R02 NOVEMBER 2002 Page 3B-65

DIRECT FUEL INJECTION

6. An ohm test of the direct injector may be made by connecting test leads to injector termi-
nals. Ohm reading should be 1.3 ± 0.3 ohm.
OHMS 60 40 30 20 15 10
100 5
200
20 0
10 30
10
5 15
0 40
VOLTS 0 4 6 8 20
2
DC AMPS 0 10

DCV ACV

X1
DVA

a 56003
a - Direct Injector

7. Carbon buildup on tip of direct injector may be removed by use of a brass wire hand
brush.
a

b
56017
a - Direct Injector
b - Tip

Page 3B-66 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

NOTE: If cylinder head is going to be replaced, remove cup washers from each direct injector
port by prying out with a flat tip screwdriver. Reinstall washers with retainers into new cylinder
head. Washers provide tension between direct injectors, cylinder head and fuel rails.

b a

55927

a - Cup Washer
b - Retainer

Fuel Rail and Direct Injector Installation

1. Use Teflon Ring Sizing Tool (91-851980–1) to compress new teflon sealing rings prior
to installation of injector into cylinder head.
2. Carefully slide fuel rail over mounting studs and onto direct injectors.
IMPORTANT: ALL fuel and air hoses attached to the fuel rails MUST be secured with
stainless steel hose clamps.
3. Secure each fuel rail with 2 nuts. Torque nuts to 33 lb. ft. (44.7 Nm).
4. Reinstall direct injector harness connectors.

a
a

55930
a - Nuts [Torque to 33 lb.ft. (44.7 Nm)]
b - Direct Injector Harness Connectors

90-855348R02 NOVEMBER 2002 Page 3B-67

DIRECT FUEL INJECTION

Air Compressor
Air compressor is a single cylinder, water cooled and lubricated by the outboard oil pump.

Air Compressor Specifications

Air Compressor Type Reciprocating Piston
(1 to 1 ratio with engine RPM)
Compressor Output @ Idle – 80 psi
@ W.O.T. – 110 psi
Cylinder Block Displacement 7.07 cu. in. (116cc)
Cylinder Bore Diameter (Standard) 2.5591 in. (65.0mm)
Taper/Out-of-Round/Wear Maxi-
mum 0.001 in. (0.025mm)
Bore Type Cast Iron
Stroke Length 1.374 in. (34.9mm)
Piston Piston Type Aluminum
Piston Diameter Dimen- 2.5578 ± .0004 in.
sion “A”
at Right
(64.97 ± 0.010mm)
Angle
(90°) to
Piston
Pin

0.500 in.

Piston Ring End Gap

Top Ring 0.0059 - 0.0098 in.
(0.15 - 0.25mm)
Middle Ring 0.0059 - 0.0098 in.
(0.15 - 0.25mm)
Bottom Ring 0.0039 - 0.014 in. (0.10 -
0.35mm)
Reeds Reed Stand Open 0.010 in. (0.25mm)
COMPRESSOR REMOVAL
1. Disconnect battery cables from battery terminals.
2. Remove top cowling.
IMPORTANT: Prior to removing flywheel cover, remove vent hose from fitting on fly-
wheel cover.
3. Remove flywheel cover.
4. Use 1/2 inch (12.7mm) drive on belt tensioner arm to relieve belt tension. Remove belt.
a

55950
a - Belt Tensioner

Page 3B-68 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

CAUTION
If engine has been recently run, air pressure outlet hose fittings may be extremely
hot. Allow components to cool off before beginning disassembly.
5. Disconnect air pressure outlet hose
6. Disconnect water outlet hose (tell-tale).
1997 Model 1998/1999 Models
a b a b

55925
55990
a - Water Outlet Hose
b - Air Outlet Hose

NOTE: On 1998/1999 Models, the water outlet hose (tell-tale) exits the opposite (port) side
of the air compressor.

90-855348R02 NOVEMBER 2002 Page 3B-69

DIRECT FUEL INJECTION

7. Disconnect oil pump inlet hose.

8. Disconnect bleed system inlet hose.
9. Disconnect excess oil return hose.
a b

55947
a - Oil Pump Inlet Hose
b - Bleed System Inlet Hose
c - Excess Oil Return Hose

10. Remove 4 bolts securing air compressor to outboard and remove compressor.

Page 3B-70 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Air Compressor Disassembly/Reassembly

NOTE: If cylinder bore is scored, air compressor must be replaced as an assembly.
NOTE: Piston and rings are not sold separately. They must be replaced as an assembly. The
connecting rod and bearings are not sold separately. They must be replaced as an assembly.
a
n

b
9
c

d 9
14

14 m
e 6
k l
9

ÇÇ
ÇÇ
9
14
ÇÇ i 9

9 9
14
6 Dielectric Grease f
9 Loctite PST Pipe Sealant
g
14 2 Cycle Outboard Oil h j

NOTE: End cap bearing and seal are not sold separately, and must be replaced as an assembly
NOTE: Piston Installation – use metal hose clamp for piston ring compressor. Stagger piston
ring openings.
a - Bolt (3 each) [Torque to 100 lb. in. (11.3 Nm)]
b - Bolt (4 each) [Torque to 100 lb. in. (11.3 Nm)]
c - End Cap Assembly (Inspect bearing for roughness)
d - O-Rings (Inspect for cuts or abrasions)
e - Bolt (4 each) [Torque to 20 lb. ft. (27.1 Nm)]
f - O-Rings (Inspect for cuts or abrasions)
g - Reed Plate (Inspect for broken or chipped reeds/stops) Maximum Reed Stand-
Open - 0.010 in. (0.254mm)
h - O-Rings (Inspect for cuts or abrasions)
i - Cylinder Head (1997 Model)
j - Bolt [Torque to 20 lb. ft. (27.1 Nm)]
k - Bolt [Torque to 20 lb. ft. (27.1 Nm)]
l - Temperature Sensor
m - Bolt [Torque to 20 lb. ft. (27.1 Nm)]
n - Cylinder Head (1998/1999 Model)

90-855348R02 NOVEMBER 2002 Page 3B-71

DIRECT FUEL INJECTION

Air Compressor Flow Diagram

ÎÎ c e

ÎÎ f
ÎÎ
a
g

d
b

w r s j
t
h
v u

l i
q
m

p
o
a - Air Inlet m - Air Regulator (80 PSI)
b - Compressor Air Inlet n - High Pressure Fuel
c - Air Filter (90 PSI)
d - Air Compressor o - Air
e - Inlet Restrictor (1997 p - Air Out (to driveshaft
Models) housing)
f - Compressor Air Intake q - Port Fuel Rail
(also is inlet restrictor r - Air Pressure Test Valve
for 1998 Models) s - Excess Fuel Return to
g - Compressor Air Outlet Vapor Separator
h - Filter Screen t - Fuel Inlet
i - Starboard Fuel Rail u - Fuel Injector
j - Fuel System Pressure v - High Pressure
Test Valve w - Low Pressure
k - Fuel Regulator
l - Tracker Valve

Page 3B-72 90-855348R02 NOVEMBER 2002

 DIRECT FUEL INJECTION

Air Compressor Pressure Test

Install Pressure Gauge Assembly (91-852087A1) to fuel rail pressure test valves. Starboard
rail has fuel pressure test valve. Port rail has air pressure test valve.
NOTE: After 15 seconds of cranking engine with starter motor, air pressure gauge should
indicate 80 PSI and fuel pressure gauge should indicate 90 PSI.

a b

c
d

55959
a - Air Pressure Gauge (Should Indicate 80 PSI)
b - Fuel Pressure Gauge (Should Indicate 90 PSI)
c - Fuel Pressure Test Valve
d - Air Pressure Test Valve

90-855348R02 NOVEMBER 2002 Page 3B-73

DIRECT FUEL INJECTION

FUEL PRESSURE AND AIR PRESSURE TROUBLESHOOTING CHART

PROBLEM CORRECTIVE ACTION

Fuel Pressure and Air Pressure are Both Low 1. Inspect air compressor air intake (air filter in fly-
wheel cover) for blockage.
2. Remove air compressor cylinder head and
inspect for scuffing of cylinder wall. Inspect for
broken reeds and/or reed stops.
3. Tracker Valve – Remove and inspect diaphragm
for cuts or tears.
4. Air Regulator – Remove and inspect diaphragm
for cuts or tears.
Fuel Pressure Low or Fuel Pressure Drops while 1. Each time key is turned to the RUN position, the
Running (Air Pressure Remains Normal) pump should operate for 2 seconds. If it does not
run, check 20 ampere fuse.
2. If pump runs but has no fuel output, check vapor
separator (remove drain plug) for fuel.
3. If no fuel present in vapor separator, check
fuel/water separator for debris. Check crankcase
mounted fuel pump for output.
4. Check high pressure pump amperage draw.
Normal draw is 6 - 9 amperes; if draw is below 2
amperes, check fuel pump filter (base of pump)
for debris. If filter is clean, replace pump. If
amperage is above 9 amperes, pump is defective
– replace pump.
5. Check low pressure electric fuel pump amperage
draw. Normal draw is 1–2 amperes; if draw is be-
low 1 ampere, check for blockage between pump
inlet fitting and vapor separator tank. If amperage
draw is above 2 amperes, replace pump.
6. Fuel Regulator – Remove and inspect diaphragm
for cuts or tears.

Page 3B-74 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

FUEL SYSTEM
Section 3C - Oil Injection System
Table of Contents
Oil Injection Components . . . . . . . . . . . . . . . . . 3C-2 Purging Air From the Engine Oil
Oil Injection Operation . . . . . . . . . . . . . . . . . . . 3C-4 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-10
1997 Model Oil Flow Schematic . . . . . . . .
1998/1999 Model Oil Flow Schematic . . .
3C-4
3C-5
Oil Pump Activation of Break-in
Sequence for Replacement Powerheads . . 3C-10 3
Oil Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Up Instructions for the
3C-6 Oil Injection Warning Systems . . . . . . . . . .
Electric Oil Pump Test
3C-12 C
Oil Injection System . . . . . . . . . . . . . . . . . . 3C-6 (1997 Models Only) . . . . . . . . . . . . . . . . . . 3C-13
Installing Oil Hoses to Engine . . . . . . . . . . 3C-7 Oil Injection System Troubleshooting
Filling the Oil Injection System . . . . . . . . . 3C-8 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-14
Priming the Oil Injection Pump . . . . . . . . . 3C-8 Engine Mounted Oil Reservoir . . . . . . . . . 3C-15

90-855348R02 NOVEMBER 2002 Page 3C-1

OIL INJECTION SYSTEM

Oil Injection Components

4
5

3
8

9
11 10 

1
2 



  
13

12
14






26

Page 3C-2 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

Oil Injection Components

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 OIL TANK
2 1 DECAL-Reservoir
3 1 SPACER
4 1 SCREW (.164-18 x .375) Drive Tight
5 1 WASHER
6 1 CAP ASSEMBLY
7 1 GASKET
8 1 SWITCH ASSEMBLY
9 3 SCREW (M8 x 35) 168 19.0
10 3 WASHER
11 3 GROMMET
12 3 BUSHING
13 1 TUBING (8 IN.)
14 1 FITTING
15 1 REMOTE OIL TANK HOLD-DOWN KIT
16 1 BUNGY CORD ASSEMBLY
17 1 OIL TANK
18 1 CAP ASSEMBLY
19 1 INSERT
20 1 O RING
21 1 ADAPTOR HOUSING
22 1 O RING
23 1 TUBE
24 1 HOSE
25 7 STA STRAP
26 1 DECAL-Caution Remote Tank

90-855348R02 NOVEMBER 2002 Page 3C-3

OIL INJECTION SYSTEM

Oil Injection Operation

Oil in this engine is not mixed with fuel before entering the combustion chamber. Oil is stored
inside the remote oil tank. Crankcase pressure will force oil from remote oil tank into engine
oil tank on side of powerhead. Oil will flow from the engine oil tank, through oil supply hose
to the oil pump. The oil pump is a solenoid design and is activated by the ECM. It includes
seven oil discharge ports. Six of the discharge ports discharge oil into the intake manifold in
front of the reed blocks. The oil passageways are machined into the intake manifold. The last
discharge port discharges oil through a hose to the air compressor for lubrication. Port and
starboard side bleed systems also supply oil to the air compressor. Excess oil from the com-
pressor returns through hose into the plenum and is ingested through the crankcase.
The ECM will change discharge rate of the oil pump, depending upon engine demand. It will
also pulse pump on initial start up to fill oil passages eliminating need to bleed oil system. The
ECM will signal oil pump to provide additional oil (50:1) for break in, as determined by the
ECM’s internal clock. After break-in, oil ratio ranges from 300 - 400:1 at idle to 60:1 at WOT.

1997 Model Oil Flow Schematic

a f

c d e
b

Cyl #1

Cyl #2

j
Cyl #3

i Cyl #4

Cyl #5

Cyl #6

h
g
a - Oil Hose to Air Com- f - Air Compressor
pressor (Passageway 7) g - Oil Reservoir
b - Excess Oil Return from h - Oil Hose to Oil Pump
Air Compressor i - Oil Pump
c - Starboard Side Bleed j - Oil Passageway (6
System each)
d - Port Side Bleed System k - Intake Manifold
e - In-Line Filter

Page 3C-4 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

1998/1999 Model Oil Flow Schematic

e
a

c d

i
h

56028
a - Oil Hose to Air Compressor
b - Excess Oil Return from Air Compressor to Intake Manifold
c - PORT Side Bleed System Oil Supply Return
Line to Intake Manifold
d - Check Valve
e - Air Compressor
f - Oil Reservoir
g - Oil Input Hose to Oil Pump
h - Oil Passageway (6 each)
i - Intake Manifold
j - Oil Pump

90-855348R02 NOVEMBER 2002 Page 3C-5

OIL INJECTION SYSTEM

Oil Injection

Set Up Instructions for the Oil Injection System

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

CAUTION
If an electric fuel pump is to be used, the fuel pressure at the engine must not exceed
4 psi. If necessary, install a pressure regulator between electrical fuel pump and en-
gine and set at 4 psi maximum.

INSTALLING REMOTE OIL TANK

1. The remote oil tank should be installed in an area in the boat where there is access for
refilling.
2. The tank should be restrained to keep it from moving around, causing possible damage.
Use the oil tank hold down kit provided. Another acceptable means of restraining the
tank would be the use of eye bolts and an elastic retaining strap about the midsection
of the tank. Verify that any metal hooks do not puncture the tank.
NOTE: When installing in tight areas, this tank will be under pressure when the engine is
operating and will expand slightly.
3. Oil hoses when routed through engine well, must be able to extend to the hose fittings
on engine.
4. Oil hoses must be arranged so they cannot become pinched, kinked, sharply bent or
stretched during operation of the outboard.
NOTE: A oil hose extension kit (41729A3) is available for the remote oil tank.

Page 3C-6 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

Installing Oil Hoses to Engine

1. Remove shipping cap from hose fitting.
2. Connect oil hose (“b” with BLUE stripe) to fitting as shown. Secure with sta-strap.
NOTE: The third fitting is a vent and does not get connected.

b c
54448
a - Hose Fitting
b - Oil Hose with BLUE Stripe
c - Fitting

3. Remove shipping cap from pulse fitting.

4. Connect the second oil hose to pulse fitting as shown. Secure with sta-strap.
5. Refer to Section 7 for proper routing of oil hoses thru clamp in the bottom cowl.
1997 Models 1998/1999 Models

e
e d
d - Pulse Fitting
e - Second Oil Hose

90-855348R02 NOVEMBER 2002 Page 3C-7

OIL INJECTION SYSTEM

Filling the Oil Injection System

1. Fill remote oil tank with the recommended oil listed in the Operation and Maintenance
Manual. Tighten fill cap.

a - Fill Cap

2. Remove fill cap from the engine oil tank and fill the tank with oil. Reinstall the fill cap.

b
a

54446
a - Engine Oil Reservoir
b - Fill Cap

Priming the Oil Injection Pump

1997 MODELS
Before starting engine for the first time, or for an engine that ran out of oil, or was
drained of oil, prime the oil injection pump. Priming will remove any air that may be in the
oil supply hose.

b
54437
a - Oil Injection Pump
b - Oil Supply Hose

CAUTION
Oil supply hose between the engine oil tank and Electric oil pump must be purged
of air before starting engine.

Page 3C-8 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

CAUTION
Prior to initial engine startup, remove oil hose between the oil pump and air com-
pressor. Manually fill the hose with TC-W3 Premium Plus 2 Cycle Outboard.
Prime the oil injection pump as follows:
1. Shift outboard to NEUTRAL position.
2. Turn the ignition key switch to the “ON” position.

3. Within the first 10 seconds after the key switch has been turned on, push in the shift inter-
rupt switch 3-5 times. This will run the pump and purge out the air.

a
54445
a - Shift Interrupt Switch

NOTE: It may take up to 1 minute to purge out the air.

1998/1999 MODELS
Before starting engine for the first time, or for an engine that ran out of oil, or was
drained of oil, prime the oil injection pump. Priming will remove any air that may be in the
pump, oil supply hose, or internal passages.

a b
a - Oil Injection Pump
b - Oil Supply Hose

CAUTION
To prevent damage to the fuel pumps, fill the engine fuel system with fuel. Other-
wise the fuel pumps will run without fuel during the priming process.

90-855348R02 NOVEMBER 2002 Page 3C-9

OIL INJECTION SYSTEM

Prime the oil injection pump as follows:

1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it feels firm.
2. Turn the ignition key switch to the “ON” position.

3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F

NOTE: It may take a few minutes for the pump to complete the priming process.

Purging Air From the Engine Oil Reservoir

1. Loosen the fill cap on the engine oil tank.
2. Start the engine. Run the engine until the all the air has been vented out of the tank and
oil starts to flow out of the tank. Re-tighten fill cap.
a

a - Fill Cap

Oil Pump Activation of Break-in Sequence for Replacement Powerheads

NOTE: Do not add oil to the fuel to provide additional lubrication during break-in. The fuel
delivery characteristics of Direct Fuel Injection engines are such that adding oil to the fuel
will provide little or no additional lubrication to the engine. Additional oil required by the en-
gine during break-in must be provided by the oil pump.
Priming the oil pump (filling pump and hoses) is required on new or rebuild engines and any
time maintenance is performed on the oiling system.
There are three methods for priming the oil pump:

Page 3C-10 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

METHOD 1 – SHIFT SWITCH ACTIVATION PRIME

This method does three things:
a. Fills the oil pump, oil supply hose feeding pump and oil hoses going to the crankcase
and air compressor.
b. Activates break-in oil ratio.
c. Initiates a new engine break-in cycle.
Refer to priming procedure following.
NOTE: Refer to DDT reference manual for break-in time period.
Within the first 10 seconds after the key switch has been turned on, move the remote control
handle from neutral into forward gear 3 to 5 times. This will automatically start the priming
process.
N
F

NOTE: It may take a few minutes for the pump to complete the priming process.

METHOD 2 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – RESET BREAK-IN

This method is the same as Method 1, except the run history and fault history are erased
from the ECM.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnostic
Software Cartridge Part. No. 91-822608-4.

METHOD 3 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – OIL PUMP PRIME

This method fills the oil pump, oil supply hose feeding pump, and oil hoses going to the
crankcase and air compressor.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnostic
Software Cartridge Part. No. 91-822608-4.

Conditions Requiring Priming the Oil Pump

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

90-855348R02 NOVEMBER 2002 Page 3C-11

OIL INJECTION SYSTEM

Oil Injection Warning Systems

LOW OIL LEVEL
The system is activated when the oil in the engine mounted oil reservoir tank drops below
50 fl. oz. (1.5 liters) You still have an oil reserve remaining for 50 minutes of full speed opera-
tion.
NOTE: The engine mounted oil reservoir tank (located beneath the top cowl) along with the
remote oil tank will have to be refilled (refer to Filling the Oil Injection System).
The warning system works as follows:
The OIL light (a) will come on and the warning horn sounds a series of four short tones. If
you continue to operate the outboard, the light will stay on and the horn will sound four short
tones every two minutes. The engine has to be shut off to reset the warning system.

a - Oil Light

NO OIL FLOW TO THE ELECTRIC OIL PUMP (1997 MODELS ONLY)

The system is activated when the flow of oil in the electric oil pump is restricted. No lubricat-
ing oil is being supplied to the engine. Stop the engine as soon as possible. Continuing to
operate the engine can result in severe engine damage.
The warning system works as follows:
The OIL light (a) and CHECK ENGINE light (b) will come on and the warning horn will begin
sounding. The warning system will automatically reduce and limit the engine speed to 3000
RPM.
The engine has to be shut off to reset the warning system.

a - Oil Light
b - Check Engine Light

Page 3C-12 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

Electric Oil Pump Test (1997 Models Only)

NOTE: 1998/1999 Model oil pumps do not activate a warning if there is an oil pump malfunc-
tion or if there are air bubbles in the oil supply hose. The oil warning system on 1998/1999
Models will only be activated if the engine mounted oil reservoir is low on oil.
1. If the warning system is activated and indicating no oil flow to the oil pump, the first
thing to do is visually check the oil supply hose going to the oil pump for signs of air.
2. If the oil supply hose is not full of oil, purge out the air following instructions in Filling the
Oil Injection System.
3. If the oil supply hose is full of oil, this indicates a problem inside the electric oil pump.
The electric oil pump is not serviceable. Replace the electric oil pump.

a
b
a - Electric Oil Pump
b - Oil Supply Hose

90-855348R02 NOVEMBER 2002 Page 3C-13

OIL INJECTION SYSTEM

Oil Injection System Troubleshooting Chart

If a problem occurs with the oil injection system, and warning horn sounds in a pulsating man-
ner, stop engine and check if problem is caused by 1) low oil level or 2) a faulty warning sensor.
Open cowling and check oil level in reservoir tank. If oil is not to top of tank, the problem is
low oil. There is a safety reserve of oil left in reservoir after low oil warning is sounded that
allows enough oil for 30 to 40 minutes of full throttle operation. Refer to troubleshooting chart
to correct problem.

Problem: Oil Level in Engine Oil Reservoir Tank is Low But Not Low in Remote Oil Tank.
Possible Cause Corrective Action
Fill cap is leaking air on the remote tank. Make sure O-rings or gaskets are in place and caps
are tight.
Remote oil hose (blue stripe) is blocked. Check length of hose for a kink.
Remote pulse hose (second hose) is blocked or Check length of hose for a kink or leakage.
punctured.
Remote pulse hose check valve is faulty (this valve Replace check valve.
is located at the engine end of the hose).
A restricted oil outlet filter in the remote tank. Remove filter and clean.
Air leak in upper portion of oil pickup tube. Replace tube.
Problem: Warning Horn Does Not Sound When Ignition Key is Turned to “ON” Position.
Possible Cause Corrective Action
Horn malfunction or open TAN wire between horn Use a jumper wire to ground TAN lead (at engine
and engine. terminal block) to engine ground. Warning horn
should sound. If not, check TAN wire between horn
and engine for open circuit and check horn.
Electronic Control Module (ECM) Check if all ECM leads are connected to harness
leads. If so, ECM may be faulty.
Using incorrect side mount remote control or igni- Refer to page Section 1D
tion/choke assembly.
Open circuit on PURPLE wire going to (+) terminal Check for battery voltage at (+) terminal of horn
of horn. when ignition key is turned on.
Problem: Warning Horn Stays on When Ignition Key is Turned to “ON” Position.
Possible Cause Corrective Action
Engine overheat sensor If horn sounds a continuous signal, the engine
overheat sensor may be faulty. Disconnect over-
heat sensor and turn ignition key to “ON” position. If
horn still sounds the engine overheat sensor is OK.
Tan wire between warning horn and engine over- Check wire for shorts.
heat sensor is shorted to ground.
Electronic Control Module (ECM) Check connections – replace ECM.
Problem: Warning Horn sounds when Engine is Running and Oil Level in Engine Reservoir is Full.
Possible Cause Corrective Action
Defective low oil sensor Disconnect both low oil sensor leads from terminal
connectors. Connect ohmmeter between leads. There
should be NO continuity through sensor. If continuity
exists, sensor is faulty.

Page 3C-14 90-855348R02 NOVEMBER 2002

 OIL INJECTION SYSTEM

Engine Mounted Oil Reservoir

REMOVAL
NOTE: If oil reservoir contains oil, the clear oil hose going to the oil pump should be plugged
upon removal to prevent oil spillage.
1. Disconnect input oil hose to oil reservoir.
2. Disconnect LIGHT BLUE leads from their respective connections.
3. Disconnect clear input hose to oil pump and plug off hose.
4. Remove three bolts securing oil reservoir to powerhead and remove reservoir.

b 55937
a - Bolts
b - Oil Pump Output Hose (Clear)

INSTALLATION
1. Secure oil reservoir to powerhead with 3 bolts. Torque bolts to 14 Ib. ft. (19.0 Nm).
2. Reconnect input oil hose to oil reservoir and secure with sta-strap.
3. Reconnect LIGHT BLUE leads to their respective bullet connectors.
4. Connect clear output hose from oil reservoir to oil pump. Secure hose with sta-straps.

90-855348R02 NOVEMBER 2002 Page 3C-15

 EMISSIONS

FUEL SYSTEM
Section 3D - Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . 3D-1 Emissions Information . . . . . . . . . . . . . . . . . . . 3D-5
What Are Emissions? . . . . . . . . . . . . . . . . . 3D-1 Manufacturer’s Responsibility: . . . . . . . . . 3D-5
Hydrocarbons – HC . . . . . . . . . . . . . . . . . . .
Carbon Monoxide – CO . . . . . . . . . . . . . . .
3D-1
3D-2
Dealer Responsibility: . . . . . . . . . . . . . . . . .
Owner Responsibility: . . . . . . . . . . . . . . . . .
3D-5
3D-6 3
Oxides of Nitrogen - NOx . . . . . . . . . . . . . .
Controlling Emissions . . . . . . . . . . . . . . . . .
3D-2
3D-2
EPA Emission Regulations: . . . . . . . . . . . .
Certification Label: . . . . . . . . . . . . . . . . . . . .
3D-6
3D-7
D
Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3D-2 Decal Location: . . . . . . . . . . . . . . . . . . . . . . 3D-8
Outboard Hydrocarbon Emissions Reductions . 3D-3 Service Replacement Certification Label . . . 3D-8
Stratified vs Homogenized Charge . . . . . . . . 3D-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-8
Homogenized Charge . . . . . . . . . . . . . . . . . 3D-4 Date Code Identification . . . . . . . . . . . . . . . 3D-8
Stratified Charge . . . . . . . . . . . . . . . . . . . . . 3D-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-8

Exhaust Emissions Standards

Through the Environmental Protection Agency (EPA), the federal government has es-
tablished exhaust emissions standards for all new marine engines sold in the U.S.

What Are Emissions?

Emissions are what comes out of the exhaust system in the exhaust gas when the en-
gine is running. They are formed as a result of the process of combustion or incomplete
combustion. To understand exhaust gas emissions, remember that both air and fuel are
made of several elements. Air contains oxygen and nitrogen among other elements;
gasolene contains mainly hydrogen and carbon. These four elements combine chemi-
cally during combustion. If combustion were complete, the mixture of air and gasoline
would result in these emissions: water, carbon dioxide and nitrogen, which are not harm-
ful to the environment. But combustion is not usually complete. Also, potentially harmful
gases can be formed during and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful
gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards
become more stringent each year. Standards are set primarily with regard to three emis-
sions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).

Hydrocarbons – HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned
during combustion in combination with oxygen. But they are not totally consumed. Some
pass through the combustion chamber and exit the exhaust system as unburned gases
known as hydrocarbons.

90-855348R02 NOVEMBER 2002 Page 3D-1

EMISSIONS

Carbon Monoxide – CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxy-
gen during the combustion process. If the carbon in the gasoline could combine with
enough oxygen (one carbon atom with two oxygen atoms), it would come out of the en-
gine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often com-
bines with insufficient oxygen (one carbon atom with one oxygen atom). This forms car-
bon monoxide, CO. Carbon monoxide is the product of incomplete combustion and is
a dangerous, potentially lethal gas.

Oxides of Nitrogen - NOx

NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that
makes up the air going into the engine. Under extremely high temperatures it combines with
oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion cham-
bers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight
it combines with unburned hydrocarbons to create the visible air pollutant known as smog.
Smog is a serious problem in California as well as many other heavily populated areas of
the United States.

Controlling Emissions
There are two principle methods of reducing emissions from a two-stroke-cycle marine en-
gine. The first method is to control the air/fuel ratio that goes into the combustion chamber.
The second is to control the time when this air/fuel mixture enters the combustion chamber.
Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.

Stoichiometric (14.7:1) Air/Fuel Ratio

In the search to control pollutants and reduce exhaust emissions, engineers have discov-
ered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio
of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1
provides the best control of all three elements in the exhaust under almost all conditions.
The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio.
At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than
14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not
be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However,
there is also NOx to consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combus-
tion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio
to decrease combustion temperatures and reduce NOx also increases HC and CO, as well
as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to
keep the air/fuel ratio as close to 14.7:1 as possible.

Page 3D-2 90-855348R02 NOVEMBER 2002

 EMISSIONS

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

90-855348R02 NOVEMBER 2002 Page 3D-3

EMISSIONS

Stratified vs Homogenized Charge

DFI engines use a stratified charge inside the combustion chamber to aid in reducing emis-
sions. All other models use a homogenized charge. The difference between the two is:

Homogenized Charge
A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This
mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing
occurs as the fuel is forced through the transfer system into the cylinder.
The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1.

Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel required for
combustion is forced into the cylinder through an injector placed in the top of the cylinder
(head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder. Sur-
rounding this bubble is air supplied by the transfer system. As the bubble is ignited and
burns, the surrounding air provides almost complete combustion before the exhaust port
opens.

Page 3D-4 90-855348R02 NOVEMBER 2002

 EMISSIONS

A stratified charge is hard to ignite, the air/fuel bubble is not evenly mixed at 14.7:1 and not
easily ignited.

Emissions Information
Manufacturer’s Responsibility:
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family and certify
these engines with the United States Environmental Protection Agency (EPA). A certifica-
tion decal/emissions control information label, showing emission levels and engine specifi-
cations directly related to emissions, must be placed on each engine at the time of manufac-
ture.

Dealer Responsibility:
When performing service on all 1998 and later outboards that carry a certification, attention
must be given to any adjustments that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner
that maintains emission levels within the prescribed certification standards.

90-855348R02 NOVEMBER 2002 Page 3D-5

EMISSIONS

Dealers are not to modify the engine in any manner that would alter the horsepower or allow
emission levels to exceed their predetermined factory specifications.
Exceptions include manufacturers prescribed changes, such as that for altitude adjust-
ments.

Owner Responsibility:
The owner/operator is required to have engine maintenance performed to maintain emis-
sion levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horse-
power or allow emissions levels to exceed their predetermined factory specifications.
Single engine exceptions may be allowed with permission from the EPA for racing and test-
ing.

EPA Emission Regulations:

All new 1998 and later outboards manufactured by Mercury Marine are certified to the
United States Environmental Protection Agency as conforming to the requirements of the
regulations for the control of air pollution from new outboard motors. This certification is con-
tingent on certain adjustments being set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed and, whenever practicable, re-
turned to the original intent of the design.
The responsibilities listed above are general and in no way a complete listing of the rules
and regulations pertaining to the EPA laws on exhaust emissions for marine products. For
more detailed information on this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww

Page 3D-6 90-855348R02 NOVEMBER 2002

 EMISSIONS

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 certifica-
tion label and is not representative of any one model. Label shown below is not to scale;
(shown at twice the normal size).
a

Emission Control 1998 b

Information PART # 37-855211 27
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): 550 RPM
Exhaust Emission Control Systems: None
Engine Lubricants: Premium Fuel/Oil Timing: Not Adjustable ECM d
Plus TC-W3 2-Cycle Outboard Ratio: Not Controlled
n Oil Adjustable
ECM Spark Plug: Champion RC12MC4 Gap: .040” e
m Family: WM9XM03.0220 Controlled Valve Clearance (Cold) mm
FEL: 100.00 GM/KW-HR Intake: N/A Exhaust: N/A
l f
3044 225 HP
cc DFI
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
g

k j h
i
a
- Spark Ignition (SI)
b
- Model year of engine and production decal part number
c
- Type and octane of fuel used to establish emission levels
d
- Timing specifications when adjustable
e
- Spark plug gap in thousandths of an inch
f
- Recommended spark plug for best engine performance
g
- Engine Horsepower rating
h
- Cubic Centimeter
i
- Valve Clearance (Four Stroke engines only)
j
- Recommended oil/fuel ratio for best engine performance
and minimal emissions
k - Month of production (Boxing month will punched)
l - FEL: Represents (Mercury Marine) statement of the maxi-mum emissions out-
put for the engine family
m - Family example:
W M9X M 03.0 2 2 0

Model Year Regulation Application Unspecified

W=1998 M=Marine 1=PWC
X=1999 2=OB
Manufacturer Displacement Technology type
Mercury Marine Liter 1=Existing
Cubic Inch 2=New

n - Engine lubricants recommended by the manufacturer

90-855348R02 NOVEMBER 2002 Page 3D-7

EMISSIONS

Decal Location:
Model Production Part No. Service Part No. Location on Engine
1998 Merc/Mar 3.0 L V6 37-855211 27 37-855577 27 Intake Plenum STBD
DFI (200 – 225 H.P.) Side
1999 Merc/Mar 3.0 L V6 37-856984 14 Intake Plenum STBD
DFI (200 – 225 H.P.) Side

Service Replacement Certification Label

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

EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
IDLE SPEED (IN GEAR): 550 RPM FAMILY: 3M9XM03.02C0
225 HP 3044 cc FEL: 34.0 g/kW-hr
TIMING (IN DEGREES): NOT ADJUSTABLE
Spark Plug: NGK PZFR5F-11
Gap: 1.1 mm (0.043 in.)

Cold Valve Clearance (mm) Intake: NA

Exhaust: NA
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC

a
a - V Notch b - Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.

Page 3D-8 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

POWERHEAD
Section 4A - Cylinder Block Assembly
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-40
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Crankshaft Installation . . . . . . . . . . . . . . . . 4A-44
Powerhead Repair Stand . . . . . . . . . . . . . . 4A-4 Piston and Connecting Rod Reassembly . . 4A-46
Crankshaft – Pistons – and Connecting Rods . 4A-6 Piston and Piston Ring Combination . . . . 4A-48
Cylinder Block and End Cap . . . . . . . . . . . . . . 4A-8 Piston Installation . . . . . . . . . . . . . . . . . . . . 4A-48
Powerhead Torque Sequence Crankcase Cover Installation . . . . . . . . . . . 4A-52
and Torque Specifications . . . . . . . . . . . . . . . . 4A-12 Assembly of Reed Blocks to
General Information . . . . . . . . . . . . . . . . . . . . .
Powerhead Removal from
4A-15 Intake Manifold . . . . . . . . . . . . . . . . . . . . . .
Exhaust Plate 1997 Model 200 DFI . . . . . . . .
4A-55
4A-56
4
Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 4A-15 Exhaust Plate 1998/1999 Model 200/225 DFI . 4A-58 A
Powerhead Disassembly . . . . . . . . . . . . . . . . . 4A-20 Cylinder Head Installation . . . . . . . . . . . . . 4A-60
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4A-31 Bleed System 1997 Model 200 DFI . . . . . . . . 4A-62
Cylinder Block and Crankcase Cover . . . 4A-31 Front Bleed View 1997 Model 200 DFI . . . . . 4A-64
Special Service Information . . . . . . . . . . . . 4A-31 Bleed System 1998 Model 200/225 DFI . . . . 4A-66
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . 4A-32 Anchor Bracket/Throttle Linkage
Pistons and Piston Rings . . . . . . . . . . . . . . 4A-33 Model 1997 200 DFI . . . . . . . . . . . . . . . . . . . . 4A-68
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . 4A-34 Anchor Bracket/Throttle Linkage 1998/1999
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-34 Model 200/225 DFI . . . . . . . . . . . . . . . . . . . . . . 4A-70
Crankshaft (and End Cap) Bearings . . . . 4A-35 Reinstalling Engine Components . . . . . . . . . . 4A-72
Reed Block Assembly . . . . . . . . . . . . . . . . . 4A-36 Powerhead Installation on
Reed Block . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-37 Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 4A-72
Connecting Rods . . . . . . . . . . . . . . . . . . . . . 4A-37 Break-ln Procedure . . . . . . . . . . . . . . . . . . . . . . 4A-77
Powerhead Reassembly and Installation . . . 4A-40

90-855348R02 NOVEMBER 2002 Page 4A-1

CYLINDER BLOCK ASSEMBLY

Specifications

Model 200/225 DFI

OUTBOARD Model 200/225
WEIGHT – 20 in. (50.8cm) Shaft 507.0 lbs. (230.0 kg)
– 25 in. (63.5cm) Shaft 512.0 lbs. (232.0 kg)
– 30 in. (76.2cm) Shaft 461 lbs. (209.3 kg)
CYLINDER Type V–6 Cylinder, Two Cycle, Loop Charged
BLOCK Displacement 185 cu. in. (3032cc)
Thermostat 120°F (48.9°C)
STROKE Length (All Models) 3.00 in. (76.2mm)
CYLINDER Diameter (Standard) 3.6265 in. (92.1131mm)
BORE 0.015 Oversize 3.640 in. (92.5mm)
0.030 Oversize 3.655 in. (92.8mm)
Taper/Out of Round/Wear Maximum 0.003 in. (0.076mm)
Bore Type Cast Iron
PISTON Piston Type Aluminum
Standard 3.6205 in. ± .0005 in.
(91.9607mm ± 0.0127mm)
0.015 Oversize 3.636 in. ± .0005 in.
(92.354mm ± .0127 mm)
0.030 Oversize 3.651 in. ± .0005 in.)
(93.1mm ± .0127 mm
PISTON DIA.
3.6205 in. ± .0005 in.
(91.973 mm ± .0127 mm)
Using a micrometer, measure dimension
Dimension “A” at location shown. Dimension “A”
“A” at Right should be 3.6205 in. ± .0005 for a STAN-
Angle (90°)
to Piston DARD size piston (new) Dimension “A”
Pin will be 0.001 – 0.0015 less if coating is
1 in. worn off piston (used)
(25.4mm)

Piston Ring End Gap

Top Ring 0.0059 - 0.0098 in.
(0.15 - 0.25mm)
Middle Ring 0.0059 - 0.0098 in.
(0.15 - 0.25mm)
Bottom Ring 0.0039 - 0.014 in.
(0.10 - 0.35mm)
Reeds Reed Stand Open (Maximum.) 0.020 in. (0.50mm)
Water Pressure @ Idle 1.5 - 4.5 psi (10 - 31 kPa)
@ Poppet valve Opening 6.5 - 6.75 psi (45 - 46.5 kPa)
@ W.O.T. 8 – 10 psi (55 - 69 kPa)

Page 4A-2 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Special Tools
1. Lifting Eye 91-90455

2. Flywheel Holder 91-52344

91–52344

54964
3. Protector Cap 91-24161

4. Flywheel Puller 91-849154T1

5. Powerhead Stand 91-812549T

6. Piston Ring Expander 91-24697

7. Lockring Removal Tool 91-52952A1

90-855348R02 NOVEMBER 2002 Page 4A-3

CYLINDER BLOCK ASSEMBLY

8. Piston Pin Tool 91-92973A1

9. Universal Puller Plate 91-37241

10. Snap Ring Pliers 91-24283

11. Lockring Installation Tool 91-91-93004A2

NOTE: If 3.4 Liter Piston Lock Ring Installer (91-93004A1) is available, then only Guide
(91-93005-1) is required to install 3 Litre piston lock rings.
12. Piston Ring Compressor 91-823237

Powerhead Repair Stand

A powerhead repair stand may be purchased from:
Bob Kerr’s Marine Tool Co.
P.O. Box 1135
Winter Garden, FL 32787
Telephone: (305) 656-2089

Page 4A-4 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Notes:

90-855348R02 NOVEMBER 2002 Page 4A-5

CYLINDER BLOCK ASSEMBLY

Crankshaft – Pistons – and Connecting Rods

21
20 14

19

1 14

95
13
15 14
95
95
11 8

17
13 16
12 10

5
15
95
18
17 9
11
14 2

3
14

4
95
7

14 2 Cycle Premium Outboard Oil

95 2-4-C With Teflon

Page 4A-6 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Crankshaft - Piston - and Connecting Rods

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 CRANKSHAFT
2 1 WEAR SLEEVE
3 1 BALL BEARING (LOWER)
4 1 RETAINING RING
5 7 SEAL RING
6 1 WOODRUFF KEY
7 1 O RING
8 2 BEARING RACE
9 88 NEEDLE ROLLER
3 PISTON (STBD-STANDARD)
10
3 PISTON (PORT-STANDARD)
11 12 LOCK RING
12 12 PISTON RING (STANDARD)
13 6 CONNECTING ROD ASSEMBLY
Apply light oil to
threads and bolt
face: 1st torque - 15
lb. in. (1.7 Nm)
2nd torque - 30 lb. ft.
14 12 SCREW (1-1/4 IN.)
(40.7 Nm)
Turn bolt an addi-
tional 90 degrees af-
ter 2nd torque is at-
tained.
15 12 BEARING CAGE
16 96 NEEDLE ROLLER BEARING
17 12 THRUST WASHER
18 204 ROLLER BEARING
19 1 MAIN BEARING (UPPER)
20 1 OIL SEAL
21 1 O RING

90-855348R02 NOVEMBER 2002 Page 4A-7

CYLINDER BLOCK ASSEMBLY

Cylinder Block and End Cap

48 58
47 57 82
42 81
49
46 80 83
41 78
40 33 31
14 45 77
30 20 71
76 84
59 39 34
32 70 75 79
57 43 21
56 54 52 44
53
72
51 73
64 73 74 A
65 12
66 55 1
14 27

67 5 19
61 25
C 86 11
85 18 26
88 4

62 87 27
63
25 6
60 14 24
50 17
12
68 2 13
20 15
69 14
B
18 14
3
33
23 14
28
29 16
7 2
9
8 28 22
10
29
37 33

95
36

35
95 38
12 Loctite Master Gasket
14 2 Cycle Premium Outboard Oil
33 Loctite 680 Retaining Compound
95 2-4-C with Teflon
A = TO FUEL PUMP B = TO ADAPTOR PLATE C = TO PRESSURE SENSOR

Page 4A-8 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Cylinder Block and End Cap

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 CYLINDER BLOCK (225)
1 1 CYLINDER BLOCK (200)
2 4 STUD (M10 x 1.5 x 64)
3 6 STUD (M10 x 1.5 x 155)
4 1 PIPE PLUG (1/8 IN.)
5 1 PIPE PLUG (3/4-14)
6 6 WATER DEFLECTOR
7 1 CHECK VALVE
8 1 TUBING (6 IN.)
9 1 CONNECTOR
10 1 PLUG
11 3 CENTER MAIN PIN
12 1 DOWEL PIN
13 6 FITTING
14 2 CHECK VALVE
15 1 ELBOW
16 6 STOP PLUG
17 12 SCREW (M8 x 35) 21 28.5
18 2 CHECK VALVE
Torque to 30 lb. ft.
19 8 SCREW (M10 x 1.5) (40.5 Nm) and rotate
90 degrees
20 2 STRAINER
21 1 PIN 65 7.3
22 1 TUBING (22-1/2 IN.)
23 1 TUBING (3-3/4 IN.)
24 1 PLUG-Serial Number
25 4 STA-STRAP
26 1 TUBING (9-1/4 IN.)
27 2 SPRING CLAMP
28 10 WASHER
29 10 NUT 50 67.8
30 1 BRACKET
31 2 SCREW (M6 x 16) 100 11.3
32 1 GUIDE BRACKET
33 1 CRANK POSITION SENSOR
34 1 SCREW (M5 x 10) 50 5.6
35 1 LOWER END CAP
36 1 O RING
37 2 OIL SEAL
38 4 SCREW (M6 x 20) 85 9.6
39 1 PLATE ASSEMBLY
40 3 MOUNT
41 3 SCREW (M10 x 45) 40 54.2
42 2 SCREW (M10 x 75) 40 54.2

90-855348R02 NOVEMBER 2002 Page 4A-9

CYLINDER BLOCK ASSEMBLY

Cylinder Block and End Cap

48 58
47 57 82
42 81
49
46 80 83
41 78
40 33 31
14 45 77
30 20 71
76 84
59 39 34
32 70 75 79
57 43 21
56 54 52 44
53
72
51 73
64 73 74 A
12
66 55 65
1
14 27

67 5 19
61 25
C 86 11
85 18 26
88 4

62 87 27
63
25 6
60 14 24
50 17
12
68 2 13
20 15
69 14
B
18 14
3
33
23 14
28
29 16
7 2
9
8 28 22
10
29
37 33

95
36

35

95
38 12 Loctite Master Gasket

14 2 Cycle Premium Outboard Oil

33 Loctite 680 Retaining Compound
95 2-4-C with Teflon
A = TO FUEL PUMP B = TO ADAPTOR PLATE C = TO PRESSURE SENSOR

Page 4A-10 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Cylinder Block and End Cap

REF. TORQUE
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
43 4 WASHER
44 2 SPACER
45 1 SPACER
46 1 BRACKET
47 2 CLAMP
48 2 SCREW (M6 x 10)
49 2 WASHER
50 2 SEAL– cylinder head
51 6 O RING
52 1 CYLINDER HEAD (STARBOARD) 225
1 CYLINDER HEAD (PORT)
53 1 CYLINDER HEAD (STARBOARD) 200
1 CYLINDER HEAD (PORT)
54 2 SEAL-thermostat
55 2 THERMOSTAT
56 2 GASKET– thermostat cover
57 2 COVER– thermostat
58 1 FITTING (PORT)
59 4 SCREW (M6 x 25) 100 11.3
Refer to Torque
Specifications (fol-
60 40 SCREW (M8 x 50)
lowing) for Cylinder
Head Torque
61 1 ELBOW (STARBOARD)
62 1 TUBING (STBD. 21 IN.)
63 1 TUBING (PORT 20-1/2 IN.)
64 1 TEMPERATURE SENSOR (PORT)
65 1 TEMPERATURE SENSOR (STARBOARD)
66 2 SCREW (M8 x 12) 17 22.6
67 2 SENSOR RETAINER
68 1 CLAMP
69 2 SCREW (M6 x 12) 100 11.3
70 1 BRACKET
71 1 TPI LEVER
72 3 SCREW-Bracket to Crankcase (M6 x 25) 55 6.2
73 6 BUSHING
74 3 GROMMET
75 1 THROTTLE POSITION SENSOR (INSIDE)
76 1 SPACER
77 1 THROTTLE POSITION SENSOR (OUTSIDE)
78 3 SCREW TPS to bracket (M5 x 65) 35 4.0
79 1 THROTTLE LINK
80 1 CLAMP
81 1 SPACER
82 1 SCREW (M8 x 20)
83 1 CLAMP
84 1 CLAMP
85 1 FITTING
86 1 STA-STRAP
87 1 PIPE PLUG
88 1 PIPE PLUG

90-855348R02 NOVEMBER 2002 Page 4A-11

CYLINDER BLOCK ASSEMBLY

Powerhead Torque Sequence and Torque Specifications

REED BLOCK MOUNTING BOLTS

90 lb. in. (10.2 Nm)

FLYWHEEL LOCKNUT
125 lb. ft. (169.5 Nm)
Important: DO NOT apply oil
to flywheel/crankshaft taper.

55979
REED ATTACHING SCREWS
25 lb. in. (2.8 Nm)

52130

55980
LOWER END CAP BOLTS
85 lb. in. (9.6 Nm)
OIL PUMP ATTACHING SCREWS
16 lb. ft. (21.7 Nm)

52132

SPARK PLUGS
20 lb. ft. (27.1 Nm)

55194

Page 4A-12 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

CRANKCASE COVER BOLTS CYLINDER HEAD BOLTS

(AND TORQUE SEQUENCE) (AND TORQUE SEQUENCE)
Add light oil to threads and bolt face: IMPORTANT
8 Bolts (M10 x 1.5 x 80) Add light oil to threads and bolt face:
30 lb. ft. (40.6 Nm) and rotate 90° Torque to 20 lb. ft. (27.1 Nm) and ro-
tate 90°

20 18
8 7 16 14
13 14

9 10 12 10

1 3
6 1 4 7
7 5

4 1

6 8
2 3
3 2
4 2

8 5 9 11

11 12
13 15
5 6
17 19 52132
55986

14 Bolts (M8 x 1.25 x 35)

28.0 lb. ft. (37.9 Nm)
PISTON ROD BOLTS
IMPORTANT: IT IS RECOMMENDED THAT RELIEF VALVE COVER BOLTS
ROD BOLTS BE DISCARDED AFTER REMOVAL 20.0 lb. ft. (27.1 Nm)
AND REPLACED WITH NEW BOLTS.
Apply light oil to threads and bolt face:
1st Torque - 15 lb. in. (1.7 Nm.)
2nd Torque - 30 lb. ft. (40.7 Nm.)
Turn bolt an additional 90° after 2nd
Torque is Attained.

51707

55987

90-855348R02 NOVEMBER 2002 Page 4A-13

CYLINDER BLOCK ASSEMBLY

INTAKE MANIFOLD
100 lb. in. (11.3 Nm)

10 9

6 5

2 1

3 4

7 8

11 12

55975

Page 4A-14 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

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

Powerhead Removal from Driveshaft Housing

1. Disconnect battery cables from battery terminals.
2. Remove top cowling.
IMPORTANT: Prior to removing flywheel cover, remove vent hose from fitting on fly-
wheel cover.
3. Remove flywheel cover.

a -Cover
b -Vent Hose

90-855348R02 NOVEMBER 2002 Page 4A-15

CYLINDER BLOCK ASSEMBLY

4. Remove two screws which secure remote control harness retainer and remove retainer.

55917
a -Screws
b -Retainer

5. Disconnect fuel hose, oil inlet hose, throttle cable and shift cable.

b
d
c
a 55918

a -Fuel Hose
b -Oil Inlet Hose
c -Throttle Cable
d -Shift Cable

6. Disconnect remote control harness from powerhead harness.

7. Disconnect warning gauge wiring harness.

Page 4A-16 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

8. Disconnect trim motor harness.

a b

55919
a -Remote Control Harness
b -Warning Gauge Harness
c -Trim Motor Harness

9. Remove 4 bolts securing bottom cowl halves and remove bottom cowling.

55932 a 55970

52352
a -Bolt

90-855348R02 NOVEMBER 2002 Page 4A-17

CYLINDER BLOCK ASSEMBLY

10. If a suitable powerhead holding fixture is available, powerhead may be removed fully
dressed. Disconnect 2 thermostat hoses, fuel rail air outlet hose, fuel cooler water hose
and tell-tale hose.

b c a a
d
55920
a -Thermostat Water Hoses
b -Fuel Rail Air Outlet Hose
c -Fuel Cooler Water Hose
d -Tell-Tale Hose

11. Disconnect shift link from upper shift shaft.

12. Remove 10 nuts and washers (5 each side) from powerhead base.

a
b

52373

a -Nuts and Washers (5 each side)

b -Shift Link

Page 4A-18 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

13. Remove plastic cap from center of flywheel and install Lifting Eye (91-90455) into
flywheel at least 5 full turns. Using a hoist, lift powerhead assembly from drive shaft
housing.
NOTE: If powerhead cannot be removed due to gasket adhesion, reinstall fore and aft pow-
erhead nuts. Install a jacking block under the aft powerhead nut. Place a pry bar under the
forward powerhead nut. Unscrew the aft nut against the jacking block while prying up on the
forward nut to break the gasket adhesion.

b
c

a
d
55955

a -Jacking Block
b -Aft Nut
c -Forward Nut
d -Pry Bar

REMOVING ENGINE COMPONENTS

Remove the following engine components by referring to the following sections:
Section 2
Starter Motor
Alternator
Ignition Modules
Electronic Control Unit
Solenoids
Crank Position Sensor
Throttle Position Sensor
Temperature Sensor
Section 3
Air Plenum
Fuel Pump
On-Board Oil Tank
Oil Pump
Fuel Rails
Vapor Separator

90-855348R02 NOVEMBER 2002 Page 4A-19

CYLINDER BLOCK ASSEMBLY

Powerhead Disassembly
1. Place powerhead in repair stand or on a bench.
2. Remove thermostat covers, thermostats and gaskets.

a a b

55973 55972
a -Thermostat Cover
b -Thermostat
c -Gasket

3. Remove cylinder heads from engine block.

b 55973
a -Cylinder Head
b -Engine Block

Page 4A-20 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

4. Remove reed block housing from cylinder block.

55975

a -Reed Block Housing

5. Inspect reeds as outlined in Cleaning and Inspection.

55976

90-855348R02 NOVEMBER 2002 Page 4A-21

CYLINDER BLOCK ASSEMBLY

LOWER END CAP

6. Remove bolts from end cap.

a a

52325
a -Crankcase Attaching End Cap Bolts

7. Remove bolts which secure crankcase cover to cylinder block.

55977

a -Crankcase Cover

Page 4A-22 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

CRANKCASE COVER REMOVED

8. Remove crankcase end cap.

55978

9. Use Powerhead Stand (91-812549) for rotating crankshaft to desired position for
removal of connecting rods.
10. Using an awl or electric pencil, scribe the cylinder identification number on each
connecting rod as shown. Reassemble connecting rods in same cylinder.

52347

90-855348R02 NOVEMBER 2002 Page 4A-23

CYLINDER BLOCK ASSEMBLY

11. Use a 3/8 in. 12 point socket to remove connecting rod bolts, then remove rod cap, roller
bearings and bearing cage from connecting rod.

52316

a -Connecting Rod Bolts

12. Push piston out of cylinder block.

13. After removal, reassemble each piston and connecting rod assembly.

CAUTION
Each connecting rod and end cap are a matched machined set and must never be
mismatched.

55966

14. Inspect pistons as outlined in Cleaning and Inspection, following.

Page 4A-24 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

15. Use Piston Ring Expander (91-24697) to remove piston rings. Always install new piston
rings.

55967
16. Using an awl, scribe identification number of connecting rod on inside of piston (1).
Reassemble piston on same connecting rod.

55968
17. Using tool (91-52952A1), remove piston pin lockrings from both ends of piston pin.
Never re-use piston pin lockrings.

55969
a -Lockring

90-855348R02 NOVEMBER 2002 Page 4A-25

CYLINDER BLOCK ASSEMBLY

IMPORTANT: Warming the piston dome using a torch lamp will ease removal and
installation of piston pin.
18. Support piston and tap out piston pin using service tool as shown.

55957
a -Piston Pin
b -Piston Pin Tool (91-92973A1)

19. Remove piston pin needle bearings (34 per piston) and locating washers (2 per piston)
as shown.
IMPORTANT: We recommend the use of new needle bearings at reassembly for last-
ing repair. However, if needle bearings must be re-used, keep each set of bearings
identified for reassembly on same connecting rod.

55958
a -Needle Bearing Locating Washers

Page 4A-26 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

20. Remove and discard O-ring seal from end cap.

21. Remove oil seals from end cap by driving seals out with a punch and hammer.
b

a 51849
a -O-ring b -Seals (2)

22. Inspect roller bearing in upper bearing carrier as outlined in Cleaning and Inspection.
NOTE: If roller bearing is damaged, replace bearing carrier assembly.
b

a c51473
a -O-Ring c -Carrier
b -Seal

23. Remove crankshaft and place in powerhead stand as shown.

CAUTION
Safety glasses should be worn when removing or installing crankshaft sealing rings.
IMPORTANT: DO NOT remove sealing rings from crankshaft unless replacement of a
sealing ring is necessary. Usually, crankshaft sealing rings do not require replacement,
unless broken.

55994
a -Sealing Rings (7)

90-855348R02 NOVEMBER 2002 Page 4A-27

CYLINDER BLOCK ASSEMBLY

24. Remove retaining ring as shown.

52336
a -Retaining Ring

25. Remove bearing race halves and roller bearings from crankshaft.
IMPORTANT: Keep same bearing races and roller bearings together.
a

52315
a -Bearing Race Halves
b -Roller Bearings

26. Inspect crankshaft ball bearing as outlined in Cleaning and Inspection, following.
IMPORTANT: DO NOT remove crankshaft ball bearing, unless replacement is re-
quired.

Page 4A-28 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

27. Remove lower ball bearing from crankshaft as follows:

a. Remove retaining ring using a pair of snap ring pliers.

a
b

c 55983

a -Crankshaft Ball Bearing

b -Pliers
c -Retaining Ring

b. Press crankshaft out of lower ball bearing as shown.

b
c

51081
a -Press
b -Powerhead Stand (91-812549)
c -Crankshaft Ball Bearing
d -Universal Puller Plate (91-37241)

90-855348R02 NOVEMBER 2002 Page 4A-29

CYLINDER BLOCK ASSEMBLY

28. Remove and inspect water pressure relief valve components for debris or damage.
Replace components as required.
1

2
3
4
5
6
7

8
9
10
12 11

13

1 - Exhaust Plate
2 - Carrier
3 - Grommet
4 - Poppet/Relief Valve
5 - Spring
6 - Gasket
7 - Inner Plate
8 - Diaphragm
9 - Washer
10 - Screw
11 - Gasket
12 - Outer Cover
13 - Bolts [Torque bolts to 20 lb. ft. (27.1 Nm)]

Page 4A-30 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Cleaning and Inspection

Cylinder Block and Crankcase Cover

IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored assem-
bly and never should be mismatched by using a different crankcase cover or cylinder
block.

CAUTION
If crankcase cover or cylinder block is to be submerged in a very strong cleaning
solution, it will be necessary to remove the crankcase cover/cylinder block bleed
system from crankcase cover/cylinder block to prevent damage to hoses and check
valves.
1. Thoroughly clean cylinder block and crankcase cover. Be sure that all sealant and old
gaskets are removed from matching surfaces. Be sure that carbon deposits are
removed from exhaust ports.
2. Inspect cylinder block and crankcase cover for cracks or fractures.
3. Check gasket surfaces for nicks, deep grooves, cracks and distortion that could cause
compression leakages.
4. Check all water and oil passages in cylinder block and crankcase cover to be sure that
they are not obstructed and that plugs are in place and tight.

Special Service Information

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

90-855348R02 NOVEMBER 2002 Page 4A-31

CYLINDER BLOCK ASSEMBLY

Cylinder Bores
1. Inspect cylinder bores for scoring, scuffing or transfer of aluminum from piston to cylinder
wall. Scoring or scuffing, if not too severe, can normally be removed by honing. If transfer
of aluminum has occurred, apply an acidic solution to areas of cylinder bore where transfer
of aluminum has occurred. After the acidic solution has removed the transferred aluminum,
thoroughly flush cylinder bores to remove any remaining acid. Cylinder walls may now be
honed to remove any glaze and to aid in seating of new piston rings.
HONING PROCEDURE
a. When cylinders are to be honed, follow the hone manufacturer’s recommendations
for use of the hone and cleaning and lubrication during honing.
b. For best results, a continuous flow of honing oil should be pumped into the work
area. If pumping oil is not practical, use an oil can. Apply oil generously and frequent-
ly on both stones and work area.

CAUTION
When honing cylinder block, remove hone frequently and check condition of cylin-
der walls. DO NOT hone any more than absolutely necessary, as hone can remove
cylinder wall material rapidly.
c. Start stroking at smallest diameter. Maintain firm stone pressure against cylinder
wall to assure fast stock removal and accurate results.
d. Localize stroking in the smallest diameter until drill speed is constant throughout
length of bore. Expand stones, as necessary, to compensate for stock removal and
stone wear. Stroke at a rate of 30 complete cycles per minute to produce best
cross-hatch pattern. Use honing oil generously.
e. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff
bristle brush and rinse thoroughly with hot water. A good cleaning is essential. If any
of the abrasive material is allowed to remain in the cylinder bore, it will cause rapid
wear of new piston rings and cylinder bore in addition to bearings. After cleaning,
bores should be swabbed several times with engine oil and a clean cloth, then wiped
with a clean, dry cloth. Cylinders should not be cleaned with kerosene or gasoline.
Clean remainder of cylinder block to remove excess material spread during honing
operation.
2. Hone all cylinder walls just enough to de-glaze walls.
3. Measure cylinder bore diameter (with a snap gauge micrometer) of each cylinder, as
shown below. Check for tapered, out-of-round (egg-shaped) and oversize bore.

52324

Page 4A-32 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Model Cylinder Block Finish Hone

200/225 3.6265 in. (92.1131mm)
0.015 in. Oversize 3.6415 in. (92.4941mm)
0.030 in. Oversize 3.6565 in. (92.8751mm)

4. If a cylinder bore is tapered, out-of-round, or worn more than 0.003 in. (0.076mm) from
standard Cylinder Block Finish Hone diameter, it will be necessary to re-bore that
cylinder to 0.015 in. (0.381mm) oversize or 0.030 in. (0.762mm) oversize and install
oversize piston and piston rings during reassembly.
NOTE: The weight of an oversize piston is approximately the same as a standard size pis-
ton; therefore, it is not necessary to re-bore all cylinders in a block just because one cylinder
requires re-boring.
5. After honing and thoroughly cleaning cylinder bores, apply light oil to cylinder walls to
prevent rusting.

Pistons and Piston Rings

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

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

a -Ring Grooves

90-855348R02 NOVEMBER 2002 Page 4A-33

CYLINDER BLOCK ASSEMBLY

MEASURING PISTON ROUNDNESS

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

Piston Dimension “A”

Standard Piston 3.6205 in. ± .0005 in.
.015 in. Oversize Piston 3.6355 in. ± .0005 in.
.030 in. Oversize Piston 3.6505 in. ± .0005 in.

2. Using a micrometer, measure dimension “A” at location shown. Dimension “A” should
be 3.6210 in. ± 0.0005 in. for a STANDARD size piston.

A 1 in.
(25.4mm)

55959
a -Dimension “A” at Right Angle (90°) to Piston Pin

Cylinder Heads
1. Inspect internal surface of cylinder heads for possible damage (as a result of piston or
foreign material striking cylinder heads).
IMPORTANT: Cylinder head warpage should not exceed 0.005 in. (0.127mm) over the
ENTIRE length of the cylinder head. If measured warpage, as determined on a surface
block, exceeds 0.005 in. (0.127mm) or a discontinuity of up to 0.001 in. (0.025mm) ex-
ists in a 1.0 in. (25.4mm) length of the cylinder head’s surface, then the cylinder head
must be replaced.
2. Replace cylinder heads as necessary.

Crankshaft
1. Inspect crankshaft to drive shaft splines for wear. (Replace crankshaft, if necessary.)
2. Check crankshaft for straightness. Maximum runout – 0.002 in. (0.0508mm). Check
runout at center main bearing surfaces with ends of crankshaft supported in V-blocks.
(Replace as necessary.)
3. Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or
scratched. (Replace as necessary.)
4. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear
and/or overheating. (Refer to Connecting Rods)

Page 4A-34 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

5. If necessary, clean crankshaft surfaces with crocus cloth.

a

c c

52323
a -Crankshaft Journals
b -Crocus Cloth
c -Work Cloth Back-and-Forth

WARNING
DO NOT spin-dry crankshaft ball bearing with compressed air.
6. Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearing.
Recheck surfaces of crankshaft. Replace crankshaft, if surfaces cannot be properly
cleaned up. If crankshaft will be re-used, lubricate surfaces of crankshaft with light oil
to prevent rust. DO NOT lubricate crankshaft ball bearing at this time.

Crankshaft (and End Cap) Bearings

IMPORTANT: When overhauling powerhead assembly, it is recommended that all
crankshaft bearings – upper/lower, center main, connecting rod and wrist pin bear-
ings – be replaced to ensure optimum powerhead performance and longevity.
1. After cleaning crankshaft, grasp outer race of crankshaft ball bearing (installed on lower
end of crankshaft) and attempt to work race back-and-forth. There should not be
excessive play.
2. Lubricate ball bearing with light oil. Rotate outer bearing race. Bearing should have
smooth action and no rust stains. If ball bearing sounds or feels rough or has catches,
remove and discard bearing. (Refer to Powerhead Removal and Disassembly -
Crankshaft Removal and Disassembly)

52326

a -Lower Ball Bearing

90-855348R02 NOVEMBER 2002 Page 4A-35

CYLINDER BLOCK ASSEMBLY

3. Thoroughly clean (with solvent) and dry crankshaft center main roller bearings.
Lubricate bearings with 2-Cycle Premium Outboard Oil.

CAUTION
DO NOT intermix halves of upper and lower crankshaft center main roller bearings.
Replace bearings in pairs only.
4. Thoroughly inspect center main roller bearings. Replace bearings if they are rusted,
fractured, worn, galled or badly discolored.

a 52153
a -Center Main Roller Bearing

5. Clean (with solvent) and dry crankshaft roller bearing that is installed in upper end cap.
Lubricate bearing with light oil.
6. Thoroughly inspect upper crank shaft roller bearing. If roller bearing is rusted, fractured,
worn, galled or badly discolored, replace roller bearing.

51473
a -Upper Roller Bearing

Reed Block Assembly

IMPORTANT: DO NOT remove reeds from reed blocks, unless replacement is neces-
sary. DO NOT turn used reeds over for re-use. Replace reeds in sets only.
1. Thoroughly clean gasket surfaces of reed blocks and reed block housing. Check for
grooves, cracks and distortion that could cause leakage. Replace parts as necessary.
2. Check for wear (indentations) on face of each reed block. Replace blocks if reeds have
made indentations.

Page 4A-36 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

3. Check for chipped and broken reeds.

56023
Allowable reed opening is 0.020 in. (0.51mm) or less. Replace reeds if either reed is stand-
ing open more than 0.020 in. (0.51mm).

Reed Block
Inspect passages in reed block to be sure that they are not obstructed.

Connecting Rods
1. Check connecting rods for alignment by placing rods on a surface plate. If light can be
seen under any portion of machined surfaces, if rod has a slight wobble on plate, or if
a 0.002 in. (0.051mm) feeler gauge can be inserted between any machined surface and
surface plate, rod is bent and must be discarded.
2. Overheating: Overheating is visible as a bluish bearing surface color that is caused by
inadequate lubrication or excessive RPM.
3. Rust: Rust formation on bearing surfaces causes uneven pitting of surfaces.

a 51853
a -Pitting

90-855348R02 NOVEMBER 2002 Page 4A-37

CYLINDER BLOCK ASSEMBLY

4. Water Marks: When bearing surfaces are subjected to water contamination, a bearing
surface “etching” occurs. This etching resembles the size of the bearing.

51853
5. Spalling: Spalling is loss of bearing surface, and it resembles flaking or chipping. Spalling
will be most evident on the thrust portion of connecting rod in line with the “I” beam.
General bearing surface deterioration could be caused by or accelerated by improper
lubrication.

a
51853
a -Spalling

6. Chatter Marks: Chatter marks are the result of a combination of low speed, low load, and
cold water temperature operation, aggravated by inadequate lubrication and/or improper
fuel. Under these conditions, the crankshaft journal is hammered by the connecting rod.
As ignition occurs in the cylinder, the piston pushes the connecting rod with tremendous
force, and this force is transferred to the connecting rod journal. Since there is little or no
load on the crankshaft, it bounces away from the connecting rod. The crankshaft then
remains immobile for a split second until the piston travel causes the connecting rod to
catch up to the waiting crankshaft journal, then hammers it. The repetition of this action
causes a rough bearing surface which resembles a tiny washboard. In some instances,
the connecting rod crank pin bore becomes highly polished. During operation, the engine
will emit a whirr and/or chirp sound when it is accelerated rapidly from idle speed to
approximately 1500 RPM, then quickly returned to idle. If the preceding conditions are
found, replace both the crankshaft and connecting rods.

a 51853
a -Chatter Marks Between Arrows

Page 4A-38 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

7. Uneven Wear: Uneven wear could be caused by a bent connecting rod.

a
51853
a -Uneven Wear Between Arrows

8. If necessary, clean connecting rod bearing surfaces, as follows:

a. Be sure that etched marks on connecting rod (crankshaft end) are perfectly aligned
with etched marks on connecting rod cap. Tighten connecting rod cap attaching
bolts securely.

CAUTION
Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of connect-
ing rod. DO NOT use any other type of abrasive cloth.
b. Clean CRANKSHAFT END of connecting rod by using CROCUS CLOTH placed
in a slotted 3/8 in. (9.5mm) diameter shaft, as shown. Chuck shaft in a drill press and
operation press at high speed while keeping connecting rod at a 90° angle to slotted
shaft.
IMPORTANT: Clean connecting rod just enough to clean up bearing surfaces. DO
NOT continue to clean after marks are removed from bearing surfaces.

52323
c. Clean PISTON PIN END of connecting rod, using same method as in Step “b”, pre-
ceding, but using 320 grit carborundum cloth instead of crocus cloth.
d. Thoroughly wash connecting rods to remove abrasive grit. Recheck bearing sur-
faces of connecting rods. Replace any connecting rods that cannot be properly
cleaned up. Lubricate bearing surfaces of connecting rods (which will be re-used)
with light oil to prevent rust.

90-855348R02 NOVEMBER 2002 Page 4A-39

CYLINDER BLOCK ASSEMBLY

Powerhead Reassembly and Installation

General
Before proceeding with powerhead reassembly, be sure that all parts to be re-used have
been carefully cleaned and thoroughly inspected, as outlined in Cleaning and Inspection,
preceding. Parts, which have not been properly cleaned (or which are questionable), can
severely damage an otherwise perfectly good powerhead within the first few minutes of op-
eration. All new powerhead gaskets MUST BE installed during reassembly.
During reassembly, lubricate parts with 2-Cycle Premium Outboard Oil whenever light oil
is specified. Part numbers of lubricants, sealers and locking compounds are listed in Sec-
tion 1A - Mercury/Quicksilver Lubricants and Sealants.
A torque wrench is essential for correct reassembly of powerhead. DO NOT attempt to
reassemble powerhead without using a torque wrench. Attaching bolts for covers, housings
and cylinder heads MUST BE torqued by tightening bolts in 3 progressive steps (following
specified torque sequence) until specified torque is reached (see Example).
EXAMPLE: If cylinder head attaching bolts require a torque of 20 Ib. ft. (27.1 Nm), a) tighten
all bolts to 5 Ib. ft. (6.7 Nm), following specified torque sequence, b) tighten all bolts to 10
Ib. ft. (13.6 Nm), following torque sequence, then finally c) tighten all bolts to 20 Ib. ft. (27.1
Nm), following torque sequence.
IMPORTANT: If lower drive shaft ball bearing has been removed, it is recommended
that a new bearing be installed as the removal process will damage the bearing.
1. If removed, press new lower crankshaft ball bearing onto crankshaft as shown. Be sure
bearing is pressed firmly against shoulder.

a b

51852
a -Crankshaft
b -Crankshaft Ball Bearing
c -Suitable Mandrel
d -Press

Page 4A-40 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

2. Reinstall retaining ring using a suitable pair of Snap Ring Pliers.

55983
a -Retaining Ring

3. If removed, spread new crankshaft sealing rings just enough to slide over crankshaft
journal.
a

51854

a -Crankshaft Sealing Rings

4. Use Piston Ring Expander and install crankshaft sealing rings into groove.

b
a

52320
a -Piston Ring Expander (91-24697)
b -Crankshaft Sealing Rings (7 Each)

90-855348R02 NOVEMBER 2002 Page 4A-41

CYLINDER BLOCK ASSEMBLY

5. Lubricate center main crankshaft roller bearings and races with light oil.

52318
a
b
a -Install so Hole is Toward Drive Shaft End of Crankshaft
b -Verify Retaining Ring Bridges the Separating Lines of the Bearing Race

6. Place center main crankshaft roller bearings on upper and lower main bearing journals
as shown.
7. Install center main bearing races as shown.
a

52315
b
a -Flywheel End
b -Drive Shaft End

Page 4A-42 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

8. Secure center main bearing races together with retaining rings. Make sure retaining ring
bridges the separating lines of the bearing race.
a a

55994
a -Center main Bearing Races

9. Install oil seals into lower end cap as follows:

a. Apply a thin bead of Loctite 271 to outer diameter of lower end cap oil seals.
b. Using suitable mandrel, press one oil seal (lip facing DOWN) into lower end cap until
firmly seated. Remove any excess Loctite.
c. Press second oil seal (lip facing DOWN) until firmly seated on first oil seal. Remove
any excess Loctite.

a
d. Lubricate oil seal lips with 2-4-C with Teflon.
e. Apply a light coat of Perfect Seal to end cap flange.
f. Lubricate O-ring seal with 2-4-C with Teflon and install over lower end cap.

a 51849

a -O-ring

90-855348R02 NOVEMBER 2002 Page 4A-43

CYLINDER BLOCK ASSEMBLY

10. Install oil seal into upper bearing carrier assembly as follows:
a. Apply a light film of 2-4-C with Teflon to outer diameter of oil seal. This will ease seal
installation into carrier.
b. Lubricate oil seal lip with 2-4-C with Teflon.
c. Use a suitable mandrel, press oil seal into carrier (lip facing DOWN) until bottomed
out on shoulder of carrier.
d. Lubricate O-ring with 2-4-C with Teflon and install on carrier.
b

a 51473
a -O-ring
b -Seal

Crankshaft Installation
SPECIAL INFORMATION
Installing A New Crankshaft Assembly Into Cylinder Block
Check crankshaft sealing ring mating surfaces in cylinder block and crankcase cover for wear
grooves caused by the crankshaft sealing rings from the previous crankshaft. If wear grooves
are present, sealing rings on the new crankshaft will have to fit into grooves without binding the
crankshaft.
Before installing crankshaft, remove any burrs that may exist on groove edges.
Lubricate sealing rings with light oil and install new crankshaft as instructed.
Install upper and lower end caps and then inspect fit between sealing rings and grooves.
Temporarily install crankcase cover and rotate crankshaft several times to check if sealing
rings are binding against crankshaft. (You will feel a drag on the crankshaft.) If sealing rings
are binding, recheck grooves for burrs. If this does not correct the problem, it is recom-
mended that the cylinder block be replaced.

Page 4A-44 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Install crankshaft as follows:

1. Lubricate crankshaft sealing rings with light oil.
2. Check cylinder block to be sure that dowel pins are in place.
a

55992
a -Dowel Pins

3. Position all crankshaft seal ring gaps straight up.

4. Align hole in each center main bearing race with dowel pin.
5. Gently push crankshaft down into position making sure that the dowel pins are lined up
with the holes in center main bearings and crankshaft seal rings are in place.

55993

90-855348R02 NOVEMBER 2002 Page 4A-45

CYLINDER BLOCK ASSEMBLY

6. Lubricate lower crankshaft end (oil seal area) with light oil, then install lower end cap.
Secure end cap to cylinder block with attaching bolts. DO NOT tighten end cap bolts at
this time.

52328
a -Lower End Cap

Piston and Connecting Rod Reassembly

1. Place needle bearings on a clean piece of paper and lubricate with 2-4-C with Teflon.
NOTE: There are 34 needle bearings per piston.
2. Place sleeve which is part of piston pin tool into connecting rod and install needle
bearings around sleeve as shown.
a

52315
a -Sleeve (Part of Tool Assembly 91-92973A1)

Page 4A-46 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

3. Place locating washers on connecting rod.

IMPORTANT: Position connecting rod part number facing towards flywheel.
4. Position piston over end of rod. Verify locating washers remain in place.

55960
a -Locating Washers

5. Insert piston pin tool and push sleeve out of piston. Keep piston pin tool in piston.

b
a

55961
a -Piston Pin Tool (91-92973A1
b -Sleeve

6. Use a mallet and tap piston pin into piston and push piston pin tool out.

55962
a -Piston Pin
b -Piston Pin Tool

90-855348R02 NOVEMBER 2002 Page 4A-47

CYLINDER BLOCK ASSEMBLY

7. Install new piston pin lockrings (one each end of piston pin) with Lockring Installation
Tool.
8. Make sure lockrings are properly seated in piston grooves.

a
a

51086 55963

a -Lockring Installation Tool (91-93004A2)

b -Lockring

Piston and Piston Ring

Combination
.078 in.

.078 in.
55964

a -Half Keystone (tapered) Piston Ring

Piston Installation
1. Before installing new piston rings, check gap between ring ends by placing each ring
in its respective cylinder, then pushing ring about 1/2 in. (12.7mm) into cylinder using
piston to assure proper position.

Page 4A-48 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

2. Check end gap of each new piston ring with a feeler gauge. End gap must be within
0.010 in. to 0.018 in. (0.254mm to 0.457mm). If end gap is greater, check other piston
rings in cylinder bore, until rings (within tolerance) are found.

52327
a -Piston Ring
b -Dot or “T” (Faces Up)
c -Feeler Gauge
d -Ring End Gap

IMPORTANT: Piston ring side with dot or letter must be facing up.

52317

a -Piston Ring
b -Dot

3. Use Piston Ring Expander (91-24697) and install piston rings (dot side up) on each
piston. Spread rings just enough to slip over piston.
4. Check piston rings to be sure that they fit freely in ring groove.

90-855348R02 NOVEMBER 2002 Page 4A-49

CYLINDER BLOCK ASSEMBLY

5. Lubricate piston, rings and cylinder wall with 2-Cycle Premium Outboard Oil.

52319

a -Piston Ring Expander

b -Dot Side “UP” on Piston Ring

6. Rotate each piston ring so end of ring is aligned with locating pin as shown.
7. Install Piston Ring Compressor.
8. Remove screws and connecting rod cap from piston rod assembly being installed.
IMPORTANT: Piston must be correctly installed and positioned as shown.
Pistons marked with the word “UP” and with the letter “P” or “S” on top of piston.
Pistons with the letter “P” must be installed in the port side of engine and the word “UP” fac-
ing toward top of engine.
Pistons with the letter “S” must be installed in the star- board side of engine and the word
“UP” toward top of engine.

UP UP
CYL 2 CYL 1
P S

UP UP
CYL 4 CYL 3
P S

UP UP
CYL 6 CYL 5
P S

Page 4A-50 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

9. Coat cylinder bore with 2-cycle oil. Match piston assembly with cylinder it was removed
from, and position piston as described below. Push piston into cylinder.

a
52328
a -Piston Ring Compressor (91-823237)

10. Apply 2-4-C with Teflon to bearing surface of connecting rod and install bearing
assembly, as shown.
11. Place connecting rod cap on connecting rod. Apply light oil to threads and face of
connecting rod bolts. Thread connecting rod bolts finger-tight while checking for correct
alignment of the rod cap as shown.
IMPORTANT: Connecting rod and connecting rod caps are matched halves. Do not
torque screws before completing the following procedure.
• Run a pencil lightly over ground area.
• If pencil stops at fracture point, loosen bolts, retighten, and check again.
NOTE: If you still feel the fracture point, discard the rod.
12. Tighten connecting rod bolts (using a 3/8 in. - 12 point socket) First torque to 15 lb. in.
(1.7 Nm) then 30 lb. ft. (40.7 Nm). Turn each bolt an additional 90° after 2nd torque is
attained. Recheck alignment between rod cap and rod as shown.

52316
a -Connecting Rod Screws

13. Rotate crankshaft several times (using powerhead stand) to assure free operation (no
binds and catching).

90-855348R02 NOVEMBER 2002 Page 4A-51

CYLINDER BLOCK ASSEMBLY

CONNECTING ROD CAP ALIGNMENT

Check each connecting rod cap for correct alignment. If not aligned, a ridge can be seen
or felt at the separating line as shown below. Correct any misalignment.

a c

b d

52381

a -Side View Incorrect – Cap on Backwards

b -End View Incorrect – Cap on Backwards
c -Side View Correct
d -End View Correct

Crankcase Cover Installation

1. Thoroughly remove all oil from mating surfaces of crankcase cover and cylinder block
with Loctite Primer 203 included in Master Gasket Kit (92-12564-1).
a

b b

55984
a -Crankcase Cover
b -Remove All Oil

Page 4A-52 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

2. Apply a thin, even coat of Loctite Master Gasket on mating surface of cylinder block.

55985

a -Loctite Master Gasket

3. Place crankcase cover in position on cylinder block. Turn 8 center main bolts in a LITTLE
at a time, (following torque sequence) compressing crankshaft seal rings until crankshaft
cover has been drawn down to cylinder block. Tighten eight bolts (a) evenly in three
progressive steps (following torque sequence).

90-855348R02 NOVEMBER 2002 Page 4A-53

CYLINDER BLOCK ASSEMBLY

4. Install remaining crankcase cover flange bolts (following torque sequence).

a
8 7

13 14

9 10

6 1 4 7

4 1

2 3
3 2

8 5

11 12

5 6
b
55986
a -Apply Light Oil to Threads and Bolt Face; 8 Bolts (M10 x 1.5 x 80); 30 lb. ft. (40.7
Nm) and Rotate 90°
b -14 Bolts (M8 x 1.25 x 35) 28 lb. ft. (38.0 Nm)

Page 4A-54 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

5. Tighten end cap bolts to specified torque.

a
52132
a -Torque Bolts to 85 lb. in. (9.6 Nm)

Assembly of Reed Blocks to Intake Manifold

c

55991
a -Intake Manifold Bolts [Torque to 100 lb. in. (11.3 Nm)]
b -Reed Block Mounting Bolts [Torque to 90 lb. in. (10.2 Nm)]
c -Reed Attaching Screws [Torque to 25 lb. in. (2.8 Nm)]

90-855348R02 NOVEMBER 2002 Page 4A-55

CYLINDER BLOCK ASSEMBLY

Exhaust Plate 1997 Model 200 DFI

35
95 36
37
38
31 3
23 23
30
26 28
142
39
32
23 22
21 20 40
29 33
27
34 95
24 1
25 A 41
18 20

19 95

17 42
11 16
15
5
10

14 43

13
7
12
8

6
4
11

8 9

142 3M Permabond #3M08155

95 2-4-C with Teflon

A = TO AIR COMPRESSOR

Page 4A-56 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Exhaust Plate 1997 Model 200 DFI

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 EXHAUST PLATE
2 2 STRAINER S/N-0G437999 & BELOW
3 1 GASKET
4 1 GASKET (LOWER)
1 SPRING
5
1 SPRING
1 1 EXHAUST PLATE
3 1 GASKET S/N-0G438000 & UP
6 1 GASKET (LOWER)
7 1 SEAL
8 2 SCREW (M8 x 35) 20 27.1
9 1 COVER
10 1 RELIEF VALVE PLATE ASSEMBLY
11 2 GASKET
12 1 SCREW Drive Tight
13 1 WASHER
14 1 DIAPHRAGM
15 1 POPPET
16 1 GROMMET
17 1 CARRIER
18 6 SCREW (M8 x 35) 25 33.9
19 3 CONNECTOR
20 2 PIPE PLUG
21 1 ELBOW (45°)
22 1 IDLE EXHAUST BOOT
23 AR STA STRAP
24 1 HOSE
25 1 FITTING – tell tale
26 1 PLUG
27 1 WASHER
28 1 CHECK VALVE
29 1 O RING
30 1 FITTING
31 1 HOSE
32 1 STRAINER, Fuel cooler
33 2 DRAIN CHECK VALVE
34 4 DOWEL PIN
35 1 NUT
36 1 WASHER
37 1 ROLLER
38 1 NUT
39 1 SHIFT LINK
40 1 BUSHING
1 UPPER SHIFT SHAFT (LONG)
41
1 UPPER SHIFT SHAFT (X–LONG)
42 1 BUSHING
43 1 COUPLING

90-855348R02 NOVEMBER 2002 Page 4A-57

CYLINDER BLOCK ASSEMBLY

Exhaust Plate 1998/1999 Model 200/225 DFI

32 31

33

34

35

24 2
28 95
30 36
29
24
142

39 23

6 5 8 37

26 27 7 9
1
25

22 95

10

13
18 16 15 14
17

38
19
20 4
21
12

18
3

11
12
142 3M Permabond #3M08155
95 2-4-C With Teflon

Page 4A-58 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Exhaust Plate 1998/1999 Model 200/225 DFI

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 EXHAUST PLATE
2 1 GASKET
3 1 GASKET (LOWER)
4 1 SEAL
5 1 CONNECTOR
6 1 CHECK VALVE FITTING
7 2 PLUG
8 2 DRAIN CHECK VALVE
9 4 DOWEL PIN
10 2 FITTING
11 1 COVER
12 2 SCREW (M8 x 35) 20 27.1
13 1 CARRIER
14 1 GROMMET
15 1 POPPET
16 1 SPRING
17 1 RELIEF VALVE PLATE ASSEMBLY
18 2 GASKET
19 1 DIAPHRAGM
20 1 WASHER
21 1 SCREW (10-16 x 3/4 IN.) Drive Tight
22 6 SCREW (M8 x 35) 25 34.0
23 1 IDLE EXHAUST BOOT
24 2 STA-STRAP
25 1 FITTING – tell tale
26 1 PLUG
27 1 WASHER
28 1 FITTING
29 1 CHECK VALVE
30 1 O RING
31 1 NUT
32 1 SLIDE
33 1 NUT
34 1 SHIFT LINK
35 1 BUSHING
1 UPPER SHIFT SHAFT (LONG)
36
1 UPPER SHIFT SHAFT (X–LONG)
37 1 BUSHING
38 1 COUPLING
39 1 HOSE (INLET)

90-855348R02 NOVEMBER 2002 Page 4A-59

CYLINDER BLOCK ASSEMBLY

Cylinder Head Installation

1. Install each cylinder head to engine block with thermostat pocket UP. Apply light oil to
cylinder head bolt threads and bolt face. Torque all bolts to 20 lb. ft. (27.1 Nm) and
rotate 90°.

20 18

16 14

12 10

1 3

7 5

6 8

4 2

9 11

13 15

17 19
52132
2. Install thermostat assembly into each cylinder head.

Page 4A-60 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

3. Install overheat temperature sensor into STARBOARD cylinder head opposite #1 spark
plug.
a b

d c

a -Thermostat 120° F (48.9° C)

b -O-Rings
c -Temperature Sensor
d -Bolt - Torque to 200 lb. in. (22.6 Nm)
e -Bolt - Torque to 100 lb. in. (11.3 Nm)

NOTE: During normal engine operating temperature, the sender electrical circuit is open
and will close if temperature reaches 200 F  8 F (93.3 C  4.4 C) thus activating the
overheat alarm.
4. Thermostat and temperature sensor installed.

55972
55940
a -Thermostat [120° F (49° C)]
b -Overheat Temperature Sensor [Torque attaching bolt to
200 lb. in. (22.6 Nm)]

90-855348R02 NOVEMBER 2002 Page 4A-61

CYLINDER BLOCK ASSEMBLY

Bleed System 1997 Model 200 DFI

10
8

11
4 3

6
12
9
1 2
7

9
5

9
18

22
14
13 19 9
9

21
16
9
17
15
20
9

9 Loctite 567 PST Pipe Sealant

Page 4A-62 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Bleed System 1997 Model 200 DFI

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 MANIFOLD-Bleed System
2 6 CHECK VALVE
3 1 ELBOW
4 1 SCREW (10-16 x 3/4 IN.) PORT Drive Tight
5 1 TUBING (9 IN.)
6 2 TUBING (5-1/4 IN.)
7 3 FITTING (Shown as Ref. 10 on page 21)
8 1 FUEL FILTER
9 1 TUBING (2-3/4 IN.)
10 1 FITTING-Tee
11 1 TUBING (9-1/2 IN.)
12 3 CAP
13 1 MANIFOLD-Bleed System
14 6 CHECK VALVE
15 1 ELBOW
16 1 SCREW (10-16 x 3/4 IN.) STARBOARD Drive Tight
17 1 TUBING (5-1/4 IN.)
18 1 TUBING (20-1/2 IN.)
19 1 TUBING (7 IN.)
20 1 TUBING (8-1/2 IN.)
21 3 FITTING (Shown as Ref. 10 on page 21)
22 3 CAP

90-855348R02 NOVEMBER 2002 Page 4A-63

CYLINDER BLOCK ASSEMBLY

Front Bleed View 1997 Model 200 DFI

Page 4A-64 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Notes:

90-855348R02 NOVEMBER 2002 Page 4A-65

CYLINDER BLOCK ASSEMBLY

Bleed System 1998 Model 200/225 DFI

14 12

13 11
29 B
A 31 31 10
27
30
28 8
8 7

4 12
32
17 3 11

8 10

9
12 5

6
21


19  10

 11
21


24 12
25 17 

23 
22
26
18 15
16
19 
24
21
23

22 
20

20

22 
23

24 

A = TO AIR HANDLER B = TO AIR COMPRESSOR

Page 4A-66 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Bleed System 1998 Model 200/225 DFI

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 MANIFOLD-Bleed System
2 6 CHECK VALVE
3 1 FITTING-STRAIGHT
4 1 SCREW (10-16 x 3/4 IN.) PORT Drive Tight
5 2 TUBING (5-1/2 IN.)
6 2 TUBING (7 IN.)
7 2 TUBING (6 IN.)
8 3 FITTING
9 1 TUBING (10-1/2 IN.)
10 3 CHECK VALVE
11 3 TUBING (1-3/4 IN.)
12 3 CHECK VALVE
13 1 TUBING (4-1/2 IN.)
14 1 TUBING (10-1/4 IN.)
15 1 MANIFOLD-Bleed System
16 6 CHECK VALVE
17 1 FITTING-STRAIGHT
18 1 SCREW (10-16 x 3/4 IN.) STARBOARD Drive Tight
19 1 TUBING (7 IN.)
20 1 TUBING (5-1/2 IN.)
21 3 FITTING
22 3 CHECK VALVE
23 3 TUBING (1-3/4 IN.)
24 3 CHECK VALVE
25 1 TUBING (4-1/2 IN.)
26 1 TUBING (9 IN.)
27 1 TUBING (1-1/4 IN.)
28 1 FITTING-Tee
29 1 TEE FITTING
30 1 TUBING (1-1/2 IN.)
31 2 STA STRAP
32 1 TUBING (13 IN.)

90-855348R02 NOVEMBER 2002 Page 4A-67

CYLINDER BLOCK ASSEMBLY

Anchor Bracket/Throttle Linkage Model 1997 200 DFI

22

95 15

21 16
18

20

22 14 19
23

17
21 20
13

95

12

11 13
2
1 4
10
9 7
A
3

5
9
6
8

7 95

95 2-4-C With Teflon

A = TO FUEL MANAGEMENT BRACKET

B = 25 lb. ft. (34.0 Nm)
C = 20 lb. ft. (27.0 Nm)
Page 4A-68 90-855348R02 NOVEMBER 2002
 CYLINDER BLOCK ASSEMBLY

Anchor Bracket/Throttle Linkage 1997 Model 200 DFI

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 SWITCH
2 2 SCREW (M3.5 x 20) 10 1.1
3 1 ANCHOR BRACKET
4 2 DRIVE SCREW
5 1 LATCH
6 2 CUP
7 3 SCREW (M8 x 25)
8 1 BUSHING
9 2 BUSHING
10 1 SPRING
11 1 ROLLER GUIDE
12 1 THROTTLE LINK
13 2 SWIVEL BUSHING
14 1 THROTTLE LEVER
15 1 SCREW (M8 x 35) 20 27.1
16 1 WASHER
17 1 PIN INSERT
18 1 BUSHING
19 1 NUT
20 2 SCREW (M6 x 70)
21 2 NUT
22 2 CAP
23 1 WASHER

90-855348R02 NOVEMBER 2002 Page 4A-69

CYLINDER BLOCK ASSEMBLY

Anchor Bracket/Throttle Linkage 1998/1999

Model 200/225 DFI





14 

95
10 
19
  
  
 



95

 

 









 34

 32

28 33


95 2-4-C with Teflon

Page 4A-70 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

Anchor Bracket/Throttle Linkage 1998/1999

Model 200/225 DFI
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm

1 THROTTLE CONTROL LEVER
2 1 SCREW (M8 x 35) 20.8 28.3
3 1 WASHER
4 1 BUSHING
5 2 SCREW (M6 x 55)
6 2 NUT
7 2 CAP
8 1 PIN INSERT
9 1 NUT 50 5.6
10 1 BEARING
11 1 CAM
12 1 BUSHING
13 1 SCREW (M8 x 40) 45 5.1
14 1 THREADED BALL
15 2 SWIVEL BUSHING
16 1 LINK
17 1 ROLLER
18 1 THROTTLE ROLLER
19 1 RETAINING RING
20 1 SCREW (M5 x 16) Drive Tight
21 1 WASHER
22 1 STAR WASHER
23 1 ANCHOR BRACKET
24 1 LATCH
25 2 SCREW-Drive
26 2 CUP
27 3 SCREW (M8 x 25) 25 33.9
28 1 SCREW (M8 x 25) 20 27.1
29 1 ROLLER GUIDE
30 1 SWITCH
31 2 SCREW (M3.5 x 20)
32 1 BRACKET
33 1 BRACKET
34 1 CABLE TIE

90-855348R02 NOVEMBER 2002 Page 4A-71

CYLINDER BLOCK ASSEMBLY

Reinstalling Engine Components

Reinstall the following Section 3
components: Air Management System
Fuel Management System
Section 2
Fuel Pump
Starter Motor
Fuel Rails
Alternator
Vapor Separator
Ignition Modules
Electronic Control Unit Oil Injection
Solenoids On-Board Oil Tank
Crank Position Sensor Oil Pump
Throttle Position Sensor
Temperature Sensor

Powerhead Installation on Driveshaft Housing

1. Install Lifting Eye (91-90455) into flywheel.

WARNING
BE SURE that Lifting Eye is threaded into flywheel as far as possible BEFORE lifting
powerhead.
2. Using a hoist, lift powerhead high enough to allow removal of powerhead from repair
stand. Remove powerhead from repair stand, being careful not to damage drive shaft
housing gasket surface of powerhead.
3. Place a new gasket around powerhead studs and into position on base of powerhead.
NOTE: If using powerhead base gasket with a gray bead impregnated in surface, position
gasket with gray bead towards powerhead.
NOTE: Prior to installing the powerhead onto drive shaft housing, verify shift shaft is
installed in gear housing and selects Forward – Neutral – Reverse as shown.

F
N

Page 4A-72 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

IMPORTANT: DO NOT apply lubricant to top of driveshaft as this will prevent drive-
shaft from fully engaging into crankshaft.
4. Apply a small amount of 2-4-C with Teflon onto driveshaft splines.
5. Use hoist to lower powerhead onto driveshaft housing. It may be necessary to turn
flywheel (aligning crankshaft splines with drive shaft splines) so that powerhead will be
fully installed.
6. Install 10 flat washers and 10 locknuts which secure powerhead to exhaust extension
plate/driveshaft housing. Torque locknuts in 3 progressive steps until secured.
7. Disconnect hoist from Lifting Eye and remove Lifting Eye from flywheel.
8. Reinstall plastic cap into center of flywheel cover.

52373

a -Locknuts and Flat Washers [Torque to 50 lb. ft. (68.0 Nm)]

9. Connect bypass water hoses to fittings on exhaust adaptor plate.

a
a
b

55920

a -Water Hose
b -Water Pressure Gauge Fitting (1997 Models)

90-855348R02 NOVEMBER 2002 Page 4A-73

CYLINDER BLOCK ASSEMBLY

10. Connect tell-tale hose and flush hose to engine block.

b 55970
a -Tell-Tale Hose
b -Flush Hose
11. Install four bolts which secure bottom cowl halves together.

52352

a
55932

a
55970
a -Bolts [Torque to 65 lb. in. (7.3 Nm)

Page 4A-74 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

12. Re-connect input fuel line with hose clamp.

52191

a -Fuel Line
b -Hose Clamp

13. Connect remote oil tank pressure hose to to crankcase fitting.

55919
a -Remote Oil Tank Pressure Hose

14. Attach relay ground harness to lower electrical plate mounting bolt. Torque bolt to 16.5
lb. ft. (22.4 Nm).
15. Attach relay positive leads (RED) to BATTERY SIDE of starter solenoid with nut. Torque
nut to 45 lb. in. (5.1 Nm).

90-855348R02 NOVEMBER 2002 Page 4A-75

CYLINDER BLOCK ASSEMBLY

16. Re-connect remote control harness to powerhead harness connector and wires as
shown.

55919
e b
a -Nut – Attach RED Relay Leads – Torque Nut to 45 lb. in.
(5.1 Nm)
b -Relays – Secure with Retained Bolts and Nuts
c -Bolt – Attach BLACK (ground) Relay leads – Torque Bolt to
16.5 lb. ft. (22.4 Nm).
d -Connect BLUE/WHITE and GREEN/WHITE Trim Leads to Lower
Cowl Trim Switch Harness.
e -Connect BLUE (sleeve) and GREEN Power Trim Leads.
f -Remote Control/Powerhead Harness

17. Install two screws which secure remote control harness retainer.

55917

a -Screws
b -Retainer

Page 4A-76 90-855348R02 NOVEMBER 2002

 CYLINDER BLOCK ASSEMBLY

18. Reinstall oil line to on board oil reservoir.

19. Slide outboard shift lever into neutral position.
20. Install throttle cable.
21. Install shift cable assembly as shown Refer to “Cable Adjustment” Section 7A.

d
a
b

c
55918

a -Throttle Cable
b -Shift Cable
c -Cable Retainer
d -Oil Hose

Refer to Section 2 of this Service Manual for engine set-up procedures.

Break-ln Procedure
CAUTION
Severe damage to the engine can result by not complying with the Engine Break-in
Procedure.

FUEL REQUIREMENTS
Do not use pre-mixed gas and oil in this engine. Use straight gasoline during engine break-in
and after engine break-in. The ECM is programmed to signal the oil pump to provide addi-
tional oil (50:1 ratio) during the first 90 minutes (1997 models) or 240 minutes (1998 and
1999 models) of operation. The ECM will monitor this period through its own internal clock.
At the end of this period, the ECM will signal the oil pump to go to a standard ratio of 300
– 400:1 @ idle and 60:1 @ W.O.T.
ENGINE BREAK-IN PROCEDURE (ALL MOELS)
Vary the throttle setting during the first hour of operation. Avoid remaining at a constant
speed for more than two minutes and avoid sustained wide open throttle.

90-855348R02 NOVEMBER 2002 Page 4A-77

 COOLING SYSTEM

POWERHEAD
Section 4B - Cooling System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Water Pressure Check . . . . . . . . . . . . . . . . . . 4B-8
Temperature Sensor . . . . . . . . . . . . . . . . . . . . 4B-1 Water Pump Cleaning and Inspection . . . . . 4B-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Problem Diagnosis . . . . . . . . . . . . . . . . . . . . 4B-11
3.0 Liter Optimax/DFI Water Flow . . . . . . . . . . . 4B-4 Water Pressure Switch . . . . . . . . . . . . . . . . . 4B-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Water Flow Diagram – 1997, 1998 and 1999
Models Through S/N . . . . . . . . . . . . . . . . . . . . . . . 4B-5
4
B
Specifications
Water Pressure
Idle 1-1/2 – 4-1/2 psi
(10.3 – 30.8kPa)
Poppet Valve Opening 6 – 7 psi
(41.1 – 47.9kPa)
W.O.T. 8-10 psi
(54.9 – 68.5kPa)

Thermostat . . . . . . . . . . . . . . 120°F (48.9°C)

Temperature Sensor
Three temperature sensors are used to provide cylinder head temperature information
to the ECM. A sensor is mounted in each cylinder head and one in the air compressor
cylinder head. The ECM uses this information to increase injector pulse width for cold
starts and to retard timing in the event of an over-heat condition.
An ohms test of the temperature sensor would be as follows:
Insert digital or analog ohmmeter test leads into both TAN/BLACK sensor leads. With
engine at temperature (F
) indicated, ohm readings should be as indicated ±10%.

90-855348R02 NOVEMBER 2002 Page 4B-1

COOLING SYSTEM

270
255
240
225
210
195
180 Temperature Sensor
Temperature (F
)

165
150
135
120
105
90
75
60
45
30
15
0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2
Resistance (k
)

Temperature Sensor Location

Starboard and Port Cylinder Heads
Horn Activation 180°F (82°C)
Speed Reduction 185°F (85°C)
(3000 RPM)
Compressor
221°F (105°C)
Horn Activation

Temperature Sensor(s)
Between Black and each TAN/BLK wire. No
Continuity
Between each lead and ground No
Continuity

NOTE: The air compressor temperature sensor and cylinder head temperature sensors are
the same part number. The ECM has been programmed to activate a warning circuit at dif-
ferent temperatures depending upon sensor location.
NOTE: The Digital Diagnostic Terminal (DDT) can be used to monitor temperature readings
from all three temperature sensors.

Page 4B-2 90-855348R02 NOVEMBER 2002

 COOLING SYSTEM

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

2. Water Pressure Gauge 91-79250A2

56725

90-855348R02 NOVEMBER 2002 Page 4B-3

COOLING SYSTEM

3.0 Liter Optimax/DFI Water Flow

Description
Cooling water enters the cooling system through the lower unit water inlets. The pump as-
sembly forces water through the water tube and exhaust adapter plate passages filling the
power head central water chamber (located behind the exhaust cavity). Water enters the
exhaust cover cavity through 6 holes (3 each side) and 1 slot (top) that connects the central
chamber to the exhaust cover cavity. Water also exits the top of the central chamber through
a strainer screen to supply water to the air compressor.
Water exits the exhaust cover cavity through 2 slots near the lower cylinders filling the water
passages around the cylinders. Water flow is directed around each cylinder sleeve by 6 wa-
ter dams.
Water flow exiting the cylinder block is controlled by the thermostats (1 in each cylinder
head) and the poppet valve (located in the exhaust adaptor plate). At low RPM (below 1500
RPM) the thermostats control water flow depending upon engine temperature. When the
thermostats are open, water passes through the cylinder heads and exits to the drive shaft
housing. At higher RPM (above 1500 RPM) the poppet valve will control the water flow.
Water that passes through the poppet valve enters water passages in the exhaust tube to
help cool the exhaust tube. Water will exit the exhaust tube through 2 slots at the top of the
exhaust relief holes area (helping keep the holes clear of carbon and salt buildup) and
through 2 holes at lower rear of exhaust tube into the drive shaft housing.
Water dumped into the drive shaft housing builds up a wall of water around the exhaust tube.
This performs 2 functions:
• Helps silence the exhaust
• Prevents air from being drawn into the pump
Water exits the engine in 3 locations:
• Excess water from the wall of water exits through the bottom aft area of the drive
shaft housing.
• Water that passes through the air compressor exits out the tell tail.
• Water exits through a strainer screen in the exhaust adaptor plate into the exhaust
tube, mixing with the exhaust gases.
To allow complete passage filling and to prevent steam pockets, all cooling passages are
interconnected. Small passages are incorporated to allow the cooling system to drain.

Page 4B-4 90-855348R02 NOVEMBER 2002

 COOLING

Water Flow Diagram

Cylinder Block and Adaptor Plate
S/N 0G899371 & Below

d h

i j Lower Unit and Water Pump

f

a g

a - Air Compressor
b - Strainer Screen for air compressor water supply – If re-
m stricted, compressor will overheat.
c - Cylinder Head Cover – Removed from head for illustra-
tion, normally part of head casting.
Drive Shaft Housing d - Thermostats (2) 120° F (48.9° C) – If stuck closed, engine
will overheat at idle.
c e - Strainer Screen Fitting for fuel cooler water supply. If
plugged, engine fuel system may vapor lock.
l f - Poppet Valve – Controls water flow at high RPM.
Note: If poppet valve is stuck open at low RPM, the engine
will not reach proper operating temperature (run cold) and

S/N 0G899372 & Above

will run rough at idle.
g - Strainer Screen for exhaust system cooling water. If
plugged, propeller shaft seals and propeller hub may be
d damaged.
h - Slots – Provides water spray to keep exhaust relief holes
clear.
k i - Exhaust Tube – Partially removed from drive shaft hous-
ing for this illustration.
j - Wall of Water – If water level height is insufficient, water
pump may draw in air resulting in an overheated engine.
k - Fuel Cooler – If internal leak occurs, fuel will be forced into
cooling system.
l - Water Outlet from Air Compressor – Connects to tell-tale
outlet on bottom cowl.
m - Rubber Water Dams (6) – If missing may result in uneven
cooling of cylinders and scuffed pistons.

90-855348R02 NOVEMBER 2002 Page 4B-5

 COOLING SYSTEM

Troubleshooting
Thermostat Test
1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and
corrosion damage that could cause leakage. Replace parts as necessary.
2. Remove and discard gasket from each thermostat.
3. Wash thermostats with clean water.
4. Using a thermostat tester, similar to the one shown, test each thermostat as follows:
a. Open thermostat valve, then insert a thread between valve and thermostat body. Al-
low valve to close against thread.
b. Suspend thermostat (from thread) and thermometer inside tester so that neither
touches the container. Bottom of thermometer must be even with bottom of thermo-
stat to obtain correct temperature of thermostat opening.
c. Fill thermostat tester with water to cover thermostat.
d. Plug tester into electrical outlet.
e. Observe temperature at which thermostat begins to open. (Thermostat will drop off
thread, that was installed in Step “a”, when it starts to open.) Thermostat must begin
to open when temperature reaches 118°-123° F (47.8°-50.6° C).
f. Continue to heat water until thermostat is completely open.
g. Unplug thermostat tester.
h. Replace thermostat, if it fails to open at the specified temperature, or if it does not
fully open.
i. If water dams are missing, head temperatures may be 30-40° higher than normal
with DDT.
NOTE: BE SURE that water in thermostat tester is allowed to cool sufficiently [below 110F
(43.3 C)] before testing the other thermostat.

51087
IMPORTANT: DO NOT operate engine without thermostats installed.

90-855348R02 NOVEMBER 2002 Page 4B-7

COOLING SYSTEM

Water Pressure Check

Using Water Pressure Gauge 91-79250A2, cut compressor water inlet hose and install tee
fitting (provided) as shown.
NOTE: This is also the same location for installing the water pressure hose for a dash
mounted water pressure gauge.

56032
b
d

d
c
d 56726

a - Compressor Water Inlet Hose

b - Water Pressure Gauge Hose
c - Tee Fitting (22-90824)
d - Hose Clamp (54-815504104)

WARNING
Shut off engine and refer to troubleshooting chart if water pressure is not within
specification. DO NOT exceed 3000 RPM in neutral.

Idle 1-1/2 – 4-1/2 psi

(10.3 – 30.8kPa)
Poppet Valve Opening 6 – 7 psi
(41.1 – 47.9kPa)
W.O.T. 8-10 psi
(54.9 – 68.5kPa)

Page 4B-8 90-855348R02 NOVEMBER 2002

 COOLING SYSTEM

Water Pump Cleaning and Inspection

1. Inspect the water tube coupling assembly for wear or damage. If necessary replace the
worn or damaged components especially the two O-rings on the inside, one at the top
and one at the bottom.
b

b 70613

a - Water Tube adapter

b - O-rings (2)

2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller
blades. Replace the impeller if this condition is found.
3. Inspect for proper bonding between the hub and the impeller. Replace the impeller if im-
proper bonding is found.

70500

a - Impeller
b - Hub

4. Inspect the impeller blades to see if they are cracked, burnt, hard or deformed. Replace
the impeller if the blades are in this condition.
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate. The depth of the groove will not affect wa-
ter pump output.

90-855348R02 NOVEMBER 2002 Page 4B-9

COOLING SYSTEM

5. Replace cover if thickness of steel at the discharge slot is 0.060 in. (1.5mm) or less or
if grooves (other than impeller sealing bead groove) in cover roof are more than 0.030
in. (0.76mm) deep.
a b

70609

a - Water Pump Face Plate

b - Water Pump Cover

6. Inspect the water pump face plate and the water pump interior for roughness and/or
grooves. Replace the appropriate components as required.
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
IMPORTANT: It is recommended that the water pump impeller be replaced whenever
the gearcase is removed for maintenance. However, if it is necessary to re-use the
impeller, DO NOT install in reverse to original rotation as premature impeller failure
will occur.

Page 4B-10 90-855348R02 NOVEMBER 2002

 COOLING SYSTEM

Problem Diagnosis
Condition Recommended Range Possible Cause
Pressure below specification @ 1-1/2 – 4-1/2psi (10.3 – 30.8kPa) •Poppet valve spring defective
idle (weak, broken, missing)
•Defective poppet valve seal
•Severe internal leak
•Low output water pump
•Inlet restriction
•Strainer screen for air compres-
sor water supply is restricted
Pressure above 5 psi (34.2kPa) 1-1/2 – 4-1/2psi (10.3 – 30.8kPa) •Plugged poppet by-pass pas-
@ idle sage or fuel cooler
Pressure does not drop between 6 – 7psi (41.1 – 47.9kPa) •Wrong poppet valve spring
1200 – 1800 RPM indicating pop- between 1200 – 1800 RPM •Low output water pump
pet valve has opened •Inlet restriction
•Poppet valve vent hole plugged
or restricted
Poppet valve flutter/water pres- 6 – 7psi (41.1 – 47.9kPa) •Poppet valve spring defective
sure drop does not start prior to between 1200 – 1800 RPM (weak, broken, strong, missing)
1500 RPM •Broken diaphragm in poppet
valve
•Severe internal leak
•Low output water pump
•Defective poppet valve seal
Poppet valve flutter/water pres- 6 – 7psi (41.1 – 47.9kPa) •Wrong poppet valve spring
sure drop does not stop prior to between 1200 – 1800 RPM •Low output water pump
1800 RPM •Inlet restriction
Pressure exceeds specification @ 8 – 10psi (54.9 – 68.5kPa) •Restriction on discharge side of
W.O.T. Note: A modified propeller or low cooling system
pitch propeller is required to •Engine mounted too high on
check water pressure @ W.O.T. if transom or trimmed too far out re-
boat is stationary. Boat must be in sulting in formation of steam
the water and secured to a dock pockets in cooling system
or trailer and run in forward gear. •If boat is not stationary but is be-
DO NOT perform check using a ing run on open water, ram effect
flush device. of water on coolant inlets @ high
speeds may increase water pres-
sure above specifications
Pressure is below specification @ 8 – 10psi (54.9 – 68.5kPa) •Inlet restriction
W.O.T. •Engine mounted too high on
transom
•Engine trimmed out too far
•Configuration of boat bottom in-
terfering with adequate flow of
water to coolant inlets
•Severe internal leak
•Low output water pump

90-855348R02 NOVEMBER 2002 Page 4B-11

COOLING SYSTEM

Water Pressure Switch

The 1998/1999 200/225 DFI Models have a water pressure sensor switch. This switch is
monitored by the ECM at 3000 RPM and above. Should the water pressure drop below a
predetermined level for more than 2 seconds, a warning horn will be activated and a warning
lamp will be illuminated. Should the low water pressure continue for more than 5 seconds,
a speed reduction circuit within the ECM will be activated and maximum engine RPM will
be limited to 3000 RPM.

a - Water Pressure Switch

NOTE: Switch activation pressure readings can be accurately checked with the Digital Diag-
nostic Terminal (DDT)

Water Pressure Switch Activation

Engine RPM Pressure
3000 4.3psi (30kPa)
3300 4.8psi (33kPa)
3850 5.8psi (40kPa)
4400 6.2psi (43kPa)
4950 6.7psi (46kPa)
5500 7.0psi (48kPa)

Page 4B-12 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

MID–SECTION
Section 5A - Clamp Bracket/Swivel
Bracket/Drive Shaft Housing
Table of Contents
1997 Model 200 DFI Transom Brackets . . . . . . 5A-2 Drive Shaft Housing and Exhaust Tube
1998/1999 Model 200/225 DFI (S/N-0G438000 & UP) . . . . . . . . . . . . . . . . . . . . 5A-10
Transom Brackets . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Drive Shaft Housing and Dyna-Float
Swivel Bracket and Steering Arm . . . . . . . . . . . . 5A-6 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12
Drive Shaft Housing and Exhaust Tube Removal and Disassembly . . . . . . . . . . . . . 5A-12
(S/N-0G437999 & BELOW) . . . . . . . . . . . . . . . . 5A-8 Reassembly and Installation . . . . . . . . . . . . 5A-17

5
A

90-855348R02 NOVEMBER 2002 Page 5A-1

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

1997 Model 200 DFI Transom Brackets

23 20
95 22 18
95
19 21 95

18
17 5
3 6

4
16
95

95
1
13
9

7 2
8 14
15

11
12

10

95 2-4-C With Teflon

Page 5A-2 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

1997 Model 200 DFI Transom Brackets

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 TRANSOM BRACKET (STBD)
2 1 TRANSOM BRACKET (PORT)
3 1 GREASE FITTING (PORT) 85 9.6
4 1 TILT TUBE
5 1 NUT (1″-14) 45 61
6 1 O RING
7 2 WAVE WASHER
8 1 NUT (7/8-14) 45 61
9 1 BOLT ASSEMBLY
10 1 NUT (.375-24) 90 10.2
11 1 GROUND WIRE
12 1 SCREW (1/4-20 x .375) 70 7.9
13 4 BOLT
14 4 WASHER
15 4 NUT
16 1 TILT LOCK LEVER ASSEMBLY
17 1 WAVE WASHER
18 2 BUSHING
19 1 STOP
20 1 KNOB
21 1 GROOVE PIN
22 1 SPRING
23 1 GROOVE PIN

90-855348R02 NOVEMBER 2002 Page 5A-3

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

1998/1999 Model 200/225 DFI Transom Brackets

 
95


 
 
95

95




 95

95






95 2-4-C With Teflon

Page 5A-4 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

1998/1999 Model 200/225 DFI Transom Brackets

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 TRANSOM BRACKET (STARBOARD)
2 1 TRANSOM BRACKET (PORT)
3 1 GREASE FITTING (PORT) 85 9.6
4 1 TILT TUBE
5 1 NUT (1 IN.-14) 45 61
6 1 O-RING
7 2 WAVE WASHER
8 1 NUT (7/8-14) 45 61
9 4 BOLT
10 4 WASHER
11 4 NUT
12 1 TILT LOCK LEVER ASSEMBLY
13 1 SPRING
14 2 BUSHING
15 1 SPRING
16 1 KNOB
17 1 GROOVE PIN
18 1 PIN

90-855348R02 NOVEMBER 2002 Page 5A-5

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Swivel Bracket and Steering Arm

28
26

27 95 30 29

22

25 32
24
31
23
B

31 95
95 17
A 18
16 19
8 21
95 6
2
20
3
15
95
7

13
14
12
6
95

95

7
1

95 11
95
5
3
9

10
95 2-4-C With Teflon

A – Torque nut to 20 lb. ft. (27.1 Nm)

B – Torque nut until it seats [DO NOT exceed 120 lb. in. (13.6 Nm) of torque], then back off 1/4 turn.

Page 5A-6 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Swivel Bracket and Steering Arm

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 SWIVEL BRACKET
2 1 O-RING
3 2 BUSHING
4 1 SPACER
5 1 OIL SEAL (LOWER)
6 2 GREASE FITTING 85 9.6
7 2 BUSHING
8 1 THRUST WASHER
1 BOTTOM YOKE (LONG – CARBON STEEL)
9
1 BOTTOM YOKE (XL–STAINLESS STEEL)
10 1 RETAINING RING
11 2 STRIKER PLATE
12 2 LOCKWASHER
13 2 NUT 25 33.9
14 2 SCREW (1/4-28 x 1/2 IN.) 100 11.3
15 1 DECAL-Serial Overlaminate
16 1 TRIM SENDER
17 2 SCREW (10-24 x 3/4 IN.) 15 1.7
18 2 LOCKWASHER
19 2 WASHER
1 SWIVEL PIN/STEERING ARM (LONG – CARBON STEEL)
20
1 SWIVEL PIN/STEERING ARM(XL–STAINLESS STEEL)
21 2 SCREW (M12 x 1.75 x 190)
22 1 BUMPER
23 2 UPPER MOUNT
24 2 WASHER
25 2 WASHER
26 2 NUT 50 67.8
27 1 CLAMP
28 3 SCREW (M8 x 35) 20 27.1
29 1 STEERING LINK ASSEMBLY
30 1 SCREW 20 27.1
31 2 NUT (.375-24)
32 2 WASHER

90-855348R02 NOVEMBER 2002 Page 5A-7

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Drive Shaft Housing and Exhaust Tube

(S/N-0G437999 & BELOW)
27

33

28
95
29 26

7
23

22
3
10
19 11
7 21
9
16
24
17
20 25
2
12 13 28
19 14
33
15 5 22
18 6 95
7 Loctite 271 Thread Locker
19 Perfect Seal
33 Loctite 680 Retaining Compound
95 2-4-C With Teflon

Page 5A-8 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Drive Shaft Housing and Exhaust Tube

(S/N-0G437999 & BELOW)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 DRIVE SHAFT HSG. (LONG)
1
1 DRIVE SHAFT HOUSING (X/XX-LONG)
2 4 STUD (M12 x 1.75 x 50) (L/X-LONG)
3 1 SCREW (M10 x 1.5 x 30) (L/X-LONG) 45 61.0
4 1 GROMMET
5 4 WASHER
6 4 NUT (M12 x 1.75) 55 74.6
7 1 PLUG
8 2 SCREW (M14 x 2 x 178)
9 1 GROUND WIRE
10 2 WASHER
11 2 WASHER
12 2 MOUNT
13 1 WASHER
14 2 NUT 90 122
15 2 CLAMP
16 4 SCREW (M8 x 35) 20 27.1
17 1 LOCKWASHER
18 2 COVER
19 2 SCREW (5/8 IN.) Drive Tight
20 1 SEAL
21 1 EXHAUST TUBE
22 8 SCREW (M8 x 35) 17 22.4
1 WATER TUBE (LONG)
23 1 WATER TUBE (X-LONG)
1 WATER TUBE (XX-LONG)
24 1 SEAL
25 1 CLAMP
26 1 SPACER
27 2 DOWEL PIN XX-LONG
4 STUD (M12 x 1.75 x 183)
28
1 STUD (M10 x 1.5 x 173)
29 1 NUT (M10 x 1.5) 55 74.6

90-855348R02 NOVEMBER 2002 Page 5A-9

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Drive Shaft Housing and Exhaust Tube (S/N-0G438000 & UP)

7 Loctite 271 Thread Locker
22
19 Perfect Seal
33 Loctite 680 Retaining Compound
95 2-4-C With Teflon

95
21

4 23

20
7

7 95

3
10
24
19 11

9
16

17
12
2 25
19 13
14 26
5 33
15 9
6
18
23
27

Page 5A-10 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Drive Shaft Housing and Exhaust Tube (S/N-0G438000 & UP)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 DRIVE SHAFT HOUSING (LONG) BLACK
1 DRIVE SHAFT HOUSING (X–LONG)
1
1 DRIVE SHAFT HOUSING (LONG) GRAY
1 DRIVE SHAFT HOUSING (X–LONG)
2 4 STUD (M12 x 1.75 x 50)
3 1 SCREW (M10 x 1.5 x 30) 45 61.0
4 1 GROMMET
5 4 WASHER
6 4 NUT (M12 x 1.75) 55 74.6
7 1 PLUG
8 2 SCREW (M14 x 2 x 178)
9 2 GROUND WIRE
10 2 WASHER
11 2 WASHER
12 2 MOUNT
13 1 WASHER
14 2 NUT 90 122
15 2 CLAMP
16 4 SCREW (M8 x 35) 20 27.1
17 1 LOCKWASHER
2 COVER (BLACK)
18
2 COVER (GRAY)
19 2 SCREW (10-16 x 7/16 IN.) Drive Tight
20 1 SEAL
21 1 EXHAUST TUBE
22 1 STRAINER
23 6 SCREW (M8 x 35) 17 22.4
1 WATER TUBE (LONG)
24
1 WATER TUBE (X-LONG)
25 1 SEAL
26 1 CLAMP
27 1 SCREW (1/4-20 x .375)

90-855348R02 NOVEMBER 2002 Page 5A-11

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Drive Shaft Housing and Dyna-Float Suspension

Refer to Powerhead Removal Section to remove powerhead. Refer to Lower Unit Re-
moval in this section to remove lower unit.

Removal and Disassembly

1. Remove shift shaft from drive shaft housing by pulling straight up on shaft.
2. Remove power trim wiring harness from exhaust adaptor plate.
3. Remove 3 bolts which secure upper mount cover to adaptor plate. Remove cover.

b
e

a - Shift Shaft
b - Wiring Harness
c - Adaptor Plate
d - Bolts
e - Upper Mount Cover

SHIFT LINKAGE ASSEMBLY

c
b

b d
c

b d
a - Shift Shaft
b - Bushing (3)
c - Lock Nut (2)
d - Washer (2)

Page 5A-12 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

4. Remove upper mount nuts and flat washers.

5. Pull mount bolts through mounts and remove mounts.

a - Upper Mount Nuts

6. Remove 4 bolts securing exhaust adaptor plate to drive shaft housing.

b
a - Bolts
b - Adaptor Plate

90-855348R02 NOVEMBER 2002 Page 5A-13

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

7. While applying upward pressure on rear of adaptor plate, use a mallet and a piece of
hardwood against the adaptor plate to loosen gasket adhesion.

a - Adaptor Plate

8. Remove 2 bolts securing water tube to adaptor plate and remove tube. Remove 6 bolts
securing exhaust tube to adaptor plate.

a
b
c

a - Bolts
b - Exhaust Tube
c - Water Tube

Page 5A-14 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

9. While tilting adaptor plate/exhaust tube assembly, use a piece of hardwood and a mallet
to loosen gasket adhesion. Remove exhaust tube.

b
a - Hardwood
b - Adaptor Plate
c - Exhaust Tube

10. Remove all gasket and gasket material from drive shaft housing and related compo-
nents.
11. Remove screw which secures each lower mount cover to drive shaft housing. Remove
covers.

b
52307
a - Screw
b - Cover

90-855348R02 NOVEMBER 2002 Page 5A-15

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

12. Remove bolts securing lower mount retainers to drive shaft housing. Remove retainers.

b
52308
a - Bolts
b - Lower Mount Retainer (One Each Side)

13. Remove lower mount nuts and rubber caps.

52308
a - Lower Mount Nuts
b - Rubber Caps

14. Remove drive shaft housing from swivel bracket by pulling alternately from top to bottom
on housing.
15. Remove upper and lower mounts by lifting them out of drive shaft housing.

Page 5A-16 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

Reassembly and Installation

1. Apply a thin coat of 2-4-C with Teflon onto inside portion of exhaust tube seal and water
tube grommet.
2. Install exhaust tube seal into drive shaft housing with tapered side of seal facing up.
3. Position drive shaft housing to plate gasket on top of housing.
4. Position leather bumper on steering arm.

c d

c
a
a

b
b

52307
S/N 0G437999 and Below S/N 0G438000 and Above
a - Exhaust Tube Seal
b - Drive Shaft Housing
c - Water Tube Grommet
d - Leather Bumper

90-855348R02 NOVEMBER 2002 Page 5A-17

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

5. Position exhaust tube and gasket on adaptor plate. Secure both to plate with 6 bolts.
Torque bolts to 21 Ib. ft. (28.5 Nm).
6. Secure tube to adaptor plate with 2 bolts. Torque bolts to 80 lb. in. (9.0 Nm).

a
c

a - Exhaust Tube
b - Gasket
c - Water Tube

7. Position adaptor plate on top of housing.

8. Secure adaptor plate to drive shaft with 4 bolts. Torque bolts to 25 lb. ft. (33.9 Nm).

a - Bolts [Torque to 25 lb. ft. (33.9 Nm)]

Page 5A-18 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

9. Apply a thin coat of Perfect Seal onto metal portion of upper dyna-float mounts.
10. Position mounts on drive shaft housing plate.
11. Install a rubber washer onto each upper mount, followed by a metal washer.
12. Push bolts thru mounts.

a b
c

a - Dyna-Float Mounts
b - Rubber Washers
c - Metal Washer

13. Install a ground strap onto port lower mount bolt.

NOTE: Apply Perfect Seal along length of lower mount bolts.
14. Insert a mounting bolt thru the short end of each lower mount.
15. Position a mount on each lower side of drive shaft
housing.
16. Install a flat washer over each lower mounting bolt.
17. Start upper mounting bolts in upper mounts and align lower mounting bolts with holes
in swivel pin yoke. Slide drive shaft housing up against yoke and bumper.
18. Secure upper mounts to steering arm with flat washers and self-locking nuts. Torque
nuts to 50 Ib. ft. (68.0 Nm).
19. Install ground strap between port lower mount bolt and swivel bracket.

90-855348R02 NOVEMBER 2002 Page 5A-19

CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

20. Secure lower mounts to swivel pin yoke with self-locking nuts. Torque nuts to 90 Ib. ft.
(122.0 Nm). Place a rubber cap over each lower mounting bolt head.

c
e

52308
a - Lower Mount
b - Nut Self Locking [Torque to 90 lb. ft. (122.0 Nm)]
c - Rubber Cap
d - Ground Strap (only one side)
e - Ground Strap (to swivel bracket)

21. Install lower mount retainers and secure each retainer with 2 bolts. (Secure ground strap
with the nearest retainer bolt and flat washer.) Torque bolts to 20 Ib. ft. (27.1 Nm).

a
52308

a - Lower Mount Retainer

b - Bolts [Torque to 20 lb. ft. (27.1 Nm)]
c - Ground Strap

Page 5A-20 90-855348R02 NOVEMBER 2002

 CLAMP BRACKET/SWIVEL BRACKET/DRIVE SHAFT HOUSING

22. Install lower mount covers and secure each cover with a screw.

52307
a - Cover
b - Screw (1 for Each Cover)

23. Install upper mount cover on adaptor plate. Secure cover with 3 bolts. Torque bolts to
20 lb. ft. (27.1 Nm).
24. Route power trim harness through grommet in adaptor plate.
25. Reinstall shift shaft with bushing into adaptor plate. Apply 2-4-C with Teflon to bushing.
f
e c
d

g
a

b
a - Shift Shaft Linkage
b - Exhaust Adaptor Plate
c - Upper Mount Cover
d - Bolts [Torque to 20 lb. ft. (27.1 Nm)]
e - Power Trim Harness
f - Grommet
g - Bushing

90-855348R02 NOVEMBER 2002 Page 5A-21

 POWER TRIM

MID-SECTION
Section 5B - Power Trim
Table of Contents
Power Trim Specifications . . . . . . . . . . . . . . . . 5B-1 Power Trim Assembly Removal
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Power Trim Components . . . . . . . . . . . . . . . . . 5B-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Power Trim - General Information . . . . . . . . . 5B-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Testing Power Trim System
Trimming Characteristics . . . . . . . . . . . . . . 5B-6 With Test Gauge Kit (91-52915A6) . . . . . 5B-35
Trailering Outboard . . . . . . . . . . . . . . . . . . . 5B-7 Up Pressure Check . . . . . . . . . . . . . . . . . . . 5B-35
Tilting Outboard Manually . . . . . . . . . . . . . 5B-7 Down Pressure Check . . . . . . . . . . . . . . . . 5B-38
Trim In Angle Adjustment . . . . . . . . . . . . . . 5B-8 Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . 5B-40
Striker Plate Replacement . . . . . . . . . . . . . 5B-8 Trim Rod End Cap Seal . . . . . . . . . . . . . . . 5B-41
Anode Plate . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9 Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-43
Trim Indicator Gauge . . . . . . . . . . . . . . . . . 5B-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-46
Fill, Check, and Purge . . . . . . . . . . . . . . . . 5B-9 Scraper Seal Replacement . . . . . . . . . . . . 5B-50 5
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 Motor and Electrical Tests/Repair . . . . . . . . . . 5B-55
V6 Power Trim Diagrams . . . . . . . . . . . . . . . . . 5B-12 Trim Pump Motor Test . . . . . . . . . . . . . . . . 5B-55 B
Trim Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 Motor Disassembly . . . . . . . . . . . . . . . . . . . 5B-55
Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5B-57
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16 Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-59
Trail Over and Shock Absorber . . . . . . . . . 5B-18 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-63
Trail Over System . . . . . . . . . . . . . . . . . . . . 5B-19 Reassembly - Motor and Pump . . . . . . . . 5B-66
Manual Tilt and Reverse . . . . . . . . . . . . . . 5B-20 Priming Power Trim System . . . . . . . . . . . 5B-68
Power Trim System Troubleshooting . . . . . . . 5B-21 Trim Sender (Optional Accessory) Test . . 5B-68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5B-22 Trim Indicator Gauge Needle Adjustment 5B-69
Power Trim Wiring Diagram . . . . . . . . . . . . 5B-24 Trim Indicator Wiring Diagrams . . . . . . . . . . . 5B-70
Electrical System Troubleshooting . . . . . . . . . 5B-25 For Boats Equipped with Commander
Troubleshooting the Down Circuit . . . . . . . . . 5B-25 Series Side Mount Remote Control . . . . . 5B-70
Troubleshooting the Up Circuit . . . . . . . . . . . . 5B-26 For Boats Equipped with Ignition/Choke
Troubleshooting the Down and Up Circuits and Main Harness Assembly . . . . . . . . . . 5B-70
(All Circuits Inoperative) . . . . . . . . . . . . . . . . . . 5B-27

Power Trim Specifications

Test Reading
Trim Up 1300 PSI (91kg/cm2) Maximum
Pressure
Trim Down 500 PSI (35kg/cm2) Minimum Pressure

90-855348R02 NOVEMBER 2002 Page 5B-1

POWER TRIM

Special Tools
1. Alignment Tool 91-11230

17238

2. Trim Rod Removal Tool 91-44486A1

51337
3. Trim Rod Guide Removal Tool 91-44487A1

51337
4. Power Trim Test Gauge Kit 91-52915A6

Page 5B-2 90-855348R02 NOVEMBER 2002

 POWER TRIM

5. Adaptor Fitting 91-82278-2 and 91-82278-3

54458
6. Spanner Wrench 91-74951

51337

7. Multi-Meter DVA Tester 91-99750A1

90-855348R02 NOVEMBER 2002 Page 5B-3

POWER TRIM

Power Trim Components

5 5
6 20
6 5 5 6 4
6 33
6 34
7 85 32
18
21

19

13 16 13
17
110
15
8 14
13

10 13
9
9
94
13

11
26
25
1 12

2
3 7
31
30
27

24
7 Loctite 271 Thread Locker 29
28
85 RTV 587 Silicone Sealer
94 Anti-Corrosion Grease
22 23
114 Power Trim and Steering Fluid

Page 5B-4 90-855348R02 NOVEMBER 2002

 POWER TRIM

Power Trim Components

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 MANIFOLD ASSEMBLY
2 9 PIPE PLUG
3 1 TILT CYLINDER ASSEMBLY
4 1 PISTON ROD
5 1 GUIDE KIT
6 1 REPAIR KIT
7 1 CHECK VALVE KIT
8 2 GUIDE ASSEMBLY
9 1 PISTON/ROD ASSEMBLY (PORT)
9 1 PISTON/ROD ASSEMBLY (STBD.)
10 1 TRIM FILTER ASSEMBLY
11 1 VALVE ASSEMBLY
12 1 E-RING
13 1 O-RING KIT
14 1 PUMP
15 1 PLUG ASSEMBLY
16 4 SCREW
17 4 WASHER
18 1 COVER
19 1 DRIVE SHAFT S/N-0G217420 & UP
20 1 TRIM MOTOR
21 2 SCREW (LONG)(S/N-0G217420 & UP)
21 2 SCREW (SHORT)
22 1 SHAFT ASSEMBLY
23 2 PIPE PLUG
24 1 GROOVE PIN
25 1 GROOVE PIN
26 1 SHAFT
27 1 ANODE ASSEMBLY
28 2 SCREW (M6 x 1 x 25) 70 7.9
29 2 WASHER
30 6 SCREW (M10 x 1.5 x 30) 40 54.2
31 6 WASHER
32 2 CLIP(S/N-0G217420 & UP)
33 2 SCREW (10-16 x .44) Drive Tight
34 2 C WASHER
NOTE: Lubricate all o-rings with Power Trim and Steering Fluid.

90-855348R02 NOVEMBER 2002 Page 5B-5

POWER TRIM

Power Trim - General Information

Description
The Power Trim System consists of an electric motor, pressurized fluid reservoir, pump, tilt
cylinder, and two trim rams.
The remote control (or trim panel) has switches that trim the outboard Up or Down and tilt
the engine for Trailering. The outboard can be trimmed and tilted under power or when the
outboard is not running.
Trimming Characteristics
NOTE: Because hull designs react differently in varying water conditions, varying the trim
position will often improve the ride and boat handling. When trimming from a mid-trim posi-
tion (with outboard trim tab in a straight fore and aft position), expect the following:
TRIMMING OUTBOARD UP (OUT):
WARNING
Excessive trim Out may reduce the stability of some high speed hulls. To correct
instability, reduce the power gradually and trim the outboard In slightly before re-
suming high speed operation. A rapid reduction in power will result in a sudden
change of steering torque and may cause additional boat instability.
Will lift boat bow, increasing top speed.
Transfers steering torque harder to port (left) on installations above 23 in. transom height.
Increases gearcase clearance over submerged objects.
Excess trim can cause porpoising and/or ventilation.

WARNING
Excessive outboard trim angle will result in insufficient water supply causing water
pump and/or powerhead overheating damage. Insure water level is above water in-
take holes whenever outboard is running.
The Up circuit actuates the up relay (under outboard cowl) and closes the motor circuit. The
electric motor drives the pump, forcing fluid thru passageways into the up side of the trim
cylinders.
The trim cylinders position the outboard at the desired trim angle in the 20 degree maximum
trim range. The system will not allow the outboard to be trimmed above the 20 degree trim
range as long as the engine RPM is above approximately 2000 RPM.
The outboard can be trimmed above the 20 degree maximum trim angle (for shallow water
operation, etc.), by keeping the engine RPM below 2000. If the RPM increases over 2000,
propeller thrust (if propeller is deep enough) will result in the trim system to return the out-
board to the 20 degree maximum trim position.
TRIMMING OUTBOARD DOWN (IN):
WARNING
Excessive speed at minimum trim In may result in undesirable and/or unsafe steer-
ing conditions. Test for handling characteristics after any adjustment is made to the
trim angle (and tilt pin location).
Aids planing, particularly with heavy loads.
Improves ride in choppy water conditions.

Page 5B-6 90-855348R02 NOVEMBER 2002

 POWER TRIM

Excess trim In can cause bow steer (boat veers to left or right).
Transfers steering torque to starboard (right).
Improves acceleration to planing speed.
The Down circuit actuates the down relay (under engine cowl) and closes the motor circuit.
The electric motor drives the pump in the opposite direction as the up circuit, forcing fluid
thru passageways into the down side of the tilt ram. The tilt ram moves the engine down to
the desired position.
Trailering Outboard
The Up circuit first moves the trim cylinders; when the trim cylinders extend fully, the tilt ram
extends to tilt the outboard to the full Up position for trailering.
Before the boat is trailered, the operator should check for clearance between the outboard
skeg and pavement to prevent damage to skeg from striking pavement.
If the outboard must be tilted for clearance between skeg and pavement, a device such as
a Transom Saver should be installed to prevent stress to boat transom from outboard weight
while the boat/outboard are being trailered.
Tilting Outboard Manually
WARNING
Before opening the manual release valve knob, insure all persons are clear of out-
board as outboard will drop to full Down when valve is opened.
The outboard can be raised or lowered manually by opening the manual release valve 3 to
4 turns counterclockwise. Close manual release valve to hold outboard at the desired tilt
position.

51353
a - Manual Release Valve

90-855348R02 NOVEMBER 2002 Page 5B-7

POWER TRIM

Trim In Angle Adjustment

WARNING
Boat operation with outboard trimmed to the full In trim angle [not using the trim
angle adjustment bolt (a)] at planing speed may result in undesirable and/or unsafe
steering conditions. A water test for handling/steering conditions is required after
any trim angle adjustments.
IMPORTANT: Some boat/motor combinations not using the trim angle adjustment
bolt and trimmed to the full In trim angle position may not exhibit any undesirable
and/or unsafe handling and/or steering characteristics at planing speed. If so, not us-
ing the trim angle adjustment bolt may be advantageous to acceleration and planing.
A water test is required to determine if these characteristics apply to a particular boat/
motor combination.

a 51353
a - Trim Angle Adjustment Bolt

Striker Plate Replacement

Visually inspect striker plates and replace if worn excessively.

c
b

27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut. Torque to 80 lb. in. (9.0 Nm)

Page 5B-8 90-855348R02 NOVEMBER 2002

 POWER TRIM

Anode Plate
Anode plate (a) is a self-sacrificing alloy plate that is consumed gradually by corrosion while
providing protection to the midsection and power trim from galvanic corrosion. Replace
anode plate when it is 50% consumed.

a
27932
a - Anode Plate

IMPORTANT: Do not paint or place protective coating on anode plate, or corrosion

protection function will be lost.
Trim Indicator Gauge
A Trim Indicator Gauge accessory kit is available for the power trim sender (if not previously
installed).
Fill, Check, and Purge - Power Trim System
TO FILL:
IMPORTANT: This trim system is pressurized. Remove Fill plug only when outboard
is tilted to the full Up position or the trim/tilt rams are fully extended. Retighten Fill
plug before tilting outboard down or retracting tilt/trim rams.
Remove Fill plug and O-ring. System is full when oil level is present at fill hole. Tight-
en Fill plug securely.

53792
a - Fill Plug and O-ring (remove to fill system, tighten securely)
b - Oil Can (fill system with Power Trim and Steering Fluid)

90-855348R02 NOVEMBER 2002 Page 5B-9

POWER TRIM

NOTE: Automatic Transmission Fluid (ATF) Type F, FA, Dexron II or Dexron lll may be used.

51368
a - Tilt Lock Lever (engage to support engine in Up position)

TO PURGE:
IMPORTANT: Fill plug and O-ring must be tightened securely before purging system.
IMPORTANT: Run Trim System in short jogs until pump is primed and trim system
moves. If trim motor is run without priming pump, driveshaft failure could result.
Cycle outboard through entire trim/tilt range 4 times. Check fluid level after purging system.
Push down on outboard when trim rams are slightly extended. If rams retract more than 1/8
in. (3.2 mm), air is present in system. Cycle system again and check fluid level.
TO CHECK:
CAUTION
Tilt outboard to full Up position and engage tilt lock lever before checking fluid lev-
el. System is pressurized. Extend trim and tilt rams fully to depressurize system.
Remove fill plug and O-ring. System is full when oil level is present at filler hole. Tighten fill
plug securely.

Page 5B-10 90-855348R02 NOVEMBER 2002

 POWER TRIM

Notes:

90-855348R02 NOVEMBER 2002 Page 5B-11

POWER TRIM

V6 Power Trim Diagrams

Trim Circuit
a

b




   

ÄÄ ÄÄ
Á ÁÄÄ
ÄÄ ÁÁ

ÁÁ
 



a - High Pressure 6 - Down Circuit Pressure Oper-

b - Low Pressure ated Valve
1 - Electric Motor 7 - Tilt Cylinder
2 - Oil Pump/Gears 8 - Up Circuit Pressure Operated
3 - Up Circuit Suction Check Valve Valve
4 - Down Circuit Suction Check 9 - Trim Cylinders
Valve 10 - Tilt Cylinder Piston
5 - Shuttle Spool 11 - Reservoir
12 - Lower Pivot Pin

Page 5B-12 90-855348R02 NOVEMBER 2002

 POWER TRIM

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

90-855348R02 NOVEMBER 2002 Page 5B-13

POWER TRIM

Tilt Circuit
a




 

ÄÄÄÄ
ÁÁ
ÄÄÁ
ÄÄÁ
Á Á


a - High Pressure
b - Low Pressure
1 - Trim Cylinders
2 - Trim Relief Valve
3 - Port Trim ram
4 - Tilt Cylinder
5 - Pump/Gears
6 - Up Circuit Suction Check Valve
7 - Electric Motor

Page 5B-14 90-855348R02 NOVEMBER 2002

 POWER TRIM

Tilt Circuit
In the up mode, as the trim rams (1) reach the limit of their travel, the mechanical check valve
(2) of the trim relief valve, in the port trim ram piston (3), contacts the cylinder cap. The pin
contact with the cover mechanically opens the shut off valve, allowing the trim relief valve
to bypass oil and perform the following functions.
• Trim Limit
While the engine is running under thrust (at high engine RPM), the high pressure develops
below the pistons. The high pressure will open the check ball on the bottom of the trim relief
valve (850-1150 psi), allowing oil to flow through the port trim ram piston. If the operator con-
tinues to depress the UP button, the up pressure will not be sufficient to overcome the pro-
peller thrust, so the trim range is limited to the length of the trim rams. When the engine thrust
falls (low engine rpms), the check ball in the trim relief valve closes, allowing oil flow to ex-
tend the tilt cylinder ram into the tilt range.
• Over Trim At High Thrust
As the operator increases the engine rpms when the engine is raised beyond the trim range,
the pressure below the pistons begin to rise. When the pressure is sufficient, the high pres-
sure will open the check ball on the bottom of the trim relief valve (850-1150 psi), allowing
oil to flow through the port trim ram piston. Oil will continue to flow through the valve until
either the engine contacts the trim rams and the mechanical shut off valve closes or the en-
gine rpm’s are reduced.
• Maximum Up Pressure Reduction
As the tilt ram extends to its limit, the up pressure below the pistons will increase and open
the trim relief check valve to relief the up pressure. If the UP button is not released, the up
flow will continue to dump over relief causing the electric motor to heat up. The thermal over-
load switch inside the motor will open, stopping the motor.

90-855348R02 NOVEMBER 2002 Page 5B-15

POWER TRIM

Down Circuit
a
b


   

  ÄÄ
ÄÄÄÄ
Á Á
ÄÄÁ
 Á Á

 





a - High Pressure
b - Low Pressure
1 - Pump/Gears
2 - Down Circuit Suction Check Valve
3 - Down Pressure Relief Valve
4 - Reservoir
5 - Up Circuit Suction Check Valve
6 - Shuttle Spool
7 - Up Circuit Pressure Operated Valve
8 - Trim Cylinders
9 - Tilt Cylinder
10 - Down Circuit Pressure Operated Valve
11 - Pivot Pin
12 - Shock Piston
13 - Trim Ram

Page 5B-16 90-855348R02 NOVEMBER 2002

 POWER TRIM

Down Circuit
When you depress the DOWN button, the power trim pump (1) is activated in the opposite
direction. As the oil pump gears begin to rotate, oil is drawn through the down circuit suction
check valve (2) and into the pump, suppling flow for the down circuit. Down circuit oil pres-
sure is regulated by the down pressure relief valve (3) (640 psi to 1050 psi) allowing excess
oil to return into the reservoir (4). Oil is blocked from returning into the reservoir by the closed
up circuit suction check valve (5). Oil under pressure then moves the shuttle spool (6) to the
right, mechanically opening the up circuit pressure operated valve (7), allowing oil from the
bottom of the trim (8) and tilt cylinders (9) to supply oil to the trim pump for the down circuit.
At this same time, oil under pressure opens the down circuit pressure operated valve (10)
allowing oil to exit through the down pressure port. The oil then continues through the down
pressure passage, through the pivot pin (11), and into the interconnecting passage of the
tilt cylinder leading to the cavity above the shock piston (12), and pushes the piston and ram
assembly in (down). As the outboard engine contacts the extended trim rams (13), the
weight of the motor, propeller thrust and pump down pressure will force the trim rams to re-
tract.

90-855348R02 NOVEMBER 2002 Page 5B-17

POWER TRIM

Trail Over and Shock Absorber

a

ÄÄ
Á ÁÄÄÁ
Á Á


 




a - High Pressure
1 - Up Circuit Pressure Operated Valve
2 - Down Circuit Pressure Operated Valve
3 - Manual Tilt Valve
4 - Tilt Cylinder
5 - Shock Piston
6 - Memory Piston
7 - Impact Relief & Trail over Valves
8 - Shock Return Valve

Page 5B-18 90-855348R02 NOVEMBER 2002

 POWER TRIM

Trail Over System

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

90-855348R02 NOVEMBER 2002 Page 5B-19

POWER TRIM

Manual Tilt and Reverse

a





ÁÄ ÄÄÁ
Ä Á
ÄÄ
Á Á
 

a - Low Pressure
1 - Manual Release Valve
2 - Tilt Cylinder
3 - Reservoir
4 - Pump
5 - Up Circuit Pressure Operated Valve
6 - Down Circuit Pressure Operated Valve
7 - Trim Relief Valve
8 - Impact relief Valve

Page 5B-20 90-855348R02 NOVEMBER 2002

 POWER TRIM

Manual Tilt System

If the outboard motor is to be raised or lowered manually, turn the manual release (tilt) valve
(1) counterclockwise approximately 3 turns to the full out position. When in the full (out) posi-
tion, oil in the tilt cylinder (2) can flow freely from the up side to the down side or from the
down side to the up side. The oil return line into the reservoir (3) is also open, allowing free
oil flow to either side of the tilt cylinder to accommodate the differential oil capacities be-
tween the tilt cylinder up side and down side cavities.
When trimming the outboard in either the up or down position, with the manual tilt valve open
or leaking, little or no movement will occur. Oil pressure from the pump (4) will move to both,
the up cavity and through the manual tilt valve into the down cavity, each cavity would have
equal pressure resulting in little or no movement.
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or
throttling back rapidly, oil in the trim system must be locked in a static position. When the
pump is not actuated, the following valves are closed:
• Up Pressure Operated Valve (5)
• Down pressure Operated Valve (6)
• Trim Relief Valve
• Impact Relief Valve (8)
• Manual Release Valve (1)
Thus, not allowing oil in the system to move in either direction.

Power Trim System Troubleshooting

IMPORTANT: Acceptable trim down leakage is no more than 1 in. (2.54cm) in a 24 hour
period.
IMPORTANT: Operate Power Trim System after each check to see if problem is cor-
rected. If problem has not been corrected, proceed to next check.
1. Check that Manual Release Valve knob is tightened to full right (clockwise) position.
2. Check trim pump fluid level and fill if necessary. (Refer to Fill, Check, and Purge - Pow-
er Trim System) preceding.
3. Check for external leaks in the system. Replace defective parts if leak is found.
4. Check for air in the system and purge if necessary. (Refer to Fill, Check, and Purge
- Power Trim System) preceding.
NOTE: When troubleshooting the hydraulic system, cleanliness, and inspection of sealing
surfaces, seals, O-rings, and moving parts is important. The internal pressures required for
proper operation of the Power Trim System require these parts to be in excellent condition.
Replace any parts that may be suspect of failure.

90-855348R02 NOVEMBER 2002 Page 5B-21

POWER TRIM

Troubleshooting
IMPORTANT: Determine if Electrical or Hydraulic problem exists.
HYDRAULIC SYSTEM TROUBLESHOOTING
IMPORTANT: Make one correction at a time. Check operation of trim system before
proceding to the next check.

CONDITION OF TRIM SYSTEM PROBLEM

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

1

3

7
4

5

51491
External Mounted Hydraulic System

Page 5B-22 90-855348R02 NOVEMBER 2002

 POWER TRIM

ELECTRICAL SYSTEM TROUBLESHOOTING

CONDITION OF TRIM SYSTEM PROBLEM

A. Trim motor does not run when trim button is depressed. 1, 2, 4, 5, 6, 7, 8
B. Trim system trims opposite of buttons. 3
C. Cowl mounted trim buttons do not activate trim system. 2, 4, 5, 6, 7

PROBLEM
1. Battery low or discharged.
2. Open circuit in trim wiring.
3. Wiring reversed in remote control.
4. Wire harness corroded through.
5. Internal motor problem (brushes, shorted armature).
6. Blown fuse.
7. Trim switch failure.
8. Verify relays are functioning correctly.
POWER TRIM RELAY TEST PROCEDURE
The trim motor relay system used on permanent magnet trim systems connect each of the
two wires from the trim motor to either ground or positive in order to allow the motor to run
in both directions.
If the motor will not run in the UP direction, it could be either the Up relay is not making con-
tact to 12 volts OR the Down relay is not making contact to ground. The opposite is true if
the system will not run Down. When the system is not energized, both relays should connect
the heavy motor leads to ground.
To test which relay is faulty if the trim system does not operate in one direction:
1. Disconnect the heavy gauge pump wires from the trim control relay.
2. Check for continuity between the heavy leads from the trim relays to ground.

Ohmmeter Resistance Scale Reading

Leads Between (Ohms) (R x 1)
GREEN and Ground 0 Full Continuity (Rx1)
BLUE and Ground 0 Full Continuity (Rx1)

Replace the relay that does not have continuity.

3. Connect a voltmeter to the heavy BLUE lead and to ground. You should have 12 volts
on the BLUE lead when the UP switch is pushed. You should should also have 12 volts
on the GREEN lead when the Down switch is pushed. Replace the relay that does not
switch the lead to positive.

90-855348R02 NOVEMBER 2002 Page 5B-23

POWER TRIM

Power Trim Wiring Diagram

3
9

8 6

53794

UP Relay DOWN Relay

BLK = Black
BLU = Blue
10 GRN = Green
RED = Red
WHT = White

Page 5B-24 90-855348R02 NOVEMBER 2002

 POWER TRIM

Electrical System Troubleshooting

GENERAL CHECKS
Before troubleshooting the Power Trim electrical system, check the following:
1. Check for disconnected wires.
2. Make certain all connections are tight and corrosion free.
3. Check that plug-in connectors are fully engaged.
4. Make certain battery is fully charged.
Refer to the preceding wiring diagram for connection points when troubleshooting the elec-
trical systems (Connection points are specified by number.)
Troubleshooting the Down Circuit
Connect Voltmeter red lead
to Point 1 and black lead to
ground.
Depress the Down trim but-
ton.

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

Battery Voltage Indicated: No Voltage Indicated:

There is an open circuit be-
•Connect Voltmeter red lead
tween Point 3 and positive
to Point 2.
(+) battery terminal.
•Depress Down trim button. •Check for loose or cor-
roded connections.
•Check wires for open.

Battery Voltage Indicated:

No Voltage Indicated:
•Pump motor wiring is defective. Relay Switch is defective.
•Pump motor is defective.
No Voltage Indicated:
Connect Voltmeter red lead
to Point 5. If battery voltage
is indicated, trim switch is
faulty. If no battery voltage,
check for loose or corroded
connection at Point 5 or
open circuit in wire supply-
ing current to Point 5.

90-855348R02 NOVEMBER 2002 Page 5B-25

POWER TRIM

Troubleshooting the Up Circuit

Connect Voltmeter red lead to

Point 8 and black lead to
ground.

Depress the Up trim button.

No Voltage Indicated:
Battery Voltage Indicated: Connect Voltmeter red lead to
Connect Voltmeter red lead to Point 7 and black lead to
Point 9. ground. Depress Up trim but-
ton. If battery voltage is indi-
cated, wire is open between
Points 7 and 8.

Battery Voltage Indicated: No Voltage Indicated:

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

Battery Voltage Indicated:

No Voltage Indicated:
•Pump motor wiring is de-
fective. Relay Switch is defective.
•Pump motor is defective.

No Voltage Indicated:

Connect Voltmeter red lead

to Point 5. If battery voltage
is indicated, trim switch is
faulty. If no battery voltage,
check for loose or corroded
connection at Point 5 or
open circuit in wire supply-
ing current to Point 5.

Page 5B-26 90-855348R02 NOVEMBER 2002

 POWER TRIM

Troubleshooting the Down and Up Circuits

(All Circuits Inoperative)
Check in-line fuse (under
cowl) to see if fuse is blown.

Blown Fuse: Fuse Not Blown:

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

Battery Voltage Indicated:

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

No Voltage Indicated: Battery Voltage Indicated:

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

Battery Voltage Indicated:

No Voltage Indicated:
Trim switch is faulty or there is
Check that voltage is being
an open circuit in wires (green-
supplied to control by perform-
white, blue-white) between trim
ing the following checks:
buttons and trim pump.
•DO NOT start engine. •Check trim switch.
•Turn ignition switch to Run •Check all trim harness con-
position. nectors for loose or cor-
•Check for voltage at any instru- roded connections.
ment, using a Voltmeter. •Check for pinched or se-
vered wires.

No Voltage Indicated:
Red wire is open between Battery Voltage Indicated:
Point 3 and red terminal on
back of the ignition switch. There is an open circuit in
•Check for loose or cor- wire between Point 5 and
roded connections. Red terminal on the back of
•Check for open in wire. the ignition switch.

90-855348R02 NOVEMBER 2002 Page 5B-27

POWER TRIM

Power Trim Assembly Removal and Installation

Removal
1. Remove clamps on transom bracket to free power trim wiring.

a 51377
a - Clamps

2. Raise outboard to full Up position and engage tilt lock lever.

50605

a - Tilt Lock Lever

Page 5B-28 90-855348R02 NOVEMBER 2002

 POWER TRIM

WARNING
Failure to support outboard as shown could result in personal injury and/or damage
to outboard or boat. Support outboard as shown to prevent engine from tipping
when power trim retaining pin is removed.

c
53791
a - Tilt Lock Lever
b - Support Tool
c - Retaining Clips

SUPPORT TOOL
3/8 in. diameter metal rod (a used shift shaft works well).

14”

a a
2”

1/4”

a - Drill holes for retaining clips

METRIC CONVERSION
14 in. = 35.56 cm 2 in. = 50.8 mm
3/8 in. = 9.5 mm 1/4 in. = 6.35 mm

90-855348R02 NOVEMBER 2002 Page 5B-29

POWER TRIM

CAUTION
Disconnect battery cables at battery before removing power trim wires from sole-
noids.
3. Disconnect power trim wires at solenoids (BLUE and BLACK).
4. Remove 2 bolts securing anode plate to bottom of trim assembly and remove anode.

a 27932
a - Anode Plate

5. Open filler cap and release any remaining pressure in the system.

53789

a - Filler Cap

Page 5B-30 90-855348R02 NOVEMBER 2002

 POWER TRIM

IMPORTANT: Outboards equipped with through-the-tilt-tube steering - remove steer-

ing link arm from end of steering cable and cable retaining nut from tilt tube.

a 51354
a - Retaining Nut

6. Remove outboard transom mounting bolts, and loosen tilt tube nut until nut is flush with
end of tilt tube thread.

a
51375

a - Transom Mount Bolts (2)

b - Tilt Tube Nut (flush with end of thread)

90-855348R02 NOVEMBER 2002 Page 5B-31

POWER TRIM

7. Remove 3 screws and washers and move starboard transom bracket.

8. Remove trim limit bolt, if installed.

a
b
c 51375
a - Screws (3)
b - Washers (3)
c - Trim Limit Bolt

IMPORTANT: Cross pin should not be reused. Replace with new cross pin.
9. Remove trim indicator sender from port side of swivel bracket.
10. Drive out cross pin, push out upper swivel pin, and remove 3 screws and washers retain-
ing trim system. Remove system from outboard.

b
a

53790
a - Cross Pin
b - Upper swivel pin
c - Port transom bracket screws and washers (3).
Remove to release trim system from outboard.
d - Trim Sender

Page 5B-32 90-855348R02 NOVEMBER 2002

 POWER TRIM

Installation
1. Paint any exposed metal surfaces to prevent corrosion.
2. Apply Loctite 271 to screws. Install trim system, starboard transom bracket, and tilt tube
nut.
3. Reinstall trim limit bolt.

a
b

d 51375

a - Screw (6) Torque to 40 lb. ft. (54.0 Nm)

b - Flatwasher (6) Install one per screw
c - Tilt Tube Nut
d - Trim Limit Bolt

4. Use a 12 volt power source to extend tilt ram up to align upper swivel shaft hole and end
of ram. Connect trim motor wires [BLUE wire to POSITIVE (+), BLACK wire to NEG-
ATIVE (–)]. If ram extends too far, retract ram by reversing wire connections.
5. Install Upper Swivel Pin with slotted end to left (port) side of engine.

b a
c

a - Upper Swivel Pin

b - Slotted end
c - Cross hole (in line with slotted end)

IMPORTANT: Cross pin should not be reused. Install a new pin.

90-855348R02 NOVEMBER 2002 Page 5B-33

POWER TRIM

6. Position slot on end of swivel shaft in line with hole in tilt ram end. Insert a punch into
tilt ram hole to align cross hole in upper swivel shaft. Tap new cross pin in until flush.
a

c b

a - Upper Swivel Shaft (Slot is in line with cross hole)

b - Chamfered end of hole (Faces away from transom)
c - Retaining pin
d - Tilt ram end

7. Connect trim motor wires to solenoids. Refer to Wiring Diagrams in this manual. Route
trim wires as specified in this manual.
8. Reinstall anode plate to bottom of trim system.
9. Apply marine sealer to shanks of mount bolts and install transom mount bolts.
IMPORTANT: Do not use an impact driver to tighten transom mount bolts.
10. Apply marine sealer to threads of mount bolts. Secure with flat washers and locknuts.
Be sure installation is watertight.
11. Tighten tilt tube nut securely.
IMPORTANT: Outboards equipped with through-the-tilt-tube steering: Tighten steer-
ing cable retaining nut securely to tilt tube.

a 51354
a - Steering Cable Retaining Nut

12. Apply Liquid Neoprene on all electrical connections.

WARNING
Electrical wires passing through cowl openings must be protected from chafing or
being cut. Follow the recommended procedures outlined in Section 1D of this
Manual. Failure to protect wires as described could result in electrical system fail-
ure and/or injury to occupants of boat.

Page 5B-34 90-855348R02 NOVEMBER 2002

 POWER TRIM

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

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

e d c b
f a
54457

a - Test Adaptor (91-822778A2)

b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
f - Brass Fitting
g - Apply Teflon Tape

90-855348R02 NOVEMBER 2002 Page 5B-35

POWER TRIM

4. Install test adaptor 91-822778A2 into manual release valve hole.

54458
a - Test Adaptor (91-822778A2)

5. Thread hose from Test Gauge Kit (91-52915A3) into brass fitting on adaptor.

c
d

b
54459
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)

6. Reinstall fill plug.

7. Disengage tilt lock lever.

Page 5B-36 90-855348R02 NOVEMBER 2002

 POWER TRIM

CAUTION
Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could re-
sult in transom bracket failure and possible injury.
8. Move outboard IN until hole in swivel bracket ear aligns with the 3rd tilt hole in transom
bracket. Lock engine in trim range by installing a 3/8 in. (9.5 mm) diameter tilt pin or two
3/8 in. (9.5 mm) hardened bolts and nuts through the transom brackets and swivel
bracket in the hole shown.

a 54460
a - Tilt Pin Hole (Install Spare Tilt Pin or Hardened Bolts and Nuts)

9. Open valve (a) and close valve (b).

a b

51374
10. Run trim UP. The minimum pressure should be 1300 P.S.I. (91 kg/cm2).
11. Run trim DOWN to release pressure and remove spare tilt pin or bolts and nuts.
12. Tilt outboard full UP and engage tilt lock lever.
13. Slowly remove Fill plug to bleed pressure.
14. Remove test gauge hose and adapter.
15. Reinstall Manual Release Valve and secure valve with circlip.
16. Retighten Fill plug.
NOTE: If pressure is less than 1300 PSI (91 kg/cm 2), troubleshoot system per instructions
on page 5B-8.

90-855348R02 NOVEMBER 2002 Page 5B-37

POWER TRIM

Down Pressure Check

IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full Up position and engage tilt lock lever.
2. Slowly remove Fill plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim as-
sembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring onto
adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test
adaptor securely using teflon tape on threads.
g

f a e d c b
54457
a - Test Adaptor (91-822778A3) e - Large O-ring (Install Last)
b - O-ring Installation Tool f - Brass Fitting
c - Small O-ring (Install 1st) g - Apply Teflon Tape
d - Medium O-ring (Install 2nd)

4. Install test adaptor 91-822778A3 into manual release valve hole.

54461

54458

a - Test Adaptor (91-822778A3)

Page 5B-38 90-855348R02 NOVEMBER 2002

 POWER TRIM

5. Thread hose from Test Gauge Kit (91-52915A3) into brass fitting on adaptor.

c
d

g
b
f 54459
a - Brass Fitting d - Hose
b - Test Gauge Assembly e - Hose (Not Used)
c - Tilt Pin (Position in Hole f - OPEN Valve
Shown) g - CLOSE Valve

6. Reinstall fill plug.

7. Disengage tilt lock lever.
8. Open valve (f) and close valve (g).
9. Run trim DOWN. Minimum pressure should be 500 P.S.I. (35 kg/cm2).
10. Tilt outboard full UP and engage tilt lock lever.
11. Slowly remove Fill plug to bleed pressure.
12. Remove test gauge hose and adaptor.
13. Reinstall manual release valve and secure valve with circlip.
14. Retighten Fill plug.
NOTE: If pressure is less than 500 PSI (35 kg/cm 2), troubleshoot system per instructions
in Power Trim System Troubleshooting section.

90-855348R02 NOVEMBER 2002 Page 5B-39

POWER TRIM

Hydraulic Repair
TRIM ROD REMOVAL AND REPAIR
NOTE: Power Trim does not have to be removed from outboard to remove trim rods.
1. Tilt outboard to full Up position and engage tilt lock lever.
2. Slowly remove Fill plug to bleed reservoir pressure.
3. Turn Manual Release Valve 3 to 4 turns (counterclockwise) to bleed remaining pressure.
4. Remove trim rod cylinder end caps using one of the special tools listed.
NOTE: Place a clean pan under trim system to catch fluid.

d
c

b
b
51337

51353
a - Trim Rod Cylinder End Cap
b - Turn Counterclockwise To Remove
c - Removal Tool (91-44487A1)
d - Spanner Wrench (91-74951)

5. Install trim rod removal tool and pull trim rod from cylinder.
a

27933
a - Trim Rod Removal Tool (91-44486A1)

Page 5B-40 90-855348R02 NOVEMBER 2002

 POWER TRIM

CLEANING AND INSPECTION - TRIM RODS AND CAPS

CAUTION
Do not remove check valve. Check valve is preset to operate at a specific pressure.
Removal and installation of check valve could result in improper operating pres-
sure and possible system damage.
NOTE: Check valve is in port side trim rod only.
6. Inspect check valve and check valve screen for debris; if debris cannot be removed, re-
place trim rod assembly. Clean trim rod with parts cleaner and dry with compressed air.

a
b

51352
a - Check valve
b - Check valve screen

Trim Rod End Cap Seal

1. Inspect trim cap end seal and replace if damaged or if seal does not keep trim rod clean.

51343
a - Seal (Remove as shown)

2. Install new seal with seal lip up.

90-855348R02 NOVEMBER 2002 Page 5B-41

POWER TRIM

TRIM ROD INSTALLATION

IMPORTANT: Components must be free of dirt and lint. Any debris in the system can
cause system to malfunction.
NOTE: Install trim rod with check valve in the port (left) cylinder.
1. Apply Power Trim and Steering Fluid on all O-rings and seals before installation.
2. Install trim rods and caps. Use installation tool (91-44487A1) or spanner wrench
(91-74951) to tighten caps securely.
3. Lubricate rod end rollers with Anti-Corrosion Grease or 2-4-C with Teflon.

a a

c c

b b

51353

a - Trim rods
b - Cylinder End Caps
c - Rod End Rollers

Page 5B-42 90-855348R02 NOVEMBER 2002

 POWER TRIM

Tilt Ram
REMOVAL - TILT ROD ASSEMBLY ONLY
NOTE: Tilt Rod Assembly can be removed from cylinder without removing entire power trim
system from outboard. Refer to Power Trim Assembly Removal and Installation to re-
move upper swivel pin.

CAUTION
Insure Power Trim System Is Depressurized Prior To Tilt Rod Removal.
1. Use spanner wrench (91-74951) to loosen tilt ram end cap.

51337

91-74951

b
c

51337
a

51364
a - End Cap
b - Spanner Wrench (91-74951) (Turn counterclockwise)
c - Tilt Rod. (Pull to remove.)

NOTE: Place a clean pan under tilt ram to catch fluid.

90-855348R02 NOVEMBER 2002 Page 5B-43

POWER TRIM

TILT RAM COMPONENTS

3
2

7
6
2
2
5
2
2
4

8
9 51372
1 - Housing - Tilt Ram
2 - O-ring* (5)
3 - Memory Piston
4 - Washer
5 - Piston Assembly
6 - End Cap
7 - Oil Seal
8 - Nut (Design 2)
9 - Tilt Rod (Design 2)
*O-ring Repair Kit Available, P.N. 811607A1 (Includes item 7, Oil Seal)

Page 5B-44 90-855348R02 NOVEMBER 2002

 POWER TRIM

TILT RAM REMOVAL - POWER TRIM SYSTEM REMOVED FROM OUTBOARD

CAUTION
Ensure trim system is depressurized prior to tilt ram removal.
1. Remove cross pin.

51366
a
a - Cross Pin (Remove as shown)

2. Remove lower swivel pin.

a
51355
a - Lower Swivel Pin (Remove as shown)

90-855348R02 NOVEMBER 2002 Page 5B-45

POWER TRIM

Disassembly
1. Secure tilt ram in a soft jawed vise. Remove tilt rod and end cap.

91-74951
c

51337

51364
a - End Cap (Turn counterclockwise to remove)
b - Spanner wrench (91-74951)
c - Tilt Rod - Pull to remove

2. Clamp tilt rod in a soft jawed vise. Remove nut to disassemble rod assembly. Remove
O-ring.
b

51340
a - O-Ring
b - Nut

Page 5B-46 90-855348R02 NOVEMBER 2002

 POWER TRIM

3. Remove washer, check valve assemblies, and piston.

NOTE: Check valve held in by roll pin can be cleaned but not removed.

51363

a - Washer
b - Check valve assembly (7)
c - Piston

4. Remove end cap from tilt rod.

51376
a - End cap

90-855348R02 NOVEMBER 2002 Page 5B-47

POWER TRIM

5. Remove allen plug.

IMPORTANT: Remove plug from same side as holes in shaft.
a b

51361
c
a - Allen plug
b - Hole in shaft
c - Do Not Remove

6. Lubricate shaft with Power Trim and Steering Fluid. Insert shaft into cylinder.

51342

7. Tap shaft into cylinder until shaft is positioned as shown.

51365

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.

Page 5B-48 90-855348R02 NOVEMBER 2002

 POWER TRIM

8. Drain as much fluid as possible from cylinder before removing memory piston.
9. Place cylinder as shown. Hold down on cylinder and inject air into shaft opening.

51353
a - Shop Cloth
b - Solid surface
c - Air nozzle

10. Remove shaft after Memory Piston Cup has been expelled. Replace allen plug removed
in Step 5 and tighten securely.
CLEANING AND INSPECTION
1. Inspect all internal parts for damage or wear. Clean and replace parts as necessary.
2. Inspect tilt rod for scratches. Replace scraper seal in rod end cap if tilt rod is scratched
or worn.
3. Slight scratches or tool marks less than 0.005 in. (0.127 mm) deep in cylinder are ac-
ceptable.

90-855348R02 NOVEMBER 2002 Page 5B-49

POWER TRIM

Scraper Seal Replacement

1. Remove components from end cap.

b
a

a - Cap
b - O-ring (2)
c - Scraper Seal

REASSEMBLY
IMPORTANT: Components must be clean for reassembly. Any debris in the system
can cause the system to malfunction.
NOTE: Refer to Tilt Ram Components for proper O-ring sizes.
1. Apply Power Trim and Steering Fluid on O-rings prior to reassembly.
2. Install O-ring on Memory Piston Cup.
3. Push memory piston all the way to the bottom of the cylinder and then fill 3/4 full with
oil before installing rod.

b
a
51372
a - O-ring
b - Memory Piston Cup (Design 1 shown)

Page 5B-50 90-855348R02 NOVEMBER 2002

 POWER TRIM

4. Assemble end cap.

b
a

b
a - End Cap
b - O-ring (2)
c - Scraper Seal

5. Lubricate seal and rod shaft with Power Trim and Steering Fluid to prevent seal damage
during assembly. Reinstall end cap.

51376
a - End Cap

6. Install components on rod. Verify check balls are properly installed in their seats.
e d
c

b
a
c

51363

51340
a - Piston
b - O-ring
c - Check Valve Assembly (7)
d - Washer
e - Bolt or Locknut. (Tighten securely)

90-855348R02 NOVEMBER 2002 Page 5B-51

POWER TRIM

NOTE: Finish filling cylinder with oil before tightening cap.

7. Lubricate the O-rings on the rod and end cap with Power Trim and Steering Fluid. Clamp
cylinder in a soft jawed vise and install tilt rod assembly. Use spanner wrench and tighten
end cap securely.
c
91-74951

b
51337

51341
a - Cylinder
b - Tilt rod assembly
c - End cap (Tighten securely.) Use spanner wrench.

TILT RAM ASSEMBLY INSTALLATION

1. Lubricate alignment tool (91-11230) and shaft. Use Power Trim and Steering Fluid.

b
a

51369
a - Alignment Tool (91-11230)
b - Shaft

Page 5B-52 90-855348R02 NOVEMBER 2002

 POWER TRIM

2. Align tilt ram and housing using alignment tool.

51348
a - Alignment Tool (91-11230)

3. Install shaft.

c
b 51352
a - Shaft
b - Groove
c - Hole [groove (b) will align with this hole.]

4. Drive pin in until flush.

51356
a - Pin (Drive Against Knurled End)

5. Install Power Trim Assembly on outboard. Refer to Installation instructions.

90-855348R02 NOVEMBER 2002 Page 5B-53

POWER TRIM

MOTOR AND PUMP REPLACEMENT

IMPORTANT: The pump is not rebuildable. If pump is defective, replace as an assem-
bly.
NOTE: Power Trim System does not have to be removed from outboard to replace pump
or motor.
1. Tilt outboard to full UP position. Depressurize power trim system, and loosen starboard
transom bracket as outlined in Removal and Installation.
2. Remove 2 allen screws to remove motor from system.
NOTE: Drive shaft is a loose part and may fall out of motor when motor is removed.

b b

53777
a - Motor
b - Screw (2)

3. Remove two screws to remove pump.

51433

a - Pump
b - Screw (2)

Page 5B-54 90-855348R02 NOVEMBER 2002

 POWER TRIM

Motor and Electrical Tests/Repair

Trim Pump Motor Test
WARNING
Do not perform this test near flammable materials, as a spark may occur while mak-
ing electrical connections.
1. Connect a 12 volt power supply to motor wires; one motor lead to POSITIVE (+) battery
terminal and the other motor lead to the NEGATIVE (–) battery terminal. Motor should
run. Reverse motor leads between battery terminals. Motor should run.

53774

2. If motor does not run, disassemble and check components.

Motor Disassembly
1. Remove 2 screws.

a a

53774
a - Screw (2)

90-855348R02 NOVEMBER 2002 Page 5B-55

POWER TRIM

2. Remove frame and armature from end cap. Use care not to drop armature.

53779
a - Frame
b - Armature
c - End Cap

Page 5B-56 90-855348R02 NOVEMBER 2002

 POWER TRIM

Armature Tests
TEST FOR SHORTS
Check armature on a Growler per the Growler manufacturer’s instructions. Replace arma-
ture if a short is indicated.
TEST FOR GROUND
Use an Ohmmeter (Rx1 scale). Connect one lead on armature shaft and other lead on com-
mutator. If continuity is indicated, armature is grounded. Replace armature.

53786
CHECKING AND CLEANING COMMUTATOR
1. If commutator is worn it may be turned on an armature conditioner or a lathe.
2. Clean commutator with “OO” sandpaper.
a

53775
a - Commutator

90-855348R02 NOVEMBER 2002 Page 5B-57

POWER TRIM

FIELD TESTS
IMPORTANT: Commutator end of armature must be installed in brushes when per-
forming the following tests.

Ohmmeter Resistance Scale Reading*

Leads Between (Ohms) (x____________)
BLUE and BLACK Motor Wires 0 (Rx1)
BLACK Motor Wire, and Frame No (Rx1)
(Motor Housing) Continuity
BLUE Motor Wire and Frame No (Rx1)
Continuity

*If specified readings are not obtained, check for:

• defective armature
• dirty or worn brushes
• dirty or worn commutator
If defective components are found, repair or replace component(s) and retest.

Page 5B-58 90-855348R02 NOVEMBER 2002

 POWER TRIM

Motor Repair
REMOVAL
NOTE: Power Trim System does not have to be removed from outboard to repair/replace
motor.
DISASSEMBLY
Refer to Motor Disassembly in this section to disassemble motor from pump.
CLEANING AND INSPECTION
Inspect O-rings and replace if necessary. Carefully inspect power cord for cuts or tears
which will allow water to enter motor. Replace cord if cut or torn. Clean, inspect, and test
motor components. Refer to Brush Replacement, Armature Test, and Field Tests for in-
spection and test procedures.

c
d e

53779

a - Frame d - Brush Card Assembly

b - Armature e - O-rings
c - Shim

90-855348R02 NOVEMBER 2002 Page 5B-59

POWER TRIM

BRUSH REPLACEMENT
1. Brush replacement is required if brushes are pitted, chipped, or if distance (a) between
the brush pigtail and end of brush holder slot is 1/16 in. or less. Check distance with ar-
mature installed.

53784
a - 1/16 in.

2. To replace brush card, disconnect spade terminal.

3. Cut crimped brush lead.
4. Remove 2 screws securing brush card to end cap.

a c

a - Spade Terminal
b - Crimped Brush Lead
c - Screws

Page 5B-60 90-855348R02 NOVEMBER 2002

 POWER TRIM

5. Install new brush card (BRUSH and SEAL KIT 828714A1).

6. Crimp metal connector onto motor lead and new brush lead.
7. Connect spade connector motor lead to brush card connector.
8. Secure brush card to end cap with 2 screws and lockwashers.
9. Inspect o-ring for cuts and abraisions. Replace o-ring as required (BRUSH and SEAL
KIT 828714A1).

c
d

b
e

53778
a - Brush Card d - Screws and
b - Metal Connector Lockwashers
c - Spade Connector e - O-ring

END CAP INSPECTION

1. Inspect seal and o-ring for cuts and abraisions. If replacement is required, install BRUSH
and SEAL KIT 828714A1.

53783
a - Seal (Apply 2-4-C with Teflon to seal lips)
b - O-ring

90-855348R02 NOVEMBER 2002 Page 5B-61

POWER TRIM

2. Inspect bushing for wear. If bushing appears to be excessively worn – grooves,

scratches, etc. – install End Frame Assembly (complete) 828715A1.

53785
a - Bushing

3. If trim motor is overheated, a thermoswitch located under brush card will open. Normally,
this switch will reset itself within 1 minute.

53781
a - Thermoswitch

Page 5B-62 90-855348R02 NOVEMBER 2002

 POWER TRIM

Reassembly
Components must be clean. Any debris in power trim system can cause system to
malfunction.
1. Install armature into end cap/brush card assembly.

53779

53784
a - Armature
b - Shim
c - End Cap Assembly
d - Armature (Spread brushes to install armature into end cap)

90-855348R02 NOVEMBER 2002 Page 5B-63

POWER TRIM

2. Install O-rings in end cap.

53784

53783
a - O-rings

Page 5B-64 90-855348R02 NOVEMBER 2002

 POWER TRIM

IMPORTANT: Attach Vise Grip pliers to armature shaft before installing frame as-
sembly. The Vise Grip pliers will prevent the armature from being drawn out of the
brush card assembly by the frame magnets while installing the frame assembly.
3. Install Vise Grip pliers on armature shaft.
4. Carefully install frame assembly over armature.
5. Position harness retainer hole over tab in end cap.
6. Secure frame assembly to end cap with 2 screws.

i e
f i

g
d
c

53776
a - Vise Grip Pliers f - Retainer Hole
b - Armature Shaft g - O-ring
c - O-ring h - Frame Assembly
d - End Cap i - Screws
e - Harness Retainer

90-855348R02 NOVEMBER 2002 Page 5B-65

POWER TRIM

Reassembly - Motor and Pump

NOTE: Drive shaft is a loose part and may fall out of position.
1. Install pump onto power trim manifold. Insure O-rings are in proper locations. Secure
with two (2) screws.
IMPORTANT Install pump with location flat facing towards starboard
transom bracket.

c d

51433
a - Pump (Flat towards starboard transom bracket)
b - Flat - faces starboard transom bracket)
c - O-rings (4)
d - Drive Shaft (Install in center hole in pump)

2. Fill pump with Power Trim and Steering Fluid prior to installing motor.

Page 5B-66 90-855348R02 NOVEMBER 2002

 POWER TRIM

3. Install motor, secure with two (2) screws. Route wiring; refer to Wiring Diagrams in this
service manual.
NOTE: Verify motor and drive shaft are aligned.

53782

c c

53777
a - Motor
b - O-ring
c - Screw (2) Tighten securely.

4. Complete reassembly of Power Trim System as outlined in Installation.

90-855348R02 NOVEMBER 2002 Page 5B-67

POWER TRIM

Priming Power Trim System

Fill system with Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) Type
F or FA. Refer to Fill, Check, and Purge on page 5B-6.
IMPORTANT: Run Trim System in short jogs until pump motor primes and trim sys-
tem moves. If trim motor is run without priming pump, drive shaft failure could result.
Trim Sender (Optional Accessory) Test
1. Check trim sender black lead for proper ground.
2. Trim outboard to full DOWN position.
3. Place ignition switch to ON position.
4. Connect Ohmmeter (Rx1 scale) leads between outboard ground and Point 1.
5. Depress UP button. Ohmmeter needle should move as the outboard is trimmed up. If
needle does not move, trim sender is defective.

22908
a - Trim Sender

Page 5B-68 90-855348R02 NOVEMBER 2002

 POWER TRIM

Trim Indicator Gauge Needle Adjustment

1. Turn ignition key to RUN position.
2. Tilt outboard to full IN position. Needle of trim indicator gauge should be in full IN
position.
3. If not, tilt outboard to full OUT position to gain access to trim sender and engage tilt lock
lever.
4. Loosen trim sender screws and reposition trim sender.
5. Tighten trim sender screws.

c d

a
e

22744
a - Trim Sender
b - Screws, loosen to rotate sender
c - Turn sender counterclockwise to raise needle reading
d - Turn sender clockwise to lower needle reading
e - Tilt lock lever

90-855348R02 NOVEMBER 2002 Page 5B-69

POWER TRIM

Trim Indicator Wiring Diagrams

For Boats Equipped with Commander Series Side Mount Remote Control

d e

22908
a - Trim Indicator
b - Remote Control
c - To Engine
d - Trim Sender
e - Engine Ground

For Boats Equipped with Ignition/Choke and Main Harness Assembly

a
c
b

e
f

d
22908
a - Trim Indicator
b - Ignition/Choke Switch
c - Power Trim Harness
d - To Engine
e - Trim Sender
f - Engine Ground

Page 5B-70 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

LOWER UNIT
Section 6A - Gear Housing Right Hand Operation
(Standard Rotation)
(Ratcheting and Non-Ratcheting)
Table of Contents
General Service Recommendations . . . . . . . 6A-1 Forward Gear Assembly . . . . . . . . . . . . . . . 6A-48
Gear Housing Specifications Shift Spool Assembly . . . . . . . . . . . . . . . . . 6A-51
(Standard Rotation) . . . . . . . . . . . . . . . . . . . . . 6A-3 Propeller Shaft Assembly . . . . . . . . . . . . . . 6A-56
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-57
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . 6A-61
Gear Housing (Drive Shaft) (Standard Rotation) Gear Housing Reassembly . . . . . . . . . . . . . . . 6A-62
(Ratcheting)(S/N-0G437999 & BELOW) Gear Housing Inspection . . . . . . . . . . . . . . 6A-62
(CASTING #1623-822442C2) . . . . . . . . . . . . 6A-10 Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . 6A-63
Gear Housing (Prop Shaft) (Standard Rotation) Forward Gear Bearing Cup . . . . . . . . . . . . 6A-64
(Ratcheting)(S/N-0G437999 & BELOW) Shift Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-65
(CASTING #1623-822442C2) . . . . . . . . . . . . 6A-12 Propeller Shaft Assembly . . . . . . . . . . . . . . 6A-67
Gear Housing (Drive Shaft)(Standard Rotation) Drive Shaft and Pinion Gear . . . . . . . . . . . 6A-68
(Non-Ratcheting) (S/N-0G438000 & UP) Gear Location/Backlashes Checking
(CASTING #1623-822442C3) . . . . . . . . . . . . 6A-14
Gear Housing (Prop Shaft)(Standard Rotation)
and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft - Bearing Preload Tool . . . . . .
6A-72
6A-72
6
(Non-Ratcheting)(S/N-0438000 & UP) Pinion Gear Location . . . . . . . . . . . . . . . . . 6A-73 A
(Casting #1623-822442C3) . . . . . . . . . . . . . . 6A-16 Bearing Carrier Assembly . . . . . . . . . . . . . 6A-75
Removal, Disassembly, Cleaning and Inspection Forward Gear Backlash . . . . . . . . . . . . . . . 6A-77
– Standard Rotation . . . . . . . . . . . . . . . . . . . . . 6A-18 Reverse Gear Backlash . . . . . . . . . . . . . . . 6A-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Drive Shaft - Bearing Preload Tool . . . . . . 6A-80
Pre-Disassembly Inspection . . . . . . . . . . . . . . 6A-21 Bearing Carrier Assembly . . . . . . . . . . . . . . . . 6A-80
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Final Installation . . . . . . . . . . . . . . . . . . . . . . 6A-80
Gear Housing and Component Disassembly 6A-22 Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . 6A-84
Water Pump Assembly . . . . . . . . . . . . . . . . 6A-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-84
Oil Seal Carrier Assembly . . . . . . . . . . . . . 6A-25 Water Pump Assembly . . . . . . . . . . . . . . . . . . . 6A-84
Bearing Carrier Assembly . . . . . . . . . . . . . 6A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-84
Drive Shaft Assembly . . . . . . . . . . . . . . . . . 6A-40 Gear Lubricant Filling Instructions . . . . . . 6A-87
Propeller Shaft Assembly and Forward Installing Gear Housing to Drive
Gear Bearing Cup . . . . . . . . . . . . . . . . . . . 6A-44 Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . 6A-87

General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part. It is
recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
Disassembly of a sub-assembly may not be necessary until cleaning and inspection re-
veals that disassembly is required for replacement of one or more components.

90-855348R02 NOVEMBER 2002 Page 6A-1

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Service procedure in this section is a normal disassembly-reassembly sequence. It is sug-

gested that the sequence be followed without deviation to assure proper repairs. When per-
forming partial repairs, follow the instructions to the point where the desired component can
be replaced, then proceed to reassembly and installation of that component in the reas-
sembly part of this section. Use the Table of Contents (preceding) to find correct page num-
ber.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, be sure that no water is present in air line.

BEARINGS
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing so
that it passes through the bearing. DO NOT spin bearing with compressed air, as this may
cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with Pre-
mium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing
race in-and-out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condition of rollers and inner bearing race by
inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles and/
or discoloration from overheating. Always replace tapered bearing and race as a set.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that the
roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded par-
ticles, uneven wear and/or discoloration from overheating. The shaft and bearing must be
replaced if the conditions described are found.

SHIMS
Keep a record of all shim amounts and location during disassembly to aid in reassembly.
Be sure to follow shimming instructions during reassembly as gears must be installed to cor-
rect depth and have the correct amount of backlash to avoid noisy operation and premature
gear failure.

SEALS
As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard
to appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter of
all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean and
dry. To ease installation, apply 2-4-C with Teflon on all O-rings. To prevent wear, apply 2-4-C
with Teflon on I.D. of oil seals.
To prevent corrosion damage after reassembly, apply Perfect Seal or 2-4-C with Teflon to
external surfaces of bearing carrier and retainer nut threads prior to installation. DO NOT
allow Perfect Seal to enter bearings or O-ring area.
NOTE: Before filling gear case, apply 10-15 psi (68.5 – 102.7kPa) of air pressure at the
VENT hole. Pressure should not drop for 15 seconds while alternately applying a 2-3 pound
force to the top of the shift shaft in the fore and aft direction.

Page 6A-2 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing Specifications (Standard Rotation)

Pinion Depth
All Models 0.025 in. (0.64mm) with Tool 91-12349A2
Using Disc #2 and Flat #4
Forward Gear Backlash
1.64:1and 1.75:1 Gear Ratios 0.017 in. to 0.028 in.
1.62:1 Gear Ratio (0.431mm to 0.711mm)
Service Replacement Pointer on line mark #1
with Backlash Indicator
Rod 91-53549
Reverse Gear Backlash
1.64:1and 1.75:1 Gear Ratios 0.030 in. to 0.050 in.
1.62:1 Gear Ratio (0.76mm to 1.27mm)
Service Replacement
Lubricant Capacity 28 fl. oz. (0.828 liter)
Forward Gear Backlash
1.87:1 Gear Ratio 0.017 in. to 0.028 in.
(High Altitude) (0.431mm to 0.711mm)
Pointer on line mark #1
with Backlash Indicator Rod 91-78473
Reverse Gear Backlash
1.87:1 Gear Ratio 0.030 in. to 0.050 in.
(High Altitude) (0.76mm to 1.27mm)
Lubricant Capacity 28 fl. oz. (0.828 liter)

Gear Ratio Teeth in Pinion Gear Teeth in Forward and

Reverse Gear
1.62:1 13 21
1.64:1 17 28
1.75:1 12 21
1.87:1 15 28

Water Pressure
Idle 1-1/2 – 4-1/2 psi
(10.3 – 30.8kPa)
Poppet Valve Opening 6 – 7 psi
(41.1 – 47.9kPa)
W.O.T. 8-10 psi
(54.9 – 68.5kPa)
Test Propeller for Static Test
12 Dia. x 15 Pitch 48-78116A40

90-855348R02 NOVEMBER 2002 Page 6A-3

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Special Tools (Ratcheting and Non-Ratcheting)

Belleville Washer 12-54048

Needle Bearing Driver 91-15755

Bearing Driver Cup 91-31106

Oil Seal Driver 91-31108

Needle Bearing Driver 91-877321

Pilot Washer 91-36571

Page 6A-4 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Driver Cup 91-36577

Universal Puller Plate 91-37241

Bearing Retainer Tool 91-43506

Backlash Indicator Rod 91-53459

90-855348R02 NOVEMBER 2002 Page 6A-5

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Drive Shaft Nut Wrench 91-56775

Dial Indicator 91-58222A1

Bearing Carrier Retainer Wrench 91-61069

Torque Wrench (lb. in.) 91-66274

Backlash Indicator Rod 91-78473

Page 6A-6 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Puller Bolt 91-85716 and Puller Jaws 91-46086A1

Dial Indicator Holding Tool 91-83155

Oil Seal Driver 91-817569

Water Pump Alignment Pins 91-821571A1

Pinion Gear Shimming Tool 91-12349A2

90-855348R02 NOVEMBER 2002 Page 6A-7

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Bearing Preload Tool 91-14311A2

Bearing Removal and Installation Tool 91-31229A7 – Includes Driver Head 91-36569: Driv-
er Head Rod 91-37323; Nut 11-24156; Pilot Washer 91-36571; Pilot Plate 91-29610; Puller/
Driver Head 91-38628; Mandrel 91-30366; Plate 91-29310; Driver Head 91-32325; Puller
Shaft 91-31229; Washer 91-34961.

Leakage Tester FT8950

Page 6A-8 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Notes:

90-855348R02 NOVEMBER 2002 Page 6A-9

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Drive Shaft) (Standard Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

29
95 95

30
95
31
32
40 28
95
41 27
95 34
42 95
39
95
95
33 95
26
95 13, 14
38

7 25
43 23
36 19
24
22 95

37 19
21
18

35 20
10
11 12 3
1 95 7 7
7

6
10 5
4
1623-
822442C2
95 9

15
6 8
7 Loctite 271 Thread Locker 16
19 Perfect Seal 17 2
117 Loctite 7649 Primer N 117
7
95 2-4-C With Teflon

Page 6A-10 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Drive Shaft) (Standard Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING
2 1 PIN
3 1 FILLER BLOCK
4 1 MAGNETIC SCREW 60 6.8
5 1 SEALING WASHER
6 2 ANODE
7 1 SCREW
8 1 NUT 60 6.8
9 1 ROLLER BEARING
10 2 DOWEL PIN
11 1 SCREW 60 6.8
12 1 SEALING WASHER
13 1 CONNECTOR (LONG/X–LONG)
14 1 CONNECTOR (XX–LONG)
15 1 PINION GEAR (Part of 43-826181A2 – 1.75:1 or 43-828072A2 – 1.62:1)
16 1 WASHER
17 1 NUT 75 101
18 1 BUSHING ASSEMBLY
19 1 OIL SEAL
20 2 O-RING
21 2 SCREW 60 6.8
22 1 RUBBER WASHER
23 1 SHIFT SHAFT (LOWER)
24 1 DRIVE SHAFT (LOWER)
25 1 KEY
26 AR SHIM
27 1 TAPERED ROLLER BEARING
28 1 RETAINER 100 135
29 1 CARRIER ASSEMBLY
30 1 O-RING
31 1 OIL SEAL
32 1 OIL SEAL
33 1 WATER PUMP ASSEMBLY
34 1 SEAL
35 1 GASKET
36 1 GASKET
37 1 FACE PLATE
38 1 IMPELLER
39 4 SCREW 60 6.8
40 1 COUPLING ASSEMBLY
41 2 O-RING
1 DRIVESHAFT KIT (LONG–20 IN.) SEE NOTE
1 DRIVESHAFT KIT (X-LONG–25 IN.) 13 SPLINES
1 DRIVESHAFT KIT (XX-LONG–30 IN.)
42 1 DRIVESHAFT KIT (LONG–20 IN.) SEE NOTE
1 DRIVESHAFT KIT (X-LONG–25 IN.) 8 SPLINES
1 DRIVESHAFT KIT (XX-LONG–30 IN.)
43 1 COUPLING

NOTE: Service replacement of the one (1) piece driveshaft is not being offered. De-
termine the length of the driveshaft and ORDER REF. #’s 24 & 42.

90-855348R02 NOVEMBER 2002 Page 6A-11

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Prop Shaft) (Standard Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

68

1
1623-
822442C2

66
44
67 95 82
45

48 82
52 46

47 57
53 82
94
49 56
82 59
54 50 55

51
60 58
64 61
95

62 95
69 63 95

71
7
65

70 95
73
72
7 Loctite 271 Thread Locker 95

82 Premium Gear Lubricant

94 Anti-Corrosion Grease
95
95 2-4-C With Teflon

Page 6A-12 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Prop Shaft) (Standard Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING
44 1 SHIFT CRANK
45 1 SHIFT SPOOL KIT
46 AR SHIM
TAPERED ROLLER BEARING
1
(USE WITH 1623-822442C2 CASTING)
47
TAPERED ROLLER BEARING
1
(USE WITH 1623-822442C3 CASTING)
1 FORWARD GEAR SET (Includes Pinion Gear)(1.75:1 GEAR RATIO)
48 FORWARD GEAR (NOTE: THIS COMPLETE GEAR SET IS A 1.62:1 GEAR RATIO REPLACING A
1
1.64:1 GEAR RATIO)
49 1 ROLLER BEARING
50 1 SPRING
51 1 SLIDING CLUTCH
52 1 DETENT PIN
53 1 CROSS PIN
54 1 PROPELLER SHAFT
1 REVERSE GEAR (1.75:1 GEAR RATIO)
55 1 REVERSE GEAR (1.64:1 GEAR RATIO)
1 REVERSE GEAR (1.62:1 GEAR RATIO)(PART OF 43-828072A2)
56 1 THRUST SPACER
57 1 THRUST RING
58 1 BALL BEARING
59 1 O-RING
60 1 BEARING CARRIER
61 1 ROLLER BEARING
62 1 OIL SEAL (INSIDE)
63 1 OIL SEAL (OUTSIDE)
64 1 TAB WASHER
65 1 RETAINER 210 285
66 1 ANODIC PLATE
1 TRIM TAB (BLACK ALUMINUM)
67
1 TRIM TAB (ANODIC) THESE REPLACEMENT
68 1 SCREW PARTS ARE NOT 40 54.2
69 1 THRUST HUB INCLUDED WITH
70 1 LOCKWASHER COMPLETE GEAR
71 1 WASHER HOUSING REPLACEMENT
72 1 TAB WASHER
73 1 PROPELLER NUT 55 74.6

90-855348R02 NOVEMBER 2002 Page 6A-13

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Drive Shaft)(Standard Rotation)

(Non-Ratcheting) (S/N-0G438000 & UP)(CASTING
#1623-822442C3)
7 Loctite 271 Thread Locker
31
95
19 Perfect Seal
117 Loctite 7649 Primer N 32
95 2-4-C With Teflon 33 95

34
42
30
44
95 43 29
36
45 28 95
41
95

35 95
27
95
13,
40 14
26
24
19
38
25
23
15
39 20
22
46, 19
47
37 21
10
11 12
3
1 95
95 7
7
6
10 5
4

95 9

16
6 8
4.75
IN/120.65MM 17
2
TORPEDO DIA. 18
7 117

Page 6A-14 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Drive Shaft)(Standard Rotation)

(Non-Ratcheting)(S/N-0G438000 & UP)
(Casting #1623-822442C3)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING (BLACK) BASIC
1 1 GEAR HOUSING (GRAY)
2 1 PIN
3 1 FILLER BLOCK
4 1 MAGNETIC SCREW 60 6.8
5 1 SEALING WASHER
6 2 ANODE
7 1 SCREW 60 6.8
8 1 NUT
9 1 ROLLER BEARING
10 2 DOWEL PIN
11 1 SCREW ASSEMBLY 60 6.8
12 1 SEALING WASHER
13 1 CONNECTOR (L/XL)
14 1 CONNECTOR (XXL)
15 1 CABLE TIE
16 1 PINION GEAR (Part of 43-828168A2)(1.75:1 - 12/21)
17 1 WASHER
18 1 NUT 70 94.9
19 1 BUSHING ASSEMBLY
20 1 OIL SEAL
21 2 O-RING
22 2 SCREW (M6 x 16) 60 6.8
23 1 RUBBER WASHER
24 1 SHIFT SHAFT (LOWER)
25 1 DRIVE SHAFT (LOWER)
26 1 KEY
27 AR SHIM SET
28 1 TAPERED ROLLER BEARING
29 1 CUP
30 1 RETAINER 100 135
31 1 CARRIER ASSEMBLY
32 1 O-RING
33 1 OIL SEAL
34 1 OIL SEAL
35 1 WATER PUMP ASSEMBLY
36 1 SEAL
37 1 GASKET
38 1 GASKET
39 1 FACE PLATE
40 1 IMPELLER
41 4 SCREW (M6 x 16) 60 6.8
42 1 COUPLING ASSEMBLY
43 1 O-RING
44 1 O-RING
45 1 DRIVE SHAFT KIT (LONG-20 IN.)
1 DRIVE SHAFT KIT (X-LONG-25 IN.) SEE NOTE
46
1 DRIVE SHAFT KIT (XX-LONG-30 IN.)
47 1 COUPLING
NOTE: Service replacement of the one (1) piece driveshaft is not being offered. Determine the length of the
driveshaft and ORDER REF. #’s 24 & 44.

90-855348R02 NOVEMBER 2002 Page 6A-15

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Prop Shaft)(Standard Rotation)

(Non-Ratcheting)(S/N-0438000 & UP)
(Casting #1623-822442C3)
75
4.75 IN/120.65MM
TORPEDO DIA. 1

52 51 48
74 95 50
82
49

54 53 82
60
56
55 65
61 82
94
57 64
82 67
58 63
62
59
68
66

72 69
95

95
70
71
95
73

95

95 95

82 Premium Gear Lubricant

94 Anti-Corrosion Grease
95 2-4-C With Teflon

Page 6A-16 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing (Prop Shaft)(Standard Rotation)

(Non-Ratcheting)(S/N-0G438000 & UP)
(Casting #1623-822442C3)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 GEAR HOUSING (BLACK) BASIC
1
1 GEAR HOUSING (GRAY)
48 1 SHIFT CRANK
49 1 SHAFT
50 1 SHIFT SPOOL
51 1 COTTER PIN
52 1 SLEEVE
53 AR SHIM SET
54 1 FORWARD GEAR (1.75:1 - 12/21)
55 1 TAPERED ROLLER BEARING
56 1 CUP
57 1 ROLLER BEARING
58 1 SPRING
59 1 SLIDING CLUTCH
60 1 DETENT PIN
61 1 CROSS PIN
62 1 PROPELLER SHAFT
63 1 REVERSE GEAR (1.75:1 - 12/21)
64 1 THRUST SPACER
65 1 THRUST RING
66 1 BALL BEARING
67 1 O-RING
68 1 BEARING CARRIER
69 1 ROLLER BEARING
70 1 OIL SEAL (INSIDE)
71 1 OIL SEAL (OUTSIDE)
72 1 TAB WASHER
73 1 COVER 210 285
74 1 ANODIC PLATE
75 1 SCREW 40 54.2

90-855348R02 NOVEMBER 2002 Page 6A-17

GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Removal, Disassembly, Cleaning and Inspection – Standard

Rotation (Ratcheting and Non-Ratcheting)
Removal
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from en-
gine before removing gear housing from drive shaft housing.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.
2. Shift engine into neutral position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller
locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propeller
shaft.

a
d
f

d e

b
51866 51871

a - Thrust Hub (Forward)

b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut

5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position.
Remove plastic cap at rear edge of drive shaft housing. While holding trim tab securely,
unthread bolt that secures trim tab and remove trim tab from gear housing.

Page 6A-18 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

6. Once trim tab is removed, remove bolt from inside of trim tab cavity.

52375
a - Bolt (Secures Trim Tab)
b - Bolt (Inside Trim Tab Cavity)
c - Ribs – Align Carefully with Trim Tab while Securing Tab

7. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo-
site side is loosened sufficiently, or drive shaft housing could be damaged.)
8. Pull gear housing away from drive shaft housing as far as the loosened nuts (in Step 9)
will allow, then remove loosened nuts. (DO NOT allow gear housing to fall, as it now is
free.)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

9. Pull gear housing from drive shaft housing.

52374
a - Side Mounting Locknut (2 Each Side)

DRAINING AND INSPECTING GEAR HOUSING LUBRICANT

1. Place gear housing in a suitable holding fixture or vise with the drive shaft in a vertical
position.
2. Position a clean drain pan under gear housing and remove Fill and Vent screws from
gear housing. Do not loose sealing washers on Fill and Vent screws.

52377

a - Fill Screw
b - Vent Screw

3. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal par-
ticles (resembling powder) indicates normal wear. Presence of larger particles (or a
large quantity of fine particles) indicates need for gear housing disassembly, and com-
ponent inspection.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

4. Note the color of gear lubricant. White or cream color indicates presence of water in lu-
bricant. Check drain pan for water separation from lubricant. Presence of water in gear
lubricant indicates the need for disassembly, and inspection of oil seals, seal surfaces,
O-rings and gear housing components.
NOTE: Gear lubricant drained from a recently run gear case will be a light chocolate brown
in color due to agitation/aeration. Oil which is stabilized will be a clear yellow brown in color.

Pre-Disassembly Inspection

Propeller Shaft

INSPECTION
1. Inspect the propeller shaft for side to side movement, as follows:
a. Position the dial indicator on the propeller shaft.
b. Push the propeller shaft to one side and zero the dial indicator.
c. Move the propeller shaft to the opposite side while observing the dial indicator. With-
out rotating the propeller shaft, reposition the dial indicator and check the up and
down deflection. A shaft deflection of more than 0.003 in. (0.08 mm) indicates a worn
propeller shaft bearing.
2. Check for a bent propeller shaft as follows:
a. Rotate the propeller shaft while observing the dial indicator. If the deflection is more
than 0.010 in. (0.25mm), a bent propeller shaft is indicated.
3. Measure propeller shaft end play. If it is in excess of 0.045 in. (1.14mm), disassemble
gear case and check condition of the reverse shoulder of the propeller shaft, reverse
gear and thrust washer. Replace components as required.

22086
a - Prop Shaft Runout
b - Prop Shaft End Play

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing and Component Disassembly

Water Pump Assembly
REMOVAL
1. Remove the water seal, water tube coupling assembly, and the water pump screws.

a
c

52749

a - Water Tube Assembly

b - Water Pump Screws (4)
c - Seal

2. Carefully slide the water pump straight up off of the drive shaft. It may be necessary to
encourage the water pump up by gently prying up on its mounting flanges with a couple
of screwdrivers.

a
b b

70487

a - Water Pump Body

b - Screw Drivers

Page 6A-22 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Remove the impeller, impeller key, the face plate and gaskets, (discard the gaskets).

70605

a - Impeller
b - Impeller Key
c - Water Pump Face Plate and Gaskets
(One on each side of the face plate)

COMPONENT INSPECTION
1. Inspect the water tube coupling assembly for wear or damage. If necessary replace the
worn or damaged components especially the two O-rings on the inside, one at the top
and one at the bottom.
b

b 70613

a - Water Tube adapter

b - O-rings (2)

2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller
blades. Replace the impeller if this condition is found.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Inspect for proper bonding between the hub and the impeller. Replace the impeller if im-
proper bonding is found.
a

70500

a - Impeller
b - Hub

4. Inspect the impeller blades to see if they are cracked, burnt, hard or deformed. Replace
the impeller if the blades are in this condition.
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate. The depth of the groove will not affect wa-
ter pump output.
5. Replace cover if thickness of steel at the discharge slot is 0.060 in. (1.5mm) or less or
if grooves (other than impeller sealing bead groove) in cover roof are more than 0.030
in. (0.76mm) deep.
a b

70609

a - Water Pump Face Plate

b - Water Pump Cover

6. Inspect the water pump face plate and the water pump interior for roughness and/or
grooves. Replace the appropriate components if any are found.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Oil Seal Carrier Assembly

REMOVAL
Remove the oil seal carrier from the gear housing. It may be necessary to gently pry up on
it with two screwdrivers.

70489

a - Oil Seal Carrier

b - Screwdrivers

INSPECTION
Inspect the oil seal carrier, O-ring, and seals for wear and/or damage. If necessary replace
defective parts as outlined following.

COMPONENT DISASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
found to be defective and are in need of repair or replacement.
1. Remove the O-ring.

a
70501

a - O-ring
b - Oil Seals (2)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

2. Remove the oil seals.

c
b

70610
a - Oil Seal Carrier
b - Oil Seals
c - Screwdriver

COMPONENT REASSEMBLY (1994/1995 MODELS)

NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.

70501

1. Assemble the small oil seal (with the lips of the oil seal facing away from the driver shoul-
der) onto the long end of the oil seal driver.

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2. Press on the oil seal driver until the driver bottoms against the carrier. Do not press so
hard as to damage the oil seal carrier while driving the oil seal.
d

a c

70611

a - Oil Seal
b - Oil Seal Driver (91-817569) use long end
c - Oil Seal Carrier
d - Press

3. Assemble the large oil seal (with the lips of the oil seal facing the driver shoulder) onto
the short end of the oil seal driver.
4. Press on the oil seal driver until the driver bottoms against the carrier. Do not press so
hard as to damage the oil seal carrier while driving the oil seal.
d

a c

70612

a - Oil Seal
b - Oil Seal Driver (91-817569) use short end
c - Oil Seal Carrier
d - Press

5. Fill the area between the seal lips with 2-4-C with Teflon. Apply 2-4-C with Teflon to the
O-ring.
6. Install the O-ring onto the oil seal carrier.

95

a 70501
95 2-4-C With Teflon

a - O-ring

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

OIL SEAL CARRIER ASSEMBLY - Component Reassembly

The oil seals in carrier assemblies are the same diameter. The bottom (first) seal lip faces
down; the top (second) seal lip faces up. Apply 2-4-C Marine Lubricant to seal lips and be-
tween seals. Press seal into carrier with suitable mandrel. Second seal should be pressed
in flush with carrier surface.

95
b

95 2-4-C With Teflon

a - Bottom Seal (Lip Faces Down)
b - Top Seal (Lip Faces Up)

Bearing Carrier Assembly

REMOVAL
1. Straighten the tab on the tab washer.

70490

a - Tab on Tab Washer

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

2. Remove the bearing carrier retainer following step a or b as follows:

CAUTION
DO NOT drill into the gear housing retainer threads when using the following proce-
dure for removing the retainer.
a. If the retainer is corroded in place, drill 4 holes in the retainer and fracture the retainer
with a chisel. Pry the remaining segments out.

23356

a - Drilled Holes

b. Remove the bearing carrier retainer using the Bearing Carrier Retainer Wrench
(91-61069).

70491

a - Bearing Carrier Retainer Wrench

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing
carrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER.
NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat
to loosen the carrier.
a

70492

a - Puller Jaws (91-46086A1)

b - Puller Bolt (91-85716)

INSPECTION
1. Clean the assembly with a suitable solvent and dry the parts thoroughly using com-
pressed air.
NOTE: If any of the following items are found to be defective complete the appropriate in-
structions in Bearing Carrier Assembly, ‘Component Disassembly and Inspection’
section.
2. Inspect the bearing carrier for signs of excessive corrosion especially in the area where
the bearing carrier touches the gear housing. If excessive corrosion is evident replace
the carrier.
a

b
50314

a - Bearing Carrier
b - Mating Surfaces

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. The condition of the bearing surface on the propeller shaft in the area that the needle
bearing (in the bearing carrier) rides is an indication of the condition of the needle bear-
ing in the bearing carrier. Replace the bearing if the surface of the shaft is pitted,
grooved, scored, worn unevenly, discolored from overheating or has embedded metal
particles.

23355

a - Propeller Shaft Bearing Contact Area

4. Inspect the reverse gear for pitted, chipped, broken teeth, hairline fractures, and exces-
sive or uneven wear. Replace the gear if any defects are found.
NOTE: If outboard jumps out of gear, inspect not only clutch dog teeth on reverse gear but
also thrust washer surface on reverse gear for excessive wear. Replace gear if wear is evi-
dent.
5. Inspect the clutch jaws of the gear for damage. Surfaces must not be chipped or rounded
off. Replace the gear if any are found.
a

23355

a - Reverse Gear Teeth

b - Thrust Washer Surface
c - Clutch Jaws

6. Inspect the reverse gear bearing for excessive movement or roughness by rotating gear.
Replace the bearing if either of these conditions exists.
7. Inspect the bearing carrier retainer for cracks and/or broken or corroded threads. Re-
place carrier if any are found.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

8. Remove the O-ring from the bearing carrier assembly.

a

23354

a - Bearing Carrier
b - O-ring

a. Inspect the O-ring for damage and/or deterioration. Replace it if necessary.

COMPONENT DISASSEMBLY AND INSPECTION

NOTE: Complete the instructions in this section only if the assembly components have been
found to be defective and are in need of repair or replacement.

CAUTION
Clamp onto the reinforcing rib of the bearing carrier ONLY, or damage to the carrier
may result.
1. Place the bearing carrier in a vise, clamping on the reinforcing rib.
2. Remove the reverse gear, thrust ring, and bearing as an assembly, using a slide hammer
puller.

e
d

b
23352
a
a - Bearing Carrier d - Reverse Gear
Reinforcing Rib e - Thrust Hub
b - Bearing Carrier f - Bearing (not seen) -
c - Slide Hammer Puller Located in the Carrier
(91-34569A1)

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Clean all components thoroughly with a suitable solvent and inspect them for damage
and/or excessive wear. Replace any parts that are found to be defective.
IMPORTANT: The bearing MUST BE replaced if removed from gear.
4. Place the universal puller plate between the thrust washer and bearing as shown and
press on the plate until it bottoms.

23351

a - Universal Puller Plate (91-37241)

b - Thrust Washer
c - Bearing

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

5. Using a suitable mandrel and the universal puller plate to support the bearing, press the
bearing from the reverse gear as shown.

a d

b c

23351

a - Universal Puller Plate (91-37241)

b - Bearing
c - Gear
d - Suitable Mandrel

a. Discard the bearing.

b. Inspect the gear, and thrust washer for excessive wear, cracks, or damage. Replace
the appropriate components if any of these conditions are found.
NOTE: Inspection of the bearing surfaces on the propeller shaft where the needles of the
bearing carrier needle bearing rolls, gives an indication of the condition of the needle bear-
ing inside the bearing carrier. Replace needle bearing in the bearing carrier if the prop shaft
is pitted, grooved, scored, worn unevenly, discolored from overheating, or has embedded
particles.
6. Perform the following step a. or b. as necessary.

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a. If Replacing the Needle Bearing and Seals: Remove the needle bearing and seals
with the tools as shown.

d 23140

a - Bearing Driver Rod (91-37323)

b - Needle Bearing c - Driver Head (91-36569)
d - Oil Seals
NOTE: Discard the needle bearing and both seals.
b. If Replacing the Seal Only: Remove the oil seals with a suitable pry bar, being care-
ful not to damage the bore of the bearing carrier.

23140

a - Oil Seals
b - Pry Bar

NOTE: Discard both of the seals.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Clean all of the components with a suitable solvent and dry the parts thoroughly using
compressed air. Be careful not to spin the bearing.
2. Lubricate the bore that the needle bearing is pressed into with Premium Gear Lubricant.
3. Assemble the needle bearing (with the numbered end of the bearing towards the driver
shoulder), onto the driver.
4. Press the needle bearing into the bearing carrier until the driver bottoms out on the bear-
ing carrier. Ensure that the numbered side of the needle bearing faces the seal end (aft
end) of the carrier.

a
b 82

50315

82 Premium Gear Lubricant

a - Needle Bearing Driver (P/N 91-15755)

b - Needle Bearing
c - Bearing Carrier
5. Thoroughly clean the bore in which the first seal is to be pressed.
6. Assemble the first seal (with the lips of the seal facing away from the driver shoulder)
onto the long end of the oil seal driver.

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7. Press on the oil seal driver until the driver bottoms onto the aft face of the bearing carrier.

50315

a - Oil Seal Driver (91-31108)

b - Oil Seal
c - Bearing Carrier

8. Apply a thin film of Loctite 271 Thread Locker to the outer diameter of the second seal.
9. Assemble the second seal (with the lips of the seal facing the driver shoulder) onto the
short end of the driver.
10. Press the oil seal with the driver until the driver bottoms out on the bearing carrier.

b 7

95

7 50315
Loctite 271 Thread Locker
95 2-4-C With Teflon

a - Driver (short end)

b - Oil Seal (lips toward driver shoulder)
c - Bearing Carrier

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

11. Wipe up all of the excess Loctite. Do not allow any of the excess Loctite to spread to
other parts of the assembly.
12. Lubricate the seal lips and fill the area between the seals with 2-4-C with Teflon.
13. Install the thrust washer and a new ball bearing onto the reverse gear. Press on the
inner race of the ball bearing using the pilot washer until the bearing bottoms out on the
gear.

b
c

23346

a - Pilot Washer (P/N 91-36571)

b - Ball Bearing
c - Thrust Hub
d - Reverse Gear

14. Lubricate the bore that the bearing is pressed into with Premium Gear Lubricant.

Page 6A-38 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

15. Press the bearing carrier onto the reverse gear and bearing until the bearing bottoms
out in bearing carrier, using the pilot washer to press against the carrier.

82

23349
82 Premium Gear Lubricant

a - Pilot Washer (91-36571)

b - Bearing Carrier
c - Reverse Gear and Bearing Assembly

16. Lubricate the O-ring with 2-4-C with Teflon and install the O-ring onto the bearing carrier.
b

95
23354

95 2-4-C With Teflon

a - O-ring
b - Bearing Carrier

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Drive Shaft Assembly

REMOVAL
1. Remove the drive shaft pinion nut as follows:
a. Place the drive shaft nut wrench onto the drive shaft. Do not loosen the retainer at
this time.
b. Insert the pinion nut adapter with the MR slot facing the pinion gear into the gear
housing. It may be necessary to slightly lift and rotate the drive shaft to align the pin-
ion gear nut into the pinion nut adapter slot.
c. Install the bearing carrier into the gear housing backwards to support the prop shaft
and to keep the pinion nut adapter aligned.
d. Place the drive shaft nut wrench over the drive shaft splines and loosen, (but do not
fully unscrew), the pinion nut by rotating the drive shaft counterclockwise.

c
70887

a - Drive Shaft Nut Wrench (91-56775)

b - Drive Shaft Bearing Retainer Wrench (91-43506)
c - Pinion Nut adapter (MR Slot) (91-61067A2)

e. If the drive shaft is broken, place propeller shaft nut wrench onto the propeller
shaft splines, hold shift shaft in forward gear and loosen, (but do not fully unscrew),
the pinion nut by rotating prop shaft counterclockwise to turn gears, thus loosening
the pinion nut.

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NOTE: The propeller shaft nut wrench is included with the pinion nut adapter kit.
c

b
70607

a - Pinion Nut adapter (91-61067A2)

b - Propeller Shaft Nut Wrench (91-61077)
c - Shift Shaft (Turn Clockwise) (Protect shaft splines with soft material)

f. Completely unscrew the drive shaft bearing retainer.

g. Completely unscrew the pinion nut by rotating the drive shaft (or the propeller shaft)
in a counterclockwise direction.
h. Remove all tools.
IMPORTANT: The pinion bearing rollers are free to fall out of the pinion bearing once
the drive shaft is removed. Be careful not to loose the (18) rollers.
2. Remove the drive shaft and all components by pulling the drive shaft straight out of the
gear housing as shown.

70608

a - Drive Shaft
b - Drive Shaft Retainer, Bearing Cup, Bearing, and Shims

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Move the prop shaft downward and to the PORT side of the gear case.
4. Retrieve the pinion gear, the washer and the nut from the inside of the gear housing.

INSPECTION
1. Clean all parts with a suitable solvent and dry the parts thoroughly using compressed
air, being careful not to spin the bearings.
2. The condition of the drive shaft bearing cup is an indication of the condition of the ta-
pered roller bearing on the drive shaft. Replace the bearing and bearing cup if the cup
is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
3. Inspect the bearing surface on the drive shaft where the needles of the lower pinion
bearing roll. Replace the drive shaft if it is pitted, grooved, scored, worn unevenly, discol-
ored from overheating, or has embedded particles.
4. Inspect the splines at both ends of the drive shaft for a worn or twisted condition. Replace
the drive shaft if either condition exists.
5. Inspect the gear for pitting, chipped or broken teeth, hairline fractures, and excessive
or uneven wear. Replace the pinion gear and the forward gear as a set if any defects
are found.

COMPONENT DISASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
found to be defective and are in need of repair or replacement.
1. Press the tapered roller bearing from the drive shaft using the universal puller plate to
support the inner race of the bearing while removing it.

70699

a - Universal Puller Plate (91-37241)

b - Tapered Roller Bearing
c - Drive Shaft

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COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Assemble a new tapered roller bearing to the drive shaft with the large O.D. of the bear-
ing facing the pinion gear end of the drive shaft.
2. Press the tapered roller bearing onto the drive shaft using the universal puller plate and
a suitable mandrel, (an old tapered roller bearing inner race).

a c

70700

a - Universal Puller Plate (91-37241)

b - Tapered Roller Bearing
c - Suitable Mandrel (Inner Race of Old Bearing)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Propeller Shaft Assembly and Forward Gear Bearing Cup

REMOVAL
1. Tilt the propeller shaft to the port side of the gear housing and remove the shaft by pulling
it straight up and out.

a
d

b
c

23348

a - Propeller Shaft Assembly

b - Shift Spool
c - Shift Crank
d - Thrust Washer (Reverse Gear)

2. Remove the forward gear bearing cup and shims. Measure and make note of the shim
thickness. If the shims are not damaged, they may be reused.

d
h
g
c e
f

a b

50780

a - Puller Shaft (91-31229) e - Puller Head (from Slide

b - Nut (11-24156) Hammer Puller Kit
c - Washer (91-34961) 91-34569A1)
d - Guide Plate f - Jaws (from Slide
(91-816243) Hammer Puller Kit)
g - Bearing Cup
h - Shims

Page 6A-44 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

COMPONENT DISASSEMBLY
NOTE: When accomplishing the next step, all of the parts are free to come apart. Work
closely over a work bench to ensure that the parts are not dropped or damaged and to avoid
personal injury.
1. Remove the spring around the clutch being careful not to over-stretch it during removal.
If the spring does not coil back to its normal position once it has been removed, it must
be replaced.
2. Remove detent pin.
3. Remove the cross pin that goes through the clutch.
4. Remove the remainder of the components (Ratcheting type assembly shown).

b e d

23350
f
a - Spring
b - Cross Pin
c - Shift Spool Assembly
d - Forward Gear Assembly
e - Sliding Clutch
f - Detent Pin

COMPONENT INSPECTION
1. Clean all the parts with a suitable solvent and dry the parts thoroughly using compressed
air, being careful not to spin bearings.
2. Inspect the sliding clutch jaws for damage. Jaws must not be chipped or rounded off.
Replace the clutch if they are.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Inspect the bearing surfaces on the propeller shaft where the needles of the bearing car-
rier needle bearing and the needles of the forward gear needle bearing roll. Replace the
propeller shaft if it is pitted, grooved, scored, worn unevenly, discolored from over-
heating, or has embedded particles.
a b

c 23355

a - Bearing Carrier Needle Bearing Contact Area

b - Forward Gear Needle Bearing Contact Area
c - Splines

4. Inspect the propeller shaft splines at both ends for a broken, worn, or twisted condition.
Replace the propeller shaft if any of these conditions exists.
5. Inspect the surface of the propeller shaft where the bearing carrier seal lips contact the
shaft. If the oil seals have made grooves, replace the propeller shaft and oil seals.
a

b 23355
a - Bearing Carrier Seal Contact Area
b - Splines

6. Inspect reverse gear thrust washer surface for wear or taper. If surface is worn or ta-
pered, propeller shaft must be replaced.
a

23355
a - Thrust Washer Surface

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

7. Inspect the propeller shaft for a bent condition.

a. V-Blocks and Dial Indicator
(1.) Position the propeller shaft bearing surfaces on V-blocks.
(2.) Adjust the height of V-blocks to level the propeller shaft.
(3.) Position the dial indicator tip just forward of the propeller shaft splines.
8. Rotate the propeller shaft and observe the dial indicator movement, If the indicator in
the dial moves more than 0.010 in. (0.25mm), replace the propeller shaft.

a 52727
a - Check Movement with Dial Indicator (P/N 91-58222A1) Here.

9. Measure propeller shaft FORWARD to REVERSE shoulder length. If measurement is

under 2.040 in. (51.82mm), replace propeller shaft.

2.040 in. (51.82mm)

23355

10. Inspect REVERSE thrust washer for wear or taper. Measure thickness of washer. If
thickness is LESS than 0.240 in. (6.1mm), replace washer.

0.240 in. (6.096mm)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Forward Gear Assembly

COMPONENT INSPECTION
1. Clean the forward gear assembly and the forward gear bearing cup with a suitable sol-
vent and dry with compressed air. Be careful not to spin the bearings.
2. Inspect the gear for pitting, chipped or broken teeth, hairline fractures, and excessive
or uneven wear. Replace the forward gear and the pinion gear as a set if any defects
are found.
3. Inspect the clutch jaws of the gear for damage. The surfaces must not be chipped or
rounded off. Replace both the forward and pinion gear as a set if any of these condi-
tions exist.
a

23351

a - Forward Gear Teeth

b - Clutch Jaws

4. Inspect the needle bearings on the inside of the forward gear and the bearing surface
on the propeller shaft. If either the needle bearing or the bearing surface of the propeller
shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles, replace the propeller shaft and remove and replace the needle bear-
ing in the forward gear as outlined in the next section.
a

23355

a - Forward Gear Needle Bearing Contact Area

5. Inspect the tapered roller bearings on the forward gear and the bearing surface on the
forward gear bearing cup. If either the roller bearings or the bearing surface of the for-
ward gear bearing cup is pitted, grooved, scored, worn unevenly, discolored from over-
heating, or has embedded particles, replace the forward gear bearing cup and remove
and replace the tapered roller bearings as outlined in the next section.

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COMPONENT DISASSEMBLY
NOTE: Forward gear can only be removed from gear housing after drive shaft and pinion
gear have been removed.
1. Reach into gear housing and lift out forward gear.
IMPORTANT: DO NOT remove tapered bearing or needle bearings from forward gear
unless replacement of bearings is required. (Bearings cannot be reused after they
have been removed.)
2. If inspection determines that replacement of forward gear tapered bearing is required,
separate gear from bearing as follows:
a. Install Universal Puller Plate (91-37241) between forward gear and tapered bearing.
b. Place assembly on press and press gear out of bearing with suitable mandrel.
NOTE: Tapered bearing and race MUST BE replaced as a set.

b
a

51870

a - Universal Puller Plate (91-37241)

b - Mandrel

3. If inspection determines that replacement of propeller shaft needle bearings is required,

remove bearing as follows:
a. Clamp forward gear in a soft jaw vise securely.
b. From toothed-side of gear, drive propeller shaft needle bearings out of gear with a
punch and hammer.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

COMPONENT REASEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Using a suitable mandrel, press the tapered roller bearing onto the forward gear by
pressing on the inner bearing race, until the bearing bottoms out on the gear mounting
shoulder.

a
23353

a - Forward Gear
b - Tapered Roller Bearing
c - Suitable Mandrel (or Inner Race from old Bearing)

2. Using the needle bearing driver (91-877321), press the needle bearing, with the the let-
tered side facing away from the gear teeth, into the forward gear until the bearing bot-
toms inside the gear.

c b

a
23350

a - Forward Gear
b - Needle Bearing (not seen)
c - Needle Bearing Driver (91-877321)

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Shift Spool Assembly

INSPECTION
1. Clean the assembly with a suitable solvent and dry the parts using compressed air.
2. Inspect the shift spool assembly for damage. Small nicks and burrs may be smoothed.
If any parts are damaged or worn excessively, it will be necessary to replace the com-
plete shift spool assembly. Individual parts are not available for the assembly.
3. Inspect the shift spool for wear in the area where the shift crank comes into contact.
a b

23356

a - Contact Area
b - Ratcheting Shift Spool

a
b

55694

a - Contact Area
b - Non-Ratcheting Shift Spool

4. Inspect to insure that the spool spins freely. It may be helpful to lightly tap the forward
(castle nut) end of the shift spool against a firm surface to align the internal parts.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

5. Inspect to insure that both ratcheting and non-ratcheting spools have 0.002-0.010 in.
(0.05-0.25 mm) end play. This end play may be achieved by turning the castle nut (clock-
wise) down on either spool until it is snug and then backing off the nut (counterclockwise)
to the first cotter pin slot.

.002 (0.05mm)
to
.010 (0.25mm)

23142
a - Ratcheting Shift Spool

.002 (0.05mm)
to
.010 (0.25mm)

55694
a - Non-Ratcheting Shift Spool

NOTE: Non-Ratcheting shift spools do not contain a spring under the castle nut.
NOTE: If the spool meets the above two criteria skip the disassembly and reassembly sec-
tion following.
NOTE: If the spool does not meet the above criteria proceed with the disassembly and reas-
sembly section following.

Page 6A-52 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

COMPONENT DISASSEMBLY
NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts due
to an improperly functioning shift spool assembly or debris in the gear housing and/or shift
spool assembly. Individual components for the shift spool are not available as replacement
parts. If the shift spool does not function properly (see the preceding Shift Spool Assembly
- Inspection section) and the following cleaning and adjustment procedures do not produce
the desired results, it will be necessary to order a new shift spool assembly.
1. Disassemble the shift spool assembly as follows:
a. Remove and discard the cotter pin.
b. Remove the castle nut and spool.
c. Clamp the spool in a vice being careful not to damage the spool.
d. Remove the retainer by unscrewing it with a pair of pliers.
e. Remove the two washers and the spring.

COMPONENT INSPECTION
1. Clean all components with a suitable solvent and dry them thoroughly with compressed
air.
2. Inspect each component for wear or damage. If any components are worn excessively,
damaged, or broken it will be necessary to replace the complete shift spool assembly.
Small nicks or burrs may be smoothed and the parts reused.

COMPONENT REASSEMBLY - RATCHETING

Assemble the shift spool and shift spool shaft as follows:
1. Place the shift spool onto the shift spool shaft.
2. Assemble the first washer, then the spring, then the second washer into the shift spool.
3. Apply Loctite 271 Thread Locker to the first 3 threads of the spool. Thread the retainer
onto the spool and tighten the retainer securely with a pair of pliers.
4. Assemble the castle nut and screw it down until it touches the washer and a slight resis-
tance is felt.
5. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole in
the shaft. If, when the castle nut is screwed down, the cotter pin slot is already aligned
at the hole in the shaft, back the castle nut off until the next available slot in the nut is
aligned with the hole in the shaft.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

6. Insert a new cotter pin and bend ends of the cotter pin in opposite directions.

23356

e a f g

b c
d 23142

a - Washers (2)
b - Spring
c - Retainer
d - Spool
e - Shift Shaft
f - Castle Nut
g - Cotter Pin

RATCHETING SHIFT SPOOL - ADJUSTMENT

NOTE: If the shift spool assembly has been disassembled and reassembled (as in the pre-
vious two sections) skip the following steps 1 through 4.
NOTE: If the shift spool assembly has not been disassembled and reassembled, do all of
the following steps.
1. Remove and discard the cotter pin.
2. Screw the castle nut down until it touches the washer and a slight resistance is felt.
3. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole in
the shaft. If, when the castle nut is screwed down, the cotter pin slot is aligned at the hole
in the shaft, back off the castle nut until the next available slot in the nut is aligned with
the hole in the shaft.
4. Insert a new cotter pin and bend ends in opposite directions.
5. Inspect to insure that the spool spins freely It may be helpful to lightly tap the forward
(castle nut) end of the shift spool shaft against a firm surface to align the internal parts.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

6. Inspect to insure that the spool has 0.002 - 0.010 in. (0.05 - 0.25mm) end play, if it
doesn’t, adjust the castle nut once again as outlined previously.

.002 (0.05mm)
to
.010 (0.25mm) 23142
7. If this adjustment did not produce the desired results it will be necessary to disassemble,
clean, and reassemble the shift spool assembly. If the spool assembly has already been
disassembled and cleaned it will be necessary to replace the shift spool assembly.

NON-RATCHETING SHIFT SPOOL - Component Reassembly and Adjustment

Assemble the shift spool and shift spool shaft as follows:
1. Place the shift spool onto the shift spool shaft.
2. Assemble the castle nut and screw it down until it touches the washer and a slight resis-
tance is felt.
3. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole in
the shaft. If, when the castle nut is screwed down, the cotter pin slot is already aligned
at the hole in the shaft, back the castle nut off until the next available slot in the nut is
aligned with the hole in the shaft.
4. Insert a new cotter pin and bend ends of the cotter pin in opposite directions.
5. Inspect to insure that the spool has 0.002 - 0.010 in. (0.05 - 0.25mm) end play, if it
doesn’t, adjust the castle nut once again as outlined previously.

a b c 55694

a - Shift Shaft
b - Spool
c - Castle Nut
d - Cotter Pin
6. If this adjustment did not produce the desired results it will be necessary to disassemble,
clean, and reassemble the shift spool assembly. If the spool assembly has already been
disassembled and cleaned it will be necessary to replace the shift spool assembly.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Propeller Shaft Assembly

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Install the sliding clutch on the propeller shaft. Align cross pin holes in the clutch with
the slot in the propeller shaft. The grooved end of the clutch should be facing the propel-
ler end of the shaft.
2. Assemble the forward gear assembly to the propeller shaft.
3. Assemble the shift spool assembly to the propeller shaft being sure to align the cross
pin hole of the shift spool shaft with the clutch.
4. Assemble the cross pin through the sliding clutch, through the propeller shaft and
through the shift spool shaft hole.
5. Install detent pin in 3rd hole in clutch.
6. Assemble the cross pin retaining spring over the propeller end of the propeller shaft and
wind it around the clutch over the cross pin hole. Be careful not to distort the spring while
assembling it. Make sure that the spring is wound on so that it does not cross over
on itself and that it lies flat against the clutch once it is assembled. If it does not
lie flat against the clutch a new spring must be installed. (Ratcheting Assembly
Shown)

e g
b
a c
d

23350

a - Sliding Clutch
b - Grooves in Clutch
c - Forward Gear Assembly
d - Cross Pin
e - Propeller Shaft
f - Spool and Actuating Shaft Assembly
g - Cross Pin Retaining Spring
h - Detent Pin

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Shift Shaft Assembly

REMOVAL
NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank
inside the gear case) without removing any of the internal components of the gear housing.
1. Remove the shift shaft bushing screws, and remove the shift shaft and bushing by pull-
ing both straight out of gear housing.

a a

70494

a - Shift Shaft Bushing Screws

2. Remove the shift crank from the inside of the gear housing. Clean it with a suitable sol-
vent and dry it thoroughly. Inspect it for wear in the areas that contact the shift spool and
inspect the splines and the diameter that goes over the locating pin for damage or wear.

c d
23350

a - Contact Area
b - Shift Crank
c - Splines
d - Diameter for Locating Pin

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

SHIFT SHAFT ASSEMBLY - Component Disassembly and Inspection

1. Slide the bushing assembly off the shift shaft. Remove the coupler from the shaft.

a c

b
70616

a - Shift Shaft Bushing

b - O-rings (2)
c - Coupler
d - Shift Shaft

2. Clean all components with a suitable solvent and dry thoroughly with compressed air.
a. Inspect the shift shaft bushing for cracking, damage, or excessive wear.
b. Inspect the oil seal inside the bushing, the sleeve, and the O-rings on the outside
of the bushing for damage or excessive wear.
c. Inspect the speedometer connector for damage or blockage.
NOTE: If any of these conditions exist, replace the appropriate components.
c

a
70617

a - Shift Shaft Bushing

b - Oil Seal (Oil Seal is Replaceable)
c - Speedometer Tube Connector

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Inspect the shift shaft splines and oil seal surface for corrosion and/or excessive wear.
Replace the shift shaft if either if these conditions are found.

b
a

70618

a - Oil Seal Surface

b - Spline

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Lightly lubricate the seats of the O-ring diameters on the bushing and the lip of the oil
seal with 2-4-C with Teflon.
2. If the speedometer connector was removed and/or replaced, lightly coat the threads of
the connector with Perfect Seal (91-34277-1). Assemble the speedometer connector
to the bushing and torque the connector to 4.5 lb. in. (0.51 Nm).

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Assemble all components as shown below.

95 h
c
b d
19

e g
f 70616
g

95

19 Perfect Seal
95 2-4-C With Teflon

a - Shift Shaft
b - Rubber Washer
c - Seal (Lip Faces Up)
d - Speedometer Connector
e - Bolt (2 ea.) [Torque to 60 lb. in. (6.8 Nm)]
f - Bushing
g - O-Rings (2 ea.)
h - Coupler

NOTE: For reinstalling the shift shaft when none of the other components of the gear hous-
ing were disassembled see the Shift Shaft Assembly, Installation.

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Pinion Bearing
REMOVAL
NOTE: Inspect the bearing surface on the drive shaft where the needles of the lower pinion
bearing roll. The condition of the drive shaft at this location gives an indication of the condi-
tion of the needle bearing. Replace lower pinion bearing (needles and race as a set) if the
drive shaft is pitted, grooved scored, worn unevenly, discolored from overheating, or has
embedded particles.
IMPORTANT: All the needle bearings (18) MUST BE in place inside bearing race while
driving the pinion bearing from the gear housing.
IMPORTANT: Do not reuse the bearing (race or rollers) once it has been removed.
Remove and discard the pinion bearing (race and rollers) using tools as shown.

d
c

70614

a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Housing Reassembly

Gear Housing Inspection
1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush. Dry
the gear housing thoroughly using compressed air. Insure that all sealants, locking
agents and debris are removed.
2. Verify the 2 oil circulation holes in the drive shaft bore and the shift shaft hole are clear
and free of debris.
3. Inspect the gear housing for excessive corrosion, impact or any other damage. Exces-
sive damage and/or corrosion requires replacement of the gear housing.
4. Inspect the bearing carrier retainer threads in the gear housing for corrosion and/or
stripped threads. Damage or corrosion to the threads requires replacement of the gear
housing.
5. Inspect bearing race/cup contact areas for evidence of bearing cup spinning. Check that
bearing cups are not loose in bearing bores. Any one bearing bore in which the race/cup
is loose will require replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the speedometer hole, clean as necessary.
Be careful not to enlarge the speedometer hole as this could cause erroneous speedom-
eter readings.
7. Make sure that the locating pins are in place in the gear housing and that the correspond-
ing holes in the drive shaft housing are not elongated. The drive shaft may break if the
housings are not aligned properly due to missing locating pins or elongated holes.

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Pinion Bearing
INSTALLATION
IMPORTANT: Install only a NEW pinion bearing. Do not reinstall a pinion bearing that
has been previously removed from a gear housing.
1. Lubricate the bore into which the pinion bearing is to be installed with Premium Gear
Lubricant.
2. Position the new pinion bearing (with the cardboard shipping sleeve in place) onto the
driver head, with the lettered and numbered side of the bearing oriented upward.
3. Insert the driver with the bearing assembly, into position (by way of the propeller shaft
bore) at the drive shaft bore as shown.

c
e d

f
a
g

82

70615

82 Premium Gear Lubricant

a - Drive Shaft Pinion Bearing

(With Cardboard Shipping Sleeve)
b - Driver Head (91-38628)
c - Puller Shaft (91-31229)
d - Washer (12-34961)
e - Nut (11-24156)
f - Pilot Washer (91-36571)
g - Puller Plate (91-29310)

4. Install the bearing by screwing down the nut until the bearing is fully seated against the
bore shoulder.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Forward Gear Bearing Cup

INSTALLATION
Forward Gear Backlash – .017 in. to .028 in. (0.43mm to 0.71mm)
NOTE: If the forward gear, forward gear bearing and cup, or gear housing were not re-
placed, install the same quantity of shims that were taken out when cup was removed. If the
forward gear, forward gear bearing/cup, or gear housing were replaced, install 0.020 in.
(0.51mm) of shims.
NOTE: If backlash has already been checked and it has determined that it needs to be ad-
justed, (see Checking Forward Gear Backlash), adding or subtracting 0.001 in. (0.03mm)
shims will change the gear backlash by the same amount.

Example 1 (if backlash is too high)

If Forward Backlash Checks: .040 in. (1.02mm)

(Subtract): .018 in. (0.46mm)

Add This Quantity of Shims: .022 in. (0.56mm)

Provides Backlash of 0.018 (0.46mm)

Example 2 (if backlash is too low)

Backlash Checks: .010 in. (0.25mm)

Subtract this Quantity of

Shims: .008 in. (0.30mm)

Provides Backlash of 0.018 (0.46mm)

1. Lubricate the bore into which the forward gear bearing cup is to be installed with Pre-
mium Gear Lubricant.
2. Place the shims into forward bore of gear housing.
3. Press the bearing cup into the gear housing using the installation tool as follows:
NOTE: Ratcheting type gear cases use bearing cup driver 91-36577. Non-ratcheting gear
cases use bearing cup driver 91-31106.

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IMPORTANT: Verify that the bearing cup is position as straight as possible to avoid
cocking it in the bore while pressing it in.

d
a b

82

50791

82 Premium Gear Lubricant

a - Hex-Head Screw
b - Bearing Cup Installation Tool (91-18605A1)
c - Driver Cup (91-36577) for ratcheting type gear cases
Driver Cup (91-31106) for non-ratcheting type gear cases.
d - Shims

Shift Shaft Assembly

INSTALLATION
1. Place the shift crank onto the locating pin in the forward section of the gear housing. En-
sure that the shift crank faces towards the left (port) side of the gear housing.

a
b 50314

a - Shift Crank
b - Locating Pin

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

2. Install the shift shaft assembly into the gear housing as shown. Engage the splined end
of the shift shaft with the shift crank. Verify O-rings are positioned properly and lubricated
with 2-4-C with Teflon. Secure shift shaft bushing with 2 screws. Torque screws to 60
lb. in. (6.8 Nm).
a

70620

a - Shift Shaft Assembly

b - Screws [Torque to 60 lb. in. (6.8 Nm)]

NOTE: If the pinion bearing needle bearings have fallen out, install 18 needles into needle
bearing outer race. Use 2-4-C with Teflon, to help hold needles in place.

95

b 23142
95 2-4-C With Teflon

a - Rollers (18)
b - Roller Bearing Outer Race

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Propeller Shaft Assembly

INSTALLATION
1. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end
of the propeller shaft assembly to the left (port) side of gear housing and rotate the shift
shaft from reverse to neutral while installing shaft (ratcheting assembly shown).

a
b

23343

a - Shift Actuating Spool

b - Shift Crank
c - Propeller Shaft Assembly

2. Operate the shift shaft to ensure that it has been properly installed. The sliding clutch
should move forward when the shift shaft is turned clockwise, and should move aft when
the shift shaft is turned counterclockwise.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Slide the rubber sleeve at top end of shift shaft down so that it just touches the oil seal
in the bushing.

a b
c
e

d
70492

a - Shift Shaft
b - Rubber Sleeve
c - Oil Seal
d - Shift Shaft Bushing
e - Speedometer Connector

NOTE: Secure the speedometer tube to the speedometer connector with a sta-strap.
Drive Shaft and Pinion Gear
INSTALLATION
NOTE: If the original shims were not retained or if pinion gear, drive shaft, drive shaft tapered
roller bearing and cup, or gear housing were replaced, start off by installing a 0.038 in. (0.96
mm) shim.
NOTE: If the original shims were retained (or measurement known) and none of the above
listed parts were replaced, reinstall the same shims or same amount of shims.

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1. Place the shims into the drive shaft housing bore.

70620

a - Shims

NOTE: For ease of installation, glue the washer to the pinion gear, using 3M Adhesive, or
Bellows Adhesive, or equivalent.
NOTE: If the backlash may have to be changed, it is recommended that Loctite 271 NOT
be applied to the pinion nut UNTIL the backlash setting is finalized. DO NOT reuse the old
pinion nut. Install a NEW pinion nut after backlash is finalized.
2. Apply Loctite 271 Thread Locker to the threads of the pinion gear nut and place the pin-
ion gear nut into the MR slot of the pinion nut adapter.
NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear.
3. Place the pinion gear and washer into the gear housing.
4. Insert the pinion nut adapter (with the nut) into the gear housing.
5. Insert the drive shaft into the gear housing drive shaft bore. It may be necessary to rotate
the drive shaft to engage the drive shaft splines into the pinion gear splines.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

6. Start the pinion nut onto the drive shaft threads by rotating the drive shaft until the nut
is snug.

b
70891

a - Pinion Gear (with the washer glued to it)

b - Pinion Nut Adaptor (91-61067A2)
c - Drive Shaft

7. Install the drive shaft tapered roller bearing cup. Apply 2-4-C with Teflon to the retainer
threads and install the retainer.
b
95

70890
95 2-4-C With Teflon

a - Tapered Roller Bearing Cup

b - Drive Shaft Retainer

8. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and
the pinion nut adaptor in position.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

9. Torque the pinion nut to 75 lb. ft. (101.7 Nm) by turning the drive shaft using the drive
shaft nut wrench and torque wrench.

7
a
7 Loctite 271 Thread Locker 70892

a - Pinion Nut Adapter (91-61067A2)

b - Drive Shaft Nut Wrench (91-56775)
c - Bearing Carrier (installed backwards)

10. Remove the bearing carrier, pinion nut adapter and drive shaft nut wrench.
11. Torque the retainer to 100 lb. ft. (136.0 Nm).

70711

a - Drive Shaft Bearing Retainer Wrench (91-43506)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Location/Backlashes Checking and Adjustment

Drive Shaft - Bearing Preload Tool
INSTALLATION
1. Install the components from the Bearing Preload Tool Kit (91-14311A1), over the drive
shaft in the order shown.

a
b

d
e

d
f
g
70496

a - Top Nut with Threaded Pipe e - Thrust Bearing

b - Nut f - Thrust Washer
c - Spring g - Water Pump Face Plate
d - Thrust Washer (2 Required) (from your gear housing)
(12-18448)

2. Pull up on the drive shaft and tighten the two (2) allen screws in the top nut of the bearing
preload tool.

70716

a - Allen Screws

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3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom
nut away from top nut.

a
b

70893

a - Distance 1 in. (25.4mm)

b - Bottom nut [screwed down approximately 1 in. (25.4mm)]

4. Rotate the drive shaft at least three full turns in a clockwise direction.
Pinion Gear Location
CHECKING AND ADJUSTING
Pinion Depth – 0.025 in. (0.64mm)
NOTE: If the bearing preload tool has not already been set up, refer to Drive Shaft - Bearing
Preload Tool, ‘Installation’ section first.
NOTE: The prop shaft and forward gear can be installed when checking pinion height IF
Pinion Height Tool 91-56048 is used.
1. Place the pinion gear shimming tool into the gear housing.
NOTE: Take the following measurements at 3 locations, rotating the drive shaft 120 degrees
between each reading (always rotate the drive shaft in a clockwise direction).
2. Insert the thickest feeler gauge that fits snugly between one tooth of the pinion gear and
high point of the shimming tool.
3. Rotate the drive shaft 120 degrees in a clockwise direction and take another reading.
4. Repeat this process until 3 readings have been taken.
5. Add the three readings together and divide the sum by 3 to get the average pinion gear
height. Make note of this average measurement.
NOTE: The average pinion gear height should be 0.025 in. (0.64mm).

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

6. If the average pinion gear height is not correct, remove the bearing preload tool, the drive
shaft retainer and the drive shaft tapered roller bearing cup. (The cup can be removed
by wiggling the drive shaft back and forth or by turning gear housing and shaking it.) Add
or subtract shims beneath the cup to obtain the proper average pinion gear height. Rein-
stall the cup and retainer. Retorque retainer to 100 lb. ft. (135.6 Nm). Reinstall the bear-
ing preload tool and rotate the drive shaft at least 3 full turns in a clockwise direction.
Recheck the pinion gear height as in step 5 above. Repeat this process until the average
pinion gear height is within specification.
b

24643

a - Pinion Gear Shimming Tool (91-12349A2) Using Disc #2 and Flat #4

b - 0.025 in. (0.64mm) Feeler Gauge

NOTE: Install a NEW pinion nut with Loctite 271 AFTER all clearances are correct.
7. When the correct pinion gear height is achieved, remove pinion nut and apply Loctite
271 to nut threads IF FORWARD GEAR and PROP SHAFT ARE INSTALLED. Reinstall
pinion nut and torque to 75 lb. ft. (101.7 Nm).

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Bearing Carrier Assembly

INSTALLATION - (FOR CHECKING BACKLASHES)
NOTE: If backlashes have already been checked and they are to specification proceed with
Bearing Carrier Assembly, ‘Final Installation’.
1. Place the bearing carrier assembly into the gear housing. It may be necessary to turn
the drive shaft to align the teeth of the pinion and the reverse gears.

a
70712

a - Bearing Carrier Assembly

2. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing
and then install the tab washer with the external tab inserted into the hole in the gear
housing.

70713

a - Gear Housing Tab Washer Alignment Hole (not seen)

b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Verify that the “V” shaped tab aligns with the “V” notch in bearing carrier.

70714

a - Tab Washer
b - “V” Tab

4. Lubricate the bearing carrier retainer threads with 2-4-C with Teflon. Start the retainer
into the gear housing threads and screw it down fully by hand.

95

70715
95 2-4-C With Teflon

a - Bearing Carrier Retainer

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Forward Gear Backlash

CHECKING
1. Apply forward pressure to propeller shaft as follows:
a. Attach puller jaws and puller bolt onto bearing carrier bosses and propeller shaft.
a

b
70719

a - Puller Jaws (91-46086A1)

b - Puller Bolt (91-85716)

b. Torque the puller bolt to 45 lb. in. (5.1 Nm). Rotate drive shaft three full turns clock-
wise and retorque the bolt to 45 lb. in. (5.1 Nm).
NOTE: If the bearing preload tool has not already been set up, see Drive Shaft - Bearing
Preload Tool, ‘Installation’ section.
2. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and
touching the “I” mark on the dial indicator tool. Tighten the indicator tool onto the drive
shaft and rotate the drive shaft so that the needle in the dial makes at least one full revo-
lution and comes to “0” on the dial indicator scale.
e f
d

b c

a
70717
a - Nuts (4) (Obtain Locally)
b - Threaded Rod [3/8 in. (9.5mm) obtain locally]
c - Dial Indicator Holding Tool (91-83155)
d - Dial Indicator (91-58222A1)
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 or 1.75:1) Backlash Indicator
Rod (91-78473) (for 1.87:1 ratio)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

3. Take the backlash readings by lightly turning the drive shaft back and forth, (no move-
ment should be noticed at the propeller shaft).
a. Observe the dial indicator and record the reading.
b. Loosen the indicator tool and rotate the drive shaft 90 degrees in a clockwise direc-
tion.
c. Repeat step 2 above and take and record another reading. Repeat step 3 until a total
of 4 backlash readings have been taken.
4. Add the four readings together and divide the sum by four. This is your average back-
lash, which should be 0.017 in. - 0.028 in. (0.431mm - 0.711mm) (for 1.64:1; 1.75:1 and
1.87 ratios).
5. If backlash is LESS than the specified minimum, REMOVE shims from in front of forward
gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite
271 to threads of nut.
6. If backlash is MORE than the specified MAXIMUM, add shims in front of forward gear
bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271
to threads of nut.
NOTE: By adding or subtracting 0.001 in. (0.03mm) shim, the backlash will change approxi-
mately 0.001 in. (0.03mm).

Reverse Gear Backlash

CHECKING
Reverse Gear Backlash – 0.030 in. to 0.050 in. (0.76mm to 1.27mm)
Although reverse gear backlash is not adjustable, it may be checked as follows:
NOTE: Torque cover nut to 210 lb. ft. (284.7 Nm).
1. Apply backward pressure on the propeller shaft as follows:
a. Install the pinion nut adaptor, washer and propeller nut as shown.

b
a

23355

a - Pinion Nut Adaptor (91-61067A2)

b - Washer (12-54048)
c - Prop Nut

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b. Torque the propeller nut to 45 lb. in. (5.1 N·m). Rotate the drive shaft 3 full turns in
a clockwise direction and retorque the propeller nut to 45 lb. in. (5.1 Nm).
2. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and
touching the “I” mark on the dial indicator tool. Tighten the indicator tool onto the drive
shaft and rotate the drive shaft so that the needle in the dial makes at least one full revo-
lution and comes to “0” on the dial indicator scale.

e f
d

b
c

70717
a - Nuts (4) (obtain locally)
b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]
c - Dial Indicator Holding Tool (91-83155)
d - Dial Indicator (91-58222A1)
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 or 1.75:1)
g - Backlash Indicator Rod (91-78473) (for 1.87:1 ratio)

3. Take the backlash readings by lightly turning the drive shaft back and forth, so as to feel
the backlash between the gears, (no movement should be noticed at the propeller
shaft).
a. Observe the dial indicator and record the reading.
b. Loosen the indicator tool and rotate the drive shaft 90 degrees in a clockwise direc-
tion.
c. Repeat step 2 above and take and record another reading. Repeat step 3 until a total
of 4 backlash readings have been taken.
4. Add the four readings together and divide the sum by four. This is your average backlash
and it should be 0.030 in. - 0.050 in. (0.76mm - 1.27mm) (for 1.64:1; 1.75:1 and 1.87:1
ratios).
If backlash is not as indicated, gear case is not properly assembled or parts are excessively
worn and must be replaced before returning gear case to service.
5. Loosen the backlash indicator tool and remove the propeller nut, washer and pinion nut
adaptor. Remove the dial indicator and all its mounting components. Do not remove
the bearing preload tool. The following instructions give specific instructions for
its removal.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Drive Shaft - Bearing Preload Tool

REMOVAL

CAUTION
Before loosening the top nut allen screws of the bearing preload tool, screw the bot-
tom nut up as close as possible to the top nut.
1. Remove the dial indicator and its supporting tooling.
2. Screw the bottom nut of the bearing preload tool until it is as close as possible to top nut.
3. Loosen the allen screws in the top nut.
4. Remove all components including the water pump face plate.

a
b

70716

a - Top Nut (with allen screws)

b - Bottom Nut
c - Water Pump Face Plate

Bearing Carrier Assembly

Final Installation
1. Remove the Bearing Carrier and lubricate the following as specified:
a. Lubricate the carrier O-ring with 2-4-C with Teflon.
b. Lubricate both the forward and aft outer diameters of the bearing carrier and gear
case area where carrier will seat with 2-4-C with Teflon.
c. Fill the space between the carrier oil seals with 2-4-C with Teflon.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

2. Place the bearing carrier assembly into the gear housing. It may be necessary to turn
the drive shaft to align the teeth of the pinion and the reverse gears.

95

70712

95 2-4-C With Teflon

a - Bearing Carrier Assembly

3. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing
and then install the tab washer with the external tab inserted into the hole in the gear
housing.

70713

a - Gear Case Alignment Hole

b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

4. Verify the “V” shaped tab aligns with the “V” notch in bearing carrier.

70714

a - Tab Washer
b - “V” Tab

5. Fill the bearing carrier retainer nut threads and corresponding gear housing threads with
2-4-C with Teflon. Start the retainer into the gear housing threads and screw it down fully
by hand.

95

70715
95 2-4-C With Teflon

a - Bearing Carrier Retainer

Page 6A-82 90-855348R02 NOVEMBER 2002

 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

IMPORTANT: Before torquing bearing carrier retainer, gear case must be bolted to
drive shaft housing or securely fastened in a gear case holding fixture to avoid pos-
sible damage to gear housing.
6. Torque the bearing carrier retainer to 210 lb. ft. (284.7 Nm). If one tab does not align up
in space between two of the notches, continue to tighten retainer until alignment is
achieved. DO NOT loosen retainer to achieve alignment.

23355
a - Bearing Carrier Retainer Wrench (91-61069)

7. Bend one tab aft (outward) into a space between two of the notches of the retainer. Bend
all the remaining tabs forward (inward).

c b

70490
a - Bearing Carrier
b - Tab
c - Retainer Notches
d - Alignment Tabs (Bend Inward)

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Oil Seal Carrier Assembly

Installation
NOTE: Apply hand pressure only to install the oil seal carrier into position. Do not hammer
it into position.
Lubricate the oil seal carrier oil seal lips, space between seals and O-ring with 2-4-C with
Teflon and install the oil seal carrier over the drive shaft and into the gear case.
a
b

c 70501

a - Oil Seal Carrier

b - Oil Seal Lips
c - O-ring

Water Pump Assembly

Installation
NOTE: The gaskets/face plate hole pattern is not symmetrical. If the holes of the gaskets/
face plate do not align with the screw holes of the gear case and/or each other, one or more
of the parts is upside down. Determine which parts are upside down and turn the appropriate
parts over.
1. Install the small hole gasket then the face plate followed by the large hole gasket onto
the gear case.
c

b
a

70720
a - Small Hole gasket
b - Face Plate
c - Large Hole Gasket

2. Place a small amount of 2-4-C with Teflon on the flat surface of the impeller key and
install the key onto the drive shaft keyway.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

IMPORTANT: When using an impeller whose blades have taken a set, face the curl of
the blades in a counterclockwise direction. DO NOT install the impeller with its
blades oriented in a reversed direction from original rotation, or premature impeller
failure will occur.
3. Assemble the water pump impeller onto the drive shaft and down over the key.

a
95

b
52725
95 2-4-C With Teflon

a - Water Pump Impeller

b - Water Pump Impeller Key

4. Install the 2 water pump locating pins through the gaskets and face plate.
5. Apply a light coat of 2-4-C with Teflon to the inside of the pump cover. Position the water
pump body over the drive shaft and water pump locating pins. Rotate the drive shaft in
a clockwise direction, while pushing down on the water pump body to ease the water
pump over the impeller blades.

c
a b

95

52751
95 2-4-C With Teflon

a - Water Pump Body

b - Water Pump Alignment Pins (91-821571A1)
c - Drive Shaft (turn clockwise while installing water pump body)

6. Hand start two (2) fasteners into the water pump assembly and remove the water pump
locating pins. Install the remaining 2 fasteners. Run all fasteners down and torque to 60
lb. in. (6.8 Nm).
7. Lightly lubricate the O-rings in the water tube coupling with 2-4-C with Teflon.

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

8. Install the water tube coupling assembly to the water pump ensuring that the O-rings are
not damaged during assembly.
IMPORTANT: If seal installed above pump housing is not at the proper height, air will
be drawn into the pump resulting in overheating of the engine.
9. Using tool provided in seal kit (26-816575A2) or water pump kit (817275A3), press seal
down over drive shaft (DO NOT GREASE DRIVE SHAFT) until tool seats against pump
housing.

52724
a - Seal Installation Tool
b - Seal

NOTE: If tool is not available, lightly press seal against housing until a height of 0.350 in.
 0.030 in. (8.9mm  0.76mm) is obtained.

0.350 in. ± 0.030 in.

52726

NOTE: Secure speedometer tube to speedometer connector with a sta-strap.

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 GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

Gear Lubricant Filling Instructions

1. Inspect Fill and Vent sealing washers for cuts or abrasions. Replace O-rings if neces-
sary.
2. Clean any metal debris from magnet on Fill plug.
IMPORTANT: Never add lubricant to gear housing without first removing Vent screw,
or gear housing cannot be filled because of trapped air. Fill gear housing ONLY when
housing is in a vertical position.
3. Slowly fill housing through Fill hole with Super Duty Lower Unit Lubricant until lubricant
flows out of Vent hole and no air bubbles are visible.
4. Install Vent screw into Vent hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling Fill screw.
5. Remove grease tube (or hose) from Fill hole and quickly install Fill screw into Fill hole.

Installing Gear Housing to Drive Shaft Housing

WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from en-
gine before installing gear housing into drive shaft housing.
1. Tilt engine to full up position and engage the tilt lock lever.
2. Apply a light coat of 2-4-C with Teflon onto drive shaft splines.

CAUTION
DO NOT allow lubricant on top of drive shaft. Excess lubricant, that is trapped in
clearance space, will not allow drive shaft to fully engage with crankshaft. Subse-
quently, tightening the gear housing nuts (while excess lubricant is on top of drive
shaft) will load the drive shaft/crankshaft and damage either or both the powerhead
and gear housing. Top of drive shaft is to be wiped free of lubricant.
3. Apply a light coat of 2-4-C with Teflon onto shift shaft splines. (DO NOT allow lubricant
on top of shift shaft.)
4. Insert a NEW trim tab bolt (with patch) into hole in rear of gear housing to drive shaft
housing machined surface.
5. Shift gear housing into NEUTRAL and place guide block anchor pin into NEUTRAL posi-
tion.

a
52189
a - Guide Block Anchor Pin

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GEAR HOUSING RIGHT HAND OPERATION (STANDARD ROTATION) (RATCHETING AND NON–RATCHETING)

6. Position gear housing so that the drive shaft is protruding into drive shaft housing.
7. Feed speedometer tube through opening in drive shaft housing.
NOTE: If, while performing Step 8, the drive shaft splines will not align with crankshaft
splines, have helper rotate flywheel slightly to align drive shaft splines with crankshaft.
8. Move gear housing up toward drive shaft housing while aligning shift shaft splines and
water tube.
9. Place flat washers onto studs (located on either side of drive shaft housing). Start a nut
on these studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab recess. DO NOT tighten bolt at this time.
11. Recheck shift shaft spline engagement and correct if necessary.
IMPORTANT: Do not force gear case up into place with attaching nuts.
12. Evenly tighten 2 nuts which were started in Step 9. Torque to 55 lb. ft. (74.6 Nm).
13. After 2 nuts (located on either side of drive shaft housing) are tightened, check shift oper-
ation as follows:
a. Place guide block anchor pin into forward gear position. Rotate flywheel clockwise
(viewed from top); propeller shaft should rotate clockwise.
b. Place guide block anchor pin into NEUTRAL position. Propeller shaft should rotate
freely clockwise/counterclockwise.
c. Place guide block anchor pin into REVERSE gear position. Rotate flywheel clock-
wise (viewed from top); propeller shaft should rotate counterclockwise.
IMPORTANT: If shifting operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
14. Install remaining washers and nuts onto drive shaft studs. Torque to 55 lb. ft. (74.6 Nm).
15. Torque bolt (started in Step 10) to 45 lb. ft. (61.0 Nm).
16. Position trim tab in gear housing aligning grooves of trim tab with ribs in trim tab pocket.
Adjust to position in which it had previously been installed, and while holding trim tab,
torque bolt to 40 lb. ft. (54.2 Nm)
17. Install plastic cap into trim tab bolt opening at rear edge of drive shaft housing.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

LOWER UNIT
Section 6B - Gear Housing Left Hand Operation
(Counter Rotation)
(Ratcheting and Non-Ratching)
Table of Contents
General Service Recommendations . . . . . . . 6B-1 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . 6B-66
Gear Housing Specifications Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . 6B-69
(Counter Rotation) . . . . . . . . . . . . . . . . . . . . . . 6B-3 Gear Housing Reassembly . . . . . . . . . . . . . . . 6B-70
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Gear Housing Inspection . . . . . . . . . . . . . . 6B-70
Gear Housing (Drive Shaft) (Counter Rotation) Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . 6B-70
(Ratcheting)(S/N-0G437999 & BELOW) Reverse Gear Bearing Adaptor Assembly 6B-71
(CASTING #1623-822442C2) . . . . . . . . . . . . 6B-10 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . 6B-75
Gear Housing (Prop Shaft) (Counter Rotation) Gear Location/Backlashes Checking
(Ratcheting)(S/N-0G437999 & BELOW) and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 6B-77
(CASTING #1623-822442C2) . . . . . . . . . . . . 6B-12 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-77
Gear Housing (Prop Shaft) (Counter Rotation) Drive Shaft and Pinion Gear . . . . . . . . . . . 6B-79
(Ratcheting)(S/N-0G437999 & BELOW) Drive Shaft - Bearing Preload Tool . . . . . . 6B-82
(CASTING #1623-822442C2) . . . . . . . . . . . . 6B-14 Checking Pinion Gear Location . . . . . . . . . 6B-83
Gear Housing (Drive Shaft) (Counter Rotation)
(Non-Ratcheting) (S/N-0G438000 & UP)
Drive Shaft - Bearing Preload Tool Removal
Adjusting Pinion Gear Location . . . . . . . . .
6B-84
6B-85
6
(CASTING #1623-822442C3) . . . . . . . . . . . . 6B-16 Checking Reverse Gear Backlash . . . . . . 6B-86 B
Gear Housing (Prop Shaft) (Counter Rotation) Forward Gear/Bearing Carrier Assembly 6B-89
(Non-Ratcheting) (S/N-0G438000 & UP) Checking Forward Gear Backlash . . . . . . 6B-101
(CASTING #1623-822442C3) . . . . . . . . . . . . 6B-18 Propeller Shaft Assembly . . . . . . . . . . . . . . . . . 6B-103
Removal, Disassembly, Cleaning and Component Reassembly . . . . . . . . . . . . . . 6B-103
Inspection – Counter Rotation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-105
(Ratcheting and Non-Ratcheting) . . . . . . . . . 6B-20 Drive Shaft and Pinion Gear . . . . . . . . . . . . . . 6B-109
Pre-Disassembly Inspection . . . . . . . . . . . . . . 6B-23 Final Installation (Ratcheting
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-23 and Non-Ratcheting) . . . . . . . . . . . . . . . . . 6B-109
Gear Housing and Component Disassembly Bearing Carrier Assembly . . . . . . . . . . . . . . . . 6B-112
and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6B-24 Final Installation (Ratcheting) . . . . . . . . . . 6B-112
Water Pump Assembly . . . . . . . . . . . . . . . . 6B-24 Final Installation (Non-Ratcheting) . . . . . . 6B-115
Oil Seal Carrier Assembly . . . . . . . . . . . . . 6B-27 Final Installation (Ratcheting
Bearing Carrier Assembly . . . . . . . . . . . . . 6B-30 and Non-Ratcheting) . . . . . . . . . . . . . . . . . 6B-117
Forward Gear Bearing Adaptor Assembly 6B-44 Oil Seal Carrier Assembly Installation . . . . . . 6B-124
Drive Shaft Assembly . . . . . . . . . . . . . . . . . 6B-46 Water Pump Assembly Installation . . . . . . . . . 6B-125
Propeller Shaft Assembly . . . . . . . . . . . . . . 6B-51 Gear Lubricant Filling Instructions . . . . . . 6B-128
Reverse Gear Assembly . . . . . . . . . . . . . . 6B-56 Installing Gear Housing to
Shift Spool Assembly . . . . . . . . . . . . . . . . . 6B-59 Drive Shaft Housing . . . . . . . . . . . . . . . . . . 6B-128
Reverse Gear Bearing Adaptor Assembly 6B-64

General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part. It is
recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
Disassembly of a sub-assembly may not be necessary until cleaning and inspection
reveals that disassembly is required for replacement of one or more components.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Service procedure in this section is a normal disassembly-reassembly sequence. It is

suggested that the sequence be followed without deviation to assure proper repairs.
When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to reassembly and installation of that
component in the reassembly part of this section. Use the Table of Contents
(preceding) to find correct page number.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, be sure that no water is present in air line.

BEARINGS
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing so
that it passes through the bearing. DO NOT spin bearing with compressed air, as this may
cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with
Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing
race in-and-out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condition of rollers and inner bearing race by
inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles
and/or discoloration from overheating. Always replace tapered bearing and race as a set.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that the
roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded
particles, uneven wear and/or discoloration from overheating. The shaft and bearing must
be replaced if the conditions described are found.

SHIMS
Keep a record of all shim amounts and location during disassembly to aid in reassembly.
Be sure to follow shimming instructions during reassembly as gears must be installed to
correct depth and have the correct amount of backlash to avoid noisy operation and
premature gear failure.

SEALS
As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard
to appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter of
all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean and
dry. To ease installation, apply 2-4-C with Teflon on all O-rings. To prevent wear, apply 2-4-C
with Teflon on I.D. of oil seals.
To prevent corrosion damage after reassembly, apply Perfect Seal or 2-4-C with Teflon to
external surfaces of bearing carrier and retainer nut threads prior to installation. DO NOT
allow Perfect Seal to enter bearings or O-ring area.
NOTE: Before filling gear case, apply 10-15 psi (68.5 – 102.7kPa) of air pressure at the
VENT hole. Pressure should not drop for 15 seconds while alternately applying a 2-3 pound
force to the top of the shift shaft in the fore and aft direction.

Page 6B-2 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing Specifications (Counter Rotation)

Pinion Depth
All Models 0.025 in. (0.64mm) with Tool 91-12349A2 Using
Disc 2 and Flat 4
Forward Gear Backlash
1.64:1and 1.75:1 Gear Ratios 0.017 in. to 0.028 in.
1.62:1 Gear Ratio (0.431mm to 0.711mm)
Service Replacement Pointer on line mark #1
with Backlash Indicator
Rod 91-53549
Reverse Gear Backlash
1.64:1and 1.75:1 Gear Ratios 0.040 in. to 0.060 in.
1.62:1 Gear Ratio (1.01mm to 1.52mm)
Service Replacement
Lubricant Capacity 28 fl. oz. (0.828 liter)
Forward Gear Backlash
1.87:1 Gear Ratio 0.017 in. to 0.028 in.
(High Altitude) (0.431mm to 0.711mm)
Pointer on line mark #1
with Backlash Indicator Rod 91-78473
Reverse Gear Backlash
1.87:1 Gear Ratio 0.040 in. to 0.060 in.
(High Altitude) (1.01mm to 1.52mm)
Lubricant Capacity 28 fl. oz. (0.828 liter)

Gear Ratio Teeth in Pinion Gear Teeth in Forward and Reverse

Gear
1.62:1 13 21
1.64:1 17 28
1.75:1 12 21
1.87:1 15 28

Water Pressure
Idle 1-1/2 – 4-1/2 psi
(10.3 – 30.8kPa)
Poppet Valve Opening 6 – 7 psi
(41.1 – 47.9kPa)
W.O.T. 8-10 psi
54.9 – 68.5kPa)
Test Propeller for Static Test
12 Dia. x 15 Pitch 48-78116A40

90-855348R02 NOVEMBER 2002 Page 6B-3

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Special Tools
Propeller Shaft 44-93003 and Load Washer 12-37429

Belleville Washer 12-54048

Needle Bearing Driver 91-15755

Oil Seal Driver 91-31108

Universal Puller Plate 91-37241

Page 6B-4 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Bearing Retainer Tool 91-43506

Backlash Indicator Rod 91-53459

Drive Shaft Nut Wrench 91-56775

Bearing Carrier Retainer Wrench 91-61069

Torque Wrench (lb. in.) 91-66274

90-855348R02 NOVEMBER 2002 Page 6B-5

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Backlash Indicator Rod 91-78473

Puller Bolt 91-85716 and Puller Jaws 91-46086A1

Forward Gear Bearing Tool 91-86943

Dial Indicator Holding Tool 91-89897

Forward Gear Installation Tool 91-815850

Puller Jaws 91-816242

Page 6B-6 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Guide Plate 91-816243

Bearing Driver 91-816244

Oil Seal Driver 91-817569

Water Pump Alignment Pins 91-821571A1

Pinion Gear Shimming Tool 91-12349A2

90-855348R02 NOVEMBER 2002 Page 6B-7

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Bearing Preload Tool 91-14311A2

Bearing Adaptor Installation Tool 91-18605A2

Bearing Removal and Installation Tool 91-31229A7 – Includes Driver Head 91-36569:
Driver Head Rod 91-37323; Nut 11-24156; Pilot Washer 91-36571; Pilot Plate 91-29610;
Puller/Driver Head 91-38628; Mandrel 91-30366; Plate 91-29310; Driver Head 91-32325;
Puller Shaft 91-31229; Washer 91-34961.

Slide Hammer Puller 91-34569A1

Page 6B-8 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Puller Bolt 91-85716 and Puller Jaws 91-46086A1

Dial Indicator 91-58222A1

Pinion Nut Adaptor 91-61067A3

Drive Shaft Adaptor 91-61077

Leakage Tester FT8950

90-855348R02 NOVEMBER 2002 Page 6B-9

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Drive Shaft) (Counter Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

28
95
95
29
95

30
31
39 27
95
40
41 95 33 26
95
38
95
95 32
25
95
37 13

7 24
42 22
19
35
23 95
21
36 18
20
17
34 19
10
11 12
3
1
95 7 7
7
6
10 5
1623- 4
822442C2

95 9

14
6 8
7 Loctite 271 Thread Locker
15
19 Perfect Seal
2
92 Loctite 7649 Primer 16
7 92
95 2-4-C With Teflon

Page 6B-10 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Drive Shaft) (Counter Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING
2 1 PIN
3 1 FILLER BLOCK
4 1 MAGNETIC SCREW 60 6.8
5 1 SEALING WASHER
6 2 ANODE
7 1 SCREW 60 6.8
8 1 NUT
9 1 ROLLER BEARING
10 2 DOWEL PIN
11 1 SCREW 60 6.8
12 1 SEALING WASHER
1 CONNECTOR (X–LONG)
13 1 CONNECTOR (XX–LONG)
PINION GEAR (Part of 43-826287A1 or 43-812975A5
14 1
or 43-828289A3)
15 1 WASHER
16 1 NUT 75 101
17 1 BUSHING ASSEMBLY
18 1 OIL SEAL
19 2 O-RING
20 2 SCREW 60 6.8
21 1 RUBBER WASHER
22 1 SHIFT SHAFT (LOWER)
23 1 DRIVE SHAFT (LOWER)
24 1 KEY
25 AR SHIM
26 1 TAPERED ROLLER BEARING
27 1 RETAINER 100 135
28 1 CARRIER ASSEMBLY
29 1 O-RING
30 1 OIL SEAL
31 1 OIL SEAL
32 1 WATER PUMP ASSEMBLY
33 1 SEAL
34 1 GASKET
35 1 GASKET
36 1 FACE PLATE
37 1 IMPELLER
38 4 SCREW 60 6.8
39 1 COUPLING ASSEMBLY
40 2 O-RING
1 DRIVESHAFT KIT (LONG–20 IN.) SEE NOTE
1 DRIVESHAFT KIT (X-LONG–25 IN.) 13 SPLINES
1 DRIVESHAFT KIT (X-LONG–30 IN.)
41 1 DRIVESHAFT KIT (LONG–20 IN.) SEE NOTE
1 DRIVESHAFT KIT (X-LONG–25 IN.) 8 SPLINES
1 DRIVESHAFT KIT (XX-LONG–30 IN.)
42 1 COUPLING
NOTE: Service replacement of the one (1) piece driveshaft is not being offered.
Determine the length of the driveshaft and ORDER REF. #’s 23 & 41.

90-855348R02 NOVEMBER 2002 Page 6B-11

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

76
1623-
822442C2

1 7

75

74
43
82
44

49 45
95 57
56
51 46
55 47
54
48 94

60 58 82
82

52 50 59
61 82
53
62 82
67
63
64 82 69
82 95
65 68
66
65 70 95
64 71 95
63
72
79 73 7
77
78 95
81 80
7 Loctite 271 Thread Locker

82 Premium Gear Lubricant 95

94 Anti-Corrosion Grease
95
95 2-4-C With Teflon

Page 6B-12 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING
43 1 SHIFT CRANK
44 1 SHIFT SPOOL KIT
45 AR SHIM
46 1 BEARING ADAPTOR ASSEMBLY (1623-822442C2 CASTING)
47 1 ROLLER BEARING
48 1 THRUST WASHER
49 1 THRUST BEARING
1 REVERSE GEAR (1.75:1 GEAR RATIO)
50 1 REVERSE GEAR (1.64:1 GEAR RATIO)
1 REVERSE GEAR (1.62:1 GEAR RATIO)
51 1 ROLLER BEARING
52 1 SPRING
53 1 SLIDING CLUTCH
54 1 CROSS PIN
55 1 DETENT PIN
56 1 PROPELLER SHAFT
1 FORWARD GEAR (Includes Pinion)(1.75:1 GEAR RATIO)
57 FORWARD GEAR (Includes Pinion)(NOTE: THIS COMPLETE GEAR SET IS A 1.62:1 GEAR RATIO
1
REPLACING A 1.64:1 GEAR RATIO)
AR SPACER SHIM .206 IN.
AR SPACER SHIM .208 IN.
AR SPACER SHIM .210 IN.
AR SPACER SHIM .212 IN.
AR SPACER SHIM .214 IN.
AR SPACER SHIM .216 IN.
58 AR SPACER SHIM .218 IN.
AR SPACER SHIM .220 IN.
AR SPACER SHIM .222 IN.
AR SPACER SHIM .224 IN.
AR SPACER SHIM .226 IN.
AR SPACER SHIM .228 IN.
AR SPACER SHIM .230 IN.

90-855348R02 NOVEMBER 2002 Page 6B-13

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

76

1623-
822442C2
1
7

75

74
43
82
44

95 49 45
57
56
51 46
55 47
54
94
48
82 60 82
58

52 50 59
61 82
53
62 82
67
63
64 82 69 95
82 68
65
66
65 70
64 71 95
95
63 72
79 73 7
77
78 95
81 80
7 Loctite 271 Thread Locker
95
82 Premium Gear Lubricant
95
94 Anti-Corrosion Grease
95 2-4-C With Teflon

Page 6B-14 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)

(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING
59 1 ROLLER BEARING
60 1 THRUST RING
61 1 BEARING ADAPTOR ASSEMBLY
62 1 ROLLER BEARING
63 2 THRUST WASHER
64 2 THRUST BEARING
65 2 THRUST RACE
66 2 KEEPER
67 1 O-RING
68 1 BEARING CARRIER ASSEMBLY
69 1 ROLLER BEARING
70 1 OIL SEAL (INSIDE)
71 1 OIL SEAL (OUTSIDE)
72 1 TAB WASHER
73 1 RETAINER 23.7 285
74 1 ANODIC PLATE
1 TRIM TAB (ANODIC)
75
1 TRIM TAB (BLACK ALUMINUM)
76 1 SCREW THESE REPLACEMENT 40 54.2
77 1 THRUST HUB PARTS ARE NOT
78 1 LOCKWASHER INCLUDED WITH
79 1 WASHER COMPLETE GEAR
80 1 TAB WASHER REPLACEMENT
81 1 PROPELLER NUT 55 74.6

90-855348R02 NOVEMBER 2002 Page 6B-15

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Drive Shaft) (Counter Rotation)

(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING
#1623-822442C3)
7 Loctite 271 Thread Locker 95
31
19 Perfect Seal 95
117 Loctite 7649 Primer N 32
95 2-4-C With Teflon 33
34
42
30
44 95
43 28
95
36
29
41
95
45 95
46 35 95

27
95
40 13
14
26
24 19
38 15
95
25
23
39 20
22
19

37 21
47 10
11 12 3
7 7
1 95
7
6
10 5
4

48 9

16
6 8
4.75
17
IN/120.65MM
18 2
TORPEDO DIA.
7
92

Page 6B-16 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Drive Shaft) (Counter Rotation)

(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING
#1623-822442C3)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING BASIC
2 1 PIN
3 1 FILLER BLOCK
4 1 MAGNETIC SCREW 60 6.8
5 1 SEALING WASHER
6 2 ANODE
7 1 SCREW 60 6.8
8 1 NUT
9 1 ROLLER BEARING
10 2 DOWEL PIN
11 1 SCREW ASSEMBLY 60 6.8
12 1 SEALING WASHER
13 1 CONNECTOR (XL)
14 1 CONNECTOR (XXL)
15 1 CABLE TIE
16 1 PINION GEAR (Part of 43-828695A1) (1.75:1 - 12/21)
17 1 WASHER
18 1 NUT 75 101
19 1 BUSHING ASSEMBLY
20 1 OIL SEAL
21 2 O-RING
22 2 SCREW (M6 x 16) 60 6.8
23 1 RUBBER WASHER
24 1 SHIFT SHAFT (LOWER)
25 1 DRIVE SHAFT (LOWER)
26 1 KEY
27 AR SHIM SET
28 1 TAPERED ROLLER BEARING
29 1 CUP
30 1 RETAINER 100 135
31 1 CARRIER ASSEMBLY
32 1 O-RING
33 1 OIL SEAL
34 1 OIL SEAL
35 1 WATER PUMP ASSEMBLY
36 1 SEAL
37 1 GASKET
38 1 GASKET
39 1 FACE PLATE
40 1 IMPELLER
41 4 SCREW (M6 x 16) 60 6.8
42 1 COUPLING ASSEMBLY
43 1 O-RING
44 1 O-RING
45 1 DRIVESHAFT KIT (X-LONG-25 IN.) SEE NOTE
46 1 DRIVESHAFT KIT (XX-LONG-30 IN.)
47 1 COUPLING
48 1 DECAL-Counter Rotation
NOTE: Service replacement of the one (1) piece driveshaft is not being offered. Determine
the length of the driveshaft and ORDER REF. #’s 24 & 44.

90-855348R02 NOVEMBER 2002 Page 6B-17

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Prop Shaft) (Counter Rotation)

(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING
#1623-822442C3)
4.75 IN/120.65MM
TORPEDO DIA.
85

84
53 49
52
82 50
51
58
54
95
66
60 55 65
64 56
63
82 94
57
82
82
67
68
59 69 82
61
62 70 95
72
77
73 71
74 79
82
82
75 78
76
75 80
95
74 81
73
82 95

83
95

82 Super Duty Gear Lubricant

95
94 Anti-Corrosion Grease
95
136 Loctite Quick Tite

Page 6B-18 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing (Prop Shaft)(Counter Rotation)

(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING
#1623-822442C3)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 GEAR HOUSING BASIC
49 1 SHIFT CRANK
50 1 SHIFT SPOOL
51 1 SPOOL
52 1 SLEEVE
53 1 COTTER PIN 55 74.6
54 AR SHIM SET
55 1 BEARING ADAPTOR ASSEMBLY
56 1 ROLLER BEARING
57 1 THRUST WASHER
58 1 THRUST BEARING
59 1 REVERSE GEAR (1.75:1 - 12/21)
60 1 ROLLER BEARING
61 1 SPRING
62 1 SLIDING CLUTCH
63 1 CROSS PIN
64 1 DETENT PIN
65 1 PROPELLER SHAFT
66 1 FORWARD GEAR (1.75:1 - 12/21)
67 AR SPACER SHIM .206 IN.
AR SPACER SHIM .208 IN.
AR SPACER SHIM .210 IN.
AR SPACER SHIM .212 IN.
AR SPACER SHIM .214 IN.
AR SPACER SHIM .216 IN.
AR SPACER SHIM .218 IN.
68
AR SPACER SHIM .220 IN.
AR SPACER SHIM .222 IN.
AR SPACER SHIM .224 IN.
AR SPACER SHIM .226 IN.
AR SPACER SHIM .228 IN.
AR SPACER SHIM .230 IN.
69 1 ROLLER BEARING
70 1 THRUST RING
71 1 BEARING ADAPTOR ASSEMBLY
72 1 ROLLER BEARING
73 2 THRUST WASHER
74 2 THRUST BEARING
75 2 THRUST RACE
76 2 KEEPER
77 1 O-RING
78 1 BEARING CARRIER ASSEMBLY
79 1 ROLLER BEARING
80 1 OIL SEAL (INSIDE)
81 1 OIL SEAL (OUTSIDE)
82 1 TAB WASHER
83 1 COVER 210 285
84 1 ANODIC PLATE
85 1 SCREW 40 54.2

90-855348R02 NOVEMBER 2002 Page 6B-19

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Removal, Disassembly, Cleaning and Inspection – Counter

Rotation (Ratcheting and Non-Ratcheting)

REMOVAL

WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from en-
gine before removing gear housing from drive shaft housing.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.
2. Shift engine into neutral position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from throughst hub (rear), then remove propel-
ler locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propel-
ler shaft.

b
51912

d 51916

a - Thrust Hub (Forward)

b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut
5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position.
Remove plastic cap at rear edge of drive shaft housing, then unthread bolt that secures
trim tab and remove trim tab from gear housing.

Page 6B-20 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Once trim tab is removed, remove bolt from inside of trim tab cavity.

52375

a - Bolt (Secures Trim Tab)

b - Bolt (Inside Trim Tab Cavity)
c - Ribs – Align Carefully with Trim Tab while Securing Tab
7. Disconnect speedometer tube, if connected.
8. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo-
site side is loosened sufficiently, or drive shaft housing could be damaged.)
9. Pull gear housing away from drive shaft housing as far as the loosened nuts (in Step 8)
will allow, then remove loosened nuts. (DO NOT allow gear housing to fall, as it now is
free.)

90-855348R02 NOVEMBER 2002 Page 6B-21

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

10. Pull gear housing from drive shaft housing.

52374

a - Side Mounting Locknut (Two Each Side)

DRAINING AND INSPECTING GEAR HOUSING LUBRICANT

1. Place gear housing in a suitable holding fixture or vise with the drive shaft in a vertical
position.
2. Position a clean drain pan under gear housing and remove Fill and Vent screws from
gear housing. Do not loose sealing washers on FILL and VENT screws.

52377
a - Fill Screw
b - Vent Screw
3. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal par-
ticles (resembling powder) indicates normal wear. Presence of larger particles (or a
large quantity of fine particles) indicates need for gear housing disassembly, and com-
ponent inspection.

Page 6B-22 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Note the color of gear lubricant. White or cream color indicates presence of water in lu-
bricant. Check drain pan for water separation from lubricant. Presence of water in gear
lubricant indicates the need for disassembly, and inspection of oil seals, seal surfaces,
O-rings and gear housing components.
NOTE: Gear lubricant drained from a recently run gear case will be a light chocolate brown
in color due to agitation/aeration. Oil which is stabilized will be a clear yellow brown in color.

Pre-Disassembly Inspection
Propeller Shaft
1. Inspect the propeller shaft for side to side movement, as follows:
a. Position the dial indicator on the propeller shaft.
b. Push the propeller shaft to one side and zero the dial indicator.
c. Move the propeller shaft to the opposite side while observing the dial indicator. With-
out rotating the propeller shaft, reposition the dial indicator and check the up and
down deflection. A shaft deflection of more than 0.003 in. (0.08 mm) indicates a worn
propeller shaft bearing.
2. Check for a bent propeller shaft as follows:
a. Rotate the propeller shaft while observing the dial indicator. If the deflection is more
than 0.009 in. (0.23 mm), a bent propeller shaft is indicated.
3. Measure propeller shaft endplay. If it is in excess of 0.093 in. (2.36mm), disassemble
gear case and check condition of the reverse shoulder of the propeller shaft, reverse
gear and thrust washer. Replace components as required.

22086
a - Prop Shaft Runout
b - Prop Shaft Endplay

90-855348R02 NOVEMBER 2002 Page 6B-23

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing and Component Disassembly and Inspection

Water Pump Assembly
REMOVAL
1. Remove the water seal, water tube coupling assembly, and the water pump screws.

a
c

52749

a - Water Tube Assembly

b - Water Pump Screws (4)
c - Seal
2. Carefully slide the water pump straight up off of the drive shaft. It may be necessary to
encourage the water pump up by gently prying up on its mounting flanges with screw-
drivers.

a
b b

70487

a - Water Pump Body

b - Screw Drivers

Page 6B-24 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Remove the impeller, impeller key, the face plate and gaskets, (discard the gaskets).

70605

a - Impeller
b - Impeller Key
c - Water Pump Face Plate and Gaskets (One on each side of the face plate)
COMPONENT INSPECTION
1. Inspect the water tube coupling assembly for wear or damage. If necessary, replace the
worn or damaged components especially the two O-rings on the inside, one at the top
and one at the bottom.

b
70613

a - Water Tube adapter

b - O-rings (2)
2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller
blades. Replace the impeller if this condition is found.

90-855348R02 NOVEMBER 2002 Page 6B-25

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Inspect for proper bonding between the hub and the impeller. Replace the impeller if im-
proper bonding is found.

70500

a - Impeller
b - Hub
4. Inspect the impeller blades to see if they are cracked, burnt, hard or deformed. Replace
the impeller if the blades are in this condition.
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate. The depth of the groove will not affect wa-
ter pump output.
5. Replace cover if thickness of steel at the discharge slot is 0.060 in. (1.5mm) or less or
if grooves (other than impeller sealing bead groove) in cover roof are more than 0.030
in. (0.76mm) deep.
a b

70609

a - Water Pump Face Plate

b - Water Pump Cover

Page 6B-26 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Oil Seal Carrier Assembly

REMOVAL
1. Remove the oil seal carrier from the gear housing. It may be necessary to gently pry up
on it with two screw drivers.

70489

a - Oil Seal Carrier

b - Screwdrivers
INSPECTION
Inspect the oil seal carrier, O-ring, and seals for wear and/or damage. If necessary, replace
defective parts as outlined following.

COMPONENT DISASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
found to be defective and are in need of repair or replacement.
1. Remove the O-ring.
b

a
70501

a - O-ring
b - Oil Seals (2)

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Remove the oil seals.

c b

70610

a - Oil Seal Carrier

b - Oil Seals
c - Screwdriver
COMPONENT REASSEMBLY (1994/1995 MODELS)
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.

70501

1. Assemble the small oil seal (with the lips of the oil seal facing away from the driver shoul-
der) onto the long end of the oil seal driver.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Press on the oil seal driver until the driver bottoms against the carrier. Do not press so
hard as to damage the oil seal carrier while driving the oil seal.

a c 70611

a - Oil Seal
b - Oil Seal Driver (91-817569) use long end
c - Oil Seal Carrier
d - Press
3. Assemble the large oil seal (with the lips of the oil seal facing the driver shoulder) onto
the short end of the oil seal driver.
4. Press on the oil seal driver until the driver bottoms against the carrier. Do not press so
hard as to damage the oil seal carrier while driving the oil seal.

a c

70612

a - Oil Seal
b - Oil Seal Driver (91-817569) use short end
c - Oil Seal Carrier
d - Press
5. Fill the area between the seal lips with 2-4-C with Teflon. Apply 2-4-C with Teflon to the
O-ring.
6. Install the O-ring onto the oil seal carrier.

95

a 70501

95 2-4-C With Teflon

a - O-ring

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT REASSEMBLY
The oil seals in carrier assemblies are the same diameter. The bottom (first) seal lip faces
down; the top (second) seal lip faces up. Apply 2-4-C with Teflon Marine Lubricant to seal
lips and between seals. Press seal into carrier with suitable mandrel. Second seal should
be pressed in flush with carrier surface.

95
b

95 2-4-C With Teflon

a - Bottom Seal (Lip Faces Down)

b - Top Seal (Lip Faces Up)
Bearing Carrier Assembly
REMOVAL
1. Straighten the tab on the tab washer.

70490

a - Tab on Tab Washer

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Remove the bearing carrier retainer following step a or b as follows:

CAUTION
DO NOT drill into the gear housing retainer threads when using the following proce-
dure for removing the retainer.
a. If the retainer is corroded in place, drill 4 holes in the retainer and fracture the retainer
with a chisel. Pry the remaining segments out.

23356

a - Drilled Holes
b. Remove the bearing carrier retainer using the Bearing Carrier Retainer Wrench
(91-61069).

70491

a - Bearing Carrier Retainer Wrench

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing
carrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER.
NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat
to loosen the carrier.

50786

a - Puller Jaws (91-46086A1)

b - Puller Bolt (91-85716)

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Lift the bearing carrier out of the gear housing. Locate and retain the thrust washer that
may be stuck to the inside surface of the bearing carrier.

50826
a

50779

a - Thrust Washer

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

5. Remove the aft thrust bearing.

50786

a - Thrust Bearing
6. Remove the aft thrust collar.

50787

a - Thrust Collar

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

7. Lift up on the propeller shaft and push down on the forward thrust collar to remove the
two keepers.

a
b

50778

50826

a - Thrust Collar
b - Keepers (2)

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

8. Remove the forward thrust collar.

50784

a - Thrust Collar

9. Remove the forward thrust bearing.

50783

a - Thrust Bearing

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

10. Form a tool using a 1/8 in. (3 mm) wire as shown in the following figure and remove the
forward gear bearing adaptor.

50786

a - Wire Tool
b - Forward Gear Bearing Adaptor
11. Shift gear case into forward gear.
NOTE: The thrust race has a tight fit in the gear housing bore. Use the Forward Gear Instal-
lation Tool (91-815850) to remove the thrust race and the forward gear together. If this at-
tempt fails, form a small hook on the end of a stiff piece of wire and while applying heat to
the outside of gear case, pull the thrust race up and out of the gear housing.
12. Remove the O-ring from inside the gear housing.
13. Remove the forward gear, thrust race, and the thrust bearing (between the gear and the
race).

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

14. Remove the forward gear shim.

50783

a - Forward Gear Installation Tool (91-815850)

b - Thrust Race
c - Forward Gear
d - Shim

INSPECTION
1. Clean the assembly and all components with a suitable solvent and dry the parts thor-
oughly using compressed air.
NOTE: If any of the following items are found to be defective complete the appropriate in-
struction(s) in Bearing Carrier Assembly, ‘Component Disassembly and Inspection’ section.

Page 6B-38 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Inspect the bearing carrier for signs of excessive corrosion especially in the area where
the bearing carrier touches the gear housing. If excessive corrosion is evident replace
the carrier.
a

b
50818

a - Bearing Carrier
b - Mating Surfaces
3. The condition of the bearing surface on the propeller shaft in the area that the needle
bearing (in the bearing carrier) rides is an indication of the condition of the needle bear-
ing in the bearing carrier. Replace the bearing if the surface of the shaft is pitted,
grooved, scored, worn unevenly, discolored from overheating or has embedded metal
particles.
a

50698

a - Propeller Shaft Bearing Contact Area

4. Inspect the forward gear for pitted, chipped, broken teeth, hairline fractures, and exces-
sive or uneven wear. Replace the forward gear and the pinion gear if any defects are
found.
5. Inspect the outer hub of the forward gear for excessive wear or damage. Replace the
forward and the pinion gear if either of these conditions exist.

90-855348R02 NOVEMBER 2002 Page 6B-39

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Inspect the clutch jaws of the gear for damage. Surfaces must not be chipped or rounded
off. Replace the forward and the pinion gear if any are found.
a

23355

a - Reverse Gear Teeth

b - Clutch Jaws
7. Inspect the thrust bearings, collars and forward gear bearing adaptor for excessive wear
in the areas where the thrust bearings come into contact with them. Replace the appro-
priate components if they are found to be defective.
8. Inspect the bearing carrier retainer for cracks and/or broken or corroded threads. Re-
place it if any are found.
9. Inspect the large O-ring for damage and/or deterioration. Replace it if either condition
is found.

COMPONENT DISASSEMBLY AND INSPECTION

NOTE: Complete the instructions in this section only if the assembly components have been
found to be defective.
NOTE: Inspection of the bearing surfaces on the propeller shaft where the needles of the
bearing carrier needle bearing rolls, gives an indication of the condition of the needle bear-
ing inside the bearing carrier. Replace needle bearing in the bearing carrier if the prop shaft
is pitted, grooved, scored, worn unevenly, discolored from overheating, or has embedded
particles.
Perform the following step 1. or 2. as necessary.

Page 6B-40 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

1. If Replacing the Needle Bearing and Seals: Remove the needle bearing and seals
with the tools as shown.

b
23140

a - Needle Bearing
b - Oil Seals
c - Driver Head (91-36569)
d - Bearing Driver Rod (91-37323)
Discard the needle bearing and both seals.
2. If Replacing the Seal Only: Remove the oil seals with a suitable pry bar, being careful
not to damage the bore of the bearing carrier.

23140

a - Oil Seals
b - Pry Bar
Discard both of the seals.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Clean all of the components with a suitable solvent and dry the parts thoroughly using
compressed air. Be careful not to spin the bearing.
2. Lubricate the bore that the needle bearing is pressed into with Premium Gear Lubricant.
3. Assemble the needle bearing (with the numbered end of the bearing towards the driver
shoulder), onto the driver.
4. Press the needle bearing into the bearing carrier until the driver bottoms out on the bear-
ing carrier. Ensure that the numbered side of the needle bearing faces the seal end (aft
end) of the carrier.

c
82
a

50788
82 Premium Gear Lubricant

a - Needle Bearing
b - Bearing Carrier
c - Needle Bearing Driver (91-15755)
5. Thoroughly clean the bore to which the first seal is to be pressed.
6. Assemble the first seal (with the lips of the seal facing away from the driver shoulder)
onto the long end of the oil seal driver.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

7. Press on the oil seal driver until the driver bottoms onto the aft face of the bearing carrier.

50788

a - Oil Seal
b - Oil Seal Driver (91-31108) (long end)
c - Bearing Carrier
8. Apply a thin film of Loctite 271 Thread Locker to the outer diameter of the second seal.
9. Assemble the second seal (with the lips seal facing the driver shoulder) onto the short
end of the driver.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

10. Press the oil seal with the driver until the driver bottoms out on the bearing carrier.

7 a
b

95

7 Loctite 271 Thread Locker

50788
95 2-4-C With Teflon

a - Driver (short end)

b - Oil Seal (lips toward driver shoulder)
c - Bearing Carrier
11. Wipe up all of the excess Loctite. Do not allow any of the excess Loctite to spread to
other parts of the assembly.
12. Lubricate the seal lips and fill the area between the seals with 2-4-C with Teflon.
Forward Gear Bearing Adaptor Assembly
INSPECTION
1. Thoroughly clean the forward gear bearing adaptor with a suitable solvent and dry it us-
ing compressed air.
NOTE: The condition of the bearing surfaces on the forward gear in the areas that the bear-
ings of the bearing adaptor and the thrust bearing rides, is an indication of the condition of
the respective bearings. Replace the bearing(s) if the surface of the gear and/or the thrust
washer is pitted, grooved, scored, worn unevenly, discolored from overheating or has em-
bedded metal particles.
2. Assemble the forward gear to the bearing adaptor. Inspect them for excessive move-
ment or roughness by rotating the gear in the adaptor. Replace the bearing in the adap-
tor if either of these conditions exist.
3. Inspect the adaptor for other signs of excessive wear or damage. Replace the adaptor
if any are found.

Page 6B-44 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT DISASSEMBLY AND REASSEMBLY

NOTE: Complete the instructions in this section only if the needle bearing in the bearing
adaptor is defective and the adaptor is to be reused.
1. Disassemble the adaptor as follows:
a. Remove the bearing from the adaptor using the bearing removal tool. Align the pins
of the tool with the holes of the adaptor and apply pressure to the center of the tool
so that the pressure is equal on both of the pins. Discard the bearing.

b
c
c
d

50874

a - Forward Gear Bearing Adaptor

b - Bearing Removal Tool (91-816245)
c - Pins
d - Universal Puller Plate
2. Assemble the adaptor as follows:
a. Lubricate the bore that the needle bearing is pressed into with 2-4-C with Teflon.
b. Assemble the needle bearing to the adaptor with the numbered end of the bearing
facing the driver shoulder.
c. Press the needle bearing into the bearing adaptor using a suitable mandrel until the
bearing bottoms in the adaptor.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Drive Shaft Assembly

REMOVAL
1. Remove the drive shaft pinion nut as follows:
a. Place the drive shaft bearing retainer wrench onto the drive shaft. Do not loosen the
retainer at this time.
b. Insert the pinion nut adapter, with the MR slot facing the pinion gear, into the gear
housing. It may be necessary to slightly lift and rotate the drive shaft to align the pin-
ion gear nut into the pinion nut adapter slot.
c. Install the bearing carrier into the gear housing backwards to support the prop shaft
and to keep the pinion nut adapter aligned.
d. Place the drive shaft nut wrench over the drive shaft splines and loosen, (but do not
fully unscrew), the pinion nut by rotating the drive shaft counterclockwise.

c
70887

a - Drive Shaft Nut Wrench (91-56775)

b - Drive Shaft Bearing Retainer Wrench (91-43506)
c - Pinion Nut adapter (91-61067A3) (MR Slot)
e. If the drive shaft is broken, place propeller shaft nut wrench onto the propeller
shaft splines, hold shift shaft in forward gear and loosen, (but do not fully unscrew),
the pinion nut by rotating prop shaft counterclockwise to turn gears, thus loosening
the pinion nut.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

NOTE: The propeller shaft nut wrench is included with the pinion nut adapter kit.
c

b
70607

a - Pinion Nut adapter (91-61067A3)

b - Propeller Shaft Nut Wrench (91-61077)
c - Shift Shaft (Turn Clockwise)(Protect Splines with Soft Material)

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Completely unscrew the drive shaft bearing retainer.

3. Completely unscrew the pinion nut by rotating the drive shaft (or the propeller shaft) in
a counterclockwise direction.
4. Remove the bearing carrier and all tools.
IMPORTANT: The pinion bearing rollers are free to fall out of the pinion bearing once
the drive shaft is removed. Be careful not to lose the (18) rollers.
5. Remove the drive shaft and all components by pulling the drive shaft straight out of the
gear housing as shown.

70608

a - Drive Shaft
b - Drive Shaft Retainer, Bearing Cup, Bearing, and Shims

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. With propeller shaft facing straight up, rotate shift lever into forward. Pull propeller shaft
up and over towards port side of gear case.
7. Form a small hook on a stiff piece of wire and attempt to hook onto the top side of the
gear and pull it out. It may be necessary to slightly move the propeller shaft from side-to-
side to dislodge the pinion gear.

50884

a - Propeller Shaft
b - Pinion Gear
c - Wire Tool

INSPECTION
1. Clean all parts with a suitable solvent and dry the parts using compressed air. DO NOT
spin the bearings.
2. The condition of the drive shaft bearing cup is an indication of the condition of the ta-
pered roller bearing on the drive shaft. Replace the bearing and bearing cup if the cup
is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
3. Inspect the bearing surface on the drive shaft where the needles of the lower pinion
bearing roll. Replace the drive shaft if it is pitted, grooved, scored, worn unevenly, discol-
ored form overheating, or has embedded particles.
4. Inspect the splines at both ends of the drive shaft for a worn or twisted condition. Replace
the drive shaft if either condition exists.
5. Inspect the gear for pitting, chipped or broken teeth, hairline fractures, and excessive
or uneven wear. Replace the pinion gear and the forward gear if any defects are
found.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT DISASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
found to be defective and are in need of repair or replacement.
1. Press the tapered roller bearing from the drive shaft using the universal puller plate to
support the inner race of the bearing while removing it.

70699

a - Universal Puller Plate (91-37241)

b - Tapered Roller Bearing
c - Drive Shaft

Page 6B-50 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Assemble a new tapered roller bearing to the drive shaft with the large O.D. of the bear-
ing facing the pinion gear end of the drive shaft.
2. Press the tapered roller bearing onto the drive shaft using the universal puller plate and
a suitable mandrel, (an old tapered roller bearing inner race).

a c

70700

a - Universal Puller Plate (91-37241)

b - Tapered Roller Bearing
c - Suitable Mandrel (Inner Race of Old Bearing)
Propeller Shaft Assembly
REMOVAL

CAUTION
Hold onto the propeller shaft assembly in the following step to avoid personal injury
and/or dropping components when turning the gear housing over.
1. While holding onto the propeller shaft, turn the gear housing over so that the bore open-
ing is facing down.
2. While moving the propeller shaft to the left (port) side of the gear housing, to allow the
shift spool to disengage from the shift crank, lower the propeller shaft out of the gear
housing.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

NOTE: The rollers of the reverse gear bearing adaptor may become dislodged while remov-
ing the propeller shaft assembly. If this occurs, inspect the bearing cage to see if it has been
damaged. If it has not been damaged simply snap the rollers back into position. If it has been
damaged it will be necessary to remove and replace the bearing as outlined in the Reverse
Gear Bearing Adaptor Assembly, ‘Component Disassembly and Reassembly’ section.

c b

50887

a - Propeller Shaft Assembly

b - Shift Spool
c - Shift Crank
3. Locate and retain the thrust race and thrust bearing which could be on top of the reverse
gear (if not, they may be stuck to the reverse gear bearing adaptor).

50887

a - Thrust Bearing and Race

Page 6B-52 90-855348R02 NOVEMBER 2002

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COMPONENT DISASSEMBLY
IMPORTANT: When accomplishing the next step, all of the parts are free to come
apart. Work closely over a work bench to ensure that the parts are not dropped or
damaged, and to avoid personal injury.
1. Remove the spring around the clutch being careful not to overstretch it during removal.
If the spring does not coil back to its normal position once it has been removed, it must
be replaced (ratcheting assembly shown).

a
b

d c
50885

a - Spring
b - Shift Spool Assembly
c - Reverse Gear Assembly
d - Sliding Clutch

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Remove detent pin.

3. Remove the cross pin that goes through the clutch dog. Remove the reverse gear and
slide the clutch off of the propeller shaft.

e
50885

d
b c 50881
a - Cross Pin
b - Clutch
c - Reverse Gear Assembly
d - Spool
e - Detent Pin

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT INSPECTION
1. Clean all the parts with a suitable solvent and dry the parts thoroughly using compressed
air, being careful not to spin bearings.
2. Inspect the sliding clutch jaws for damage. Jaws must not be chipped or rounded off.
Replace the clutch if they are (ratcheting assembly shown).

23350

a - Jaws
3. Inspect the bearing surfaces on the propeller shaft where the needles of the bearing car-
rier needle bearing and the needles of the forward gear needle bearing roll. Replace the
propeller shaft if it is pitted, grooved, scored, worn unevenly, discolored from overheat-
ing, or has embedded particles.
a b

50698
c

a - Bearing Carrier Needle Bearing Contact Area

b - Reverse Gear Needle Bearing Contact Area
c - Splines
4. Inspect the propeller shaft splines at both ends for a broken, worn, or twisted condition.
Replace the propeller shaft if any of these conditions exists.
5. Inspect the surface of the propeller shaft where the bearing carrier seal lips contact the
shaft. If the oil seals have made grooves, replace propeller shaft and seals.

50698

a - Bearing Carrier Seal Contact Area

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Inspect the propeller shaft for a bent condition.

V-Blocks and Dial Indicator
a. Position the propeller shaft bearing surfaces on V-blocks.
b. Adjust the height of V-blocks to level the propeller shaft.
c. Position the dial indicator tip just forward of the propeller shaft splines.

a
52727

a - Check Movement with Dial Indicator (91-58222A1) Here

7. Rotate the propeller shaft and observe the dial indicator movement. If the indicator in
the dial moves more than 0.009 in. (0.23mm), replace the propeller shaft.
Reverse Gear Assembly
COMPONENT INSPECTION
1. Clean the reverse gear assembly with a suitable solvent and dry thoroughly with com-
pressed air. Be careful not to spin the bearings.
2. Inspect the gear for pitting, chipped or broken teeth, hairline fractures, and excessive
or uneven wear. Replace the reverse gear if any defects are found.
3. Inspect the clutch jaws of the gear for damage. The surfaces must not be chipped or
rounded off. Replace the reverse gear if any of these conditions exist.
a

23351

a - Reverse Gear Teeth

b - Clutch Jaws

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NOTE: The needle bearing in the reverse gear should not be removed unless damage has
been found. Inspect to ensure that all of the needles are present and in position. The needles
may have become dislodged while removing the gear from the propeller shaft (and/or while
removing the propeller shaft assembly from the gear housing). They may be snapped back
into place as long as no damage has occurred to the bearing cage.
4. Inspect the needle bearings on the inside of the reverse gear and the bearing surface
on the propeller shaft. If either the needle bearings, or the bearing surface of the propel-
ler shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has
embedded particles, replace the propeller shaft and remove and replace the needle
bearing in the reverse gear as outlined in the next section.
a

50698

a - Forward Gear Needle Bearing Contact Area

COMPONENT DISASSEMBLY
NOTE: Complete the instructions in this section only if the needle bearing in the gear has
been found to be defective and the reverse gear is to be reused. Bearings that have become
dislodged may be snapped back into position. If this is the only problem that exists it is not
necessary to replace the needle bearing.
1. Press the reverse gear needle bearing out using suitable mandrel.
a

50778

a - Reverse Gear Needle Bearing

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
IMPORTANT: The appearance of the forward and reverse gear is almost identical.
Identify individual gears by measuring outside diameter of gear face.

a b

3.75 in. (9.5 cm) 4.10 in. (10.4 cm) 50885

a - Reverse Gear
b - Forward Gear

a
REVERSE FORWARD
b

3.75″ (9.5cm)
50885
1997/1998/1999 Models
a - Reverse Gear is Smaller in Diameter for 97/98/99 Models
b - No Groove in Reverse Gear for 97/98/99 Models

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Press the needle bearing into the reverse gear.

50789

a - Reverse Gear
b - Needle Bearing
c - Bearing Driver (91-816244)(Ratcheting gear cases)
Bearing Driver (91-86943) (Non-Ratcheting gear cases)
Shift Spool Assembly
INSPECTION
1. Clean the assembly with a suitable solvent and dry the parts using compressed air.
2. Inspect the shift spool assembly for damage. Small nicks and burrs may be smoothed.
If any parts are damaged or worn beyond repair it will be necessary to replace the com-
plete shift spool assembly. Individual parts are not available for the assembly.
3. Inspect the shift spool for wear in the area where the shift crank comes into contact.

a
b

23356

a - Contact Area
b - Ratcheting Shift Spool

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

a
b

55694
a - Contact Area
b - Non-Ratcheting Shift Spool
4. Inspect to insure that the spool spins freely (it may be helpful to lightly tap the forward
[castle nut] end of the shift spool shaft against a firm surface to align the internal parts).
5. Inspect to insure that the spool has no more than 0.002-0.010 (0.05-0.25 mm) end play.

.002 (0.05mm)
to
.010 (0.25mm)

a
23142
a - Ratcheting Spool

.002 (0.05mm)
to
.010 (0.25mm)

55694
a - Non-Ratcheting Spool

Page 6B-60 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT DISASSEMBLY - (RATCHETING)

NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts of
the assembly due to an improperly functioning shift spool assembly or debris in the gear
housing and/or shift spool assembly. Individual components for the shift spool are not avail-
able as replacement parts. If the shift spool does not function properly (see the preceding
Shift Spool Assembly - Inspection section) and the following cleaning and adjustment proce-
dures do not produce the desired results, it will be necessary to order a new shift spool as-
sembly.
Disassemble the shift spool assembly as follows:
1. Remove and discard the cotter pin.
2. Remove the castle nut and the spool.
3. Clamp the spool in a vice being careful not damage the spool.
4. Remove the retainer by unscrewing it with a pair of pliers.
5. Remove the two washers and the spring.

COMPONENT DISASSEMBLY - (NON-RATCHETING)

NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts of
the assembly due to an improperly functioning shift spool assembly or debris in the gear
housing and/or shift spool assembly. Individual components for the shift spool are not avail-
able as replacement parts. If the shift spool does not function properly (see the preceding
Shift Spool Assembly - Inspection section) and the following cleaning and adjustment proce-
dures do not produce the desired results, it will be necessary to order a new shift spool as-
sembly.
Disassemble the shift spool assembly as follows:
1. Remove and discard the cotter pin.
2. Remove the castle nut and the spool.

COMPONENT INSPECTION
1. Clean all components with a suitable solvent and dry them with compressed air.
2. Inspect each component for wear or damage. If any components are worn beyond re-
pair, damaged, or broken it will be necessary to replace the complete shift spool assem-
bly. Small nicks or burrs may be smoothed and the parts reused.

COMPONENT REASSEMBLY - (RATCHETING)

Assemble the shift spool and shift spool shaft as follows:
1. Place the shift spool onto the shift spool shaft.
2. Assemble the first washer, then the spring, then the second washer into the shift spool.
3. Apply Loctite 271 Thread Locker to the first three threads of the spool. Thread the retain-
er onto the spool and tighten the retainer securely with a pair of pliers.
4. Assemble the castle nut and screw it down until it touches the washer and a slight resis-
tance is felt.
5. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole in
the shaft. If, when the castle nut is screwed down, the cotter pin slot is already aligned
at the hole in the shaft, back the castle nut off until the next available slot in the nut is
aligned with the hole in the shaft.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Insert a new cotter pin and bend ends of the cotter pin in opposite directions.

23356

e a g
7 f

b
d c
7 Loctite 271 Thread Locker 23142

a - Washers (2)
b - Spring
c - Retainer
d - Spool
e - Shift Shaft
f - Castle Nut
g - Cotter Pin

COMPONENT REASSEMBLY - (NON-RATCHETING)

Assemble the shift spool and shift spool shaft as follows:
1. Place the shift spool onto the shift spool shaft.
2. Assemble the castle nut and screw it down until it touches the washer and a slight
resistance is felt.
3. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole in
the shaft. If, when the castle nut is screwed down, the cotter pin slot is already aligned
at the hole in the shaft, back the castle nut off until the next available slot in the nut is
aligned with the hole in the shaft.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Insert a new cotter pin and bend ends of the cotter pin in opposite directions.
d

a b c 55694

a - Shift Spool Shaft

b - Shift Spool
c - Castle Nut
d - Cotter Pin

ADJUSTMENT
NOTE: If the shift spool assembly has been disassembled and reassembled (as in the pre-
vious two sections) skip the following instructions, (1 through 4).
NOTE: If the shift spool assembly has not been disassembled and reassembled, do all of
the following steps.
1. Remove and discard the cotter pin.
2. Screw the castle nut down until it touches the washer and a slight resistance is felt.
3. Loosen the castle nut until the cotter pin slot of the castle nut is aligned with the hole in
the shaft. If, when the castle nut is screwed down, the cotter pin slot is not aligned at the
hole in the shaft, back off the castle nut until the next available slot in the nut is aligned
with the hole in the shaft.
4. Insert a new cotter pin and bend ends in opposite directions.
5. Inspect to insure that the spool spins freely (it may be helpful to lightly tap the forward
[castle nut] end of the shift spool shaft against a firm surface to align the internal parts).
6. Inspect to insure that the spool has no more than 0.002-0.010 (0.05-0.25 mm) end play,
if it does adjust the castle nut once again as outlined previously.

0.002 (0.05mm)
to
0.010 (0.25mm)

23142
a - Ratcheting Type Spool
b - Non-Ratcheting Type Spool

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

7. If this adjustment did not produce the desired results it will be necessary to disassemble,
clean, and reassemble the shift spool assembly. If the spool assembly has already been
disassembled and cleaned it will be necessary to replace the shift spool assembly.
Reverse Gear Bearing Adaptor Assembly
REMOVAL
Remove the reverse gear bearing adaptor using the tools as shown. Remove, measure and
make note of the shim thickness. If the shims are not damaged, they may be reused.

a d
b c

e
f

50780

a - Bolt (91-31229)
b - Nut (11-24156)
c - Guide Plate (91-816243)
d - Washer (91-34961)
e - Puller Head (from Slide Hammer Puller Kit 90-34569A1)
f - Jaws (91-816242)

INSPECTION
1. Thoroughly clean the reverse gear bearing adaptor with a suitable solvent and dry it us-
ing compressed air.
NOTE: The condition of the bearing surfaces on the reverse gear in the areas that the bear-
ings of the bearing adaptor and the thrust bearing rides, is an indication of the condition of
the respective bearings. Replace the bearing if the surface of the gear and/or the thrust
washer is pitted, grooved, scored, worn unevenly, discolored from overheating or has em-
bedded metal particles.
2. Assemble the reverse gear, the thrust bearing, and the thrust race, to the bearing adap-
tor. Inspect them for excessive movement or roughness by rotating the gear in the adap-
tor. Replace the bearing in the adaptor and/or the thrust bearing if either of these condi-
tions exist.
3. Inspect the adaptor for other signs of excessive wear or damage. Replace the adaptor
if any are found.

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REVERSE GEAR BEARING ADAPTOR ASSEMBLY - COMPONENT DISASSEMBLY AND

REASSEMBLY
NOTE: Complete the instructions in this section only if the needle bearing in the bearing
adaptor is defective and the adaptor is to be reused.
1. Disassemble the adaptor as follows:
a. Remove the bearing from the adaptor using a suitable mandrel.
b. Discard the bearing.
2. Assemble the adaptor as follows:
a. Lubricate the bore that the needle bearing is to be pressed into with 2-4-C with Tef-
lon.
b. Position the needle bearing on the adaptor with the numbered end of the bearing
facing the driver shoulder.
c. Press the needle bearing into the bearing adaptor using a suitable mandrel until the
bearing is flush with the face of the adaptor.

95
b
c

50790
95 2-4-C With Teflon

a - Reverse Gear Bearing Adaptor

b - Suitable Mandrel
c - Bearing

90-855348R02 NOVEMBER 2002 Page 6B-65

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Shift Shaft Assembly

REMOVAL
NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank
inside the gear case) without removing any of the internal components of the gear housing.
1. Remove the shift shaft bushing screws, and remove the shift shaft and bushing by pull-
ing them straight out of gear housing.

a a

70494

a - Shift Shaft Bushing Screws

2. Remove the shift crank from the inside of the gear housing. Clean it with a suitable sol-
vent and dry it thoroughly. Inspect it for wear in the areas that contact the shift spool and
inspect the splines and the diameter that goes over the locating pin for damage or exces-
sive wear.

c d
23350

a - Contact Area
b - Shift Crank
c - Splines
d - Diameter for Locating Pin

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT DISASSEMBLY AND INSPECTION

1. Slide the bushing assembly off of the straight end of the shift shaft. Remove the coupler
from the shaft.

a c

b 70616

a - Shift Shaft Bushing

b - O-rings (2)
c - Coupler
d - Shift Shaft
2. Clean all components with a suitable solvent and dry thoroughly with compressed air.
a. Inspect the shift shaft bushing for cracking, damage, or excessive wear.
b. Inspect the seal inside the bushing, the sleeve, and the O-rings on the outside of the
bushing for damage or excessive wear.
c. Inspect the speedometer connector for damage or blockage.
If any of these conditions exist, replace the appropriate components. The oil seal is a
replaceable component.

a 70617

a - Shift Shaft Bushing

b - Seal (Lips Face Up)
c - Speedometer Tube Connector
3. Inspect the shift shaft splines and seal surface for corrosion and/or excessive wear. Re-
place the shift shaft if either if these conditions are found.

b a

a - Seal Surface
b - Spline

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

COMPONENT REASSEMBLY
NOTE: Complete the instructions in this section only if the assembly components have been
disassembled and repaired or replaced.
1. Lightly lubricate the seats of the O-ring diameters on the bushing and the lip of the oil
seal with 2-4-C with Teflon.
2. If the speedometer connector was removed and/or replaced, lightly coat the threads of
the connector with Perfect Seal (91-34277-1). Assemble the speedometer connector
to the bushing and torque the connector to 4.5 lb. in. (0.5 Nm).
3. Assemble all components as shown below.

c b
95
d
19

e
f
g h

g
70616
a

19 Perfect Seal (92-34227-1)

95 2-4-C With Teflon

a - Shift Shaft
b - Rubber Washer
c - Seal (Lip Faces Up)
d - Speedometer Connector
e - Bolt (2 ea.) [Torque to 60 lb. in. (6.8 Nm)]
f - Bushing
g - O-Rings (2 ea.)
h - Coupler

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Pinion Bearing
REMOVAL
NOTE: Inspect the bearing surface on the drive shaft where the needles of the lower pinion
bearing roll. The condition of the drive shaft at this location give an indication of the condition
of the needle bearing. Replace lower pinion bearing (needles and race as a set) if the drive
shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has em-
bedded particles.
IMPORTANT: All the needle bearings (18) MUST BE in place inside bearing race while
driving the pinion bearing from the gear housing.
IMPORTANT: Do not reuse the bearing (race or rollers) once it has been removed.
Remove and discard the pinion bearing (race and rollers) using tools as shown.

d
c

70614

a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Housing Reassembly

Gear Housing Inspection
1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush. Dry
the gear housing using compressed air. Ensure that all sealants, locking agents and de-
bris are removed.
2. Verify the 2 oil circulation holes in the drive shaft bore and shift shaft hole are clear and
free of debris.
3. Inspect the gear housing for excessive corrosion, impact or any other damage. Exces-
sive damage and/or corrosion requires replacement of the gear housing.
4. Inspect the bearing carrier retainer threads in the gear housing for corrosion and/or
stripped threads. Excessive damage to the the threads requires replacement of the gear
housing.
5. Inspect bearing race/cup contact areas for evidence of bearing cup spinning. Check that
bearing cups are not loose in bearing bores. Any one bearing bore in which the race/cup
is loose will require replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the speedometer hole, clean as necessary.
Be careful not to enlarge the speedometer hole as this could cause erroneous speedom-
eter readings.
7. Verify that the locating pins are in place in the gear housing and that the corresponding
holes in the drive shaft housing are not elongated. The drive shaft may break if the hous-
ings are not aligned properly due to missing locating pins or elongated holes.
Pinion Bearing
INSTALLATION
IMPORTANT: Install only a NEW pinion bearing (race and rollers). Do not reinstall a
pinion bearing that has been previously removed from a gear housing.
1. Lubricate the bore into which the pinion bearing is to be installed with Premium Gear
Lubricant .
2. Position the new pinion bearing (with the cardboard shipping sleeve in place) onto the
driver head, with the lettered and numbered side of the bearing oriented upward.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Insert the driver with the bearing assembly, into position (by way of the propeller shaft
bore) at the drive shaft bore as shown.

c
e d

fa
g

82

82 Premium Gear Lubricant 70615

a - Drive Shaft Pinion Bearing (with cardboard sleeve)

b - Driver Head (91-38628)
c - Puller Shaft (91-31229)
d - Washer (12-34961)
e - Nut (11-24156)
f - Pilot Washer (91-36571)
g - Puller Plate (91-29310)
4. Install the bearing by screwing down the nut until the bearing is fully seated against the
bore shoulder.
Reverse Gear Bearing Adaptor Assembly
INSTALLATION
NOTE: If the reverse gear, reverse gear adaptor, large thrust bearing, or bearing race in the
gear housing were not replaced, install the same shims (or the same thickness of shims that
were taken out when adaptor was removed. If the reverse gear, reverse gear adaptor, large
thrust bearing, bearing race, or gear housing were replaced, install 0.008 in. (0.51 mm) of
shims.
1. Lubricate the bore into which the reverse gear bearing adaptor is to be installed with
2-4-C with Teflon.
2. Place the shims into reverse bore of gear housing.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Position the bearing adaptor in the gear housing.

95
50781
95 2-4-C With Teflon

a - Bearing Adaptor
b - Shims
IMPORTANT: The appearance of the forward and reverse gear is almost identical.
Identify individual gears by measuring outside diameter of gear face.
a b

3.75 in. (9.5 cm) 4.10 in. (10.4 cm) 50885

a - Reverse Gear
b - Forward Gear
a
REVERSE FORWARD
b

3.75″ (9.5cm)
50885
1997/1998/1999 Models
a - Reverse Gear is Smaller in Diameter for 97/98/99 Models
b - No Groove in Reverse Gear for 97/98/99 Models

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Position the reverse gear (without the thrust race or thrust bearing) into the gear housing
and into the adaptor.

50781

a - Reverse Gear

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

5. Press the bearing adaptor into the gear housing using the installation tool as follows:
IMPORTANT: Be sure that the bearing adaptor is positioned as straight as possible
to avoid cocking it in the bore while pressing it in.
a. Lubricate the threads of the installation tool with 2-4-C with Teflon.
b. Turn the hex-head screw of the installation tool until the bearing adaptor bottoms out
on the gear housing shoulder. DO NOT continue to turn the tool once the screw re-
sistance goes up noticeably.

95

50791
95 2-4-C With Teflon

a - Hex-Head Screw
b - Bearing Adaptor Installation Tool (91-18605A1)
c - Reverse Gear
c. Remove the installation tool and the reverse gear.

Page 6B-74 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Shift Shaft Assembly

INSTALLATION
1. Place the shift crank onto the locating pin in the forward section of the gear housing. En-
sure that the shift crank faces towards the left (port) side of the gear housing.

a
b
50314
a - Shift Crank
b - Locating Pin
2. Install the shift shaft assembly into the gear housing. Engage the splined end of the shift
shaft with the shift crank. Verify O-rings are positioned properly and lubricated with
2-4-C with Teflon. Secure shift shaft bushing with 2 screws. Torque screws to 60 lb. in.
(6.8 Nm).

95
a

70620
95 2-4-C With Teflon

a - Shift Shaft Assembly

b - Screws [Torque to 60 lb. in. (6.8 Nm)]

90-855348R02 NOVEMBER 2002 Page 6B-75

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

NOTE: If the pinion bearing needle bearings have fallen out, install 18 needles into needle
bearing outer race. Use 2-4-C with Teflon, to help hold needles in place.

95

23142
95 2-4-C With Teflon

a - Rollers (18)
b - Roller Bearing Outer Race

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Gear Location/Backlashes Checking and Adjustment

Reverse Gear
INSTALLATION (FOR CHECKING BACKLASH ONLY)
1. Lubricate the large reverse gear thrust bearing with Premium Gear Lubricant and posi-
tion first the thrust race, then the bearing into the gear housing and onto the reverse gear
bearing adaptor.

82
a

50882
82 Premium Gear Lubricant

a - Thrust Bearing
b - Thrust Race
c - Reverse Gear Bearing Adaptor

90-855348R02 NOVEMBER 2002 Page 6B-77

GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

IMPORTANT: The appearance of the forward and reverse gear is almost identical.
Identify individual gears by measuring outside diameter of gear face.

a b

3.75 in. (9.5 cm) 4.10 in. (10.4 cm) 50885

a - Reverse Gear
b - Forward Gear

a
REVERSE FORWARD
b

3.75″ (9.5cm)
50885
1997/1998/1999 Models
a - Reverse Gear is Smaller in Diameter for 97/98/99 Models
b - No Groove in Reverse Gear for 97/98/99 Models
2. Install the reverse gear into the gear housing and into the reverse gear bearing adaptor.

a
cb

d
50884

a - Reverse Gear
b - Thrust Bearing
c - Thrust Race (under Bearing)
d - Reverse Gear Bearing Adaptor

Page 6B-78 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Drive Shaft and Pinion Gear

INSTALLATION (FOR CHECKING GEAR LOCATION AND BACKLASHES ONLY)
NOTE: If the original shims were not retained or if pinion gear, drive shaft, drive shaft tapered
roller bearing and cup, or gear housing were replaced, start off by installing a 0.038 in. (0.96
mm) shims.
NOTE: If the original shims were retained (or measurement known) and none of the above
listed parts were replaced, reinstall the original shims (or an amount of shims equal to the
original shims).
1. Place the shims into the drive shaft housing bore at the location shown.

70620

a - Shims

NOTE: For ease of installation, glue the washer to the pinion gear, using 3M Adhesive
(92-25234), or Bellows Adhesive (92-86166), or equivalent.
2. Apply Loctite 271 Thread Locker to the threads of the pinion nut and position the pinion
gear nut in the MR slot of the pinion nut adapter.
NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear.
3. Place the pinion gear (with the washer glued to it) into the gear housing.
4. Insert the drive shaft into the gear housing drive shaft bore. It may be necessary to rotate
the drive shaft to engage the drive shaft splines into the pinion gear splines.
5. Temporarily install the propeller shaft (without the sliding clutch installed) into reverse
gear.
6. Insert the pinion nut adaptor (with the nut) into the gear housing. It may be necessary
to raise the drive shaft slightly to clear the tool.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

7. Start the pinion nut onto the drive shaft threads by rotating the drive shaft until the nut
is snug.

b 70891
a - Pinion Gear (with the washer glued to it)
b - Pinion Nut Adaptor (91-61067A3)
c - Drive Shaft
8. Install the drive shaft tapered roller bearing cup followed by the retainer.

70890
a - Tapered Roller Bearing Cup
b - Drive Shaft Retainer
9. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and
the pinion nut adaptor in position.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

10. Torque the pinion nut by turning the drive shaft using the drive shaft nut wrench and
torque wrench with the appropriate socket to 75 lb. ft. (101.7 Nm).

a
70892

a - Pinion Nut Adaptor (91-61067A2)

b - Drive Shaft Nut Wrench (91-56775)
c - Bearing Carrier (installed backwards)
11. Remove bearing carrier, pinion nut adaptor and drive shaft nut wrench.
12. Torque retainer to 100 lb. ft. (135.6 Nm).

70711
a - Drive Shaft Bearing Retainer Wrench (91-43506)
13. Remove retainer wrench.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Drive Shaft - Bearing Preload Tool

INSTALLATION
NOTE: Ensure that the top nut and the bottom nut of the bearing preload tool are screwed
as close together as possible prior to proceeding with the following step.
1. Install the components from the Bearing Preload Tool Kit (91-14311A1), over the drive
shaft in the order shown.

a
b

d
e
d

f
g
70496

a - Top Nut with Threaded Pipe

b - Nut
c - Spring
d - Thrust Washer (2 Required) (12-18448)
e - Thrust Bearing
f - Thrust Washer
g - Water Pump Face Plate (from your gear housing)
2. Pull up on the drive shaft and tighten the two (2) allen screws in the top nut of the bearing
preload tool.

a
a

70716

a - Allen Screws

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Measure distance (a) and increase that distance by 1 in. (25.4mm) by turning bottom
nut away from top nut.

a
b

70893
a - Measure distance and increase by 1 in. (25.4mm)
b - Bottom Nut [screwed down by approximately 1 in. (25.4mm)]
4. Rotate the drive shaft at least three full turns in a clockwise direction.
Checking Pinion Gear Location
Pinion Gear Location Specification: .025 in. (0.64 mm)
1. Place the pinion gear shimming tool into the gear housing.
NOTE: Take the following measurements at 3 locations, rotating the drive shaft 120 degrees
between each reading (always rotate the drive shaft in a clockwise direction).
2. Insert the thickest feeler gauge that fits snugly between one tooth of the pinion gear and
high point of the shimming tool.
b

24643
a - Pinion Gear Shimming Tool 91-12349A2 Using Disc #2 and Flat #4
b - 0.025 in. (0.64mm) Feeler Gauge
3. Rotate the drive shaft 120 degrees in a clockwise direction and take another reading.
4. Repeat this process until 3 readings have been taken.
5. Add the three readings together and divide the sum by 3 to get the average pinion gear
height.
6. A. If the (average) pinion gear location does not meet the specification of 0.025 in. (0.64
mm) continue with the instructions on the following section.
B. If the (average) pinion gear location meets specification, skip the following section
and go on to the Reverse Gear Backlash, ‘Checking’ section.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Drive Shaft - Bearing Preload Tool Removal

CAUTION
Before loosening the top nut allen screws of the bearing preload tool, screw the bot-
tom nut up as close as possible to the top nut.
1. Screw the bottom nut of the bearing preload tool until it is as close as possible to top nut.
2. Loosen the allen screws in the top nut.
3. Remove all components including the water pump face plate.

70716

a - Top Nut (with allen screws)

b - Bottom Nut
c - Water Pump Face Plate

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Adjusting Pinion Gear Location

NOTE: Adding 0.001 in. (0.03mm) shims will increase the gear location by 0.001 in.
(0.03mm). Subtracting 0.001 in. (0.03mm) will decrease the gear location by 0.001 in.
(0.03mm).
1. Remove the drive shaft retainer and the drive shaft tapered roller bearing cup. (The cup
can be removed by wiggling the drive shaft back and forth or by turning gear housing
over and shaking it.) Add or subtract shims beneath the cup to obtain the proper average
pinion gear height.
2. Install the drive shaft tapered roller bearing cup, then the retainer.

70890

a - Tapered Roller Bearing Cup

b - Drive Shaft Retainer
3. Torque the retainer to 100 lb. ft. (135.6 Nm).

70711

a - Drive Shaft Bearing Retainer Wrench (91-43506)

4. Reinstall the drive shaft bearing preload tool as outlined in the Drive Shaft - Bearing Pre-
load Tool, ‘Installation section.
5. Recheck the pinion gear height as outlined in the Pinion Gear Location, ‘Checking’ sec-
tion.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Checking Reverse Gear Backlash

Reverse Gear Backlash Specification: 0.040-0.060 in. (1.01mm-1.5 mm).
NOTE: If the bearing preload tool has not already been set up see Drive Shaft - Bearing Pre-
load Tool, ‘Installation’ section first.
NOTE: The reverse gear bearing adaptor installation tool is used to apply a light preload
to the reverse gear in the following steps.
1. Install the reverse gear bearing adaptor installation tool into the gear housing to hold the
reverse gear against the thrust bearing as follows:
a. Assemble the reverse gear bearing adaptor installation tool into the gear housing
and tighten it by hand until a slight resistance is felt.
b. Torque the adaptor’s driver bolt to 45 lb. in. (5.1 Nm).

a
b

70973
a - Torque Wrench (91-66274)
b - Driver Bolt
c - Bearing Adaptor Installation Tool (91-18605A1)
d - Reverse Gear

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Install a dial indicator as shown in the following figure.

f, g
e
d

b
c

70717
a - Nuts (4) (obtain locally)
b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]
c - Dial Indicator Holding Tool (91-89897)
d - Dial Indicator (91-58222A1)
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 or 1.75:1)
g - Backlash Indicator Rod (91-78473) (for 1.87:1)
3. Align the dial indicator pointer so that it is perpendicular to and touching the “I” mark on
the dial indicator tool. Tighten the indicator tool onto the drive shaft and rotate the drive
shaft so that the needle in the dial makes at least one full revolution and comes to the
“0” mark on the dial indicator scale.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Take the backlash readings by lightly turning the drive shaft back and forth, so as to feel
the backlash between the gears.
a. Observe the dial indicator and record the reading.
b. Loosen the indicator tool and rotate the drive shaft 90 degrees in a clockwise direc-
tion.
c. Repeat step 3 an 4 above until a total of 4 backlash readings have been taken.
5. Add the four readings together and divide the sum by four. This is your average backlash
and it should be 0.040 in. - 0.060 in. (1.0mm - 1.5mm) (for 1.64:1, 1.75:1 and 1.87:1 ra-
tios).
NOTE: If backlash needs to be adjusted, (see Checking Reverse Gear Backlash), adding
0.001 in. (0.03 mm) shims will reduce the gear backlash by approximately 0.001 in.
(0.03mm). Subtracting 0.001 in. (0.03mm) shims will increase backlash by approximately
the same amount.

Example 1 (if backlash is too high)

Backlash checks: .070 in. (1.79 mm)

(subtract) middle
of .050 in. (1.27 mm)
specification:
You get: .020 in. (0.50 mm)

add this quantity of shims

Example 2 (if backlash is too low)

middle of specification: .050 in. (1.27 mm)

Backlash checks: .020 in. (0.50 mm)

(subtract) You get: .030 in. (0.76 mm)

subtract this quantity of shims

Page 6B-88 90-855348R02 NOVEMBER 2002

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Forward Gear/Bearing Carrier Assembly

CHECKING FORWARD GEAR BACKLASH – (RATCHETING)
NOTE: If backlashes have already been checked and they are to specification, proceed with
Bearing Carrier Assembly, ‘Final Installation’ section.
1. Install the appropriate spacer shim into the gear housing.

55428
a - Shim
2. Temporarily install the propeller shaft (without sliding clutch installed) into the reverse
gear. Position the shift crank so propeller shaft will rest on the crank.
3. Lubricate the thrust bearing with Premium Gear Lubricant and place it onto the forward
gear.

a
82

b 50785
82 Premium Gear Lubricant

a - Thrust Bearing
b - Forward Gear

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Place the thrust race on top of the thrust bearing with the wide flat side against the
thrust bearing.

50785

a - Thrust Race
b - Wide Flat Side
5. Install a load washer (12-37429) over a propeller shaft (44-93003) so that it seats
against the REAR shoulder of the clutch spline teeth.

c 55088
a

a - Load Washer (12-37429)

b - Shoulder
c - Propeller Shaft (44-93003)
6. Install propeller shaft with load washer into gear housing.

55623
a - Propeller Shaft (44-93003)
b - Load Washer (12-37249

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7. Assemble the forward gear installation tool to the forward gear, then place it down over
the propeller shaft. Ensure that the thrust race seats evenly onto the shim. Tap the thrust
race down lightly with a soft tool, do not damage the thrust race surface.

b
d

55624
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear
c - Spacer Shim
d - Load Washer (12-37429)
e - Thrust Race
8. Install the forward gear bearing adaptor using a hook tool (which was fashioned when
the adaptor was removed) as shown. Ensure that the adaptor seats evenly against the
thrust race.

55430
a - Hook Tool
b - Forward Gear Installation Tool (91-815850)
c - Forward Gear Bearing Adaptor
d - Thrust Race

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9. Remove the hook tool and while holding down on the forward gear remove the forward
gear installation tool.

55430
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear Bearing Adaptor
c - Forward Gear
10. Install the bearing carrier over the propeller shaft pushing bearing carrier down until it
is fully seated.

55429

a - Propeller Shaft
b - Bearing Carrier

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11. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing.
Install the tab washer with the external tab inserted into the hole in the gear housing.

b
50779

a - Gear Housing Tab Washer Alignment Groove

b - Alignment Tab of Tab Washer
12. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.

70714

a - Tab Washer
b - “V” Tab

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13. Lubricate the bearing carrier retainer threads with 2-4-C with Teflon. Start the retainer
into the gear housing threads and screw it down fully by hand.

95

50881
95 2-4-C With Teflon

a - Bearing Carrier Retainer

14. Torque the bearing carrier retainer to 210 lb. ft. (284.7 Nm) to seat forward gear assem-
bly in gear case.

23355
a - Bearing Carrier Retainer Wrench (91-61069)
NOTE: Drill a 3/8″ (22.2mm) diameter hole through the side (PROPELLER NUT END) of
a 5″ x 2″ (127mm x 50.8mm) long piece of PVC pipe. A screwdriver may be inserted through
pipe into propeller shaft splines to prevent PVC pipe from turning while tightening retaining
nut.

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15. Install a 5″ x 2″ (127mm x 50.8mm) long piece of PVC pipe (obtain locally) over propeller
shaft and secure it against the bearing carrier with a flat washer and nut.

a d f h

g
c e j k
b i 51882
a - Prop Nut
b - Flat Washer
c - PVC Pipe [5″ x 2″ (127mm x 50.8mm)]
d - Retainer
e - Tab Washer
f - Bearing Carrier
g - Prop Shaft
h - Bearing Adaptor
i - Shim
j - Forward Gear
k - Load Washer
16. Tighten nut to 45 lb. in. (5.1 N·m). This will seat the forward gear against the forward
thrust bearing and tends to hold the propeller shaft from moving when measuring back-
lash.

CHECKING FORWARD GEAR BACKLASH – NON-RATCHETING

1. Install the appropriate spacer shim into the gear housing.

55428
a - Shim

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Apply Premium Gear Lubricant to thrust bearing and install thrust bearing and thrust
race onto forward gear bearing adaptor.

82
c

55220

82 Premium Gear Lubricant

a - Bearing Adaptor
b - Thrust Washer
c - Thrust Bearing
3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor as-
sembly.

55221

a - Forward Gear Installation Tool (91-815850)

b - Forward Gear/Bearing Adaptor Assembly

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4. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying
downward pressure to bearing adaptor, remove installation tool from assembly.

55431

a - Forward Gear Bearing Adaptor

5. Install the bearing carrier over the propeller shaft pushing bearing carrier down until it
is fully seated.

55429
a - Propeller Shaft
b - Bearing Carrier

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing.
Install the tab washer with the external tab inserted into the hole in the gear housing.

c
50779

a - Gear Housing Tab Washer Alignment Hole (not seen)

b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer
7. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.

70714
a - Tab Washer
b - “V” Tab

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

8. Lubricate the bearing carrier retainer threads with 2-4-C with Teflon. Start the retainer
into the gear housing threads and screw it down fully by hand.

95

50881
95 2-4-C With Teflon

a - Bearing Carrier Retainer

9. Torque the bearing carrier retainer to 210 lb. ft. (284.7 Nm) to seat forward gear assem-
bly in gear case.

23355
a - Bearing Carrier Retainer Wrench (91-61069)
NOTE: Drill a 3/8″ (22.2mm) diameter hole through the side (PROPELLER NUT END) of
a 5″ x 2″ (127mm x 50.8mm) long piece of PVC pipe. A screwdriver may be inserted through
pipe into propeller shaft splines to prevent PVC pipe from turning while tightening retaining
nut.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

10. Install a 5″ x 2″ (127mm x 50.8mm) long piece of PVC pipe (obtain locally) over propeller
shaft and secure it against the bearing carrier with a flat washer and nut.

a
d f h

g
c e j k
b i 51882
a - Prop Nut
b - Flat Washer
c - PVC Pipe [5″ x 2″ (127mm x 50.8mm)]
d - Retainer
e - Tab Washer
f - Bearing Carrier
g - Prop Shaft
h - Bearing Adaptor
i - Shim
j - Forward Gear
k - Load Washer
11. Tighten nut to 45 lb. in. (5.1 N·m). This will seat the forward gear against the forward
thrust bearing and tends to hold the propeller shaft from moving when measuring back-
lash.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Checking Forward Gear Backlash

NOTE: If the bearing preload tool has not already been set up, see Drive Shaft - Bearing
Preload Tool, ‘Installation’ section first.
1. Install a dial indicator as shown in the following figure.
e f
d

b
c

70717
a - Nuts (4) (obtain locally)
b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]
c - Dial Indicator Holding Tool (91-89897)
d - Dial Indicator (91-58222A1)
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 and 1.75:1 ratios)
Backlash Indicator Rod (91-78473 (for 1.87:1 ratio)
2. Align the dial indicator pointer so that it is perpendicular to and touching the “I” mark on
the dial indicator tool. Tighten the indicator tool onto the drive shaft and rotate the drive
shaft so that the needle in the dial makes at least one full revolution and comes to “0”
on the dial indicator scale.
3. Take the backlash readings by lightly turning the drive shaft back and forth.
a. Observe the dial indicator and record the reading.
b. Loosen the indicator tool and rotate the drive shaft 90 degrees in a clockwise
direction.
c. Repeat step 3 above and take and record another reading. Repeat step 3 until a total
of 4 backlash readings have been taken.

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4. Add the four readings together and divide the sum by 4. This is your average backlash,
which should be 0.017 in. - 0.028 in. (0.431mm - 0.711mm) (for 1.64:1; 1.75:1 and 1.87:1
ratios).
5. If backlash is MORE than the specified MAXIMUM, REMOVE shims from in front of for-
ward gear bearing race to obtain correct backlash. When reinstalling pinion nut, apply
Loctite 271 to threads of nut.
6. If backlash is LESS than the specified MINIMUM, add shims in front of forward gear
bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite 271
to threads of nut.
NOTE: By adding or subtracting 0.001 in. (0.03mm) shim, the backlash will change approxi-
mately 0.001 in. (0.03mm).
7. Remove the propeller nut, washer, and the pinion nut adaptor.
a. If the Backlash is to Specification, skip the next step (7b), and go on to step 8
following.
b. If the Backlash is not to Specification, complete the following instructions to in-
stall a different size spacer shim under the forward gear thrust race.
(1.) Remove the bearing carrier retainer, tab washer, and the bearing carrier.
(2.) Using the hook tool, remove the forward gear bearing adaptor.
(3.) Insert the forward gear installation tool into the forward gear and remove the for-
ward gear, thrust bearing and thrust race.
(4.) Remove the spacer shim.
(5.) Complete the instruction found in section Forward Gear/Bearing Carrier As-
sembly, ‘Installation - (For Checking Forward Gear Backlash)’.
(6.) Recheck backlash as outlined in the Checking Forward Gear Backlash,
section.
8. Remove the following items as outlined following:
a. Remove the bearing carrier retainer, tab washer, and the bearing carrier.
b. Using the hook tool remove the forward gear bearing adaptor.
c. Insert the forward gear installation tool into the forward gear and remove the forward
gear, thrust bearing and thrust race.
d. Remove the propeller shaft.
e. Remove the spacer shim.
f. Drive Shaft - Bearing Preload Tool, ‘Removal’ section.
g. Drive Shaft Assembly, ‘Removal’ section.
h. Remove the reverse gear.
9. Reinstall the following items as outlined in the following sections:
a. Drive Shaft and Pinion Gear, ‘Installation (For Checking Gear Location and Back-
lashes Only)’ section.
b. Drive Shaft - Bearing Preload Tool, ‘Installation’ section.

Page 6B-102 90-855348R02 NOVEMBER 2002

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Propeller Shaft Assembly

Component Reassembly
IMPORTANT: The appearance of the forward and reverse gear is almost identical.
Identify individual gears by measuring outside diameter of gear face.

a b

3.75 in. (9.5 cm) 4.10 in. (10.4 cm) 50885

a - Reverse Gear
b - Forward Gear

a
REVERSE FORWARD
b

3.75″ (9.5cm)
50885
1997/1998/1999 Models
a - Reverse Gear is Smaller in Diameter for 97/98 Models
b - No Groove in Reverse Gear for 97/98 Models

1. Assemble the sliding clutch on the propeller shaft, being sure to align cross pin holes
in the clutch with the slot in the propeller shaft. Make sure that the sliding clutch is placed
on the propeller shaft with the grooved end of the clutch facing the propeller end of the
shaft.
2. Assemble the reverse gear onto the propeller shaft.

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3. Assemble the shift spool assembly to the propeller shaft being sure to align the cross
pin hole of the shift spool shaft with the clutch slot.

a b
50881

a - Propeller Shaft
b - Sliding Clutch
c - Reverse Gear
d - Shift Spool Assembly
4. Assemble the cross pin through the sliding clutch, through the propeller shaft and
through the shift spool shaft hole.
5. Install detent pin in third hole in clutch.

d
c
e

a f
b 50885
a - Propeller Shaft
b - Sliding Clutch
c - Cross Pin
d - Reverse Gear
e - Shift Spool Assembly
f - Detent Pin

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Assemble the cross pin retaining spring over the propeller shaft and wind it around the
clutch over the cross pin hole. Be careful not to distort the spring while assembling it.
Make sure that the spring is wound on so that it does not cross over on itself and
that it lies flat against the clutch once it is assembled. If it does not lie flat against
the clutch a new spring must be installed.

b a
50885

a - Sliding Clutch
b - Propeller Shaft
c - Cross Pin Retaining Spring
Installation
1. Lubricate the large thrust bearing with Premium Gear Lubricant and position first the
thrust race then the bearing into the gear housing onto the reverse gear bearing adaptor.

82
a

c
50882
82 Premium Gear Lubricant

a - Thrust Bearing
b - Thrust Race
c - Reverse Gear Bearing Adaptor

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

2. Rotate the shift crank toward the aft end of the gear housing until it touches against the
bearing adaptor and hold it in this position.

b 50885

a - Shift Crank
b - Bearing Adaptor
IMPORTANT: Be careful when inserting the propeller shaft assembly into the gear
housing as the needle bearings in the reverse gear bearing adaptor can become dis-
lodged. If it is suspected that a needle has become dislodged, remove the propeller
shaft assembly and inspect the needle bearing cages for damage. If the cages have
not been damaged and a needle bearing is mispositioned, it can be snapped back
into place.
3. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end
of the propeller shaft assembly to the left (port) side of gear housing and begin to lower
it into the gear housing.

b
50888

a - Shift Actuating Spool

b - Shift Crank
c - Propeller Shaft Assembly
Page 6B-106 90-855348R02 NOVEMBER 2002
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4. With the propeller shaft assembly tilted to the port side of the gear housing, continue to
lower the assembly until the reverse gear hub comes into contact with the reverse gear
bearing adaptor and the propeller shaft is fully inserted into the reverse gear.

50888

a - Propeller Shaft
b - Reverse Gear Hub
c - Bearing Adaptor
5. Slowly move the propeller shaft to the center of the housing and lower the reverse gear
into the bearing adaptor. The shift spool should engage with the shift crank as the propel-
ler shaft centers itself.

c
50885

a - Reverse Gear
b - Bearing Adaptor
c - Shift Spool
d - Shift Crank

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Operate the shift shaft to ensure that it has been properly installed. The sliding clutch
should move forward when the shift shaft is turned clockwise, and should move aft when
the shift shaft is turned counterclockwise.
7. Make sure that the O-rings are present and positioned correctly. Install the screws that
secure the shift shaft bushing and torque them to 60 lb. in. (6.8 Nm).

a a

70494

a - Screws (2)
b - Shift Shaft Bushing
8. Slide the rubber sleeve at top end of shift shaft down so that it just touches the oil seal
in the bushing.

b
c

70492

a - Shift Shaft
b - Rubber Sleeve
c - Oil Seal
d - Shift Shaft Bushing

Page 6B-108 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Drive Shaft and Pinion Gear

Final Installation (Ratcheting and Non-Ratcheting)
1. Place the shims into the drive shaft housing bore at the location shown.

70620

a - Shims
NOTE: For ease of installation, glue the washer to the pinion gear, using 3M Adhesive, or
Bellows Adhesive, or equivalent.
2. Apply Loctite Type 271 Thread Locker to the threads of the NEW pinion gear NUT and
assemble the pinion gear nut into the MR slot of the pinion nut adaptor.
NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear.
3. Place the pinion gear (with the washer glued to it) into the gear housing.
4. Insert the drive shaft into the gear housing drive shaft bore. It may be necessary to rotate
the drive shaft to engage the drive shaft splines into the pinion gear splines.
5. Insert the pinion nut adaptor (with the nut assembled to it) into the gear housing. It may
be necessary to raise the drive shaft slightly to clear the tool.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Start the pinion nut onto the drive shaft threads by rotating the drive shaft until the nut
is snug.

b 7
70891
7 Loctite 271 Thread Locker

a - Pinion Gear (with the washer glued to it)

b - Pinion Nut Adaptor (91-61067A3)
c - Drive Shaft
7. Install the drive shaft tapered roller bearing cup then the retainer.

70890

a - Tapered Roller Bearing Cup

b - Drive Shaft Retainer
8. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and
the pinion nut adaptor in position.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

9. Torque the pinion nut by turning the drive shaft using the drive shaft nut wrench and
torque wrench with the appropriate socket to 75 lb. ft. (101.7 Nm).

a
70892

a - Pinion Nut Adaptor (91-61067A2)

b - Drive Shaft Nut Wrench (91-56775)
c - Bearing Carrier (installed backwards)
10. Remove the bearing carrier, pinion nut adaptor and drive shaft nut wrench.
11. Torque the retainer to 100 lb. ft. (135.6 Nm).

70711
a - Drive Shaft Bearing Retainer Wrench (91-43506)
12. Remove the retainer wrench.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Bearing Carrier Assembly

Final Installation (Ratcheting)
1. Install the appropriate spacer shim into the gear housing.

50782

a - Shim
2. Lubricate the thrust bearing with Premium Gear Lubricant and place it onto the forward
gear.

82

a
b 50785
82 Premium Gear Lubricant

a - Thrust Bearing
b - Forward Gear

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3. Place the thrust hub on top of the thrust bearing with the wide flat side against the thrust
bearing.

50785

a - Thrust Hub
b - Wide Flat Side
4. Use the Forward Gear Installation Tool (91-815850) to install the forward gear down
over the propeller shaft. Ensure that the thrust hub seats evenly onto the shim. Tap the
race down lightly using a soft punch. Do not damage the thrust race surface.

50783

a - Forward Gear Installation Tool (91-815850)

b - Forward Gear
c - Spacer Shim

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

5. Install the forward gear bearing adaptor using a hook tool (which was fashioned when
the adaptor was removed) as shown. Ensure that the adaptor seats evenly against the
thrust race.

50881

a - Hook Tool
b - Forward Gear Installation Tool (91-815850)
c - Forward Gear Bearing Adaptor
d - Thrust Race
6. Remove the hook tool and while holding down on the forward gear, remove the forward
gear installation tool.

50881
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear Bearing Adaptor
c - Forward Gear

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Final Installation (Non-Ratcheting)

1. Install appropriate spacer shim into the gear housing.

50782

a - Shim
2. Apply Gear Lubricant to thrust bearing and install thrust bearing and thrust race onto
forward gear bearing adaptor.

82 c

55220

82 Premium Gear Lubricant

a - Bearing Adaptor
b - Thrust Washer
c - Thrust Bearing

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Insert Forward Gear Installation Tool (91-815850) into forward gear/bearing adaptor as-
sembly.

55221

a - Forward Gear Installation Tool (91-815850)

b - Forward Gear/Bearing Adaptor Assembly
4. Install tool with adaptor assembly over propeller shaft and into gear housing. Applying
downward pressure to bearing adaptor, remove installation tool from assembly.

55202

a - Forward Gear Bearing Adaptor

Page 6B-116 90-855348R02 NOVEMBER 2002

 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Final Installation (Ratcheting and Non-Ratcheting)

1. Ensure that the top of the bearing adaptor is clean and install the small thrust race on
top of the bearing adaptor.

50880

a - Thrust Race
b - Forward Gear Bearing Adaptor
c - Forward Gear
2. Lubricate the small thrust bearing with Premium Gear Lubricant and install it on top of
the thrust race.

82

50783

82 Premium Gear Lubricant

a - Small Thrust Bearing

b - Forward Gear Bearing Adaptor

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

3. Assemble the thrust collar with its STEPPED SIDE DOWN toward the small thrust
bearing.

50784
a - Thrust Collar
b - Small Thrust Bearing
4. Pull up slightly on the propeller shaft to gain access to the groove on the shaft for the
keepers. Assemble the two keepers into the groove and lower the propeller shaft.

a
c b

50826
50778
a - Propeller Shaft (slightly lifted)
b - Keepers (2)
c - Thrust Collar

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

5. Install the second thrust collar with its STEPPED SIDE UP.

50787

a - Propeller Shaft
b - Thrust Collar
6. Lubricate the second thrust bearing with Premium Gear Lubricant and install it to the top
of the thrust collar.

82

50786
82 Premium Gear Lubricant

a - Thrust Bearing
b - Thrust Collar

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

7. Lubricate the second small thrust bearing race with Premium Gear Lubricant. Assemble
it to the surface inside of the bearing carrier as shown.

82

50779
82 Premium Gear Lubricant

a - Thrust Race
b - Bearing Carrier
8. Lubricate the large O-ring with 2-4-C with Teflon and assemble into the gear housing as
shown following.

95
a

95 50886
2-4-C With Teflon

a - O-ring
9. Prepare the bearing carrier for installation as follows:
a. Lubricate the outer diameter of the bearing carrier with 2-4-C with Teflon.
b. Fill the space between the carrier oil seals with 2-4-C with Teflon.
c. Lubricate the needle bearing with Premium Gear Lubricant.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

10. Install the bearing carrier assembly into the gear housing.

95
82 95

50826
82 Premium Gear Lubricant
95 2-4-C With Teflon

a - Bearing Carrier Assembly

11. Align the bearing carrier “V” shaped notch with the alignment hole in the gear housing
and then install the tab washer with the external tab inserted into the hole in the gear
housing.

70713

a - Gear Case Alignment Hole

b - “V” Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

12. Insure that the “V” shaped tab aligns with the “V” notch in bearing carrier.

70714

a - Tab Washer
b - “V” Tab
13. Fill the bearing carrier retainer nut threads and corresponding gear housing threads
(360°) with 2-4-C with Teflon. Start the retainer into the gear housing threads and screw
it down fully by hand.

95

70715
95 2-4-C With Teflon

a - Bearing Carrier Retainer

IMPORTANT: Before torquing bearing carrier retainer, gear case must be bolted to
drive shaft housing or securely fastened in a gear case holding fixture to avoid pos-
sible damage to gear housing.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

14. Torque the bearing carrier retainer to 210 lb. ft. (284.7 Nm). If one tab does not align up
in space between two of the notches, continue to tighten retainer until alignment is
achieved. DO NOT loosen retainer to achieve alignment.

23355

a - Bearing Carrier Retainer Wrench (91-61069)

15. Bend one tab aft (outward) into a space between two of the notches of the retainer. Bend
all the remaining tabs forward (inward).

c b

70490

a - Bearing Carrier
b - Tab
c - Retainer Notches
d - Alignment Tabs (Bend Inward)

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Oil Seal Carrier Assembly Installation

NOTE: Apply hand pressure only to install the oil seal carrier into position. Do not hammer
it into position.
Lubricate the oil seal carrier oil seal lips, between oil seals and O-ring with 2-4-C with Teflon
and install the oil seal carrier over the drive shaft and into the gear case.

b
95

c 95

70501
95 2-4-C With Teflon

a - Oil Seal Carrier

b - Oil Seal Lips
c - O-ring

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Water Pump Assembly Installation

NOTE: The gaskets/face plate hole pattern is not symmetrical. If the holes of the gaskets/
face plate do not align with the screw holes of the gear case and/or each other, one or more
of the parts is upside down. Determine which parts are upside down and turn the appropriate
parts over.
1. Reinstall filler block in housing, if removed.
2. Install the small hole gasket then the face plate followed by the large hole gasket onto
the gear case.

c
b
a

70720

a - Filler Block
b - Small Hole Gasket
c - Face Plate
d - Large Hole Gasket
3. Place a small amount of 2-4-C with Teflon on the flat surface of the impeller key and
install the key onto the drive shaft keyway.
IMPORTANT: When using an impeller whose blades have taken a set, face the curl of
the blades in a counterclockwise direction. DO NOT install the impeller with its
blades oriented in a reversed direction from original rotation, or premature impeller
failure will occur.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

4. Assemble the water pump impeller onto the drive shaft and down over the key.

95

b
52725
95 2-4-C With Teflon

a - Water Pump Impeller

b - Water Pump Impeller Key
5. Install the 2 water pump locating pins through the gaskets and face plate.
6. Apply a light coat of 2-4-C with Teflon to the inside of the pump cover. Position the water
pump body over the drive shaft and water pump locating pins. Rotate the drive shaft in
a clockwise direction, while pushing down on the water pump body to ease the water
pump over the impeller blades.

c
a b
95

52751
95 2-4-C With Teflon

a - Water Pump Body

b - Water Pump Alignment Pins (91-821571A1)
c - Drive Shaft (turn clockwise while installing water pump body)
7. Hand start two (2) fasteners into the water pump assembly and remove the water pump
locating pins. Install the remaining 2 fasteners. Run all fasteners down and torque to 60
lb. in. (6.8 Nm).
8. Lightly lubricate the O-rings in the water tube coupling with 2-4-C with Teflon.

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

9. Install the water tube coupling assembly to the water pump ensuring that the O-rings are
not damaged during assembly.
IMPORTANT: If seal installed above pump housing is not at the proper height, air will
be drawn into the pump resulting in overheating of the engine.
10. Using tool provided in seal kit (26-816575A2) or water pump kit (817275A3), press seal
down over drive shaft (DO NOT GREASE DRIVE SHAFT) until tool seats against pump
housing.

a
b

52724

a - Tool
b - Seal
11. If tool is not available, lightly press seal against housing until a height of 0.350 in. ± 0.030
in. (8.9mm ± 0.76mm) is obtained.

0.350 in. ± 0.030 in.

(8.9mm ± 0.76mm)

52726

a - Speedometer Connector
NOTE: Secure speedometer tube to speedometer connector with sta-strap.

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GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

Gear Lubricant Filling Instructions

1. Inspect Fill and Vent sealing washers for cuts or abrasions. Replace washers if neces-
sary.
2. Clean any metal debris from magnet on Fill plug.
IMPORTANT: Never apply lubricant to gear housing without first removing Vent
screw, or gear housing cannot be filled because of trapped air. Fill gear housing
ONLY when housing is in a vertical position.
3. Slowly fill housing through Fill hole with Premium Lower Unit Lubricant until lubricant
flows out of Vent hole and no air bubbles are visible.
4. Install Vent screw into Vent hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling Fill screw.
5. Remove grease tube (or hose) from Fill hole and quickly install Fill screw into Fill hole.
Installing Gear Housing to Drive Shaft Housing
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from en-
gine before installing gear housing into drive shaft housing.
1. Tilt engine to full up position and engage the tilt lock lever.
2. Apply a light coat of 2-4-C with Teflon onto drive shaft splines.

CAUTION
DO NOT allow lubricant on top of drive shaft. Excess lubricant, that is trapped in
clearance space, will not allow drive shaft to fully engage with crankshaft. Subse-
quently, tightening the gear housing nuts (while excess lubricant is on top of drive
shaft) will load the drive shaft/crankshaft and damage either or both the powerhead
and gear housing. Top of drive shaft is to be wiped free of lubricant.
3. Apply a light coat of 2-4-C with Teflon onto shift shaft splines. (DO NOT allow lubricant
on top of shift shaft.)
4. Insert a NEW trim tab bolt (with patch) into hole in rear of gear housing to drive shaft
housing machined surface.
5. Shift gear housing into NEUTRAL and place guide block anchor pin into NEUTRAL posi-
tion.

a
52189

a - Guide Block Anchor Pin

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 GEAR HOUSING LEFT HAND OPERATION (COUNTER ROTATION) (RATCHETING AND NON-RATCHETING)

6. Position gear housing so that the drive shaft is protruding into drive shaft housing.
7. Feed speedometer tube through opening in drive shaft housing.
NOTE: If, while performing Step 8, the drive shaft splines will not align with crankshaft
splines, lower the gear case enough to reach in and turn the drive shaft by hand slightly to
align drive shaft splines with crankshaft.
8. Move gear housing up toward drive shaft housing while aligning shift shaft splines and
water tube with water tube guide (in water pump cover).
9. Place flat washers onto studs (located on either side of drive shaft housing). Start a nut
on these studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab recess. DO NOT tighten bolt at this time.
11. Recheck shift shaft spline engagement and correct if necessary.
IMPORTANT: Do not force gear case up into place with attaching nuts.
12. Evenly tighten 2 nuts which were started in Step 9. Torque to 55 lb. ft. (74.6 Nm).
13. After 2 nuts (located on either side of drive shaft housing) are tightened, check shift oper-
ation as follows:
a. Place guide block anchor pin into FORWARD gear position. Rotate flywheel clock-
wise (viewed from top); propeller shaft should rotate counterclockwise.
b. Place guide block anchor pin into NEUTRAL position. Propeller shaft should rotate
freely clockwise/counterclockwise.
c. Place guide block anchor pin into REVERSE gear position. Rotate flywheel clock-
wise (viewed from top); propeller shaft should rotate clockwise.
IMPORTANT: If shifting operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
14. Install remaining washers and nuts onto drive shaft studs. Torque to 55 lb. ft. (74.6 Nm).
15. Torque bolt (started in Step 10) to 45 lb. ft. (61.0 Nm).
16. Position trim tab in gear housing aligning grooves of trim tab with ribs in trim tab pocket.
Adjust to position in which it had previously been installed, and while holding trim tab,
torque bolt to 40 lb. ft. (54.2 Nm).
17. Install plastic cap into trim tab bolt opening at rear edge of drive shaft housing.

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 ATTACHMENTS/CONTROL LINKAGE

ATTACHMENTS/CONTROL LINKAGE
Section 7 B
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 7-1 Installation Requirements . . . . . . . . . . . . . . 7-15
Ride Guide Steering Cable/Attaching Kit Parallel Routed Steering Cables and
Installation (92876A1) . . . . . . . . . . . . . . . . . . . 7-2 Attaching Kit Installation . . . . . . . . . . . . . . 7-16
Single Cable - . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Opposite Side Routed Steering Cables
Maintenance Instructions . . . . . . . . . . . . . . 7-4 and Attaching Kit Installation . . . . . . . . . . 7-27
Ride Guide Steering Cable/Attaching Kit Trim Tab Adjustment . . . . . . . . . . . . . . . . . . 7-37
Installation (92876A3) . . . . . . . . . . . . . . . . . . . 7-5 Ride Guide Steering Attachment
Dual Cable - Single Outboard . . . . . . . . . . 7-5 Extension Couplers . . . . . . . . . . . . . . . . . . 7-38
Super Ride-Guide Steering Kit Installation 7-6 Maintenance Instructions . . . . . . . . . . . . . . 7-39
Steering Cable Mounting Tube Installation 7-7 Transom Mounted Ride Guide Attaching
Installing Steering Cables . . . . . . . . . . . . . 7-8 Kit Installation (73770A1) . . . . . . . . . . . . . . . . . 7-41
Coupler Installation . . . . . . . . . . . . . . . . . . . 7-10 Attaching Kit Installation . . . . . . . . . . . . . . . 7-41
Installing Link Rod . . . . . . . . . . . . . . . . . . . 7-11 Maintenance Instructions . . . . . . . . . . . . . . 7-44
Maintenance Instructions . . . . . . . . . . . . . . 7-14 Clevis Attaching Kit Installation (A-70599A2) 7-45
Ride Guide Steering Cable/ Attaching Kit Installation Instructions . . . . . . . . . . . . . . . . 7-45
Installation (92876A6) . . . . . . . . . . . . . . . . . . . 7-15 Maintenance Instructions . . . . . . . . . . . . . . 7-45
Dual Cable - Dual Outboard . . . . . . . . . . . 7-15

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ATTACHMENTS/CONTROL LINKAGE

Ride Guide Steering Cable/Attaching Kit Installation

(92876A1)
Single Cable -
Refer to “Quicksilver Accessories Guide” to determine correct length of steering cable
and remote control cables.
IMPORTANT: Steering cable and remote control cables must be the correct length,
sharp bends on too-short cables result in “kinks”; too-long cables require unneces-
sary bends and/or loops. Both conditions place extra stress on the cables and will
reduce the performance of the steering system.

INSTALLING RIDE GUIDE CABLE TO OUTBOARD TILT TUBE

IMPORTANT: Before installing steering cable in tilt tube, lubricate entire cable end
with 2-4-C with Teflon.
NOTE: Ride Guide steering cable is lubricated at the factory and requires no additional lubri-
cation at initial installation.
1. Lubricate seal inside of outboard tilt tube and entire cable end with 2-4-C with Teflon.
2. Insert steering cable end through outboard tilt tube and secure steering cable to tilt tube
with steering cable attaching nut as shown. Torque nut to 35 lb. ft. (47.5 Nm).

c b

28160

a - Seal
b - Cable End
c - attaching Nut

Page 7-2 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING LINK ROD INSTALLATION

IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” - Part Number 10-849838) and
self locking nuts (“b” & “c” - Part Number 11-826709113). These locknuts must never
be replaced with common nuts (non locking) as they will work loose and vibrate off
freeing the link rod to disengage.

WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown over-
board exposing them to serious injury or death.
3. Assemble steering link rod to steering cable with two flat washers and nylon insert lock-
nut (Part Number 11-826709113). Tighten locknut until it seats, then back nut off 1/4
turn.
4. Production Outboards - Assemble steering link rod to engine with special washer
head bolt (Part Number 10-849838) and nylon insert locknut (Part Number
11-826709113). First torque bolt to 20 lb. ft. (27.1 Nm), then torque locknut to 20 lb. ft.
(27.1 Nm).
High Performance Outboards - An access hole is provided through the bottom cowl
to ease installation of the link rod connecting bolt. Remove the BACK plug for installation
and reinstall after installation.

a
d

a - Bolt (849838)
b - Locknut (11-826709113)
c - Locknut (11-826709113)
d - Washer
WARNING
After installation is complete (and before operating outboard), check that boat will
turn right when steering wheel is turned right and that boat will turn left when steer-
ing wheel is turned left. Check steering through full range (left and right) and at all
tilt angles to assure interference-free movement.

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ATTACHMENTS/CONTROL LINKAGE

Maintenance Instructions
Maintenance inspection is owner’s responsibility and must be performed at intervals speci-
fied, following:
Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)
*Severe Service - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered Severe Service.
1. Carefully check steering system components for wear. Replace worn parts.
2. Check steering system fasteners to be sure that they are torqued to correct specifica-
tions.
NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
lubrication at initial installation.

WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock of
cable could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate transom
end of steering cables through grease fittings with 2-4-C with Teflon. Lubricate exposed
portion of cable end with 2-4-C with Teflon.
4. Lubricate pivot point of steering link rod and ball joint of link rod with 4 Cycle 5W40 En-
gine Oill.
5. Inspection and lubrication of steering head assembly (rotary or straight rack) should be
performed once each year (by your Authorized Dealer) or whenever steering mount
and/or steering head are disassembled, or if steering effort has increased. Lubricate
with 2-4-C with TeflonGrease Fitting.

a
c
a b
28169
a - Grease Fitting
b - Cable End
c - Pivot Point/Link Arm
d - Ball Joint

Page 7-4 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Ride Guide Steering Cable/Attaching Kit Installation

(92876A3)
Dual Cable - Single Outboard
WARNING
Super Ride-Guide Steering (dual cables) MUST BE USED with this attaching kit.
Failure to adhere to this requirement could result in steering system failure.
Refer to Quicksilver Accessories Guide to determine correct length of steering cables
and remote control cables.
IMPORTANT: Steering cables and remote control cables MUST BE THE CORRECT
LENGTH, sharp bends on too-short cables result in kinks; too-long cables require
unnecessary bends and/or loops. Both conditions place extra stress on the cables
and will reduce the performance of the steering system.

CAUTION
With this kit installed, the upper (outboard) mounting bolts MUST BE installed so
that hex head end of bolts is on the inside of boat transom, as illustrated. Failure
to install upper mounting bolts, as shown in illustration, could result in interference
between steering cable nut and ends of mounting bolts when outboard is tilted up.

CAUTION
Marine sealer must be used on shanks bolts to make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when tightening transom bolts.
Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard to tran-
som with 4 bolts, flat washers and locknuts, as shown. Be sure that installation is water-tight.
Install upper bolts so that hex head end of bolts is on the inside of boat transom.

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ATTACHMENTS/CONTROL LINKAGE

Super Ride-Guide Steering Kit Installation

IMPORTANT: Both gear racks or rotary steering heads must be installed so that both
steering cables will be routed together on the same side of the boat and will
push-and-pull together.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with Su-
per Ride-Guide Kit.
2. Make sure that both gear racks or rotary steering heads are installed so that both steer-
ing cables are routed together down starboard side of boat and will push-and-pull to-
gether.

a
b c
b
a - Gear Rack
b - Steering Cables
c - Rotary Steering Heads

Page 7-6 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Steering Cable Mounting Tube Installation

IMPORTANT: Spacers must be installed between outboard swivel bracket and
mounting bracket for steering cable mounting tube to provide proper spacing be-
tween steering cables.
Secure mounting bracket for steering cable mounting tube on to swivel bracket of outboard.

a
d

d
c 28163

a - Mounting Bracket for Steering Cable Mounting Tube

b - Spacer (2)
c - Locking Retainer (2)
d - Bolts (4) - 7/8 in. (22mm) Long - Torque to 100 lb. in.(11.3 Nm), then Bend Cor-
ner Tabs of Locking Retainers Up and Against Flats on Each Bolt

WARNING
Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube to outboard swivel
bracket to prevent bolts from turning out.
Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 lock-
ing tab washers. Verify longer threaded end of tube is toward starboard side of boat.

90-855348R02 NOVEMBER 2002 Page 7-7

ATTACHMENTS/CONTROL LINKAGE

Temporarily adjust tube so that longer threaded end of tube extends out the same distance
as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d

a
c 51891
a - Steering Cable Mounting Tube (End of Tube with Longer Threads Toward
Starboard Side of Boat)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab Washer)

Installing Steering Cables

IMPORTANT: Lubricate inside of outboard tilt tube, inside of steering cable mounting
tube and rubber O-ring seal (located in outboard tilt tube) with 2-4-C with Teflon be-
fore installing steering cables.
Lubricate inside of outboard tilt tube and inside of steering cable mounting tube with 2-4-C
with Teflon. Verify rubber O-ring seal (located in outboard tilt tube) is lubricated.

95

51890

95 2-4-C With Teflon

a - Seal

Page 7-8 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Insert steering cable ends through outboard tilt tube and cable mounting tube. Thread steer-
ing cable attaching nuts on to tubes hand tight.
NOTE: Torque steering cable attaching nuts only after final steering adjustments have been
made.

b a
d

51891
c
a - Cable Ends (2)
b - Tilt Tube
c - Cable Mounting Tube
d - Attaching Nut (2)

Place a mark on steering cable mounting tube 5/8 in. (16mm) from end of mounting tube.
Slide plastic spacer, O-ring and cap over steering cable.
5/8″(16mm)

51890
a c d e
a - Mark
b - Mounting Tube
c - Plastic Spacer
d - O-ring
e - Cap

90-855348R02 NOVEMBER 2002 Page 7-9

ATTACHMENTS/CONTROL LINKAGE

Thread cap onto steering cable mounting tube, up to mark.

51890
a b
a - Mark
b - Cap

Coupler Installation
WARNING
Locknuts must be used with bolts to secure steering cables to coupler. Failure to
adhere to this requirement could result in steering system failure.
Slide coupler onto steering cable ends and secure each steering cable to coupler with bolt
and locknut as shown. Tighten to a torque of 20 Ib. ft. (27.1 Nm).

b c

a 51888
a - Coupler
b - Bolt (2)
c - Locknut (2)

Page 7-10 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Installing Link Rod

WARNING
Steering link rod MUST BE secured between outboard steering arm and steering
coupler, using special washer head bolt (10-849838) and two nylon insert locknuts
(11-826709113), as shown. Both special washer head bolt and nylon insert locknuts
MUST BE tightened as specified.
Lubricate hole in steering coupler, with 2-4-C with Teflon. Assemble steering link rod to
steering coupler, using 2 flat washers (one each side of coupler) and nylon insert locknut.
Tighten locknut until it seats [DO NOT exceed 120 Ib. in. (13.6 Nm) of torque], then back
nut off 1/4 turn.
Lubricate ball joint in steering link rod with SAE 30W Motor Oil. Secure link rod to outboard
steering arm, using special washer head bolt (10-849838) provided and nylon insert locknut
as shown. Torque special bolt to 20 Ib. ft. (27.1 Nm), then torque locknut to 20 Ib. ft. (27.1
N·m).

80

e
b

a
d
80 28172
79 4 Cycle 5W40 Engine Oil

a - Steering Coupler
b - Steering Link Rod
c - Flat Washer (2)
d - Nylon Insert Locknut - Torque until it seats [DO NOT exceed 120 lb. in. (14.0
Nm) of torque], then back nut off 1/4 turn
e - Special Washer Head Bolt (10-849838) - Torque to 20 lb. ft. (27.1 Nm)
f - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 Nm)

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ATTACHMENTS/CONTROL LINKAGE

STEERING SYSTEM TENSION ADJUSTMENT

IMPORTANT: After this dual steering cable attachment kit is installed, there must be
proper tension in forward mounted steering cable tor this attachment kit to operate
properly. Not enough tension will cause slack (or play) in steering system. Too much
tension will cause steering cables to bind. Perform the following steps to adjust for
correct tension.
Loosen adjustment nuts and pull steering cable mounting tube (by hand) away from end of
steering cable (to remove slack in steering system). Tighten adjustment nuts against mount-
ing bracket and check system for slack (play.) If steering system is too tight, readjust tube
toward end of steering cable or, if too much slack (play) exists in system, readjust tube away
from end of steering cable. Tighten nuts against mounting bracket and readjust, if neces-
sary.
b

a
c d

51887

a - Steering Cable Mounting Tube

b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steering System
d - Adjust Tube in This Direction to Reduce Tension from Steering System

After steering system tension is adjusted correctly, tighten adjustment nuts against mount-
ing bracket, to a torque of 35 Ib. ft. (47.4 Nm) and bend a tab lock washer against flat on
each adjustment nut.

c
c a
51887

a - Steering Cable Mounting Tube

b - Adjustment Nuts; Torque to 35 lb. ft. (47.4 Nm)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment Nut)

Page 7-12 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib. ft.
(47.5 Nm).

a
51889

a - Cable Attaching Nut

b - “V” Groove

NOTE: Cable attaching nuts with a “V” groove around the outer circumference of the nut
are self locking and do not require locking sleeves.
Install rubber bumpers on inside of each locking sleeve.

a 51889
Install locking sleeves over steering cable attaching nuts and secure with cotter pins.
Spread ends of cotter pins. Be sure to install cotter pin so that it is located in between attach-
ing nut and grease fitting.

f
e
c a

b
a
d b
c
d
51890
a - Steering Cable Attaching Nut d - Grease Fitting
[Torque to 35 lb. ft. (47.5 Nm)] e - Steering Cable
b - Locking Sleeve (If Equipped) Mounting Tube
c - Cotter Pin f - Outboard Tilt Tube

WARNING
After installation is complete (and before operating outboard, check that boat will
turn right when steer ing wheel is turned right and that boat will turn left when steer-
ing wheel is turned left. Check steering through full range (left and right) at all tilt
angles to assure interference-free movement.

90-855348R02 NOVEMBER 2002 Page 7-13

ATTACHMENTS/CONTROL LINKAGE

Maintenance Instructions
Maintenance inspection is owner’s responsibility and must be performed at intervals speci-
fied, following:

Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)

*Severe Service - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered Severe Service.
1. Carefully check steering system components for wear. Replace worn parts.
2. Check steering system fasteners to be sure that they are torqued to correct specifica-
tions.
NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
lubrication at initial installation.

WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock
could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate transom
end of steering cables through grease fittings with 2-4-C with Teflon.
4. Lubricate ball joint of link rod/steering coupler and pivot point of steering link rod with
4 Cycle 5W40 Engine Oil.
5. Inspection and lubrication of steering head assembly (rotary or straight rack) should be
performed once each year (by your Authorized Dealer) or whenever steering mount
and/or steering head are disassembled, or if steering effort has increased. Lubricate
with 2-4-C with Teflon.

80 95

d
b
c

a a
79

28170
95
79 4 Cycle 5W40 Engine Oil
95 2-4-C With Teflon
a - Grease Fitting
b - Cable End
c - Pivot Point/Link Rod
d - Ball Joint

Page 7-14 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Ride Guide Steering Cable/ Attaching Kit Installation

(92876A6)
Dual Cable - Dual Outboard
WARNING
Super Ride-Guide Steering (dual cables) MUST BE USED with this attaching kit.
Failure to adhere to this requirement could result in steering system failure.
Refer to Quicksilver Accessories Guide to determine correct length of steering cable and
remote control cables.
IMPORTANT: Steering cable and remote control cables MUST BE THE CORRECT
LENGTH, sharp bends on too-short cables result in kinks; too-long cables require
unnecessary bends and/or loops. Both conditions place extra stress on the cables.
Installation Requirements
IMPORTANT: The distance from each outboard’s centerline to the side of transom
opening MUST BE a minimum of 16 in. (40.6cm).
This kit contains all necessary parts to connect both outboards to Ride-Guide Steering
Cables for 23-1/2 in. through 27-1/2 in. (59.7cm through 69.9cm) outboard centerline spac-
ing. If outboard centerline distance is other then specified, refer to end of the instruction
manual for optional extension couplers.
DETERMINE ROUTING OF STEERING CABLES
Use “1” or “2,” following, to route steering cables:
1. Parallel cable routing: Cables routed together down starboard side of boat Refer to
Parallel Routed Steering Cables and Attaching Kit Installation, immediately follow-
ing.
2. Opposite side cable routing: One cable routed down starboard side of boat and one
cable routed down port side of boat. Refer to Opposite Side Routed Steering Cables
and Attaching Kit Installation.

90-855348R02 NOVEMBER 2002 Page 7-15

ATTACHMENTS/CONTROL LINKAGE

CAUTION
With this kit installed, the upper (outboard) mounting bolts MUST BE installed so
that hex head end of bolts is on the inside of boat transom, as illustrated. Failure
to install upper mounting bolts, as shown in illustration, could result in interference
between outer steering cable locking sleeve and ends of mounting bolts when out-
board is tilted up.

Install upper bolts so that hex head end of bolts is on the inside of boat transom.
Parallel Routed Steering Cables and Attaching Kit Installation
(Both Steering Cables Routed Together Down Starboard Side of Boat)

SUPER RIDE-GUIDE STEERING KIT INSTALLATION

IMPORTANT: Steering cable must be installed into tilt tube of port outboard before
outboard is mounted on boat transom.
IMPORTANT: Both gear racks or rotary steering heads must be installed so that both
steering cables will be routed together on the same side of the boat and will push-
and-pull together.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with the
kit.
2. Make sure that both gear racks or rotary steering heads are installed so that both steer-
ing cables are routed together and will push-and-pull together.

a
b b a
a - Straight Rack (Left); Rotary Steering (Right)
b - Steering Cables (Install so that Both Cables Will Push and Pull Together)

Page 7-16 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING CABLE INSTALLATION STARBOARD OUTBOARD

IMPORTANT: Mounting bracket for steering cable mounting tube MUST BE secured
to outboard swivel bracket, using 5/8 in. (16mm) long bolts supplied with this dual
cable - dual outboard attaching kit.
Secure mounting bracket for steering cable mounting tube, onto swivel bracket of starboard
outboard.

d
d
c

b a 28164
a - Mounting Bracket for Steering Cable Mounting Tube
b - “J” Clip - Supplied with Outboard
c - Locking Retainers (2)
d - Bolts (4) - 5/8 in. (16mm ) Long - Torque to 100 lb. in. (11.3 Nm), then Bend
Corner Tabs of Locking Retainers Up and Against Flats on Each Bolt
WARNING
Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube to outboard swivel
bracket, to prevent bolts from turning out.
Install steering cable mounting tube into mounting bracket with 2 adjusting nuts and 2 lock-
ing tab washers. Be sure longer threaded end of tube is toward starboard side of boat.
Temporarily adjust tube, so that longer threaded end of tube extends out the same distance
as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d

95

a
c
95 2-4-C With Teflon
51891
a - Steering Cable Mounting Tube (End of Tube with Longer Threads
Toward Starboard Side of Boat)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab Washer)

90-855348R02 NOVEMBER 2002 Page 7-17

ATTACHMENTS/CONTROL LINKAGE

IMPORTANT: Lubricate inside of steering cable mounting tube with 2-4-C with Teflon
before installing steering cable.
Lubricate inside of steering cable mounting tube (starboard outboard) with 2-4-C with Tef-
lon.
Insert steering cable end through cable mounting tube and thread steering cable attaching
nut onto tube hand tight.
NOTE: Torque steering cable attaching nut only after final steering adjustments have been
made.

c
b
51887
a - Cable End
b - Cable Mounting Tube
c - Attaching Nut

Place a mark on steering cable mounting tube 5/8 in. (16mm) from end of mounting tube.
Slide plastic spacer, O-ring and cap over steering cable.
5/8″(16mm)

a d
c e
51890
a - Mark
b - Mounting Tube
c - Plastic Spacer
d - O-ring
e - Cap

Page 7-18 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Thread cap onto steering cable mounting tube, up to mark.

a b
51890
a - Mark
b - Cap

STEERING CABLE INSTALLATION - PORT OUTBOARD

IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-
cated inside tilt tube with 2-4-C with Teflon, before installing steering cable.
Lubricate inside of port outboard’s tilt tube and rubber O-ring seal with 2-4-C with Teflon.
a

95

51890
95 2-4-C With Teflon
a - Seal

90-855348R02 NOVEMBER 2002 Page 7-19

ATTACHMENTS/CONTROL LINKAGE

Insert steering cable end through tilt tube of port outboard and thread steering cable attach-
ing nut onto tilt tube hand tight.
NOTE: Torque steering cable attaching nuts only after final steering adjustments have been
made.

c b

51887

a - Cable End
b - Tilt Tube
c - Attaching Nut

Page 7-20 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING LINK ROD INSTALLATION

WARNING
Steering link rods MUST BE secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
nuts (11-826709113), as shown. Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
Lubricate holes in ends of steering cables with SAE 30W Motor Oil. Assemble steering link
rods to steering cable ends of each outboard, using flat washers and nylon insert locknuts.
Tighten locknuts until they seat [DO NOT exceed 120 Ib. in. (13.6 Nm) of torque], then back
nut off 1/4 turn.
Lubricate ball joints in steering link rods with SAE 30W Motor Oil. Secure link rods to out-
board steering arms, using special washer head bolts (10-849838) provided and nylon in-
sert locknuts as shown. Torque special bolts to 20 Ib. ft. (27.1 Nm) then torque locknuts to
20 Ib. ft. (27.1 Nm).

79 79
c c 79
79
e e

a a

a
b b
f f
d d
28166

e
c
79
79
e
f a

d 50061
a
79 4 Cycle 5W40 Engine Oil b
a - Flat Washer (2 Each Link Rod)
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT
Exceed 120 lb. in. (13.6 Nm) of Torque], Then Back Off 1/4 Turn
c - Special Washer Head Bolt (10-849838) - Torque to 20 lb. ft. (27.1 Nm)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 Nm)
e - Steering Link Rod
f - Steering Cable End

90-855348R02 NOVEMBER 2002 Page 7-21

ATTACHMENTS/CONTROL LINKAGE

STEERING ARM EXTENSION BRACKET INSTALLATION

Secure a steering arm extension bracket to each outboard’s steering arm.

b
d
d

c
c

51889
a - Steering Arm (Port Outboard Shown)
b - Extension Bracket
c - Locking Retainer (2 Each Bracket)
d - Bolts (2 Each Bracket) 1-1/4 in. (31.8mm) Long - Torque to 280 lb. in. (31.6
Nm), Then Bend Corner Tabs of Locking Retainers Up Against Flats on
Each Bolt

WARNING
Locking retainer corner tabs MUST BE bent up and against flats on each bolt that
secures extension bracket to outboard steering arm to prevent bolts from turning
out.

STEERING COUPLER ASSEMBLY AND INSTALLATION

1. Position outboards so that they are facing straight forward. (Distance between threaded
hole centers of steering arm extensions MUST BE equal to distance between propeller
shaft centerlines.)
2. Lubricate inside of rubber sleeves with 2-4-C with Teflon and slide sleeves on steering
coupler.
3. Work rubber bushings onto threaded ends of steering eyes.
4. Thread jam nut on starboard steering eye.

Page 7-22 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

5. Thread steering eyes equally into coupler, so that distance between hole centers of
steering eye ball joints is equal to distance between threaded hole centers of steering
arm extensions. Exposed threads of steering eyes MUST BE of equal length and
threads MUST NOT extend out from coupler more than 2-3/4 in. (69.9mm).
c d e b a b d c

95 50061
95 2-4-C With Teflon
a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut

WARNING
Both steering eyes must be threaded into coupler 3/4 in. (19mm) minimum. Thread
length of steering eye is 3-1/2 in. (88.9mm), so exposed thread must not extend out
of coupler more than 2-3/4 in. (69.9mm). Failure to adhere to this requirement could
result in steering system failure.
6. Lubricate ball joint in steering eyes, with SAE 30W Motor Oil.
7. Assemble steering coupler between outboard steering arm extension brackets, using
special washer head bolts (10-849838) provided and nylon insert locknuts as shown.
IMPORTANT: With assembled steering coupler in- stalled and before tightening spe-
cial washer head bolts/locknuts, check outboard alignment. Distance between cen-
ters of special washer head bolts MUST BE equal to distance between propeller shaft
center lines, for proper steering. It adjustment is necessary, temporarily remove spe-
cial washer head bolt/locknut from one steering eye and turn eye in or out to correct
alignment.
8. Torque special washer head bolts to 20 Ib. ft. (27.1 Nm), then torque locknuts to 20 Ib.
ft. (27.1 Nm).

WARNING
Both steering eyes MUST BE threaded into coupler 3/4 in. (19mm) minimum, and
jam nut must be tightened against coupler to prevent coupler from turning. Torque
“jam” nut to 20 Ib. ft. (27.1 Nm).
9. Tighten jam nut against coupler. Torque jam nut to 20 Ib. ft. (27.1 Nm).
10. Spray Corrosion Guard on exposed threads of steering eyes and position rubber bush-
ings and rubber sleeves to cover exposed threads of steering eyes.

90-855348R02 NOVEMBER 2002 Page 7-23

ATTACHMENTS/CONTROL LINKAGE

79 f 79 a f
79
79

28167
g g
79

79

d b d
c
h h

f
79
f c e a 79 50061

79 f 79

g h
50061

79 4 Cycle 5W40 Engine Oil

a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut - Torque (Against Coupler) to 20 lb. ft. (27.1 Nm)
f - Special Washer Head Bolt (10-849838) - Torque to 20 lb.ft. (27.1 Nm)
g - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 Nm)
h - Steering Arm Extension Bracket

Page 7-24 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES)

IMPORTANT: For proper operation of this dual cable - dual outboard steering installa-
tion, there MUST BE proper tension in the steering system. NOT ENOUGH tension will
cause slack (play) in steering system. TOO MUCH tension will cause steering cables
to bind. Perform the following steps to correctly adjust tension.
1. Loosen adjustment nuts and pull steering cable mounting tube (by hand) away from end
of steering cable (to remove slack in steering system). Tighten adjustment nuts against
mounting bracket and check system for slack (play). If steering system is too tight, read-
just tube toward end of steering cable or, if too much slack (play) exists in system, read-
just tube away from end of steering cable. Tighten nuts against mounting bracket and
readjust, if necessary.
b

c d

51887
a - Steering Cable Mounting Tube
b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steering System
d - Adjust Tube in This Direction to Reduce Tension from Steering System

2. After steering system tension is adjusted correctly, tighten adjustment nuts against
mounting bracket, to a torque of 35 Ib. ft. (47.5 Nm) and bend a tab lock washer against
a flat on each nut.

c c a 51887

a - Steering Cable Mounting Tube

b - Adjustment Nuts Torque to 35 lb. ft. (47.5 N·m)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment Nut

90-855348R02 NOVEMBER 2002 Page 7-25

ATTACHMENTS/CONTROL LINKAGE

3. Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib. ft. (47.5
Nm).

51887
a - Cable Attaching Nut

WARNING
After installation is complete [and before operating outboard(s)], check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) at all
tilt angles to assure interference-free movement.
Adjust trim tabs of both outboards, as outlined in Trim Tab Adjustment, following.

Page 7-26 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

Opposite Side Routed Steering Cables and Attaching Kit Installation

(One Cable Routed down Starboard Side of Boat and One Cable Routed down Port
Side of Boat)

SUPER RIDE-GUIDE STEERING KIT INSTALLATION

IMPORTANT: Steering cable must be installed into tilt tube of port outboard before
outboard is mounted on boat transom.
Install Super Ride-Guide Steering Kit in accordance with instructions included with Super
Ride-Guide Kit.

STEERING CABLE INSTALLATION - STARBOARD OUTBOARD

IMPORTANT: Mounting bracket for steering cable mounting tube MUST BE secured
to outboard swivel bracket, using 5/8 in. (16mm) long bolts supplied with this dual
cable - dual outboard attaching kit.
1. Secure mounting bracket for steering cable mounting tube, onto swivel bracket of star-
board outboard.

d
d
c

b a
28164
a - Mounting Bracket for Steering Cable Mounting Tube
b - “J” Clip - Supplied with Outboard
c - Locking Retainers (2)
d - Bolts (4) - 5/8 in. (16mm) Long - Torque to 100 lb. in. (11.3 Nm), Then Bend
Corner Tabs of Locking Retainers Up and Against Flats on Each Bolt

WARNING
Locking retainer corner tabs MUST BE bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube, to prevent bolts from
turning out.

90-855348R02 NOVEMBER 2002 Page 7-27

ATTACHMENTS/CONTROL LINKAGE

2. Install Steering Cable mounting tube into mounting bracket with 2 adjusting nuts and 2
locking tab washers. Verify longer threaded end of tube is toward center of boat transom.
3. Temporarily adjust tube, so that longer threaded end of tube extends out the same dis-
tance as the outboard tilt tube. Do not tighten adjustment nuts at this time.
b d

95

51891

a c
95 2-4-C With Teflon
a - Steering Cable Mounting Tube (End of Tube with Longer
Threads Toward Center of Boat Transom)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab Washer)

IMPORTANT: Lubricate inside of steering mounting tube with 2-4-C with Teflon before
installing steering cable.
4. Lubricate inside of steering cable mounting tube (starboard outboard) with 2-4-C with
Teflon.
5. Insert steering cable end (steering cable routed down port side of boat) through cable
mounting tube and thread steering cable attaching nut onto tube hand tight.
NOTE: Torque steering cable attaching nut only after final steering adjustments have been
made.
a

b c 51887
a - Steering Cable End
b - Mounting Tube
c - Attaching Nut

Page 7-28 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

6. Place a mark on steering cable mounting tube 5/8 in (16mm) from end of mounting tube.
Slide plastic spacer, O-ring and cap over steering cable.
5/8″(16mm)

e d c b
51890
a - Mark
b - Mounting Tube
c - Plastic Spacer
d - O-ring
e - Cap

7. Thread cap (e) onto steering cable mounting tube, up to mark (a).

a 51888
a - Mark
b - Cap

90-855348R02 NOVEMBER 2002 Page 7-29

ATTACHMENTS/CONTROL LINKAGE

STEERING CABLE INSTALLATION - PORT OUTBOARD

IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-
cated inside tilt tube with 2-4-C with Teflon, before installing steering cable.
1. Lubricate inside of port outboard’s tilt tube and rubber O-ring seal with 2-4-C with Teflon.

95

51890
95 2-4-C With Teflon
a - Seal

2. Insert steering cable end (steering cable routed down starboard side of boat) through
tilt tube of port outboard and thread steering cable attaching nut onto tilt tube hand tight.
NOTE: Torque steering cable attaching nut only after final steering adjustments have been
made.

c a

51887
a - Steering Cable End
b - Tilt Tube
c - Attaching Nut

Page 7-30 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING LINK ROD INSTALLATION

WARNING
Steering link rods MUST BE secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
nuts (11-826709113), as shown. Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
1. Lubricate holes in ends of steering cables with 4 Cycle 5W40 Engine Oil. Assemble
steering link rods to steering cable ends of each outboard, using flat washers and nylon
insert locknuts. Tighten locknuts until they seat [DO NOT exceed 120 lb. in. (13.6 Nm)
of torque], then back nut off 1/4 turn.
2. Lubricate ball joints in steering link rods with 4 Cycle 5W40 Engine Oil. Secure link rods
to outboard steering arms, using special washer head bolts (10-849838) provided and
nylon insert locknuts as shown. Torque special bolts to 20 lb. ft. (27.1 Nm) then torque
locknuts to 20 Ib. ft. (27.1 Nm).

79
79
e c 79
c 79
e
a
a

b f d d f b
28165
c e
79
79

e
f a

d
50061

a
79 4 Cycle 5W40 Engine Oil b
a - Flat Washer (2 Each Link Rod)
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT
Exceed 120 lb. in. (13.6 Nm) of Torque], Then Back Off 1/4 Turn
c - Special Washer Head Bolt (10-849838) - Torque to 20 lb. ft. (27.1 Nm)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 Nm)
e - Steering Link Rod
f - Steering Cable End

90-855348R02 NOVEMBER 2002 Page 7-31

ATTACHMENTS/CONTROL LINKAGE

STEERING ARM EXTENSION BRACKET INSTALLATION

Secure a steering arm extension bracket to each outboard’s steering arm.

d
d

c c

51889
a - Steering Arm (Port Outboard Shown)
b - Extension Bracket
c - Locking Retainer (2 Each Bracket)
d - Bolts (2 Each Bracket) 1-1/4 in. (31.8mm) Long - Torque to 280 lb. in. (31.6
Nm), Then Bend Corner Tabs of Locking Retainers Up Against
Flats on Each Bolt
WARNING
Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that
secures extension bracket to outboard steering arm, to prevent bolts from turning
out.

Page 7-32 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING COUPLER ASSEMBLY AND INSTALLATION

1. Position outboards so that they are facing straight forward. (Distance between threaded
hole centers of steering arm extensions MUST BE equal to distance between propeller
shaft centerlines.)
2. Lubricate inside of rubber sleeves with 2-4-C with Teflon and slide sleeves on steering
coupler.
3. Work rubber bushings onto threaded ends of steering eyes.
4. Thread jam nut on starboard steering eye.
5. Thread steering eyes equally into coupler, so that distance between hole centers of
steering eye ball joints is equal to distance between threaded hole centers of steering
arm extensions. Exposed threads of steering eyes MUST BE of equal length and
threads MUST NOT extend out from coupler more than 2-3/4 in. (69.9mm).
c d e b a b d c

95 50061
95 2-4-C With Teflon
a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut

WARNING
Both steering eyes must be threaded into coupler 3/4 in. (19mm) minimum. Thread
length of steering eye is 3-1/2 in. (88.9mm), so exposed thread must not extend out
of coupler more than 2-3/4 in. (69.9mm). Failure to adhere to this requirement could
result in steering system failure.
6. Lubricate ball joint in steering eyes with 4 Cycle 5W40 Engine Oil.
7. Assemble steering coupler between outboard steering arm extension brackets, using
special washer head bolts (10-849838) provided and nylon insert locknuts, as shown.
IMPORTANT: With assembled steering coupler installed and before tightening spe-
cial washer head bolts/locknuts, check outboard alignment. Distance between cen-
ters of special washer head bolts MUST BE equal to distance between propeller shaft
center lines, for proper steering. If adjustment is necessary, temporarily remove spe-
cial washer head bolt/locknut from one steering eye and turn eye in or out to correct
alignment.

90-855348R02 NOVEMBER 2002 Page 7-33

ATTACHMENTS/CONTROL LINKAGE

8. Torque special washer head bolts to 20 Ib. ft. (27.1 N·m), then torque locknuts to 20 Ib.
ft. (27.1 Nm).

WARNING
Both steering eyes MUST BE threaded into coupler 3/4 in. (19mm) minimum, and
jam nut must be tightened against coupler to prevent coupler from turning. Torque
“jam” nut to 20 Ib. ft. (27.1 Nm).
9. Tighten jam nut against coupler. Torque jam nut to 20 Ib. ft. (27.1 Nm).
10. Spray Corrosion Guard on exposed threads of steering eyes and position rubber bush-
ings and rubber sleeves to cover exposed threads of steering eyes.

79 f
f 79
79 a
80

g g 28174

79
79

d b d
c
h h

f
79
f c e a 79 50061

79 f
79
c

g
h 50061
79 4 Cycle 5W40 Engine Oil

a - Coupler
b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut - Torque (Against Coupler) to 20 lb. ft. (27.1 Nm)
f - Special Washer Head Bolt (10-849838) - Torque to 20 lb.ft. (27.1 Nm)
g - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 Nm)
h - Steering Arm Extension Bracket

Page 7-34 90-855348R02 NOVEMBER 2002

 ATTACHMENTS/CONTROL LINKAGE

STEERING SYSTEM TENSION ADJUSTMENT

(PARALLEL ROUTED STEERING CABLES)
IMPORTANT: For proper operation of this dual cable - dual outboard steering installa-
tion, there MUST BE proper tension in the steering system. NOT ENOUGH tension will
cause slack (play) in steering system. TOO MUCH tension will cause steering cables
to bind. Perform the following steps to correctly adjust tension.
1. Loosen adjustment nuts and pull steering cable mounting tube (by hand) away from end
of steering cable (to remove slack in steering system.) Tighten adjustment nuts against
mounting bracket and check system for slack (play.) If steering system is too tight, read-
just tube toward end of steering cable or, if too much slack (play) exists in system, read-
just tube away from end of steering cable. Tighten nuts against mounting bracket and
readjust, if necessary.

b a

d c
51887
a - Steering Cable Mounting Tube
b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steering System
d - Adjust Tube in This Direction to Reduce Tension from Steering System

2. After steering system tension is adjusted correctly, tighten adjustment nuts against
mounting bracket to a torque of 35 Ib. ft. (47.5 Nm) and bend a tab lock washer against
a flat on each nut.
b

c c a 51887
a - Steering Cable Mounting Tube
b - Adjustment Nuts; Torque to 35 lb. ft. (47.5 Nm)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment Nut)
3. Tighten steering cable attaching nuts of each steering cable to a torque of 35 Ib. ft. (47.5
Nm).

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ATTACHMENTS/CONTROL LINKAGE

NOTE: Cable attaching nuts with a “V” groove around outer circumference are self locking
and do not require locking sleeves.
4. Install rubber bumpers on inside of each locking sleeve.

51889

a - Rubber Bumper
b - Sleeve

5. Install locking sleeves over steering cable attaching nuts and secure with cotter pins.
Spread ends of cotter pins. Be sure to install cotter pin so that it is located in between
attaching nut and grease fitting.

c b
a
b c
d
a d

51889
e f 51888
a - Steering Cable Attaching Nut [Torque to 35 lb. ft. (47.5 Nm)]
b - Locking Sleeve (If Equipped)
c - Cotter Pin
d - Grease Fitting
e - Steering Cable Mounting Tube (Starboard Outboard)
f - Outboard Tilt Tube (Port Outboard)
WARNING
After installation is complete (and before operating outboard), check that boat will
turn right when steering wheel is turned right and that boat will turn left when steer-
ing wheel is turned left. Check steering through full range (left and right) at all tilt
angles to assure interference-free movement.
6. Adjust trim tabs of both outboards, as outlined in Trim Tab Adjustment, following.

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 ATTACHMENTS/CONTROL LINKAGE

Trim Tab Adjustment

DUAL OUTBOARD - COUNTER ROTATION INSTALLATION
1. Shift outboard into NEUTRAL and make sure ignition key is at “OFF” position.
2. Remove plastic cap from rear of drive shaft housing and loosen bolt and trim tab.
3. Position trim tabs of both outboards straight to rear of outboard, so that tabs are aligned
with gear housing center line.
4. Tighten both trim tab bolts securely and replace plastic caps. No further adjustment will
be required.

DUAL OUTBOARD - NON COUNTER ROTATION INSTALLATION

1. Check trim tab position as follows:
IMPORTANT: Initial trim tab setting for both outboards should be straight to rear of
outboard, so that tabs are aligned with gear housing center line. Refer to “If neces-
sary, adjust trim tab as follows,” following.
a. Operate boat at normal cruise throttle setting and adjust trim to optimum setting.
b. If boat pulls to the right (starboard), trailing edge of trim tab must be moved to the
right (when viewing outboard from behind). If boat pulls to the left (port), trailing edge
of trim tab must be moved to the left.
2. If necessary, adjust trim tab as follows:
a. Shift outboard into NEUTRAL and make sure ignition key is at “OFF” position.
b. Remove plastic cap from rear of drive shaft housing and loosen bolt and trim tab.
IMPORTANT: Trim tabs MUST BE set in the same position on both outboards.
c. If boat pulls to the right, adjust trailing edges of both trim tabs to the right. If boat pulls
to the left, adjust trailing edges of both trim tabs to the left.
d. Tighten both trim tab bolts securely and replace plastic caps.
e. Operate boat per Check trim tab position as follows, preceding, to check trim tab
setting. Readjust trim tabs, if necessary.

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ATTACHMENTS/CONTROL LINKAGE

Ride Guide Steering Attachment Extension Couplers

Outboard Center Required Couplers

Line Distance Between Steering Eyes

22-1/2 in. through 24-1/2 in.

12 in. (30.5cm) Coupler
(57.2cm through 62.2cm)

23-1/2 in. through 27-1/2 in. 15 in. (38.1cm) Coupler

(59.7cm through 69.9cm) (Supplied with this kit)

26-1/2 in. through 30-1/2 in. 18 in. (45.7cm) Coupler

(67.3cm through 75.5cm)

30 in. through 34 in. 9 in. (22.9cm) Coupler and 12 in

(76.3cm through 86.4cm) (30.5cm) Coupler (Connected together with coupler link rod)

33 in. through 37 in. 12 in. (30.5cm) Coupler and 12 in. (30.5cm) Coupler
(Connected together with coupler link rod)

a - 18 in. (45.7cm) Coupler (97932-3)

b - 15 in. (38.1cm) Coupler (97932-2)
c - 12 in. (30.5cm) Coupler (97932-1)
d - 9 in. (22.9cm) Coupler (97932-4)
e - Coupler Link Rod (98181A1)

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 ATTACHMENTS/CONTROL LINKAGE

WARNING
When 2 couplers are connected together with coupler link rod, a lock washer must
be used on each side of coupler link rod, and link rod must be torqued to 20 Ib. ft.
(27.1 Nm) into end of each coupler.

a b a

c 51890

a - Couplers Connected Together

b - Lock washers
c - Coupler Link Rod [Torque to 20 lb. ft. (27.1 Nm) into End of Each Coupler]

Maintenance Instructions
Maintenance inspection is owner’s responsibility and must be performed at intervals speci-
fied, following:
Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)
*Severe Service - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered Severe Service.
1. Carefully check steering system components for wear. Replace worn parts.
2. Check steering system fasteners to be sure that they are torqued to correct specifica-
tions.
NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
lubrication at initial installation.

WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock of
cable could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate transom
end of steering cables through grease fittings with 2-4-C with Teflon. Lubricate exposed
portion of cable ends with 2-4-C with Teflon.

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ATTACHMENTS/CONTROL LINKAGE

4. Lubricate pivot points of steering link rods and ball joints of link rods/steering coupler
with 4 Cycle 5W40 Engine Oil.
5. Inspection and lubrication of steering head assembly (rotary or straight rack) should be
performed once each year (by your Authorized Dealer) or whenever steering mount
and/or steering head are disassembled, or if steering effort has increased. Lubricate
with 2-4-C with Teflon.

d d
a c c

a a b
a b 28168
Lubrication Points for Parallel Cable Routing Installations

d
d

c
c

b a a a a b
Lubrication Points for Opposite Side Cable Routing Installations 28175

a - Grease Fitting
b - Cable End
c - Pivot Point/Link Rod
d - Ball Joint

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 ATTACHMENTS/CONTROL LINKAGE

Transom Mounted Ride Guide Attaching

Kit Installation (73770A1)
Attaching Kit Installation
1. Lubricate both holes in pivot block (Figure 1) with 2-4-C with Teflon.
2. Place pivot block on pivot spacer and secure to transom bracket with 3/8 in. x 2-1/2 in.
(9.5mm x 63.5mm) bolt, flat washer and locknut, as shown in Figure 1. Torque locknut
to 20 Ib. ft. (27.1 Nm).

a b i h

95
f
k c g
d
l

j
e
Figure 1
95 2-4-C With Teflon

a - Ride-Guide Cable
b - Ride-Guide Yoke
c - Pivot Block
d - Pivot Spacer
e - 15 in. (381mm) (Centerline of Attaching Kit Pivot to Centerline of Outboard)
f - Pivot Attaching Locknut [Torque to 20 lb. ft. (27.1 Nm)]
g - Outboard Steering Arm
h - “Clevis Kit”
i - Ride-Guide Cable Attaching Locknut [Torque to 10 lb. ft. (13.6 Nm)]
j - Bolt [3/8 in. x 2-1/2 in. (9.5mm x 63.5mm)]
k - Flat Washer
l - Transom Bracket

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ATTACHMENTS/CONTROL LINKAGE

3. Place Ride-Guide yoke on pivot block and secure with 7/16 in. x 1-3/4 in. (11.1mm x
44.5mm) bolt and locknut, as shown in Figures 1 and 2. Torque locknut to 10 Ib. ft. (13.6
Nm), then back off 1/4-turn.

g f

b
c

e
Figure 2

a - Transom Backing Plate

b - Bolt [5/16 in. x 3-1/4 in. (7.9mm x 82.5mm)]
c - Locknut [Torque to 10 lb. ft. (13.6 Nm)]
d - Ride-Guide Yoke Attaching Locknut [Torque to 10 lb. ft. (13.6 Nm)]
Then Back Off 1/4-Turn
e - 2-3/8 in. (60.3mm) Maximum Transom Thickness
f - Bolt [ 7/16 in. x 1-3/4 in. (11.1mm x 44.5mm)]
g - Ride-Guide Yoke
4. Install one cable tube jam nut onto steering cable tube. Place tab washer over
Ride-Guide yoke, then insert cable tube through tab washer and yoke. Install second
cable tube jam nut onto cable tube but do not tighten at this time. (Figure 3)

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 ATTACHMENTS/CONTROL LINKAGE

5. Position transom attaching kit on transom as

a. Determine centerline of outboard, then measure 15 in. (38.1cm) over from this cent-
erline and draw a vertical line on transom. (Figure 1)
b. Position attaching kit on transom so that transom bracket is centered on the 15
in. (38.1mm) (Figure 1) at a height where the center of Ride-Guide yoke is even
with, or not more than 1/2 in. (12.7mm) above top edge of transom. (Figure 3)

f h j
e a e
f
i
k
c

g
b
d
Figure 3

a - Ride-Guide Yoke
b - 0 in. to 1/2 in. (0mm to 12.8mm) (Center of Ride-Guide Yoke to Top of Transom
c - Top of Transom
d - Transom Bracket
e - Cable Tube Jam Nuts [ Torque to 35 lb. ft. (47.5 Nm)]
f - Tab Washer
g - After Jam Nuts Are Torqued to Specification, Bend Locking Tabs against Nuts
h - Cable Guide Tube
i - Ride-Guide Cable Attaching Nut [Torque to 35 lb. ft. (47.5 Nm)]
j - Clevis Kit
k - Clevis Attaching Locknut [Torque to 20 lb. ft. (27.1 Nm)]
NOTE: When drilling through transom, be sure that holes are drilled perpendicular to tran-
som.
6. With attaching kit positioned as outlined preceding, use 3 holes in transom bracket as
a guide and drill three 11/32 in. (8.7mm) holes through transom.
7. Use a marine-type sealer on three 5/16 in. x 3-1/4in. (7.9mm x 82.6mm) bolts. Secure
attaching kit to transom, using transom backing plate, 3 bolts (with sealer) and 3 lock-
nuts, installed as shown in Figure 2. Torque lock nuts to 10 Ib. ft. (13.5 Nm).

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ATTACHMENTS/CONTROL LINKAGE

STEERING CABLE INSTALLATION

1. Lubricate steering cable end with 2-4-C with Teflon (92-825407A12).
2. Install steering cable through steering cable tube and secure to cable tube with cable
attaching nut. (Figure 3) Do not tighten cable attaching nut at this time.
3. Attach Ride-Guide cable to outboard steering arm, using the proper “Clevis Kit.” Installa-
tion instructions for clevis are with “Clevis Kit.”
4. Adjust 2 large jam nuts on cable tube of attaching kit, so that steering wheel is in normal
straight-driving position with outboard in straight-running position. Torque each jam nut
to 35 Ib. ft. (47.5 Nm), then bend a side of tab washer against flat of each jam nut. (Figure
3)
5. Torque Ride-Guide cable attaching nut (which secures cable to guide tube) to 35 Ib. ft.
(47.5 Nm). (Figure 3) Install locking sleeve over cable attaching nut and secure with cot-
ter pin. Spread ends of cotter pin.

WARNING
After installation is completed (and before operating outboard), check that boat will
turn right when steering wheel is turned right and that boat will turn left when steer-
ing wheel is turned left. Check steering through full range (left and right) at all tilt
angles to assure interference-free movement.
Maintenance Instructions
Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, following:
Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)
*Severe Service - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered “Severe Service.”

CAUTION
Core of steering cable must be fully retracted into cable housing when lubricating
cable. If cable is lubricated while extended, hydraulic lock of cable could occur.
1. Lubricate outboard end of Ride-Guide steering cable (through grease fitting next to
cable attaching nut) with 2-4-C with Teflon.
NOTE: Ride-Guide steering cable is lubricated at the factory and requires no additional lu-
brication at initial installation.
2. Lubricate all steering system pivot points (and exposed portion of steering cable core)
with 2-4-C with Teflon. Lubricate at intervals specified preceding.
3. Carefully check steering system components for wear (at intervals specified, preced-
ing). Replace worn parts.
4. Check steering system fasteners (at intervals specified, preceding) to be sure that they
are torqued to correct specifications (Figures 1, 2 and 3 preceding).

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 ATTACHMENTS/CONTROL LINKAGE

Clevis Attaching Kit Installation (A-70599A2)

NOTE: This kit is used to attach Ride-Guide cable to outboard steering arm ONLY when
Transom Mounted Ride-Guide Attaching Kit is being used. If Ride-Guide cable is in-
stalled through outboard tilt tube, then Steering Link Rod must be used.
Installation Instructions
1. Install clevis to steering cable as shown.
2. Lubricate 3/8 in. x 1-3/8 in. (9.5mm x 34.9mm) bolt (area without threads) with 2-4-C with
Teflon, then secure clevis to steering cable with this bolt and a locknut. Torque locknut
to 10 Ib. ft. (13.6 Nm).
a 95 e
b f
g
h
i
j
c d
95 2-4-C With Teflon
a - Clevis
b - Steering Cable
c - Bolt [3/8 in. x 1-3/8 in. (9.5mm x 34.9mm)]
d - Clevis to Steering Cable Locknut [Torque to 10 lb. ft. (13.6 Nm)]
e - Bolt [3/8 in. x 1-1/4 in. (9.5mm x 31.8mm)] [Torque to 20 lb. ft. (27.1 Nm)]
f - Thin Washer [1/16 in. (1.6mm) Thick]
g - Spacer
h - Thick Washer [1/8 in. (3.2mm) Thick]
i - Engine Steering Arm
j - Clevis to Engine Locknut [Torque to 20 lb. ft. (27.1 Nm)]
3. Lubricate spacer (supplied with this kit) with 2-4-C with Teflon.
4. Attach clevis to top of outboard steering arm with a 3/8 in. x 1-1/4 in. (9.5mm x 31.8mm)
bolt, thin washer, spacer, thick washer (thick washer must be installed between clevis
and steering arm) and locknut, as shown. Torque bolt to 20 Ib. ft. (27.1 Nm), then torque
locknut to 20 Ib. ft. (27.1 Nm).
Maintenance Instructions
Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, following:
Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)
*Severe Service - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered Severe Service.
1. Carefully check steering system components (at intervals specified, preceding) for
wear. Replace worn parts.
2. Check steering system fasteners (at intervals specified, preceding) to be sure that they
are torqued to correct specifications.
3. Lubricate clevis pivot points with a drop of light oil. Lubricate at intervals specified, pre-
ceding.

90-855348R02 NOVEMBER 2002 Page 7-45