30 40M

MODELS
30/40 (2 CYLINDER)
30¯30 Marathon¯30 Sea Pro
40¯40 Marathon¯40 Sea Pro
With Serial Numbers

United States . . 0G044027 and ABOVE
Belgium . . . . . . . 09855139 and ABOVE
Printed in U.S.A. ã 1997, Mercury Marine 90-826148R2 MARCH 1997

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 dealer’s 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
90-826148R2 MARCH 1997 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 an 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 the lifting eye is threaded
into flywheel a minimum of 5 turns.
2. Connect a hoist of suitable strength to the lifting
eye.
EXAMPLE:
90-826148 R2 MARCH 1997 LOWER UNIT - 6A-7
Revision No. 1 Section Description
Month of Printing Section Number
Year of Printing Part of Section Letter
Page Number
ii 90-826148R2 MARCH 1997
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
Electrical
2
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
Fuel System
3
B - Carburetor
C - Oil Injection
Section 4 - Powerhead
Section 5 - Mid-Section
Powerhead
4
5
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim Mid-Section
C - Manual Tilt
Section 6 - Lower Unit
6
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage Lower Unit
B - Tiller Handle
Section 8 - Manual Starter
Attachments/
Control Linkage
7
Manual Starter
8
90-826148R2 MARCH 1997 iii

IMPORTANT INFORMATION 1
A
SPECIFICATIONS
Table of Contents
Page
General Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A-1
1A-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

General Specifications
Model 30/40
HORSEPOWER Model 30 30 (22.4)
(KW) Model 40 40 (29.8)
OUTBOARD 15 in. (38 cm) 156 lbs. (70.7kg)
WEIGHT 20 in. (51 cm) 161 lbs. (73.0kg)
22-1/2 in. (57 cm) 166 lbs. (75.3kg)
CYLINDER Type Two Cylinder - Two Cycle
BLOCK Displacement 39.3 cu. in. (644.4 cc)
STROKE Length 2.796 in. (71 mm)
CYLINDER Diameter (Standard) 2.993 in. (76 mm)
BORE Diameter [Oversize 0.015 (.381 mm)] 3.007 in. (76.38 mm)
Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Cylinder Finish Hone (I.D.) 2.993 in. (76 mm)
CRANKSHAFT Top Main Bearing Journal 1.375 in. (34.93 mm)
Center Main Bearing Journal 1.216 in. (30.89 mm)
Bottom Ball Bearing Journal 1.385 in. (35.17 mm)
Connecting Rod Journal 1.181 in. (29.99 mm)
Runout 0.003 in. (0.076 mm)
CONNECTING Piston Pin End (I.D.) 0.957 in. (24.31 mm)
ROD Crankpin End (I.D.) 1.499 in. (38.07 mm)
PISTON Piston Type Aluminum
O.D. at Skirt (Standard) 2.988 in. (75.90 mm)
O.D. at Skirt [Oversize 0.015 (.381 mm)] 3.003 in. (76.28 mm)
Ring End Gap 0.010 in. - 0.018 in.
(0.25 mm - 0.46 mm)
REEDS Reed Stand Open (Maximum) 0.020 in. (0.508 mm)
Reed Stop -- Model 30 0.090 in. (2.286 mm)
-- Model 40 Not Adjustable
GEAR Gear Ratio 2.0:1
HOUSING Gearcase Capacity 14.9 oz. (440 mL)
Lubricant Type Quicksilver Gear Lube Premium Blend
Forward Gear - No. of Teeth-Type 26 Spiral/Bevel
Pinion Gear - No. of Teeth-Type 13 Spiral/Bevel
Pinion Height 0.025 in. (0.64 mm)
Forward Gear Backlash No Adjustment
Reverse Gear Backlash No Adjustment
Water Pressure
With Thermostat + Poppet
-- @ W.O.T. 5 -- 7 PSI @ 5000 RPM
-- @ Idle 0.5 -- 1.5 PSI @ 750 RPM
All Models W/O Thermostat + Poppet
-- @ W.O.T. 5 -- 7 PSI @ 5000 RPM
-- @ Idle 0 -- 1 PSI @ 750 RPM
Poppet Valve Opening 1994-1997 900-1000 RPM
Poppet Valve Opening 1998 & Newer 3000-3500 RPM
90-826148R2 MARCH 1997 IIMPORTANT INFORMATION - 1A-1

Model 30/40
MID Transom Height - Short Shaft 15 in. (38 cm)
SECTION - Long Shaft 20 in. (51 cm)
Steering Pivot Range 90°
Tilt Pin Positions 5 + Shallow Water
Total Tilt Angle 70°
Allowable Transom Thickness 2-3/8 in. (60.3mm)
FUEL Fuel Pump Pressure
SYSTEM -- @ W.O.T. 4-7 PSI (28-43 kPa)
-- @ Idle 2-1/2 -- 4 PSI (17-27 kPa)
Recommended Gasoline Automotive Regular or Unleaded
with a Minimum Pump Posted
Octane Rating of 87
Fuel Tank Capacity 6.6 U.S. Gallons
(5 Imp. Gals.; 25 Liters)
Break-in Gasoline Ratio
Manual Outboard 25:1
Electric Start Outboard 50:1 (In Fuel Tank)
OIL Recommended Oil Quicksilver TC-W II or TC-W III
INJECTION 2-Cycle Outboard Oil
Oil Tank Capacity/Approx. Time 50.5 fl. oz. (1.5 liters) 4.7 Hours @
5250 RPM
Reserve Capacity/Approx. Time 30 Minutes @ 5250
Output (cc/min.) w/Pump @ Full Open 8.5 cc/10 Minutes @ 900 RPM
STARTING Manual Start Recoil
SYSTEM Electric Start 12 Volt
Starter Draw (Under Load) 95 Amperes
(No Load) 20 Amperes
CHARGING Alternator Output Single Phase (12 Pole)
SYSTEM -- Electric Start
Red Stator 18 Amperes @ 3000 RPM
Black Stator 14 Amperes @ 5000 RPM
-- Manual Start 9 Amperes @ 3000 RPM
BATTERY Battery Rating 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
IGNITION Type Capacitor Discharge
SYSTEM Spark Plug Type (NGK) BP8H-N-10
Spark Plug Gap 0.040 in. (1.0mm)
Optional Plug (NGK) BPZ8H-N-10*
0.040 in. (1.0mm)
Firing Order 1-2
1A-2 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Model 30/40
CARBURETOR Idle RPM 700 - 800 RPM
SPECIFICATIONS (In Forward Gear)
Full Throttle RPM Range
-- Model 30/ 40 Sea Pro/Marathon 4500 - 5500 RPM
-- Model 40 5000 - 5500 RPM
Idle Mixture Screw Adjustment
(Preset - Turns Out) 1-1/2 ±1/4 (All Models Except 40 MLL)
1-3/4 ±1/4 (WME-38 Carb on 40 MLL)
Float Level 9/16 in. (14.29mm)
Main Jet
-- 30 Manual (WME-36/36A)/(WME-63) 0.054 in.
-- 30 Electric (WME-37/37A)/(WME-64) 0.054 in.
-- 40 Manual (WME-38)/(WME-66) 0.066 in.
-- 40 Electric (WME-39/39A)/(WME-67) 0.066 in.
-- 30 EHO (WME-42/42A)/(WME-65) 0.054 in.
TIMING Models with (S/N-0G59999 & Below) 3°BTDC ± 3°
SPECIFICATIONS Idle (Not Adjustable)
25°± 3°
Maximum BTDC @ 2500-5500 RPM (Not Adjustable)
Models with (S/N-0G590000 & Above)
Idle 8 BTDC ±1°
8°BTDC 1
Maximum Spark Advance 1 Turn Clockwise After Contacting
Throttle Plate
90-826148R2 MARCH 1997 IIMPORTANT INFORMATION - 1A-3

B
MAINTENANCE
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Gear Case Lubricant Capacity . . . . . . . . . 1B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Quicksilver Lubricant/Sealant . . . . . . . . . . . . 1B-1
Inspection and Maintenance Schedule . . . . 1B-2
Before Each Use . . . . . . . . . . . . . . . . . . . . 1B-2
After Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-2
Every 100 Hours of Use or Once Yearly,
Whichever Occurs First . . . . . . . . . . . . . . . 1B-2
Every 300 Hours of Use or Three Years 1B-2
Before Periods of Storage . . . . . . . . . . . . 1B-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . 1B-3
(S/N-0G589999 & Below) . . . . . . . . . . . . . 1B-3
(S/N-0G590000 & Above) . . . . . . . . . . . . . 1B-3
Checking Power Trim Fluid . . . . . . . . . . . . . . 1B-5
Gear Case Lubrication . . . . . . . . . . . . . . . . . . 1B-6
Draining Gear Case . . . . . . . . . . . . . . . . . . 1B-6
Checking Lubricant Level and Filling
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Propeller Replacement . . . . . . . . . . . . . . . . . . 1B-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Corrosion Control Anode . . . . . . . . . . . . . . . . 1B-8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Fuel Tank Filter . . . . . . . . . . . . . . . . . . . . 1B-9
Fuel Line And Primer Bulb . . . . . . . . . . 1B-9
Flushing The Cooling System . . . . . . . . . . . . 1B-10
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Protecting External Outboard
Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
Protecting Internal Outboard
Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
Positioning Outboard for Storage . . . . . . 1B-11
Battery Storage . . . . . . . . . . . . . . . . . . . . . 1B-11
1B-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Specifications
Gear Case Lubricant Capacity

Gear Case Ratio Capacity
2.00:1 14.9 fl. oz. (440 mL)
Special Tools
P/N 44357A2 Flushing Kit.
Quicksilver
Lubricant/Sealant
Description Part Number
Gear Lubricant-Premium 92-19007A24
Blend
Anti-Corrosion Grease 92-78376A6
2-4-C Marine Lubricant 92-825407A12
w/Teflon
SAE 30W Motor Oil Obtain Locally
90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-1

Inspection and Maintenance Every 100 Hours of Use or Once
Yearly, Whichever Occurs First
Schedule
1. Lubricate all lubrication points. Lubricate more
frequently when used in salt water.
Before Each Use 2. Inspect and clean spark plugs.
1. Check that lanyard stop switch stops the engine. 3. Check engine fuel filter for contaminants.
2. Visually inspect the fuel system for deterioration 4. Adjust carburetor(s) (if required).*
or leaks.
3. Check outboard for tightness on transom. 5. Check engine timing setup.*
4. Check steering system for binding or loose com- 6. Check corrosion control anodes. Check more fre-
ponents. quently when used in salt water.
5. Remote Control Models - Visually check steering 7. Drain and replace gear case lubricant.
link rod fasteners for proper tightness. 8. Lubricate splines on the drive shaft.
6. Check propeller blades for damage. 9. Check power trim fluid.
10. Inspect battery.
After Each Use 11. Check control cable adjustments. *
1. Flush out the outboard cooling system if operat- 12. Remove engine deposits with Quicksilver Power
ing in salt or polluted water. Tune Engine Cleaner.
2. Wash off all salt deposits and flush out the ex- 13. Check tightness of bolts, nuts, and other fasten-
haust outlet of the propeller and gear case with ers.
fresh water if operating in salt water.
* These items should be serviced by an authorized
dealer.
Every 300 Hours of Use or Three

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

Refer to Storage Procedure (Page 1B-10).

Lubrication Points
ITEM TYPE OF FRESH WATER SALT WATER
DESCRIPTION
NO. LUBRICANT FREQUENCY FREQUENCY
Throttle/Shift linkage
1
Pivot Points
2 Upper Shift Shaft Quicksilver 2-4-C
Marine Lubricant
3 Swivel Pin
100 Hours of Use or
Ride Guide Steering Once in Season
4
Cable
5 Tilt Tube/Co-Pilot
Steering Link Rod
6 SAE 30W Motor Oil
Pivot Points 100 Hours of Use or Once in Season
Quicksilver Special
7 Propellor Shaft Lubricant 101 Anti-
Corrosion Grease
Starter Motor Pinion
8 SAE 10W Motor Oil
Gear
9 Gear Housing Bear- Quicksilver Special
* ing Carrier Lubricant 101
10 Quicksilver Gear
Gear Housing
à Lube
Engine Crankshaft
Quicksilver 2-4-C
D Splines to Drive Shaft Once in Season
Marine Lubricant
Splines
* Refer to lubrication instructions outlined in “Salt Water Cor-
rosion - Gear Housing Bearing Carrier and Cover Nut”
of this section (see “Table of Contents”).
à Refer to “Gear Housing Lubrication”of this section (see
“Table of Contents”).
(S/N-0G590000 & Above)
D Refer to “Gear Housing Removal and Installation”(Sec-
tion 5).
1 1 1
(S/N-0G589999 & Below)

1
1
1
1
1
1 1 1 1 55759
1
1
1

Electric and Remote Control Models
52662
2 - Upper Shift Shaft Lubrication

Tiller Handle Models
3
5
3 - Swivel Pin Grease Fittings 4 - Ride Guide Steering Grease Fitting

5 - Tilt Tube/Co-Pilot Grease Fitting
WARNING 6 - Steering Link Rod Pivot Point Lubrication
Core of steering cable (transom end) must be ful-

ly retracted into cable housing before lubricating
cable. If cable is lubricated while extended, hy-
draulic lock of cable could occur.
With core of Ride Guide Steering cable (transom 7
end) fully retracted, lubricate transom end of steering
cable thru grease fitting and exposed portion of cable
end with Quicksilver 2-4-C Marine Lubricant. Lubri-
cate all pivot points with SAE 30W engine oil.
50551
7 - Propeller Shaft Lubrication

Checking Power Trim Fluid
1. Tilt outboard to the full up position and engage
the tilt support pin.
a
52661
8 - Starter Motor Pinion Gear Lubrication

a - Tilt Support Pin
2. Remove fill cap and check fluid level. The fluid

level should be even with the bottom of the fill
hole. Add Quicksilver Power Trim & Steering
Fluid or automotive transmission fluid (ATF) Type
F, FA, or Dexron III.
9
50558
9 - Gear Housing Lubrication

Gear Case Lubrication
When adding or changing gear case lubricant, visual-
ly check for the presence of water in the lubricant. If
water is present, it may have settled to the bottom
and will drain out prior to the lubricant, or it may be
mixed with the lubricant, giving it a milky colored ap-
pearance. If water is noticed, have the gear case
checked by your dealer. Water in the lubricant may a
result in premature bearing failure or, in freezing tem-
peratures, will turn to ice and damage the gear case.
Whenever you remove the fill/drain plug, examine
the magnetic end for metal particles. A small amount
of metal filings or fine metal particles indicates nor- b
mal gear wear. An excessive amount of metal filings
or larger particles (chips) may indicate abnormal
gear wear and should be checked by an authorized
dealer.
a - Lubricant Vent Plug/Washer
WARNING b - Lubricant Fill Plug/Washer
If gear housing is installed on outboard, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before work- 4. Inspect gear lubricant for metal particles (lubri-
ing near the propeller. cant will have a “metal flake”appearance). Pres-
ence of fine metal particles (resembling powder)
CAUTION on the FILL plug bar magnet indicates normal
Do not use automotive grease in the gear hous- wear. The presence of metal chips on the FILL
ing. Use only Quicksilver Gear Lube or Quicksil- plug bar magnet indicates the need for gear
ver Super-Duty Lower Unit Lubricant. housing disassembly and components inspec-
tion.
5. Note color of gear lubricant. White or cream color
Draining Gear Case indicates presence of water in lubricant. Gear lu-
1. Tilt outboard so that lubricant in gear housing will bricant which has been drained from a gear hous-
drain toward front of housing, out fill hole and into ing recently in operation will have a yellowish col-
clean container. or due to lubricant agitation/aeration. This is
normal and should not be confused with the pres-
IMPORTANT: Inspect FILL and VENT plug wash- ence of water.
ers for damage. Use new washer as needed.
6. Presence of water in gear lubricant indicates the
2. Remove lubricant FILL plug and washer. Note need for disassembly and inspection of oil seals,
amount of metal particles on magnetic FILL plug. seal surfaces, O-rings, water pump gaskets as
Remove all magnetic particles from FILL plug. well as gear housing components for damage.
3. Remove VENT plug and washer and allow all lu-
bricant to drain.
Checking Lubricant Level and Filling
Gear Case
IMPORTANT: Never add lubricant to gear hous-
ing without first removing VENT plug, as trapped
air will prevent housing from being filled. Fill gear
housing only when outboard is in operating posi-
tion.

NOTE: Refer to “Specifications,”for gear housing 5. Pull propeller straight off shaft. If propeller is
lubricant capacity. seized to the shaft and cannot be removed, have
the propeller removed by an authorized dealer.
1. With outboard in operating position, insert lubri-
cant tube into fill hole.
2. Fill gear housing until excess lubricant flows from Installation
VENT hole.
3. Install VENT plug and washer. WARNING
4. Install FILL plug and washer. If the propeller shaft is rotated while the engine
is in gear, there is the possibility that the engine
will crank over and start. To prevent this type of
accidental engine starting and possible serious
Propeller Replacement injury caused from being struck by a rotating pro-
peller, always shift outboard to neutral position
and remove spark plug leads when you are serv-
Removal icing the propeller.
1. Shift outboard to neutral (N) position.
CAUTION
2. Remove the spark plug leads to prevent engine
from starting. If the propeller moves forward-and-aft on the pro-
peller shaft (is loose), re-tighten the propeller
3. Straighten the bent tabs on the propeller nut re- nut. Operation with a loose propeller could cause
tainer. damage to the thrust hub and gear housing dur-
ing acceleration, deceleration or when shifting
gears.
IMPORTANT: To assure that the propeller re-
mains secure on the shaft during the season, pe-
riodically check propeller shaft nut for tightness.
1. To aid in future removal of the propeller, liberally
coat the propeller shaft spline with one of the fol-
lowing Quicksilver lubricants:
· Special Lubricant 101
a · Anti-Corrosion Grease
a - Tabs · 2-4-C Marine Lubricant
4. Place a block of wood between gear case and 2. Place forward thrust hub on propeller shaft.
propeller to hold propeller and remove propeller
nut.
b a
50551
a - Thrust Hub
b - Propeller Shaft

3. While aligning splines, place Quicksilver propel-
ler and tab washer on propeller shaft.
Corrosion Control Anode
The trim tab on the gear case is a corrosion control
4. To prevent propeller from rotating, place a flat
anode and Models which have the longer type of
block of wood between the anti-ventilation plate
transom brackets will have a second anode installed.
and the propeller.
An anode helps protect the outboard against galvan-
5. Thread propeller nut on propeller shaft. Tighten ic corrosion by sacrificing its metal to be slowly
securely with wrench [minimum of 55 lb. ft. (75.0 eroded instead of the outboard metals.
N·m) of torque] and bend tab washer to secure
propeller nut.
6. After first use, bend the tab straight, re-tighten
propeller nut [minimum of 55 lb. ft. (74.6 N×m) of
torque] and again bend tab washer to secure nut.
Check propeller periodically for tightness.
a
a
b
b
51119
a - Trim Tab
a - Tab Washer b - Anode
b - Propeller Nut
NOTE: Corrosion control anodes requires periodic
inspection especially in salt water which will acceler-
ate the erosion. To maintain this corrosion protection,
always replace the anode before it is completely
eroded. Never paint or apply a protective coating on
the anode as this will reduce effectiveness of the
anode.

Fuel Tank 1. To remove fuel line clamps, grip clamp with pliers
and bend over, lapping hook backward.
Maintenance
The inside of the fuel tank should be cleaned once
each season. Dirt or water may have entered the fuel
tank during refilling. Clean the tank by flushing with
clean, lead-free gasoline or kerosene.
FUEL TANK FILTER

If a fuel restriction problem is encountered, the fuel
filter on end of outlet tube may be obstructed. Re-
move cover and inspect filter for varnish, dirt or de-
posits. Clean filter by rinsing in clean, lead-free gaso-
line or kerosene.
c
b
51115
a
2. To install fuel line clamps, grip hose clamp with

pliers and push down on hook with screwdriver
d until hooks interlock.
51046
a - Fuel Tank Filter

b - Pick-Up Tube
c - Cover
d - Gasket
FUEL LINE AND PRIMER BULB

Periodically check fuel line and primer bulb for
cracks, breaks, restrictions or chafing. Check all fuel
51115
line connections for tightness. All fuel line connec-
tions must be clamped securely.
Primer bulb assembly has 2 check valves: Fuel inlet
(toward tank) and a fuel outlet (toward engine).
The fuel inlet valve allows fuel to fill primer bulb but
closes to prevent fuel from returning to tank when
bulb is squeezed. The fuel outlet valve opens when
primer bulb is squeezed to allow fuel flow to carbure-
tor, but closes as bulb is released to prevent fuel from
returning to primer bulb.

Flushing The Cooling 5. Check for a steady stream of water flowing out of
the water pump indicator hole. Continue flushing
System the outboard for 3 to 5 minutes, carefully monitor-
ing water supply at all times.
WARNING
To avoid possible injury when flushing, remove
the propeller. Refer to Propeller Replacement.
1. Remove propeller (refer to Propeller Replace-
ment). Install the flushing attachment so the rub-
ber cups fit tightly over the cooling water intake
holes.
6. Stop the engine, turn off the water, and remove

the flushing attachment. Reinstall the propeller.
Storage
The major consideration in preparing your outboard
for storage is to protect it from rust, corrosion, and
2. Attach a water hose to the flushing attachment. damage caused by freezing of trapped water.
Turn on the water and adjust the flow so water is The following storage procedures should be followed
leaking around the rubber cups to ensure the en- to prepare your outboard for out-of-season storage
gine receives an adequate supply of cooling wa- or prolonged storage (two months or longer).
ter.
CAUTION
Never start or run your outboard (even momen-
tarily) without water circulating through all the
cooling water intake holes in the gear case to pre-
vent damage to the water pump (running dry) or
overheating of the engine.
Fuel System
IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid
during storage and can damage the fuel system.
If the gasoline being use contains alcohol, it is
advisable to drain as much of the remaining gas-
3. Start the engine and run it at idle speed in neutral oline as possible from the fuel tank, remote fuel
shift position. line, and engine fuel system.
4. Adjust water flow (if necessary) so excess water Fill the fuel system (tank, hoses, fuel pump and car-
continues leaking out from around the rubber buretors) with treated (stabilized) fuel to help prevent
cups to ensure the engine is receiving an ade- formation of varnish and gum. Proceed with following
quate supply of cooling water. instructions.

1. Portable Fuel Tank - Pour the required amount of Gear Case
Quicksilver Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank 1. Drain and refill the gear case lubricant (refer to
back and forth to mix stabilizer with the fuel. maintenance procedure).
2. Permanently Installed Fuel Tank - Pour the re-
quired amount of Quicksilver Gasoline Stabilizer Positioning Outboard for Storage
(follow instructions on container) into a separate
container and mix with approximately one quart 1. Store outboard in an upright (vertical) position to
(one liter) of gasoline. Pour this mixture into fuel allow water to drain out of outboard.
tank.
3. Place the outboard in water or connect flushing CAUTION
attachment for circulating cooling water. Run the If outboard is stored tilted up in freezing tempera-
engine for ten minutes to allow treated fuel to ture, trapped cooling water or rain water that may
reach the carburetors. have entered the propeller exhaust outlet in the
gear case could freeze and cause damage to the
outboard.
Protecting External Outboard
Components
Battery Storage
1. Lubricate all outboard components listed in the
Inspection and Maintenance Schedule. 1. Follow the battery manufacturers instructions for
storage and recharging.
2. Touch up any paint nicks. See your dealer for
touch-up paint. 2. Remove the battery from the boat and check wa-
ter level. Recharge if necessary.
3. Spray Quicksilver Corrosion Guard on engine ex-
terior, electrical components, and other metal 3. Store the battery in a cool, dry place.
surfaces (except corrosion control anodes). 4. Periodically check the water level and recharge
the battery during storage.
Protecting Internal Outboard

Components
NOTE: Before performing the following steps, make
sure the fuel system has been prepared for storage.
Refer to Fuel System (Page 1B-10).
1. Place the outboard in water or connect flushing
attachment for circulating cooling water. Start the
engine and let it run in neutral to warm up.
2. With engine running at fast idle, stop the fuel flow
by disconnecting the remote fuel line. When en-
gine begins to stall, quickly spray Quicksilver
Storage Seal into carburetor until engine stops
from lack of fuel.
3. Remove the spark plugs and inject a five second
spray of Quicksilver Storage Seal around the in-
side of each cylinder.
4. Rotate the flywheel manually several times to
distribute the storage seal in the cylinders. Rein-
stall spark plugs.

C
GENERAL INFORMATION
Table of Contents
Page
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1
Conditions Affecting Performance . . . . . . . . . 1C-1
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Weight distribution . . . . . . . . . . . . . . . . . 1C-2
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Trimming Outboard “OUT”(“UP”) . . . . 1C-2
Trimming Outboard
“IN”(“DOWN”) . . . . . . . . . . . . . . . . . . . . 1C-2
Water Absorption . . . . . . . . . . . . . . . . . . 1C-2
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3
Detonation . . . . . . . . . . . . . . . . . . . . . . . . 1C-3
Following Complete Submersion . . . . . . . . . . 1C-3
Salt Water Submersion
(Special Instructions) . . . . . . . . . . . . . . . . . . 1C-3
Submerged While Running (Special
Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3
Submerged Engine (Fresh Water)
(Plus Special Instructions) . . . . . . . . . . . . . 1C-4
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-4
Propeller Information Chart - 30 HP . . . . . 1C-6
Propeller Information Chart - 40 HP . . . . . 1C-7
1C-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Serial Number Location Corporations internationally have settled on adop-
tion of I.S.O. (International Standards Organization)
The Outboard serial number is located on the lower engine test standards, as set forth in I.S.O. 3046
starboard side of the engine block. A serial number standardizing the computation of horsepower from
is also located on the starboard side of the swivel data obtained on the dynamometer, correcting all val-
bracket. ues to the power that the engine will produce at sea
a level, at 30% relative humidity at 77°F (25°C) tem-
OGXXXXXX perature and a barometric pressure of 29.61 inches
19XX
b of mercury.
XXXX
c
Summer conditions of high temperature, low baro-
metric pressure and high humidity all combine to re-
duce the engine power. This, in turn, is reflected in
e decreased boat speeds--as much as 2 or 3 miles-
d
XX per-hour (3 or 5 Km per-hour) in some cases. (Refer
a - Serial Number to previous chart.) Nothing will regain this speed for
b - Model Year the boater, but the coming of cool, dry weather.
c - Model Description
d - Year Manufactured
In pointing out the practical consequences of weath-
e - Certified Europe Insignia er effects, an engine--running on a hot, humid sum-
mer day--may encounter a loss of as much as 14%
of the horsepower it would produce on a dry, brisk
spring or fall day. The horsepower, that any internal
Conditions Affecting combustion engine produces, depends upon the
Performance density of the air that it consumes and, in turn, this
density is dependent upon the temperature of the air,
its barometric pressure and water vapor (or humidity)
content.
Weather
Accompanying this weather-inspired loss of power is
a second but more subtle loss. At rigging time in early
spring, the engine was equipped with a propeller that
allowed the engine to turn within its recommended
RPM range at full throttle. With the coming of the
summer weather and the consequent drop in avail-
able horsepower, this propeller will, in effect, become
too large. Consequently, the engine operates at less
than its recommended RPM.
Due to the horsepower/RPM characteristics of an en-
gine, this will result in further loss of horsepower at
the propeller with another decrease in boat speed.
This secondary loss, however, can be regained by
switching to a smaller pitch propeller that allows the
engine to again run at recommended RPM.
For boaters to realize optimum engine performance
under changing weather conditions, it is essential
that the engine have the proper propeller to allow it
to operate at or near the top end of the recommended
maximum RPM range at wide-open-throttle with a
normal boat load.
Not only does this allow the engine to develop full
It’s a known fact that weather conditions exert a pro- power, but equally important is the fact that the en-
found effect on power output of internal combustion gine also will be operating in an RPM range that dis-
engines. Therefore, established horsepower ratings courages damaging detonation. This, of course, en-
refer to the power that the engine will produce at its hances overall reliability and durability of the engine.
rated RPM under a specific combination of weather
conditions.
90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1C-1

Boat TRIM
WEIGHT DISTRIBUTION TRIMMING OUTBOARD “OUT” (“UP”)
1. Proper positioning of the weight inside the boat WARNING

(persons and gear) has a significant effect on the
boat’s performance, for example: Excessive trim “out” also may reduce the stabil-
ity of some high speed hulls. To correct instabili-
a. Shifting weight to the rear (stern) ty at high speed, reduce the power GRADUALLY
(1.) Generally increases top speed. and trim the outboard “in” slightly before resum-
ing high speed operation. (Rapid reduction in
(2.) If in excess, can cause the boat to por-
power will cause a sudden change of steering
poise.
torque and may cause additional momentary
(3.) Can make the bow bounce excessively in boat instability.)
choppy water.
1. Will lift bow of boat, generally increasing top
(4.) Will increase the danger of the following speed.
- wave splashing into the boat when com-
2. Transfers steering torque harder to left on single
ing off plane.
outboard installations below 23 in. (584mm) tran-
b. Shifting weight to the front (bow) som height.
(1.) Improves ease of planing off. 3. Increases clearance over submerged objects.
(2.) Generally improves rough water ride. 4. In excess, can cause porpoising and/or ventila-
(3.) If excessive, can make the boat veer left tion.
and right (bow steer). 5. If trimmed out beyond the water pickup, reduced
water supply can cause overheating resulting in
BOTTOM engine damage.
For maximum speed, a boat bottom should be
nearly a flat plane where it contacts the water and TRIMMING OUTBOARD “IN” (“DOWN”)
particularly straight and smooth in fore-and-aft di-
rection. WARNING
1. Hook: Exists when bottom is concave in fore- Excessive speed at minimum trim “in” may
and-aft direction when viewed from the side. cause undesirable and/or unsafe steering condi-
When boat is planing, “hook”causes more lift on tions. Each boat should be tested for handling
bottom near transom and allows bow to drop, characteristics after any adjustment is made to
thus greatly increasing wetted surface and re- the angle (trim adjustment bolt relocation.)
ducing boat speed. “Hook”frequently is caused
1. Will help planing off, particularly with a heavy
by supporting boat too far ahead of transom while
load.
hauling on a trailer or during storage.
2. Usually improves ride in choppy water.
2. Rocker: The reverse of hook and much less
common. “Rocker”exists if bottom is convex in 3. In excess, can cause boat to veer to the left or
fore-and-aft direction when viewed from the side, right (bow steer).
and boat has strong tendency to porpoise. 4. Transfers steering torque harder to right (or less
3. Surface Roughness: Moss, barnacles, etc., on to the left) on single outboard installations.
boat or corrosion of outboard’s gear housing in- 5. Improves planing speed acceleration (by moving
crease skin friction and cause speed loss. Clean trim adjustment bolt one hole closer to transom).
surfaces when necessary.
WATER ABSORPTION
It is imperative that all through hull fasteners be
coated with a quality marine sealer at time of installa-
tion. Water intrusion into the transom core and/or in-
ner hull will result in additional boat weight (reduced
boat performance), hull decay and eventual structur-
al failure.

CAVITATION Detonation usually can be prevented if:
Cavitation is caused by water vapor bubbles forming 1. The engine is correctly set up.
either from a sharp edge or angle on the gear case
2. Diligent maintenance is applied to combat the
or from an irregularity in the propeller blade itself.
detonation causes.
These vapor bubbles flow back and collapse when
striking the surface of the propeller blade resulting in
the erosion of the propeller blade surface. If allowed
to continue, eventual blade failure (breakage) will
occur.
Engine
DETONATION
Detonation in a 2-cycle engine resembles the “ping-
ing”heard in an automobile engine. It can be other-
wise described as a tin-like “rattling” or “plinking”
sound.
Detonation is an explosion of an unburned portion of 51115
the fuel/air charge after the spark plug has fired. Det-
onation creates severe shock waves in the engine, Damaged Piston Resulting from Detonation
and these shock waves often find or create a weak-
ness: The dome of a piston, cylinder head/gasket,
piston rings or piston ring lands, piston pin and roller
bearings. Following Complete
A few of the most common causes of detonation in a Submersion
marine 2-cycle application are as follows:
· Over-advanced ignition timing.
Salt Water Submersion (Special
· Use of low octane gasoline. Instructions)
· Propeller pitch too high (engine RPM below rec-
Due to the corrosive effect of salt water on internal
ommended maximum range).
engine components, complete disassembly is nec-
· Lean fuel mixture at or near wide-open-throttle. essary before any attempt is made to start the en-
· Spark plugs (heat range too hot - incorrect reach gine.
- cross-firing).
· Inadequate engine cooling (deteriorated cooling Submerged While Running (Special
system).
Instructions)
· Combustion chamber/piston deposits (result in
higher compression ratio). When an engine is submerged while running, the
possibility of internal engine damage is greatly in-
creased. If, after engine is recovered and with spark
plugs removed, engine fails to turn over freely when
turning flywheel, the possibility of internal damage
(bent connecting rod and/or bent crankshaft) exists.
If this is the case, the powerhead must be disas-
sembled.

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

3. After initial propeller installation, the following
common conditions may require that the propel-
ler be changed to a lower pitch:
a. Warmer weather and great humidity will
cause an RPM loss.
b. Operating in a higher elevation causes an
RPM loss.
c. Operating with a damaged propeller or a dirty
boat bottom or gear housing will cause an
RPM loss.
d. Operation with an increased load (additional
passengers, equipment, pulling skiers, etc.).

Propeller Information Chart - 30 HP
Wide Open Throttle RPM: 4500-5500
Recommended Transom Height: 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction: 2:1
Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part
Blades Boat Weight Length Range Number
(LBS) (MPH)
10” 19” 3 Alum. Up To 800 Up To 15’ 36-45 48-73146A40
10” 17” 3 Alum. Up To 1000 Up To 15’ 31-45 48-73144A40
10” 16” 3 Steel 700-1200 13 - 16’ 28-36 48-91818A5
10” 16” 3 Alum. 700-1200 13 - 16’ 28-36 48-73142A40
10-1/8” 15” 3 Steel 900-1500 14 - 16’ 26-34 48-76232A5
10-1/8” 15” 3 Alum. 900-1500 14 - 16’ 26-34 48-73140A40
10-1/4” 14” 3 Steel 1200-1800 15 - 17’ 24-32 48-76230A5
10-3/8” 14” 3 Alum. 1200-1800 15 - 17’ 24-32 48-816706A40
10-3/8” 13” 3 Steel 1400-2000 15 - 18’ 21-29 48-76228A5
10-1/2” 13” 3 Alum. 1400-2000 15 - 18’ 21-29 48-816704A40
10-5/8” 12” 3 Steel 1600-2200 16 - 19’ 18-27 48-79792A5
10-3/4” 12” 3 Alum. 1600-2200 16 - 19’ 18-27 48-816702A40
11-5/8” 11” 3 Steel 1800-2400 16 - 20’ 15-25 48-823478A5
10-7/8” 11” 3 Alum. 1800-2400 16 - 20’ 15-25 48-85632A40
12” 10-1/2” 3 Alum. 1900-2600 17 -21’ 14-23 48-42740A10
11-1/4” 10” 3 Alum. 2000-2700 18 - 21’ 10-21 48-73132A40
12-1/4” 9” 3 Steel Workboat 18’Up 6-18 48-97868A10
12-1/4” 9” 3 Alum. Workboat 6-18 48-87818A10
12-1/2” 8” 3 Alum. Workboat/ 1-15 48-42738A10
Houseboat
Thrust Hub: 73345 (Forward)

Propeller Drive Hub: 43676
Diffuser Rings: 32201 (Aluminum)

Propeller Information Chart - 40 HP
Wide Open Throttle RPM: 5000-5500
Recommended Transom Height: 15”, 20”, 22-1/2”
Right Hand Rotation Standard
Gear Reduction: 2:1
Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part
Blades Boat Weight Length Range Number
(LBS) (MPH)
10” 19” 3 Alum. Up To 800 Up To 15’ 38-45 48-73146A40
10” 17” 3 Alum. Up To 1000 Up To 15’ 33-40 48-73144A40
10” 16” 3 Steel 700-1200 13 - 16’ 30-36 48-91818A5
10” 16” 3 Alum. 700-1200 13 - 16’ 30-36 48-73142A40
10-1/8” 15” 3 Steel 900-1500 14 - 16’ 28-34 48-76232A5
10-1/8” 15” 3 Alum. 900-1500 14 - 16’ 28-34 48-73140A40
10-1/4” 14” 3 Steel 1200-1800 15 - 17’ 26-32 48-76230A5
10-3/8” 14” 3 Alum. 1200-1800 15 - 17’ 26-32 48-816706A40
10-3/8” 13” 3 Steel 1400-2000 15 - 18’ 23-29 48-76228A5
10-1/2” 13” 3 Alum. 1400-2000 15 - 18’ 23-29 48-816704A40
10-5/8” 12” 3 Steel 1600-2200 16 - 19’ 20-27 48-79792A5
10-3/4” 12” 3 Alum. 1600-2200 16 - 19’ 20-27 48-816702A40
11-5/8” 11” 3 Steel 1800-2400 16 - 20’ 17-25 48-823478A5
10-7/8” 11” 3 Alum. 1800-2400 16 - 20’ 17-25 48-85632A40
12” 10-1/2” 3 Alum. 1900-2600 17 - 19’ 16-23 48-42740A10
11-1/4” 10” 3 Alum. 2000-2700 18 - 21’ 14-21 48-73132A40
12-1/4” 9” 3 Steel Workboat/ 18’Up 10-18 48-97868A10
Pontoon Boat
12-1/4” 9” 3 Alum. Workboat/ 10-18 48-87818A10
Pontoon Boat
12-1/2” 8” 3 Alum. Workboat/ 1-15 48-42738A10
Houseboat
Thrust Hub: 73345 (Forward)

Propeller Drive Hub: 43676
Diffuser Rings: 32201 (Aluminum)

D
OUTBOARD MOTOR INSTALLATION

Table of Contents
Page
Notice to Installer and Owner . . . . . . . . . . . . 1D-1
Boat Horsepower Capacity . . . . . . . . . . . . . . 1D-1
Outboard Remote Control . . . . . . . . . . . . . . . 1D-1
Selecting Accessories For The Outboard . . 1D-1
Selecting Steering Cables and Remote
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2
Locate Centerline Of The Outboard . . . . . . . 1D-2
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-2
Installing Outboard to Boat Transom . . . . . . 1D-3
Models Without Transom Bracket
Thumb Screws . . . . . . . . . . . . . . . . . . . . . . 1D-3
Models With Transom Bracket
Thumb Screws . . . . . . . . . . . . . . . . . . . . . . 1D-4
Fastening outboard to the boat transom 1D-5
Single Steering Cable and Steering Link
Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . 1D-5
Installing Ride Guide Steering Cable
To The Outboard . . . . . . . . . . . . . . . . . . . . 1D-5
Steering Link Rod Installation . . . . . . . . . 1D-6
Remote Control Installation . . . . . . . . . . . . . . 1D-6
Required Side Mount Remote Control or
Ignition Key Switch Assembly . . . . . . . . . . . . 1D-7
Boats Equipped with Side Mount Remote
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7
Boats Equipped with Panel Or
Console Mount Remote Control . . . . . . . 1D-7
Remote Wiring Connections . . . . . . . . . . . . . 1D-7
Electric Start Remote Control Model . . . 1D-7
Manual Start Models Using Quicksilver
2000 Series Side Mount Remote Control 1D-7
Shift and Throttle Cable Installation
To The Outboard . . . . . . . . . . . . . . . . . . . . . . . 1D-8
Shift Cable Installation . . . . . . . . . . . . . . . . 1D-8
Throttle Cable Installation . . . . . . . . . . . . . 1D-9
Battery Connections . . . . . . . . . . . . . . . . . . . . 1D-10
Set Up Instructions For Oil Injection System 1D-10
Filling The Oil Injection System . . . . . . . . 1D-10
Bleeding Air From The Oil
Injection System . . . . . . . . . . . . . . . . . . . . . 1D-11
Adjusting The Oil Injection Pump . . . . . . 1D-11
Propeller Installation . . . . . . . . . . . . . . . . . . . . 1D-11
Tilt Pin Adjustment . . . . . . . . . . . . . . . . . . . . . 1D-12
Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 1D-13
1D-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Notice to Installer and Owner Outboard Remote Control
This manual as well as safety labels posted on the The remote control connected to your 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.
DANGER WARNING
DANGER - Immediate hazards which WILL result Avoid serious injury or death from a sudden un-
in severe personal injury or death. expected acceleration when starting your en-
gine. The design of this outboard requires that
WARNING the remote control used with it must have a built
in start-in-gear protection device.
WARNING - Hazards or unsafe practices which
COULD result in severe personal injury or death.
CAUTION Selecting Accessories For

CAUTION - Hazards or unsafe practices which The Outboard
could result in minor injury or product or proper-
ty damage. Genuine Mercury Marine Quicksilver Accessories
have been specifically designed and tested for your
outboard.
Boat Horsepower Capacity Mercury Marine Quicksilver accessories are avail-

able from Mercury Marine dealers.
U.S. COAST GUARD CAPACITY Some accessories not manufactured or sold by Mer-
cury Marine are not designed to be safely used with
MAXIMUM HORSEPOWER XXX
your outboard or outboard operating system. Acquire
MAXIMUM PERSON and read the installation, operation, and mainte-
CAPACITY (POUNDS) XXX nance manuals for all your selected accessories.
MAXIMUM WEIGHT
CAPACITY XXX WARNING
Check with your dealer before installation of ac-
Do not overpower or overload your boat. Most boats cessories. The misuse of acceptable accesso-
will carry a required capacity plate indicating the ries or the use of unacceptable accessories can
maximum acceptable power and load as determined result in serious injury, death, or product failure.
by the manufacturer following certain federal guide-
lines. If in doubt, contact your dealer or the boat man-
ufacturer.
WARNING
Using an outboard that exceeds the maximum
horsepower limit of a boat can:
1. Cause loss of boat control
2. Place too much weight at the transom altering
the designed flotation characteristics of the
boat.
3. Cause the boat to break apart particularly
around the transom area. Overpowering a
boat can result in serious injury, death, or
boat damage.
90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1D-1

Selecting Steering Cables Lifting Outboard
and Remote Control Cables WARNING
Refer to “Quicksilver Accessories Guide” to deter- Verify that the lifting ring is threaded into the fly-
mine correct length of steering cables and remote wheel a minimum of 5 turns and that hoist has a
control cables. maximum lift capacity over 500 lbs. (227 kg) BE-
IMPORTANT: Steering cables and remote control FORE lifting outboard.
cables must be the correct length. Sharp bends 1. Electric Start Models - Remove plastic cap from
on too-short cables result in “kinks”; too-long center of flywheel. Thread lifting ring into flywheel
cables require unnecessary bends and/or loops. hub a minimum of 5 turns. Replace plastic cap af-
Both conditions place extra stress on the cables. ter installation.
Locate Centerline Of The

Outboard
Locate (and mark with pencil) the vertical centerline
of boat transom.
A B
a
C D
a - Centerline of Transom a - Lifting Ring
NOTE: Dimensions “A”& “B”and “C”& “D”are equal

length.
2. Manual Start Models - Use lifting eye on engine
IMPORTANT: During installation of dual out- and lift outboard on boat transom.
boards, the following is recommended. A mini-
mum of 221/2 inches (570mm) centerline to cent-
erline width is recommended. This is required to
alleviate cowling interference during lock to lock
turns if one outboard would be in the full tilt posi-
tion, while the other outboard(s) are in the verti-
cal running position.

Installing Outboard to Boat Use a 17/32 inch (13.5mm) diameter drill bit and drill
two mounting holes for the upper set of mounting
Transom bolts and two holes for the lower set of mounting
bolts.
NOTE: If using “Transom Drilling Fixture”
Models Without Transom Bracket 91-98234A2), use holes (a) when drilling outboard
Thumb Screws mounting holes
a a
b c
a
a
b
a - Use These Drilling Holes
b - Centerline of Transom
NOTE: On some boats because of transom interfer-

a - Mounting Bolts (4)
b - Flat Washers (4) ence, it may be necessary to install the steering cable
c - Locknuts (4) before fastening the outboard to the transom.
Position outboard on boat transom. Align the mount-
WARNING ing holes in the transom brackets that will place the
DO NOT, under any circumstances, allow upper outboard nearest to the recommended mounting
outboard mounting bolts to be closer than 1 inch height.
(25.4mm) to top of boat transom. Upper mount- Apply marine sealer to shanks of mounting bolts (not
ing bolts must never be installed thru shims. threads) and secure outboard to transom with 4 bolts,
NOTE: When drilling into a fiberglass boat, place flat washers and locknuts, as shown. Be sure that in-
masking tape directly onto boat where mounting stallation is water-tight.
holes will be drilled to help prevent fiberglass from
chipping.
Measure the transom height of your boat. The boat
bottom should be aligned or be within 1 in. (25mm)
below the anti-ventilation plate of the outboard.
0-1 in. a - Locknuts (4)

b - Flat Washers (4)
(0-25mm)
c - Marine Sealer
d - 1/2 Inch Diameter Bolts (4)
a - Anti-ventilation Plate
CAUTION
Marine sealer must be used on shanks bolts to
make a water-tight installation.

Measure the transom height of your boat. The boat
WARNING bottom should be aligned or be within 1 in. (25mm)
Before operation, the outboard must be correctly below the anti-ventilation plate of the outboard.
installed with four mounting bolts shown. Failure
to correctly fasten outboard could result in out-
board ejecting off boat transom causing serious
injury, death, or property damage. a
Models With Transom Bracket

Thumb Screws 0-1 in.
(0-25mm)
a - Anti-Ventilation Plate
IMPORTANT: Outboards with transom bracket

thumb screws can be secured to the boat tran-
som, using optional Quicksilver Accessory Out-
board Mounting Kit ( “a” P/N 812432A5), to allow
a for quick removal and installation of outboard.
Refer to installation instructions supplied with
the mounting kit before drilling any mounting
holes in the boat transom.
a - Transom Bracket Thumb Screws

a
WARNING
DO NOT, under any circumstances, allow the
cupped washers on the ends of the thumb
screws to be closer than 1 inch (25.4mm) to top
of (real) boat transom, not shims.
NOTE: When drilling into a fiberglass boat, place
masking tape directly onto boat where mounting a - Mounting Kit
holes will be drilled to help prevent fiberglass from
chipping.
WARNING
Outboard must be fastened to boat transom one
of two ways, permanently fastened to transom
with thumb screws, and mounting bolts (pro-
vided), or secured to the transom using the op-
tional outboard mounting kit (P/N 812432A5)
should the outboard strike an underwater object
or be steered into a sharp turn. Failure to fasten
outboard correctly to the boat transom with
mounting bolts or optional mounting kit could re-
sult in outboard ejecting suddenly off boat tran-
som causing serious injury or death, boat dam-
age or loss of outboard.

FASTENING OUTBOARD TO THE BOAT
TRANSOM
Single Steering Cable and
Type 1 Bracket Steering Link Rod
Drill two 1/2 in. (12.5mm) holes thru a lower set of Installation
mounting holes and fasten outboard to boat transom NOTE: These instructions are for single cable-single
with two 1/2 in. (12.5mm) mounting bolts, flatwashers outboard installations. Instructions for mounting dual
and locknuts (provided). engines are included with the applicable dual engine
Type 2 Bracket attaching kit. Refer to “Quicksilver Accessories
Guide”to determine correct kit.
Drill two 3/8 in. (9.5mm) holes thru the lower mount-
ing holes and fasten outboard to the boat transom Refer to “Quicksilver Accessories Guide” to deter-
with two 3/8 in. (9.5mm) mounting bolts, flat washers mine correct length of steering cable.
and locknuts (provided). IMPORTANT: Steering cable must be correct
Type 1 Bracket Type 2 Bracket length. Sharp bends on too-short of a cable re-
sult in “kinks;”too-long of a cable require unnec-
essary bends and/or loops. Both conditions
Tighten Transom Tighten Transom place extra stress on the cable.
Clamp Handles Clamp Handles
Install steering mount and steering wheel in accor-
dance with installation instructions that accompany
each.
Installing Ride Guide Steering Cable

b To The Outboard
b
IMPORTANT: Before installing steering cable in
tilt tube, lubricate entire cable end with Quicksil-
ver 2-4-C Marine Lubricant.
c
a a c NOTE: Ride Guide steering cable is lubricated at the
factory and requires no additional lubrication at initial
d installation.
d
1. Lubricate inside of outboard tilt tube and entire
a - Locknuts (2) cable end with Quicksilver 2-4-C Marine
b - Flat Washers (2) Lubricant.
c - Mounting Bolts (2)
d - Marine Sealer
2. Insert steering cable end thru outboard tilt tube
and secure steering cable to tilt tube with steering
CAUTION cable attaching nut, as shown. Torque nut to 35
lb. ft. (47.5 N·m).
Marine sealer must be used on shanks bolts to
make a water-tight installation.
c b
a
a - Tilt Tube
b - Cable End
c - Attaching Nut

3. Place a mark on the tilt tube, 1/4 in. (6.4mm) from 1. Assemble steering link rod to steering cable with
end of tilt tube. Install plastic spacer, o-ring and two flat washers and nylon insert locknut
cap onto steering cable as shown. (11-34863). Tighten locknut until it seats, then
back nut off 1/4 turn.
1/4 in.
(6.4mm c d 2. Assemble steering link rod to engine with special
)
b
washer head bolt (10-823919) and nylon insert
locknut (11-34863). First torque bolt to 20 lb. ft.
(27.1 N·m), then torque locknut to 20 lb. ft. (27.1
N·m).
a - Mark
b - Plastic Spacer
c - O-ring
d - Cap
4. Thread cap onto the tilt tube up to the 1/4 in. a - Washer Head Bolt
(6.4mm) mark. b - Nylon Insert Locknut
c - Nylon Insert Locknut
d - Flat Washer (2)
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
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-
ment.
a - Cap
Remote Control Installation
Steering Link Rod Installation Refer to “Quicksilver Accessories Guide” to deter-
mine correct length of remote control cables.
IMPORTANT: The steering link rod that connects
the steering cable to the engine must be fastened IMPORTANT: Remote control cables must be cor-
using special washer head bolt (“a”) (10-823919) rect length. Sharp bends on too-short of cables
and self locking nuts (“b” & “c”) (11-34863). result in “kinks;” too-long of cables require un-
These locknuts must never be replaced with necessary bends and/or loops. Both conditions
common nuts (non locking) as they will work place extra stress on the cables.
loose and vibrate off freeing the link rod to disen- IMPORTANT: Install control cables to remote
gage. control and mount remote control BEFORE at-
taching control cables to engine. Refer to instal-
WARNING lation instructions included with remote control.
Disengagement of a steering link rod can result
in the boat taking a full, sudden, sharp turn. This
potentially violent action can cause occupants to
be thrown overboard exposing them to serious
injury or death.
Required Side Mount
Remote Control or Ignition
Key Switch Assembly
Boats Equipped with Side Mount
Remote Control
a
A Quicksilver Commander 2000 series Side Mount
Remote Control equipped with a warning horn must b
c
be used with this outboard. This warning horn is nec-
a
essary for the engine warning system.
a - Remote Wire Harness

b - Engine Wire Harness Connector
c - Holder
Manual Start Models Using

a Quicksilver 2000 Series Side Mount
Remote Control
a -Warning Horn
1. Route the remote control harness around the
Boats Equipped with Panel Or back of the engine block as shown. Position the
harness so that the harness will not interfere with
Console Mount Remote Control shift and throttle operation.
A Quicksilver Ignition Key/Choke Assembly
equipped with a warning horn must be used with this
engine. This warning horn is necessary for the en-
gine warning system.
a
a - Remote Control Harness
2. Fasten the black wire from the remote control

harness to engine ground and connect the black/
yellow from the remote control harness to the
a - Warning Horn
black/yellow engine wire as shown.
Remote Wiring Connections
Electric Start Remote Control Model a

1. Route the remote wiring harness to the back of
the engine block as shown. ENGINE GROUND
2. Plug the remote wiring harness into the engine a b

wiring harness connector.
BLK/YEL BLK/YEL
3. Push connectors into the holder. a - Black Wire
b - Black/Yellow Lead

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

1. Position remote control and outboard into neu- b
tral.
2. Measure distance “a”between mounting pin and

middle of the barrel holder.
c d
a
a - Move Cable Barrel To Attain The Measured Distance
Taken In Step 2
b - Cable Barrel
c - Barrel Holder-- Place Barrel Into Bottom Hole
d - Retainer
5. Check shift cable adjustments as follows:

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

Throttle Cable Installation 4. Check throttle cable adjustment as follows:
1. Position remote control into neutral. a. Shift outboard into gear a few times to acti-
vate the throttle linkage. Make sure to rotate
N the propeller shaft while shifting into reverse.
F N R
2. Install cable to the throttle lever. Secure with re- b. Return remote control to neutral. Place a thin
tainer. piece of paper between throttle arm and idle
stop. Adjustment is correct when the paper
can be removed without tearing, but has
some drag on it. Readjust cable barrel if nec-
essary.
b
a b
a - Throttle Cable
b - Retainer
a
3. Adjust the cable barrel so that the installed

throttle cable will hold the throttle arm against the
stop.
a - Throttle Arm
b - Idle Stop
5. Lock the barrel holder in place with the cable

latch.
c
b
a - Cable Barrel -- Adjust To Hold Throttle Arm Against Stop

b - Throttle Arm
c - Barrel Holder -- Place barrel Into Top Hole

Battery Connections Set Up Instructions For Oil
CAUTION Injection System
For dual outboard installations, the BLACK (--) CAUTION
battery cable of each engines starter motor
ground circuit, MUST BE connected to each oth- Oil injected engines additionally, must be run on
er by a common circuit (cable) capable of carry- a 50:1 gasoline/oil mixture in the fuel tank for the
ing the starting current of each engines’starter first 10 gallons of fuel. Refer to engine break-in
motor. [i.e. A locally obtained battery cable con- procedure in the Operation & Maintenance
nected between the NEGATIVE (--) terminal of Manual.
each outboards cranking battery.]
CAUTION
CAUTION If an electric fuel pump is to be used on engines
Failure to observe correct polarity when con- with oil injection, the fuel pressure at the engine
necting battery cables to battery, will result in must not exceed 6 psi (41.1 kPa). If necessary, in-
damage to the charging system. stall a pressure regulator between electrical fuel
pump and engine and set at 6 psi maximum.
1. Connect battery cables (from engine) to battery.
Connect RED battery cable to POSITIVE termi-
nal and BLACK battery cable to NEGATIVE (--) Filling The Oil Injection System
battery terminal. 1. Check oil level using the sight gauge in front of
the outboard.
2. Remove the fill cap and fill tank with oil. The oil
tank capacity is 50.5 fl. oz. (1.5 liters).

Bleeding Air From The Oil Injection Adjusting The Oil Injection Pump
System When carburetor linkage is at idle position, alignment
IMPORTANT: If air exists in either the oil pump in- mark on oil injection arm should be in-line with mark
let hose or oil pump outlet hose, the air MUST BE on pump as shown. If necessary, adjust link rod.
bled from the hose(s) or engine damage may oc-
cur.
BLEEDING AIR FROM THE OIL PUMP INLET

HOSE
1. With the engine not running, place a shop towel
below the oil pump.
2. Loosen bleed screw four (4) turns and allow oil to
flow out of the bleed hole until no air bubbles exist
in the inlet hose.
BLEEDING AIR FROM THE OIL PUMP OUTLET

b
HOSE
3. If any air bubbles are present in the outlet hose, c a
they can be purged from the hose by removing
a - Alignment Mark
link rod from the oil pump and rotating the pump b - Mark On Pump
arm fully clockwise while operating engine at c - Link Rod
1000 to 1500 RPM.
Propeller Installation
WARNING
If the propeller shaft is rotated while the engine
is in gear, there is the possibility that the engine
will crank over and start. To prevent this type of
accidental engine starting and possible serious
b d injury caused from being struck by a rotating pro-
peller, always shift outboard to neutral position
and remove spark plug leads when you are serv-
icing the propeller.
1. Shift outboard to neutral (N) position.
c a 2. Remove leads from spark plugs to prevent en-
e gine from starting.
a - Inlet Hose
b - Outlet Hose
3. Coat the propeller shaft with Quicksilver Anti-
c - Bleed Screw Corrosion Grease.
d - Link Rod IMPORTANT: To prevent the propeller hub from
e - Pump Arm
corroding and seizing to the propeller shaft, es-
pecially in salt water, always apply a coat of
Quicksilver Anti-Corrosion Grease to the entire
shaft at the recommended maintenance intervals
and also each time the propeller is removed.

4. Install thrust washer, propeller, propeller nut re-
tainer, and propeller nut onto the shaft.
Tilt Pin Adjustment
b WARNING
d
DO NOT operate boat without the tilt pin in-
stalled. Failure to install tilt pin could result in
outboard kicking up when operated in reverse
causing serious injury, death, or property dam-
age.
Place tilt pin in desired hole in the transom bracket so
c the outboard will run perpendicular to the water when
a the boat is running at full speed. This allows the boat
to be driven parallel to the water.
a - Thrust Washer
b - Propeller
c - Propeller Nut Retainer
d - Propeller Nut
5. Place propeller retainer over pins. Place a block

of wood between gear case and propeller and
tighten propeller nut to 55 lb. ft. (75 N·m), aligning
flat sides of the propeller nut with tabs on the pro-
peller nut retainer.
a
a
a - Tilt Pin
Consider the following lists carefully when adjusting
the tilt pin.
PLACING TILT PIN IN LOWER HOLES CAN:

1. Lower the bow.
a - Pins
2. Result in quicker planing off, especially with a
heavy load or a stern heavy boat.
6. Secure propeller nut by bending tabs up and
against the flats on the propeller nut. 3. Generally improve the ride in choppy water.
4. Increase steering torque or pull to the right (with
a the normal right hand rotation propeller).
5. In excess, lower the bow of some boats to a point
where they begin to plow with their bow in the wa-
ter while on plane. This can result in an unex-
pected turn in either direction called “bow steer-
ing”or “over steering”if any turn is attempted or
if a significant wave is encountered.
a
a - Tabs

PLACING TILT PIN IN UPPER HOLES CAN: MODELS WITHOUT POWER TRIM
1. Lift the bow out of the water. Operate your boat at normal cruising speed trimmed
to desired position by installing the “tilt pin”in the de-
2. Generally increase top speed.
sired tilt pin hole. Turn your boat left and right and
3. Increase clearance over submerged objects or a note the direction the boat turns more easily.
shallow bottom.
If adjustment is necessary, loosen trim tab bolt and
4. Increase steering torque or pull to the left at a nor- make small adjustments at a time. If the boat turns
mal installation height (with the normal right hand more easily to the left, move the trailing edge of trim
rotation propeller). tab to the left. If the boat turns more easily to the right
5. In excess, cause boat “porpoising”(bouncing) or move the trailing edge of trim tab to the right. Retigh-
propeller ventilation. ten bolt and retest.
Trim Tab Adjustment

Propeller steering torque will cause your boat to pull
in one direction. This steering torque is a normal thing
that results from your outboard not being trimmed so
the propeller shaft is parallel to the water surface.
The trim tab can help to compensate for this steering a
torque in many cases and can be adjusted within lim-
its to reduce any unequal steering effort.
NOTE: Trim tab adjustment will have little effect re-
ducing steering torque if the outboard is installed with
the anti-ventilation plate approximately 2 inches (50
mm) or more above the boat bottom.
a - Trim Tab

ELECTRICAL
2
A
IGNITION
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Stator/Trigger (Electric Models) . . . . . . . . . . . . . . . 2A-2
Starter Motor Components . . . . . . . . . . . . . . . . . . . 2A-4
Electrical Components (S/N-0G380074/
Bel-Manual-9928507/BEL-Elec
9928480 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Electrical (S/N-USA-0G380075 Thru 0G589999/
Bel-ManuaL-9928508/BEL-Elec-9928481 Thru
9973099) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8
Electrical Components
(S/N-USA-0G590000/ BEL-9973100 & Above) . . 2A-10
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Ignition Component Description . . . . . . . . . . . . . . . 2A-12
Principle of Operation with
Timing Protection Module (TPM) . . . . . . . . . . . 2A-12
Mercury/Mariner 30/40 (2 cyl.) ADI Ignition
System (With Electronic Spark Advance) . . . . . . . 2A-13
Principle Of Operation,
CDM without Timing Protection Module (TPM) 2A-14
Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Capacitor Discharge Modules (CDM) . . . . . . . 2A-14
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Capacitor Charging #1 CDM . . . . . . . . . . . . . . . 2A-15
Capacitor Charging #2 CDM . . . . . . . . . . . . . . . 2A-16
#1 Cylinder Trigger Circuit . . . . . . . . . . . . . . . . . 2A-17
Ignition Coil Circuit . . . . . . . . . . . . . . . . . . . . . . . 2A-18
Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-19
Ignition Test Procedures . . . . . . . . . . . . . . . . . . . . . . 2A-21
Direct Voltage Adapter (DVA) Test
for Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-21
Ignition Diagnostic Procedures . . . . . . . . . . . . . . . . 2A-22
Testing Ignition Components . . . . . . . . . . . . . . . . . . 2A-23
Resistance Tests . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23
Timing Protection Module . . . . . . . . . . . . . . . 2A-23
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23
Trigger (S/N-0G589999 & Below) . . . . . . . . 2A-23
Trigger (S/N-0G590000 & Above) . . . . . . . . 2A-23
Capacitor Discharge Module P/N822779 . 2A-24
Ignition Components Removal . . . . . . . . . . . . . . . . 2A-27
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-27
2A-0 - ELECTRICAL 90-826148R2 MARCH 1997

Specifications
IGNITION Type Capacitor Discharge
SYSTEM Spark Plug Type (NGK) BP8H-N-10
Optional Plug (NGK) BPZ8H-N-10*
Firing Order 1-2
TIMING Models With (S/N-0G589999 & Below) Idle 3° BTDC ± 3° (Not
SPECIFICATIONS Adjustable)
Maximum BTDC @ 2500-5500 RPM (Not Adjust- 25° BTDC ± 3°
able)
Models With (S/N-0G590000 & Above) Idle 8° BDTC ± 1°
Maximum Spark Advance 1 Turn Clockwise After
Contacting Throttle Plate
Special Tools
1. Flywheel Holder 91-52344 4. Spark Gap Tester 91-63998A1
2. Flywheel Puller 91-73687A1

5. TPI/CDM Test Harness 84-825207A1
(S/N-0G589999 & Below)
3. Volt/Ohm/DVA Meter 91-99750
6. TPI/CDM Test Harness 84-825207A2

(S/N-0G590000 & Above)
90-826148R2 MARCH 1997 ELECTRICAL - 2A-1

STATOR/TRIGGER (ELECTRIC MODELS)
1 4
6 2
3
7
8
5
9
10
12
11
13
51
14
17
15
16
51 Loctite 222 (92-809818)

STATOR/TRIGGER (ELECTRIC MODELS)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SEAL–Rest (Use where applicable)
2 1 REST (OIL INJECTION) I.D. of rest rope hole is 1/4 IN.
3 1 PLUG–Starter Handle
2 1 REST KIT I.D. of rest rope hole is 1/3 IN.
3 1 PLUG–Starter Handle
4 1 GROMMET–Oil Tank
5 1 PLUG–Primer Hole
6 2 NUT (M6 x 1)
7 2 WASHER
8 2 SPACER
9 4 WING NUT
10 4 WASHER
11 4 WASHER (Neoprene)
12 1 COVER–Flywheel
13 5 SCREW (M5 x 30) 50 5.6
14 1 STATOR
15 1 O RING (S/N-USA-0G589999/BEL-9973099 & BELOW)
16 1 TRIGGER ASSEMBLY
17 1 TRIGGER ASSEMBLY (S/N-USA-0G590000/BEL-9973100 & ABOVE)

Starter Motor Components
2 4
5
10
14
8
9
1 6 7
25
12 11 8
15 14
13
25
25
25 Liquid Neoprene (92-25711--2)

Starter Motor Components
TORQUE
REF.
1 1 STARTER MOTOR
2 1 THRU BOLT 70 7.9
3 1 DRIVE KIT
4 1 DRIVE ASSEMBLY
5 1 DRIVE CAP
6 1 ARMATURE
7 1 COMMUTATOR CAP
8 1 BRUSH & SPRING KIT
9 1 BRUSH HOLDER
10 2 SCREW
11 1 LOCKWASHER
12 1 NUT (1/4-20) 60 6.8
13 1 BATTERY CABLE (5/16) (POSITIVE)
14 3 SCREW (M8 x 45) 16.5 22.3
15 1 CABLE (BLACK–6 IN. – 1/4 IN. Terminals)

ELECTRICAL COMPONENTS (S/N-0G380074/
BEL-MANUAL-9928507/BEL-ELEC-9928480 & Below)
25
12 14
3
51 13
25 17 15
10
4 16
25 2
1 25
9 6 8
11 7 5
43
44 18
40 19
42 2021
22
41
25
23
38
25
24
39
36 31
34 25
37 33
35 25
25 32
27
25
28
30 25
29
26

51 Loctite “222” Small Screw Threadlocker (92-809818)
Note: Apply Liquid Neoprene to all ring eyelet wiring terminals.

S/N-0G380074/BEL-MAN-9928507/BEL-ELEC-9928480 &Below
TORQUE
REF.
1 2 NUT (1/4-20) 50 5.6
2 2 LOCKWASHER
3 1 CABLE ASSEMBLY (BLACK–4 IN.)
4 1 SOLENOID ASSEMBLY
5 1 BUSHING ELECTRIC
6 1 GROMMET
7 2 SCREW (M6 x 25) 40 4.5
8 2 NUT (8–32) 20 2.3
9 1 CABLE (RED) ELECTRIC
10 1 BATTERY CABLE (NEGATIVE)
11 1 INSULATOR
12 1 RETAINER
13 1 STATOR (MANUAL)
14 5 SCREW (M5 x 30) 50 5.6
15 1 O RING
16 1 TRIGGER
17 1 HARNESS ASSEMBLY
18 1 PLATE–Electrical
19 3 BUSHING–Flanged
20 3 GROMMET
21 3 WASHER
22 3 SCREW (M6 x 25) 100 11.3
23 1 SCREW (M6 x 14) Drive Tight
24 1 TPM ASSEMBLY
25 3 SCREW (M5 x 20) 80 9.0
26 1 HARNESS ASSEMBLY–Engine (MANUAL)
27 1 HARNESS ASSEMBLY–Engine (ELECTRIC)
28 1 TERMINAL BLOCK
29 2 SCREW (M5 x 12) MANUAL
30 2 SCREW (10–16 x 3/8 IN.)
31 AR STA–STRAP
32 1 VOLTAGE REGULATOR
33 1 J–CLIP ELECTRIC
34 1 CABLE (BLACK–11 IN.)
35 2 SCREW (M6 x 35) 80 9.0
36 1 CABLE (BLACK–9 IN.)
37 1 SCREW (10-16 x 3/5 IN.)
38 2 CDM ASSEMBLY
39 4 SCREW (M6 x 14) 80 9.0
40 2 HI–TENSION CABLE KIT
41 2 BOOT KIT
42 2 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
42 2 SPARK PLUG (NGK# BPZ-8H-N-10) 240 20 27.1
43 1 SOCKET ASSEMBLY–FUSE ELECTRIC
44 1 FUSE

ELECTRICAL (S/N-USA-0G380075 Thru 0G589999/
BEL-MANUAL-9928508/BEL-ELEC-9928481 THRU 9973099)
NOTE: APPLY LIQUID NEOPRENE TO ALL RING END WIRING TERMINALS.

ELECTRICAL (S/N-USA-0G380075 THRU 0G589999/
BEL-MANUAL-9928508/BEL-ELEC-9928481 THRU 9973099)
TORQUE
REF.
1 5 SCREW (M5 x 30) MANUAL 50 5.6
2 1 STATOR
3 1 O RING
4 1 TRIGGER
6 2 BUSHING
7 2 GROMMET
8 2 NUT (8-32)
9 2 SCREW (M6 x 25) ELECTRIC 40 4.5
10 2 NUT (1/4-20) 50 5.6
11 2 LOCKWASHER
12 1 INSULATOR (RED)
13 1 RETAINER (ELECTRIC HANDLE)
14 1 SCREW
15 1 BATTERY CABLE (NEGATIVE–ELECTRIC)
16 2 CDM ASSEMBLY
17 2 HI-TENSION CABLE
18 1 BOOT
2 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
19 2 SPARK PLUG (NGK#BPZ–8H–N–10) 240 20 27.1
20 4 SCREW (M6 x 14) 80 9.0
22 1 CABLE (MANUAL)
23 1 SCREW (M6 x 14) 80 9.0
24 1 SCREW (M5 x 12)(ELECTRIC)
25 1 SCREW (M8 x 12)(MANUAL)
26 6 BUSHING
27 3 GROMMET DESIGN I
28 3 SCREW (M6 x 30)
29 3 BUSHING–Flanged
30 3 GROMMET DESIGN II
31 3 WASHER
32 3 SCREW (M6 x 35) 100 11.3
33 1 TPM ASSEMBLY
34 3 SCREW (M5 x 20) 80 9.0
35 3 STA–STRAP
36 1 VOLTAGE REGULATOR ELECTRIC
37 2 SCREW (M6 x 35) 80 9.0
38 1 CONDUIT
39 1 TERMINAL BLOCK
40 2 SCREW (10–16 x 3/8 IN.) MANUAL
41 2 SCREW (M5 x 12)
44 1 HARNESS (ELECTRIC)

ELECTRICAL COMPONENTS
(S/N-USA-0G590000/ BEL-9973100 & Above)
NOTE: APPLY LIQUID NEOPRENE TO ALL RING END WIRING TERMINALS.

ELECTRICAL COMPONENTS
(S/N-USA-0G590000/BEL-9973100 & ABOVE)
TORQUE
REF.
1 5 SCREW (M5 x 30) 50 5.6
2 1 STATOR MANUAL
3 2 PLUG
4 1 TRIGGER
5 1 CABLE TIE (4 IN.)
7 2 BUSHING
8 2 GROMMET
9 2 NUT (8-32)
11 2 NUT (1/4-20) 50 5.6
12 2 LOCKWASHER
13 1 INSULATOR (RED)
14 1 RETAINER (ELECTRIC HANDLE)
15 1 SCREW
16 1 BATTERY CABLE (NEGATIVE–ELECTRIC)
17 2 CDM ASSEMBLY
18 2 HI-TENSION CABLE
19 1 BOOT
20 2 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
21 2 SPARK PLUG (NGK#BPZ–8H–N–10) 240 20 27.1
22 1 CABLE MANUAL
23 1 SCREW (M8 x 12)
24 4 SCREW (M6 x 14) 60 6.7
26 1 SCREW (M5 x 12) 60 6.7
27 1 WASHER
28 1 SCREW (M6 x 14) 60 6.7
29 1 WASHER
30 6 BUSHING
31 3 GROMMET
32 3 SCREW (M6 x 30)
1 REV LIMITER (MANUAL)
33
1 REV LIMITER (ELECTRIC)
34 2 SCREW (M6 x 25) 30 3.4
35 4 STA–STRAP (8 IN.)
36 1 VOLTAGE REGULATOR
38 1 CONDUIT
41 1 CONDUIT
1 POWERHEAD

Theory of Operation Ignition Component
The ignition system is alternator-driven with distri- Description
butor-less capacitor discharge. Major components of
the ignition system are the flywheel, stator, trigger,
timing protection module (TPM), capacitor discharge Principle of Operation with Timing
modules (CDM) and spark plugs.
Protection Module (TPM)
The stator assembly is mounted stationary below the
flywheel and has 2 (red stator has 3) capacitor charg- Under normal circumstances, the TPM controls:
ing coils wound in series. The flywheel is fitted with 1. Spark timing by monitoring the trigger pulses and
6 permanent magnets inside the outer rim. As the fly- engine temperature.
wheel rotates the permanent magnets pass the ca-
pacitor charging coils causing the coils to produce 2. Advances spark timing quickly to 25° BTDC un-
AC voltage (230 - 330 volts). The AC voltage then is der hard acceleration conditions.
conducted to the capacitor discharge module (CDM) 3. Provides over-speed protection if engine RPM
where it is rectified and stored in a capacitor. Part of exceeds 5800. This occurs in 2 stages. Initially,
the stator voltage (20 - 25 volts) is sent to the timing timing is retarded from 25° BTDC to 14° BTDC.
protection module (TPM) to power the timing circuit. If RPM continues to increase above 6500, TPM
The trigger assembly (also mounted under the fly- will shut ignition off momentarily until RPM drops
wheel) has 1 coil. The flywheel has a another perma- below 6500.
nent magnet located around the center hub. As the 4. Provides an idle stabilizer function by advancing
flywheel rotates, this hub magnet passes the trigger timing when engine RPM drops below 600. At
coil. This causes the trigger coil to produce a AC volt- crank speed of 300 RPM, timing can be as high
age pulse which is sent to the TPM. The TPM delays as 10° BTDC.
this signal depending on engine RPM and forwards
5. Provides warning control of OVER-HEAT and
a trigger signal to a electronic switch (SCR) within the
LOW-OIL conditions. Warning is provided
CDM.
through activation of a continuous tone warning
The SCR switch discharges the stored voltage of the horn for either condition. An OVER-HEAT condi-
capacitor into the primary side of the CDM’s ignition tion occurs when engine temperature rises
coil. above 190° F ± 8° (88° C ± 13°). The TPM will
Capacitor voltage within the CDM is amplified as high intermittently interrupt the ignition voltage to the
as 45000 volts to jump the gap at the spark plug. capacitor discharge modules (CDM) to reduce
maximum RPM to approximately 2500. The RPM
The preceding sequence occurs once-per-engine- will be limited and the warning horn will activate
revolution for each cylinder. until engine temperature drops below 170° F ± 8°
Spark timing is changed (advanced/retarded) elec- (77° C ± 13°).
tronically by the TPM monitoring trigger pulses. During a LOW-OIL condition, the TPM activates
the warning horn when switch in engine-mounted
IMPORTANT: If the engine misfires, runs rough or oil tank is shorted to ground (closed). Engine
does not start, the ignition system should be RPM is NOT limited during a LOW-OIL condition.
checked using a Multi-Meter/DVA Tester
(91-99750), or a voltmeter (capable of measuring
400 volts DC, or higher) and Direct Voltage Adap-
tor (91-89045).

Mercury/Mariner 30/40 (2 cyl.) ADI IGNITION SYSTEM (With
Electronic Spark Advance)
d
S b
N
N e
c
S
S
GRN/WHT
BLK/YEL g
N
N BLK f
BLK
h
S BLK/YEL
WHT
GRN
S
GRN/WHT
WHT
WHT
S
GRN/WHT
N
WHT/BLK
GRN/WHT
S
N e
BLK/YEL
YEL
BLK/YEL
a
f g
YEL
Wires to
Voltage
Regulator
GRN/WHT
WHT
WHT/BLK
WHT
GRN/WHT
WHT
BLK
#1 Power
Acceleration
GRN
Cylinder Supply
Detector j
Control
Timing
k
RPM
Counter Control
TAN/BLU
BLK
LT BLU
BLK
PUR
#2
TAN
Speed
Cylinder
Warning l
LT BLU
n Limiter Circuit
Control
m
a - Battery Charging Coils (8) i - Stop Switch
b - Ignition Charge Coils (2) j - Neutral Start Switch
c - Trigger k - Temperature Sender
d - CDM #1 l - Low Oil Switch
e - Capacitor m- Warning Horn
f - SCR n- Timing & Protection Module
g - Coil
h - CDM #2

Principle Of Operation, CDM without Trigger Coil
Timing Protection Module (TPM) One Piece assembly, containing two trigger coils-one
The ignition system is alternator-driven with distribu- for each cylinder located under flywheel. Is charged
tor-less capacitor discharge. Major components of by single magnet on flywheel hub. Trigger pulses are
the ignition system are the flywheel, stator, trigger, sent to TPM or CDM.
capacitor discharge modules (CDM and spark plugs. NOTE: Trigger assemblies are different between
The stator assembly is mounted stationary below the TPM and non-TPM systems.
flywheel and has 3 capacitor charging coils wound in
series. The flywheel is fitted with 6 permanent mag-
nets inside the outer rim. As the flywheel rotates the Stator
permanent magnets pass the capacitor charging Located under the flywheel in the stator assembly are
coils causing the coils to produce AC voltage (260 -
3 charge coils wound in series, they provide voltage
320 volts). The AC voltage then is conducted to the to the capacitor discharge modules (CDM). The
capacitor discharge module (CDM) where it is recti-
charge coils also provide voltage to power the timing
fied and stored in a capacitor. circuit in the TPM or CDM.
The trigger assembly (also mounted under the fly-
wheel) has 2 coil. The flywheel has another perma-
nent magnet located around the center hub. As the Capacitor Discharge Modules (CDM)
flywheel rotates, the magnet passes the trigger coil.
This causes the trigger coil to produce a AC voltage Each module contains an ignition coil and amplifier
pulse which is sent to an electronic switch (SCR) circuitry which produces approximately 45000 volts
within the CDM. at the spark plugs.
The SCR switch discharges the stored voltage of the

capacitor into the primary side of the CDM’s ignition Flywheel
coil.
Contains 6 magnets (12 pole) around circumference.
Capacitor voltage within the CDM is amplified as high
One magnet located on inner hub for trigger. Outer
as 45000 volts to jump the gap at the spark plug.
magnets are for battery charge coils and ignition
The proceeding sequence occurs once-per-engine- charge coils.
revolution for each cylinder.
NOTE: The inner trigger hub are different be-
Spark timing is changed (advanced/retarded) by ro- tween TPM and non-TPM systems.
tating the trigger assembly which changes each trig-
ger coil position in relation to the permanent magnets
on the flywheel center hub.
A rev-limiter (over-speed protection) circuit is con-
tained inside the trigger assembly. The trigger
pulse(s) provide power for the rev-limiter circuit, this
circuit in turn counts the trigger pulses to determine
engine RPM. IF the engine RPM increases above
the specified RPM limit, the rev limiter will prevent the
trigger pulses from reaching the CDM eliminating
spark delivery to the cylinder. The Rev limiter will start
to limit at 5900 ± 150 RPM and fully limit at 6200 ± 150
RPM.

Theory of Operation CAPACITOR CHARGING #1 CDM
This outboard ignition system is alternator–driv- The STATOR assembly is mounted to the block
en (distributor–less) capacitor discharge sys- below the flywheel and has 3 CAPACITOR
tem. Major components of the ignition system CHARGING COILS wound in series. The FLY-
are the flywheel, stator, trigger, capacitor dis- WHEEL is fitted with 6 permanent magnets in-
charge modules (CDM’s) and spark plugs. Each side the outer rim. The flywheel rotates the per-
capacitor discharge module functions as a com- manent magnets past the capacitor charging
bination switchbox and secondary ignition coil. coils–causing the coils to produce AC voltage
(260–320 volts). The AC voltage is then con-
ducted to the CAPACITOR DISCHARGE MOD-
ULES (CDM), where it is rectified (DC) and
stored in a capacitor. The stator voltage return
path is through the ground wire of the other CDM
and back through that CDM’s charging coil wire
to the capacitor charging coils.
a S N b
N
S
c
S
_ 1 N
S N
+
+
2 _
N
S
S
f N
N S
BLK
YEL
h YEL
BLK
WHT/GRN
PPL
Return Voltage d
Source Voltage
BLK/YEL
g
BLK
Capacitor-
Coil-
SCR- BLK
GRN/WHT
Diode- WHT
a - Battery Charging Coils e - CDM #2

b - Trigger Coils f - Rev. Limiter
c - Capacitor Charge Coils g - Stop Switch
d - CDM #1 h - To Voltage Regulator

CAPACITOR CHARGING #2 CDM
The flywheel rotates the permanent magnets
past the capacitor charging coils–causing the
coils to produce AC voltage (260–320 volts).
The opposite voltage pulse is then conducted to
the CAPACITOR DISCHARGE MODULES
(CDM), where it is rectified (DC) and stored in a
capacitor. The stator voltage return path is
through the ground wire of the other CDM and
back through that CDM’s charging coil wire to the
capacitor charging coils.
S N
b
a N
S
S c
_ 1 N
S N
+
+
2 _
N
S
S
N
f
N S
BLK
h YEL
YEL
BLK
WHT/GRN
PPL
Return Voltage d
Source Voltage
BLK/YEL
g
BLK
Capacitor-
Coil-
BLK
SCR- GRN/WHT
WHT
Diode- e


#1 Cylinder Trigger Circuit A positive voltage pulse (N–S) will activate the
electronic switch (SCR) inside the capacitor dis-
The TRIGGER assembly (also mounted under charge module (CDM). The switch discharges
the flywheel) has one coil for each cylinder. the capacitor voltage through the coil primary
These coils are mounted adjacent to the fly- windings. The return voltage pulse exits the
wheel center hub. The center hub of the flywheel CDM through the ground wire and returns
contains a permanent magnet with one north– through the trigger ground. Once inside the trig-
south transitions. As the flywheel rotates, the ger the voltage will supply the bias capacitor with
magnet north–south transitions pass the trigger a negative charge. For the next trigger in se-
coils. This causes the trigger coils to produce a quence to activate its CDM (SCR), the positive
voltage pulse which is sent to the respective ca- trigger voltage must first over come this offset
pacitor discharge module (CDM). bias capacitor voltage. The delay produced by
having to over come this offset bias capacitor
voltage prevents the timing from electronically
advancing as engine speed increases.
S N
b
a N
S
S c
_ 1 N
S N
+
+
2 _
N
S
S
N
f
N S
BLK
h YEL
YEL
BLK
WHT/GRN
PPL
Return Voltage d
Source Voltage
BLK/YEL
g
BLK
Capacitor-
Coil-
SCR- BLK
GRN/WHT
Diode- WHT


Ignition Coil Circuit
As the capacitor voltage flows through the pri-
mary windings of the ignition coil, a voltage is in-
duced into the ignition coil secondary windings.
This secondary voltage rises to the level re-
quired to jump the spark plug gap and return to
ground. This secondary voltage can, if neces-
sary, reach approximately 40,000 volts. To com-
plete the secondary voltage path, the released
voltage enters the ground circuit of CDM mod-
ule.
S N
b
a N
S
S
c
_ 1 N
S N
+
+
2 _
N
S
S
N
f
N S
BLK
h YEL
YEL
BLK
WHT/GRN
PPL
Return Voltage d
Induced Voltage
BLK/YEL
g
BLK
Capacitor-
Coil-
SCR- BLK
GRN/WHT
Diode- WHT


Stop Circuit
To stop the engine, the stop switch is closed al-
lowing the capacitor charge current from the sta-
tor to drain directly to ground. NOTE: The CDM
contains a zener diode (not shown for clarity).
This diode prevents overcharging of the capaci-
tor (and possible failure) if the SCR does not re-
ceive a trigger pulse.
S N
b
a N
S
S c
_ 1 N
S N
+
+
2 _
N
S
S
N
f
N S
BLK
h YEL
YEL
BLK
WHT/GRN
PPL
Return Voltage d
BLK/YEL
g
BLK
Capacitor-
Coil-
SCR- BLK
GRN/WHT
Diode- WHT


To bypass a CDM with a failed stator voltage NOTE 1: This test will work on 3 & 4 cylinder
return path, install the DVA adaptor harness (to engines, however the number of CDM’s
allow easy access to the wire connectors) and (cylinders) that function correctly will vary.
using the test jumper P/N 91–818812A1 (or NOTE 2: It is possible to ground one of the stator
equavilant) connect the stator charge wire to the leads to ground (bypassing the CDM and
CDM ground lead. This will allow the remaining harness). Do Not damage the wire connector by
CDM to function correctly. clamping the connector to ground with a bolt.
S N
b
a N
S
S c
_ 1 N
S N
+
+
2 _
N
S
S
N
e
N S
BLK
g YEL
YEL
BLK
WHT/GRN
PPL
Return Voltage d
Source Voltage
BLK/YEL
f
BLK
Capacitor-
Coil-
SCR- BLK
GRN/WHT
Diode- WHT
i
a - Battery Charging Coils
b - Trigger Coils
c - Capacitor Charge Coils
d - CDM #1
e - Rev. Limiter
f - Stop Switch
g - To Voltage Regulator
h - DVA Adaptor Harness P/N 84-825207A2
i - Test Jumper P/N 91-818812A1

Ignition Test Procedures – DO NOT CHANGE meter selector switch posi-
tion while engine is running and/or being
Direct Voltage Adapter (DVA) Test “cranked”.
for Stator – ALL COMPONENTS MUST BE GROUNDED
during tests. Running or “cranking” engine
with TPM or CDM ungrounded may damage
WARNING components.
DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do *If using a meter with a built-in DVA, the DVA/400 VDC (or
not touch ignition components and/or metal test higher) test position should be used.
probes while engine is running and/or being
NOTE: Test leads are not supplied with the DVA. Use
“cranked”. STAY CLEAR OF SPARK PLUG
test leads supplied with meter.
LEADS. To assure personal safety, each individu-
al spark plug lead should be grounded to engine. Test procedures and specifications are provided for
checking primary ignition voltage while the en-
WARNING gine is running and/or being “cranked” with all har-
nesses connected.
When testing or servicing the ignition system,
high voltage is present. DO NOT TOUCH OR DIS- Install test harness between ignition harness and
CONNECT any ignition parts while engine is run- CDM as shown.
ning, while key switch is on or while battery b a
cables are connected.
CAUTION
Failure to comply with the following items may
result in damage to the ignition system.
1. DO NOT reverse battery cable connections. The
battery negative cable is (-) ground.
c
2. DO NOT “spark” battery terminals with battery
cable connections to check polarity.
3. DO NOT disconnect battery cables while engine a - Stator/Trigger Harness
is running. b - Test Harness (P/N 91-825207A1)
c - Capacitor Discharge Module (P/N 822779)
4. DO NOT crank engine when CDMs or TPM are
not grounded to engine. a b c
CAUTION
To protect against meter and/or component dam-
age, observe the following precautions:
– 400 VDC* test position (or higher) MUST BE
used for all tests.
– INSURE the Positive (+) lead/terminal of DVA is
connected to the Positive (+) receptacle of me- a - Stator/Trigger Harness
ter b - Test Harness (P/N 91-825207A2)
c - Capacitor Discharge Module (P/N 827509)
Selector Switch Voltage Reading*

TEST RED Lead BLACK Lead
Position @ (300 - 4000) RPM
Red Test Harness
Stator 400 DVA Ground 190 - 320
(Green/White)
Stator 40 DVA Green or White/Green Ground 20 - 40
* If voltage is low, disconnect one Capacitor Discharge Module (CDM) connector at a time while
monitoring voltage reading.
If voltage rises, replace that CDM. If voltage does not rise, replace stator.

Ignition Diagnostic
IMPORTANT: If outboard appears to have an igni-
Procedures tion system failure, it is recommended that be-
TROUBLESHOOTING TIP: With engine running, fore beginning in-depth troubleshooting:
use inductive timing light to check spark advance of a. Check ground leads on Timing Protection
each cylinder as throttle is opened and closed. If tim- Module, Capacitor Discharge Modules and
ing advances and retards smoothly on each cylinder, ground lead between ignition plate and en-
ignition system is MOST LIKELY functioning proper- gine block for proper continuity.
ly.
b. Disconnect and reconnect ignition harness
connectors to verify proper continuity.
PROBLEM CORRECTION
1. No Spark or Weak Spark on Both Cylinders No Spark - Trigger, Stator or Timing Protection
Module (TPM)
Weak Spark - Stator
2. No Spark or Weak Spark on 1 Cylinder Capacitor Discharge Module (CDM)
3. Timing Fluctuates - Note: It is normal for timing to Defective Engine Temperature Sensor
fluctuate 2°-3° @ Idle. Defective TPM
- If engine over-heats [above
190° F (88° C)], TPM will limit
engine RPM to 2500.
- If engine RPM exceeds 5800,
TPM will retard timing from 25
BTDC TO 14° BTDC.
- If RPM exceeds 6500 RPM,
TPM will momentarily shut
ignition off until RPM drops
below 6500.
- If engine RPM drops below
600, idle stabilizer in TPM will
advance timing to as high as
10° BTDC @ cranking speed
of 300 RPM.
4. Timing will not Advance on both Cylinders Defective TPM
5. Timing will not Advance on 1 Cylinder Check wiring between CDM and TPM. If wiring is
OK, replace CDM.
6. Engine Misfires @ High RPM Defective CDM
Defective TPM
7. Engine Hard to Start when Cold Defective Fuel Enrichment Valve
Defective TPM
8. Engine Misfires @ Low RPM but Runs Smooth @ Defective Harness (loose connections) between
High RPM TPM and CDM
Defective CDM
Defective TPM
Defective Stator
9. Engine Starts Hard when Hot Defective TPM
10. Engine will not Run over 2500 RPM and is not Defective Temperature Sensor
Over-Heating. Defective TPM
11. Engine Occasionally Misfires Replace Standard Spark Plug with Inductor Plug

Testing Ignition Components TRIGGER (S/N-0G589999 & BELOW)
A resistance check can be made on trigger coil be-
tween WHITE/BLACK and WHITE leads. Ohmmeter
Resistance Tests should indicate between 1100 - 1300 ohms.
TIMING PROTECTION MODULE

Normally, if timing advances and retards with corre-
sponding changes in RPM, most likely the TPM is
functioning correctly. Refer to “Ignition Diagnostic
Procedures” preceding, for individual failure sce-
narios.
TRIGGER (S/N-0G590000 & ABOVE)
STATOR
A resistance check can be made on charge coils.
Ohmmeter should indicate as follows:
Black Stator between GREEN/WHITE and GREEN
leads (525-625 ohms)
Red Stator between GREEN/WHITE and WHITE/
55767
GREEN leads (660-710 ohms).
A resistance test is not used on the trigger. Test trig-

ger as outlined under “Trigger Output Test”.
Trigger Output Test 20 DVA Scale

Positive Meter Negative Meter DVA Reading
L d (+)
Lead ( ) L d (–)
Lead ( )
White Test Black Test Har- 2 - 8 Volts
H
Harness L
Leadd L d
ness Lead
If reading is below specifications replace trigger. If

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

CAPACITOR DISCHARGE MODULE P/N822779 A resistance check can be made of the CDM as fol-
a lows:
a - Test Harness P/N 91-825270A1

b - Capacitor Discharge Module P/N 822779
CAPACITOR DISCHARGE MODULE RESISTANCE CHECK-ANALOG METER

Connect Positive (+) Connect Negative (–) Ohms
Reading
Meter Lead To: Meter Lead To: Scale
White Pin or White Test
Ground Lead RX1 40 10
Harness Lead
GRN/WHT Pin or Red Ground Lead R X 1*
Continuity
Test Harness Lead Diode Reading
GRN/WHT Pin or Red R X 1K*
Ground Lead No Continuity
Test Harness Lead Diode Reading
GRN/WHT Pin or Red BLK/YEL Pin or Black R X 1K*
No Continuity
Test Harness Lead Test Harness Lead Diode Reading
BLK/YEL Pin or Black GRN/WHT Pin or Red R X 1*
Continuity
Test Harness Lead Test Harness Lead Diode Reading
Coil Tower Ground Lead R X 10 1000 300
NOTE: Due to the differences in test meters battery polarity, results other than specified may be obtained. In
such a case, reverse meter leads and re-test. If test results then read as specified on all tests CDM is O.K.. The
diode measurements above will be opposite if using a Fluke equivalent multimeter.
CAPACITOR DISCHARGE MODULE RESISTANCE CHECK-DIGITAL METER

Reading
White PIn or White Test
Ground Lead Ω or 200 40 10 Ohms
Harness Lead
GRN/WHT Pin or Red Ground Lead * OL or OUCH
Test Harness Lead
GRN/WHT Pin or Red *
Ground Lead .400-.900
Test Harness Lead
GRN/WHT Pin or Red BLK/YEL Pin or Black * .400-.900
Test Harness Lead Test Harness Lead
BLK/YEL Pin or Black GRN/WHT Pin or Red * OL or OUCH or 1.
Test Harness Lead Test Harness Lead
Coil Tower Ground Lead Ω or 2K .800-1.200 KΩ
diode measurements above will be as specified if using a Fluke equivalent multimeter.

Capacitor Discharge Module (P/N 827509) Ohms Test
a - Spark Plug Wire IMPORTANT: Spark Plug Wires Are Screwed into CDM.
b - Part Number: 827509
Date Code:0415 (Julian Date and Year: 5=1995)
c - Pins are Labeled: A:Black - Ground
B:Black/Yellow - Stop Circuit
C:White - Trigger
D:Green - Stator
d - Capacitor Discharge Module P/N 827509
e - Test Harness P/N 91-825207A2
A resistance check, although not necessary for any troubleshooting procedure, can be made of the CDM as fol-
lows:
NOTE: This test can be performed using the test harness (p/n 84-825207A2). Do Not connect the test harness
plug to the stator/trigger engine wire harness.
CAPACITOR DISCHARGE MODULE RESISTANCE CHECK - ANALOG METER

Results:
Ground Pin (A)/ or Black White (C)/ or White Test
R x 100 1250 300 Ohms
Test Harness Lead Harness Lead
Green (D)/ or Green Test Ground Pin (A)/ or Black R x 100
Continuity
Harness Lead Test Harness Lead Diode Reading*
Ground Pin (A) or Black Green (D)/ or Green Test R x 100
No Continuity
Test Harness Lead Harness Lead Diode Reading*
Green (D)/ or Green Test Black/Yellow (B)/ or Black/ R x 100
No Continuity
Harness Lead Yellow Test Harness Lead Diode Reading*
Black/Yellow (B)/ or Black/ Green (D)/ or Green Test R x 100
Continuity
Yellow Test Harness Lead Harness Lead Diode Reading*
Spark Plug Terminal Ground Pin (A) or Black
R x 100 1000 300 Ohms
(At Spark Plug Boot) Test Harness Lead
NOTE: Due to the differences in test meters battery polarity, results other than specified may be obtained. In such
a case, reverse meter leads and re-test. If test results then read as specified on all tests CDM is O.K.. The diode
measurements above will be opposite if using a Fluke equivalent multimeter.

CAPACITOR DISCHARGE MODULE RESISTANCE CHECK - DIGITAL METER
Results:
Ground Pin (A)/ or Black White (C)/ or White Test
Ω or 2K 1.125-1.375 KΩ
Green (D)/ or Green Test Ground Pin (A)/ or Black
OL or OUCH
Harness Lead Test Harness Lead
Ground Pin (A) or Black Green (D)/ or Green Test
.400-.900
Green (D)/ or Green Test Black/Yellow (B)/ or Black/
.400-.900
Harness Lead Yellow Test Harness Lead
Black/Yellow (B)/ or Black/ Green (D)/ or Green Test
OL or OUCH
Yellow Test Harness Lead Harness Lead
Spark Plug Terminal Ground Pin (A) or Black
Ω or 2K .950-1.150 KΩ
(At Spark Plug Boot) Test Harness Lead
diode measurements above will be as specified if using a Fluke equivalent multimeter.

Ignition Components 5. Install Crankshaft Protector Cap (91-24161) on
the end of crankshaft, then install Flywheel Puller
Removal (91-73687A1) into flywheel.
6. Remove flywheel.
Flywheel NOTE: Neither heat or hammer should be used on
flywheel to aid in removal as damage to flywheel or
1. Remove flywheel nuts and washers. electrical components under flywheel may result.
2. Remove flywheel cover.
a a
a b
55122
a - Flywheel Puller (91-73687A1)
b - Flywheel
a a
55120
a - Nuts and Washers
WARNING
Engine could possibly start when turning fly-
wheel during removal and installation; therefore,
disconnect (and isolate) spark plug leads from
spark plugs to prevent engine from starting.
3. Disconnect spark plug leads from spark plugs.
4. While holding flywheel with Flywheel Holder
(91-52344), remove flywheel nut and washer.
a 55121
a - Flywheel Holder (91-52344)

ELECTRICAL
2
B
CHARGING & STARTING SYSTEM

Table of Contents Page
Checking Positive Brushes and Terminals 2B-15
Page Testing Negative Brushes For Ground . . . . 2B-15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Recommended Battery . . . . . . . . . . . . . . . . . . . . 2B-1
Operating Engine Without Battery . . . . . . . . . . 2B-1
Specific Gravity Readings . . . . . . . . . . . . . . . . . . . . 2B-2
Specific Gravity Cell Comparison Test . . . . . . . 2B-2
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Charging a Discharged
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Winter Storage of Batteries . . . . . . . . . . . . . . . . . . . 2B-3
Battery Charging System
(14 or 18 Ampere Alternator) . . . . . . . . . . . . . . . . . 2B-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Electric Start Models . . . . . . . . . . . . . . . . . . . 2B-4
Manual Start Models . . . . . . . . . . . . . . . . . . . 2B-4
Battery Charging System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Stator Ohms Test-Alternator Coils Only . . . . . . 2B-5
9 Ampere Manual Stator
(S/N-0G589999 & Below) . . . . . . . . . . . . . . . 2B-5
9 Ampere manual Stator
(S/N-0G590000 & Above) . . . . . . . . . . . . . . 2B-5
14 Ampere Stator . . . . . . . . . . . . . . . . . . . . . . 2B-5
16 Ampere Stator
(S/N-0G590000 & Above) . . . . . . . . . . . . . . 2B-5
18 Ampere Stator . . . . . . . . . . . . . . . . . . . . . . 2B-5
Alternator System Test . . . . . . . . . . . . . . . . . . . . 2B-6
9 Ampere Stator . . . . . . . . . . . . . . . . . . . . . . . 2B-6
9 Ampere Stator (S/N-0G589999 & Below) 2B-6
9 Ampere Stator (S/N-0G590000 & Above) 2B-6
14/16/18 Ampere Stator . . . . . . . . . . . . . . . . 2B-6
Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Voltage Regulator/Rectifier Test
Models with (S/N-0G590000 & Above) . . . . . . 2B-9
Diode Test: . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Test Results: . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Diode Test: . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Test Results (1ST reading): . . . . . . . . . . . . . 2B-9
Test Results (2ND reading): . . . . . . . . . . . . . 2B-9
SCR Test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Test Results (Both Test): . . . . . . . . . . . . . . . . 2B-9
Tachometer Circuit Test: . . . . . . . . . . . . . . . . 2B-9
Test Results: . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10
Starter Motor Amperes Draw . . . . . . . . . . . . . . . 2B-10
Starting System Components . . . . . . . . . . . . . . 2B-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10
Troubleshooting the Starting Circuit . . . . . . . . . 2B-10
Starter Solenoid Test . . . . . . . . . . . . . . . . . . . 2B-10
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 2B-14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Armature Test For Shorts . . . . . . . . . . . . . . . 2B-14
Armature Test For Ground . . . . . . . . . . . . . . 2B-15
2B-0 - ELECTRICAL 90-826148R2 MARCH 1997

Specifications
STARTING Manual Start Recoil
SYSTEM Electric Start 12 Volt
Starter Draw (Under Load) 95 Amperes
(No Load) 20 Amperes
CHARGING Alternator Output Single Phase (12 Pole)
SYSTEM – Electric Start 14 Amperes @ 5000 RPM
– Manual Start 9 Amperes @ 3000 RPM
Special Tools
1. Volt/Ohm/DVA Meter 91-99750 Recommended Battery
A 12 volt battery with a “Cold Cranking Amperage”
rating minimum of 465 amperes.
Operating Engine Without Battery

If desired (or in an emergency), engines equipped
with an alternator can be started and operated with-
out a battery (either disconnected or removed) if
“WARNING”, below, is followed.
Battery
WARNING
Precautions Before operating engine with battery leads dis-
connected from battery, disconnect stator leads
When charging batteries, an explosive gas mixture
(Yellow) from rectifier. Insulate (tape) stator lead
forms in each cell. A portion of this gas escapes thru
ring terminals.
holes in vent plugs and may form an explosive atmo-
sphere around battery if ventilation is poor. This ex-
plosive gas may remain in or around battery for sev-
eral hours after it has been charged. Sparks or
flames can ignite this gas and cause an internal ex-
plosion which may shatter the battery.
The following precautions should be observed to pre-
vent an explosion.
1. DO NOT smoke near batteries being charged or
which have been charged very recently.
2. DO NOT break live circuits at terminals of batter-
ies because a spark usually occurs at the point
where a live circuit is broken. Always be careful
when connecting or disconnecting cable clamps
on chargers. Poor connections are a common
cause of electrical arcs which cause explosions.
3. DO NOT reverse polarity of battery cables on bat-
tery terminals.
CAUTION
If battery acid comes into contact with skin or
eyes, wash skin immediately with a mild soap.
Flush eyes with water immediately and see a doc-
tor.
90-826148R2 MARCH 1997 ELECTRICAL - 2B-1

Specific Gravity Readings 4. Hold hydrometer vertically and draw in just
enough liquid from battery cell so that float is free-
Use a hydrometer (a) to measure specific gravity of floating. Hold hydrometer at eye level so that float
electrolyte in each cell. is vertical and free of outer tube, then take read-
ing at surface of liquid. Disregard curvature
where liquid rises against float stem due to capil-
lary action.
5. Avoid dropping electrolyte on boat or clothing, as
it is extremely corrosive. Wash off immediately
with baking soda solution.
Specific gravity of electrolyte varies not only with per-
centage of acid in liquid but also with temperature.As
a temperature drops, electrolyte contracts, so that spe-
cific gravity increases. Unless these variations in
specific gravity are taken into account, specific grav-
ity obtained by hydrometer may not give a true indica-
tion of concentration of acid in electrolyte.
A fully charged battery will have a specific gravity
reading of approximately 1.270 at an electrolyte tem-
perature of 80° F (27° C). If electrolyte temperature
is above or below 80° F, additions or subtractions
must be made in order to obtain a hydrometer read-
ing corrected to 80° F standard. For every 10° F (3.3°
C) above 80° F, add 4 specific gravity points (.004) to
hydrometer reading. Example: A hydrometer reading
of 1.260 at 110° F (43° C) would be 1.272 corrected
to 80° F, indicating a fully charged battery.
22532
For every 10° below 80° F, subtract 4 points (.004)
Hydrometer measures percentage of sulfuric acid in from the reading. Example: A hydrometer reading of
battery electrolyte in terms of specific gravity. As a 1.272 at 0° F (-18° C) would be 1.240 corrected to 80°
battery drops from a charged to a discharged condi- F, indicating a partially charged battery.
tion, acid leaves the solution and chemically com-
bines with the plates, causing a decrease in specific
gravity of electrolyte. An indication of concentration Specific Gravity Cell Comparison
of electrolyte is obtained with a hydrometer. Test
When using a hydrometer, observe the following
This test may be used when an instrumental tester is
points:
not available. To perform this test, measure specific
1. Hydrometer must be clean (inside and out) to in- gravity of each cell, regardless of state of charge, and
sure an accurate reading. interpret results as follows: If specific gravity read-
2. Never take hydrometer readings immediately af- ings show a difference between highest and lowest
ter water has been added. Water must be thor- cell of .050 (50 points) or more, battery is defective
oughly mixed with electrolyte by charging for at and should be replaced.
least 15 minutes at a rate high enough to cause
vigorous gassing.
3. If hydrometer has built-in thermometer, draw liq-
uid in several times to ensure correct tempera-
ture before taking reading.

Electrolyte Level Winter Storage of Batteries
Check electrolyte level in battery regularly. A battery Battery companies are not responsible for battery
in use in hot weather should be checked more fre- damage, either in winter storage or in dealer stock,
quently because of more rapid loss of water. If elec- if the following instructions are not observed:
trolyte level is found to be low, then distilled water
1. Remove battery from its installation as soon as
should be added to each cell until liquid level rises ap-
possible and remove all grease, sulfate and dirt
proximately 3/16” (4.8mm) over plate. DO NOT
from top surface by running water over top of bat-
OVERFILL, because this will cause loss of electro-
tery. Be sure, however, that vent caps are tight
lyte and result in poor performance, short life and ex-
beforehand, and blow off all excess water thor-
cessive corrosion.
oughly with compressed air. Check water level,
making sure that plates are covered.
CAUTION
2. When adding distilled water to battery, be ex-
During service, only distilled water should be
tremely careful not to fill more than 3/16” (4.8mm)
added to the battery, not electrolyte.
over plate inside battery. Battery solution or elec-
trolyte expands from heat caused by charging.
Overfilling battery will cause electrolyte to over-
Charging a Discharged flow (if filled beyond 3/16” over plate).
Battery 3. Grease terminal bolts well with Quicksilver 2-4-C

Marine Lubricant, and store battery in COOL-
The following basic rules apply to any battery charg- DRY place. Remove battery from storage every
ing situation: 30-45 days, check water level (add water if nec-
1. Any battery may be charged at any rate (in am- essary), and put on charge for 5 or 6 hours at 6
peres) as long as spilling of electrolyte (from vio- amperes. DO NOT FAST CHARGE.
lent gassing) does not occur and as long as elec- 4. If specific gravity drops below 1.240, check bat-
trolyte temperature does not exceed 125° F (52° tery for reason, and then recharge. When gravity
C). If spewing of electrolyte occurs, or if electro- reaches 1.260, discontinue charging. To check
lyte temperature exceeds 125° F, charging rate specific gravity, use a hydrometer, which can be
(in amperes) must be reduced or temporarily purchased locally.
halted to avoid damage to the battery.
5. Repeat preceding charging procedure every
2. Battery is fully charged when, over a 2-hour peri- 30-45 days, as long as battery is in storage.
od at a low charging rate (in amperes), all cells When ready to place battery back in service, re-
are gassing freely (not spewing liquid electro- move excess grease from terminals (a small
lyte), and no change in specific gravity occurs. amount is desirable on terminals at all times), re-
Full charge specific gravity is 1.260-1.275, cor- charge again as necessary and re-install battery.
rected for electrolyte temperature with electrolyte
level at 3/16” (4.8mm) over plate. For most satis- WARNING
factory charging, lower charging rates in am-
peres are recommended. Hydrogen and oxygen gases are produced dur-
ing normal battery operation or charging. Sparks
3. If, after prolonged charging, specific gravity of at or flame can cause this mixture to ignite and ex-
least 1.230 on all cells cannot be reached, battery plode, if they are brought near the battery. Sulfu-
is not in optimum condition and will not provide ric acid in battery can cause serious burns, if
optimum performance; however, it may continue spilled on skin or in eyes. Flush or wash away im-
to provide additional service, if it has performed mediately with clear water.
satisfactorily in the past.
4. To check battery voltage while cranking engine
with electric starter motor, place RED (+) lead of
tester on POSITIVE (+) battery terminal and
BLACK (–) lead of tester on NEGATIVE (–) bat-
tery terminal. If the voltage drops below 91/2 volts
while cranking, the battery is weak and should be
recharged or replaced.

Battery Charging System Battery Charging System
(14 or 18 Ampere Alternator) Troubleshooting
A fault in the battery charging system usually will
Description cause the battery to become undercharged. Check
The battery charging system components are the battery electrolyte level, and charge battery. See
stator, voltage regulator and battery. Alternating cur- “Electrolyte Level”, and “Charging a Discharged
rent (generated in stator alternator coils) flows to the Battery”.
voltage regulator, which changes the alternating cur- If battery will NOT accept a satisfactory charge, re-
rent to direct current for charging the battery. place battery.
ELECTRIC START MODELS If battery accepts a satisfactory charge, determine

the cause of the charging system problem as follows.
a 1. Check for correct battery polarity [RED cable to
POSITIVE (+) battery terminal]. If polarity was in-
correct, check for damaged rectifier. See “REC-
b TIFIER TEST”.
2. Check for loose or corroded battery connections.
3. Visually inspect wiring between stator and bat-
tery for cuts, chafing; and disconnected, loose or
corroded connection.
4. Excessive electrical load (from too many acces-
RED SLEEVE
sories) will cause battery to run down.
c
If visual inspection determines that battery connec-
tions and wiring are OK, perform the following stator
52684 and rectifier tests.
a - Stator
b - Regulator
c - Battery
The charging system may be damaged by: 1) re-
versed battery cables, 2) running the engine with bat-
tery cables disconnected and stator leads connected
to rectifier, and 3) an open circuit, such as a broken
wire or loose connection.
MANUAL START MODELS
52657
a - 9 Ampere Stator
b - Terminal Block

Stator Ohms Test-Alternator Coils 16 AMPERE STATOR (S/N-0G590000 & ABOVE)
Only Test Leads Resistance Scale Reading
NOTE: Stator can be tested without removing from (Ohms) (x−−−−)
engine. Between YEL- .16 – .19* .16 – .19*
LOW Leads (R x 1)
1. Disconnect both yellow (stator leads) from termi- Between either No Continuity No Continuity
nals on rectifier (or terminal block) or disconnect YELLOW Lead (R x 1000)
bullet connectors from voltage regulator. and Ground
2. Use an ohmmeter and perform the following test.

18 AMPERE STATOR
IMPORTANT: If stator is mounted on engine,
black stator lead (if provided) must be grounded Test Leads Resistance Scale Reading
to powerhead when testing. (Ohms) (x−−−−)
3. Replace stator if readings are outside ranges Between YEL- .16 – .18* .22 – .24*
shown. LOW Leads (R x 1)
Between either No Continuity No Continuity
YELLOW Lead (R x 1000)
9 AMPERE MANUAL STATOR (S/N-0G589999 & and Ground
BELOW)
*DC Resistance of these windings generally is less than 1.5
Test Leads Resistance Scale Reading Ohms. If a reading resembling a short is obtained, this would
(Ohms) (x−−−−) be acceptable.
Between YEL- .17 – .19* .17 – .19*
LOW Leads (R x 1)
and Ground
9 AMPERE MANUAL STATOR (S/N-0G590000 &

ABOVE)
Test Leads Resistance Scale Reading

(Ohms) (x−−−−)
Between YEL- .16 – .19* .16 – .19*
LOW Leads (R x 1)
and Ground
14 AMPERE STATOR
Test Leads Resistance Scale Reading

(Ohms) (x−−−−)
Between YEL- .22 – .24* .22 – .24*
LOW Leads (R x 1)
and Ground

Alternator System Test 5. If cranking voltage is acceptable, disconnect
larger diameter RED harness wire from starter
9 AMPERE STATOR solenoid terminal.
IMPORTANT: Rectifier (optional accessory) must 6. Remove smaller diameter RED wire (sense lead)
be functioning properly for accurate test results from starter solenoid terminal and connect to the
to be obtained. positive (+) terminal of a 9 volt transistor battery.
Ground the negative (–) terminal of the 9 volt bat-
1. Remove RED lead from (+) terminal of rectifier. tery to the engine.
2. Connect RED (+) ammeter lead to rectifier (+) ter- 7. Connect RED (+) ammeter lead to larger diame-
minal and BLACK (–) ammeter lead to RED recti- ter RED harness wire, and BLACK (–) ammeter
fier lead. lead to POSITIVE terminal on starter solenoid.
3. With engine running at the indicated RPM, the 8. Secure starter wires away from flywheel.
ammeter should indicate the following approxi-
mate amperes: 9. With engine running at the indicated RPM’s, the
ammeter should indicate the following appropri-
ate amperes:
9 AMPERE STATOR (S/N-0G589999 & BELOW)
RPM AMPERES
RPM AMPERES
Idle 2
Idle 0
9 Ampere 1000 7
Stator 1000 0.2
14 Ampere
A 2000 12
2000 6.5 Black Stator
3000 13
3000 9.0
4000 13.5
9 AMPERE STATOR (S/N-0G590000 & ABOVE) 5000 14
RPM AMPERES RPM AMPERES

Idle 0 Idle 2.8
9 Ampere 16 Ampere
Stator 1000 0.6 Stator 1000 9.3
2000 8.0 2000 16
3000 9.0
RPM AMPERES
4. If proper ampere readings are not obtained, re-
Idle 3
place stator.
1000 9.5
18 Ampere
A 2000 17
14/16/18 AMPERE STATOR
Red Stator
1. Check battery voltage at battery with engine run- 3000 18
ning. 4000 18
2. If battery voltage is above 14.5 volts, replace volt- 5000 18
age regulator/rectifier. Check condition of battery
as overcharging may have damaged battery.
3. If battery voltage is below 14.5 volts, charge bat-
tery; refer to “CHARGING A DISCHARGED BAT-
TERY”. If battery can NOT be satisfactorily
charged, replace battery.
4. If battery accepts a satisfactory charge, check
battery voltage while cranking engine; refer to
“CHARGING A DISCHARGED BATTERY”. If
cranking voltage is not acceptable, replace bat-
tery.

10. A reading of 14 amperes at 5000 RPM indicates
the charging system is functioning properly. The
battery being discharged is due to the amperage
draw on the system being greater than the am-
perage output of the engine charging system.
11. If ammeter reads less than required amperes @
5000 RPM, test the stator; refer to “Stator Ohm
Test (Alternator Coils Only)”. If stator tests OK,
replace voltage regulator.
d
c
b
51000
a - Voltage Regulator/Rectifier
b - Red Lead (2)
c - Yellow Lead (2)
d - Grey Lead

Rectifier Test
d
WARNING a
c
Disconnect battery leads from battery before
testing rectifier.
NOTE: Rectifier can be tested without removing from
engine. b
1. Disconnect all wires from terminals on rectifier.
f
2. Use an ohmmeter (R x 1000 scale) and perform
the following test. Refer to drawing for rectifier
terminal identification. e
07300
a - Terminal
b - Terminal
c - Terminal
d - Stator Terminals
e - Positive Terminal
f - Ground
Rectifier Test (continued)

Connect red meter lead to ground, black lead alternately
to terminals “a” and “c”.
Continuity Indicated No Continuity Indicated

Connect black meter lead to ground, red lead Connect black meter lead to ground, red lead
alternately to terminals “a” and “c”. alternately to terminals “a” and “c”.
No Continuity Indicated Continuity Indicated.

Connect black meter lead to terminal “b”, red Replace Rectifier.
lead alternately to terminals “a” and “c”.
No Continuity Indicated. Continuity Indicated

Replace Rectifier. Connect black meter lead to terminal “b”, red
lead alternately to terminals “a” and “c”.
Continuity Indicated No Continuity Indicated.

Connect red meter lead to terminal “b”, Replace Rectifier.
black lead alternately to terminals “a”
and “c”.
Continuity Indicated. No Continuity Indicated

Replace Rectifier. Connect red meter lead to terminal “b”,
black lead alternately to terminals “a”
and “c”.
No Continuity Indicated. Continuity Indicated. No Continuity Indicated. Continuity Indicated.

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

VOLTAGE REGULATOR/RECTIFIER SCR TEST:
TEST - Models with (S/N-0G590000 & 1. Set Ohm meter to R X 1k scale.
Above) 2. Connect Red (+) meter lead to regulator case.
NOTE: Voltage regulator/rectifier specifications are 3. Connect Black (–) meter lead to one YELLOW
given for informational purposes only, use the ap- regulator Lead. Test. Connect Black (–) meter
propriate troubleshooting techniques previously lead to the other YELLOW lead.
mentioned to find the faulty component in the charg-
ing system. TEST RESULTS (BOTH TEST):
15,000-∞ OHMS (15k -∞)
TACHOMETER CIRCUIT TEST:

1. Set Ohm meter to R X 1k scale.
2. Connect Red (+) meter lead to GREY regulator
lead.
3. Connect Black (–) meter lead to regulator case.
TEST RESULTS:
10,000 - 50,000 OHMS (10k - 50k)
DIODE TEST:
1. Set Ohm meter to R X 10 scale.
2. Connect Red (+) meter lead to RED regulator
lead.
3. Connect Black (–) meter lead to YELLOW regula-
tor lead.
TEST RESULTS:
100 - 400 OHMS
DIODE TEST:
1. Set Ohm meter to R X 1k scale.
2. Connect Black (–) meter lead to RED regulator
lead.
3. Connect Red (+) meter lead to YELLOW regula-
tor lead. Test. Then change Red (+) meter lead to
the other YELLOW regulator lead for 2ND test
reading.
TEST RESULTS (1ST READING):

40,000 to ∞ OHMS
TEST RESULTS (2ND READING):

∞ OHMS (No needle movement)

Starting System STARTER SOLENOID TEST
Test starter solenoid as follows:
1. Disconnect all leads from solenoid terminals.
Starter Motor Amperes Draw
2. Use an ohmmeter, set to (R x 1 scale) and con-
Starter Motor Part No Load Normal nect between solenoid terminals 3 and 4.
No. Amp. Draw Amp. Draw 3. Connect a 12-volt supply between solenoid ter-
50-822462 20 Amps 95 Amps minals 1 and 2. Solenoid should click and meter
Starter Motor Teeth 10 should read zero ohms.
4. If meter does not read zero ohms (full continuity),
replace solenoid.
Starting System Components
The starting system consists of the following compo-
nents.
1. Battery
2. Starter Solenoid
3. Neutral Start Switch
4. Starter Motor
5. Ignition Switch
Description
The function of the starting system is to crank the en-
gine. The battery supplies electrical energy to crank 4 1
the starter motor. When the ignition switch is turned
to “START” position, the starter solenoid is activated
and completes the starting circuit between the bat-
tery and starter.
a b
The neutral start switch opens the start circuit when
the shift control lever is not in neutral. This prevents
accidental starting when engine is in gear. 3 2
14354
CAUTION a - Ohmmeter Leads
b - 12-Volt Supply
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. Troubleshooting the Starting Circuit
Before beginning the starting circuit troubleshooting
flow chart, following, check first for the following con-
ditions:
1. Make sure 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 in-line fuse in RED wire; see diagram.
The following “STARTING CIRCUIT TROUBLESHOOTING FLOW CHART” is designed as an aid to trouble-
shooting the starting circuit. This flow chart will accurately locate any existing malfunction. Location of “TEST
POINTS” (called out in the chart) are numbered in diagram below.
(S/N-0G589999 & Below)
TO TPM TO SOLENOID
TO TPM
RED SLEEVE
VOLTAGE
REGULATOR
ELECTRIC START TILLER HANDLE

MODEL NEUTRAL START SWITCH
7 LOCATED ON LOWER ENGINE COWL
1
(S/N-0G590000 & Above)
TO SOLENOID
TO
ENGINE
2 GROUND
3
5
6
RED SLEEVE
B
M ELECTRIC START TILLER HANDLE
C MODEL NEUTRAL START SWITCH
A LOCATED ON LOWER ENGINE COWL
S M NEUTRAL START SWITCH

(LOCATED IN CONTROL
HOUSING IF ENGINE IS
4 EQUIPPED WITH REMOTE
52904 CONTROL)
Starting Circuit Troubleshooting Flow Chart
Starter Motor Does Not Turn
SAFETY WARNING: Disconnect BLACK (starter motor)

cable from starter solenoid test point 1 BEFORE making
tests 1-thru-7 to prevent unexpected engine cranking.
TEST 1
Use an ohmmeter (R x 1 scale) and connect meter leads be-
tween NEGATIVE (-) battery post and common powerhead
ground.
No continuity indicated; there is an open circuit in the BLACK Continuity Indicated

NEGATIVE (-) battery cable between the NEGATIVE (-) battery Proceed to TEST 2, on next page.
post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.

* Battery Voltage
TEST 2
a. Disconnect BLACK ground wire(s) from Test Point 2.
b. Connect voltmeter between common engine ground and Test Point 2.
No voltage reading; c. Turn ignition key to “Start” position.
proceed to TEST 3.
TEST 3 12 Volt Reading*

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

No voltage reading; 12 Volt Reading
Neutral start switch on lower engine cowl is open
proceed to TEST 4. Defective starter solenoid. or BLACK or WHITE switch leads are disconnected
or damaged.
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 4. Neutral start switch is open, or YELLOW/RED
No voltage reading; b. Turn ignition key to “Start” position. wire is open between Test Points 4 and 3.
proceed to TEST 5.
TEST 5
Connect voltmeter between common 12 Volt Reading*
No voltage reading; engine ground and Test Point 5. Defective ignition switch.
proceed to TEST 6.
TEST 6
Connect voltmeter between common engine ground and Test Point 6.
No voltage reading; check RED wire between 12 Volt Reading*

battery (+) positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6.
Check for open RED wire between test points 5 and 6.
TEST 7
a. Connect voltmeter between common engine ground and Test Point 1.
b. Turn ignition key to “Start” position.
No voltage reading; De- 12 Volt Reading*

fective starter solenoid. Should hear solenoid click; proceed to TEST 8.
TEST 8
a. Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1.
b. Connect voltmeter between common engine ground and Test Point 7
c. Turn ignition key to “Start” position.
No voltage reading; check BLACK cable 12 Volt Reading*

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

Starter Motor Disassembly
1. Remove two (2) thru bolts and commutator end
Removal cap, taking care not to lose brush springs.
CAUTION
Disconnect battery leads from battery before re- a
moving starter.
1. Disconnect battery leads from battery.
c
2. Disconnect BLACK cable (w/YELLOW sleeve).
3. Remove 3 bolts.
4. Remove starter.
a
b
52664
a - Thru Bolts
b - Commutator End Cap
b c - Brush Springs
a
2. Pull armature from starter frame.
3. Remove locknut.
c
52669
a - Black Cable (w/YELLOW sleeve)
b - Bolts (3)
c - Black Cable (Negative Battery Lead)
51711
a - Armature
b - Locknut

4. Remove components from armature. b. Clean the commutator slots after undercut-
ting.
d e f c. De-burr the commutator lightly with No. 00
sandpaper, then clean the commutator.
d. Check the armature on a growler for shorts.
See “TESTING”, following.
9. Open-circuited armatures often can be saved
where and open circuit is obvious and repairable.
The most likely place for an open circuit is at the
commutator bars. Long cranking periods over-
heat the starter motor so that solder in the con-
a c nections melts. The poor connections cause arc-
b ing and burning of the commutator bars.
10. Repair bars, that are not too badly burned, by re-
soldering the leads in bars (using rosin flux sol-
der) and turning down the commutator in a lathe
11658
to remove burned material, then undercut the
a - Spacer
b - Spring
mica.
c - Drive Assembly 11. Clean out the copper or brush dust from slots be-
d - Drive End Cap
e - Armature Shaft
tween the commutator bars.
f - Washer 12. Check the armature for shorts and ground. See
“TESTING”.
Cleaning and Inspection

1. Clean all motor parts. Testing
2. Check pinion teeth for chips, cracks or excessive
ARMATURE TEST FOR SHORTS
wear.
Check armature for short circuits by placing on growl-
3. Replace the drive clutch spring and/or collar, if
er and holding hack saw blade over armature core
tension is not adequate, or if wear is excessive.
while armature is rotated. If saw blade vibrates, ar-
4. Check that the brush holder is not damaged or is mature is shorted. Re-check after cleaning between
not holding the brushes against the commutator. commutator bars. If saw blade still vibrates, replace
armature.
5. Replace brushes that are pitted or worn to less
than 1/4 in. (6.4mm) in length. Refer to “BRUSH
REPLACEMENT”, following.
6. Replace a damaged or excessively worn bushing
in the end cap.
7. Check the armature conductor (commutator bar
junction) for a firm connection. A poor connection
usually results in a burned commutator bar.
8. Re-surface and undercut a rough commutator, as
follows:
CAUTION
Do not turn down the commutator excessively.
a. Re-surface the commutator and undercut the 11669
insulation between the commutator bars 1/3
in. (0.8mm) to the full width of the insulation,
make sure that the undercut is flat.

ARMATURE TEST FOR GROUND TESTING NEGATIVE BRUSHES FOR GROUND
1. Set ohmmeter to (R x 1 scale). Place one lead of Set ohmmeter to (R x 1 scale). Place one lead of
ohmmeter on armature core (or shaft) and other ohmmeter on the negative brush and the other lead
lead on commutator, as shown. on the end cap (bare metal). If the meter indicates NO
continuity, replace the negative brush. Repeat this
2. If meter indicates continuity, armature is
procedure on the other negative brush.
grounded and must be replaced.
a b
11675
11674
CHECKING POSITIVE BRUSHES AND TERMI- a - Negative (-) Brushes
NALS b - End Cap
1. Connect ohmmeter (R x 1 scale) leads between

positive brushes.
2. Ohmmeter must indicate full continuity (zero re-
sistance). If resistance is indicated, check lead to
positive terminal solder connection. If connection
cannot be repaired, brushes must be replaced.
Refer to “BRUSH REPLACEMENT”.
11673
a - Positive Brushes

Brush Replacement Reassembly
IMPORTANT: Replace brushes that are pitted or 1. Lubricate helix threads and drive end cap bush-
worn to less than 1/4 in. (6.4mm) in length. ing with SAE 10W oil.
1. Install positive brushes into commutator end cap. 2. Install components onto armature shaft.
c b a
d
d e
g f
e
a
b
f 11658
a - Washer
g b - Helix Threads
11660 c - Armature Shaft
d - Drive End Cap
a - Positive (+) Terminal e - Drive Assembly
b - Long Brush Lead f - Spring
c - Push Lead Into Slot g - Spacer
d - Insulating Washer
e - Flat Washer 3. Install locknut.
f - Lock Washer
g - Nut a
2. Install components.
b
c
a
d
51711
b
a a - Locknut
11656
a - Positive (+) Brushes
b - Negative (–) Brushes
c - Brush Holder
d - Bolts (Fasten Negative Brushes and Holder)

4. Construct a brush retainer tool as shown. 5. Place springs and brushes into brush holder and
hold in place with brush retainer tool.
6. Lubricate bushing with one drop of SAE 10W oil.
DO NOT over-lubricate.
11661
a - Brush Retainer Tool
b - Bushing
7. Position armature into starter frame so that com-

mutator end of armature is at end of starter frame
where permanent magnets are recessed 1 in.
(25.4mm). Align marks as shown.
8. Install commutator end cap onto starter frame;
align marks as shown, and remove brush retainer
tool.
9. Install thru bolts and torque to 70 lbs. in. (7.9
N·m).
c
c
Brush Retainer Tool Layout (Full Size)
a
18-Gauge Sheet Metal
METRIC
SCALE
3” = 76.2mm
b
2” = 50.8mm
1-3/4” = 44.5mm
1-11/16”= 42.9mm 52659
3/4” = 19.1mm
1/2” = 12.7mm
a - Alignment Marks
b - Alignment Marks
Brush Retainer Tool Side View (Full Size) c - Bolt (2) Torque to 70 lb. in. (7.9 N⋅m)

Installation
1. Secure starter to block with three (3) bolts.
Torque bolts to 16.6 lb. ft. (22.5 N·m). Secure
NEGATIVE battery lead to block with bottom bolt.
2. Connect battery lead (BLACK w/YELLOW
sleeve) to starter. Torque attaching nut to 60 lb.
in. (6.8 N·m).
b a
c 52669
a - Bolts (3)
b - Black Cable (w/YELLOW sleeve)
c - Black Cable (Negative Battery Lead)

ELECTRICAL
2
C
TIMING, SYNCHRONIZING & ADJUSTING

Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Tiller Handle Model
(S/N-0G589999 & Below) . . . . . . . . . . . . . . . . . . . . . 2C-2
Timing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Tiller Handle Model with
Mechanical Spark Advance
(S/N-0G590000 & Above) . . . . . . . . . . . . . . . . . . . . . 2C-4
Timing And Maximum Spark Advance
Adjustments - Mechanical Spark Advance
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Adjusting Idle Timing . . . . . . . . . . . . . . . . . . . 2C-5
Adjusting Maximum Spark Advance . . . . . . 2C-6
Shift Link Rod Installation and Adjustment
to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-6
Throttle Cable Installation . . . . . . . . . . . . . . . . . . . . . 2C-7
Oil Pump Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8
2C-0 - ELECTRICAL 90-826148R2 MARCH 1997

Specifications
Idle RPM (In Forward Gear) 700-800 RPM
Full Throttle RPM Range
-- Model 30, 40 Sea Pro, 40 Marathon 4500-5500 RPM
-- Model 40 5000-5500 RPM
Spark Plug Type (NGK) BP8H-N-10
SPECIFICATIONS Gap 0.040 in. (1.0mm)
Optional Plug (NGK)** BPZ8H-N-10*
Gap 0.040 in. (1.0mm)
Firing Order 1-2
Models with (S/N-0G589999 & Below) -- Idle 3°BTDC ± 3°(Not Adjustable)
Maximum BTDC @ 2500-5500 RPM 25°BTDC ± 3°(Not Adjustable)
Models with (S/N-0G590000 & Above) -- Idle 8°BTDC ± 1°
Maximum Spark Advance 1 Turn Clockwise After
Contacting Throttle Plate
** Suppressor (Inductor) Spark Plug.
3. Timing Light P/N *91-99379
WARNING
Engine could start when turning flywheel to
check timing. Remove all spark plugs from en-
gine to prevent engine from starting.
Special Tools
1. Service Tachometer P/N *91-59339
*May be obtained locally.
4. Spark Gap Tool P/N 91-63988A1
55002
*May be obtained locally.
2. MercTach Interface Module P/N 91-825824A-2
54315
90-826148R2 MARCH 1997 ELECTRICAL - 2C-1

Tiller Handle Model 5. Tighten throttle cable jam nuts.
e a
(S/N-0G589999 & Below) b
1. With engine off and gear shift in neutral position,
loosen cam follower screw.
2. Back off idle speed screw until the throttle shutter
positioner does not touch the taper of idle speed
screw. (Throttle plate closed).
3. Loosen throttle cable jam nuts.
a
c
d
d d
b 52300
a - Cam Follower Roller
b - Throttle Cam
c - Mounting Bracket
d - Throttle Cable Sleeve
e - Cam Follower Screw
a
c
52301
a - Cam Follower Screw
b - Throttle Shutter Positioner
c - Jam Nut
d - Idle Speed Screw
4. With throttle at idle position, place cam follower

roller against throttle cam. Center the roller with
raised mark on throttle cam by adjusting the posi-
tion of throttle cable sleeves in the mounting Cable Slack
bracket. Min. 1/16 in. (1.59 mm)
b Max. 1/8 in. (3.18 mm)
NOTE: When positioning throttle cables, a minimum 52300
of 1/16 in. (1.59 mm) to a maximum of 1/8 in. (3.18 a - Throttle Cam
mm) slack must be allowed to prevent throttle cables b - Link Rod Ball
from binding. (Rock throttle cam side to side and
measure the amount of throttle cam travel at link rod
ball. 6. With cam follower resting on throttle cam, tighten
the cam follower screw.

7. With throttle at idle position, turn idle speed screw
clockwise “In”until a gap of 0.005 in. - 0.040 in. WARNING
(0.13 mm - 1.02 mm) is achieved between throttle Keep clear of propeller while cranking and run-
cam and cam follower. ning the outboard motor.
9. Connect the electrical harness and fuel line to en-
0.005 in. - 0.040 in. gine.
(0.13 mm - 1.02 mm) 10. With the outboard in the water, start engine and
allow to warm up.
11. Adjust idle speed screw in “FORWARD”gear to
specification.
NOTE: When setting idle mixture, DO NOT adjust
leaner than necessary to attain reasonably smooth
idling. When in doubt, stay to the slightly rich side of
the adjustment.
12. With engine running at idle speed in “FOR-
WARD”gear, turn mixture screw “In”(clockwise)
until engine starts to “bog” down and misfire.
Back out 1/4 turn or more.
52300
13. Check for too lean of mixture on acceleration.
b - Throttle Cam (Engine will “bog” on acceleration). Readjust if
c - Cam Follower Screw necessary.
14. Re-adjust idle speed screw in “FORWARD”gear
to specification.
8. Turn idle mixture screw in (clockwise) until 15. Check for too lean of mixture on acceleration.
LIGHTLY seated then, back out to an initial set- (Engine will “bog” on acceleration). Readjust if
ting of 1-1/4 turns. necessary.
16. Re-adjust idle speed screw in “FORWARD”gear
to specification.
Timing Adjustments
NOTE: No timing adjustments are required for the
30/40 model outboard with (S/N-0G589999 & Be-
low).
a - Carburetor
b - Mixture Screw

Tiller Handle Model with 6. Tighten throttle cable jam nuts.
c
Mechanical Spark Advance b
a
(S/N-0G590000 & Above)
1. Check all electrical connections to ensure they
are tight and secure (including battery connec-
tions on electric start models).
e
b
d
55762
d
b - Cam Follower Roller
c - Throttle Cam
e - Mounting Bracket
a c b
55896
d
a - Idle Speed Screw
b - Cam Follower Screw
c - Throttle Shutter Positioner
d - Jam Nuts
5. With throttle at idle position, place cam follower Cable Slack

roller against throttle cam. Center the roller with Min. 1/16 in. (1.59 mm)
raised mark on throttle cam by adjusting the posi- Max. 1/8 in. (3.18 mm)
tion of throttle cable sleeves in the mounting
bracket on tiller handle models or throttle link rod a
on remote control models.
NOTE: When positioning throttle cables, a minimum 55762
of 1/16 in. (1.59 mm) to a maximum of 1/8 in. (3.18
mm) slack must be allowed to prevent throttle cables a - Link Rod Ball
from binding. (Rock throttle cam side to side and b - Throttle Cam
measure the amount of throttle cam travel at link rod
ball.
7. With cam follower resting on throttle cam, tighten
the cam follower screw.

8. With throttle at idle position, turn idle speed screw
clockwise “IN”until a gap of 0.005 in. - 0.040 in. WARNING
(0.13 mm - 1.02 mm) is achieved between throttle Keep clear of propeller while cranking and run-
cam and cam follower. This will open the throttle ning the outboard motor.
shutter enough to keep the engine running near
idle speed after starting. 10. Connect the fuel line to the engine and electrical
harness on electric engines.
0.005 in. -- 0.040 in.
(o.13 mm - 1.02 mm) 11. With the outboard in the water, start engine,
b check tell-tale, and allow to warm up.
a
12. Adjust idle speed screw in “FORWARD”gear to
specification; (750 ± 50 rpm)
13. Check the idle timing and maximum spark ad-
vance. (If not within specifications, adjustment
will be required).
d
a. Idle timing: 8 ± 1 degrees B.T.D.C.
c b. Maximum spark advance: (22 - 28 Degrees,

Reference only). One (1) Turn clockwise after
contacting throttle plate.
TIMING AND MAXIMUM SPARK ADVANCE AD-

JUSTMENTS - MECHANICAL SPARK ADVANCE
MODELS
IMPORTANT: Setting the idle timing is required
55762
before adjusting the maximum spark advance.
b - Throttle Cam ADJUSTING IDLE TIMING
c - Cam Follower Screw 14. With the engine “OFF”, snap the trigger link rod
socket off ball stud and:
a. Extend rod length to “ADVANCE”timing
9. Turn idle mixture screw in (clockwise) until
LIGHTLY seated then, back out to an initial set- b. Shorten rod length to “RETARD”timing
ting of 1-1/2 turns. 15. Snap link rod onto ball stud, re-start engine and
cycle the throttle mechanism through part throttle
and back to idle three (3) times. Re-check idle
timing and idle R.P.M. specification. Re-adjust if
necessary.
a - Carburetor
b - Mixture Screw

ADJUSTING MAXIMUM SPARK ADVANCE 21. Adjust carburetor for best performance, after
IMPORTANT: Setting the idle timing is required clearing the engine. With engine running at idle
before adjusting the maximum spark advance. speed in “FORWARD”gear, turn mixture screw
“IN” (clockwise) until engine starts to loose
16. Turn engine off. R.P.M., fire unevenly, and or misfires. Back out
17. Position twist grip or remote control lever to maxi- 1/4 turn or more. (See General Specifications for
mum throttle opening, (wide open throttle). minimum and maximum adjustment).
18. Loosen jam nut and turn screw counter-clock- 22. Check for too lean of mixture on acceleration.
wise until screw no longer makes contact with (Engine will “hesitate”or “stall”on acceleration).
throttle bracket platform. Readjust mixture if necessary.
19. Turn screw in (clockwise) until screw just makes 23. Re-adjust idle speed screw in “FORWARD”gear
contact with the throttle bracket platform and then to specification.
give screw one (1) additional turn clockwise and
tighten jam nut.
Shift Link Rod Installation
and Adjustment to Engine
Install cables into the remote control following the
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.
1. Position remote control and outboard into neu-
tral.
c
N
b
a
55882
a - Throttle Bracket Platform

b - Screw
c - Jam Nut
2. Measure distance “a”between mounting pin and

20. With engine idling at specified R.P.M. in “FOR- middle of the barrel holder.
WARD” gear, loosen cam follower screw and
place cam follower roller against throttle cam and
tighten cam follower screw. Cycle the throttle
mechanism through part throttle and back to idle.
Recheck in gear idle R.P.M.. a
NOTE: When setting idle mixture, DO NOT adjust
leaner than necessary to attain reasonably smooth
idling. When in doubt, stay to the slightly rich side of
highest R.P.M..
b
c
a - Distance Between Pin and Middle of Barrel Holder
b - Mounting Pin
c - Barrel Holder

3. Push-in on the cable end until resistance is felt.
Adjust the cable barrel (b) to attain the measured
Throttle Cable Installation
distance “a”taken in Step 2. 1. Position remote control into neutral.
4. Place cable barrel into the bottom hole in the bar- N
rel holder. Fasten cable to pin with retainer.
b
2. Install cable to the throttle lever. Secure with re-
tainer.
b
a
a - Throttle Cable
b - Retainer
3. Adjust the cable barrel so that the installed

c d throttle cable will hold the throttle arm against the
stop.
a - Move Cable Barrel To Attain The Measured Distance

Taken In Step 2
b - Cable Barrel
c - Barrel Holder-- Place Barrel Into Bottom Hole
d - Retainer
5. Check shift cable adjustments as follows:

a. Shift remote control into forward. The propel-
ler shaft should be locked in gear. If not, ad-
just the barrel closer to the cable end.
b. Shift remote control into neutral. The propel-
ler shaft should turn freely without drag. If not, a
adjust the barrel away from the cable end.
Repeat steps a and b.
c
c. Shift remote control into reverse while turning b
propeller. The propeller shaft should be
locked in gear. If not, adjust the barrel away
from the cable end . Repeat steps a thru c. a - Cable Barrel -- Adjust To Hold Throttle Arm Against Stop
b - Throttle Arm
d. Shift remote control back to neutral. The pro- c - Barrel Holder -- Place barrel Into Top Hole
peller shaft should turn freely without drag. If
not, adjust the barrel closer to the cable end.
Repeat steps a thru d.

4. Check throttle cable adjustment as follows: Oil Pump Adjustment
a. Shift outboard into gear a few times to acti- While holding throttle arm at idle position, adjust
vate the throttle linkage. Make sure to rotate length of link rod so the stamped mark of oil pump
the propeller shaft while shifting into reverse. body aligns with stamped mark of oil pump lever.
F N R
b. Return remote control to neutral. Place a thin

piece of paper between throttle arm and idle
stop. Adjustment is correct when the paper c
can be removed without tearing, but has b
some drag on it. Readjust cable barrel if nec-
essary.
b
52365
a - Alignment Mark
a b - Link Rod
c - Oil Pump Lever
a - Throttle Arm
b - Idle Stop
5. Lock the barrel holder in place with the cable

latch.

ELECTRICAL
2
D
WIRING DIAGRAMS
Table of Contents
Page
30/40 Manual Start Ignition Diagram
(S/N 0G380074 & Below) . . . . . . . . . . . . . . . . . . . 2D-1
(S/N 0G380075 Thru S/N 0G589999) . . . . . . . . 2D-2
30/40 Electric Start / Tiller Handle
Ignition Diagram (S/N 0G380074 & Below) . . . . 2D-3
30/40 Electric Start / Tiller Handle Ignition
Diagram (S/N 0G380075 Thru S/N 0G589999) 2D-4
30/40 Electric Start Ignition Diagram
(S/N 0G380074 & Below) . . . . . . . . . . . . . . . . . . . 2D-5
(S/N 0G380075 Thru S/N 0G589999) . . . . . . . . 2D-6
30/40 Manual Start / Tiller Handle Ignition
Diagram (S/N-0G590000 & Above) . . . . . . . . . . . 2D-7
30 Electric Start Tiller Handle Ignition Diagram
(S/N-0G590000 & Above) . . . . . . . . . . . . . . . . . . . 2D-8
(S/N-0G590000 & Above) . . . . . . . . . . . . . . . . . . . 2D-9
30/40 Electric Start / Power Trim Ignition
Diagram (S/N-0G590000 & Above) . . . . . . . . . . . 2D-10
14 Ampere Stator Charging Diagram . . . . . . . . . 2D-11
14 Ampere Stator Charging Diagram
With Battery Isolator . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Commander 2000 Side Mount Remote
Control (Electric Start With Warning Horn)
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Commander 3000 Panel Mount Control . . . . . . . 2D-14
Commander 2000 Key Switch Test . . . . . . . . . . . 2D-15
Instrument Wiring Connections . . . . . . . . . . . . . . 2D-16
Without Light Switch . . . . . . . . . . . . . . . . . . . . 2D-16
With Light Switch . . . . . . . . . . . . . . . . . . . . . . . 2D-16
Instrument/Lanyard Stop Switch Wiring Diagram 2D-17
Engine Synchronizer Wiring Diagram-
Commander Gauges . . . . . . . . . . . . . . . . . . . . . . . 2D-18
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-19
Instrument/Lanyard Stop Switch
Wiring Diagram (Dual Outboard) . . . . . . . . . . . . . 2D-20
QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . . . 2D-22
Tachometer Wiring Diagram . . . . . . . . . . . . . . 2D-22
Wiring Diagram A . . . . . . . . . . . . . . . . . . . . 2D-22
Wiring Diagram B . . . . . . . . . . . . . . . . . . . . 2D-22
Water Temperature Gauge . . . . . . . . . . . . . . . 2D-22
Wiring Diagram A . . . . . . . . . . . . . . . . . . . . 2D-22
Wiring Diagram B . . . . . . . . . . . . . . . . . . . . 2D-22
Engine Synchronizer Wiring Diagram . . . . . . 2D-23
Light Bulb Position A . . . . . . . . . . . . . . . . . 2D-23
Light Bulb Position B . . . . . . . . . . . . . . . . . 2D-23
Cleaning Gauges . . . . . . . . . . . . . . . . . . . . 2D-24
2D-0 - ELECTRICAL 90-826148R2 MARCH 1997

30/40 Manual Start Ignition Diagram (S/N 0G380074 & Below)
4
1
2 3
6
10
7
9
52618
1 - Engine Temperature Sensor BLK = Black

2 - Timing and Protection Module (TPM) BLU = Blue
3 - Trigger BRN = Brown
4 - Stator GRY = Gray
5 - Terminal Block GRN = Green
6 - Neutral Start Switch ORN = Orange
7 - Emergency Stop Switch PNK = Pink
8 - Stop Button PUR = Purple
9 - Horn RED = Red
10- Capacitor Discharge Module (CDM) Tan = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
90-826148R2 MARCH 1997 ELECTRICAL - 2D-1

(S/N 0G380075 Thru S/N 0G589999)
a b
GRN/WHT
DCBA
WHITE
BLK/YEL
BLACK
BLACK
ABCD
BLK/YEL
WHT/BLK
GRN/WHT
GRN/WHT
WHT/BLK
BLK/YEL
BLACK
BLACK
YELLOW YELLOW YELLOW
GRN/WHT GRN/WHT
YELLOW
YELLOW
BLACK WHT/GRN WHT/GRN

GRN/WHT
WHT/BLK
GRN/WHT
WHITE WHT/BLK WHT/BLK
AB
AB
GRN/WHT WHITE WHITE
WHT/GRN
WHT/BLK
WHITE
LT.BLU
TAN/LT.BLU
PURPLE
BLACK
WHITE
TAN
j k D--BLACK
C--PURPLE
B--TAN/LT.BLU
A--LT.BLU
GROUND
BLACK
BLACK
BLACK
BLK/YEL
BLK/YEL
D B
C A
WHITE
10GA BLK
TAN
BD
AC
D--BLACK
C--PURPLE
B--TAN/LT.BLU
A--PLUG
16GA BLK/YEL
BLACK WHITE
16GA WHITE
16GA TAN/LT.BLU
BLACK BLACK
18GA TAN/LT.BLU
18GA PURPLE
16GA BLACK
i d c
GROUND
16GA BLK/YEL
16GA BLK/YEL
18GA PURPLE
16GA WHITE
16GA BLACK
18GA TAN/LT.BLU
16GA BLACK
16GA BLACK
16GA TAN/LT.BLU
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
PURPLE
TAN
ORN = Orange
BLACK
BLK/YEL
BLACK
BLK/YEL
e PNK = Pink
PUR = Purple
RED = Red
Tan = Tan
WHT = White
YEL = Yellow
LIT = Light
h g f DRK = Dark
a - CDM 1 g - Lanyard Stop Switch

b - CDM 2 h - Push Button Stop Switch
c - Stator i - Neutral Switch
d - Trigger j - Terminal Block
e - Head Temperature Sensor k - TPM Module
f - Warning Horn

30/40 Electric Start / Tiller Handle Ignition Diagram
(S/N 0G380074 & Below)
1 - Engine Temperature Sensor
2 - Timing and Protection Module (TPM)
3 - Trigger
4 - Stator
5 - Starter
6 - Starter Relay
7 - 12VDC Battery
8 - 20 Ampere Fuse
9 - Voltage Regulator
10- Neutral Start Switch
11 - Low Oil Switch
12- Engine Harness
13- Capacitor Discharge Module (CDM)
14 Emergency Stop Switch
15 Stop Button
16 Horn
17 Start Button
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

90-826148R2 MARCH 1997
Orange
Purple
Yellow
Brown
Green
White
Black
Light
Gray
Dark
Blue
Pink
Red
Tan
=
=
=
=
=
=
=
=
=
=
=
=
=
=
FLYWHEEL ASSEMBLY
BLK
BLU
BRN
GRN
ORN
PNK
PUR
RED
DRK
Tan
WHT
YEL
LIT
GRY
STATOR ASSEMBLY
TRIGGER ASSEMBLY
GRN/WHT
30/40 Electric Start / Tiller Handle Ignition Diagram
WHT/GRN
WARNING HORN
YELLOW
YELLOW
FEMALE MALE
WHT/BLK
WHITE
18GA TAN/LT.BLU TAN TAN

14GA PURPLE PURPLE PURPLE
16GA BLK/YEL 2 2 BLK/YEL
1 3 3 1
16GA RED/PPL 16GA RED/PPL 8 4 4 8 RED
PUSH BUTTON
AB 16GA RED 7 5 5 7
6 6 START SWITCH
16GA YEL/RED YEL/RED RED
AB 16GA YEL/BLK YEL/BLK YEL/RED
BLK/YEL 16GA GRAY GRAY
BLK/YEL 16GA BLK/YEL
14GA BLACK BLACK
16GA GRN/WHT
WHT/BLK
GRAY 16GA GRAY

WHITE
16GA LT.BLU/WHT LANYARD STOP

GRN/WHT
YELLOW
YELLOW
WHT/GRN
SWITCH
TAN 16GA TAN/LT.BLU
WHITE 16GA WHITE BLK/YEL BLK/YEL
RED 14GA RED BLACK BLACK
RED 16GA RED
16GA TAN/LT.BLU
16GA BLACK
16GA YEL/BLK
CA AC 18GA PURPLE
DB BD 18GA TAN/LT.BLU PUSH BUTTON
18GA LT.BLUE STOP SWITCH
TAN/LT.BLU
A- LT.BLU
B- TAN/LT.BLU
(S/N 0G380075 Thru S/N 0G589999)
C- PURPLE BLK/YEL BLK/YEL

GRN/WHT
WHT/BLK
GRN/WHT
GRN/WHT
GRN/WHT
WHT/BLK
WHT/BLK
BLK/YEL
YELLOW
YELLOW
WHT/GRN
GRN/WHT
BLACK
BLK/YEL
D- BLACK BLACK
BLACK
BLACK
PURPLE
LT.BLU
WHITE
BLACK
BLACK
WHITE
WHITE
BLACK
WHITE
GROUND
14GA BLK
TAN
10GA BLK
16GA BLK
14GA BLK
16GA BLK
TAN/LT.BLU
BLACK
BLACK
BLACK
DCBA HEAD
TEMPERATURE
SENSOR
10GA BLACK
16GA WHITE
BLACK
CDM TPM
MODULE GROUND
ASSEMBLY LOW- OIL
SWITCH
16GA LT.BLUE
16GA RED GXL
16GA BLK
16GA BLK
BLACK
WHITE
16GA RED/PPL
16GA RED/PPL
16GA YEL/RED
14GA RED
16GA RED
LT.BLU/WHT
16GA BLK
GRN/WHT
LT.BLU
LT.BLU
STARTER
CDM
ASSEMBLY
YELLOW GRAY
YELLOW RED
RED
BLACK
BLACK
ABCD VOLTAGE
BLACK REGULATOR
GRN/WHT
WHT/BLK
BLK/YEL
START
SOLENOID
NEUTRAL
SWITCH
2D-4 - ELECTRICAL
BLK W/ YEL ENDS
30/40 Electric Start Ignition Diagram (S/N 0G380074 & Below)
5
4
1 2
3
9
14
10
13
11
7
14
12
52905
1 - Engine Temperature Sensor

2 - Timing and Protection Module (TPM)
3 - Trigger
4 - Stator
5 - Starter
6 - Starter Relay BLK = Black
7 - 12VDC Battery BLU = Blue
8 - 20 Ampere Fuse BRN = Brown
9 - Voltage Regulator GRY = Gray
10- Neutral Start Switch GRN = Green
11- Low Oil Switch ORN = Orange
12- Engine Harness PNK = Pink
13- Fuel Enrichment Valve PUR = Purple
14- Capacitor Discharge Module (CDM) RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark

(S/N 0G380075 Thru S/N 0G589999)
ASSEMBLY
ASSEMBLY
GRN/WHT
CDM
CDM
DCBA
WHITE
BLK/YEL
BLACK
BLACK
ABCD
BLK/YEL
WHT/BLK
GRN/WHT
GRN/WHT
WHT/BLK
BLK/YEL
BLACK
BLACK
GRN/WHT GRN/WHT
YELLOW
YELLOW
BLACK WHT/GRN WHT/GRN

GRN/WHT
WHT/BLK
GRN/WHT
REGULATOR
WHITE WHT/BLK WHT/BLK

VOLTAGE
AB
AB
FLYWHEEL ASSEMBLY
MODULE
GRN/WHT WHITE WHITE
TRIGGER ASSEMBLY
STATOR ASSEMBLY
WHT/GRN
TPM
WHT/BLK
WHITE
LT.BLU
TAN/LT.BLU
PURPLE
RED
RED
GRAY
BLACK
WHITE
TAN
GROUND
BLACK
BLACK
BLACK
BLK/YEL
BLK/YEL
D- BLACK
C- PURPLE
B- TAN/LT.BLU
A- LT.BLU
D B
C A
GRAY
WHITE
14GA BLK
16GA BLK
10GA BLK
14GA BLK
RED
RED
TAN
BLK W/ YEL ENDS
BD
AC
16GA RED
16GA RED/PPL
16GA GRAY
16GA BLK/YEL
STARTER
16GA WHITE
16GA TAN/LT.BLU
18GA LT.BLUE
18GA TAN/LT.BLU
18GA PURPLE
16GA BLACK
16GA RED
14GA RED
SOLENOID
START
10GA BLACK
GROUND
BLACK
BLACK
BLACK
BLACK
COWL MOUNTED
TRIM SWITCH
16GA YEL/RED
16GA BLK 16GA BLK
14GA RED
16GA RED
16GA RED
16GA RED/PPL
RED/PPL
16GA RED/PPL
DN
UP
GRN/WHT GRN/WHT
GRN/WHT
LT.BLU/WHT LT.BLU/WHT
TRIM UP
LT.BLU/WHT
RELAY
BLACK
RED RED
14 BLACK
BLUE BLUE
LT.BLU/WHT LT.BLU/WHT
PUMP
TRIM
TRIM DOWN
RELAY
BLACK
RED RED
14 BLACK
GREEN GREEN
GRN/WHT GRN/WHT
BLACK WHITE 16GA WHITE

BLACK BLACK 16GA LT.BLUE
16GA BLK
16GA BLK
NEUTRAL
SWITCH
TAN/LT.BLU 16GA TAN/LT.BLU
YEL/BLK 16GA YEL/BLK

14GA BLACK
16GA GRAY
16GA YEL/BLK
16GA YEL/RED
16GA RED/PPL
16GA BLK/YEL
14GA PURPLE
18GA TAN/LT.BLU
BLK = Black
GROUND
BLU = Blue
BLACK
BRN = Brown
16GA LT.BLU/WHT
GRY = Gray
16GA GRN/WHT
GRN = Green
7
LT.BLU
LT.BLU ORN = Orange
6
PNK = Pink
5
3
LOW- OIL
ENRICHMENT
4
SWITCH
PUR = Purple
TEMPERATURE
SOLENOID
RED = Red
SENSOR
FUEL
HEAD
Tan = Tan
CONTROL
REMOTE
WHT = White
TO
YEL = Yellow
LIT = Light
DRK = Dark

30/40 Manual Start / Tiller Handle Ignition Diagram
(S/N-0G590000 & Above)
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
e RED = Red
Tan = Tan
WHT = White
YEL = Yellow
LIT = Light
d DRK = Dark
g
b
a
i
a - Rev Limiter f - Electrical Plate to Block

b - CDM 2 g - Temperature Switch
c - CDM 1 h - Warning Horn
d - Trigger i - Push Button Stop Switch
e - Stator j - Lanyard Stop Switch

30 Electric Start Tiller Handle Ignition Diagram
(S/N-0G590000 & Above)
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

30/40 Electric Start Ignition Diagram (S/N-0G590000 & Above)
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green i
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red f g h
Tan = Tan
WHT = White j
YEL = Yellow
LIT = Light
DRK = Dark
n m l k
a - Trigger h - Electrical Plate To Block
b - Stator i - Starter
c - Remote Control j - Start Solenoid
d - 20 Amp Fuse k - Voltage Regulator
e - Fuel Enrichment Solenoid l - Rev. Limiter
f - Oil Level Switch m - CDM 2
g - Head Temperature Switch n - CDM 1

30/40 Electric Start / Power Trim Ignition Diagram
(S/N-0G590000 & Above)
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

14 Ampere Stator Charging Diagram
BLK = Black
GRY = Gray
RED = Red
YEL = Yellow
RED SLEEVE
a - Stator/Alternator Assembly
b - Voltage Regulator
c - 20 Amp Fuse
d - Starter Solenoid
e - Gray Wire to Tachometer

14 Ampere Stator Charging Diagram With Battery Isolator
BLK = Black
GRY = Gray
RED = Red
YEL = Yellow
b
d
c g
51930
a - Stator/Alternator Assembly e - Gray Wire to Tachometer

b - Voltage Regulator f - Battery Isolation
c - 20 Amp Fuse g - To Engine Harness
d - Starter Solenoid

Commander 2000 Side Mount Remote Control (Electric Start
With Warning Horn) Wiring Diagram
e d
a
f
b
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray c
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
a - Ignition/Choke Switch d - Tachometer/Accessories Harness Connector

b - Emergency Stop Switch e - Wiring Harness Connector
c - Neutral Start Switch f - Warning Horn

Commander 3000 Panel Mount Control
RED = Red
YEL = Yellow
Neutral Interlock
Switch

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:
BLK = Black
PUR = Purple
RED = Red
YEL = Yellow
KEY CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:

POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK
OFF
RUN
START
CHOKE*
*Key switch must be positioned to “RUN” or

“START” and key pushed in to actuate choke for
this test.
NOTE: If meter readings are other than specified in
the preceding tests, verify that switch and not wiring
is faulty. If wiring checks ok, replace switch.

Instrument Wiring Connections
Without Light Switch
NOTE: ANY INSTRUMENT WIRING HARNESS LEADS NOT USED MUST BE TAPED BACK TO THE HAR-
NESS.
Speedometer
Tachometer
Temperature/Oil
Warning Panel Volt Meter
a b
c
TAN/WHT
TAN/BLK
51820
d
a - Tachometer Receptacle-From Control Box or Ignition/ Wire Where To
Choke Switch
b - Tachometer Wiring Harness BLK=BLACK GROUND
c - Lead to Optional Visual Warning Kit (Taped Back to Har- TAN/WHT=TAN/WHITE OIL LIGHT
ness)
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
With Light Switch GRY=GRAY TACHOMETER

BRN/WHT=BROWN/WHITE TRIM GAUGE
TAN/BLU=TAN/BLUE VISUAL WARNING KIT (OPT.)
Speedometer
Tachometer
To 12V Temperature/Oil
Warning Panel Volt Meter
a b
c
TAN/WHT
TAN/BLK 51819
d

Instrument/Lanyard Stop IMPORTANT: On installations where gauge
options will not be used, tape back any unused
Switch Wiring Diagram wiring harness leads.
g
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORN = Orange
PNK = Pink
PUR = Purple
RED = Red f
TAN = Tan
WHT = White d e
YEL = Yellow
LIT = Light
DRK = Dark
c
b a
k
h
52715
a - Ignition/Choke Switch h - Remote Control
b - Lanyard Stop Switch i - Power Trim Harness Connector
c - Lead Not Used On Outboard Installations j - Connect Wires Together with Screw and Hex Nut (2
d - Retainer Places); Apply Quicksilver Liquid Neoprene to Connections
e - Tachometer and Slide Rubber Sleeve over Each Connection
f - Trim Indicator Gauge (Optional) k - Lead to Optional Visual Warning Kit
g - Temperature Gauge

Engine Synchronizer Wiring
Diagram-Commander
Gauges
1. Wiring Diagram -- Gauge needle to point toward
slow running engine.
TACHOMETER TACHOMETER
STARBOARD ENGINE PORT ENGINE
SYNCHRONIZER
GAUGE
BATT GND BATT GND
SENDER SENDER
STARBOARD PORT
SYNCHRONIZER
BOX
2. Wiring Diagram -- Gauge needle to point toward

fast running engine.
TACHOMETER TACHOMETER
STARBOARD ENGINE PORT ENGINE
SYNCHRONIZER
GAUGE
BATT GND BATT GND
SENDER SENDER
STARBOARD PORT
SYNCHRONIZER
BOX

Notes:

Instrument/Lanyard Stop Switch
Wiring Diagram (Dual Outboard)
d d
k
g c b
BLK = Black l
BLU = Blue
BRN = Brown BATT GND
GRY = Gray
GRN = Green
d
SENDER
ORN = Orange
PNK = Pink
PUR = Purple
e
a
RED = Red
TAN = Tan
WHT = White
YEL = Yellow
LIT = Light
DRK = Dark
o
n
h
PORT INSTALLATION
52716
a - Ignition/Choke Switch f - Trim Indicator Gauge
b - Lanyard Stop Switch g - Temperature Gauge
c - Lead Not Used on Outboard Installations h - Remote Control
d - Retainer i - Synchronizer Gauge
e - Tachometer j - Synchronizer Box

IMPORTANT: On installations where gauge
options will not be used, tape back and isolate
any unused wiring harness leads.
i BATT GND
SENDER
e
a
j f
STARBOARD INSTALLATION
52654
k - Lanyard/Diode n - Connect Wires Together with Screw and Hex Nut (4

l - “Y”Harness Places);Apply Quicksilver Liquid Neoprene to Connections
m - Power Trim Harness Connector and Slide Rubber Sleeve over Each Connection.
o - Lead to Visual Warning Kit

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. +12 Volt
Light Switch Position Light Bulb to the
Wire Switched Position
WIRING DIAGRAM A
Use this wiring diagram when using a separate light
switch for instrument lighting. Connect to
Negative (--)
+12 Volt Ground
Connect to
Light Switch + 12 Volt
Wire Position Light Bulb to the
Switched Position
Connect to Connect to SEND

+ 12 Volt Negative (--)
Ground
Connect to Tan Lead Located

at the Tachometer Receptacle on
Commander Side Mount Remote
Control or Tan Lead Coming From
Accessory Ignition/Choke Assembly
WIRING DIAGRAM B
Use this wiring diagram when instrument lighting is
wired directly to the ignition key switch. (Instrument
lights are on when ignition key is turned on.)
51106
Position Light Bulb to the
WIRING DIAGRAM B Unswitched Position
Use this wiring diagram when instrument lighting is

wired directly to the ignition key switch. (Instrument Connect to
lights are on when ignition key switch is turned on.) Negative (--)
Connect to Ground
Position Light Bulb to the + 12 Volt
Unswitched Position
Connect to Connect to
+ 12 Volt Negative (--)
Ground SEND
Connect to Tan Lead Located

at the Tachometer Receptacle on
Commander Side Mount Remote
Control or Tan Lead Coming From
Accessory Ignition/Choke Assembly
51105
51106

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
Switched Position
b
SEND
28086
a - Lead from Temperature Sender
b - Engine/Remote Control Harness
Engine Synchronizer Wiring Diagram

51106
LIGHT BULB POSITION A Synchronizer wiring can be accomplished two differ-
Use this position when using a separate light switch ent ways as an option to the user.
for instrument lighting. Wiring Diagram -- Gauge needle to point toward
slow running engine
Unswitched Position
Tachometer Tachometer
Synchronizer
Starboard Engine Port Engine
Gauge
+ 12 Volt
Light Switch
Wire
SEND
Synchronizer
51105 Box
52566

Wiring Diagram -- Gauge needle to point toward
fast running engine
Tachometer Tachometer
Starboard Engine Synchronizer Port Engine
Gauge
Synchronizer
Box
52565
CLEANING GAUGES
Clean gauge by washing with fresh water to remove
sand and salt deposits. Wipe off with a soft cloth
moistened with water. The gauge may be scored or
damaged if wiped with abrasive material (sand, sa-
line or detergent compounds, etc.) or washed with
solvents such as trichloroethylene, turpentine, etc.

FUEL SYSTEM
3
A
FUEL PUMP
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Fuel Pump (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
Fuel Pump (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-7
Problem: Air Bubbles in Fuel Line . . . . . . 3A-7
Problem: Lack of Fuel Pump Pressure . . 3A-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8
Check Valve Assembly . . . . . . . . . . . . . . . . . . . . 3A-8
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 3A-8
3A-0 - FUEL SYSTEM 90-826148R2 MARCH 1997

Specifications
Fuel Pump Pressure:
@ 5000 RPM 4.0 - 7.0 PSI
@ 750 RPM 2.5 - 4.0 PSI
Electric fuel pump pressure, if used, must be lim-
ited to no more than 6.0 PSI.
90-826148R2 MARCH 1997 FUEL SYSTEM - 3A-1

FUEL PUMP (MANUAL)
20
19 21
20
A
B 22
7
6 23
A 1
11 3 4
14 5
12 5 10
4 2
3
9 15
16
13 23 8 18
19
26
17
23
23 C
23 24
23
30
32 25
29
23
28
31
27
19 Perfect Seal (92-34227-1)
A = TO CARBURETOR B = TO INTAKE MANIFOLD C = TO CRANKCASE

FUEL PUMP (MANUAL)
TORQUE
REF.
1 1 FUEL PUMP ASSEMBLY
2 1 DIAPHRAGM KIT
3 2 RUBBER CHECK VALVE
4 2 CHECK VALVE
5 2 RETAINER
6 1 SPRING
7 1 CAP
8 1 SPRING
9 1 CAP
10 1 GASKET--Boost
11 1 GASKET
12 1 DIAPHRAGM
13 1 GASKET--Pulse
14 1 BASE
15 1 PLATE
16 2 SCREW--pump to crankcase (M6 x 1 x 50) 55 6.2
17 2 SCREW--pump 55 6.2
18 1 FITTING
19 1 PRIMER BULB
20 2 HOSE (9-1/2 IN.)
21 1 SLEEVE
22 1 HOSE
23 AR STA-STRAP
24 1 HOSE (3-1/4 IN.)
25 1 INSULATOR
26 1 HOSE (MOLDED)
27 1 FUEL FILTER
28 1 BRACKET
29 1 NUT (M6 x 1) Drive Tight
30 1 HOSE (14-1/4 IN.)
31 1 FUEL CONNECTOR
32 1 SCREW 100 11.3

FUEL PUMP (ELECTRIC)
21
22
23 24
25
25 29
22 23
26 25
20
25 28 7
19 6 25
27 1
A 3
B 4
5 10
5
4 2
11 3
98 15
14 16
25
12
13 18
37 19
32
35 17
A 25 25
36
25 30
38 C
33
31
34
41
42
44 40
46
25 39
43
45
47
D
47
46
A
19 Perfect Seal (92-34227-1)
A = TO OIL PUMP B = TO MANIFOLD C = TO CRANKCASE D = TO TEE

FUEL PUMP (ELECTRIC)
TORQUE
REF.
1 1 FUEL PUMP ASSEMBLY
2 1 DIAPHRAGM KIT
3 2 RUBBER CHECK VALVE
4 2 CHECK VALVE
5 2 RETAINER
6 1 SPRING
7 1 CAP
8 1 SPRING
9 1 CAP
10 1 GASKET--Boost
11 1 GASKET
12 1 DIAPHRAGM
13 1 GASKET--Pulse
14 1 BASE
15 1 PLATE
16 2 SCREW--pump to crankcase (M6 x 1 x 50) 55 6.2
17 2 SCREW--pump (M5 x .8 x 40) 55 6.2
18 1 FITTING
19 1 CLAMP
20 1 SCREW (M6 x 16)
21 1 SOLENOID VALVE
22 2 STA--STRAP
23 2 HOSE (11 1/2 IN.)
1 SLEEVE (1/2 x 5 IN.)
24
1 SLEEVE (3/8 x 7-1/2 IN.)
25 AR STA--STRAP
26 1 TEE FITTING
27 1 HOSE (4 IN.)
28 1 HOSE (3-1/4 IN.)
29 1 HOSE
30 1 HOSE (3-1/4 IN.)
31 1 INSULATOR
1 HOSE (MOLDED)
32
1 TUBING (9 IN.)
33 1 TEE (DESIGN I)
34 1 CONNECTOR (DESIGN II)
35 1 TUBING (4 IN.)
36 1 CHECK VALVE
37 1 HOSE (1-1/2 IN.)
38 1 TUBING (1-1/4 IN.)
39 1 FUEL FILTER
40 1 BRACKET
41 1 NUT (M6 x 1) Drive Tight
42 1 HOSE (14 1/4 IN.)
43 1 FUEL CONNECTOR
44 1 SCREW
45 1 PRIMER BULB
46 2 HOSE (9-1/2 IN.) ELECTRIC HANDLE
AR SLEEVE (3/8 x 7-1/2 IN.)
47
1 SLEEVE (1/2 x 5 IN.)

Theory of Operation Checking For Restricted Fuel Flow
The fuel pump is a crankcase-pressure-operated, di- Caused By Anti-siphon Valves
aphragm-type pump. Crankcase pulsating pressure While anti-siphon valves are helpful from a safety
is transferred by way of a passage (hole) from the stand-point, they clog, they may be too small, or they
crankcase to the fuel pump. may have too heavy a spring. The pressure drop that
When the piston travels upward, a vacuum is created occurs with these valves can create operational
in the crankcase. This vacuum pulls in the fuel pump problems and/or powerhead damage by restricting
diaphragm, the inlet check valve (in fuel pump) is flow of fuel. Some symptoms of restricted (lean) fuel
opened and, and fuel is drawn into fuel pump. flow, are:
¯ Loss of fuel pump pressure
Downward motion of the piston forces out the fuel ¯ Loss of power
pump diaphragm, closes the inlet check valve (to ¯ High speed surging
keep fuel from returning to fuel tank) and opens the ¯ Preignition/detonation (piston dome erosion)
outlet check valve, forcing fuel to the carburetors. ¯ Outboard hesitates upon acceleration
¯ Outboard runs rough
¯ Outboard quits and cannot be restarted
Troubleshooting ¯ Outboard will not start
¯ Vapor lock
WARNING Any type of anti-siphon device must be located be-
FIRE AND EXPLOSION HAZARD. Observe fire tween the outboard fuel inlet and fuel tank outlet. A
prevention rules, particularly NO SMOKING. Be- method of checking [if such a device (or bad fuel) is
fore servicing any part of the fuel system, discon- a problem source] is to operate the outboard with a
nect electrical system at the battery. Drain the separate fuel supply which is known to be good.
fuel system completely. Use an approved con- If it is found that the anti-siphon valve is the cause of
tainer to collect and store fuel. Wipe up any spil- the problem, either 1) replace the anti-siphon valve,
lage immediately. Materials used to contain spil- or 2) replace it with a solenoid-operated fuel shutoff
lage must be disposed of in an approved valve.
receptacle. Any fuel system service must be per-
formed in a well ventilated area.
FUEL LEAKAGE FROM ANY PART OF THE FUEL

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

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

Reassembly 3. With retainer installed in pump body, break re-
tainer rod (a) from retainer (b) by bending side-
ways.
Check Valve Assembly
1. Insert retainer (a) thru plastic disc (b) and rubber
check valve (c). a
b
b
a 23601
a - Retainer Rod
c b - Retainer
23601
a - Retainer 4. Reinstall rod (a) into retainer cap (b) and, use a
b - Plastic Disc small hammer or hammer and punch to tap rod
c - Rubber Check Valve down into retainer until flush with top of retainer.
a
2. Install check valves and retainers into fuel pump
body.
23610
a - Rod
b - Retainer Cap
Fuel Pump Assembly

1. Assemble remaining components as shown in
“Fuel Pump Exploded View”.
2. Install bolts and torque to 55 lb. in. (6.2 N·m).
a
a
51267
23601 a - Bolt (2) Torque to 55 lb. in. (6.2 N×m)

FUEL SYSTEM
3
B
CARBURETOR
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1
WME Carburetor Specifications . . . . . . . . . . 3B-1
Jet Orifice Size Chart . . . . . . . . . . . . . . . . . . . 3B-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4
Fuel System Fuel Flow . . . . . . . . . . . . . . . . . . 3B-6
Manual Start Models . . . . . . . . . . . . . . . . . 3B-6
Electric Start Models . . . . . . . . . . . . . . . . . 3B-7
Electric Start
Tiller Handle Models . . . . . . . . . . . . . . . . . 3B-8
Carburetor Adjustments . . . . . . . . . . . . . . . . . 3B-9
Initial Starting Adjustment . . . . . . . . . . . . . 3B-9
Idle Speed Adjustment . . . . . . . . . . . . . . . 3B-9
Idle Mixture Screw Adjustment . . . . . . . . 3B-9
Carburetor Float Adjustment . . . . . . . . . . 3B-9
Main (High Speed) Jet Adjustment . . . . . 3B-10
Rejetting Carburetors For
High Altitude Operation . . . . . . . . . . . . . . . 3B-11
Fuel System Troubleshooting . . . . . . . . . . . . 3B-12
General Information . . . . . . . . . . . . . . . . . . 3B-12
Enrichener System
Electric Start Models . . . . . . . . . . . . . . . . . . . . 3B-15
Enrichener Valve Test . . . . . . . . . . . . . . . . 3B-16
3B-0 - FUEL SYSTEM 90-826148R2 MARCH 1997

Specifications
Idle RPM 700 - 800 RPM (In Forward Gear)
Wide Open Throttle (W.O.T.) RPM

- Model 30/40 Marathon/40 Seapro 4500 - 5500 RPM
- Model 40 5000 - 5500 RPM
Idle Mixture Screw Adjustment (Preset-Turns Out) 1-1/2 ± 1/4
Float Level 9/16 in. (14.29mm)
WME Carburetor Specifications

NOTE: Carburetor Number Stamped at Top of Carburetor Flange.
Carburetor Number Model H.P. Main Jet Bowl Back Float Setting Pre-Set Idle
Size Vent Jet Drag Jet Screw (Open)
WME-36 / WME-36A 30 H.P. 0.054 in. None None 9/16 in. 1-1/2 Turns
Manual (14.29 mm)
Electric (14.29 mm)
WME-38 40 H.P. 0.066 in. None None 9/16 in. 1-1/2 Turns
Manual (14.29 mm)
Electric (14.29 mm)
EHO (14.29 mm)
WME-63 30 H.P 0.054 in. None None 9/16 in. 1-1/2 Turns
Manual (14.29 mm)
Electric (14.29 mm)
EHO (14.29 mm)
Manual (14.29 mm)
Electric (14.29 mm)
90-826148R2 MARCH 1997 FUEL SYSTEM - 3B-1

Jet Orifice Size Chart Special Tools
NOTE: Thread size for jets is 10-32. P/N 91-36392 Carburetor Scale
Jet Orifice Part

Size-inches Number
0.040 19266040
0.042 1399-5315
0.044 1395-7394
0.046 1399-5317
0.048 1395-6246
73656
0.050 1395-6028
0.052 1395-6359
0.054 1399-5225
0.056 1399-5213
0.058 1395-7831
0.060 1395-6487
0.062 1399-4217
0.064 1399-4216
0.066 1399-4215
0.068 1395-6029
0.070 1395-6030
0.072 1395-6207
0.074 1399-3794
0.076 1399-3796
0.078 1395-6680
0.080 1395-6201
0.082 1399-3518
0.084 1399-3517
0.086 1395-5815
0.088 1395-6202
0.090 1395-6247
0.092 1395-5733
0.094 1395-8423
0.096 1399-6249
0.098 1395-7335

Notes:

CARBURETOR
7 Loctite 271 (92-809820)

CARBURETOR
TORQUE
REF.
1 CARBURETOR (MANUAL – 40) (WME 66)
1 CARBURETOR (ELECTRIC – 40) (WME 67)
1 1 CARBURETOR (MANUAL – 30) (WME 63)
1 CARBURETOR (ELECTRIC/ELECTRIC HANDLE – 30) (WME 64)
1 CARBURETOR (ELECTRIC HANDLE – 30)(WME 65)
2 1 RETAINING RING
3 1 LEVER–Oil (ELECTRIC)
4 1 SCREW–Lever Retainer Drive Tight
5 1 THROTTLE VALVE
6 2 SCREW–Throttle valve 6 0.7
7 1 GASKET–Flange
8 1 GASKET–Cover plate
9 1 COVER PLATE
10 2 SCREW–Cover plate 18 2.1
11 1 SPRING–Idle needle
12 1 IDLE NEEDLE
13 1 LEVER
1 BUSHING–Throttle Shaft
14 1 BUSHING–Throttle Shaft (WME-63 THRU 67)
15 1 SPRING–Throttle return
16 1 THROTTLE SHAFT (ELECTRIC)
17 1 THROTTLE SHAFT (MANUAL)
18 1 SCREW–Throttle adjustment Drive Tight
19 1 SPRING–Idle adjustment (WME-36 THRU 42A)
1 SCREW–Idle speed
20 1 SCREW–Idle speed (WME-63 THRU 67)
21 1 FITTING (Part of Ref # 1) (ELECTRIC)
22 1 FITTING (Part of Ref # 1) (MANUAL)
23 1 INLET NEEDLE VALVE
24 1 GASKET–Nozzle Well
25 1 FLOAT SHAFT
26 1 FLOAT
27 1 GASKET–Fuel bowl
1 FUEL BOWL (MANUAL & WME-42)
28 1 FUEL BOWL (ELECTRIC)
29 1 FITTING (Part of Ref # 28) (MANUAL & WME-42)
30 4 SCREW–Fuel Bowl 18 2.1
1 MAIN FUEL JET (.066 - 40 H.P.)
31 1 MAIN FUEL JET (.054 - 30 H.P.) 14 1.6
32 1 SEAL–Drain plug
33 1 PLUG KIT 22 2.5
34 2 SCREW (M6 x 55) Drive Tight
35 1 PLUG–Cap
36 1 COVER–Carburetor
37 2 SCREW (M8 x 100) Hex Head Cap 100 11.3
38 1 PLATE–Carburetor
39 1 ROLLER

Fuel System Fuel Flow
MANUAL START MODELS
NOTE: The manual starting primer bulb is designed

WARNING to provide a rich fuel mixture to the engine during cold
All safety precautions should be adhered to start conditions. When the primer bulb is pressed in,
when testing the primer bulb system. Fuel fuel is forced from the primer bulb into the intake
should be directed into suitable container and all manifold via hose and fitting on the side of the man-
flammable materials extinguished and sources ifold. When the primer bulb is released , a suction is
of spark turned off. created in the bulb and fuel is drawn into the bulb
though a hose from the carburetor float bowl. Remov-
ing the primer hose from the intake manifold and
pressing the primer bulb will determine if the primer
is working properly as fuel should be expelled from
the hose whenever the primer bulb is pressed.

ELECTRIC START MODELS

ELECTRIC START TILLER HANDLE MODELS

Carburetor Adjustments Carburetor Float Adjustment
1. Remove carburetor as outlined in “Carburetor
Removal,” following.
Initial Starting Adjustment
2. Remove fuel bowl and gasket and check float lev-
Turn idle mixture screw adjustment “in” (clockwise) el using a carburetor scale.
until it seats lightly then, back off 1-1/2 turns.
a
b
Idle Speed Adjustment 9/16 in.
(14.29 mm)
1. Adjust engine idle RPM as outlined in Section 2C
“Timing/Synchronizing/Adjusting.”
Idle Mixture Screw Adjustment With Gasket

Removed
1. Start engine and allow to warm-up. Throttle back
engine to idle for about one minute.
2. With engine running at idle speed in “Forward”
52372
gear --turn idle mixture screw IN (clockwise) until
engine starts to “bog” down and misfire. Back out
a - Metal Tab
1/4 turn or more. b - Inlet Needle
3. Attach Spring Clip on Inlet Needle to metal float

tab and place needle into its seat.
a
b
55883
a - Metal Float Tab
b - Spring Clip
4. If necessary, adjust float level by bending metal

tab (on float) to which inlet needle is clipped.
52280
a - Idle Mixture Screw
3. Check for too lean mixture on acceleration.

4. DO NOT adjust leaner than necessary to attain
reasonably smooth idling. When in doubt, stay on
the slightly rich side of the adjustment. Bend Tab Here for
Float Level Adjustment

Main (High Speed) Jet Adjustment
The carburetor has a fixed high speed jet. Extreme b b
changes in weather (temperature and humidity) and/
or elevation may result in a too lean or rich fuel mix-
ture at wide-open-throttle, which may require a
change in the high speed jet. A smaller size main jet
will lean the fuel mixture, and a larger size jet will en-
rich the fuel mixture.
c
a
d
a
a - Carburetor Number Location

b - Off Idle Transfer Ports
c - Idle Speed Screw
d - Idle Pickup Tube
c
52372
a - Idle Mixture Screw

b - High Speed Jet a
c - Bowl Drain (Remove Plug)
b c
a - Idle Pickup Tube
b - Bowl Vent Tube
c - Main Jet Plug

Rejetting Carburetors For High Alti-
tude Operation
The carburetor jet installed at the manufacturer is for
engine operation at sea level through an elevation of
2500 feet (762m) above sea level. If the engine is to
be operated at an altitude higher than 2500 feet
above sea level, it will be necessary to rejet (remove
the carburetor jets and install jets with a different ori-
fice size) the carburetors. Each time the engine is to
be operated at a different elevation from the previous
time, refer to the “Carburetor Jet Charts” following,
and rejet the carburetors for elevation engine will be
operated at.
High Altitude Jet Chart

Engine Operation
High Speed
Elevation
Jet Size
(Above Sea Level)
2500’ - 5000’ .002” smaller
(750 - 1500m) (than standard jet)
5000’ - 7500’ .004” smaller
(1500 - 2250m) (than standard jet)
7500’ and Up .006” smaller
(2250m and Up) (than standard jet)
*Standard Jets listed are for operation of engine from 0 ft-2500
ft. (0-762 M) of elevation.

Fuel System
1. Propeller
Troubleshooting
2. Spark Plugs
3. Ignition Timing
General Information 4. Ignition Spark Voltage
Problems that are thought to be caused by the fuel 5. Cylinder Compression
system may, in reality, be something completely dif-
ferent. Items, that are shown in the list on the right, 6. Reed Valves
could give the impression that there is a problem in Typical symptoms and solutions in troubleshooting a
the fuel system. fuel system are shown below:
Problem: Engine Turns Over but Will Not Start or Starts Hard When Cold
Improper starting procedure used. Review starting procedure as outlined in “Operation
and Maintenance Manual.”
Fuel tank empty or too low. Improperly mixed fuel. Check fuel in tank and replace or add whichever is
Contaminants (water,dirt, etc.) in fuel. necessary.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all-the-way and free from any contaminants.
Pinched, cut, restricted fuel line or loose fuel line Inspect all fuel lines and replace as needed. Tighten
connection. fuel line connections.
Dirty or restricted fuel filter. Inspect and replace or clean all fuel filters.
Choke solenoid or enrichment valve not operating. Inspect solenoid or valve and wiring. Replace as re-
quired.
Needle and seat in carburetor that is either stuck Refer to carburetor disassembly in this section.
open (flooding) or closed (no fuel).
Improper carburetor jet, restricted jet or idle mixture Refer to carburetor adjustments in this section.
screw out of adjustment.
Improper float level. Refer to carburetor adjustments in this section.
Low fuel pump pressure. Refer to Section 3B for Fuel Pump Testing.
Defective anti-siphon valve. Refer to Section 3B.

Improperly mixed fuel. Contaminants(water, dirt, Check fuel in tank and replace if necessary.
etc.) in fuel.
Fuel tank air vent closed or restricted. Check air vent on tank. Vent must be open all-the-
way and free from any contaminants.
A pinched, cut or restricted fuel line. Also loose fuel Inspect all fuel lines and replace as needed. Inspect
line connection. and tighten all fuel line connections.
Dirty or restricted fuel filter. Inspect and replace or clean all fuel filters.
Low fuel pump pressure. Refer to Section 3B “Fuel Pumps.”
Defective anti-siphon valve. Refer to Section 3B “Fuel Pumps.”
Needle and seat in carburetor that is either stuck Refer to carburetor adjustments in this section.
open or closed.
Improper carburetor jet, restricted jet or idle mixture Refer to carburetor adjustments in this section.
screw out of adjustment.
Improper float level. Refer to carburetor adjustments in this section.
Carburetor loose on intake manifold. Check tightness of carburetor nuts.
Using a pressure oil can, apply 2-cycle oil around
reed block housing/crankcase housing matching
Reed block loose or gasket defective. surfaces and carburetor base. If engine RPM
changes, tighten bolts/nuts or replace gaskets as
required.
Improperly routed or restricted bleed hose(s). Refer to bleed hose routing in “Powerhead” section.
Damaged fuel pump diaphragm. Refer to Section 3B, “Fuel Pump.”
Carburetor mixing chamber cover leaking air. Tighten screws or replace gasket.
Off idle holes plugged. Blow with compressed air.
Main nozzle or idle nozzle air bleed holes plugged. Blow with compressed air.
Damaged reeds. Refer to Section 4A for reed inspection.
Fuel pick-up outlet tube in fuel tank cracked. Replace

Problem: Engine Floods
Dirt or debris are preventing inlet needle from seat- Flush out inlet seat and clean inlet needle.
ing.
Worn inlet needle. Replace
Punctured float Replace.
Incorrect float setting Reset float.
Problem: Engine Runs Too Rich

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

Problem: Unable to Reduce Engine RPM to Slow Idle
Chipped or broken reeds on reed block. Replace reeds.
Problem: Rough Idle
Excessive pre-load on reeds. Replace reeds.
Problem: Engine Runs Too Lean

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

Enrichener System The enrichener system is pressurized by squeezing
the fuel line primer bulb or by the fuel pump when the
(Electric Start Models) engine is being cranked. When the ignition key is
turned to the “on” position and pushed in (and held
The enrichener system provides the engine with ex-
in), current is sent to the valve causing it to open,
tra fuel charge for ease of starting cold engine. The
which allows pressurized fuel to pass thru a hose to
system consists of an electrically operated enrichen-
a fitting on the intake manifold. When the key (or
er valve which is connected by a hose to the intake
choke button) is released, the valve will return to the
manifold.
closed position. The valve can be operated manually
by pressing and holding button located at bottom of
valve. The small hose connected to fitting at the base
of the oil pump relieves excess crankcase pressure
at the oil pump drive.
52668
Small Hose - Connect to Fitting at Base of Oil Pump
Large Hose - Connect to Fitting on Intake Manifold
Connect to Fitting
on bowl of carbu-
retor
Enrichener Valve Manual Operation Button 52667

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

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

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

Valve is O.K. Check hoses and fittings from valve to carbu-
retor for leaks or obstructions.
No Fuel Flow from Fitting

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

FUEL SYSTEM
3
C
OIL INJECTION
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
Oil Injection Components . . . . . . . . . . . . . . . . . . . 3C-2
Oil Injection Components . . . . . . . . . . . . . . . . . . . 3C-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 3C-4
Oil Injection System . . . . . . . . . . . . . . . . . . . . . 3C-4
Oil Injection Flow System(Variable Ratio
Oil Pump) S/N-0G589999 & Below . . . . . . . . 3C-5
Oil Injection Flow System (Variable Ratio
Oil Pump) S/N-0G590000 & Above . . . . . . . . 3C-6
Pump Drive Assembly (Variable Ratio
Oil Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Carburetor/Oil Pump Synchronization . . . . . 3C-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-8
Bleeding Air From Oil Injection
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-8
Bleeding Air From Oil Pump Inlet Hose . 3C-8
Bleeding Air From Oil Pump Outlet Hose 3C-8
3C-0 - OIL INJECTION SYSTEM 90-826148R2 MARCH 1997

Specifications
Recommended Oil Quicksilver TC-WII or
TC-W III 2- Cycle Outboard Oil
Oil Tank Capacity/Approx. Time 50.5 fl. oz. (1.5 Liters)
Oil Injection 4.7 Hours @ 5250 RPM
Reserve Capacity/Approx. Time 30 Minutes @ 5250
Output w/Pump @ Full Open 8.5cc/10 Minutes @ 900 RPM
90-826148R2 MARCH 1997 OIL INJECTION SYSTEM - 3C-1

Oil Injection Components
7 6
8
9
2
3
11
12
21
15
20 19 95
18
13
17 14
10
16 30
22
24
23
25
27
28
29
95
26
95 2-4-C With Teflon (92-825407A12)

Oil Injection Components
TORQUE
REF.
1 2 BUSHING-Flanged
2 2 GROMMET
3 1 OIL TANK ASSEMBLY
4 1 CAP ASSEMBLY
5 1 GASKET
6 1 RETAINER
7 1 NUT-Push
8 1 VENT ASSEMBLY
9 1 VALVE
10 2 STA-STRAP
11 2 CLAMP
12 1 TUBING (4-3/4 IN.)
13 1 ELBOW
14 1 TUBING (1-1/4 IN.)
15 1 GROMMET
16 1 SPACER
17 1 SWITCH
18 1 SCREW (.164-18 x .375)
19 1 WASHER
20 1 TUBING (10”)
21 1 STA-STRAP
22 1 DRIVEN GEAR
23 1 BEARING ASSEMBLY
24 1 BUSHING (FLANGED)
25 1 BUSHING
26 1 OIL INJECTION PUMP
27 1 O RING
28 1 O RING
29 2 SCREW (M5 x 20) 50 5.6
30 1 LINK

Theory of Operation Oil Injection System
The oil injection system delivers a oil mixture thru a 1. Oil Reservoir
variable ratio oil pump. The oil reservoir gravity feeds oil to the oil pump.
The reservoir contains a low oil sensor which ac-
The engine mounted oil reservoir holds 50.5 (1.5 Li-
tivates a warning horn when 7 fl. oz. (200cc) of oil
ters) which will provide 4.5 hours of running time at
remains in the reservoir.
wide open throttle.
2. Oil Injection Pump
A low oil warning horn will be activated when 7 fl. oz.
The crankshaft driven oil pump is a variable ratio
(200cc) of oil remains in the reservoir. This will pro-
oil pump which provides an oil/fuel mixture of
vide approximately 30 minutes of wide open throttle
100:1 @ idle and 60:1 @ WOT.
running before oil is depleted.
3. Check Valve Vent
The crankshaft driven oil pump injects oil into the fuel
Provides air to oil reservoir for proper venting and
before the fuel pump.
also prevents oil leaks when outboard is tilted for-
ward.
4. 2 PSI Check Valve
This valve prevents gasoline from being forced
into oil line.
5. Low Oil Sensor
When oil level in reservoir drops to approximately
7 fl. oz. (200cc), the sensor will signal warning
module to activate warning horn.
6. Timing and Protection Module (TPM) for
(S/N-0G589999 & Below)
If the oil in the reservoir drops to less than 7 fl. oz.
(200 cc), the low oil sensor in the reservoir will
signal the warning module to activate the warning
horn. If the powerhead temperature should ex-
ceed 190°±8°F (88°±13°C), the overheat tem-
perature sensor in the water jacket cover will sig-
nal the warning module to activate the warning
horn.

Oil Injection Flow System (Variable Ratio Oil Pump) S/N-0G589999 & Below
a
h
e
b
52881
a - Fuel Pump f - Vent

b - Fuel Filter g - Fill Cap
c - Check Valve (2 PSI) h - Oil Level Sight Gauge
d - Carburetor i - Fuel Line Connector
e - Oil Pump

Oil Injection Flow System (Variable Ratio Oil Pump) S/N-0G590000 & Above
a
h
e
b
a - Fuel Pump f - Vent

b - Fuel Filter g - Fill Cap
c - Check Valve (2 PSI) h - Oil Level Sight Gauge 52881
d - Carburetor i - Fuel Line Connector
e - Oil Pump

Pump Drive Assembly (Variable Ratio c
b
Oil Pump)
a
e
b d
52044
d
a - Oil Pump
a b - O-Ring (2)
c - Driven Gear
d - Drive Gear
e - Crankshaft
52897
a - Oil Inlet
b - Bleed Screw Adjustments
c - Oil Outlet
d - Oil Pump
Carburetor/Oil Pump Synchroniza-
tion
While holding throttle arm at idle position, adjust
d length of link rod so that stamped mark of oil pump
body aligns with stamped mark of oil pump lever, and
lever is in closed position.
b a
e
a
c
52044 b
52899
a - Driven Gear
b - Bushing (2) a - Mark on Body
c - O-ring (2) b - Mark on Lever
d - Oil Pump c - Link Rod
e - Apply Needle Bearing Assembly Lubricant to Shaft

Troubleshooting Oil Pump Volume (Flow) Test
WARNING
Bleeding Air From Oil Injection The input fuel line TEE fitting from which the oil
System line was removed MUST BE CAPPED OFF to pre-
vent fuel leakage while the engine is running.
CAUTION NOTE: The following specifications are determined
If air exists in either oil pump hose (inlet or out- with the outboard running off a remote fuel supply
let), the air MUST BE bled from hose(s) or engine with pre-mix fuel. The oil pump output hose (clear)
damage may occur. must be disconnected from the input fuel line TEE fit-
ting and directed into a graduated container. The in-
BLEEDING AIR FROM OIL PUMP INLET HOSE put fuel line TEE fitting from which the oil line was re-
moved MUST BE CAPPED OFF to prevent fuel
With engine not running, place a shop towel below oil leakage while the engine is running.
pump. Loosen bleed screw three to four turns and al-
low air bubbles to exit inlet hose. Torque bleed screw
to 25 lb. in. (2.8 N·m). This procedure also allows oil
pump to fill with oil.
a
BLEEDING AIR FROM OIL PUMP OUTLET d
HOSE
Purge air from outlet hose by running engine (on 50:1
gasoline/oil mixture in fuel tank) at idle speed until no
air bubbles are present in outlet hose.
c
b
a
52900
b a - Bleed Screw
b - Inlet Hose
c - Outlet Hose
d - Cap Off
c
Flow specifications are as follows:
52899
a - Bleed Screw @ 900 RPM with oil pump link arm DISCONNECTED
b - Inlet Hose and pump arm rotated FULL CLOCKWISE and
c - Outlet Hose HELD AGAINST PUMP CASTING = 8.5cc ±10% in
10 minutes.

POWERHEAD
4
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Cylinder Block Components . . . . . . . . . . . . . . . . . 4-4
Induction Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Crankshaft/Piston/Flywheel . . . . . . . . . . . . . . . . . 4-8
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . . 4-10
Crankshaft Disassembly . . . . . . . . . . . . . . . . . . . . 4-12
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . 4-13
Piston and Connecting Rod Disassembly . . . . . 4-14
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4-16
Cylinder Block and Crankcase Cover . . . . . . 4-16
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Honing Procedure . . . . . . . . . . . . . . . . . . . 4-17
Pistons and Piston Rings . . . . . . . . . . . . . . . . 4-18
Cleaning Piston Ring Grooves . . . . . . . . . 4-18
Measuring Piston Roundness . . . . . . . . . . 4-18
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Reed Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Powerhead Reassembly and Installation . . . . . . 4-21
General Information . . . . . . . . . . . . . . . . . . . . . 4-21
End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Assembling Rod to Piston . . . . . . . . . . . . . . . . 4-22
Piston Ring Installation . . . . . . . . . . . . . . . . . . 4-23
Crankshaft Installation . . . . . . . . . . . . . . . . . . . 4-25
Installing Rods to Crankshaft . . . . . . . . . . . . . 4-26
Connecting Rod Cap Alignment . . . . . . . . . . . 4-27
Crankcase Cover to Block . . . . . . . . . . . . . . . 4-27
Intake/Reed Block Manifold Installation . . . . 4-29
Thermostat Cover Installation . . . . . . . . . . . . 4-30
30/40 Bleed Hose Routing . . . . . . . . . . . . . . . . . . 4-31
Powerhead Installation . . . . . . . . . . . . . . . . . . . . . 4-32
Test Run Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Break-in Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4-0 - POWERHEAD 90-826148R2 MARCH 1997

Specifications
Type 2 Cyl. Loop Charged
BLOCK
Displacement 39.3 cu. in. (644.4cc)
REED VALVE OPENING Opening (Max. Allowable) 0.020 in. (0.50mm)
STROKE Length 2.796 in. (71.0mm)
Dia. Standard 2.993 in. (76.0mm)
CYLINDER BORE
Taper/Out of Round Max 0.003 in. (0.08mm)
PISTON Dia. Standard* 2.988 in. (75.90mm)
End Gap 0.010 in. to 0.018 in.
PISTON RING
(0.254mm to 0.457mm)
With Thermostat + Poppet
@ Idle 1/2 - 1-1/2 PSI @750 RPM
@ W.O.T. 5 - 7 PSI @ 5000 RPM
WATER PRESSURE
@ Idle 0 - 1 PSI @ 750 RPM
@W.O.T. 5 - 7 PSI @ 5000 RPM
*See important information below.
IMPORTANT: Using a micrometer, measure di-
mension “A” at location shown. Dimension “A”
should be 2.988 in. ± .001 for a STANDARD size
piston.
TOP
Dimension “A”
at Right Angle
(90°) to Piston CENTER
Pin
0.50 in.
(12.7mm)
“A”
BOTTOM
52676
90-826148R2 MARCH 1997 POWERHEAD - 4-1

Special Tools 9. Universal Puller Plate 91-37241
1. Lifting Eye 91-90455
2. Flywheel Holder 91-52344

10. Snap Ring Pliers 91-24283
73790
3. Flywheel Puller 91-73687A1
11. Piston Lock Ring Installer 91-77109A1
4. Powerhead Stand 91-827001A1

12. Torque Wrench (0-200 lb. ft.) 91-32610*
13. Torque Wrench (0-150 lb. in.) 91-66274*
5. Piston Ring Expander 91-24697
14. Compression Tester 91-29287
6. Lock Ring Removal Tool 91-52952A1 54965
7. Piston Pin Tool 91-74607A2
8. Driver Head 91-55919

Notes:

Cylinder Block Components
48
49
47
35
36 37 45
43 44
42
38 50
9
9 33 41
46
39 40
34 2
33 30
32
29
1
9
2
28
28 9 3
9
1
75
11 4
15
31
12
25 10 6
14 13 14 5
27 19
26
9
18
9
7
17 19
95
8
16
9
20
9
24
21
22
23
9 Loctite Pipe Sealant with Teflon (592) 33 Loctite “RCA/680”Retaining Compound

(92-809833)
14 2 Cycle Outboard Oil (92-13249A24) 75 Loctite “518”Master Gasket (92-12564-2)
19 Perfect Seal (92-34227-1) 95 2-4-C With Teflon (92-825407A12)

Cylinder Block Components
TORQUE
REF.
1 1 CYLINDER BLOCK
2 2 PIPE PLUG (1/8 Hex Head-Brass)
3 1 ROLL PIN (Used on models prior to 1998)
4 6 SCREW (M8 x 80 Hex flange head) 200 16.5 22.4
5 1 CARRIER ASSEMBLY
6 1 CHECK VALVE
7 1 CHECK VALVE
8 1 FITTING (BARBED-ELECTRIC)
9 4 SCREW (M8 x 40 Hex Flange Head) 200 16.5 22.4
10 1 CONNECTOR (Male)
11 2 PIN-CENTER MAIN
12 1 DOWEL PIN
13 1 PIPE PLUG (1/8 IN.-Brass)
14 1 PIPE PLUG (3/8-18)
15 2 ELBOW
16 1 END CAP
17 1 OIL SEAL
18 1 OIL SEAL
19 1 O RING
20 3 SCREW (M8 x 1.25 x 20 Hex flange head) 200 16.5 22.4
21 1 O RING (Included with Ref #1)
22 1 COVER MANUAL
23 2 SCREW (M5 x .8 x 20 Hex Washer Head)
24 1 GASKET-Cylinder block (Inc. w/ Ref #1)
25 1 TUBING (1-1/2 IN.)
26 1 CHECK VALVE (Double End)
27 1 TUBING (5-1/2 IN.)
28 1 ELBOW (1/8-MALE)
29 1 SCREW (#10-16 x .60 Self Tap) Drive Tight
30 1 SENDER-Temperature (DESIGN I)
31 1 SENDER-Temperature (DESIGN II)
32 1 RETAINER-Sender
33 1 WASHER
34 1 SCREW (#10-16 x .60 Self Tap) Drive Tight
35 2 SCREW (Qty. of 4 on Electric)
36 1 CLAMP ELECTRIC
37 1 CLAMP
38 2 STUD (M6 x 1 x 44 Double end)
39 1 PLATE-SERIAL #
40 1 GASKET-Poppet cover (Included with Ref #1)
41 1 POPPET
42 1 DIAPHRAGM
43 1 WASHER (Special)
44 1 SCREW (# 10-16 x .75)
45 1 SPRING (S/N-USA-0G590000 /BEL-9973100 & Above)
46 1 THERMOSTAT (130 Degrees)
45 1 SPRING (S/N-USA-0G589999 /BEL-9973099 & Below)
46 1 THERMOSTAT (120 Degrees)
47 4 COVER
48 1 SCREW (M8 x 1.25 x 25) (Incl. w/ Ref #1) 200 16.5 22.4
49 1 SCREW (8-18 x .31 Self Tap) (International) Drive Tight
50 1 GASKET-Thermostat (Included w/ Ref #1)

INDUCTION MANIFOLD
7
16
33
6
5
4 8
3
15
9
A
14 11
12 10
13
33 Loctite 680 (92-809833)
A = TO BASE OF OIL PUMP

INDUCTION MANIFOLD
TORQUE
REF.
INDUCTION MANIFOLD (S/N-0G380074/
1
BEL-9905360 & BELOW)
1
INDUCTION MANIFOLD (S/N-0G380075/
1
BEL-9905361 & ABOVE)
2 1 CHECK VALVE
3 1 FITTING (Barbed)
DOWEL PIN (Component of Ref #1) (S/N-0G380074/
4 4
BEL-9905360 & BELOW)
5 2 STUD (M6 x 1 x 44)
6 2 STUD (M6 x 1 x 55)(STUD ATTACHING)
7 2 SCREW (M6 x 40)(SCREW ATTACHING)
8 1 TUBING (12 1/2 IN.)
SCREW (M8 x 30) (S/N-OG380075/
8 200 16.5 22.4
9 BEL-9905361 & UP)
8 SCREW (M8 x 1.25 x 25 Hex flange head) 200 16.5 22.4
10 2 REED ASSEMBLY
TAB WASHER
11 2 S/N-USA-0G380074/BEL-(30)-9905360/
BEL-(40)-9905385 & BELOW
12 2 RETAINER--Reed (40 H.P.)
13 2 RETAINER--Reed (30 H.P.)
14 2 SCREW (M6 x 1 x 16 Hex head cap) 100 11.3
15 1 GASKET--Manifold
1 REED VALVE (30 H.P.) S/N-USA-0G380075/BEL-9905361 & ABOVE
16
1 REED VALVE (40 H.P.) S/N-USA-0G380075/BEL-9905386 & ABOVE

CRANKSHAFT/PISTON/FLYWHEEL
2
4
95
22
21
11 14
19
10
18
15
17
20 7
14
21 5
17
15
14
16
7 12
14 14
6
12
8
13
9 14
95
14 2 Cycle Outboard Oil (92-13249A24)
95 2-4-C With Teflon (92-825407A12)

CRANKSHAFT/PISTON/FLYWHEEL
TORQUE
REF.
1 1 NUT (M16 x 1.5) 95 129
2 1 WASHER
3 1 FLYWHEEL (ELECTRIC) S/N-USA-0G590000/BEL-9973100 & ABOVE
4 1 FLYWHEEL (MANUAL)
3 1 FLYWHEEL(ELECTRIC)S/N-US-0G589999/BEL-9973099 & BELOW
4 1 FLYWHEEL (MANUAL)
5 1 CRANKSHAFT ASSEMBLY
6 1 GEAR ASSEMBLY (DRIVER)
7 2 KEY
8 1 BALL BEARING
9 1 RETAINING RING
10 1 ROLLER BEARING ASSEMBLY
11 1 OIL SEAL
12 1 BEARING ASSEMBLY--Center main
13 14 ROLLER
14 1 RING--Seal
15 2 CONNECTING ROD ASSEMBLY
16 4 SCREW (1/4--28) 192 16 21.7
18 58 NEEDLE ROLLER
19 4 THRUST WASHER
2 PISTON (STANDARD) S/N-USA-0G590000/BEL-9973100 & ABOVE
AR PISTON (.015 O.S.)
20
2 PISTON (STANDARD)S/N-USA-0G589999/BEL-9973099 & BELOW
AR PISTON (.015 O.S.)
21 4 RING--Lock
1 PISTON RING SET (STANDARD)
22
AR PISTON RING SET (.015 O.S.)

Torque Sequence Powerhead Removal
1. Disconnect battery leads from battery (if applica-
ble).
Intake Manifold Bolts
2. Remove spark plug leads from spark plugs.
Torque bolts to 16.5 lb. ft. (22.4 N·m).
3. Disconnect remote control harness from engine
6 5 (if applicable) - or lanyard and stop button/horn
wiring on manual models.
4. Disconnect fuel connector from engine. Fuel line
must also be removed at either engine tray or fuel
2 1 filter.
5. Remove throttle and shift cables.
6. Remove BLACK ground lead between power-
head and engine tray.
7. Remove tell-tale hose from powerhead.
8. Remove anti-start in gear cable on manual start
3 4 models and disconnect neutral switch bullet con-
nectors on all models.
9. Remove primer hoses from carb and manifold on
manual start models and remove recoil starter.
10. Remove bolt, nut and flat washer securing upper
7 8 drive shaft housing cover and remove cover.
Crankcase Cover Bolts

Torque bolts to 16.5 lb. ft. (22.4 N·m).
4 3
8 a
7
2 1
10 9
52687
a - Bolt, Nut, Flat Washer
5 6

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

drive shaft housing.
52689
a - Lifting Eye (P/N 91-90455)
12. Remove 6 bolts securing powerhead to drive

shaft housing.
52690
a a
52688
a - Bolt (6)

NOTE: Refer to appropriate sections in service
manual for removal of individual fuel and electrical
Crankshaft Disassembly
sub-assemblies from powerhead. 1. Remove center main bearing.
Component/Assembly Section
Starter Motor 2B
Ignition Switch Box 2A*
Ignition Coil 2A*
Starter Solenoid 2B*
Voltage Regulator/Rectifier 2B*
Flywheel 2A
Stator Assembly 2A*
Trigger Assembly 2A*
Air Silencer 3B
Carburetor and Linkage 3B
52906
Fuel Pump 3A
Fuel Enrichment Valve 3B
Shift Cable Latch Assembly 7A 2. Remove rod cap bolts and keep components with
Control Cable Anchor Bracket 7A respective connecting rod. Reattach caps to re-
Warning Module 3C* spective rod as each piston/rod assembly is re-
moved. CAPS MUST BE INSTALLED IN SAME
Oil Pump 3C DIRECTION ON SAME ROD or BEARING
FAILURE WILL RESULT.
*NOTE: All ignition and electrical components can be
removed and installed as an assembly.
52907
3. Remove main bearing sealing ring.
52908

CAUTION Crankshaft Inspection
Removal of lower crankshaft bearing will dam- · Inspect crankshaft to drive shaft splines for wear.
age bearing and will require replacement. (Replace crankshaft, if necessary.)
4. Inspect lower bearing for roughness and exces- · Check crankshaft for straightness [(0.003 in.
sive looseness. Remove retaining ring and bear- (0.076mm) maximum]. (Replace as necessary.)
ing only if necessary. · Inspect crankshaft oil seal surfaces. Sealing sur-
faces must not be grooved, pitted or scratched.
b (Replace as necessary.)
· Check all crankshaft bearing surfaces for rust, wa-
a ter marks, chatter marks, uneven wear and/or
overheating. (Refer to “Connecting Rods”.)
· If necessary, clean crankshaft surfaces with cro-
cus cloth as shown.
a - Retaining Ring
b - Bearing
· Thoroughly clean (with solvent) and dry crank-

51081 shaft and crankshaft ball bearings. Recheck sur-
faces of crankshaft. Replace crankshaft if sur-
a - P/N 91-827001A1 faces cannot be properly cleaned up. If crankshaft
b - P/N 91-37241 will be reused, lubricate surfaces with 2 cycle oil
to prevent rust. DO NOT lubricate ball bearings at
5. Inspect oil drive gear for cracks and excessive this time.
wear. Replace if necessary.
WARNING
DO NOT spin-dry crankshaft ball bearing with
compressed air.
a
51084
a - Oil Drive Gear
b - Key

Piston and Connecting Rod CAUTION
Disassembly Safety glasses should be worn when removing or
installing lock rings.
1. Remove piston rings. Always install new piston
rings. 3. Remove piston pin lock rings using awl. Always
install new lock rings.
a
52680
a - Piston Ring Expander (P/N 91-24697) 52679
4. Remove piston pin.

2. Scribe cylinder number (1 or 2) on inside of each
piston and rod assembly as they are removed to a b
insure reassembly of correct piston to same con-
necting rod.
52678
a - Piston Pin Tool (91-74607A2)

b - Piston Pin
5. Remove piston pin needle bearings (29 per pis-

ton pin) and locating washers (“a”2 per piston) as
shown.
1 a
52681
a - Mark Piston & Rod for Correct Reassembly
a 52677
a - Locating Washers

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
inadequate lubrication and/or improper fuel.
Under these conditions, the crankshaft journal is
hammered by the connecting rod. As ignition
a occurs in the cylinder, the piston pushes the
connecting rod with tremendous force, and this
51853
force is transferred to the connecting rod journal.
a - Pitting
Since there is little or no load on the crankshaft,
it bounces away from the connecting rod. The
4. Water Marks: When bearing surfaces are crankshaft then remains immobile for a split
subjected to water contamination, a bearing second until the piston travel causes the
surface “etching”occurs. This etching resembles connecting rod to catch up to the waiting
the size of the bearing. crankshaft journal, then hammers 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. During operation,
the engine will emit a “whirr”and/or “chirp”sound
when it is accelerated rapidly from idle speed to
approximately 1500 RPM, then quickly returned
to idle. If the preceding conditions are found,
replace both the crankshaft and connecting
rod(s).
51853
a
51853
a - Chatter Marks Between Arrows

7. Uneven Wear: Uneven wear could be caused by
a bent connecting rod.
Cylinder Block and Crankcase Cover
IMPORTANT: Crankcase cover and cylinder
block are matched, line-bored assembly should
not be mismatched by using a different crank-
case cover or cylinder block.
a
51853
a - Uneven Wear Between Arrows
CAUTION
Crocus cloth MUST BE USED to clean bearing
surface at CRANKSHAFT END OF CONNECTING
ROD.
320 grit Carborundum cloth MUST BE USED to
clean bearing surface at PISTON PIN END OF
CONNECTING ROD.
VERIFY CAP TO ROD ALIGNMENT BEFORE
TORQUING ROD BOLTS.
DO NOT continue to clean connecting rod bear-
ing surfaces after marks have been removed.
c
52651
· Inspect cylinder block and crankcase cover for
cracks or fractures.
a b · Check gasket surfaces for nicks, deep grooves,
cracks and distortions that could cause compres-
sion leakages.
· Check that all water passages in cylinder block
are not obstructed. Check locating pins in cylinder
block that they are tight.
· Check crankcase cover fuel/bleed passages that
they are not obstructed. Verify that check valves
d in crankcase cover are not damaged.
NOTE: Wash rod to remove abrasive grit and · Thoroughly clean cylinder block and crankcase
apply 2 cycle oil to bearing surfaces to cover. Verify that all sealant and old gaskets are
prevent rust. 51083 removed from matching surfaces. Clean all car-
bon deposits from exhaust ports.
a - 320 Carborundum Cloth
b - Crocus Cloth · Inspect spark plug holes for stripped or damaged
c - To Drill Motor threads.
d - Torque to 16 lb. (21.7 N×m)
NOTE: Wash rod to remove abrasive grit and apply

2 cycle oil to bearing surfaces to prevent rust.

e. Thoroughly clean cylinder bores with hot wa-
CAUTION ter and detergent. Scrub well with a stiff
If crankcase cover and cylinder block is to be bristle brush and rinse thoroughly with hot
submerged in a very strong cleaning solution, it water. A good cleaning is essential. If any of
will be necessary to remove the crankcase cover/ the abrasive material is allowed to remain in
cylinder block bleed system from cover/cylinder the cylinder bore, it will cause rapid wear of
block to prevent damage to hoses and check new piston rings and cylinder bore in addition
valves. to bearings. After cleaning, bores should be
swabbed several times with engine oil and a
clean cloth, then wiped with a clean, dry cloth.
Cylinder Bores Cylinders should not be cleaned with kero-
sene or gasoline. Clean remainder of cylinder
1. Inspect cylinder bores for scoring, scuffing or a block to remove excess material spread dur-
transfer of aluminum from piston to cylinder wall. ing honing operation.
Scoring or scuffing, if NOT TOO SEVERE, can
normally be removed by honing. If a transfer of 2. Hone all cylinder walls just enough to de-glaze
aluminum has occurred, an acidic solution such walls.
as “TIDY BOWL CLEANER”should be applied to 3. Measure cylinder bore diameter (with a snap
the areas of the cylinder bore where transfer of gauge micrometer) at top, middle and bottom of
aluminum has occurred. After the acidic solution each cylinder, as shown below. Check for
has removed the transferred aluminum, tapered, out-of-round (egg-shaped) and
thoroughly flush the cylinder bore(s) to remove oversize bore.
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
a. When cylinders are to be honed, follow the
hone manufacturer’s recommendations for
use of the hone and cleaning and lubrication
during honing.
b. For best results, a continuous flow of honing
oil should be pumped into the work area. If
pumping oil is not practical, use an oil can.
Apply oil generously and frequently on both
stones and work area.
52886
CAUTION
When honing cylinder block, remove hone fre- CYLINDER BORE SIZE
quently and check condition of cylinder walls.
DO NOT hone any more than absolutely neces- PISTON SIZE CYLINDER BLOCK
sary, as hone can remove cylinder wall material FINISH HONE
rapidly. Standard Diameter 2.993 in.
76.022 mm
c. Start stroking at smallest diameter. Maintain
firm stone pressure against cylinder wall to .015 Oversize 3.007 in.
assure fast stock removal and accurate re- 76.38 mm
sults.
d. Localize stroking in the smallest diameter un- 4. If a cylinder bore is tapered, out-of-round or worn
til drill speed is constant throughout length of more than 0.003 in. (0.076mm) from standard
bore. Expand stones, as necessary, to com- “Cylinder Block Finish Hone”diameter (refer to
pensate for stock removal and stone wear. chart, preceding), it will be necessary to re-bore
Stroke at a rate of 30 complete cycles per that cylinder(s) to 0.015 in. (0.381mm) oversize
minute to produce best cross-hatch pattern. or re-sleeve and install oversize piston(s) and
Use honing oil generously. piston rings during reassembly.

IMPORTANT: Ports must be deburred after hon- CLEANING PISTON RING GROOVES
ing.
Keystone (tapered) ring grooves
NOTE: The weight of an oversize piston is approxi-
mately the same as a standard size piston; therefore, CAUTION
it is not necessary to re-bore all cylinders in a block
Care must be taken not to scratch the side sur-
just because one cylinder requires re-boring.
faces of the ring groove. Scratching the side sur-
5. After honing and thoroughly cleaning cylinder face of the ring groove will damage the ring
bores, apply light oil to cylinder walls to prevent groove.
rusting.
1. Use a bristle brush and carbon remover solution
to remove carbon from side surfaces.
Pistons and Piston Rings 2. A tool can be made for cleaning the inner
diameter of the tapered ring grooves. The tool
IMPORTANT: If engine was submerged while en- can be made from a broken tapered piston ring
gine was running, piston pin and/or connecting with the side taper removed to enable the inside
rod may be bent. If piston pin is bent, piston must edge of the ring to reach the inner diameter of the
be replaced (Piston pins are not sold separately). groove. Carefully scrape carbon from inner
If piston pin is bent, connecting rod must be diameter of ring grooves. Care must be taken not
checked for straightness (refer to “Connecting to damage the grooves by scratching the side
Rods,” following, for checking straightness). surfaces of the grooves.
1. Inspect pistons for scoring and excessive piston Piston with two half keystone (half tapered) rings
skirt wear.
2. Check tightness of piston ring locating pins.
Locating pins must be tight.
Enlarged View of Piston Ring Grooves
MEASURING PISTON ROUNDNESS
a Piston has a barrel profile shape and is not a true di-

ameter.
1. Using a micrometer, measure dimension “A”at
location shown. Dimension “A” should be as
indicated in chart following.
Dimension
Piston
52672 “A”
a - Locating Pins
Standard Piston 2.988 in. ±.001 in.
.015 in. Oversize Piston 3.003in. ±.001in.
3. Thoroughly clean pistons. Carefully remove
carbon deposits from pistons, with a soft wire
brush or carbon remove solution. Do not burr or
round off machined edges.
Dimension “A”
Inspect piston ring grooves for wear and carbon ac- at Right Angle
(90°) to Piston
cumulation. If necessary, scrape carbon from piston Pin
ring grooves being careful not to scratch sides of
grooves. Refer to procedure following for cleaning 0.50 in.
(12.7mm)
piston ring grooves.
“A”
52676

Check Valve Thermostat
NOTE: Check valve can be replaced by removing in- Wash thermostat with clean water. Using a thermo-
take manifold when powerhead is attached to drive- stat tester, similar to the one shown, test thermostat
shaft housing. as follows:
The check valve is a 3/16 in. (4.76 mm) diameter · Open thermostat valve, then insert a thread be-
brass casing containing a nylon ball-valve. It can be tween valve and thermostat body. Allow valve to
damaged by hot combustion blow-by into crankcase close against thread.
(ie.: backfire, or a hole in top of piston, etc.).
· Suspend thermostat (from thread) and thermom-
TO CHECK: Inspect check valve by looking through eter inside tester so that neither touches the con-
hole. If light can be seen the nylon ball is bad (prob- tainer. Bottom of thermometer must be even with
ably melted); REPLACE valve. If you see no light, in- bottom of thermostat to obtain correct thermostat
sert fine wire into check valve hole to see if there is opening.
slight movement of nylon ball. If ball moves, valve is
· Fill thermostat tester with water to cover thermo-
O.K. Replace valve if ball does not move.
stat.
Install check valve into check valve holder as shown.
· Plug tester into electrical outlet.
Air · Observe temperature at which thermostat begins
to open. Thermostat will drop off thread when it
starts to open. Thermostat must begin to open
a when temperature reaches 5°F (3°C) above des-
ignated stamping on bottom of thermostat.
b · Continue to heat water until thermostat is com-

pletely open.
· Unplug tester unit.
· Replace thermostat, if it fails to open at the speci-
fied temperature, or if it does not fully open.
Air
51080
a - Check Valve
b - Check Valve Holder
51087

Reed Blocks Reed should lie flat. There should be no pre-load
(pressure between reed and reed-block), although a
NOTE: Do not disassemble reed block unless neces- slight pre-load is tolerable.
sary.
The maximum allowable opening between reed and
S/N 0G380075 & Above
reed-block is .020 in. (0.5mm). This must be checked
with a flat blade feeler gauge, as shown.
If the opening exceeds .020 in. (0.5 mm), or if the
reed is chipped, cracked or otherwise damaged, re-
place.
S/N 0G380074 & Below
.020 Max
a
52883
f
CAUTION
Replace locking tab-Washer. DO NOT REUSE.
b
c
d
e 52695
a - Reed Block
b - Reed (2 Sets)
c - Retaining Washer (40 HP Only)
d - Tab Washer
e - Bolt
f - Reed Stop (30 HP Only)
IMPORTANT: Do not “flop”(reverse) the reed pet-
als for additional use - replace reed when neces-
sary.

REASSEMBLY S/N 0G380074 & BELOW Powerhead Reassembly and
If reed block was disassembled, reassemble by lo-
cating reeds on pins with retaining washer. Using Installation
new tab washer, insert bolt and torque to 60 lb. in.
(6.8 N·m); then, if necessary, continue the torque to General Information
align flat on hex-head to locking tab (e). DO NOT ex-
Before proceeding with powerhead reassembly, be
ceed 100 lb. in. (11.3 N·m) of torque. Bend up lock tab
sure that all parts to be reused have been carefully
to secure bolt position.
cleaned and thoroughly inspected, as outlined in
“Cleaning and Inspection”. Parts, which have not
been properly cleaned (or which are questionable),
can severely damage an otherwise perfectly good
powerhead within a few minutes of operation. All new
powerhead gaskets must be installed during assem-
bly.
During reassembly, lubricate parts with Quicksilver
2-Cycle Outboard Oil whenever 2-cycle oil is speci-
b fied, and Quicksilver 2-4-C Marine Lubricant when-
c ever grease is specified.
d
e CAUTION
Any GREASE used for bearings INSIDE the pow-
a erhead MUST BE gasoline soluble. Use only
Quicksilver Needle Bearing Assembly Lubricant.
52896
a - Reed DO NOT use 2-4-C Marine Lubricant, or other lu-
b - Pins bricants inside the powerhead, or damage may
c - Retaining Washer occur.
d - Tab Washer
e - Bolt - Torque to 60 lb. in. (6.8 N×m) A torque wrench is essential for correct reassembly
of powerhead. Do not attempt to reassemble power-
REASSEMBLY S/N 0G380075 & ABOVE head without using a torque wrench.
If reed block was disassembled, reassemble by lo-

cating reeds and reed stops on pins. Secure to reed End Cap
plate with bolt, washer, and nut. Torque to 60 lb. in. 1. Clean thoroughly, including seal and O-ring
(6.8 N·m). seats; remove Perfect Seal residue and clean
cap-to-head mating surface.
f 2. Using suitable mandrel, press oil seals into cap
b until fully seated.
a
NOTE: Lip of smaller seal faces away from power-
head. Lip of larger seal faces towards powerhead.
c
d e
K
a - Reeds
b - Locating Pins
c - Reed Stops
d - Washer
A 2-4-C w/Teflon (92-825407A12)
e - Bolt K Perfect Seal (92-34227-1) 52683
f - Nut

Assembling Rod to Piston 3. Place locating rings on connecting rod, carefully
place piston over end of rod. Refer to scribed
CAUTION identification number for matching rod to piston
and direction of assembly (which side of rod is
DO NOT intermix new needle bearings with used “UP”).
needle bearings. Needle bearings MUST BE RE-
PLACED AS A SET. DO NOT intermix needle bear-
ings from one connecting rod with those of
another connecting rod.
b
1. Place clean needle bearings on a clean sheet of 1
paper and lubricate with Quicksilver Needle
Bearing Lubricant.
Service Tip
1 52675
a
a - Scribed Identification Number
b - Locating Washer
4. Push sleeve from piston using piston pin tool.
a b
51228
If the tip of an awl can be inserted between needle
bearings, one or more needles are missing and must
be replaced.
52674
2. Install needle bearings.

a - Sleeve
b - Piston Pin Tool (91-74607A2)
a b
5. Place piston pin over tool, and tap into position
(driving tool out other side).
51081
a - Needle Bearings (29)
b - Sleeve [from Piston Pin Tool (91-74607A2)]
52678
a - Piston Pin Tool (P/N 91-74607A2)

6. Install new piston pin lock rings (each side of pis- NOTE: Shaft of Lock ring Installation Tool
ton) using Lockring Tool (91-77109A1). 91-77109A1 must be modified (shortened) to 1.050
in. (26.7 mm).
7. Make sure lockrings are properly seated in piston
grooves. 1.050 in. (26.7 mm)
CAUTION
Do not re-use piston pin lockrings. Use only new
lockrings and make sure they are properly seated
in piston grooves.
b Piston Ring Installation

IMPORTANT: Piston ring side with letter or mark
must be facing up.
a DOT
Piston rings are TAPERED top side, and flat (rectan-

gular) on the bottom side (half-keystone rings).
51086
a - Lockring Installation Tool (91-77109A1)
b - Lockring (2)
Enlarged View of
Piston Ring Grooves
CAUTION
Care must be taken not to scratch the side sur-
faces of ring groove. Scratching this area will
damage the ring groove.
51086

1. Install piston ring in appropriate groove on piston 4. Remove connecting rod cap from connecting rod
using Piston Ring Expander Tool. Spread rings being installed.
just enough to slip over piston.
5. Install each piston with “UP”identification facing
2. Check piston rings to be sure they fit freely in flywheel end. Pistons MUST be installed in this
groove. Lubricate rings and cylinder wall with direction.
2-cycle oil.
UP
a
52680
a - Piston Ring Expander Tool (P/N 91-24697)
CAUTION
Pistons must be installed very carefully into cyl-
3. Align piston ring end gaps with ring locating pins
inders. Piston rings can not be inspected thru ex-
as shown. Check locating pins making sure they
haust ports.
are tight.
6. Bottom end of cylinder bore has taper which per-
mits the insertion of the piston into block without
a using a piston ring compressor. Place piston
carefully into cylinder.
52672
a - Locating Pins
52880

Crankshaft Installation CAUTION
1. If lower bearing and gear were removed from Safety glasses should be worn when removing or
crankshaft, slide gear in place (note keyway and installing ring seal.
key in gear to crankshaft assembly). Install bear-
ing to crankshaft using an arbor press and suit- 3. Install ring seal to crankshaft.
able mandrel.
CAUTION
2. Install main bearing retaining ring after pressing
main bearing tight against oil gear. Any grease used for bearings INSIDE the power-
head MUST BE gasoline soluble. Use only Quick-
silver Needle Bearing Assembly Lubricant. DO
NOT use 2-4-C Marine Lubricant, or other lubri-
cants inside powerhead, or damage to engine
b may occur.
a 4. Grease crankshaft journal with Quicksilver
Needle Bearing Assembly Lubricant to hold bear-
c ing in place. Position needle bearings on journal.
There are 14 bearings for center main.
Flywheel End
51084
a - Lower Bearing
b - Gear
c - Retaining Ring
a
52686
a - Seal Ring
C Needle Bearing Assy. Lub.

(92-825265A1)

IMPORTANT: Snap ring groove faces up towards Installing Rods to Crankshaft
flywheel.
1. Oil rod and bearing cage with 2-cycle oil.
5. Attach main bearing races with holes towards
lower gear end of crankshaft. Secure each main 2. Pull rod into place and install bearing cages as
bearing race with retaining ring. Lubricate top shown.
main bearing with 2-cycle engine oil and install to
crankshaft as shown.
a c
b 52888 a
a - Main Bearing Race
b - Retaining Ring (Groove Faces Flywheel)
c - Top Main Bearing (One Piece)
6. Position cylinder block and piston rods as shown.
52893
Insert locating pins (a). a - Bearing Cage
a a a
NOTE: Clean rod bolt/rod cap bolt holes of oil and de-
bris before reassembly.
IMPORTANT: The rod cap and rod must be
aligned and held together when threading oiled
bolt. Check that mating surfaces are tight togeth-
er after bolt enters threads in piston rod.
3. Place rod cap over bearing cages. While holding
cap to rod, insert slightly oiled bolts and lightly
tighten while observing cap to rod alignment.
52885
Lower End Flywheel End

7. Place crankshaft into cylinder block; align and
seat top and center main bearings so that locat-
ing pins on block align with holes in each bearing
race.
a
52892
a - Rod Cap
52887

Connecting Rod Cap Alignment Crankcase Cover to Block
1. Check each connecting rod for correct alignment 1. Install upper seal on crankshaft and seat seal
by carefully running fingernails up and down against bearing w/lips facing bearing.
edge of rod cap. If not aligned, a ridge can be
seen or felt at the separating line. Correct any
misalignment.
Front View Front View
Correct Incorrect
Side View Side View Side View 52879

Correct Incorrect Incorrect
a - Oil Seal (Lubricate Inside with 2-4-C Marine Lubricant)
Space Ridge 2. Apply LOCTITE MASTER GASKET SEALANT

to clean block surface. Instructions in kit must be
followed exactly.
IMPORTANT: Extend sealer to edge on each cen-
ter main journal to prevent blow-by between cyl-
inders.
PE-51224
2. When connecting rods are attached, and bolts

drawn down finger tight, torque rod-cap bolts to
15 lb. in. (1.7 N·m). Recheck alignment. Re-
torque bolts to 16.0 lb. ft. (21.7 N·m). Recheck
alignment.
52891
Sealant “Bead Pattern” Indicated by Bold Line
Above

3. Install end cap assembly (lubricate seals with 5. Insert clean bolts and finger tighten.
2-cycle engine oil) to block. Apply Perfect Seal to
IMPORTANT: Torque crank case cover bolts
flange of end cap (a).
FIRST before torquing end cap cover bolts.
6. Torque bolts to 16.5 lb. ft. (22.4 N·m) following se-
quence shown below.
a
1
52884
52651
a - End Cap Flange
4. Place crankcase cover onto block.

4 3
8
7
2 1
10 9
b
a 52889
a - Crankcase Cover
b - End Cap
5 6
52894
NOTE: Inspect all hoses on reinstallation. Replace if
necessary.

Intake/Reed Block Manifold 3. Install reed block manifold and intake manifold
with gasket to cylinder block.
Installation
S/N 0G380074 & Below
1. Place engine on repair stand or on bench.
NOTE: Powerhead repair stand 91-827001A1 can
be used.
2. Install check valve/holder.
S/N 0G380075 & Above
52895
a - Check Valve/Holder

4. Install bolts and torque to 16.5 lb. ft. (22.4 N·m) Thermostat Cover Installation
in sequence shown below.
1. Install thermostat components into cylinder
block. Torque bolts to 16.5 lb. ft. (22.4 N·m).
ELECTRIC MODELS 1994 THRU 1997

ALL MODELS 1998 AND ABOVE
6 5
2 1
3 4 52653
MANUAL MODELS 1994 THRU 1997

7 8
52890
a
52652
a - Plug - Apply Loctite Pipe Sealant with Teflon (592) to

Threads

30/40 Bleed Hose Routing
a
52882
a - Check Valves
IMPORTANT: If engine smokes excessively at idle and/or runs rough (chugs) at off-idle when acceler-
ating, inspect check valves in bleed hoses for proper functioning. Check valves should flow in one
direction only.

Powerhead Installation 1. Thread lifting eye at least 5 turns into flywheel.
The following components/assemblies can be

installed prior to installation of powerhead on drive-
shaft housing:
Component/Assembly Section
Starter Motor 2B
Capacitor Discharge Module 2A*
Starter Solenoid 2B* a
Voltage Regulator/Rectifier 2B*
Flywheel 2A
Stator Assembly 2A*
Trigger Assembly 2A*
Air Silencer 3B
Carburetor and Linkage 3B
Fuel Pump 3A
Fuel Enrichment Valve 3B 52689
Shift Cable Latch Assembly 7A a - Lifting Eye (P/N 91-90455)
Control Cable Anchor Bracket 7A

Warning Module 3C* 2. Remove all old gasket material from powerhead
base and matching drive shaft housing surface.
Oil Pump 3C
3. Install new powerhead base gasket.
* Note: All ignition and electrical components can be
4. Apply a light coat of Special Lubricant 101 to drive
installed as an assembly.
shaft splines. DO NOT apply lubricant to TOP of
drive shaft as grease may preload drive shaft/
crankshaft resulting in damage to powerhead
and/or gear housing.
5. Secure powerhead to drive shaft housing with 6
bolts. Torque bolts to 29.2 lb ft. (39.6 N·m).
NOTE: New trigger for mechanical spark advance for
1998 and newer models does not use roll pin to lock
trigger in place. Trigger must be loose. For models
before 1998, roll pin is required to hold trigger. Insert
into hole as shown.
a
a
52688
55884
a - Bolt (6) Torque to 29.2 lb. ft. (39.6 N×m)
a - Roll Pin

6. Install upper drive shaft housing cover and se-
cure cover with bolt, nut and flat washer.
Break-in Procedure
! CAUTION
Severe damage to the engine can result by not
complying with the Engine Break-in Procedure.
MODELS WITH OIL INJECTION
Engine Break-in Fuel Mixture
Use a 50:1 (2%) gasoline/oil mixture in the first tank
of fuel. Use of this fuel mixture combined with oil from
the oil injection system will supply adequate lubrica-
tion during engine break-in.
a
Engine Break-in Procedure
Vary the throttle setting during the first hour of opera-
tion. During the first hour of operation, avoid remain-
ing at a constant speed for more than two minutes
and avoid sustained wide open throttle.
MODELS WITHOUT OIL INJECTION
Engine Break-in Fuel Mixture
52687
a - Bolt, Nut, Washer Use a 25:1 (4%) gasoline/oil mixture in the first tank
of fuel.
Engine Break-in Procedure
Test Run Procedure Vary the throttle setting during the first hour of opera-
tion. During the first hour of operation, avoid remain-
CAUTION ing at a constant speed for more than two minutes
and avoid sustained wide open throttle.
While priming fuel system with primer bulb prior
to starting engine, inspect all fuel line connec-
tions and components for gasoline leaks. Repair
any fuel leaks BEFORE starting outboard.
CAUTION
When engine is started, IMMEDIATELY check
that water pump is operating. Operation of water
pump is indicated by water discharging from “tell
tale”.
While test running outboard, check powerhead as-
sembly for leaks and/or unusual noises. Make any re-
pairs BEFORE placing outboard in service.

MID-SECTION
5
A
CLAMP/SWIVEL BRACKETS AND

DRIVE SHAFT HOUSING
Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Clamp Bracket Components . . . . . . . . . . . . . . . . 5A-2
Clamp Bracket Components . . . . . . . . . . . . . . . . 5A-3
Swivel Tube Components . . . . . . . . . . . . . . . . . . . 5A-4
Swivel Tube Components . . . . . . . . . . . . . . . . . . . 5A-5
Swivel Bracket Components . . . . . . . . . . . . . . . . 5A-6
Swivel Bracket Components . . . . . . . . . . . . . . . . 5A-7
Drive Shaft Housing Components . . . . . . . . . . . . 5A-8
Drive Shaft Housing Components . . . . . . . . . . . . 5A-9
Driveshaft Housing Components . . . . . . . . . . . . . 5A-10
Driveshaft Housing Components . . . . . . . . . . . . . 5A-11
Drive Shaft Housing Disassembly/Reassembly 5A-12
5A-0 - MID-SECTION 90-826148R2 MARCH 1997

Notes:
90-826148R2 MARCH 1997 MID-SECTION - 5A-1

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

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

Clamp Bracket Components
TORQUE
REF.
1 CLAMP BRACKET (BLACK) PORT SHORT
1 CLAMP BRACKET (GRAY) 1 lower mounting hole
1
1 CLAMP BRACKET (BLACK) PORT LONG
1 CLAMP BRACKET (GRAY) 3 lower mounting holes
1 CLAMP BRACKET (BLACK) STBD. SHORT
1 CLAMP BRACKET (GRAY) 1 lower mounting hole
2
1 CLAMP BRACKET (BLACK) STBD. LONG
1 CLAMP BRACKET (GRAY) 3 lower mounting holes
3 2 THUMB SCREW ASSEMBLY
4 2 HANDLE
5 2 RIVET MANUAL
6 2 WASHER
7 2 SCREW (Hex shoulder) 60 6.8
8 1 NUT (M10 x 1.5) 28 37.9
9 1 WASHER
10 1 ANODE
11 2 WASHER
12 2 SCREW (M6 x 25) 60 6.8
13 1 STUD (M10 x 277)
14 1 SPACER
4 NUT (.500-20) (LONG) Drive Tight
15 2 NUT (.500-20) (SHORT) (TOP) Drive Tight
2 NUT (M10 x 1.5) (SHORT) (BOTTOM) Drive Tight
4 WASHER (LONG)
16 2 WASHER (SHORT) (TOP)
2 WASHER (SHORT) (BOTTOM)
4 SCREW (.500-20 x 4”) (LONG)
17 2 SCREW (.500-20 x 4”) (SHORT) (TOP)
2 SCREW (SHORT) (BOTTOM)
18 1 SEAL KIT
19 1 O RING
20 1 SPACER
21 1 NUT (M10 x 1.5) 28 37.9
22 1 WASHER
23 1 TILT LOCK PIN
24 1 SPRING
25 1 LEVER-Shallow Water Drive
26 1 ROLL PIN
27 1 CAP-Tilt Stop Pin
28 1 ROLL PIN
29 1 BUSHING
30 1 PIN-Tilt Stop
31 1 BUSHING (PLASTIC)
32 1 ROD-Shallow Water Drive
33 1 BUSHING (PLASTIC)
34 1 BUSHING
35 1 ARM
36 1 LINK ROD
37 1 SPRING

Swivel Tube Components
95
3
5
4
95
6
7
8
94
10
11
13 12
94 Anti-Corrosion Grease (92-78376A6)

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

Swivel Tube Components
TORQUE
REF.
1 SWIVEL TUBE HEAD (BLACK)
1
1 SWIVEL TUBE HEAD (GRAY)
1 HANDLE -Carrying (BLACK)
2
1 HANDLE -Carrying (GRAY)
3 1 TAB WASHER
4 2 SCREW (M10 x 45 Hex head cap) 32 43.4
5 1 NUT (.375-24)
6 1 LEVER-Co-pilot
7 1 WASHER
8 1 ROD (THREADED)
9 1 BRAKE PLATE
10 1 DISC-Brake
11 1 PLATE-Swivel Head
12 1 DISC-Brake
13 2 SCREW (HEX SHOULDER) 70 7.9

Swivel Bracket Components
66 Loctite “242”Removable Threadlocker (92-809821)

95 2-4-C With Teflon (92-825407A12)
A - Tighten nut until it seats and then back off 1/4 turn.
B - Tighten nut to 32 lb. ft. (43.4 N·m) and then back off 1/4 turn.

Swivel Bracket Components
TORQUE
REF.
1 1 LINK ROD
2 1 SCREW (1-1/2 IN.) 240 20 27.1
3 1 WASHER
4 2 WASHER
5 2 NUT (.375-24)
6 1 PUCK-Co-pilot (NON HANDLE MODELS)
1 SWIVEL BRACKET ASSEMBLY (BLACK)
7
1 SWIVEL BRACKET ASSEMBLY (GRAY)
8 1 BUSHING (UPPER)
9 3 GREASE FITTING
10 1 BUSHING (LOWER)
11 1 SEAL
12 1 GREASE FITTING
13 1 CABLE ASSEMBLY
14 1 WASHER
15 1 NUT (.875-14)
16 1 COTTER PIN
17 1 PIVOT PIN-Reverse Lock
1 SCREW (M8 x 10) (HANDLE)
18
1 SCREW (M8 x 1.25 x 25)
19 1 BOOT-Rubber NON HANDLE
20 1 SPRING
21 1 WASHER
22 1 TILT TUBE
23 1 NUT (.875-14)
24 1 DECAL-Co-pilot
25 1 PIN (TRILOBE)
26 2 BUSHING
27 1 PIVOT PIN (UPPER)
28 1 STRAP-Tilt Stop (NON POWER TRIM)
29 1 LINK-Reverse Lock (UPPER)
30 1 LEVER-Reverse Lock
31 1 NUT
32 2 PIN-Reverse Lock
33 2 SPRING-Reverse Lock
34 1 LINK-Reverse Lock
35 1 WASHER 1/8 IN. DIA. LINK ROD
36 1 ARM-Reverse Lock
37 1 REVERSE LOCK
38 1 WASHER
39 1 NUT
34 1 LINK-Reverse Lock
35 1 WASHER 3/16 IN. DIA. LINK ROD
36 1 ARM-Reverse Lock
37 1 REVERSE LOCK
38 1 WASHER (Use where applicable)
40 2 NUT

Drive Shaft Housing Components
18 17
16
21
24
23 19
22
26
20 15
25
14
13
30
12
28 27
29 11
31
10
9
32
8
33
34 6
36 7
48
35
51
50 5
33
49
38 37 47
4
39
3
40 43
46 2 1
45
41 42 44
33 Loctite “RCA/680”Retaining Compound (92-809833)

Drive Shaft Housing Components
TORQUE
REF.
1 2 SCREW (M8 x 1.25 x 55) 198 16.5 22.4
2 1 GROMMET-Water Tube
3 1 CLAMP-Water Tube
4 1 SEAL-Water Tube
1 WATER TUBE (SHORT)
5
1 WATER TUBE (LONG)
6 1 EXHAUST TUBE
7 3 SCREW (M8 x 1.25 x 45) 198 16.5 22.4
8 1 GASKET-Drive Shaft Housing
1 ADAPTOR PLATE (BLACK)
9
1 ADAPTOR PLATE (GRAY)
10 4 DOWEL PIN
11 1 SCREW (M10 x .75) 198 16.5 22.4
12 1 SEAL-Bottom Cowl
13 1 COUPLER
14 1 GROMMET-Shift Shaft
15 1 SHIFT SHAFT (UPPER)
16 1 WASHER
17 1 PIN-Shift Link
18 1 COTTER PIN
19 2 SCREW (M12 x 1.75 x 162)
20 1 MOUNT
21 4 SCREW (M8 x 1.25 x 45)
22 2 WASHER
23 2 WASHER
24 2 NUT (M12 x 1.75) 50 67.8
1 TRIM COVER (BLACK)
25
1 TRIM COVER (GRAY)
26 1 BUMPER
27 1 SCREW (M5 x .8 x 60)
28 1 WASHER
29 1 NUT (M5 x .8)

Driveshaft Housing Components
18 17
16
21
24 19
23
22
26
20 15
25
14
13
30
12
28 27
29 11
31
10
9
32
8
33
34 6
36 7
48
35
51
50 5
33
49
38 37 47
4
39
40 3
43
46 2 1
41 42 44 45
A
33 Loctite “RCA/680”Retaining Compound (92-809833)
A - Torque the rear TOP and then the BOTTOM lower mount bolt/nut first; then torque the FRONT bolt/nut. After
torquing the front bolt/nut, retorque the rear top and bottom bolt/nut.

Driveshaft Housing Components
TORQUE
REF.
30 1 SEAL-Exhaust Bucket
31 1 EXHAUST BUCKET
32 1 BUMPER-Trim Cover
33 1 SEAL-Exhaust Tube
34 1 SEAL-Idle Relief
35 6 SCREW (M10 x 110) 29 39.3
1 DRIVESHAFT HOUSING (SHORT-BLACK)
1 DRIVESHAFT HOUSING (SHORT-GRAY)
36
1 DRIVESHAFT HOUSING (LONG-BLACK)
1 DRIVESHAFT HOUSING (LONG-GRAY)
1 STUD (M10 x 1.5 x 50) (SHORT/LONG)
37
1 STUD (M10 x 1.5 x 114) (X-LONG)
38 2 SCREW (M8 x 1.25 x 120)
39 1 MOUNT (LOWER)
1 COVER-Mount (BLACK)
40
1 COVER-Mount (GRAY)
41 1 WASHER
42 1 NUT (M10) 40 54.2
43 2 SCREW (10-16 x .38)
44 1 SCREW (M8 x 1.25 x 65)
45 1 LOCKWASHER
46 1 CABLE ASSEMBLY
47 1 BUMPER (FRONT)
48 1 MOUNT (LOWER)
1 COVER-Mount (BLACK)
49
1 COVER-Mount (GRAY)
50 3 WASHER
51 3 NUT (M8 x 1.25) 240 20 27.1

Drive Shaft Housing WARNING
Disassembly/Reassembly Failure to support outboard as shown could re-
Servicing components such as steering arm, drive sult in personal injury and/or damage to out-
shaft housing, exhaust assembly and swivel bracket board or boat.
will usually require powerhead and/or gear housing a
removal.
Refer to SECTION 4 for powerhead removal and b
SECTION 6 for gear housing removal.
The transom bracket, lower mount bracket, tilt tube
and lower engine mounts can be serviced without
powerhead/gear housing removal. However, OUT- c
BOARD MUST BE SUPPORTED BEFORE SERV-
ICING COMPONENTS.
51078
a - Hoist
b - Rope
c - Lifting Eye (91-90455)
IMPORTANT: All gaskets should be replaced
when removing powerhead and/or disassem-
bling drive shaft housing. Corresponding gasket
mating surfaces should be cleaned of any gasket
material before installing new gaskets.

MID SECTION
5
B
POWER TRIM
Table of Contents
Page Page
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Power Trim System Removal . . . . . . . . . . . . 5B-29
Power Trim Components . . . . . . . . . . . . . . . . 5B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-30
Power Trim Mounting . . . . . . . . . . . . . . . . . . . 5B-4 Shock Rod Removal . . . . . . . . . . . . . . . . . 5B-30
Theory Of Operation . . . . . . . . . . . . . . . . . . . . 5B-6 Shock Rod Disassembly . . . . . . . . . . . . . . . . 5B-31
Memory Piston Removal . . . . . . . . . . . . . . 5B-33
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6
Trim Motor Removal . . . . . . . . . . . . . . . . . 5B-34
Trimming Characteristics . . . . . . . . . . . . . 5B-6
Oil Pump Removal . . . . . . . . . . . . . . . . . . . 5B-35
Trimming Outboard “Up” (“Out”) . . . . . 5B-6
Tilt Relief Valve Removal . . . . . . . . . . . . . 5B-35
Trimming Outboard “Down” (“In”) . . . . 5B-6
Suction Seat Removal . . . . . . . . . . . . . . . . 5B-36
Trailering Outboard . . . . . . . . . . . . . . . . . . 5B-7
Pilot Check Valve Assembly Removal . . 5B-36
Tilting Outboard Up and Down
Cleaning/Inspection/Repair . . . . . . . . . . . . . . 5B-37
Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-7
Trim “In” Angle Adjustment . . . . . . . . . . . . 5B-7 Trim Motor Electrical Tests . . . . . . . . . . . . 5B-37
Power Trim Flow Diagrams . . . . . . . . . . . 5B-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-38
Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9 O-Ring and Seal Placement . . . . . . . . . . . 5B-38
.................................... 5B-10 O-Ring and Seal Placement . . . . . . . . . . . 5B-39
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 Power Trim Reassembly . . . . . . . . . . . . . . . . 5B-40
.................................... 5B-12
Tilt Relief Valve Reassembly . . . . . . . . . . 5B-40
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . 5B-13
Suction Seat Reassembly . . . . . . . . . . . . 5B-40
.................................... 5B-14
Pilot Check Valve Reassembly . . . . . . . . 5B-41
Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5B-15
Oil Pump Reassembly . . . . . . . . . . . . . . . . 5B-41
.................................... 5B-16
Trim Motor Reassembly . . . . . . . . . . . . . . 5B-42
Shock Function Up . . . . . . . . . . . . . . . . . . 5B-17
Shock Rod Reassembly . . . . . . . . . . . . . . 5B-42
.................................... 5B-18
Shock Rod Installation . . . . . . . . . . . . . . . 5B-44
Shock Function Return . . . . . . . . . . . . . . . 5B-19
Manual Release Valve Installation . . . . . 5B-44
.................................... 5B-20
Bleeding Power Trim Unit . . . . . . . . . . . . . 5B-44
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21
Power Trim System Installation . . . . . . . . . . 5B-45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5B-22
Preliminary Checks . . . . . . . . . . . . . . . . . . 5B-22
Hydraulic System Troubleshooting
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23
Outboard Will Not Hold Tilted Position
During Reverse And/Or Trails Out
During High Speed Deceleration . . . . 5B-23
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-25
Trim system leaks down with manual
release valve closed . . . . . . . . . . . . . . . 5B-25
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-26
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . 5B-27
Troubleshooting the Power Trim
Electrical System . . . . . . . . . . . . . . . . . . . . 5B-28
5B-0 - MID-SECTION 90-826148R2 MARCH 1997

Special Tools
1. Spanner Wrench P/N 91-74951
2. Lock-Ring Pliers P/N 91-822778A3
3. Expanding Rod P/N CG 41-11
4. Collet P/N CG 41-14
90-826148R2 MARCH 1997 MID-SECTION - 5B-1

POWER TRIM COMPONENTS
25
11 B 20
A 13
12
25
14 24 25
23 21
22
2
G
15
110 16 110
8
17 28 27
C
6
32
110 29
30 26
10 31
9 D
1 7
3
4
19
3
E
5
18

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

POWER TRIM
TORQUE
REF.
1 POWER TRIM ASSEMBLY (S/N-USA-0G124404/BEL-9948794 & BELOW)
1
1 POWER TRIM ASSEMBLY (S/N-USA-0G124405/BEL-9948795 & ABOVE)
– 1 O RING KIT
1 SHOCK ROD ASSY. (S/N-USA-0G124404/BEL-9948794 & BELOW)
2
1 SHOCK ROD ASSY. (S/N-USA-0G124405/BEL-9948795 & ABOVE) 45 61
3 1 PILOT CHECK ASSEMBLY 120 13.6
4 1 TILT RELIEF VALVE ASSEMBLY 120 13.6
5 1 SUCTION SEAT ASSEMBLY 120 13.6
6 1 PUMP ASSEMBLY
7 1 BALL & SPRING
8 1 SCREW 70 7.9
9 1 FILTER
10 1 O RING
11 1 MOTOR ASSEMBLY
12 4 SCREW 80 9.0
13 4 WASHER
14 1 CABLE
15 1 O RING
16 1 COUPLER
17 1 MEMORY PISTON
18 1 MANUAL RELEASE VALVE ASSEMBLY Drive Tight
19 1 RESERVOIR PLUG Drive Tight
– 1 HARNESS ASSEMBLY–Trim
20 1 HARNESS ASSEMBLY–Trim DESIGN I
21 2 RELAY
22 2 BRACKET
23 2 GROMMET
24 2 SCREW (M6 x 1 x 25)
25 1 SCREW (10-16 x 5/8–Self-Tap)
26 1 BRACKET
27 1 HARNESS-Trim
28 2 SCREW (M6 x 25) DESIGN II
29 2 RELAY ASSEMBLY
30 2 BRACKET
31 2 GROMMET
32 2 BUSHING
A - TORQUE CYLINDER CAP TO 45 LB. FT. (61 N⋅M)
B - TORQUE SCREW TO 80 LB. IN. (9.0 N⋅M)
C - TORQUE SCREW TO 70 LB. IN. (7.9 N⋅M)
D - TORQUE PILOT CHECK PLUG TO 120 LB. IN. (13.6 N⋅M)
E - TORQUE TILT RELIEF PLUG TO 120 LB. IN. (13.6 N⋅M)
F - TORQUE SUCTION SEAT PLUG TO 120 LB. IN. (13.6 N⋅M)
G - TORQUE SHOCK PISTON TO 45 LB. FT. (61 N⋅M)

POWER TRIM MOUNTING
9
10
11
8
7
3
1

POWER TRIM MOUNTING
TORQUE
REF.
1 1 PIN–anchor (14MM)
2 2 BUSHING
3 2 BUSHING
4 2 WASHER
5 2 NUT
6 2 SCREW (M10 x 40)
7 2 WASHER
8 2 NUT
9 1 SCREW (10-16 x .38) DRIVE TIGHT
10 1 C WASHER
11 2 CLIP

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

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

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

POWER TRIM FLOW DIAGRAMS
TRIM UP
Reservoir and Feed Oil
Oil Under Pressure
Return Oil b
a
u
t s
n v c
o w
d
w q r
p e
m
Á Á Á
Á Á
Up Pressure
2530 psi
l (min)
h
k
i g
j
f
a- Electric Motor n- Oil Pump

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

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

TILT UP
Oil Under Pressure
Return Oil b
a
u t c
s v d
e
n o w
w
q r
p
Á ÁÁ Á
Tilt Relief
m Pressure
l
ÁÁ Á 500–600 psi
h
k
i
g
j
f


TILT UP
In the up mode, as the trim rod (b) extends from the
cylinder, the memory piston (e) clears or uncovers
the pressure relief passage. Oil from the up cavity
will enter this passage and open the tilt pressure re-
lief valve (k). This valve lowers the amount of pres-
sure available to lift the outboard motor. With the en-
gine in forward gear, and at high engine rpm, the oil
pressure available will not be able to overcome the
propeller thrust, limiting the trim range to below the
pressure relief orifice. When the engine rpm’s fall or
if engine is not in forward gear, the oil pressure is
available to extend the trim ram (b) up into the tilt
range.

MAXIMUM TILT
Oil Under Pressure b
Return Oil
a
v cd
Tilt Relief
t Pressure
u s 500–600 psi
n o w
w q r
p
m
Á ÁÁ Á
ÁÁ Á
l
h
k
i g
j
f


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

TRIM DOWN
Oil Under Pressure
Return Oil b
a
Down Relief
500–800 psi
u t
s
n
o w v cd
w q r
p e
m
m
l Á ÁÁ ÁÁ
ÁÁ
l
k h
k
i g
j
f


DOWN MODE
When the trim switch is activated in the down posi-
tion, the electric motor (a) will rotate the pump (n) in
the opposite direction. With the pump gears rotating
backwards, the flow of oil is reversed. Oil is drawn
through the filter, past the feed check ball (m), into the
down circuit oil pick–up and finally into the oil pump.
The pump feeds pressurized oil into the down pas-
sages, oil will slide the shuttle valve (p) into the up cir-
cuit pressure operated valve (l). The shuttle valve will
mechanically open the pressure operated valve and
allow oil, from the up cavity of the trim cylinder (f), to
return into the oil pump. This returning oil, from the
up cavity, will supply the oil required for the down cir-
cuit. The oil is blocked from returning into the reser-
voir by the ball (p) inside the up circuit feed valve. Oil,
under pressure, opens the pressure operated valve
(h) and enters the down passages inside of the man-
ifold (f). The manifold passage connects into the trim
cylinder passage leading to the top of the cylinder.
The cavity, inside the cylinder, above the shock pis-
ton (d) is the down cavity. As the down cavity fills with
oil, the trim ram (b) retracts into the cylinder, lowering
the outboard motor. Oil from the up cavity exits the
cylinder and is drawn back into the pump through the
open pressure operated valve (l). When the trim ram
reached full travel, the oil pressure inside the down
circuit will rise until the down pressure relief valve (q)
opens, bypassing oil back into the reservoir(t). When
the trim button is released, and the oil pump stops
supplying pressure, both of the pressure operated
valves (h & l) will close and; if open, the down pres-
sure regulating valve (q) will close. The closed
valves will lock the fluid on either side of the shock
piston (d), holding the outboard motor in position.

SHOCK FUNCTION UP
Oil Under Pressure
Return Oil b
a
u t s
v cd
n o
w w 1550–1850 psi
q r
p e
m
Á ÁÁ ÁÁ
l
h
k
i g
j
f


SHOCK FUNCTION UP
Oil inside the down cavity is locked in a static position
by the closed pressure operated valve (h), the manu-
al release valve (j) and the tilt relief valve (k). If the
outboard strikes an underwater object while in for-
ward gear the trim ram (b) will try to rapidly extend
from the cylinder , the pressure increases inside the
trim cylinder down cavity and connecting passages.
The rise in pressure will seat the check ball (r) inside
the suction valve (g), preventing fluid from returning
into the reservoir. When the pressure increases to
the level required, the impact relief valves (c), located
inside the shock piston (d), will open and allow the
fluid to pass through the shock piston. As the fluid
passes through the piston, the trim ram (b) will extend
from the trim cylinder. The memory piston (e) is held
in position by vacuum, created by the oil in the up
cavity being locked in a static position. Therefore; oil
passing through the trim ram piston is trapped be-
tween the memory piston (e) and shock piston (d).

SHOCK FUNCTION
RETURN
Oil Under Pressure b
Return Oil
u t
s cd
v
n o
w
w q r
p e
Á Á ÁÁ
m
Á Á ÁÁ
ÁÁ
l h
k
i
g
j
f


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

MANUAL TILT
Return Oil b
a
u t s
n
o
cd
w q r w v
p e
Á ÁÁ Á
m
Á
l h
k
i g
j f


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

Troubleshooting Follow preliminary checks before proceeding to trou-
bleshooting flow diagrams (following).
Support outboard with tilt lock pin when servicing
power trim system.
IMPORTANT: After debris or failed components Preliminary Checks
have been found (during troubleshooting proce- IMPORTANT: Operate Power Trim system after
dure) it is recommended that unit be disas- each check to see if problem has been corrected.
sembled completely and ALL O-rings be re- If problem has not been corrected proceed to
placed. Check ball valve components and next check.
castings must be cleaned using engine cleaner
and compressed air or replaced prior to re-as- 1. Check that manual release valve is tightened to
sembly. full right (clockwise) position.
IMPORTANT: Power trim system is pressurized. 2. Check trim pump fluid level with outboard in full
Outboard must be in the full “UP” position (trim “UP” position and fill if necessary. Refer to
rod fully extended) prior to fill/drain plug, or man- “Bleeding Power Trim Unit”.
ual release valve removal. 3. Check for external leaks in Power Trim system.
Refer to instructions following if disassembly is re- Replace defective part(s) if leak is found.
quired when servicing. 4. Outboard not holding tilted position (falls down to
trim position) indicates debris or defective com-
ponents in trim assembly. Clean or replace com-
ponents as required.

Hydraulic System Troubleshooting Flow Chart
OUTBOARD WILL NOT HOLD TILTED POSITION

DURING REVERSE AND/OR TRAILS OUT
DURING HIGH SPEED DECELERATION
Manual release Inspect manual release valve Manual release valve and
valve and O-ring O-rings appear to be O.K.
damaged Clean and reinstall manu-
al release valve
Trim will not hold

Replace manual release reverse thrust Trim system holds
valve and O-rings
reverse thrust:
Testing complete
Trim system holds Remove and inspect pis-

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

age identified O.K. - Clean and reinstall
PO check valve assembly
Replace PO check
valve assembly Trim system holds
reverse thrust:
Testing complete
Trim will not hold
Trim system holds reverse thrust
reverse thrust:
Testing complete
continued on next page

continued
Remove suction seat as-

sembly and inspect for
debris and/or damage
Suction seat assembly

Debris and/or damage appears O.K. - Clean and
identified reinstall suction seat as-
sembly
Replace suction seat

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

TRIM SYSTEM LEAKS DOWN WITH

MANUAL RELEASE VALVE CLOSED
Manual release Inspect manual release valve Manual release valve and O-
valve and O-ring rings appear to be O.K. - Clean
damaged and reinstall manual release
valve
Replace manual re- Trim system leaks

lease valve and O- down
Trim system does
rings
not leak down:
Testing complete
Remove tilt relief valving
Trim system does and inspect O-rings and
not leak down: seals for debris and/or
Testing complete damage
Debris and/or dam- Tilt relief valving and O-rings

age identified appear to be O.K. - Clean and
reinstall tilt relief valving
Trim system leaks Trim system does

Replace tilt relief valving
down not leak down:
Testing complete
Trim system does Remove PO check valve

not leak down: assembly, inspect O-
Testing complete rings and seals for dam-
age
Debris and/or damage PO check valve appears

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

continued
Inspect memory piston

O-ring and cylinder
bore
Cylinder bore appears
Cylinder bore appears rough and/or debris
smooth with no debris found in cylinder
Replace memory pis-

ton and shock piston Trim leaks down
O-rings
Trim system does

not leak down:
Testing complete Replace trim system

Troubleshooting the Power Trim Electrical System
Trim Switch UP Trim Switch UP
(Remote Control DN (Panel Mounted) DN
Mounted)
BLU/WHT
Fuse Holder
GRN/WHT
BLU/WHT or PUR
GRN/WHT or GRN
RED
Remote Control
RED
Fuse Holder
2 RED/PUR
– + RED/PUR
B
RED
A
Battery
Starter Bolt
Solenoid GRN/WHT
BLU/WHT
Down Relay 3
GRN/WHT LT. GRN/WHT
GRN
14 BLK
RED LT. GRN/WHT
BLK
LT.BLU/WHT LT. BLU/WHT

BLUE
14 BLK
RED
BLK
LT. BLU/WHT
Up Relay 4 1
UP
DN
Cowl Switch
Trim Pump Motor

Troubleshooting the Power Trim Electrical System
Refer to wiring diagram on preceding page for location of wire connections.
Problem Possible Cause Remedy
Trim Switch “UP” is inopera- 1. Open wire between Wire Connection (1) 1. Check for a open connection or cut
tive, but the Cowl Switch “UP” and Trim Switch. wire.
does operate. 2. Faulty Trim Switch. 2. Replace
Cowl Switch “UP” is inopera- 1. Open wire between Wire Connection (2) 1. Check for a open connection or cut
tive, but the Trim Switch “UP” and Solenoid. wire.
does operate. 2. Faulty Cowl Switch. 2. Replace
Trim Switch “UP” and Cowl 1. Open wire between Wire Connection (1) 1. Check for an open connection.
Switch “UP” are both inopera- and the Up Relay
tive. 2. Open BLK wire between ground and UP 2. Check for an open connection.
Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
Up Relay
4. Faulty Up Relay . 4. Replace
Trim Switch “DOWN” is inop- 1. Open wire between Wire Connection (3) 1. Check for a open connection or cut
erative, but the Cowl Switch and Trim Switch. wire.
“DOWN” does operate. 2. Faulty Trim Switch. 2. Replace
Cowl Switch “DOWN” is inop- 1. Open wire between Wire Connection (2) 1. Check for a open connection or cut
erative, but the Trim Switch and Solenoid. wire.
“DOWN” does operate. 2. Faulty Cowl Switch. 2. Replace
Trim Switch “DOWN” and 1. Open wire between Wire Connection (3) 1. Check for an open connection.
Cowl Switch “DOWN” are and the Up Relay.
both inoperative. 2. Open BLK wire between ground and 2. Check for an open connection.
Down Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
Down Relay.
4. Faulty Down Relay. 4. Replace
Trim Switch “UP” and 1. 20 AMP Fuse blown. 1. Replace fuse. Locate the cause of
“DOWN” are both inoperative, 2. Faulty trim switch. the blown fuse. Check electrical wiring
but the Cowl Switch does op- 3. Wire is open between fuse holder and for a shorted circuit.
erate. solenoid. 2. Replace
4. Wire is open between fuse holder and 3. Check for a open connection or cut
trim switch. wire.
4. Check for a loose or corroded con-
nection.
Trim Switch and Cowl Switch 1. One of the Trim Pump Motor wires is 1. Check wire connections (4) for loose
are both inoperative. open between the motor and the Relays. or corroded condition.
2. Faulty trim pump motor. 2. If voltage is present at connections
(4) when the appropriate trim button is
pressed, than motor is faulty. Replace
motor.
Trim system operates (motor 1. The Trim or Cowl switch is shorted. 1. Replace
runs) without pressing the
switches.

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

a
move clamps.
a - Trilobe Pin
b - Upper Pivot Pin
5. Remove the sacrificial anode.
a - Power Trim Wire Harness Clamps
a
a - Sacrificial Anode

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

4. Secure power trim assembly in a soft jaw vise. Shock Rod Disassembly
5. Unscrew end cap assembly from cylinder using NOTE: The only serviceable items on the shock rod
spanner wrench 91-74951. assembly are the o-rings and wiper ring. If shock rod
requires any other repair, replace shock rod assem-
bly.
6. Remove shock rod assembly from cylinder. c
b
a
a - End Cap
b - Shock Piston
c - O-ring
d - Wiper Ring
1. Place shock rod assembly on clean work surface.

2. Remove bolt from end of shock rod.
a - Bolt

3. Remove check ball components from shock rod
piston. CAUTION
When removing shock piston, spanner wrench
4. Remove o-ring from shock rod piston.
must have 1/4 in. x 5/16 in. long pegs to avoid
damage to shock piston.
5. Place shock rod into soft jawed vise and apply
heat to loosen piston using torch lamp (P/N
91-63209).
6. Loosen shock rod piston using spanner wrench
c [1/4 in. x 5/16 in. (6.4mm x 8mm) long pegs].
b
7. Allow shock rod piston to cool. Remove from
a shock
rod.
51147
a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring
51146
a b
51146
a - Spanner Wrench
b - Shock Rod Piston
8. Inspect check valve for debris; clean debris from

check valve if found. If debris cannot be cleaned
from check valve, replace shock piston as an as-
sembly.
9. Clean shock and components with compressed
air.

10. Remove inner o-ring from shock rod piston. Memory Piston Removal
15. Remove memory piston from cylinder using one
of two methods:
a. Using lock ring pliers (Craftsman P/N 4735)
or suitable tool.
b
a
51199
a - Shock Piston
b - O-ring
11. Remove cylinder end cap assembly from shock

rod. b. Blowing compressed air into manual release
12. Inspect shock. If wiper (located in cap) has failed valve hole using adaptor (P/N 91-822778A3).
to keep rod clean, replace wiper.
13. Place end cap on clean work surface.
WARNING
Memory piston cup may be expelled at a high
14. Remove rod wiper, inner o-ring, and outer o-ring.
velocity when air pressure is applied. Failure to
place cylinder as shown below could result in
personal injury.
NOTE: Point cylinder opening down and away. Use
a shop rag or towel to avoid damage to the memory
piston.
a
a
c
b
51145 b
a - Rod Wiper
b - Inner O-ring d
c - Outer O-ring
a - Adaptor
b - Air Hose
c - Memory Piston Exit
d - Shop Rag

16. Remove o-ring from memory piston. Trim Motor Removal
1. Secure power trim assembly in soft jawed vise.
2. Remove screws securing trim motor to manifold.
3. Remove motor assembly.
b
a - O-ring
a - Trim Motor
b - Screw (4)

Oil Pump Removal Tilt Relief Valve Removal
1. Remove oil filter and pump from manifold. NOTE: The following procedures requires the use of
a Snap-On blind hole removal tool #CG-4111 with
IMPORTANT: DO NOT disassemble the oil pump.
5/16” attachment #41-12. Or a removal tool can be
The pump is not serviceable.
fabricated with the material and specifications listed
a below.
3 1/4”
b
1/4”
e
4 1/2”
d
a
c
f
a - Removal Tool made from .060 Stainless Steel Rod
a - Screw (2)
b - Oil Pump
c - Spring
d - Filter
e - O-Ring
f - Down Relief Ball

1. Unscrew plug from manifold and remove spring Suction Seat Removal
and poppet assembly.
1. Unscrew plug from manifold and remove ball.
NOTE: Do not lose shim that may be lodged in the
plug. 2. Use a pin punch and knock the filter and suction
seat out from the inside of the manifold cavity.
2. Use the removal tool and pull out the pilot valve.
CAUTION
DO NOT use any tool on the suction seat as any
damage to the surface will not allow the ball to
seat.
a
a
b
c
b b d
b
b
c
d a - Filter
e b - Suction Seat
f g c - Ball
h
d - Plug
a - Tilt Relief Valve Assembly
b - O-Rings
c - Actuator Pin
d - Pilot Valve
Pilot Check Valve Assembly Removal
e - Poppet Assembly 1. Unscrew both plugs.
f - Spring
g - Shim 2. Remove both springs and poppets.
h - Plug
IMPORTANT: Inspect poppet assembly for debris
in the area shown. If debris is found on poppet re-
place poppet.
a - Debris Under Valve Tip

b - Rubber Seat

3. Use the (.060 wire) removal tool (see previous Cleaning/Inspection/Repair
page) and push out the spool and one seat.
IMPORTANT: Components must be dirt and lint
4. From opposite side, use a punch and push out free. Slightest amount of debris in Power Trim
the remaining seat. system could cause system to malfunction.
Clean shock rod and components with parts cleaner
and dry with compressed air.
It is recommended that all O-rings in trim system be
replaced. Use O-Ring Kit 25-827668A1.
Lubricate all O-rings with power trim fluid.
Trim Motor Electrical Tests

1. Connect a 12 volt supply to motor leads. If motor
fails to run, replace pump motor.
IMPORTANT: Trim Motor is not serviceable. If mo-
tor fails to run, replace motor assembly
a
b
c
d
e
d
a b c
a - Plug (2)
b - Spring (2)
c - Poppet Assembly (2)
d - Seat (2)
e - Spool (1)
IMPORTANT: Inspect poppet assemblies for de-
bris in the area shown. If debris is found on pop-
pets replace poppets.
a - Debris Under Valve Tip

b - Rubber Seat

Reassembly
O-Ring and Seal Placement
O-Rings and Seals are part of O-Ring Kit 25-827668A1
r
p
o
l
n
m
i
w
h
v a
b c
w d
h
g
w
i u
e t s

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

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

2. Place actuator pin into pilot valve.
3. Install and seat the pilot valve into manifold. Seat a
the pilot valve using a 9/32″ or 7 mm socket on
OUTSIDE diameter of the pilot valve.
IMPORTANT: The pilot valve must be seated us- b
ing a suitable mandrel on the OUTSIDE diameter.
4. Install poppet, spring, shim (if used) and plug. c
Torque plug to 120 lb. in. (13.5 N·m).
a - Filter
b - Suction Seat
c - Ball
a d - Plug - Torque to 120 lb. in (13.5 N⋅m)
b
b b
b
c
d
e f g h
a - Tilt Relief Valve Assembly
b - O-Rings
c - Actuator Pin
d - Pilot Valve
e - Poppet Assembly
f - Spring
g - Shim
h - Plug - Torque to 120 lb. in (13.5 N⋅m)

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

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

Trim Motor Reassembly Shock Rod Reassembly
1. Align coupler between oil pump and motor. 1. Install lubricated o-rings to end cap.
2. Install trim motor and secure with four (4) screws. 2. Install rod wiper.
Torque screws to 80 lb. in. (9.0 N·m).
a
c
f
b
c
e
51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
d
3. Install lubricated o-rings to shock piston.
b c
a 51199
a - Shock Piston
b - O-ring
c - O-ring
a - Coupler
b - O-ring
c - Trim Pump Motor
d - Ground Strap
e - Lock Washer (1)
f - Screws (4) - Torque to 80 lb. in (9.0 N⋅m)

4. Clamp shock rod in soft jawed vise. 9. Remove shock rod assembly from vise.
5. Position cylinder end cap onto rod as shown. 10. Install ball, seat, and spring (five sets) to shock
rod piston.
b c
a
51147
51146
CAUTION a - Spring (5)

When installing shock rod piston, spanner b - Seat (5)
wrench must have1/4 in. x 5/16 in. (6.4mm x8mm) c - Ball (5)
long pegs to avoid damage to shock rod piston.
6. Apply Loctite Grade “A” (271) to threads on shock
11. Secure components with shock piston bolt.
rod.
Torque bolt to 45 lb.in. (61 Nm).
7. Install shock rod piston.
8. Tighten shock rod piston securely using spanner
wrench (1/4 in. x 5/16 in. long pegs). If a torquing
type spanner tool is used to tighten shock piston,
then torque to 45 lb. ft. (61 N⋅m).
a
b a
a - Bolt - Torque to 45 lb. ft. (61 N⋅m)
51146
a - Shock Rod Piston - Torque to 45 lb. ft (61 N⋅m)

b - Spanner Wrench

Shock Rod Installation Manual Release Valve Installation
1. Place trim cylinder in soft jawed vice. 1. Install “E” clip (if removed) and lubricate O-Rings
with power trim fluid.
2. Install lubricated o-ring to memory piston and
place into cylinder. Push memory piston all the 2. Insert manual release valve into manifold and
way to bottom. tighten securely.
a
b
a - Memory Piston
b - O-ring
3. Fill cylinder three inches (76.2mm) from top of Bleeding Power Trim Unit
cylinder using Dexron III, (ATF) automatic trans-
mission fluid. If not available, use Quicksilver 1. Secure power trim unit in soft jawed vise.
Power Trim and Steering Fluid.
2. Remove reservoir plug. Add power trim fluid until
4. Install shock rod into cylinder until power trim fluid its even with the bottom of the fill hole. Reinstall
flows through oil blow off ball passage. Fill re- plug.
maining cylinder to just below the cylinder
3. Close the manual release valve. (Turn full clock-
threads.
wise).
a - Oil Blow Off Ball Passage
CAUTION
End cap must not make contact with shock rod
piston when tightening. Shock rod piston must a - Reservoir Plug
be positioned in cylinder deep enough to avoid
contact.
5. Tighten end cap securely using spanner wrench 4. Connect the positive lead to (blue) trim motor
[3/16 in. x 5/16 in. (4.8mm x 8mm) long pegs].. If wire and negative lead to (green) trim motor wire
a torquing type spanner tool is used to tighten end and drive shock rod to the up position.
cap, then torque to 45 lb. ft. (61.0 N·m).
5. Using a 12 volt power supply, connect the posi-
tive lead to the (green) trim motor wire, and the
negative lead to the (blue) trim motor wire and
drive the shock rod to the down position.
6. Recheck fluid level with rod fully extended, add
fluid if required and repeat cycle until fluid level
stays even with the bottom of the fill hole.

Power Trim System 4. Install sacrificial anode to clamp brackets. Fasten
ground strap between anode and clamp bracket.
Installation Torque bolts to 60 lb. in. (6.8 N⋅m).
1. Lubricate lower pivot pin, mounting holes and
bushings with 2-4-C Marine Lubricant.
2. Install lower pivot pin bushings into the clamp
brackets and trim unit.
a - Ground Wire
b - Sacrificial Anode
a
5. Lubricate the upper pivot pin and mounting holes
with 2-4-C Marine Lubricant.
6. Fasten shock rod with the upper pivot pin.
NOTE: Pivot pin should be installed with grooved end
b inserted first.
a - Bushing (2) Install into each Clamp Bracket

b - Bushing (2) Install into each side of Trim Unit
3. Install lower pivot pin. Secure with flat washers

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

7. Secure upper pivot pin with trilobe pin. Press tri- 11. Secure wire harness with clamps as shown.
lobe pin in until its fully seated.
a - Trilobe Pin
8. Re-connect trim wire harness leads (see wiring

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

MID-SECTION
5
C
GAS ASSIST
MANUAL TILT
Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Clamp Bracket (Gas Assist Trim) . . . . . . . . . 5C-2
Hydraulic Assist Adjustments . . . . . . . . . . . . 5C-4
Manual Trim System Removal . . . . . . . . . . . 5C-4
Manual Trim System Installation . . . . . . . . . . 5C-5
5C-0 - MID-SECTION 90-826148R2 MARCH 1997

Notes:
90-826148R2 MARCH 1997 MID-SECTION - 5C-1

CLAMP BRACKET (GAS ASSIST TRIM)

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

CLAMP BRACKET (GAS ASSIST TRIM)
TORQUE
REF.
1 CLAMP BRACKET (BLACK) PORT
1
1 CLAMP BRACKET (GRAY)
1 CLAMP BRACKET (BLACK) STARBOARD
2
1 CLAMP BRACKET (GRAY)
3 2 THUMB SCREW ASSEMBLY
4 2 HANDLE
5 2 RIVET MANUAL
6 2 WASHER
7 2 SCREW (Hex shoulder) 60 6.8
8 1 ANODE
9 2 WASHER
10 2 SCREW (M6 x 25) 60 6.8
11 2 NUT (.500-20) Drive Tight
12 2 WASHER
13 2 SCREW (.500-20 x 4 IN.)
14 1 DECAL-Tilt Lock
15 1 DECAL-Warning
16 1 CAP--Tilt Stop Pin
17 1 ROLL PIN
18 1 BUSHING
19 1 PIN--Tilt Stop
20 1 TRIM, Hydraulic assist
21 1 CABLE
22 1 TILT LEVER
23 1 TILT KNOB GAS ASSIST TRIM
24 1 LEVER ARM
25 1 WAVE WASHER
26 1 ROLL PIN (1/8 x 3/4 IN.)
27 1 LINK
28 1 NUT
29 1 ANCHOR PIN (14MM)
30 2 BUSHING
31 2 BUSHING GAS ASSIST TRIM &
32 2 WASHER POWER TRIM MOUNTING
33 2 NUT
34 2 SCREW (M10 x 40)
35 2 WASHER
36 2 NUT
37 1 TILT LOCK PIN NON POWER TRIM
38 1 SPRING

Hydraulic Assist Manual Trim System
Adjustments Removal
1. Tilt outboard to the full up position and support
WARNING with tilt stop pin.
This hydraulic assist system’s contents are un-
der pressure. Do not puncture disassemble or
apply heat or flame.
IMPORTANT: If debris or leaking is found, unit
must be replaced This hydraulic assist system is
NOT SERVICEABLE. Replace is necessary.
1. Check manual release cam adjustment. Cam a
must open and close freely. Adjust cam link rod
as necessary.
a - Tilt Stop Pin

b
a 2. Remove the trilobe pin.

3. Drive out the upper pivot pin.
a - Link Rod
b - Manual Release Lever
2. Check for external leaks in the manual tilt system. a

Replace unit if leak is found.
a - Trilobe Pin
b - Upper Pivot Pin

4. Disconnect link rod from cam lever. Manual Trim System
5. Remove tilt lock pin. Remove nuts and washers
securing the lower pivot pin. Remove anode bolt Installation
to remove ground strap. Remove lower anchor 1. Apply 2-4-C Marine Lubricant (92-90018A12) to
pin. Retain the anchor pin bushings from the surface of lower anchor pin and anchor pin hole.
clamp brackets and trim unit. Place trim into proper position. Install anchor pin
6. Remove trim unit. and bushings into anchor pin hole and clamp
brackets. Install nuts and washers to anchor pin
and tighten securely. Install ground strap and
anode bolt.
2. Install tilt lock pin.
c
a
d
f
e
b
a - Tilt Lock Pin
b - Link Rod d
c - Cam Lever c
d - Nut (2)
e - Anode Bolt/Ground Strap
f - Pivot Pin a - Tilt Lock Pin
b - Nut (2)
c - Anode Bolt/Ground Strap
d - Pivot Pin

3. Apply 2-4-C Marine Lubricant (92-90018A12) to
surface of upper pivot pin, pivot hole and shock
rod hole.
4. Position trim into position and drive pivot pin into
swivel bracket and through shock rod until pivot
pin is flush with swivel bracket. Drive trilobe pin
into its hole until seated.
a - Trilobe Pin
b - Upper Pivot Pin
5. Connect link rod onto cam lever.

6. Check manual release cam adjustment. Cam
must open and close freely. Adjust cam link rod
as necessary.
c
a
a - Link Rod
b - Cam Lever
c - Manual Release Lever

LOWER UNIT
6
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General Service Recommendations . . . . . . . . . . 6-2
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Gear Housing Components (Drive Shaft) . . . . . 6-6
Gear Housing Components (Propeller Shaft) . . 6-8
Draining and Inspecting Gear Lubricant . . . . . . . 6-10
Propeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Gear Housing Removal . . . . . . . . . . . . . . . . . . . . 6-11
Water Pump Seals . . . . . . . . . . . . . . . . . . . . . . 6-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Upper Drive Shaft Bearing . . . . . . . . . . . . . . . 6-16
Pinion Gear Bearing . . . . . . . . . . . . . . . . . . . . 6-16
Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Propeller Shaft Disassembly . . . . . . . . . . . . . 6-19
Propeller Shaft and Carrier Inspection . . . . . . . . 6-19
Clutch Dog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Reverse Gear Bearing . . . . . . . . . . . . . . . . . . 6-20
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Gear Housing Reassembly . . . . . . . . . . . . . . . . . 6-22
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . . . 6-22
Pinion Bearing Race . . . . . . . . . . . . . . . . . . . . 6-23
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Pinion Gear/Drive Shaft Assembly . . . . . . . . 6-24
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Gear Housing Pressure Test . . . . . . . . . . . . . . . . 6-27
Gear Housing Installation . . . . . . . . . . . . . . . . . . . 6-27
Filling Gear Housing with Lubricant . . . . . . . . 6-27
Installing Gear Housing to Drive
Shaft Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Trim Tab Adjustment and Replacement . . . . 6-29
Propeller Installation . . . . . . . . . . . . . . . . . . . . 6-30
6-0 - LOWER UNIT 90-826148R2 MARCH 1997

Specifications
Gear Ratio 2.00:1
Gearcase Capacity 14.9 fl. oz. (440 mL)
Lubricant Type Quicksilver Gear Lube Premium Blend
Forward Gear
Number Of Teeth 26
Type Spiral/Bevel
Pinion Gear
Number Of Teeth 13
Type Spiral/Bevel
Pinion Height No Adjustment
Forward Gear Backlash No Adjustment
Reverse Gear Backlash No Adjustment
Water Pressure
With Thermostat & Poppet
-@ W.O.T. 5 - 7 PSI @ 5000 RPM
-@ Idle 0.5 - 1.5 PSI @ 750 RPM
-@ W.O.T. 5 - 7 PSI @ 5000 RPM
-@ Idle 0 - 1 PSI @ 750 RPM
NOTE: Before filling gear case, apply 10-15 PSI of air

pressure at the VENT hole. Pressure should not drop
for 15 seconds while alternately applying a 2-3 pound
force to the top of the shift shaft in the fore and aft
direction.
90-826148R2 MARCH 1997 LOWER UNIT - 6-1

General Service Roller bearing condition is determined by inspecting
the surface of the shaft that the roller bearing sup-
Recommendations ports. Check shaft surface for pitting scoring, groov-
ing, imbedded particles, uneven wear and/or discol-
There may be more than one way to “disassemble”
oration from overheating. The shaft and bearing
or “reassemble” a particular part(s), therefore, it is
must be replaced if such a condition exists.
recommended that the entire procedure be read prior
to repair.
IMPORTANT: Read the following before attempt- Seals
ing any repairs.
As a normal procedure, all O-rings and oil seals
In many cases, disassembly of a sub-assembly may SHOULD BE REPLACED without regard to appear-
not be necessary until cleaning and inspection re- ance. To prevent leakage around seals, apply Loctite
veals that disassembly is required for replacement of 271 to outer diameter of all metal case seals. When
one or more components. using Loctite on seals or threads, surfaces must be
Service procedure order in this section is a normal clean and dry. Apply 2-4-C w/Teflon on all O-rings
disassembly-reassembly sequence. and on I.D. of oil seals. Apply 2-4-C w/Teflon to exter-
nal surfaces of bearing carrier.
Threaded parts are right hand (RH), unless other-
wise indicated.
When holding, pressing or driving is required, use
soft metal vise jaw protectors or wood for protection
of parts. Use a suitable mandrel (one that will contact
only the bearing race) when pressing or driving bear-
ings.
Whenever compressed air is used to dry a part, verify
that no water is present in air line.
Bearings
All bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air.
Air should be directed at the bearing so that it passes
through the bearing. DO NOT spin bearing with com-
pressed air as this may cause bearing to score from
lack of lubrication. After cleaning, lubricate bearings
with Quicksilver Gear Lubricant. DO NOT lubricate
tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bear-
ing race side wear. Work inner bearing race in-and-
out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condi-
tion of rollers and inner bearing race by inspecting
bearing cup for pitting, scoring, grooves, uneven
wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and
race as a set.
Inspect gear housing for bearing races that have
spun in their respective bores. If race(s) have spun,
gear housing must be replaced.

Special Tools 4. Bearing Puller Tool 91-27780
1. Bearing 31-85560
54978
2. Driver 91-13779
5. Mandrel 91-36571
6. Universal Puller Plate 91-37241
3. Bearing Puller & Installation Tool 91-31229A7

a. Nut 11-24156
b. Washer (2) 12-34961
7. Driver Head 91-37312

c. Plate 91-29310
d. Shaft 91-31229
8. Driver 91-817011

9. Driver Rod 91-37323 12. Driver 91-817007
13. Mandrel 91-825198
14. Pilot 91-825199
10. Drive Shaft Holding Tool 91-825196

15. Spring Hook 91-825200A1
11. Mandrel 91-825197

16. Driver 91-826872
17. Leakage Tester FT8950

Notes:

Gear Housing Components (Drive Shaft)
95
23
24
22
7 28
29
25 95
14
74 26 87 30
12
7
13 95 31 95
95 15
95 32
21 27
33
34
16 2 36
17
35
18
3 37
20 38
39
19
11
5
10 4
87
9
7
8 7 6
74 Loctite 405 (Obtain Locally)
87 Super Duty Gear Lubricant (92-13783A24)
95 2-4-C With Teflon (92-825407A12)

Gear Housing Components (Drive Shaft)
TORQUE
REF.
-- 1 GEAR HOUSING (SHORT-BLACK)
-- 1 GEAR HOUSING (LONG-BLACK)
-- 1 GEAR HOUSING (X-LONG-BLACK)
-- 1 GEAR HOUSING (SHORT-GRAY)
-- 1 GEAR HOUSING (LONG-GRAY)
-- 1 GEAR HOUSING (X-LONG-GRAY)
1 GEAR HOUSING (BASIC-BLACK)
1
1 GEAR HOUSING (BASIC-GRAY)
2 1 SEAL/PLATE KIT
3 1 PLATE (Part Of Ref #2)
4 1 SCREW (.375-16 x .25) 55 6.2
5 1 WASHER-Sealing
6 1 DRAIN SCREW (MAGNETIC) 55 6.2
7 1 WASHER-Sealing
8 1 NUT 50 67.8
9 1 PINION GEAR
10 1 BEARING ASSEMBLY-Roller
11 1 CUP (Part Of Ref #10)
12 4 SCREW (M6 x 16) 60 6.8
13 1 WATER PUMP ASSEMBLY
14 1 SEAL-Water Tube (SHORT/LONG)
15 1 WASHER
16 1 KEY
17 1 WASHER
18 1 GASKET
19 1 GASKET (LOWER)
20 1 FACE PLATE
21 1 IMPELLER
22 1 WATER PUMP BASE ASSEMBLY
23 1 SEAL-Oil
24 1 SEAL-Oil
25 1 O RING
26 1 BALL BEARING
1 DRIVESHAFT (SHORT)
27 1 DRIVESHAFT (LONG)
1 DRIVESHAFT (X-LONG)
28 1 NUT (INCLUDED WITH REF #35)
29 1 CABLE TIE
30 1 BOOT-Shift Shaft
31 1 RETAINER-Shift Shaft
32 1 O RING
33 1 O RING
34 1 WASHER
1 SHIFT SHAFT (SHORT)
35 1 SHIFT SHAFT (LONG)
1 SHIFT SHAFT (X-LONG)
36 1 WASHER
37 1 ROLL PIN
38 1 CAM-Shift
39 1 PIN

Gear Housing Components (Propeller Shaft)
43
45
42
47
44
46 41 40
56
55 54
1
40
53
69 52
70 95
48 51
7 87 50
68
87 49
64
67 65
66 72
60
7 71
63 61
62
59
58
7 87
95
57
87
95
94

87 Super Duty Gear Lubricant (92-13783A24)
94 Anti-Corrosion Grease (92-78376A6)
95 2-4-C With Teflon (92-825407A12)

Gear Housing Components (Propeller Shaft)
TORQUE
REF.
-- 1 GEAR HOUSING (SHORT-BLACK)
-- 1 GEAR HOUSING (LONG-BLACK)
-- 1 GEAR HOUSING (X-LONG-BLACK)
-- 1 GEAR HOUSING (SHORT-GRAY)
-- 1 GEAR HOUSING (LONG-GRAY)
-- 1 GEAR HOUSING (X-LONG-GRAY)
1 GEAR HOUSING (BASIC-BLACK)
1
1 GEAR HOUSING (BASIC-GRAY)
40 2 DOWEL PIN
41 1 GASKET Water Tube
42 1 TUBE
43 1 PLUG-RUBBER
44 1 SCREEN-Water Inlet
45 1 TRIM TAB
46 1 SCREW (M8 x 20) 186 15.5 20.1
47 1 WASHER
48 1 FORWARD GEAR ASSEMBLY
50 1 CUP
51 1 ROLLER BEARING
52 1 FOLLOWER-Cam
53 1 SPRING
54 1 PIN-Cross
55 1 CLUTCH
56 1 SPRING
57 1 PROPELLER SHAFT
58 1 REVERSE GEAR
59 1 BALL BEARING
60 1 BEARING CARRIER
61 1 O RING
62 1 NEEDLE BEARING
63 1 OIL SEAL
64 1 OIL SEAL
65 2 TAB WASHER (Use where applicable)
66 2 WASHER (Replaces Tab Washer)
2 SCREW (M8 x 25 - Cap Screw) 198 16.5 22.4
67
2 SCREW (Washer-Head Screw) 198 16.5 22.4
68 1 THRUST HUB
69 1 PROP NUT KIT 55 74.6
70 1 TAB WASHER
71 4 SCREW (SHORT/LONG) 40 54.2
72 4 WASHER

Draining and Inspecting Propeller Removal
Gear Lubricant WARNING
WARNING If gear housing is not removed from outboard,
before attempting to remove or install the propel-
If gear housing is installed on outboard, discon- ler, remove (and isolate) spark plug leads from
nect (and isolate) spark plug leads from spark spark plugs to prevent outboard from starting.
plugs before working near the propeller.
1. Bend tabs of tab washer (a) away from nut (b).
1. With gear housing in normal running position,
place a clean pan under housing and remove
vent plug and fill/drain plug (with gaskets).
51119
a - Vent Plug/Washer
2. Use a block of wood (a) to prevent propeller from
b - Fill/Drain Plug/Washer rotating. Remove nut and pull components from
shaft.
2. Inspect gear lubricant for metal particles (lubri-
cant will have a “metal flake”appearance). Pres-
ence of fine metal particles (resembling powder)
on the drain plug magnet indicates normal wear. a
Metal chips on the magnet indicate the need for
gear housing disassembly and component in-
spection.
3. Note color of gear lubricant. White or cream color
indicates presence of water. Gear lubricant
drained from a gear case assembled with Special
Lubricant 101 or a gear case recently in operation
will have a yellowish color due to lubricant agita-
tion/aeration. This is normal and should not be
confused with the presence of water.
4. Presence of water indicates the need for disas-
sembly and inspection of oil seals, o-rings, gas- 50552
kets and components for damage.

Gear Housing Removal 4. Make a scribe line showing alignment of trim tab
to gear case and remove trim tab bolt and wash-
er.
WARNING
To prevent accidental engine starting, remove b
(and isolate) spark plug leads from spark plugs
before removing gear housing.
1. Remove (and isolate) spark plug leads from
spark plugs.
2. Shift into NEUTRAL.
a
3. Loosen jam nut. Unscrew attaching nut to separate
shift shaft.
b 52835
a - Bolt and Washer
b - Scribe Line
5. Remove nut and washer in trim tab cavity.

a
52832
a - Jam Nut
b - Attaching Nut
52835
a - Nut and Washer

6. Remove 4 bolts securing gear case to drive shaft 8. Remove cover, washer (above impeller), impel-
housing. ler, key and washer (below impeller).
9. Remove cover gasket, base plate and base gas-
ket.
52836
d
a - Bolt (4)
e
NOTE: If water tube seal remained in drive shaft
housing, remove seal from housing and reinstall on
water pump cover. Secure seal to cover with Loctite f
405.
7. Remove 4 bolts securing pump cover.

g
a
b
52692
a - Cover
b - Washer (above impeller)
c - Impeller
d - Key
e - Washer (below impeller)
f - Cover Gasket
g - Base Plate
52830 h - Base Gasket
a - Seal
b - Bolt (4)
NOTE: Replace impeller if:
-- Impeller blades are cracked, torn or worn.
NOTE: Replace cover if thickness of steel at dis- -- Impeller is glazed or melted (caused by in
charge slots is 0.060 in. (1.524mm) or less, or if sufficient water supply.)
groove(s)(other than impeller sealing groove) in cov- -- Rubber portion of impeller is not bonded to
er roof are more than 0.030 in. (0.762mm) deep. impeller hub.

10. Remove and/or replace exhaust deflector plate if NOTE: When removing propeller shaft assembly,
damaged. cam follower may dislodge. Retrieve follower from
gear housing
13. Remove propeller shaft assembly.
a
52832 a
52864
a - Exhaust Deflector Plate
a - Propeller Shaft
11. Remove bearing carrier attaching bolts and lock-
ing tab washers. Discard tab washers. 14. Remove pinion nut and discard.
15. Remove drive shaft assembly and pinion gear.
51043
a
b
b
52864
a - Drive Shaft Holding Tool (91-825196)
a - Bolts and Tab Washers b - Pinion Gear
b - Tab Washers
12. Using Puller (91-27780), remove carrier assem-

bly from gear case.
52829
a - Puller (91-27780)

16. Remove FORWARD gear. 18. Insert pinion bearing race PULLER
(91-825200A1) through gear case and position
inside of pinion bearing race. Insert DRIVER
(91-13779) into puller through drive shaft cavity
and drive out race.
a
52870
a - Forward Gear 52844
a - Puller (91-825200A1)
17. Remove shift shaft assembly b - Driver (91-13779)
19. Remove FORWARD bearing race with PULLER

(91-27780).
a
b
52841
a - Shift Shaft Assembly
53838
a - Race
b - Puller (91-27780)

Water Pump Seals 3. With lip of ribbed neoprene O.D. seal facing to-
wards small shoulder of Mandrel (91-825197),
NOTE: All gaskets, seals and o-rings should be re- press seal into carrier until mandrel bottoms on
placed as a normal repair procedure during gear carrier.
case disassembly.
NOTE: DO NOT use a screwdriver to remove seals
from carrier as carrier may be damaged.
1. Using a suitable mandrel, press both seals from
carrier.
a
a
Press Seals Out

In This Direction 52853
d
a - Seal (Ribbed Neoprene)
52692
a - Neoprene Ribbed Seal
NOTE: Apply a light coat of 2-4-C w/Teflon
b - Metal Cased Seal (92-825407A12) to the lips of both seals after instal-
c - Carrier lation in carrier.
d - O-ring
2. Apply Loctite 271 to the O.D. of the metal cased 4. Apply a light coat of 2-4-C w/Teflon to the new o-
seal. With seal lip facing away from the large ring and install on carrier.
shoulder of MANDREL (91-825197), press seal
into carrier until mandrel bottoms on carrier.
a
52825
a - O-ring
b
52850
a - Seal (Metal Cased)
b - Mandrel (91-825197)

Inspection Pinion Gear Bearing
1. Inspect bearing for rust, roughness or discolor-
ation from lack of lubricant.
Upper Drive Shaft Bearing
2. If bearing is damaged, bearing and race must be
1. Inspect bearing for rust, roughness or discolor- replaced as an assembly.
ation from lack of lubricant.
3. If race appears to have spun in drive shaft bore,
2. DO NOT remove bearing from drive shaft unless gear case housing must be replaced.
bearing must be replaced as removal process will
damage bearing.
a
3. If bearing must be replaced, position drive shaft
assembly in vise (jaws of vise supporting only
bearing) and while holding drive shaft, strike top
of drive shaft with lead hammer and drive bearing
off. b
52823
a - Bearing
b - Race
Pinion Gear
a 1. Inspect pinion gear teeth for rust, chipping, ex-
cessive wear (teeth are sharp edged) or broken.
2. If pinion gear teeth are damaged, also inspect
forward and reverse gear teeth for damage.
3. Replace gears as required.
a - Bearing
4. To install new bearing, thread old pinion nut 3/4
way onto drive shaft. Position Universal Puller
Plate (91-37241) under bearing and press on pin-
ion nut while holding drive shaft until bearing
seats against shoulder.
a
52839
Forward Gear
b 1. Inspect forward gear teeth for rust, chipping, ex-
c cessive wear (teeth are sharped edged), or bro-
ken teeth.
2. Inspect forward gear clutch jaws for wear.
Rounded jaws indicate the following:
52387
a - Old Pinion Nut (Nut Should be Above Drive Shaft)
a. Improper shift cable adjustment.
b - Bearing b. Engine idle speed too high.
c - Universal Puller Plate (91-37241)

c. Shifting too slowly. 4. Use a suitable mandrel to press needle bearing
out of forward gear.
52874
3. Inspect propeller shaft forward gear bearing sur-
face to determine condition of forward gear
needle bearing. If bearing surface is discolored 52873
(from lack of lubricant), pitted or worn, propeller
shaft and bearing should be replaced. a. - Mandrel (14mm socket)
b - Bearing
5. Use Driver 91-826872 to press new needle bear-

ing into forward gear. Press on NUMBERED side
b
of bearing.
52874
a a
52846
a - Bearing Surface
b - Bearing
52847
a - Driver (P/N 91-826872)
b - Bearing

6. Inspect forward gear tapered bearing and race Shift Shaft
for rust, roughness or excessive wear (loose-
ness). 1. Inspect shift cam for wear or galling. Replace
cam if necessary.
7. If bearing is in serviceable condition, DO NOT re-
move bearing from gear as removal process will 2. If cam is worn, inspect cam follower in end of pro-
damage bearing. peller shaft for wear.
8. If bearing must be replaced, remove bearing from
gear using Universal Puller Plate (91-37241) and
suitable mandrel.
9. Replace bearing and race as a set. Use suitable
mandrel to press bearing onto gear. PRESS b
ONLY ON INNER RACE when installing bearing.
b
a
52845
a a - Cam Follower
b - Shift Cam
3. Inspect shift shaft boot for deterioration.

4. Inspect shift shaft carrier o-ring for cuts or abra-
sions. It is a good service procedure to replace all
o-rings, seals and gaskets regardless of appear-
ance.
REMOVAL 51119
a - Universal Puller Plate (91-37241)
b - Mandrel (15/16 in. socket)
a
52828
a - Boot
b - O-ring
INSTALLATION
a - Mandrel (1-1/8 in. socket)

Propeller Shaft Disassembly
1. Remove propeller shaft from carrier and disas-
semble shaft.
a - Prop Shaft
b - Retaining Spring
c - Clutch Dog
d - Cross Pin
52877
e - Cam Follower Spring
f - Cam Follower
2. Remove reverse gear and bearing from carrier
with Puller 91-27780.
Propeller Shaft and Carrier
Inspection
Clutch Dog
a
1. Inspect clutch jaws for chips or rounding off.
2. If wear is present, inspect corresponding forward
or reverse gear matching jaws for similar wear.
Replace appropriate components as required.
52824
52840
a - Reverse Gear and Bearing
b - Puller (91-27780)
Cam Follower
1. Inspect cam follower for wear or galling.
2. If wear is present, inspect corresponding shift
cam for wear. Replace if worn.
52822

Reverse Gear 4. Install new bearing using a suitable mandrel.
PRESS ONLY ON INNER RACE when installing
1. Inspect reverse gear teeth for rust, chipping ex- bearing.
cessive wear (teeth are sharped edged) or bro-
ken teeth.
2. Inspect reverse gear clutch jaws for wear.
Rounded jaws indicate the following:
a. Improper shift cable adjustment.
d
b. Engine idle speed too high.
c. Shifting too slowly.
51289
a
b c
REMOVAL 51269
a - Bearing
b - Reverse Gear
c - Universal Puller Plate (91-37241)
d - Driver (91-37312)
52875
Reverse Gear Bearing

1. Inspect bearing for rust, roughness or excessive
wear (looseness).
a
2. If bearing is in serviceable condition, DO NOT re-
move bearing from gear as removal will damage
bearing.
b
3. If bearing must be replaced, remove bearing from
gear using Universal Puller Plate (91-37241) and
Driver (91-37312).
INSTALLATION 52867
a - Mandrel (1-1/4 in. socket)
b - Bearing

Bearing Carrier 4. Apply a light coat of Special Lubricant 101
(92-13872A1) to O.D. of bearing.
NEEDLE BEARING 5. Install bearing using Mandrel 91-817011.
1. The condition of the carrier needle bearing can 6. Press bearing into carrier until mandrel bottoms
be determined by inspecting its running surface on carrier.
on the propeller shaft.
2. If the shaft is discolored (from lack of oil) or pitted,
replace bearing and shaft.
3. Bearing can be removed by using Driver Rod b
(91-37323) and Driver (91-37312). Removing
bearing will also remove both propeller shaft
seals.
52861
a - Bearing
c b - Mandrel (91-817011)
7. Apply Loctite 271 (92-823089--1) to O.D. of small

diameter seal.
8. With seal lip FACING AWAY FROM LARGE
d SHOULDER of Mandrel 91-817007, press seal
into carrier until mandrel bottoms on carrier.
51264
a - Driver Rod (91-37323)
b - Driver (91-37312)
c - Needle Bearing b
d - Seals
52862
a - Seal
b - Mandrel (91-817007)

9. Apply Loctite 271 to O.D. of large diameter seal. Gear Housing Reassembly
10. With seal lip FACING TOWARDS SMALL IMPORTANT: The 30/40 gear case assembly does
SHOULDER of Mandrel 91-817007, press seal not have have any shims for the gear assemblies.
into carrier until mandrel bottoms on carrier. Backlash cannot be adjusted. The mechanic
must verify that all bearing races are firmly
seated in the gear case during reassembly and
that all gear case components are in serviceable
b condition. Prior to installing the seal carrier and
water pump assembly on the drive shaft, the
FORWARD gear should be held stationary (with
a screw driver or similar tool). While pulling up on
the drive shaft, lightly turn the shaft back and
a forth. A light “clicking” sound should be heard
indicating the presence of backlash between
FORWARD and PINION gears. If this backlash is
not present, the pinion gear race and/or forward
gear race are not fully seated. Races should be
removed and inspected for debris. Reinstall
races and check backlash. If backlash is still not
present, replace gear housing.
52863
a - Seal
b - Mandrel (91-817007) Shift Shaft Assembly
11. Bearing carrier o-ring should be inspected for 1. Apply 2-4-C w/Teflon (92-825407A12) to new o-
cuts and abrasions. rings and install o-rings on shift shaft and carrier.
NOTE: It is a good repair procedure to replace all o- 2. Install carrier on shift shaft.
rings and seals regardless of appearance.
IMPORTANT: When installing shift shaft assem-
12. Apply 2-4-C w/Teflon to o-ring and install on carri- bly into gear housing, DO NOT BOTTOM OUT
er. SHAFT IN HOUSING. Pull up on shift shaft until
13. Using suitable mandrel, press reverse gear as- shift boot is not deformed. If shaft is bottomed
sembly into carrier. out, cross pin in clutch dog will be bent by cam
follower when tightening carrier bolts.
3. Install shift shaft/carrier assembly into gear hous-
b ing.
c 4. Secure boot to carrier with sta-strap.
a
52827
a - O-ring
b - Mandrel (3/4 in. Socket)
c - Reverse Gear Assembly

5. Position shift shaft so ramp faces towards propel- Pinion Bearing Race
ler shaft.
1. Apply Super Duty Gear Lubricant (92-13783A24)
d to O.D. of race.
c
2. Position race in gear housing (NUMBERS UP -
TAPERED SIDE FACING DOWN).
b a 3. Draw race up into housing until seated.
a f
d
b
c
e
e
52841
a - O-rings
b - Carrier
c - Boot
d - Sta-strap
e - Ramp
52842
a - Threaded Rod (91-31229)

b - Washer (2) (12-34961)
c - Bearing (31-85560)
d - Plate (91-29310)
e - Pilot (91-825199)
f - Nut (11-24156)
g - Mandrel (91-825198)

Forward Gear Pinion Gear/Drive Shaft Assembly
1. Apply Super Duty Gear Lubricant to O.D. of race. 1. Clean pinion nut and pinion nut threads of drive
Install forward gear bearing race into housing us- shaft with Loctite Primer T (92-59327-1).
ing Mandrel 91-36571 and propeller shaft. Use a
2. Position pinion bearing into race while installing
lead hammer on prop shaft to prevent damage to
drive shaft and pinion gear into housing.
threads. Bearing carrier should be installed to
keep prop shaft centered while seating race. 3. Apply Loctite 271 (92-809819) to pinion nut
threads.
4. Install new pinion nut, with rounded corners FAC-
ING pinion gear, onto drive shaft.
5. Using Drive Shaft Holding Tool (91-825196) to
hold drive shaft, torque pinion nut to 50 lb. ft. (67.8
N·m).
51043
a b c
d
52843
a - Race
b - Mandrel (91-36571) b
NOTE: Remove drain plug/magnet assembly from
gear case (if installed) to prevent possible breakage
of magnet if struck by forward gear. a
1. Install forward gear and bearing assembly into

forward gear race.
52864
a - Pinion Nut [Torque to 50 lb. ft. (67.8 N·m)]
b - Pinion Gear
c - Pinion Bearing
d - Drive Shaft Holding Tool
52870
a - Forward Gear Assembly

Propeller Shaft 6. Install cam follower.
1. Slide clutch (SHORT SHOULDER FACES FOR-

WARD GEAR) over propeller shaft aligning cross
pin hole with slot in propeller shaft.
2. Insert cam follower spring into propeller shaft.
3. Using a 3/16 in. Allen wrench or similar device,
compress the follower spring enough to insert the
cross pin partially through clutch.
4. Remove wrench and press cross pin through a
clutch and propeller shaft until flush.
c
a 52826
a - Cam Follower
7. Install propeller shaft assembly into gear case.
b
52851
a - Short Shoulder
b - Allen Wrench
c - Cross Pin
5. Reinstall retaining spring. POSITION SPRING

SO AS SPRING COILS LAY FLAT IN CLUTCH
GROOVE. a 52864
a a - Propeller Shaft Assembly
Bearing Carrier
1. Install carrier into gear case.
2. Install new locking tab washers onto retaining
bolts and torque bolts to 16.5 lb ft. (22.4 N·m).
52854
a - Spring
NOTE: Applying 2-4-C w/Teflon to cam follower will a
aid in retention of follower in propeller shaft during
installation of propeller shaft assembly into gear
case. b
52865
a - Carrier
b - Bolts and Tab Washers [Torque to 200 lb. in. (22.6 N·m)]

Water Pump 4. Install impeller and nylon washer.
1. Install water pump seal carrier.

2. Install exhaust deflector plate, if removed. a
b
b a
52832
a - Seal Carrier
b - Exhaust Deflector
52869
3. Install base gasket, base plate, pump cover gas- a - Impeller
ket (NEOPRENE STRIP FACES UP), nylon b - Nylon Washer
washer and impeller key.
NOTE: Apply a light coat of 2-4-C w/Teflon to inside
of pump cover to ease installation of cover over im-
d peller.
c
b 5. Install pump cover. Rotate drive shaft CLOCK-

f WISE while pressing cover down over impeller.
e 6. Apply Loctite 271 to retaining bolts and torque
bolts to 60 lb. in. (6.8 N·m).
a
52868
a - Base Gasket
b - Base Plate
c - Cover Gasket
d - Neoprene Strip
e - Nylon Washer a
f - Key
IMPORTANT: If impeller being installed has been 52830
a - Cover
previously used and vanes have taken a “set,” b - Bolts [Torque to 60 lb. in. (6.8 N·m)]
DO NOT INSTALL THE IMPELLER WITH THE
VANES REVERSED FROM THEIR PREVIOUS
“SET” AS VANE BREAKAGE WILL OCCUR
SHORTLY AFTER UNIT IS RETURNED TO SER-
VICE.

Gear Housing Pressure Test Gear Housing Installation
1. Remove vent plug and install pressure test gauge.
Tighten securely. Filling Gear Housing with Lubricant
NOTE: Gear housing lubricant capacity is approxi-
mately 14.9 fl. oz. (440 ml).
WARNING
If gear housing is installed on outboard, disconnect
(and isolate) spark plug leads from spark plugs before
working near the propeller.
CAUTION
Do not use automotive grease in the gear housing.
Use only Quicksilver Gear Lube.
1. Remove any gasket material from “Fill” and “Vent”
plugs and gear housing. Install new gaskets on “Fill”
and “Vent”plugs.
IMPORTANT: Never add lubricant without removing
“Vent” plug. Gear housing cannot be filled because of
trapped air. Fill gear housing when driveshaft is in a
vertical position.
2. Pressurize housing to 10-15 p.s.i. and observe gauge 2. Remove “Fill”plug and gasket.
for 5 minutes. 3. Insert lubricant tube in “Fill”hole, then remove “Vent”
3. Rotate drive shaft, prop shaft and move shift rod while plug and gasket.
housing is pressurized to check for leaks. 4. Fill until excess lubricant flows out of “Vent”hole.
5. Replace this “Vent”plug and gasket.
6. Install “Fill”plug and gasket.
a
4. If pressure drop is noted immerse housing in water.
5. Re-pressurize to 10-15 p.s.i. and check for air
bubbles.
6. Replace leaking seals as necessary. Retest housing.
NOTE: It should hold 10-15 p.s.i. for 5 minutes.
a - “Vent”Plug
7. Remove tester from housing and install vent plug.
7. Torque “Fill”and “Vent”screws to 55 lb. in. (6.2

N·m).

Installing Gear Housing to Drive 6. Install 4 bolts and washers, (two each side).
Torque bolts to 40 lb. ft. (54.2 M·m).
Shaft Housing
WARNING
Disconnect (and isolate) spark plug leads before
installing gear housing onto drive shaft housing.
1. Position shift lever in NEUTRAL gear position. a
52836
a - Bolt and Washers (2 each side) [Torque Bolt to 40 lb. ft.
(54.2 N·m)]
a NOTE: After reconnecting shift shaft, bottom of jam
nut should be approximately flush with top of spray
plate.
52872
a - Shift Lever
7. Reconnect shift shaft with coupler nut and jam
nut. Tighten jam nut against coupler nut.
2. Tilt engine to full “Up”position. Engage tilt lock le-
ver.
3. Shift gear housing into NEUTRAL. Propeller
shaft will rotate freely in either direction.
IMPORTANT: Liberally apply 2-4-C Marine Lubri-
cant w/Teflon to drive shaft splines.
4. Apply 2-4-C w/Teflon to drive shaft splines.
5. Position drive shaft into drive shaft housing.
Move gear housing upwards in drive shaft hous- c a
ing while aligning both shift shafts, water tube
seal and drive shaft splines.
NOTE: If the drive shaft splines will not align with the
crankshaft splines, rotate flywheel slightly while b
pushing gear housing into drive shaft housing.
52834
a - Coupler Nut
b - Jam Nut
c - Spray Plate

8. Install locknut and washer. Torque nut to 40 lb. ft. Trim Tab Adjustment and
(54.2 N·m).
Replacement
IMPORTANT: The trim tab is made of a special
alloy to aid in protecting the drive shaft housing
and gear housing from galvanic corrosion (cor-
rosion and pitting of metal surfaces). Do not
paint or place protective coating on the trim tab,
or trim tab corrosion protection function will be
a lost.
Replace trim tab if 50% (or more) consumed. Mark lo-
cation of old trim tab on anti-ventilation plate before
removal; install new trim tab in same location.
1. Check trim tab position as follows:
a. Operate boat at the speed at which it would
normally be operated.
b. If the boat pulls to the right (starboard), the
trailing edge of trim tab must be moved to the
right. If the boat pulls to the left (port), the trail-
52833
ing edge of trim tab must be moved to the left.
a - Locknut and Washer [Torque Nut to 40 lb. ft. (54.2 N·m)] 2. If necessary, adjust trim tab as follows:
a. Shift engine control into NEUTRAL and turn
9. Check shift operation. ignition key to “OFF”position.
a. In NEUTRAL, propeller shaft should turn NOTE: Loosen trim tab bolt sufficiently to allow trim
freely in either direction. tab to disengage from locking ridges in gear case be-
fore attempting to move tab. DO NOT strike trim tab
b. In FORWARD, propeller shaft SHOULD NOT with a hard object to make adjustments.
TURN COUNTERCLOCKWISE.
b. If boat pulls to the left, adjust trailing edge of
c. In REVERSE, propeller shaft SHOULD NOT trim tab to the left. If boat pulls to the right, ad-
TURN IN EITHER DIRECTION. just trailing edge of trim tab to the right.
IMPORTANT: If shift operation is not as described, a
remove the gear housing and correct the shift opera-
tion.
b
c
52835
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Bolt and Washer; Torque Bolt to 15.8 lb. ft. (21.4
N·m)

Propeller Installation
WARNING
Disconnect and isolate spark plug leads when work-
ing near the propeller to prevent the outboard from
starting.
1. Apply one of the following Quicksilver products on pro-
peller shaft splines.
-- Special Lubricant 101 (92-13872A1)
-- 2-4-C Marine Lubricant w/Teflon (92-825407A12)
2. Install components.
c a
d b
50551
a - Thrust Hub; Flat Surface Towards Propeller
b - Propeller
c - Tab Washer; Bend Tabs Down Against Nut Flats
d - Locknut; Torque to 55 lb. ft. (74.5 N·m)
CAUTION
Do not misinterpret propeller shaft movement for
propeller movement. Propeller and propeller
shaft may move fore-and-aft. However, the pro-
peller itself should not move fore-and-aft on the
propeller shaft.
3. Re-check propeller nut for tightness after first
use. Check for tightness periodically, especially
if a stainless propeller is used.

ATTACHMENTS/CONTROL
LINKAGE
7
A
THROTTLE/SHIFT LINKAGE
Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
Throttle Linkage Components
(S/N-0G589999 & Below) . . . . . . . . . . . . . . . 7A-2
Throttle Linkage (S/N-0G589999 & Below) . 7A-3
Throttle Linkage
(S/N-0G590000 & Above) . . . . . . . . . . . . . . . 7A-4
Bottom Cowl/Shift Components . . . . . . . . . . 7A-6
7A-0 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997

Notes:
90-826148R2 MARCH 1997 ATTACHMENTS/CONTROL LINKAGE - 7A-1

Throttle Linkage Components (S/N-0G589999 & Below)
95
51 95
8
3 4 5 6 7
9 66
10
11
12 15
1 16
13 14
95
17
18
20 19
24 21
22
33
23
33 Loctite 680 (Obtain Locally)
51 Loctite “222”Small Screw Threadlocker (92-809818)

66 Loctite “242”Removable Threadlocker (92-809821)
95 2-4-C With Teflon (92-825407A12)

Throttle Linkage (S/N-0G589999 & Below)
TORQUE
REF.
1 1 BUMPER-Throttle Stop
2 1 WASHER
3 1 BUMPER-Throttle Stop
4 1 LEVER-Throttle Control
5 1 BALL-Threaded
6 1 BUSHING KIT
7 1 INSERT
8 1 SCREW (M10 x 45) 16.7 22.6
9 1 NUT (M6) Drive Tight -
But Joint Must Move
Freely
10 1 WASHER
11 1 RETAINER
12 1 INSERT-Pin
13 1 PIN
14 1 LINK-Throttle Control
15 2 SOCKET-Ball
16 1 NUT
17 1 NUT (M6) 100 11.3
18 1 WASHER
19 1 CAM-Throttle Control
20 1 BUSHING
21 1 SCREW (M6 x 16) 100 11.3
22 1 BRACKET-Throttle Cable (2 HOLES)
23 1 BRACKET-Throttle Cable (3 HOLES)
24 1 STUD (M6 x 1 x 44)

THROTTLE LINKAGE (S/N-0G590000 & Above)
51 95
95
8
7
3 4 5 6
2 66
28 25
9
14 17
10 20 24
16
11 15
1
12
13
27 30
26 29
23 22
21
19
18
51 Loctite 222 (92-809818)
66 Loctite 242 (92-809821)
95 2-4-C With Teflon (92-825407A12)

THROTTLE LINKAGE (S/N-0G590000 & ABOVE)
TORQUE
REF.
1 1 BUMPER--Throttle Stop
2 1 WASHER
3 1 BUMPER--Throttle Stop
4 1 LEVER--Throttle Control
5 1 BALL--Threaded
6 1 BUSHING KIT
7 1 INSERT
8 1 SCREW (M10 x 45) 16.7 22.6
Drive Tight --
9 1 NUT (M6) But Joint Must Move
Freely
10 1 WASHER
11 1 RETAINER
12 1 INSERT--Pin
13 1 PIN
14 1 LINK--Throttle Control
15 2 SOCKET--Ball
16 1 NUT
17 1 WASHER
18 1 SCREW (M6 x 16) 100 11.3
19 1 BRACKET-Throttle Cable
20 1 SPARK ARM
21 1 THROTTLE CAM
22 1 SPRING
23 1 BUSHING
24 1 WAVE WASHER
25 1 SCREW (M6 x 35)
26 1 SCREW (M5 x 35)
27 1 NUT
28 1 SPARK CONTROL LINK
29 2 SOCKET--Ball
30 1 NUT

Bottom Cowl/Shift Components

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

TORQUE
REF.
1 1 SPRING-Detent
2 2 SPRING-Backing
3 1 PLATE
4 2 SCREW (M5 x 14) 75 8.5
5 1 STRAP-Horizontal Shift Shaft
6 1 SCREW (M6 x 1 x 16) 100 11.3
7 1 CLAMP-Horizontal Shift Shaft
8 2 SCREW (M6 x 1 x 30) 100 11.3
9 1 SWITCH
10 2 SCREW (M3 x .5 x 20) Drive Tight
11 1 PLATE-Switch
12 1 CAP-Intermediate Lever
13 1 SCREW (M6 x 16) 100 11.3
14 1 BUSHING
15 1 LEVER-Intermediate
16 1 INSERT
17 1 PIN
18 1 BUSHING
19 1 NYLINER
20 1 RETAINER
21 1 WASHER
22 1 NUT (M6) Drive Tight - But
23 1 NUT (M6) Joint Must Be Free
24 1 WASHER
25 1 LINK-Shift
26 1 NYLINER
27 1 HARNESS ELECTRIC HANDLE
28 1 HARNESS ADAPTOR
29 1 SHIFT SHAFT-Horizontal
30 1 LEVER-Interlock Actuating
31 1 COTTER PIN
32 1 SCREW (M10-16 x .38 Self Tap)
33 1 CABLE (BLACK-7 1/2”)
34 1 SHIFT ROD
35 2 COTTER PIN
36 2 PIN-Shift Rod
37 2 LOCKWASHER
38 1 LEVER-Shift
39 1 WAVE WASHER
40 1 SCREW (M5 x .8 x 16)
41 1 LATCH
42 1 CUP
43 2 DRIVE SCREW
44 1 SEAL


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

TORQUE
REF.
45 1 PLUG-Stop Switch
46 1 RETAINER
47 1 STOP SWITCH
48 1 LANYARD STOP SWITCH
49 1 GROMMET
50 1 SWITCH (ELECTRIC HANDLE)
51 1 SEAL-Throttle Cable
52 1 SEAL-Throttle Cable
1 BOTTOM COWL (BLACK)
53
1 BOTTOM COWL (GRAY)
54 1 PLUG-Shift Lever
55 1 SHIFT HANDLE
1 GROMMET
56
1 GROMMET (SPLIT - POWER TRIM)
57 1 PLUG-Warning Alarm (ELECTRIC)
58 1 SEAL-Warning Horn
59 1 ALARM
60 1 WASHER
61 1 SCREW (M5 x .8 x 12) Drive Tight
62 1 SWITCH ASSEMBLY (POWER TRIM)
63 1 PLUG-Trim Switch
64 1 RETAINER
65 1 SCREW (M10-16 x 1/2 Self Tap) 75 8.5
66 1 SCREW (M5 x 16)-Interlock Cable
67 1 SCREW (M6 x 16) 100 11.3
68 1 CAM-Latch
69 1 WAVE WASHER
70 1 BUSHING
71 1 FITTING-Telltale
72 2 STA-STRAP
73 1 TUBING (15”)
74 1 BUSHING
1 LEVER-Cowl Latch (BLACK)
75
1 LEVER-Cowl Latch (GRAY)
76 4 SCREW (M6 x 25) 100 11.3
77 4 BUSHING
78 4 GROMMET

ATTACHMENTS/CONTROL
LINKAGE
7
B
TILLER HANDLE
Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
Tiller Handle Components . . . . . . . . . . . . . . . 7B-2
Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-3
Adjustments
Tiller Handle Model
(S/N-0G589999 & Below) . . . . . . . . . . . . . . . 7B-4
Adjustments
Tiller Handle Model with
(S/N-0G590000 & Above) . . . . . . . . . . . . . . . 7B-5
7B-0 - ATTACHMENTS/CONTROL LINKAGE 90-826148R2 MARCH 1997

Notes:
90-826148R2 MARCH 1997 ATTACHMENTS/CONTROL LINKAGE - 7B-1

Tiller Handle Components
1
5 2
3
4 8
6
95
7 9
95
10
95
95
95
26 27 11
31
30 12
29 13
14
15
28 16
17
24 25
23 19
18
20
22
21
95 2-4-C With Teflon (92-825407A12)

Tiller Handle
TORQUE
REF.
1 1 COVER KIT
2 1 PULLEY
3 1 CASE (Part of Ref #1)
4 1 SCREW (10-16 x 1/2”Self Tap) 20 2.3
5 1 CABLE--Throttle
6 1 CABLE--Throttle
7 1 SLEEVE--Insulation
8 2 SCREW (M8 x 1.25 Hex flange head) 16.5 22.4
1 COVER--Side (BLACK)
9
1 COVER--Side (GRAY)
10 1 BUSHING
1 ARM--Steering Handle (BLACK)
11
1 ARM--Steering Handle (GRAY)
12 1 RETAINER
13 1 SCREW (M5 x .8 x 12 Hex Flange Head) 35 4.0
14 1 SCREW (M6 x 1 x 25 Hex Head Cap)
15 1 LOCK--Throttle
16 1 SPRING
17 1 KNOBS--Throttle
18 1 TILLER TUBE
1 DECAL (TURTLE/RABBIT)
19
1 DECAL (SLOW/FAST)
20 1 HANDLE--Throttle
21 1 GRIP--Throttle Handle
22 1 SWITCH--Stop
23 2 SCREW (M10 x 90 Hex Head Cap) 35 47.5
24 1 TAB WASHER
25 1 CLIP--Cable Retainer
26 1 BUMPER
1 BRACKET--Tiller (BLACK)
27
1 BRACKET--Tiller (GRAY)
28 1 PLUG
29 1 WAVE WASHER
30 1 BUSHING
31 1 WASHER

Adjustments 5. Tighten throttle cable jam nuts.
e a
Tiller Handle Model b
(S/N-0G589999 & Below)
a c
d d d
52300
b b - Throttle Cam
c - Mounting Bracket
e - Cam Follower Screw
c
52301
b - Throttle Shutter Positioner
c - Jam Nut

roller against throttle cam. Center the roller with Cable Slack
raised mark on throttle cam by adjusting the posi- Min. 1/16 in. (1.59 mm)
tion of throttle cable sleeves in the mounting b Max. 1/8 in. (3.18 mm)
bracket. 52300
NOTE: When positioning throttle cables, a minimum a - Throttle Cam
b - Link Rod Ball
mm) slack must be allowed to prevent throttle cables
from binding. (Rock throttle cam side to side and 6. With cam follower resting on throttle cam, tighten
measure the amount of throttle cam travel at link rod the cam follower screw.
ball.

Adjustments 5. Tighten throttle cable jam nuts.
c
Tiller Handle Model with b
a
(S/N-0G590000 & Above)
b
e
d
55762
d
b - Cam Follower Roller
c - Throttle Cam
e - Mounting Bracket
a c
b
55896
d
a - Idle Speed Screw
b - Cam Follower Screw
c - Throttle Shutter Positioner
d - Jam Nuts

roller against throttle cam. Center the roller with
raised mark on throttle cam by adjusting the posi- Cable Slack
tion of throttle cable sleeves in the mounting Min. 1/16 in. (1.59 mm)
Max. 1/8 in. (3.18 mm)
bracket on tiller handle models or throttle link rod
on remote control models.
a
NOTE: When positioning throttle cables, a minimum
mm) slack must be allowed to prevent throttle cables 55762
from binding. (Rock throttle cam side to side and
measure the amount of throttle cam travel at link rod a - Link Rod Ball
ball. b - Throttle Cam
6. With cam follower resting on throttle cam, tighten the

cam follower screw.

MANUAL STARTER
8
Table of Contents
Page
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Manual Start Components . . . . . . . . . . . . . . . 8-2
Manual Start Components . . . . . . . . . . . . . . . 8-3
Rewind Starter Disassembly . . . . . . . . . . . . . 8-4
Cleaning and Inspection . . . . . . . . . . . . . . . . . 8-5
Rewind Starter Reassembly . . . . . . . . . . . . . 8-5
Adjusting Rewind Spring Tension . . . . . . . . . 8-7
Starter Interlock Cable Adjustment . . . . . . . . 8-7
8-0 - MANUAL STARTER 90-826148R2 MARCH 1997

Notes:
90-826148R2 MARCH 1997 MANUAL STARTER - 8-1

Manual Start Components
2
1 3
5
15
16 6
7
36 4
8
35
9
34 10
33
14
32 11
31 12
95
30 13
29
17
28
18
27
95
19
20
26
25 21
24
22
23
95 2-4-C With Teflon (92-825407A12)

Manual Start Components
TORQUE
REF.
1 1 SEAL-Handle rest
2 2 NUT (M6 x 1)
3 2 WASHER
4 2 SPACER-Handle rest
5 1 REST-Starter Handle
6 1 HANDLE-Starter
7 1 RETAINER
8 4 WING NUT 90 10.2
9 4 WASHER
10 4 GROMMET
11 4 BUSHING
12 4 GROMMET
13 4 WASHER
1 RECOIL STARTER (S/N-USA-0G239163/BEL-9864479 & BELOW)
-
1 RECOIL STARTER (S/N-USA-0G239164/BEL-9864480 & ABOVE)
14 1 HOUSING
15 1 RETAINING RING
16 1 BUSHING-Rope
17 1 LOCKWASHER
18 1 SPRING/KEEPER ASSEMBLY
19 1 SHEAVE-Starter
20 1 STARTER ROPE
21 1 SPRING
22 1 CAM
23 1 SCREW (1/4-20) 135 15.3
24 2 RETAINING RING
25 2 CAM
26 2 SPRING
27 3 SCREW (10-16 x 1 IN.)
28 1 RETAINER
29 1 CAM
1 LEVER (S/N-USA-0G239163/BEL-9864479 & BELOW)
30
1 LEVER (S/N-USA-0G239164/BEL-9864480 & ABOVE)
31 1 SPRING
32 1 CABLE-Interlock
33 1 SCREW (M5 x .8 x 16)
34 1 WASHER
35 1 SCREW (10-16 x .625)
36 1 COTTER PIN

Rewind Starter Disassembly 4. Remove cam retainer.
a b
WARNING
When disassembling and reassembling rewind a
starter, SAFETY GLASSES must be worn in case
rewind spring uncoils out of the housing.
1. Untie knot in starter rope and release starter rope
to allow rewind spring to unwind.
2. Remove retaining clip and attaching screw which
secures shift interlock cable to starter housing.
3. Remove rewind starter from engine.
b a
c c 51605
a - Screws
b - Retainer
5. Remove cam and spring.
c c
51606
a - Retaining Clip
b - Screw
c - Bolts (4)
a
b
51605
a - Cam
b - Spring

6. Remove starter sheave.
1. Clean components in solvent and dry with com-
pressed air.
2. Inspect rewind spring for kinks, burrs, corrosion
of breakage.
3. Inspect starter sheave, rope guide and starter
housing for nicks, grooves, cracks, wear or dis-
tortion, especially area of rope travel.
4. Inspect bushing, starter drive pawl and spring for
wear or damage.
5. Inspect starter rope for wear.
6. Replace components as necessary.
Rewind Starter Reassembly

a b 51605 WARNING
a - Starter Sheave When reassembling rewind starter, SAFETY
b - Screw
GLASSES must be worn in case rewind spring
uncoils out of the housing.
1. Install spring/cover assembly into sheave.
7. Spring is replaced as a spring/cover assembly.
a
a
51607
51607
a - Spring Assembly
a - Spring Assembly

2. Install starter sheave to housing and secure in 4. Position cam lever spring into recess of starter
place with screw. Torque to 135 lb. in. (15.3 N·m). housing and re-install cam lever.
a
a b 51605
a - Starter Sheave
b - Screw
28375
a - Cam Lever
3. Install interlock lever. b - Cam Lever Spring
5. Install cam retainer and secure with screws.
a b
a
28374
51605
a - Screws
a - Interlock Lever b - Cam Retainer

Adjusting Rewind Spring Starter Interlock Cable
Tension Adjustment
1. Rotate sheave counterclockwise until it stops IMPORTANT: Lubricate core wire of interlock
(coil is bound). Then back off one full turn, plus cable with light oil prior to making adjustments.
what is needed to align rope end with hole in
1. While rotating the propeller shaft, place the gear
housing. Never back off sheave less than one full
shift lever into REVERSE.
turn.
2. Return the gear shift lever to NEUTRAL without
2. Route starter rope thru rope guide in housing. Tie
going past neutral detent.
a slip knot in rope approximately 12 in. (305 mm)
from end of rope. 3. Place end of interlock cable over pin of cam lever
and secure with hair pin (Figure 4.)
4. Secure interlock cable to starter housing using
adjusting screw. Do not tighten screw at this time.
5. Adjust interlock cable to align raised mark of cam
lever with pointer of rewind housing.
51605 a
NOTE: Check operation of rewind and rewind ten-
sion before outboard installation. d
b
3. Install rewind starter to engine. e
4. Pull starter rope thru bracket, handle, and rope
retainer. Secure rope retainer with knot in rope.
b a
28376
a - Interlock Cable
b - Hair Pin
c c c - Adjustment Screw
d - Raised Mark of Cam Lever
e - Pointer of Rewind Housing
6. Tighten cable adjustment screw and check ad-

justment after 4 or 5 shift cycles.
c c
d
51606
a - Retaining Clip
b - Screw
c - Nuts (4) Torque to 90 lb. in. (10.2 N·m)
d - Bracket

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How should one safely service an outboard engine?

How should one safely service an outboard engine?

What safety precautions should be taken when the intake or exhaust is exposed?

What safety precautions should be taken when the intake or exhaust is exposed?

MODELS

With Serial Numbers

Printed in U.S.A. ã 1997, Mercury Marine 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 i

90-826148 R2 MARCH 1997 LOWER UNIT - 6A-7

Revision No. 1 Section Description

Month of Printing Section Number

Year of Printing Part of Section Letter

90-826148R2 MARCH 1997 iii

1A-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 IIMPORTANT INFORMATION - 1A-1

1A-2 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 IIMPORTANT INFORMATION - 1A-3

1B-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Gear Case Lubricant Capacity

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-1

Every 300 Hours of Use or Three

Before Periods of Storage

1B-2 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

(S/N-0G589999 & Below)

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-3

2 - Upper Shift Shaft Lubrication

3 - Swivel Pin Grease Fittings 4 - Ride Guide Steering Grease Fitting

Core of steering cable (transom end) must be ful-

7 - Propeller Shaft Lubrication

1B-4 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

8 - Starter Motor Pinion Gear Lubrication

2. Remove fill cap and check fluid level. The fluid

9 - Gear Housing Lubrication

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-5

1B-6 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-7

1B-8 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

FUEL TANK FILTER

2. To install fuel line clamps, grip hose clamp with

a - Fuel Tank Filter

FUEL LINE AND PRIMER BULB

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-9

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

1B-10 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Protecting Internal Outboard

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1B-11

1C-0 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1C-1

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

1. Proper positioning of the weight inside the boat WARNING

1C-2 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1C-3

1C-4 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1C-5

Thrust Hub: 73345 (Forward)

1C-6 - IMPORTANT INFORMATION 90-826148R2 MARCH 1997

Thrust Hub: 73345 (Forward)

90-826148R2 MARCH 1997 IMPORTANT INFORMATION - 1C-7