Mercury Mariner 4, 5, 6 4 Stroke Sevice Manual

SERVICE
MANUAL
MODELS
Mercury/Mariner
4 ⋅ 5 ⋅ 6 (4-Stroke)
Starting Serial Numbers

0R000001 and Above
Printed in U.S.A. 2000, Mercury Marine 90-857138R1 MAY 2000

Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal in-
jury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual

This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these prod-
ucts, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which in-
cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-857138R1 MAY 2000 Page i

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

A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manu-
al, it should be understood that proper cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
Personnel should not work on or under an outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.
Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explana-
tory.
EXAMPLE:
90-826883 R1 JANUARY 1998 Page - 6A-7
Revision No. 1 Section Number
Month of Printing Part of Section Letter
Year of Printing Page Number
Page ii 90-857138R1 MAY 2000

Service Manual Outline
Section 1 - Important Information
Important Information
1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Electrical
2
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Fuel System
3
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
Powerhead
4
B - Carburetor
C - Emissions
Section 4 - Powerhead
A - Cylinder Head
Mid-Section
5
B - Cylinder Block/Crankcase
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
Lower Unit
6
Section 6 - Lower Unit
Section 7 - Attachments/Control Linkage
A - Shift Linkage
B - Tiller Handle
Attachment/Control Linkage
7
Section 8 - Manual Starter
Section 9 - Color Diagrams
Manual Starter
8
Color Diagrams
9
90-857138R1 MAY 2000 Page iii

SPECIFICATIONS
IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Charts . . . . . . . . . . . . . . 1A-8
Specifications
Model 4/5/6 (4-Stroke)

Model 4 4 hp (2.9 kW)
HORSEPOWER
(kW)
OUTBOARD Short Shaft 55 lbs. (25.0 kg)
WEIGHT Long Shaft 57 lbs. (26.0 kg)
RECOMMENDED GASOLINE Automotive Unleaded
FUEL with a Minimum Pump Posted
Octane Rating of 87
ENGINE OIL CAPACITY
ENGINE OIL Either 15 fl oz. or 450 ml.
SAE SAE SAE 10W-30 viscosity oil is recom-
25W-40 10W-30 mended for use in all temperatures.
F° C° SAE 25W-40 viscosity oil may be used at
temperatures above 40° F (4° C).
+100 +38
+80 +27 Use Quicksilver 4-Cycle Marine Oil with

+60 +16
the proper viscosity for the expected
OIL temperature in your area (see range
+40 +4 thermometer on left). If not available, use
+20 –7
a premium quality 4-cycle engine oil, cer-
tified to meet or exceed anyone of the
–18
0 following American Petroleum Institute
(API) service classifications SH, SG, SF,
CF-4, CE, CD, CDll.
Alternator (Optional) Type:

CHARGING
Lighting Coil 12 Volt 60 Watt
SYSTEM
(Non Regulated Lighting Coil)
Readings taken @
Lighting Coil Resistance 0.31 - 0.47 Ω (YEL/RED - YEL/RED)
68°F (20°C).
Battery Charging Rectifier (Optional) 2 Amperes (Rectified)
STARTING Manual Start Recoil Starter
SYSTEM
90-857138R1 MAY 2000 Page 1A-1

SPECIFICATIONS
Type Capacitor Discharge Ignition

Spark Plug:
Type NGK DCPR6E
Gap 0.035 in. (0.9 mm)
Hex Size 5/8 in. (16 mm)
Torque 13 lb-ft. (17.5 Nm)
Firing Order 1
IGNITION
Ignition Timing: (Fixed) 25° ± 1° B.T.D.C.
SYSTEM
Capacitor Charge Coil Resistance 95 - 134 Ω (WHT - BLK/RED)
Readings taken @
Trigger Coil Resistance 149 - 243 Ω (RED/WHT - BLK)
68°F (20°C).
Ignition Coil Resistance:
Primary 0.02 - 0.38 Ω
Secondary (W/o Boots) 3000 - 4400 Ω
Spark Plug Boot 3500 - 5200 Ω
Engine Speed Limiter 6300 ± 200 RPM
Oil Pressure Switch (Red Light) Continuity Below 3.5 psi ± 0.7 psi
(24.5 ± 5 kPa)
Idle rpm (Out Of Gear) 1300 ± 50 rpm
Idle rpm (In Forward Gear) 1100 ± 50 rpm
Wide Open Throttle rpm (WOT)
4/5 (1999 & 2000) 4500 -5500
4/5/6 (2001 & Newer) 5000 - 6000
Pilot (Idle Mixture) Screw
4/5/6 (1999 & 2000) 3 ± 1/2 Turns Out
European Models Only
2001 & Newer
4 2-1/8 ± 1/2 Turns Out
5 1-1/2 ± 1/2 Turns Out
6 2-3/4 ± 1/2 Turns Out
All Other Models Non-Adjustable
Venturi Bore Diameter
4/5 13.5 mm
6 15 mm
CARBURETOR Main Jet Size
4/5 (1999 & 2000) #70
4 (2001 & Newer) #58
5 (2001 & Newer) #65
6 (2000 & Newer) #75
4 (Bodensee) #55
5 (Bodensee) #62
6 (Bodensee) #68
Pilot Jet
4 (1999 & 2000) #40
5 (1999 & 2000) #42
4/5 (2001 & Newer) #38
6 (2000 & Newer) #45
4/5 (Bodensee) #38
6 (Bodensee) #42
Float Height 0.35 - 0.39 in. (9 - 10 mm)
Page 1A-2 90-857138R1 MAY 2000

SPECIFICATIONS
Fuel Pump Type External (Plunger/Diaphragm)

Fuel Pump:
FUEL Pressure 2.5 - 5.0 psi (17 - 35 kPa)
SYSTEM Plunger Stroke 0.059 in. (1.5 mm)
Diaphragm Stroke 0.059 in. (1.5 mm)
Fuel Tank Capacity 3.2 US Gallons
Type 4 Stroke Cycle – Over Head Valve
CYLINDER
Displacement 7.5 cu. in. (123 cc)
BLOCK
Number of Cylinders 1
STROKE Length 1.77 in. (45 mm)
Diameter
Standard 2.323 in. (59.00 mm)
CYLINDER
Oversize-0.020 in. (0.50 mm) 2.343 in. (59.50 mm)
BORE
Taper/Out of Round Maximum 0.003 in. (0.076 mm)
Bore Type Steel
Piston Type Aluminum
O.D. at Skirt
PISTON
Piston to Cylinder Clearance 0.001 - 0.002 in.
PISTON
(0.020 - 0.055 mm)
CLEARANCE
Piston Clearance Limit 0.006 in. (0.15 mm)
Ring End Gap (Installed)
Top 0.006 - 0.014 in. (0.15 - 0.35 mm)
Middle 0.012 - 0.020 in. (0.30 - 0.50 mm)
Bottom (Oil Ring) 0.008 - 0.016 in. (0.20 - 0.40 mm)
RINGS
Side Clearance:
Top 0.0015 - 0.003 in. (0.04 - 0.08 mm)
Middle 0.0012 - 0.003 in. (0.03 - 0.07 mm)
Compression Ratio
With Decompression 8.5:1
4/5 (1999 & 2000) 42 psi ± 14 psi (0.29 ± 0.1 MPa)
COMPRESSION
RATIO
4/5 (2001 & Newer) 9.5:1
6 (2000 & Newer) 42 psi ± 14 psi (0.29 ± 0.1 MPa)
Outer Diameter 0.6299 in. (16.00 mm)

Diameter of Piston Pin Hole 0.6300 in. (16.002 mm)
PISTON PIN Clearance between Piston Pin and
Piston Pin Hole 0.0001 - 0.0005 in.
(0.002 mm - 0.012 mm)
Oil Clearance (Big End) 0.002 - 0.003 in. (0.053 - 0.079 mm)
CONNECTING Side Clearance (Big End) 0.008 - 0.016 in.
ROD (0.20 - 0.40 mm)
Small End Inside Diameter 0.6303 in. (16.01 mm)
90-857138R1 MAY 2000 Page 1A-3

SPECIFICATIONS
Crankshaft Runout Less than 0.002 in. (0.05 mm)

Diameter of Crank Pin (A) 1.179 - 1.177 in.
(29.94 - 29.91 mm)
Outer Diameter of Crankshaft in Oil
Pan Bearing (B) 0.983 - 0.982 in.
(24.98 - 24.96 mm)
A B
CRANKSHAFT
Camshaft Dimensions
Intake/Exhaust “A”
4 (1999 & 2000) A 0.993 in. (25.24 mm)
5 (1999 & 2000) 1.047 in. (26.59 mm)
6 (2000) 1.115 in. (28.33 mm)
4/5/6 (2001 & Newer) 1.115 in. (28.33 mm)
Bearing Diameter “B” 0.550 in. (13.98 mm)
CAMSHAFT
B
Inside Diameter of Oil Pan Bearing:

Crankshaft “A” 0.985 in. (25.01 mm)
Camshaft “B” B 0.5515 in. (14.01 mm)
A
OIL PAN
Crankshaft to Oil Pan Bearing

Clearance 0.0006 - 0.0015 in. (0.015 - 0.040 mm)
Camshaft to Oil Pan Bearing
Clearance 0.0008 - 0.002 in. (0.02 - 0.05 mm)
Page 1A-4 90-857138R1 MAY 2000

SPECIFICATIONS
Free Length (Intake/Exhaust) “a”

Tilt Limit “b” (Intake/Exhaust)
4/5 (1999) a = 1.260 in. (32.0 mm)
b = 0.044 in. (1.12 mm)
4/5/6 (2000 & Newer) a = 1.378 in. (35.0 mm)
b b = 0.044 in. (1.12 mm)
VALVE SPRING
Compressed Pressure (Installed)
Intake/Exhaust:
Closed Height 0.965 in. (24.4 mm)
4/5 (1999 & 2000) 17 lbf. (7.7 kgf)
6 (2000) 24 lbf. (10.8 kgf)
4/5/6 (2001 & Newer) 24 lbf. (10.8 kgf)
Open Height 0.709 in. (17.4 mm)
4/5 (1999 & 2000) 31 lbf. (14.0 kgf)
6 (2000) 39.4 lbf. (17.9 kgf)
4/5/6 (2001 & Newer) 39.4 lbf. (17.9 kgf)
Direction of Winding (Intake/Exhaust) Right Hand
Warp Limit * 0.0012 in. (0.03 mm)
CYLINDER HEAD * Lines indicate

straight edge
measurement
Valve Dimensions
“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness
90-857138R1 MAY 2000 Page 1A-5

SPECIFICATIONS
Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.002 - 0.005 in. (0.06 - 0.14 mm)
Exhaust 0.004 - 0.007 in. (0.11 - 0.19 mm)
Valve Dimensions:
“A” Head Diameter
Intake 0.980 - 0.988 in. (24.9 - 25.1 mm)
Exhaust 0.941 - 0.949 in. (23.9 - 24.1 mm)
“B” Face Width
Intake 0.102 in. (2.6 mm)
Exhaust 0.102 in. (2.6 mm)
“C” Seat Width
“D” Margin Thickness
VALVES Intake 0.028 in. (0.7 mm)
Stem Outside Diameter
Intake 0.216 in. (5.48 mm)
Guide Inside Diameter
Intake 0.2165 in. (5.5 mm)
Stem To Guide Clearance
Intake 0.0008 - 0.0017 in. (0.020 - 0.044 mm)
Exhaust 0.0018 - 0.0028 in. (0.045 - 0.072 mm)
Stem Run-out Limit (max.) 0.0006 in. (0.016 mm)
Valve Opening Temperature 122°F - 129°F (50°C - 54°C)

THERMOSTAT Full Open Temperature 145°F - 153°F (63°C - 67°C)
Valve Lift (Minimum) 0.12 in. (3 mm)
Page 1A-6 90-857138R1 MAY 2000

SPECIFICATIONS
Pump Type Trochoid

Engine Oil Pressure* (Warm Engine):
@ 1300 rpm 4.0 psi (0.03 MPa) Minimum
Engine Oil Pan Capacity 0.95 pt (450 ml)
Oil Pump Clearance:
Inner Rotor to Outer Rotor “A” 0.006 in. (0.15 mm) or Less
Outer Rotor to Body “B” 0.005 - 0.008 in. (0.12 - 0.20 mm)
Rotor to Body (Side) “C” 0.0008 - 0.0028 in. (0.02 - 0.07 mm)
Height of Outer Rotor “D” 0.236 in. (5.99 mm)
Relief Valve Operating Pressure* 31 - 40 psi (2.2 - 2.8 kg/cm2)
LUBRICATION 216 - 275 kPa
SYSTEM
D
A B
C
Transom Height - Short Shaft 17 in. (38 cm)

- Long Shaft 22 in. (51 cm)
Steering Pivot Range 78°
Tilt Pin Positions 6
MID-SECTION
Total Tilt Angle 75°
Tilt Angle 4° - 24°
Shallow Water Tilt Angle 32.5°
Allowable Transom Thickness 2.2 in. (55 mm)
Gear Ratio 2.15:1
Gearcase Capacity 6.5 fl oz (195 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 28 Spiral/Bevel
GEAR HOUSING Pinion Gear
(2.15:1) Number of Teeth 13 Spiral/Bevel
Pinion Height Floating
Forward Gear Backlash No Adjustment
Water Pressure:
@ 1300 rpm (Idle) Neutral 2.3 - 3.6 psi (16 - 25 kPa)
@ 5000 rpm 8 - 15 psi (55 - 103.5 kPa)
* Oil pressure specifications listed were obtained with oil at 165°F (75°C)
Water pressure readings will vary with thermostat operation.
90-857138R1 MAY 2000 Page 1A-7

SPECIFICATIONS
Propeller Information Charts

Mercury/Mariner 4 (4-Stroke)
Wide Open Throttle RPM : 5000-6000
Recommended Transom Heights : 15”, 20”
Right Hand Rotation Standard
Gear Reduction : 2.15:1
Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
8-3/8” 9” 3 Alum Up to 400 Up to 14’ 12-18 48-812950T1
8-3/8” 8” 3 Alum 300-500 13-15’ 10-16 48-812950
8-3/8” 7” 3 Alum 400-700 14-16’ 8-13 48-812949*
8-3/8” 6” 3 Alum 600+ 15’+ 1-11 48-16144
8-3/8” 6” 3 Alum Sailboat 1-8 48-812951A1

8-3/8” 9” 3 Alum Up to 500 Up to 14’ 12-18 48-812950T1
8-3/8” 8” 3 Alum 400-700 13-15’ 10-16 48-812950*
8-3/8” 7” 3 Alum 500-900 14-16’ 8-13 48-812949
8-3/8” 6” 3 Alum 600+ 15’+ 1-11 48-16144
8-3/8” 6” 3 Alum Sailboat 1-8 48-812951A1

8-3/8” 9” 3 Alum Up to 500 Up to 14’ 14-21 48-812950T1
8-3/8” 8” 3 Alum 500-800 13-15’ 12-18 48-812950*
8-3/8” 7” 3 Alum 600-1100 14-16’ 10-14 48-812949
8-3/8” 6” 3 Alum 800+ 15’+ 1-12 48-16144
8-3/8” 6” 3 Alum Sailboat 1-9 48-812951A1
*Standard propeller shipped with outboard.
Page 1A-8 90-857138R1 MAY 2000

MAINTENANCE
Section 1B - Maintenance B
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Gear Case Lubricant Capacity . . . . . . . . . . . . . . . 1B-1 Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Oil Changing Procedure . . . . . . . . . . . . . . . . . . . . . 1B-8
Quicksilver Lubricant/Sealant . . . . . . . . . . . . . . . . 1B-2 Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection and Maintenance Schedule . . . . . . . . . . . 1B-3 Gear Case Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Gear Case Lubricant Capacity . . . . . . . . . . . . . . . 1B-9
After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Draining Gear Case . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Every 100 Hours of Use or Once Yearly, Checking Lubricant Level and Refilling
Whichever Occurs First . . . . . . . . . . . . . . . . . . . . . 1B-3 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Flushing The Cooling System . . . . . . . . . . . . . . . . . . . 1B-4 Storage Preparations . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Protecting External Engine Components . . . . . 1B-10
Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Protecting Internal Engine Components . . . . . . 1B-11
Corrosion Control Anode . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Positioning Outboard for Storage . . . . . . . . . . . . 1B-11
Specifications
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
2.15:1 6.6 fl oz. (195.0 ml)
Special Tools
1. Grease Gun 91-37299A1
90-857138R1 MAY 2000 Page 1B-1

MAINTENANCE
Quicksilver Lubricant/Sealant
1. Quicksilver Anti-Corrosion Grease P/N 92-850735A1
2. 2-4-C Marine Lubricant with Teflon P/N 92-850736A1
3. SAE 10-30W Motor Oil P/N 92-802833A1
4. Quicksilver Gear Lubricant P/N 92-19007A24
Page 1B-2 90-857138R1 MAY 2000

MAINTENANCE
Inspection and Maintenance Schedule

Before Each Use
1. Check engine oil level.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear case
with fresh water if operating in salt water.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Change engine oil. The oil should be changed more often when the engine is operated
under adverse conditions such as extended trolling.
3. Inspect and clean spark plugs.
4. Check fuel line filter for contaminants.
5. Check corrosion control anode. Check more frequently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft.∗
8. Check tightness of bolts, nuts, and other fasteners.
9. Replace water pump impeller.∗
∗ These items should be serviced by an authorized dealer.
90-857138R1 MAY 2000 Page 1B-3

MAINTENANCE
Flushing The Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted, or muddy water. This will help prevent a buildup of deposits from clogging the inter-
nal water passages.
NOTE: Do not run the engine while flushing the cooling system.
1. Remove plug and gasket and thread-in hose coupling.
2. Attach a water hose to the hose coupling. Turn on the water gently and flush the cooling
system for 3 to 5 minutes.
3. Remove the thread-in hose coupling and reinstall plug and gasket.
a - Plug and Gasket

b - Hose Coupling
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or al-
low open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an ap-
proved receptacle. Any fuel system service must be performed in a well ventilated area. In-
spect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other
signs of deterioration or damage. If any of these conditions is found, the fuel line or primer
bulb must be replaced.
Engine Fuel Filter
Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace.
Page 1B-4 90-857138R1 MAY 2000

MAINTENANCE
Corrosion Control Anode

Your outboard has a corrosion control anode installed to the gear case. An anode helps pro-
tect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded in-
stead of the outboard metals.
The anode requires periodic inspection especially in salt water which will accelerate the ero-
sion. 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 effective-
ness of the anode.
a - Anode
Spark Plug Inspection

Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart in General Information Section.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs fin-
ger tight, and tighten 1/4 turn or torque to 13 lb-ft (17.5 Nm).
90-857138R1 MAY 2000 Page 1B-5

MAINTENANCE
Lubrication Points
Lubricate Points 1 thru 5 with Quicksilver 2-4-C with Teflon Marine Lubricant or Spe-
cial Lubricant 101.
1. Co-Pilot – Lubricate threads.
2. Swivel Bracket – Lubricate fitting.
2
3. Transom Clamp Screws – Lubricate threads.
NOTE: Lubricating points 4 and 5 require disassembly of the product. These points should
be lubricated at least once a year by an authorized dealer.
4. Tiller Handle Rubber Bushing – Lubricate internal diameter.
4
5. Shift Handle Detent – Lubricate detent.
Page 1B-6 90-857138R1 MAY 2000

MAINTENANCE
Lubricate Point 6 with Light Weight Oil

6. Tilt Pivot.
Lubricate Point 7 with Quicksilver Anti-Corrosion Grease or 2-4-C with Teflon Marine
Lubricant.
7. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the pro-
peller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from cor-
roding to the shaft.
90-857138R1 MAY 2000 Page 1B-7

MAINTENANCE
Changing Engine Oil

ENGINE OIL CAPACITY
15 fl oz. (450 mL)
OIL CHANGING PROCEDURE
1. Place outboard in an upright slightly tilted position.
2. Turn the steering on the outboard to gain access to the drain plug. Remove drain plug
and drain engine oil into an appropriate container. Lubricate the seal on the drain plug
with oil and reinstall.
a - Drain Plug
IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will
have a milky color to it; oil contaminated with fuel will smell strongly of fuel. If con-
taminated oil is noticed, have the engine checked by your dealer.
OIL FILLING
IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when
checking oil.
Remove the oil fill cap and refill with 15 fl oz. (450 mL) of oil. Reinstall the oil fill cap.
Idle engine for five minutes and check for leaks. Stop engine and check oil level on dipstick.
Add oil if necessary.
Page 1B-8 90-857138R1 MAY 2000

MAINTENANCE
Gear Case Lubrication

Gear Case Lubricant Capacity
Gear Case Ratio Capacity
2.15:1 6.6 fl oz. (195 mL)
When adding or changing gear case lubricant, visually 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 appearance.
If water is noticed, have the gear case checked by your dealer. Water in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
Also examine the gear case lubricant for metal particles. A small amount of metal filings or
fine metal particles indicates normal 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.
Draining Gear Case
1. Place outboard in a vertical operating position.
2. Place drain pan below outboard.
3. Remove fill/drain plug and vent plug and drain lubricant.
a - Fill/Drain Plug
b - Vent Plug
90-857138R1 MAY 2000 Page 1B-9

MAINTENANCE
Checking Lubricant Level and Refilling Gear case

1. Place outboard in a vertical operating position.
2. Remove vent plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubri-
cant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
d
b
a - Vent Plug/Sealing Washer
b - Lubricant Tube
c - Vent Hole
d - Fill/Drain Plug and Sealing Washer
Storage Preparations
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (stabi-
lized) fuel to help prevent formation of varnish and gum. Proceed with following instructions.
1. Portable Fuel Tank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow
instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with
the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline
Stabilizer (follow instructions on container) into a separate container and mix with ap-
proximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment for circulating cooling water.
Run the engine for ten minutes to allow treated fuel to fill the fuel system.
Protecting External Engine Components
1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control
anodes).
Page 1B-10 90-857138R1 MAY 2000

MAINTENANCE
Protecting Internal Engine Components

NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared for
storage.
1. Change the engine oil.
2. 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.
3. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line.
When engine begins to stall, quickly spray Quicksilver Storage Seal into carburetor until
engine stops from lack of fuel.
4. Remove the spark plugs and inject a five second spray of Quicksilver Storage Seal
around the inside of each cylinder.
5. Rotate the flywheel manually several times to distribute the storage seal in the cylinders.
Reinstall spark plugs.
Gear Case
Drain and refill the gear case lubricant (refer to maintenance procedure).
Positioning Outboard for Storage
1. Carry, transport or store the outboard only in these two positions. These positions will
prevent oil from draining out of the crankcase.
a. Upright
b. Tiller Side Down
2. Never carry, store or transport the outboard in these positions. Engine damage could
result from oil draining out of the crankcase.
CAUTION
If outboard is on a boat and is stored tilted up in freezing temperature, trapped cool-
ing water or rain water that may have entered the propeller exhaust outlet in the gear
case could freeze and cause damage to the outboard.
90-857138R1 MAY 2000 Page 1B-11

GENERAL INFORMATION
Section 1C - GENERAL INFORMATION C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7
Conditions Affecting Performance . . . . . . . . . . . . . . . 1C-2 Propeller Removal/Installation . . . . . . . . . . . . . . . . . . 1C-8
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Compression Check . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . . . . . . 1C-11
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Following Complete Submersion . . . . . . . . . . . . . . . . 1C-6 Painting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Submerged While Running . . . . . . . . . . . . . . . . . . 1C-6 Cleaning & Painting Aluminum Propellers &
Salt Water Submersion . . . . . . . . . . . . . . . . . . . . . . 1C-6 Gear Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Fresh Water Submersion . . . . . . . . . . . . . . . . . . . . 1C-6 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Instructions for “Wet” Application . . . . . . . . . . . . 1C-13
90-857138R1 MAY 2000 Page 1C-1

GENERAL INFORMATION
Serial Number Location

The Outboard serial number is located on the lower starboard side of the engine block. A
serial number is also located on the top side of the swivel bracket.
a
OGXXXXXX
19XX bb
XXXX
cc
e
dd
XX
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
Conditions Affecting Performance

Weather
Rated hp
Horsepower Loss
Due to Atmosphere
Conditions
Summer hp
Secondary Loss Due to
Propeller Becoming To
Large for Summer
Horsepower
RPM Drop Due

to Weather
ENGINE RPM Rated RPM
It is a known fact that weather conditions exert a profound effect on power output of internal
combustion engines. Therefore, established horsepower ratings refer to the power that the
engine will produce at its rated rpm under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards Or-
ganization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation
of horsepower from data obtained on the dynamometer, correcting all values to the power
that the engine will produce at sea level, at 30% relative humidity at 77° F (25° C) tempera-
ture and a barometric pressure of 29.61 inches of mercury.
Page 1C-2 90-857138R1 MAY 2000

GENERAL INFORMATION
Summer Conditions of high temperature, low barometric pressure and high humidity all
combine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as
much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.)
Nothing will regain this speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine--running on a hot,
humid summer day--may encounter a loss of as much as 14% of the horsepower it would
produce on a dry, brisk spring or fall day. The horsepower, that any internal combustion en-
gine produces, depends upon the density of the air that it consumes and, in turn, this density
is dependent upon the temperature of the air, its barometric pressure and water vapor (or
humidity) content.
Accompanying this weather-inspired loss of power is a second but more subtle loss. At rig-
ging time in early spring, the engine was equipped with a propeller that allowed the engine
to turn within its recommended rpm range at full throttle. With the coming of the summer
weather and the consequent drop in available horsepower, this propeller will, in effect, be-
come too large. Consequently, the engine operates at less than its recommended rpm.
Due to the horsepower/rpm characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss, how-
ever, can be regained by switching to a smaller pitch propeller that allows the engine to again
run at recommended rpm.
For boaters to realize optimum engine performance under changing weather conditions, it
is essential that the engine have the proper propeller to allow it to operate at or near the top
end of the recommended maximum rpm range at wide-open-throttle with a normal boat
load.
Not only does this allow the engine to develop full power, but equally important is the fact
that the engine also will be operating in an rpm range that discourages damaging detona-
tion. This, of course, enhances overall reliability and durability of the engine.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant ef-
fect on the boat’s performance, for example:
a. Shifting weight to the rear (stern).
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in choppy water.
(4.) Will increase the danger of the following - wave splashing into the boat when
coming off plane.
b. Shifting weight to the front (bow).
c. Adjusting tilt pin to achieve best performance and handling.
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer left and right (bow steer).
BOTTOM
For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water
and particularly straight and smooth in fore-and-aft direction.
90-857138R1 MAY 2000 Page 1C-3

GENERAL INFORMATION
1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the
side. When boat is planing, “hook” causes more lift on bottom near transom and allows
bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook”
frequently is caused by supporting boat too far ahead of transom while hauling on a
trailer or during storage.
2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is con-
vex in fore-and-aft direction when viewed from the side, and boat has strong tendency
to porpoise.
3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear
housing increase skin friction and cause speed loss. Clean surfaces when necessary.
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in additional
boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on
the gear case, from an irregularity in the propeller blade itself or from improper engine instal-
lation (too high). 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 contin-
ue, eventual blade failure (breakage) will occur.
Page 1C-4 90-857138R1 MAY 2000

GENERAL INFORMATION
Engine
DETONATION
Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It
can be otherwise described as a tin-like “rattling” or “plinking” sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug
has fired. Detonation creates severe shock waves in the engine, and these shock waves
often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings
or piston ring lands, piston pin and bearings.
A few of the most common causes of detonation in a marine 4-cycle application are as
follows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine rpm below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot - incorrect reach - cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
• Combustion chamber/piston deposits (result in higher compression ratio).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
51115
Damaged Piston Resulting from Detonation
90-857138R1 MAY 2000 Page 1C-5

GENERAL INFORMATION
Following Complete Submersion

Submerged While Running (Special Instructions)
When an engine is submerged while running, the possibility of internal engine damage is
greatly increased. If, after engine is recovered and with spark plugs removed, engine fails
to turn over freely when turning flywheel, the possibility of internal damage (bent connecting
rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled.
Salt Water Submersion (Special Instructions)
Due to the corrosive effect of salt water on internal engine components, complete disassem-
bly is necessary before any attempt is made to start the engine.
Fresh Water Submersion (Special Instructions)
1. Recover engine as quickly as possible.
2. Remove cowling.
3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt
to start engine if sand has entered powerhead, as powerhead will be severely damaged.
Disassemble powerhead if necessary to clean components.
4. Drain engine oil. Do not refill engine oil at this time.
5. Drain carburetor and clean fuel pump assembly.
6. Remove spark plug and get as much water as possible out of powerhead. Most water
can be eliminated by placing engine in a horizontal position (with spark plug holes down)
and rotating flywheel.
7. Pour alcohol into carburetor throat (alcohol will absorbed water). Again rotate flywheel.
8. Turn engine over and pour alcohol into spark plug opening and rotate flywheel.
9. Turn engine over (place spark plug openings down) and pour engine oil into throat of
carburetor while rotating flywheel to distribute oil throughout crankcase.
10. Again turn engine over and pour approximately one teaspoon of engine oil into spark
plug opening. Again rotate flywheel to distribute oil in cylinder.
11. Dry all wiring and electrical components using compressed air.
12. Reinstall spark plug.
13. Refill engine crankcase with fresh oil.
14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
15. 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.
Page 1C-6 90-857138R1 MAY 2000

GENERAL INFORMATION
Propeller Selection
For in-depth information on marine propellers and boat performance - written by marine en-
gineers - see your Authorized Dealer for the illustrated “What You Should Know About
Quicksilver Propellers...and Boat Performance Information” (Part No. 90-86144).
For best all around performance from your outboard/boat combination, select a propeller
that allows the engine to operate in the upper half of the recommended full throttle rpm range
with the boat normally loaded (refer to Specifications). This rpm range allows for better ac-
celeration while maintaining maximum boat speed.
If changing conditions cause the rpm to drop below the recommended range (such as warm-
er, more humid weather, operation at higher elevations, increased boat load or a dirty boat
bottom/gear case) a propeller change or cleaning may be required to maintain performance
and ensure the outboard’s durability.
Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a bal-
anced-steering condition (steering effort equal in both directions) without causing the pro-
peller to “break loose”.
Refer to “Quicksilver Accessory Guide” for a complete list of available propellers.
1. Select a propeller that will allow the engine to operate at or near the top of the recom-
mended full throttle rpm range (listed in “Specifications,” preceding) with a normal load.
Maximum engine speed (rpm) for propeller selection exists when boat speed is maxi-
mum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle,
should not be used in determining correct propeller.) Normally, there is a 150-350 rpm
change between propeller pitches.
2. If full throttle operation is below the recommended range, the propeller MUST BE
changed to one with a lower pitch to prevent loss of performance and possible engine
damage.
3. After initial propeller installation, the following common conditions may require that the
propeller 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.).
90-857138R1 MAY 2000 Page 1C-7

GENERAL INFORMATION
Propeller Removal/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 start-
ing and possible serious injury caused from being struck by a rotating propeller,
always shift outboard to neutral position and remove spark plug leads when you
are servicing the propeller
1. Remove the spark plug leads to prevent engine from starting.
2. Shift outboard to neutral position.

N
3. Straighten and remove cotter pin.
a - Cotter Pin
4. Place a block of wood between gear case and propeller to hold propeller and remove
propeller nut.
a - Block of Wood
b - Propeller Nut
Page 1C-8 90-857138R1 MAY 2000

GENERAL INFORMATION
5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed,
have the propeller removed by an authorized dealer.
a
a - Propeller
b - Propeller Nut
6. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubri-
cant with Teflon.
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller
shaft, especially in salt water, always apply a coat of the recommended lubricant to
the entire propeller shaft at the recommended maintenance intervals and also each
time the propeller is removed.
7. Install front thrust washer, propeller, rear thrust hub and propeller nut onto the shaft.
8. Place a block of wood between gear case and propeller to prevent rotation and tighten
propeller nut. Secure propeller nut to the shaft with cotter pin.
d
c
a
b
a - Front Thrust Washer
b - Propeller
c - Rear Thrust Hub
d - Propeller Nut
e - Cotter Pin
90-857138R1 MAY 2000 Page 1C-9

GENERAL INFORMATION
Compression Check
1. Remove spark plugs.
2. Install compression gauge in spark plug hole.
3. Hold throttle plate at W.O.T.
4. Crank the engine over until the compression reading peaks on the gauge. Record the
reading.
5. Check and record compression of cylinder. A reading below 36 psi might indicate a total
engine wear problem.
Maximum (psi)* Minimum (psi)*

50 36
*Compression listed above is with decompression assembly in operation.
Maximum (psi)* Minimum (psi)*

130 100
*Compression listed above is with decompression assembly not in operation. (Rocker arm
on exhaust side is removed)
6. Compression check is important because an engine with low compression cannot be
tuned successfully to give peak performance. It is essential, therefore, that improper
compression be corrected before proceeding with an engine tuneup.
7. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored
or scorched paint, visually inspect cylinder for scoring or other damage as outlined in
Section 4 “Powerhead.”
Page 1C-10 90-857138R1 MAY 2000

GENERAL INFORMATION
Cylinder Leakage Testing

NOTE: Cylinder leakage testing*, along with compression testing, can help the mechanic
pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine
cylinder. Refer to the manufactures tester instructions for proper testing procedures.
* Courtesy of Snap-On-Tools
Cylinder Leakage Tester (Snap-On-Tools MT324)

NOTE: Spark plug hole is a 12 mm diameter. Use Snap-On Tool MT26-18 adapter with valve
core removed.
Analysis
Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leak-
age. It is important only that cylinders have somewhat consistent reading between them.
Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger
percentage of cylinder leakage than smaller engines.
If excessive leakage is present, first check that the piston is at top dead center of it’s com-
pression stroke. Leakage will naturally occur if the exhaust or intake valve is open.
To determine the cause of high percentage leaks, you must locate where the air is escaping
from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust
pipe, crankcase fill plug. Use the following table to aid in locating the source of cylinder
leakage:
Indicates Possible
Air Escaping From:
Defective:
Carburetor Intake Valve
Exhaust System Exhaust Valve
Crankcase Fill Plug Piston or Rings
Cylinder Head Gasket
90-857138R1 MAY 2000 Page 1C-11

GENERAL INFORMATION
Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne par-
ticles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite,
disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover
or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Quicksilver’s Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Quicksilver’s EDP Propeller Black.
GEAR HOUSINGS
The following procedures should be used in refinishing gear housings. This procedure will
provide the most durable paint system available in the field. The materials recommended
are of high quality and approximate marine requirements. The following procedure will pro-
vide a repaint job that compares with a properly applied factory paint finish. It is recom-
mended that the listed materials be purchased from a local Ditzler Automotive Finish Supply
Outlet. The minimum package quantity of each material shown following is sufficient to refin-
ish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint
blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly
adhere to the surface nor will the coating be sufficiently thick to resist future paint
blistering.
6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufactur-
ers instructions, allowing proper induction period for permeation of the epoxy primer and
catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coating
assemblies.
8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and
DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four col-
ors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.
Page 1C-12 90-857138R1 MAY 2000

GENERAL INFORMATION
CAUTION
Be sure to comply with instructions on the label for ventilation and respirators. Us-
ing a spray gun, apply one half to one mil even film thickness. Let dry, flash off for
five minutes and apply another even coat of one half to one mil film thickness. This
urethane paint will dry to the touch in a matter of hours, but will remain sensitive
to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode.
10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to main-
tain good continuity circuitry between trim tab and gear housing.
Decal Application
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing
old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for “Wet” Application
NOTE: The following decal installation instructions are provided for a “Wet” installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia** “Joy” and “Drift” are known to be
compatible for this process.
** Automotive Body Filler Squeegee
** Do not use a soap that contains petroleum based
solvents.
SERVICE TIP: Placement of decals using the “Wet” application will allow time to posi-
tion decal. Read entire installation instructions on this technique before proceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun-
light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C)
for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean application
surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface thor-
oughly with clean water.
DECAL APPLICATION
1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as
wetting solution.
90-857138R1 MAY 2000 Page 1C-13

GENERAL INFORMATION
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal
installation. This will ensure that the vinyl decal keeps it’s shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing from
“adhesive side” of decal.
3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wet-
ting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position pre-wetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting
solution with overlapping strokes to the outer edge of the decal. Continue going over the
decal surface until all wrinkles are gone and adhesive bonds to the cowl surface.
7. Wipe decal surface with soft paper towel or cloth.
8. Wait 10 - 15 minutes.
9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at
a 180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with
stick pin and press out the entrapped air or wetting solution with your thumb (moving toward
the puncture).
Page 1C-14 90-857138R1 MAY 2000

OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation D
Table of Contents
Notice to Installer and Owner . . . . . . . . . . . . . . . . . . . 1D-2 Tilt Pin Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4
Boat Horsepower Capacity . . . . . . . . . . . . . . . . . . 1D-2 Setting The Operating Angle Of Your Outboard . 1D-4
Selecting Accessories For The Outboard . . . . . . 1D-2 Engine Over-Speed Protection System . . . . . . . . 1D-5
Installing Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6
Fastening Security Line . . . . . . . . . . . . . . . . . . . . . 1D-4
90-857138R1 MAY 2000 Page 1D-1

Notice to Installer and Owner

This manual as well as safety labels posted on the outboard use the following safety alerts
to draw your attention to special safety instructions that should be followed.
DANGER
DANGER – Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING – Hazards or unsafe practices which COULD result in severe personal injury
or death.
CAUTION
CAUTION – Hazards or unsafe practices which could result in minor injury or product or
property damage.
Boat Horsepower Capacity

U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
Do not overpower or overload your boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1.
cause loss of boat control 2. place too much weight at the transom altering the de-
signed flotation characteristics of the boat or 3. cause the boat to break apart partic-
ularly around the transom area. Overpowering a boat can result in serious injury,
death, or boat damage.
Selecting Accessories For The Outboard

Genuine Mercury Marine Quicksilver Accessories have been specifically designed and
tested for your outboard.
Mercury Marine Quicksilver accessories are available from Mercury Marine dealers.
Some accessories not manufactured or sold by Mercury Marine are not designed to be safe-
ly used with your outboard or outboard operating system. Acquire and read the installation,
operation, and maintenance manuals for all your selected accessories.
Page 1D-2 90-857138R1 MAY 2000

Installing Outboard
1. Measure the transom height of your boat. The boat bottom should be aligned or be within
1 in. (25 mm) above the anti-ventilation plate of the outboard.
1-2 in.
(25 - 50 mm)
a - Anti-Ventilation Plate
2. Place outboard on center line of transom.
3. Tighten transom clamp handles.
90-857138R1 MAY 2000 Page 1D-3

Fastening Security Line

WARNING
If the length of security line being used is long enough to allow the outboard to dis-
engage off the boat transom but is too short to not allow the outboard to submerge
behind the boat and stop running, the outboard could continue running and propel
itself back into the boat with the propeller rotating under power. This exposes the
occupants to serious injury or death.
The primary purpose for installing a security line is to prevent loss of the outboard if the out-
board becomes detached from the boat transom.
An effective security line should be of a working strength of at least five times the weight of
the outboard.
The security line should be attached between the boat and outboard following one of these
steps.
Step 1. The length of the security line should be short enough and affixed in a manner to
prevent the outboard from rising up and disengaging off the boat transom.
Step 2. The length of the security line should be long enough and affixed in a manner to per-
mit a detached outboard to submerge completely behind the boat and stop running but not
too short that could allow the outboard to continue running and propel itself back into the
boat.
Tilt Pin Adjustment

Setting The Operating Angle Of Your Outboard
1. The vertical operating angle of your outboard is adjusted by changing the position of the
tilt pin in the adjustment holes provided. Proper adjustment allows the boat to run stable,
achieve optimum performance, and minimize steering effort.
a
a - Tilt Pin
2. The tilt pin should be adjusted so the outboard is positioned to run perpendicular to the
water when the boat is running at full speed. This allows the boat to be driven parallel
to the water.
3. Arrange passengers and load in the boat so the weight is distributed evenly.
Page 1D-4 90-857138R1 MAY 2000

Engine Over-Speed Protection System

The system is activated if the engine speed should ever exceed the maximum allowable lim-
it. This will protect the engine from mechanical damage.
Anytime the engine over-speed system is activated, the system will automatically reduce
the engine speed to within the allowable limit. If engine over-speed continues, have the out-
board checked by your dealer.
NOTE: Your engine speed should never reach the maximum limit to activate the system un-
less the propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty.
RPM
90-857138R1 MAY 2000 Page 1D-5

Installation Drawings
a – 17-1/2 in. (444.5 mm)
b – 8-17/64 in. (209.9 mm)
c – 10-7/16 in. (265.1 mm)
d – 12-51/64 in. (325 mm)
75° e – 12-63/64 in. (329.8 mm)
f – 14-11/64 in. (360 mm)
a g – 13-49/64 in. (349.7 mm)
h – 19-3/32 in. (485 mm)
i – 14-3/8 in. (365.1 mm)
j – 11-5/8 in. (295.3 mm)
k – 4-5/16 in. (109.5 mm)
l – 2-1/16 in. (52.4mm)
b m – Short – 17-1/8 in. (435 mm)
c Long – 22-1/8 in. (562 mm)
Ultra Long – 27-1/8 in. (689 mm)
n – Short – 25-3/4 in. (654.1 mm)
Long – 30-3/4 in. (781.1 mm)
Ultra Long – 35-3/4 in. (908.1 mm)
o – 4-45/64 in. (119.5 mm)
p – 8-17/64 in. (209.9 mm)
e q – Short – 25-5/8 in. (650.9 mm)
Long – 29-9/16 in. (750.9 mm)
g f Ultra Long – 33-1/2 in. (850.9 mm)
h 145° d
i
j
m
l
n
75°
o
12°
p
q
Page 1D-6 90-857138R1 MAY 2000

IGNITION SYSTEM
ELECTRICAL
Section 2A - Ignition System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 2
Direct Voltage Adaptor Specifications . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2A-1
2A-2
CDI Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11
Ignition Components Removal and
A
Electrical Components . . . . . . . . . . . . . . . . . . . . . 2A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Capacitor Charging Coil . . . . . . . . . . . . . . . . 2A-17
Direct Voltage Adaptor Specifications . . . . . 2A-6 Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-18
Capacitor Charging Coil . . . . . . . . . . . . . . . . . 2A-6 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-19
Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 CDI Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-20
Specifications
Spark Plug:
Type NGK DCPR6E
Gap 0.035 in. (0.9 mm)
Torque 13 lb-ft (17.5 N·m)
Firing Order 1
IGNITION
SYSTEM
Readings taken @
68°F (20°C).
Primary 0.02 - 0.38 Ω
Secondary (w/o Boots) 3000 - 4400 Ω
Engine Speed Limiter 6300 ± 200 RPM
(24.5 ± 5 kPa) @ 68°F (20°C)
Direct Voltage Adaptor Specifications
Selector Switch DVA Leads

Test Volts @ 300-2000 RPM
Position Red Black
Black/Yellow
Ignition Coil PRI 400 VDC Ground 120-300
Lead
Black/Red
Charge Coil 400 VDC Ground 150-325
Lead
Stop Circuit 400 VDC Brown Lead Ground 175-300
90-857138R1 MAY 2000 Page 2A-1

IGNITION SYSTEM
Special Tools
1. Strap Wrench (91-24937A1)
2. Spark Gap Tester (91-63998A1)
3. Magneto Analyzer Model 9800 (91-76032)
Page 2A-2 90-857138R1 MAY 2000

IGNITION SYSTEM
4. Flywheel Puller (91-83164M)
5. Multi-Meter/DVA Tester (91-99750) or DMT 2000 Digital Tachometer/Multi-Meter

(91-854009A1)
a b
a - Multi-Meter/DVA Tester 91-99750

b - DMT 2000 Digital Tachometer/Multi-Meter 91-854009A1
6. Flywheel Holder/Puller (91-804552)
57518
90-857138R1 MAY 2000 Page 2A-3

IGNITION SYSTEM
Electrical Components
1
2
7
5
4 6
22
21
20
10
18
13 11
15
19
12
17 16 14
Page 2A-4 90-857138R1 MAY 2000

IGNITION SYSTEM
Electrical Components
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in. lb-ft Nm
1 1 NUT 40 54
2 1 WASHER
3 1 FLYWHEEL
4 1 CLAMP
5 1 SCREW Drive Tight
6 1 EXCITER COIL
7 2 SCREW 14 1.5
8 1 IGNITION COIL
9 1 BOOT
10 2 BOLT (M6 x 20mm) 70 8
11 1 REAR DAMPER
1 CD UNIT (4/5 H.P.)
12
1 CD UNIT (6 H.P.)
13 1 FRONT DAMPER
14 1 SLEEVE
15 1 CLAMP
17 1 WARNING LAMP
18 1 STOP SWITCH
19 1 LANYARD
20 1 GROMMET
21 1 PULSER COIL
90-857138R1 MAY 2000 Page 2A-5

IGNITION SYSTEM
Description
A single cylinder capacitor discharge ignition (CDI) system is utilized on this model. Major
components of this system are the flywheel/magneto, capacitor charging coil, CDI unit, igni-
tion coil and a spark plug. A stop switch is provided which shorts the trigger coil to ground
preventing ignition from taking place.
Test Procedures
IMPORTANT: When using an ohmmeter for any resistance test, always zero meter
movement whenever scales are changed.
IMPORTANT: If engine misfires, runs rough or does not start, the ignition system
should be checked with a volt meter capable of measuring 400 VDC or higher and di-
rect voltage adaptor (91-89045) or multi-meter/DVA tester (91-99750). Follow instruc-
tions in test manual included with DVA or multi-meter DVA tester.
Direct Voltage Adaptor Specifications
Selector Switch DVA Leads

Test Volts (1) @ 300-2000 RPM
Position Red Black
Black/Yellow
Ignition Coil PRI 400 VDC Ground 120-300
Lead
Black/Red
Charge Coil 400 VDC Ground 150-325
Lead
Stop Circuit 400 VDC Brown Lead Ground 175-300
(1) Reading at cranking and/or idle speed.
IMPORTANT: If DVA or Multi-Meter/DVA Tester is not available, alternate tests can be
performed using an ohmmeter and a Models 9800 Merc-o-tronic Magneto Analyzer
(91-76032), as follows.
Capacitor Charging Coil
CAUTION
DO NOT rotate flywheel during test or damage to meter may result.
1. Use an ohmmeter to perform the following test.
95-143Ω
2. If meter readings are other than specified, replace capacitor charging coil. Refer to “Igni-
tion Components Removal and Installation,” following.
Page 2A-6 90-857138R1 MAY 2000

IGNITION SYSTEM
Trigger Coil
CAUTION
149-223Ω
2. If meter readings are other than specified, replace trigger coil. Refer to “Ignition Compo-
nents Removal and Installation,” following.
Ignition Coil
A. SPARK TEST
1. Install spark gap tester (91-63998A1) between high tension spark plug lead and engine
ground.
56274
2. Crank engine over using starter rope. Spark should occur at tester.
3. If test yields no spark, or engine will not run properly, proceed to tests B thru E.
90-857138R1 MAY 2000 Page 2A-7

IGNITION SYSTEM
B. RESISTANCE TEST
1. Use an ohmmeter to perform the following primary winding test.
0.02-0.38Ω
2. Use an ohmmeter to perform the following secondary winding test.

NOTE: High tension cables must have spark plug cap removed before testing. Cap contains
5k ohm resistor.
IMPORTANT: To remove spark plug cap from high tension leads, turn cap counter-
clockwise while applying slight outward pressure. DO NOT PULL HARD or lead may
be damaged. To install cap, turn cap clockwise threading cap onto high tension lead.
55852
Page 2A-8 90-857138R1 MAY 2000

IGNITION SYSTEM
3500 - 5200Ω
55853
3000-4400Ω
3. If meter readings are other than specified, replace ignition coil. Refer to “Ignition Compo-
nent Removal Installation,” following.
90-857138R1 MAY 2000 Page 2A-9

IGNITION SYSTEM
C. POWER TEST - OPTIONAL

IMPORTANT: A model 9800 Merc-o-tronic Magneto Analyzer (91-76032) with coil se-
lector switch set on “CDI” must be used for test C thru E.
1. Connect magneto analyzer test leads to ignition coil.
a - Black Analyzer Test Leads - Connected to Ignition Coil Ground

b - Red Analyzer Test Lead - Connected to Spade Connector of Ignition Coil
c - Large Red Analyzer Test Lead - Connected to High Tension Spark Plug Lead
(Wire Spring Inside Spark Plug Boot)
2. Turn “Hi-Lo” current control knob all the way left past “Lo” position.
3. Set analyzer to position 1 “Coil Power Test.”
4. Slowly turn current control knob clockwise while noting current value on scale 1.
5. When current value reaches 1.7 to 2.1 amperes, stop turning current control knob and
note 5 mm spark gap; it should be firing steadily.
6. If spark is faint, intermittent or no spark occurs at 2.1 amperes, replace ignition coil.
7. If ignition coil checks out OK, proceed to Test D “High Speed Test.”
D. HIGH SPEED TEST - OPTIONAL
CAUTION
This test must be completed as quickly as possible and immediately upon comple-
tion, turn the “Hi-Lo” knob fully counterclockwise and put selector switch in “off”
position.
1. Turn current control knob clockwise for maximum reading on meter scale 1. Do not ex-
ceed meter range (4 amps).
2. The 5mm spark gap should be firing constantly.
3. If spark is faint, intermittent or no spark occurs, the ignition coil is defective at high speed
and must be replaced.
4. Turn current control knob fully counterclockwise and put selector switch to “off.”
5. If ignition coil checks out OK, proceed to Test E “Surface Insulation Test.”
Page 2A-10 90-857138R1 MAY 2000

IGNITION SYSTEM
E. SURFACE INSULATION TEST - OPTIONAL
CAUTION
Complete this test as rapidly as possible, as it is a severe test on the coil.
1. Remove large red test lead from high tension spark plug lead.
2. Plug insulation test probe into “Probe Test” jack on analyzer.
3. Set analyzer to position 1. “Coil Power Test.”
4. Turn “Hi-Lo” current control knob to “Hi” position but DO NOT exceed meter range (4
amps).
IMPORTANT: DO NOT allow test probe to linger too long at any one point.
5. Pass insulation test probe over insulating surfaces of the ignition coil and high tension
leads.
6. If coil or high tension lead insulation is cracked, leaking or damaged, a steady spark dis-
charge will occur between the cracked or leaking surface and the test probe.
NOTE: A faint spark does not indicate damaged coil.
7. Turn current control knob fully counterclockwise and put selector switch in “off” position.
8. Replace ignition coil and leads if any surface is damaged.
CDI Unit
IMPORTANT: The CDI unit can only be tested satisfactorily using a volt meter (capa-
ble of measuring 400 volts DC or higher) and Direct Voltage Adaptor (91-99045), or
Multi-Meter/DVA Tester (91-99750). Follow instructions in test manual included with
DVA or Multi-Meter/DVA Tester.
Test Selector Switch DVA Leads Volts (1)
Position @ 300 - 2000 RPM
RED BLACK
Ign. Coil Primary 400 VDC Ground BLACK/YELLOW 120 - 300
Charge Coil 400 VDC BLACK/RED Ground 150 - 325
Stop Circuit 400 VDC BROWN Ground 175 - 300
NOTE: 2000 model year outboards have model name stamped on surface top, Indicating
outer tube color, rev. limit (rpm), and ignition timing.
a - Model Name
b - Outer Tube
Model Name Outer Tube Color Rev. Limit (rpm) Ignition Timing
CU2526 BLACK 5900 BTDC 5 - 25
CU2564 GRAY 5900 BTDC 25
CU2568 BLUE 6300 BTDC 25
90-857138R1 MAY 2000 Page 2A-11

IGNITION SYSTEM
Ignition Components Removal and Installation

Flywheel
NOTE: Flywheel assembly may be removed through the use of a Strap Wrench
(91-24937A1) or Flywheel Holder/Puller (91-804552)
REMOVAL – STRAP WRENCH METHOD

1. Remove rewind starter. Refer to Section 8.
CAUTION
Do not strike flywheel with a hard object, as flywheel damage could occur.
WARNING
Engine could possibly start when turning flywheel during removal and installation;
therefore, disconnect spark plug lead to prevent engine from starting.
1. Use strap wrench to hold starter pulley. Loosen flywheel nut until nut is flush with end
of crankshaft.
2. Remove three bolts and starter pulley.
.
b d
c
a
57523
56278
91-24937A1
a - Strap Wrench
b - Starter Pulley
c - Flywheel Nut
d - Bolts (3)
e - Starter Pulley
Page 2A-12 90-857138R1 MAY 2000

IGNITION SYSTEM
3. Use puller to pull flywheel.

4. Remove puller, flywheel nut, washer, flywheel and key.
91-83164M 57524
a - Puller
INSTALLATION
1. Install flywheel key.
2. Install flywheel, washer and nut onto end of crankshaft.
d
b
a
56280 57522
a - Flywheel Key
b - Flywheel
c - Washer
d - Nut
90-857138R1 MAY 2000 Page 2A-13

IGNITION SYSTEM
INSTALLATION – Continued
1. Install starter pulley and three bolts and lockwashers. Torque to 70 lb-in. (8 Nm).
2. Hold starter pulley with strap wrench. Torque nut to 40 lb-ft (54.0 Nm).
b
c e
d
56278 57523
91-24937A1
a - Starter Pulley
b - Bolts/Lockwashers (3)
c - Starter Pulley
d - Strap Wrench
e - Nut
3. Reinstall rewind starter and start-in-gear protection link rod, as outlined in Section 8
“Rewind Starter”.
REMOVAL – FLYWHEEL HOLDER/PULLER METHOD

1. Remove rewind starter. Refer to Section 8.
2. Remove three bolts and starter pulley.
a
56278
a - Bolts (3)
b - Starter Pulley
Page 2A-14 90-857138R1 MAY 2000

IGNITION SYSTEM
3. Secure flywheel holder to flywheel with 3 bolts. Loosen flywheel nut until nut is flush with
end of crankshaft. Do not remove nut at this time.
a
91-804552
57521
a - Flywheel Holder
b - Bolts (3)
4. Thread flywheel puller into flywheel holder. While holding flywheel, tighten puller against
crankshaft until flywheel loosens. Remove flywheel holder/puller. Remove flywheel nut.
Remove flywheel.
57519
a - Flywheel Puller
90-857138R1 MAY 2000 Page 2A-15

IGNITION SYSTEM
INSTALLATION
1. Install flywheel key.
2. Install flywheel, washer and nut onto end of crankshaft.
d b
56280 57522
a - Flywheel Key
b - Flywheel
c - Washer
d - Nut
3. Secure flywheel holder to flywheel with 3 bolts.

4. Torque flywheel nut to 40 lb-ft (54.0 Nm)
57520
a - Flywheel Holder
b - Bolts (3)
Page 2A-16 90-857138R1 MAY 2000

IGNITION SYSTEM
Capacitor Charging Coil

REMOVAL
1. Remove flywheel. Refer to “Flywheel” - “Removal” preceding.
2. Remove screw and clamp.
3. Disconnect BLACK/RED and WHITE coil leads from CDI unit leads.
4. Remove screws securing capacitor charging coil, then remove coil.
d c
a b
56284
a - Screw c - Screws (2)

b - Clamp d - Capacitor Charging Coil
INSTALLATION
1. Route capacitor charging coil leads, as shown and place coil over mounting bosses of
crankcase cover.
2. Secure coil with 2 screws. Torque screws to 14 lb-in. (1.6 Nm).
3. Secure coil leads/sleeve, using wire clamp and screw. Tighten screw securely.
4. Connect BLACK/RED and WHITE capacitor charging coil leads to CDI unit leads.
b c
a
e b
56285
a - Coil Leads d - Wire Clamp

b - Coil e - Screw
c - Screws (2)
5. Reinstall flywheel, as outlined in “Flywheel” - “Installation,” preceding.
90-857138R1 MAY 2000 Page 2A-17

IGNITION SYSTEM
Trigger Coil
REMOVAL
1. Disconnect RED/WHITE coil lead from CDI unit.
2. Remove 2 screws and pull trigger coil from housing.
56286
a - Screws (2)
b - Trigger Coil
INSTALLATION
1. Route coil leads through rubber grommet and connect RED/WHITE coil lead to CDI unit
lead.
2. Secure trigger coil using screws. Make sure to attach ground wire under screw as
shown.
d
b
a
56286
a - Rubber Grommet
b - Trigger Coil
c - Screws (2)
d - Ground Wire
Page 2A-18 90-857138R1 MAY 2000

IGNITION SYSTEM
Ignition Coil
REMOVAL
1. Disconnect BLACK/YELLOW CDI unit lead from coil.
2. Disconnect high tension plug lead from spark plug.
3. Remove bolts, and washers and remove coil while disconnecting BLACK ground wires.
d
e a
57522
a - BLACK/YELLOW CDI Lead

b - Coil
c - Bolts (2)
d - Washers (2)
e - BLACK Ground Wires
INSTALLATION
1. Secure ignition coil using bolts and washers. Torque bolts to 70 lb-in. (8 Nm). Make sure
to connect BLACK ground wires as shown.
2. Reconnect BLACK/YELLOW CDI unit lead to ignition coil.
d c
e
57522
a - Coil
b - Bolts (2)
c - Washers (2)
d - BLACK Ground Wires
e - BLACK/YELLOW CDI Lead
90-857138R1 MAY 2000 Page 2A-19

IGNITION SYSTEM
CDI Unit
REMOVAL
1. Disconnect 4 CDI unit lead bullet connectors, BLACK/YELLOW CDI unit lead at ignition
coil and BLACK CDI unit ground lead from ignition coil mounting bolt.
2. Slide CDI unit out of rubber brackets.
e e d
c b
a
57522
a - Bullet Connectors
b - BLACK/YELLOW CDI Lead
c - BLACK CDI Ground Lead
d - CDI Unit
e - Rubber Brackets
INSTALLATION
1. Slide CDI unit into rubber brackets.
2. Connect 4 CDI unit lead bullet connectors, BLACK/YELLOW CDI unit lead to ignition
coil and BLACK CDI unit ground lead under ignition coil mounting bolt.
Page 2A-20 90-857138R1 MAY 2000

CHARGING SYSTEM
ELECTRICAL
Section 2B - Charging System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
2B-2
2B-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier (Battery Charging) . . . . . . . . . . . . . . . . .
2B-4
2B-5
B
Lighting Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Rectifier Diode Test (Optional) . . . . . . . . . . . 2B-3 Battery Connections . . . . . . . . . . . . . . . . . . . . 2B-7
Lighting Coil Removal and Installation . . . . . . . 2B-4 Special Operating Instructions . . . . . . . . . . . 2B-7
Specifications
Alternator (Optional) Type:
CHARGING Lighting Coil 12 Volt 60 Watt
SYSTEM (Non Regulated Lighting Coil)
Readings taken @ Lighting Coil Resistance 0.31 - 0.47 Ω (YEL/RED - YEL/RED)
68°F (20°C). Battery Charging Rectifier (Optional) 5 Amperes (Rectified)
90-857138R1 MAY 2000 Page 2B-1

CHARGING SYSTEM
Special Tools
1. Multi-Meter/DVA Tester (91-99750)
2. DMT 2000 Digital Tachometer/Multi-meter (91-854009A1)
Page 2B-2 90-857138R1 MAY 2000

CHARGING SYSTEM
Test Procedures
IMPORTANT: When using an ohmmeter for any resistance test, always zero meter
movement whenever scales are changed.
Lighting Coil
CAUTION
0.31 - 0.47 Ω
YEL/RED
YEL/RED
2. If meter readings are other than specified, replace lighting coil. Refer to “Ignition Compo-
nents Removal and Installation,” following.
Rectifier Diode Test (Optional)
CONTINUITY TEST
1. Connect ohmmeter between YEL and RED rectifier leads (note reading), then reverse
test leads. Continuity should be found in only one direction.
2. Replace rectifier if reading are the same for both tests.
RED
YEL
90-857138R1 MAY 2000 Page 2B-3

CHARGING SYSTEM
Lighting Coil Removal and Installation

Removal
1. Remove manual starter. Refer to Section 8.
2. Remove flywheel. Refer to Section 2A.
3. Remove screw and clamp.
4. Disconnect both YELLOW/RED coil leads.
5. Remove screws securing lighting coil, then remove coil.
c
b
a 56284
a - Screw c - Screws (2)

b - Clamp d - Lighting Coil
Installation
1. Route lighting coil leads, as shown and place coil over mounting bosses of crankcase
cover.
2. Secure coil with 2 screws. Torque screws to 14 lb-in. (1.6 Nm).
3. Secure coil leads/sleeve, using wire clamp and screw. Tighten screw securely.
4. Connect both YELLOW/RED lighting coil leads to rectifier or lighting harness.
c
d
a
e
56285
a - Lighting Coil Leads d - Wire Clamp

b - Coil e - Screw
c - Screws (2)
5. Install flywheel. Refer to Section 2A.
6. Install manual starter. Refer to Section 8.
Page 2B-4 90-857138R1 MAY 2000

CHARGING SYSTEM
Rectifier (Battery Charging)

Installation
1. This rectifier kit provides DC current for battery charging, and must be installed in con-
junction with Alternator Kit.
2. Secure rectifier to crankcase cover, as shown.
b
c
d
a
e
57352 57353
a - Threaded Boss
b - Alternator Leads
c - Rectifier
d - Screw and Lockwasher
e - Clamp
f - Fuse Holder
90-857138R1 MAY 2000 Page 2B-5

CHARGING SYSTEM
3. Remove and discard rubber plug from bottom cowl.

4. Refer to Wiring Diagram “A” and route extension harness thru opening in bottom cowl.
c
a b
57354 57355
a - Plug
b - Harness
c - Clamp (existing)
d - Grommet (provided)
5. Push rubber grommet of extension harness, into opening in bottom cowl.
57356
a - Rubber Grommet
Page 2B-6 90-857138R1 MAY 2000

CHARGING SYSTEM
6. Make all wiring connections, as shown in wiring diagram “A”.
a
b
e
WIRING DIAGRAM “A” Rectifier Kit Installation

a - Alternator Kit (16837A2)
b - Rectifier
c - Fuse Holder with 10 Amp Fuse
d - Extension Harness - 22 in. (56 cm) Long
e - Battery Harness - 69 in. (175 cm) Long
f - Battery
Battery Connections
CAUTION
Failure to observe correct polarity when connecting battery harness leads to bat-
tery, will result in damage to the charging system.
House battery in a battery box and secure in a favorable position in boat.
Connect red battery harness lead to positive (+) battery terminal and black battery harness
lead to negative (–) battery terminal.
Special Operating Instructions
CAUTION
Disconnect both (2) yellow/red alternator leads (refer to Wiring Diagram “A”) before
operating outboard motor without battery harness leads connected to battery.
90-857138R1 MAY 2000 Page 2B-7

TIMING AND SYNCHRONIZATION
ELECTRICAL
Section 2C - Timing and Synchronization
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 TDC Timing Mark Alignment . . . . . . . . . . . . . 2C-3 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Check Timing . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 C
Specifications
Spark Plug:
Type NGK DCPR6E
Gap 0.035 in. (0.9 mm)
Torque 13 lb-ft (17.5 Nm)
Firing Order 1
IGNITION
SYSTEM
Readings taken @
68°F (20°C).
Primary 0.02 - 0.38 Ω
Secondary (W/o Boots) 3000 - 4400 Ω
Engine Speed Limiter 6300 ± 200 rpm
(24.5 ± 5 kPa) @ 68°F (20°C)
90-857138R1 MAY 2000 Page 2C-1

Special Tools
1. Dial Indicator Gauge Kit (91-58222A1)
2. Dial Indicator Adaptor Kit (91-83155)
3. Timing Light (91-99379)
Page 2C-2 90-857138R1 MAY 2000

4. Multi-Meter/DVA Tester (91-99750)
5. DMT 2000 Digital Tachometer/Multi-Meter (91-854009A1)
90-857138R1 MAY 2000 Page 2C-3

Ignition Timing
TDC Timing Mark Alignment
IMPORTANT: As this ignition system is fixed, no adjustment to ignition timing is pos-
sible. If ignition timing is not within specifications, refer to “Test Procedures” follow-
ing to locate faulty component(s).
1. Remove spark plug.
2. Install dial indicator through spark plug opening in cylinder head.
91-58222A1
57254 91-83155
3. Rotate flywheel to bring piston to TDC position. Check that crankcase cover/cylinder
block TDC mark is aligned with timing mark on flywheel.
a - TDC Mark
b - Timing Mark
IMPORTANT: If timing mark on flywheel is not in alignment with crankcase cover/cyl-
inder block TDC mark, check for (and correct) one or more of the following possible
causes:
a. Dial indicator has been improperly set up or misread.
b. Flywheel key is sheared.
c. Flywheel is installed incorrectly.
4. Remove dial indicator and adaptors.
5. Install spark plug and connect high tension spark plug lead.
Page 2C-4 90-857138R1 MAY 2000

Check Timing
1. Connect timing light (91-99379) to engine.
2. Start engine and allow it to warm up to normal operating temperature.
3. Throttle engine back to idle and shift into “Forward” gear.
4. With engine idling in “Forward” gear, use timing light and check flywheel timing mark
alignment. Idle timing should be 25° B.T.D.C.
5. With engine in “Forward” gear, fully advance throttle to W.O.T. position. Use timing light
and check that timing mark of flywheel maintains alignment with crankcase cover/cylin-
der block 25° B.T.D.C. timing mark.
a - 25° B.T.D.C.
b - Timing Mark of Flywheel
90-857138R1 MAY 2000 Page 2C-5

WIRING DIAGRAM
ELECTRICAL
Section 2D - Wiring Diagram
Table of Contents
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
2
D
90-857138R1 MAY 2000 Page 2D-1

WIRING DIAGRAM
Wiring Diagram
j BLK = Black
RED RED BLU = Blue
BRN = Brown
YEL YEL GRY = Gray
GRN = Green
k ORN = Orange
YEL PNK = Pink
+ – YEL
c i PUR = Purple
RED = Red
TAN = Tan
WHT = White
BLK
l YEL = Yellow
h LIGHT - GRN
YEL -RED
YEL -RED
BLK
BLK-YEL
BLK
g d
RED – WHT RED – WHT
BLK
BRN BRN
BLK – RED BLK – RED
WHT WHT WHT
LIGHT - GRN LIGHt – GRN
f
BLK
e RED – WHT
WHT
BLK – RED
BRN
BLK-YEL
a - Crank Position Sensor g - Stop Switch

b - Ignition Charge Coil h - Lighting Coil (Optional)
c - Oil Pressure Switch i - Rectifier (Optional)
d - Ignition Coil j - Fuse –10 Amp (Optional)
e - CDI Unit k - Battery
f - Oil Lamp l - Light Extension Harness (Optional)
Page 2D-2 90-857138R1 MAY 2000

FUEL PUMP & INTREGAL FUEL TANK
FUEL SYSTEM
Section 3A - Fuel Pump & Integral Fuel Tank
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Fuel Pump Disassembly . . . . . . . . . . . . . . . . . . . 3A-5
Quicksilver Lubricants and Service Aids . . . . . . 3A-1 Fuel Pump Reassembly . . . . . . . . . . . . . . . . . . . . 3A-7
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Integral Fuel Tank (4 HP Models Only) . . . . . . . 3A-9
Fuel Pump Removal and Installation . . . . . . . . . 3A-4
3
Specifications A
Fuel Pump Type External (Plunger/Diaphragm)

Fuel Pump:
FUEL Pressure 2.5 - 5.0 psi (17 - 35 kPa)
SYSTEM Plunger Stroke 0.059 in. (1.5 mm)
Diaphragm Stroke 0.059 in. (1.5 mm)
Fuel Tank Capacity 3.2 US Gallons
Quicksilver Lubricants and Service Aids

Part No. Description
92-828000A12 4-Cycle Outboard Oil
WARNING
FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO
SMOKING. Before servicing any part of the fuel system, disconnect electrical sys-
tem at the battery. Drain the fuel system completely. Use an approved container to
collect and store fuel. Wipe up any spillage immediately. Materials used to contain
spillage must be disposed of in an approved receptacle. Any fuel system service
must be performed in a well ventilated area.
FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EX-
PLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH.
Careful periodic inspection of the entire fuel system is mandatory, particularly after
engine storage. All fuel components, including fuel tanks, whether plastic, metal,
or fiberglass, fuel lines, primer bulbs, fittings, swelling, and must be inspected for
corrosion. Any sign of leakage or deterioration necessitates replacement before
further engine operation.
90-857138R1 MAY 2000 Page 3A-1

Fuel Pump
15
1 2
3
4 19
5 10
6
7
8
9 11
12
16 13
14
17
18
Page 3A-2 90-857138R1 MAY 2000

Fuel Pump
TORQUE
REF.
REF
1 1 PUMP COVER
2 1 STOP - CHECK VALVE (CLEAR PLASTIC)
3 1 CHECK VALVE
4 1 PLATE
5 2 SCREW
6 1 GASKET
7 1 DIAPHRAGM
8 1 SPRING
9 1 PUMP BODY
10 4 SCREW (M3x5)
11 1 SPRING
12 1 PLUNGER
13 1 O-RING SEAL
14 AR HOSE CLAMP
15 1 OUTLET HOSE
16 1 INLET HOSE
17 2 FILTER
18 1 FUEL CONNECTOR
19 2 SCREW 70 8
90-857138R1 MAY 2000 Page 3A-3

Fuel Pump Removal and Installation

REMOVAL
1. Remove the fuel hoses from the fuel pump.
2. Remove the two mounting screws and remove the fuel pump.
INSTALLATION
1. Place O-ring seal on the back side of the fuel pump and install the pump. Tighten screws
to the specified torque.
2. Reconnect the fuel hoses and secure fuel hoses with hose clamps.
Fuel Pump Mounting Screws

70 lb-in. (8 Nm)
e
f Back View
ÅÅ
ÅÅ
ÅÅ
e
d
b
110
a
110 4-Stroke Outboard Oil (92-828000A12)
a - Fuel Pump
b - O-Ring
c - Outlet Fuel Hose
d - Inlet Fuel Hose
e - Hose Clamps (2)
f - Screws (2) M6 x 25 mm
Page 3A-4 90-857138R1 MAY 2000

Fuel Pump Disassembly

1. Remove screws and separate the pump cover from the pump body.
c
a - Pump Cover
b - Gasket
c - Pump Body
d - Screw (4)
2. Remove diaphragm by pushing in the plunger while turning the diaphragm 90° clock-
wise or counterclockwise.
f
a
c
d
e
a - Diaphragm
b - Spring
c - Pump Body
d - Spring
e - Plunger
f - Unlock Diaphragm - Rotate 90°
90-857138R1 MAY 2000 Page 3A-5

3. Remove screws and plate from pump cover to inspect check valve.
a
b
c
d
a - Stop - Check Valve (Clear Plastic)

b - Check Valve
c - Plate
d - Screw (2)
4. Inspect check valve, gasket, and diaphragm. Replace if damaged.

5. Replace plunger if tip is worn or grooved.
d
a b c
a - Check Valve
b - Diaphragm
c - Gasket
d - Plunger Tip
Page 3A-6 90-857138R1 MAY 2000

Fuel Pump Reassembly

1. Align the recess in the stop, check valve and plate with the projection on the pump cover.
b
d
c
a
a - Check Valve
b - Plate
c - Align Recess On Back Side of Plate With Projection
d - Screws (2)
2. Align the slot in the plunger with the projection in the pump body.
3. Assemble the plunger, springs and diaphragm to the pump body.
4. Lock the diaphragm in place by setting the foot of the diaphragm into the plunger slot
and rotating the diaphragm 90°.
a
b
c
d
e
a - Diaphragm
b - Spring
c - Pump Base
d - Spring
e - Plunger
f - Lock Diaphragm - Rotate 90°
90-857138R1 MAY 2000 Page 3A-7

5. Install the pump body to the pump cover with four screws.
b
c
a - Pump Cover
b - Gasket
c - Pump Body
d - Screws (4)
Page 3A-8 90-857138R1 MAY 2000

Integral Fuel Tank (4 HP Models Only)

Disassembly/Assembly
1. Turn fuel cock knob to off position.
2. Disconnect fuel hose from fuel cock.
3. Remove nuts, washers, rubber mounts, spacers and screws and lift fuel tank from it’s
mounts.
4. Empty any remaining fuel from tank into a suitable container.
Cleaning/Inspection
1. Flush fuel tank with clean fuel.
2. Inspect fuel tank, and fuel cock for signs of leakage or damage. Replace components
as necessary.
3. Inspect fuel filter screen on fuel cock for sediment build-up. Clean dirty screen with sol-
vent or replace fuel cock if screen is damaged.
4. Replace in-line fuel filters if dirty.
5. Replace fuel tank cap, sealing ring, or gasket if damaged.
90-857138R1 MAY 2000 Page 3A-9

INTEGRAL FUEL TANK (4 HP MODELS ONLY)

2
3
5
6
4
7
8
5
6
9
7
6 10
8
37 11
38
17
1
17
16
12
6
7
17 13 35
34 18
7
17
36
17 14 13
15 19
20
33 17
17 17
21
32 24 17
23
17
22 25
17
26
17
17
28
31 27
30
29
Page 3A-10 90-857138R1 MAY 2000

INTEGRAL FUEL TANK (4 HP MODELS ONLY)

REF
REF.
NO. QTY. DESCRIPTION
1 FUEL TANK
1
1 FUEL TANK (BODENSEE)
1 FUEL CAP
2
1 FUEL CAP (BODENSEE)
3 1 GASKET
4 1 SEAL
5 2 SCREW
6 4 WASHER
7 5 RUBBER MOUNT
8 2 SPACER
9 1 BOLT
10 1 SCREW
11 1 CLAMP
12 1 RUBBER MOUNT
13 2 NUT
14 1 BRACKET
15 1 BRACKET
16 1 TUBING (9-7/8 IN.)
17 14 CLIP
18 1 TUBING (14 IN.)
19 1 FUEL COCK
20 2 SCREW
21 1 TUBING (1-3/8 IN.)
22 1 TUBING (8-1/2 IN.)
23 1 TEE FITTING
24 1 TUBING (5-1/4 IN.)
25 2 STA STRAP
26 1 CONNECTOR
27 1 HOSE (1-3/4 IN.)
28 1 FUEL CONNECTOR
29 1 BOLT
30 1 WASHER
31 1 PROTECTOR
32 1 FUEL FILTER
33 1 HOSE (7-1/8 IN.)
34 1 SLEEVE
35 1 BOLT (M6x45) (4 HP)
1 BOLT (M6x40) (5/6 HP)
36 1 BOLT (M6x30) (4 HP)
1 BOLT (M6x25) (5/6 HP)
37 1 PLATE
38 1 SPACER
90-857138R1 MAY 2000 Page 3A-11

CARBURETOR
FUEL SYSTEM
Section 3B - Carburetor
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Carburetor Removal and Installation . . . . . . . . . 3B-7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Carburetor Disassembly . . . . . . . . . . . . . . . . . . . . 3B-8
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . . 3B-6 Carburetor Reassembly . . . . . . . . . . . . . . . . . . . 3B-10
3
Specifications B
Idle rpm (Out Of Gear) 1300 ± 50 rpm

Idle rpm (In Forward Gear) 1100 ± 50 rpm
Wide Open Throttle rpm (WOT)
4/5 (1999 & 2000) 4500 -5500
4/5/6 (2001 & Newer) 5000 - 6000
4/5/6 (1999 & 2000) 3 ± 1/2 Turns Out
European Models Only
2001 & Newer
4 2-1/8 ± 1/2 Turns Out
5 1-1/2 ± 1/2 Turns Out
6 2-3/4 ± 1/2 Turns Out
All Other Models Non-Adjustable
Venturi Bore Diameter
4/5 13.5 mm
6 15 mm
CARBURETOR Main Jet Size
4/5 (1999 & 2000) #70
4 (2001 & Newer) #58
5 (2001 & Newer) #65
6 (2000 & Newer) #75
4 (Bodensee) #55
5 (Bodensee) #62
6 (Bodensee) #68
Pilot Jet
4 (1999 & 2000) #40
5 (1999 & 2000) #42
4/5 (2001 & Newer) #38
6 (2000 & Newer) #45
4/5 (Bodensee) #38
6 (Bodensee) #42
Float Height 0.35 - 0.39 in. (9 - 10 mm)
90-857138R1 MAY 2000 Page 3B-1

CARBURETOR
Special Tools
1. Carburetor Scale P/N 91-36392
55847
WARNING
FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO SMOKING. Before
servicing any part of the fuel system, disconnect electrical system at the battery. Drain the fuel sys-
tem completely. Use an approved container to collect and store fuel. Wipe up any spillage immediate-
ly. Materials used to contain spillage must be disposed of in an approved receptacle. Any fuel system
service must be performed in a well ventilated area.
FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EXPLOSION HAZARD
WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH. Careful periodic inspection of the entire
fuel system is mandatory, particularly after engine storage. All fuel components, including fuel tanks,
whether plastic, metal, or fiberglass, fuel lines, primer bulbs, fittings, swelling, and must be inspected
for corrosion. Any sign of leakage or deterioration necessitates replacement before further engine
operation.
Page 3B-2 90-857138R1 MAY 2000

CARBURETOR
Notes:
90-857138R1 MAY 2000 Page 3B-3

CARBURETOR
Fuel System
33 19
34 17
21
35 2
3
32
4 20
18
1 5
36
6
7
40
8
41 37 9
38
10
39
15
16 11
12
31 29
13
30
14
22
23
28 26
27
24 25
Page 3B-4 90-857138R1 MAY 2000

CARBURETOR
Fuel System
TORQUE
REF.
REF
1 CARBURETOR (4 H.P.)
1 1 CARBURETOR (5 H.P.)
1 CARBURETOR (6 H.P.)
2 1 STOP SCREW
3 1 SPRING
1 PILOT JET (4 H.P.)
4 1 PILOT JET (5 H.P.)
1 PILOT JET (6 H.P.)
5 1 PILOT SCREW SET
1 MAIN NOZZLE (4 H.P.)
6 1 MAIN NOZZLE (5 H.P.)
1 MAIN NOZZLE (6 H.P.)
1 MAIN JET (4 H.P.)
7 1 MAIN JET (5 H.P.)
1 MAIN JET (6 H.P.)
8 1 FLOAT VALVE
9 1 CLIP
10 1 FLOAT PIN
11 1 FLOAT
12 1 GASKET
13 1 FLOAT BOWL
14 2 SCREW (M4 x 12 mm)
15 1 DRAIN SCREW (M5 x 6 mm)
16 1 O RING
17 1 INLET MANIFOLD
18 1 O RING
19 2 BOLT (M6 x 25 mm) 70 8
1 INSULATOR GASKET (4/5 H.P.)
20
1 INSULATOR GASKET (6 H.P.)
21 2 GASKET
22 1 TUBING
23 1 CLIP
24 1 FUEL PUMP
25 1 O RING
26 2 SCREW (M6 x 25 mm) 70 8
27 1 CHOKE ROD
28 1 BUSHING
29 1 BOLT (M6 x 14 mm) 70 8
30 1 WASHER
31 1 CLAMP
32 1 CHOKE LINK WIRE
33 1 BOLT (M6 x 20 mm) 70 8
34 1 BRACKET
35 1 COLLAR
36 2 COLLAR
37 1 NUT
38 1 AIR SILENCER
39 1 FLAME TRAP
40 2 BOLT (M6 x 85 mm) 70 8
41 2 WASHER
90-857138R1 MAY 2000 Page 3B-5

CARBURETOR
Carburetor Adjustments
Idle Speed - Initial Setting
1. Turn pilot mixture screw in (clockwise) until lightly seated than back out to an initial set-
ting of 3 ± 1/2 turns.
2. Start engine and run at slow/idle speed in forward gear. Turn pilot screw in until engine
starts to lose rpm, than back out 1/4 turn and adjust for best performance.
NOTE: Allow time for engine to stabilize between adjustments. DO NOT adjust leaner than
necessary to attain reasonably smooth idle.
If the engine hesitates on acceleration, readjust the pilot screw.
a - Pilot Mixture Screw
Idle Speed
1. Adjustment:
• Tightening the screw increases engine speed.
• Loosening the screw reduces engine speed.
Idle RPM
1300 rpm Out of Gear
1100 rpm in Gear
ÅÅÅ
Å
ÅÅ
a - Idle Adjustment Screw
Page 3B-6 90-857138R1 MAY 2000

CARBURETOR
Carburetor Removal and Installation

REMOVAL
1. Disconnect fuel supply from engine.
2. Remove the rewind starter.
3. Disconnect the fuel hose and breather hose.
4. Remove the two bolts securing the flame trap and carburetor to the intake manifold.
5. Disconnect the choke cable and throttle linkage from the carburetor. Remove carbure-
tor.
INSTALLATION
1. Reconnect the choke cable and throttle linkage.
2. Install the carburetor as shown.
3. Reinstall the fuel hose and breather hose. Fasten the fuel hose with a hose clamp.
Carburetor Mounting Bolts Torque

70 lb-in. (8 Nm)
j
c l k
j
b
a
i
b
g
f
e
h
d
a - Fuel Hose g - Choke Cable

b - Hose Clamp (2) h - Air Silencer
c - Breather Hose i - Insulator Gasket
d - Bolt (2) M6 x 85 mm j - Gasket
e - Flat Washer (2) k - Intake Manifold
f - Collar (2) l - Throttle Linkage
90-857138R1 MAY 2000 Page 3B-7

CARBURETOR
Carburetor Disassembly
1. Remove drain screw and drain the carburetor before disassembly.
2. Remove the float bowl.
3. Remove the idle stop screw and pilot jet.
g
h f
a
d
b
c
e
a - Drain Screw f - Pilot Jet
b - O-Ring Seal g - Idle Stop Screw
c - Float Bowl h - Spring
d - Gasket i - Pilot Screw
e - Screw (2) j - Spring
4. Push out float pin in the direction shown and remove the float.
a
c b
e
a - Knurled End of the Float d - Float

Pin e - Inlet Needle
b - Pull Out Direction f - Float Pin
c - Inserting Direction
Page 3B-8 90-857138R1 MAY 2000

CARBURETOR
5. Remove the main jet.
6. Remove the main nozzle. The nozzle should drop out. If not, carefully push the nozzle
out as shown.
b b
a - Main Jet
b - Main Nozzle
Inspection
1. Clean the main jet, main nozzle, pilot jet and pilot screw thoroughly with compressed
air before installation.
2. Inspect the tip of the needle valve and pilot mixture screw for wear.
3. Inspect float for wear in the float arm that contacts the needle valve.
90-857138R1 MAY 2000 Page 3B-9

CARBURETOR
Carburetor Reassembly
1. Install the needle valve assembly onto the metal tab.
2. Install the float.
a - Inlet Needle Assembly

b - Float
c - Float Pin
d - Inserting Direction
3. Check the float lever using a carburetor scale. Adjust float level by bending the metal
tab to which the inlet needle is installed.
Float Level
0.35 - 0.39 in. (9 - 10 mm)
Page 3B-10 90-857138R1 MAY 2000

CARBURETOR
4. Reassemble the carburetor.

h
i
j
a e
b
d
c
a - Drain Screw-M5 x 6 mm g - Main Nozzle
b - Gasket-Drain Screw h - Idle Screw
c - Screws (4) M4 x 12 mm i - Spring
d - Float Bowl j - Pilot Jet
e - Gasket -Float Bowl k - Pilot Screw
f - Main Jet l - Spring
90-857138R1 MAY 2000 Page 3B-11

EMISSIONS
FUEL SYSTEM
Section 3C – Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . 3C-2 Stratified Charge . . . . . . . . . . . . . . . . . . . . . 3C-5
What Are Emissions? . . . . . . . . . . . . . . . . . 3C-2 Emissions Information . . . . . . . . . . . . . . . . . . . 3C-6
Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . 3C-2 Manufacturer’s Responsibility . . . . . . . . . . 3C-6
Carbon Monoxide – CO . . . . . . . . . . . . . . . 3C-2 Dealer Responsibility . . . . . . . . . . . . . . . . . 3C-6
Oxides of Nitrogen - NOx . . . . . . . . . . . . . .
Controlling Emissions . . . . . . . . . . . . . . . . .
3C-2
3C-2
Owner Responsibility . . . . . . . . . . . . . . . . .
EPA Emission Regulations . . . . . . . . . . . .
3C-6
3C-7
3
Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3C-3 Manufacturer’s Certification Label . . . . . . . . . 3C-8 C
Outboard Hydrocarbon Service Replacement Certification Label . . . 3C-9
Emissions Reductions . . . . . . . . . . . . . . . . . . . 3C-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9
8 1/3% # Per Year Over 9 Model Years . . 3c-3 Date Code Identification . . . . . . . . . . . . . . . 3C-9
Stratified Vs Homogenized Charge . . . . . . . . 3C-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-9
Homogenized Charge . . . . . . . . . . . . . . . . . 3C-4 Decal Location . . . . . . . . . . . . . . . . . . . . . . . 3C-9
90-857138R1 MAY 2000 Page 3C-1

EMISSIONS
Exhaust Emissions Standards

Through the Environmental Protection Agency (EPA), the federal government has estab-
lished exhaust emissions standards for all new marine engines sold in the U.S.
What Are Emissions?
Emissions are what comes out of the exhaust system in the exhaust gas when the engine
is running. They are formed as a result of the process of combustion or incomplete combus-
tion. To understand exhaust gas emissions, remember that both air and fuel are made of
several elements. Air contains oxygen and nitrogen among other elements; gasoline con-
tains mainly hydrogen and carbon. These four elements combine chemically during com-
bustion. If combustion were complete, the mixture of air and gasoline would result in these
emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment.
But combustion is not usually complete. Also, potentially harmful gases can be formed dur-
ing and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful
gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards be-
come more stringent each year. Standards are set primarily with regard to three emissions:
hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).
Hydrocarbons – HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned dur-
ing combustion in combination with oxygen. But they are not totally consumed. Some pass
through the combustion chamber and exit the exhaust system as unburned gases known
as hydrocarbons.
Carbon Monoxide – CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxygen
during the combustion process. If the carbon in the gasoline could combine with enough
oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the
form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insuffi-
cient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO.
Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially
lethal gas.
Oxides of Nitrogen - NOx
NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that
makes up the air going into the engine. Under extremely high temperatures it combines with
oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion cham-
bers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight
it combines with unburned hydrocarbons to create the visible air pollutant known as smog.
Smog is a serious problem in California as well as many other heavily populated areas of
the United States.
Controlling Emissions
There are two principle methods of reducing emissions from a two-stroke-cycle marine en-
gine. The first method is to control the air/fuel ratio that goes into the combustion chamber.
The second is to control the time when this air/fuel mixture enters the combustion chamber.
Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.
Page 3C-2 90-857138R1 MAY 2000

EMISSIONS
Stoichiometric (14.7:1) Air/Fuel Ratio

In the search to control pollutants and reduce exhaust emissions, engineers have discov-
ered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio
of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1
provides the best control of all three elements in the exhaust under almost all conditions.
The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio.
At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than
14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not
be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However,
there is also NOx to consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combus-
tion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio
to decrease combustion temperatures and reduce NOx also increases HC and CO, as well
as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to
keep the air/fuel ratio as close to 14.7:1 as possible.
OUTBOARD HYDROCARBON
EMISSIONS REDUCTIONS
8 1/3% PER YEAR OVER 9 MODEL YEARS
120
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08
90-857138R1 MAY 2000 Page 3C-3

EMISSIONS
STRATIFIED VS HOMOGENIZED CHARGE

At certain operating conditions, DFI engines use a stratified charge inside the combustion
chamber to aid in reducing emissions. All other models exclusively use a homogenized
charge. The difference between the two is:
Homogenized Charge
A homogenized charge has the air/fuel particles mixed evenly throughout the cylinder. This
mixing occurs inside the carburetor venturi, reed blocks, crankcase and/or combustion
chamber. Additional mixing occurs as the fuel is forced through the transfer system into the
cylinder. The homogenized charge has an air/fuel ratio of approximately 14.7:1 and is uni-
form throughout the cylinder.
Page 3C-4 90-857138R1 MAY 2000

EMISSIONS
Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel required for
combustion is forced into the cylinder through an injector placed in the top of the cylinder
(head). The injector sprays an air/fuel mixture in the form of a cloud into the cylinder. Sur-
rounding this cloud is air supplied by the transfer system. As the cloud is ignited and burns,
the surrounding air provides almost complete combustion before the exhaust port opens.
A stratified charge engine concentrates a rich mixture in the vicinity of the spark plug (air/fuel
ratio less than 14.7:1). Elsewhere, the mixture is very lean or is comprised of air only.
90-857138R1 MAY 2000 Page 3C-5

EMISSIONS
Emissions Information
Manufacturer’s Responsibility
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family and certify
these engines with the United States Environmental Protection Agency (EPA). A certifica-
tion decal/emissions control information label, showing emission levels and engine specifi-
cations directly related to emissions, must be placed on each engine at the time of manufac-
ture.
Dealer Responsibility
When performing service on all 1998 and later outboards that carry a certification, attention
must be given to any adjustments that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner
that maintains emission levels within the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow
emission levels to exceed their predetermined factory specifications.
Exceptions include manufacturers prescribed changes, such as that for altitude adjust-
ments.
Owner Responsibility
The owner/operator is required to have engine maintenance performed to maintain emis-
sion levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horse-
power or allow emissions levels to exceed their predetermined factory specifications.
Exceptions:
• Carburetor jets may be changed for high altitude use in accordance with factory rec-
ommendations.
• Single engine exceptions may be allowed with permission from the EPA for racing
and testing.
Page 3C-6 90-857138R1 MAY 2000

EMISSIONS
EPA Emission Regulations

All new 1998 and later outboards manufactured by Mercury Marine are certified to the
United States Environmental Protection Agency as conforming to the requirements of the
regulations for the control of air pollution from new outboard motors. This certification is con-
tingent on certain adjustments being set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed and, whenever practicable, the
product returned to the original intent of the design.
The responsibilities listed above are general and in no way a complete listing of the rules
and regulations pertaining to the EPA laws on exhaust emissions for marine products. For
more detailed information on this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww
90-857138R1 MAY 2000 Page 3C-7

EMISSIONS
Manufacturer’s Certification Label

The certification label must be placed on each engine at the time of manufacture and must
be replaced in the same location if damaged or removed. Shown below is a typical certifica-
tion label and is not representative of any one model. Label shown below is not to scale;
(shown at twice the normal size).
Emission Control a
Information
This engine conforms to 2000 Model Year U.S. EPA regulations for Marine SI engines.
Refer to Owners Manual for required maintenance
j Family: WM9XM.323220 Idle Speed (in neutral): 1100 RPM b

i FEL: 120 GM/KW-HR 4-5-6 (4-Stoke) 123 cc c
h Timing (in degrees): Not Adjustable CDI Controlled
d
Standard Spark Plug:
Gap:
JULY
g e
Suppressor Spark Plug: NGK DPR6E 1999
Gap: 0.035″ (0.9 mm)
Intake: 0.6-0.14
f Valve Clearance (Cold) mm
Exhaust: 0.11-0.19
a - Spark Ignition (SI)

b - Idle Speed (In Neutral)
c - Cubic Centimeter
d - Engine Horsepower Rating
e - Month and Year of Production
f - Valve Clearance (Four Stroke engines only)
g - Recommended spark plug for best engine performance
h - Timing specifications when adjustable
i - FEL: Represents (Mercury Marine) statement of the maximum emissions output
for the engine family
j - Family example
Y M9X M1596 2 G 0
Type of Product
0=General Outboard
Model Year Regulation J=Sport Jet
Y=2000 M=Marine H=High Performance
Manufacturer Displacement Technology Cycle Type
Mercury Marine Liter Type C=2 Stroke
Cubic Inch 1=Old G=4 Stroke
2=New
3=Sport Jet
Page 3C-8 90-857138R1 MAY 2000

EMISSIONS
Service Replacement Certification Label

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine out-
boards have a visible and legible emission certification label. If this label is missing
or damaged, replacement labels can be obtained from Mercury Marine.
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label over
the old label. Use a suitable solvent to remove any traces of the old label adhesive from the
display location.
Date Code Identification
Cut and remove a “V” notch through the month of engine manufacture before installing the
new label. The month of manufacture can be found on the old label. If the label is missing
or the date code illegible, contact Mercury Marine Technical Service for assistance.
Emission Control 123 2000
Information cc PART #3R1-72089-2
This engine conforms to 2000 Model Year
U.S. EPA regulations for marine SI engines. Idle Speed (in neutral): 1300±50 RPM
Refer to Owners Manual Timing: Not Adjustable
for required maintenance
Family: YM9XM.323220 Spark Plug: NGK DPR6E
Gap: 0.035” (0.9 mm)
FEL: 120 GM/KW-HR Valve Clearance (Cold) mm

Intake: 0.06-0.14 Exhaust: 0.11-0.19
4-5-6 HP
4-Stroke
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
b
a
a
a - “V” Notch
b - Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.
Decal Location
Model Production Part No. Service Part No. Location on Engine
1999 Merc/Mar 4/5 HP 37-856984 18 37-856985 18 Front of Cylinder Block
(4-Stroke)
2000 Merc/Mar 4/5/6 HP 3R1-72089-2 37-804651A00 Front of Cylinder Block
(4-Stroke)
2001 Merc/Mar 4 HP 3R1-72089-3 37-804651A01 Valve Cover
(4-Stroke)
2001 Merc/Mar 5/6 HP 3R1-72089-3 37-804651A01 Front of Cylinder Block
(4-Stroke)
90-857138R1 MAY 2000 Page 3C-9

CYLINDER HEAD
POWERHEAD
Section 4A - Cylinder Head
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 4A-13
Quicksilver Lubricants and Service Aids . . . . . . 4A-3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Cylinder Head Resurfacing . . . . . . . . . . . . . 4A-14
Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-6 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-18
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Cylinder Head Reassembly . . . . . . . . . . . . . . . . 4A-21
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 4A-11 Cylinder Head Installation . . . . . . . . . . . . . . . . . 4A-23
4
Specifications A
Free Length (Intake/Exhaust) “a”
Tilt Limit “b” (Intake/Exhaust)
4/5 (1999) a = 1.260 in. (32.0 mm)
b = 0.044 in. (1.12 mm)
4/5/6 (2000 & Newer) a = 1.378 in. (35.0 mm)
b b = 0.044 in. (1.12 mm)
VALVE SPRING
Compressed Pressure (Installed)
Intake/Exhaust:
4/5 (1999 & 2000) 17 lbf. (7.7 kgf)
6 (2000) 24 lbf. (10.8 kgf)
4/5/6 (2001 & Newer) 24 lbf. (10.8 kgf)
4/5 (1999 & 2000) 31 lbf. (14.0 kgf)
6 (2000) 39.4 lbf. (17.9 kgf)
4/5/6 (2001 & Newer) 39.4 lbf. (17.9 kgf)
Direction of Winding (Intake/Exhaust) Right Hand
Warp Limit * 0.0012 in. (0.03 mm)
CYLINDER HEAD
* Lines indicate
straight edge
measurement
90-857138R1 MAY 2000 Page 4A-1

CYLINDER HEAD
4/5 = 5 (1999 & 2000) 6 = 6 (2000)

4/5/6 = 6 (2001)
CYLINDER
HEAD 5
IDENTIFICATION
Valve Dimensions
“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness
Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.002 - 0.005 in. (0.06 - 0.14 mm)
Exhaust 0.004 - 0.007 in. (0.11 - 0.19 mm)
Valve Dimensions:
“A” Head Diameter
Intake 0.980 - 0.988 in. (24.9 - 25.1 mm)
Exhaust 0.941 - 0.949 in. (23.9 - 24.1 mm)
“B” Face Width
“C” Seat Width
“D” Margin Thickness
VALVES Intake 0.028 in. (0.7 mm)
Stem Outside Diameter
Intake 0.216 in. (5.48 mm)
Guide Inside Diameter
Intake 0.2165 in. (5.5 mm)
Stem To Guide Clearance
Intake 0.0008 - 0.0017 in. (0.020 - 0.044 mm)
Exhaust 0.0018 - 0.0028 in. (0.045 - 0.072 mm)
Stem Run-out Limit (max.) 0.0006 in. (0.016 mm)
Page 4A-2 90-857138R1 MAY 2000

CYLINDER HEAD
Special Tools
1. Valve Seat Cutter Kit (Obtain Locally).
55848

92-802878-57 Quicksilver Power Tune
90-857138R1 MAY 2000 Page 4A-3

CYLINDER HEAD
Cylinder Block
17 23
110
24
18
19 20
13
25
26
14
15
22
21
110
8 15
6 110
16
7
9
10
2
1
12
11
4
‘
5
110
1
12
110 4 Cycle Oil (92-828000A12)
Page 4A-4 90-857138R1 MAY 2000

CYLINDER HEAD
Cylinder Block
TORQUE
REF.
REF
1 1 CYLINDER BLOCK
2 1 OIL SEAL
3 1 BALL BEARING
4 1 FILLER CAP
5 1 O RING
6 1 CAP
7 1 GASKET
8 2 BOLT 70 8
9 2 BREATHER TUBE
10 2 WASHER
11 1 TUBING
12 2 CLAMP
1 CYLINDER HEAD (4/5 H.P.)
13
1 CYLINDER HEAD (6 H.P.)
14 1 GASKET
15 2 DOWEL PIN
16 1 GASKET
17 1 THERMOSTAT COVER
18 1 GASKET
19 1 THERMOSTAT 126 degrees F (52 degrees C)
20 2 BOLT (M8 x 90 mm) 18 24.5
21 2 BOLT (M8 x 60 mm) 18 24.5
22 1 SPARK PLUG (NGK#DCPR6E) 13 17.5
23 1 COVER
24 1 GASKET
25 4 BOLT (M6 x 20 mm) 70 8
26 4 WASHER
– 1 GASKET SET
– 1 POWERHEAD (4 H.P.)
90-857138R1 MAY 2000 Page 4A-5

CYLINDER HEAD
Intake/Exhaust Valves
14
13
12
110
11
110 8
7
10 6
14
13
12
11
5
3
9 110
110
7
4
2
110
3
7 Loctite 271 (92-809820)

110 4 Cycle Oil (92-828000A12)
Page 4A-6 90-857138R1 MAY 2000

CYLINDER HEAD
Intake/Exhaust Valves
TORQUE
REF.
REF
1 CAMSHAFT (4 H.P.)
1 1 CAMSHAFT (5 H.P.)
1 CAMSHAFT (6 H.P.)
2 2 LIFTER
3 2 PUSH ROD
4 1 PLATE
5 2 PIVOT BOLT 18 24.5
6 2 ROCKER ARM
7 2 PIVOT
8 2 NUT 90 10
9 1 EXHAUST VALVE
10 1 INTAKE VALVE
11 2 SEAT
12 2 SPRING
13 2 RETAINER
14 4 VALVE KEEPER
90-857138R1 MAY 2000 Page 4A-7

CYLINDER HEAD
Adjustments
Valve Clearance
IMPORTANT: Make all valve adjustments while engine temperature is cool.
NOTE: Inspect cover gasket for cuts or tears. Replace gasket if damaged.
1. Remove cylinder cover and spark plug.
a
c
57252
a - Cylinder Head Cover
b - Cover Gasket
c - Spark Plug
2. Remove fuel pump.
ÅÅ
ÅÅÅ
Å
a
57231
a - Fuel Pump
Page 4A-8 90-857138R1 MAY 2000

CYLINDER HEAD
3. Rotate flywheel until raised mark on camshaft is visible through fuel pump hole and
notched mark on flywheel aligns with TDC mark on block casting. Piston is now at top
dead center and valve clearance may now be checked with feeler gauge.
b
a
c e
d
a - Raised Mark on Camshaft

b - Notched Mark on Flywheel
c - TDC Mark
d - 5° BTDC Mark on Block Casting
e - 25° BTDC Mark on Block Casting
4. Measure valve clearance with a feeler gauge. Adjust if out of specification.
57250
a - Intake Valve
b - Exhaust Valve
Valve Clearance (Cold)
Intake 0.002 - 0.005 in. (0.06 - 0.14 mm)
Exhaust 0.004 - 0.007 in. (0.11 - 0.19 mm)
90-857138R1 MAY 2000 Page 4A-9

CYLINDER HEAD
5. If valve clearance adjustment is necessary, hold pivot and loosen lock nut.
6. Insert feeler gauge between rocker arm and valve.
7. Adjust the valve clearance by turning the pivot.
8. When proper clearance is achieved, hold pivot and tighten lock nut. Torque lock nut to
90 lb-in. (10 Nm).
9. Recheck valve clearance.
a
b
d
e
a - Pivot
b - Lock Nut [Torque to 90 lb-in. (10 Nm)]
c - Rocker Arm
d - Feeler Gauge
e - Valve
10. Reinstall cylinder cover. Torque 4 bolts to 70 lb-in. (8 Nm).

11. Reinstall fuel pump. Drive 2 attaching screws tight.
12. Reinstall spark plug. Torque plug to 13 lb-ft (17.5 Nm).
Page 4A-10 90-857138R1 MAY 2000

CYLINDER HEAD
Cylinder Head Removal

Refer to Section 4B for cylinder head removal procedures.
Cylinder Head Disassembly

IMPORTANT: Note the location of valve train components for reassembly in their orig-
inal location.
1. Loosen lock nuts.
57250
a - Lock nuts (2)
2. Remove pivots and rocker arms.

3. Remove 2 pivot bolts and guide plate.
c
e d
b a
f
57247
a - Lock Nut
b - Pivot
c - Rocker Arm
d - Pivot Bolt
e - Guide Plate
f - Guide Tabs Face UP
90-857138R1 MAY 2000 Page 4A-11

CYLINDER HEAD
4. Place a rag under the cylinder head to support the valves. Using a suitable box end
wrench, depress valve spring to release valve keepers. Remove keepers (2), valve
spring retainer, valve spring and valve spring seat.
57338
a - Box End Wrench
b - Rag
d
c
b
a
57246
a - Keepers (2) per Valve
b - Valve Spring Retainer
c - Valve Spring
d - Valve Spring Seat
Page 4A-12 90-857138R1 MAY 2000

CYLINDER HEAD
Cleaning and Inspection

Cylinder Head
1. Inspect the cylinder head for mineral deposit blockage/corrosion in the water passage
ways, clean any deposits/corrosion observed.
2. Inspect the cylinder head for carbon deposits In combustion chamber (use round scrap-
er to clean away deposits). Be careful not to scratch or remove material.
a
EX IN
a
57255
a - Water Passages
b - Combustion Chamber
3. Using a straight edge and a thickness gauge inspect cylinder head for warpage. Re-
place cylinder head If out of specification.
Cylinder Head Warpage Limit

0.0012 in. (0.03 mm)
90-857138R1 MAY 2000 Page 4A-13

CYLINDER HEAD
Cylinder Head Resurfacing

1. Place 400-600 grit wet sandpaper on flat surface.
2. Resurface the head using a figure eight motion until within the specifications.
NOTE: Rotate the head several times during the resurfacing procedure to avoid removing
to much material from one side.
57249
VALVE GUIDE INSPECTION

1. Measure the valve guide bore (a). If valve guide wear is out of specification, replace the
cylinder head.
55794
Valve Standard Inside Diameter Out of Limit to Use

Intake 0.2165 in. (5.5 mm) 0.2181 in. (5.54 mm) or greater
Exhaust 0.2165 in. (5.5 mm) 0.2192 in. (5.57 mm) or greater
Page 4A-14 90-857138R1 MAY 2000

CYLINDER HEAD
VALVE SEAT RECONDITIONING

Clean the carbon deposits from the combustion chambers and valve seats and check for
pitting.
Several different types of equipment are available for reseating valve seats. Follow the
equipment manufacturer’s instructions.
Measure valve seat width. Resurface the valve seat if not in specification.
55799
a - Valve Seat Width
Valve Seat Width Specification “a”

Standard Value Limit that requires repair
Intake Valve Seat 0.031 in. (0.8 mm) 0.070 in. (1.8 mm) or more
Exhaust Valve Seat 0.031 in. (0.8 mm) 0.070 in. (1.8 mm) or more
To reface valve seat, use a 60°, 45° or 15° cutter and finish with 60° valve seat cutter.
a - Valve Seat Cutter
NOTE: Turn cutter clockwise only. Continue turning as cutter is lifted off valve seat
55795
90-857138R1 MAY 2000 Page 4A-15

CYLINDER HEAD
NOTE: If resurfacing the valve seats is required, resurface the valve seats to the specified
angle shown in chart.
c
b
a
55798
Valve Seat Angle Specifications

a 15°
b 45°
c 60°
CORRECT VALVE SEAT POSITION
55800
Standard Value “a” Limit that needs Repair

Intake Valve 0.031 in. (0.8 mm) 0.0708 in. (1.8 mm) or greater
Exhaust Valve 0.031 in. (0.8 mm) 0.0708 in. (1.8 mm) or greater
NOTE: After resurfacing the seats, inspect for even valve seating. Apply Prussian Blue com-
pound or erasable felt-tipped marker ink to the valve faces. Insert the valves and then lift
them and snap them closed against their seats several times. Do not allow the valve to rotate
on the seat. The seating surface, as shown by the transferred marking compound, should
have good contact all the around.
Page 4A-16 90-857138R1 MAY 2000

CYLINDER HEAD
VALVE SEAT POSITIONS AND CORRECTIONS

Condition: The valve seat is centered on valve face but it is too wide.
55799
Valve Seat Cutter Set Desired Results

Use 15° Cutter To reduce valve seat
Lightly 60° Cutter width
Condition: The valve seat is in the middle of the valve face but it is too narrow.
55800

Use 45° Cutter To achieve a uniform valve seat
width
Condition: Valve seat is too narrow and it is near valve margin.
55801

Use 15° Cutter, First To center the seat and to achieve its
45° Cutter width
90-857138R1 MAY 2000 Page 4A-17

CYLINDER HEAD
Condition: Valve seat is too narrow and is located near the bottom edge of the valve face.
55802

Use 60° Cutter, First To center the seat and to increase
45° Cutter its width
Valves
1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned
valves.
2. Measure the valve stem diameter to check for wear. Replace valves if not within specifi-
cation.
55810
a - Valve Stem Diameter
Valve Stem Diameter

Standard Value Out of limit to use; replace valve
Intake Valve 0.216 in. (5.48 mm) 0.2145 in. (5.45 mm) or less
Exhaust Valve 0.214 in. (5.44 mm) 0.213 in. (5.41 mm) or less
3. Check the valve face for pitting. Valve faces that are pitted must be replaced or refaced.
NOTE: Several different types of equipment are available for refacing valves. Follow the
equipment manufacturer’s instructions.
Page 4A-18 90-857138R1 MAY 2000

CYLINDER HEAD
4. Check the margin thickness (a) of the valves after the valves have been ground. Any
valve with a margin thickness of less than the specification, should be replaced.
45 °
55809
Margin Thickness “a”

Intake Valve 0.028 - 0.047 in.
Exhaust Valve (0.7 - 1.2 mm)
5. Measure valve stem runout, replace if out of specification.
55811
Valve Stem Runout Limit (Max.)

Intake Valve
0.0006 in. (0.016 mm)
Exhaust Valve
6. After repair of valve seat, lap the valve for proper fitting to valve seat.
7. Apply lapping compound to valve seat and lap valve while turning valve with valve lap-
per.
8. Apply lapping compound in 3 sequences; coarse compound first followed by medium
and then fine compound last.
IMPORTANT: Before using lapping compound of a different grade, completely re-

move previously used compound.
IMPORTANT: After lapping is complete, wash valve and valve seat removing all lap-
ping compound from them.
90-857138R1 MAY 2000 Page 4A-19

CYLINDER HEAD
Valve Springs
1. Check each spring under load on a spring tester. Replace any weak springs.
55796
Valve Spring Compressed Pressure (Installed)

4/5 (1999 & 2000) 17 lbf. (7.7 kgf)
6 (2000) 24 lbf. (10.8 kgf)
4/5/6 (2001 & Newer) 24 lbf. (10.8 kgf)
4/5 (1999 & 2000) 31 lbf. (14.0 kgf)
6 (2000) 39.4 lbf. (17.9 kgf)
4/5/6 (2001 & Newer) 39.4 lbf. (17.9 kgf)
2. Check free length limit of each spring. Replace if out of specification.
55846
Valve Spring Free Length Limit

4/5 (1999 & 2000) 1.260 in. (32.0mm)
6 (2000) 1.378 (35.0mm)
4/5/6 (2001 & Newer) 1.378 (35.0mm)
3. Check each spring on a flat surface using a square. Rotate spring and check space be-
tween the top coil and square. Replace if out of specification.
55797
Page 4A-20 90-857138R1 MAY 2000

CYLINDER HEAD
Valve Spring Tilt Specification “a”

Less than 0.044 in. (1.12 mm)
90-857138R1 MAY 2000 Page 4A-21

CYLINDER HEAD
Cylinder Head Reassembly

IMPORTANT: Reassemble valve train components in their original location.
1. Install valves, lower seats, springs,spring retainers and keepers.
NOTE: Compress valve springs using a suitable box end wrench.
e 110
d
c
b
a
110
110 4-Stroke Outboard Oil (92-828000A12) 57246
a - Keepers (2) per Valve

b - Valve Spring Retainer
c - Valve Spring
d - Valve Spring Seat
e - Intake Valve
2. Place a clean rag under the head to support the valves. Use a suitable box end wrench
to compress springs while installing valve keepers.
57338
a - Box End Wrench
b - Clean Rag
Page 4A-22 90-857138R1 MAY 2000

CYLINDER HEAD
3. Install rocker arm plate and 2 pivot bolts. Torque pivot bolts to 18 lb-ft (24.4 Nm).
a b
c
57247
a - Guide Plate
b - Pivot Bolts [Torque to 18 lb-ft (24.5 Nm)]
c - Guide Plate Tabs Face UP
4. Install rocker arms, pivots and lock nuts.

IMPORTANT: Do not tighten pivots and lock nuts. Rocker arms must be loose until
after cylinder head assembly is installed on cylinder block and head bolts torqued.
Push rods can then be aligned with rocker arms. Refer to valve adjustment procedure
at that time.
b c
57247
a - Rocker Arm
b - Pivot
c - Lock Nut
90-857138R1 MAY 2000 Page 4A-23

CYLINDER HEAD
Cylinder Head Installation

Refer to Section 4B for proper cylinder head installation procedures with torque specifica-
tions and sequences.
1. Perform valve clearance adjustment at the beginning of this section.
2. Install cylinder head cover with new gasket.
3. Install spark plug.
d
b
57252
a - Gasket (New)
b - Cylinder Head Cover
c - Bolts (4) M6 x 20 mm
d - Spark Plug
Cylinder Head Cover Bolt Torque

70 lb-in. (8 Nm)
Spark Plug Torque

13 lb-ft (17.5 Nm)
Cylinder Head Identification Mark

NOTE: 2000 model year outboards have hp located on cylinder head. Cylinder head will be
marked with a 5 or 6; 5 designating 4 and 5 hp, and 6 designating 6 hp. The letter below the
number designates nothing. At 2001 model year, all (4/5/6) will be marked with a 6.
6
B
Page 4A-24 90-857138R1 MAY 2000

CYLINDER BLOCK AND CRANKCASE
POWERHEAD
Section 4B - Cylinder Block and Crankcase
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Removing Powerhead Components . . . . . . . . 4B-13
Powerhead - General Information . . . . . . . . . . . 4B-5 Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-14
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-22
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Powerhead Reassembly . . . . . . . . . . . . . . . . . . 4B-31
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-10 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-43
Specifications 4
B
Type 4 Stroke Cycle – Over Head Valve
CYLINDER
Displacement 7.5 cu. in. (123 cc)
BLOCK
Number of Cylinders 1
STROKE Length 1.77 in. (45 mm)
Diameter
CYLINDER
BORE
Taper/Out of Round Maximum 0.003 in. (0.076 mm)
Bore Type Steel
Piston Type Aluminum
O.D. at Skirt
PISTON
Piston to Cylinder Clearance 0.001 - 0.002 in.
PISTON
(0.020 - 0.055 mm)
CLEARANCE
Piston Clearance Limit 0.006 in. (0.15 mm)
Ring End Gap (Installed)
Top 0.006 - 0.014 in. (0.15 - 0.35 mm)
Middle 0.012 - 0.020 in. (0.30 - 0.50 mm)
RINGS
Side Clearance:
Top 0.0015 - 0.003 in. (0.04 - 0.08 mm)
Middle 0.0012 - 0.003 in. (0.03 - 0.07 mm)
Compression Ratio
With Decompression 8.5:1
COMPRESSION 4/5 (1999 & 2000) 42 psi ± 14 psi (0.29 ± 0.1 MPa)
RATIO
4/5 (2001 & Newer) 9.5:1
6 (2000 & Newer) 42 psi ± 14 psi (0.29 ± 0.1 MPa)
Outer Diameter 0.6299 in. (16.00 mm)
Diameter of Piston Pin Hole 0.6300 in. (16.002 mm)
PISTON PIN Clearance between Piston Pin and
Piston Pin Hole 0.0001 - 0.0005 in.
(0.002 mm - 0.012 mm)
90-857138R1 MAY 2000 Page 4B–1

Oil Clearance (Big End) 0.002 - 0.003 in. (0.053 - 0.079 mm)
CONNECTING Side Clearance (Big End) 0.008 - 0.016 in.
ROD (0.20 - 0.40 mm)
Small End Inside Diameter 0.6303 in. (16.01 mm)
Crankshaft Runout Less than 0.002 in. (0.05 mm)

Diameter of Crank Pin (A) 1.179 - 1.177 in.
(29.94 - 29.91 mm)
Outer Diameter of Crankshaft in Oil
Pan Bearing (B) 0.983 - 0.982 in.
(24.98 - 24.96 mm)
A B
CRANKSHAFT
Camshaft Dimensions
Intake/Exhaust “A”
4 (1999 & 2000) A 0.993 in. (25.24 mm)
5 (1999 & 2000) 1.047 in. (26.59 mm)
6 (2000) 1.115 in. (28.33 mm)
4/5/6 (2001 & Newer) 1.115 in. (28.33 mm)
Bearing Diameter “B” 0.550 in. (13.98 mm)
CAMSHAFT
B
Inside Diameter of Oil Pan Bearing:

Crankshaft “A” 0.985 in. (25.01 mm)
Camshaft “B” B 0.5515 in. (14.01 mm)
A
OIL PAN
Crankshaft to Oil Pan Bearing

Clearance 0.0006 - 0.0015 in. (0.015 - 0.040 mm)
Camshaft to Oil Pan Bearing
Clearance 0.0008 - 0.002 in. (0.02 - 0.05 mm)
Page 4B–2 90-857138R1 MAY 2000

Valve Opening Temperature 122°F - 129°F (50°C - 54°C)

THERMOSTAT Full Open Temperature 145°F - 153°F (63°C - 67°C)
Valve Lift (Minimum) 0.12 in. (3 mm)
Pump Type Trochoid
Engine Oil Pressure* (Warm Engine):
@ 1300 rpm
Engine Oil Pan Capacity 21.0 psi (0.15 MPa) Minimum
Oil Pump Clearance: 0.95 pt (450 ml)
Inner Rotor to Outer Rotor “A”
Outer Rotor to Body “B” 0.006 in. (0.15 mm) or Less
Rotor to Body (Side) “C” 0.005 - 0.008 in. (0.12 - 0.20 mm)
Height of Outer Rotor “D” 0.0008 - 0.0028 in. (0.02 - 0.07 mm)
Relief Valve Operating Pressure* 0.236 in. (5.99 mm)
LUBRICATION 31 - 40 psi (2.2 - 2.8 kg/cm2)
SYSTEM 216 - 275 kPa
D
A B
C
* Oil pressure specifications listed were obtained with oil at 165°F (75°C)
90-857138R1 MAY 2000 Page 4B–3

Special Tools
1. Piston Ring Expander (P/N 91-24697).
2. Puller Assembly (P/N 91-83165M)
3. Driver (P/N 91-84529M) NLA
4. Mandrel (P/N 91-83272M) NLA
5. Piston Ring Compressor (P/N FT 2997)
Page 4B–4 90-857138R1 MAY 2000


92-809819 Loctite 271
92-809822 Loctite Pipe Sealant w/Teflon-567
92-828000A12 4-Cycle Outboard Oil
Powerhead - General Information

Powerhead “Disassembly” and “Reassembly” instructions are printed in a sequence that
should be followed to assure best results when removing or replacing powerhead compo-
nents. If complete disassembly is not necessary, start reassembly at point that disassembly
was stopped. Usually, complete disassembly of the entire powerhead will be required.
If major powerhead repairs are to be performed remove powerhead from drive shaft hous-
ing. Powerhead removal is not required for 1) valve adjustment and 2) minor repairs on com-
ponents such as ignition systems or carburetor.
90-857138R1 MAY 2000 Page 4B–5

Cylinder Block
17 23
110
24
18
19 20
13
25
26
14
15
22
21
110
8 15
6 110
16
7
9
10
2
1
12
11
5
110
1
12
110 4 Cycle Oil (92-828000A12)
Page 4B–6 90-857138R1 MAY 2000

Cylinder Block
TORQUE
REF.
REF
1 1 CYLINDER BLOCK
2 1 OIL SEAL
3 1 BALL BEARING
4 1 FILLER CAP
5 1 O RING
6 1 CAP
7 1 GASKET
8 2 BOLT 70 8
9 2 BREATHER TUBE
10 2 WASHER
11 1 TUBING
12 2 CLAMP
1 CYLINDER HEAD (4/5 H.P.)
13
1 CYLINDER HEAD (6 H.P.)
14 1 GASKET
15 2 DOWEL PIN
16 1 GASKET
17 1 THERMOSTAT COVER
18 1 GASKET
19 1 THERMOSTAT 126 degrees F (52 degrees C)
20 2 BOLT (M8 x 90 mm) 18 24.5
21 2 BOLT (M8 x 60 mm) 18 24.5
22 1 SPARK PLUG (NGK#DCPR6E) 13 17.5
23 1 COVER
24 1 GASKET
25 4 BOLT (M6 x 20 mm) 70 8
26 4 WASHER
– 1 GASKET SET
90-857138R1 MAY 2000 Page 4B–7

Crankshaft
110
7
110
6 9
10
11
7
110
110
110 4 Cycle Oil (92-828000A12)
Page 4B–8 90-857138R1 MAY 2000

Crankshaft
TORQUE
REF.
REF
1 1 CRANKSHAFT
2 1 WASHER
3 1 KEY
4 1 CONNECTING ROD
5 2 BOLT 106 12
6 1 PISTON PIN
7 2 E RING
1 PISTON (STANDARD) (4/5 H.P.)
AR PISTON (.05 MM O/S) (4/5 H.P.)
8
1 PISTON (STANDARD) (6 H.P.)
AR PISTON (.05 MM O/S) (6 H.P.)
1 PISTON RING-TOP (STANDARD)
9
AR PISTON RING-TOP (.05 MM O/S)
1 PISTON RING-SECOND (STANDARD)
10
AR PISTON RING-SECOND (.05 MM O/S)
1 OIL RING (STANDARD)
11
AR OIL RING (.05 MM O/S)
AR = As Required
90-857138R1 MAY 2000 Page 4B–9

Oil Pan
7 1
3
4
4
11
7 5 5
7 14
40 6 6
7
8 15
12
9 13
9
39 16
10
38
37
36
35
17
110
34
110
33
18
95
32
30
31 95
29
95
27 19
28 20
110
27
21
22
26
23
7 Loctite 271 (92-809820)
9 Loctite PST Pipe Sealant (92-809822) 25

24
95 2-4-C With Teflon (92-825407A12)
110 4 Cycle Oil (92-828000A12)
Page 4B–10 90-857138R1 MAY 2000

Oil Pan
TORQUE
REF.
REF
1 1 SCREW (M5 x 16 mm) 31 3.5
2 1 STOPPER
3 1 TUBING
4 2 SEAL
5 2 SCREW (M5 x 16 mm) 31 3.5
6 2 WASHER
7 1 STRAINER HOUSING
8 1 STRAINER
9 1 CUP
10 2 DOWEL PIN
11 1 LEAD WIRE
12 1 OIL PRESSURE SWITCH
13 1 GROMMET
14 3 BOLT (M6 x 20 mm) 70 8
15 1 EXHAUST PLATE
16 1 GASKET
17 1 OIL PAN
18 3 BOLT (M6 x 40 mm) 80 9
19 1 ROTOR-OUTER
20 1 PIN
21 1 ROTOR-INNER
22 1 O RING
23 1 COVER
24 2 BOLT (M6 x 16 mm) 70 8
25 2 BOLT (M6 x 20 mm) 70 8
26 1 HOUSING
27 2 OIL SEAL
28 1 SPACER
29 1 GASKET
30 1 OIL SEAL
31 1 DRAIN BOLT
32 1 WASHER
33 6 BOLT (M8 x 40 mm) 221 18.5 25
34 1 GASKET
35 1 CONTROL PLUNGER
36 1 SPRING
37 1 O RING
38 1 SEAT
39 1 COVER
40 1 BOLT (M6 x 16 mm) 70 8
– 1 GASKET SET
90-857138R1 MAY 2000 Page 4B–11

Torque Sequence
Oil Pan
4
6
2 8
1 7
5
3
Cylinder Block Identification Mark

NOTE: 2000 model year outboards have hp located on cylinder block.
4, 5 or 6
Page 4B–12 90-857138R1 MAY 2000

Powerhead Removal
1. Drain out the engine oil.
2. Remove or disconnect the following components:

a. Starter lock rod.
b. Choke wire
c. Throttle Cables
d. Stop switch, oil warning light and oil pressure wire connections
e. Ground wires at the ignition coil and exciter coil wires.
f. Fuel inlet hose.
3. Remove the six powerhead mounting bolts and lift powerhead upwards.
a - Bolts (6) M8 x 40 mm
Removing Powerhead Components

1. Remove the following components:
a. Rewind starter assembly.
b. Remove the flywheel following instructions in Section 2A of this manual.
c. Exciter coil and pulsator coil.
d. Ignition coil.
e. Fuel pump and carburetor.
90-857138R1 MAY 2000 Page 4B–13

Powerhead Disassembly
1. Remove bolts from seal housing.
2. Use soft face hammer to loosen oil seal housing.
a - Oil Seal Housing

b - Bolt (2) M6 x 20 mm
c - Gasket
3. Use puller 91- 83165M to remove seals from the oil seal housing.
91-83165M
a
a - Oil Seal
b - Spacer
Page 4B–14 90-857138R1 MAY 2000

4. Remove the 9 bolts that fasten the oil pan to the cylinder block and cylinder head.
5. Break the oil pan seal. Pry up the oil pan at pry tab and in the open space beneath the
oil pan.
a - Oil Pan
b - Pry Tab
c - Pry Location Beneath the Oil Pan
6. Remove the oil pan.
90-857138R1 MAY 2000 Page 4B–15

7. Disassemble the oil pan.
r
p
s a
q
d
j k
c
n o
l
g
m
f h
i
a - Screw M5 x 16 mm k - Cover
b - Clamp l - Seat
c - Pipe m - O-Ring Seal
d - Screw (2) M5 x 16 mm n - Spring
e - Washer o - Plunger
f - Seal (2) p - Grommet
g - Body q - Oil Pressure Sensor
h - Strainer r - Exhaust Plate with Gasket
i - Cup s - Bolt (3) M6 x 20 mm
j - Bolt M6 x 16 mm
Page 4B–16 90-857138R1 MAY 2000

8. Disassemble the oil pump
a
b
d
e
f
a - Bolt (2) M6 x 20 mm
b - Cover
c - O-Ring Seal
d - Rotor - Outer
e - Rotor - Inner
f - Pin
9. Pull out the lower oil seal.
a - Lower Oil Seal
90-857138R1 MAY 2000 Page 4B–17

10. Pull out the camshaft and remove both valve lifters.
NOTE: Keep intake and exhaust valve components separate and reinstall in original loca-
tion.
a - Camshaft
b - Valve Lifters
11. Remove the Cylinder Head Assembly.
e
a
d
c
a - Cylinder Head
b - Push Rods (2)
c - Cylinder Head Cover
d - Thermostat
e - Intake Manifold
Page 4B–18 90-857138R1 MAY 2000

12. Remove piston assembly from the crankshaft.
d
a
f
b
e
c
a - Connecting Rod
b - Cap
c - Bolt (2)
d - Piston Pin
e - Clip (2)
f - Piston
13. Press the crankshaft out of the cylinder block.
a - Press
b - Flywheel Nut - Thread Onto End of Crankshaft
c - Crankshaft
d - Washer
90-857138R1 MAY 2000 Page 4B–19

14. Pry out the upper oil seal.
a - Upper Oil Seal
15. If the replacement of the upper ball bearing is necessary, use puller 91-83165M and pull
out the bearing.
91-83165M
a - Upper Ball Bearing

b - Puller 91-83165M
Page 4B–20 90-857138R1 MAY 2000

16. Remove the breather cap.
a - Screw (2)
b - Breather Cap
c - Gasket
17. Remove the breather tubes and wave washers.
a - Breather Tube (2)

b - Wave Washer (2)
90-857138R1 MAY 2000 Page 4B–21

Inspection
Measuring Cylinder Bore
1. Measure the cylinder bore diameter “d” at three locations in both X and Y axis.
2. If the cylinder bore is beyond the limits listed in the tables below, it will be necessary to
bore or replace the cylinder block.
Standard Value Out of the Limit

2.323 in. (59.00 mm) If 2.326 in. (59.07 mm) or more, cylinder can be
bored to accept oversize piston
0.020 in. (0.50 mm) Oversize If 2.345 in. (59.57 mm) or more, cylinder block
2.343 in. (59.50 mm) needs replacement.
X
d
d Y
Measuring Diameter of the Piston Skirt

Measure diameter of the piston

2.321 in. (58.96 mm) If 2.319 in. (58.90 mm) or less, piston needs
replacement.
0.020 in. (0.50 mm) Oversize If 2.339 in. (59.40 mm) or more, cylinder block
2.341 in. (59.460 mm) needs replacement.
Measuring Piston Clearance (Clearance Between Piston and Cylinder)

Minimum cylinder bore measurement
– maximum piston measurement
= piston clearance

0.001 - 0.002 in. (0.020 – 0.055 mm) If 0.006 in. (0.15 mm) or more, requires
replacement.
Page 4B–22 90-857138R1 MAY 2000

Measuring Outer Diameter of Piston Pin

0.6299 in. (16 mm) If 0.6287 in. (15.97 mm) or less requires
replacement
Measuring Diameter of the Piston Pin Hole

0.6300 in. (16.002 mm) Depends on clearance between piston pin and
hole.
Clearance Between Piston Pin and Piston Pin Hole

0.0001 - 0.0005 in. (0.002 – 0.012 mm) If 0.00157 in. (0.04 mm) or more requires
replacement
1. Subtract the piston pin diameter from the piston pin hole diameter.
Measuring Piston Ring Side Clearance

Top 0.0015 - 0.003 in. (0.04 – 0.08 mm) If 0.0039 in. (0.10 mm) or more requires
replacement
Second 0.0012 - 0.003 in. (0.03 – 0.07 mm) If 0.0035 in. (0.09 mm) or more requires
replacement
Oil 0.0004 - 0.007 in. (0.01 – 0.18 mm) If 0.0082 in. (0.21 mm) or more requires
replacement
1. Measure between piston ring and ring groove.
90-857138R1 MAY 2000 Page 4B–23

Measuring Piston Ring End Gap

Top 0.006 - 0.014 in. (0.15 – 0.35 mm) If 0.020 in. (0.5 mm) or more requires
replacement
Second 0.012 - 0.020 in. (0.30 – 0.50 mm) If 0.028 in. (0.7 mm) or more requires
replacement
Oil 0.008 - 0.016 in. (0.20 – 0.40 mm) If 0.024 in. (0.6 mm) or more requires
replacement
Push piston rings into cylinder approximately 0.8 in. (20 mm) deep. Push in the rings using
the piston.
Measuring Diameter of the Small End of Connecting Rod

0.6303 in. (16.01 mm) If 0.6315 in. (16.04 mm) or more requires
replacement
Measuring Side Clearance of the Big End of Connecting Rod

0.008 - 0.016 in. (0.2 – 0.4 mm) If 0.027 in. (0.7 mm) or more requires replacement
Page 4B–24 90-857138R1 MAY 2000

Measuring Diameter of Crank Pin “A”

1.179 in. (29.94 mm) If 1.177 in. (29.91 mm) or less requires
replacement
Measuring Outer Diameter of Crankshaft in the Oil Pan Bearing “B”

0.983 in. (24.98 mm) If 0.982 in. (24.96 mm) or less requires
replacement
Measuring Oil Clearance at Big End of Connecting Rod Using Plastigauge

0.002 - 0.003 in. (0.053 - 0.079 mm) If 0.0035 in. (0.090 mm) or more requires
replacement
1. Clean all the oil from the connecting rod and crank pin.
2. Place the connecting rod on the crank pin.
3. Place a piece of plastigauge on the crank pin.
IMPORTANT: Do not rotate connecting rod when measuring clearance.
4. Install the connecting rod cap. Torque bolts to 106 lb-in. (12 Nm).
5. Remove the connecting rod cap and measure the compressed plastigauge to check the
connecting rod oil clearance. Out of specification, replace.
90-857138R1 MAY 2000 Page 4B–25

Measuring Camshaft Lobe Height “A” Intake/Exhaust

NOTE: 2000 model year outboards have hp mark located on cam gear as shown below. For
2001 model year, all will have 6 hp camshaft.

4 hp - 0.993 in. (25.24 mm) 0.983 in. (24.96 mm) or less requires replacement
Measuring Camshaft Bearing Diameter “B”

0.550 in. (13.98 mm) 0.549 in. (13.95 mm) or less requires replacement
CAM ID
4 (1999 & 2000) 4
A
5 (1999 & 2000) 5
6 (2000) 6
4/5/6 (2001) 6
B
Measuring Inside Diameter of Oil Pan Bearing - Crankshaft

0.985 in. (25.01 mm) Depends of clearance
Clearance Between the Oil Pan Bearing and Crankshaft

0.0006 - 0.0015 in. (0.015 – 0.040 mm) If 0.002 in. (0.06 mm) or more requires replacement
Subtract the crankshaft diameter from the oil pan bearing diameter.
Page 4B–26 90-857138R1 MAY 2000

Measuring Inside Diameter of Oil Pan Bearing - Camshaft

0.5515 in. (14.01 mm) Depends of clearance
Clearance Between the Oil Pan Bearing and Camshaft

0.0008 - 0.002 in. (0.02 - 0.05 mm) If 0.0028 in. (0.07 mm) or more requires
replacement
Subtract the camshaft diameter from the oil pan diameter.
Inspecting Push Rod

1. Inspect push rod for straightness, replace if bent.
2. Replace push rod if corroded or if tips of rod are worn.
Inspecting Valve Lifter
1. Replace valve lifter if worn or corroded.
a - Push Rod
b - Valve Lifter
90-857138R1 MAY 2000 Page 4B–27

Measuring Depth of Oil Pump Body

0.236 in. (6.0 mm) If 0.238 in. (6.06 mm) or more requires replacement
Measuring Inside Diameter of Oil Pump Body

0.909 in. (23.09 mm) If 0.910 in. (23.13 mm) or more requires
replacement
Page 4B–28 90-857138R1 MAY 2000

Measuring Clearance Between Inner and Outer Rotors “A”

0.006 in. (0.15 mm) or less If 0.008 in. (0.20 mm) or more requires replacement
Measure Clearance Between Outer Rotor and Body “B”

0.005 - 0.008 in. (0.12 - 0.20 mm) If 0.010 in. (0.25 mm) or more requires replacement
A
B
Measuring Height of Oil Pump Outer Rotor

0.236 in. (5.99 mm) If 0.234 in. (5.96 mm) or less requires replacement
Measuring Side Clearance Between Oil Pump Outer Rotor and Body
0.0008 - 0.0028 in. (0.02 - 0.07 mm) If 0.004 in. (0.10 mm) or more requires replacement
a b
a - Straight Edge
b - Clearance Measured Using a Feeler Gauge
90-857138R1 MAY 2000 Page 4B–29

Measuring/Testing Thermostat
1. Inspect thermostat, replace if stuck or damaged.
2. Use Measurement Test following to measure:

a. Valve opening temperature.
b. Valve lift.
MEASUREMENT TEST
1. Tie a piece of thread (or other non-conductive material) onto the thermostat.
2. Suspend the thermostat in water.
3. Heat water slowly while observing the thermostat.
a - Valve Lift
Water Temperature Valve Lift
Below 122° F (50° C) 0 in. (0 mm)
Above 145° F (67° C) Minimum 0.12 in. (3 mm)
Page 4B–30 90-857138R1 MAY 2000

Powerhead Reassembly
General
Before proceeding with powerhead reassembly, be sure that all parts to be reused have
been carefully cleaned and thoroughly inspected as outlined in “Cleaning and Inspection,”
preceding. Parts, which have not been properly cleaned (or which are questionable), can
severely damage an otherwise perfectly good powerhead within the first few minutes of
operation.
New gaskets MUST BE installed during reassembly.
During reassembly, lubricate parts with Quicksilver 4-Cycle Outboard Oil whenever “light
oil” is specified. Quicksilver part numbers of lubricants, sealers and locking compounds are
listed under “Quicksilver Lubricants and Service Aids,” preceding.
A torque wrench is required for correct reassembly of powerhead. DO NOT attempt to reas-
semble powerhead without using a torque wrench. Attaching bolts for covers and housings
MUST BE torqued by tightening bolts in 3 progressive steps (following specified torque se-
quence) until specified torque is reached. Powerhead torques are listed under “Torque
Specifications,” preceding.
1. Install new oil seal using a suitable mandrel.
a - Oil Seal – Press in Until it Bottoms Out
90-857138R1 MAY 2000 Page 4B–31

2. Install the breather tubes and wave washers.
a - Breather Tube (2)

b - Wave Washer (2)
3. Install the breather cap.
a - Screw (2)
b - Breather Cap
c - Gasket
Breather Cap Screw Torque
70 lb-in. (8 Nm)
Page 4B–32 90-857138R1 MAY 2000

4. Press the top bearing into housing using a suitable mandrel (numbered side of bearing
facing oil pan). Press only on bearing outer race and until the bearing is fully seated in
the housing.
110

a - Top Bearing – Press in Until it Bottoms Out
5. Press oiled crankshaft into the top bearing. Make sure the crankshaft is seated against
the top bearing.
6. Check to see if the top bearing and crankshaft are fully seated. Lay a straight edge
across the cylinder block and measure the distance between top of gear and straight
edge. The distance should be 1/32 in. (0.7 mm).
c 1/32 in. (0.7 mm)
a - Press Crankshaft into Top Bearing Until it is Fully Seated

b - Straight Edge
c - Required Distance Between Gear and Straight Edge
90-857138R1 MAY 2000 Page 4B–33

7. Assemble connecting rod to piston, secure with piston pin and new piston pin clips.
NOTE: Make sure the connecting rod is orientated correctly for reassembling (3H6 mark
must face the oil pan).
NOTE: Reassemble the piston so that the arrow faces the camshaft.
NOTE: 4/5 hp has flat top piston. 6 hp has dome type piston. 6 hp will be marked on top of
piston.
d
4/5 hp 6 hp
c
110
a 3H6 d e
110
f
4-Stroke Outboard Oil (92-828000A12)
a - Connecting Rod (3H6 must Face the Oil d - Piston Pin Clip (2)
Pan) e - Direction Arrow (Must Face The Camshaft)
b - Piston f - Piston Pin Clips Should Bridge the Notch in
c - Piston Pin the Piston
Piston Ring and Piston Identification Marks
Size Top Piston Ring Second Piston Ring Piston
1N 2N
or UP UP
Standard Size N 6
NOTE: Some early mod-

els may not have these
identification marks
NOTE: 6 hp will have a
6 on top of piston
1N 50 2N UP
50 UP
or
Oversize N
NOTE: Some early mod-

0.5
els may not have these

identification marks
0.5
Page 4B–34 90-857138R1 MAY 2000

CAUTION
Eye protection must be worn while installing piston rings.
IMPORTANT: Do Not mistake the top and second piston rings. The rings are different
and must be installed in correct order.
NOTE: The piston ring end gaps must be staggered as shown to avoid alignment with the
piston pin.
8. Install the oil ring as follows:
a. Set the oil ring expander in the oil ring groove. Position the ring ends with the 120°
location as shown. Match the ring ends correctly as shown in Figure1.
b. While holding down the oil ring ends by a thumb, install the upper side rail. Position
the end gap at 13/16 in. (20 mm) to the left of the oil ring ends.
c. As in the same manner as the above step b, install the lower side rail. Position the
end gap at 13/16 in. (20 mm) to the right of the oil ring ends.
9. Install the top and second ring in the correct order. Install the piston rings with the mark-
ing side facing up.
10. Make sure the rotation of the piston rings are smooth.
11. Position the piston end gaps at the positions shown.
91-24697
a
Figure 1
Incorrect
b
c
k h
Correct
60°
d 13/16 in.
(20 mm) j
Piston ID
e
4/5 (1999 & 2000) No Mark 13/16 in.
(20 mm)
6 (2000) 6 60°
4/5/6 (2001) 6 i g
a - Top Ring – Chrome g - End Gap – Top Ring

b - Second Ring – Tapered h - End Gap – Second Ring
c - Upper Side Rail i - End Gap – Upper Side Rail
d - Oil Ring Expander j - End Gap – Oil Ring Expander
e - Lower Side Rail k - End Gap – Lower Side Rail
f - Install Rings With Marking
Side Facing Up
90-857138R1 MAY 2000 Page 4B–35

12. Lubricate piston, rings, connecting rod journals and cylinder bore with engine oil.
13. Use Piston Ring Compressor (FT 2997) to compress rings.
14. Position mark 3H6 towards oil pan.
15. Position the direction arrow < towards the cam shaft.
16. Install the piston assembly.
Connecting Rod Bolt Torque

1st Torque: 53 lb-in. (6 Nm)
2nd Torque: 106 lb-in. (12 Nm)
FT 2997
b
d
3H6
a
c
110
3H6
110
3H6
a - Piston Ring Compressor (FT2997)
b - Position Mark 3H6 Towards Oil Pan
c - Direction Arrow (Must Face The Camshaft)
d - Connecting Rod Bolts (2)
Page 4B–36 90-857138R1 MAY 2000

17. Install the lifters at this time.

18. Reassemble the camshaft. Align the mark on the camshaft with the mark on the timing
gear.
CAM ID
4 (1999 & 2000) 4
5 (1999 & 2000) 5
6 (2000) 6
4/5/6 (2001) 6
110
c
110
b
4-Stroke Outboard Oil (92-828000A12)
a - Lifters
b - Camshaft
c - Alignment Marks
19. Reinstall the cylinder head.
NOTE: Be sure cylinder head and cylinder block gasket surfaces are clean and free of oil.
Cylinder Head Bolt Torque

18 lb-ft (24.5 Nm)
d
c b
a - Make Sure Gaskets Surfaces are Clean and Free of Oil
b - Cylinder Head
c - Push Rods (2)
d - Gasket
e - Bolt (2) M8 x 90 mm
f - Bolts (2) M8 x 60 mm
90-857138R1 MAY 2000 Page 4B–37

20. Reinstall covers and intake manifold to the cylinder head.
Covers and Intake Manifold Bolt Torque

(a) Thermostat Cover Bolts: 70 lb-in. (8 Nm)
(g) Intake Manifold Bolts: 70 lb-in. (8 Nm)
(k) Cylinder Head Cover Bolts: 70 lb-in. (8 Nm)
b
g
c
d h
e
i
j
k
a - Bolt (2) M6 x 40 mm h - Intake Manifold
b - Throttle Cable Bracket i - O-Ring Seal
c - Spacer (2) j - Bolt (4) M6 x 20 mm
d - Thermostat Cover k - Flat Washer (4)
e - Gasket l - Cylinder Head Cover
f - Thermostat m - Gasket
g - Bolt (2) M6 x 25 mm
Page 4B–38 90-857138R1 MAY 2000

21. Reinstall the parts shown to the oil pan.
Covers and Intake Manifold Bolt Torque

(a) Clamp Screw: 31 lb-in. (3.5 Nm)
(d) Oil Pump Body Bolt: 31 lb-in. (3.5 Nm)
(j) Oil Pressure Relief Valve Bolt: 70 lb-in. (8 Nm)
(s) Exhaust Plate Bolt: 70 lb-in. (8 Nm)
r
p
s a
q
9
b
110 7
d
j k
c
n o
l
g
m
110 f h
7 Loctite “271” (92-809819)

9 Loctite Pipe Sealant w/Teflon-567 (92-809822)
a - Screw M5 x 16 mm k - Cover
b - Clamp l - Seat
c - Pipe m - O-Ring Seal
d - Screw (2) M5 x 16 mm n - Spring
e - Flat Washer (2) o - Plunger
f - Seal (2) p - Grommet
g - Body q - Oil Pressure Sensor
h - Strainer r - Exhaust Plate with Gasket
i - Cup s - Bolt (3) M6 x 20 mm
j - Bolt M6 x 16 mm
90-857138R1 MAY 2000 Page 4B–39

22. Install new oil seal in the oil pan using a suitable mandrel.
a - Oil Seal
23. Install the oil pan. Torque bolts following torque sequence.
e
f
a
4
b c 2 8
9
d
1 7
5
a - Oil Pan
b - Gasket - Oil Pan
c - Gasket - Cylinder Head
d - Washer - Place on Crankshaft
e - Bolt with Washers (6) M8 × 40 mm
f - Bolt with Washers (3) M6 × 40 mm
Oil Pan Bolt Torque

M8 × 40 mm Bolt (6): 18.5 lb-ft (25 Nm)
M6 × 40 mm Bolt (3): 80 lb-in. (9 Nm)
Page 4B–40 90-857138R1 MAY 2000

24. Reinstall the oil pump.

25. Prime the oil pump by pouring approximately 1 fl oz. (30 ml) of engine oil into the oil pump
inlet side.
a
g b
d
110
e
f

a - Bolt (2) M6 X 16 mm
b - Cover
c - O-Ring Seal
d - Rotor - Outer
e - Rotor - Inner
f - Pin
g - Match the Pin With the Pocket in the Inner Rotor
h - Pour Approximately 1 fl oz. (30 ml) of Engine Oil into the Oil Pump Inlet Side
Oil Pump Cover Bolt Torque

70 lb-in. (8 Nm)
90-857138R1 MAY 2000 Page 4B–41

26. Support oil seal housing and install two seals and spacer. Use driver and mandrel as
shown.
9184529M
d
9183172M
a - Seal
b - Spacer
c - Driver
d - Mandrel
27. Reinstall the oil seal housing.
a - Oil Seal Housing

b - Bolt (2) M6 x 20 mm
c - Gasket
Oil Seal Housing Bolt Torque
70 lb-in. (8 Nm)
Page 4B–42 90-857138R1 MAY 2000

Powerhead Installation
1. Secure powerhead (with new gasket) onto drive shaft housing using 6 bolts. Torque
bolts to 70 lb-in. (8 Nm).
Powerhead Mounting Bolt Torque

70 lb-in. (8 Nm)
56327
a - Powerhead Mounting Bolts with Washers (6) M6 x 30 mm
2. Install the following components/assemblies referring to the listed service manual

section(s).
Component/Assembly Section
a Rewind Starter 8
b Flywheel/CDI Unit/Ignition Coils 2A
c Carburetor 3B
d Fuel Pump 3A
e Throttle Linkage 7
90-857138R1 MAY 2000 Page 4B–43

MID-SECTION
MID-SECTION
Section 5
Table of Contents
Quicksilver Lubricants and Service Aids . . . . 5-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 5-2 Clamp Bracket/Swivel Bracket . . . . . . . . . 5-8
Clamp Brackets . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Drive Shaft Housing . . . . . . . . . . . . . . . . . . 5-11
Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Bottom Cowling . . . . . . . . . . . . . . . . . . . . . . 5-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Water Tube . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

92-825407A12 2-4-C with Teflon Marine Lubricant
92-809820 Loctite 271
92-13783A24 Quicksilver Super Duty Gear Lubricant
5
90-857138R1 MAY 2000 Page 5-1

MID-SECTION
Driveshaft Housing
5
4
95
6
1
8
10
11
12
13
14
7 Loctite 271 (92-809820)

95 2-4-C With Teflon (92-825407A12)
Page 5-2 90-857138R1 MAY 2000

MID-SECTION
Driveshaft Housing
TORQUE
REF.
REF
1 DRIVESHAFT HOUSING (SHORT)
1
1 DRIVESHAFT HOUSING (LONG)
2 1 BUSHING
3 1 EXHAUST PLUG
4 1 GASKET
5 2 DOWEL PIN
6 6 BOLT 70 8
7 1 WATER PLUG
8 1 GASKET
9 1 GROMMET
10 1 GROMMET
11 1 HOUSING
12 1 BUSHING (LONG)
13 1 RETAINER
2 SCREW (SHORT)
14
2 SCREW (LONG)
90-857138R1 MAY 2000 Page 5-3

MID-SECTION
Clamp Brackets
95
17 24 23
28
18
6 1
5 25
19
20
21
30 29
22 31
95
95
16 26
4 33
15
32
27
11 14 95
95
14
2
95
15 10
4
13 95 9
12
37 7
8
36
35
34
95 2-4-C With Teflon (92-825407A12)
Page 5-4 90-857138R1 MAY 2000

MID-SECTION
Clamp Brackets
TORQUE
REF.
REF
1 1 STARBOARD CLAMP BRACKET
2 1 PORT CLAMP BRACKET
3 1 BOLT
4 2 WASHER
5 1 WASHER
6 1 NUT 25 2.8
7 1 DISTANCE PLATE
8 2 SCREW 36 4
9 1 SPRING
10 1 TILT STOPPER
11 1 GRIP
12 2 BOLT 70 8
13 1 SET PLATE
14 2 BUSHING
15 2 CLAMP SCREW KIT
16 2 WASHER
17 1 THRUST ROD
18 1 SPRING
19 1 SPRING
20 1 WASHER
21 1 SCREW
22 1 SWIVEL BRACKET A
23 1 SWIVEL BRACKET B
24 1 THRUST PLATE
25 1 BUSHING–UPPER
26 1 BUSHING–LOWER
27 2 THRUST PLATE
28 4 BOLT 70 8
29 1 SCREW
30 1 SPRING
31 1 WASHER
32 2 GREASE FITTING
33 2 CAP
34 1 REVERSE LOCK ARM
35 2 BOLT 70 8
36 1 SPRING
37 1 SPRING
90-857138R1 MAY 2000 Page 5-5

MID-SECTION
Cowling
21
3
2
11 14
8
13
12
9 17
16
10 15
7
6 18
19
20
4
5
Page 5-6 90-857138R1 MAY 2000

MID-SECTION
Cowling
REF
REF.
NO. QTY. DESCRIPTION
1 TOP COWL (BLACK)
1
1 TOP COWL (SILVER)
2 1 SEAL
3 1 GROMMET
4 1 BOTTOM COWL
5 1 GROMMET
6 1 GROMMET
7 1 GROMMET
8 4 BOLT
9 4 WASHER
10 1 GROMMET
11 1 COVER HOOK
12 1 BOLT
13 1 WASHER
14 1 WAVE WASHER
15 1 BUSHING
16 1 SEAL RING
17 1 HOOK LEVER
18 1 FLUSH PLUG
19 1 TOOL KIT
20 1 ROPE
1 DECAL-EPA INFO(1999)(SEE NOTE)
21
1 DECAL-EPA INFO(2000)(SEE NOTE)
NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY
MISSING OR UNREADABLE EPA LABEL.
90-857138R1 MAY 2000 Page 5-7

MID-SECTION
Disassembly
Refer to parts view on page 5A-4 and disassemble mid-section components as required.
Reassembly
Clamp Bracket/Swivel Bracket
1. Install tilt lever spring over tilt lever.
2. Place tilt lever/spring in pocket of swivel bracket.
a
c
b
b
a
56370
56371
a - Tilt Lever Spring

b - Tilt Lever
c - Nylon Bushing Halves (2); Coat I.D. with 2-4-C w/Teflon Marine Lubricant
3. Secure tilt lever/spring to swivel bracket, using plate, lock washers and bolts. Torque
bolts to 70 lb-in. (8 Nm).
4. Secure tilt spring to starboard clamp bracket, using screw and washer.
d
f
b e
56372
a - Plate d - Tilt Spring

b - Lock Washer (2) e - Screw
c - Bolt (2) f - Washer
Page 5-8 90-857138R1 MAY 2000

MID-SECTION
5. Secure clamp brackets to swivel bracket.

a
d d c
e
b f
56374
56373
a - Swivel Bracket
b - Bolt; Installed from Port Side
c - Clamp Bracket (Port)
d - Washers (2); Coat with 2-4-C w/Teflon Marine Lubricant
e - Clamp Bracket (Starboard)
f - Tilt Lever Indexed in Starboard Clamp Bracket
c
a
56375
56376
a - Tilt Lever Indexed in Port Clamp Bracket

b - Washer
c - Nut; Torque to 25 lb-in. (2.8 Nm)
90-857138R1 MAY 2000 Page 5-9

MID-SECTION
a
b b
56379
a - Tie Bar
b - Screws (2); Torque Screws to 36 lb-in. (4 Nm)
56377
a - Nylon Bushing Halves

b - Rubber Mount - Upper
c - Rubber Mount - Lower
d - Friction Plate
Page 5-10 90-857138R1 MAY 2000

MID-SECTION
Drive Shaft Housing

1. Apply a thin coat of 2-4-C w/Teflon Marine Lubricant to both inside and outside diameters
of rubber mounts.
2. Install rubber mounts and nylon bushing halves onto drive shaft housing.
b
c
56378
a - Nylon Bushing Halves (2); Coat with 2-4-C w/Teflon Marine Lubricant
b - Rubber Mount - Upper (Marked “Up”)
c - Rubber Mount - Lower
3. Install drive shaft housing into swivel bracket, positioning rubber mounts and nylon
bushing halves, as shown.
IMPORTANT: Rubber face of friction plate and area of drive shaft housing traveled by
friction plate must be free of lubrication.
4. Install friction plate into pocket of swivel bracket.
5. Install rear half of swivel bracket over drive shaft housing, and secure it to front half, us-
ing 4 bolts with washers. Torque bolts to 70 lb-in. (8 Nm).
6. Install steering friction knob, spring and washer.
c d e
58504
a - Rear Half d - Spring
b - Bolt (4) e - Washer
c - Steering Friction Knob
90-857138R1 MAY 2000 Page 5-11

MID-SECTION
7. Install tilt lock pin.

8. Secure reverse lock hook onto bosses of swivel bracket.
c
d
b
e
a
56381 56382
a - Tilt Lock Pin

b - Reverse Lock Hook
c - Spring - Port
d - Spring - Starboard
e - Bolts (2); Torque Bolts to 70 lb-in. (8 Nm)
Bottom Cowling
1. Attach components to bottom cowl and secure bottom cowl to drive shaft housing, as
shown.
e
d
56383
a - Bottom Cowl
b - Bolt with Washer (4); Torque Bolts to 70 lb-in. (8 Nm)
c - Guide Pins (2)
d - Water Tube
e - Water Tube Seal
Page 5-12 90-857138R1 MAY 2000

MID-SECTION
Water Tube
1. Install water tube into drive shaft housing, as shown.
a a
b
c
d
56384 56385
a - Water Tube
b - Water Tube Seal
c - Guide Plate
d - Screw (2)
2. Install shift linkage, as outlined in Section 8 “Shift Linkage.”

3. Install powerhead, as outlined in Section 4A “Powerhead.”
4. Install gear housing, as outlined in Section 6 “Gear Housing.”
90-857138R1 MAY 2000 Page 5-13

GEAR HOUSING
GEAR HOUSING
Section 6
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Forward, Reverse and Pinion Gears . . . . . . 6-20
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Quicksilver Lubricants and Service Aids . . . . . . . 6-3 Sliding Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . . . . 6-4 Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Gear Housing (Prop Shaft) . . . . . . . . . . . . . . . . . . 6-6 Water Pump Components . . . . . . . . . . . . . . . 6-21
Draining and Inspecting Gear Housing Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Propeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Gear Housing Reassembly . . . . . . . . . . . . . . . . . 6-22
Gear Housing Removal . . . . . . . . . . . . . . . . . . . . . 6-9 Lower Drive Shaft Needle Bearing . . . . . . . . 6-22
Gear Housing Disassembly . . . . . . . . . . . . . . . . . 6-10 Forward Gear Bearing . . . . . . . . . . . . . . . . . . 6-23
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Pinion Gear and Drive Shaft . . . . . . . . . . . . . 6-24
Water Pump Housing and Impeller . . . . . . . . 6-13 Water Pump Base and Shift Shaft . . . . . . . . 6-25
Water Pump Base and Shift Shaft . . . . . . . . 6-14 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Forward Gear and Bearing . . . . . . . . . . . . . . 6-17 Impeller and Water Pump Housing . . . . . . . . 6-30
Lower Drive Shaft Needle Bearing . . . . . . . . 6-18 Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Water Pickup Screen . . . . . . . . . . . . . . . . . . . 6-33
Water Pickup Screen . . . . . . . . . . . . . . . . . . . 6-19
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 6-19
Gear Housing Installation . . . . . . . . . . . . . . . . . . .
Propeller Installation . . . . . . . . . . . . . . . . . . . . . . .
6-33
6-35
6
Gear Housing/Bearing Carrier Castings . . . 6-19 Filling Gear Housing with Lubricant . . . . . . . . . . 6-36
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Specifications
Gear Ratio 2.15:1
Gearcase Capacity 6.5 fl oz (195 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 28 Spiral/Bevel
GEAR HOUSING Pinion Gear
(2.15:1) Number of Teeth 13 Spiral/Bevel
Pinion Height Floating
Forward Gear Backlash No Adjustment
Water Pressure*:
@ 1300 rpm (Idle) Neutral 2.3 - 3.6 psi (16 - 25 kPa)
@ 5000 rpm 8 - 15 psi (55 - 103.5 kPa)
*Water pressure readings will vary with thermostat operation.
90-857138R1 MAY 2000 Page 6-1

GEAR HOUSING
Special Tools
1. Lower Drive Shaft Bearing Drive (91-17351) NLA
2. Puller (91-27780)
3. Puller Assembly (91-83165M)
4. Mandrel (91-83174M) NLA
Page 6-2 90-857138R1 MAY 2000

GEAR HOUSING
5. Driver Rod (91-84529M) NLA

92-13872A1 Special Lubricant 101
92-19007A24 Quicksilver Gear Lubricant
92-34227-1 Perfect Seal
90-857138R1 MAY 2000 Page 6-3

GEAR HOUSING
Gear Housing (Drive Shaft)

32 95
95
30
33
29 26
34 27
87
12
28
36 25
14 24
95
23
35
13
87
37 22
38
95
39 21
40
2 41 20
1
19
3
4 11 18
7
10
6 17
7 8 16
5 9
15
95
4 7
3
7 Loctite 271 (92-809820)
87 Super Duty Gear Lubricant (92-13783A24)
95 2-4-C With Teflon (92-825407A12)
Page 6-4 90-857138R1 MAY 2000

GEAR HOUSING
Gear Housing (Drive Shaft)

TORQUE
REF.
REF
– 1 GEAR HOUSING (SHORT)
– 1 GEAR HOUSING (LONG)
1 1 GEAR HOUSING (BASIC)
2 1 BEARING
3 2 PLUG
4 2 GASKET
5 1 BOLT 70 8
6 1 WASHER
7 1 PINION GEAR
8 1 WATER STRAINER
9 1 SCREW 70 8
10 1 BOLT 70 8
11 1 WASHER
1 DRIVESHAFT (SHORT)
12
1 DRIVESHAFT (LONG)
13 1 BEARING
14 1 KEY
15 1 GASKET
AR SHIM (0.1)
16
AR SHIM (0.15)
17 1 OIL SEAL
18 1 WATER PUMP HOUSING–LOWER
19 1 GASKET
20 1 GUIDE PLATE
21 1 GASKET
22 1 IMPELLER
23 1 LINER
24 1 WATER PUMP HOUSING–UPPER
25 2 SEAL
26 1 HOSE
27 4 BOLT 70 8
28 4 WASHER
29 1 SEAL
30 1 WATER TUBE (SHORT)
31 1 WATER TUBE (LONG)
32 1 GROMMET
1 CAM ROD (SHORT)
33
CAM ROD (LONG)
34 1 ROLL PIN
35 1 RETAINER
36 1 BOLT 70 8
37 1 O RING
38 1 BUSHING
39 1 O RING
40 1 CLUTCH CAM
41 1 ROLL PIN
AR = As Required
90-857138R1 MAY 2000 Page 6-5

GEAR HOUSING
Gear Housing (Prop Shaft)
63
64
48
1
50
49 94
46 47
45
44
43
42
87
62
61
60
57
87 95
55 58
54 59
53
56
87 Super Duty Gear Lubricant (92-13783A24)

51 52 94 Anti-Corrosion Grease (92-78376A6)
95
95 2-4-C With Teflon (92-825407A12)
Page 6-6 90-857138R1 MAY 2000

GEAR HOUSING
Gear Housing (Prop Shaft)

TORQUE
REF.
REF
– 1 GEAR HOUSING (SHORT)
– 1 GEAR HOUSING (LONG)
1 1 GEAR HOUSING-BASIC
42 1 BEARING
AR SHIM (0.1)
43
AR SHIM (0.15)
44 1 FORWARD GEAR
45 1 PUSH ROD
46 1 RETAINER
47 1 CLUTCH
48 1 PIN
49 1 SPRING
50 1 PROPELLER SHAFT
51 1 WASHER
52 1 REVERSE GEAR
53 1 BEARING
54 1 OIL SEAL
55 1 O RING
56 1 BEARING CARRIER
57 2 BOLT 70 8
58 1 THRUST HOLDER
OPT. PROPELLER (6 PITCH)
OPT. PROPELLER (6 PITCH – SAILBOAT)
59 1 PROPELLER (7 PITCH – 4 H.P. STANDARD)
1 PROPELLER (8 PITCH - 5 H.P. STANDARD)
OPT PROPELLER (9 PITCH)
60 1 WASHER
61 1 PROP NUT
62 1 COTTER PIN
63 1 BOLT 70 8
64 1 ANODE
90-857138R1 MAY 2000 Page 6-7

GEAR HOUSING
Draining and Inspecting Gear Housing Lubricant

1. Remove “OIL” (fill) plug and “OIL LEVEL” (vent) plug. Let gear housing lubricant drain
into clean drain pan.
NOTE: 2000 model year and later outboards have upper and lower water drain holes.
b
c
a
56387
a - Fill Plug
b - Vent Plug
c - Water Drain Holes
2. Inspect lubricant for metal particles. Presence of a small amount of fine particles (resem-
bling powder) indicates normal wear. Presence of larger particles or a large quantity of
fine particles indicates need for gear housing disassembly and component inspection.
3. Note the color of lubricant. White or cream color indicates presence of water in lubricant.
4. Check drain pan for water separation from lubricant. Presence of water in lubricant indi-
cates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, gas-
kets and gear housing components.
Propeller Removal
WARNING
To prevent accidental engine starting remove and isolate spark plug lead from
spark plug before removing gear housing, place a block of wood between the anti-
ventilation plate and propeller, to protect hands from propeller blades while turning
propeller nut.
1. Remove cotter pin.
2. Place a block of wood between anti-ventilation plate and propeller blade.
a
56388 56389
a - Cotter Pin
b - Block of Wood
Page 6-8 90-857138R1 MAY 2000

GEAR HOUSING
3. Remove nut, washer, propeller and thrust hub.
a b
d
56390
a - Nut
b - Washer
c - Propeller
d - Thrust Hub
Gear Housing Removal

WARNING
To prevent accidental engine starting, remove (and isolate) spark plug lead from
spark plug BEFORE removing gear housing.
1. Remove (and isolate) spark plug lead from spark plug.
2. Shift outboard into “Reverse” gear.
3. Tilt (and lock) outboard to full “Up” position.
4. Remove plug.
5. Loosen bolt to loosen shift shaft clamp.
c
a b
56391 56392
a - Plug
b - Bolt
c - Shift Shaft Clamp
90-857138R1 MAY 2000 Page 6-9

GEAR HOUSING
6. Remove bolts with washers.

7. Guide gear housing from drive shaft housing.
a
56306
56393
a - Bolts with Washers
Gear Housing Disassembly

Bearing Carrier
1. Remove two bolts that secures bearing carrier.
CAUTION
Make sure to keep gear housing from falling when bearing carrier loosens.
2. Clamp propeller shaft in soft jaw vise. Use soft face mallet to strike gear housing approxi-
mately midway between anti-ventilation plate and bearing carrier cavity.
56394 56395
a - Bolts (2)
b - Bearing Carrier
Page 6-10 90-857138R1 MAY 2000

GEAR HOUSING
3. Pull propeller shaft from bearing carrier. Retain cam follower with propeller shaft.
4. Remove O-ring.
a
b
56396 56397
a - Propeller Shaft
b - Cam Follower
c - O-ring
IMPORTANT: Propeller shaft bearing is damaged during removal. Do not remove
bearing unless replacement is necessary. Refer to “Cleaning and Inspection,” follow-
ing.
5. Remove propeller shaft bearing using puller assembly with suitable jaws and suitable
plate.
NOTE: Propeller shaft bearing has to be removed (see step 5) before removing propeller
shaft oil seal.
6. Remove propeller shaft oil seal, using puller assembly with suitable jaws and suitable
plate.
91-83165M 91-83165M e
b b
c c c c
d d
56398 56399
a - Propeller Shaft Bearing

b - Puller Assembly
c - Suitable Jaws
d - Suitable Plate
e - Propeller Shaft Oil Seal
90-857138R1 MAY 2000 Page 6-11

GEAR HOUSING
Propeller Shaft
1. Remove reverse gear and washer.
2. Remove cam follower and guide.
d
56400
c
56401
a - Reverse Gear
b - Washer
c - Cam Follower
d - Guide
3. Using a punch, tap cross pin from sliding clutch. Leave punch in hole to retain spring at
this time.
4. Put end of shaft against solid object. Remove punch from sliding clutch, and slowly re-
lease spring compression.
a d
56402
c 56403
a - Sliding Clutch
b - End of Shaft
c - Punch
d - Sliding Clutch
Page 6-12 90-857138R1 MAY 2000

GEAR HOUSING
5. Remove spring.
6. Remove sliding clutch.
b 56405
56404
a - Spring
b - Sliding Clutch
Water Pump Housing and Impeller

1. Remove 4 bolts with flat washers.
2. Remove water pump housing components and drive pin from drive shaft.
56406 56407
a - Bolts (4)
b - Drive Pin
3. Remove water pickup tube.

4. Remove water tube seal.
56408 56409
a - Pick-up Tube
b - Water Tube Seal
90-857138R1 MAY 2000 Page 6-13

GEAR HOUSING
5. Remove water pickup seal.

6. Remove water pump impeller.
56411
56410
a - Water Pick-up Seal

b - Water Pump Impeller
7. Remove insert.
56412
a - Insert
Water Pump Base and Shift Shaft

1. Remove gasket.
2. Remove plate and gasket.
b
a
56413 56414
a - Gasket
b - Plate
c - Gasket
Page 6-14 90-857138R1 MAY 2000

GEAR HOUSING
3. Remove bolt, washer and retainer plate.

4. Remove shift shaft assembly and bushing.
e
a
c
b
56416
56415
a - Bolt
b - Washer
c - Retainer Plate
d - Shift Shaft Assembly
e - Bushing
5. Remove O-ring.
6. Remove water pump base.
b
a
56417 56418
a - O-ring
b - Water Pump Base
90-857138R1 MAY 2000 Page 6-15

GEAR HOUSING
7. Remove gasket.
8. Support water pump in a vise and remove drive shaft oil seal using puller assembly with
suitable jaws.
91-83265M
d
c
d
56419
56420
a - Gasket
b - Drive Shaft Oil Seal
c - Puller Assembly
d - Suitable Jaws
9. Remove water pickup tube seal.
56421
a - Water Pick-up Tube Seal
Page 6-16 90-857138R1 MAY 2000

GEAR HOUSING
Drive Shaft
IMPORTANT: Retain shim(s) for reassembly.
1. Remove shim(s).
2. Remove drive shaft assembly and pinion gear.
a
b
56422 56423
a - Shims
b - Drive Shaft Assembly
c - Pinion Gear
Forward Gear and Bearing

1. To remove forward gear, strike open end of gear housing on a block of wood as shown,
dislodging gear from bearing. Make sure to retain shim(s) found behind gear for reas-
sembly.
IMPORTANT: Forward gear bearing is damaged during removal. DO NOT remove
bearing unless replacement is necessary. Refer to “Cleaning and Inspection” follow-
ing.
2. Remove forward gear bearing using puller.
a
c
b 91-27780
56425 56426
a - Open End of Gear Housing
b - Forward Gear Bearing
c - Puller
90-857138R1 MAY 2000 Page 6-17

GEAR HOUSING
Lower Drive Shaft Needle Bearing

1. Drive lower drive shaft needle bearing from gear housing, using bearing removal/instal-
lation tool.
91-17351
d
c
56427
a - Lower Drive Shaft Needle Bearing

b - Collar: Installed on End of Driver Rod
c - Driver Rod
d - Guide Bushing: Seated in Water Pump Base Cavity of Gear Housing
Zinc Anode
1. Remove and replace zinc anode if more than 50% consumed.
NOTE: 2000 model year outboards have rectangular style zinc anode.
56428
b
57757
a - Zinc Anode (1999)

b - Rectangular Style Zinc Anode (2000 and Later)
Page 6-18 90-857138R1 MAY 2000

GEAR HOUSING
Water Pickup Screen

1. Remove screw and water pickup screen.
a
b
56429
a - Screw
b - Water Pick-up Screen

Gear Housing/Bearing Carrier Castings
1. Thoroughly clean gear housing/bearing carrier castings. Be sure all old gasket material
is removed from mating surfaces and that carbon deposits have been removed from ex-
haust passages.
2. Inspect castings for cracks or fractures.
3. Inspect upper and lower water drain holes to ensure they are not clogged.
a - Water Drain Holes

4. Check sealing surfaces for nicks, deep grooves and distortion which could cause leaks.
5. Check water passages for obstructions.
Bearings
BALL BEARINGS
CAUTION
DO NOT spin-dry ball bearings with compressed air.
1. Clean bearing in solvent and dry with compressed air.
2. Bearing should be free of rust stains.
3. Attempt to work inner bearing race in-and-out. There should not be excessive play.
90-857138R1 MAY 2000 Page 6-19

GEAR HOUSING
4. Lubricate ball bearing with Quicksilver Gear Lube. Rotate inner bearing race. Bearing
should have smooth action. If ball bearing sounds or feels rough or has catches, remove
and discard bearing. Refer to “Disassembly” preceding.
56430
NEEDLE BEARING
1. Clean needle bearings in solvent and dry with compressed air.
2. Replace bearing if needles are rusted, fractured, worn, galled badly, discolored, or if
area of shaft that bearing contacts is worn or pitted. Refer to “Drive Shaft” following.
56431
Forward, Reverse and Pinion Gears

1. Replace gear if gear teeth or clutch teeth are chipped, worn or cracked.
b b
a
56432
a - Gear Teeth
b - Clutch Teeth
Page 6-20 90-857138R1 MAY 2000

GEAR HOUSING
Propeller Shaft
1. Replace propeller shaft if any of the following conditions exist:
a. Splines are twisted or worn.
b. Oil seal surfaces are deeply grooved; allowing water to enter gear housing.
c. Sliding clutch slot worn.
d. Propeller nut threads stripped, damaged or excessively worn.
a
b a
d
c
56433
2. Check propeller shaft for straightness. Place shaft on either balance wheels or “V”
blocks and rotate shaft while observing spline area for bend (wobble). Replace shaft (if
bent).
Sliding Clutch
1. Replace sliding clutch if jaws are rounded or chipped or splines are damaged or worn.
b
56434
a - Jaws
b - Splines
Cam Follower
1. Replace cam follower if end of follower shows signs of wear.
56435
Water Pump Components

1. Replace water pump components if worn, grooved or if components show evidence of
over heat or other damage.
90-857138R1 MAY 2000 Page 6-21

GEAR HOUSING
Drive Shaft
1. Replace drive shaft if any of the following conditions exist:
a. Splines are twisted or worn.
b. Lower drive shaft needle bearing race surfaces are pitted or worn. Replace corre-
sponding bearing as well.
c. Oil seal surfaces are deeply grooved or pitted allowing grease to wash off crankshaft
splines or water to enter gear housing.
a c a
c b
a - Splines
b - Bearing Race Surface
c - Oil Seal Surface
Shift Shaft
Inspect shift shaft/cam for signs of wear, damaged roll pins or bent shaft.
56436
Gear Housing Reassembly

Lower Drive Shaft Needle Bearing
1. Place drive shaft needle bearing onto end of driver rod of bearing removal/installation
tool. (Numbered side of bearing toward tool.)
b
a
91-17351
56437
a - Drive Shaft Needle Bearing

b - End of Driver Rod
Page 6-22 90-857138R1 MAY 2000

GEAR HOUSING
2. Drive lower drive shaft needle bearing into gear housing, using bearing removal/installa-
tion tool.
91-17351
b
c
56438
a - Lower Drive Shaft Needle Bearing: Installed on End of Driver Rod

b - Guide Bushing: Seated in Water Pump Cavity of Gear Housing
c - Driver Rod: Tap in with Hammer Until Head of Driver Rod Seats Against Guide
Bushing
Forward Gear Bearing

1. Install forward gear ball bearing (numbered side of bearing toward tool) using driver rod
and mandrel.
91-84529M
c
a
91-84532M
56439
a - Forward Gear Ball Bearing

b - Driver Rod
c - Mandrel
90-857138R1 MAY 2000 Page 6-23

GEAR HOUSING
Forward Gear
1. Install shim(s) removed during disassembly on forward gear.
2. Install forward gear into bearing, using propeller shaft and bearing carrier as a guide.
d
b
c
56440 56441
a - Shims
b - Forward Gear
c - Propeller Shaft
d - Bearing Carrier
Pinion Gear and Drive Shaft

NOTE: Rotate drive shaft when installing to align splines with pinion gear.
1. Install drive shaft into pinion gear as shown.
c
a
56423 56422
a - Drive Shaft
b - Pinion Gear
c - Shims
2. Reinstall shims removed during disassembly.
Page 6-24 90-857138R1 MAY 2000

GEAR HOUSING
Water Pump Base and Shift Shaft

IMPORTANT: Seal should be installed flush with water pump base as shown.
1. Push new oil seal into water pump base using rod and mandrel.
2. Lubricate seal lip with 2-4-C w/Teflon Marine Lubricant.
91-84529M
95
b 91-84530M
56443
d
95 2-4-C With Teflon (92-825407A12) 56442
a - Oil Seal
b - Water Pump Base
c - Rod
d - Mandrel
3. Install new water pump base gasket.

4. Install water pump base.
a b
56419 56418
a - Water Pump Base Gasket

b - Water Pump Base
90-857138R1 MAY 2000 Page 6-25

GEAR HOUSING
IMPORTANT: Make sure taper of cam is opposite to bend in shift shaft as shown.
5. Secure cam to shift shaft with roll pin and install (center) pin in shaft.
6. Lubricate O-ring with 2-4-C w/Teflon Marine Lubricant and install into water pump base.
95
c d
b
a
95 2-4-C With Teflon (92-825407A12) 56444 56417
a - Cam
b - Roll Pin
c - Center Pin
d - O-ring
7. Slide bushing on shift shaft.

8. Position taper of cam toward drive shaft and insert shift shaft into gear housing.
56445 56416
a - Bushing
b - Shift Shaft
c - Taper
Page 6-26 90-857138R1 MAY 2000

GEAR HOUSING
9. Install retainer plate, washer and bolt. Torque bolt to 70 lb-in. (8 Nm).
10. Install water pickup tube seal and apply 2-4-C w/Teflon Marine Lubricant to I.D. of seal.
95
d
c
a
b
56415 56446
95 2-4-C With Teflon (92-825407A12)
a - Retainer Plate
b - Washer
c - Bolt
d - Seal
Propeller Shaft
1. Install sliding clutch so that cross pin hole of clutch aligns with slot in propeller shaft.
2. Install spring.
b d
c
a
56405 56404
a - Sliding Clutch
b - Cross Pin Hole
c - Slot
d - Spring
90-857138R1 MAY 2000 Page 6-27

GEAR HOUSING
3. Mount a suitable screwdriver or drift punch in a vise. Tool must 1) fit into end of propeller
shaft and 2) compress spring as shown.
4. Compress spring beyond cross pin hole and insert punch thru cross pin holes to retain
spring as shown.
5. Install cross pin opposite to punch driving punch out of clutch as cross pin is installed.
Cross pin should be centered into clutch, as shown.
d d
b
a
b
b
c b
d
56448
56449
a - Suitable Screwdriver Blade or Punch
b - Punch
c - Spring
d - Cross Pin
6. Apply a small amount of 2-4-C w/Teflon Marine Lubricant to hold guide and cam follower
in place. Install guide and cam follower into end of propeller shaft.
7. Install reverse gear and washer onto propeller shaft as shown.
a
95
56400
95 2-4-C With Teflon (92-825407A12)
b
56401
a - Guide c - Reverse Gear
b - Cam Follower d - Washer
Page 6-28 90-857138R1 MAY 2000

GEAR HOUSING
Bearing Carrier
1. Install propeller shaft oil seal into bearing carrier using driver rod and mandrel.
2. Lubricate lip of oil seal using 2-4-C w/Teflon Marine Lubricant.
CAUTION
Press only on bearing outer race when installing.
3. Press propeller shaft bearing (from numbered side) into carrier using mandrel.
95
91-84529M d
91-84536M
b
e
91-83174M
95 2-4-C With Teflon (92-825407A12) 56450 56451
a - Propeller Shaft Oil Seal d - Propeller Shaft Bearing

b - Driver Rod e - Mandrel
c - Mandrel
4. Install new O-ring and lubricate with 2-4-C w/Teflon Marine Lubricant.
5. Install bearing carrier onto propeller shaft as shown.
95
56397 56396
95 2-4-C With Teflon (92-825407A12)
a - O-ring
90-857138R1 MAY 2000 Page 6-29

GEAR HOUSING
6. Install bearing carrier and propeller shaft assembly into gear housing.
7. Secure carrier assembly with 2 bolts and washers. Torque bolts to 70 lb-in. (8 Nm).
56452 56394
a - Bolts (2)
Impeller and Water Pump Housing

1. Install gasket and plate.
2. Install gasket.
b
c
56414 56413
a - Gasket
b - Plate
c - Gasket
Page 6-30 90-857138R1 MAY 2000

GEAR HOUSING
3. Install water pump insert into water pump housing making sure to position locating tab
of insert into slot of housing.
4. Install water pick-up tube seal. Lubricate I.D. of seal with 2-4-C w/Teflon Marine
Lubricant.
95
a
d
b c
56412 56410
95 2-4-C With Teflon (92-825407A12)
a - Water Pump Insert

b - Locating Tab
c - Slot
d - Pick-up Tube Seal
5. Install water tube seal into base so rubber tabs insert into holes. Lubricate I.D. of seal
with 2-4-C Marine Lubricant.
6. Install water pickup tube into seal as shown.
d
c
56409 56453
95 2-4-C With Teflon (92-825407A12)
a - Water Tube Seal

b - Rubber Tabs
c - Holes
d - Water Pick-up Tube
90-857138R1 MAY 2000 Page 6-31

GEAR HOUSING
7. Lubricate drive pin with 2-4-C w/Teflon Marine Lubricant and place into flat of shaft as
shown. Install water pump impeller over drive pin.
95
95 2-4-C With Teflon (92-825407A12) 56454
a - Drive Pin
b - Water Pump Impeller
8. Apply a light coat of 2-4-C w/Teflon Marine Lubricant to the inside of the water pump im-
peller insert.
9. While rotating drive shaft clockwise, push down on water pump housing to cover impel-
ler guiding water pickup tube into seal.
10. Secure water pump housing to gear housing with four bolts and washers. Torque bolts
to 70 lb-in. (8 Nm).
95
b
c
d
56406
56455
95 2-4-C With Teflon (92-825407A12)
a - Rotate Drive Shaft Clockwise d - Seal

b - Water Pump Housing e - Bolts/Washers (4)
c - Water Pickup Tube
Page 6-32 90-857138R1 MAY 2000

GEAR HOUSING
Zinc Anode
1. Secure zinc anode with bolt. Torque bolt to 70 lb-in. (8 Nm).
b
a c b
56428
a - Zinc Anode (1999)

b - Bolt
c - Zinc Anode (2000 and Later)
Water Pickup Screen
1. Secure pick-up screen using screw.
b
a
56429
a - Pick-up Screen
b - Screw
Gear Housing Installation

WARNING
To prevent accidental engine starting remove (and isolate) spark plug lead from
spark plug before installing gear housing.
1. Remove and isolate spark lead from spark plug.
2. Tilt and lock outboard to full “UP” position.
90-857138R1 MAY 2000 Page 6-33

GEAR HOUSING
IMPORTANT: Both gear housing and outboard shift lever must be shifted into reverse
when installing gear housing to enable the shift shaft to align with clamp.
3. Shift outboard shift lever to “Reverse.”
4. While rotating propeller shaft, push down on shift shaft to place gear housing into “Re-
verse” gear. Propeller shaft will not rotate more than a few degrees in either direction
when in reverse.
5. Lubricate splines of drive shaft with 2-4-C w/Teflon Marine Lubricant.
6. Guide gear housing into driveshaft housing while aligning the following.
a. Driveshaft and splines into upper drive shaft seal guide tube and into crankshaft
splines. It may be necessary to rotate flywheel to align splines.
b. Shift shaft with hole in clamp located on end of upper shift shaft and out thru grommet
in driveshaft housing which operates reverse lock hook.
c. Seal of water pump housing with water tube.
7. Secure gear housing to driveshaft housing using 2 bolts and flat washers. Torque bolts
to 70 lb-in. (8 Nm).
d
a
d
b
56306
56393
a - Drive Shaft c - Water Tube

b - Shift Shaft d - Bolts (2)
8. Secure upper shift shaft and lower shift shaft together using clamp. Tighten bolt secure-
ly.
9. Check shift operation for gearcase neutral and shift handle neutral to be in sync. Read-
just shift handle clamp if necessary.
10. Install plug.
a
b
c
56392 56391
a - Clamp c - Plug
b - Bolt
Page 6-34 90-857138R1 MAY 2000

GEAR HOUSING
Propeller Installation
CAUTION
To prevent accidental engine starting remove (and isolate) spark plug lead from
spark plug. Put a block of wood between anti-ventilation plate and propeller blade.
1. Coat propeller shaft with one of the following Quicksilver products:
a. Anti-Corrosion Grease
b. 2-4-C w/Teflon Marine Lubricant
2. Install thrust hub, propeller, washer and nut onto propeller shaft, starting propeller nut
by hand.
NOTE: Thrust plate on thrust hub is available as a separate part. Replace if worn.
3. Put a block of wood between anti-ventilation plate and propeller. Torque nut to 150 lb-in.
(17 Nm).
f g
b
d c
a
56390 56389
a - Thrust Hub e - Thrust Plate

b - Propeller f - Block of Wood
c - Washer g - Anti-Ventilation Plate
d - Nut
4. Secure nut with cotter pin.
56388
a - Cotter Pin
90-857138R1 MAY 2000 Page 6-35

GEAR HOUSING
Filling Gear Housing with Lubricant

IMPORTANT: DO NOT use automotive lubricant in gear housing. Use only Quicksilver
Gear Lube.
1. Remove any old gasket material from “OIL” and “OIL LEVEL” plugs and from around
plug openings of gear housing.
2. Install new gaskets on “OIL” and “OIL LEVEL” plugs.
IMPORTANT: Never add lubricant to gear housing without first removing “OIL LEV-
EL” (vent) plug, as trapped air will prevent housing from being filled. Fill gear housing
only when outboard is in operating position.
3. With outboard in operating position, insert lubricant tube into “OIL” (fill) hole.
4. Fill gear housing with lubricant, until excess starts to flow from “OIL LEVEL” (vent) hole
(approximately 6.5 fl oz. [195 mL] of Quicksilver Gear Lube).
5. Install “OIL LEVEL” (vent) plug.
6. Remove lubricant tube and install “OIL” (fill) plug.
a c
56456 56387
a - Fill Hole
b - Vent Hole
c - Vent Plug
d - Fill Plug
Page 6-36 90-857138R1 MAY 2000

SHIFT LINKAGE
CONTROLS
Section 7A - Shift Linkage
Table of Contents
Shift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Reassembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . 7A-5

7
A
90-857138R1 MAY 2000 Page 7A-1

SHIFT LINKAGE
Shift Components
4 5 6
7
95
2
3 8
95
12
10
11
95 2-4-C With Teflon (92-825407A12)
Page 7A-2 90-857138R1 MAY 2000

SHIFT LINKAGE
Shift Components
TORQUE
REF.
REF
1 1 SHIFT LEVER
2 1 BALL
3 1 SPRING
4 2 O RING
5 1 PIN
6 1 COTTER PIN
7 1 BOLT Drive Tight
8 1 SHIFT ROD LEVER
1 SHIFT ROD (SHORT)
9
1 SHIFT ROD (LONG)
10 1 WASHER
11 1 JOINT (SET)
90-857138R1 MAY 2000 Page 7A-3

SHIFT LINKAGE
Removal/Disassembly
1. Remove powerhead referring to Section 4A “Powerhead” Also remove gear housing
referring to Section 6, “Gear Housing.”
2. Remove screw and slide lever off shaft of shift lever.
3. Remove upper shift shaft and lever assembly.
d
a b
c 57235 57236
a - Screw
b - Slide Lever
c - Shift Lever Shaft
d - Shift Shaft Lever Assembly
4. Disconnect starter lock rod snap and remove rod.
b
a
56990
a - Starter Lock Rod Snap

b - Rod
Page 7A-4 90-857138R1 MAY 2000

SHIFT LINKAGE
5. Remove shift lever.

6. Remove detent ball and spring.
a c
b
57238 57239
a - Shift Lever
b - Detent Ball
c - Spring
Reassembly/Installation
1. Lubricate detent spring and ball with 2-4-C with Teflon Marine Lubricant and install ball
and spring in cavity as shown.
2. Install two O-rings on shaft of shift lever. Coat shaft and O-rings with 2-4-C with Teflon
Marine Lubricant and install shift lever.
e
d
a
b
95
c
95
57239 56539
95 2-4-C With Teflon (92-825407A12)
a - Detent Spring
b - Ball
c - Cavity
d - O-rings (2)
e - Shift Lever Shaft
90-857138R1 MAY 2000 Page 7A-5

SHIFT LINKAGE
3. Install starter lock rod and secure with snap.
b
a
56990
a - Starter Lock Rod

b - Snap
4. Install upper shift shaft assembly into drive shaft housing.

5. Secure lever on shaft of shift lever with screw as shown. Tighten screw securely.
d b
57236 c 57235
a - Shift Shaft Assembly

b - Lever
c - Shaft
d - Screw
6. Reinstall powerhead. Refer to Section 4B “Powerhead.”

7. Reinstall gear housing. Refer to Section 6 “Gear Housing.”
Page 7A-6 90-857138R1 MAY 2000

TILLER HANDLE
CONTROLS
Section 7B - Tiller Handle
Table of Contents
Steering Handle . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-5
Steering Handle . . . . . . . . . . . . . . . . . . . . . . . . . 7B-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-9

7
B
90-857138R1 MAY 2000 Page 7B-1

TILLER HANDLE
Steering Handle
34
33
32
31
30
29
28
23 24 25
27
25
22 95
21 26
20 95
18
19 17
16
1
15
14
95 2
13 3
12
11 9 4
5
8
7
6
10 95 2-4-C With Teflon (92-825407A12)
Page 7B-2 90-857138R1 MAY 2000

TILLER HANDLE
Steering Handle
TORQUE
REF.
REF
– 1 STEERING HANDLE KIT
1 1 STEERING HANDLE
2 1 RIVET
3 1 THROTTLE SHAFT
4 1 BRACKET
5 1 SCREW DRIVE TIGHT
6 1 ADJUSTING SCREW
7 1 WASHER
8 1 FRICTION PIECE
9 1 NUT
11 1 GRIP
12 1 SHAFT-RUBBER
13 1 BUSHING
14 1 DECAL
15 2 STUD TIGHT
16 1 WASHER
17 1 SPACER
18 2 BUSHING
19 1 BUMPER
20 1 STOPPER
21 2 LOCKWASHER
22 2 NUT 70 8
24 1 CLAMP
25 2 THROTTLE WIRE
26 2 COLLAR
27 1 BRACKET
28 2 BOLT 70 8
29 1 THROTTLE DRUM
30 1 THROTTLE ROD
31 1 THROTTLE OPENER
32 1 COLLAR
33 1 WASHER
34 1 BOLT 70 8
90-857138R1 MAY 2000 Page 7B-3

TILLER HANDLE
Removal
1. Remove J-Clip Screw.
2. Remove throttle drum retaining bolt.
3. Loosen throttle cable adjustment nuts and remove cables from drum.
c
b
57230
a - J-Clip Screw
b - Bolt
c - Nuts (2)
4. Remove 2 nuts and lockwashers securing retaining plate.
c
a
57010
a - Nuts (2)
b - Lockwashers (2)
c - Retaining Plate
Page 7B-4 90-857138R1 MAY 2000

TILLER HANDLE
5. Remove cable ends from pulley of throttle shaft and remove tiller handle from bottom
cowl.
c d e
b
f a 57011
a - Cable Ends
b - Retainer Plate
c - Inner Bushing
d - Outer Bushing
e - Sleeve
f - Nylon Washer
Disassembly
1. Slide outer bushing, sleeve and nylon washer (hidden) from handle.
a
c
b
57009
a - Outer Bushing
b - Sleeve
c - Nylon Washer
90-857138R1 MAY 2000 Page 7B-5

TILLER HANDLE
2. Remove screw from handle grip.

3. Remove handle grip from handle.
b
a
c b
56613 56614
a - Screw
b - Handle Grip
c - Handle
4. Remove rubber spacer and nylon bushing from throttle shaft.

5. Remove screw and plate from handle. Then pull throttle shaft from handle.
d e
b a
f
56615 c
56616
a - Rubber Spacer d - Plate
b - Nylon Bushing e - Handle
c - Screw f - Throttle Shaft
6. Remove adjusting screw and washer from friction block. Then slide block off shaft.
d
a
56617
a - Adjusting Screw
b - Washer
c - Friction Block
d - Throttle Shaft
Page 7B-6 90-857138R1 MAY 2000

TILLER HANDLE
Reassembly
1. Slide friction block over throttle shaft and secure adjustment screw to block, using wash-
er and nut.
2. Install throttle shaft into handle and secure with screw and plate.
g h
e c
a
b
b f
56616
56617
a - Friction Block
b - Throttle Shaft
c - Adjustment Screw
d - Washer
e - Nut
f - Screw
g - Plate
h - Handle
3. Install nylon bushing and rubber spacer over throttle shaft.
4. Apply 2-4-C Marine Lubricant to handle and install handle grip aligning arrow of grip with
boss of handle.
a f
b
d
56615 56614
c 95
95 2-4-C With Teflon (92-825407A12)
a - Rubber Space
b - Nylon Bushing
c - Handle
d - Handle Grip
e - Aligning Arrow
f - Boss
90-857138R1 MAY 2000 Page 7B-7
TILLER HANDLE
5. Pushing handle grip against rubber spacer, to align holes and secure grip to end of
throttle shaft, using screw.
6. Apply 2-4-C Marine Lubricant to handle and install nylon washer, spacer and outer bush-
ing onto tiller handle.
c
f
95 d
e
b
a
95 2-4-C With Teflon (92-825407A12)
56613
a - Screw
b - Handle Grip
c - Nylon Washer
d - Handle
e - Spacer
f - Outer Bushing
7. Lubricate pulley of throttle shaft, with 2-4-C w/Teflon Marine Lubricant.
95
95 2-4-C With Teflon (92-825407A12) 56545
a - Pulley
Page 7B-8 90-857138R1 MAY 2000

TILLER HANDLE
Installation
1. Install inner bushing in bottom cowl. Lubricate bushing with 2-4-C w/Teflon Marine Lubri-
cant.
95
95 2-4-C With Teflon (92-825407A12)

57500
a - Inner Bushing
2. Insert throttle cables through plate and inner bushing.
a
b
57499
a - Cables
b - Retainer Plate
90-857138R1 MAY 2000 Page 7B-9

TILLER HANDLE
3. Install nylon washer, spacer and outer bushing onto tiller handle.
a
c
57502
a - Nylon Washer
b - Spacer
c - Outer Bushing
4. Connect throttle cables to cable drum in tiller handle and (while keeping throttle cables
in their respective locating pockets) install tiller handle assembly onto bottom cowl. Se-
cure tiller arm with 2 nuts and lockwashers. Torque nuts to 70 lb-in. (8 Nm).
b
c
57501
a - Cable Drum
b - Locating Pockets (hidden)
c - Nuts and Lockwashers [Torque to 70 lb-in. (8 Nm)]
d - Verify wire harness is clear of retainer plate stop when tiller handle is tilted up
Page 7B-10 90-857138R1 MAY 2000

TILLER HANDLE
5. Route throttle cables to carburetor and secure with j-clip.

6. Slide throttle cable ends into throttle drum. Secure throttle drum with bolt.
7. Place end of throttle cable jackets into retaining bracket.
8. With throttle arm of carburetor against idle speed screw, remove slack from throttle
cables with adjustment nuts.
d
c
57230
a - J-clip
b - Throttle Drum
c - Bolt
d - Adjustment Nuts
90-857138R1 MAY 2000 Page 7B-11

MANUAL STARTER
MANUAL STARTER
Section 8
Table of Contents
Recoil Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . 8-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

92-809819 Loctite 271
90-857138R1 MAY 2000 Page 8-1

MANUAL STARTER
Recoil Starter
22
26
23 24
25 27
15
18 20 21
19
28
17 20
29
16 1
95
10
9 2
11
12
3
15
4 5 4
6
7 6
95 7
8
14
13
7 Loctite 271 (92-809820)

95 2-4-C With Teflon (92-825407A12)
Page 8-2 90-857138R1 MAY 2000

MANUAL STARTER
Recoil Starter
TORQUE
REF.
REF
– 1 RECOIL STARTER ASSEMBLY
1 1 STARTER HOUSING
2 1 SPRING SET
3 1 REEL
4 2 RETURN SPRING
5 1 FRICTION SPRING
6 2 RATCHET
7 1 FRICTION PLATE
8 1 BOLT 70 8
9 1 SEAL PLATE
10 1 STARTER ROPE
11 1 STARTER HANDLE
12 1 ROPE ANCHOR
13 1 STARTER PULLEY
14 3 BOLT 70 8
15 2 ROD SNAP
16 1 STARTER LOCK ROD
17 1 STARTER LOCK CAM
19 1 COLLAR
20 2 WASHER
21 1 SPRING
22 1 STARTER LOCK
24 1 SPRING
25 1 COLLAR
26 3 BOLT 70 8
27 3 LOCKWASHER
28 1 CLAMP
29 1 LOCKWASHER
90-857138R1 MAY 2000 Page 8-3

MANUAL STARTER
Removal
1. Remove top cowl.
2. Disconnect interlock link rod.
3. Remove three bolts and lift manual starter assembly.
56489
57229
a - Link Rod
b - Bolts (3)
Installation
1. Install rewind assembly, using bolts and lockwashers. Torque bolts to 70 lb-in. (8 Nm).
Reconnect interlock link rod.
b
a
c
57229
a - Rewind Assembly
b - Bolts/Lockwashers
c - Link Rod
Page 8-4 90-857138R1 MAY 2000

MANUAL STARTER
Disassembly
WARNING
When disassembling rewind starter, SAFETY GLASSES must be worn, in case
spring should uncoil.
CAUTION
Starter sheave must be firmly held against spring tension to prevent spring from
unwinding.
1. Pull starter rope until rope is fully unwound from sheave. Hold sheave in this position,
complete steps 2 and 3.
2. Lift end of rope from knot recess and untie or cut off knot. Pull remaining rope from starter
sheave.
c
b a
56491
56492
a - Starter Rope
b - Sheave
c - End of Rope
d - Knot Recess
3. Allow sheave to slowly unwind to release spring tension.

4. Untie or cut off knot and pull starter tope from retainer and handle.
IMPORTANT: Melt ends of starter rope to prevent fraying.
a d b
57225 56493
a - Sheave
b - Knot
c - Retainer
d - Handle
90-857138R1 MAY 2000 Page 8-5

MANUAL STARTER
5. Remove bolt.
6. Lift starter sheave assembly from housing.
7. Disassemble components as shown.
57225
57224
a - Bolt
8. Lift spring housing and coiled spring out of starter housing.

9. If necessary, remove rope guide.
b
c
57226 56469
a - Spring Housing and Coiled Spring

b - Starter Housing
c - Rope Guide
Page 8-6 90-857138R1 MAY 2000

MANUAL STARTER
10. Remove starter interlock screw, lockwasher, flat washer, spring, collar (hidden) and cam.
11. Remove screw, washer, spring, collar, and starter lock.
k
i f
e d
j
c
b
h a
g
a - Starter Interlock Screw g - Screw

b - Lockwasher h - Washer
c - Flat Washer i - Spring
d - Spring j - Collar
e - Collar (hidden) k - Starter Lock
f - Cam

1. Clean components in solvent and dry with compressed air.
WARNING
Spring tension is strong enough to cause serious injury if spring is released.
IMPORTANT: It is not necessary to remove rewind spring from housing for inspec-
tion.
2. If necessary, remove rewind spring from spring housing, by carefully unwinding coiled
spring.
a
b
56474
57226
a - Rewind Spring
b - Spring Housing
3. Inspect rewind spring for kinks, burrs, corrosion or breakage.
4. Inspect starter sheave, rope guide and starter housing for nicks, grooves, cracks, wear
or distortion, especially area of rope travel.
5. Inspect interlock components, springs, ratchet pawls, and friction plate for wear or dam-
age.
6. Inspect starter rope for wear.
7. Replace components as necessary.
90-857138R1 MAY 2000 Page 8-7

MANUAL STARTER
Reassembly
CAUTION
When reassembling rewind starter, safety glasses must be worn in case spring
should uncoil out of housing.
1. Apply a small amount of 2-4-C Marine Lubricant in starter housing as shown.
56655
95 2-4-C With Teflon (92-825407A12)
a - 2-4-C Marine Lubricant
2. Apply a thin coat of non-metallic low temperature grease to spring cavity of starter hous-
ing.
3. Place outer hook of starter spring in slot of housing and wind spring clockwise into spring
cavity.
4. Install spring/housing assembly into starter housing while positioning inner spring hook
onto starter housing tab.
b
d f
c 56474 57226
a - Outer Hook
b - Starter Spring
c - Slot
d - Starter Housing
e - Inner Spring Hook
f - Starter Housing Tab
Page 8-8 90-857138R1 MAY 2000

MANUAL STARTER
5. Apply a small amount of 2-4-C Marine Lubricant in starter housing and install sheave.
6. Install ratchet pawls, and pawl springs into starter sheave as shown.
a
95
57226
95 2-4-C With Teflon (92-825407A12)

b 57224
a - Pawl Springs (2)
b - Ratchet Pawls (2)
7. Apply Loctite 271 to bolt. Torque bolt to 70 lb-in. (8 Nm).
a
7
7 Loctite 271 (92-809820)

57225
a - Bolt
90-857138R1 MAY 2000 Page 8-9

MANUAL STARTER
8. Install rope guide if previously removed. Install interlock components, if removed, as

shown. Apply Loctite 271 to threads on screw (a) and screw (g) and tighten securely.
i f
e
d
j
c
b
7
h a
7
g
7 Loctite 271 (92-809820) 57227
a - Screw
b - Lockwasher
c - Flat Washer
d - Spring
e - Collar (hidden)
f - Interlock Cam
g - Screw
h - Flat Washer
i - Spring
j - Collar (hidden)
k - Starter Lock
Page 8-10 90-857138R1 MAY 2000

MANUAL STARTER
9. Tie knot as shown, thread rope thru retainer and handle.

10. Thread starter rope thru rope guide, starter housing and starter sheave. Tie knot in end
of rope as shown in inset and pull knot tight.
b a
f e
a
c
g
56500 56535
a - Knot
b - Retainer
c - Handle
d - Starter Rope
e - Rope Guide
f - Starter Housing
g - Starter Sheave
11. Turn sheave 2-1/2 turns CLOCKWISE with rope coiling into sheave. Hold rope in slot
while turning sheave 3 turns COUNTERCLOCKWISE. Allow sheave to slowly rewind
remainder of loose rope.
b c
56536
a - Turn Sheave 2-1/2 Turns Clockwise

b - Slot
c - Turn Sheave 3 Turns Counterclockwise
12. Pull starter handle and check for the following:

a. Smooth operation of starter pawls.
b. Free movement of starter rope.
c. Starter rope rewinds completely.
13. Install manual starter assembly on engine as shown on page 8-4.
90-857138R1 MAY 2000 Page 8-11

COLOR DIAGRAMS
COLOR DIAGRAMS
Table of Contents
4/5/6 (4-Stroke) Wiring Diagram . . . . . . . . . . . Page 9-3 4/5/6 (4-Stroke) Oil Flow Diagram . . . . . . . . . Page 9-7
4/5/6 (4-Stroke) Water Flow Diagram . . . . . . Page 9-5
90-857138R1 MAY 2000 Page 9-1

COLOR DIAGRAMS
Page 9-2 90-857138R1 MAY 2000

COLOR DIAGRAMS
4/5/6 (4-STROKE)
WIRING DIAGRAM
90-857138R1 MAY 2000 Page 9-3

4/5/6 (4-Stroke) Wiring Diagram
1. Lighting Coil (Optional)

2. Crank Position Sensor
3. Light Extension Harness (Optional) 3
4. Connection To 12 Volt Battery (Optional)
1
5. Rectifier (Optional)
6. Fuse –10 Amp (Optional)
4
7. Ignition Coil
8. CDI Unit
2 6
9. Stop Switch
10. Oil Lamp 5
11. Oil Pressure Switch
7
12. Ignition Charge Coil
12
10
11
58088
COLOR DIAGRAMS
4/5/6 (4-STROKE)
WATER FLOW DIAGRAM
90-857138R1 MAY 2000 Page 9-5

4/5/6 (4-Stroke) Water Flow Diagram
58555
COLOR DIAGRAMS
4/5/6 (4-STROKE)
OIL FLOW DIAGRAM
90-857138R1 MAY 2000 Page 9-7

4/5/6 (4-Stroke) Oil Flow Diagram
Pressurized Oil
Splash Oil
58556

Mercury Mariner 4, 5, 6 4 Stroke Sevice Manual

Uploaded by

Copyright:

Available Formats

Mercury Mariner 4, 5, 6 4 Stroke Sevice Manual

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mercury Mariner 4, 5, 6 4 Stroke Sevice Manual

Uploaded by

Copyright:

Available Formats

What safety precautions should be observed when servicing an engine?

What safety precautions should be observed when servicing an engine?

What are the main components of a manual starter assembly?

What are the main components of a manual starter assembly?

SERVICE

Starting Serial Numbers

Printed in U.S.A. 2000, Mercury Marine 90-857138R1 MAY 2000

Notice to Users of This Manual

90-857138R1 MAY 2000 Page i

Cleanliness and Care of Outboard Motor

90-826883 R1 JANUARY 1998 Page - 6A-7

Revision No. 1 Section Number

Month of Printing Part of Section Letter

Year of Printing Page Number

Page ii 90-857138R1 MAY 2000

90-857138R1 MAY 2000 Page iii

Model 4/5/6 (4-Stroke)

+80 +27 Use Quicksilver 4-Cycle Marine Oil with

Alternator (Optional) Type:

90-857138R1 MAY 2000 Page 1A-1

Type Capacitor Discharge Ignition

Float Height 0.35 - 0.39 in. (9 - 10 mm)

Page 1A-2 90-857138R1 MAY 2000

Fuel Pump Type External (Plunger/Diaphragm)

Outer Diameter 0.6299 in. (16.00 mm)

90-857138R1 MAY 2000 Page 1A-3

Crankshaft Runout Less than 0.002 in. (0.05 mm)

Inside Diameter of Oil Pan Bearing:

Crankshaft to Oil Pan Bearing

Page 1A-4 90-857138R1 MAY 2000

Free Length (Intake/Exhaust) “a”

Warp Limit * 0.0012 in. (0.03 mm)

CYLINDER HEAD * Lines indicate

90-857138R1 MAY 2000 Page 1A-5

Valve/Valve Seat/Valve Guides:

Valve Opening Temperature 122°F - 129°F (50°C - 54°C)

Page 1A-6 90-857138R1 MAY 2000

Pump Type Trochoid

Transom Height - Short Shaft 17 in. (38 cm)

90-857138R1 MAY 2000 Page 1A-7

Propeller Information Charts

Approx. Approx. Speed

Approx. Approx. Speed

Approx. Approx. Speed

*Standard propeller shipped with outboard.

Page 1A-8 90-857138R1 MAY 2000

90-857138R1 MAY 2000 Page 1B-1

2. 2-4-C Marine Lubricant with Teflon P/N 92-850736A1

3. SAE 10-30W Motor Oil P/N 92-802833A1

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

Page 1B-2 90-857138R1 MAY 2000

Inspection and Maintenance Schedule

90-857138R1 MAY 2000 Page 1B-3

Flushing The Cooling System

a - Plug and Gasket

Page 1B-4 90-857138R1 MAY 2000

Corrosion Control Anode

Spark Plug Inspection

90-857138R1 MAY 2000 Page 1B-5