SERVICE

MANUAL
MODELS
200 • 225 OPTIMAX
DIRECT FUEL INJECTION
With Serial Numbers
United States . . . 0G386496 and Above

Printed in U.S.A. 1998, Mercury Marine 90-855348R1 JANUARY 1998

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

90-855348R1 JANUARY 1998 i

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

EXAMPLE:

90-855348 R1 JANUARY 1998 LOWER UNIT - 6A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

Page Number
ii 90-855348R1 JANUARY 1998
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
Fuel System
3
B - Direct Fuel Injection
C - Oil Injection
D - Emissions
Section 4 - Powerhead
Powerhead
4
5
A - Cylinder Block Assembly
B - Cooling System Mid-Section
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim
Section 6 - Lower Unit
A - Right Hand Rotation
B - Left Hand Rotation
Lower Unit
6
Section 7 - Attachments/Control Linkage
Attachments/
Control Linkage
7

90-855348R1 JANAURY 1998 iii

IMPORTANT
INFORMATION
1
A

SPECIFICATIONS
Table of Contents
Page
Master Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1A-1

1A-0 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Master Specifications
Model 200/225 DFI
HORSEPOWER Model 200 200 (149.2)
(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 (Std) 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 (Max.) 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)
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

90-855348R1 JANAUARY1998 IMPORTANT INFORMATION - 1A-1

Master Specifications
Model 200/225 DFI
FUEL Fuel Gasoline w/Oil Injection
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil Quicksilver 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)
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)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw 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

1A-2 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Master Specifications
Model 200/225 DFI
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)

Idle RPM (Not Adjustable – Controlled
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 microm-
eter, measure dimension “A” at location
shown. Dimension “A” should be 3.6205
in. ± .0005 for a STANDARD size piston
Dimension (new) Dimension “A” will be 0.001 – 0.0015
“A” at Right
less if coating is worn off piston (used)
Angle (90°)
to Piston Pin
1 in.
(25.4mm)

90-855348R1 JANAUARY1998 IMPORTANT INFORMATION - 1A-3

Master 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)

1A-4 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

IMPORTANT 1
INFORMATION
B

MAINTENANCE
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Corrosion Control Anode . . . . . . . . . . . . . . . . . . . . . . 1B-4
Gear Case Lubricant Capacity . . . . . . . . . . . . . . 1B-1 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . 1B-1 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Inspection and Maintenance Schedule . . . . . . . . . . 1B-2 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Checking Power Trim Fluid . . . . . . . . . . . . . . . . . . . . 1B-7
After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Every 100 Hours of Use or Once yearly, Gear Case Lubricant Capacity . . . . . . . . . . . . . . 1B-7
Whichever Occurs First . . . . . . . . . . . . . . . . . . . . 1B-2 Draining Gear Case . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Before Periods of Storage . . . . . . . . . . . . . . . . . . 1B-2 Checking Lubricant Level and Refilling Gear
Flushing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Flushing Cooling System with Engine NOT Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Running (Using Cowl Flush Plug) . . . . . . . . . . . . 1B-3 Compressor Air Intake Filter . . . . . . . . . . . . . . . . . . . 1B-9
Flushing Cooling System with Engine Running 1997 Model Compressor Air Intake Filter . . . . . 1B-9
(Using Flushing Attachment 44357A2) . . . . . . . 1B-3 1998 Model Compressor Air intake Filter . . . . . 1B-9
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Fuel Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Water Separating Fuel Filter . . . . . . . . . . . . . . . . 1B-4 Cleaning the Cooling Water Strainer . . . . . . . . . . . 1B-10
Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4

1B-0 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Specifications Quicksilver Lubricant/Sealant
1. Quicksilver Anti-Corrosion Grease P/N
92-78376A6
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. 2-4-C Marine Lubricant with Teflon P/N
92-825407A12

2. Grease Gun 91-37299A1

3. SAE 30W Motor Oil P/N 97959

4. Quicksilver Gear Lubricant P/N 92-19007A24

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-1

Inspection and Maintenance Before Periods of Storage
Schedule FUEL SYSTEM
Before Each Use IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid
1. Check that lanyard stop switch stops the engine. during storage and can damage the fuel system.
2. Visually inspect the fuel system for deterioration If the gasoline being used contains alcohol, it is
or leaks. advisable to drain as much of the remaining gas-
oline as possible from the fuel tank, remote fuel
3. Check outboard for tightness on transom. line and engine fuel system.
4. Check steering system for binding or loose com- Fill the fuel system (tank, hoses, fuel pump, carbure-
ponents. tors and fuel injection systems) with treated (stabi-
5. Visually check steering link rod fasteners for lized) fuel to help prevent formation of varnish and
proper tightness. gum. Proceed with following:
6. Check propeller blades for damage. 1. Portable Fuel Tank – Pour the required amount of
Quicksilver Gasoline Stabilizer (follow instruc-
After Each Use tions on container) into fuel tank. Tip fuel tank
back and forth to mix stabilizer with the fuel.
1. Flush out the outboard cooling system if operat-
ing in salt or polluted water. 2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Quicksilver Gasoline Stabilizer
2. Wash off all salt deposits and flush out the ex- (follow instructions on container) into a separate
haust outlet of the propeller and gear case with container and mix with approximately one quart
fresh water if operating in salt water. (one liter) of gasoline. Pour this mixture into fuel
tank.
Every 100 Hours of Use or Once
3. Place the outboard in water or connect flushing
yearly, Whichever occurs first attachment for circulating cooling water. Run the
1. Lubricate all lubrication points. Lubricate more engine for ten minutes to allow treated fuel to fill
frequently when used in salt water. the fuel system.
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 fre-
quently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft.∗
8. Check power trim fluid.
9. Inspect battery.
10. Check control cable adjustments.∗
11. Remove engine deposits with Quicksilver Power
Tune Engine Cleaner.
12. Check tightness of bolts, nuts, and other fasten-
ers.
13. Replace water pump impeller (more often if over-
heating occurs or reduced water pressure is
noted).∗
∗ These items should be serviced by an authorized
dealer.

1B-2 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Flushing Engine 3. With the outboard in the normal operating posi-
tion (vertical), partially open water tap (IT IS NOT
NECESSARY to use full water pressure) and ad-
just water flow so that there is a significant water
Flushing Cooling System with loss around the rubber cups.
Engine NOT Running (Using Cowl
4. Start engine and idle in NEUTRAL. Increase en-
Flush Plug) gine speed, not to exceed 2500 RPM.
Flush the internal water passages of the outboard 5. Flush or service engine as required. Verify ade-
with fresh water after each use in salt, polluted or quate cooling water is provided.
muddy water. This will help prevent a buildup of de-
posits from clogging the internal water passages. a. Water must be discharged thru “tell tale.”

1. Remove the plug from fitting in the bottom IMPORTANT: Prevent engine overheating. If wa-
cowl. ter flow is insufficient, stop engine and deter-
mine 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 out-
board in upright position until all water has
2. Attach a water hose to the fitting. Turn water on drained from drive shaft housing to prevent wa-
and flush for 3 to 5 minutes. ter from entering the powerhead via drive shaft
NOTE: Engine can be stoppped or running at idle housing and exhaust ports.
speed when flushing the cooling system. Do not flush
engine using a water system that exceeds 45psi.
Fuel System
Flushing Cooling System with ! WARNING
Engine Running (Using Flushing Avoid serious injury or death from gasoline fire
Attachment 44357A2) or explosion. Carefully follow all fuel system
service instructions. Always stop the engine
WARNING and DO NOT smoke or allow open flames or
sparks in the area while servicing any part of
When flushing, verify that area in vicinity of pro- the fuel system.
peller is clear and that no person is standing
nearby – to avoid possible injury. It is recom- Before servicing any part of the fuel system, stop en-
mended to remove propeller as a precautionary gine and disconnect the battery. Drain the fuel sys-
measure. tem completely. Use an approved container to collect
and store fuel. Wipe up any spillage immediately. Ma-
1. Install Quicksilver Flushing Attachment 44357A2 terial used to contain spillage must be disposed of in
(or equivalent tool) on the gear housing from the an approved receptacle. Any fuel system service
FRONT side, positioning the rubber cups over must be performed in a well ventilated area. Inspect
the water intake openings. any completed service work for sign of fuel leakage.
2. Connect hose [1/2 in.(12.7mm) I.D. or larger] be-
tween flushing attachment and water tap.
IMPORTANT: To prevent water pump damage, do
not start or run engine unless cooling water is
flowing.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-3

Fuel Line Filter Corrosion Control Anode
The gear case has two corrosion control anodes.
Another anode is installed on the bottom of the tran-
som bracket assembly. An anode helps protect the
outboard against galvanic corrosion by sacrificing its
metal to be slowly eroded instead of the outboard
metals.
a

a - Gear Case Anodes (2)

b - Transom Bracket Anode

Water Separating Fuel Filter Each anode requires periodic inspection especially
NOTE: The warning system will turn on when water in salt water which will accelerate the erosion. To
in the fuel filter reaches the full level. Refer to “Warn- maintain this corrosion protection, always replace
ing System” in Features & Controls Section. the anode before it is completely eroded. Never paint
or apply a protective coating on the anode as this will
This filter removes moisture and also debris from the reduce effectiveness of the anode.
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 direc-
tion 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.
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.

1B-4 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Spark Plug Inspection Fuse Replacement
Inspect spark plugs at the recommended intervals The electric starting circuit is protected from overload
by an 20 AMP fuse. If the fuse is blown, the electric
1. Remove the spark plug leads by twisting the rub-
starter motor will not operate. Try to locate and cor-
ber boots slightly and pull off. Inspect spark plug
rect the cause of the overload. If the cause is not
boots and replace if cracked.
found, the fuse may blow again. Replace the fuse
with a fuse of the same rating.

e
f
g
h
2. Remove the spark plugs to inspect and clean.
Replace spark plug if electrode is worn or the in-
sulator is rough,cracked, broken, blistered or
fouled.
The electrical wiring circuits on the outboard are pro-
3. Set the spark plug gap. See Specification Chart tected from overload by fuses in the wiring. If a fuse
in General Information Section. 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:
4. Before reinstalling spark plugs, clean away dirt e. Electric Fuel Pump Circuits – 20 AMP Fuse.
on the spark plug seats. Install plugs finger tight, f. Fuel/Air Injector Circuits – 20 AMP Fuse.
and tighten 1/4 turn or torque to 20 lb. ft. (27 N·m).
g. Starting Circuit – 20 AMP Fuse.
h. Ignition Coil/Oil Pump Circuit – 20 AMP Fuse.
Battery Inspection
The battery should be inspected at periodic intervals
to ensure proper engine starting capability.
IMPORTANT: Read the safety and maintenance
instructions which accompany your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against move-
ment.
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 noncon-
ductive shield to prevent accidental shorting of
battery terminals.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-5

Lubrication Points 5. Tilt Tube -- Lubricate through fitting.

Lubricate Point 1 with Quicksilver Special Lu-

bricant 101.
1. Trim Rod Ball Ends -- Turn the ball ends to work
the lubricant into the ball sockets.

5
! WARNING
The end of the steering cable must be fully re-
tracted into the outboard tilt tube before adding
lubricant. Adding lubricant to steering cable
when fully extended could cause steering cable
1 to become hydraulically locked. An hydrauli-
Lubricate Point 2 with Quicksilver Anti-Corro- cally locked steering cable will cause loss of
sion Grease or 2-4-C Marine Lubricant with Te- steering control, possibly resulting in serious
flon. injury or death.
2. Propeller Shaft -- Refer to Propeller Replacement 6. Steering Cable Grease Fitting (If Equipped) -- Ro-
for removal and installation of the propeller. Coat tate steering wheel to fully retract the steering
the entire propeller shaft with lubricant to prevent cable end (a) into the outboard tilt tube. Lubricate
the propeller hub from corroding and seizing to through fitting (b).
the shaft.
Lubricate Points 7 With Light Weight Oil.
2 7. Steering Link Rod Pivot Points -- Lubricate pivot
points.

6-b 6-a

Lubricate Points 3 thru 6 with Quicksilver 2-4-C

Marine Lubricant with Teflon or Special Lubri-
cate 101.
3. Swivel Bracket -- Lubricate through fitting.
4. Tilt Support Lever -- Lubricate through fitting. 7

1B-6 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Checking Power Trim Fluid Gear Case Lubrication
8. Tilt outboard to the full up position and engage
the tilt support lock.
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)

8
Draining Gear Case
9. Remove fill cap and check fluid level. The fluid
level should be even with the bottom of the fill WARNING
hole. Add Quicksilver Power Trim & Steering
Fluid. If not available, use automotive (ATF) auto- If gear housing is installed on outboard, to avoid
matic transmission fluid. accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before work-
9 ing near the propeller.

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

a
b

a - Vent Screw w/Sealing Washer

b - Fill Screw w/Sealing Washer

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-7

4. Inspect gear lubricant for metal particles (lubri- Storage
cant will have a “metal flake” appearance). Pres-
ence of a small amount of fine metal particles (re-
FUEL SYSTEM
sembling powder) on the fill screw bar magnet
indicates normal gear wear. An excessive IMPORTANT: Gasoline containing alcohol (etha-
amount of metal filings or larger particles (chips) nol or methanol) can cause a formation of acid
may indicate abnormal wear and requires gear during storage and can damage the fuel system.
housing disassembly and component inspection. If the gasoline being used contains alcohol, It is
advisable to drain as much of the remaining gas-
5. Note color of gear lubricant. White or cream color
oline as possible from the fuel tank, remote fuel
indicates presence of water in lubricant. Gear lu-
line, and engine fuel system.
bricant which has been drained from a gear case
recently in operation will have a yellowish color Fill the fuel system (tank, hoses, fuel pumps, and fuel
due to lubricant agitation/aeration. This is normal injection systems) with treated (stabilized) fuel to
and should not be confused with the presence of help prevent formation of varnish and gum. Proceed
water. with following instructions.
6. Presence of water in gear lubricant indicates the 1. Portable Fuel Tank – Pour the required amount of
need for disassembly and inspection of oil seals, Quicksilver Gasoline Stabilizer (follow instruc-
seal surfaces, o-rings, water pump gaskets as tions on container) into fuel tank. Tip fuel tank
well as gear housing components for damage. back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Quicksilver Gasoline Stabilizer
Checking Lubricant Level and (follow instructions on container) into a separate
Refilling Gear Case container and mix with approximately one quart
(one liter) of gasoline. Pour this mixture into fuel
IMPORTANT: Never add lubricant to gear hous- tank.
ing without first removing VENT screw, as
trapped air will prevent housing from being filled. 3. Place the outboard in water or connect flushing
Fill gear housing only when outboard is in oper- attachment for circulating cooling water. Run the
ating position. engine for ten minutes to allow treated fuel to fill
the fuel system.
1. With outboard in vertical position, insert lubricant
tube into fill hole.
PROTECTING INTERNAL ENGINE
2. Slowly fill housing thru “FILL” hole with Quicksil- COMPONENTS
ver Gear Lubricant until lubricant flows out of
NOTE: Before performing make sure the fuel system
“VENT” hole and no air bubbles are visible.
has been prepared for storage.
3. Install vent screw into “VENT” hole.
1. Remove spark plugs and add approximately one
IMPORTANT: DO NOT lose more than one fluid ounce (30ml) of engine oil into each spark plug
ounce (30cc) of gear lubricant while reinstalling hole.
“FILL” screw.
2. Rotate the flywheel manually several times to
4. Remove grease tube (or hose) from fill hole and distribute the oil in the cylinders. Reinstall spark
quickly install fill screw into “FILL” hole. 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 pres-
ent.
a

a - Vent Screw
b - Fill Screw

1B-8 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

PROTECTING EXTERNAL OUTBOARD

ÄÄÄÄ
COMPONENTS

ÄÄÄÄ
1. Lubricate all outboard components listed in the
Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Quicksilver Corrosion Guard on engine ex-
terior (except corrosion control anodes).

GEAR CASE
REMOVAL
Drain and refill the gear case lubricant.
Remove the filter through the top opening in the fly-
wheel cover.
POSITIONING OUTBOARD FOR STORAGE
Store outboard in an upright (vertical) position to al- INSTALLATION
low water to drain out of outboard.
Tuck the filter into the filter pocket. White side of the
filter facing out. Spread out the filter so that it fits into
CAUTION the channel that surrounds the pocket.
If outboard is stored tilted up in freezing tempera-
ture, trapped cooling water or rain water that may
have entered the propeller exhaust outlet in the 1998 Model Compressor Air intake
gear case could freeze and cause damage to the Filter
outboard.

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

Compressor Air Intake Filter

1997 Model Compressor Air Intake The filter should be changed every 100 hours of op-
Filter eration, or once a season. Never run the engine
without the air filter.
The air filter keeps dust and dirt out of the air com-
pressor. The filter is a layered type filter that contains
4 separate filter elements. The filter is not cleanable. Removal
The pores in the filter elements clog permanently, re-
quiring filter replacement. We recommend changing Remove flywheel cover from the engine. Remove
the filter every 100 hours of operation, or once a sea- cover (a) and the filter (b).
son. Never run the engine without the air fil-
ter.
Installation
Install filter (b) into the cover. Fasten cover with four
screws.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1B-9

Cleaning the Cooling Water TIMING ADJUSTMENT FOR HIGH ALTITUDE
OPERATION
Strainer Timing is not adjustable and is controlled automati-
cally by the Electronic Control Unit.

The cooling water strainer (a) filters the cooling water

flowing to the fuel cooler and air compressor. We rec-
ommend cleaning this strainer every 100 hours of op-
eration, or once a season.
1. Remove the bottom cowl. Disconnect the water
hose from the strainer plug.
2. Remove and clean the strainer.
3. Apply Loctite Pipe Sealant w/Teflon (92-88504)
to strainer threads and reinstall strainer. Recon-
nect water hose and secure with sta-strap.

1B-10 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

IMPORTANT 1
INFORMATION
C

GENERAL INFORMATION
Table of Contents
Page Page
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . 1C-1 1997 Model Powerhead Starboard View . . . . . . . . 1C-10
Conditions Affecting Performance . . . . . . . . . . . . . . 1C-1 1997 Model 200 Powerhead Port View . . . . . . . . . 1C-11
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1 1997 Model 200 Powerhead Top View . . . . . . . . . 1C-12
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 1997 Model 200 Powerhead Aft View . . . . . . . . . . 1C-13
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . 1C-4 1998 Model 200/225 Powerhead Starboard View 1C-14
Water Pressure Check . . . . . . . . . . . . . . . . . . . . . 1C-4 1998 Model 200/225 Powerhead Port View . . . . . 1C-15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 1998 Model 200/225 Powerhead Top View . . . . . 1C-16
Following Complete Submersion . . . . . . . . . . . . . . . 1C-5 1998 Model 200/225 Powerhead Aft View . . . . . . 1C-17
Salt Water Submersion . . . . . . . . . . . . . . . . . . . . . 1C-5 1998 Model 200/225 Powerhead Front View . . . . 1C-18
Submerged While Running . . . . . . . . . . . . . . . . . 1C-5
Propeller Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1C-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-6
Painting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8
Cleaning & Painting Aluminum Propellers &
Gear Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9
Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9
Instructions for “Wet” Application . . . . . . . . . . . . 1C-9

1C-0 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Serial Number Location Conditions Affecting
The engine serial number is located on the lower Performance
starboard side of the engine block. A serial number
is also located on the starboard side of the swivel
bracket. Weather

a
OGXXXXXX
19XX
b
XXXX
c

e
d
XX

a - Serial Number d - Year Manufactured

b - Model Year e - Certified Europe Insignia
c - Model Designation

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 combi-
nation of weather conditions.
Corporations internationally have settled on adop-
tion of I.S.O. (International Standards Organization)
engine test standards, as set forth in I.S.O. 3046
standardizing the computation of horsepower from
data obtained on the dynamometer, correcting all val-
ues to the power that the engine will produce at sea
level, at 30% relative humidity at 77° F (25°C) tem-
perature and a barometric pressure of 29.61 inches
of mercury.
Summer conditions of high temperature, low baro-
metric pressure and high humidity all combine to re-
duce 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.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-1

In pointing out the consequences of weather effects, (1.) Improves ease of planing off.
an engine – running on a hot, humid summer day –
(2.) Generally improves rough water ride.
may loose as much as 14% of the horsepower it
would produce on a dry, brisk spring or fall day. The (3.) If excessive, can make the boat veer
horsepower that any internal combustion engine pro- back-and-forth (bow steer).
duces depends upon the density of the air that it con-
sumes and this density is dependent upon the tem- BOTTOM
perature of the air, its barometric pressure and water
1. Boat Bottom: For maximum speed, a boat bot-
vapor (or humidity) content.
tom should be nearly a flat plane where it con-
Accompanying this weather-inspired loss of power is tacts the water and particularly straight and
a second but more subtle loss. At rigging time in early smooth in fore-and-aft direction.
spring, the engine was equipped with a propeller that
a. Hook: Exists when bottom is concave in fore-
allowed the engine to run within its recommended
and -aft direction when viewed from the side.
RPM range at full throttle. With the coming of the
When boat is planing, “hook” causes more lift
summer weather and the consequent drop in avail-
on bottom near transom and allows bow to
able horsepower, this propeller will, in effect, become
drop, thus greatly increasing wetted surface
too large. Consequently, the engine operates at less
and reducing boat speed. “Hook” frequently
than its recommended RPM.
is caused by supporting boat too far ahead of
Due to the horsepower/RPM characteristics of an en- transom while hauling on a trailer or during
gine, this will result in further loss of horsepower at storage.
the propeller with another decrease in boat speed.
b. Rocker: The reverse of hook and much less
This secondary loss can be regained by switching to
common. “Rocker” exists if bottom is convex
a smaller pitch propeller that allows the engine to run
in fore-and-aft direction when viewed from
again at recommended RPM.
the side, and boat has strong tendency to por-
To obtain optimum engine performance under poise.
changing weather conditions, the engine MUST be
c. Surface Roughness: Moss, barnacles, etc.,
propped to allow it to operate at or near the top end
on boat or corrosion of motor’s gear housing
of the recommended maximum RPM range at wide-
increase skin friction and cause speed loss.
open-throttle with a normal boat load.
Clean surfaces when necessary.
This will allow the engine to develop full power while
d. Gear Housing: If unit is left in the water, ma-
operating in an RPM range that discourages damag-
rine vegetation may accumulate over a peri-
ing detonation.
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
Boat cause the engine to overheat.

WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat
(persons and gear) has a significant effect on the
boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to por-
poise.
(3.) Can make the bow bounce excessively in
choppy water.
(4.) Will increase the danger of the following
wave splashing into the boat when com-
ing off plane.
b. Shifting weight to the front (bow)

1C-2 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

TRIM WATER ABSORPTION
It is imperative that all through hull fasteners be
TRIMMING OUTBOARD “OUT” (UP) coated with a quality marine sealer at time of installa-
tion. Water intrusion into the transom core and/or in-
WARNING ner hull will result in additional boat weight (reduced
Excessive trim “out” also may reduce the stabil- boat performance), hull decay and eventual structur-
ity of some high speed hulls. To correct instabili- al failure.
ty at high speed, reduce the power GRADUALLY
and trim the outboard “in” slightly before resum- CAVITATION
ing high speed operation. (Rapid reduction in Cavitation is caused by water vapor bubbles forming
power will cause a sudden change of steering either from a sharp edge or angle on the gear case
torque and may cause additional momentary or from an irregularity in the propeller blade itself.
boat instability.) These vapor bubbles flow back and collapse when
1. Will lift bow of boat, generally increasing top striking the surface of the propeller blade resulting in
speed. the erosion of the propeller blade surface. If allowed
to continue, eventual blade failure (breakage) will
2. Transfers steering torque harder to left on single
occur.
outboard installations below 23 in. (584mm) tran-
som height.
VENTILATION
3. Increases clearance over submerged objects.
Ventilation occurs when air is drawn from the water’s
4. In excess, can cause porpoising and/or ventila- surface (excessive trim out angle) or from the engine
tion. exhaust flow (wrong propeller/propeller hardware
5. If trimmed out beyond the water pickup, reduced installed or gear case labyrinth seal worn) into the
water supply can cause overheating resulting in propeller blades. These air bubbles strike the propel-
engine damage. ler blade surface and cause erosion of the blade sur-
face. If allowed to continue, eventual blade failure
TRIMMING OUTBOARD “IN” (DOWN) (breakage) will occur.
CHARACTERISTICS

WARNING
Excessive speed at minimum trim “in” may
cause undesirable and/or unsafe steering condi-
tions. Each boat should be tested for handling
characteristics after any adjustment is made to
the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy
load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or
right (bow steer).
4. Transfers steering torque harder to right (or less
to the left) on single outboard installations.
5. Improves planing speed acceleration (by moving
trim adjustment bolt one hole closer to transom).

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-3

Engine Compression Engine
Engine compression should be checked with engine
block warm, throttle shutter wide open, all spark DETONATION
plugs removed and using a fully charged battery. Detonation in a 2-cycle engine resembles the “ping-
Normal compression for all cylinders should be 90 to ing” heard in an automobile engine. It can be other-
110 psi (616.3 – 753.3 kPa). Cylinders should not wise described as a tin-like “rattling” or “plinking”
vary more than 15 psi (103.4 kPa) between one sound.
another. A variance of more than 15 psi would
Detonation is an explosion of an unburned portion of
indicate the need for a power head inspection/
the fuel/air charge after the spark plug has fired. Det-
disassembly.
onation creates severe shock waves in the engine,
and these shock waves often find or create a weak-
ness: The dome of a piston, cylinder head/gasket,
Water Pressure Check piston rings or piston ring lands, piston pin and roller
NOTE: To perform these checks, a Water Pressure bearings.
Gauge Kit, (91-79250A2) is recommended. A few of the most common causes of detonation in a
1. Water pressure at idle, in NEUTRAL, is 1-1/2 - marine 2-cycle application are as follows:
4-1/2 psi. (10.3 - 30.8 kPa). a. Over-advanced ignition timing.
2. Water pressure should increase, then drop to 4-6 (1.) Use of low octane gasoline.
psi. (27. - 41 kPa) prior to 2500 RPM (due to pop-
pet valve opening at 2500 RPM). (2.) Propeller pitch too high (engine RPM be-
low recommended maximum range).
3. At 2500 RPM, water should not exceed 12 psi
(82.7 kPa). (3.) Lean fuel mixture at or near wide-open-
throttle.
4. Static test (boat stationary - operate in forward
gear with a cut down propeller) at 5000 RPM or (4.) Spark plugs (heat range too hot – incor-
above is 8 - 10 psi. (54.8 - 68.5 kPa). rect reach – cross-firing).
(5.) Inadequate engine cooling (deteriorated
CAUTION cooling system).
A modified propeller or low pitch propeller is re- (6.) Combustion chamber/piston deposits
quired to perform the above static test. Static test (result in higher compression ratio).
requires the boat be stationary in the water se-
Detonation usually can be prevented if:
cured to a dock or trailer and run in forward gear.
1. The engine is correctly set up.
DO NOT use a flush device for this test.
2. Diligent maintenance is applied to com-
bat the detonation causes.

51115
Damaged Piston Resulting from Detonation

1C-4 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Following Complete 6. Drain water from air compressor system as fol-
lows:
Submersion a. Dry or replace the air filter for the compressor.
b. Remove air outlet hose for the air compressor
Salt Water Submersion and drain water from compressor and hose.
Reinstall hose.
Due to the corrosive effect of salt water on internal
engine components, complete disassembly is nec- c. Remove the air hose from bottom of port side
essary before any attempt is made to start the en- fuel rail and drain water. Reinstall hose.
gine. 7. Drain water from engine as follows:
a. Remove air sensor from front of the air ple-
num. Tilt up the outboard and drain water out
Submerged While Running of the air plenum through the air sensor
When an engine is submerged while running, the mounting hole. Reinstall Sensor.
possibility of internal engine damage is greatly in- b. Remove spark plugs from engine.
creased. If, after engine is recovered and with spark
plugs removed, engine fails to turn over freely when c. Rotate flywheel manually to blow out any wa-
turning flywheel, the possibility of internal damage ter from the cylinders.
(bent connecting rod and/or bent crankshaft) exists. d. Add approximately one ounce (30ml) of en-
If this is the case, the powerhead must be disas- gine oil into each spark plug hole. Rotate the
sembled. flywheel manually several times to distribute
the oil in the cylinders. Reinstall spark plugs.
SUBMERGED ENGINE (FRESH WATER)
8. Drain water from the oil injection system as fol-
IMPORTANT: Engine should be run within 2 lows:
hours after recovery, or serious internal damage
a. Remove remote oil hose (black without blue
may occur. If unable to start engine in this period,
stripe) from pulse fitting on starboard side of
disassemble engine and clean all parts. Apply oil
engine.
as soon as possible.
b. Drain any water from hose and reconnect.
NOTE: If sand has entered the air intake on the en-
gine, do not attempt to the start the engine. Sand will c. If water was present in hose, check for water
cause internal engine damage. disassembly is re- in the remote oil tank. Drain tank if water is
quired to clean all internal engine components of present.
sand.
9. Disassemble the engine starter motor and dry
1. Recover engine from water as quickly as possi- components.
ble.
10. Prime the oil injection pump as follows:
2. Remove cowling.
a. Fill the engine fuel system with fuel. Connect
3. Clean the exterior of the outboard with fresh fuel hose and squeeze primer bulb until it fells
water. firm.
4. Dry all wiring and electrical components using b. Turn the ignition key switch to the “ON” posi-
compressed air. tion.
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. c. Within the first 10 seconds after the key
switch has been turned on, move the remote
d. Remove the water separating fuel filter and
control handle from neutral into forward gear
empty contents.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-5

 3 to 5 times. This will automatically start the 4. Bend tabs of propeller tab washer away from
priming process. thrust hub (rear), then remove propeller locknut,
tab washer, thrust hub (rear), propeller and thrust
N hub (forward) from propeller shaft.
F
a

NOTE: Audible click from the oil pump will tell you the
pump is priming. It may take a few minutes for the b
pump to complete the priming process.
51866
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. d
f
12. If engine fails to start, determine cause (fuel,
electrical or mechanical). c

Propeller Replacement d e

51871
Removal a - Thrust Hub (Forward)
b - Propeller Shaft
WARNING c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
When removing or installing propeller, verify re- e - Tab Washer
mote control is in NEUTRAL position and that key f - Propeller Nut
switch is “OFF.” Place a block of wood between
the anti-ventilation plate and propeller to prevent
accidental engine starting and to protect hands Installation
from propeller blades while removing propeller 1. To aid in future removal of the propeller, coat the
nut. propeller shaft splines with one of the following
1. Disconnect high tension leads from spark plugs Quicksilver lubricants:
and remove spark plugs from engine. – Anti-Corrosion Grease
– 2-4-C w/Teflon
2. Shift engine into neutral position. – Special Lubricant 101
3. Tilt engine to full up position and engage tilt lock 2. Place forward thrust hub onto propeller shaft.
lever.

1C-6 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

3. Align splines and slide propeller onto shaft.
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.

a e
22750
a - Forward Thrust Hub
c
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 d
washer and torque propeller nut to 55 lb. ft. (74.6
N·m). Verify nut is recessed into tab washer while
applying torque. c - Locking Tab Washer (Bend Tabs into Thrust Hub Grooves)
d - Propeller Nut
6. Bend 3 tabs from locking tab washer down into e - Rear Thrust Hub
grooves of propeller hub to secure propeller nut.
7. After first use, bend three tabs straight and retor-
que propeller nut [55 lb. ft. (74.6 N·m)]. Bend tabs
down into propeller hub grooves (check periodi-
cally for tightness.)

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-7

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

1. Wash gear housing with a muriatic acid base

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

1C-8 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Decal Application DECAL APPLICATION
1. Mix 1/2 ounce (16 ml) of dish washing liquid in one
gallon (4 l) of cool water to use as wetting solu-
Decal Removal tion.
1. Mark decal location before removal to assure NOTE: Leave protective masking, if present, on the
proper alignment of new decal. face of decal until final steps of decal installation. This
will ensure that the vinyl decal keeps it’s shape during
2. Carefully soften decal and decal adhesive with a installation.
heat gun or heat blower while removing old decal.
2. Place the decal face down on a clean work sur-
3. Clean decal contact area with a 1:1 mixture of iso- face and remove the paper backing from “adhe-
propyl alcohol and water. sive side” of decal.
4. Thoroughly dry decal contact area and check for 3. Using a spray bottle, flood the entire “adhesive
a completely cleaned surface. side” of the decal with the pre-mixed wetting solu-
tion.

Instructions for “Wet” Application 4. Flood area where the decal will be positioned
with wetting solution.
NOTE: The following decal installation instructions
5. Position pre-wetted decal on wetted surface and
are provided for a “Wet” installation. All decals
slide into position.
should be applied wet.
6. Starting at the center of the decal, “lightly”
TOOLS REQUIRED squeegee out the air bubbles and wetting solu-
tion with overlapping strokes to the outer edge of
1. Plastic Squeegee*
the decal. Continue going over the decal surface
2. Stick Pin until all wrinkles are gone and adhesive bonds to
the cowl surface.
3. Dish Washing Liquid/Detergent without am-
monia** “Joy” and “Drift” are known to be com- 7. Wipe decal surface with soft paper towel or cloth.
patible for this process.
8. Wait 10 - 15 minutes.
** Automotive Body Filler Squeegee
9. Starting at one corner, “carefully and slowly” pull
** Do not use a soap that contains petroleum based the masking off the decal surface at a 180° angle.
solvents.
NOTE: To remove any remaining bubbles, pierce the
SERVICE TIP: Placement of decals using the decal at one end of the bubble with stick pin and
“Wet” application will allow time to position de- press out the entrapped air or wetting solution with
cal. Read entire installation instructions on this your thumb (moving toward the puncture).
technique before proceeding.

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

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

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-9

1997 Model Powerhead Starboard View

23

22

16 15

14
1
13
21 12
11 2
17
10

9 8 7 6 3
4
20

19 18

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

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

1C-10 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

1997 Model 200 Powerhead Port View
5
21

1 2
20 4
3
6

15

19

14
18
8
13

12
17

16 11
10 9

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

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-11

1997 Model 200 Powerhead Top View
1
17 2 3
16
4

5
6

7
14
13

15

12

11 9

10
1 - Compressed Air (IN) 10 -Electric Fuel Pump
2 - Fuel Pressure Regulator 11 -Water Separating Fuel Filter
3 - Port Fuel Rail 12 -Starter Motor
4 - Fuel Return Hose to 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
9 - Vapor Separator

1C-12 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

1997 Model 200 Powerhead Aft View
27 1 2
3
26
24 25
4
5
6

23 7
16
22

17
8
15

18
14
21

19
13
20

9
10

12 11

1 - Air Compressor Cooling Water (OUT) to Tell-Tale 16 -Exhaust Pressure Sensor Connector
2 - Alternator 17 -#1 Ignition Coil
3 - Compressed Air (IN) 18 -#3 Ignition Coil
4 - Air Fitting Screen 19 -#5 Ignition Coil
5 - Fuel Pressure Test Valve 20 -Air Pressure Regulator
6 - Fuel Injector 21 -Fuel Pressure Regulator
7 - Tracker Diaphragm 22 -Port Fuel Rail
8 - Starboard Fuel Rail 23 -Air Pressure Test Valve
9 - Air Hose 24 -Fuel Return Hose to Fuel Cooler
10 -Fuel Hose 25 -Fuel (IN) Hose
11- Not Used 26 -Air Compressor
12 -Water Pressure Plug 27 -Air Inlet for Air Compressor
13 -#6 Ignition Coil
14 -#4 Ignition Coil
15 -#2 Ignition Coil

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-13

1998 Model 200/225 Powerhead Starboard View
2 5

1 3
4

12
13
23 14

22 15

11
7
17 10

6
16
10
21
17
8
20
9
19

18
56822
1- Fuel Pressure Test Valve 18 - Poppet Valve Assembly
2- Air Hose 19 - Air Hose
3- Electronic Control Module 20 - Fuel Hose
4- Starter Motor 21 - Fuel Injector
5- Throttle Plate/Air Plenum Assembly 22 - Starboard Fuel Rail
6- Air Temperature Sensor 23 - Direct Injector
7- Oil Hose to Air Compressor
8- Oil Hose from Oil Tank to Oil Pump
9- Oil Pump
10 - Main Power Relay
11 - Starter Solenoid
12 - Electric Fuel Pump Fuse (20 Ampere)
13 - ECM Fuse (20 Ampere)
14 - Harness Fuse (20 Ampere)
15 - Oil Pump Fuse (20 Ampere)
16 - Trim UP Relay
17 - Trim DOWN Relay

1C-14 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

1998 Model 200/225 Powerhead Port View
6 7
4
3
5 8

2
10
11
1 27

22

12

28
21
26 25 24 13
20

14

23
15

16
17
19 18 56032
1- High Pressure Fuel Pump 18 - Fuel Cooler Water Outlet Hose
2- Fuel Outlet Hose 19 - Oil Hose to Oil Pump
3- Vapor Separator Vent Hose 20 - 2 PSI Check Valve
4- Throttle Position Sensor (2 Each) 21 - Oil Reservoir
5- Oil Hose to Air Compressor 22 - Pluse Fuel Pump
6- Air Compressor 23 - Water Sensor
7- Air Inlet Hose to Air Compressor 24 - Low Pressure Fuel Pump
8- Tell-Tale Hose 25 - Fuel/Water Separator Filter
9- Temperature Sensor 26 - Vapor Separator
10 - Air Pressure Valve 27 - Water Inlet Hose to Fuel Cooler
11 - Fuel Injector 28 - Fuel Inlet Hose to Fuel Cooler
12 - Fuel Cooler
13 - Port Fuel Rail
14 - Fuel Return Hose to Vapor Separator
15 - Air Hose
16 - Fuel Hose
17 - Air Exit to Exhaust Adaptor Plate

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-15

1998 Model 200/225 Powerhead Top View
15 1
14

13
3
12
4

11

10

56824
1- Water Outlet (Tell-Tale) Hose
2- Air Inlet Nozzle for Air Compressor
3- Water Inlet Hose to Fuel Cooler
4- Air Compressor
5- Fuel Cooler
6- Oil Reservoir
7- Throttle Position Sensors (TPS) (2 each)
8- Manifold Absolute Pressure (MAP) Sensor Hose
9- Throttle Plate Assembly
10 - Oil Return Hose from Air Compressor
11 - Starter Motor
12 - Crank Position Sensor Harness
13 - Belt Tensioner
14 - Air Hose (80 PSI) to Fuel Rail
15 - 60 Ampere Alternator

1C-16 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

1998 Model 200/225 Powerhead Aft View
1
23
2

22
3
21
4
20
25
24
4
13
5

19 14 12

18 11
15

9
17
7
16 10

55990
1 - 60 Ampere Alternator 18 -Port Fuel Rail
2 - Compressed Air (IN) 19 -Fuel Regulator
3 - Fuel Pressure Test Valve 20 -Fuel (IN) Hose
4 - Fuel Injector 21 -Air Pressure Test Valve
5 - Tracker Valve 22 -Air Compressor
6 - Starboard Fuel Rail 23 -Air Inlet Hose to Air Compressor
7 - Air Hose 24 - Water Pressure Sensor
8 - Fuel Hose 25 - Manifold Absolute Pressure Sensor
9 - Water Pressure Sensor Hose
10 -#5 Ignition Coil
11- #3 Ignition Coil
12 -#1 Ignition Coil
13 -MAP Sensor
14 -#2 Ignition Coil
15 -#4 Ignition Coil
16 -#6 Ignition Coil
17 -Air Regulator

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1C-17

1998 Model 200/225 Powerhead Front View

1
2

13

11

12

4
5
10

7
56825
9 8

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

1C-18 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

IMPORTANT 1
INFORMATION
D

A B

C D

OUTBOARD MOTOR INSTALLATION

Table of Contents
Page Page
Notice to Installer and Owner . . . . . . . . . . . . . . . . . . 1D-1 Shift and Throttle Cable Installation to the
Boat Horsepower Capacity . . . . . . . . . . . . . . . . . . . . 1D-1 Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7
Outboard Remote Control . . . . . . . . . . . . . . . . . . . . . 1D-1 Shift Cable Installation . . . . . . . . . . . . . . . . . . . . . 1D-7
Selecting Accessories For The Outboard . . . . . . . . 1D-1 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Remote Wiring Connections . . . . . . . . . . . . . . . . . . 1D-10
Selecting Steering Cables and Remote Routing Location for Wiring and Hoses thru
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Clamp in Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . 1D-10
Determining Recommended Outboard Mounting Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-10
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Warning Gauge Harness . . . . . . . . . . . . . . . . . . 1D-11
Locating Centerline of Boat Transom . . . . . . . . . . . 1D-3 Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . 1D-12
Installation Specifications . . . . . . . . . . . . . . . . . . . . . . 1D-3 Front Clamp and Cowl Reassembly . . . . . . . . . 1D-12
Drilling Outboard Mounting Holes . . . . . . . . . . . . . . 1D-3 Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Applying Counter Rotation Decals . . . . . . . . . . . 1D-3 Connecting Fuel Hose to Engine . . . . . . . . . . . 1D-13
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Portable fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Installing Outboard To Boat Transom . . . . . . . . . . . 1D-4 Permanent Fuel Tank . . . . . . . . . . . . . . . . . . . . . 1D-13
Single Steering Cable and Steering link Rod Fuel Hose Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Fuel Hose connection . . . . . . . . . . . . . . . . . . . . . 1D-13
Installing Ride Guide Cable to Outboard Set Up Instructions for Oil Injection System . . . . . 1D-13
Tilt Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Filling Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
Steering Link Rod Installation . . . . . . . . . . . . . . . 1D-5 Oil Injection System . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Remote Control Installation . . . . . . . . . . . . . . . . . . . . 1D-6 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Counter (Left Hand) Rotation Outboards . . . . . 1D-6 Priming the Oil Injection Pump . . . . . . . . . . . . . 1D-15
Required Side Mount Remote Control or Ignition Purging Air From the Engine Oil Tank . . . . . . . 1D-16
Key Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6 Trim In Angle Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-16
Boats Equipped with Side Mount Remote Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6
Boats Equipped with Panel or Console Mount
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6

1D-0 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Notice to Installer and Owner Outboard Remote Control
This manual as well as safety labels posted on the The remote control connected to the outboard must
outboard use the following safety alerts to draw your be equipped with a start-in-gear protection device.
attention to special safety instructions that should be This prevents the engine from starting when the out-
followed. board is in gear.

WARNING WARNING
WARNING – Hazards or unsafe practices which Avoid serious injury or death from a sudden un-
COULD result in severe personal injury or death. expected acceleration when starting the engine.
The design of this outboard requires that the re-
CAUTION mote control used with it must have a built in
start-in-gear protection device.
CAUTION – Hazards or unsafe practices which
could result in minor injury or product or proper-
ty damage.
Selecting Accessories For
The Outboard
Boat Horsepower Capacity Some accessories not manufactured or sold by Mer-
cury Marine are not designed to be safely used with
U.S. COAST GUARD CAPACITY these outboards or outboard operating system. Ac-
MAXIMUM HORSEPOWER XXX quire and read the installation, operation and mainte-
MAXIMUM PERSON
nance manuals for all selected accessories.
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT Electric Fuel Pump
CAPACITY XXX
If an external mounted electric fuel pump is used, the
Do not overpower. Most boats will carry a required fuel pressure must not exceed 4 psi at the engine. If
capacity plate indicating the maximum acceptable necessary, install a pressure regulator to regulate the
power and load as determined by the manufacturer pressure.
following certain federal guidelines. If in doubt, con-
tact the boat manufacturer.
WARNING
WARNING The misuse of acceptable accessories or the use
of unacceptable accessories can result in seri-
Using an outboard that exceeds the maximum ous injury, death or product failure.
horsepower limit of a boat can 1. cause loss of
boat control 2. place too much weight at the tran-
som altering the designed flotation characteris-
tics of the boat or 3. cause the boat to break apart Selecting Steering Cables
particularly around the transom area. Overpow-
ering a boat can result in serious injury, death or and Remote Control Cables
boat damage. Refer to “Quicksilver Accessories Guide” to deter-
mine 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.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-1

Determining Recommended WARNING
Outboard Mounting Height Boat instability can occur at high speeds by
installing engine at the wrong transom height.
Contact the boat manufacturer for their recom-
mendations for a specific engine installation.

26 in.
(660m
m)
25 in.
(635m
m)
24 in.
(609m
m) b
23 in.
(584m c
m)
e 22 in.
(560m
e m)
21 in.
(533m a
m)
20 in. d
(508m
m)
19 in.
(482m
m)

10 20 30 40 50 60 70 80

NOTE: Add 5 in. (127mm) for XL models and 10 in. d. This line may be preferred to determine out-
(254mm) for XXL models to listed outboard mounting board mounting height dimension for dual
height. outboard installation.
a. This solid line is recommended to determine e. Outboard mounting height (height of out-
the outboard mounting height. board transom brackets from bottom of boat
transom). For heights over 22 in. (560mm), a
IMPORTANT: Increasing the height of outboard
propeller, that is specifically designed for sur-
generally will provide the following: 1) Less
facing operation, such as the “Laser” and “Mi-
steering torque, 2) more top speed, 3) greater
rage” series, usually are preferred.
boat stability, but, 4) will cause more prop “break
loose” which may be particularly noticeable f. Maximum boat speed anticipated.
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 out-
board mounting height dimension, if maxi-
mum speed is the only objective.

1D-2 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Locating Centerline of Boat outboard mounting bolts to be closer than 1 in.
(25.4 mm) from top of boat transom. Upper
Transom mounting bolts must never be installed thru
shims.
Locate (and mark with pencil) vertical centerline (a)
of boat transom. 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.
A B Use a 17/32 inch (13.5mm) diameter drill bit and drill
4 mounting holes perpendicular to and thru the tran-
som.
a
IMPORTANT: If using “Transom Drilling Fixture”
C D (part number 91-98234A2), use drill guide holes
marked “A” when drilling outboard mounting
a - Centerline of Transom holes.
NOTE: Dimensions “A” & “B” and “C” & “D” are equal
length.

Installation Specifications
a
a
b b

a
a – Transom Opening – Minimum
Single Engine – 33-3/8 in. (848 mm) a - Centerline of Transom
Dual Engines – 59-3/4in. (1518 mm) b - Transom Drilling Fixture (91-98234A2)

b – Engine Center Line For Dual Engine

26 in. (660mm) Minimum IMPORTANT: During installation of dual or multi-
ple V-6 product, the following is recommended.
A minimum of 26 inches (660mm) centerline to
centerline width is recommended. This is re-
Drilling Outboard Mounting quired to alleviate cowling interference during
Holes lock to lock turns if one outboard would be in the
full tilt position, while the other outboard(s) are in
IMPORTANT: Before drilling any mounting holes, the vertical running position.
carefully read “Determining Recommended Out-
board Mounting Height,” preceding. There is a
3/4 in. (19 mm) difference between outboard Applying Counter Rotation Decals
mounting holes in transom brackets.
IMPORTANT: For dual outboard counter rotation
WARNING installations, the left-hand rotation outboard is
generally placed on the port side of boat tran-
DO NOT, under any circumstances, allow upper som.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-3

Apply “COUNTER ROTATION”decal (supplied with
left-hand rotation outboard) onto bottom cowl (rear)
Installing Outboard To Boat
of right-hand rotation outboard. Match decal place- Transom
ment with left-hand rotation outboard.
IMPORTANT: If boat is equipped with thru tilt tube
steering, steering cable end must be installed
a b into tilt tube of outboard (port outboard only for
dual outboard installations) before securing out-
board to transom. Refer to “Steering Cable and
Steering Link Rod Installation” following.
Refer to “Determining Recommended Outboard Mo-
tor Mounting Height”, preceding and position out-
board on boat transom, to align mounting holes in
transom bracket that will place the outboard nearest
a - Counter Rotation Decal (Left-Hand Rotation Outboard) to the recommended mounting height.
b - Counter Rotation Decal (Right-Hand Rotation Outboard)
CAUTION
Marine sealer must be used on shanks bolts to
Lifting Outboard make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when
WARNING tightening transom bolts.
Verify lifting ring is threaded on crankshaft a Apply marine sealer to shanks of mounting bolts (not
minimum of 5 turns and that hoist has a maxi- threads) and secure outboard to transom with 4 bolts,
mum lift capacity over 500 lbs. (227 kg) BEFORE flat washers and locknuts, as shown. Be sure that in-
lifting outboard. stallation is water-tight.
Remove cowling from outboard. Remove plastic cap
from center of flywheel. Thread lifting eye (a) into fly- WARNING
wheel hub a minimum of 5 turns. Replace plastic cap Before operating, outboard(s) MUST BE SE-
after installation. Connect hoist [minimum lift capac- CURED to boat transom with four 1/2 in. diameter
ity of 500 Ibs. (227 kg)] to lifting eye. Lift outboard and bolts and locknuts, as follows: 2 bolts must be in-
place on boat transom. stalled thru upper mounting holes and 2 bolts
b thru lower mounting holes. Installation must be
water-tight and outboard should be checked for
tightness on the transom during operation. Fail-
ure to bolt outboard to transom (using 4 bolts and
a locknuts, as shown) may result in damage to boat
and/or loss of outboard and possible injury to oc-
cupants of boat.

b
c
b
a - Lifting Eye (91-75132)
b - Hoist

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

1D-4 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Single Steering Cable and Steering Link Rod Installation
Steering link Rod Installation IMPORTANT: The steering link rod that connects
the steering cable to the engine must be fastened
NOTE: These instructions are for single cable-single using special washer head bolt (“a” – Part Num-
outboard installations. Instructions for mounting dual ber 10-14000) and self locking nuts (“b” & “c” –
engines are included with the applicable dual engine Part Number 11-34863). These locknuts must
attaching kit. Refer to “Quicksilver Accessories never be replaced with common nuts (non lock-
Guide” to determine correct kit. ing) as they will work loose and vibrate off freeing
Refer to “Quicksilver Accessories Guide” to deter- the link rod to disengage.
mine correct length of steering cable.
IMPORTANT: Steering cable must be correct
WARNING
length. Sharp bends on too-short of a cable re- Disengagement of a steering link rod can result
sult in “kinks;” too-long of a cable require unnec- in the boat taking a full, sudden, sharp turn. This
essary bends and/or loops. Both conditions potentially violent action can cause occupants to
place extra stress on the cable. be thrown overboard exposing them to serious
injury or death.
Install steering mount and steering wheel in accor-
dance with installation instructions that accompany 3. Assemble steering link rod to steering cable with
each. two flat washers (d) and nylon insert locknut (“b”
– Part Number 11-34863). Tighten locknut (b) un-
til it seats, then back nut off 1/4 turn.
Installing Ride Guide Cable to 4. Assemble steering link rod to engine with special
Outboard Tilt Tube washer head bolt (“a” – Part Number 10-14000)
and nylon insert locknut (“c” – Part Number
IMPORTANT: Before installing steering cable in 11-34863). First torque bolt (a) to 20 lb. ft. (27.0
tilt tube, lubricate entire cable end with Quicksil- N·m), then torque locknut (c) to 20 lb. ft. (27.0
ver 2-4-C w/Teflon Marine Lubricant. N·m).
NOTE: Ride Guide steering cable is lubricated at the
factory and requires no additional lubrication at initial
installation. a
1. Lubricate seal (a) inside of outboard tilt tube and
entire cable end (b) with Quicksilver 2-4-C w/Te- d
flon Marine Lubricant.
2. Insert steering cable end thru outboard tilt tube
and secure steering cable to tilt tube with steering b
cable attaching nut (c), as shown. Torque nut to
35 lb. ft. (41.0 N·m).

95 95
c

c b WARNING
After installation is complete (and before operat-
ing outboard), check that boat will turn right
when steering wheel is turned right and that boat
a will turn left when steering wheel is turned left.
Check steering thru full range (left and right) and
at all tilt angles to assure interference-free move-
95 ment.
28160

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

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-5

Remote Control Installation Required Side Mount
Refer to “Quicksilver Accessories Guide” to deter- Remote Control or Ignition
mine correct length of remote control cables.
IMPORTANT: Remote control cables must be cor-
Key Switch Assembly
rect length. Sharp bends on too-short cables re-
sult in “kinks;” too-long cables require unneces- Boats Equipped with Side Mount
sary bends and/or loops. Both conditions place Remote Control
extra stress on the cables.
A Quicksilver Commander 2000 series Side Mount
IMPORTANT: Install control cables to remote Remote Control equipped with a warning horn must
control and mount remote control BEFORE at- be used with this outboard. This warning horn is nec-
taching control cables to engine. Refer to instal- essary for the engine warning system.
lation instructions included with remote control.

Counter (Left Hand) Rotation

Outboards
IMPORTANT: Counter rotating (left hand) gear
cases can be identified by a “L” stamped into the
end of the propeller shaft.
On counter (left hand) rotation outboards, the shift a
guide block moves aft for FORWARD and towards a -Warning Horn
the bow for REVERSE. This is opposite motion
compared to a standard (right hand) rotation out- Boats Equipped with Panel or
board.
Console Mount Remote Control
The Quicksilver Commander Series Dual Engine
Console Mount Control, P/N 88688A22, is required A Quicksilver Ignition Key/Choke Assembly
to shift the counter rotation outboard. The installation equipped with a warning horn must be used with this
instructions shipped with the control explain the pro- engine. This warning horn is necessary for the en-
cedure required to connect this control to a counter gine warning system.
rotation outboard.
a
IMPORTANT: If the counter rotation outboard is
rigged similar to a standard rotation outboard OR
if a standard rotation outboard is rigged similar
to a counter rotation outboard, the reverse gear
and bearing in the gear case must function as for-
ward gear. THE REVERSE GEAR/BEARING ARE
NOT DESIGNED TO CARRY THE SUSTAINED
LOADS THAT ARE GENERATED WHEN RUN-
NING UNDER CONSTANT HIGH RPM AND a - Warning Horn
THRUST CONDITIONS.

1D-6 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Shift and Throttle Cable OUTBOARD SHIFTING DIRECTION
On counter rotation outboards, the shift linkage
Installation to the Outboard moves in the opposite direction compared to a stan-
dard rotation outboard.
Shift Cable Installation STANDARD ROTATION GEAR OUTBOARDS
Install cables into the remote control following the Forward Gear Reverse Gear
instructions provided with the remote control.
NOTE: Install the shift cable to the engine first. The
shift cable is the first cable to move when the remote
control handle is moved out of neutral.

COUNTER ROTATION OUTBOARDS

Counter rotating (left hand) gear cases can be identi-
fied by a “L” stamped into the end of the propeller COUNTER ROTATION OUTBOARDS
shaft. Forward Gear
Reverse Gear
The Quicksilver Dual Engine Console Mount Control,
P/N 88688A22 or 88688A52, is required to shift the
counter rotation outboard. The installation instruc-
tions shipped with the control explain the procedure
required to connect this control to a counter rotation
outboard.
IMPORTANT: If the counter rotation outboard is
rigged similar to a standard rotation outboard OR
if a standard rotation outboard is rigged similar
to a counter rotation outboard, the reverse gear
and bearing in the gear case must function as for-
ward gear. THE REVERSE GEAR/BEARING ARE
NOT DESIGNED TO CARRY THE SUSTAINED
LOADS THAT ARE GENERATED WHEN RUN-
NING UNDER CONSTANT HIGH RPM AND
THRUST CONDITIONS.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-7

INSTALLATION 2. Position remote control and outboard into neu-
IMPORTANT: Step 1 must be followed for proper tral.
adjustment of the shift cable. N
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. 3. Slide the shift cable retainer forward until resis-
b. Move the remote control handle from neutral tance is felt, then slide cable anchor toward rear
into reverse and advance the handle to full until resistance is felt. Center the anchor pin be-
speed position. Slowly return the handle back tween resistance points.
to the neutral. Place a mark (b) on the cable
against the cable end guide.
a
c. Make a center mark (c), midway between
marks (“a”and “b”). Align the cable end guide
against this center mark when installing cable
to the engine.

STANDARD ROTATION OUTBOARDS

a
a - Anchor Pin
4. Align the shift cable end guide with the center
b mark as instructed in Step 1.

c
5. Place shift cable on anchor pin. Adjust cable bar-
rel 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
COUNTER ROTATION OUTBOARDS a
a b

a - Cable Barrel
b - Nylon Washer
c 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, ad-
just cable barrel closer to cable end guide.
b. Shift remote control into neutral. The prop-
shaft should turn freely without drag. If not,

1D-8 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

 b. Shift remote control into neutral. The prop- 4. Check throttle cable adjustment as follows:
shaft should turn freely without drag. If not,
a. Shift outboard into gear a few times to acti-
adjust barrel away from cable end guide. Re-
vate the throttle linkage. Make sure to rotate
peat steps a and b.
the propeller shaft while shifting into reverse.
c. Shift remote control into reverse while turning
propeller. The propshaft should lock solidly in F N R
gear. If not, adjust barrel away from cable end
guide. Repeat steps a thru 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 thru d.
b. Return remote control to neutral. Place a thin
Throttle Cable piece of paper between idle adjustment
screw and idle stop. Adjustment is correct
INSTALLATION when the paper can be removed without tear-
ing, but has some drag on it. Readjust cable
1. Position remote control into neutral. barrel if necessary.
N IMPORTANT: The idle stop screw must be touch-
ing the stop.
b

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

a - Idle Adjustment Screw

b - Idle Stop
5. Lock the barrel holder in place with the cable
a latch.
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

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-9

Remote Wiring Connections Routing Location for Wiring
Connect wiring. Place harness into the holder. and Hoses thru Clamp in
Bottom Cowl
IMPORTANT: Sufficient slack must exist in en-
gine 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 the front
clamp and separate the front end of the bottom cowl.
1. Remove the front clamp.

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

a - Front Clamp
Separate the front end of the bottom cowl as follows:
a. Remove the 2 front screws (a).

1D-10 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

 b. Loosen the rear 2 screws (b). Warning Gauge Harness

a
1. Connect the harness extension to gauge and en-
gine.

b 1 6

2 3 45

a - Remove Front Screws

b - Loosen Rear Screws - Remove Rubber Plug for Access to
Lower Screw
2. Separate the bottom cowl.

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

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-11

Battery Connections Front Clamp and Cowl Reassembly
Single Outboard 1. Fasten the clamp over the wiring, hoses, and
cables as shown.
a

(+)

(–) 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 negative (–) termi-
nals on starting batteries.

ÇÇÇÇ
ÇÇÇÇ
b c

ÇÇÇÇ
ÇÇ
ÉÉ ÇÇ
ÉÉ d
a
ÇÇÉÉ
e
g f
(–)

(–)

a - Battery Cables
b - Remote Wiring Harness
d - Ground Cable (Same Wire Size As Engine Battery Cable –
c - Warning Gauge Wiring Harness
. . Connect Between Negative (–) Terminals
d - Control Cables
e - Oil Hose with Blue Stripe
f - Fuel Hose
g - Oil Hose

1D-12 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

Fuel Connections with oil injection, the fuel pressure at the engine
must not exceed 4 psi. If necessary, install a pres-
Connecting Fuel Hose to Engine sure regulator between electrical fuel pump and
engine and set at 4 psi maximum.

MOUNTING OIL TANK

Portable fuel tank
1. Mount the remote oil tank in the boat. The tank
Select a suitable location in boat within engine fuel should be restrained from moving. Use the oil
line length limitations and secure tank in place. tank hold down kit provided.
2. Arrange the hoses so they will not get pinched,
Permanent Fuel Tank kinked, or stretched during operation.
These should be installed in accordance with indus- NOTE: A Quicksilver Accessory oil hose extension
try and federal safety standards which include rec- kit (41729A3) is available.
ommendations 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

CONNECTING OIL HOSE WITH BLUE STRIPE
Connect fuel hose to fitting with hose clamp.
3. Remove shipping cap from fitting and connect oil
hose (a). Fasten hose with sta-strap.

a
a - Hose Clamp

Set Up Instructions for Oil

Injection System a
CAUTION
Be careful not to get dirt or other contamination
in tanks, hoses or other components of the oil in-
jection system during installation.

CAUTION a - Oil Hose with Blue Stripe

If an electric fuel pump is to be used on engines

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-13
CONNECTING OIL HOSE WITHOUT BLUE STRIPE NOTE: Lift up the clamp to gain access to front screw.
4. Remove shipping cap from fitting and connect
hose (a). 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.
8. Fasten clamp into cowl with two bolts.
a

a - Bolts
a

Filling Fuel System

a - Clamp Screws (2) NOTE: For initial start of a new engine or for an en-
gine that ran out of fuel, or was drained of fuel, the
7. Fasten bottom cowl together.
fuel system should to be filled as follows.

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

1D-14 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

• Turn the ignition key switch to the ON position for Priming the Oil Injection Pump
three seconds. This operates the electric fuel
pump. Before starting engine for the first time, prime the
oil injection pump. Priming will remove any air that
• Turn the ignition key switch back to the OFF posi- may be in the pump, oil supply hose, or internal pas-
tion, and squeeze the primer bulb again until it sages.
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 a b
listed in the Operation and Maintenance Manual. a - Oil Injection Pump
Tighten fill cap. b - Oil Supply Hose

a CAUTION
CAUTION
To prevent damage to the fuel pumps, fill the en-
gine fuel system with fuel. Otherwise the fuel
pumps will run without fuel during the priming
process.
Prime the oil injection pump as follows:
a - Fill Cap
1. Fill the engine fuel system with fuel. Connect fuel
2. Remove cap and fill engine oil tank with oil. Rein-
hose and squeeze primer bulb until it fells firm.
stall the fill cap.
2. Turn the ignition key switch to the “ON” position.
b

3. Within the first 10 seconds after the key switch

a - Engine Oil Tank has been turned on, move the remote control
b - Fill Cap
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.

90-855348R1 JANUARY 1998 IMPORTANT INFORMATION - 1D-15

Purging Air From the Engine Oil Tank boat when engine is trimmed extremely under or
in.
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
a - Tilt Pin

Trim “In” Angle Adjustment Trim Tab Adjustment

Some outboard boats, particularly some bass boats, Propeller steering torque may cause your boat to pull
are built with a greater than normal transom angle in one direction. This steering torque results from
which will allow the outboard to be trimmed further your outboard not being trimmed so the propeller
“in” or “under”. This greater trim “under” capability is shaft is parallel to the water surface. The trim tab can
desirable to improve acceleration, reduce the angle help compensate for this steering torque and can be
and time spend in a bow high boat attitude during adjusted within limits to reduce any unequal steering
planing off, and in some cases, may be necessary to effort.
plane off a boat with aft live wells, given the variety of
available propellers and height range of engine in- MODELS WITHOUT POWER STEERING
stallations. Operate your boat at normal cruising speed, trimmed
However, once on plane, the engine should be to desired position. Turn your boat left and right and
trimmed to a more intermediate position to a avoid a note the direction the boat turns more easily.
bow-down planing condition called “plowing”. Plow- If adjustment is necessary, loosen trim tab bolt until
ing can cause “bow steering” or “over steering” and trim tab moves freely (does not rub against locking
inefficiently consumes horsepower. In this condition, ridges). DO NOT strike tab to make adjustments.
if attempting a turn or encountering a diagonal, mod- Make small adjustments at a time. If the boat turns
erate wake, a more abrupt turn than intended may re- more easily to the left, move the trailing edge of trim
sult. tab to the left. If the boat turns more easily to the right
In rare circumstances, the owner may decide to limit move the trailing edge of trim tab to the right. Position
the trim under. This can be accomplished by pur- trim tab in one of the locating grooves BEFORE tight-
chasing a stainless steel tilt pin (P/N 17–49930A1) ening bolt to prevent damage to holding mechanism.
and inserting it through whatever pin hole is desired. Torque bolt to 40 lb. ft. (54.0 N·m) and retest.
The non-stainless steel shipping bolt should not be
used in this application other than on a temporary ba- MODELS WITH POWER STEERING
sis. Trim tab adjustment is not required. The trailing edge
of the trim tab should be set straight back.
WARNING
Avoid possible serious injury or death. Adjust
outboard to an intermediate trim position as
soon as boat is on plane to avoid possible ejec-
tion due to boat spin-out. Do not attempt to turn

1D-16 - IMPORTANT INFORMATION 90-855348R1 JANUARY 1998

ELECTRICAL

2
A

55990

IGNITION SYSTEM
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Troubleshooting with the Digital Diagnostic
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Troubleshooting without Digital Diagnostic
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 1997 DFI Troubleshooting without the DDT . . . . . 2A-11
Flywheel/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 1998 DFI Troubleshooting without DDT . . . . . . . . 2A-14
Flywheel/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Flywheel Removal and Installation . . . . . . . . . . . . . 2A-18
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Flywheel Cover Removal and Installation . . . . 2A-18
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Electronic Control Module (ECM) Removal and
Electronic Control Module (ECM) . . . . . . . . . . . . 2A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-19
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Ignition Module Removal and Installation . . . . . . . 2A-20
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Crank Position Sensor Removal and Installation . 2A-21
Crank Position Sensor . . . . . . . . . . . . . . . . . . . . . 2A-8 Throttle Position Sensors (TPS) Removal and
Throttle Position Sensor (TPS) . . . . . . . . . . . . . . 2A-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-21
Charging System Alternator . . . . . . . . . . . . . . . . . 2A-8
Manifold Absolute Pressure (MAP) Sensor . . . 2A-9
Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . 2A-9
Direct Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9
Disconnecting Harness Connectors from
Ignition Coils and/or Injectors . . . . . . . . . . . . . . . 2A-9
1998 EPA Certified . . . . . . . . . . . . . . . . . . . . . . . . 2A-9

2A-0 - ELECTRICAL 90-855348R1 JANUARY 1998

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)

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

1. Volt/Ohm Meter 91-99750A1

4. Adapter Harness 84-822560A5

2. Digital Diagnostic Terminal 91-823686A2 5. Service Tachometer 91-59339

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-1

Flywheel Holder 91-52344

91–52344

54964
Protector Cap 91-24161

Flywheel Puller 91-73687A1

2A-2 - ELECTRICAL 90-855348R1 JANUARY 1998

Notes:

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-3

Electrical Components
1617A
14 18
15

19
13
9

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

39 TO
BLOCK

54
42

30

45
48
47 43
32 46

41
40
52 44
29 51 50 53
49
56 55
6 Dielectric Grease (92-823506--1)
25 Liquid Neoprene (92-25711--2)
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

2A-4 - ELECTRICAL 90-855348R1 JANUARY 1998

 Electrical Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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)

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-5

Flywheel/Alternator

9
8

13
6

11 5

4
12
10

14

15
1

14

2A-6 - ELECTRICAL 90-855348R1 JANUARY 1998

Flywheel/Alternator
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 ALTERNATOR
2 1 SPRING
3 1 BEARING
4 1 BELT TENSIONER
5 1 BUSHING
6 1 SCREW (M10 x 45) 200 22.6
7 1 PULLEY
8 1 SCREW (M10 x 35) 300 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
Ignition System • Calculates the precise fuel and ignition timing re-
quirements based on engine speed, throttle posi-
tion, manifold pressure and coolant temperature.
Theory of Operation • Controls fuel injectors for each cylinder, direct in-
jectors for each cylinder and ignition for each cyl-
When the ignition key is turned to the RUN position, inder.
battery voltage is applied to the main relay through
the PURPLE wire. The main relay is then closed and • Controls all alarm horn and warning lamp func-
D.C. current from the battery or charging system is tions.
transferred through the main relay 20 Amp fuse to the • Supplies tachometer signal to gauge.
positive terminal of all 6 ignition coil primary wind-
ings. The negative terminal of the coil primary is con- • Controls RPM limit function.
nected to engine ground through the Electronic Con- • Monitors shift interrupt switch.
trol 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 Flywheel
of the 24 teeth on the flywheel and supplies a trigger
signal to the ECM. When the ECM receives this sig- 24 teeth under the flywheel ring gear provide engine
nal, the ECM will then open the ground circuit of the rpm and crankshaft position information to the ECM
coil primary. The magnetic field in the ignition coil pri- through the crank position sensor.
mary will then collapse cutting across the coil sec-
ondary winding creating a high voltage charge
(50,000 volts) that is sent to the spark plug. Ignition Coils
Inductive type ignition coils are used on the DFI
Electronic Control Module (ECM) engines.
Ignition Coil Ohm Test
The ECM requires 8 VDC minimum to operate. If the
ECM should fail, the engine will stop running. 1997 Models
The inputs to the ECM can be monitored and tested
Connect meter leads
by the Digital Diagnostic Terminal 91-823686A2 us- between each coil teri- 0.67 ± 0.1

ing adaptor harness 84-822560A5. mal pin.
The ECM performs the following functions:

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-7

1998 Models Charging System Alternator
Connect meter leads be- Battery charging system is contained within the belt
tween primary terminal driven alternator, including the regulator. At cranking
0.38 - 0.78

(GRN/Striped) and ground speeds, electrical power for the engine is provided by
(Black) terminal pin. the boat battery – minimum recommended size is
Connect meter leads be- 750, or 1,000 MCA, cold cranking amperes. Above
tween spark plug wire/high 650 RPM for 1997 Models (550 RPM on 1998 Mod-
8.1 - 8.9 k
els), all electrical power is provided by the alternator.
voltage tower and ground
terminal pin. Should engine rpm drop below 650 (550 RPM on
1998 Models), the alternator is not capable of provid-
ing sufficient output and the battery becomes the pri-
Crank Position Sensor mary source of electrical power. Once the engine is
running and rpm is 650 or higher, the engine will con-
Senses 24 teeth located on flywheel under ring gear. tinue to run should the battery become shorted or dis-
Supplies the ECM with crank position information connected.
and engine speed. If sensor should fail, the engine Alternator output (when hot) to the battery @ 2000
will stop running. RPM is approximately 33 - 38 amperes.
Throttle Position Sensor (TPS)
Two (2) Throttle Position Sensors are used in con-
junction 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 Model – RPM will be limited to 3000 rpm. If
both TPS’s should fail, on 1997 and 1998 model en-
gines, 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.

2A-8 - ELECTRICAL 90-855348R1 JANUARY 1998

Manifold Absolute Pressure (MAP) Disconnecting Harness Connectors
Sensor from Ignition Coils and/or Injectors
The map sensor is mounted between the cylinder
heads. A vacuum hose connects the map sensor to a
the intake manifold. The ECM regulates fuel flow, in
part, based on manifold absolute 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 in-
creases, the ECM decreases fuel flow.
Direct Injectors
6 direct injectors (1 per cylinder) are used to inject a 54871
fuel/air mix into cylinders. Injectors are mounted be-
tween fuel rails and cylinder heads.
a - Wire Clip (push center down to remove)
Direct Injector Ohm Test
(Injector Lead Disconnected)
Connect meter leads
between each injector 1 - 1.6
1998 EPA Certified
terminal pin.
All new outboards manufactured by Mercury
Fuel Injectors Marine are certified with the United States En-
vironmental Protection Agency as conform-
6 fuel injectors (1 per cylinder) are used to provide ing to the requirements of the regulations for
fuel from the fuel rail to the direct injectors. The fuel the control of air pollution from new outboard
injectors are mounted in the fuel rail. motors.
Fuel Injector Ohm Test
(Injector Lead Disconnected) Troubleshooting
Connect meter leads
between each injector 1.7 - 1.9
The ECM is designed such that if a sensor
terminal pin. fails, the ECM will compensate so that the
engine does not go into an over-rich condi-
tion.
Disconnecting a sensor for troubleshooting
purposes may have no noticeable effect.

The Digital Diagnostic Terminal must be

used to thoroughly check ECM system
components.

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-9

Troubleshooting with the Troubleshooting Without
Digital Diagnostic Terminal Digital Diagnostic Terminal
Troubleshooting without the DDT is limited to check-
ing resistance on some of the sensors.
Typical failures usually do not involve the ECM. Con-
b nectors, set-up, and mechanical wear are most likely
a
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
c 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 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.
d • 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 recorded as a
Fault in the ECM Fault History. Use the DDT to
view and clear the fault history when trouble-
a - Digital Diagnostic Terminal (91-823686A2) shooting/repair is completed.
b - Software Cartridge (91-822608--4) (91-822608--5) • If all cylinders exhibit similar symptoms, the prob-
c - DDT Reference Manual (90-825159-2)
d - Adapter Harness (84-822560A--5)
lem is with a sensor or harness input to the ECM.
• If problem is speed related or intermittent, it is
The Quicksilver Digital Diagnostic Terminal (DDT) probably connector or contact related. Inspect
has been developed specifically to help technicians connectors for corrosion, loose wires or loose
diagnose and repair Mercury Marine 2 and 4 cycle pins. Secure connector seating; use dielectric
engines. compound 92-823506-1.
Attach the diagnostic cable to the ECM diagnostic • Inspect the harness for obvious damage:
connector and plug in the software cartridge. You will pinched wires, chaffing.
be able to monitor sensors and ECM data values in-
cluding status switches. • Secure grounds and all connections involving
ring terminals (coat with Liquid Neoprene
The ECM program can help diagnose intermittent en- 92-25711--2).
gine problems. It will record the state of the engine
sensors and switches for a period of time and then • Check fuel pump terminals.
can be played back to review the recorded informa- • Check fuel pump pressure.
tion.
• Check air compressor pressure.
Refer to the Digital Diagnostic Terminal Reference
Manual for complete diagnostic procedures.

2A-10 - ELECTRICAL 90-855348R1 JANUARY 1998

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 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 ECM not functioning Injection System:

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 us-
ing Inductive Timing Light
91-99379.
–Check battery voltage (RED/YEL
Lead) @ ignition coils.
– Check for blown fuse (C15).
– 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 pres-
sure should be 10 ± 1 psi greater
than the air pressure.

1.5 Sheared Flywheel Key Remove flywheel and inspect key.

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-11

 1997 DFI Troubleshooting Guide (continued)
Symptom Cause Action
Engine cranks but will not start 1.6 Low fuel pressure Check for fuel leaks. If fuel pres-
(continued) sure leaks down faster than air
pressure, seals on fuel pump may
be leaking. Check air system pres-
sure, 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
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. TPS
reading 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 fe-
ness connection is poor. male connectors.

2.7 Loose connectors or improper- Inspect all connectors and harness

ly attached spark leads leads for proper termination. In-
spect 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 grey with alu-
minum specs, this indicates inter-
nal mechanical damage requiring
immediate attention before return-
ing engine to service.

3.3 Flywheel key sheared Remove flywheel and inspect key.

2A-12 - ELECTRICAL 90-855348R1 JANUARY 1998

 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

or tracker diaphragm. and 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 3000 5.1 Fouled spark plug See 3.2
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 Mer-
cury Marine Service Department
for correct adjustment procedures.

5.4 TPS sensor malfunction See 2.5

6. Engine runs rough above 3000 6.1 Fouled spark plug See 3.2
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 improper- Inspect all connectors and harness

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

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-13

1998 DFI Troubleshooting without DDT
1998 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.

2A-14 - ELECTRICAL 90-855348R1 JANUARY 1998

 1998 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 (C15).
– Check battery voltage to fuse
from key switch
(PURPLE Lead).
– Check for shorted stop wire
(BLK/YEL).
– Check crank position sensor
seting [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.

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-15

 1998 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 >700) 4.1 Broken fuel pressure regulator Measure fuel pressure. Remove
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

2A-16 - ELECTRICAL 90-855348R1 JANUARY 1998

 1998 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.

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-17

Flywheel Removal and FLYWHEEL REMOVAL
1. Remove alternator/air compressor belt from fly-
Installation wheel by using breaker bar to release belt ten-
sioner.
Flywheel Cover Removal and
Installation

1997 MODELS:
Removal
c
Remove flywheel cover by lifting off. Disconnect vent a
hose (a).
Installation
Reconnect vent hose (a) to fitting in flywheel cover. b
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
(b) for the air compressor.

a
56829
a - Belt
b - Tensioner
c - Breaker Bar
2. Remove flywheel nut.

1998 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 (a), and then push-
ing the cover down onto the rear pin and air intake
tube (b) for the air compressor.

a a

56828
a - Flywheel Holding Tool (91-52344)

2A-18 - ELECTRICAL 90-855348R1 JANUARY 1998

3. Remove flywheel. Electronic Control Module
a (ECM) Removal and
Installation
Removal
b 1. Remove top cowling.
2. Disconnect ECM harness connectors.
3. Remove 3 bolts securing ECM.
a

56827
a - Puller (91-73687A1
b - Protector Cap (91-24161) (HIDDEN)

FLYWHEEL INSTALLATION
1. Reinstall flywheel with nut and washer.
2. Torque flywheel nut to 125 lb. ft. (169.5 N·m)
3. Use breaker bar to relieve belt tensioner and rein-
stall alternator/air compressor belt.
4. Reinstall flywheel cover.
5. Reinstall top cowling.

55941
a

a
a - Bolts

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

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-19

Ignition Module Removal and 1998 MODEL – IGNITION MODULE (COIL)
Removal
Installation
1. Remove top cowling.
1997 MODEL – IGNITION MODULE (COIL) 2. Disconnect module harness.
Removal 3. Remove spark plug lead from spark plug.
1. Remove top cowling. 4. Remove module attaching bolts.
2. Disconnect module harness.
3. Remove spark plug lead from spark plug.
4. Remove module attaching bolts.

55990
a - Ignition Modules (6)
a
Installation

a - Ignition Modules (6) CAUTION

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

2A-20 - ELECTRICAL 90-855348R1 JANUARY 1998

Crank Position Sensor Throttle Position Sensors
Removal and Installation (TPS) Removal and
Removal Installation
1. Remove top cowling. Removal
2. Remove sta-strap securing sensor harness and 1. Remove top cowling.
disconnect harness.
2. Disconnect sensor harness.
3. Remove two bolts securing sensor bracket.
3. Remove screws securing sensors to bracket.
4. Remove bolt securing sensor to bracket.
1997 Models
c

b
a
d

a
51627
a - Sta-strap
b - Harness 1998 Models
c - Bracket Bolts
d - Sensor Bolt
a

Installation
1. Secure sensor to bracket with bolt. Torque bolt to
50 lb. in. (5.6 N·m).
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 be-
tween sensor and flywheel teeth.
3. Torque bracket bolts to 100 lb. in. (11.3 N·m).
4. Reconnect sensor harness.
5. Secure harness with sta-strap.
a - Throttle Sensors
6. Reinstall top cowling.
Installation
1. Secure sensors to bracket with screws. Torque
screws to 20 lb. in. (2.3 N·m).
2. Reconnect harness.
3. Reinstall top cowling.

90-855348R1 JANUARY 1998 ELECTRICAL - 2A-21

ELECTRICAL

2
B

51708

BATTERY CHARGING SYSTEM

AND STARTING SYSTEM
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Alternator Torque Specifications . . . . . . . . . . . . . . 2B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
System Components . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Alternator Description . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Diagnosis of Alternator System on Engine . . 2B-4
Alternator Assembly . . . . . . . . . . . . . . . . . . . . . 2B-5
Alternator System Circuitry Test . . . . . . . . . . . 2B-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Alternator Belt Tension Adjustment . . . . . . . . . . . 2B-14
Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Troubleshooting the Starter Circuit . . . . . . . . . 2B-15
Starter Circuit Troubleshooting Flow Chart . . 2B-16
Starter Removal and Installation . . . . . . . . . . . 2B-17
Starter Cleaning, Inspection and Testing . . . . . . 2B-19
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 2B-19
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Starter Reassembly . . . . . . . . . . . . . . . . . . . . . . 2B-21
Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . . 2B-23
Commander 2000 Key Switch Test . . . . . . . . . . . 2B-24

2B-0 - ELECTRICAL 90-855348R1 JANUARY 1998

Specifications
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)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw 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)

Alternator Torque Specifications

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

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

2. Ammeter (Obtain Locally)

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-1

Starter Motor

4
3
5

2
113

10

7
8
16 6
9
11

16 14
17 13 12 15 7
113 4 Cycle Oil (92-828000A12) A
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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
A – Torque bottom starter bolt to 21.0 lb. ft. (28.5 N·m)

2B-2 - ELECTRICAL 90-855348R1 JANUARY 1998

Replacement Parts 3. Never disconnect the alternator output lead, reg-
ulator harness or battery cables when the alter-
! WARNING nator is being driven by the engine.
4. Always remove NEGATIVE (–) battery cable from
Electrical, ignition and fuel system components
battery before working on alternator system.
on your Mercury/Mariner outboard are designed
and manufactured to comply with U. S. Coast 5. When installing battery, be sure to connect the
Guard Rules and Regulations to minimize risks NEGATIVE (–) (GROUNDED) battery cable to
of fire and explosions. Use of replacement elec- NEGATIVE (–) battery terminal and the POSI-
trical, ignition or fuel system components, which TIVE (+) battery cable to POSITIVE (+) battery
do not comply with these rules and regulations, terminal.
could result in a fire or explosion hazard and 6. When using a charger or booster battery, connect
should be avoided. it in parallel with existing battery (POSITIVE to
POSITIVE; NEGATIVE to NEGATIVE).

System Components
The battery charging system consists of the alterna- Alternator Description
tor, battery, ignition switch, starter solenoid and the The alternator employs a rotor, which is supported in
wiring which connects these components. 2 end frames by ball bearings, and is driven at 2.5
times engine speed. The rotor contains a field wind-
ing enclosed between 2 multiple-finger pole pieces.
a
The ends of the field winding are connected to 2
brushes which make continuous sliding contact with
c the slip rings. The current (flowing through the field
winding) creates a magnetic field that causes the ad-
jacent fingers of the pole pieces to become alternate
north and south magnetic poles.
A 3-phase stator is mounted directly over the rotor
pole pieces and between the 2 end frames. It con-
sists of 3 windings wound 120° electrically out-of-
phase on the inside of a laminated core. The wind-
d ings are connected together on one end, while the
other ends are connected to a full-wave rectifier
bridge.
The rectifier bridge contains 8 diodes which allows
current to flow from ground, through the stator and to
b
To the output terminal, but not in the opposite direction.
51708
a - Alternator
When current is supplied to the rotor field winding,
b - Battery and the rotor is turned, the movement of the magnetic
c - 20 Ampere Fuse fields created induces an alternating current into the
d - Starter Solenoid stator windings. The rectifier bridge changes this al-
ternating current to direct current which appears at
the output terminal. A diode trio is connected to the
Precautions stator windings to supply current to the regulator and
the rotor field during operation.
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 of the termi-
nals on the alternator, except as specifically in-
structed.

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-3

Voltage output of the alternator is controlled by a tran- Diagnosis of Alternator System on
sistorized voltage regulator that senses the voltage
Engine
at the battery and regulates the field current to main-
tain alternator voltage for properly charging the bat- 1. If problem is an undercharged battery, verify con-
tery. Current output of the alternator does not require dition has not been caused by excessive acces-
regulation, as maximum current output is self-limited sory current draw or by accessories which have
by the design of the alternator. As long as the voltage accidentally left on.
is regulated within the prescribed limits, the alterna-
2. Check physical condition and state of charge of
tor cannot produce excessive current. A cutout relay
battery. Battery must be at least 75% (1.230 spe-
in the voltage regulator also is not required, as the
cific gravity) of fully charged to obtain valid results
rectifier diodes prevent the battery from discharging
in the following tests. If not, charge battery before
back through the stator.
testing system.
A small amount of current is supplied by the excita-
tion circuit in the regulator to the rotor field to initially
start the alternator charging. Once the alternator be-
gins 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.

2B-4 - ELECTRICAL 90-855348R1 JANUARY 1998

3. Inspect entire alternator system wiring for de- 4. Check alternator drive belt for cracks and fraying.
fects. Check all connections for tightness and Replace if necessary. Check belt tension. Adjust
cleanliness, particularly battery cable clamps if necessary, as outlined under “Drive Belt Re-
and battery terminals. placement and Adjustment.”
IMPORTANT: RED output lead from alternator
must be tight. A darkened RED sleeve indicates
lead was loose and becoming hot. Alternator Assembly

g
f

j i

e
h

c a
d b 51683

a - Pulley Nut
b - Pulley
c - Spacer
d - Frame and Rotor Assembly
e - Brush Holder
f - Brush Cover
g - Regulator
h - Rectifier (Diode Assembly)
i - Insulator
j - End Cover

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-5

Alternator System Circuitry Test 3. Voltmeter should indicate battery voltage. If cor-
rect voltage is not present, check sensing circuit
Using a 0-20 volt DC voltmeter, perform the following (RED lead) for loose or dirty connections or dam-
tests: aged wiring.

OUTPUT CIRCUIT a
1. Connect POSITIVE (+) voltmeter lead to alterna-
tor terminal B (output terminal). Connect NEGA-
TIVE (–) lead to case ground on alternator.
2. Shake alternator wiring harness. Meter should in-
dicate battery voltage and should not vary. If
proper reading is not obtained, check for loose or
dirty connections or damaged wiring. 200
10060
OHMS 4030 201510
20 30
5
0
10 10 15
5 40
00 4 6 8 20
VOLTS 2 10
a 0
DC AMPS

DCV ACV

DVA

OHMS 4030 2015 10

10060 5
200
20 0
10 10 15 30
5 40
0
VOLTS
0
DC AMPS0
2 4 6 8
10
20 56024
a - Sense Lead (RED)

DCV ACV
VOLTAGE OUTPUT
1. Using a 0-20 volt DC voltmeter, connect POSI-
DVA
TIVE (+) lead of voltmeter to TERMINAL B of al-
ternator and NEGATIVE (–) lead of voltmeter to
engine ground.

56025
a - Terminal B

OHMS 4030 2015 10

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

1. Unplug RED and PURPLE lead connector from

alternator.
DCV ACV

2. Connect POSITIVE (+) voltmeter lead to RED

lead and NEGATIVE (–) voltmeter lead to ground.
DVA

56025
a - Terminal B

2B-6 - ELECTRICAL 90-855348R1 JANUARY 1998

2. Start engine and allow to warm up. Increase en- 5. With TERMINAL F grounded, voltage should rise
gine RPM from idle to 2000. Normal voltage out- to within the normal range (13.5 – 15.1). If voltage
put should be 13.5 – 15.1 volts. If voltage reading rises, replace the regulator.
is greater than normal, replace voltage regulator.
6. If the voltage DOES NOT rise to within the normal
3. If voltage reading is less than normal, fabricate a range with TERMINAL F grounded, perform
tool from a piece of stiff wire to the following spec- “CURRENT OUTPUT” test.
ifications:
CURRENT OUTPUT
1. With engine shut off, install ammeter (capable of
0.060 in. (1.52mm)
reading 60+ amperes) in series between TERMI-
NAL B on alternator and POSITIVE (+) terminal
13/16 in. (20.6mm) of battery.
2. Start engine and allow to warm up. Advance RPM
to 2000.
8 in. (203mm)
3. Insert tool, previously fabricated for VOLTAGE
4. Insert bent end of tool through end cover and
OUTPUT, through end cover and ground TERMI-
ground TERMINAL F.
NAL F.

51683 a

b d

OHMS 4030201510
10060 5
200
20 30 0
10 10
5 15 40
00 2 4 6 8
VOLTS 20 56026
0
DC AMPS 10
c
DCV ACV

20 a - Terminal F
b - Tool
DVA
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 output is
a low, a disassembly of the alternator is necessary
c 56027 to inspect and test individual components.
b
a - Terminal F
b - Tool
c - Jumper Wire to Engine Ground (Attach to end of Tool)

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-7

Repair DISASSEMBLY AND TEST
1. Remove 3 screws and nut securing end cover
REMOVAL and remove insulator and cover.
1. Remove top cowling. c
2. Disconnect battery cables from battery.
3. Disconnect wiring harness from alternator.
d
4. Use a breaker bar to release belt tensioner and
remove alternator belt.
5. Remove attaching bolts and remove alternator.

c
a
a
51683
a - Cover
b - Screws
b c - Nut
d - Insulator
2. Remove 5 screws securing regulator and brush
assembly.
c c
56829
a - Belt
b - Tensioner
c - Breaker Bar
d - Attaching Bolts

51680

a - Regulator
b - Brush Assembly
c - Screws

NOTE: Proper regulator operation can be deter-

mined by VOLTAGE OUTPUT and CURRENT OUT-
PUT, previous. If regulator does not meet specifica-
tions, replace regulator. Torque regulator screws to
17 lb. in. (1.9 N·m).

2B-8 - ELECTRICAL 90-855348R1 JANUARY 1998

NOTE: Brushes are replaced as an assembly. In- Reverse leads – NEGATIVE lead on POSITIVE stud
spect assembly for stuck brushes or excessive brush and POSITIVE lead on each diode assembly. NO
wear. Normal exposed brush length is 0.156 in. CONTINUITY should be observed. If continuity is ob-
(4.0mm). Minimum exposed brush length is 0.059 in. served in both tests, or NO CONTINUITY is observed
(1.5mm). in both tests, the rectifier assembly is defective and
must be replaced. Torque rectifier screws to 17 lb. in.
3. Remove 4 screws securing rectifier (diode as-
(1.9 N·m).
sembly) to alternator.

b c

b 51684 a 51679
a - Positive Stud
a - Screws
b - Negative Ohm Lead
b - Rectifier (Diode Assembly)
c - Positive Ohm Lead
NOTE: To test rectifier assembly, touch POSITIVE
(+) lead from ohmmeter to POSITIVE stud and NEG-
ATIVE (–) lead from ohmmeter to each diode termi-
nal. The ohmmeter should indicate continuity.

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

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-9

IMPORTANT: Depending on the polarity of the 2. Measure the outer diameter of the slip rings using
ohmmeter, reversed readings may be obtained – vernier calipers. STANDARD DIAMETER: 0.567
I.E. – CONTINUITY is observed when the NEGA- in. (14.4mm); MINIMUM DIAMETER: 0.551 in.
TIVE lead touches the POSITIVE stud and NO (14.0mm). If slip ring diameter is less than mini-
CONTINUITY is observed when the POSITIVE mum, rotor is not considered serviceable and al-
lead touches the POSITIVE stud. ternator should be replaced.
IMPORTANT: The regulator, rectifier and brush
assembly are the only components individually
replaceable on this alternator. If the rotor or sta-
tor is defective, the entire rotor, stator and hous-
ing must be replaced as an assembly.
IMPORTANT: Clean anti-corrosion paint from
electrical connections prior to reassembly. Coat
all electrical connections with LIQUID NEO-
PRENE (92-25711-1).

ROTOR TEST
1. Inspect slip ring surface for roughness, abnormal
wear and/or burning. If such conditions exist, ro- 51680
tor is not considered serviceable and alternator 3. Inspect rotor for an open circuit. Using an ohm-
should be replaced. meter, check for continuity between slip rings.
Resistance should not exceed 3 ohms. If no con-
tinuity exists, rotor is defective.

a
a

51684
a - Slip Rings

51682
a - Slip Rings

2B-10 - ELECTRICAL 90-855348R1 JANUARY 1998

4. Check rotor for short to ground. NO CONTINU- STATOR TEST
ITY should exist between slip rings and rotor
1. With rectifier removed, use an ohmmeter to
shaft. If CONTINUITY exists, rotor is defective.
check for a short circuit between each stator lead
and the stator frame. If CONTINUITY exists, sta-
tor is defective.

a
b

51683
a - Slip Rings
b - Rotor Shaft
51682
a - Stator Leads
b - Frame
2. Inspect stator for open circuit. Using an ohmme-
ter, check for an open circuit between each of the
stator leads. If no continuity exists, stator is de-
fective.

51682
a - Stator Leads

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-11

REASSEMBLY 3. Secure regulator to alternator with 2 screws [1 in.
(25.4mm) long]; 1 screw [0.25 in. (6.4mm) long]
1. Position rectifier assembly over stator leads.
and lockwashers. DO NOT tighten screws at this
b time.

c
b

51683 a
a - Rectifier Assembly b 51684
b - Stator Leads
a - Regulator
2. Form stator leads in a clockwise loop and secure b - Screws [1 in. (25.4mm)]
leads to rectifier with 4 screws. Torque screws to c - Screw [0.25 in. (6.4mm)]
17 lb. in. (1.9 N·m). 4. Secure brush assembly with 2 screws – [0.25 in.
(6.4mm) long] and [0.312 in. (8.0mm) long].

c
b

a
b
a
a

b 51684 51680
a - Stator Leads a - Brush Assembly
b - Screws [Torque to 17 lb. in. (1.9 N·m)] b - Screw [0.25 in. (6.4mm)]
c - Screw [0.312 in.(8.0mm)]

2B-12 - ELECTRICAL 90-855348R1 JANUARY 1998

5. Install end cover. Secure cover with 3 screws. 2. Before reinstalling pulley, verify spacer is in-
Torque screws to 23 lb. in. (2.6 N·m). Install termi- stalled on rotor shaft.
nal insulator. Torque nut to 36 lb. in. (4.1 N·m).

d a

a 51683
a - Spacer
3. Torque pulley nut to 50 lb. ft. (67.8 N·m).

51683
a - Cover Installation
b - Screw [Torque to 23 lb. in. (2.6 N·m)]
c - Terminal Insulator 1. Secure alternator to engine block with 2 attaching
d - Nut [Torque to 36 lb. in. (4.1 N·m)] bolts. Torque bolts to 40 lb. ft. (54.2 N·m).
2. Install alternator belt in groove of flywheel, alter-
PULLEY nator and compressor pulley.
1. While holding rotor shaft, remove pulley nut. 3. Reconnect electrical harness to alternator.
a d

c
c
a

b
b

51679

a - Pulley
b - Rotor Shaft
c - Nut
56829
a - Belt
b - Tensioner
c - Breaker Bar
d - Attaching Bolts

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-13

Alternator Belt Tension Starter System
Adjustment STARTER MOTOR AMPERES DRAW
Correct alternator belt tension is maintained by a belt STARTER MOTOR NO LOAD NORMAL
tensioner assembly. PART NO. AMP. DRAW AMP. DRAW
a
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 com-
55936 pletes the starter circuit between the battery and
a - Belt Tensioner Assembly 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 continuously for
more than 30 seconds. Allow a 2 minute cooling
period between starting attempts.

2B-14 - ELECTRICAL 90-855348R1 JANUARY 1998

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” posi-
tion.
3. Check terminals for corrosion and loose connec-
tions.
4. Check cables and wiring for frayed and worn in-
sulation.
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

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-15

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/RED
No voltage reading: 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

2B-16 - ELECTRICAL 90-855348R1 JANUARY 1998

 TEST 7
a. Connect voltmeter between common engine and Test Point1.
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

Starter Removal and Installation INSTALLATION

1. Secure starter to engine with 3 bolts.
REMOVAL Torque top attaching bolts to 23 lb. ft. (31.2 N·m).
Torque bottom attaching bolt to 21 lb. ft. (28.5
! CAUTION N·m).
Disconnect battery leads from battery before re- 2. Secure BLACK cable (with YELLOW sleeve) to
moving starter. POSITIVE (+) terminal on starter. Torque nut to
60 lb. in. (6.8 N·m).
1. Disconnect BLACK cable (with YELLOW sleeve)
from starter. a
2. Remove 2 upper bolts and 1 lower bolt securing
starter and remove starter.
b

c
b
a
c 52135
a - Top Bolts [Torque to 23 lb. ft. (31.2 N·m)]
b - Bottom Bolt [Torque to 21 lb. ft. (28.5 N·m)]
c - BLACK Cable (with YELLOW sleeve)
52135 d - Nut [Torque to 60 lb. in. (6.8 N·m)]
a - BLACK (with YELLOW sleeve) POSITIVE (+) 12-Volt
Cable
b - Upper Mounting Bolts
c - Lower Mounting Bolt

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-17

DISASSEMBLY 5. Remove armature (with drive end cap) from start-
er frame.
1. Remove starter as outlined in “Starter Removal
and Installation,” preceding. 6. Remove locknut and remove drive assembly
from armature shaft.
2. Remove 2 through bolts from starter.
3. Tap commutator end cap to loosen and remove
from frame. Do not loose brush springs.

b
11646
a - Through Bolts a
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 fol-
lows:
a. Remove hex nut and washers from POSI- 51711
TIVE (+) terminal and remove POSITIVE a - Hold Armature Shaft with Wrench on Hex Portion of Drive
brushes and terminal as an assembly. Assembly

b. Remove 2 bolts securing NEGATIVE (–) e g

brushes and brush holder to end cap. f

a c
b

a b c

11658
a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
c d e - Drive End Cap
b 11656 f - Armature Shaft
g - Washer
a - Brush Holder
b - Positive Brushes
c - Negative Brushes
d - Positive Terminal

2B-18 - ELECTRICAL 90-855348R1 JANUARY 1998

Starter Cleaning, Inspection 8. Open-circuited armatures often can be repaired.
The most likely place for an open circuit is at the
and Testing commutator bars, as a result of long cranking pe-
riods. Long cranking periods overheat the starter
motor so that solder in the connections melts and
CLEANING and INSPECTION is thrown out. The resulting poor connections
then cause arcing and burning of the commutator
1. Clean all starter motor parts. bars.
2. Check pinion teeth for chips, cracks or excessive 9. Repair bars, that are not excessively burned, by
wear. resoldering the leads in bars (using rosin flux sol-
3. Replace the drive clutch spring and/or collar if der) and turning down the commutator in a lathe
tension is not adequate or if wear is excessive. to remove burned material, then undercut the
mica.
4. Inspect brush holder for damage or for failure to
hold brushes against commutator. 10. Clean out the copper or brush dust from slots be-
tween the commutator bars.
5. Replace brushes that are pitted or worn to less
than 1/4 in. (6.4mm) in length. 11. Check the armature for ground. See the following
procedure (“Testing”).
6. Inspect the armature conductor (commutator bar
junction) for a tight connection. A loose connec-
tion (excessive heat from prolonged cranking
TESTING
melts solder joints) results in a burned commuta-
tor bar. Armature Test for Shorts
7. Resurface and undercut a rough commutator as Check armature for short circuits by placing on growl-
follows: er and holding hack saw blade over armature core
while armature is rotated. If saw blade vibrates, ar-
! CAUTION mature is shorted. Recheck after cleaning between
commutator bars. If saw blade still vibrates, replace
Do not turn down the commutator excessively.
armature.
a. Resurface the commutator and undercut the
insulation between the commutator bars 1/32
in. (0.8mm) to the full width of the insulation
and so that the undercut is flat.
b. Clean the commutator slots after undercut-
ting.
c. Sand the commutator lightly with No. 00
sandpaper to remove burrs, then clean the
commutator.
d. Recheck the armature on a growler for shorts
as specified in the following procedure (“Test-
ing”).

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.

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-19

2. If meter indicates continuity, armature is Testing Negative Brushes for Ground
grounded and must be replaced.
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 indi-
cates NO continuity, replace the NEGATIVE brush.
Repeat this procedure on the other NEGATIVE
brush.

51711

CHECKING POSITIVE BRUSHES AND

TERMINAL
Set ohmmeter to (R x 1 scale). Connect meter leads a
between POSITIVE brushes. Meter must indicate full 51711
continuity or zero resistance. If resistance is indi- a - NEGATIVE (–) Brushes
cated, inspect lead to brush and lead to POSITIVE b - End Cap
terminal solder connection. If connection cannot be
repaired, brushes must be replaced.

51711
a - POSITIVE (+) Brushes

2B-20 - ELECTRICAL 90-855348R1 JANUARY 1998

Starter Reassembly b. Install NEGATIVE brushes (along with brush
holder).
1. If brushes were removed, replace as follows:
a. Install POSITIVE brushes (along with POSI-
TIVE terminal) into commutator end cap. b
a c

d
a

b b a
11656
a - POSITIVE (+)Brushes
c b - NEGATIVE (–) Brushes
c - Brush Holder
d - Bolts (Fasten NEGATIVE Brushes and Holder)

d 2. If removed, reinstall parts on armature shaft. Use

a new locknut and tighten securely on end of
shaft.
e
e f g
f
52131
a - End Cap
b - POSITIVE Brushes
c - POSITIVE Terminal
d - Insulating Block
e - Insulating Washer
f - Hex Nut
d

a b c

11658
a - Locknut
b - Spacer
b c - Spring
d - Drive Assembly
e - Drive End Cap
f - Armature Shaft
c g - Washer
3. Lubricate helix threads on armature shaft with a
drop of SAE 10W oil.
a 51713 4. Lubricate bushing in drive end plate with a drop
a - POSITIVE (+) Terminal of SAE 10W oil.
b - Long Brush Lead
c - Push Lead into Slot 5. Position armature into starter frame.

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-21

6. Lubricate bushing (located in commutator end 8. Place springs and brushes into brush holder and
cap) with one drop of SAE 10W oil. DO NOT over- hold in place with brush retainer tool.
lubricate.
a

51713
a - Brush Retainer Tool

a - Bushing (DO NOT overlubricate) 9. Install commutator end cap onto starter frame.
Align marks on frame with alignment marks on
7. To prevent damage to brushes and springs when
end caps. Remove brush retainer tool. Install
installing commutator end cap, it is recom- through bolts and torque to 70 lb. in. (8.0 N·m).
mended that a brush retaining tool be made as
shown:

2-1/6″

5″ 9/16″
a

1-3/4″
52130
a - Alignment Marks

2B-22 - ELECTRICAL 90-855348R1 JANUARY 1998

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

DCV ACV

DVA

3 1

b 4
2

a - 12-VOLT Supply
b - VOA Leads

90-855348R1 JANUARY 1998 ELECTRICAL - 2B-23

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
23894
“RUN” or “START” and key pushed in to actuate
choke for this test.
KEY CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:
POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK

OFF

RUN

START

CHOKE*

2B-24 - ELECTRICAL 90-855348R1 JANUARY 1998

ELECTRICAL

2
C

TIMING, SYNCHRONIZING AND ADJUSTING

Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Crank Position Sensor Adjustment (All Models) . . . 2C-2
Throttle Cam Adjustment (1997 Models) . . . . . . . . . 2C-3
Maximum Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Throttle Plate Stop Screws . . . . . . . . . . . . . . . . . . 2C-3
Throttle Cam Adjustment
(1998 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4
Maximum Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Throttle Plate Screw . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Throttle Position Sensor (TPS) Adjustment
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Idle Speed (All Models) . . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Alternator Belt Tension Adjustment (All Models) . . . 2C-5

2C-0 - ELECTRICAL 90-855348R1 JANUARY 1998

Specifications 2. Digital Diagnostic Terminal 91-823686A2

1997 & 1998 MODELS

FULL THROTTLE RPM 5000 - 5750

RANGE
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 3. Cable [10 ft. (3.05m)]* 84-5003A1
THROTTLE POSITION
SENSOR 1
(INNER TPS)
@ IDLE 4.33 ± 0.10 VDC
@ W.O.T. 1.00 ± 0.25 VDC
THROTTLE POSITION
SENSOR 2
(OUTTER TPS)
@ IDLE 0.52 ± 0.10 VDC 4. ECM Harness 84-822560A5
@ W.O.T. 4.5 ± 0.25 VDC
[ Light Duty Use

Special Tools
1. Service Tachometer 91-59339

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

6. Tachometer Adaptor 91-825824A2

*Cable is provided with Digital Diagnostic Terminal

91-823686A2

90-855348R1 JANUARY 1998 ELECTRICAL - 2C-1

Crank Position Sensor Throttle Cam Adjustment
Adjustment (All Models) (1997 Models)
1. Remove flywheel cover. 1. Loosen throttle cam roller screw so the roller
moves freely. Allow the roller to rest on the
2. Using a feeler gauge, measure the air gap be-
throttle cam. Adjust the idle stop screw on the
tween the crank position sensor and a tooth on
throttle arm and align mark on cam with center of
the flywheel. It should be 0.040 in. ± 0.020 in.
roller.
[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). a
IMPORTANT: Crank Position Sensor must be per- c
pendicular to flywheel tooth.
d
3. Reinstall flywheel cover.
d b e
c

b a 54452

a - Throttle Cam Roller Screw

b - Throttle Cam
c - Idle Stop Screw
d - Alignment Mark
51533 e - Roller
a - Air Gap [0.040 in. ±0.020 in.(1.02mm ±0.51mm)]
b - Crank Position Sensor
c - Flywheel Tooth
d - Bracket Screws [Torque to 105 lb. in.(11.9 N·m)]
IMPORTANT: A new replacement crank position
sensor will have a felt pad on the end of the sen-
sor. Install the new sensor with the pad touching
the flywheel; this will result in a gap of 0.030
(0.762mm)

a
a - Felt Pad on a New Crank Position Sensor

2C-2 - ELECTRICAL 90-855348R1 JANUARY 1998

2. Hold throttle arm against idle stop. Tighten throttle Throttle Plate Stop Screws
cam roller screw so that roller just touches throttle
cam. 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
c
in. (0.279mm) (#80 drill). Contact the Mercury Ma-
d rine Technical Service Department for proper ad-
justment procedure.

b
a

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

Maximum Throttle a - Screws (DO NOT Adjust from Factory Setting)

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

90-855348R1 JANUARY 1998 ELECTRICAL - 2C-3

Throttle Cam Adjustment Maximum Throttle
(1998 Models) 1. Hold throttle arm against full throttle stop.
1. Loosen cam follower screw allowing cam follow- 2. Adjust full throttle stop screw to allow full throttle
er to move freely. valve opening while maintaining a 0.010 in.
(0.254 mm) clearance between arm of throttle
2. Allow roller to rest on throttle cam. Adjust idle stop shaft and stop on attenuator box.
screw on throttle arm to align cam roller in the
pocket of the throttle cam. 3. Tighten jam nut on full throttle stop screw.
3. Tighten roller arm screw to provide clearance of 4. Check for free play (roller lifts from cam) between
0.005 in. ±0.005 in. (0.127 mm ±0.127 mm) be- roller and cam at full throttle to prevent linkage
tween roller and cam. from binding. Readjust full throttle stop screw, if
necessary.
a e d
b

a
c
55982
d

a - Throttle Arm
b - Stop
e 55967
c - Full Throttle Stop Screw
a - Roller Arm Screw d - Throttle Shaft Arm
b - Roller e - 0.010 in. (0.254mm) Clearance
c - Throttle Cam f - Stop on Attenuator Box
d - Wide Open Throttle Stop Screw
e - Idle Stop Screw

2C-4 - ELECTRICAL 90-855348R1 JANUARY 1998

Throttle Plate Screw Alternator Belt Tension
IMPORTANT: DO NOT adjust throttle plate stop Adjustment (All Models)
screw from factory setting. The throttle plate
clearance is set @ 0.092 in. (02.34mm) (#42 drill). Correct alternator belt tension is maintained by a belt
Contact the Mercury Marine Technical Service tensioner assembly.
Department for proper adjustment procedure. a
a

a - Throttle Plate Stop Screw 55936

a - Belt Tensioner Assembly

Throttle Position Sensor

(TPS) Adjustment (All
Models)
The Throttle Position Sensors are not adjustable.
TPS settings can be monitored with the Digital Diag-
nostic 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.

90-855348R1 JANUARY 1998 ELECTRICAL - 2C-5

ELECTRICAL

2
D

51820

WIRING
Table of Contents
Page
Power Trim Wiring Diagram . . . . . . . . . . . . . . . . . . . 2D-1
Instrument Wiring Connections . . . . . . . . . . . . . . . . . 2D-2
Commander 3000 Classic Panel Remote
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3
Commander 3000 Panel Remote Control . . . . . . . . 2D-4
Commander 3000/3000 Clasic Components . . . . . 2D-6
Instrument/Lanyard Stop Switch Wiring
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8
Oil Level Gauge Wiring Diagram . . . . . . . . . . . . . . . 2D-9
Instrument/Lanyard Stop Switch Wiring
Diagram (Dual Outboard) . . . . . . . . . . . . . . . . . . . . 2D-10
QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . . . . . 2D-12
Tachometer Wiring Diagram . . . . . . . . . . . . . . . 2D-12
Water Temperature Gauge . . . . . . . . . . . . . . . . 2D-12
Oil Level Gauge Wiring . . . . . . . . . . . . . . . . . . . . 2D-13
Sender Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Engine Synchronizer Wiring Diagram . . . . . . . 2D-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14
Multi-Function Gauge . . . . . . . . . . . . . . . . . . . . . . . . 2D-15
Warning System Signals . . . . . . . . . . . . . . . . . . 2D-16
Warning System Operation . . . . . . . . . . . . . . . . 2D-18
Low Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . 2D-18
Oil Pump Not Functioning Electrically . . . . 2D-18
Engine Overheat . . . . . . . . . . . . . . . . . . . . . . 2D-18
Ignition Coil, Sensor, Injector or Warning
Horn Not Functioning . . . . . . . . . . . . . . . . . . 2D-18
Throttle Sensor Not Functioning . . . . . . . . . 2D-18
Water Separating Fuel Filter Is Full of
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-19
Engine Over-Speed Protection
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-19
Panel Mount Remote Control Wiring
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-20
1997 Model 200 DFI Wiring Diagram . . . . . . . . . . 2D-21
1998 Model 200/225 DFI Wiring Diagram . . . . . . . 2D-22

2D-0 - ELECTRICAL 90-855348R1 JANUARY 1998

Power Trim Wiring Diagram

c
b
a

l
e

h
j i

a - Tach. Connector j.- UP Solenoid

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

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-1

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

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

2D-2 - ELECTRICAL 90-855348R1 JANUARY 1998

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

a - Neutral Interlock Switch

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-3

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

2D-4 - ELECTRICAL 90-855348R1 JANUARY 1998

Notes:

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-5

Commander 3000/3000 Classic Components

1 3
2 95

13
10 9
12 95
11
95

8 21
5 95
18
16
6
19
95
95

20 24
95
15
22
28 14 17 23

95

7
17
7 23

25

7
27
26

7 Loctite 271 (92-809820)

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

2D-6 - ELECTRICAL 90-855348R1 JANUARY 1998

 Commander 3000/3000 Classic Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 HOUSING-Control (Panel Mount)
1 1 HOUSING-Control (Console Mount)
2 1 BOLT-Locking (Special) 150 12.5 16.9
3 5 SPRING
4 1 ROLLER
5 1 BUSHING
6 1 SWITCH ASSY-Neutral Start (2 Ring Terminals)
6 1 SWITCH ASSY-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″)

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-7

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

2D-8 - ELECTRICAL 90-855348R1 JANUARY 1998

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 q - Oil Level Sender Unit

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

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-9

Instrument/Lanyard Stop Switch Wiring Diagram
(Dual Outboard)

d k d

c b
g
l
BATT
BLK=BLACK
GND 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 h - Remote Control
b - Lanyard Stop Switch i - Synchronizer Gauge
c - Lead not used on Outboard Installations j - Synchronizer Module
d - Retainer k - Lanyard Switch (Isolation) Diode
e - Tachometer
f - Trim Indicator Gauge
g - Temperature Gauge

2D-10 - ELECTRICAL 90-855348R1 JANUARY 1998

IMPORTANT: On installations where gauge op-
tions will not be used, tape back and isolate un-
used wiring harness leads
g

BATT GND

i
SENDER

a
e

j
f

STARBOARD INSTALLATION 52206

l - Y Harness Sleeve over each Connection.

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

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-11

QSI Gauge Wiring Diagrams Water Temperature Gauge

WIRING DIAGRAM A
Tachometer Wiring Diagram Use this wiring diagram when using a separate light
Tachometer dial on back side of case must be set to switch for instrument lighting.
position number 4. b c
WIRING DIAGRAM A
Use this wiring diagram when using a separate light
switch for instrument lighting. d
a
b
c

a SEND
d

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 Recep-
tacle on Commander Side Mount Remote Control or TAN
51106 Lead coming from Accessory Ignition/Choke Assembly.
a - Connect to + 12 Volt
b - +12 Volt Light Switch Wire WIRING DIAGRAM B
c - Position Light Bulb to the Switched Position
d - Connect to NEGATIVE (–) Ground Use this wiring diagram when instrument lighting is
wired directly to the ignition key switch. (Instrument
WIRING DIAGRAM B lights are on when ignition key is turned on.)
Use this wiring diagram when instrument lighting is b
wired directly to the ignition key switch. (Instrument
lights are on when ignition key switch is turned on.)

b c
a
a
c

SEND

d 51105
51106 a - Connect to +12 Volt
b - Position Light Bulb to the Unswitched Position
a - Connect to +12 Volt c - Connect to NEGATIVE (–) Ground
b - Position Light Bulb to the Unswitched Position d - Connect to TAN Lead located at the Tachometer Recep-
c - Connect to NEGATIVE (–) Ground tacle on Commander Side Mount Remote Control or TAN
Lead coming from Accessory Ignition/Choke Assembly

2D-12 - ELECTRICAL 90-855348R1 JANUARY 1998

Route TAN lead on starboard side of engine to engi- LIGHT BULB POSITION B
ne/remote control harness. Connect as shown.
Use this position when instrument lighting is wired di-
IMPORTANT: Tape back and isolate any unused rectly to the ignition key switch. (Instrument lights are
wiring harness leads. on when ignition key switch is turned on.)
a
a

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

51112
Oil Level Gauge Wiring
a - Position Light Bulb to the Unswitched Position
b - Sender
LIGHT BULB POSITION A
Use this position when using a separate light switch SENDER WIRING
for instrument lighting. a
b

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

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

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-13

Engine Synchronizer Wiring Diagram Wiring Diagram – Gauge needle to point toward
slow running engine
LIGHT BULB POSITION A a c
b
Use this position when using a separate light switch
for instrument lighting.
b

GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE
51107
SEND
a - Tachometer Starboard Engine
b - Synchronizer Gauge
c - Tachometer Port Engine
d - Synchronizer Module

51105 Wiring Diagram – Gauge needle to point toward

a - +12 Volt Light Switch Wire fast running engine
b - Position Light Bulb to the Unswitched Position
a c
b
LIGHT BULB POSITION B
Use this position when instrument lighting is wired di-
rectly to the ignition key switch. (Instrument lights are
on when ignition key switch is turned on.)
a

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

a - Tachometer Starboard Engine

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

Maintenance
Clean gauge by washing with fresh water to remove
51106 sand and salt deposits. Wipe off with a soft cloth
a - Position Light Bulb to the Switched Position moistened with water. The gauge may be scored or
b - Sender
damaged if wiped with abrasive material (sand, sa-
Synchronizer wiring can be accomplished two differ- line or detergent compounds, etc.) or washed with
ent ways as an option to the user. solvents such as trichloroethylene, turpentine, etc.

2D-14 - ELECTRICAL 90-855348R1 JANUARY 1998

Multi-Function Gauge

Dip Switch Setting/Testing

NOTE: The multi-function gauge “Dip Switch” must a
be set on the back of gauge prior to operation. 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” settings and
BEFORE securing the gauge to dashboard of b
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 a - Gauge Lights (Red)
position). b - Gauge L.C.D. Bar Graph (Black)

a
Outboard Multi-Function Gauge
Setting
Model Dip Switch Setting
Test Display (All)
1 2 3 4

a Open
275 hp (3.4 Litre) Out-
1 2 3 4
boards
1 2 3 4 (single engine)
b
Open
Open 135-250 hp Outboards
52095 1 2 3 4
(single engine)
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 Open
mode. The gauge Temp, Batt, Oil, and Fuel red “Note” On Dual
warning lights should be alternately flashing “On” 1 2 3 4
Engine/Single Fuel
and “Off”; the Black L.C.D. bar graphs should be Tank Applications:
cycling. (This indicates that all gauge functions Position Dip Switch 4
are operational.) “Open” *
Open
3. Turn ignition switch to the “Off” position. Reset
the gauge “Dip Switch” to the correct operating * Dip Switch (4) in “Open Position” For Dual Engine Single
position for the outboard application. Fuel Tank Applications. Switches 1,2,3 Must Be In Specified
Model Position.

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-15

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 wiring harness.

b
b
a
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.
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

Engine Light Heat Fuel Reduction Activated
Light Light Light (approx. 3000 RPM)
Power Up/System Check Single Yes Yes Yes Yes No
Beep
Low Oil 4 Beep... Yes No
2 Min-
utes Off
No Oil Flow Continu- Yes Yes Yes
(1997 Models Only) ous (Limits to 3000 RPM)
Beep
Over Heat Continu- Yes Yes
ous (Limits to 3000 RPM)
Beep
Water In Fuel 4 Beep... Yes
2 Min-
utes Off
Over Speed Continu- Yes
ous (activated at 5800
Beep 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 psi Yes Yes Yes Yes
(Limits to 3000 RPM)

2D-16 - ELECTRICAL 90-855348R1 JANUARY 1998

 Problem Horn Check Low Oil Over Water In Engine Speed
Engine Light Heat Fuel Reduction Activated
Light Light Light
Horn Failure N/A Yes No
Battery Voltage too high No Yes Yes – If battery volt-
(16V) or too low (11V) or age is less than 10.4
very low (9.5V) V – RPM is reduced
to 3000.
If voltage is 9.5V or
less, RPM is reduced
to idle.
Over Heat Cyl. Head/Com- Continu- Yes Yes
pressor ous
Beep
Throttle Sensor Failure Continu- Yes 1997 Model – Speed
ous In- does not reduce if
termittant only 1 sensor fails.
Beeping 1998 Model – Speed
does reduce if 1 sen-
sor fails.
On 1997 and 1998
Models –
RPM is reduced to
Idle speed only if both
sensors fail.

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-17

Warning System Operation ENGINE OVERHEAT

LOW OIL LEVEL a

The system is activated when the engine tempera-

ture is too hot.
The system is activated when the oil in the engine The TEMP light (a) will come on and the warning horn
mounted oil reservoir tank drops below 50 fl. oz. (1.5 begins sounding. The warning system will automati-
liters) You still have an oil reserve remaining for 50 cally limit the engine speed to 3000 RPM.
minutes of full speed operation.
NOTE: The engine mounted oil reservoir tank (lo- IGNITION COIL, SENSOR, INJECTOR OR
cated beneath the top cowl) along with the remote oil WARNING HORN NOT FUNCTIONING
tank will have to be refilled.
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 PUMP NOT FUNCTIONING ELECTRICALLY
The system is activated if an ignition coil, sensor, in-
jector or warning horn is not functioning correctly.
a The CHECK ENGINE light (a) will turn on.

THROTTLE SENSOR NOT FUNCTIONING

The system is activated if the oil pump stops function-

ing electrically. No lubricating oil is being supplied to
the engine. Stop the engine as soon as possible.
Continuing to operate the engine can result in severe a
engine damage.
The OIL light (a) and CHECK ENGINE light (b) will The system is activated if the throttle sensors are not
come on and the warning horn will begin sounding. functioning correctly.
The warning system will automatically reduce and The CHECK ENGINE light (a) will turn on and the
limit the engine speed to 3000 RPM. The engine has warning horn will begin sounding.
to be shut off to reset the warning system.

2D-18 - ELECTRICAL 90-855348R1 JANUARY 1998

WATER SEPARATING FUEL FILTER IS FULL OF ENGINE OVER-SPEED PROTECTION SYSTEM
WATER

a
a

The system is activated when the engine speed ex-

The water level detection warning is activated when ceeds the maximum allowable RPM.
water in the water separating fuel filter reaches the
Anytime the engine over-speed system is activated,
full level. The water can be removed from the filter.
the warning horn (a) begins to sound continuously.
The WATER DETECTION light (a) will come on and The system will automatically reduce the engine
the warning horn will begin sounding a series of four speed to within the allowable limit.
beeps. If you continue to operate the outboard, the
NOTE: Engine speed should never reach the maxi-
light will stay on and the horn will sound every two
mum limit to activate the system unless the propeller
minutes.
is ventilating, an incorrect propeller is being used, or
the propeller is faulty.

90-855348R1 JANUARY 1997 ELECTRICAL - 2D-19

Panel Mount Remote Control Wiring Installation
a b
r
f
25
e
d g h
c
i
u

s
k
l o
j n
p
m
t
q
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
25 Liquid Neoprene (92-25711--2) LIT = Light
DRK = Dark

a - (+) 12 Volt Terminal

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

2D-20 - ELECTRICAL 90-855348R1 JANUARY 1998

 1997 Model 200 DFI Wiring Diagram
15
14 18 19 20
1 - Fuel Injector #1
1 2 10
2 - Fuel Injector #2 3 4 5 6 7 8 9 16
3 - Fuel Injector #3 17
4 - Direct Injector #1 11
5 - Direct Injector #2
6 - Direct Injector #3
7 - Direct Injector #4 12
8 - Direct Injector #5
9 - Direct Injector #6
10- Oil Pump 13
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
29- Remote Control Connector
30- 12 Volt Battery
31- Starter Solenoid
32- Temperature Gauge
33- Low Oil Light
34- Over-Heat Light 21
35- Water In Fuel Light
36- Check Engine Light 44
37- Digital Diagnostic Terminal Connector
38- Starter
39- To Remote Trim Switch
40- Cowl Mounted Trim Switch
41- Trim-Down Relay
27 26 25 24
42- Trim-Up Relay
43- Trim Pump
44- Electronic Control Module
45- Coil #6
46- Coil #5 28
47- Coil #4
48- Coil #3
49- Coil #2
22
42 41 40
50- Coil #1 36
51- Fuel Injector #4 35
52- Fuel Injector #5
53 52 51
53- Fuel Injector #6 50 49 48 47 46 45 37 34
33
38
32 23
31 29
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple 39
RED = Red
TAN = Tan
WHT = White 30
YEL = Yellow
LT. = Light
DK. = Dark 43

90-855348R1 JANUARY 1998 ELECTRICAL - 2D-21

 1998 Model 200/225 DFI Wiring Diagram
1 - Fuel Injector #1 1 2 3 4 5 6 8 12 13
2 - Fuel Injector #2 7 9 10
3 - Fuel Injector #3 11
4 - Direct Injector #1 14
5 - Direct Injector #2
6 - Direct Injector #3
7 - Direct Injector #4

GRY
BLK
PPL
8 - Direct Injector #5 B A B A B A
B A B A B A B A B A B A A B C D C B A C B A C B A

PNK/ORG
ORG/PNK
PNK/BRN
9 - Direct Injector #6

PNK/RED
BRN/PNK

RED/PNK
A B C

WHT/BRN
BRN/WHT

WHT/YEL
ORG/WHT

WHT/DK.BLU
DK.BLU/WHT
YEL/WHT
WHT/RED
RED/WHT

WHT/ORG

WHT/PPL
PPL/WHT

BLK

YEL
RED/YEL

BLU/YEL

BLK/GRN
BLK/ORG

LT.BLU/WHT
PPL/YEL
LT.BLU/GRN
10- Oil Pump

BLK/ORG
LT.BLU/BLK

GRY/RED
PPL/YEL

BLK/GRN
LT.BLU/RED

BLU/YEL
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) BLK

20- Digital Diagnostic Terminal Connector BLK

21- Compressor Temperature Sensor BLK/TAN BLK

22- Fuel Pump Circuit 20 Ampere Fuse BLK

BLK BLK
23- Fuel/Air Injector Circuit 20 Ampere Fuse

WHT/DK.BLU

LT.BLU/GRN

LT.BLU/RED

LT.BLU/BLK
24- Starting Circuit 20 Ampere Fuse

WHT/ORG
ORG/WHT

BRN/WHT

PNK/ORG
WHT/BRN

ORG/PNK

BLK/ORG

PNK/BRN
BRN/PNK

RED/BLU
RED/BLU
PPL/YEL
25- Ignition Coils and Oil Pump Circuits 20 Ampere Fuse GRN/PPL 1 1 PPL BLK/ORG

BLK
BLK

YEL
BLK/ORG BLK
26- Fuel Pump #2 (Outside Vapor Separator) PPL/WHT
PNK/PPL
2
3
2
3
BLU/YEL
LT.BLU/WHT TAN TAN 15
27- Fuel Pump #1 (Inside Vapor Separator) YEL/WHT 4
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 TAN/WHT
28- 12 Volt Battery PNK/YEL
RED/WHT
5
6
5
6
TAN/LT.BLU
TAN/BLK
TAN/PPL 16
29- Starter Solenoid PNK/RED 7 7
30- To Remote Control Trim Switch DK.BLU/WHT 8 8 PNK/LT.BLU BLK BLK
17
WHT/PPL 9 9 TAN/PPL BLK/RED BLK
31- Remote Control PPL/PNK 10 10 TAN
32- Auxilliary WHT/YEL 11 11
YEL/PNK 12 12345678 12345678 12345678910 11 12 BLK/GRN BLK/ORG LT.BLU
33- Check Engine Light WHT/RED 13
910
11
1719
11
1822
21
02
3141
12 2
56 91011
34 1719
11
18 22
21
02
3411
122
56 12
34 22
11
3411
22
3242
51
52
61
62
7182
921
78230
0
93312 13 BLK/YEL LT.BLU LT.BLU 18
34- Water In Fuel Light RED/PNK 14 14 BLK/RED
15 15
35- Over-Heat Light PNK/DK.BLU
DK.BLU/PNK 16 16
GRY
BLK/GRN

36- Low Oil Light GRN/YEL 17

38 17 ORG
BLK/GRN
TAN/GRN
TAN/BLK
TAN/BLK
37- Temperature Gauge GRN/RED
BLK
18
19
18
19
WHT
LT.BLU
TAN TAN/BLU 19a
38- Electronic Control Module BLK/TAN 20 20 TAN/GRN
BLK

39- Main Power Relay

BLK
BLK/TAN 21 21
GRN/BLU 22 22 BLK/TAN BLK/GRN TAN/BLK
40- Trim Down Relay GRN/ORG 23 37 23 GRN TAN/BLK 19b
41- Trim Up Relay
42- Cowl Mounted Trim Switch
GRN/BRN 24
41 40 39 36 24
25
YEL/PPL

43- Trim Pump 35 26

27
WHT
DK.BLU
B
A
DDT
20
44- 60 Ampere Alternator 28 DK.BLU
34

DK.BLU/PNK
PNK/DK.BLU
29
42

GRN/ORG
GRN/BRN
45- Starter

GRN/BLU
GRN/RED

GRN/PPL
GRN/YEL
RED/YEL

RED/YEL

RED/YEL
RED/YEL

RED/YEL

RED/YEL
PNK/PPL
PPL/PNK

PNK/YEL
YEL/PNK
30 GRY/RED BLK/GRN
46- Ignition Coil #6 33 31 BLK/GRN TAN/BLK
21

BLK
BLK

BLK

BLK

BLK
GRN

BLK
32 BRN BRN TAN/BLK
47- Ignition Coil #5
B A B A B A A B C A B C A B C A B C A B C A B C
48- Ignition Coil #4 ORG

49- Ignition Coil #3 UP

PNK/LT.BLU
TAN/BLK
RED/WHT
RED/BLK
A
B 22
50- Ignition Coil #2 DN TAN/WHT

51- Ignition Coil #1 TAN

87a

87a

87a
30
85

87
30

30
85

86
87

86
85

87
86
PPL
52- Fuel Injector #4 PPL
RED/WHT A
23

GRN/WHT

BLK
GRN/WHT
GRN
RED

RED
BLK

BLK

BLK
BLU
31 32

RED
RED/PPL

RED/WHT
PPL
B

YEL/PPL
RED/BLU

LT.BLU/WHT

LT.BLU/WHT
53- Fuel Injector #5 1 BLK/YEL
54- Fuel Injector #6 2 PPL
54 53 52
51 50 49 47 46
3
4
TAN/LT.BLU
BLK
RED A
24
48 5 GRY
RED/PPL B

6
7 YEL/RED

BLK = Black
30 8 RED/PPL RED/WHT
RED/YEL
A
B 25
BLU = Blue
BRN = Brown RED/BLK A
BLK B
GRY = Gray RED/PPL RED/PPL
RED/BLK A
GRN = Green BLK B
ORN = Orange
45 44 43
PNK = Pink A B C RED

RED

YEL/RED
PUR = Purple RED

RED

PPL
RED = Red
RED
26
RED RED
TAN = Tan
WHT = White
RED

BLK
RED BLK
27
YEL = Yellow BLK W/YEL ENDS BLK W/YEL ENDS

LT. = Light 28
DK. = Dark 29

2D-22 - ELECTRICAL 90-855348R1 JANUARY 1998

FUEL SYSTEM

3
A

FUEL PUMP
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Fuel Pump Pressure @ W.O.T. . . . . . . . . . . . . . . 3A-1
Fuel Pump Pressure @ Idle . . . . . . . . . . . . . . . . 3A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
Fuel Pump Description/Operation . . . . . . . . . . . . . . 3A-4
Testing Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5
Fuel Pump Removal/Disassembly . . . . . . . . . . . . . . 3A-6
Cleaning/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8

3A-0 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Specifications Special Tools
Fuel Pressure Gauge 91-16850
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 con-
junction with engine mechanical fuel pump, must be
limited to no more than 4 psi. (27.4kPa)

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3A-1

Fuel Pump

19

20

22
A
7 18
6
1 4
2 5
11
5
13 2 4 3

14
9
17 18
10
8 15
12

16 B

21

22
23

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

3A-2 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 Fuel Pump
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 1 FUEL PUMP ASSEMBLY
1 1 FUEL PUMP
2 2 CHECK VALVE
3 1 DIAPHRAGM KIT
4 2 RUBBER CHECK VALVE
5 2 RETAINER
6 1 SPRING
7 1 CAP
8 1 SPRING
9 1 CAP
10 1 DIAPHRAGM
11 1 GASKET–boost
12 1 GASKET–pulse
13 1 GASKET
14 1 PLATE
15 1 FITTING
2 SCREW–fuel pump (M5 x 40) 55 6.2
16
2 SCREW–pump to crankcase (M6 x 50) 55 6.2
17 1 BASE
18 2 SPRING CLAMP
19 1 HOSE
20 1 SLEEVE-Insulating (10-1/2 IN.)
21 1 HOSE
22 2 CLAMP (15.3)
23 1 CONNECTOR

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3A-3

Fuel Pump Checking for Restricted Fuel Flow
Caused by Anti-Siphon Valves
Description/Operation
While anti-siphon valves may be helpful from a safety
The fuel pump is a crankcase-pressure-operated, di-
stand-point, they clog with debris, they may be too
aphragm-type pump. Crankcase pulsating pressure
small, or they may have too heavy a spring. The pres-
(created by the up-and-down movement of piston) is
sure drop across these valves can create operational
transferred to fuel pump by way of a passage (hole)
problems and/or powerhead damage by restricting
between crankcase and fuel pump.
fuel flow to the fuel pump and carburetor(s). Some
When piston is in an upward motion, a vacuum is symptoms of restricted (lean) fuel flow which could
created in the crankcase, thus pulling in a fuel/air be caused by use of an anti-siphon valve are:
mixture (from carburetor) into crankcase. This vacu-
1. Loss of fuel pump pressure
um also pulls in on the fuel pump diaphragm, thus the
inlet check valve (in fuel pump) is opened and fuel 2. Loss of power
(from fuel tank) is drawn into fuel pump.
3. High speed surging
Downward motion of the piston forces the fuel/air
4. Pre-ignition/detonation (piston dome erosion)
mixture out of the crankcase into the cylinder. This
motion also forces out on the fuel pump diaphragm, 5. Outboards cuts out or hesitates upon accelera-
which closes the inlet check valve (to keep fuel from tion
returning to fuel tank) and opens the outlet check 6. Outboards runs rough
valve, thus forcing fuel to the carburetors.
7. Outboard quits and cannot be restarted
8. Outboard will not start
Fuel Pump Specifications
9. Vapor lock
NOTE: Fuel pressure should be measured between
Since any type of anti-siphon device must be located
in-line fuel filter and carburetors.
between the outboard fuel inlet and fuel tank outlet,
Fuel Pump Pressure at Wide Open Throttle: a simple method of checking [if such a device (or bad
Maximum: 10 PSI fuel) is a problem source] is to operate the outboard
with a separate fuel supply which is known to be
Normal: 6 - 8 PSI
Minimum: 4 PSI (With Water Separating Fuel Filter) good, such as a remote fuel tank.

Fuel Pump Pressure at Idle: If it is found that the anti-siphon valve is the cause of
the problem, either 1) remove the anti-siphon valve
Normal : 2 - 3 PSI or 2) replace it with a solenoid-operated fuel shut off
Minimum: 1 PSI valve.
Electric Fuel Pump Pressure, if used, must be limited
to no more than 4 PSI.

3A-4 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Testing Fuel Pump
Install clear fuel hose(s) between fuel pump and car-
buretor(s). Run engine, and inspect fuel passing thru
hose(s) for air bubbles. If air bubbles are found, see
“Air Bubbles in Fuel Line,” below. If air bubbles are
NOT found, see “Lack of Fuel Pump Pressure,”
below.

Problem: Air Bubbles in Fuel Line

Low fuel in tank. Fill tank with fuel.
Loose fuel line connection. Check and tighten all connectors.
Fuel pump fitting loose. Tighten fitting.
A hole or cut in fuel line. Check condition of all fuel lines and replace
Fuel Pump anchor screw(s) loose. Tighten all screws evenly and securely.
Fuel Pump filter cover anchor screw loose. Tighten screws securely.
Fuel pump filter gasket worn out. Replace Gasket.
Fuel pump gasket(s) worn out. Rebuild fuel pump.
Problem: Lack of Fuel Pump Pressure
An anti-siphon valve. See ‘‘Checking for Restricted Fuel Flow” preceding.
Air in fuel line. See ‘‘Air Bubbles in Fuel Line”, above.
A dirty or clogged fuel filter. Clean or replace fuel filter.
The fuel pickup in fuel tank is clogged or dirty. Clean or replace pickup.
Worn out fuel pump diaphragm. Rebuild fuel pump.
Worn out check valve(s) in fuel pump. Rebuild fuel pump.
A leaky check valve gasket. Rebuild fuel pump.
Pulse hole(s) plugged. Remove fuel pump and clean out holes.
Hole in pulse hose. Replace pulse hose.
Loose pulse hose. Tighten connection(s).
Excessive fuel hose length. Cut fuel hose to proper length.
Fuel hose internal diameter too small. Use 5/16 I.D. fuel hose.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3A-5

Fuel Pump Cleaning/Inspection
Removal/Disassembly 1. Clean fuel pump housing, check valves, pulse
chamber and pump base in solvent and dry all but
IMPORTANT: Fuel pump diaphragm and gaskets check valves with compressed air.
should not be re-used once fuel pump is disas-
sembled. 2. Inspect each check valve for splits or chips.
1. Disconnect fuel hoses from fuel pump. 3. Inspect boost springs for weakness or breakage.
2. Disconnect pulse hose. 4. Inspect fuel pump housing, pulse chamber and
base for cracks or rough gasket surface and re-
3. Remove two mounting screws. place if any are found.
4. Remove fuel pump from engine. 5. Inspect fitting on fuel pump housing for loosening
or any signs of fuel or air leaks. Replace or tighten
c fitting if a leak is found.
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

3A-6 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Reassembly 4. Reinstall rod into retainer cap and, use a small
hammer or hammer and punch to tap rod down
1. Insert retainer thru plastic disc and rubber check into retainer until flush with top of retainer.
valve.
c
b
a

a b

23601 23601
a - Retainer a - Rod
b - Plastic Disc b - Retainer Cap
c - Rubber Check Valve
5. Place boost spring into pump body and place cap
2. Install check valves and retainers into fuel pump onto boost spring.
body.
c

50161 b
3. With retainer installed in pump body, break re-
tainer rod from retainer by bending sideways.

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

23601
a - Rod
b - Retainer Cap

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3A-7

6. Assemble remainder of components as shown Installation
and install retaining screws thru to align.
1. Install pump onto engine. Torque to 55 Ib. in. (6.2
Reverse View of Pump Body N·m).
2. Install hoses onto proper fittings and secure with
sta-straps.
3. Run engine and check for leaks.

52362

3A-8 - FUEL SYSTEM 90-855348R1 JANUARY 1998

FUEL SYSTEM

3
B

55988

DIRECT FUEL INJECTION

Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Fuel Management Assembly Removal . . . . . . . . . 3B-24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Reed Block Assembly Removal . . . . . . . . . . . . 3B-27
1997 Model 200 DFI Fuel/Air Management System 3B-2 Reed Block Assembly Installation . . . . . . . . . . . 3B-27
1997 Model 200 DFI Reed Block/Flywheel Cover . 3B-4 Air Temperature Sensor Removal . . . . . . . . . . 3B-27
1997 Model 200 DFI Vapor Separator . . . . . . . . . . . 3B-6 Air Temperature Sensor Installation . . . . . . . . . 3B-27
1997 Model 200 DFI Fuel Rails . . . . . . . . . . . . . . . . 3B-8 Throttle Plate Assembly Removal . . . . . . . . . . . 3B-28
1998 Model 200/225 DFI Fuel/Air Management . 3B-10 Throttle Plate Assembly Installation . . . . . . . . . 3B-28
1998 Model 200/225 DFI Air Handler Components 3B-12 Vapor Separator Disassembly . . . . . . . . . . . . . . 3B-28
1998 Model 200/225 DFI Vapor Separator . . . . . . 3B-14 Vapor Separator Reassembly . . . . . . . . . . . . . . 3B-30
1998 Model 200/225 DFI Fuel Rails . . . . . . . . . . . 3B-16 Air Plenum Installation . . . . . . . . . . . . . . . . . . . . 3B-31
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-18 Vapor Separator Installation . . . . . . . . . . . . . . . 3B-31
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-19 Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . 3B-32
DFI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-20 Fuel Rail Disassembly . . . . . . . . . . . . . . . . . . . . 3B-34
Installation and Removal of High Pressure Fuel Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . 3B-39
and Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . 3B-42
High Pressure Hose Removal . . . . . . . . . . . . . . 3B-23 Tracker Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-45
Fuel Rail Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3B-47
Direct Injector Removal . . . . . . . . . . . . . . . . . . . 3B-48
Fuel Rail and Direct Injector Installation . . . . . 3B-50
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-51
Air Compressor Disassembly/Reassembly . . . 3B-54
Air Compressor Flow Diagram . . . . . . . . . . . . . 3B-55
Air Compressor Pressure Test . . . . . . . . . . . . . 3B-56

3B-0 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Specifications 4. Flat Washer (2 each)

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) 5. Seal/Teflon Ring Installation Tool -- 91-851980
Electric Fuel Pump Amperage Draw . . 6--9Amps
Fuel Injector Ohm Resistance . . . . . . . . 1.8 ± 0.1W
Direct Injector Ohm Resistance . . . . . . 1.3 ±0.3W
56015
6. Seal/Teflon Ring Sizing Tool -- 91-851980--1
Special Tools
1. Single Fuel/Air Pressure Gauge 160 PSI --
91-16850A2
*Note: To convert 100 psi gauge 91-16850A1 to 160
psi gauge, order upgrade 91-16850--1.
56014
7. Volt/Ohm Meter -- 91-99750A1

2. Dual Fuel/Air Pressure Gauge 160 PSI --

91-852087A1

8. Clamp Tool -- 91-

55295 56963
3. Screw (5mm x 25mm) (2 each) -- 10-40073 25

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-1

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

3B-2 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1997 Model 200 DFI Fuel/Air Management System
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-3

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
9 Loctite Pipe Sealant with Teflon (592) 24 25 A
9
96 Loctite Quick Tite (Obtain Locally) B
17
A = TO COMPRESSOR B= TO OIL TANK
C = Apply Loctite Quick Tite to O.D. of flywheel cover grommets. Apply a light coat of 2-4-C Marine Lubricant 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. (1524m) sea level.

3B-4 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1997 Model 200 DFI Reed Block/Flywheel Cover
REF. TORQUE
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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
 = COMPONENT OF POWERHEAD

= COMPONENT OF ENGINE GASKET SET

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-5

1997 Model 200 DFI Vapor Separator

A = TO FLYWHEEL COVER

3B-6 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1997 Model 200 DFI Vapor Separator
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-7

1997 Model 200 DFI Fuel Rails
3
14
6
5 A
10 8 27
21 23

22
16

1 22 16
2
4 14

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

16
22

C
D
15

11
12 14

14

14
13
28

31
29
31
14 2 Cycle Outboard Oil (92-13249A24) 30

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

3B-8 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1997 Model 200 DFI Fuel Rails
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 3 SCREW 100 11.3
2 1 PULLEY
3 1 AIR COMPRESSOR
4 1 REED PLATE KIT
5 4 SCREW (M8 x 35) 240 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 HOSE (MOLDED) MOLDED HOSES HAVE BEEN REPLACED
28 1 HOSE (MOLDED) WITH CHECK VALVE DESIGN LISTED BELOW
27 1 TUBING (8 IN.)
28 1 TUBING (19 IN.)
29 1 CHECK VALVE CHECK VALVE DESIGN
30 1 TUBING (8 IN.)
31 2 CLAMP

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-9

1998 Model 200/225 DFI Fuel/Air Management

4 3 4

2
7 32
B
6

31
30 33
27 21
34

32
8 35

32
A 29
25
13 12
22
28 14 36
13
41
32
25 15
11 37
26

25 10
24

25
17
16 9

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

3B-10 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1998 Model 200/225 DFI Fuel/Air Management
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 10 13.6
22 1 CLAMP-(STARBOARD)
23 11 SCREW (M6 x 45) 120 10 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.)

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-11

1998 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 8
18 7

14 34

23
15 17 16

A = TO OIL TANK B = TO AIR COMPRESSOR

3B-12 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1998 Model 200/225 DFI Air Handler Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
– 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 198 17 22.4
24 1 BRACKET
25 3 SCREW 198 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)

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-13

1998 Model 200/225 DFI Vapor Separator
2

4
5

18

7
10
8
9 3
19 13

11
8 12

15

14

16
17

3B-14 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1998 Model 200/225 DFI Vapor Separator
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-15

1998 Model 200/225 DFI Fuel Rails
2 3 
13 15
28
15 12
 14 15
15
24 4
29

28 30

28
22 31
28 11

28
28
 16
21

7
6 28


28 8


23 17
54 28
19 18
27 27
5

9
20
26 90°
27 9

27
25  10
26
54 Mineral Oil

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

3B-16 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 1998 Model 200/225 DFI Fuel Rails
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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) 240 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 399 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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-17

Air Compressor

1 9

8
17

7
9

ÇÇÇ
ÇÇÇ
ÇÇÇ
19
20

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

14

16
24

3B-18 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 Air Compressor
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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) 240 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) 240 20 27.1

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-19

DFI Operation

5
2 3
4 6

1 26 27

28
29
25
30

24
31 7

23

32

16 8
22

15 9
14

19 13 10
17

18

20 12
11

21

3B-20 - FUEL SYSTEM 90-855348R1 JANUARY 1998

AIR INDUCTION THROUGH CRANKCASE cylinder. After the compressor piston changes direc-
Combustion air enters the cowl through holes located tion, the intake reeds close and the exhaust reeds
in the top aft end of the cowl. The cowl liner directs open allowing compressed air into the hose (9) lead-
this air to the bottom of the powerhead. This limits the ing to the air/fuel rails (4). An orifice (6) is installed in
exposure of salt air to the components inside the en- the line between the compressor and air rail – to
gine cowl. smooth the pulses transmitted from the compressor
to the air rail.
Once inside the cowl the air enters the plenum
through the throttle shutter(s) (17) which are located The air/fuel rails contain two passages; one for fuel,
the second is the air passage. The air passage is
in the plenum assembly (18). The air then continues
common between all the cylinders included in the rail.
through the reed valves (15) and into the crankcase A hose connects the starboard rail air passage to the
(32). The throttle shutter(s) are actuated by the air compressor. Another hose connects the star-
throttle shaft. Mounted onto a separate shaft are two board air rail passage to the port air rail passage. An
throttle position sensors (TPS) (13). These sensors air pressure regulator (5) will limit the amount of pres-
tell the engine control unit (ECM) (8) the position of sure developed inside the air passages to approxi-
the throttle. mately 10 psi below the pressure of the fuel inside the
fuel passages (i.e. 80 psi air vs 90 psi fuel). Air exiting
2 TPS’s are installed on the DFI engine for safety re- the pressure regulator is returned into the exhaust
dundancy. If one TPS should fail, the dash mounted adaptor and exits thru the propeller.
CHECK ENGINE light will flash and the warning horn
will sound. The 1997 Model engine will continue to FUEL
perform normally; the 1998 Model engine speed will
Fuel for the engine is stored in a typical fuel tank (1).
be reduced to 3000 RPM. If both TPS’s should fail,
A primer bulb (26) is installed into the fuel line to allow
engine speed will be reduced to idle. DFI engines re-
priming of the fuel system. A crankcase mounted
quire large amounts of air into the cylinders at idle
pulse driven diaphragm fuel pump (25) draws fuel
speed. To accomplish this, the throttle shutters are
through the fuel line, primer bulb, fuel pump assem-
partially open at low engine speeds. The dual TPS
bly and then pushes the fuel thru a water separating
system reads the shaft movement in both directions,
fuel filter (23). This filter removes any contaminates
one reads movement up (increasing resistance),
and water before the fuel reaches the vapor separa-
while the other reads the same movement as down
tor (22). Fuel vapors are bled into the air compressor
(decreasing resistance). The ECM reads both and
inlet in the front of the flywheel cover preventing a va-
calculates the throttle shutter position.
por lock of the electric fuel pump assembly which is
AIR COMPRESSOR SYSTEM mounted in the vapor separator. The electric fuel
pump is different than the fuel pump that is utilized on
Air from inside the engine cowl is drawn into the com- the standard EFI engine (non DFI), and is capable of
pressor (12) through the flywheel cover. This cover developing fuel pressures in excess of 90 psi. Fuel in-
acts like a muffler to quiet compressor noise and side the rail must remain pressurized at exactly 10 psi
contains a filter (11) to prevent the ingestion of debris over the air rail pressure or the ECM (map) calibra-
into the compressor. A restrictor is located between tions will be incorrect. Fuel from the vapor separator
the filter and compressor. The restrictor design low- is supplied to the top of one fuel rail. A fuel line con-
ers the compressor intake noise and should be re- nects the bottom of the first rail to the opposite fuel
moved at altitudes above 5000 feet. The compressor rail. Fuel is stored inside the rail until an injector
is driven by a serpentine belt (10) from a pulley opens. A fuel pressure regulator (2) controls pres-
mounted on the crankshaft (16), and is automatically sure in the fuel rails, and allows excess fuel to return
self adjusted using a single idler pulley. This air com- into the vapor separator. The fuel regulator not only
pressor is a single cylinder unit containing a connect- regulates fuel pressure but also regulates it at
ing rod, piston, rings, bearings, reed valves, and a approximately 10 p.s.i. higher than whatever the air
crankshaft. The compressor is water cooled to lower rail pressure is. The fuel regulator diaphragm is held
the temperature of the air charge and is lubricated by closed with a spring that requires 10 p.s.i. to force the
oil from the engine oil pump assembly. As the com- diaphragm off the diaphragm seat. The back side of
pressor piston moves downward inside the cylinder, the diaphragm is exposed to air rail pressure. As the
air is pulled through the filter, reed valves and into the air rail pressure increases, the fuel pressure needed

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-21

to open the regulator will equally increase. Example: occur if the battery is dead). The system will run off
If there is 50 p.s.i. of air pressure on the air rail side of the alternator.
of the diaphragm, 60 p.s.i. of fuel pressure will be re-
quired to open the regulator. The return fuel line (24) OPERATION
to the vapor separator is water cooled. This design is The operation of the system happens in milliseconds
used to prevent cold fuel from the fuel tank hitting the (ms); exact timing is critical for engine performance.
hot fuel returning from the fuel rail and flashing off the As the crankshaft rotates, air is drawn into the crank-
light ends (boiling over). case through the throttle shutters, into the plenum,
To equalize the pulses developed by the pumps (both and through the reed valves. As the piston nears bot-
air and fuel) a tracker diaphragm (3) is installed in the tom-dead-center, air from the crankcase is forced
starboard rail. The tracker diaphragm is positioned through the transfer system into the cylinder. As the
between the fuel and air passages. The tracker dia- crankshaft continues to rotate the exhaust and intake
phragm is a rubber diaphragm which expands and ports close. With these ports closed, fuel can be in-
retracts depending upon which side of the diaphragm jected into the cylinder. The ECM will receive a signal
senses the pressure increase (pulse). from the throttle position sensor (TPS), engine tem-
perature sensor (TS) and the crank position sensor
OIL (flywheel speed and position sensor). With this in-
formation the ECM refers to the fuel calibration
Oil in this engine is not mixed with the fuel before en-
(maps) to determine when to activate (open and
tering the combustion chamber. Oil is stored inside a
close) the injectors and fire the ignition coils. With the
standard remote oil reservoir (21). Crankcase pres-
piston in the correct position, the ECM opens the fuel
sure will force oil from the remote oil reservoir into the
injector (27), 90 psi fuel is discharged into a ma-
oil storage tank (20) on the side of the powerhead. Oil
chined cavity inside the air chamber of the air/fuel
will flow from the oil storage tank into the oil pump
rail. This mixes the fuel with the air charge. Next the
(19). The oil pump is a solenoid design. It is activated
direct injector (28) will open, discharging the air/fuel
by the ECM and includes 7 pistons with correspond-
mixture into the combustion chamber. The direct in-
ing discharge ports. The oil pump is mounted directly
jector directs the mixture at the bowl located in top of
onto the powerhead. Each cylinder is lubricated by
the piston. The piston’s bowl directs the air/fuel mix-
one of the discharge ports. The oil is discharged into
ture into the center of the combustion chamber. This
the crankcase in front of the reed blocks. The seventh
air fuel mixture is then ignited by the spark plug (29).
passage connects to the hose that leads to the air
compressor for lubrication. Excess oil from the com- Compressor Notes: To aid in starting when the air
pressor returns into the plenum and is ingested rail pressure is low and before the compressor has
through the crankcase. time to build pressure, the direct injector is held open
by the ECM. This allows the compression from inside
The ECM will change the discharge rate of the oil the cylinders to pressurize the air rail faster (1 or 2
pump, depending upon engine demand. The ECM strokes, or 600 of crankshaft rotation).
will also pulse the pump on initial start up to fill the oil
Idle Notes: Idle quality is controlled by fuel volume
passages eliminating the need to bleed the oil sys-
and fuel timing. The throttle shutters will be open at
tem. The ECM provides additional oil for break in, as
idle speeds. The shift cut-out switch will interrupt the
determined by its internal clock. The oil ratio ranges
fuel to 3 of the cylinders to assist in shifting.
from 300 - 400:1 at idle to 60:1 at WOT. A DFI engine
will use less oil than a non-DFI engine. The TPS signals the ECM to change the fuel and
spark without movement of the throttle shutters. The
ELECTRICAL throttle cam is manufactured to allow the TPS sensor
shaft to move before opening the throttle shutters.
The electrical system consists of the ECM, crank
position sensor (flywheel speed & crankshaft posi- The crankshaft position sensor is different from the
tion) (31), throttle position sensor (TPS), MAP sensor standard 3.0 litre sensor. The crank position sensor
(14), engine temperature sensor (30), ignition coils is a hall effect sensor and serves two functions (fly-
(7) and injectors (fuel & direct). The engine requires wheel speed and position).
a battery to start (i.e. the ignition and injection will not

3B-22 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Installation and Removal of High Pressure Hose Installation
High Pressure Fuel and Air 1. Use Clamp Tool 91- to install new hose clamps.

Hoses
! CAUTION
To prevent failure of high pressure fuel and air
hoses, proper tools must be used when remov- a
ing or reinstalling high pressure hoses. Sharp
side cutter or end cutter should be used to re-
move hose clamps. Clamp Tool 91- must be used
to install new hose clamps. Do not use screw-
type clamps to secure hoses as damage to hose 56959
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 oc-
cur.
56963

56960
56962
a - Hose Clamp
b - Clamp Tool 91-
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

56963

! CAUTION
Do not use sharp side cutter or end cutter to
crimp clamps. Damage to clamp may occur re-
sulting in hose leakage.
56961
a - Too Loose
b - Too Tight – Roll Crimp Touching
c - Correct Tightness – Small Air Gap Between Roll Crimp

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-23

Fuel Management Assembly 3. Disconnect water separator sensor lead.
4. Disconnect External electric fuel pump harness
Removal connector.
! 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 (STAR-
BOARD fuel rail) and depressing valve core.

55937
a - Sensor Lead
b b - Harness Connector
a
5. Disconnect internal electric fuel pump harness
connector.
6. Remove sta-strap securing air temperature sen-
sor harness to fuel hose.
55923
a - Starboard Fuel Rail
7. Remove vapor separator vent hose to air ple-
b - Fuel Pressure Port num.
2. Place suitable container underneath vapor sepa- NOTE: Upper fuel hose goes to electric pump beside
rator drain plug and remove plug. fuel/water separator. Lower fuel hose goes to fuel
cooler.

c
a

c 55933
a
a - Harness Connector
55933 b - Sta-Strap
a - Drain Plug c - Fuel Hoses

3B-24 - FUEL SYSTEM 90-855348R1 JANUARY 1998

8. Remove the fuel inlet hose from the pulse fuel 11. Disconnect throttle cam link rod and the Throttle
pump. Position Sensor link rod.
9. Remove the fuel outlet hose and fuel return hose
from the vapor separator. b
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.

a
b

a - Throttle Link Rod

b - Throttle Position Sensor Link Rod
c 12. Disconnect MAP Sensor hose and compressor
oil return hose from air management assembly.

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

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.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-25

1997 Model 1997 Model

a
55194
a - Oil Inlet Hose
1998 Model
53645
a - Allen Screws
a

b
55989
a - Oil Hoses
b - Oil Inlet Hose
15. Remove 12 allen screws securing fuel manage-
ment assembly to powerhead and remove as-
sembly.

3B-26 - FUEL SYSTEM 90-855348R1 JANUARY 1998

16. Remove 12 bolts securing air management as- Reed Block Assembly Installation
sembly to crankcase and remove assembly.
1. Secure oil pump adaptor plate to air plenum with
1998 Model 3 bolts. Torque bolts to 16 lb. ft. (21.7 N·m).
2. Secure air plenum to reed plate with 2 screws.
Drive screws tight.
a
Air Temperature Sensor Removal
Remove 3 screws securing sensor and remove sen-
sor.

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

Reed Block Assembly Removal

1. Remove 2 screws securing air plenum to reed
plate assembly.
55971
2. Remove 3 bolts securing oil pump adaptor plate
a - Sensor
to air plenum assembly.

Air Temperature Sensor Installation

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

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-27

Throttle Plate Assembly Removal Vapor Separator Disassembly
NOTE: The throttle plate assembly is calibrated and 1. Remove 7 screws securing separator cover and
preset for proper running characteristics and emis- remove cover.
sions at the factory. Other than complete assembly
removal from the air plenum, no further disassembly a a
should be made. a

Remove 4 bolts securing throttle plate assembly to

air plenum and remove assembly.
a

a
a a

56055
a - Screws (7 each)
2. Inspect seal in fuel pump chamber of separator
tank for cuts and abraisions. Replace seal if nec-
a essary. If seal is serviceable, apply 2-4-C w/Te-
flon Marine Lubricant (92-825407A12) to seal
b lips.

55936
a - Bolts
b - Throttle Plate Assembly

Throttle Plate Assembly Installation

Secure throttle plate assembly to air plenum with 4
bolts. Torque bolts to 100 lb. in. (11.3 N·m).

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

3B-28 - FUEL SYSTEM 90-855348R1 JANUARY 1998

3. Fuel pump may be removed from cover by wig- 6. Loosen screw securing float assembly and re-
gling slightly while pulling outward. move float. Inspect float for deterioration or fuel
retention. Replace float as required.
IMPORTANT: On 1998 Models,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
a

56058

a - Screw
b - Float
7. Remove phenolic sealing plate and inspect im-
b bedded neoprene seal on both sides of plate for
c a
cuts or abraisions. Replace plate/seal assembly
56057
as required.
a - Filter Screen a
b - Harness Connector
c - Pump
5. Inspect seal above fuel pump for cuts or abra-
sions. Replace seal if necessary. Apply 2-4-C w/
Teflon to seal lips. b
a

56059

a - Plate
b - Seal

56058
a - Seal (Seal shoulder faces out)

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-29

Vapor Separator Reassembly 4. Connect electrical harness to fuel pump. Inspect
fuel pump filter screen for debris. Remove screen
1. Reinstall phenolic sealing plate onto vapor sepa- and clean as required.
rator cover.
5. Seat fuel pump and harness into separator cover
2. Secure float, needle and pivot pin assembly to being careful not to pinch harness.
separator cover with screw. Torque screw to 10
lb. in. (1.1 N·m).

c
d

b a
e c b
56057

56058 a - Harness
b - Filter
a - Sealing Plate c - Fuel Pump
b - Float
c - Needle 6. Apply 2-4-C w/Teflon to lips of seal in separator
d - Pivot Pin tank.
e - Screw [Torque to 10 lb. in. (1.1 N·m)]
3. Apply 2-4-C w/Teflon to lips of seal in separator
cover.

56058 56056
a - Seal (Seal shoulder faces out)
a - Seal (Seal shoulder faces up/out)

3B-30 - FUEL SYSTEM 90-855348R1 JANUARY 1998

7. Install separator cover with pump onto separator Vapor Separator Installation
tank.
1. Secure vapor separator to air plenum with 3
8. Secure cover to tank with 7 screws. Torque bolts. Torque bolts to 45 lb. in. (5.1 N·m).
screws to 30 lb. in. (3.4 N·m).
2. Connect fuel inlet hose from pulse pump.
a a a 3. Connect fuel outlet hose and fuel return hose to
vapor separator.

a
a a
b
56055

a
a - Screws [Torque to 30 lb. in. (3.4 N·m)]

Air Plenum Installation

Secure plenum to crankcase with 12 bolts. Torque d
bolts to 100 lb. in. (11.3 N·m).

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

55971
a - Air Plenum
b - Bolts [Torque to 100 lb. in. (11.3 N·m)]

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-31

4. Connect water separator sensor lead to water Fuel Rail Removal
separator.
5. Connect external electric fuel pump harness. ! 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 (STAR-
BOARD fuel rail) and depressing valve core.
1997 Model

55937
a - Sensor Lead
b - Harness Connector b
a
6. Connect internal electric fuel pump harness.
7. Secure air temperature sensor leads to fuel hose
with sta-strap.
55923
a - Starboard Fuel Rail
b - Fuel Pressure Port
1998 Model

b
a

b
a

c
55933

a - Electric Fuel Pump Harness Connector

b - Sta-Strap 56119
c - Fuel Return Hose a - Starboard Fuel Rail
b - Fuel Pressure Port

3B-32 - FUEL SYSTEM 90-855348R1 JANUARY 1998

2. Remove fuel injector harness from each injector 1998 Model
by compressing spring clip with flat tip screw-
IMPORTANT: On 1998 Models, if air inlet or outlet
driver while pulling on connector.
hose clamps are removed, it is recommended
that the respective air inlet and outlet hose be re-
placed to avoid the possibility of future air leaks.

b
c a
c
a d

55922
a - Spring Clip
b - Fuel Injector
c - Harness Connector
3. Remove fuel inlet hose, fuel outlet hose and air
a - Air Hose
hose from fuel rail. b - Retainer
1997 Model c - Allen Screws (remove)
d - Air Hose Clamp
a
1998 Model

b d

56140
c b 55931 a - Air Hose
a - Air Hose b - Fuel Hose
b - Air Outlet Hose c - Allen Screws
c - Fuel Hose d - Air Hose Clamp

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-33

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

a
a
55924
a - Filter d
NOTE: It is recommended that direct injectors re-
main in the cylinder head (if they are not to be re- a
placed) while removing the fuel rail. The direct injec- a
tors have a teflon seal which may expand if the
injector is removed from the head. This expansion
may cause reinstallation difficulty or require the re- e
placement of the seal.
e

4. Remove 2 nuts securing fuel rail.

5. As fuel rail is removed, use a flat tip screwdriver 56007
to hold direct injectors in cylinder head. a - Fuel Injector
b - Tracker Valve
c - Fuel Regulator
d - Air Regulator
e - Hose Adaptor (contains o-ring seal)

b 55926
a - Fuel Rail
b - Direct Injectors

3B-34 - FUEL SYSTEM 90-855348R1 JANUARY 1998

1998 Model 2. Gently pry up on injector to loosen o-ring adhe-
sion and remove injector.
a a 1997 Model
a
b d

a
c

a a

56122 56005
a - Fuel Injector 1998 Model
b - Fuel Regulator
c - Air Regulator
d - Tracker Valve

FUEL INJECTOR REMOVAL

1. Remove 2 screws securing injector.
1997 Model

56125

56006
a - Screws
1998 Model

56125
a - Screws

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-35

3. 1997 Models Only – Remove fuel nozzle from 1998 Model
fuel rail.
NOTE: Move nozzle with small tip screwdriver, then a
tap fuel rail on hard surface to dislodge nozzle. On
1998 models, the fuel injector is positioned differently
on the fuel rail and separate fuel nozzles are not re-
quired. b

a
56124
a - Fuel Injector
b - O-Rings
5. An ohm test of the fuel injector may be made by
connecting test leads to injector terminals. Ohm
reading should be 1.8 ± 0.1 ohm.
OHMS 60 40 30 20 15 10
100 5
200
56004 10
5
20
10 30
15
0

0 40
a - Nozzle VOLTS0 2
4 6 8
10
20
DC AMPS 0

4. Inspect fuel injector and fuel nozzle orifices for

foreign debris; o-rings for cuts or abraisions and
plastic components for heat damage. Replace DCV ACV

components as required.
1997 Model X1
DVA

c
56002

c 56016
a - Fuel Injector
b - Fuel Nozzle (1997 Model Only)
c - O-Rings

3B-36 - FUEL SYSTEM 90-855348R1 JANUARY 1998

FUEL INJECTOR INSTALLATION NOTE: Apply anti-seize grease (obtain locally) or
2-4-C w/Teflon to fuel injector attaching screw
1. Insert fuel nozzle with orifice facing direct injector
threads.
opening.
2. Insert fuel injector into fuel rail with connector
1997 Model
pins facing towards bottom of fuel rail.
b 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 N·m).
1997 Model

a
b
a
c
56001
a - Fuel Nozzle (1997 Model Only)
b - Direct Injector Opening
56006
a - Injector
b - Retainer
c - Screws [Torque to 70 lb. in. (7.9 N·m)]

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-37

1998 Model

56125

a - Screws [Torque to 70 lb. in. (7.9 N·m)]

3B-38 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Fuel Pressure Regulator
Regulator Closed Regulator Open

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

ÇÇ ÇÇ ÇÇ ÇÇ
12
7
6 12
ÇÇ ÇÇ 7
6

11 11
8 8
10 10

9 9

1 - Top Cover The fuel regulator is mounted on the port fuel rail,
2 - Expansion Plug near the top. This regulator relies on both air and
3 - O-ring
4 - Spring Retainer spring pressure to control the fuel pressure. Inside
5 - Spring the regulator assembly is a 10 lb. spring, this spring
6 - O-ring holds the diaphragm against the diaphragm seat.
7 - Diaphragm Seat The contact between the diaphragm and diaphragm
8 - Air Rail
9 - Air Passage (from Air Compressor)
seat closes the passage between the incoming fuel
10- Fuel Return Passage (to Vapor Separator) (from the electric fuel pump) and the fuel return pas-
11- Fuel Inlet Passage (from Electric Fuel Pump) sage.
12- Diagram Assembly
13- Calibration Screw (Do Not Turn) When the engine is not running (no air pressure on
the spring side of the diaphragm) the fuel pressure
required to move the diaphragm is 10 psi.
The fuel pump is capable of delivering more fuel than
the engine can consume. Excess fuel flows through When the engine is running, air pressure from the air
the fuel pressure regulator, interconnecting pas- compressor (80 psi) is routed through the air pas-
sages/hoses, fuel cooler, and back to the vapor sepa- sages, to the spring side of the fuel pressure regula-
rator tank. This constant flow of fuel means that the tor diaphragm.
fuel system is always supplied with cool fuel, thereby The air pressure (80 psi) and spring pressure (10 psi)
preventing the formation of fuel vapor bubbles and combine to regulate system fuel pressure to 90 psi -
minimizing the chances of vapor lock. or 10 psi higher than the air pressure in the DFI sys-
The fuel pressure regulator is calibrated to raise the tem fuel/air rails.
fuel pressure to 10 psi above the air pressure.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-39

FUEL REGULATOR REMOVAL 1998 Model
1. Remove 4 screws securing regulator and remove c b d
regulator.
a
1997 Model

56127
a - Diaphragm
55999 b - Spring
b c - Cup
d - O-Ring
a - Screws
b - Fuel Regulator
FUEL REGULATOR INSTALLATION
1998 Model
NOTE: Apply a light coat of 2-4-C w/Teflon to dia-
phragm surface and o-ring to aid in the retention of
diaphragm and o-ring on fuel rail during reassembly.
a 1. Position diaphragm on fuel rail.
2. Position o-ring on fuel rail.
3. Position spring and cup onto diaphragm.
1997 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 required. a
1997 Model
c
c
b
a d
b

56008

d
55997 a - Diaphragm
b - O-Ring
a - Diaphragm
c - Spring
b - Spring
d - Cup
c - Cup
d - O-Ring

3B-40 - FUEL SYSTEM 90-855348R1 JANUARY 1998

1998 Model 1998 Model

a a
b

a
56126
c a - Screws [Torque to 70 lb. in. (7.9 N·m)]

56128
a - Diaphragm
b - O-Ring
c - Spring
d - Cup
NOTE: Apply anti-seize grease (obtain locally) or
2-4-C w/Teflon to regulator attaching screw threads.
4. Place cover over spring/cup/diaphragm assem-
bly and secure with 4 screws. Torque screws to
70 lb. in. (7.9 N·m).
1997 Model

a a

55999

a - Screws [Torque to 70 lb. in. (7.9 N·m)]

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-41

Air Pressure Regulator
Regulator Closed Regulator Open

1 2 1 2

3 3
12 12
4 4

5 5

11 ÇÇ ÇÇ 6
11 ÇÇ ÇÇÇ 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 achieved, the spring compresses, allowing the dia-
pressure inside the rails to approximately 80 psi. phragm to move. The diaphragm moves away from
the diaphragm seat, allowing air to exit through the di-
The air regulator uses a spring (pressure) to control
aphragm seat, into the excess air passage leading to
the air pressure. This spring (80 psi) holds the dia-
the exhaust adaptor plate.
phragm against the diaphragm seat. The contact
area blocks (closes) the air inlet passage from the ex-
cess air, return passage. As the air pressure rises
(below the diaphragm), it must reach a pressure
equal to or greater than the spring pressure holding
the diaphragm closed. Once this pressure is

3B-42 - FUEL SYSTEM 90-855348R1 JANUARY 1998

AIR REGULATOR REMOVAL 1998 Model
1. Remove 4 screws securing regulator and remove
regulator.
1997 Model

a a

c
b

a
56000

a - Screws 56130
b - Air Regulator a - Diaphragm
b - Spring
1998 Model c - Cup
a
AIR REGULATOR INSTALLATION
NOTE: Apply a light coat of 2-4-C w/Teflon to dia-
phragm surface to aid in the retention of diaphragm
b on fuel rail during reassembly.
1. Position diaphragm, spring and cup onto fuel rail.
1997 Model
a
56129 c
a - Screws b
b - Air Regulator
2. Inspect regulator diaphragm for cuts or tears. Re-
place as required.
a
1997 Model

55998
a - Diaphragm
b - Spring
a c - Cup
1998 Model
b c b
c
a

56009 56131
a - Diaphragm
a - Diaphragm
b - Spring
b - Spring
c - Cup
c - Cup

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-43

NOTE: Apply anti-seize grease (obtain locally) or 1997 Model
2-4-C w/Teflon to regulator attaching screw threads.
NOTE: Due to the stiffness of the regulator spring, it a
is recommended that 2 longer screws (5mm x 25mm
long) (10-40073 25) and 2 flat washers (12-30164)
be installed through cover first to begin compression.
This will allow 2 shorter screws (5mm x 15mm long)
to be installed. Remove 2 long screws w/flat washers
and install remaining 2 short screws (5mm x 15mm). b
Torque screws to 70 lb. in. (7.9 N·m).
1997 Model
a
56000

b b a - Screws
c c b - Air Regulator
1998 Model
a

56010 a
a - Cover 56129
b - Screws (5mm x 25mm) (10-40073 25) a - Screws
c - Flat Washers (12-30164) b - Air Regulator
1998 Model 2. Inspect regulator diaphragm for cuts or tears. Re-
place as required.
b b
c
c

56132

a - Cover
b - Screws (5mm x 25mm) (10-40073 25)
c - Flat Washers (12-30164)

3B-44 - FUEL SYSTEM 90-855348R1 JANUARY 1998

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 After the engine starts, and the fuel and air pressure
2 - Spring Retainer (not shown) reach normal operating range, the fuel pressure will
3 - Spring
4 - O-ring compress the spring and the diaphragm will move
5 - Diaphragm (at rest) Seat slightly away from the seat (to a neutral position). At
6 - Air Rail this point the pressure on both sides of the tracker di-
7 - Air Passage (from Air Compressor) aphragm is equal (10 psi spring pressure + 80 psi air
8 - Fuel Inlet Passage (from Electric Fuel Pump)
9 - Diagram Assembly
pressure = 90 psi fuel pressure).
Any air or fuel pressure “spikes” on one side of the di-
aphragm will transfer this pressure rise to the other
The tracker is located on the starboard fuel/air rail as-
system (air or fuel) on the other side of the dia-
sembly. The DFI system must maintain a constant 10
phragm. Both systems will have a momentary in-
psi pressure difference between the fuel pressure
crease in pressure so that the 10 psi difference be-
and air pressure in the rails, at all times. The tracker
tween air and fuel system pressures can be
is designed to maintain the 10 psi differential when
maintained.
the air or fuel pressure suddenly raises (i.e. pulses
generated by the compressor’s piston or by the fuel NOTE: To prevent excessive wear in the seat, the
injectors opening and closing). The tracker contains tracker is calibrated to allow the diaphragm to be
a spring on the air side of the diaphragm. This spring slightly away from the seat during normal operation.
positions the diaphragm against the diaphragm’s
seat (when the engine is not running).

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-45

TRACKER VALVE REMOVAL 1998 Model
1. Remove 4 screws securing tracker valve and re-
move tracker assembly.
1997 Model c
a

a 56012
a - Screws
1998 Model
a
56136
a - Diaphragm
b - Spring
c - O-Ring

TRACKER VALVE INSTALLATION

NOTE: Apply a light coat of 2-4-C w/Teflon to tracker
a 56135 diaphragm and cover o-ring to aid in their retention on
a - Screws fuel rail while reinstalling tracker valve to fuel rail.
2. Inspect tracker diaphragm for cuts tear. NOTE: Apply anti-seize grease (obtain locally) or
3. Inspect tracker cover o-ring for cuts and abrai- 2-4-C w/Teflon to tracker valve attaching screw
sions. Replace components as required. threads.
1997 Model 1. Position diaphragm, spring and o-ring onto fuel
rail.
1997 Model

c a b

c
b

56011
a - Diaphragm
b - Spring
c - O-Ring
56013
a - Diaphragm
b - Spring
c - O-Ring

3B-46 - FUEL SYSTEM 90-855348R1 JANUARY 1998

1998 Model Fuel Rail Cleaning
c After all fuel injectors, air regulator, tracker valve, fuel
regulator, inlet hoses and outlet hoses have been re-
b
moved, the fuel rails may be flushed out with a suit-
able 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 N·m).
Torque 9/16″ (14.3mm) hose fittings on fuel rails to
a 35 lb. ft. (47.5 N·m).
1997 ModelTop View
a - Diaphragm
b - Spring
c - O-Ring
2. Place cover over diaphragm/spring/o-ring as-
sembly and secure with 4 screws. Torque screws a
to 70 lb. in. (7.9 N·m).
1997 Model

b
55995
b 56012
a a - 1/2″ (12.7mm) Fitting
b - 9/16″ (14.3mm) Fitting
a - Cover
b - Screws [Torque to 70 lb. in. (7.9 N·m)] Bottom View
1998 Model
b

a
a

b 56135
a - Cover
b - Screws [Torque to 70 lb. in. (8.0 N·m)]

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-47

1998 Model Direct Injector Removal
1. Remove harness connectors from direct injec-
tors.
a
c 2. Remove direct injector from cylinder head

a - Air Hose
b - Retainer
c - Allen Screws [Torque to 60 lb. in. (6.8 N·m)
1998 Model 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 pres-
ent, sealing ring may be reused.

c 4. Inspect o-rings and cork gasket for cuts or abrai-

sions. Replace components as required.

a
Ä
56140
Ä
a - Air Hose
b - Fuel Hose
c - Allen Screws [Torque to 60 lb. in. (6.8 N·m)]
c Ä a

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

3B-48 - FUEL SYSTEM 90-855348R1 JANUARY 1998

5. If teflon seal requires replacement, use teflon ring 6. An ohm test of the direct injector may be made by
installation tool 91-851980 to slide new seal onto connecting test leads to injector terminals. Ohm
injector. Following installation of teflon ring, the reading should be 1.3 ± 0.3 ohm.
teflon ring sizing tool (91-851980–1) can be used
OHMS 60 40 30 20 15 10
to compress the teflon seal to aid in the installa- 200
100 5
20 0
tion of the injector into the cylinder head. 10
5
10
15
30
40
0 20
VOLTS 0 4 6 8
2
1997 Model DC AMPS 0 10

ÄÄ
ÄÄ
DCV ACV

ÄÄ
ÄÄ
ÄÄ
X1
DVA

ÄÄ
a e
b d
c

a 56003
a - Teflon Seal a - Direct Injector
b - Seal Installation Tool (91-851980)
7. Carbon buildup on tip of direct injector may be re-
c - Cork Gasket
d - O-Ring moved by use of a brass wire hand brush.
e - O-Ring
a
1998 Model

ÄÄ
ÄÄ
ÄÄ
ÄÄ
ÄÄ
ÄÄ
b
a b d d 56017
c a - Direct Injector
b - Tip

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-49

NOTE: If cylinder head is going to be replaced, re- Fuel Rail and Direct Injector
move cup washers from each direct injector port by
Installation
prying out with a flat tip screwdriver. Reinstall wash-
ers with retainers into new cylinder head. Washers 1. Use Teflon Ring Sizing Tool (91-851980–1) to
provide tension between direct injectors, cylinder compress new teflon sealing rings prior to instal-
head and fuel rails. lation of injector into cylinder head.
2. Carefully slide fuel rail over mounting studs and
onto direct injectors.
IMPORTANT: On 1998 Models,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
b a 33 lb. ft. (44.7 N·m).
4. Reinstall direct injector harness connectors.

55927
a
a - Cup Washer a
b - Retainer

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

3B-50 - FUEL SYSTEM 90-855348R1 JANUARY 1998

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 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)
COMPRESSOR REMOVAL
1. Disconnect battery cables from battery terminals.
2. Remove top cowling.
IMPORTANT: On 1998 Models,Prior to removing
flywheel cover, remove vent hose from fitting on
flywheel cover.
3. Remove flywheel cover.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-51

4. Use 1/2 inch (12.7mm) drive on belt tensioner 1998 Model
arm to relieve belt tension. Remove belt.
a b
a

55950
a - Belt Tensioner

! CAUTION
If engine has been recently run, air pressure out-
let hose fittings may be extremely hot. Allow
components to cool off before beginning disas-
sembly.
5. Disconnect air pressure outlet hose
6. Disconnect water outlet hose (tell-tale).
1997 Model
a
b

55990
a - Water Outlet Hose
b - Air Outlet Hose

55925

a - Water Outlet Hose

b - Air Outlet Hose

3B-52 - FUEL SYSTEM 90-855348R1 JANUARY 1998

NOTE: On 1998 Models, the water outlet hose (tell- 10. Remove 4 bolts securing air compressor to out-
tale) exits the opposite (port) side of the air compres- board and remove compressor.
sor.
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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-53

Air Compressor NOTE: The piston and rings are not sold separately.
They must be replaced as an assembly.
Disassembly/Reassembly
The connecting rod and bearings are not sold sepa-
NOTE: If cylinder bore is scored, air compressor rately. They must be replaced as an assem-
must be replaced as an assembly. bly.

b
c
9

14 9

14
e m
6

k l

ÇÇ
ÇÇ
9
ÇÇ i 9

14
9
14 9

f
6 Dielectric Grease (92-823506--1)
9 Loctite PST Pipe Sealant (92-809822) g
j
14 2 Cycle Outboard Oil (92-13249A24) h
NOTE: End cap bearing and seal are not sold sepa- g - Reed Plate (Inspect for broken or chipped reeds/stops)
rately. End cap must be replaced as an assembly Maximum Reed Stand-Open - 0.010 in. (0.254mm)
h - O-Rings (Inspect for cuts or abraisions)
NOTE: Piston Installation – use a metal hose clamp i - Cylinder Head (1997 Model)
for piston ring compressor. Stagger piston ring open- j - Bolt [Torque to 20 lb. ft. (27.1 N·m)]
k - Bolt [Torque to 20 lb. ft. (27.1 N·m)]
ings. l - Temperature Sensor
a - Bolt (3 each) [Torque to 100 lb. in. (11.3 N·m)] m - Bolt [Torque to 20 lb. ft. (27.1 N·m)]
b - Bolt (4 each) [Torque to 100 lb. in. (11.3 N·m)] n - Cylinder Head (1998 Model)
c - End Cap Assembly (Inspect bearing for roughness)
d - O-Rings (Inspect for cuts or abraisions)
e - Bolt (4 each) [Torque to 20 lb. ft. (27.1 N·m)]
f - O-Rings (Inspect for cuts or abraisions)

3B-54 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Air Compressor Flow Diagram

ÏÏ
ÏÏ
e
c

ÏÏ f
ÏÏ
a

ÏÏ g

d
b

w r s j
t
h
v u

l i
q
m

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-55

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

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

3B-56 - FUEL SYSTEM 90-855348R1 JANUARY 1998

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 pump amperage draw.
Normal draw is 4 - 8 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 8 amperes, pump is defective
– replace pump.
5. Fuel Regulator – Remove and inspect diaphragm
for cuts or tears.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3B-57

FUEL SYSTEM

3
C

55194

OIL INJECTION SYSTEM

Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
Oil Injection Components . . . . . . . . . . . . . . . . . . . . . . 3C-2
Oil Injection Operation . . . . . . . . . . . . . . . . . . . . . 3C-4
1997 Model Oil Flow Schematic . . . . . . . . . . . . . 3C-4
1998 Model Oil Flow Schematic . . . . . . . . . . . . . 3C-5
Set Up Instructions for the Oil Injection System 3C-6
Installing Remote Oil Tank . . . . . . . . . . . . . . . 3C-6
Installing Oil Hoses to Engine . . . . . . . . . . . . . . . 3C-6
Filling the Oil Injection System . . . . . . . . . . . . . . 3C-7
Priming the Oil Injection Pump . . . . . . . . . . . . . . 3C-7
1997 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Priming the Oil Injection Pump . . . . . . . . . . . . . . 3C-8
1998 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-8
Purging Air From the Engine Oil Reservoir . . . . 3C-8
Oil Pump Activation of Break-in Sequence for
Replacement Powerheads . . . . . . . . . . . . . . . . . . 3C-8
Method 1 – Shift Switch Activation Prime . . 3C-8
Method 2 – (DDT) Digital Diagnostic
Terminal – Reset Break-in . . . . . . . . . . . . . . . 3C-9
Method 3 – (DDT) Digital Diagnostic
Terminal – Oil Pump Prime . . . . . . . . . . . . . . 3C-9
Oil Injection Warning Systems . . . . . . . . . . . . . . 3C-9
Low Oil Level (1997 and 1998 Models) . . . . 3C-9
No Oil Flow to the Electric Oil Pump
(1997 Models Only) . . . . . . . . . . . . . . . . . . . . . 3C-9
Electric Oil Pump Test (1997 Models Only) . . 3C-10
Oil Injection System Trouble Shooting Chart . 3C-11
Trouble Shooting the Oil Injection System 3C-11
Engine Mounted Oil Reservoir . . . . . . . . . . . . . 3C-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-13

3C-0 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Notes:

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-1

Oil Injection Components

3C-2 - FUEL SYSTEM 90-855348R1 JANUARY 1998

 Oil Injection Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 14 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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-3

Oil Injection Operation
Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil is stored inside the re-
mote oil tank. Crankcase pressure will force oil from the remote oil tank into the engine oil tank (g) on the side
of the powerhead. Oil will flow from the engine oil tank through the oil supply hose (h) to the oil pump (i). The
oil pump is a solenoid design and is activated by the ECM, it includes seven oil discharge ports. Six of the oil
pump discharge ports discharge oil into the intake manifold (k) in front of the reed blocks. The oil passageways
(j) are machined into the intake manifold. The last oil pump discharge port discharges oil through hose (a) to the
air compressor (f) for lubrication. The port and starboard side bleed systems (c and d) also supply oil to the air
compressor for lubrication. Excess oil from the compressor returns through hose (b) into the plenum and is in-
gested 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 the oil passages eliminating the need to bleed the oil system. The ECM
will signal the oil pump to provide additional oil (50:1) for break in, as determined by the ECM’s internal clock.
After break-in, the 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

Cyl #4
i

Cyl #5

Cyl #6

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

3C-4 - FUEL SYSTEM 90-855348R1 JANUARY 1998

1998 Model Oil Flow Schematic

e
a

c d

i
h

f
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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-5

Oil Injection Installing Oil Hoses to Engine
1. Remove shipping cap from hose fitting (a).
Set Up Instructions for the Oil 2. Connect oil hose (“b” with blue stripe) to fitting as
shown. Secure with sta-strap.
Injection System
NOTE: The third fitting (c) is a vent and does not get
CAUTION connected.
Be careful not to get dirt or other contamination
in tanks, hoses or other components of the oil in-
jection 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 engine and set at 4 psi
maximum.
a
INSTALLING REMOTE OIL TANK

b c
54448

3. Remove shipping cap from pulse fitting (d).

4. Connect the second oil hose (e) 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.
1. The remote oil tank should be installed in an area 1997 Models
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 ac- d
ceptable 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 e
expand slightly.
1998 Models
3. Oil hoses when routed thru engine well, must be
able to extend to the hose fittings on engine.
4. Oil hoses must be arranged so they cannot be-
come pinched, kinked, sharply bent or stretched
during operation of the outboard.
NOTE: A Quicksilver Accessory oil hose extension
kit (41729A3) is available for the remote oil tank.

e
d

3C-6 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Filling the Oil Injection System CAUTION
1. Fill remote oil tank with the recommended oil Oil supply hose between the engine oil tank and
listed in the Operation and Maintenance Manual. Electric oil pump must be purged of air before
Tighten fill cap. starting engine.

a CAUTION
Prior to initial engine startup, remove oil hose be-
tween the oil pump and air compressor. Manually
fill the hose with Quicksilver TC-W3 Premium
Plus 2 Cycle Outboard.
a - Fill Cap Prime the oil injection pump as follows:
2. Remove fill cap from the engine oil tank and fill 1. Shift outboard to “NEUTRAL” position.
the tank with oil. Reinstall the fill cap.
2. Turn the ignition key switch to the “ON” position.

b
a

54446 3. Within the first 10 seconds after the key switch

a - Engine Oil Reservoir has been turned on, push in the shift interrupt
b - Fill Cap switch 3-5 times. This will run the pump and
purge out the air.
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.

a
54445
a - Shift Interrupt Switch
a
NOTE: It may take up to 1 minute to purge out the air.

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-7

Priming the Oil Injection Pump Purging Air From the Engine Oil
(Continued) Reservoir
1. Loosen the fill cap on the engine oil tank.
1998 MODELS
2. Start the engine. Run the engine until the all the
Before starting engine for the first time, or for an air has been vented out of the tank and oil starts
engine that ran out of oil, or was drained of oil, to flow out of the tank. Re-tighten fill cap.
prime the oil injection pump. Priming will remove any
air that may be in the pump, oil supply hose, or inter- a
nal passages.

a - Fill Cap

a b Oil Pump Activation of Break-in

a - Oil Injection Pump
b - Oil Supply Hose Sequence for Replacement
Powerheads
CAUTION
NOTE: Do not add oil to the fuel to provide additional
To prevent damage to the fuel pumps, fill the en- lubrication during break-in. The fuel delivery charac-
gine fuel system with fuel. Otherwise the fuel teristics of Direct Fuel Injection engines are such that
pumps will run without fuel during the priming adding oil to the fuel will provide little or no additional
process. lubrication to the engine. Additional oil required by
Prime the oil injection pump as follows: the engine during break-in must be provided by the
oil pump.
1. Fill the engine fuel system with fuel. Connect fuel
hose and squeeze primer bulb until it fells firm. Priming the oil pump (filling pump and hoses) is re-
quired on new or rebuild engines and any time main-
2. Turn the ignition key switch to the “ON” position. tenance is performed on the oiling system.
There are three methods for priming the oil pump:

METHOD 1 – SHIFT SWITCH ACTIVATION

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

NOTE: It may take a few minutes for the pump to

complete the priming process.

3C-8 - FUEL SYSTEM 90-855348R1 JANUARY 1998

METHOD 2 – (DDT) DIGITAL DIAGNOSTIC Oil Injection Warning Systems
TERMINAL – RESET BREAK-IN
This method is the same as Method 1, except the run LOW OIL LEVEL (1997 AND 1998 MODELS)
history and fault history are erased from the ECM. The system is activated when the oil in the engine
Refer to procedure in the Technician Reference mounted oil reservoir tank drops below 50 fl. oz. (1.5
Manual provided with the Digital Diagnostic Software liters) You still have an oil reserve remaining for 50
Cartridge Part. No. 91-822608-4. minutes of full speed operation.
NOTE: The engine mounted oil reservoir tank (lo-
METHOD 3 – (DDT) DIGITAL DIAGNOSTIC cated beneath the top cowl) along with the remote oil
TERMINAL – OIL PUMP PRIME tank will have to be refilled (refer to Filling the Oil In-
This method fills the oil pump, oil supply hose feeding jection System).
pump, and oil hoses going to the crankcase and air The warning system works as follows:
compressor.
The OIL light (a) will come on and the warning horn
Refer to procedure in the Technician Reference sounds a series of four short tones. If you continue to
Manual provided with the Digital Diagnostic Software operate the outboard, the light will stay on and the
Cartridge Part. No. 91-822608-4. horn will sound four short tones every two minutes.
The engine has to be shut off to reset the warning
system.
Conditions Requiring Priming the Oil Pump
Condition Priming Procedure
New engine Use Method 1 or 2 a
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 sup- Use Method 3
ply hose feeding pump NO OIL FLOW TO THE ELECTRIC OIL PUMP
Oil pump removed Use Method 3 (1997 MODELS ONLY)
Oil injection hoses Use Method 3 The system is activated when the flow of oil in the
drained electric oil pump is restricted. No lubricating oil is be-
ing supplied to the engine. Stop the engine as soon
as possible. Continuing to operate the engine can re-
sult 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.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-9

Electric Oil Pump Test (1997 Models
Only)
NOTE: 1998 Model oil pumps do not activate a warn-
ing if there is an oil pump malfunction or if there are
air bubbles in the oil supply hose. The oil warning
system on 1998 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

3C-10 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Oil Injection System Trouble Open the cowling on engine and check oil level in en-
gine reservoir tank. If oil is not to the top of tank, the
Shooting Chart
problem is low oil. There is a safety reserve of oil left
in the reservoir after the low oil warning is sounded
TROUBLE SHOOTING THE OIL INJECTION that allows you enough oil for 30 to 40 minutes of full
SYSTEM throttle operation. Refer to troubleshooting chart to
If a problem occurs with the oil injection system and correct the problem.
the warning horn sounds in a pulsating manner, stop
engine and check if problem is caused by (1) low oil
level or (2) a faulty warning sensor.
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 1D-6
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.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-11

 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 over-
heat sensor may be faulty. Disconnect overheat sen-
sor and turn ignition key to “ON” position. If horn still
sounds the engine overheat sensor is OK.
Tan wire between warning horn and engine overheat Check wire for shorts.
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 an ohmmeter between leads.
There should be NO continuity through sensor. If
continuity exists, sensor is faulty.

3C-12 - FUEL SYSTEM 90-855348R1 JANUARY 1998

Engine Mounted Oil Reservoir 2. Disconnect LIGHT BLUE leads from their re-
spective connections.
REMOVAL 3. Disconnect clear input hose to oil pump and plug
NOTE: If oil reservoir contains oil, the clear oil hose off hose.
going to the oil pump should be plugged upon remov- 4. Remove three bolts securing oil reservoir to pow-
al to prevent oil spillage. erhead and remove reservoir.
1. Disconnect input oil hose to oil reservoir.

b 55937
a - Bolts INSTALLATION
b - Oil Pump Output Hose (Clear)
1. Secure oil reservoir to powerhead with 3 bolts.
Torque bolts to 14 Ib. ft. (19.0 N·m).
2. Reconnect input oil hose to oil reservoir and se-
cure 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.

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3C-13

FUEL SYSTEM

3
D
Emission Control 1998
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
Refer to Owners Manual for required maintenance. Idle Speed (in gear): 550 RPM
Exhaust Emission Control Systems: None
Engine Lubricants: Quicksilver Fuel/Oil Timing: Not Adjustable ECM
Premium Plus TC-W3 2-Cycle Ratio: Not Controlled
Outboard Oil Adjustable
ECM Spark Plug: Champion RC12MC4 Gap: .040”
Family: WM9XM03.0220 Controlled Valve Clearance (Cold) mm
FEL: 100.00 GM/KW-HR Intake: N/A Exhaust: N/A

3044 225 HP
cc DFI
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC

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

3D-0 - FUEL SYSTEM 90-855348R1 JANUARY 1998

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3D-1

As the air/fuel ratio becomes leaner, combustion
temperatures increase. Higher combustion tempera-
tures raise the NOx content of the exhaust. But, enri-
chening the air/fuel ratio to decrease combustion
temperatures 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 pos-
sible.

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

3D-2 - FUEL SYSTEM 90-855348R1 JANUARY 1998

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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3D-3

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

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

3D-4 - FUEL SYSTEM 90-855348R1 JANUARY 1998

CERTIFICATION LABEL:
The certification label must be placed on each engine
at the time of manufacture and must be replaced in
the same location if damaged or removed. Shown
below is a typical certification label and is not repre-
sentative of any one model. Label shown below is not
to scale; (shown at twice the normal size).

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: Quicksilver Fuel/Oil Timing: Not Adjustable ECM d
Premium Plus TC-W3 2-Cycle Ratio: Not Controlled
n Outboard 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
g
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC

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 output 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

90-855348R1 JANUARY 1998 FUEL SYSTEM - 3D-5

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

3D-6 - FUEL SYSTEM 90-855348R1 JANUARY 1998

POWERHEAD

4
A

CYLINDER BLOCK ASSEMBLY

Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-39
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Exhaust Plate 1997 Model 200 DFI . . . . . . . . . . . . 4A-40
Powerhead Repair Stand . . . . . . . . . . . . . . . . . . . 4A-2 Exhaust Plate 1997 Model 200 DFI . . . . . . . . . . . . 4A-41
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Exhaust Plate 1998 Model 200/225 DFI . . . . . . . . . 4A-42
Crankshaft -- Pistons -- and Connecting Rods . . . . . 4A-4 Exhaust Plate 1998 Model 200/225 DFI . . . . . . . . . 4A-43
Cylinder Block and End Cap . . . . . . . . . . . . . . . . . . . 4A-6 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-44
Powerhead Torque Sequence and Bleed System 1997 Model 200 DFI . . . . . . . . . . . . 4A-46
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-10 Bleed System 1997 Model 200 DFI . . . . . . . . . . . . 4A-47
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Front Bleed View 1997 Model 200 DFI . . . . . . . . . . 4A-48
Powerhead Removal from Driveshaft Housing . . . 4A-13 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-49
Powerhead Disassembly . . . . . . . . . . . . . . . . . . . . . 4A-16 Bleed System 1998 Model 200/225 DFI . . . . . . . . . 4A-50
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . 4A-23 Bleed System 1998 Model 200/225 DFI . . . . . . . . . 4A-51
Cylinder Block and Crankcase Cover . . . . . . . . 4A-23 Reinstalling Engine Components . . . . . . . . . . . . . . 4A-51
Special Service Information . . . . . . . . . . . . . . . . 4A-23 Anchor Bracket/Throttle Linkage Model 1997
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-23 200 DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-52
Pistons and Piston Rings . . . . . . . . . . . . . . . . . . 4A-25 Anchor Bracket/Throttle Linkage 1997
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-25 Model 200 DFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-26 Anchor Bracket/Throttle Linkage 1998
Crankshaft (and End Cap) Bearings . . . . . . . . . 4A-26 Model 200/225 DFI . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-54
Reed Block Assembly . . . . . . . . . . . . . . . . . . . . . 4A-27 Anchor Bracket/Throttle Linkage 1998
Reed Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27 Model 200/225 DFI . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-55
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28 Powerhead Installation on Driveshaft Housing . . . 4A-56
Powerhead Reassembly and Installation . . . . . . . . 4A-29 Break-ln Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-59
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . 4A-32
Piston and Connecting Rod Reassembly . . . . . 4A-33
Piston and Piston Ring Combination . . . . . . . . . 4A-35
Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4A-35
Crankcase Cover Installation . . . . . . . . . . . . . . . 4A-37
Assembly of Reed Blocks to Intake Manifold . . 4A-38

4A-0 - POWERHEAD 90-855348R1 JANUARY 1997

Specifications Water Pressure
Block @ Idle . . . . . . . . . . . . . . . . . . . 1-1/2 -- 4-1/2 psi
@ Poppet Valve Opening . . 6-1/2 -- 6-3/4 psi
Type . . . . . . . . . . . . . . . . . 60°V, 2 Cycle @ W.O.T . . . . . . . . . . . . . . . . 8 -- 10 psi
Displacement . . . . . . . . . . 185.9 cu. in. (3047cc)
Engine Weight
Reed Valve Opening
20 in. (50.8cm) Shaft . . . 440 lbs. (199.8kg)
Opening (Max.) . . . . . . . . 0.020 in. (0.50mm) 25 in. (63.5cm) Shaft . . . 445 lbs. (202.0kg)
Stroke 30 in. (76.2cm) Shaft . . . 461 lbs. (209.3kg)

Length . . . . . . . . . . . . . . . . 3.00 in. (76.2mm)

Cylinder Bore Special Tools
Dia. Standard . . . . . . . . . . 3.625 in. (92.1mm) 1. Lifting Eye 91-90455
0.015 Oversize . . . . . . . . 3.640 in. (92.5mm)
0.030 Oversize . . . . . . . . 3.655 in. (92.8mm)

Taper/Out of Round Max. 0.003 in. (0.076mm)

Piston
Dia. Standard . . . . . . . . . . 3.6210 in. ±.0005 in.
(91.973 mm ±.0127 mm)
0.015 Oversize . . . . . . . . . 3.636 in. ±.0005 in.
(92.354mm ±.0127 mm)
0.030 Oversize . . . . . . . . . 3.651 in. ±.0005 in.) 2. Flywheel Holder 91-52344
(93.1mm ±.0127 mm)

91--52344
IMPORTANT: Using a micrometer, measure di-
mension “A” at location shown. Dimension “A”
should be 3.6210 in. ±.0005 for a STANDARD size
piston.

54964
3. Protector Cap 91-24161
Dimension “A”
at Right Angle
(90°) to Piston
Pin
A 1 in.
(25.4mm) 4. Flywheel Puller 91-73687A1

55959

Piston Ring
End Gap . . . . . . . . . . . 0.010 in. to 0.018 in.
(0.254mm to 0.457mm)

90-855348R1 JANUARY 1998 POWERHEAD - 4A-1

5. Powerhead Stand 91-30591A1 10. Snap Ring Pliers 91-24283

6. Piston Ring Expander 91-24697 11. Lockring Installation Tool 91-91-93004A2

NOTE: If 3.4 Liter Piston Lock Ring Installer

(91-93004A1) is available, then only Guide
7. Lockring Removal Tool 91-52952A1 (91-93005-1) is required to install 3 Litre piston lock
rings.
12. Piston Ring Compressor 91-823237

8. Piston Pin Tool 91-92973A1

9. Universal Puller Plate 91-37241

13. Compression Tester 91-29287

54965

Powerhead Repair Stand

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

4A-2 - POWERHEAD 90-855348R1 JANUARY 1997

Notes:

90-855348R1 JANUARY 1998 POWERHEAD - 4A-3

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 Outboard Oil (92-13249A24)

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

4A-4 - POWERHEAD 90-855348R1 JANUARY 1997

 Crankshaft -- Pistons -- and Connecting Rods
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 N·m)
2nd torque - 30 lb. ft.
14 12 SCREW (1-1/4 IN.)
(40.7 N·m)
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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-5

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 44
52
72
51 73
73 74 A
64 12
66 55 1
14 27

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

62 87 27

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

38
95
12 Loctite Master Gasket (92-12564-2)
14 2 Cycle Outboard Oil (92-13249A24)
33 Loctite 680 (92-809833)
95 2-4-C w/Teflon (92-825407A12)

A -- TO FUEL PUMP B = TO ADAPTOR PLATE C = TO PRESSURE SENSOR

4A-6 - POWERHEAD 90-855348R1 JANUARY 1997

 CYLINDER BLOCK AND END CAP
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 N·m) and ro-
tate 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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-7

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 44
52
72
51 73
73 74 A
64 12
66 55 1
14 27

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

62 87 27

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

38
95
12 Loctite Master Gasket (92-12564-2)

14 2 Cycle Outboard Oil (92-13249A24)

33 Loctite 680 (92-809833)
95 2-4-C w/Teflon (92-825407A12)

A -- TO FUEL PUMP B = TO ADAPTOR PLATE C = TO PRESSURE SENSOR

4A-8 - POWERHEAD 90-855348R1 JANUARY 1997

 Cylinder Block and End Cap
REF. TORQUE
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 page 4A-11
60 40 SCREW (M8 x 50) 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) 200 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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-9

Powerhead Torque Sequence and
Torque Specifications
REED BLOCK MOUNTING BOLTS
90 lb. in. (10.2 N·m)

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

55979
REED ATTACHING SCREWS
25 lb. in. (2.8 N·m)

52130

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

52132

SPARK PLUGS
20 lb. ft. (27.1 N·m)

55194

4A-10 - POWERHEAD 90-855348R1 JANUARY 1997

Powerhead Torque Sequence and
CYLINDER HEAD BOLTS
Torque Specifications (AND TORQUE SEQUENCE)
CRANKCASE COVER BOLTS
(AND TORQUE SEQUENCE) IMPORTANT
Add light oil to threads and bolt face:
Add light oil to threads and bolt face: Torque to 20 lb. ft. (27.1 N·m) and ro-
8 Bolts (M10 x 1.5 x 80)
tate 90°
30 lb. ft. (40.6 N·m) and rotate 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 N·m)

PISTON ROD BOLTS RELIEF VALVE COVER BOLTS

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

51707

55987

90-855348R1 JANUARY 1998 POWERHEAD - 4A-11

Powerhead Torque
Sequence (Continued)
Intake Manifold
100 lb. in. (11.3 N·m)

10 9

6 5

2 1

3 4

7 8

11 12

55975

4A-12 - POWERHEAD 90-855348R1 JANUARY 1997

General Information Powerhead Removal from
Powerhead “Disassembly” and “Reassembly” Driveshaft Housing
instructions are printed in a sequence that should be
followed to assure best results when removing or re- 1. Disconnect battery cables from battery terminals.
placing powerhead components. If complete disas- 2. Remove top cowling.
sembly is not necessary, start reassembly at point
IMPORTANT: Prior to removing flywheel cover,
disassembly was stopped. (Refer to “Table of Con-
remove vent hose from fitting on flywheel cover.
tents,”preceding.)
3. Remove flywheel cover.
If major powerhead repairs are to be performed, re-
move powerhead from drive shaft housing. Removal a
of powerhead is not required for 1) inspection of cylin-
der walls and 2) minor repairs on components such
as ignition system, carburetors, reed blocks, cylinder b
heads and checking operation of thermostats.

a - Cover
b - Vent Hose
4. Remove two screws which secure remote control
harness retainer and remove retainer.

55917
a - Screws
b - Retainer

90-855348R1 JANUARY 1998 POWERHEAD - 4A-13

5. Disconnect fuel hose, oil inlet hose, throttle cable 9. Remove 4 bolts securing bottom cowl halves and
and shift cable. remove bottom cowling.

b
d a
c
a 55918
55932
a - Bolt

a - Fuel Hose
b - Oil Inlet Hose
c - Throttle Cable
d - Shift Cable
6. Disconnect remote control harness from
powerhead harness. a
7. Disconnect warning gauge wiring harness.
8. Disconnect trim motor harness.

52352
a - Bolt
a b

55919
a - Remote Control Harness
b - Warning Gauge Harness a 55970
c - Trim Motor Harness a - Bolt

4A-14 - POWERHEAD 90-855348R1 JANUARY 1997

10. If a suitable powerhead holding fixture is avail- NOTE: If powerhead cannot be removed due to gas-
able, powerhead may be removed fully dressed. ket adhesion, reinstall fore and aft powerhead nuts.
Disconnect 2 thermostat hoses, fuel rail air outlet Install a jacking block under the aft powerhead nut.
hose, fuel cooler water hose and tell-tale hose. 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 ad-
hesion.

b
c

b c a a
d
55920
a - Thermostat Water Hoses a
b - Fuel Rail Air Outlet Hose d
c - Fuel Cooler Water Hose 55955
d - Tell-Tale Hose
a - Jacking Block
11. Disconnect shift link from upper shift shaft. b - Aft Nut
c - Forward Nut
12. Remove 10 nuts and washers (5 each side) from d - Pry Bar
powerhead base.
a
b

52373
a - Nuts and Washers (5 each side)
b - Shift Link
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 as-
sembly from drive shaft housing.

90-855348R1 JANUARY 1998 POWERHEAD - 4A-15

REMOVING ENGINE COMPONENTS Powerhead Disassembly
Remove the following engine components by refer- 1. Place powerhead in repair stand or on a bench.
ing to the following sections:
2. Remove thermostat covers, thermostats and
Section 2 gaskets.
Starter Motor
Alternator a
Ignition Modules
a
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

55973
a - Thermostat Cover

55972
a - Thermostat
b - Gasket

4A-16 - POWERHEAD 90-855348R1 JANUARY 1997

3. Remove cylinder heads from engine block. 5. Inspect reeds as outlined in “Cleaning and
Inspection”.
a

b 55973

a - Cylinder Head
b - Engine Block
4. Remove reed block housing from cylinder block.
55976
a 6. Remove bolts from end cap.

LOWER END CAP

a a

55975
a - Reed Block Housing 52325
a - Crankcase Attaching End Cap Bolts

90-855348R1 JANUARY 1998 POWERHEAD - 4A-17

7. Remove bolts which secure crankcase cover to 10. Using an awl or electric pencil, scribe the cylinder
cylinder block. identification number on each connecting rod as
shown. Reassemble connecting rods in same
cylinder.
a

55977 52347
a - Crankcase Cover
8. Remove crankcase end cap. 11. Use a 3/8 in. 12 point socket to remove
connecting rod bolts, then remove rod cap, roller
CRANKCASE COVER REMOVED bearings and bearing cage from connecting rod.

52316
a - Connecting Rod Bolts

55978
12. Push piston out of cylinder block.
9. Use Powerhead Stand (91-812549) for rotating 13. After removal, reassemble each piston and
crankshaft to desired position for removal of connecting rod assembly.
connecting rods.

4A-18 - POWERHEAD 90-855348R1 JANUARY 1997

 16. Using an awl, scribe identification number of
! CAUTION
connecting rod on inside of piston (1).
Each connecting rod and end cap are a matched Reassemble piston on same connecting rod.
machined set and must never be mismatched.

55966
55968
17. Using tool (91-52952A1), remove piston pin lock-
14. Inspect pistons as outlined in “Cleaning and rings from both ends of piston pin. Never re-use
Inspection,”following. piston pin lockrings.
15. Use Piston Ring Expander (91-24697) to remove
piston rings. Always install new piston rings.

55967
55969
a - Lockring

90-855348R1 JANUARY 1998 POWERHEAD - 4A-19

IMPORTANT: Warming the piston dome using a 20. Remove and discard O-ring seal from end cap.
torch lamp will ease removal and installation of
21. Remove oil seals from end cap by driving seals
piston pin.
out with a punch and hammer.
18. Support piston and tap out piston pin using
service tool (91-92973A1) as shown.
b

a
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
55957
carrier assembly.
a - Piston Pin
b - Piston Pin Tool (91-92973A1)
b
19. Remove piston pin needle bearings (34 per
piston) and locating washers (2 per piston) as
shown.
IMPORTANT: We recommend that you use new
needle bearings at reassembly for lasting repair.
However, if needle bearings must be re-used,
keep each set of bearings identified for reas-
sembly on same connecting rod.

a c

51473
a - O-Ring
b - Seal
c - Carrier

55958
a - Needle Bearing Locating Washers

4A-20 - POWERHEAD 90-855348R1 JANUARY 1997

23. Remove crankshaft and place in powerhead IMPORTANT: Keep same bearing races and roller
stand as shown. bearings together.
IMPORTANT: DO NOT remove crankshaft sealing
rings from crankshaft, unless replacement of a a
sealing ring(s) is necessary. Usually, crankshaft
sealing rings do not require replacement, unless
broken.

! CAUTION
Safety glasses should be worn when removing or
installing crankshaft sealing rings.
b

52315
a - Bearing Race Halves
b - Roller Bearings
Inspect crankshaft ball bearing as outlined in “Clean-
ing and Inspection,”following.
IMPORTANT: DO NOT remove crankshaft ball
bearing, unless replacement is required.
26. Remove lower ball bearing from crankshaft as
follows:
55994
a - Sealing Rings (7) a. Remove retaining ring using a pair of snap
ring pliers.
24. Remove retaining ring as shown.

a a
b

52336
a - Retaining Ring c 55983
25. Remove bearing race halves and roller bearings a - Crankshaft Ball Bearing
from crankshaft. b - Pliers
c - Retaining Ring

90-855348R1 JANUARY 1998 POWERHEAD - 4A-21

 b. Press crankshaft out of lower ball bearing as 27. Remove and inspect water pressure relief valve
shown. components for debris or damage. Replace
components as required.
a

b
c

51081
a - Press
b - Powerhead Stand (91-812549)
c - Crankshaft Ball Bearing
d - Universal Puller Plate (91-37241)

2
3
4
5
6
7

8
9
10
12 11

13

1 - Exhaust Plate 8 - Diaphragm

2 - Carrier 9 - Washer
3 - Grommet 10- Screw
4 - Poppet/Relief Valve 11- Gasket
5 - Spring 12- Outer Cover
6 - Gasket 13- Bolts [Torque bolts to 20 lb. ft. (27.1 N·m)]
7 - Inner Plate

4A-22 - POWERHEAD 90-855348R1 JANUARY 1997

Cleaning and Inspection Special Service Information
Grooves in Cylinder Block Caused By Crank-
shaft Sealing Rings
Cylinder Block and Crankcase Cover
Grooves in cylinder block caused by crankshaft seal-
IMPORTANT: Crankcase cover and cylinder ing rings are not a problem, except if installing a new
block are a matched, line-bored assembly and crankshaft and the new sealing rings on crankshaft
never should be mismatched by using a different do not line up with existing grooves in cylinder block.
crankcase cover or cylinder block. If installing a new crankshaft, refer to crankshaft in-
stallation, Powerhead Reassembly section to deter-
mine if powerhead can be used.

Cylinder Bores
1. Inspect cylinder bores for scoring, scuffing or a
transfer of aluminum from piston to cylinder wall.
Scoring or scuffing, if NOT TOO SEVERE, can
normally be removed by honing. If a transfer of
aluminum has occurred, an acidic solution such
as “TIDY BOWL CLEANER”should be applied to
the areas of the cylinder bore where transfer of
aluminum has occurred. After the acidic solution
has removed the transferred aluminum,
thoroughly flush the cylinder bore(s) to remove
any remaining acid. Cylinder walls may now be
honed to remove any glaze and to aid in the
seating of new piston rings.

HONING PROCEDURE
! CAUTION
a. When cylinders are to be honed, follow the
It crankcase cover or cylinder block is to be sub- hone manufacturer’s recommendations for
merged in a very strong cleaning solution, it will use of the hone and cleaning and lubrication
be necessary to remove the crankcase cover/cy- during honing.
linder block bleed system from crankcase cover/
b. For best results, a continuous flow of honing
cylinder block to prevent damage to hoses and
oil should be pumped into the work area. If
check valves.
pumping oil is not practical, use an oil can.
1. Thoroughly clean cylinder block and crankcase Apply oil generously and frequently on both
cover. Be sure that all sealant and old gaskets are stones and work area.
removed from matching surfaces. Be sure that
carbon deposits are removed from exhaust ports. ! CAUTION
2. Inspect cylinder block and crankcase cover for When honing cylinder block, remove hone fre-
cracks or fractures. quently and check condition of cylinder walls.
3. Check gasket surfaces for nicks, deep grooves, DO NOT hone any more than absolutely neces-
cracks and distortion that could cause sary, as hone can remove cylinder wall material
compression leakages. rapidly.

4. Check all water and oil passages in cylinder block c. Start stroking at smallest diameter. Maintain
and crankcase cover to be sure that they are not firm stone pressure against cylinder wall to
obstructed and that plugs are in place and tight. assure fast stock removal and accurate re-
sults.
d. Localize stroking in the smallest diameter un-
til drill speed is constant throughout length of
bore. Expand stones, as necessary, to com-
pensate for stock removal and stone wear.

90-855348R1 JANUARY 1998 POWERHEAD - 4A-23

 Stroke at a rate of 30 complete cycles per 4. If a cylinder bore is tapered, out-of-round or worn
minute to produce best cross-hatch pattern. more than 0.003 in. (0.076mm) from standard
Use honing oil generously. “Cylinder Block Finish Hone”diameter (refer to
chart, preceding), it will be necessary to re-bore
e. Thoroughly clean cylinder bores with hot wa-
that cylinder(s) to 0.015 in. (0.381mm) oversize
ter and detergent. Scrub well with a stiff
or 0.030 in. (0.762mm) oversize and install
bristle brush and rinse thoroughly with hot
oversize piston(s) and piston rings during
water. A good cleaning is essential. If any of
reassembly.
the abrasive material is allowed to remain in
the cylinder bore, it will cause rapid wear of NOTE: The weight of an oversize piston is approxi-
new piston rings and cylinder bore in addition mately the same as a standard size piston; therefore,
to bearings. After cleaning, bores should be it is not necessary to re-bore all cylinders in a block
swabbed several times with engine oil and a just because one cylinder requires re-boring.
clean cloth, then wiped with a clean, dry cloth.
5. After honing and thoroughly cleaning cylinder
Cylinders should not be cleaned with kero-
bores, apply light oil to cylinder walls to prevent
sene or gasoline. Clean remainder of cylinder
rusting.
block to remove excess material spread dur-
ing honing operation.
2. Hone all cylinder walls just enough to de-glaze
walls.
3. Measure cylinder bore diameter (with a snap
gauge micrometer) of each cylinder, as shown
below. Check for tapered, out-of-round
(egg-shaped) and oversize bore.

52324
200/225 DFI Models

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)

4A-24 - POWERHEAD 90-855348R1 JANUARY 1997

Pistons and Piston Rings MEASURING PISTON ROUNDNESS

IMPORTANT: If engine was submerged while en- Piston has a barrel profile shape and is not a true di-
gine was running, piston pin and/or connecting ameter.
rod may be bent. If piston pin is bent, piston must 1. Using a micrometer, measure dimension “A”at
be replaced. (Piston pins are not sold separately location shown. Dimension “A” should be as
because of matched fit into piston.) If piston pin indicated in chart following.
is bent, connecting rod must be checked for
straightness (refer to “Connecting Rods,” fol- Piston Dimension “A”
lowing, for checking straightness). Standard Piston 3.6210 in. ±.0005 in.
1. Inspect pistons for scoring and excessive piston .015 in. Oversize Piston 3.636 in. ±.0005 in.
skirt wear.
.030 in. Oversize Piston 4.383 in. ±.0005 in.
2. Check tightness of piston ring locating pins.
Locating pins must be tight. 2. Using a micrometer, measure dimension “A”at
location shown. Dimension “A”should be 3.6210
3. Thoroughly clean pistons. Carefully remove
in. ± 0.0005 in. for a STANDARD size piston.
carbon deposits from pistons, with a soft wire
brush or carbon remove solution. Do not burr or
round off machined edges.
Inspect piston ring grooves for wear and carbon ac-
cumulation. 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.
A 1 in.
(25.4mm)
CLEANING PISTON RING GROOVES
Keystone (tapered) ring grooves
55959
! CAUTION a - Dimension “A”at Right Angle (90°) to Piston Pin

Care must be taken not to scratch the side sur-

faces of the ring groove. Scratching the side sur- Cylinder Heads
face of the ring groove will damage the ring
groove. 1. Inspect internal surface of cylinder heads for
possible damage (as a result of piston or foreign
1. Use a bristle brush and carbon remover solution
material striking cylinder heads).
to remove carbon from side surfaces.
IMPORTANT: Cylinder head warpage should not
2. A tool can be made for cleaning the inner
exceed 0.005 in. (0.127mm) over the ENTIRE
diameter of the tapered ring grooves. The tool
length of the cylinder head. If measured warpage,
can be made from a broken tapered piston ring
as determined on a surface block, exceeds 0.005
with the side taper removed to enable the inside
in. (0.127mm) or a discontinuity of up to 0.001 in.
edge of the ring to reach the inner diameter of the
(0.025mm) exists in a 1.0 in. (25.4mm) length of
groove. Carefully scrape carbon from inner
the cylinder head’s surface, then the cylinder
diameter of ring grooves. Care must be taken not
head must be replaced.
to damage the grooves by scratching the side
surfaces of the grooves. 2. Replace cylinder head(s) as necessary.
Piston with two half keystone (half tapered) rings

a - Ring Grooves

90-855348R1 JANUARY 1998 POWERHEAD - 4A-25

Crankshaft Crankshaft (and End Cap) Bearings
1. Inspect crankshaft to drive shaft splines for wear. IMPORTANT: When overhauling powerhead as-
(Replace crankshaft, if necessary.) sembly, it is recommended that all crankshaft
bearings -- upper/lower, center main, connecting
2. Check crankshaft for straightness. Maximum
rod and wrist pin bearings -- be replaced to en-
runout -- 0.002 in. (0.0508mm). Check runout at
sure optimum powerhead performance and lon-
center main bearing surfaces with ends of
gevity.
crankshaft supported in v-blocks. (Replace as
necessary.) 1. After cleaning crankshaft, grasp outer race of
crankshaft ball bearing (installed on lower end of
3. Inspect crankshaft oil seal surfaces. Sealing
crankshaft) and attempt to work race back-and-
surfaces must not be grooved, pitted or
forth. There should not be excessive play.
scratched. (Replace as necessary.)
2. Lubricate ball bearing with light oil. Rotate outer
4. Check all crankshaft bearing surfaces for rust,
bearing race. Bearing should have smooth ac-
water marks, chatter marks, uneven wear and/or
tion and no rust stains. If ball bearing sounds or
overheating. (Refer to “Connecting Rods”.)
feels “rough”or has “catches,”remove and dis-
5. If necessary, clean crankshaft surfaces with card bearing. (Refer to “Powerhead Removal
crocus cloth. and Disassembly - Crankshaft Removal and
Disassembly”).

a
b

c c 52326
a - Lower Ball Bearing
3. Thoroughly clean (with solvent) and dry crank-
shaft center main roller bearings. Lubricate bear-
ings with 2-Cycle Outboard Oil.

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.

4A-26 - POWERHEAD 90-855348R1 JANUARY 1997

 ! CAUTION Reed Block Assembly
DO NOT intermix halves of upper and lower IMPORTANT: DO NOT remove reeds from reed
crankshaft center main roller bearings. Replace blocks, unless replacement is necessary. DO
bearings in pairs only. NOT turn used reeds over for re-use. Replace
reeds in sets only.
4. Thoroughly inspect center main roller bearings.
Replace bearings if they are rusted, fractured, 1. Thoroughly clean gasket surfaces of reed blocks
worn, galled or badly discolored. 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 block(s), if reeds have made
indentations.
3. Check for chipped and broken reeds.

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.

a 56023
Allowable reed opening is 0.020 in. (0.51mm) or less.
Replace reeds if either reed is standing open more
than 0.020 in. (0.51mm).
51473
a - Upper Roller Bearing

Reed Block
Inspect passages in reed block to be sure that they
are not obstructed.

90-855348R1 JANUARY 1998 POWERHEAD - 4A-27

Connecting Rods 5. Spalling: Spalling is the loss of bearing surface,
and it resembles flaking or chipping. Spalling will
1. Check connecting rods for alignment by placing be most evident on the thrust portion of the
rods on a surface plate. If light can be seen under connecting rod in line with the “I”beam. General
any portion of machined surfaces, if rod has a bearing surface deterioration could be caused by
slight wobble on plate, or if a 0.002 in. (0.051mm) or accelerated by improper lubrication.
feeler gauge can be inserted between any
machined surface and surface plate, rod is bent
and must be discarded.
2. Overheating: Overheating is visible as a bluish
bearing surface color that is caused by
inadequate lubrication or excessive RPM.
3. Rust: Rust formation on bearing surfaces
causes uneven pitting of surface(s).
a
51853
a - Spalling
6. Chatter Marks: Chatter marks are the result of a
combination of low speed - low load - cold water
temperature operation, aggravated by inade-
quate lubrication and/or improper fuel. Under
these conditions, the crankshaft journal is ham-
a mered by the connecting rod. As ignition occurs
in the cylinder, the piston pushes the connecting
51853
a - Pitting rod with tremendous force, and this force is trans-
ferred to the connecting rod journal. Since there
4. Water Marks: When bearing surfaces are is little or no load on the crankshaft, it bounces
subjected to water contamination, a bearing away from the connecting rod. The crankshaft
surface “etching”occurs. This etching resembles then remains immobile for a split second until the
the size of the bearing. piston travel causes the connecting rod to catch
up to the waiting crankshaft journal, then ham-
mers it. The repetition of this action causes a
rough bearing surface(s) which resembles a tiny
washboard. In some instances, the connecting
rod crank pin bore becomes highly polished. Dur-
ing 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 condi-
tions are found, replace both the crankshaft and
51853 connecting rod(s).

a
51853
a - Chatter Marks Between Arrows

4A-28 - POWERHEAD 90-855348R1 JANUARY 1997

7. Uneven Wear: Uneven wear could be caused by but using 320 grit carborundum cloth instead
a bent connecting rod. of crocus cloth.
d. Thoroughly wash connecting rods to remove
abrasive grit. Recheck bearing surfaces of
connecting rods. Replace any connecting
rod(s) that cannot be properly “cleaned up.”
Lubricate bearing surfaces of connecting
rods (which will be re-used) with light oil to
prevent rust.

a
51853
Powerhead Reassembly and
a - Uneven Wear Between Arrows Installation
8. If necessary, clean connecting rod bearing
surfaces, as follows:
General
a. Be sure that “etched” marks on connecting
rod (crankshaft end) are perfectly aligned Before proceeding with powerhead reassembly, be
with “etched”marks on connecting rod cap. sure that all parts to be re-used have been carefully
Tighten connecting rod cap attaching bolts cleaned and thoroughly inspected, as outlined in
securely. “Cleaning and Inspection,”preceding. Parts, which
have not been properly cleaned (or which are ques-
! CAUTION tionable), can severely damage an otherwise per-
fectly good powerhead within the first few minutes of
Crocus cloth MUST BE USED to clean bearing
operation. All new powerhead gaskets MUST BE in-
surface at crankshaft end of connecting rod. DO
stalled during reassembly.
NOT use any other type of abrasive cloth.
During reassembly, lubricate parts with Quicksilver
b. Clean CRANKSHAFT END of connecting
2-Cycle Outboard Lubricant whenever “light oil” is
rod by using CROCUS CLOTH placed in a
specified. Quicksilver part numbers of lubricants,
slotted 3/8 in. (9.5mm) diameter shaft, as
sealers and locking compounds and tools are listed
shown. Chuck shaft in a drill press and opera-
in “Powerhead General Information,”preceding.
tion press at high speed while keeping con-
necting rod at a 90°angle to slotted shaft. A torque wrench is essential for correct reassembly
of powerhead. DO NOT attempt to reassemble pow-
IMPORTANT: Clean connecting rod just enough
erhead without using a torque wrench. Attaching
to clean up bearing surfaces. DO NOT continue
bolts for covers, housings and cylinder heads MUST
to clean after marks are removed from bearing
BE torqued by tightening bolts in 3 progressive steps
surfaces.
(following specified torque sequence) until specified
torque is reached (see “Example,”following).
EXAMPLE: If cylinder head attaching bolts require a
torque of 20 Ib. ft. (27.1 N·m), a) tighten all bolts to 5
Ib. ft. (6.7 N·m), following specified torque sequence,
b) tighten all bolts to 10 Ib. ft. (13.6 N·m), following
torque sequence, then finally c) tighten all bolts to 20
Ib. ft. (27.1 N·m), following torque sequence.

52323
c. Clean PISTON PIN END of connecting rod,
using same method as in Step “b”, preceding,

90-855348R1 JANUARY 1998 POWERHEAD - 4A-29

IMPORTANT: If lower drive shaft ball bearing has 3. If removed, spread new crankshaft sealing rings
been removed, it is recommended that a new just enough to slide over crankshaft journal.
bearing be installed as the removal process will
damage the bearing.
a

1. If removed, press new lower crankshaft ball

bearing onto crankshaft as shown. Be sure
bearing is pressed firmly against shoulder.

a - Crankshaft Sealing Rings

c
4. Use Piston Ring Expander (91-24697) and install
crankshaft sealing rings into groove.
a b

51854

51852
a - Crankshaft
b - Crankshaft Ball Bearing
c - Suitable Mandrel
d - Press
2. Reinstall retaining ring using a suitable pair of
Snap Ring Pliers.
b
a

52320
a - Piston Ring Expander (91-24697)
b - Crankshaft Sealing Rings (7 Each)

55983

a - Retaining Ring

4A-30 - POWERHEAD 90-855348R1 JANUARY 1997

5. Lubricate center main crankshaft roller bearings 8. Secure center main bearing races together with
and races with light oil. 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 Type 271 (92-
32609-1) to outer diameter of lower end cap
oil seals (a).
a b. Using suitable mandrel, press one oil seal (lip
b facing DOWN) into lower end cap until firmly
52318
seated. Remove any excess Loctite.
a - Install so Hole is Toward Drive Shaft End of Crankshaft
b - Verify Retaining Ring Bridges the Separating Lines of the c. Press second oil seal (lip facing DOWN) until
Bearing Race firmly seated on first oil seal. Remove any ex-
cess Loctite.
6. Place center main crankshaft roller bearings on
upper and lower main bearing journals as shown.
7. Install center main bearing races as shown.

d. Lubricate oil seal lips with 2-4-C w/Teflon

(92-825407A12).
e. Apply a light coat of Perfect Seal
(92-34227-1) to end cap flange.
f. Lubricate O-ring seal with 2-4-C w/Teflon
(92-825407A12) and install over lower end
cap.

b 52315 a 51849
a - Flywheel End
b - Drive Shaft End a - O-ring

90-855348R1 JANUARY 1998 POWERHEAD - 4A-31

10. Install oil seal into upper bearing carrier Install upper and lower end caps and then inspect fit
assembly as follows: between sealing rings and grooves. Temporarily in-
stall crankcase cover and rotate crankshaft several
a. Apply a light film of 2-4-C w/Teflon
times to check if sealing rings are binding against
(92-825407A12) to outer diameter of oil seal;
crankshaft. (You will feel a drag on the crankshaft.) If
this will ease seal installation into carrier.
sealing rings are binding, recheck grooves for burrs.
b. Lubricate oil seal lip with 2-4-C w/Teflon. If this does not correct the problem, it is recom-
c. Use a suitable mandrel, press oil seal into mended that the cylinder block be replaced.
carrier (lip facing DOWN) until bottomed out Install crankshaft as follows:
on shoulder of carrier.
1. Lubricate crankshaft sealing rings with light oil.
d. Lubricate O-ring with 2-4-C w/Teflon and in-
2. Check cylinder block to be sure that dowel pins
stall on carrier.
are in place.
b
a

a 55992
51473

a - O-ring a - Dowel Pins

b - Seal
3. Position all crankshaft seal ring gaps straight up.
4. Align hole in each center main bearing race with
Crankshaft Installation dowel pin.
5. Gently push crankshaft down into position
SPECIAL INFORMATION making sure that the dowel pins are lined up with
Installing A New Crankshaft Assembly Into Cylin- the holes in center main bearings and crankshaft
der Block seal rings are in place.
Check the crankshaft sealing ring mating surfaces in
the cylinder block and crankcase cover for wear
grooves that were caused by the crankshaft sealing
rings from the previous crankshaft. If wear grooves
are present, the sealing rings on the new crankshaft
will have to fit into the grooves without binding the
crankshaft.
Before installing crankshaft, remove any burrs that
may exist on groove edges.
Lubricate sealing rings with light oil and install new
crankshaft as instructed.
55993

4A-32 - POWERHEAD 90-855348R1 JANUARY 1997

6. Lubricate lower crankshaft end (oil seal area) Position piston over end of rod. Verify locating wash-
with light oil, then install lower end cap. Secure ers remain in place.
end cap to cylinder block with attaching bolts. DO
NOT tighten end cap bolts at this time.

a
a

55960
a - Locating Washers
4. Insert piston pin tool (91-92973A1) and push
sleeve out of piston. Keep piston pin tool in
piston.
52328
a- Lower End Cap

b
Piston and Connecting Rod a
Reassembly
1. Place needle bearings on a clean piece of pa-
per and lubricate with 2-4-C w/Teflon
(92-825407A12).
NOTE: There are 34 needle bearings per piston.
2. Place sleeve which is part of piston pin tool 55961
(91-92973A1) into connecting rod and install
needle bearings around sleeve as shown. a - Piston Pin Tool (91-92973A1)
b - Sleeve
a
5. Use a mallet and tap piston pin into piston and
push piston pin tool out.

52315 b

a - Sleeve (Part of Tool Assy. 91-92973A1)

3. Place locating washers on connecting rod.
IMPORTANT: Position connecting rod part num-
ber facing towards flywheel.

55962
a - Piston Pin
b - Piston Pin Tool

90-855348R1 JANUARY 1998 POWERHEAD - 4A-33

6. Install new piston pin lockrings (one each end of
piston pin) with Lockring Installation Tool
(91-93004A2).
7. Make sure lockrings are properly seated in piston
grooves.

b
a

55963
a - Lockring Installation Tool

51086
a - Lockring Installation Tool (91-93004A2)
b - Lockring

4A-34 - POWERHEAD 90-855348R1 JANUARY 1997

Piston and Piston Ring
Combination
.078 in.

.078 in.
55964

a - Half Keystone (tapered) Piston Ring IMPORTANT: Piston ring side with dot or letter
must be facing up.

Piston Installation a
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.
b
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, 52317
until rings (within tolerance) are found. a - Piston Ring
b - Dot
3. Use Piston Ring Expander (91-24697) and install
a 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.
b 5. Lubricate piston, rings and cylinder wall with
2-Cycle Outboard Oil.
c
a

52327
a - Piston Ring
b - Dot or “T”(Faces Up)
c - Feeler Gauge
d - Ring End Gap 52319

a - Piston Ring Expander

b - Dot Side “UP”on Piston Ring

90-855348R1 JANUARY 1998 POWERHEAD - 4A-35

6. Rotate each piston ring so end of ring is aligned 9. Coat cylinder bore with 2-cycle oil. Match piston
with locating pin as shown. assembly with cylinder it was removed from, and
position piston as described below. Push piston
7. Install Piston Ring Compressor.
into cylinder.
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”facing 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.
a
52328
a - Piston Ring Compressor (91-823237)
UP UP
CYL 2 CYL 1
10. Apply 2-4-C w/Teflon to bearing surface of
P S connecting rod and install bearing assembly, as
shown.
11. Place connecting rod cap on connecting rod.
UP UP
CYL 4 CYL 3
Apply light oil to threads and face of connecting
P S rod bolts. Thread connecting rod bolts finger-tight
while checking for correct alignment of the rod
cap as shown.
UP UP IMPORTANT: Connecting rod and connecting
CYL 6 CYL 5
P S rod caps are matched halves. Do not torque
screws before completing the following proce-
dure.
· 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.

4A-36 - POWERHEAD 90-855348R1 JANUARY 1997

12. Tighten connecting rod bolts (using a 3/8 in. - 12 Crankcase Cover Installation
point socket) First torque to 15 lb. in. (1.7 N·m)
then 30 lb. ft. (40.7 N·m). Turn each bolt an 1. Thoroughly remove all oil from mating surfaces of
additional 90° after 2nd torque is attained. crankcase cover and cylinder block with Loctite
Recheck alignment between rod cap and rod as Primer 203 included in Master Gasket Kit
shown. (92-12564-1).

a a

b b

52316
a - Connecting Rod Screws
13. Rotate crankshaft several times (using
powerhead stand) to assure free operation (no
binds and catching).
Connecting Rod Cap Alignment
Check each connecting rod cap for correct align- 55984
ment. If not aligned, a ridge can be seen or felt at the a - Crankcase Cover
separating line as shown below. Correct any mis- b - Remove All Oil
alignment. 2. Apply a thin, even coat of Loctite Master Gasket
on mating surface of cylinder block.
a

a c

b d

52381 55985
a - Side View Incorrect -- Cap on Backwards a - Loctite Master Gasket (92-12564-1)
b - End View Incorrect -- Cap on Backwards
c - Side View Correct
d - End View Correct

90-855348R1 JANUARY 1998 POWERHEAD - 4A-37

3. Place crankcase cover in position on cylinder 5. Tighten end cap bolts to specified torque.
block. Turn the 8 center main bolts in a LITTLE at
a time, (following torque sequence) compressing
crankshaft seal rings until crankshaft cover has
been drawn down to cylinder block. Tighten eight
bolts (a) evenly in three progressive steps
(following torque sequence).
4. Install remaining crankcase cover flange bolts
(following torque sequence).
a
a
52132
8 7 a - Torque Bolts to 85 lb. in. (9.6 N·m)

13 14
Assembly of Reed Blocks to Intake
Manifold
9 10

1 4 c
6 7

4 1

2 3
3 2
b

8 5

a
11 12

5 6
b
55986 55991
a - Apply Light Oil to Threads and Bolt Face; a - Intake Manifold Bolts [Torque to 100 lb. in. (11.3 N·m)]
8 Bolts (M10 x 1.5 x 80); b - Reed Block Mounting Bolts [Torque to 90 lb. in.
30 lb. ft. (40.7 N·m) and Rotate 90° (10.2 N·m)]
b - 14 Bolts (M8 x 1.25 x 35) c - Reed Attaching Screws [Torque to 25 lb. in. (2.8 N·m)]
28 lb. ft. (38.0 N·m)

4A-38 - POWERHEAD 90-855348R1 JANUARY 1997

Notes:

90-855348R1 JANUARY 1998 POWERHEAD - 4A-39

Exhaust Plate 1997 Model 200 DFI
35
95 36
37
38
31 3
23 23
30
26 28
62

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

62 3M Permabond #3MO8155 (Obtain Locally)

95 2-4-C With Teflon (92-825407A12)
A = TO AIR COMPRESSOR

4A-40 - POWERHEAD 90-855348R1 JANUARY 1997

 Exhaust Plate 1997 Model 200 DFI
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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) 240 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) 300 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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-41

Exhaust Plate 1998 Model 200/225 DFI

62 3M Permabond #3MO8155 (Obtain Locally)

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

4A-42 - POWERHEAD 90-855348R1 JANUARY 1997

 Exhaust Plate 1998 Model 200/225 DFI
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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) 240 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) 300 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)

90-855348R1 JANUARY 1998 POWERHEAD - 4A-43

Cylinder Head Installation 2. Install thermostat assembly into each cylinder
head.
1. Install each cylinder head to engine block with
thermostat pocket “UP”. Apply light oil to cylinder 3. Install overheat temperature sensor into
head bolt threads and bolt face. Torque all bolts STARBOARD cylinder head opposite#1 spark
to 20 lb. ft. (27.1 N·m) and rotate 90°. plug.

20 18
a b
16 14
e

12 10
d c
1 3

7 5

6 8
a - Thermostat 120°F (48.9°C)
4 2 b - O-Rings
c - Temperature Sensor
9 11 d - Bolt - Torque to 200 lb. in. (22.6 N·m)
e - Bolt - Torque to 100 lb. in. (11.3 N·m)

13 15

17 19
52132

4A-44 - POWERHEAD 90-855348R1 JANUARY 1997

NOTE: During normal engine operating tempera-
ture, the sender electrical circuit is open and will
close if temperature reaches 200°F ± 8°F (93.3°C
± 13.3°C) thus activating the overheat alarm.
4. Thermostat and temperature sensor installed.
a

55972
a - Thermostat [143°F (61.7°C)]

55940
a - Overheat Temperature Sensor [Torque attaching bolt to
200 lb. in. (22.6 N·m)]

90-855348R1 JANUARY 1998 POWERHEAD - 4A-45

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 PST Pipe Sealant (92-809822)

4A-46 - POWERHEAD 90-855348R1 JANUARY 1997

 Bleed System 1997 Model 200 DFI
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-47

Front Bleed View 1997 Model 200 DFI

4A-48 - POWERHEAD 90-855348R1 JANUARY 1997

Notes:

90-855348R1 JANUARY 1998 POWERHEAD - 4A-49

Bleed System 1998 Model 200/225 DFI
14 12

13 8
29 B
A 31 31 12
9
30
10 7
7 17

4 12
32
17 3 8

7 12

11
12 5

6
21
a
18 b 12

c 8
21
d a
24 12
25 15 e
f
23 b
22
26
16 13 18 c
14
24
21
23

22 d
19

19

22 e
23

24 f

A = TO AIR HANDLER B = TO AIR COMPRESSOR

4A-50 - POWERHEAD 90-855348R1 JANUARY 1997

 Bleed System 1998 Model 200/225 DFI
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 (Shown as Ref.10 on page 16)
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 (Shown as Ref. 10 on page 16)
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.)

Reinstalling Engine Section 3

Air Management System
Components Fuel Management System
Fuel Pump
Reinstall the following components:
Fuel Rails
Section 2 Vapor Separator
Starter Motor
Oil Injection
Alternator
On-Board Oil Tank
Ignition Modules
Oil Pump
Electronic Control Unit
Solenoids
Crank Position Sensor
Throttle Position Sensor
Temperature Sensor

90-855348R1 JANUARY 1998 POWERHEAD - 4A-51

Anchor Bracket/Throttle Linkage Model 1997 200 DFI

A = TO FUEL MANAGEMENT BRACKET

B = 25 lb. ft. (34.0 N·m)
C = 20 lb. ft. (27.0 N·m)

4A-52 - POWERHEAD 90-855348R1 JANUARY 1997

 Anchor Bracket/Throttle Linkage 1997 Model 200 DFI
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-53

Anchor Bracket/Throttle Linkage 1998 Model 200/225 DFI

22
21
20

14 18
7
95
10 17
19
12 11 5
13 6 2
5 6
15
4

95

16 15

3 7

8
9
23
1

31
30

26
24
25 34

29 32

28 33
27

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

4A-54 - POWERHEAD 90-855348R1 JANUARY 1997

 Anchor Bracket/Throttle Linkage 1998 Model 200/225 DFI
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 THROTTLE CONTROL LEVER
2 1 SCREW (M8 x 35) 250 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

90-855348R1 JANUARY 1998 POWERHEAD - 4A-55

Powerhead Installation on 4. Apply a small amount of 2-4-C w/Teflon
(92-825407A12) onto driveshaft splines.
Driveshaft Housing 5. Use hoist to lower powerhead onto driveshaft
1. Install Lifting Eye (91-90455) into flywheel. housing. It may be necessary to turn flywheel
(aligning crankshaft splines with drive shaft
! WARNING splines) so that powerhead will be fully installed.
BE SURE that Lifting Eye is threaded into fly- 6. Install 10 flat washers and 10 locknuts which
wheel as far as possible BEFORE lifting power- secure powerhead to exhaust extension
head. plate/driveshaft housing. Torque locknuts in 3
progressive steps until secured.
2. Using a hoist, lift powerhead high enough to allow
removal of powerhead from repair stand. 7. Disconnect hoist from Lifting Eye and remove
Remove powerhead from repair stand, being Lifting Eye from flywheel.
careful not to damage drive shaft housing gasket 8. Reinstall plastic cap into center of flywheel cover.
surface of powerhead.
3. Place a new gasket around powerhead studs and a
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
52373
R a - Locknuts and Flat Washers [Torque to 50 lb. ft. (68.0 N·m)]
9. Connect bypass water hoses to fittings on
exhaust adaptor plate.

a
a
b

IMPORTANT: DO NOT apply lubricant to top of 55920

driveshaft as this will prevent driveshaft from ful- a - Water Hose
ly engaging into crankshaft. b - Water Pressure Gauge Fitting (1997 Models)

4A-56 - POWERHEAD 90-855348R1 JANUARY 1997

10. Connect tell-tale hose and flush hose to engine
block.

b 55970
a
a - Tell-Tale Hose 55970
b - Flush Hose
a - Bolts [Torque to 65 lb. in. (7.3 N·m)]
11. Install four bolts which secure bottom cowl halves
together. 12. Re-connect input fuel line with hose clamp.

a
55932
a - Bolts [Torque to 65 lb. in. (7.3 N·m)] 52191
a - Fuel Line
b - Hose Clamp

52352
a - Bolts [Torque to 65 lb. in. (7.3 N·m)]

90-855348R1 JANUARY 1998 POWERHEAD - 4A-57

13. Connect remote oil tank pressure hose to to 14. Attach relay ground harness to lower electrical
crankcase fitting. plate mounting bolt. Torque bolt to 16.5 lb. ft.
(22.4 N·m).
Attach relay positive leads (RED) to BATTERY
SIDE of starter solenoid with nut. Torque nut to 45
lb. in. (5.1 N·m).
15. Re-connect remote control harness to power-
head harness connector and wires as shown.

c
55919
a - Remote Oil Tank Pressure Hose
a

55919
e b
a - Nut -- Attach RED Relay Leads -- Torque Nut to 45 lb. in.
(5.1 N·m)
b - Relays -- Secure with Retained Bolts and Nuts
c - Bolt -- Attach BLACK (ground) Relay leads -- Torque Bolt to
16.5 lb. ft. (22.4 N·m).
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

4A-58 - POWERHEAD 90-855348R1 JANUARY 1997

16. Install two screws which secure remote control
harness retainer.
Break-ln Procedure
! CAUTION
Severe damage to the engine can result by not
complying with the Engine Break-in Procedure.
a
FUEL REQUIREMENTS
Do not use pre-mixed gas and oil in this engine. Use
straight gasoline during engine break-in and after en-
gine break-in. The ECM is programmed to signal the
oil pump to provide additional oil (50:1 ratio) during
the first 90 minutes of operation. The ECM will moni-
tor this period through its own internal clock. At the
b 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.

55917 ENGINE BREAK-IN PROCEDURE (ALL

a - Screws MODELS)
b - Retainer
Vary the throttle setting during the first hour of opera-
17. Reinstall oil line to on board oil reservoir. tion. Avoid remaining at a constant speed for more
18. Slide outboard shift lever into neutral position. than two minutes and avoid sustained wide open
throttle.
19. Install throttle cable.
20. 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 “Timing/
Synchronizing/Adjusting” for engine set-up proce-
dures.

90-855348R1 JANUARY 1998 POWERHEAD - 4A-59

POWERHEAD

4
B

COOLING SYSTEM
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2
3.0 Liter Optimax/DFI Water Flow . . . . . . . . . . . . . . 4B-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2
Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Water Pressure Check . . . . . . . . . . . . . . . . . . . . . 4B-5
Water Pump Cleaning and Inspection . . . . . . . . 4B-5
Problem Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Water Pressure Switch . . . . . . . . . . . . . . . . . . . . . 4B-8

4B-0 - POWERHEAD 90-855348R1 JANUARY 1998

Specifications Temperature Sensor
Water Pressure Three temperature sensors are used to provide cylin-
der head temperature information to the ECM. A sen-
Idle 1-1/2 – 4-1/2 psi sor is mounted in each cylinder head and one in the
(10.3 – 30.8kPa) air compressor cylinder head. The ECM uses this in-
formation to increase injector pulse width for cold
Poppet Valve Opening 6 – 7 psi
starts and to retard timing in the event of an over-heat
(41.1 – 47.9kPa)
condition.
W.O.T. 8-10 psi
(54.9 – 68.5kPa) An ohms test of the temperature sensor would be as
follows:
Thermostat . . . . . . . . . . . . . . 120°F (48.9°C) Insert digital or analog ohmmeter test leads into both
TAN/BLACK sensor leads. With engine at tempera-
ture (F
) indicated, ohm readings should be as indi-
cated ±10%.

270
255
240
225
210
195
180 Temperature Sensor
Temperature (F
)

165
150
135
120
105
90
75
60
45
30
15
0
0 0.2 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 Temperature Sensor(s)
Starboard and Port Cyl- Between Black and No
inder Heads each TAN/BLK wire. Continuity
Horn Activation 180°F (82°C) Between each lead and No
Speed Reduction 185°F (85°C) ground Continuity
(3000 RPM)
Compressor NOTE: The air compressor temperature sensor and
Horn Activation 221°F (105°C) cylinder head temperature sensors are the same part
number. The ECM has been programmed to activate
a warning circuit at different temperatures depending
upon sensor location.
NOTE: The Digital Diagnostic Terminal (DDT) can be
used to monitor temperature readings from all three
temperature sensors.

90-855348R1 JANUARY 1998 POWERHEAD - 4B-1

Special Tools Water flow exiting the cylinder block is controlled by
the thermostats (1 in each cylinder head) and the
1. Volt/Ohm Meter 91-99750A1 poppet valve (located in the exhaust adaptor plate).
At low RPM (below 1500 RPM) the thermostats con-
trol 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 pop-
pet 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
2. Water Pressure Gauge 91-79250A2 a wall of water around the exhaust tube. This per-
forms 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 bot-
tom aft area of the drive shaft
housing.
• Water that passes through the
air compressor exits out the
56725
tell tail.
• Water exits through a strainer
3.0 Liter Optimax/DFI Water screen in the exhaust adaptor
plate into the exhaust tube,
Flow mixing with the exhaust
gases.
To allow complete passage filling and to prevent
Description steam pockets, all cooling passages are intercon-
Cooling water enters the cooling system through the nected. Small passages are incorporated to allow the
lower unit water inlets. The pump assembly forces cooling system to drain.
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 water dams.

4B-2 - POWERHEAD 90-855348R1 JANUARY 1998

Water Flow Diagram

Cylinder Block and Adaptor Plate

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
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.

90-855348R1 JANUARY 1998 POWERHEAD - 4B-3

Troubleshooting NOTE: BE SURE that water in thermostat tester is al-
lowed to cool sufficiently [below 110°F (43.3° C)] be-
fore testing the other thermostat.
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. Allow
valve to close against thread.
b. Suspend thermostat (from thread) and ther-
mometer inside tester so that neither touches
the container. Bottom of thermometer must
be even with bottom of thermostat to obtain
correct temperature of thermostat opening.
51087
c. Fill thermostat tester with water to cover ther-
mostat. IMPORTANT: DO NOT operate engine without
d. Plug tester into electrical outlet. thermostats installed.
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.

4B-4 - POWERHEAD 90-855348R1 JANUARY 1998

Water Pressure Check Water Pump Cleaning and Inspection
Using Water Pressure Gauge 91-79250A2, cut com- 1. Inspect the water tube coupling assembly for
pressor water inlet hose and install tee fitting (pro- wear or damage. If necessary replace the worn
vided) as shown. or damaged components especially the two O-
rings on the inside, one at the top and one at the
NOTE: This is also the same location for installing the
bottom.
water pressure hose for a dash mounted water pres-
sure gauge. b

a
a

b 70613

a - Water Tube adapter

b - O-rings (2)
2. Inspect the water pump impeller for wear on the
56032 end, top and bottom of the impeller blades. Re-
b place the impeller if this condition is found.
d 3. Inspect for proper bonding between the hub and
the impeller. Replace the impeller if improper
bonding is found.
d
c a
d 56726
b

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. 70500

a - Impeller
Idle 1-1/2 – 4-1/2 psi b - Hub
(10.3 – 30.8kPa)
4. Inspect the impeller blades to see if they are
Poppet Valve Opening 6 – 7 psi cracked, burnt, hard or deformed. Replace the
(41.1 – 47.9kPa) impeller if the blades are in this condition.
W.O.T. 8-10 psi
IMPORTANT: The circular groove formed by the
(54.9 – 68.5kPa)
impeller sealing bead should be disregarded
when inspecting cover and plate. The depth of
the groove will not affect water pump output.

90-855348R1 JANUARY 1998 POWERHEAD - 4B-5

5. Replace cover if thickness of steel at the dis- IMPORTANT: It is recommended that all seals and
charge slot is 0.060 in. (1.5mm) or less or if gaskets be replaced (as a normal repair proce-
grooves (other than impeller sealing bead dure) to assure effective repair.
groove) in cover roof are more than 0.030 in.
IMPORTANT: It is recommended that the water
(0.76mm) deep.
pump impeller be replaced whenever the gear-
a b case 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.

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. Re-
place the appropriate components as required.

4B-6 - POWERHEAD 90-855348R1 JANUARY 1998

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
Pressure does not drop between 6 – 7psi (41.1 – 47.9kPa) between •Wrong poppet valve spring
1200 – 1800 RPM indicating pop- 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) between •Poppet valve spring defective
sure drop does not start prior to 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) between •Wrong poppet valve spring
sure drop does not stop prior to 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 check •Engine mounted too high on
water pressure @ W.O.T. if boat is transom or trimmed too far out re-
stationary. Boat must be in the sulting in formation of steam pock-
water and secured to a dock or ets in cooling system
trailer and run in forward gear. DO •If boat is not stationary but is be-
NOT perform check using a flush ing run on open water, ram effect
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 wa-
ter to coolant inlets
•Severe internal leak
•Low output water pump

90-855348R1 JANUARY 1998 POWERHEAD - 4B-7

Water Pressure Switch
The 1998 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 se-
conds, a warning horn will be activated and a warning
lamp will be illuminated. Should the low water pres-
sure continue for more than 5 seconds, a speed re-
duction 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 Diagnostic Termi-
nal (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)

4B-8 - POWERHEAD 90-855348R1 JANUARY 1998

MID-SECTION

5
A

CLAMP BRACKET/SWIVEL BRACKET/

DRIVE SHAFT HOUSING
Table of Contents
Page
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
1997 Model 200 DFI Transom Brackets . . . . . . . . . . 5A-2
1998 Model 200/225 DFI Transom Brackets . . . . . . 5A-4
Swivel Bracket and Steering Arm . . . . . . . . . . . . . . . 5A-6
Drive Shaft Housing and Exhaust Tube
(S/N-0G437999 & BELOW) . . . . . . . . . . . . . . . . . . . 5A-8
Drive Shaft Housing and Exhaust Tube
(S/N-0G438000 & UP) . . . . . . . . . . . . . . . . . . . . . . . 5A-10
Drive Shaft Housing and Dyna-Float
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12
Removal and Disassembly . . . . . . . . . . . . . . . . . 5A-12
Reassembly and Installation . . . . . . . . . . . . . . . 5A-15

5A-0 - MID-SECTION 90-855348R1 JANUARY 1998

Notes:

90-855348R1 JANUARY 1998 MID-SECTION - 5A-1

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 (92-825407A12)

5A-2 - MID-SECTION 90-855348R1 JANUARY 1998

 1997 Model 200 DFI Transom Brackets
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 (1²-14) 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

90-855348R1 JANUARY 1998 MID-SECTION - 5A-3

1998 Model 200/225 DFI Transom Brackets

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

5A-4 - MID-SECTION 90-855348R1 JANUARY 1998

 TRANSOM BRACKETS
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 MID-SECTION - 5A-5

Swivel Bracket and Steering Arm

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

A -- Torque nut to 20 lb. ft. (27.1 N·m)

B -- Torque nut until it seats [DO NOT exceed 120 lb. in. (13.6 N·m) of torque], then back off 1/4 turn.

5A-6 - MID-SECTION 90-855348R1 JANUARY 1998

 Swivel Bracket and Steering Arm
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 MID-SECTION - 5A-7

Drive Shaft Housing and Exhaust Tube
(S/N-0G437999 & BELOW)

7 Loctite 271 (92-809820)

19 Perfect Seal (92-34227-1)
33 Loctite 680 (92-809833)
95 2-4-C With Teflon (92-825407A12)

5A-8 - MID-SECTION 90-855348R1 JANUARY 1998

 Drive Shaft Housing and Exhaust Tube
(S/N-0G437999 & BELOW)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 MID-SECTION - 5A-9

Drive Shaft Housing and Exhaust Tube (S/N-0G438000 & UP)
7 Loctite 271 (92-809820)
19 Perfect Seal (92-34227-1)
33 Loctite 680 (92-809833)
95 2-4-C With Teflon (92-825407A12)

5A-10 - MID-SECTION 90-855348R1 JANUARY 1998

 Drive Shaft Housing and Exhaust Tube (S/N-0G438000 & UP)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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)

90-855348R1 JANUARY 1998 MID-SECTION - 5A-11

Drive Shaft Housing and SHIFT LINKAGE ASSEMBLY

Dyna-Float Suspension
Refer to “Powerhead Removal” Section to Re-
move Powerhead. Refer to “Lower Unit Removal”
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. a - Shift Shaft
b - Bushing (3)
3. Remove 3 bolts which secure upper mount cover c - Lock Nut (2)
to adaptor plate. Remove cover. d - Washer (2)
4. Remove upper mount nuts and flat washers.
b
e 5. Pull mount bolts thru mounts and remove
mounts.
d

a - Shift Shaft a - Upper Mount Nuts

b - Wiring Harness
c - Adaptor Plate
d - Bolts
e - Upper Mount Cover

5A-12 - MID-SECTION 90-855348R1 JANUARY 1998

6. Remove 4 bolts securing exhaust adaptor plate 8. Remove 2 bolts securing water tube to adaptor
to drive shaft housing. plate and remove tube. Remove 6 bolts securing
exhaust tube to adaptor plate.
a

a a
b
c

a - Bolts
b - Adaptor Plate
7. While applying upward pressure on rear of adap-
tor plate, use a mallet and a piece of hardwood
a - Bolts
gainst the adaptor plate to loosen gasket adhe-
b - Exhaust Tube
sion. c - Water Tube
9. While tilting adaptor plate/exhaust tube assem-
a bly, use a piece of hardwood and a mallet to loos-
en gasket adhesion. Remove exhaust tube.

a - Adaptor Plate

b
a - Hardwood
b - Adaptor Plate
c - Exhaust Tube
10. Remove all gasket and gasket material from
drive shaft housing and related components.

90-855348R1 JANUARY 1998 MID-SECTION - 5A-13

11. Remove screw which secures each lower mount 12. Remove bolts securing lower mount retainers to
cover to drive shaft housing. Remove covers. drive shaft housing. Remove retainers.

b
b 52308
52307 a - Bolts
a - Screw b - Lower Mount Retainer (One Each Side)
b - Cover 13. Remove lower mount nuts and rubber caps.

52308
a - Lower Mount Nuts
b - Rubber Caps

5A-14 - MID-SECTION 90-855348R1 JANUARY 1998

14. Remove drive shaft housing from swivel bracket
by pulling alternately from top to bottom on hous-
ing.
15. Remove upper and lower mounts by lifting them
out of drive shaft housing. c d

a
Reassembly and Installation
1. Apply a thin coat of 2-4-C Marine Lubricant onto
inside portion of exhaust tube seal and water
tube grommet.
b
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.

d
SN OG438000 -
a - Exhaust Tube Seal
b - Drive Shaft Housing
c - Water Tube Grommet
c d - Leather Bumper

52307

SN OG437999 ¯
a - Exhaust Tube Seal
b - Drive Shaft Housing
c - Water Tube Grommet
d - Leather Bumper

90-855348R1 JANUARY 1998 MID-SECTION - 5A-15

5. Position exhaust tube and gasket on adaptor 7. Position adaptor plate on top of housing.
plate. Secure both to plate with 6 bolts. Torque
8. Secure adaptor plate to drive shaft with 4 bolts.
bolts to 21 Ib. ft. (28.5 N·m).
Torque bolts to 25 lb. ft. (33.9 N·m).
6. Secure tube to adaptor plate with 2 bolts. Torque
bolts to 80 lb. in. (9.0 N·m).
a

a
c

b a

a - Bolts [Torque to 25 lb. ft. (33.9 N·m)]

9. Apply a thin coat of Perfect Seal onto metal por-
tion 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 - Exhaust Tube
b - Gasket a
c - Water Tube
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.

5A-16 - MID-SECTION 90-855348R1 JANUARY 1998

15. Position a mount on each lower side of drive shaft 21. Install lower mount retainers and secure each
housing. retainer with 2 bolts. (Secure ground strap with
the nearest retainer bolt and flat washer.) Torque
16. Install a flat washer over each lower mounting
bolts to 20 Ib. ft. (27.1 N·m).
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 c
and bumper.
18. Secure upper mounts to steering arm with flat
washers and self-locking nuts. Torque nuts to 50
Ib. ft. (68.0 N·m).
19. Install ground strap between port lower mount b
bolt and swivel bracket.
20. Secure lower mounts to swivel pin yoke with self-
locking nuts. Torque nuts to 90 Ib. ft. (122.0 N·m).
Place a rubber cap over each lower mounting bolt a
head.

52308
a - Lower Mount Retainer
b - Bolts [Torque to 20 lb. ft. (27.1 N·m)]
c - Ground Strap

a 22. Install lower mount covers and secure each cov-

er with a screw.
d

c
e

b
b

52308
a - Lower Mount
b - Nut [Torque to 90 lb. ft. (122.0 N·m)]
c - Rubber Cap
d - Ground Strap (only one side)
e -- Ground Strap (to swivel bracket) a

52307
a - Cover
b - Screw (1 for Each Cover)

90-855348R1 JANUARY 1998 MID-SECTION - 5A-17

23. Install upper mount cover on adaptor plate. Se-
cure cover with 3 bolts. Torque bolts to 20 lb. ft.
(27.1 N·m).
24. Route power trim harness thru grommet in adap-
tor plate.
25. Reinstall shift shaft with bushing into adaptor
plate. Apply 2-4-C w/Teflon to bushing.

f
e
c

a - Shift Shaft Linkage

b - Exhaust Adaptor Plate
c - Upper Mount Cover
d - Bolts [Torque to 20 lb. ft. (27.1 N·m)]
e - Power Trim Harness
f - Grommet
g - Bushing

5A-18 - MID-SECTION 90-855348R1 JANUARY 1998

MID-SECTION

5
B

53789

POWER TRIM
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Scraper Seal Replacement . . . . . . . . . . . . . . . . 5B-26
Power Trim Components . . . . . . . . . . . . . . . . . . . . . . 5B-2 Motor and Electrical Tests/Repair . . . . . . . . . . . . . . 5B-28
Power Trim - General Information . . . . . . . . . . . . . . 5B-4 Trim Pump Motor Test . . . . . . . . . . . . . . . . . . . . 5B-28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5B-29
Trimming Characteristics . . . . . . . . . . . . . . . . . . . 5B-4 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-29
Trailering Outboard . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-30
Tilting Outboard Manually . . . . . . . . . . . . . . . . . . 5B-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-33
Trim “IN” Angle Adjustment . . . . . . . . . . . . . . . . . 5B-5 Reassembly - Motor and Pump . . . . . . . . . . . . 5B-34
Striker Plate Replacement . . . . . . . . . . . . . . . . . . 5B-6 Priming Power Trim System . . . . . . . . . . . . . . . 5B-35
Anode Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Trim Sender (Optional Accessory) Test . . . . . . 5B-35
Trim Indicator Gauge . . . . . . . . . . . . . . . . . . . . . . 5B-6 Trim Indicator Gauge Needle Adjustment . . . . 5B-36
Fill, Check, and Purge - Power Trim Trim Indicator Wiring Diagrams . . . . . . . . . . . . . . . 5B-37
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Quicksilver Commander Series Side
Power Trim System Troubleshooting . . . . . . . . . . . . 5B-7 Mount Remote Control . . . . . . . . . . . . . . . . . . . 5B-37
Power Trim Wiring Diagram . . . . . . . . . . . . . . . . 5B-10 Quicksilver Ignition/Choke and Main
Electrical System Troubleshooting . . . . . . . . . . . . . 5B-11 Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . 5B-37
Troubleshooting the “DOWN” Circuit . . . . . . . . . . . 5B-11
Troubleshooting the “UP” Circuit . . . . . . . . . . . . . . 5B-12
Troubleshooting the “DOWN” and “UP”
Circuits (All Circuits Inoperative) . . . . . . . . . . . . . . 5B-13
Power Trim Assembly
Removal and Installation . . . . . . . . . . . . . . . . . . . . . 5B-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16
Testing Power Trim System With Test
Gauge Kit (91-52915A3) . . . . . . . . . . . . . . . . . . 5B-17
“UP” Pressure Check . . . . . . . . . . . . . . . . . . . . . 5B-18
“DOWN” Pressure Check . . . . . . . . . . . . . . . . . . 5B-19
Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21
Trim Rod End Cap Seal . . . . . . . . . . . . . . . . . . . 5B-22
Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22

5B-0 - MID-SECTION 90-855348R1 JANUARY 1998

Power Trim Specifications 5. Adaptor Fitting 91-82278-2 and 91-82278-3

Test Reading
Trim “UP” 1300 PSI (91kg/cm2)
Maximum Pressure
Trim “DOWN” 500 PSI (35kg/cm2)
Minimum Pressure

54458
Special Tools
1. Alignment Tool 91-11230
6. Spanner Wrench 91-74951

17238

2. Trim Rod Removal Tool 91-44486A1

51337
51337
7. Multi-Meter DVA Tester 91-99750A1
3. Trim Rod Guide Removal Tool 91-44487A1

51337
4. Power Trim Test Gauge Kit 91-52915A6

73835

90-855348R1 JANUARY 1998 MID-SECTION - 5B-1

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
29
28
7 Loctite 271 (92-809820)
85 RTV Silicone Sealer (92-91601-1) 22 23
94 Anti-Corrosion Grease (92-78376A6)
110 Power Trim and Steering Fluid (92-90100A12)

5B-2 - MID-SECTION 90-855348R1 JANUARY 1998

 Power Trim Components
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-3

Power Trim - General The trim cylinders position the outboard at the de-
sired trim angle in the 20 degree maximum trim
Information range. The system will not allow the outboard to be
trimmed above the 20 degree trim range as long as
Description the engine RPM is above approximately 2000 RPM.
The Power Trim System consists of an electric motor, The outboard can be trimmed above the 20 degree
pressurized fluid reservoir, pump, tilt cylinder, and maximum trim angle (for shallow water operation,
two trim rams. etc.), by keeping the engine RPM below 2000. If the
RPM increases over 2000, propeller thrust (if propel-
The remote control (or trim panel) has switches that ler is deep enough) will result in the trim system to re-
trim the outboard “Up” or “Down” and tilt the engine turn the outboard to the 20 degree maximum trim po-
for “Trailering”. The outboard can be trimmed and sition.
tilted under power or when the outboard is not run-
ning.
TRIMMING OUTBOARD “DOWN” (IN):
! WARNING
Trimming Characteristics
Excessive speed at minimum trim “In” may result
NOTE: Because hull designs react differently in vary- in undesirable and/or unsafe steering condi-
ing water conditions, varying the trim position will of- tions. Test for handling characteristics after any
ten improve the ride and boat handling. When trim- adjustment is made to the trim angle (and tilt pin
ming from a mid-trim position (with outboard trim tab location).
in a straight fore and aft position), expect the follow-
ing: Aids planing, particularly with heavy loads.
Improves ride in choppy water conditions.
TRIMMING OUTBOARD “UP” (OUT): Excess trim “In” can cause “bow steer” (boat veers to
left or right).
! WARNING
Transfers steering torque to starboard (right).
Excessive trim “Out” may reduce the stability of
some high speed hulls. To correct instability, re- Improves acceleration to planing speed.
duce the power gradually and trim the outboard The “Down” circuit actuates the “down” relay (under
“In” slightly before resuming high speed opera- engine cowl) and closes the motor circuit. The elec-
tion. A rapid reduction in power will result in a tric motor drives the pump in the opposite direction as
sudden change of steering torque and may the “up” circuit, forcing fluid thru passageways into
cause additional boat instability. the “down” side of the tilt ram. The tilt ram moves the
Will lift boat bow, increasing top speed. engine down to the desired position.
Transfers steering torque harder to port (left) on in-
stallations above 23 in. transom height.
Trailering Outboard
Increases gearcase clearance over submerged ob-
jects. The “Up” circuit first moves the trim cylinders; when
the trim cylinders extend fully, the tilt ram extends to
Excess trim can cause “porpoising” and/or ventila- tilt the outboard to the full “Up” position for trailering.
tion.
Before the boat is trailered, the operator should
! WARNING check for clearance between the outboard skeg and
pavement to prevent damage to skeg from striking
Excessive outboard trim angle will result in in- pavement.
sufficient water supply causing water pump and/
or powerhead overheating damage. Insure water If the outboard must be tilted for clearance between
level is above water intake holes whenever out- skeg and pavement, a device such as a “Transom
board is running. Saver” should be installed to prevent stress to boat
transom from outboard weight while the boat/out-
The “Up” circuit actuates the “up” relay (under out- board are being trailered.
board cowl) and closes the motor circuit. The electric
motor drives the pump, forcing fluid thru passage-
ways into the “up” side of the trim cylinders.

5B-4 - MID-SECTION 90-855348R1 JANUARY 1998

Tilting Outboard Manually Trim “In” Angle Adjustment
! WARNING ! WARNING
Before opening the manual release valve knob, Boat operation with outboard trimmed to the full
insure all persons are clear of outboard as out- “In” trim angle [not using the trim angle adjust-
board will drop to full “Down” when valve is ment bolt (a)] at planing speed may result in un-
opened. desirable and/or unsafe steering conditions. A
water test for handling/steering conditions is re-
The outboard can be raised or lowered manually by
quired after any trim angle adjustments.
opening the manual release valve 3 to 4 turns coun-
terclockwise. Close manual release valve to hold out- IMPORTANT: Some boat/motor combinations
board at the desired tilt position. not using the trim angle adjustment pin (a) and
trimmed to the full “In” trim angle position may
not exhibit any undesirable and/or unsafe handl-
ing and/or steering characteristics at planing
a
speed. If so, not using the trim angle adjustment
bolt (a) may be advantageous to acceleration and
planing. A water test is required to determine if
these characteristics apply to a particular boat/
motor combination.

51353
a - Manual Release Valve

a 51353
a - Trim Angle Adjustment Bolt

90-855348R1 JANUARY 1998 MID-SECTION - 5B-5

Striker Plate Replacement Trim Indicator Gauge
Visually inspect striker plates (a) and replace if worn A Quicksilver Trim Indicator Gauge accessory kit is
excessively. available for the power trim sender (if not previously
installed).

c
b 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.
a Remove “Fill” plug and O-ring. System is full
when oil level is present at fill hole. Tighten “Fill”
plug securely.
27930
a - Striker Plate (2)
b - Lockwasher
c - Locknut. Torque to 80 lb. in. (9.0 N·m)

Anode Plate
Anode plate (a) is a self-sacrificing alloy plate that is
b
consumed gradually by corrosion while providing
protection to the midsection and power trim from gal-
vanic corrosion. Replace anode plate when it is 50% a
consumed.

53792
a - Fill Plug and O-ring (remove to fill system, tighten securely)
b - Oil Can (fill system with Quicksilver Power Trim and
Steering Fluid)

a 27932
a - Anode Plate
IMPORTANT: Do not paint or place protective
coating on anode plate, or corrosion protection
function will be lost.

5B-6 - MID-SECTION 90-855348R1 JANUARY 1998

NOTE: Automatic Transmission Fluid (ATF) Type F, TO CHECK:
FA, Dexron II or Dexron lll may be used.
! CAUTION
Tilt outboard to full “Up” position and engage tilt
lock lever before checking fluid level. System is
pressurized. Extend trim and tilt rams fully to de-
pressurize system.
Remove fill plug and O-ring. System is full when oil
level is present at filler hole. Tighten fill plug securely.

a
Power Trim System
Troubleshooting
IMPORTANT: Acceptable trim down leakage is no
more than 1 in. (2.54cm) in a 24 hour period.
51368
a - Tilt Lock Lever (engage to support engine in “Up” position) IMPORTANT: Operate Power Trim System after
each check to see if problem is corrected. If prob-
lem has not been corrected, proceed to next
TO PURGE: check.
IMPORTANT: Fill plug and O-ring must be tight-
ened securely before purging system. 1. Check that Manual Release Valve knob is tight-
ened to full right (clockwise) position.
IMPORTANT: Run Trim System in short “jogs”
until pump is primed and trim system moves. If 2. Check trim pump fluid level and fill if necessary.
trim motor is run without priming pump, drive- (Refer to “Fill, Check, and Purge - Power Trim
shaft failure could result. System”) preceding.

Cycle outboard through entire trim/tilt range 4 times. 3. Check for external leaks in the system. Replace
Check fluid level after purging system. defective parts if leak is found.

Push down on outboard when trim rams are slightly 4. Check for air in the system and purge if neces-
extended. If rams retract more than 1/8 in. (3.2 mm), sary. (Refer to “Fill, Check, and Purge - Power
air is present in system. Cycle system again and Trim System”) preceding.
check fluid level. NOTE: When troubleshooting the hydraulic system,
cleanliness, and inspection of sealing surfaces,
seals, O-rings, and moving parts is important. The in-
ternal pressures required for proper operation of the
Power Trim System require these parts to be in excel-
lent condition. Replace any parts that may be sus-
pect of failure.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-7

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 proceeding 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.
2 10
7. Upper check valve not seating in port side trim ram.
1
8. Check condition of battery.
9. Replace motor assembly.
10. Broken motor/pump drive shaft.
3

5
6
51491

5B-8 - MID-SECTION 90-855348R1 JANUARY 1998

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 arma-
ture).
6. Blown fuse(s).
7. Trim switch failure.
8. Verify solenoids are functioning correctly.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-9

Power Trim Wiring Diagram

3
9

8 6

53794
UP Relay DOWN Relay

BLK = Black
BLU = Blue
10 GRN = Green
RED = Red
WHT = White

5B-10 - MID-SECTION 90-855348R1 JANUARY 1998

Electrical System 2. Make certain all connections are tight and corro-
sion free.
Troubleshooting 3. Check that plug-in connectors are fully engaged.
GENERAL CHECKS 4. Make certain battery is fully charged.
Before troubleshooting the Power Trim electrical sys- Refer to the preceding four wiring diagrams for con-
tem, check the following: nection points when troubleshooting the electrical
systems (Connection points are specified by num-
1. Check for disconnected wires. ber.)

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

Battery Voltage Indicated: No Voltage Indicated:

•Connect Voltmeter red lead There is an open circuit be-
to Point 2. tween Point 3 and positive
•Depress “Down” trim but- (+) battery terminal.
ton. •Check for loose or cor-
roded connections.
•Check wires for open.

Battery Voltage Indicated:

No Voltage Indicated:
•Pump motor wiring is de- Relay Switch is defective.
fective.
•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.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-11

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
button. If battery voltage is in-
dicated, 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.

5B-12 - MID-SECTION 90-855348R1 JANUARY 1998

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 •Check all trim harness con-
“Run” 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.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-13

Power Trim Assembly ! WARNING
Removal and Installation Failure to support outboard as shown could re-
sult in personal injury and/or damage to out-
Removal board or boat.

1. Remove clamps on transom bracket to free

power trim wiring.
a
a

a 51377
a - Clamps
2. Raise outboard to full “Up” position and engage
tilt lock lever.
c
53791
a - Tilt Lock Lever
b - Support Tool
c - Retaining Clips

IMPORTANT: Support outboard as shown above

to prevent engine from tipping when power trim
retaining pin is removed.

a SUPPORT TOOL
3/8 in. diameter metal rod (a used shift shaft works
well).
14”

a a
2”

1/4”
50605
a - Tilt Lock Lever 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

5B-14 - MID-SECTION 90-855348R1 JANUARY 1998

 ! CAUTION
Disconnect battery cables at battery before re-
moving power trim wires from solenoids.
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 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 27932
a - Anode Plate
5. Open filler cap and release any remaining pres-
sure in the system.
b

51375
53789
a - Transom Mount Bolts (2)
a - Filler Cap b - Tilt Tube Nut (flush with end of thread)
IMPORTANT: Outboards equipped with thru-the-
tilt-tube steering - remove steering link arm from
end of steering cable and cable retaining nut
from tilt tube.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-15

7. Remove 3 screws and washers and move star- Installation
board transom bracket.
1. Paint any exposed metal surfaces to prevent cor-
8. Remove trim limit bolt, if installed. rosion.
2. Apply Loctite 271 to screws. Install trim system,
starboard transom bracket, and tilt tube nut.
3. Reinstall trim limit bolt.

a
b
c 51375
a - Screws (3)
b - Washers (3)
c - Trim Limit Bolt
IMPORTANT: Cross pin (a) should not be reused.
Replace with new cross pin. a
9. Remove trim indicator sender from port side of b
swivel bracket.
10. Drive out cross pin, push out upper swivel pin, d 51375
and remove 3 screws and washers retaining trim
system. Remove system from outboard. a - Screw (6) Torque to 40 lb. ft. (54.0 N·m)
b - Flatwasher (6) Install one per screw
c - Tilt Tube Nut
b d - Trim Limit Bolt
a
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 POS-
ITIVE (+), BLACK wire to NEGATIVE (–)]. If ram
extends too far, retract ram by reversing wire con-
nections.

d 5. Install Upper Swivel Pin with slotted end to left

(port) side of engine.

b a
c c
a - Upper Swivel Pin
b - Slotted end
c - Cross hole (in line with slotted end)
53790 IMPORTANT: Cross pin should not be reused.
a - Cross Pin Install a new pin.
b - Upper swivel pin
c - Port transom bracket screws and washers (3). Remove to
release trim system from outboard.
d - Trim Sender

5B-16 - MID-SECTION 90-855348R1 JANUARY 1998

6. Position slot on end of swivel shaft in line with 11. Apply Quicksilver Liquid Neoprene
hole in tilt ram end. Insert a punch into tilt ram hole (91-25511--2) on all electrical connections.
to align cross hole in upper swivel shaft. Tap new
cross pin in until flush. ! WARNING
a Electrical wires passing through cowl openings
must be protected from chafing or being cut. Fol-
low the recommended procedures outlined in
c b Section 1 of this Manual. Failure to protect wires
as described could result in electrical system
failure and/or injury to occupants of boat.

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 tight-
en transom mount bolts.
Apply marine sealer to threads of mount bolts. Se-
cure with flat washers and locknuts. Be sure installa-
tion is watertight.
10. Tighten tilt tube nut securely.
IMPORTANT: Outboards equipped with thru-the-
tilt-tube steering: Tighten steering cable retaining
nut securely to tilt tube.

a 51354
a - Steering Cable Retaining Nut

90-855348R1 JANUARY 1998 MID-SECTION - 5B-17

Testing Power Trim System With Test 4. Install test adaptor 91-822778A2 into manual re-
lease valve hole.
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 addi-
tional repair.

“UP” Pressure Check

IMPORTANT: Insure battery is fully charged be-
fore performing tests.
1. Tilt outboard to full “Up” position and engage tilt
lock lever.
2. Slowly remove “Fill” plug to bleed pressure from
reservoir. a
3. Remove circlip securing manual release valve
and unscrew release valve from trim assembly.
54458
NOTE: A small amount of trim fluid may drip from
a - Test Adaptor (91-822778A2)
manual release valve hole. Place a suitable contain-
er under trim assembly to collect any leakage. 5. Thread hose from Test Gauge Kit (91-52915A3)
into brass fitting on adaptor.
NOTE: Assemble test adaptor by using o-ring instal-
lation 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. a

g
e

c
d
e d c b
f a
54457

a - Test Adaptor (91-822778A2)

b - O-ring Installation Tool
c - Small O-ring (Install 1st) b
d - Medium O-ring (Install 2nd)
54459
e - Large O-ring (Install Last)
f - Brass Fitting a - Brass Fitting
g - Apply Teflon Tape 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.

5B-18 - MID-SECTION 90-855348R1 JANUARY 1998

 16. Retighten “Fill” plug.
! CAUTION
NOTE: If pressure is less than 1300 PSI (91 kg/cm 2),
Failure to install spare tilt pin (or hardened bolts troubleshoot system per instructions on page 5B-8.
and nuts) in hole shown could result in transom
bracket failure and possible injury.
8. Move outboard “IN” until hole in swivel bracket “DOWN” Pressure Check
“ear” aligns with the 3rd tilt hole in transom brack-
et. Lock engine in trim range by installing a 3/8 in. IMPORTANT: Insure battery is fully charged be-
(9.5 mm) diameter tilt pin or two 3/8 in. (9.5 mm) fore performing tests.
hardened bolts and nuts thru the transom brack- 1. Tilt outboard to full “Up” position and engage tilt
ets and swivel bracket in the hole shown. 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 assembly.
NOTE: A small amount of trim fluid may drip from
manual release valve hole. Place a suitable contain-
er under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using o-ring instal-
lation 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
a 54460 teflon tape on threads.
a - Tilt Pin Hole (Install Spare Tilt Pin or Hardened Bolts and
Nuts)
g
9. Open valve (a) and close valve (b).

e d c b
f a
54457

a - Test Adaptor (91-822778A3)

a b b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
51374 f - Brass Fitting
g - Apply Teflon Tape
10. Run trim “UP”. The minimum pressure should be
1300 P.S.I. (91 kg/cm2).
11. Run trim “DOWN” to release pressure and re-
move 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.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-19

4. Install test adaptor 91-822778A3 into manual re- 6. Reinstall fill plug.
lease valve hole.
7. Disengage tilt lock lever.
8. Open valve (f) and close valve (g).
9. Run trim “DOWN”. Minimum pressure should be
54461 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 on Page 5B-8.
a

54458
a - Test Adaptor (91-822778A3)
5. Thread hose from Test Gauge Kit (91-52915A3)
into brass fitting on adaptor.

c
d

g
b
f 54459
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
f - OPEN Valve
g - CLOSE Valve

5B-20 - MID-SECTION 90-855348R1 JANUARY 1998

Hydraulic Repair 5. Install trim rod removal tool and pull trim rod from
cylinder.
TRIM ROD REMOVAL AND REPAIR
a
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 pres-
sure.
3. Turn Manual Release Valve 3 to 4 turns (counter-
clockwise) to bleed remaining pressure.
4. Remove trim rod cylinder caps.
NOTE: Place a clean pan under trim system to catch
fluid. 27933
a - Trim Rod Removal Tool (91-44486A1)

CLEANING AND INSPECTION - TRIM RODS

AND CAPS
! CAUTION
a
Do not remove check valve (a). Check valve is
b preset to operate at a specific pressure. Removal
b and installation of check valve could result in im-
proper operating pressure and possible system
damage.
NOTE: Check valve is in port side trim rod only.
1. Inspect check valve and check valve screen for
debris; if debris cannot be removed, replace trim
51353
rod assembly. Clean trim rod with parts cleaner
a - Trim Rod Cylinder Cap
b - Turn Counterclockwise To Remove and dry with compressed air.

51337
a - Removal Tool (91-44487A1)
b - Spanner Wrench (91-74951)

b 51352
a - Check valve
b - Check valve screen

90-855348R1 JANUARY 1998 MID-SECTION - 5B-21

Trim Rod End Cap Seal Tilt Ram
1. Inspect trim cap end seal and replace if damaged REMOVAL - TILT ROD ASSEMBLY ONLY
or if seal does not keep trim rod clean.
NOTE: Tilt Rod Assembly can be removed from
a cylinder without removing entire power trim system
from outboard. Refer to page 5B-14 to remove upper
swivel pin.

! CAUTION
Insure Power Trim System Is Depressurized Prior
To Tilt Rod Removal.
51343 1. Use spanner wrench (91-74951) to loosen tilt
a - Seal (Remove as shown) ram end cap.
2. Install new seal with seal lip up.

TRIM ROD INSTALLATION

IMPORTANT: Components must be free of dirt
and lint. Any debris in the system can cause sys-
tem to malfunction.
NOTE: Install trim rod with check valve in the port
(left) cylinder.
51337
1. Apply Quicksilver Power Trim and Steering Fluid
on all O-rings and seals before installation. 91-74951
2. Install trim rods and caps. Use installation tool b
(91-44487A1) or spanner wrench (91-74951) to
tighten caps securely. c
3. Lubricate rod end rollers with Quicksilver Anti-
Corrosion Grease or 2-4-C w/Teflon.
51337
a
a a

c c

b b 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.
51353
a - Trim rods
b - Cylinder end caps
c - Rod end rollers (lubricate with Quicksilver Anti-Corrosion
Grease or 2-4-C w/Teflon

5B-22 - MID-SECTION 90-855348R1 JANUARY 1998

TILT RAM COMPONENTS TILT RAM REMOVAL - POWER TRIM SYSTEM RE-
MOVED FROM OUTBOARD
3
2 ! CAUTION
Insure trim system is depressurized prior to tilt
1 ram removal.
1. Remove cross pin.

7
6
2
2
5
2
2
4
a 51366
8 a - Cross Pin (Remove as shown)

9 2. Remove lower swivel pin.

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) a
*O-ring Repair Kit Available, P.N. 811607A1 (Includes item 7,
Oil Seal) 51355
a - Lower Swivel Pin (Remove as shown)

90-855348R1 JANUARY 1998 MID-SECTION - 5B-23

Disassembly NOTE: Check valve held in by roll pin can be cleaned
but not removed.
1. Secure tilt ram in a soft jawed vise. Remove tilt
rod and cap.
b
91-74951
c a

51337

b
c

51363
a - Washer
51364 b - Check valve assembly (7)
a - Cap (Turn counterclockwise to remove) c - Piston
b - Spanner wrench (91-74951)
c - Tilt Rod - Pull to remove
4. Remove end cap from tilt rod.

2. Clamp tilt rod in a soft jawed vise. Remove nut to

disassemble rod assembly. Remove O-ring.
b

a
a

51376
a - End cap

51340
a - O-Ring
b - Nut

3. Remove washer, check valve assemblies, and

piston.

5B-24 - MID-SECTION 90-855348R1 JANUARY 1998

5. Remove allen plug.
! WARNING
IMPORTANT: Remove plug from same side as
Memory Piston Cup may be expelled at a high ve-
holes in shaft.
locity when air pressure is applied. Failure to
a b place cylinder as shown below could result in
personal injury.
8. Drain as much fluid as possible from cylinder be-
fore removing memory piston.
9. Place cylinder as shown. Hold down on cylinder
and inject air into shaft opening.
c 51361
a - Allen plug
b - Hole in shaft
c - Do Not Remove c
6. Lubricate shaft with Quicksilver Power Trim and
Steering Fluid. Insert shaft into cylinder.

a
51342
7. Tap shaft into cylinder until shaft is positioned as
shown. 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.
51365 (0.127 mm) deep in cylinder are acceptable.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-25

Scraper Seal Replacement 4. Assemble end cap.

1. Remove components from end cap.

b
a

b
a

c b
a - End Cap
b - O-ring (2)
c - Scraper Seal
b 5. Lubricate seal and rod shaft with Power Trim and
Steering Fluid to prevent seal damage during as-
a - Cap sembly. Reinstall end cap.
b - O-ring (2)
c - Scraper Seal
a

REASSEMBLY
IMPORTANT: Components must be clean for
reassembly. Any debris in the system can cause
the system to malfunction.
51376
NOTE: Refer to “Tilt Ram Components” for proper O- a - End Cap
ring sizes.
6. Install components on rod. Verify check balls are
1. Apply Quicksilver Power Trim and Steering Fluid properly installed in their seats.
on O-rings prior to reassembly.
e d
2. Install O-ring on Memory Piston Cup.
3. Push memory piston all the way to the bottom of c
the cylinder and then fill 3/4 full with oil before
installing rod. b
a
c

51363

b
a
51372
a - O-ring
b - Memory Piston Cup (Design 1 shown)

51340
a - Piston
b - O-ring
c - Check Valve Assembly (7)
d - Washer
e - Bolt or Locknut. (Tighten securely)
NOTE: Finish filling cylinder with oil before tightening
cap.

5B-26 - MID-SECTION 90-855348R1 JANUARY 1998

7. Lubricate the O-rings on the rod and end cap with 2. Align tilt ram and housing using alignment tool.
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.
a
c
91-74951

b
51337 51348
a - Alignment Tool (91-11230)
3. Install shaft.

a
a

c
51341
a - Cylinder b 51352
b - Tilt rod assembly a - Shaft
c - End cap (Tighten securely.) Use spanner wrench. b - Groove
c - Hole [groove (b) will align with this hole.]

TILT RAM ASSEMBLY INSTALLATION 4. Drive pin in until flush.

1. Lubricate alignment tool (91-11230) and shaft.
Use Quicksilver Power Trim and Steering Fluid.

a
b
a

51369
a - Alignment Tool (91-11230)
b - Shaft 51356
a - Pin (Drive Against Knurled End)
5. Install Power Trim Assembly on outboard. Refer
to “Installation” instructions on page 5B-16.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-27

MOTOR AND PUMP REPLACEMENT Motor and Electrical Tests/
IMPORTANT: The pump is not rebuildable. If
pump is defective, replace as an assembly. Repair
NOTE: Power Trim System does not have to be re-
moved from outboard to replace pump or motor. Trim Pump Motor Test
1. Tilt outboard to full “UP” position. Depressurize ! WARNING
power trim system, and loosen starboard tran-
som bracket as outlined in “Removal and Instal- Do not perform this test near flammable materi-
lation” on pages 5B-14. als, as a spark may occur while making electrical
connections.
2. Remove 2 allen screws to remove motor from
system. 1. Connect a 12 volt power supply to motor wires;
one motor lead to POSITIVE (+) battery terminal
NOTE: Drive shaft is a loose part and may fall out of and the other motor lead to the NEGATIVE (–)
motor when motor is removed. battery terminal. Motor should run. Reverse mo-
tor leads between battery terminals. Motor
a should run.

b b

53777
a - Motor
b - Screw (2)
3. Remove two screws to remove pump.
53774

b 2. If motor does not run, disassemble and check

components.

51433
a - Pump
b - Screw (2)

5B-28 - MID-SECTION 90-855348R1 JANUARY 1998

Motor Disassembly Armature Tests
1. Remove 2 screws. TEST FOR SHORTS
Check armature on a Growler per the Growler man-
ufacturer’s instructions. Replace armature if a short
is indicated.

TEST FOR GROUND

1. Use an Ohmmeter (Rx1 scale). Connect one lead
on armature shaft and other lead on commutator.
a a If continuity is indicated, armature is grounded.
Replace armature.

53774
a - Screw (2)
2. Remove frame and armature from end cap. Use
care not to drop armature.

53786

b CHECKING AND CLEANING COMMUTATOR

1. If commutator is worn it may be turned on an ar-
mature conditioner or a lathe.
2. Clean commutator with “OO” sandpaper.
a

53775
53779 a - Commutator
a - Frame
b - Armature
c - End Cap

90-855348R1 JANUARY 1998 MID-SECTION - 5B-29

FIELD TESTS Motor Repair
IMPORTANT: Commutator end of armature must
be installed in brushes when performing the fol- REMOVAL
lowing tests. NOTE: Power Trim System does not have to be re-
moved from outboard to repair/replace motor.
Ohmmeter Resistance Scale Reading*
Leads Between (Ohms) (x____________)
BLUE and BLACK 0 (Rx1) DISASSEMBLY
Motor Wires Refer to “Motor Disassembly” on page 5B-29 to
BLACK Motor No (Rx1) disassemble motor from pump.
Wire, and Frame Continuity
(Motor Housing)
CLEANING AND INSPECTION
BLUE Motor Wire No (Rx1)
and Frame Continuity Inspect O-rings and replace if necessary. Carefully
inspect power cord for cuts or tears which will allow
*If specified readings are not obtained, check for: water to enter motor. Replace cord if cut or torn.
Clean, inspect, and test motor components. Refer to
• defective armature
“Brush Replacement”, “Armature Test”, and
• dirty or worn brushes “Field Tests” for inspection and test procedures.
• dirty or worn commutator
If defective components are found, repair or replace
component(s) and retest. a

c
d e

53779

a - Frame
b - Armature
c - Shim
d - Brush Card Assembly
e - O-rings

5B-30 - MID-SECTION 90-855348R1 JANUARY 1998

BRUSH REPLACEMENT 5. Install new brush card (BRUSH and SEAL KIT
1. Brush replacement is required if brushes are 828714A1).
pitted, chipped, or if distance (a) between the 6. Crimp metal connector onto motor lead and new
brush pigtail and end of brush holder slot is brush lead.
1/16 in. or less. Check distance with armature
installed. 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
a 828714A1).

c
d

53784 b
a - 1/16 in. e
2. To replace brush card, disconnect spade termi-
nal.
3. Cut crimped brush lead.
4. Remove 2 screws securing brush card to end 53778
cap. a - Brush Card
b - Metal Connector
c - Spade Connector
a c d - Screws and Lockwashers
e - O-ring

a - Spade Terminal
b - Crimped Brush Lead
c - Screws

90-855348R1 JANUARY 1998 MID-SECTION - 5B-31

END CAP INSPECTION 3. If trim motor is overheated, a thermoswitch lo-
cated under brush card will open. Normally, this
1. Inspect seal and o-ring for cuts and abraisions. If
switch will reset itself within 1 minute.
replacement is required, install BRUSH and
SEAL KIT 828714A1.

b
53781
53783 a - Thermoswitch

a - Seal (Apply 2-4-C w/Teflon to seal lips)

b - O-ring
2. Inspect bushing for wear. If bushing appears to
be excessively worn – grooves, scratches, etc. –
install END FRAME ASSEMBLY (COMPLETE)
828715A1.

53785
a - Bushing

5B-32 - MID-SECTION 90-855348R1 JANUARY 1998

Reassembly 2. Install O-rings in end cap.

IMPORTANT: Components must be clean. Any

debris in power trim system can cause system to
malfunction.
1. Install armature into end cap/brush card assem-
bly.

c
a

53784

53779

53783
a - O-rings

53784
a - Armature
b - Shim
c - End Cap Assembly
d - Armature (Spread brushes to install armature into end cap)

90-855348R1 JANUARY 1998 MID-SECTION - 5B-33

IMPORTANT: Attach Vise Grip pliers to arma- Reassembly - Motor and Pump
ture shaft before installing frame assembly. The
Vise Grip pliers will prevent the armature from NOTE: Drive shaft is a loose part and may fall out of
being drawn out of the brush card assembly by position.
the frame magnets while installing the frame as- 1. Install pump onto power trim manifold. Insure O-
sembly. rings are in proper locations. Secure with two (2)
3. Install Vise Grip pliers on armature shaft. screws.
4. Carefully install frame assembly over armature. IMPORTANT: Install pump with location flat fac-
ing towards starboard transom bracket.
5. Position harness retainer hole over tab in end
cap. c d
6. Secure frame assembly to end cap with 2 screws.
a

i e
f i

g b
d
c
c

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)

53776
a - Vise Grip Pliers
b - Armature Shaft
c - O-ring
d - End Cap
e - Harness Retainer
f - Retainer Hole
g - O-ring
h - Frame Assembly
i - Screws

5B-34 - MID-SECTION 90-855348R1 JANUARY 1998

2. Fill pump with Quicksilver Power Trim and Steer- Priming Power Trim System
ing Fluid prior to installing motor.
1. Fill system with Quicksilver Power Trim and
3. Install motor, secure with two (2) screws. Route Steering Fluid or Automatic Transmission Fluid
wiring; refer to Wiring Diagrams in this service (ATF) Type F or FA. Refer to “Fill, Check, and
manual. Purge” on page 5B-6.
NOTE: Verify motor and drive shaft are aligned. IMPORTANT: Run Trim System in short “jogs”
until pump motor primes and trim system moves.
If trim motor is run without priming pump, drive
shaft failure could result.

a 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.
b 5. Depress “UP” button. Ohmmeter needle should
move as the outboard is trimmed up. If needle
does not move, trim sender is defective.

53782

c c a

22908
a - Trim Sender

53777
a - Motor
b - O-ring
c - Screw (2) Tighten securely.
4. Complete reassembly of Power Trim System as
outlined in “Installation” on page 5B-16.

90-855348R1 JANUARY 1998 MID-SECTION - 5B-35

Trim Indicator Gauge Needle Adjust- 5. Tighten trim sender screws.
ment
b
1. Turn ignition key to “RUN” position.
2. Tilt outboard to full “IN” position. Needle of trim in-
dicator gauge should be in full “IN” position. c d
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 a
sender. 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

5B-36 - MID-SECTION 90-855348R1 JANUARY 1998

Trim Indicator Wiring
Diagrams

For Boats Equipped with Quicksilver Commander Series Side Mount Remote
Control

d e

22908

a - Trim Indicator d - Trim Sender

b - Remote Control e - Engine Ground
c - To Engine

For Boats Equipped with Quicksilver 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

90-855348R1 JANUARY 1998 MID-SECTION - 5B-37

LOWER UNIT

6
A
70486

GEAR HOUSING
RIGHT HAND OPERATION
(STANDARD ROTATION)
(RATCHETING AND NON-RATCHETING)
Table of Contents
Page Page
General Service Recommendations . . . . . . . . . . . . . 6A-1 Gear Housing Reassembly . . . . . . . . . . . . . . . . . . . 6A-39
Gear Housing Specifications (Standard Rotation) . 6A-2 Gear Housing Inspection . . . . . . . . . . . . . . . . . . 6A-39
Forward/Reverse Gear Backlash and Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40
Pinion Depth (Ratcheting and Non-Ratcheting) 6A-2 Forward Gear Bearing Cup . . . . . . . . . . . . . . . . 6A-40
Special Tools (Ratcheting and Non-Ratcheting) . . . 6A-2 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-41
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-42
Gear Housing (Drive Shaft) (Standard Rotation) Drive Shaft and Pinion Gear . . . . . . . . . . . . . . . . 6A-43
(Ratcheting)(S/N-0G437999 & BELOW)(CASTING Gear Location/Backlashes Checking
#1623-822442C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6 and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-45
Gear Housing (Prop Shaft) (Standard Rotation) Drive Shaft - Bearing Preload Tool . . . . . . . . . . 6A-45
(Ratcheting)(S/N-0G437999 & BELOW)(CASTING Pinion Gear Location . . . . . . . . . . . . . . . . . . . . . . 6A-45
#1623-822442C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8 Bearing Carrier Assembly . . . . . . . . . . . . . . . . . . 6A-46
Gear Housing (Drive Shaft)(Standard Rotation) Forward Gear Backlash . . . . . . . . . . . . . . . . . . . 6A-47
(Non-Ratcheting)(S/N-0G438000 & UP)(CASTING Reverse Gear Backlash . . . . . . . . . . . . . . . . . . . 6A-48
#1623-822442C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Drive Shaft - Bearing Preload Tool . . . . . . . . . . 6A-49
Gear Housing (Prop Shaft)(Standard Rotation) Bearing Carrier Assembly . . . . . . . . . . . . . . . . . . . . . 6A-50
(Non-Ratcheting)(S/N-0G438000 & UP)(CASTING Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50
#1623-822442C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12 Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . . . . 6A-52
Removal, Disassembly, Cleaning and Inspection Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
-- Standard Rotation (Ratcheting and Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . 6A-52
Non-Ratcheting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Gear Lubricant Filling Instructions . . . . . . . . . . . 6A-53
Pre-Disassembly Inspection . . . . . . . . . . . . . . . . . . . 6A-16 Installing Gear Housing to Drive Shaft
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-53
Gear Housing and Component Disassembly . . . . 6A-16
Water Pump Assembly . . . . . . . . . . . . . . . . . . . . 6A-16
Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . . 6A-18
Bearing Carrier Assembly . . . . . . . . . . . . . . . . . . 6A-20
Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6A-27
Propeller Shaft Assembly and Forward
Gear Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . 6A-29
Forward Gear Assembly . . . . . . . . . . . . . . . . . . . 6A-32
Shift Spool Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-33
Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-36
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-37
Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39

6A-0 - LOWER UNIT 90-855348R1 JANUARY 1998

General Service Roller bearing condition is determined by inspecting
the bearing surface of the shaft that the roller bearing
Recommendations supports. Check shaft surface for pitting, scoring,
grooving, imbedded particles, uneven wear and/or
There may be more than one way to “disassemble”
discoloration from overheating. The shaft and bear-
or “reassemble” a particular part(s). It is recom-
ing must be replaced if the conditions described are
mended that the entire procedure be read prior to re-
found.
pair.
IMPORTANT: Read the following before attempt- SHIMS
ing any repairs.
Keep a record of all shim amounts and location dur-
Disassembly of a sub-assembly may not be neces- ing disassembly to aid in reassembly. Be sure to fol-
sary until cleaning and inspection reveals that disas- low shimming instructions during reassembly as
sembly is required for replacement of one or more gears must be installed to correct depth and have the
components. correct amount of backlash to avoid noisy operation
Service procedure in this section is a normal disas- and premature gear failure.
sembly-reassembly sequence. It is suggested that
the sequence be followed without deviation to assure SEALS
proper repairs. When performing partial repairs, fol- As a normal procedure, all O-rings and oil seals
low the instructions to the point where the desired SHOULD BE REPLACED without regard to appear-
component can be replaced, then proceed to “reas- ance. To prevent leakage around oil seals, apply Loc-
sembly and installation” of that component in the tite 271 to outer diameter of all metal case oil seals.
reassembly part of this section. Use the “Table of When using Loctite on seals or threads, surfaces
Contents”(on back of section divider) to find correct must be clean and dry. To ease installation, apply
page number. Quicksilver 2-4-C w/Teflon on all O-rings. To prevent
Threaded parts are right hand (RH), unless other- wear, apply 2-4-C w/Teflon on I.D. of oil seals.
wise indicated. To prevent corrosion damage after reassembly, ap-
When holding, pressing or driving is required, use ply Quicksilver Perfect Seal or 2-4-C w/Teflon to ex-
soft metal vise jaw protectors or wood for protection ternal surfaces of bearing carrier and retainer nut
of parts. Use a suitable mandrel (one that will contact threads prior to installation. DO NOT allow Perfect
only the bearing race) when pressing or driving bear- Seal to enter bearings or O-ring area.
ings. NOTE: Before filling gear case, apply 10-15 psi (68.5
Whenever compressed air is used to dry a part, be -- 102.7kPa) of air pressure at the VENT hole. Pres-
sure that no water is present in air line. sure should not drop for 15 seconds while alternately
applying a 2-3 pound force to the top of the shift shaft
BEARINGS in the fore and aft direction.

Upon disassembly of gear housing, all bearings must

be cleaned and inspected. Clean bearings with sol-
vent and dry with compressed air. Air should be di-
rected at the bearing so that it passes thru the bear-
ing. DO NOT spin bearing with compressed air, as
this may cause bearing to score from lack of lubrica-
tion. After cleaning, lubricate bearings with Quicksil-
ver Gear Lubricant. DO NOT lubricate tapered bear-
ing cups until after inspection.
Inspect all bearings for roughness, catches and bear-
ing race side wear. Work inner bearing race in-and-
out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condi-
tion of rollers and inner bearing race by inspecting
bearing cup for pitting, scoring, grooves, uneven
wear, imbedded particles and/or discoloration from
overheating. Always replace tapered bearing and
race as a set.
90-855348R1 JANUARY 1998 LOWER UNIT - 6A-1
Gear Housing Specifications W.O.T. 8-10 psi
(54.9 -- 68.5kPa)
(Standard Rotation) Test Propeller for Static Test
12 Dia. x 15 Pitch 48-78116A40
Forward/Reverse Gear
Backlash and Pinion Depth
(Ratcheting and Non-Ratcheting) Special Tools
Pinion Depth (Ratcheting and
All Models 0.025 in. (0.64mm) with Non-Ratcheting)
Tool 91-12349A2 Using
Bellville Washer 12-54048
Disc #2 and Flat #4
Forward Gear Backlash
1.64:1and 1.75:1 Gear 0.017 in. to 0.028 in.
Ratios (0.431mm to 0.711mm)
1.62:1 Gear Ratio Pointer on line mark #1
Service Replacement with Backlash Indicator
Rod 91-53549 Needle Bearing Driver 91-15755
Reverse Gear Backlash
1.64:1and 1.75:1 Gear 0.030 in. to 0.050 in.
Ratios (0.76mm to 1.27mm)
1.62:1 Gear Ratio
Service Replacement
Lubricant Capacity 28 fl. oz. (0.828 liter) Bearing Driver Cup 91-31106
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 Oil Seal Driver 91-31108
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 Pin- Teeth in For- Needle Bearing Driver 91-33491
ion Gear ward and Re-
verse 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)

6A-2 - LOWER UNIT 90-855348R1 JANUARY 1998

Pilot Washer 91-36571 Backlash Indicator Rod 91-53459

Drive Shaft Nut Wrench 91-56775

Driver Cup 91-36577

Dial Indicator 91-58222A1

Universal Puller Plate 91-37241

Bearing Carrier Retainer Wrench 91-61069

Bearing Retainer Tool 91-43506

Torque Wrench (lb. in.) 91-66274

Backlash Indicator Rod 91-78473

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-3

Puller Bolt 91-85716 and Puller Jaws 91-46086A1 Bearing Preload Tool 91-14311A2

Dial Indicator Holding Tool 91-83155

Bearing Removal and Installation Tool 91-31229A7

-- Includes Driver Head 91-36569: Driver Head Rod
91-37323; Nut 11-24156; Pilot Washer 91-36571;
Oil Seal Driver 91-817569 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.

Water Pump Alignment Pins 91-82157A1

Pinion Gear Shimming Tool 91-12349A2

Leakage Tester FT8950

6A-4 - LOWER UNIT 90-855348R1 JANUARY 1998

Notes:

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-5

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
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
16

17 2
7 Loctite 271 (92-809820)
19 Perfect Seal (92-34227-1)
7
92
92 Loctite 7649 Primer (92-809824)
95 2-4-C With Teflon (92-825407A12)

6A-6 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Drive Shaft) (Standard Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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. Determine the length
of the driveshaft and ORDER REF. #’s 24 & 42.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-7

Gear Housing (Prop Shaft) (Standard Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

68

1
1623-
822442C2

66
44
67 95 87
45

48 87
52 46

47 57
53 87
94
49 56
87 59
54 50 55

51
60 58
64 61
95

62 95
69 63 95

71
7
65

70 95
73
72
95

7 Loctite 271 (92-809820)

87 Quicksilver Gear Lubricant (92-19007A24) 95

94 Anti-Corrosion Grease (92-78376A6)

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

6A-8 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Prop Shaft) (Standard Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-9

Gear Housing (Drive Shaft)(Standard
Rotation)(Non-Ratcheting)
(S/N-0G438000 & UP)(CASTING #1623-822442C3)
7 Loctite 271 (92-809820)
19 Perfect Seal (92-34227-1) 31
95
92 Loctite 7649 Primer (92-809824)
32
95 2-4-C With Teflon (92-825407A12)
33 95

34
42
30
44
95 43 29
36
45 28 95
41
95

35 95
27
95
40 13

26
24
19
38
25
23
15
39 20
22
47 19

37 21
10
11 12
3
1 95
95 7
7
6
10 5
4

95 9

16
6 8
17
2
4.75 18
IN/120.65MM 7
TORPEDO DIA.
92

6A-10 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Drive Shaft)(Standard
Rotation)(Non-Ratcheting)(S/N-0G438000 & UP)
(Casting #1623-822442C3)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 drive-
shaft and ORDER REF. #’s 24 & 44.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-11

Gear Housing (Prop Shaft)(Standard
Rotation)(Non-Ratcheting)(S/N-0438000 & UP) (Casting
#1623-822442C3)
4.75 IN/120.65MM 75

TORPEDO DIA. 1

52 51 48
74 95 87 50
49

54 53 87
60 56
55 65
61 87
94
57 67 64
87
58
62 63
59 68
66

72 69 95

95
70
71
95
73

95

95 95

87 Super Duty Gear Lubricant (92-13783A24)

94 Anti-Corrosion Grease (92-78376A6)

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

6A-12 - LOWER UNIT 90-855348R1 JANUARY 1998

Gear Housing (Prop Shaft)(Standard
Rotation)(Non-Ratcheting)(S/N-0G438000 & UP)(Casting
#1623-822442C3)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-13

Removal, Disassembly, 5. Mark gear housing and trim tab so that trim tab
can be reinstalled in the same position. Remove
Cleaning and Inspection -- plastic cap at rear edge of drive shaft housing.
While holding trim tab securely, unthread bolt that
Standard Rotation secures trim tab and remove trim tab from gear
(Ratcheting and housing.

Non-Ratcheting) 6. Once trim tab is removed, remove bolt from in-

side of trim tab cavity.

REMOVAL
c
WARNING
Disconnect high tension leads from spark plugs a
and remove spark plugs from engine before re- b
moving gear housing from drive shaft housing.
1. Disconnect high tension leads from spark plugs b
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.

52375
b a - Bolt (Secures Trim Tab)
51866 b - Bolt (Inside Trim Tab Cavity)
c - Ribs -- Align Carefully with Trim Tab while Securing Tab
7. Loosen the side mounting locknuts. (DO NOT at-
d tempt to remove one nut before opposite side is
f
loosened sufficiently, or drive shaft housing could
be damaged.)
c
8. Pull gear housing away from drive shaft housing
as far as the loosened nuts (in Step 9) will allow,
d then remove loosened nuts. (DO NOT allow gear
e
housing to fall, as it now is free.)

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

6A-14 - LOWER UNIT 90-855348R1 JANUARY 1998

9. Pull gear housing from drive shaft housing. 3. Inspect gear lubricant for metal particles. Pres-
ence of a small amount of fine metal particles (re-
sembling powder) indicates normal wear. Pres-
ence of larger particles (or a large quantity of fine
particles) indicates need for gear housing disas-
sembly, and component inspection.
4. Note the color of gear lubricant. White or cream
color indicates presence of water in lubricant.
Check drain pan for water separation from lubri-
a cant. Presence of water in gear lubricant indi-
cates 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
52374
clear yellow brown in color.
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

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-15

Pre-Disassembly Inspection Gear Housing and Compo-
Propeller Shaft
nent Disassembly
INSPECTION Water Pump Assembly
1. Inspect the propeller shaft for side to side move- REMOVAL
ment, as follows:
1. Remove the water seal, water tube coupling as-
a. Position the dial indicator on the propeller sembly, and the water pump screws.
shaft.
a
b. Push the propeller shaft to one side and zero c
the dial indicator.
c. Move the propeller shaft to the opposite side
while observing the dial indicator. Without ro-
tating the propeller shaft, reposition the dial
indicator and check the up and down deflec-
tion. A shaft deflection of more than 0.003 in. b
(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 52749
indicated.
a - Water Tube Assembly
3. Measure propeller shaft end play. If it is in excess b - Water Pump Screws (4)
of 0.045 in. (1.14mm), disassemble gear case c - Seal
and check condition of the reverse shoulder of
2. Carefully slide the water pump straight up off of
the propeller shaft, reverse gear and thrust wash-
the drive shaft. It may be necessary to encourage
er. Replace components as required.
the water pump up by gently prying up on its
mounting flanges with a couple of screwdrivers.

a a
b b

22086
70487
a - Prop Shaft Runout
b - Prop Shaft End play a - Water Pump Body
b - Screw Drivers

6A-16 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Remove the impeller, impeller key, the face plate 3. Inspect for proper bonding between the hub and
and gaskets, (discard the gaskets). the impeller. Replace the impeller if improper
bonding is found.

a
a

70500

b a - Impeller
b - Hub

70605 4. Inspect the impeller blades to see if they are

cracked, burnt, hard or deformed. Replace the
a - Impeller impeller if the blades are in this condition.
b - Impeller Key
c - Water Pump Face Plate and Gaskets IMPORTANT: The circular groove formed by the
(One on each side of the face plate) impeller sealing bead should be disregarded
WATER PUMP ASSEMBLY - Component when inspecting cover and plate. The depth of
Inspection the groove will not affect water pump output.

1. Inspect the water tube coupling assembly for 5. Replace cover if thickness of steel at the dis-
wear or damage. If necessary replace the worn charge slot is 0.060 in. (1.5mm) or less or if
or damaged components especially the two O- grooves (other than impeller sealing bead
rings on the inside, one at the top and one at the groove) in cover roof are more than 0.030 in.
bottom. (0.76mm) deep.
a b
b

70609
b 70613 a - Water Pump Face Plate
b - Water Pump Cover
a - Water Tube adapter
b - O-rings (2) 6. Inspect the water pump face plate and the water
pump interior for roughness and/or grooves. Re-
2. Inspect the water pump impeller for wear on the
place the appropriate components if any are
end, top and bottom of the impeller blades. Re-
found.
place the impeller if this condition is found.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-17

Oil Seal Carrier Assembly OIL SEAL CARRIER ASSEMBLY - Component
Disassembly
REMOVAL NOTE: Complete the instructions in this section only
1. Remove the oil seal carrier from the gear hous- if the assembly components have been found to be
ing. It may be necessary to gently pry up on it with defective and are in need of repair or replacement.
two screwdrivers. 1. Remove the O-ring.
b

a
a
70501
b
a - O-ring
b - Oil Seals (2)
70489 2. Remove the oil seals.
a - Oil Seal Carrier
b - Screwdrivers

OIL SEAL CARRIER ASSEMBLY - Inspection

1. Inspect the oil seal carrier, O-ring, and seals for c
wear and/or damage. If necessary replace defec- b
tive parts as outlined following.
a

70610

a - Oil Seal Carrier

b - Oil Seals
c - Screwdriver

6A-18 - LOWER UNIT 90-855348R1 JANUARY 1998

OIL SEAL CARRIER ASSEMBLY - Component 5. Fill the area between the seal lips with 2-4-C
Reassembly (1994/1995 MODELS) w/Teflon. Apply 2-4-C w/Teflon to the O-ring.
NOTE: Complete the instructions in this section only 6. Install the O-ring onto the oil seal carrier.
if the assembly components have been disas-
95
sembled and repaired or replaced.

70501

1. Assemble the small oil seal (with the lips of the oil a 70501
seal facing away from the driver shoulder) onto 95 2-4-C With Teflon (92-825407A12)
the long end of the oil seal driver.
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 a - O-ring
seal.
OIL SEAL CARRIER ASSEMBLY - Component
d Reassembly (96/97/98 MODELS)
The oil seals in 1996/1997 carrier assemblies are the
b 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 between seals.
a c Press seal into carrier with suitable mandrel. Second
seal should be pressed in flush with carrier surface.
70611
95
a - Oil Seal
b - Oil Seal Driver (91-817569) use long end b
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

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

a - Bottom Seal (Lip Faces Down)
a b - Top Seal (Lip Faces Up)
c

70612

a - Oil Seal
b - Oil Seal Driver (91-817569) use short end
c - Oil Seal Carrier
d - Press

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-19

Bearing Carrier Assembly b. Remove the bearing carrier retainer using the
Bearing Carrier Retainer Wrench
REMOVAL (91-61069).

1. Straighten the tab on the tab washer.

70491

a - Bearing Carrier Retainer Wrench

70490
3. Pull the bearing carrier from the gear housing by
a - Tab on Tab Washer
pulling on the outer ring of the bearing carrier.
2. Remove the bearing carrier retainer following POSITION PULLER JAWS CLOSE TO BOSSES
step a or b as follows: IN CARRIER.
NOTE: If the bearing carrier is seized in the gear
CAUTION housing, it may be necessary to use heat to loosen
DO NOT drill into the gear housing retainer the carrier.
threads when using the following procedure for
removing the retainer. a
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.

a
70492

a - Puller Jaws (91-46086A1)

b - Puller Bolt (91-85716)

23356

a - Drilled Holes

6A-20 - LOWER UNIT 90-855348R1 JANUARY 1998

BEARING CARRIER ASSEMBLY - Inspection 5. Inspect the clutch jaws of the gear for damage.
Surfaces must not be chipped or rounded off. Re-
1. Clean the assembly with a suitable solvent and
place the gear if any are found.
dry the parts thoroughly using compressed air.
a
NOTE: If any of the following items are found to be
defective complete the appropriate instruction(s) in
“Bearing Carrier Assembly”, ‘Component Disassem-
bly and Inspection’section found on page 6A-22.
2. Inspect the bearing carrier for signs of excessive
corrosion especially in the area where the bear-
ing carrier touches the gear housing. If excessive
corrosion is evident replace the carrier. b
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.
b 7. Inspect the bearing carrier retainer for cracks
50314
and/or broken or corroded threads. Replace car-
a - Bearing Carrier rier if any are found.
b - Mating Surfaces
8. Remove the O-ring from the bearing carrier as-
3. The condition of the bearing surface on the pro- sembly.
peller shaft in the area that the needle bearing (in a
the bearing carrier) rides is an indication of the
condition of the needle bearing in the bearing car-
rier. Replace the bearing if the surface of the shaft
is pitted, grooved, scored, worn unevenly, discol-
ored from overheating or has embedded metal
particles. b
a

23355

a - Propeller Shaft Bearing Contact Area

23354
4. Inspect the reverse gear for pitted, chipped, bro-
ken teeth, hairline fractures, and excessive or un- a - Bearing Carrier
even wear. Replace the gear if any defects are b - O-ring
found. a. Inspect the O-ring for damage and/or deterio-
NOTE: If outboard jumps out of gear, inspect not only ration. Replace it if necessary.
clutch dog teeth on reverse gear but also thrust
washer surface on reverse gear for excessive wear.
Replace gear if wear is evident.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-21

BEARING CARRIER ASSEMBLY - Component IMPORTANT: The bearing MUST BE replaced if
Disassembly and Inspection removed from gear.
NOTE: Complete the instructions in this section only 4. Place the universal puller plate between the
if the assembly components have been found to be thrust washer and bearing as shown and press
defective and are in need of repair or replacement. on the plate until it bottoms.

CAUTION
Clamp onto the reinforcing rib of the bearing car-
rier 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 bear- a
ing as an assembly, using a slide hammer puller.
b
e
d

f
c

c 23351

a - Universal Puller Plate (91-37241)

b - Thrust Washer
c - Bearing
b
a 23352

a - Bearing Carrier Reinforcing Rib

b - Bearing Carrier
c - Slide Hammer Puller (91-34569A1)
d - Reverse Gear
e - Thrust Hub
f - Bearing (not seen) - Located in the Carrier
3. Clean all components thoroughly with a suitable
solvent and inspect them for damage and/or ex-
cessive wear. Replace any parts that are found to
be defective.

6A-22 - LOWER UNIT 90-855348R1 JANUARY 1998

5. Using a suitable mandrel and the universal puller NOTE: Inspection of the bearing surfaces on the pro-
plate to support the bearing, press the bearing peller shaft where the needles of the bearing carrier
from the reverse gear as shown. needle bearing rolls, gives an indication of the condi-
tion of the needle bearing inside the bearing carrier.
Replace needle bearing in the bearing carrier if the
prop shaft is pitted, grooved, scored, worn unevenly,
discolored from overheating, or has embedded par-
d ticles.
a
6. Perform the following step a. or b. as necessary.
a. If Replacing the Needle Bearing and
Seals: Remove the needle bearing and seals
with the tools as shown.

b c

23351 b
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 exces-
sive wear, cracks, or damage. Replace the d
appropriate components if any of these con- 23140
ditions are found.
a - Bearing Driver Rod (91-37323)
b - Needle Bearing
c - Driver Head (91-36569)
d - Oil Seals
(1.) Discard the needle bearing and both
seals.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-23

 b. If Replacing the Seal Only: Remove the oil BEARING CARRIER ASSEMBLY Component
seals with a suitable pry bar, being careful not reassembly
to damage the bore of the bearing carrier.
NOTE: Complete the instructions in this section only
a if the assembly components have been disas-
sembled and repaired or replaced.
1. Clean all of the components with a suitable sol-
vent and dry the parts thoroughly using com-
b pressed air. Be careful not to spin the bearing.
2. Lubricate the bore that the needle bearing is
pressed into with Quicksilver Gear Lubricant
(92-13783A24).
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 bearing carrier.
Ensure that the numbered side of the needle
bearing faces the seal end (aft end) of the carrier.

23140

a - Oil Seals
b - Pry Bar
a
b 87
(1.) Discard both of the seals.

50315

87 Quicksilver Gear Lubricant (92-19007A24)

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.

6A-24 - LOWER UNIT 90-855348R1 JANUARY 1998

7. Press on the oil seal driver until the driver bottoms 10. Press the oil seal with the driver until the driver
onto the aft face of the bearing carrier. bottoms out on the bearing carrier.

a
a

b 7
b
95

c c

50315 50315

a - Oil Seal Driver (91-31108) 7 Loctite 271 (92-809820)

b - Oil Seal 95 2-4-C With Teflon (92-825407A12)
c - Bearing Carrier
8. Apply a thin film of Loctite 271 (92-809820) to the a - Driver (short end)
outer diameter of the second seal. b - Oil Seal (lips toward driver shoulder)
c - Bearing Carrier
9. Assemble the second seal (with the lips of the
11. Wipe up all of the excess Loctite. Do not allow any
seal facing the driver shoulder) onto the short end
of the excess Loctite to spread to other parts of
of the driver.
the assembly.
12. Lubricate the seal lips and fill the area between
the seals with 2-4-C w/Teflon (92-825407A12).

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-25

13. Install the thrust washer and a new ball bearing 15. Press the bearing carrier onto the reverse gear
onto the reverse gear. Press on the inner race of and bearing until the bearing bottoms out in bear-
the ball bearing using the pilot washer until the ing carrier, using the pilot washer to press against
bearing bottoms out on the gear. the carrier.

b
c b

87

23346
23349
a - Pilot Washer (P/N 91-36571) 87 Quicksilver Gear Lubricant (92-19007A24)
b - Ball Bearing
c - Thrust Hub a - Pilot Washer (91-36571)
d - Reverse Gear b - Bearing Carrier
c - Reverse Gear and Bearing Assembly
14. Lubricate the bore that the bearing is pressed into
with Quicksilver Gear Lubricant (92-13783A24). 16. Lubricate the O-ring with 2-4-C w/Teflon and
install the O-ring onto the bearing carrier.
b

95
23354

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

a - O-ring
b - Bearing Carrier

6A-26 - LOWER UNIT 90-855348R1 JANUARY 1998

Drive Shaft Assembly e. If the drive shaft is broken, place propeller
shaft nut wrench onto the propeller shaft
REMOVAL splines, hold shift shaft in forward gear and
loosen, (but do not fully unscrew), the pinion
1. Remove the drive shaft pinion nut as follows: nut by rotating prop shaft counterclockwise to
a. Place the drive shaft nut wrench onto the turn gears, thus loosening the pinion nut.
drive shaft. Do not loosen the retainer at this NOTE: The propeller shaft nut wrench is included
time. with the pinion nut adapter kit.
b. Insert the pinion nut adapter with the MR slot c
facing the pinion gear into the gear housing.
It may be necessary to slightly lift and rotate
the drive shaft to align the pinion gear nut into
the pinion nut adapter slot. a
c. Install the bearing carrier into the gear hous-
ing 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.

b
70607
b
a - Pinion Nut adapter (91-61067A2)
b - Propeller Shaft Nut Wrench (91-61077)
c - Shift Shaft (Turn Clockwise) (Protect shaft splines w/soft
material)
f. Completely unscrew the drive shaft bearing
retainer.
g. Completely unscrew the pinion nut by rotat-
ing the drive shaft (or the propeller shaft) in a
counterclockwise direction.
h. Remove all tools.

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)

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-27

IMPORTANT: The pinion bearing rollers are free 4. Inspect the splines at both ends of the drive shaft
to fall out of the pinion bearing once the drive for a worn or twisted condition. Replace the drive
shaft is removed. Be careful not to loose the (18) shaft if either condition exists.
rollers.
5. Inspect the gear for pitting, chipped or broken
2. Remove the drive shaft and all components by teeth, hairline fractures, and excessive or uneven
pulling the drive shaft straight out of the gear wear. Replace the pinion gear and the forward
housing as shown. gear as a set if any defects are found.

DRIVE SHAFT ASSEMBLY - Component

a Disassembly
NOTE: Complete the instructions in this section only
b 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.

70608

a - Drive Shaft
b - Drive Shaft Retainer, Bearing Cup, Bearing, and Shims b
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 a
from the inside of the gear housing.

DRIVE SHAFT ASSEMBLY - Inspection

1. Clean all parts with a suitable solvent and dry the
parts thoroughly using compressed air, being
careful not to spin the bearings. 70699
2. The condition of the drive shaft bearing cup is an a - Universal Puller Plate (91-37241)
indication of the condition of the tapered roller b - Tapered Roller Bearing
bearing on the drive shaft. Replace the bearing c - Drive Shaft
and bearing cup if the cup is pitted, grooved,
scored, worn unevenly, discolored from over-
heating, or has embedded 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, discolored from over-
heating, or has embedded particles.

6A-28 - LOWER UNIT 90-855348R1 JANUARY 1998

DRIVE SHAFT ASSEMBLY - Component Propeller Shaft Assembly and
Reassembly
Forward Gear Bearing Cup
NOTE: Complete the instructions in this section only
if the assembly components have been disas- REMOVAL
sembled and repaired or replaced. 1. Tilt the propeller shaft to the port side of the gear
1. Assemble a new tapered roller bearing to the housing and remove the shaft by pulling it straight
drive shaft with the large O.D. of the bearing fac- up and out.
ing 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 suit-
able mandrel, (an old tapered roller bearing inner
race).

a 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
70700 f
a - Universal Puller Plate (91-37241)
b - Tapered Roller Bearing
c - Suitable Mandrel (Inner Race of Old Bearing)

a b

50780

a - Puller Shaft (91-31229)

b - Nut (11-24156)
c - Washer (91-34961)
d - Guide Plate (91-816243)
e - Puller Head (from Slide Hammer Puller Kit 91-34569A1)
f - Jaws (from Slide Hammer Puller Kit)
g - Bearing Cup
h - Shims

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-29

PROPELLER SHAFT ASSEMBLY - Component PROPELLER SHAFT ASSEMBLY - Component
Disassembly Inspection
NOTE: When accomplishing the next step, all of the 1. Clean all the parts with a suitable solvent and dry
parts are free to come apart. Work closely over a the parts thoroughly using compressed air, being
work bench to ensure that the parts are not dropped careful not to spin bearings.
or damaged and to avoid personal injury.
2. Inspect the sliding clutch jaws for damage. Jaws
1. Remove the spring around the clutch being care- must not be chipped or rounded off. Replace the
ful not to over-stretch it during removal. If the clutch if they are.
spring does not coil back to its normal position
3. Inspect the bearing surfaces on the propeller
once it has been removed, it must be replaced.
shaft where the needles of the bearing carrier
2. Remove detent pin. needle bearing and the needles of the forward
gear needle bearing roll. Replace the propeller
3. Remove the cross pin that goes through the
shaft if it is pitted, grooved, scored, worn uneven-
clutch.
ly, discolored from overheating, or has em-
4. Remove the remainder of the components bedded particles.
(Ratcheting type assembly shown). a b
a
e d
b

c
c 23355

a - Bearing Carrier Needle Bearing Contact Area

b - Forward Gear Needle Bearing Contact Area
c - Splines
f 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 ex-
ists.
5. Inspect the surface of the propeller shaft where
23350 the bearing carrier seal lips contact the shaft. If
a - Spring the oil seals have made grooves, replace the pro-
b - Cross Pin peller shaft and oil seals.
c - Shift Spool Assembly
d - Forward Gear Assembly
a
e - Sliding Clutch
f - Detent Pin

b 23355
a - Bearing Carrier Seal Contact Area
b - Splines

6A-30 - LOWER UNIT 90-855348R1 JANUARY 1998

6. Inspect reverse gear thrust washer surface for 9. Measure propeller shaft FORWARD to RE-
wear or taper. If surface is worn or tapered, pro- VERSE shoulder length. If measurement is un-
peller shaft must be replaced. der 2.040 in. (51.82mm), replace propeller shaft.
2.040 in. (51.82mm)
a

23355
23355 10. Inspect REVERSE thrust washer for wear or ta-
a - Thrust Washer Surface per. Measure thickness of washer. If thickness is
7. Inspect the propeller shaft for a bent condition. LESS than 0.240 in. (6.1mm), replace washer.

a. V-Blocks and Dial Indicator 0.240 in. (6.096mm)

(1.) Position the propeller shaft bearing sur-

faces 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 in-
dicator 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.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-31

Forward Gear Assembly ored from overheating, or has embedded par-
ticles, replace the forward gear bearing cup and
COMPONENT INSPECTION remove and replace the tapered roller bearings
as outlined in the next section.
1. Clean the forward gear assembly and the forward
gear bearing cup with a suitable solvent and dry FORWARD GEAR ASSEMBLY - Component
with compressed air. Be careful not to spin the Disassembly
bearings. NOTE: Forward gear can only be removed from gear
2. Inspect the gear for pitting, chipped or broken housing after drive shaft and pinion gear have been
teeth, hairline fractures, and excessive or uneven removed.
wear. Replace the forward gear and the pinion 1. Reach into gear housing and lift out forward gear.
gear as a set if any defects are found.
IMPORTANT: DO NOT remove tapered bearing or
3. Inspect the clutch jaws of the gear for damage. needle bearings from forward gear unless re-
The surfaces must not be chipped or rounded off. placement of bearings is required. (Bearings
Replace both the forward and pinion gear as cannot be reused after they have been removed.)
a set if any of these conditions exist.
2. If inspection determines that replacement of for-
a
ward gear tapered bearing is required, separate
gear from bearing as follows:
a. Install Universal Puller Plate (91-37241) be-
tween forward gear and tapered bearing.
b. Place assembly on press and press gear out
b of bearing with suitable mandrel.
NOTE: Tapered bearing and race MUST BE re-
placed as a set.
b
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 pro-
peller shaft. If either the needle bearing or the
bearing surface of the propeller shaft is pitted,
grooved, scored, worn unevenly, discolored from 51870
overheating, or has embedded particles, replace a - Universal Puller Plate (91-37241)
the propeller shaft and remove and replace the b - Mandrel
needle bearing in the forward gear as outlined in 3. If inspection determines that replacement of pro-
the next section. peller shaft needle bearings is required, remove
a bearing as follows:
a. Clamp forward gear in a soft jaw vise
securely.
b. From toothed-side of gear, drive propeller
23355 shaft needle bearings out of gear with a
punch and hammer.
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 forward gear bearing cup
is pitted, grooved, scored, worn unevenly, discol-

6A-32 - LOWER UNIT 90-855348R1 JANUARY 1998

FORWARD GEAR ASSEMBLY - Component Shift Spool Assembly
Reassembly
NOTE: Complete the instructions in this section only INSPECTION
if the assembly components have been disas- 1. Clean the assembly with a suitable solvent and
sembled and repaired or replaced. dry the parts using compressed air.
1. Using a suitable mandrel, press the tapered roller 2. Inspect the shift spool assembly for damage.
bearing onto the forward gear by pressing on the Small nicks and burrs may be smoothed. If any
inner bearing race, until the bearing bottoms out parts are damaged or worn excessively, it will be
on the gear mounting shoulder. necessary to replace the complete shift spool as-
sembly. 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.
c a b

a
23353
23356
a - Forward Gear
b - Tapered Roller Bearing a - Contact Area
c - Suitable Mandrel (or Inner Race from old Bearing) b - Ratcheting Shift Spool

2. Using the needle bearing driver, press the needle

bearing, with the the lettered side facing away a
b
from the gear teeth, into the forward gear until the
bearing bottoms inside the gear.

c b
55694
a - Contact Area
b - Non-Ratcheting Shift Spool

23350

a - Forward Gear
b - Needle Bearing (not seen)
c - Needle Bearing Driver (91-33491)

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-33

4. Inspect to insure that the spool spins freely (it NOTE: If the spool meets the above two criteria skip
may be helpful to lightly tap the forward [castle the disassembly and reassembly section following.
nut] end of the shift shaft against a firm surface to
NOTE: If the spool does not meet the above criteria
align the internal parts).
proceed with the disassembly and reassembly sec-
5. Inspect to insure that both ratcheting and non- tion following.
ratcheting spools have 0.002-0.010 in.
(0.05-0.25 mm) end play. This end play may be SHIFT SPOOL ASSEMBLY - Component
achieved by turning the castle nut (clockwise) Disassembly
down on either spool until it is snug and then NOTE: Disassembly of the shift spool is for cleaning
backing off the nut (counterclockwise) to the first and inspection of the internal parts due to an improp-
cotter pin slot. erly 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 re-
placement parts. If the shift spool does not function
properly (see the preceding “Shift Spool Assembly -
Inspection”section) and the following cleaning and
.002 (0.05mm)
to adjustment procedures do not produce the desired
.010 (0.25mm) 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.
a c. Clamp the spool in a vice being careful not to
damage the spool.
23142
d. Remove the retainer by unscrewing it with a
a - Ratcheting Shift Spool pair of pliers.
e. Remove the two washers and the spring.

SHIFT SPOOL ASSEMBLY - Component

.002 (0.05mm) Inspection
to
.010 (0.25mm) 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, dam-
aged, or broken it will be necessary to replace the
complete shift spool assembly. Small nicks or
burrs may be smoothed and the parts reused.

55694
a - Non-Ratcheting Shift Spool
NOTE: Non-Ratcheting shift spools do not contain a
spring under the castle nut.

6A-34 - LOWER UNIT 90-855348R1 JANUARY 1998

SHIFT SPOOL ASSEMBLY (RATCHETING) - SHIFT SPOOL ASSEMBLY (RATCHETING) -
Component Reassembly Adjustment
1. Assemble the shift spool and shift spool shaft as NOTE: If the shift spool assembly has been
follows: disassembled and reassembled (as in the previous
two sections) skip the following instructions, (1
a. Place the shift spool onto the shift spool shaft.
through 4).
b. Assemble the first washer, then the spring,
NOTE: If the shift spool assembly has not been dis-
then the second washer into the shift spool.
assembled and reassembled, do all of the following
c. Apply Loctite 271 (92-809820) to the first 3 steps.
threads of the spool. Thread the retainer onto
1. Remove and discard the cotter pin.
the spool and tighten the retainer securely
with a pair of pliers. 2. Screw the castle nut down until it touches the
washer and a slight resistance is felt.
d. Assemble the castle nut and screw it down
until it touches the washer and a slight resis- 3. Loosen the castle nut until the cotter pin slot of the
tance is felt. castle nut is aligned with the hole in the shaft. If,
when the castle nut is screwed down, the cotter
e. Loosen the castle nut until the cotter pin slot
pin slot is aligned at the hole in the shaft, back off
of the castle nut is aligned with the hole in the
the castle nut until the next available slot in the
shaft. If, when the castle nut is screwed down,
nut is aligned with the hole in the shaft.
the cotter pin slot is already aligned at the
hole in the shaft, back the castle nut off until 4. Insert a new cotter pin and bend ends in opposite
the next available slot in the nut is aligned directions.
with the hole in the shaft.
5. Inspect to insure that the spool spins freely (it
f. Insert a new cotter pin and bend ends of the may be helpful to lightly tap the forward [castle
cotter pin in opposite directions. nut] end of the shift spool shaft against a firm sur-
face to align the internal parts).
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.

23356
.002 (0.05mm)
e a f g to
.010 (0.25mm)

23142
b c 7. If this adjustment did not produce the desired re-
d sults it will be necessary to disassemble, clean,
23142
and reassemble the shift spool assembly. If the
a - Washers (2) spool assembly has already been disassembled
b - Spring and cleaned it will be necessary to replace the
c - Retainer shift spool assembly.
d - Spool
e - Shift Shaft
f - Castle Nut
g - Cotter Pin

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-35

SHIFT SPOOL ASSEMBLY (NON-RATCHETING) Propeller Shaft Assembly
- Component Reassembly and Adjustment
COMPONENT REASSEMBLY
1. Assemble the shift spool and shift spool shaft as
follows: NOTE: Complete the instructions in this section only
if the assembly components have been disas-
a. Place the shift spool onto the shift spool shaft. sembled and repaired or replaced.
b. Assemble the castle nut and screw it down 1. Install the sliding clutch on the propeller shaft.
until it touches the washer and a slight resis- Align cross pin holes in the clutch with the slot in
tance is felt. the propeller shaft. The grooved end of the clutch
c. Loosen the castle nut until the cotter pin slot should be facing the propeller end of the shaft.
of the castle nut is aligned with the hole in the 2. Assemble the forward gear assembly to the pro-
shaft. If, when the castle nut is screwed down, peller shaft.
the cotter pin slot is already aligned at the
hole in the shaft, back the castle nut off until 3. Assemble the shift spool assembly to the propel-
the next available slot in the nut is aligned ler shaft being sure to align the cross pin hole of
with the hole in the shaft. the shift spool shaft with the clutch.
d. Insert a new cotter pin and bend ends of the 4. Assemble the cross pin through the sliding
cotter pin in opposite directions. clutch, through the propeller shaft and through
the shift spool shaft hole.
e. Inspect to insure that the spool has 0.002 -
0.010 in. (0.05 - 0.25mm) end play, if it 5. Install detent pin in 3rd hole in clutch.
doesn’t, adjust the castle nut once again as 6. Assemble the cross pin retaining spring over the
outlined previously. 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
d 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 as-
sembled. If it does not lie flat against the
clutch a new spring must be installed. (Ratch-
eting Assembly Shown)

e g
a c b
b 55694 a c
a - Shift Shaft
d
b - Spool
c - Castle Nut
d - Cotter Pin
f. If this adjustment did not produce the desired f
results it will be necessary to disassemble,
clean, and reassemble the shift spool assem-
bly. If the spool assembly has already been
disassembled and cleaned it will be neces- h
sary to replace the shift spool assembly.

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

6A-36 - LOWER UNIT 90-855348R1 JANUARY 1998

Shift Shaft Assembly SHIFT SHAFT ASSEMBLY - Component
Disassembly and Inspection
REMOVAL 1. Slide the bushing assembly off the shift shaft. Re-
NOTE: It is possible to remove and service the shift move the coupler from the shaft.
shaft assembly (but not the shift crank inside the gear a c
case) without removing any of the internal compo-
nents of the gear housing.
1. Remove the shift shaft bushing screws, and re-
move the shift shaft and bushing by pulling both d
straight out of gear housing.

b
70616

a - Shift Shaft Bushing

b - O-rings (2)
c - Coupler
a a 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,
70494 damage, or excessive wear.
a - Shift Shaft Bushing Screws b. Inspect the oil seal inside the bushing, the
2. Remove the shift crank from the inside of the gear sleeve, and the O-rings on the outside of the
housing. Clean it with a suitable solvent and dry bushing for damage or excessive wear.
it thoroughly. Inspect it for wear in the areas that c. Inspect the speedometer connector for dam-
contact the shift spool and inspect the splines age or blockage.
and the diameter that goes over the locating pin
for damage or wear. If any of these conditions exist, replace the ap-
a propriate components.
c

b
b

c d
23350

a - Contact Area
b - Shift Crank
c - Splines a
d - Diameter for Locating Pin 70617

a - Shift Shaft Bushing

b - Oil Seal (Oil Seal is Replaceable)
c - Speedometer Tube Connector

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-37

a - Shift Shaft Bushing SHIFT SHAFT ASSEMBLY - Component
b - Oil Seal (Oil Seal is Replaceable) Reassembly
c - Speedometer Tube Connector
NOTE: Complete the instructions in this section only
3. Inspect the shift shaft splines and oil seal surface
if the assembly components have been disas-
for corrosion and/or excessive wear. Replace the
sembled and repaired or replaced.
shift shaft if either if these conditions are found.
1. Lightly lubricate the seats of the O-ring diameters
on the bushing and the lip of the oil seal with
2-4-C w/Teflon (92-825407A12).
2. If the speedometer connector was removed and/
or replaced, lightly coat the threads of the con-
b nector with Quicksilver Perfect Seal
a (91-34277-1). Assemble the speedometer con-
nector to the bushing and torque the connector to
4.5 lb. in. (0.51 N·m).
3. Assemble all components as shown below.
70618

a - Oil Seal Surface

b - Spline
a

95
c
b d
19

e
f
g
19 Perfect Seal (92-34227-1) 95
95 2-4-C With Teflon (92-825407A12)

70616

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 N·m)]
f - Bushing
g - O-Rings (2 ea.)
h - Coupler
NOTE: For reinstalling the shift shaft when none of
the other components of the gear housing were dis-
assembled see the “Shift Shaft Assembly”, “Installa-
tion”.

6A-38 - LOWER UNIT 90-855348R1 JANUARY 1998

Pinion Bearing Gear Housing Reassembly
REMOVAL Gear Housing Inspection
NOTE: Inspect the bearing surface on the drive shaft 1. Clean the gear housing thoroughly with a suitable
where the needles of the lower pinion bearing roll. solvent and a hard bristle brush. Dry the gear
The condition of the drive shaft at this location gives housing thoroughly using compressed air. Insure
an indication of the condition of the needle bearing. that all sealants, locking agents and debris are
Replace lower pinion bearing (needles and race as removed.
a set) if the drive shaft is pitted, grooved scored, worn
unevenly, discolored from overheating, or has em- 2. Verify the 2 oil circulation holes in the drive shaft
bedded particles. bore and the shift shaft hole are clear and free of
debris.
IMPORTANT: All the needle bearings (18) MUST
BE in place inside bearing race while driving the 3. Inspect the gear housing for excessive corrosion,
pinion bearing from the gear housing. impact or any other damage. Excessive damage
and/or corrosion requires replacement of the
IMPORTANT: Do not reuse the bearing (race or gear housing.
rollers) once it has been removed.
4. Inspect the bearing carrier retainer threads in the
1. Remove and discard the pinion bearing (race and gear housing for corrosion and/or stripped
rollers) using tools as shown. threads. Damage or corrosion to the threads re-
quires replacement of the gear housing.
5. Inspect bearing race/cup contact areas for evi-
dence of bearing cup spinning. Check that bear-
ing cups are not loose in bearing bores. Any one
d bearing bore in which the race/cup is loose will re-
c quire replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the
speedometer hole, clean as necessary. Be care-
ful not to enlarge the speedometer hole as this
b could cause erroneous speedometer readings.
7. Make sure 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 housings are not
aligned properly due to missing locating pins or
a elongated holes.

70614

a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-39

Pinion Bearing Forward Gear Bearing Cup

INSTALLATION INSTALLATION
IMPORTANT: Install only a NEW pinion bearing. Forward Gear Backlash -- .017 in. to .028 in.
Do not reinstall a pinion bearing that has been (0.43mm to 0.71mm)
previously removed from a gear housing.
NOTE: If the forward gear, forward gear bearing and
1. Lubricate the bore into which the pinion bearing cup, or gear housing were not replaced, install the
is to be installed with Quicksilver Gear Lubricant same quantity of shims that were taken out when cup
(92-19007A24). was removed. If the forward gear, forward gear bea-
ring/cup, or gear housing were replaced, install 0.020
2. Position the new pinion bearing (with the card-
in. (0.51mm) of shims.
board shipping sleeve in place) onto the driver
head, with the lettered and numbered side of the NOTE: If backlash has already been checked and it
bearing oriented upward. has determined that it needs to be adjusted, (see
Checking Forward Gear Backlash), adding or sub-
3. Insert the driver with the bearing assembly, into
tracting 0.001 in. (0.03mm) shims will change the
position (by way of the propeller shaft bore) at the
gear backlash by the same amount.
drive shaft bore as shown.
Example 1 (if backlash is too high)
c
e If Forward Backlash Checks: .040 in. (1.02mm)
d

(Subtract): .018 in. (0.46mm)

Add This Quantity of Shims: .022 in. (0.56mm)

f
a
g Provides Backlash of 0.018 (0.46mm)

87 Example 2 (if backlash is too low)

Backlash Checks: .010 in. (0.25mm)

70615
87 Quicksilver Gear Lubricant (92-19007A24) Subtract this Quantity of
Shims: .008 in. (0.30mm)
a - Drive Shaft Pinion Bearing (With Cardboard Shipping
Sleeve)
b - Driver Head (91-38628) Provides Backlash of 0.018 (0.46mm)
c - Puller Shaft (91-31229)
d - Washer (12-34961)
e - Nut (11-24156)
f - Pilot Washer (91-36571)
g - Puller Plate (91-29310) 1. Lubricate the bore into which the forward gear
4. Install the bearing by screwing down the nut until bearing cup is to be installed with Quicksilver
the bearing is fully seated against the bore Gear Lubricant (92-19007A24).
shoulder. 2. Place the shim(s) into forward bore of gear hous-
ing.

6A-40 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Press the bearing cup into the gear housing using Shift Shaft Assembly
the installation tool as follows:
NOTE: Ratcheting type gear cases use bearing cup INSTALLATION
driver 91-36577. Non-ratcheting gear cases use 1. Place the shift crank onto the locating pin in the
bearing cup driver 91-31106. forward section of the gear housing. Ensure that
IMPORTANT: Verify that the bearing cup is posi- the shift crank faces towards the left (port) side of
tion as straight as possible to avoid cocking it in the gear housing.
the bore while pressing it in.

d
a b

c
a
87
b 50314

50791 a - Shift Crank

b - Locating Pin
87 Quicksilver Gear Lubricant (92-19007A24) 2. Install the shift shaft assembly into the gear hous-
a - Hex-Head Screw ing as shown. Engage the splined end of the shift
b - Bearing Cup Installation Tool (91-18605A1) shaft with the shift crank. Verify O-rings are posi-
c - Driver Cup (91-36577) for ratcheting type gear cases. tioned properly and lubricated with 2-4-C w/Te-
Driver Cup (91-31106) for non-ratcheting type gear cases. flon. Secure shift shaft bushing with 2 screws.
d - Shims
Torque screws to 60 lb. in. (6.8 N.m).
a

70620

a - Shift Shaft Assembly

b - Screws [Torque to 60 lb. in. (6.8 N·m)]

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-41

NOTE: If the pinion bearing needle bearings have Propeller Shaft Assembly
fallen out, install 18 needles into needle bearing outer
race. Use 2-4-C w/Teflon (92-825407A12), to help INSTALLATION
hold needles in place.
1. To allow for the engagement of the shift spool with
the shift crank, tilt the propeller end of the propel-
ler shaft assembly to the left (port) side of gear
housing and rotate the shift shaft from reverse to
neutral while installing shaft (ratcheting assem-
95 bly shown).
a
c

b 23142
95 2-4-C With Teflon (92-825407A12)

a - Rollers (18)
b - Roller Bearing Outer Race

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.

6A-42 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Slide the rubber sleeve at top end of shift shaft Drive Shaft and Pinion Gear
down so that it just touches the oil seal in the
bushing. INSTALLATION
NOTE: If the original shims were not retained or if pin-
ion 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(s).
a b NOTE: If the original shims were retained (or mea-
c
surement known) and none of the above listed parts
e were replaced, reinstall the same shims or same
amount of shims.
1. Place the shim(s) into the drive shaft housing
bore.
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.

70620

a - Shim(s)
NOTE: For ease of installation, glue the washer to
the pinion gear, using 3M Adhesive (92-25234), or
Quicksilver Bellows Adhesive (92-86166), or equiva-
lent.
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 (92-809820) to the threads of
the pinion gear nut and place the pinion gear nut
into the MR slot of the pinion nut adapter.
NOTE: Install the pinion gear nut with the flat side of
the nut away from the pinion gear.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-43

3. Place the pinion gear and washer into the gear 8. Install the bearing carrier into the gear housing
housing. backwards to hold the propeller shaft and the pin-
ion nut adaptor in position.
4. Insert the pinion nut adapter (with the nut) into the
gear housing. 9. Torque the pinion nut to 75 lb. ft. (101.7 N·m) by
turning the drive shaft using the drive shaft nut
5. Insert the drive shaft into the gear housing drive
wrench and torque wrench.
shaft bore. It may be necessary to rotate the drive
shaft to engage the drive shaft splines into the
pinion gear splines.
6. Start the pinion nut onto the drive shaft threads by
rotating the drive shaft until the nut is snug.
b
c

7
a
b 7 Loctite 271 (92-809820) 70892
70891

a - Pinion Gear (with the washer glued to it) a - Pinion Nut Adapter (91-61067A2)
b - Pinion Nut Adaptor (91-61067A2) b - Drive Shaft Nut Wrench (91-56775)
c - Drive Shaft c - Bearing Carrier (installed backwards)

7. Install the drive shaft tapered roller bearing cup. 10. Remove the bearing carrier, pinion nut adapter
Apply 2-4-C w/Teflon to the retainer threads and and drive shaft nut wrench.
install the retainer. 11. Torque the retainer to 100 lb. ft. (136.0 N·m).
b 95

a a

70890
95 2-4-C With Teflon (92-825407A12)
70711
a - Tapered Roller Bearing Cup
b - Drive Shaft Retainer a - Drive Shaft Bearing Retainer Wrench (91-43506)

6A-44 - LOWER UNIT 90-855348R1 JANUARY 1998

Gear Location/Backlashes 3. Measure distance (a) and increase that distance
by 1 in. (25.4mm) by turning bottom nut away
Checking and Adjustment from top nut.

Drive Shaft - Bearing Preload Tool

INSTALLATION
1. Install the components from the Bearing Preload a
Tool Kit (91-14311A1), over the drive shaft in the b
order shown.

a
b

c
70893

a - Distance 1 in. (25.4mm)

d b - Bottom nut [screwed down approximately 1 in. (25.4mm)]
e 4. Rotate the drive shaft at least three full turns in a
clockwise direction.
d
f Pinion Gear Location
g
CHECKING AND ADJUSTING
70496
Pinion Depth -- 0.025 in. (0.64mm)
a - Top Nut with Threaded Pipe NOTE: If the bearing preload tool has not already
b - Nut been set up, refer to “Drive Shaft - Bearing Preload
c - Spring Tool”, ‘Installation’section first.
d - Thrust Washer (2 Required) (12-18448)
e - Thrust Bearing NOTE: The prop shaft and forward gear can be
f - Thrust Washer installed when checking pinion height IF Pinion
g - Water Pump Face Plate (from your gear housing)
Height Tool 91-56048 is used.
2. Pull up on the drive shaft and tighten the two (2)
1. Place the pinion gear shimming tool into the gear
allen screws in the top nut of the bearing preload
housing.
tool.
NOTE: Take the following measurements at 3 loca-
tions, rotating the drive shaft 120 degrees between
each reading (always rotate the drive shaft in a clock-
wise direction).
2. Insert the thickest feeler gauge that fits snugly
a between one tooth of the pinion gear and high
point of the shimming tool.
a 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
70716 sum by 3 to get the average pinion gear height.
a - Allen Screws
Make note of this average measurement.

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-45

The average pinion gear height should be 0.025 in. Bearing Carrier Assembly
(0.64mm).
6. If the average pinion gear height is not correct, re- INSTALLATION - (FOR CHECKING
move the bearing preload tool, the drive shaft re- BACKLASHES)
tainer and the drive shaft tapered roller bearing NOTE: If backlashes have already been checked
cup. (The cup can be removed by wiggling the and they are to specification proceed with “Bearing
drive shaft back and forth or by turning gear hous- Carrier Assembly”, ‘Final Installation’section found
ing and shaking it.) Add or subtract shims be- on page 6A-50.
neath the cup to obtain the proper average pinion
gear height. Reinstall the cup and retainer. Retor- 1. Place the bearing carrier assembly into the gear
que retainer to 100 lb. ft. (135.6 N·m). Reinstall housing. It may be necessary to turn the drive
the bearing preload tool and rotate the drive shaft shaft to align the teeth of the pinion and the re-
at least 3 full turns in a clockwise direction. Re- verse gears.
check the pinion gear height as in step 5 above.
Repeat this process until the average pinion gear
height is within specification.

70712
b
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 in-
serted into the hole in the gear housing.

a a

c
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. b
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 N·m).
70713

a - Gear Housing Tab Washer Alignment Hole (not seen)

b - “V”Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

6A-46 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Verify that the “V”shaped tab aligns with the “V” Forward Gear Backlash
notch in bearing carrier.
CHECKING
1. Apply forward pressure to propeller shaft as fol-
lows:
b
a. Attach puller jaws and puller bolt onto bearing
carrier bosses and propeller shaft.
a

70714

a - Tab Washer b
b - “V”Tab 70719
4. Lubricate the bearing carrier retainer threads
a - Puller Jaws (91-46086A1)
with 2-4-C w/Teflon (92-825407A12). Start the b - Puller Bolt (91-85716)
retainer into the gear housing threads and screw
it down fully by hand. b. Torque the puller bolt to 45 lb. in. (5.1 N·m).
Rotate drive shaft three full turns clockwise
and retorque the bolt to 45 lb. in. (5.1 N·m).
NOTE: If the bearing preload tool has not already
been set up, see “Drive Shaft - Bearing Preload Tool”,
‘Installation’section found on page 6A-45 first.

95

70715

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

a - Bearing Carrier Retainer

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-47

2. Install a dial indicator and align the dial indicator 5. If backlash is LESS than the specified minimum,
pointer so that it is perpendicular to and touching REMOVE shim(s) from in front of forward gear
the “I”mark on the dial indicator tool. Tighten the bearing race to obtain correct backlash. When re-
indicator tool onto the drive shaft and rotate the installing pinion nut, apply Loctite 271 to threads
drive shaft so that the needle in the dial makes at of nut.
least one full revolution and comes to “0”on the
6. If backlash is MORE than the specified MAXI-
dial indicator scale.
MUM, add shim(s) in front of forward gear bear-
e f ing race to obtain correct backlash. When rein-
stalling pinion nut, apply Loctite 271 to threads of
d nut.
NOTE: By adding or subtracting 0.001 in. (0.03mm)
shim, the backlash will change approximately 0.001
a in. (0.03mm).

Reverse Gear Backlash

b c
CHECKING
Reverse Gear Backlash -- 0.030 in. to 0.050 in.
(0.76mm to 1.27mm)
a
Although reverse gear backlash is not adjustable, it
70717 may be checked as follows:
a - Nuts (4) (Obtain Locally) NOTE: Torque cover nut to 210 lb. ft. (284.7 N·m).
b - Threaded Rod [3/8 in. (9.5mm) obtain locally]
c - Dial Indicator Holding Tool (91-83155) 1. Apply backward pressure on the propeller shaft
d - Dial Indicator (91-58222A1) as follows:
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 or 1.75:1) a. Install the pinion nut adaptor, washer and pro-
Backlash Indicator Rod (91-78473) (for 1.87:1 ratio) peller nut as shown.
3. Take the backlash readings by lightly turning the
drive shaft back and forth, (no movement should b
be noticed at the propeller shaft). a
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 2 above and take and record
another reading. Repeat step 3 until a total of
4 backlash readings have been taken.
c
4. Add the four readings together and divide the
sum by four. 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 ratios).
23355

a - Pinion Nut Adaptor (91-61067A2)

b - Washer (12-54048)
c - Prop Nut

6A-48 - LOWER UNIT 90-855348R1 JANUARY 1998

 b. Torque the propeller nut to 45 lb. in. (5.1 N·m). If backlash is not as indicated, gear case is not prop-
Rotate the drive shaft 3 full turns in a clock- erly assembled or parts are excessively worn and
wise direction and retorque the propeller nut must be replaced before returning gear case to ser-
to 45 lb. in. (5.1 N·m). vice.
2. Install a dial indicator and align the dial indicator 5. Loosen the backlash indicator tool and remove
pointer so that it is perpendicular to and touching the propeller nut, washer and pinion nut adaptor.
the “I”mark on the dial indicator tool. Tighten the Remove the dial indicator and all its mounting
indicator tool onto the drive shaft and rotate the components. Do not remove the bearing pre-
drive shaft so that the needle in the dial makes at load tool. The following instructions give
least one full revolution and comes to “0”on the specific instructions for its removal.
dial indicator scale.

e f Drive Shaft - Bearing Preload Tool

d
REMOVAL

CAUTION
a Before loosening the top nut allen screws of the
bearing preload tool, screw the bottom nut up as
close as possible to the top nut.
b
c 1. Remove the dial indicator and its supporting tool-
ing.
2. Screw the bottom nut of the bearing preload tool
until it is as close as possible to top nut.
a 3. Loosen the allen screws in the top nut.
4. Remove all components including the water
70717 pump face plate.
a - Nuts (4) (obtain locally)
b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]
c - Dial Indicator Holding Tool (91-83155) a
d - Dial Indicator (91-58222A1)
e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 or 1.75:1)
b
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 back- c
lash 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 direction.
c. Repeat step 2 above and take and record 70716
another reading. Repeat step 3 until a total of a - Top Nut (with allen screws)
4 backlash readings have been taken. b - Bottom Nut
c - Water Pump Face Plate
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).

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-49

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 in-
Final Installation serted into the hole in the gear housing.
1. Remove the Bearing Carrier and lubricate the fol-
lowing as specified:
a. Lubricate the carrier O-ring with 2-4-C w/Te- a
flon (92-825407A12).
b. Lubricate both the forward ad aft outer diame- c
ters of the bearing carrier and gear case area
where carrier will seat with 2-4-C w/Teflon.
c. Fill the space between the carrier oil seals
with 2-4-C w/Teflon.
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 re-
verse gears. b

95

70713

a - Gear Case Alignment Hole

b - “V”Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

70712

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

a - Bearing Carrier Assembly

6A-50 - LOWER UNIT 90-855348R1 JANUARY 1998

4. Verify the “V”shaped tab aligns with the “V”notch IMPORTANT: Before torquing bearing carrier re-
in bearing carrier. tainer, gear case must be bolted to drive shaft
housing or securely fastened in a gear case hold-
ing fixture to avoid possible damage to gear
housing.
6. Torque the bearing carrier retainer to 210 lb. ft.
b (284.7 N·m). If one tab does not align up in space
between two of the notches, continue to tighten
retainer until alignment is achieved. DO NOT
loosen retainer to achieve alignment.

a
70714

a - Tab Washer 23355

b - “V”Tab
a - Bearing Carrier Retainer Wrench (91-61069)
5. Fill the bearing carrier retainer nut threads and
corresponding gear housing threads with 2-4-C 7. Bend one tab aft (outward) into a space between
w/Teflon (92-825407A12). Start the retainer into two of the notches of the retainer. Bend all the re-
the gear housing threads and screw it down fully maining tabs forward (inward).
by hand.
d

c b

95

70490
70715
a - Bearing Carrier
95 2-4-C With Teflon (92-825407A12)
b - Tab
c - Retainer Notches
a - Bearing Carrier Retainer d - Alignment Tabs (Bend Inward)

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-51

Oil Seal Carrier Assembly 2. Place a small amount of 2-4-C w/Teflon on the flat
surface of the impeller key and install the key onto
Installation the drive shaft keyway.
IMPORTANT: When using an impeller whose
NOTE: Apply hand pressure only to install the oil seal
blades have taken a set, face the curl of the
carrier into position. Do not hammer it into position.
blades in a counterclockwise direction. DO NOT
1. Lubricate the oil seal carrier oil seal lips, space install the impeller with its blades oriented in a
between seals and O-ring with 2-4-C w/Teflon reversed direction from original rotation, or
and install the oil seal carrier over the drive shaft premature impeller failure will occur.
and into the gear case.
3. Assemble the water pump impeller onto the drive
a shaft and down over the key.
b
a
95

c 70501 b
a - Oil Seal Carrier 52725
b - Oil Seal Lips
c - O-ring
95 2-4-C With Teflon (92-825407A12)

a - Water Pump Impeller

b - Water Pump Impeller Key
Water Pump Assembly 4. Install the 2 water pump locating pins through the
gaskets and face plate.
Installation
5. Apply a light coat of 2-4-C w/Teflon to the inside
NOTE: The gaskets/face plate hole pattern is not of the pump cover. Position the water pump body
symmetrical. If the holes of the gaskets/face plate do over the drive shaft and water pump locating
not align with the screw holes of the gear case and/or pins. Rotate the drive shaft in a clockwise direc-
each other, one or more of the parts is upside down. tion, while pushing down on the water pump body
Determine which part(s) is (are) upside down and to ease the water pump over the impeller blades.
turn the appropriate part(s) over.
c
1. Install the small hole gasket then the face plate a b
followed by the large hole gasket onto the gear
case.
95
c

b
a

52751
95 2-4-C With Teflon (92-825407A12)
70720 a - Water Pump Body
b - Water Pump Alignment Pins (91-821571A1)
a - Small Hole gasket c - Drive Shaft (turn clockwise while installing water pump
b - Face Plate body)
c - Large Hole Gasket

6A-52 - LOWER UNIT 90-855348R1 JANUARY 1998

6. Hand start two (2) fasteners into the water pump Gear Lubricant Filling Instructions
assembly and remove the water pump locating
pins. Install the remaining 2 fasteners. Run all 1. Inspect “Fill”and “Vent”sealing washers for cuts
fasteners down and torque to 60 lb. in. (6.8 N·m). or abrasions. Replace O-rings if necessary.
7. Lightly lubricate the O-rings in the water tube 2. Clean any metal debris from magnet on “Fill”
coupling with 2-4-C w/Teflon (92-825407A12). plug.
8. Install the water tube coupling assembly to the IMPORTANT: Never add lubricant to gear hous-
water pump ensuring that the O-rings are not ing without first removing “Vent” screw, or gear
damaged during assembly. housing cannot be filled because of trapped air.
Fill gear housing ONLY when housing is in a ver-
IMPORTANT: If seal installed above pump hous- tical position.
ing is not at the proper height, air will be drawn
into the pump resulting in overheating of the en- 3. Slowly fill housing thru “Fill”hole with Quicksilver
gine. Super Duty Lower Unit Lubricant until lubricant
flows out of “Vent”hole and no air bubbles are vis-
9. Using tool (a) provided in seal kit (26-816575A2) ible.
or water pump kit (817275A3), press seal (b)
down over drive shaft (DO NOT GREASE DRIVE 4. Install “Vent”screw into “Vent”hole.
SHAFT) until tool seats against pump housing. IMPORTANT: DO NOT lose more than one fluid
ounce (30cc) of gear lubricant while reinstalling
“Fill” screw.
a 5. Remove grease tube (or hose) from “Fill” hole
and quickly install “Fill”screw into “Fill”hole.
b

Installing Gear Housing to Drive

Shaft Housing

WARNING
Disconnect high tension leads from spark plugs
and remove spark plugs from engine before in-
stalling gear housing into drive shaft housing.
52724
If tool is not available, lightly press seal against 1. Tilt engine to full up position and engage the tilt
housing until a height of 0.350 in. ± 0.030 in. lock lever.
(8.9mm ± 0.76mm) is obtained. 2. Apply a light coat of 2-4-C w/Teflon onto drive
shaft splines.

CAUTION
0.350 in. ±0.030 in. DO NOT allow lubricant on top of drive shaft. Ex-
cess lubricant, that is trapped in clearance
space, will not allow drive shaft to fully engage
with crankshaft. Subsequently, tightening the
gear housing nuts (while excess lubricant is on
top of drive shaft) will load the drive shaft/crank-
shaft and damage either or both the powerhead
and gear housing. Top of drive shaft is to be
wiped free of lubricant.
52726
NOTE: Secure speedometer tube to speedometer 3. Apply a light coat of 2-4-C w/Teflon onto shift
connector with a sta-strap. shaft splines. (DO NOT allow lubricant on top of
shift shaft.)

90-855348R1 JANUARY 1998 LOWER UNIT - 6A-53

4. Insert a NEW trim tab bolt (with patch) into hole IMPORTANT: If shifting operation is not as de-
in rear of gear housing to drive shaft housing ma- scribed, preceding, the gear housing must be re-
chined surface. moved and the cause corrected.
5. Shift gear housing into NEUTRAL and place 14. Install remaining washers and nuts onto drive
guide block anchor pin into NEUTRAL position. shaft studs. Torque to 55 lb. ft. (74.6 N·m).
15. Torque bolt (started in Step 10) to 45 lb. ft. (61.0
N·m).
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,
a and while holding trim tab, torque bolt to 40 lb. ft.
(54.2 N·m)
52189
17. Install plastic cap into trim tab bolt opening at rear
a - Guide Block Anchor Pin
edge of drive shaft housing.
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 cor-
rect 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 N·m).
13. After 2 nuts (located on either side of drive shaft
housing) are tightened, check shift operation as
follows:
a. Place guide block anchor pin into forward
gear position. Rotate flywheel clockwise
(viewed from top); propeller shaft should ro-
tate 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 clockwise
(viewed from top); propeller shaft should ro-
tate counterclockwise.

6A-54 - LOWER UNIT 90-855348R1 JANUARY 1998

LOWER UNIT

6
B
50881

GEAR HOUSING
LEFT HAND OPERATION
(COUNTER ROTATION)
(RATCHETING AND NON-RATCHETING)
Table of Contents
Page Page
General Service Recommendations . . . . . . . . . . . . . 6B-1 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-49
Gear Housing Specifications (Counter Rotation) . . 6B-2 Drive Shaft and Pinion Gear . . . . . . . . . . . . . . . . 6B-50
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Drive Shaft - Bearing Preload Tool . . . . . . . . . . 6B-52
Gear Housing (Drive Shaft) (Counter Rotation) Pinion Gear Location . . . . . . . . . . . . . . . . . . . . . . 6B-53
(Ratcheting)(S/N-0G437999 & BELOW)(CASTING Drive Shaft - Bearing Preload Tool . . . . . . . . . . 6B-54
#1623-822442C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-6 Pinion Gear Location . . . . . . . . . . . . . . . . . . . . . . 6B-54
Gear Housing (Prop Shaft) (Counter Rotation) Reverse Gear Backlash . . . . . . . . . . . . . . . . . . . 6B-55
(Ratcheting)(S/N-0G437999 & BELOW)(CASTING Forward Gear/Bearing Carrier Assembly . . . . . 6B-56
#1623-822442C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8 Forward Gear Backlash . . . . . . . . . . . . . . . . . . . 6B-62
Gear Housing (Drive Shaft) (Counter Rotation) Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6B-64
(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING Component Reassembly . . . . . . . . . . . . . . . . . . . 6B-64
#1623-822442C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12 Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6B-65
Gear Housing (Prop Shaft) (Counter Rotation) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-65
(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING Drive Shaft and Pinion Gear . . . . . . . . . . . . . . . . . . 6B-67
#1623-822442C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Final Installation (Ratcheting and
Removal, Disassembly, Cleaning and Inspection -- Non-Ratcheting) . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-67
Counter Rotation (Ratcheting and Bearing Carrier Assembly . . . . . . . . . . . . . . . . . . . . . 6B-69
Non-Ratcheting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-16 Final Installation (Ratcheting) . . . . . . . . . . . . . . . 6B-69
Pre-Disassembly Inspection . . . . . . . . . . . . . . . . . . . 6B-18 Oil Seal Carrier Assembly . . . . . . . . . . . . . . . . . . . . 6B-75
Gear Housing and Component Disassembly . . . . 6B-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-75
Forward Gear Bearing Adaptor Assembly . . . . 6B-29 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . 6B-75
Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . 6B-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-75
Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . 6B-34 Gear Lubricant Filling Instructions . . . . . . . . . . . 6B-77
Reverse Gear Assembly . . . . . . . . . . . . . . . . . . . 6B-37 Installing Gear Housing to Drive Shaft Housing 6B-77
Shift Spool Assembly . . . . . . . . . . . . . . . . . . . . . . 6B-39
Reverse Gear Bearing Adaptor Assembly . . . . 6B-42
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6B-43
Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-45
Gear Housing Reassembly . . . . . . . . . . . . . . . . . . . 6B-45
Gear Housing Inspection . . . . . . . . . . . . . . . . . . 6B-45
Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-46
Reverse Gear Bearing Adaptor Assembly . . . . 6B-46
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6B-48
Gear Location/Backlashes Checking and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-49

6B-0 - LOWER UNIT 90-855348R1 JANUARY 1998

General Service Roller bearing condition is determined by inspecting
the bearing surface of the shaft that the roller bearing
Recommendations supports. Check shaft surface for pitting, scoring,
grooving, imbedded particles, uneven wear and/or
There may be more than one way to “disassemble”
discoloration from overheating. The shaft and bear-
or “reassemble” a particular part(s). It is recom-
ing must be replaced if the conditions described are
mended that the entire procedure be read prior to re-
found.
pair.
IMPORTANT: Read the following before attempt- SHIMS
ing any repairs.
Keep a record of all shim amounts and location dur-
Disassembly of a sub-assembly may not be neces- ing disassembly to aid in reassembly. Be sure to fol-
sary until cleaning and inspection reveals that disas- low shimming instructions during reassembly as
sembly is required for replacement of one or more gears must be installed to correct depth and have the
components. correct amount of backlash to avoid noisy operation
Service procedure in this section is a normal disas- and premature gear failure.
sembly-reassembly sequence. It is suggested that
the sequence be followed without deviation to assure SEALS
proper repairs. When performing partial repairs, fol- As a normal procedure, all O-rings and oil seals
low the instructions to the point where the desired SHOULD BE REPLACED without regard to appear-
component can be replaced, then proceed to “reas- ance. To prevent leakage around oil seals, apply
sembly and installation” of that component in the Loctite 271 to outer diameter of all metal case oil
reassembly part of this section. Use the “Table of seals. When using Loctite on seals or threads, sur-
Contents”(on back of section divider) to find correct faces must be clean and dry. To ease installation,
page number. apply Quicksilver 2-4-C w/Teflon (92-825407A12)
Threaded parts are right hand (RH), unless other- on all O-rings. To prevent wear, apply 2-4-C w/Teflon
wise indicated. on I.D. of oil seals.
When holding, pressing or driving is required, use To prevent corrosion damage after reassembly, ap-
soft metal vise jaw protectors or wood for protection ply Quicksilver Perfect Seal or 2-4-C w/Teflon to ex-
of parts. Use a suitable mandrel (one that will contact ternal surfaces of bearing carrier and retainer nut
only the bearing race) when pressing or driving bear- threads prior to installation. DO NOT allow Perfect
ings. Seal to enter bearings or O-ring area.
Whenever compressed air is used to dry a part, be NOTE: Before filling gear case, apply 10-15 psi (68.5
sure that no water is present in air line. -- 102.7kPa) of air pressure at the VENT hole. Pres-
sure should not drop for 15 seconds while alternately
BEARINGS applying a 2-3 pound force to the top of the shift shaft
in the fore and aft direction.
Upon disassembly of gear housing, all bearings must
be cleaned and inspected. Clean bearings with sol-
vent and dry with compressed air. Air should be di-
rected at the bearing so that it passes thru the bear-
ing. DO NOT spin bearing with compressed air, as
this may cause bearing to score from lack of lubrica-
tion. After cleaning, lubricate bearings with Quicksil-
ver Gear Lubricant. DO NOT lubricate tapered bear-
ing cups until after inspection.
Inspect all bearings for roughness, catches and bear-
ing race side wear. Work inner bearing race in-and-
out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condi-
tion of rollers and inner bearing race by inspecting
bearing cup for pitting, scoring, grooves, uneven
wear, imbedded particles and/or discoloration from
overheating. Always replace tapered bearing and
race as a set.
90-855348R1 JANUARY 1998 LOWER UNIT - 6B-1
Gear Housing Specifications W.O.T. 8-10 psi
54.9 -- 68.5kPa)
(Counter Rotation) Test Propeller for Static Test
12 Dia. x 15 Pitch 48-78116A40
Backlash and Pinion Depth
(Ratcheting and Non-Ratcheting)
Pinion Depth
Special Tools
Propeller Shaft 44-93003 and Load Washer
All Models 0.025 in. (0.64mm) with 12-37429
Tool 91-12349A2 Using
Disc 2 and Flat 4
Forward Gear Backlash
1.64:1and 1.75:1 Gear 0.017 in. to 0.028 in.
Ratios (0.431mm to 0.711mm)
1.62:1 Gear Ratio Pointer on line mark #1 Bellville Washer 12-54048
Service Replacement with Backlash Indicator
Rod 91-53549
Reverse Gear Backlash
1.64:1and 1.75:1 Gear 0.040 in. to 0.060 in.
Ratios (1.01mm to 1.52mm)
1.62:1 Gear Ratio
Service Replacement
Needle Bearing Driver 91-15755
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
Oil Seal Driver 91-31108
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 Pin- Teeth in For-

ion Gear ward and Re- Universal Puller Plate 91-37241
verse 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)

6B-2 - LOWER UNIT 90-855348R1 JANUARY 1998

Bearing Retainer Tool 91-43506 Backlash Indicator Rod 91-78473

Puller Bolt 91-85716 and Puller Jaws 91-46086A1

Backlash Indicator Rod 91-53459

Forward Gear Bearing Tool 91-86943

Drive Shaft Nut Wrench 91-56775

Dial Indicator Holding Tool 91-89897

Bearing Carrier Retainer Wrench 91-61069

Forward Gear Installation Tool 91-815850

Puller Jaws 91-816242

Torque Wrench (lb. in.) 91-66274

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-3

Guide Plate 91-816243 Bearing Preload Tool 91-14311A2

Bearing Driver 91-816244

Bearing Adaptor Installation Tool 91-18605A2

Oil Seal Driver 91-817569

Bearing Removal and Installation Tool 91-31229A7

-- Includes Driver Head 91-36569: Driver Head Rod
91-37323; Nut 11-24156; Pilot Washer 91-36571; Pi-
lot Plate 91-29610; Puller/Driver Head 91-38628;
Water Pump Alignment Pins 91-82157A1 Mandrel 91-30366; Plate 91-29310; Driver Head
91-32325; Puller Shaft 91-31229; Washer 91-34961.

Pinion Gear Shimming Tool 91-12349A2

6B-4 - LOWER UNIT 90-855348R1 JANUARY 1998

Slide Hammer Puller 91-34569A1 Pinion Nut Adaptor 91-61067A3

Puller Bolt 91-85716 and Puller Jaws 91-46086A1

Drive Shaft Adaptor 91-61077

Dial Indicator 91-58222A1

Leakage Tester FT8950

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-5

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
95 26
41 33 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
15
7 Loctite 271 (92-809820) 2
16
19 Perfect Seal (92-34227-1)
92
7
92 Loctite 7649 Primer (92-809824)
95 2-4-C With Teflon (92-825407A12)

6B-6 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Drive Shaft) (Counter Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-7

Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

76
1623-
822442C2

1 7

75

74
43
87
44

49
95
45
57
51 56
46
55 47
54
94
48
60 87
87 58

50 59
52 87
61
53
62 87
67
63
64 87 69
87 95
65 68
66
65 70 95
64 71 95

63 72
79 73 7
77
95
78
81 80
7 Loctite 271 (92-809820)
95
87 Quicksilver Gear Lubricant (92-19007A24)
94 Anti-Corrosion Grease (92-78376A6)
95
95 2-4-C With Teflon (92-825407A12)

6B-8 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-9

Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)

76

1623-
822442C2
1
7

75

74
43
87
44

49
95
45
57
51 56
46
55 47
54
94
48
60
87 58 87

50 59
52
61 87
53
62 87
67
63
64 87 69
95
87
65 68
66
65 70
64 71 95
95
63 72
79 73 7
77
78 95
81 80

7 Loctite 271 (92-809820)

95
87 Quicksilver Gear Lubricant (92-19007A24)
94 Anti-Corrosion Grease (92-78376A6) 95
95 2-4-C With Teflon (92-825407A12)

6B-10 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Prop Shaft) (Counter Rotation)(Ratcheting)
(S/N-0G437999 & BELOW)(CASTING #1623-822442C2)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 210 285
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

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-11

Gear Housing (Drive Shaft) (Counter Rotation)
(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING
#1623-822442C3)
7 Loctite 271 (92-809820) 95

19 Perfect Seal (92-34227-1)

31
95
92 Loctite 7649 Primer (92-809824) 32
95 2-4-C With Teflon (92-825407A12) 33
34
42
30
44 95
43 28
95
36
29
41
95
45 95
35 95

27
95
40 13

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
17
2
4.75 18

IN/120.65MM 7
TORPEDO DIA.
92

6B-12 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Drive Shaft) (Counter Rotation)
(Non-Ratcheting) (S/N-0G438000 & UP) (CASTING
#1623-822442C3)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
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 (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 drive-
shaft and ORDER REF. #’s 24 & 44.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-13

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
87 50
51
58
54
95
66
60 55 65
64 56
63
87 94
57
87
87
67

59 69 87
61
62 70 95
72
77
73 71
74 79
87
87
75 78
76
75 80
95
74 81
73
82 95

83
95

87 Super Duty Gear Lubricant (92-13783A24)

95
94 Anti-Corrosion Grease (92-78376A6)
95
96 Loctite Quick Tite (Obtain Locally)

6B-14 - LOWER UNIT 90-855348R1 JANUARY 1998

 Gear Housing (Prop Shaft)(Counter Rotation)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 GEAR HOUSING (BLACK) BASIC
1 1 GEAR HOUSING (GRAY)
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

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-15

Removal, Disassembly, 5. Mark gear housing and trim tab so that trim tab
can be reinstalled in the same position. Remove
Cleaning and Inspection -- plastic cap at rear edge of drive shaft housing,
then unthread bolt that secures trim tab and re-
Counter Rotation move trim tab from gear housing.
(Ratcheting and 6. Once trim tab is removed, remove bolt from in-
Non-Ratcheting) side of trim tab cavity.

REMOVAL
c
WARNING
a
Disconnect high tension leads from spark plugs
and remove spark plugs from engine before re-
moving gear housing from drive shaft housing.
b
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.

52375
a - Bolt (Secures Trim Tab)
b - Bolt (Inside Trim Tab Cavity)
c - Ribs -- Align Carefully with Trim Tab while Securing Tab
b
7. Disconnect speedometer tube, if connected.
51912
8. Loosen the side mounting locknuts. (DO NOT at-
c tempt to remove one nut before opposite side is
loosened sufficiently, or drive shaft housing could
be damaged.)
e 9. 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.)
f

d 51916
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut

6B-16 - LOWER UNIT 90-855348R1 JANUARY 1998

10. Pull gear housing from drive shaft housing. 3. Inspect gear lubricant for metal particles. Pres-
ence of a small amount of fine metal particles (re-
sembling powder) indicates normal wear. Pres-
ence of larger particles (or a large quantity of fine
particles) indicates need for gear housing disas-
sembly, and component inspection.
4. Note the color of gear lubricant. White or cream
color indicates presence of water in lubricant.
Check drain pan for water separation from lubri-
a cant. Presence of water in gear lubricant indi-
cates 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
52374 clear yellow brown in color.
a - Front Mounting Locknut
b - Side Mounting Locknut (One 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

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-17

Pre-Disassembly Inspection Gear Housing and
Propeller Shaft
Component Disassembly
Water Pump Assembly
INSPECTION
1. Inspect the propeller shaft for side to side move- REMOVAL
ment, as follows:
1. Remove the water seal, water tube coupling as-
a. Position the dial indicator on the propeller sembly, and the water pump screws.
shaft.
a
b. Push the propeller shaft to one side and zero c
the dial indicator.
c. Move the propeller shaft to the opposite side
while observing the dial indicator. Without ro-
tating the propeller shaft, reposition the dial
indicator and check the up and down deflec-
b
tion. 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 52749
indicated.
a - Water Tube Assembly
3. Measure propeller shaft endplay. If it is in excess b - Water Pump Screws (4)
of 0.093 in. (2.36mm), disassemble gear case c - Seal
and check condition of the reverse shoulder of
2. Carefully slide the water pump straight up off of
the propeller shaft, reverse gear and thrust wash-
the drive shaft. It may be necessary to encourage
er. Replace components as required.
the water pump up by gently prying up on its
mounting flanges with screwdrivers.

a a
b b

22086
a - Prop Shaft Runout 70487
b - Prop Shaft Endplay
a - Water Pump Body
b - Screw Drivers

6B-18 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Remove the impeller, impeller key, the face plate 3. Inspect for proper bonding between the hub and
and gaskets, (discard the gaskets). the impeller. Replace the impeller if improper
bonding is found.

a a

b
c

70605

a - Impeller
b - Impeller Key 70500
c - Water Pump Face Plate and Gaskets
(One on each side of the face plate) a - Impeller
b - Hub
WATER PUMP ASSEMBLY - COMPONENT 4. Inspect the impeller blades to see if they are
INSPECTION cracked, burnt, hard or deformed. Replace the
1. Inspect the water tube coupling assembly for impeller if the blades are in this condition.
wear or damage. If necessary, replace the worn IMPORTANT: The circular groove formed by the
or damaged components especially the two O- impeller sealing bead should be disregarded
rings on the inside, one at the top and one at the when inspecting cover and plate. The depth of
bottom. the groove will not affect water pump output.
b 5. Replace cover if thickness of steel at the dis-
charge 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.
a (0.76mm) deep.
a b

b
70613

a - Water Tube adapter

b - O-rings (2)
2. Inspect the water pump impeller for wear on the 70609
end, top and bottom of the impeller blades. Re- a - Water Pump Face Plate
place the impeller if this condition is found. b - Water Pump Cover

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-19

Oil Seal Carrier Assembly OIL SEAL CARRIER ASSEMBLY - COMPONENT
DISASSEMBLY
REMOVAL NOTE: Complete the instructions in this section only
1. Remove the oil seal carrier from the gear hous- if the assembly components have been found to be
ing. It may be necessary to gently pry up on it with defective and are in need of repair or replacement.
two screw drivers. 1. Remove the O-ring.
b

a
a
b 70501

a - O-ring
b - Oil Seals (2)
70489
2. Remove the oil seals.
a - Oil Seal Carrier
b - Screwdrivers

OIL SEAL CARRIER ASSEMBLY - INSPECTION

1. Inspect the oil seal carrier, O-ring, and seals for
wear and/or damage. If necessary, replace de- c
fective parts as outlined following. b

70610

a - Oil Seal Carrier

b - Oil Seals
c - Screwdriver

6B-20 - LOWER UNIT 90-855348R1 JANUARY 1998

OIL SEAL CARRIER ASSEMBLY - COMPONENT 5. Fill the area between the seal lips with 2-4-C
REASSEMBLY (1994/1995 MODELS) w/Teflon. Apply 2-4-C w/Teflon to the O-ring.
NOTE: Complete the instructions in this section only 6. Install the O-ring onto the oil seal carrier.
if the assembly components have been disas-
sembled and repaired or replaced. 95

70501

1. Assemble the small oil seal (with the lips of the oil a 70501
seal facing away from the driver shoulder) onto
the long end of the oil seal driver. 95 2-4-C With Teflon (92-825407A12)
2. Press on the oil seal driver until the driver bottoms
against the carrier. Do not press so hard as to a - O-ring
damage the oil seal carrier while driving the oil OIL SEAL CARRIER ASSEMBLY - COMPONENT
seal. REASSEMBLY (1996/1997 MODELS)
d
The oil seals in 1996/1997 carrier assemblies are the
same diameter. The bottom (first) seal lip faces
b down; the top (second) seal lip faces up. Apply 2-4-C
w/Teflon Marine Lubricant to seal lips and between
seals. Press seal into carrier with suitable mandrel.
a c Second seal should be pressed in flush with carrier
surface.
70611
a - Oil Seal
95
b - Oil Seal Driver (91-817569) use long end
c - Oil Seal Carrier b
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

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

a c a - Bottom Seal (Lip Faces Down)
b - Top Seal (Lip Faces Up)

70612

a - Oil Seal
b - Oil Seal Driver (91-817569) use short end
c - Oil Seal Carrier
d - Press

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-21

Bearing Carrier Assembly b. Remove the bearing carrier retainer using the
Bearing Carrier Retainer Wrench
REMOVAL (91-61069).

1. Straighten the tab on the tab washer.

70491

70490 a - Bearing Carrier Retainer Wrench

a - Tab on Tab Washer

3. Pull the bearing carrier from the gear housing by
pulling on the outer ring of the bearing carrier.
2. Remove the bearing carrier retainer following POSITION PULLER JAWS CLOSE TO BOSSES
step a or b as follows: IN CARRIER.

CAUTION NOTE: If the bearing carrier is seized in the gear

housing, it may be necessary to use heat to loosen
DO NOT drill into the gear housing retainer the carrier.
threads when using the following procedure for
removing the retainer.
b
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

50786

a - Puller Jaws (91-46086A1)

b - Puller Bolt (91-85716)

6B-22 - LOWER UNIT 90-855348R1 JANUARY 1998

4. Lift the bearing carrier out of the gear housing. 5. Remove the aft thrust bearing.
Locate and retain the thrust washer that may be
stuck to the inside surface of the bearing carrier.

50826 50786

a a - Thrust Bearing
6. Remove the aft thrust collar.

50779

a - Thrust Washer

50787

a - Thrust Collar

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-23

7. Lift up on the propeller shaft and push down on 8. Remove the forward thrust collar.
the forward thrust collar to remove the two
keepers.

a
b

50784

a - Thrust Collar
9. Remove the forward thrust bearing.
50778

a
a

50783

50826 a - Thrust Bearing

a - Thrust Collar
b - Keepers (2)

6B-24 - LOWER UNIT 90-855348R1 JANUARY 1998

10. Form a tool using a 1/8 in. (3 mm) wire as shown 12. Remove the O-ring from inside the gear housing.
in the following figure and remove the forward
13. Remove the forward gear, thrust race, and the
gear bearing adaptor.
thrust bearing (between the gear and the race).
14. Remove the forward gear shim.

b
b

d
50786

a - Wire Tool 50783

b - Forward Gear Bearing Adaptor
a - Forward Gear Installation Tool (91-815850)
11. Shift gear case into forward gear. b - Thrust Race
NOTE: The thrust race has a tight fit in the gear hous- c - Forward Gear
d - Shim
ing bore. Use the Forward Gear Installation Tool
(91-815850) to remove the thrust race and the for-
ward gear together. If this attempt fails, form a small BEARING CARRIER ASSEMBLY - INSPECTION
hook on the end of a stiff piece of wire and while ap- 1. Clean the assembly and all components with a
plying heat to the outside of gear case, pull the thrust suitable solvent and dry the parts thoroughly us-
race up and out of the gear housing. ing compressed air.
NOTE: If any of the following items are found to be
defective complete the appropriate instruction(s) in
“Bearing Carrier Assembly”, ‘Component Disassem-
bly and Inspection’section.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-25

2. Inspect the bearing carrier for signs of excessive 4. Inspect the forward gear for pitted, chipped, bro-
corrosion especially in the area where the bear- ken teeth, hairline fractures, and excessive or un-
ing carrier touches the gear housing. If excessive even wear. Replace the forward gear and the pin-
corrosion is evident replace the carrier. ion gear if any defects are found.
a 5. Inspect the outer hub of the forward gear for ex-
cessive wear or damage. Replace the forward
and the pinion gear if either of these conditions
exist.
6. Inspect the clutch jaws of the gear for damage.
Surfaces must not be chipped or rounded off. Re-
place the forward and the pinion gear if any are
found.
a

b b
50818

a - Bearing Carrier
b - Mating Surfaces
3. The condition of the bearing surface on the pro-
peller shaft in the area that the needle bearing (in
the bearing carrier) rides is an indication of the 23355
condition of the needle bearing in the bearing car-
a - Reverse Gear Teeth
rier. Replace the bearing if the surface of the shaft b - Clutch Jaws
is pitted, grooved, scored, worn unevenly, discol-
ored from overheating or has embedded metal 7. Inspect the thrust bearings, collars and forward
particles. gear bearing adaptor for excessive wear in the
a areas where the thrust bearings come into con-
tact with them. Replace the appropriate compo-
nents if they are found to be defective.
8. Inspect the bearing carrier retainer for cracks
and/or broken or corroded threads. Replace it if
50698
any are found.
a - Propeller Shaft Bearing Contact Area

6B-26 - LOWER UNIT 90-855348R1 JANUARY 1998

9. Inspect the large O-ring for damage and/or dete- b. If Replacing the Seal Only: Remove the oil
rioration. Replace it if either condition is found. seals with a suitable pry bar, being careful not
to damage the bore of the bearing carrier.
BEARING CARRIER ASSEMBLY - COMPONENT
DISASSEMBLY AND INSPECTION a
NOTE: Complete the instructions in this section only
if the assembly components have been found to be b
defective.
NOTE: Inspection of the bearing surfaces on the pro-
peller shaft where the needles of the bearing carrier
needle bearing rolls, gives an indication of the condi-
tion of the needle bearing inside the bearing carrier.
Replace needle bearing in the bearing carrier if the
prop shaft is pitted, grooved, scored, worn unevenly,
discolored from overheating, or has embedded par-
ticles.
1. Perform the following step a. or b. as necessary.
a. If Replacing the Needle Bearing and 23140
Seals: Remove the needle bearing and seals
a - Oil Seals
with the tools as shown. b - Pry Bar
(1.) Discard both of the seals.
d
BEARING CARRIER ASSEMBLY - COMPONENT
REASSEMBLY
NOTE: Complete the instructions in this section only
if the assembly components have been disas-
sembled and repaired or replaced.
1. Clean all of the components with a suitable sol-
c vent and dry the parts thoroughly using com-
pressed air. Be careful not to spin the bearing.
a 2. Lubricate the bore that the needle bearing is
pressed into with Quicksilver Gear Lubricant
(92-13783A24).
3. Assemble the needle bearing (with the numbered
end of the bearing towards the driver shoulder),
onto the driver.

b
23140

a - Needle Bearing
b - Oil Seals
c - Driver Head (91-36569)
d - Bearing Driver Rod (91-37323)
(1.) Discard the needle bearing and both
seals.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-27

4. Press the needle bearing into the bearing carrier 7. Press on the oil seal driver until the driver bottoms
until the driver bottoms out on the bearing carrier. onto the aft face of the bearing carrier.
Ensure that the numbered side of the needle
bearing faces the seal end (aft end) of the carrier.

b
c
87
a
a

50788

a - Oil Seal
50788 b - Oil Seal Driver (91-31108) (long end)
87 Quicksilver Gear Lubricant (92-19007A24) c - Bearing Carrier
8. Apply a thin film of Loctite 271 (92-809820) to the
a - Needle Bearing
b - Bearing Carrier outer diameter of the second seal.
c - Needle Bearing Driver (91-15755) 9. Assemble the second seal (with the lips seal fac-
5. Thoroughly clean the bore to which the first seal ing the driver shoulder) onto the short end of the
is to be pressed. driver.
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.

6B-28 - LOWER UNIT 90-855348R1 JANUARY 1998

10. Press the oil seal with the driver until the driver Forward Gear Bearing Adaptor
bottoms out on the bearing carrier.
Assembly
INSPECTION
1. Thoroughly clean the forward gear bearing adap-
tor with a suitable solvent and dry it using com-
7 a pressed air.
b NOTE: The condition of the bearing surfaces on the
forward gear in the areas that the bearings of the
95
bearing adaptor and the thrust bearing rides, is an in-
dication 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
c unevenly, discolored from overheating or has em-
bedded metal particles.
2. Assemble the forward gear to the bearing adap-
tor. Inspect them for excessive movement or
roughness by rotating the gear in the adaptor.
Replace the bearing in the adaptor 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.

7 Loctite 271 (92-809820)

50788
95 2-4-C With Teflon (92-825407A12)
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 w/Teflon (92-825407A12).

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-29

FORWARD GEAR BEARING ADAPTOR 2. Assemble the adaptor as follows:
ASSEMBLY - COMPONENT DISASSEMBLY AND
a. Lubricate the bore that the needle bearing is
REASSEMBLY
pressed into with 2-4-C w/Teflon
NOTE: Complete the instructions in this section only (92-825407A12).
if the needle bearing in the bearing adaptor is defec-
b. Assemble the needle bearing to the adaptor
tive and the adaptor is to be reused.
with the numbered end of the bearing facing
1. Disassemble the adaptor as follows: the driver shoulder.
a. Remove the bearing from the adaptor using c. Press the needle bearing into the bearing
the bearing removal tool. Align the pins of the adaptor using a suitable mandrel until the
tool with the holes of the adaptor and apply bearing bottoms in the adaptor.
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

6B-30 - LOWER UNIT 90-855348R1 JANUARY 1998

Drive Shaft Assembly e. If the drive shaft is broken, place propeller
shaft nut wrench onto the propeller shaft
REMOVAL splines, hold shift shaft in forward gear and
1. Remove the drive shaft pinion nut as follows: loosen, (but do not fully unscrew), the pinion
nut by rotating prop shaft counterclockwise to
a. Place the drive shaft bearing retainer wrench turn gears, thus loosening the pinion nut.
onto the drive shaft. Do not loosen the retain-
er at this time. NOTE: The propeller shaft nut wrench is included
with the pinion nut adapter kit.
b. Insert the pinion nut adapter, with the MR slot
facing the pinion gear, into the gear housing. c
It may be necessary to slightly lift and rotate
the drive shaft to align the pinion gear nut into
the pinion nut adapter slot.
a
c. Install the bearing carrier into the gear hous-
ing 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.

b
b 70607

a - Pinion Nut adapter (91-61067A3)

b - Propeller Shaft Nut Wrench (91-61077)
c - Shift Shaft (Turn Clockwise)(Protect Splines w/Soft
Material)
2. Completely unscrew the drive shaft bearing re-
tainer.
3. Completely unscrew the pinion nut by rotating the
drive shaft (or the propeller shaft) in a counter-
clockwise direction.
4. Remove the bearing carrier and all tools.

70887

a - Drive Shaft Nut Wrench (91-56775)

b - Drive Shaft Bearing Retainer Wrench (91-43506)
c - Pinion Nut adapter (91-61067A3) (MR Slot)

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-31

IMPORTANT: The pinion bearing rollers are free 7. Form a small hook on a stiff piece of wire and at-
to fall out of the pinion bearing once the drive tempt to hook onto the top side of the gear and
shaft is removed. Be careful not to lose the (18) pull it out. It may be necessary to slightly move
rollers. the propeller shaft from side-to-side to dislodge
the pinion gear.
5. Remove the drive shaft and all components by
pulling the drive shaft straight out of the gear
housing as shown.
c

a
a
b

50884

a - Propeller Shaft
70608 b - Pinion Gear
c - Wire Tool
a - Drive Shaft
b - Drive Shaft Retainer, Bearing Cup, Bearing, and Shims
6. With propeller shaft facing straight up, rotate shift
lever into forward. Pull propeller shaft up and
over towards port side of gear case.

6B-32 - LOWER UNIT 90-855348R1 JANUARY 1998

DRIVE SHAFT ASSEMBLY - INSPECTION DRIVE SHAFT ASSEMBLY - COMPONENT
DISASSEMBLY
1. Clean all parts with a suitable solvent and dry the
parts using compressed air. DO NOT spin the NOTE: Complete the instructions in this section only
bearings. if the assembly components have been found to be
defective and are in need of repair or replacement.
2. The condition of the drive shaft bearing cup is an
indication of the condition of the tapered roller 1. Press the tapered roller bearing from the drive
bearing on the drive shaft. Replace the bearing shaft using the universal puller plate to support
and bearing cup if the cup is pitted, grooved, the inner race of the bearing while removing it.
scored, worn unevenly, discolored from over-
heating, or has embedded 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, c
scored, worn unevenly, discolored form over-
heating, 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 b
gear if any defects are found.

70699

a - Universal Puller Plate (91-37241)

b - Tapered Roller Bearing
c - Drive Shaft

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-33

DRIVE SHAFT ASSEMBLY - COMPONENT Propeller Shaft Assembly
REASSEMBLY
REMOVAL
NOTE: Complete the instructions in this section only
if the assembly components have been disas-
sembled and repaired or replaced.
CAUTION
Hold onto the propeller shaft assembly in the fol-
1. Assemble a new tapered roller bearing to the
lowing step to avoid personal injury and/or drop-
drive shaft with the large O.D. of the bearing fac-
ping components when turning the gear housing
ing the pinion gear end of the drive shaft.
over.
2. Press the tapered roller bearing onto the drive
1. While holding onto the propeller shaft, turn the
shaft using the universal puller plate and a suit-
gear housing over so that the bore opening is fac-
able mandrel, (an old tapered roller bearing inner
ing down.
race).
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 pro-
peller shaft out of the gear housing.
NOTE: The rollers of the reverse gear bearing adap-
b tor may become dislodged while removing the pro-
peller shaft assembly. If this occurs, inspect the bear-
ing cage to see if it has been damaged. If it has not
a c been damaged simply snap the rollers back into posi-
tion. If it has been damaged it will be necessary to re-
move and replace the bearing as outlined in the “Re-
verse Gear Bearing Adaptor Assembly”,
‘Component Disassembly and Reassembly’section
found on page 6B-45.

c b

70700

a - Universal Puller Plate (91-37241)

a
b - Tapered Roller Bearing
c - Suitable Mandrel (Inner Race of Old Bearing)

50887

a - Propeller Shaft Assembly

b - Shift Spool
c - Shift Crank

6B-34 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Locate and retain the thrust race and thrust bear- PROPELLER SHAFT ASSEMBLY -
ing which could be on top of the reverse gear (if COMPONENT DISASSEMBLY
not, they may be stuck to the reverse gear bear-
IMPORTANT: When accomplishing the next step,
ing adaptor).
all of the parts are free to come apart. Work close-
ly over a work bench to ensure that the parts are
not dropped or damaged, and to avoid personal
a injury.
1. Remove the spring around the clutch being care-
ful 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

50887

a - Thrust Bearing and Race

d c
50885

a - Spring
b - Shift Spool Assembly
c - Reverse Gear Assembly
d - Sliding Clutch
2. Remove detent pin.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-35

3. Remove the cross pin that goes through the PROPELLER SHAFT ASSEMBLY -
clutch dog. Remove the reverse gear and slide COMPONENT INSPECTION
the clutch off of the propeller shaft.
1. Clean all the parts with a suitable solvent and dry
the parts thoroughly using compressed air, being
careful not to spin bearings.
a
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).
a

e
50885

23350

a - Jaws
3. Inspect the bearing surfaces on the propeller
shaft where the needles of the bearing carrier
d needle bearing and the needles of the forward
b c 50881 gear needle bearing roll. Replace the propeller
shaft if it is pitted, grooved, scored, worn uneven-
ly, discolored from overheating, or has em-
bedded particles.
a b
a - Cross Pin
b - Clutch
c - Reverse Gear Assembly
d - Spool
e - Detent Pin

c
50698

a - Bearing Carrier Needle Bearing Contact Area

b - Reverse Gear Needle Bearing Contact Area
c - Splines
4. Inspect the propeller shaft splines at both ends
for a broken, worn, or twisted condition. Replace
the propeller shaft if any of these conditions ex-
ists.

6B-36 - LOWER UNIT 90-855348R1 JANUARY 1998

5. Inspect the surface of the propeller shaft where Reverse Gear Assembly
the bearing carrier seal lips contact the shaft. If
the oil seals have made grooves, replace propel- COMPONENT INSPECTION
ler shaft and seals. 1. Clean the reverse gear assembly with a suitable
a solvent and dry thoroughly 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 reverse gear if any defects
50698 are found.
a - Bearing Carrier Seal Contact Area 3. Inspect the clutch jaws of the gear for damage.
The surfaces must not be chipped or rounded off.
6. Inspect the propeller shaft for a bent condition.
Replace the reverse gear if any of these condi-
a. V-Blocks and Dial Indicator tions exist.
(1.) Position the propeller shaft bearing sur- a
faces 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. b

23351

a - Reverse Gear Teeth

b - Clutch Jaws
NOTE: The needle bearing in the reverse gear
should not be removed unless damage has been
found. Inspect to ensure that all of the needles are
present and in position. The needles may have be-
a come dislodged while removing the gear from the
propeller shaft (and/or while removing the propeller
shaft assembly from the gear housing). They may be
52727 snapped back into place as long as no damage has
a - Check Movement with Dial Indicator (91-58222A1) Here occurred to the bearing cage.
7. Rotate the propeller shaft and observe the dial in- 4. Inspect the needle bearings on the inside of the
dicator movement. If the indicator in the dial reverse gear and the bearing surface on the pro-
moves more than 0.009 in. (0.23mm), replace the peller shaft. If either the needle bearings, or the
propeller shaft. bearing surface of the propeller 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

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-37

REVERSE GEAR ASSEMBLY - COMPONENT IMPORTANT: The appearance of the forward and
DISASSEMBLY reverse gear is almost identical. There are two
ways to distinguish between the reverse and for-
NOTE: Complete the instructions in this section only
ward gears. The reverse gear has a shorter hub
if the needle bearing in the gear has been found to be
and it has a groove cut into the back of the gear
defective and the reverse gear is to be reused. Bear-
just inside the thrust bearing race.
ings that have become dislodged may be snapped
back into position. If this is the only problem that ex- a
REVERSE FORWARD
ists it is not necessary to replace the needle bearing. b
1. Press the reverse gear needle bearing out using
suitable mandrel.
a

4² (10.2cm) 50885

1994/1995/1996 Models

a - Shorter Hub
b - Groove
50778 a
REVERSE FORWARD
a - Reverse Gear Needle Bearing b

REVERSE GEAR ASSEMBLY - COMPONENT

REASSEMBLY
NOTE: Complete the instructions in this section only
if the assembly components have been disas-
sembled and repaired or replaced. 3.75² (9.5cm)

1997/1998 Models 50885

a - Reverse Gear is Smaller in Diameter for 97/98 Models

b - No Groove in Reverse Gear for 97/98 Models
1. Press the needle bearing into the reverse gear.
c

50789

a - Reverse Gear
b - Needle Bearing
c - Bearing Driver (91-816244)(Ratcheting gear cases)
Bearing Driver (91-86943) (Non-Ratcheting gear cases)

6B-38 - LOWER UNIT 90-855348R1 JANUARY 1998

Shift Spool Assembly 4. Inspect to insure that the spool spins freely (it
may be helpful to lightly tap the forward [castle
INSPECTION nut] end of the shift spool shaft against a firm sur-
1. Clean the assembly with a suitable solvent and face to align the internal parts).
dry the parts using compressed air. 5. Inspect to insure that the spool has no more than
2. Inspect the shift spool assembly for damage. 0.002-0.010 (0.05-0.25 mm) end play.
Small nicks and burrs may be smoothed. If any
parts are damaged or worn beyond repair it will
be necessary to replace the complete shift spool
assembly. Individual parts are not available for .002 (0.05mm)
the assembly. to
.010 (0.25mm)
3. Inspect the shift spool for wear in the area where
the shift crank comes into contact.
a
b
a
23142
a - Ratcheting Spool

.002 (0.05mm)
to
.010 (0.25mm)
23356

a - Contact Area
b - Ratcheting Shift Spool

a
b

55694
55694 a - Non-Ratcheting Spool
a - Contact Area
b - Non-Ratcheting Shift Spool

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-39

SHIFT SPOOL ASSEMBLY (RATCHETING) - SHIFT SPOOL ASSEMBLY (RATCHETING) -
COMPONENT DISASSEMBLY COMPONENT REASSEMBLY
NOTE: Disassembly of the shift spool is for cleaning 1. Assemble the shift spool and shift spool shaft as
and inspection of the internal parts of the assembly follows:
due to an improperly functioning shift spool assembly
a. Place the shift spool onto the shift spool shaft.
or debris in the gear housing and/or shift spool as-
sembly. Individual components for the shift spool are b. Assemble the first washer, then the spring,
not available as replacement parts. If the shift spool then the second washer into the shift spool.
does not function properly (see the preceding “Shift c. Apply Loctite 271 (92-809820) to the first
Spool Assembly - Inspection”section) and the follow- three threads of the spool. Thread the retain-
ing cleaning and adjustment procedures do not pro- er onto the spool and tighten the retainer se-
duce the desired results, it will be necessary to order curely with a pair of pliers.
a new shift spool assembly.
d. Assemble the castle nut and screw it down
1. Disassemble the shift spool assembly as follows: until it touches the washer and a slight resis-
a. Remove and discard the cotter pin. tance is felt.
b. Remove the castle nut and the spool. e. Loosen the castle nut until the cotter pin slot
of the castle nut is aligned with the hole in the
c. Clamp the spool in a vice being careful not
shaft. If, when the castle nut is screwed down,
damage the spool.
the cotter pin slot is already aligned at the
d. Remove the retainer by unscrewing it with a hole in the shaft, back the castle nut off until
pair of pliers. the next available slot in the nut is aligned
with the hole in the shaft.
e. Remove the two washers and the spring.
f. Insert a new cotter pin and bend ends of the
SHIFT SPOOL ASSEMBLY (NON-RATCHETING) cotter pin in opposite directions.
- COMPONENT DISASSEMBLY
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 as-
sembly. Individual components for the shift spool are
not available as replacement parts. If the shift spool
23356
does not function properly (see the preceding “Shift
Spool Assembly - Inspection”section) and the follow- e a g
ing cleaning and adjustment procedures do not pro- 7 f
duce 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 the spool.

SHIFT SPOOL ASSEMBLY - COMPONENT

INSPECTION b
1. Clean all components with a suitable solvent and d c
Loctite 271 (92-809820) 23142
dry them with compressed air. 7

2. Inspect each component for wear or damage. If a - Washers (2)

any components are worn beyond repair, dam- b - Spring
aged, or broken it will be necessary to replace the c - Retainer
complete shift spool assembly. Small nicks or d - Spool
e - Shift Shaft
burrs may be smoothed and the parts reused. f - Castle Nut
g - Cotter Pin

6B-40 - LOWER UNIT 90-855348R1 JANUARY 1998

SHIFT SPOOL ASSEMBLY (NON-RATCHETING) SHIFT SPOOL ASSEMBLY - ADJUSTMENT
- COMPONENT REASSEMBLY
NOTE: If the shift spool assembly has been
1. Assemble the shift spool and shift spool shaft as disassembled and reassembled (as in the previous
follows: two sections) skip the following instructions, (1
through 4).
a. Place the shift spool onto the shift spool shaft.
NOTE: If the shift spool assembly has not been dis-
b. Assemble the castle nut and screw it down
assembled and reassembled, do all of the following
until it touches the washer and a slight resis-
steps.
tance is felt.
1. Remove and discard the cotter pin.
c. Loosen the castle nut until the cotter pin slot
of the castle nut is aligned with the hole in the 2. Screw the castle nut down until it touches the
shaft. If, when the castle nut is screwed down, washer and a slight resistance is felt.
the cotter pin slot is already aligned at the
3. Loosen the castle nut until the cotter pin slot of the
hole in the shaft, back the castle nut off until
castle nut is aligned with the hole in the shaft. If,
the next available slot in the nut is aligned
when the castle nut is screwed down, the cotter
with the hole in the shaft.
pin slot is not aligned at the hole in the shaft, back
d. Insert a new cotter pin and bend ends of the off the castle nut until the next available slot in the
cotter pin in opposite directions. nut is aligned with the hole in the shaft.
d 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 sur-
face to align the internal parts).
6. Inspect to insure that the spool has no more than
a b c 55694 0.002-0.010 (0.05-0.25 mm) end play, if it does
adjust the castle nut once again as outlined pre-
a - Shift Spool Shaft viously.
b - Shift Spool
c - Castle Nut
e - Cotter Pin

0.002 (0.05mm)
to
0.010 (0.25mm)

23142
a - Ratcheting Type Spool

7. If this adjustment did not produce the desired re-

sults 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.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-41

Reverse Gear Bearing Adaptor REVERSE GEAR BEARING ADAPTOR
ASSEMBLY - INSPECTION
Assembly
1. Thoroughly clean the reverse gear bearing adap-
REMOVAL tor with a suitable solvent and dry it using com-
pressed air.
1. Remove the reverse gear bearing adaptor using
the tools as shown in the next figure. Remove, NOTE: The condition of the bearing surfaces on the
measure and make note of the shim thickness. If reverse gear in the areas that the bearings of the
the shims are not damaged, they may be reused. bearing adaptor and the thrust bearing rides, is an in-
dication of the condition of the respective bearings.
Replace the bearing(s) if the surface of the gear and/
a or the thrust washer is pitted, grooved, scored, worn
d
b c 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 adaptor. In-
spect them for excessive movement or rough-
e ness by rotating the gear in the adaptor. Replace
the bearing in the adaptor and/or the thrust bear-
f ing 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.

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)

6B-42 - LOWER UNIT 90-855348R1 JANUARY 1998

REVERSE GEAR BEARING ADAPTOR Shift Shaft Assembly
ASSEMBLY - COMPONENT DISASSEMBLY AND
REASSEMBLY REMOVAL
NOTE: Complete the instructions in this section only NOTE: It is possible to remove and service the shift
if the needle bearing in the bearing adaptor is defec- shaft assembly (but not the shift crank inside the gear
tive and the adaptor is to be reused. case) without removing any of the internal compo-
nents of the gear housing.
1. Disassemble the adaptor as follows:
1. Remove the shift shaft bushing screws, and re-
a. Remove the bearing from the adaptor using move the shift shaft and bushing by pulling them
a suitable mandrel. straight out of gear housing.
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 w/Teflon
(92-825407A12).
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 a
adaptor using a suitable mandrel until the a
bearing is flush with the face of the adaptor.

70494

a - Shift Shaft Bushing Screws

2. Remove the shift crank from the inside of the gear
housing. Clean it with a suitable solvent and dry
95
b it thoroughly. Inspect it for wear in the areas that
c contact the shift spool and inspect the splines
and the diameter that goes over the locating pin
for damage or excessive wear.
a

b
a

50790
95 2-4-C With Teflon (92-825407A12) c d
a - Reverse Gear Bearing Adaptor 23350
b - Suitable Mandrel
c - Bearing a - Contact Area
b - Shift Crank
c - Splines
d - Diameter for Locating Pin

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-43

SHIFT SHAFT ASSEMBLY - COMPONENT SHIFT SHAFT ASSEMBLY - COMPONENT
DISASSEMBLY AND INSPECTION REASSEMBLY
1. Slide the bushing assembly off of the straight end NOTE: Complete the instructions in this section only
of the shift shaft. Remove the coupler from the if the assembly components have been disas-
shaft. sembled 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
Quicksilver 2-4-C w/Teflon (92-825407A12).
2. If the speedometer connector was removed and/
or replaced, lightly coat the threads of the con-
nector with Quicksilver Perfect Seal
(91-34277-1). Assemble the speedometer con-
70616 nector to the bushing and torque the connector to
4.5 lb. in. (0.5 N·m).
a - Shift Shaft Bushing
b - O-rings (2) 3. Assemble all components as shown below.
c - Coupler
c b
d - Shift Shaft
95
d
2. Clean all components with a suitable solvent and 19
dry thoroughly with compressed air.
a. Inspect the shift shaft bushing for cracking,
damage, or excessive wear. e
b. Inspect the seal inside the bushing, the f
sleeve, and the O-rings on the outside of the g
bushing for damage or excessive wear.
c. Inspect the speedometer connector for dam-
age or blockage.
If any of these conditions exist, replace the appropri-
ate components. The oil seal is a replaceable compo-
nent.
a
c

b
19 Perfect Seal (92-34227-1)
95 2-4-C With Teflon (92-825407A12)

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
70616
corrosion and/or excessive wear. Replace the
shift shaft if either if these conditions are found. a - Shift Shaft
b - Rubber Washer
b a c - Seal (Lip Faces Up)
d - Speedometer Connector
e - Bolt (2 ea.) [Torque to 60 lb. in. (6.8 N·m)]
f - Bushing
g - O-Rings (2 ea.)
a - Seal Surface h - Coupler
b - Spline

6B-44 - LOWER UNIT 90-855348R1 JANUARY 1998

Pinion Bearing Gear Housing Reassembly
REMOVAL
Gear Housing Inspection
NOTE: Inspect the bearing surface on the drive shaft
where the needles of the lower pinion bearing roll. 1. Clean the gear housing thoroughly with a suitable
The condition of the drive shaft at this location give solvent and a hard bristle brush. Dry the gear
an indication of the condition of the needle bearing. housing using compressed air. Insure that all
Replace lower pinion bearing (needles and race as sealants, locking agents and debris are removed.
a set) if the drive shaft is pitted, grooved, scored, 2. Verify the 2 oil circulation holes in the drive shaft
worn unevenly, discolored from overheating, or has bore and shift shaft hole are clear and free of
embedded particles. debris.
IMPORTANT: All the needle bearings (18) MUST 3. Inspect the gear housing for excessive corrosion,
BE in place inside bearing race while driving the impact or any other damage. Excessive damage
pinion bearing from the gear housing. and/or corrosion requires replacement of the
IMPORTANT: Do not reuse the bearing (race or gear housing.
rollers) once it has been removed. 4. Inspect the bearing carrier retainer threads in the
1. Remove and discard the pinion bearing (race and gear housing for corrosion and/or stripped
rollers) using tools as shown. threads. Excessive damage to the the threads re-
quires replacement of the gear housing.
5. Inspect bearing race/cup contact areas for evi-
dence of bearing cup spinning. Check that bear-
ing cups are not loose in bearing bores. Any one
d bearing bore in which the race/cup is loose will
require replacement of the gear housing.
c 6. Inspect for blockage in water inlet holes and the
speedometer hole, clean as necessary. Be care-
ful not to enlarge the speedometer hole as this
could cause erroneous speedometer readings.
b 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 housings are not
aligned properly due to missing locating pins or
elongated holes.
a

70614

a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-45

Pinion Bearing Reverse Gear Bearing Adaptor
INSTALLATION Assembly
IMPORTANT: Install only a NEW pinion bearing INSTALLATION
(race and rollers). Do not reinstall a pinion bear- NOTE: If the reverse gear, reverse gear adaptor,
ing that has been previously removed from a gear large thrust bearing, or bearing race in the gear hous-
housing. ing were not replaced, install the same shim(s) (or the
1. Lubricate the bore into which the pinion bearing same thickness of shim(s) that were taken out when
is to be installed with Quicksilver Gear Lubricant adaptor was removed. If the reverse gear, reverse
(92-19007A24). gear adaptor, large thrust bearing, bearing race, or
gear housing were replaced, install 0.008 in. (0.51
2. Position the new pinion bearing (with the card- mm) of shims.
board shipping sleeve in place) onto the driver
head, with the lettered and numbered side of the 1. Lubricate the bore into which the reverse gear
bearing oriented upward. bearing adaptor is to be installed with 2-4-C
w/Teflon (92-825407A12).
3. Insert the driver with the bearing assembly, into
position (by way of the propeller shaft bore) at the 2. Place the shim(s) into reverse bore of gear hous-
drive shaft bore as shown. ing.
3. Position the bearing adaptor in the gear housing.
c
e d

fa
g a

b b

87

95
70615
87 Quicksilver Gear Lubricant (92-19007A24) 50781
95 2-4-C With Teflon (92-825407A12)
a - Drive Shaft Pinion Bearing (w/cardboard sleeve)
b - Driver Head (91-38628)
a - Bearing Adaptor
c - Puller Shaft (91-31229)
b - Shims
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 shoul-
der.

6B-46 - LOWER UNIT 90-855348R1 JANUARY 1998

IMPORTANT: The appearance of the forward and 5. Press the bearing adaptor into the gear housing
reverse gear is almost identical. There are two using the installation tool as follows:
ways to distinguish between the reverse and for-
IMPORTANT: Be sure that the bearing adaptor is
ward gears. The reverse gear has a shorter hub
positioned as straight as possible to avoid cock-
and it has a groove cut into the back of the gear
ing it in the bore while pressing it in.
just inside the thrust bearing race.
a a. Lubricate the threads of the installation tool
REVERSE FORWARD with 2-4-C w/Teflon (92-825407A12).
b
b. Turn the hex-head screw of the installation
tool until the bearing adaptor bottoms out on
the gear housing shoulder. DO NOT continue
to turn the tool once the screw resistance
goes up noticeably.

4² (10.2cm) 50885

1994/1995/1996 Models
95
a - Shorter Hub a
b - Groove
a
REVERSE FORWARD
b
b

3.75² (9.5cm)

1997/1998 Models 50885

a - Reverse Gear is Smaller in Diameter for 97/98 Models c

b - No Groove in Reverse Gear for 97/98 Models
4. Position the reverse gear (without the thrust race
or thrust bearing) into the gear housing and into
the adaptor. 50791
95 2-4-C With Teflon (92-825407A12)

a - Hex-Head Screw
b - Bearing Adaptor Installation Tool (91-18605A1)
c - Reverse Gear
c. Remove the installation tool and the reverse
gear.
a

50781

a - Reverse Gear

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-47

Shift Shaft Assembly NOTE: If the pinion bearing needle bearings have
fallen out, install 18 needles into needle bearing outer
INSTALLATION race. Use 2-4-C w/Teflon, to help hold needles in
1. Place the shift crank onto the locating pin in the place.
forward section of the gear housing. Ensure that
the shift crank faces towards the left (port) side of
the gear housing.

95

a
b
b
50314
a - Shift Crank
b - Locating Pin 23142

2. Install the shift shaft assembly into the gear hous-

95 2-4-C With Teflon (92-825407A12)
ing. Engage the splined end of the shift shaft with
a - Rollers (18)
the shift crank. Verify O-rings are positioned b - Roller Bearing Outer Race
properly and lubricated with 2-4-C w/Teflon. Se-
cure shift shaft bushing with 2 screws. Torque
screws to 60 lb. in. (6.8 N·m).

95
a

70620
95 2-4-C With Teflon (92-825407A12)

a - Shift Shaft Assembly

b - Screws [Torque to 60 lb. in. (6.8 N·m)]

6B-48 - LOWER UNIT 90-855348R1 JANUARY 1998

Gear Location/Backlashes IMPORTANT: The appearance of the forward and
reverse gear is almost identical. There are two
Checking and Adjustment ways to distinguish between the reverse and for-
ward gears. The reverse gear has a shorter hub
Reverse Gear and it has a groove cut into the back of the gear
just inside the thrust bearing race.
INSTALLATION (FOR CHECKING BACKLASH a
ONLY) REVERSE FORWARD
b
1. Lubricate the large reverse gear thrust bearing
with Quicksilver Gear Lubricant (92-13783A24)
and position first the thrust race, then the bearing
into the gear housing and onto the reverse gear
bearing adaptor.

4² (10.2cm) 50885

1994/1995/1996 Models

a - Shorter Hub
b - Groove
87 a
REVERSE FORWARD
a b

b
3.75² (9.5cm)

1997/1998 Models 50885

a - Reverse Gear is Smaller in Diameter for 97/98 Models

b - No Groove in Reverse Gear for 97/98 Models
c
2. Install the reverse gear into the gear housing and
50882
into the reverse gear bearing adaptor.

87 Quicksilver Gear Lubricant (92-19007A24)

a - Thrust Bearing
b - Thrust Race
c - Reverse Gear Bearing Adaptor

a
cb

d
50884

a - Reverse Gear
b - Thrust Bearing
c - Thrust Race (under Bearing)
d - Reverse Gear Bearing Adaptor

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-49

Drive Shaft and Pinion Gear 4. Insert the drive shaft into the gear housing drive
shaft bore. It may be necessary to rotate the drive
INSTALLATION (FOR CHECKING GEAR shaft to engage the drive shaft splines into the
LOCATION AND BACKLASHES ONLY) pinion gear splines.
NOTE: If the original shims were not retained or if pin- 5. Temporarily install the propeller shaft (without the
ion gear, drive shaft, drive shaft tapered roller bearing sliding clutch installed) into reverse gear.
and cup, or gear housing were replaced, start off by
installing a 0.038 in. (0.96 mm) shim(s). 6. Insert the pinion nut adaptor (with the nut) into the
gear housing. It may be necessary to raise the
NOTE: If the original shims were retained (or mea- drive shaft slightly to clear the tool.
surement known) and none of the above listed parts
were replaced, reinstall the original shims (or an 7. Start the pinion nut onto the drive shaft threads by
amount of shims equal to the original shims). rotating the drive shaft until the nut is snug.

1. Place the shim(s) into the drive shaft housing

bore at the location shown. c

b 70891
a - Pinion Gear (with the washer glued to it)
b - Pinion Nut Adaptor (91-61067A3)
c - Drive Shaft
a

70620

a - Shim(s)
NOTE: For ease of installation, glue the washer to
the pinion gear, using 3M Adhesive (92-25234), or
Quicksilver Bellows Adhesive (92-86166), or equiva-
lent.
2. Apply Loctite 271 (92-809820) 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.

6B-50 - LOWER UNIT 90-855348R1 JANUARY 1998

8. Install the drive shaft tapered roller bearing cup 12. Torque retainer to 100 lb. ft. (135.6 N·m).
followed by the retainer.

70711
a - Drive Shaft Bearing Retainer Wrench (91-43506)
70890
13. Remove retainer wrench.
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 pin-
ion nut adaptor in position.
10. Torque the pinion nut by turning the drive shaft
using the drive shaft nut wrench and torque
wrench with the appropriate socket to 75 lb. ft.
(101.7 N·m).

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.
90-855348R1 JANUARY 1998 LOWER UNIT - 6B-51
Drive Shaft - Bearing Preload Tool 3. Measure distance (a) and increase that distance
by 1 in. (25.4mm) by turning bottom nut away
INSTALLATION from top nut.
NOTE: Ensure that the top nut and the bottom nut of
the bearing preload tool are screwed as close togeth-
er as possible prior to proceeding with the following
step.
a
1. Install the components from the Bearing Preload b
Tool Kit (91-14311A1), over the drive shaft in the
order shown.

a
b

c 70893

a - Measure distance and increase by 1 in. (25.4mm)

d b - Bottom Nut [screwed down by approximately 1 in.
(25.4mm)]
e
4. Rotate the drive shaft at least three full turns in a
d clockwise direction.
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

6B-52 - LOWER UNIT 90-855348R1 JANUARY 1998

Pinion Gear Location B. If the (average) pinion gear location meets
specification, skip the following section and go on
CHECKING to the “Reverse Gear Backlash”, ‘Checking’sec-
Pinion Gear Location Specification: .025 in. (0.64 tion.
mm)
1. Place the pinion gear shimming tool into the gear
housing.
NOTE: Take the following measurements at 3 loca-
tions, rotating the drive shaft 120 degrees between
each reading (always rotate the drive shaft in a clock-
wise direction).
2. Insert the thickest feeler gauge that fits snugly
between one tooth of the pinion gear and high
point of the shimming tool.

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) con-
tinue with the instructions on the following sec-
tion.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-53

Drive Shaft - Bearing Preload Tool 2. Install the drive shaft tapered roller bearing cup,
then the retainer.
REMOVAL

CAUTION b
Before loosening the top nut allen screws of the
bearing preload tool, screw the bottom nut up as
close as possible to the top nut.
1. 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. a
3. Remove all components including the water
pump face plate.

a
70890
b
a - Tapered Roller Bearing Cup
b - Drive Shaft Retainer
c
3. Torque the retainer to 100 lb. ft. (135.6 N·m).

70716

a - Top Nut (with allen screws)

b - Bottom Nut
c - Water Pump Face Plate

Pinion Gear Location

ADJUSTING
70711
NOTE: Adding 0.001 in. (0.03mm) shims will in-
crease the gear location by 0.001 in. (0.03mm). Sub- a - Drive Shaft Bearing Retainer Wrench (91-43506)
tracting 0.001 in. (0.03mm) will decrease the gear lo- 4. Reinstall the drive shaft bearing preload tool as
cation by 0.001 in. (0.03mm). outlined in the “Drive Shaft - Bearing Preload
1. Remove the drive shaft retainer and the drive Tool”, ‘Installation”section.
shaft tapered roller bearing cup. (The cup can be 5. Recheck the pinion gear height as outlined in the
removed by wiggling the drive shaft back and “Pinion Gear Location”, ‘Checking’section.
forth or by turning gear housing over and shaking
it.) Add or subtract shims beneath the cup to ob-
tain the proper average pinion gear height.

6B-54 - LOWER UNIT 90-855348R1 JANUARY 1998

Reverse Gear Backlash 2. Install a dial indicator as shown in the following
figure.
CHECKING
f
Reverse Gear Backlash Specification: e
0.040-0.060 in. (1.01mm-1.5 mm).
d
NOTE: If the bearing preload tool has not already
been set up see “Drive Shaft - Bearing Preload Tool”,
‘Installation’section first.
a
NOTE: The reverse gear bearing adaptor installation
tool is used to apply a light preload to the reverse
gear in the following steps.
b
1. Install the reverse gear bearing adaptor installa- c
tion 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 a
tighten it by hand until a slight resistance is
felt.
70717
b. Torque the adaptor’s driver bolt to 45 lb. in. a - Nuts (4) (obtain locally)
(5.1 N·m). b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]
c - Dial Indicator Holding Tool (91-89897)
d - Dial Indicator (91-58222A1)
a e - Indicator Pointer
f - Backlash Indicator Rod (91-53459) (for 1.64:1 or 1.75:1)
b g - Backlash Indicator Rod (91-78473) (for 1.87:1)
3. Align the dial indicator pointer so that it is perpen-
dicular to and touching the “I”mark on the dial in-
dicator tool. Tighten the indicator tool onto the
c drive shaft and rotate the drive shaft so that the
needle in the dial makes at least one full revolu-
tion and comes to the “0”mark on the dial indica-
tor scale.
4. Take the backlash readings by lightly turning the
drive shaft back and forth, so as to feel the back-
lash between the gears.
d a. Observe the dial indicator and record the
reading.
70973 b. Loosen the indicator tool and rotate the drive
a - Torque Wrench (91-66274) shaft 90 degrees in a clockwise direction.
b - Driver Bolt
c - Bearing Adaptor Installation Tool (91-18605A1) c. Repeat step 3 an 4 above until a total of 4
d - Reverse Gear 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 ratios).

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-55

NOTE: If backlash needs to be adjusted, (see Check- Forward Gear/Bearing Carrier
ing Reverse Gear Backlash), adding 0.001 in. (0.03
Assembly
mm) shims will reduce the gear backlash by approxi-
mately 0.001 in. (0.03mm). Subtracting 0.001 in. CHECKING FORWARD GEAR BACKLASH --
(0.03mm) shims will increase backlash by approxi- (RATCHETING)
mately the same amount.
NOTE: If backlashes have already been checked
Example 1 (if backlash is too high) and they are to specification, proceed with “Bearing
Carrier Assembly”, ‘Final Installation’section.
Backlash checks: .070 in. (1.79 mm)
1. Install the appropriate spacer shim into the gear
(subtract) middle housing.
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 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 Quicksilver
Gear Lubricant (92-13783A24) and place it onto
the forward gear.
a
87

b 50785
87 Quicksilver Gear Lubricant (92-19007A24)

a - Thrust Bearing
b - Forward Gear

6B-56 - LOWER UNIT 90-855348R1 JANUARY 1998

4. Place the thrust race on top of the thrust bearing 7. Assemble the forward gear installation tool to the
with the wide flat side against the thrust bear- forward gear, then place it down over the propel-
ing. ler shaft. Ensure that the thrust race seats evenly
onto the shim. Tap the thrust race down lightly
a with a soft tool, do not damage the thrust race sur-
face.

50785

a - Thrust Race
b - Wide Flat Side
5. Install a load washer (12-37429) over a 44-93003
propeller shaft so that it seats against the REAR
shoulder of the clutch spline teeth.

b
55624
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear
c - Spacer Shim
d - Load Washer (12-37429)
c e - Thrust Race
a 55088
a - Load Washer (12-37429) 8. Install the forward gear bearing adaptor using a
b - Shoulder hook tool (which was fashioned when the adaptor
c - Propeller Shaft (44-93003) was removed) as shown. Ensure that the adaptor
6. Install propeller shaft with load washer into gear seats evenly against the thrust race.
housing.

55623 55430
a - Propeller Shaft (44-93003) a - Hook Tool
b - Load Washer (12-37249) b - Forward Gear Installation Tool (91-815850)
c - Forward Gear Bearing Adaptor
d - Thrust Race

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-57

9. Remove the hook tool and while holding down on 11. Align the bearing carrier “V”shaped notch with
the forward gear remove the forward gear instal- the alignment hole in the gear housing. Install the
lation tool. tab washer with the external tab inserted into the
hole in the gear housing.

c
55430
50779
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear Bearing Adaptor
c - Forward Gear a - Gear Housing Tab Washer Alignment Hole (not seen)
b - “V”Shaped Notch in Bearing Carrier
10. Install the bearing carrier over the propeller shaft c - Alignment Tab of Tab Washer
pushing bearing carrier down until it is fully
seated. 12. Insure that the “V”shaped tab aligns with the “V”
notch in bearing carrier.

70714
55429 a - Tab Washer
b - “V”Tab
a - Propeller Shaft
b - Bearing Carrier

6B-58 - LOWER UNIT 90-855348R1 JANUARY 1998

13. Lubricate the bearing carrier retainer threads 15. Install a 5² x 2² (127mm x 50.8mm) long piece of
with 2-4-C w/Teflon (92-825407A12). Start the PVC pipe (obtain locally) over propeller shaft and
retainer into the gear housing threads and screw secure it against the bearing carrier with a flat
it down fully by hand. washer and nut.

a a d f h

g
95
c e j k
b i 51882
a - Prop Nut
b - Flat Washer
c - PVC Pipe [5² x 2² (127mm x 50.8mm)]
d - Retainer
e - Tab Washer
f - Bearing Carrier
g - Prop Shaft
h - Bearing Adaptor
50881 i - Shim
95 2-4-C With Teflon (92-825407A12) j - Forward Gear
k - Load Washer
a - Bearing Carrier Retainer
16. Tighten nut to 45 lb. in. (5.1 N·m). This will seat
14. Torque the bearing carrier retainer to 210 lb. ft. the forward gear against the forward thrust bear-
(284.7 N·m) to seat forward gear assembly in ing and tends to hold the propeller shaft from
gear case. moving when measuring backlash.

CHECKING FORWARD GEAR BACKLASH --

NON-RATCHETING
1. Install the appropriate spacer shim into the gear
housing.

23355
a - Bearing Carrier Retainer Wrench (91-61069)
NOTE: Drill a 3/8² (22.2mm) diameter hole through
the side (PROPELLER NUT END) of a 5² x 2²
(127mm x 50.8mm) long piece of PVC pipe. A screw-
driver may be inserted thru pipe into propeller shaft 55428
splines to prevent PVC pipe from turning while tight-
a - Shim
ening retaining nut.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-59

2. Apply Quicksilver Gear Lubricant to thrust bear- 3. Insert Forward Gear Installation Tool
ing and install thrust bearing and thrust race onto (91-815850) into forward gear/bearing adaptor
forward gear bearing adaptor. assembly.

87
c

b
a

55220

87 Quicksilver Gear Lubricant (92-19007A24)

a - Bearing Adaptor 55221
b - Thrust Washer a - Forward Gear Installation Tool (91-815850)
c - Thrust Bearing 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.

55431
a - Forward Gear Bearing Adaptor

6B-60 - LOWER UNIT 90-855348R1 JANUARY 1998

5. Install the bearing carrier over the propeller shaft 7. Insure that the “V”shaped tab aligns with the “V”
pushing bearing carrier down until it is fully notch in bearing carrier.
seated.

70714

a - Tab Washer
55429 b - “V”Tab
a - Propeller Shaft 8. Lubricate the bearing carrier retainer threads
b - Bearing Carrier with 2-4-C w/Teflon (92-825407A12). Start the
6. Align the bearing carrier “V”shaped notch with retainer into the gear housing threads and screw
the alignment hole in the gear housing. Install the it down fully by hand.
tab washer with the external tab inserted into the
hole in the gear housing. a

95

c
50881
50779 95 2-4-C With Teflon (92-825407A12)

a - Gear Housing Tab Washer Alignment Hole (not seen) a - Bearing Carrier Retainer
b - “V”Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-61

9. Torque the bearing carrier retainer to 210 lb. ft. Forward Gear Backlash
(284.7 N·m) to seat forward gear assembly in
gear case. CHECKING
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

a a

23355 b
c
a - Bearing Carrier Retainer Wrench (91-61069)
NOTE: Drill a 3/8² (22.2mm) diameter hole through
the side (PROPELLER NUT END) of a 5² x 2²
(127mm x 50.8mm) long piece of PVC pipe. A screw-
driver may be inserted thru pipe into propeller shaft a
splines to prevent PVC pipe from turning while tight-
ening retaining nut. 70717
10. Install a 5² x 2² (127mm x 50.8mm) long piece of a - Nuts (4) (obtain locally)
PVC pipe (obtain locally) over propeller shaft and b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]
secure it against the bearing carrier with a flat c - Dial Indicator Holding Tool (91-89897)
washer and nut. d - Dial Indicator (91-58222A1)
e - Indicator Pointer
a f - Backlash Indicator Rod (91-53459) (for 1.64:1 and 1.75:1
d f h ratios) Backlash Indicator Rod (91-78473 (for 1.87:1 ratio)
2. Align the dial indicator pointer so that it is perpen-
dicular to and touching the “I”mark on the dial in-
dicator 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 revolu-
tion and comes to “0”on the dial indicator scale.
g 3. Take the backlash readings by lightly turning the
c e j k drive shaft back and forth.
b i 51882
a - Prop Nut a. Observe the dial indicator and record the
b - Flat Washer reading.
c - PVC Pipe [5² x 2² (127mm x 50.8mm)]
d - Retainer b. Loosen the indicator tool and rotate the drive
e - Tab Washer shaft 90 degrees in a clockwise direction.
f - Bearing Carrier
g - Prop Shaft c. Repeat step 4 above and take and record
h - Bearing Adaptor another reading. Repeat step 4 until a total of
i - Shim 4 backlash readings have been taken.
j - Forward Gear
k - Load Washer 4. Add the four readings together and divide the
11. Tighten nut to 45 lb. in. (5.1 N·m). This will seat sum by 4. This is your average backlash, which
the forward gear against the forward thrust bear- should be 0.017 in. - 0.028 in. (0.431mm -
ing and tends to hold the propeller shaft from 0.711mm) (for 1.64:1; 1.75:1 and 1.87:1 ratios).
moving when measuring backlash.

6B-62 - LOWER UNIT 90-855348R1 JANUARY 1998

5. If backlash is MORE than the specified MAXI- a. Remove the bearing carrier retainer, tab
MUM, REMOVE shim(s) from in front of forward washer, and the bearing carrier.
gear bearing race to obtain correct backlash.
b. Using the hook tool remove the forward gear
When reinstalling pinion nut, apply Loctite 271 to
bearing adaptor.
threads of nut.
c. Insert the forward gear installation tool into
6. If backlash is LESS than the specified MINIMUM,
the forward gear and remove the forward
add shim(s) in front of forward gear bearing race
gear, thrust bearing and thrust race.
to obtain correct backlash. When reinstalling pin-
ion nut, apply Loctite 271 to threads of nut. d. Remove the propeller shaft.
NOTE: By adding or subtracting 0.001 in. (0.03mm) e. Remove the spacer shim.
shim, the backlash will change approximately 0.001 f. “Drive Shaft - Bearing Preload Tool”, ‘Remov-
in. (0.03mm). al’section.
7. Remove the propeller nut, washer, and the pinion g. “Drive Shaft Assembly”, ‘Removal’section.
nut adaptor.
h. Remove the reverse gear.
a. If the Backlash is to Specification, skip the
next step (8b), and go on to step 9 following. 9. Reinstall the following items as outlined in the fol-
lowing sections:
b. If the Backlash is not to Specification,
complete the following instructions to install a a. “Drive Shaft and Pinion Gear”, ‘Installation
different size spacer shim under the forward (For Checking Gear Location and Back-
gear thrust race. lashes Only)’section.
(1.) Remove the bearing carrier retainer, tab b. “Drive Shaft - Bearing Preload Tool”, ‘Installa-
washer, and the bearing carrier. tion’section.
(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 Assem-
bly”, ‘Installation - (For Checking Forward
Gear Backlash)’section found on page
6B-58.
(6.) Recheck backlash as outlined in the “For-
ward Gear Backlash”, ‘Checking’section.
8. Remove the following items as outlined following:

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-63

Propeller Shaft Assembly 3. Assemble the shift spool assembly to the propel-
ler shaft being sure to align the cross pin hole of
Component Reassembly the shift spool shaft with the clutch slot.

IMPORTANT: The appearance of the forward and

reverse gear is almost identical. There are two c
ways to distinguish between the reverse and for-
ward gears. The reverse gear has a shorter hub
and it has a groove cut into the back of the gear d
just inside the thrust bearing race.
a
REVERSE FORWARD
b

a b
50881

50885 a - Propeller Shaft

4² (10.2cm)
b - Sliding Clutch
c - Reverse Gear
1994/1995/1996 Models d - Shift Spool Assembly
a - Shorter Hub 4. Assemble the cross pin through the sliding
b - Groove clutch, through the propeller shaft and through
a the shift spool shaft hole.
REVERSE FORWARD
b 5. Install detent pin in third hole in clutch.

d
c
e
3.75² (9.5cm)

1997/1998 Models 50885

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 a f
sure that the sliding clutch is placed on the pro- b 50885
peller shaft with the grooved end of the clutch fac-
a - Propeller Shaft
ing the propeller end of the shaft. b - Sliding Clutch
2. Assemble the reverse gear onto the propeller c - Cross Pin
d - Reverse Gear
shaft. e - Shift Spool Assembly
f - Detent Pin

6B-64 - LOWER UNIT 90-855348R1 JANUARY 1998

6. Assemble the cross pin retaining spring over the
propeller shaft and wind it around the clutch over
Propeller Shaft Assembly
the cross pin hole. Be careful not to distort the Installation
spring while assembling it. Make sure that the
spring is wound on so that it does not cross 1. Lubricate the large thrust bearing with Quicksil-
over on itself and that it lies flat against the ver Gear Lubricant (92-13783A24) and position
clutch once it is assembled. If it does not lie first the thrust race then the bearing into the gear
flat against the clutch a new spring must be housing onto the reverse gear bearing adaptor.
installed.

c 87
a

c
50882
87 Quicksilver Gear Lubricant (92-19007A24)

b a a - Thrust Bearing
50885
b - Thrust Race
a - Sliding Clutch c - Reverse Gear Bearing Adaptor
b - Propeller Shaft 2. Rotate the shift crank toward the aft end of the
c - Cross Pin Retaining Spring
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 pro-
peller shaft assembly into the gear housing as
the needle bearings in the reverse gear bearing
adaptor can become dislodged . If it is suspected
that a needle has become dislodged, remove the
propeller shaft assembly and inspect the needle
bearing cages for damage. If the cages have not
been damaged and a needle bearing is misposi-
tioned, it can be snapped back into place.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-65

3. To allow for the engagement of the shift spool with 4. With the propeller shaft assembly tilted to the port
the shift crank, tilt the propeller end of the propel- side of the gear housing, continue to lower the as-
ler shaft assembly to the left (port) side of gear sembly until the reverse gear hub comes into
housing and begin to lower it into the gear hous- contact with the reverse gear bearing adaptor
ing. and the propeller shaft is fully inserted into the re-
verse gear.

c
b
50888
50888
a - Shift Actuating Spool
b - Shift Crank a - Propeller Shaft
c - Propeller Shaft Assembly b - Reverse Gear Hub
c - Bearing Adaptor
5. Slowly move the propeller shaft to the center of
the housing and lower the reverse gear into the
bearing adaptor. The shift spool should engage
with the shift crank as the propeller shaft centers
itself.

c
50885

a - Reverse Gear
b - Bearing Adaptor
c - Shift Spool
d - Shift Crank

6B-66 - LOWER UNIT 90-855348R1 JANUARY 1998

6. Operate the shift shaft to ensure that it has been
properly installed. The sliding clutch should move
Drive Shaft and Pinion Gear
forward when the shift shaft is turned clockwise, Final Installation (Ratcheting and
and should move aft when the shift shaft is turned
counterclockwise. Non-Ratcheting)
7. Make sure that the O-rings are present and posi- 1. Place the shim(s) into the drive shaft housing
tioned correctly. Install the screws that secure the bore at the location shown.
shift shaft bushing and torque them to 60 lb. in.
(6.8 N·m).

a a

70494

a - Screws (2)
b - Shift Shaft Bushing a
8. Slide the rubber sleeve at top end of shift shaft
down so that it just touches the oil seal in the
bushing.

a
70620

a - Shim(s)
b
NOTE: For ease of installation, glue the washer to
c the pinion gear, using 3M Adhesive (92-25234), or
Quicksilver Bellows Adhesive (92-86166), or equiva-
lent.
2. Apply Loctite Type 271 (92-809820) to the
threads of the NEW pinion gear NUT and as-
d
semble the pinion gear nut into the MR slot of the
pinion nut adaptor.
70492
NOTE: Install the pinion gear nut with the flat side of
the nut away from the pinion gear.
a - Shift Shaft
b - Rubber Sleeve 3. Place the pinion gear (with the washer glued to it)
c - Oil Seal into the gear housing.
d - Shift Shaft Bushing
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.

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-67

5. Insert the pinion nut adaptor (with the nut as- 9. Torque the pinion nut by turning the drive shaft
sembled to it) into the gear housing. It may be using the drive shaft nut wrench and torque
necessary to raise the drive shaft slightly to clear wrench with the appropriate socket to 75 lb. ft.
the tool. (101.7 N·m).
6. Start the pinion nut onto the drive shaft threads by
rotating the drive shaft until the nut is snug.

c
b

a c

b 7 a
70891
7 Loctite 271 (92-809820) 70892

a - Pinion Gear (with the washer glued to it)

b - Pinion Nut Adaptor (91-61067A3) a - Pinion Nut Adaptor (91-61067A2)
c - Drive Shaft b - Drive Shaft Nut Wrench (91-56775)
7. Install the drive shaft tapered roller bearing cup c - Bearing Carrier (installed backwards)
then the retainer. 10. Remove the bearing carrier, pinion nut adaptor
and drive shaft nut wrench.
b 11. Torque the retainer to 100 lb. ft. (135.6 N·m).

a
a

70890

a - Tapered Roller Bearing Cup 70711

b - Drive Shaft Retainer a - Drive Shaft Bearing Retainer Wrench (91-43506)
8. Install the bearing carrier into the gear housing 12. Remove the retainer wrench.
backwards to hold the propeller shaft and the pin-
ion nut adaptor in position.

6B-68 - LOWER UNIT 90-855348R1 JANUARY 1998

Bearing Carrier Assembly 3. Place the thrust hub on top of the thrust bearing
with the wide flat side against the thrust bear-
Final Installation (Ratcheting) ing.

1. Install the appropriate spacer shim into the gear

housing.

a 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.
50782

a - Shim
2. Lubricate the thrust bearing with Quicksilver
Gear Lubricant (92-13783A24) and place it onto
the forward gear.
a
87

a
b 50785 50783

87 Quicksilver Gear Lubricant (92-19007A24) a - Forward Gear Installation Tool (91-815850)

b - Forward Gear
a - Thrust Bearing c - Spacer Shim
b - Forward Gear

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-69

5. Install the forward gear bearing adaptor using a Final Installation (Non-Ratcheting)
hook tool (which was fashioned when the adaptor
was removed) as shown. Ensure that the adaptor 1. Install appropriate spacer shim into the gear
seats evenly against the thrust race. housing.

c
a

50782
50881 a - Shim

a - Hook Tool 2. Apply Quicksilver Gear Lubricant to thrust bear-

b - Forward Gear Installation Tool (91-815850) ing and install thrust bearing and thrust race onto
c - Forward Gear Bearing Adaptor forward gear bearing adaptor.
d - Thrust Race
6. Remove the hook tool and while holding down on
the forward gear, remove the forward gear instal-
lation tool.
87 c

a
b
b

c
55220

87 Quicksilver Gear Lubricant (92-19007A24)

a - Bearing Adaptor
b - Thrust Washer
c - Thrust Bearing

50881

a - Forward Gear Installation Tool (91-815850)

b - Forward Gear Bearing Adaptor
c - Forward Gear

6B-70 - LOWER UNIT 90-855348R1 JANUARY 1998

3. Insert Forward Gear Installation Tool Final Installation (Ratcheting and
(91-815850) into forward gear/bearing adaptor
Non-Ratcheting)
assembly.
1. Ensure that the top of the bearing adaptor is clean
and install the small thrust race on top of the bear-
ing adaptor.

b b

55221
a - Forward Gear Installation Tool (91-815850)
b - Forward Gear/Bearing Adaptor Assembly
4. Install tool with adaptor assembly over propeller 50880
shaft and into gear housing. Applying downward
pressure to bearing adaptor, remove installation a - Thrust Race
tool from assembly. b - Forward Gear Bearing Adaptor
c - Forward Gear
2. Lubricate the small thrust bearing with Quicksil-
ver Gear Lubricant (92-13783A24) and install it
on top of the thrust race.

87
a

55202 50783
a - Forward Gear Bearing Adaptor 87 Quicksilver Gear Lubricant (92-19007A24)

a - Small Thrust Bearing

b - Forward Gear Bearing Adaptor

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-71

3. Assemble the thrust collar with its STEPPED
SIDE DOWN toward the small thrust bearing.

a
b

50778

a - Thrust Collar
b - Keepers

50784 5. Install the second thrust collar with its STEPPED

SIDE UP.
a - Thrust Collar
b - Small Thrust Bearing
a
4. Pull up slightly on the propeller shaft to gain ac-
cess to the groove on the shaft for the keepers.
Assemble the two keepers into the groove and
lower the propeller shaft.

a
b

b 50787

a - Propeller Shaft
b - Thrust Collar

50826

a - Propeller Shaft (slightly lifted)

b - Keepers (2)
c - Thrust Collar

6B-72 - LOWER UNIT 90-855348R1 JANUARY 1998

6. Lubricate the second thrust bearing with Quick- 8. Lubricate the large O-ring with 2-4-C w/Teflon
silver Gear Lubricant (92-13783A24) and install (92-825407A12) and assemble into the gear
it to the top of the thrust collar. housing as shown following.

87

95
a

50886
95 2-4-C With Teflon (92-825407A12)

a - O-ring
50786
87 Quicksilver Gear Lubricant (92-19007A24) 9. Prepare the bearing carrier for installation as fol-
lows:
a - Thrust Bearing
b - Thrust Collar
a. Lubricate the outer diameter of the bearing
carrier with 2-4-C w/Teflon (92-825407A12).
7. Lubricate the second small thrust bearing race
with Quicksilver Gear Lubricant (92-13783A24). b. Fill the space between the carrier oil seals
Assemble it to the surface inside of the bearing with 2-4-C w/Teflon.
carrier as shown. c. Lubricate the needle bearing with Quicksilver
Gear Lubricant (92-13783A24).

87

50779
87 Quicksilver Gear Lubricant (92-19007A24)

a - Thrust Race
b - Bearing Carrier

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-73

10. Install the bearing carrier assembly into the gear 12. Insure that the “V”shaped tab aligns with the “V”
housing. notch in bearing carrier.

95
87 95
b

70714

a - Tab Washer
b - “V”Tab
50826 13. Fill the bearing carrier retainer nut threads and
87 Quicksilver Gear Lubricant (92-19007A24) corresponding gear housing threads (360°) with
95 2-4-C With Teflon (92-825407A12) 2-4-C w/Teflon (92-825407A12). Start the retain-
er into the gear housing threads and screw it
a - Bearing Carrier Assembly down fully by hand.
11. Align the bearing carrier “V”shaped notch with
the alignment hole in the gear housing and then 95
install the tab washer with the external tab in-
serted into the hole in the gear housing.

a a

70715
b 95 2-4-C With Teflon (92-825407A12)

a - Bearing Carrier Retainer

IMPORTANT: Before torquing bearing carrier re-
tainer, gear case must be bolted to drive shaft
70713 housing or securely fastened in a gear case hold-
ing fixture to avoid possible damage to gear
a - Gear Case Alignment Hole housing
b - “V”Shaped Notch in Bearing Carrier
c - Alignment Tab of Tab Washer

6B-74 - LOWER UNIT 90-855348R1 JANUARY 1998

14. Torque the bearing carrier retainer to 210 lb. ft.
(284.7 N·m). If one tab does not align up in space
Oil Seal Carrier Assembly
between two of the notches, continue to tighten Installation
retainer until alignment is achieved. DO NOT
loosen retainer to achieve alignment. NOTE: Apply hand pressure only to install the oil seal
carrier into position. Do not hammer it into position.
1. Lubricate the oil seal carrier oil seal lips, between
oil seals and O-ring with 2-4-C w/Teflon
(92-825407A12) and install the oil seal carrier
over the drive shaft and into the gear case.
a

b
95

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 re- c 95
maining tabs forward (inward). 95 2-4-C With Teflon (92-825407A12) 70501

d a - Oil Seal Carrier

b - Oil Seal Lips
c - O-ring
a

Water Pump Assembly

Installation
c b 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 part(s) is (are) upside down and
turn the appropriate part(s) over.
70490 1. Reinstall filler block in housing, if removed.
a - Bearing Carrier
b - Tab
c - Retainer Notches
d - Alignment Tabs (Bend Inward)

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-75

2. Install the small hole gasket then the face plate 5. Install the 2 water pump locating pins through the
followed by the large hole gasket onto the gear gaskets and face plate.
case.
6. Apply a light coat of 2-4-C w/Teflon
d (92-825407A12) to the inside of the pump cover.
Position the water pump body over the drive shaft
c and water pump locating pins. Rotate the drive
b shaft in a clockwise direction, while pushing
a down on the water pump body to ease the water
pump over the impeller blades.

c
a b
95

70720

a - Filler Block
b - Small Hole Gasket
c - Face Plate
d - Large Hole Gasket
3. Place a small amount of 2-4-C w/Teflon 52751
(92-825407A12) on the flat surface of the impel- 95 2-4-C With Teflon (92-825407A12)
ler key and install the key onto the drive shaft key-
a - Water Pump Body
way. b - Water Pump Alignment Pins (91-821571A1)
IMPORTANT: When using an impeller whose c - Drive Shaft (turn clockwise while installing water pump
body)
blades have taken a set, face the curl of the
blades in a counterclockwise direction. DO NOT 7. Hand start two (2) fasteners into the water pump
install the impeller with its blades oriented in a assembly and remove the water pump locating
reversed direction from original rotation, or pins. Install the remaining 2 fasteners. Run all
premature impeller failure will occur. fasteners down and torque to 60 lb. in. (6.8 N·m).
4. Assemble the water pump impeller onto the drive 8. Lightly lubricate the O-rings in the water tube
shaft and down over the key. coupling with 2-4-C w/Teflon (92-825407A12).
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 hous-
a ing is not at the proper height, air will be drawn
into the pump resulting in overheating of the en-
95 gine.

b
52725
95 2-4-C With Teflon (92-825407A12)

a - Water Pump Impeller

b - Water Pump Impeller Key

6B-76 - LOWER UNIT 90-855348R1 JANUARY 1998

10. Using tool provided in seal kit (26-816575A2) or 3. Slowly fill housing thru “Fill”hole with Quicksilver
water pump kit (817275A3), press seal down Super Duty Lower Unit Lubricant until lubricant
over drive shaft (DO NOT GREASE DRIVE flows out of “Vent”hole and no air bubbles are vis-
SHAFT) until tool seats against pump housing. ible.
4. Install “Vent”screw into “Vent”hole.
IMPORTANT: DO NOT lose more than one fluid
a ounce (30cc) of gear lubricant while reinstalling
“Fill” screw.
b
5. Remove grease tube (or hose) from “Fill” hole
and quickly install “Fill”screw into “Fill”hole.

Installing Gear Housing to Drive

Shaft Housing
52724

a - Tool
WARNING
b - Seal Disconnect high tension leads from spark plugs
11. If tool is not available, lightly press seal against and remove spark plugs from engine before in-
housing until a height of 0.350 in. ± 0.030 in. stalling gear housing into drive shaft housing.
(8.9mm ± 0.76mm) is obtained. 1. Tilt engine to full up position and engage the tilt
lock lever.
2. Apply a light coat of 2-4-C w/Teflon onto drive
0.350 in. ±0.030 in.
shaft splines.
(8.9mm ± 0.76mm)
CAUTION
DO NOT allow lubricant on top of drive shaft. Ex-
a cess lubricant, that is trapped in clearance
space, will not allow drive shaft to fully engage
with crankshaft. Subsequently, tightening the
gear housing nuts (while excess lubricant is on
top of drive shaft) will load the drive shaft/crank-
shaft and damage either or both the powerhead
52726 and gear housing. Top of drive shaft is to be
a - Speedometer Connector wiped free of lubricant.
NOTE: Secure speedometer tube to speedometer 3. Apply a light coat of 2-4-C w/Teflon onto shift
connector with sta-strap. shaft splines. (DO NOT allow lubricant on top of
shift shaft.)
4. Insert a NEW trim tab bolt (with patch) into hole
Gear Lubricant Filling Instructions in rear of gear housing to drive shaft housing ma-
1. Inspect “Fill”and “Vent”sealing washers for cuts chined surface.
or abrasions. Replace washers if necessary. 5. Shift gear housing into NEUTRAL and place
2. Clean any metal debris from magnet on “Fill” guide block anchor pin into NEUTRAL position.
plug.
IMPORTANT: Never apply lubricant to gear hous-
ing without first removing “Vent” screw, or gear
housing cannot be filled because of trapped air.
Fill gear housing ONLY when housing is in a ver-
tical position.
a
52189
a - Guide Block Anchor Pin

90-855348R1 JANUARY 1998 LOWER UNIT - 6B-77

6. Position gear housing so that the drive shaft is IMPORTANT: If shifting operation is not as de-
protruding into drive shaft housing. scribed, preceding, the gear housing must be re-
moved and the cause corrected.
7. Feed speedometer tube through opening in drive
shaft housing. 14. Install remaining washers and nuts onto drive
shaft studs. Torque to 55 lb. ft. (74.6 N·m).
NOTE: If, while performing Step 8, the drive shaft
splines will not align with crankshaft splines, lower 15. Torque bolt (started in Step 10) to 45 lb. ft. (61.0
the gear case enough to reach in and turn the drive N·m).
shaft by hand slightly to align drive shaft splines with
16. Position trim tab in gear housing aligning grooves
crankshaft.
of trim tab with ribs in trim tab pocket. Adjust to
8. Move gear housing up toward drive shaft housing position in which it had previously been installed,
while aligning shift shaft splines and water tube and while holding trim tab, torque bolt to 40 lb. ft.
with water tube guide (in water pump cover). (54.2 N·m).
9. Place flat washers onto studs (located on either 17. Install plastic cap into trim tab bolt opening at rear
side of drive shaft housing). Start a nut on these edge of drive shaft housing.
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 cor-
rect 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 N·m).
13. After 2 nuts (located on either side of drive shaft
housing) are tightened, check shift operation as
follows:
a. Place guide block anchor pin into FORWARD
gear position. Rotate flywheel clockwise
(viewed from top); propeller shaft should ro-
tate 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 clockwise
(viewed from top); propeller shaft should ro-
tate clockwise.

6B-78 - LOWER UNIT 90-855348R1 JANUARY 1998

ATTACHMENTS/CONTROL
LINKAGE

7
Table of Contents
Page Page
Ride Guide Steering Cable/Attaching Kit Installation Transom Mounted Ride Guide Attaching Kit
(92876A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Installation (73770A1) . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Single Cable - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Attaching Kit Installation . . . . . . . . . . . . . . . . . . . . 7-24
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7-26
Ride Guide Steering Cable/ Clevis Attaching Kit Installation (A-70599A2) . . . . . 7-26
Attaching Kit Installation Installation Instructions . . . . . . . . . . . . . . . . . . . . . 7-26
(92876A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7-27
Dual Cable - Single Outboard . . . . . . . . . . . . . . . . 7-3
Super Ride-Guide Steering Kit Installation . . . . . . 7-3
Steering Cable Mounting Tube Installation . . . . . . 7-4
Installing Steering Cables . . . . . . . . . . . . . . . . . . . . 7-4
Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Installing Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 7-7
Ride Guide Steering Cable/ Attaching Kit Installation
(92876A6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Dual Cable - Dual Outboard . . . . . . . . . . . . . . . . . . 7-8
Installation Requirements . . . . . . . . . . . . . . . . . . . . 7-8
Parallel Routed Steering Cables and Attaching
Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Opposite Side Routed Steering
Cables and Attaching Kit Installation . . . . . . . . . . 7-16
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7-22
Ride Guide Steering Attachment Extension
Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Maintenance Instructions . . . . . . . . . . . . . . . . . . . 7-23

7-0 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

Ride Guide Steering Cable/ INSTALLING RIDE GUIDE CABLE TO
OUTBOARD TILT TUBE
Attaching Kit Installation IMPORTANT: Before installing steering cable in
(92876A1) tilt tube, lubricate entire cable end with Quicksil-
ver 2-4-C w/Teflon.
NOTE: Ride Guide steering cable is lubricated at the
Single Cable - factory and requires no additional lubrication at initial
installation.
Refer to “Quicksilver Accessories Guide” to de-
termine correct length of steering cable and remote 1. Lubricate seal (a) inside of outboard tilt tube and
control cables. entire cable end (b) with Quicksilver 2-4-C
w/Teflon.
IMPORTANT: Steering cable and remote control
cables must be the correct length, sharp bends 2. Insert steering cable end thru outboard tilt tube
on too-short cables result in “kinks”; too-long and secure steering cable to tilt tube with steering
cables require unnecessary bends and/or loops. cable attaching nut (c), as shown. Torque nut to
Both conditions place extra stress on the cables 35 lb. ft. (47.5 N·m).
and will reduce the performance of the steering
system.

c b

28160

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-1

STEERING LINK ROD INSTALLATION Maintenance Instructions
IMPORTANT: The steering link rod that connects Maintenance inspection is owner’s responsibility and
the steering cable to the engine must be fastened must be performed at intervals specified, following:
using special washer head bolt (“a” - Part Num-
ber 10-14000) and self locking nuts (“b” & “c” - Normal Service - Every 50 hrs. of operation or 60
Part Number 11-34863). These locknuts must days (whichever comes first)
never be replaced with common nuts (non lock- *Severe Service - Every 25 hrs. of operation or 30
ing) as they will work loose and vibrate off freeing days (whichever comes first)
the link rod to disengage.
*Operation in a salt water area is considered
WARNING “Severe Service.”

Disengagement of a steering link rod can result 1. Carefully check steering system components for
in the boat taking a full, sudden, sharp turn. This wear. Replace worn parts.
potentially violent action can cause occupants to 2. Check steering system fasteners to be sure that
be thrown overboard exposing them to serious they are torqued to correct specifications.
injury or death.
NOTE: Ride-Guide Steering Cables are lubricated at
3. Assemble steering link rod to steering cable with the factory and require no additional lubrication at ini-
two flat washers (d) and nylon insert locknut (“b” tial installation.
- Part Number 11-34863). Tighten locknut (b) un-
til it seats, then back nut off 1/4 turn. WARNING
4. Production Outboards - Assemble steering link Core of each steering cable (transom end) must
rod to engine with special washer head bolt (“a” be fully retracted into cable housing before lubri-
- Part Number 10-14000) and nylon insert locknut cating cable. If cable is lubricated while ex-
(“c”- Part Number 11-34863). First torque bolt (a) tended, hydraulic lock of cable could occur.
to 20 lb. ft. (27.1 N·m), then torque locknut (c) to
20 lb. ft. (27.1 N·m). 3. With core of Ride-Guide Steering Cable (transom
High Performance Outboards - An access hole end) fully retracted, lubricate transom end of
is provided through the bottom cowl to ease steering cables thru grease fittings (a) with 2-4-C
installation of the link rod connecting bolt. Re- w/Teflon (92-825407A12). Lubricate exposed
move the BACK plug for installation and reinstall portion of cable end (b) with 2-4-C w/Teflon.
after installation. 4. Lubricate pivot point (c) of steering link rod and
ball joint (d) of link rod with SAE 30 Weight Oil.
a
5. Inspection and lubrication of steering head as-
d sembly (rotary or straight rack) should be per-
formed once each year (by your Authorized Deal-
er) or whenever steering mount and/or steering
head are disassembled, or if steering effort has
b increased. Lubricate with 2-4-C w/Teflon. Ride
Guide Steering Cable / Attaching Kit Installation
(92876A3).

c d

WARNING
After installation is complete (and before operat-
ing outboard), check that boat will turn right
when steering wheel is turned right and that boat a
will turn left when steering wheel is turned left. c
a b
Check steering thru full range (left and right) and 28169
at all tilt angles to assure interference-free move-
ment.

7-2 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

Ride Guide Steering Cable/ Apply marine sealer to shanks of mounting bolts (not
threads) and secure outboard to transom with 4 bolts,
Attaching Kit Installation flat washers and locknuts, as shown. Be sure that in-
stallation is water-tight.
(92876A3)
Install upper bolts so that hex head end of bolts is on
the inside of boat transom.
Dual Cable - Single Outboard

WARNING
Quicksilver 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 de-
termine 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 Super Ride-Guide Steering Kit
the cables and will reduce the performance of the
steering system. Installation
IMPORTANT: Both gear racks or rotary steering
CAUTION heads must be installed so that both steering
With this kit installed, the upper (outboard) cables will be routed together on the same side
mounting bolts MUST BE installed so that hex of the boat and will push-and-pull together.
head end of bolts is on the inside of boat tran- 1. Install Super Ride-Guide Steering Kit in accor-
som, as illustrated. Failure to install upper dance with instructions included with Super Ride-
mounting bolts, as shown in illustration, could Guide Kit.
result in interference between steering cable nut
and ends of mounting bolts when outboard is 2. Make sure that both gear racks or rotary steering
tilted up. heads are installed so that both steering cables
are routed together down starboard side of boat
CAUTION and will push-and-pull together.

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.

a
b b c
a - Gear Rack
b - Steering Cables
c - Rotary Steering Heads

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-3

Steering Cable Mounting Tube Install steering cable mounting tube into mounting
bracket with 2 adjusting nuts and 2 locking tab wash-
Installation
ers. Verify longer threaded end of tube is toward star-
IMPORTANT: Spacers (b) must be installed be- board side of boat.
tween outboard swivel bracket and mounting Temporarily adjust tube so that longer threaded end
bracket for steering cable mounting tube to pro- of tube extends out the same distance as the out-
vide proper spacing between steering cables. board tilt tube. Do not tighten adjustment nuts at this
Secure mounting bracket for steering cable mount- time.
ing tube on to swivel bracket of outboard.
d
b
b

a
d a
c 51891

e 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 d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab
c Washer)
a - Mounting Bracket for Steering Cable Mounting Tube 28163
b - Spacer (2)
c - Locking Retainer (2)
d - Bolts (4) - 7/8 in. (22mm) Long - Torque to 100 lb. in. Installing Steering Cables
(11.3 N·m), then Bend Corner Tabs of Locking Retainers
Up and Against Flats on Each Bolt IMPORTANT: Lubricate inside of outboard tilt
tube, inside of steering cable mounting tube and
rubber O-ring seal (located in outboard tilt tube)
WARNING with Quicksilver 2-4-C w/Teflon before installing
Locking retainer corner tabs, MUST BE bent up steering cables.
and against flats on each bolt that secures Lubricate inside of outboard tilt tube and inside of
mounting bracket for steering cable mounting steering cable mounting tube with Quicksilver 2-4-C
tube to outboard swivel bracket to prevent bolts w/Teflon. Verify rubber O-ring seal (a) (located in out-
from turning out. board tilt tube) is lubricated.

95

51890

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

7-4 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

Insert steering cable ends (a) thru outboard tilt tube Coupler Installation
(b) and cable mounting tube (c). Thread steering
cable attaching nuts (d) on to tubes hand tight. WARNING
NOTE: Torque steering cable attaching nuts only af- Locknuts must be used with bolts to secure
ter final steering adjustments have been made. steering cables to coupler. Failure to adhere to
b a this requirement could result in steering system
failure.
d
Slide coupler (a) onto steering cable ends and secure
each steering cable to coupler with bolt (b) and lock-
nut (c) as shown. Tighten to a torque of 20 Ib. ft. (27.1
N·m).

c
51891
Place a mark (a) on steering cable mounting tube (b)
5/8 in. (16mm) from end of mounting tube. Slide plas- b c
tic spacer (c), O-ring (d) and cap (e) over steering
cable.

5/8² (16mm) b

b
a 51888

Installing Link Rod

WARNING
a c d e Steering link rod MUST BE secured between out-
51890
board steering arm and steering coupler, using
special washer head bolt (10-14000) and two ny-
Thread cap (e) onto steering cable mounting tube, up lon insert locknuts (11-34863), as shown. Both
to mark (a). special washer head bolt and nylon insert lock-
nuts MUST BE tightened as specified.
Lubricate hole in steering coupler, with Quicksilver
2-4-C w/Teflon. Assemble steering link rod to steer-
ing coupler, using 2 flat washers (one each side of
coupler) and nylon insert locknut. Tighten locknut un-
til it seats [DO NOT exceed 120 Ib. in. (13.6 N·m) of
torque], then back nut off 1/4 turn.

a
e
51890

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-5

Lubricate ball joint in steering link rod with SAE 30W Loosen adjustment nuts and pull steering cable
Motor Oil. Secure link rod to outboard steering arm, mounting tube (by hand) away from end of steering
using special washer head bolt (10-14000) provided cable (to remove slack in steering system). Tighten
and nylon insert locknut as shown. Torque special adjustment nuts against mounting bracket and check
bolt to 20 Ib. ft. (27.1 N·m), then torque locknut to 20 system for slack (play.) If steering system is too tight,
Ib. ft. (27.1 N·m). 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
80 against mounting bracket and readjust, if necessary.
b
e
b

c a d

f 51887
a - Steering Cable Mounting Tube
a b - Adjustment Nuts
d c - Adjust Tube in This Direction to Remove Slack from Steer
80
ing System
80 30W 4 Cycle Engine Oil (92-97959) d - Adjust Tube in This Direction to Reduce Tension from
28172 Steering System

a - Steering Coupler After steering system tension is adjusted correctly,

b - Steering Link Rod tighten adjustment nuts against mounting bracket, to
c - Flat Washer (2) a torque of 35 Ib. ft. (47.4 N·m) and bend a tab lock
d - Nylon Insert Locknut - Torque until it seats [DO NOT
exceed 120 lb. in. (14.0 N·m) of torque], then back nut off washer against flat on each adjustment nut.
1/4 turn
e - Special Washer Head Bolt (10-14000) - Torque to 20 lb. ft. b
(27.1 N·m)
f - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 N·m)

STEERING SYSTEM TENSION ADJUSTMENT

IMPORTANT: After this dual steering cable at-
tachment 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 steer-
ing system. Too much tension will cause steering
cables to bind. Perform the following steps to ad- c
just for correct tension. c a
51887

a - Steering Cable Mounting Tube

b - Adjustment Nuts; Torque to 35 lb. ft. (47.4 N·m)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment
Nut)

7-6 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

Tighten steering cable attaching nuts of each steer-
ing cable to a torque of 35 Ib. ft. (47.5 N·m). WARNING
After installation is complete (and before operat-
b ing outboard(s), check that boat will turn right
when steer- ing wheel is turned right and that
boat will turn left when steering wheel is turned
left. Check steering thru full range (left and right)
at all tilt angles to assure interference-free move-
a ment.
51889
a - Cable Attaching Nut
b - “V”Groove Maintenance Instructions
NOTE: Cable attaching nuts with a “V” groove Maintenance inspection is owner’s responsibility and
around the outer circumference of the nut are self must be performed at intervals specified, following:
locking and do not require locking sleeves.
Install rubber bumpers (a) on inside of each locking Normal Service - Every 50 hrs. of operation or 60
sleeve (b). 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
b Service.”
1. Carefully check steering system components for
a wear. Replace worn parts.
51889
2. Check steering system fasteners to be sure that
Install locking sleeves over steering cable attaching they are torqued to correct specifications.
nuts and secure with cotter pins. Spread ends of cot-
ter pins. Be sure to install cotter pin so that it is located NOTE: Ride-Guide Steering Cables are lubricated at
in between attaching nut and grease fitting. the factory and require no additional lubrication at ini-
tial installation.

f
e
WARNING
c a Core of each steering cable (transom end) must
be fully retracted into cable housing before lubri-
cating cable. If cable is lubricated while ex-
tended, hydraulic lock could occur.
b
a
d b
c
d
51890
a - Steering Cable Attaching Nut [Torque to 35 lb. ft. (47.5
N·m)]
b - Locking Sleeve (If Equipped)
c - Cotter Pin
d - Grease Fitting
e - Steering Cable Mounting Tube
f - Outboard Tilt Tube

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-7

3. With core of Ride-Guide Steering Cable (transom
end) fully retracted, lubricate transom end of
Ride Guide Steering Cable/
steering cables thru grease fittings (a) with 2-4-C Attaching Kit Installation
w/Teflon (92-825407A2).
(92876A6)
4. Lubricate ball joint (d) of link rod/steering coupler
and pivot point (c) of steering link rod with SAE
30W Motor Oil. Dual Cable - Dual Outboard
5. Inspection and lubrication of steering head as-
sembly (rotary or straight rack) should be per- WARNING
formed once each year (by your Authorized Deal-
Quicksilver Super Ride-Guide Steering (dual
er) or whenever steering mount and/or steering
cables) MUST BE USED with this attaching kit.
head are disassembled, or if steering effort has
Failure to adhere to this requirement could result
increased. Lubricate with 2-4-C w/Teflon.
in steering system failure.

80 95 Refer to “Quicksilver Accessories Guide” to de-

termine correct length of steering cable and remote
control cables.
d IMPORTANT: Steering cable and remote control
b
cables MUST BE THE CORRECT LENGTH, sharp
c 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.

a a Installation Requirements
80 28170
IMPORTANT: The distance from each outboard’s
95 centerline to the side of transom opening MUST
BE a minimum of 16 in. (40.6cm).
80 30W 4 Cycle Engine Oil (92-97959) This kit contains all necessary parts to connect both
95 2-4-C With Teflon (92-825407A12) outboards to Ride-Guide Steering Cables for 23-1/2
in. thru 27-1/2 in. (59.7cm thru 69.9cm) outboard
centerline spacing. If outboard centerline distance is
other then specified, refer to end of this 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 In-
stallation,” immediately following.
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 In-
stallation,” located on page 7-16 of this section.

7-8 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

 2. Make sure that both gear racks or rotary steering
CAUTION heads are installed so that both steering cables
With this kit installed, the upper (outboard) are routed together and will push-and-pull to-
mounting bolts MUST BE installed so that hex gether.
head end of bolts is on the inside of boat tran-
som, 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 outboard is tilted up.

a
b b a

a - Straight Rack (Left); Rotary Steering (Right)

b - Steering Cables (Install so that Both Cables Will Push and
Pull Together)

STEERING CABLE INSTALLATION

STARBOARD OUTBOARD
IMPORTANT: Mounting bracket for steering
cable mounting tube MUST BE secured to out-
board swivel bracket, using 5/8 in. (16mm) long
Install upper bolts so that hex head end of bolts is on bolts supplied with this dual cable - dual out-
the inside of boat transom. board attaching kit.
Secure mounting bracket for steering cable mount-
ing tube, onto swivel bracket of starboard outboard.
Parallel Routed Steering Cables and
Attaching Kit Installation
(Both Steering Cables Routed Together Down
Starboard Side of Boat)

SUPER RIDE-GUIDE STEERING KIT d

d
INSTALLATION c
IMPORTANT: Steering cable must be installed
into tilt tube of port outboard before outboard is
mounted on boat transom.
Both gear racks or rotary steering heads must be b a 28164
installed so that both steering cables will be a - Mounting Bracket for Steering Cable Mounting Tube
routed together on the same side of the boat and b - “J”Clip - Supplied with Outboard
c - Locking Retainers (2)
will push- and-pull together. d - Bolts (4) - 5/8 in. (16mm ) Long - Torque to 100 lb. in. (11.3
N·m), then Bend Corner Tabs of Locking Retainers Up and
1. Install Super Ride-Guide Steering Kit in accor-
Against Flats on Each Bolt
dance with instructions included with Super
Ride-Guide Kit.
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.

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-9

Install steering cable mounting tube into mounting Place a mark (a) on steering cable mounting tube (b)
bracket with 2 adjusting nuts and 2 locking tab wash- 5/8 in. (16mm) from end of mounting tube. Slide plas-
ers. Be sure longer threaded end of tube is toward tic spacer (c), O-ring (d) and cap (e) over steering
starboard side of boat. cable.
Temporarily adjust tube, so that longer threaded end
of tube extends out the same distance as the out- 5/8² (16mm)
board tilt tube. Do not tighten adjustment nuts at this
time.
b
d
b

a d e
c
51890

Thread cap (e) onto steering cable mounting tube, up

a to mark (a).
c 51891
95

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

a - Steering Cable Mounting Tube (End of Tube with Longer
Threads Toward Starboard Side of Boat)
b - Mounting Bracket
c - Locking Tab Washers (2)
d - Adjustment Nuts (Flats of Nuts Facing Toward Locking Tab
Washer)
IMPORTANT: Lubricate inside of steering cable
mounting tube with 2-4-C w/Teflon before install- a e
ing steering cable. 51890

Lubricate inside of steering cable mounting tube

(starboard outboard) with 2-4-C w/Teflon.
Insert steering cable end (a) thru cable mounting
tube (b) and thread steering cable attaching nut (c)
onto tube hand tight.
NOTE: Torque steering cable attaching nut only after
final steering adjustments have been made.

c b
51887

7-10 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

STEERING CABLE INSTALLATION - Insert steering cable end (b) thru tilt tube (c) of port
PORT OUTBOARD outboard and thread steering cable attaching nut (d)
onto tilt tube hand tight.
IMPORTANT: Lubricate inside of port outboard’s
tilt tube and rubber O-ring seal located inside tilt NOTE: Torque steering cable attaching nuts only af-
tube with 2-4-C w/Teflon, before installing steer- ter final steering adjustments have been made.
ing cable.
Lubricate inside of port outboard’s tilt tube and rubber
O-ring seal (a) with 2-4-C w/Teflon. b

95
a
d c

51887

51890

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

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-11

STEERING LINK ROD INSTALLATION Both special washer head bolt and nylon insert
locknuts MUST BE tightened as specified.
WARNING c
Steering link rods MUST BE secured between 80
outboard steering arm and steering cable end, e
using special washer head bolt (10-14000) and
two nylon insert locknuts (11-34863), as shown.

d
50061

c 80
c 80 80
80
e e

a a

b b
f f
d d
28166

80

f a

a
b
80 30W 4 Cycle Engine Oil (92-97959)

a - Flat Washer (2 Each Link Rod) Lubricate holes in ends of steering cables with SAE
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT 30W Motor Oil. Assemble steering link rods to steer-
Exceed 120 lb. in. (13.6 N·m) of Torque], Then Back Off
1/4 Turn ing cable ends of each outboard, using flat washers
c - Special Washer Head Bolt (10-14000) - Torque to 20 lb. and nylon insert locknuts. Tighten locknuts until they
ft. (27.1 N·m) seat [DO NOT exceed 120 Ib. in. (13.6 N·m) of
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 N·m) torque], then back nut off 1/4 turn.
e - Steering Link Rod
f - Steering Cable End Lubricate ball joints in steering link rods with SAE
30W Motor Oil. Secure link rods to outboard steering
arms, using special washer head bolts (10-14000)
provided and nylon insert locknuts as shown. Torque
special bolts to 20 Ib. ft. (27.1 N·m) then torque lock-
nuts to 20 Ib. ft. (27.1 N·m).

7-12 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

STEERING ARM EXTENSION BRACKET STEERING COUPLER ASSEMBLY AND
INSTALLATION INSTALLATION
Secure a steering arm extension bracket to each out- Position outboards so that they are facing straight
board’s steering arm. forward. (Distance between threaded hole centers of
steering arm extensions MUST BE equal to distance
between propeller shaft centerlines.)
b Lubricate inside of rubber sleeves with 2-4-C w/Te-
d flon and slide sleeves on steering coupler.
d
Work rubber bushings onto threaded ends of steer-
ing eyes.
Thread jam nut on starboard steering eye.
a
Thread steering eyes equally into coupler, so that dis-
tance between hole centers of steering eye ball joints
c is equal to distance between threaded hole centers
c
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).
51889
a - Steering Arm (Port Outboard Shown) c d e b a b d c
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 N·m), Then Bend Corner Tabs of Locking
Retainers Up Against Flats on Each Bolt 95

50061
WARNING 95 2-4-C With Teflon (92-825407A12)
Locking retainer corner tabs MUST BE bent up a - Coupler
b - Rubber Sleeve
and against flats on each bolt that secures exten-
c - Steering Eye
sion bracket to outboard steering arm to prevent d - Rubber Bushing
bolts from turning out. e - Jam Nut

WARNING
Both steering eyes must be threaded into cou-
pler 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 re-
quirement could result in steering system failure.

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-13

Lubricate ball joint in steering eyes, with SAE 30W Torque special washer head bolts to 20 Ib. ft. (27.1
Motor Oil. N·m), then torque locknuts to 20 Ib. ft. (27.1 N·m).
Assemble steering coupler between outboard steer-
ing arm extension brackets, using special washer WARNING
head bolts (10-14000) provided and nylon insert Both steering eyes MUST BE threaded into cou-
locknuts as shown. pler 3/4 in. (19mm) minimum, and jam nut must be
IMPORTANT: With assembled steering coupler tightened against coupler to prevent coupler
in- stalled and before tightening special washer from turning. Torque “jam” nut to 20 Ib. ft. (27.1
head bolts/locknuts, check outboard alignment. N·m).
Distance between centers of special washer Tighten “jam”nut against coupler. Torque “jam”nut to
head bolts MUST BE equal to distance between 20 Ib. ft. (27.1 N·m).
propeller shaft center lines, for proper steering.
Spray Quicksilver Corrosion Guard on exposed
It adjustment is necessary, temporarily remove
threads of steering eyes and position rubber bush-
special washer head bolt/locknut from one steer-
ings and rubber sleeves to cover exposed threads of
ing eye and turn eye in or out to correct align-
steering eyes.
ment.

80 f 80 a f
80
80

28167
80 g g
80

d b d
c
h h

80
f c e a 80 50061
80 80

f
c

g h
50061
80 30W 4 Cycle Engine Oil (92-97959)

a - Coupler f - Special Washer Head Bolt (10-14000) - Torque to 20 lb.ft.

b - Rubber Sleeve (27.1 N·m)
c - Steering Eye g - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 N·m)
d - Rubber Bushing h - Steering Arm Extension Bracket
e - Jam Nut - Torque (Against Coupler) to 20 lb. ft.
(27.1 N·m)

7-14 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

STEERING SYSTEM TENSION ADJUSTMENT Tighten steering cable attaching nuts of each steer-
(PARALLEL ROUTED STEERING CABLES) ing cable to a torque of 35 Ib. ft. (47.5 N·m).
IMPORTANT: For proper operation of this dual
cable - dual outboard steering installation, 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.
Loosen adjustment nuts and pull steering cable a
mounting tube (by hand) away from end of steering 51887
cable (to remove slack in steering system). Tighten a - Cable Attaching Nut
adjustment nuts against mounting bracket and check
system for slack (play). If steering system is too tight, WARNING
readjust tube toward end of steering cable or, if too
much slack (play) exists in system, readjust tube After installation is complete [and before operat-
away from end of steering cable. Tighten nuts ing outboard(s)], check that boat will turn right
against mounting bracket and readjust, if necessary. when steering wheel is turned right and that boat
will turn left when steering wheel is turned left.
b Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement.
a
Adjust trim tabs of both outboards, as outlined in
“Trim Tab Adjustment”, following.

c d
51887

a - Steering Cable Mounting Tube

b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steer-
ing System
d - Adjust Tube in This Direction to Reduce Tension from
Steering System
After steering system tension is adjusted correctly,
tighten adjustment nuts against mounting bracket, to
a torque of 35 Ib. ft. (47.5 N·m) 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)

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-15

Opposite Side Routed Steering Install Steering Cable mounting tube into mounting
bracket with 2 adjusting nuts and 2 locking tab wash-
Cables and Attaching Kit Installation
ers. Verify longer threaded end of tube is toward cen-
(One Cable Routed down Starboard Side of Boat ter of boat transom.
and One Cable Routed down Port Side of Boat) Temporarily adjust tube, so that longer threaded end
of tube extends out the same distance as the out-
SUPER RIDE-GUIDE STEERING KIT board tilt tube. Do not tighten adjustment nuts at this
INSTALLATION time.
IMPORTANT: Steering cable must be installed
into tilt tube of port outboard before outboard is b d
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
95 a
cable mounting tube MUST BE secured to out-
board swivel bracket, using 5/8 in. (16mm) long
c 51891

bolts supplied with this dual cable - dual out-

board attaching kit. 95 2-4-C With Teflon (92-825407A12)
Secure mounting bracket for steering cable mount- a - Steering Cable Mounting Tube (End of Tube with Longer
ing tube, onto swivel bracket of starboard outboard. 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 mount-
ing tube with 2-4-C w/Teflon (92-825407A12) be-
d fore installing steering cable.
d
c Lubricate inside of steering cable mounting tube
(starboard outboard) with 2-4-C w/Teflon.
Insert steering cable end (a) (steering cable routed
down port side of boat) thru cable mounting tube (b)
b a and thread steering cable attaching nut (c) onto tube
28164 hand tight.
a - Mounting Bracket for Steering Cable Mounting Tube NOTE: Torque steering cable attaching nut only after
b - “J”Clip - Supplied with Outboard
c - Locking Retainers (2) final steering adjustments have been made.
d - Bolts (4) - 5/8 in. (16mm) Long - Torque to 100 lb. in.
(11.3 N·m), Then Bend Corner Tabs of Locking Retainers a
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
b c
tube, to prevent bolts from turning out.
51887

7-16 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

Place a mark (a) on steering cable mounting tube (b) STEERING CABLE INSTALLATION -
5/8 in (16mm) from end of mounting tube. Slide plas- PORT OUTBOARD
tic spacer (c), O-ring (d) and cap (e) over steering
IMPORTANT: Lubricate inside of port outboard’s
cable.
tilt tube and rubber O-ring seal located inside tilt
5/8² (16mm) tube with 2-4-C w/Teflon, before installing steer-
ing cable.
Lubricate inside of port outboard’s tilt tube and rubber
O-ring seal (a) with 2-4-C w/Teflon.

95
a
a

e d c b
51890
Thread cap (e) onto steering cable mounting tube, up
to mark (a).

51890
e
95 2-4-C With Teflon (92-825407A12)
Insert steering cable end (b) (steering cable routed
down starboard side of boat) thru tilt tube (c) of port
outboard and thread steering cable attaching nut (d)
onto tilt tube hand tight.
NOTE: Torque steering cable attaching nut only after
a 51888 final steering adjustments have been made.

d b

c
51887

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-17

STEERING LINK ROD INSTALLATION Lubricate ball joints in steering link rods with SAE
30W Motor Oil. Secure link rods to outboard steering
WARNING arms, using special washer head bolts (10-14000)
provided and nylon insert locknuts as shown. Torque
Steering link rods MUST BE secured between
special bolts to 20 lb. ft. (27.1 N·m) then torque lock-
outboard steering arm and steering cable end,
nuts to 20 Ib. ft. (27.1 N·m).
using special washer head bolt (10-14000) and
two nylon insert locknuts (11-34863), as shown. c
Both special washer head bolt and nylon insert 80
locknuts MUST BE tightened as specified.
e
Lubricate holes in ends of steering cables with SAE
30W Motor Oil. Assemble steering link rods to steer-
ing 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 N·m) of
torque], then back nut off 1/4 turn. d
50061

80
80
e c 80
c 80
e
a
a

d d
f f b
b 28165
e
80

f a

a
b
a - Flat Washer (2 Each Link Rod)
b - Nylon Insert Locknut - Torque Until it Seats [DO NOT
Exceed 120 lb. in. (13.6 N·m) of Torque], Then Back Off
1/4 Turn
c - Special Washer Head Bolt (10-14000) - Torque to 20
lb.ft. (27.1 N·m)
d - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 N·m)
e - Steering Link Rod
f - Steering Cable End

7-18 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

STEERING ARM EXTENSION BRACKET Thread steering eyes equally into coupler, so that dis-
INSTALLATION tance between hole centers of steering eye ball joints
is equal to distance between threaded hole centers
Secure a steering arm extension bracket to each out-
of steering arm extensions. Exposed threads of
board’s steering arm.
steering eyes MUST BE of equal length and threads
MUST NOT extend out from coupler more than 2-3/4
b in. (69.9mm).

d c d e b a b d c
d

a 95 50061

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

a - Coupler
c c b - Rubber Sleeve
c - Steering Eye
d - Rubber Bushing
e - Jam Nut

WARNING
Both steering eyes must be threaded into cou-
51889 pler 3/4 in. (19mm) minimum. Thread length of
a - Steering Arm (Port Outboard Shown) steering eye is 3-1/2 in. (88.9mm), so exposed
b - Extension Bracket thread must not extend out of coupler more than
c - Locking Retainer (2 Each Bracket) 2-3/4 in. (69.9mm). Failure to adhere to this re-
d - Bolts (2 Each Bracket) 1-1/4 in. (31.8mm) Long - Torque to
280 lb. in. (31.6 N·m), Then Bend Corner Tabs of Locking quirement could result in steering system failure.
Retainers Up Against Flats on Each Bolt

WARNING
Locking retainer corner tabs, MUST BE bent up
and against flats on each bolt that secures exten-
sion bracket to outboard steering arm, to prevent
bolts from turning out.

STEERING COUPLER ASSEMBLY AND

INSTALLATION
Position outboards so that they are facing straight
forward. (Distance between threaded hole centers of
steering arm extensions MUST BE equal to distance
between propeller shaft centerlines.)
Lubricate inside of rubber sleeves with 2-4-C w/Te-
flon and slide sleeves on steering coupler.
Work rubber bushings onto threaded ends of steer-
ing eyes.
Thread jam nut on starboard steering eye.

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-19

Lubricate ball joint in steering eyes with SAE 30W Torque special washer head bolts to 20 Ib. ft. (27.1
Motor Oil. N·m), then torque locknuts to 20 Ib. ft. (27.1 N·m).
Assemble steering coupler between outboard steer-
ing arm extension brackets, using special washer WARNING
head bolts (10-14000) provided and nylon insert Both steering eyes MUST BE threaded into cou-
locknuts, as shown. pler 3/4 in. (19mm) minimum, and jam nut must be
IMPORTANT: With assembled steering coupler tightened against coupler to prevent coupler
installed and before tightening special washer from turning. Torque “jam” nut to 20 Ib. ft. (27.1
head bolts/locknuts, check outboard alignment. N·m).
Distance between centers of special washer Tighten “jam”nut against coupler. Torque “jam”nut to
head bolts MUST BE equal to distance between 20 Ib. ft. (27.1 N·m).
propeller shaft center lines, for proper steering.
Spray Quicksilver Corrosion Guard on exposed
If adjustment is necessary, temporarily remove
threads of steering eyes and position rubber bush-
special washer head bolt/locknut from one steer-
ings and rubber sleeves to cover exposed threads of
ing eye and turn eye in or out to correct align-
steering eyes.
ment.

80
f f 80
80 a
80

28174
80 g g 80

d b d
c
h h

f
f c e a 80 50061
80 80
80 f
c

g h
50061
80 30W 4 Cycle Engine Oil (92-97959)
a - Coupler f - Special Washer Head Bolt (10-14000) - Torque to 20 lb.ft.
b - Rubber Sleeve (27.1 N·m)
c - Steering Eye g - Nylon Insert Locknut - Torque to 20 lb. ft. (27.1 N·m)
d - Rubber Bushing h - Steering Arm Extension Bracket
e - Jam Nut - Torque (Against Coupler) to 20 lb. ft. (27.1 N·m)

7-20 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

STEERING SYSTEM TENSION ADJUSTMENT Tighten steering cable attaching nuts of each steer-
(PARALLEL ROUTED STEERING CABLES) ing cable to a torque of 35 Ib. ft. (47.5 N·m).
IMPORTANT: For proper operation of this dual NOTE: Cable attaching nuts with a “V” groove
cable - dual outboard steering installation, there around outer circumference are self locking and do
MUST BE proper tension in the steering system. not require locking sleeves.
NOT ENOUGH tension will cause slack (play) in
Install rubber bumpers (a) on inside of each locking
steering system. TOO MUCH tension will cause
sleeve (b).
steering cables to bind. Perform the following
steps to correctly adjust tension. b
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,
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 a
against mounting bracket and readjust, if necessary.
51889
Install locking sleeves over steering cable attaching
nuts and secure with cotter pins. Spread ends of cot-
ter pins. Be sure to install cotter pin so that it is located
in between attaching nut and grease fitting.

a
b
d c
a - Steering Cable Mounting Tube 51887
b - Adjustment Nuts
c - Adjust Tube in This Direction to Remove Slack from Steer-
ing System
d - Adjust Tube in This Direction to Reduce Tension from
Steering System
After steering system tension is adjusted correctly, c b
tighten adjustment nuts against mounting bracket to a
a torque of 35 Ib. ft. (47.5 N·m) and bend a tab lock
washer against a flat on each nut. d
b

f
51888
a - Steering Cable Attaching Nut [Torque to 35 lb. ft. (47.5
N·m)]
c b - Locking Sleeve (If Equipped)
c a c - Cotter Pin
51887
d - Grease Fitting
a - Steering Cable Mounting Tube e - Steering Cable Mounting Tube (Starboard Outboard)
b - Adjustment Nuts; Torque to 35 lb. ft. (47.5 N·m) f - Outboard Tilt Tube (Port Outboard)
c - Tab Lock Washer (Bend Against Flat on Each Adjustment
Nut)

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-21

 c. If boat pulls to the right, adjust trailing edges
WARNING of both trim tabs to the right. If boat pulls to the
After installation is complete [and before operat- left, adjust trailing edges of both trim tabs to
ing outboard(s)], check that boat will turn right the left.
when steering wheel is turned right and that boat d. Tighten both trim tab bolts securely and re-
will turn left when steering wheel is turned left. place plastic caps.
Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement. e. Operate boat per “Check trim tab position
as follows,”preceding, to check trim tab set-
Adjust trim tabs of both outboards, as outlined in ting. Readjust trim tabs, if necessary.
“Trim Tab Adjustment,” following.

Ride Guide Steering Attachment

Trim Tab Adjustment Extension Couplers
DUAL OUTBOARD - COUNTER ROTATION Outboard Center Required Coupler(s)
INSTALLATION Line Distance Between Steering Eyes

1. Shift outboard into neutral and make sure ignition 22-1/2 in. thru 24-1/2 in. 12 in. (30.5cm) Coupler
key is at “OFF”position. (57.2cm thru 62.2cm)
2. Remove plastic cap from rear of drive shaft hous- 23-1/2 in. thru 27-1/2 in. 15 in. (38.1cm) Coupler
ing and loosen bolt and trim tab. (59.7cm thru 69.9cm) (Supplied with this kit)
3. Position trim tabs of both outboards straight to
rear of outboard, so that tabs are aligned with 26-1/2 in. thru 30-1/2 in. 18 in. (45.7cm) Coupler
(67.3cm thru 75.5cm)
gear housing center line.
4. Tighten both trim tab bolts securely and replace 30 in. thru 34 in. 9 in. (22.9cm) Coupler and 12 in
plastic caps. No further adjustment will be re- (76.3cm thru 86.4cm) (30.5cm) Coupler (Connected
quired. together with coupler link rod)

33 in. thru 37 in. 12 in. (30.5cm) Coupler and

DUAL OUTBOARD - NON COUNTER ROTATION 12 in. (30.5cm) Coupler (Con-
INSTALLATION nected together with coupler
1. Check trim tab position as follows: link rod)

IMPORTANT: Initial trim tab setting for both out-

boards should be straight to rear of outboard, so
that tabs are aligned with gear housing center
line. Refer to “If necessary, adjust trim tab as fol- a
lows,” following.
a. Operate boat at normal cruise throttle setting
and adjust trim to optimum setting. b
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 c
pulls to the left (port), trailing edge of trim tab
must be moved to the left.
2. If necessary, adjust trim tab as follows: d
a. Shift outboard into NEUTRAL and make sure
ignition key is at “OFF”position.
b. Remove plastic cap from rear of drive shaft e
a - 18 in. (45.7cm) Coupler (97932-3)
housing and loosen bolt and trim tab. b - 15 in. (38.1cm) Coupler (97932-2)
IMPORTANT: Trim tabs MUST BE set in the same c - 12 in. (30.5cm) Coupler (97932-1)
d - 9 in. (22.9cm) Coupler (97932-4)
position on both outboards.
e - Coupler Link Rod (98181A1)

7-22 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

 *Severe Service - Every 25 hrs. of operation or 30
WARNING days (whichever comes first)
When 2 couplers are connected together with *Operation in a salt water area is considered “Se-
coupler link rod, a lock washer must be used on vere Service.”
each side of coupler link rod, and link rod must
be torqued to 20 Ib. ft. (27.1 N·m) into end of each 1. Carefully check steering system components for
coupler. wear. Replace worn parts.

a b a 2. Check steering system fasteners to be sure that

they are torqued to correct specifications.
NOTE: Ride-Guide Steering Cables are lubricated at
the factory and require no additional lubrication at ini-
tial installation.

WARNING
Core of each steering cable (transom end) must
be fully retracted into cable housing before lubri-
c 51890 cating cable. If cable is lubricated while ex-
a - Couplers Connected Together
tended, hydraulic lock of cable could occur.
b - Lock washers 3. With core of Ride-Guide Steering Cable (transom
c - Coupler Link Rod [Torque to 20 lb. ft. (27.1 N·m) into End
of Each Coupler]
end) fully retracted, lubricate transom end of
steering cables thru grease fittings (a) with 2-4-C
w/Teflon (92-825407A12). Lubricate exposed
Maintenance Instructions portion of cable ends (b) with 2-4-C w/Teflon.
4. Lubricate pivot points (c) of steering link rods and
Maintenance inspection is owner’s responsibility and
ball joints (d) of link rods/steering coupler with
must be performed at intervals specified, following:
SAE 30W Motor Oil.
Normal Service - Every 50 hrs. of operation or 60
5. Inspection and lubrication of steering head as-
days (whichever comes first)
sembly (rotary or straight rack) should be per-
formed once each year (by your Authorized Deal-
er) or whenever steering mount and/or steering
head are disassembled, or if steering effort has
increased. Lubricate with 2-4-C w/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

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-23

Transom Mounted Ride
Guide Attaching Kit
Installation (73770A1)

Attaching Kit Installation

1. Lubricate both holes in pivot block (Figure 1) with
Quicksilver 2-4-C w/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 N·m).

a b i h

95
f
k c g
d
l

j
e
95 2-4-C With Teflon (92-825407A12)
Figure 1
a - Ride-Guide Cable 3. Place Ride-Guide yoke on pivot block and secure
b - Ride-Guide Yoke with 7/16 in. x 1-3/4 in. (11.1mm x 44.5mm) bolt
c - Pivot Block
d - Pivot Spacer and locknut, as shown in Figures 1 and 2. Torque
e - 15 in. (381mm) (Centerline of Attaching Kit Pivot to Cent- locknut to 10 Ib. ft. (13.6 N·m), then back off
erline of Outboard) 1/4-turn.
f - Pivot Attaching Locknut [Torque to 20 lb. ft. (27.1 N·m)]
g - Outboard Steering Arm g f
h - “Clevis Kit”
i - Ride-Guide Cable Attaching Locknut [Torque to 10 lb. ft.
(13.6 N·m)] d
j - Bolt [3/8 in. x 2-1/2 in. (9.5mm x 63.5mm)]
k - Flat Washer
l - Transom Bracket a

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 N·m)]
d -
Ride-Guide Yoke Attaching Locknut [Torque to 10 lb. ft.
(13.6 N·m)] 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

7-24 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

4. Install one cable tube jam nut onto steering cable centerline and draw a vertical line on tran-
tube. Place tab washer over Ride-Guide yoke, som. (Figure 1)
then insert cable tube thru tab washer and yoke.
Install second cable tube jam nut onto cable tube
b. Position attaching kit on transom so that tran-
but do not tighten at this time. (Figure 3)
som bracket is centered on the 15 in.
5. Position transom attaching kit on transom as (38.1mm) (Figure 1) at a height where the
center of Ride-Guide yoke is even with, or
a. Determine centerline of outboard, then mea-
not more than 1/2 in. (12.7mm) above top
sure 15 in. (38.1cm) over from this
edge of transom. (Figure 3)

f h j
e a e
f
i
k
c

g
b
d
Figure 3
a - Ride-Guide Yoke 2. Install steering cable thru steering cable tube and
b - 0 in. to 1/2 in. (0mm to 12.8mm) (Center of Ride-Guide secure to cable tube with cable attaching nut.
Yoke to Top of Transom
c - Top of Transom (Figure 3) Do not tighten cable attaching nut at
d - Transom Bracket this time.
e - Cable Tube Jam Nuts [ Torque to 35 lb. ft. (47.5 N·m)]
f - Tab Washer 3. Attach Ride-Guide cable to outboard steering
g - After Jam Nuts Are Torqued to Specification, Bend Lock- arm, using the proper “Clevis Kit.”Installation in-
ing Tabs against Nuts structions for clevis are with “Clevis Kit.”
h - Cable Guide Tube
i - Ride-Guide Cable Attaching Nut [Torque to 35 lb. ft. 4. Adjust 2 large jam nuts on cable tube of attaching
(47.5 N·m)] kit, so that steering wheel is in normal straight-
j - “Clevis Kit” driving position with outboard in straight-running
k - Clevis Attaching Locknut [Torque to 20 lb. ft. (27.1 N·m)]
position. Torque each jam nut to 35 Ib. ft. (47.5
NOTE: When drilling thru transom, be sure that holes N·m), then bend a side of tab washer against flat
are drilled perpendicular to transom. of each jam nut. (Figure 3)
6. With attaching kit positioned as outlined preced- 5. Torque Ride-Guide cable attaching nut (which
ing, use 3 holes in transom bracket as a guide secures cable to guide tube) to 35 Ib. ft. (47.5
and drill three 11/32 in. (8.7mm) holes thru tran- N·m). (Figure 3) Install locking sleeve over cable
som. attaching nut and secure with cotter pin. Spread
ends of cotter pin.
7. Use a marine-type sealer on three 5/16 in. x
3-1/4in. (7.9mm x 82.6mm) bolts. Secure attach-
ing kit to transom, using transom backing plate, WARNING
3 bolts (with sealer) and 3 locknuts, installed as After installation is completed (and before oper-
shown in Figure 2. Torque lock nuts to 10 Ib. ft. ating outboard), check that boat will turn right
(13.5 N·m). when steering wheel is turned right and that boat
will turn left when steering wheel is turned left.
STEERING CABLE INSTALLATION Check steering thru full range (left and right) at all
tilt angles to assure interference-free movement.
1. Lubricate steering cable end with Quicksilver
2-4-C w/Teflon (92-825407A12).

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-25

Maintenance Instructions Installation Instructions
Lubrication and maintenance inspection is owner’s 1. Install clevis to steering cable as shown.
responsibility and must be performed at intervals
2. Lubricate 3/8 in. x 1-3/8 in. (9.5mm x 34.9mm)
specified, following:
bolt (area without threads) with 2-4-C w/Teflon,
Normal Service - Every 50 hrs. of operation or 60 then secure clevis to steering cable with this bolt
days (whichever comes first) and a locknut. Torque locknut (item “d”) to 10 Ib.
ft. (13.6 N·m).
*Severe Service - Every 25 hrs. of operation or 30
days (whichever comes first) a
95 e
*Operation in a salt water area is considered “Se- b
vere Service.” f
g
CAUTION h
Core of steering cable must be fully retracted into
i
cable housing when lubricating cable. If cable is
lubricated while extended, hydraulic lock of j
cable could occur.
c d
1. Lubricate outboard end of Ride-Guide steering
cable (thru grease fitting next to cable attaching
nut) with Quicksilver 2-4-C w/Teflon. 95 2-4-C With Teflon (92-825407A12)
NOTE: Ride-Guide steering cable is lubricated at the a - Clevis
factory and requires no additional lubrication at initial b - Steering Cable
installation. 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
2. Lubricate all steering system pivot points (and N·m)]
exposed portion of steering cable core) with e - Bolt [3/8 in. x 1-1/4 in. (9.5mm x 31.8mm)]
[Torque to 20 lb. ft. (27.1 N·m)]
Quicksilver 2-4-C w/Teflon. Lubricate at intervals f - Thin Washer [1/16 in. (1.6mm) Thick]
specified preceding. g - Spacer
h - Thick Washer [1/8 in. (3.2mm) Thick]
3. Carefully check steering system components for i - Engine Steering Arm
wear (at intervals specified, preceding). Replace j - Clevis to Engine Locknut [Torque to 20 lb. ft. (27.1 N·m)]
worn parts.
3. Lubricate spacer (supplied with this kit) with
4. Check steering system fasteners (at intervals 2-4-C w/Teflon.
specified, preceding) to be sure that they are
4. Attach clevis to top of outboard steering arm with
torqued to correct specifications. (Figures 1, 2
a 3/8 in. x 1-1/4 in. (9.5mm x 31.8mm) bolt, thin
and 3)
washer, spacer, thick washer (thick washer must
be installed between clevis and steering arm)
and locknut, as shown. Torque bolt (item “e”) to
Clevis Attaching Kit 20 Ib. ft. (27.1 N·m), then torque locknut (item “j”)
to 20 Ib. ft. (27.1 N·m).
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 installed thru outboard tilt tube,
then “Steering Link Rod”must be used.

7-26 - ATTACHMENTS/CONTROL LINKAGE 90-855348R1 JANUARY 1998

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 “Se-
vere 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, preceding.

90-855348R1 JANUARY 1998 ATTACHMENTS/CONTROL LINKAGE - 7-27