Optimax 75 90 115 DFI-2004 and Up

75 90 115 Optimax.
qxd 4/16/2003 9:06 AM Page 1
75/90/115 Optimax
75/90/115
Optimax
Direct Fuel Injection
Starting Model Year 2004

90-889785 April 2003
Starting Model Year 2004
Serial Number 0T801000 & Up
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com

Frankston Road P.O. Box 1939 (Parc Industriel de Petit-Rechain)
P.O. Box 80 Fond du Lac, WI 54936-1939 USA B-4822 Verviers/Belgium
Dandenong, Victoria 3175 Australia
English Version 90-889785
©April 2003, Mercury Marine. All rights reserved. Printed in U.S.A. International Version 90-892302
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.
90-889785 APRIL 2003 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:
90-859769 R1 JULY 2003 - 6A-7
Revision No. 1
Month of Printing Section Number
Year of Printing Part of Section Letter
Page Number
Page ii 90-889785 APRIL 2003
Service Manual Outline
Section 1 - General Information & Specifications
General Information
& Specifications 1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Electrical
2
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Fuel System
3
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Direct Fuel Injection
Powerhead
4
C - Oil Injection
D - Emissions
Section 4 - Powerhead
A - Powerhead
Mid-Section
5
B - Cooling
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
Gear Housing
6
B - Power Trim
Section 6 - Gear Housing
Section 7 - Attachments/Control Linkage
Section 8 - Color Diagrams
Attachment/Control Linkage
7
Color Diagrams
8
90-889785 APRIL 2003 Page iii

SPECIFICATIONS
IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Master Specifications . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants and
Propeller Information Charts . . . . . . . . . . . . . . . . 1A-7 Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10
Master Specifications
Model 75/90/115 DFI
HORSEPOWER Model 75 55.2 kw (75)
(HP) Model 90 66.2 kw (90)
Model 115 84.6 kw (115)
Full Throttle RPM (75/90/115) 5000 - 5750
Idle RPM (In Gear) (75/90/115) 625 – 675

RPM Limiter
Model 75/90/115 5800
OUTBOARD Model 75/90/115
WEIGHT – 20 in. (50.8cm) Shaft 163.3 kg (360.0 lbs.)
– 25 in. (63.5cm) Shaft 168.7 kg (372.0 lbs.)
CYLINDER Type 3 Cylinder, Two Cycle, Direct Injected
BLOCK Displacement 1523.5 cc (92.9 cu. in.) In-line
Thermostat 61°C (142°F)
Water Pressure
Idle 20.6 – 41.3 kPa (3 – 6 psi)
Poppet Valve Opening 48.3 – 62.1 kPa (7 – 9 psi)
W.O.T. 75.8 – 96.5 kPa (11 – 14 psi)
STROKE Length (All Models) 76.2mm (3.00 in.)
CYLINDER Diameter (Std) 92.1131 mm (3.6265 in.)
BORE Diameter 0.038 mm (0.015 in.) Over- 92.4941 mm (3.6415 in.)
size
Diameter 0.076 mm (0.030 in.) Over- 92.875 mm (3.6565 in.)
size
Taper/Out of Round/Wear Maximum 0.076 mm (0.003 in.)
Bore Type Cast Iron
Compression 620 – 758 kPa (90 – 110 psi)♦
CRANKSHAFT Maximum Runout 0.0508 mm (0.002 in.)
♦When performing cylinder compression test, place lanyard switch in the OFF position to pre-
vent operation of direct injectors or remove fuse controlling fuel and direct injectors.
90-889785 APRIL 2003 Page 1A-1

Made for: Francesco Mannarino papullo@tin.it
SPECIFICATIONS
Model 75/90/115 DFI

PISTON Piston Type Aluminum
Diameter Standard 91.9226 mm ± 0.0127 mm (3.619 in. ±
.0005 in.)
Diameter 0.038 mm (0.015 in.) Over- 92.3036 mm ± 0.0127 mm
size (3.634 in. ± 0.0005 in.)
92.6846 mm ± 0.0127 mm
Diameter 0.076 mm (0.030 in.) Over- (3.649 in. ± 0.0005 in.)
size
PISTON
DIAMETER 91.9226 mm ± .0127 mm
(3.619 in. ± .0005 in.)Using a microme-
Dimension
“A” at Right ter, measure dimension “A” at location
Angle (90°) shown. Dimension “A” should be 3.619
to Piston Pin in. ± .0005 for a STANDARD size piston
(new) Dimension “A” will be 0.001 -
1.0 in. 0.0015 less if coating is worn off piston
25.4 mm
(used)
REEDS Reed Stand 0pen (Max.) 0.50 mm (0.020 in.)
Page 1A-2 90-889785 APRIL 2003

SPECIFICATIONS
Model 75/90/115 DFI

Gear Ratio 2.33:1
Gearcase Capacity 655 ml (22.5 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 28 Spiral/Bevel
Pinion Gear
Pinion Height 0.64 mm (0.025 in.)
Pinion Gear Locating Tool (91-12349A2)
MODEL 75/90 Flat #8
GEARCASE Disc #3
Forward Gear Backlash 0.012-0.019 in. (0.30-0.48mm)

Backlash Indicator Tool (91-78473)
Mark #4
Water Pressure
@ 750 RPM (Idle) 20.6 - 41.3 kPa (3.0-6.0 psi)
@ 5750 RPM (WOT) 75.8 - 96.5 kPa (11.0-14.0 psi)
Prop Shaft Runout (Maximum) 0.23 mm (0.009 in.)
Gear Ratio 2.07:1
Gearcase Capacity 655 ml (22.5 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Pinion Gear
Pinion Height 0.64 mm (0.025 in.)
Pinion Gear Locating Tool (91-12349A2)
MODEL 115 Flat #8
GEARCASE Disc #3
Forward Gear Backlash 0.33-0.48 mm (0.013-0.019 in.)

Backlash Indicator Tool (91-19660--1)
Mark #1
Water Pressure
@ 750 RPM 20.6 - 41.3 kPa (3 - 6 psi)
@ 5750 RPM (WOT) 75.8 - 96.5 kPa (11 - 14 psi)
Prop Shaft Runout (Maximum) 0.23 mm (0.009 in.)
90-889785 APRIL 2003 Page 1A-3

SPECIFICATIONS
Model 75/90/115 DFI

MID Power Trim (Total Tilt Range) 75°
SECTION Power Trim (Tilt Range) 20°
Maximum amount of acceptable leak
down in 24 hrs. 25.4 mm (1 in.)
Steering Pivot Range 60°
Tilt Pin Adjustment Positions 5
Allowable Transom Thickness 6.03 cm (2-3/8 in.)
DIRECT Injectors
INJECTION – Quantity 3
– Injectors are Crank Angle Driven
by ECM
– #1 Cylinder Fuel Injector RED/BLUE + BROWN/PINK Leads
– #1 Cylinder Air Injector RED/BLUE + BROWN/WHT Leads
– #2 Cylinder Fuel Injector RED/BLUE + RED/PINK Leads
– #2 Cylinder Air Injector RED/BLUE + RED/WHT Leads
– #3 Cylinder Fuel Injector RED/BLUE + ORANGE/PINK Leads
– #3 Cylinder Air Injector RED/BLUE + ORANGE/WHT Leads
Fuel Line Pressure @ Injectors 744.6 ± 13.8 kPa (108 ± 2 psi)*

Air Pressure 648.1 ± 13.8 kPa (94 ± 2 psi)*
High and Low Pressure Electric Fuel
Pump Amperage Draw 10 - 14 Amperes
Low Pressure Electric Fuel Pump 1 - 2 Amperes

Output 165.5 - 179.3 kPa (24 - 26 psi)
Fuel Pump Ohm Resistance 1.0 – 1.8 Ω

Fuel Injector Ohm Resistance 1.8 ± 0.1 Ω
Direct Injector Ohm Resistance 1.3 ± 0.3 Ω
Fuel/Air Differential 96.5 ± 6.9 kPa (14.0 ± 1.0 psi)
*The fuel/air differential must remain at 96.5 kPa (14.0 psi). If this differential is not main-
tained, the engine will exhibit poor running characteristics; i.e. – poor idling, spark plug
fouling etc. Example: if the fuel pressure is 744.6 kPa (108.0 psi), air pressure should be
648.1 kPa (94.0 psi).
Page 1A-4 90-889785 APRIL 2003

SPECIFICATIONS
Model 75/90/115 DFI

FUEL Fuel Gasoline with Oil Injection
SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil TC-W3 Premium Plus or Optimax 2
Cycle Outboard Oil
Gasoline/Oil Ratio
– @ Idle 300 - 400:1
– @ WOT 50:1
Fuel Pressure!
Crankcase Pump
– @ Idle Normal – 13.7 - 20.5 kPa (2-3 psi)
Minimum – 6.8 kPa (1 psi)
– @ WOT Normal – 41.0 - 54.8 kPa (8-10 psi)
Maximum – 68.5 kPa (10 psi)
STARTING Starter Draw (Under Load) 150 Amperes
SYSTEM Starter Draw (No Load) 60 Amperes
Minimum Brush Length 65.4 mm (0.25 in.)
Battery Rating* 1000 (Minimum) Marine Cranking Amps
750 (Minimum) Cold Cranking Amps
105 (Minimum) Ampere Hours
IGNITION Type Digital Inductive
SYSTEM Firing Order 1-2-3
Spark Plug Type NGK PZFR6H
Spark Plug Gap 0.8 mm (0.030 in.)
Maximum Timing Not Adjustable; Controlled by ECM
Idle Timing Not Adjustable; Controlled by ECM
Throttle Position Sensor
@ Idle 0.17 - 1.05 vdc
@ W.O.T 3.76 - 4.64 vdc
Crank Position Sensor
Air Gap 0.635 mm - 1.01 mm
(0.025 in. - 0.040 in.)
CHARGING Alternator Output (Regulated) 32 - 38 Amperes @ 2000 RPM @ Bat-
SYSTEM tery
52 - 60 Amperes @ 2000 RPM @
Alternator
Brush Length Standard Exposed Length: 10.5 mm
(0.413 in.)
Minimum. Exposed Length: 1.5 mm
(0.059 in.)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw** 0.585 mA (Ignition Switch Off)
150.0 mA (Ignition Switch On)
♦Electric fuel pump pressure, if used in conjunction with engine mechanical fuel pump, must be limited to
no more than 27.4 kPa (4 psi).
*Refer to Section 2B for additional information concerning battery selection.
**All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in
the OFF position and an amperage draw of not more than 350.0 mA with ignition key in the ON position.
90-889785 APRIL 2003 Page 1A-5

SPECIFICATIONS
Model 75/90/115 DFI

Air Compressor Type Reciprocating Piston
(1.14 to 1 ratio with engine RPM)
Compressor Output @ Idle – 648.1 kPa (94 psi)
Cylinder Block Displacement 60 cc (3.66 cu. in.)
Cylinder Bore Diameter (Standard) 52.0 mm (2.0472 in.)
Taper/Out of Round/Wear Maxi-
mum 0.025 mm (0.001 in.)
Bore Type Cast Iron
Stroke Length 27.9 mm (1.100 in.)
Piston Piston Type Aluminum
Piston Diameter 51.95 ± 0.010 mm
(2.0453 ± .0004 in.)
Dimen-
sion “A”
at Right
Angle
(90°) to
Piston Pin
0.300 in.
Piston Ring End Gap

Top Ring 0.15 - 0.30 mm
(0.0059 - 0.0118 in.)
Middle Ring 0.15 - 0.30 mm
(0.0059 - 0.0118 in.)
Bottom Ring 0.10 - 0.35 mm
(0.0039 - 0.014 in.)
Reeds Reed Stand Open 0.25 mm (0.010 in.)
Page 1A-6 90-889785 APRIL 2003

SPECIFICATIONS
Propeller Information Charts

Optimax 75
Wide Open Throttle RPM : 5000-5750
Recommended Transom Heights : 20 in. (50.8 cm) and 25 in. (63.5 cm)
Right Hand Rotation Standard
Gear Reduction : 2.33:1
Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13-1/2″ 26″ 3 Steel Up to 1500 Up to 16′ 44-57 48-16996A46
13-1/2″ 24″ 3 Steel Up to 1800 Up to 17′ 40-51 48-16994A46
12-1/2″ 23″ 3 Alum 1400-1900 16-17′ 38-48 48-77350A45
13-1/2″ 22″ 3 Steel 1500-2000 16-17′ 35-46 48-16992A46
12-3/4″ 21″ 3 Alum 1600-2200 16-18′ 33-43 48-77348A45
13-1/4″ 20″ 3 Steel 1800-2400 16-18′ 31-40 48-16990A46
13″ 19″ 3 Alum 1900-2600 17-19′ 29-38 48-77346A45
13″ 18″ 3 Steel 2100-2900 17-19′ 27-35 48-16988A46
13-1/4″ 17″ 3 Alum 2300-3200 18-20′ 25-32 48-77344A45
13-1/8″ 16″ 3 Steel 2500-3500 19-21′ 23-31 48-16986A46
13-1/4″ 16″ 3 Alum 2500-3500 19-21′ 23-31 48-854360A45
13-3/4″ 15″ 3 Alum 2800-3900 20-22′ 21-29 48-77342A45
13-3/8″ 14″ 3 Steel 3100-4400 21-23′ 19-26 48-17314A46
14″ 13″ 3 Alum 3500-5000 21-24′ 15-23 48-77340A45
14″ 12″ 3 Steel 4000+ work boat 11-19 48-17312A46
14″ 11″ 3 Alum 4500+ pontoon/work 1-16 48-77338A45
90-889785 APRIL 2003 Page 1A-7

SPECIFICATIONS
Propeller Information Charts

Optimax 90
Recommended Transom Heights : 20 in. (50.8 cm) and 25 in. (63.5 cm)

13-1/2″ 26″ 3 Steel Up to 1900 Up to 16′ 44-57 48-16996A46
13-1/2″ 24″ 3 Steel Up to 2100 Up to 17′ 40-51 48-16994A46
12-1/2″ 23″ 3 Alum 1700-2300 16-17′ 38-48 48-77350A45
13-1/2″ 22″ 3 Steel 1800-2400 16-18′ 35-46 48-16992A46
12-3/4″ 21″ 3 Alum 1900-2600 16-18′ 33-43 48-77348A45
13-1/4″ 20″ 3 Steel 2100-2800 17-19′ 31-40 48-16990A46
13″ 19″ 3 Alum 2200-3100 17-20′ 29-38 48-77346A45
13″ 18″ 3 Steel 2400-3400 18-20′ 27-35 48-16988A46
13-1/4″ 17″ 3 Alum 2600-3800 19-21′ 25-32 48-77344A45
13-1/8″ 16″ 3 Steel 2900-4200 20-22′ 23-31 48-16986A46
13-1/4″ 16″ 3 Alum 2900-4200 20-22′ 23-31 48-854360A45
13-3/4″ 15″ 3 Alum 3300-4600 21-23′ 21-29 48-77342A45
13-3/8″ 14″ 3 Steel 3600-5200 21-24′ 19-26 48-17314A46
14″ 13″ 3 Alum 4000-5900 22-25′ 15-23 48-77340A45
14″ 12″ 3 Steel 5000+ work boat 11-19 48-17312A46
Page 1A-8 90-889785 APRIL 2003

SPECIFICATIONS
Optimax 115
Recommended Transom Heights : 20 in. (50.8 cm), 25 in. (63.5 cm)

13-1/2″ 26″ 3 Steel Up to 1800 Up to 17′ 51-65 48-16996A45
13-1/2″ 24″ 3 Steel Up to 2100 Up to 18′ 45-58 48-16994A45
12-1/2″ 23″ 3 Alum 1800-2400 16-18′ 43-55 48-77350A45
13-1/2″ 22″ 3 Steel 1900-2600 16-18′ 40-52 48-16992A45
12-3/4″ 21″ 3 Alum 2100-2800 16-19′ 38-49 48-77348A45
13-1/4″ 20″ 3 Steel 2200-3100 17-19′ 36-46 48-16990A45
13″ 19″ 3 Alum 2400-3400 17-19′ 33-43 48-77346A45
13″ 18″ 3 Steel 2600-3700 18-20′ 31-40 48-16988A45
13-1/4″ 17″ 3 Alum 2900-4100 18-21′ 29-37 48-77344A45
13-1/8″ 16″ 3 Steel 3200-4500 19-22′ 26-34 48-16986A45
13-3/4″ 15″ 3 Alum 3600-5000 19-23′ 24-31 48-77342A45
13-3/8″ 14″ 3 Steel 4000-5700 21-25′ 22-29 48-17314A45
14″ 13″ 3 Alum 4400-6400 22-26′ 20-27 48-77340A45
14″ 12″ 3 Steel 5200+ pontoon 17-23 48-17312A45
14″ 10″ 3 Steel 8000+ houseboat/ 1-18 48-17310A45
work
90-889785 APRIL 2003 Page 1A-9

SPECIFICATIONS
Mercury/Quicksilver Lubricants, Sealants, and Adhesives

Tube Mercury Part Quicksilver Part
Description
Ref. No. Number Number
Needle Bearing
4 92-802868A1 N/A
Assembly Lubricant
6 Dielectric Grease 92-823506-1 92-823506-1
Loctite 271
7 92-809819 92-809819
Threadlocker
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2-cycle Premium
14 92-802813A1 92-802813Q1
Outboard Oil
19 Perfect Seal 92-34227-1 92-34227-1
25 Liquid Neoprene 92-25711-3 92-25711-3
27 Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining
33 92-809833 92-809833
Compound
34 Special Lubricant 101 92-802865A1 92-802865Q1
U-joint and Gimbal
42 92-802870A1 92-802870Q1
Bearing Grease
Loctite 222
51 92-809818 92-809818
Threadlocker
Loctite 242
66 92-809821 92-809821
Threadlocker
4-cycle 25W40
79 92-802837A1 92-802837Q1
Engine Oil
Premium Gear
82 92-802846A1 92-802846Q1
Lubricant
High Performance
87 92-802854A1 92-802854Q1
Gear Lube
Engine Coupler
91 92-802869A1 92-802869Q1
Spline Grease
Anti-Corrosion
94 92-802867A1 92-802867Q1
Grease
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
Power Trim and
114 92-802880A1 92-802880Q1
Steering Fluid
Page 1A-10 90-889785 APRIL 2003

SPECIFICATIONS

Description
Premium Plus
115 2-cycle TC-W3
92-802824A1 92-802824Q1
Outboard Oil
RTV 587 Silicone
116 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust
119 92-802878-56 92-802878Q56
Inhibitor
120 Corrosion Guard 92-802878-55 92-802878Q55
15W40 4-cycle Diesel
121 92-877695K1 92-877695Q1
Engine Oil
Extended Life
122 92-877770K1 92-877770K1
Antifreeze/Coolant
Marine Engine
123 NA 92-813054A2
Coolant
Fuel System
124 Treatment and 92-802876A1 92-802876Q1
Stabilizer Concentrate
Heat Transfer
125 92-805701-1 NA
Compound
126 Liquid Gasket 92-808137 NA
127 T442 Sealant 92-862258 NA
Loctite 5900 Ultra
128 Black RTV Silicone 92-809826 NA
Sealant
Loctite Gasket
129 92-809828-1 NA
Remover
Sealer Kit, Two Part
130 NA 92-65150-1
Epoxy
131 Anti-seize Compound 92-881091K1 NA
Torco MTF Gear Oil
132 (For Dry Sump 92-849684-1 NA
Drives)
Optimol Longtime PD
133 92-848767 NA
2
Dexron III Automatic
134 Obtain Locally Obtain Locally
Transmission Fluid
135 Loctite 592 Obtain Locally Obtain Locally
136 Loctite Quick Tite Obtain Locally Obtain Locally
137 Isopropyl Alcohol Obtain Locally Obtain Locally
138 Hot Glue Obtain Locally Obtain Locally
90-889785 APRIL 2003 Page 1A-11

SPECIFICATIONS

Description
1
Cyanacrylate
1
Adhesive
3M Permabond
#3M08155
Loctite 598 RTV
Sealant
146 Insulating Compound 92-41669-1 NA
Hydraulic Helm
147 NA 92-862014Q1
Steering Fluid
Optimol White T
148 92-847206 NA
Grease
2-cycle Performance
149 92-813743A2 NA
Blend Outboard Oil
Page 1A-12 90-889785 APRIL 2003

MAINTENANCE
Section 1B - Maintenance B
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . 1B-9
Mercury/Quicksilver Lubricants and Sealants 1B-2 Compressor Air intake Filter . . . . . . . . . . . . . . 1B-10
Inspection and Maintenance Schedule . . . . . 1B-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Every 100 Hours of Use or Once Yearly, Checking Power Trim Fluid . . . . . . . . . . . . . . . 1B-14
Whichever Occurs First . . . . . . . . . . . . . . . 1B-3 Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . 1B-15
Every 300 Hours of Use or Every Three Draining Gearcase . . . . . . . . . . . . . . . . . . . 1B-15
Years, Whichever Occurs First . . . . . . . . . 1B-3 Checking Gearcase Lubricant Level
Flushing Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 and Refilling Gearcase . . . . . . . . . . . . . . . 1B-15
Flushing Cooling System – Using Storage Preparation . . . . . . . . . . . . . . . . . . . . . 1B-16
Flushing Attachment 44357A2 . . . . . . . . . 1B-4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Protecting Internal Engine Components . 1B-17
Fuel Line Inspection . . . . . . . . . . . . . . . . . . 1B-5 Protecting External Outboard
Water Separating Fuel Filter . . . . . . . . . . . 1B-5 Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Draining Water from Fuel Filter Chamber 1B-6 Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-7 Positioning Outboard for Storage . . . . . . . 1B-17
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . 1B-8 Battery Storage . . . . . . . . . . . . . . . . . . . . . . 1B-17
Specifications
FUEL Fuel Gasoline with Oil Injection

SYSTEM Recommended Gasoline Unleaded 87 Octane Minimum
Recommended Oil TC-W3 Premium Plus or Optimax 2
Cycle Outboard Oil
IGNITION Spark Plug Type NGK PZFR6H
SYSTEM Spark Plug Gap 1.1 mm (0.043 in.)
STARTING Battery Rating 1000 (Minimum) Marine Cranking Amps
SYSTEM 750 (Minimum) Cold Cranking Amps
GEAR Gearcase Capacity 655.0 ml (22.5 fl. oz.)
HOUSING Water Pressure
@ 750 RPM (Idle) 27.6 - 48.3 kPa (4.0-7.0 psi)
@ 5750 RPM (WOT) 75.8 - 96.5 kPa (11.0-14.0 psi)
90-889785 APRIL 2003 Page 1B-1

MAINTENANCE
Special Tools
Grease Gun 91-37299Q2
Flushing Attachment 44357Q2
Mercury/Quicksilver Lubricants and Sealants

NOTE: Refer to Section 1A for lubricants and sealants chart.
Page 1B-2 90-889785 APRIL 2003

MAINTENANCE
Inspection and Maintenance Schedule

Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use

1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear-
case with fresh water if operating in salt water.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First

1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Replace water separating fuel filter.
4. Replace compressor air intake filter.
5. Check corrosion control anodes. Check more frequently when used in salt water.
6. Drain and replace gearcase lubricant.
7. Lubricate splines on the drive shaft and shift shaft.∗
8. Check power trim fluid.
9. Inspect battery.
10. Check control cable adjustments.∗
11. Check tightness of bolts, nuts, and other fasteners.
Every 300 Hours of Use or Every Three Years, Whichever Occurs First
1. Replace water pump impeller (more often if overheating occurs or reduced water
pressure is noted).∗
2. Inspect alternator and air compressor drive belt for wear. Replace as required.
∗ These items should be serviced by an authorized dealer.
90-889785 APRIL 2003 Page 1B-3

MAINTENANCE
Flushing Engine
Flushing Cooling System – Using Flushing Attachment 44357A2
WARNING
When flushing, verify that area in vicinity of propeller is clear and that no person
is standing nearby – to avoid possible injury. It is recommended to remove pro-
peller as a precautionary measure.
1. Install Quicksilver Flushing Attachment 44357Q2 (or equivalent tool) on the gear
housing from the FRONT side, positioning the rubber cups over the water intake
openings.
2. Connect hose [12.7 mm (1/2 in.) I.D. or larger] between flushing attachment and water
tap.
IMPORTANT: To prevent water pump damage, do not start or run engine unless
cooling water is flowing.
3. With the outboard in the normal operating position (vertical), partially open water tap
(IT IS NOT NECESSARY to use full water pressure) and adjust water flow so that
there is a significant water loss around the rubber cups.
4. Start engine and idle in NEUTRAL. Increase engine speed, not to exceed 2500 RPM.
5. Flush or service engine as required. Verify adequate cooling water is provided.
a. Water must be discharged through tell tale.
IMPORTANT: Prevent engine overheating. If water flow is insufficient, stop engine
and determine cause before continuing.
b. Flush until discharge water is clear. In salt-water areas, run outboard 3 to 5 minutes.
c. Stop engine before turning off water.
6. Stop engine, turn water off and remove flushing attachment from gear housing.
IMPORTANT: While flushing and after flushing, keep outboard in upright position
until all water has drained from drive shaft housing to prevent water from entering
the powerhead via drive shaft housing and exhaust ports.
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel sys-
tem.
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.
Inspect any completed service work for sign of fuel leakage.
Page 1B-4 90-889785 APRIL 2003

MAINTENANCE
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.
Water Separating Fuel Filter
NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
This filter removes moisture and also debris from the fuel. If the filter or filter chamber be-
comes filled with water, the water can be removed. If the filter becomes plugged with de-
bris, the filter must be replaced with a new filter.
1. Use the shaft of a screwdriver between the lugs on the filter cap and unscrew the filter.
2. Lubricate the O-ring seals with oil.
3. Install the fuel filter and tighten securely.
ob00414
a - Filter
b - Seals
IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the prim-
er bulb until firm, forcing fuel into the filter.
90-889785 APRIL 2003 Page 1B-5

MAINTENANCE
Draining Water from Fuel Filter Chamber
b
a c
ob00415
a - Drain hose
b - Fitting
c - Drain screw
NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warn-
ing system will turn on. Draining the water from the fuel filter chamber is required.
1. Pull the drain hose off the right side fitting. Hold the open end of the hose over a con-
tainer. Loosen drain screw and drain the fuel filter chamber. Tighten drain screw and
attach hose.
IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing
the primer bulb until firm, forcing fuel into the chamber.
Page 1B-6 90-889785 APRIL 2003

MAINTENANCE
Corrosion Control Anode

The gearcase has two corrosion control anodes. Another anode is installed on the bottom
of the transom bracket assembly. An anode helps protect the outboard against galvanic
corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
ob59572
a - Gearcase anodes
b - Transom bracket anode
Each anode requires periodic inspection, especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is com-
pletely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
90-889785 APRIL 2003 Page 1B-7

MAINTENANCE
Spark Plug Inspection

Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect
spark plug boots and replace if cracked.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart in General Information Section.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs
finger tight, and tighten 1/4 turn or torque to 27 Nm (20 lb. ft.).
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting ca-
pability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to posi-
tive and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Page 1B-8 90-889785 APRIL 2003

MAINTENANCE
Fuse Replacement
IMPORTANT: Always carry spare SFE 5 and SFE 20 AMP fuses.
Wiring circuits on the outboard are protected from overload by fuses. If the silver band is
broken, the fuse is blown. If a fuse is blown, locate and correct the cause of the overload.
If the cause is not found, the fuse may blow again. Always replace blown fuse with a new
fuse having the same rating.
The fuses and circuits are identified as follows:
a b
d c
ob00398
Model 75/90/115
a - SmartCraft data bus circuit – SFE 5 ampere fuse.
b - Accessories – SFE 20 ampere fuse.
c - Ignition coil circuit – SFE 20 ampere fuse.
d - Electric fuel pump/ECM driver power/oil pump circuit/fuel and direct injectors
– SFE 20 ampere fuse.
90-889785 APRIL 2003 Page 1B-9

MAINTENANCE
Compressor Air intake Filter

The filter should be changed every 100 hours of operation, or once a season. Never run
the engine without the air filter.
Removal
1. Remove flywheel cover from engine.
2. Remove side cover from engine.
ob00412
a - Filter
3. Remove 3 screws securing air filter cover and remove filter.
00384
a - Screws (3)
b - Air filter cover
Page 1B-10 90-889785 APRIL 2003

MAINTENANCE
Installation
1. Install filter into the cover. Fasten cover with 3 screws.
a - Oil tank/air attenuator

b - Filter
c - Cover
d - Screws – drive tight
90-889785 APRIL 2003 Page 1B-11

MAINTENANCE
Lubrication Points
1. Lubricate the following with Anti-Corrosion Grease or 2-4-C with Teflon.
• Propeller shaft – Refer to Section 1D, Propeller Installation for removal and
installation of the propeller. Coat the entire propeller shaft with lubricant to prevent
the propeller hub from corroding and seizing to the shaft.
a - Propeller shaft
2. Lubricate the following with 2-4-C with Teflon or Special Lubricant 101.
• Swivel bracket – Lubricate through fitting.
• Tilt support lever – Lubricate through fitting.
a - Swivel bracket
b - Tilt support lever
• Tilt tube – Lubricate through fitting.
ob57834
a
a - Tilt tube
Page 1B-12 90-889785 APRIL 2003

MAINTENANCE
• Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract
the steering cable end into the outboard tilt tube. Lubricate through fitting.
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube
before adding lubricant. Adding lubricant to steering cable when fully extended
could cause steering cable to become hydraulically locked. An hydraulically
locked steering cable will cause loss of steering control, possibly resulting in se-
rious injury or death.
a b
a - Lubrication fitting
b - Steering cable end
3. Lubricate the following with light weight oil.

• Steering link rod pivot points – Lubricate pivot points.
a
a - Pivot points
90-889785 APRIL 2003 Page 1B-13

MAINTENANCE
Checking Power Trim Fluid

1. Tilt outboard to the full up position and engage the tilt support lock.
a - Tilt support lever
2. Remove fill cap and check fluid level. The fluid level should be even with the bottom
of the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.
ob53967
a - Fill cap
Page 1B-14 90-889785 APRIL 2003

MAINTENANCE
Gearcase Lubrication
75/90/115 Gearcase Capacity 655 ml (22.5 fl. oz.)
When adding or changing gearcase 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 gearcase 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 gearcase.
Draining Gearcase
1. Place outboard in a vertical operating position.
2. Remove vent plug, fluid level plug and fill/drain plug. Drain lubricant into suitable con-
tainer.
b
a
c
ob59571
a - Vent plug c - Fill/drain plug

b - Fluid level plug
Checking Gearcase Lubricant Level and Refilling Gearcase

1. Place outboard in a vertical operating position.
2. Remove vent plug and fluid level plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the fluid level
hole.
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and fluid level plug with sealing washers
before removing the lubricant tube.
5. Remove lubricant tube and reinstall fill/drain plug with sealing washer.
b
a
c
ob59571
a - Vent plug c - Fill/drain plug

b - Fluid level plug
90-889785 APRIL 2003 Page 1B-15

MAINTENANCE
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust,
corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of
season storage or prolonged storage (two months or longer).
CAUTION
Never start or run your outboard (even momentarily) without water circulating
through all the cooling water intake holes in the gearcase to prevent damage to
the water pump (running dry) or overheating of the engine.
Fuel system
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a for-
mation of acid during storage and can damage the fuel system. If the gasoline be-
ing used contains alcohol, it is advisable to drain as much of the remaining gaso-
line 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 (sta-
bilized) fuel to help prevent formation of varnish and gum. Proceed with following instruc-
tions.
1. Portable Fuel Tank – Pour the required amount of Gasoline Stabilizer (follow instruc-
tions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the
fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Gasoline Stabilizer
(follow instructions on container) into a separate container and mix with approximate-
ly one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Drain the water separating fuel filter chamber (refer to Draining Water from Fuel Fil-
ter in this section) . Empty the fuel into a suitable container and discard the filter prop-
erly.
4. Premix the following in a container:
8cc (0.27 oz) or 2 teaspoons of Quickleen Lubricant.
8cc (0.27 oz) or 2 teaspoons of Fuel Stabilizer.
5. Remove fuel water separator filter and pour mixture into filter chamber. Reinstall fuel
water separator filter.
6. Prime the fuel system as outlined in the Starting Procedure.
7. Place the outboard in water or connect flushing attachment for circulating cooling wa-
ter. Run the engine at idle speed for 5 minutes to allow treated fuel to fill the fuel sys-
tem.
Page 1B-16 90-889785 APRIL 2003

MAINTENANCE
Protecting Internal Engine Components

NOTE: Make sure the fuel system has been prepared for storage.
1. Remove the spark plugs and add approximately 30ml (1 oz) of engine oil into each
spark plug hole. Rotate the flywheel manually several times to distribute the oil in the
cylinders. Reinstall spark plugs.
Protecting External Outboard Components
1. Lubricate all outboard components listed in the Inspection and Maintenance
Schedule.
2. Touch up any paint nicks. See your dealer for touch-up paint.
3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes).
Gearcase
1. Drain and refill the gearcase lubricant (refer to maintenance procedure).
Positioning Outboard for Storage
1. Store outboard in an upright (vertical) position to allow water to drain out of outboard.
CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or
rain water that may have entered the propeller exhaust outlet in the gearcase
could freeze and cause damage to the outboard.
Battery Storage
1. Follow the battery manufacturers instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
90-889785 APRIL 2003 Page 1B-17

GENERAL INFORMATION
Section 1C - General Information C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1 75/90/115 Powerhead Starboard View . . . . . 1C-9
Conditions Affecting Performance . . . . . . . . . 1C-2 75/90/115 Powerhead Port View . . . . . . . . . . 1C-10
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 75/90/115 Powerhead Top View . . . . . . . . . . . 1C-11
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 75/90/115/ Powerhead Aft View . . . . . . . . . . . 1C-12
Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-13
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Color Impregnated Top Cowls . . . . . . . . . . 1C-13
Engine Compression . . . . . . . . . . . . . . . . . . 1C-5 Cleaning & Painting Aluminum Propellers
Following Complete Submersion . . . . . . . . . . 1C-6 & Gear Housings . . . . . . . . . . . . . . . . . . . . . 1C-13
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-6 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Submerged While Running . . . . . . . . . . . . 1C-6 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-15
75/90/115 Powerhead Front View . . . . . . . . . 1C-8 Instructions for Wet Application . . . . . . . . . 1C-15
Serial Number Location

The engine serial number is located on the top of the engine block. A serial number is also
located on the starboard side of the swivel bracket.
a
OGXXXXXX
20XX
b
XXXX
c
e
d
XX
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
90-889785 APRIL 2003 Page 1C-1

GENERAL INFORMATION
Conditions Affecting Performance

Weather
Weather conditions exert a profound effect on power output of internal combustion en-
gines. 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
Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the compu-
tation of horsepower from data obtained on the dynamometer. All values are corrected
to the power that the engine will produce at sea level, at 30% relative humidity, at 25°C
(77° F) temperature, and a barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure and high humidity all
combine to reduce engine power. This is reflected in decreased boat speeds – as much
as 2 or 3 mph. Nothing will regain this speed for the boater but the coming of cool, dry
weather.
In pointing out the consequences of weather effects, an engine – running on a hot, humid
summer day – may loose as much as 14% of the horsepower it would produce on a dry,
brisk spring or fall day. The horsepower that any internal combustion engine produces
depends upon the density of the air that it consumes and this density is dependent upon
the temperature of the air, its barometric pressure and water vapor (or humidity) content.
Accompanying this weather inspired loss of power is a second but more subtle loss. At
rigging time in early spring, the engine was equipped with a propeller that allowed the en-
gine to run within its recommended RPM range at full throttle. With the coming of the sum-
mer weather and the consequent drop in available horsepower, this propeller will, in ef-
fect, become too large. Consequently, the engine operates at less than its recommended
RPM.
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss
can be regained by switching to a smaller pitch propeller that allows the engine to run
again at recommended RPM.
Page 1C-2 90-889785 APRIL 2003

GENERAL INFORMATION
To obtain optimum engine performance under changing weather conditions, the engine
MUST be propped to allow it to operate at or near the top end of the recommended maxi-
mum RPM range at wide open throttle with a normal boat load.
This will allow the engine to develop full power while operating in an RPM range that dis-
courages damaging detonation.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant
effect on the boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to 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)
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer back and forth (bow steer).
BOTTOM
1. Boat Bottom: For maximum speed, a boat bottom should be nearly a flat plane where
it contacts the water and particularly straight and smooth in fore and aft direction.
a. 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.
b. Rocker: The reverse of hook and much less common. Rocker exists if bottom is
convex in fore and aft direction when viewed from the side, and boat has strong
tendency to porpoise.
c. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of motor’s gear
housing increase skin friction and cause speed loss. Clean surfaces when neces-
sary.
d. Gear Housing: If unit is left in the water, marine vegetation may accumulate over
a period of time. This growth MUST be removed from unit before operation, as it
may clog the water inlet holes in the gear housing and cause the engine to over-
heat.
90-889785 APRIL 2003 Page 1C-3

GENERAL INFORMATION
Trim
TRIMMING OUTBOARD UP (OUT)
WARNING
Excessive trim out also may reduce the stability of some high speed hulls. To cor-
rect instability at high speed, reduce the power GRADUALLY and trim the out-
board in slightly before resuming high speed operation. (Rapid reduction in pow-
er will cause a sudden change of steering torque and may cause additional mo-
mentary boat instability.)
1. Will lift bow of boat, generally increasing top speed.
2. Transfers steering torque harder to left on single outboard installations below 58.4 cm
(23 in.) transom height.
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced water supply can cause overheating
resulting in engine damage.
TRIMMING OUTBOARD DOWN (IN) CHARACTERISTICS
WARNING
Excessive speed at minimum trim in may cause undesirable and/or unsafe steer-
ing conditions. Each boat should be tested for handling characteristics after any
adjustment is made to the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or right (bow steer).
4. Transfers steering torque harder to right (or less to the left) on single outboard installa-
tions.
5. Improves planing speed acceleration (by moving trim adjustment bolt one hole closer
to transom).
WATER ABSORPTION
It is imperative that all thru-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 addition-
al boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle
on the gearcase or from an irregularity in the propeller blade itself. These vapor bubbles
flow back and collapse when striking the surface of the propeller blade resulting in the ero-
sion of the propeller blade surface. If allowed to continue, eventual blade failure (break-
age) will occur.
VENTILATION
Ventilation occurs when air is drawn from the water’s surface (excessive trim out angle)
or from the engine exhaust flow (wrong propeller/propeller hardware installed or gearcase
labyrinth seal worn) into the propeller blades. These air bubbles strike the propeller blade
surface and cause erosion of the blade surface. If allowed to continue, eventual blade fail-
ure (breakage) will occur.
Page 1C-4 90-889785 APRIL 2003

GENERAL INFORMATION
Engine
DETONATION
Detonation in a 2-cycle engine resembles the pinging heard in an automobile engine. It
can be otherwise described as a tin-like rattling or plinking sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark
plug has fired. Detonation creates severe shock waves in the engine, and these shock
waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston
rings or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 2-cycle application are as
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).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
ob51115
Engine Compression
Engine compression should be checked with engine block warm, throttle shutter wide
open, all spark plugs removed and using a fully charged battery. Normal compression for
all cylinders should be 620.5 to 758.4 kPa (90 to 110 psi). Cylinders should not vary more
than 103.4 kPa (15 psi) between one another. A variance of more than 15 psi would indi-
cate the need for a powerhead inspection/disassembly.
90-889785 APRIL 2003 Page 1C-5

GENERAL INFORMATION
Following Complete Submersion

Salt Water Submersion
Due to the corrosive effect of salt water on internal engine components, complete disas-
sembly is necessary before any attempt is made to start the engine.
Submerged While Running

When an engine is submerged while running, the possibility of internal engine damage
is greatly increased. If, after engine is recovered and with spark plugs removed, engine
fails to turn over freely when turning flywheel, the possibility of internal damage (bent con-
necting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be dis-
assembled.
SUBMERGED ENGINE (FRESH WATER)

IMPORTANT: Engine should be run within 2 hours after recovery, or serious inter-
nal damage may occur. If unable to start engine in this period, disassemble engine
and clean all parts. Apply oil as soon as possible.
NOTE: If sand has entered the air intake on the engine, do not attempt to the start the
engine. Sand will cause internal engine damage. Disassembly is required to clean all in-
ternal engine components of sand.
1. Recover engine from water as quickly as possible.
2. Remove cowling.
3. Clean the exterior of the outboard with fresh water.
4. Dry all wiring and electrical components using compressed air.
5. Drain water from fuel system as follows:
a. Disconnect remote fuel hose from engine.
b. Loosen fuel/water separator chamber drain screw and fuel pump chamber drain
screw and drain fuel/water. Retighten both drain screws.
c. Remove the fuel hose from bottom of port side fuel rail and drain fuel/water. Rein-
stall hose.
6. Drain water from air compressor system as follows:
a. Dry or replace the air filter for the compressor.
b. Remove air outlet hose for the air compressor and drain water from compressor
and hose. Reinstall hose.
7. Drain water from engine as follows:
a. Tilt up the outboard and and allow water to drain from crankcase area into air ple-
num. Draw water out of air plenum through throttle plate opening using a suitable
hose or pump.
b. Remove spark plugs from engine.
c. Rotate flywheel manually to blow out any water from the cylinders.
d. Add approximately 30 ml (1 oz) of engine oil into each spark plug hole. Rotate the
flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.
Page 1C-6 90-889785 APRIL 2003

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

Optional remote oil tank –
a. Remove remote oil hose from fitting on top of engine oil reservoir.
b. Drain any water from hose and reconnect.
c. If water was present in hose, check for water in the remote oil tank. Drain tank if
water is present.
Engine oil reservoir –
d. Remove engine oil reservoir from engine and drain all oil/water from reservoir.
9. Disassemble the engine starter motor and dry components.
10. Prime the oil injection pump as follows:
a. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb
until it fells firm.
b. Turn the ignition key switch to the “ON” position.
c. Within the first 10 seconds after the key switch has been turned on, move the re-
mote control handle from neutral into forward gear 3 to 5 times. This will automati-
cally start the priming process.
N
F
NOTE: Audible click from the oil pump will tell you the pump is priming. It may take a few
minutes for the pump to complete the priming process.
11. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
12. If engine fails to start, determine cause (fuel, electrical or mechanical).
90-889785 APRIL 2003 Page 1C-7

GENERAL INFORMATION
75/90/115 Powerhead Front View
!
!%
!$
!#
"
'
!"
!!
!*
&
) %
$
ob00356
(
1 - MAP sensor 9 - Trim pump bullet connectors

2 - Air plenum 10 - Throttle body assembly
3 - Pulse fuel pump 11 - Starter motor
4 - Smart craft connector 12 - Starter solenoid
5 - Air temperature sensor con- 13 - Air compressor temperature
nector sensor connector
6 - Air temperature sensor 14 - Air compressor temperature
7 - MAP sensor connector sensor
8 - Cowl tilt switch connectors 15 - Air compressor air inlet
Page 1C-8 90-889785 APRIL 2003

GENERAL INFORMATION
75/90/115 Powerhead Starboard View

"%
"$
"# "(
!
""
"!
"'
"&
"*
!*
!!
!) ) "
!& !"
!'
$ #
(
%
!(
&
!$ !#
!% '
ob00398
1 - MAP sensor 17 - Propulsion control module
2 - Throttle body assembly 18 - Positive battery cable
3 - Air temperature sensor 19 - #3 Ignition coil
4 - Oil filter 20 - #2 Ignition coil
5 - Trim motor connectors 21 - #1 Ignition coil
6 - Cowl tilt switch connector 22 - Fuses (3–20 amp) (1–5 amp)
7 - Neutral switch connectors 23 - 95 psi air hose from air com-
8 - Negative battery cable pressor
9 - Throttle position sensor 24 - Air compressor temperature
10 - Starter motor sensor
11 - Starter solenoid 25 - Tell–tale (water outlet from air
12 - Oil pump compressor)
13 - Trim DOWN relay 26 - 100 ampere fuse (alternator)
14 - Trim UP relay 27 - Digital diagnostic terminal
connector
15 - Main power relay
28 - Crank position sensor
16 - Slave solenoid
90-889785 APRIL 2003 Page 1C-9

GENERAL INFORMATION
75/90/115 Powerhead Port View
$ '
" %
#
!
& (
"% )
!%
!$
"&
"$ !*
"' !&
!# !#
"(
!!
!(
!)
!'
"# "*
"! !"
$
""
ob00525
1 - Air plenum 14 - Low pressure electric fuel

2 - Throttle cables pump
3 - Fuel/Water separator filter 15 - Vapor separator
4 - Vapor separator vent hose 16 - Vapor separator drain fittings
5 - 2 pin terminal connector for al- 17 - Vapor separator drain hose
ternator 18 - Water sensor connector
6 - Output terminal of alternator 19 - Throttle cable anchor point
7 - Fuel out 744.6 kPa (108 psi) 20 - Shift cable anchor point
8 - High pressure electric fuel 21 - Engine harness connector
pump (inside vapor separator) 22 - Smart craft connector
9 - Electric fuel pump connector 23 - Pulse fuel pump vacuum hose
10 - Low pressure fuel test port 24 - Fuel/Water sensor
11 - Excess fuel return to vapor 25 - Pulse fuel pump vacuum hose
separator 26 - Pulse fuel pump
12 - Muffler for excess air return to 27 - Wide open throttle stop screw
driveshaft housing 28 - Fuel inlet hose to pulse fuel
13 - Vapor separator drain screw pump
Page 1C-10 90-889785 APRIL 2003

GENERAL INFORMATION
75/90/115 Powerhead Top View
"
!"
!
!!
$
!*
)
'
ob00397
&
1 - Air Compressor 7 - Throttle Plate Adjustment

2 - Fuel 744.6 kPa (108 psi) to Screw
Fuel Rail 8 - Starter Motor
3 - 60 Ampere Alternator 9 - Belt Tensioner
4 - Fuel Water Separator Filter 10 - Air Compressor Inlet Nozzle
5 - MAP Sensor 11 - Air Compressor Water Outlet
6 - Throttle Plate Assembly to Tell-Tale
12 - Air Hose 648.1 kPa (94 psi) to
Fuel Rail
90-889785 APRIL 2003 Page 1C-11

GENERAL INFORMATION
75/90/115/ Powerhead Aft View
!! !"
!
!#
!$
!* ""
!%
" )
#
"!
( !&
!'
"*
'
$
!(
& !"
!)
%
ob53592
1 - High pressure fuel hose 744.6 12 - Water Out (tell-tale) from Air
kPa (108 psi) Compressor
2 - Electric fuel pump connector 13 - Air Pressure 648.1 kPa (94
3 - Low pressure fuel test port psi)
4 - Excess fuel return to vapor 14 - #1 Fuel injector
separator 15 - Fuel Rail
5 - Muffler for excess air return to 16 - #2 Fuel injector
driveshaft housing 17 - Air pressure test valve
6 - Fuel pressure test valve 18 - #3 Fuel injector
7 - Air Regulator 19 - Cowl tilt switch connector
8 - Fuel Regulator 20 - #3 Ignition Coil
9 - Thermostat 61.6° C (143° F) 21 - #2 Ignition Coil
10 - Water inlet hose to air com- 22 - #1 Ignition Coil
pressor
11 - Temperature sensor
Page 1C-12 90-889785 APRIL 2003

GENERAL INFORMATION
Painting Procedures
Color Impregnated Top Cowls
The Optimax top cowls are constructed of a new material in which the exterior color is
impregnated to a depth of approximately 1.58 mm (1/16 in.).
MAINTENANCE
The cowl can be cleaned using a mild non-abrasive soap. The surface luster can be pre-
served by using a non-abrasive automotive polish (polish designed for clear coat finishes)
and buffing with a terry cloth type towel. Abrasive type polishes or cleaners should not be
used as they will damage the cowl finish.
REPAIR
Light scratches should be removed by using a non-abrasive automotive polish (polish de-
signed for clear coat finishes) and buffing with a terry cloth type towel. Abrasive type polish-
es should not be used as they will damage the cowl finish.
Medium scratches can be removed by using 600 to 1000 grit sandpaper. The surface luster
can then be restored by using a non-abrasive automotive polish (polish designed for clear
coat finishes) and buffing with a terry cloth type towel. Abrasive type polishes should not
be used as they will damage the cowl finish.
For deep scratches or for those that penetrate through the exterior finish, automotive body
filler can be used to fill the damaged area. 600 to 1000 grit sand paper should be used to
smooth the surface area. It is then recommended that the entire cowl then be painted, to
achieve an even luster, using normal Mercury Marine approved paint and 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 Re-
mover or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Mercury/Quicksilver’s EDP Propeller Black.
90-889785 APRIL 2003 Page 1C-13

GENERAL INFORMATION
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
provide 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 Sup-
ply Outlet. The minimum package quantity of each material shown following is sufficient
to refinish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove
paint blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not prop-
erly adhere to the surface nor will the coating be sufficiently thick to resist future
paint blistering.
6. Mix epoxy chromate primer (DP-90LF) with equal part catalyst (DP-402LF) per
manufacturers instructions, allowing proper induction period for permeation of the
epoxy primer and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coat-
ing assemblies.
8. Use Ditzler Urethane DU9300 for Mercury Phantom Black, DU34334 for Mariner
Light Grey, and DU35466 for Force Charcoal, and DU33414M for Sea Ray White.
Catalyze all four colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents
per Ditzler label.
CAUTION
Be sure to comply with instructions on the label for ventilation and respirators.
Using 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 sensi-
tive 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.
Page 1C-14 90-889785 APRIL 2003

GENERAL INFORMATION
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 remov-
ing old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for Wet Application
NOTE: The following decal installation instructions are provided for a wet installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia. Do not use a soap that contains
petroleum based solvents.
** Automotive Body Filler Squeegee
SERVICE TIP: Placement of decals using the wet application will allow time to posi-
tion decal. Read entire installation instructions on this technique before proceed-
ing.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct
sunlight. Air and surface temperature should be between 15°C (60°F) and 38°C
(100°F) for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean applica-
tion surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface
thoroughly with clean water.
90-889785 APRIL 2003 Page 1C-15

GENERAL INFORMATION
DECAL APPLICATION
1. Mix 16 ml (1/2 oz) of dish washing liquid in 4 liter (1 gallon) of cool water to use as wet-
ting solution.
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal
installation. This will ensure that the vinyl decal keeps it’s shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing
from adhesive side of decal.
3. Using a spray bottle, flood the entire adhesive side of the decal with the pre-mixed
wetting 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 to-
ward the puncture).
Page 1C-16 90-889785 APRIL 2003

OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation D
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Throttle Cable Installation . . . . . . . . . . . . . 1D-13
Installation Specifications (All Models) . . . . . 1D-2 Filling Fuel System . . . . . . . . . . . . . . . . . . . . . . 1D-14
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . 1D-2 Filling The Oil Injection Tank . . . . . . . . . . . . . . 1D-14
Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Priming the Oil Injection Pump . . . . . . . . . . . . 1D-15
Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Propeller Installation . . . . . . . . . . . . . . . . . . 1D-16
Determining Recommended Outboard Trim-In Stop Adjustment . . . . . . . . . . . . . . . 1D-17
Mounting Height . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Paddle Wheel Speed Sensor Installation . . . 1D-28
Installing Outboard . . . . . . . . . . . . . . . . . . . . . . 1D-6 Parts Provided . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Electrical, Fuel Hose, and Control Cables . . 1D-7 Selecting Location . . . . . . . . . . . . . . . . . . . . 1D-18
Front Cover Assembly . . . . . . . . . . . . . . . . 1D-7 Transom Angle Requirements . . . . . . . . . . 1D-19
Remote Wiring Harness . . . . . . . . . . . . . . . 1D-8 Installing Bracket . . . . . . . . . . . . . . . . . . . . . 1D-19
Battery Cable Connections . . . . . . . . . . . . 1D-9 Routing the Cable . . . . . . . . . . . . . . . . . . . . 1D-20
Fuel Hose Connection . . . . . . . . . . . . . . . . 1D-10 Paddle Wheel Removal and Installation . 1D-21
Shift Cable Installation . . . . . . . . . . . . . . . . 1D-11 Wire connections . . . . . . . . . . . . . . . . . . . . . 1D-21
Special Tools
Lift Ring 91-90455T
90-889785 APRIL 2003 Page 1D-1

Installation Specifications (All Models)

aa
a
b
a – Transom Opening – Minimum b – Engine Center Line For Dual Engine

Single Engine – 848 mm (33-3/8 in.) 660 mm (26 in.) Minimum
Dual Engines – 1518 mm (59-3/4in.)
Lifting Outboard
1. Remove flywheel cover. Thread lifting ring into flywheel a minimum of 5 turns.
ob00413
a - Lifting ring (91-90455)
Page 1D-2 90-889785 APRIL 2003

Steering Cable
STARBOARD SIDE ROUTED CABLE
2. Lubricate O-ring seal and entire cable end.
95
Tube Mercury Part Num- Quicksilver Part

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
3. Insert steering cable into tilt tube.
4. Torque nut to specification.
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb.ft. Nm
a 1 NUT 35 47.5
90-889785 APRIL 2003 Page 1D-3

Steering Link Rod

1. Install steering link rod per illustration.
a - Special bolt (10-849838)

b - Nylon insert locknut (11-826709113)
c - Flat washer (2)
d - Nylon insert locknut (11-826709113)
TORQUE
REF
REF.
a 1 BOLT 20 27
b 1 NUT 20 27
d 1 LOCKNUT Tighten until locknut
seats, then back off
1/4 turn
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special bolt (“a” - part number 10-848838) and self locking
nuts (“b” & “c” - part number 11-826709113). These locknuts must never be re-
placed with common nuts (non-locking) as they will work loose and vibrate off,
freeing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown
overboard exposing them to serious injury or death.
Page 1D-4 90-889785 APRIL 2003

Determining Recommended Outboard Mounting Height

660 mm
(26 in.)
635 mm b
(25 in.)
609 mm
(24 in.)
e 584 mm
(23 in.) c
Outboard
Mounting
Height 560 mm b
(22 in.)
e
533 mm
(21 in.) a
508 mm
d
(20 in.)
482 mm
(19 in.)
10 20 30 40 50 60 70 80
Maximum Boat Speed Anticipated
NOTE: Add 127 mm (5 in.) for XL models and 254 mm (10 in.) for XXL models to listed
outboard mounting height.
a - This solid line is recommended to determine the outboard mounting height. In-
creasing the height of outboard generally will provide the following: 1) Less
steering torque, 2) more top speed, 3) greater boat stability, but, 4) will cause
more prop break loose which may be particularly noticeable when planing off
or with heavy load.
b - These broken lines represent the extremes of known successful outboard
mounting height dimensions.
c - This line may be preferred to determine outboard mounting height dimension, if
maximum speed is the only objective.
d - This line may be preferred to determine outboard mounting height dimension
for dual outboard installation.
e - Outboard mounting height (height of outboard transom brackets from bottom of
boat transom). For heights over 560 mm (22 in.), a propeller, that is designed
for surfacing operation is usually preferred.
NOTICE TO INSTALLER:
IMPORTANT: The outboard should be mounted high enough on the transom so that
the exhaust relief hole remains at least 25.4 mm (1 in.) above the water line when
the engine is running at idle speed. This will prevent exhaust restriction.
The mounting height of the outboard must not exceed 635 mm (25 in.) for L models,
762 mm (30 in.) for XL models and 889 mm (35 in.) for XXL models. Mounting the
outboard higher may cause damage to the gear case components.
90-889785 APRIL 2003 Page 1D-5

Installing Outboard
1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template
(located in this manual) to boat transom.
2. Mark and drill four 13.5 mm (17/32 in.) mounting holes.
3. Refer to Determining Recommended Outboard Mounting Height, preceding and

install outboard to the nearest recommended mounting height.
4. Fasten outboard with provided mounting hardware shown.
d
b
a
a - 1/2 in. diameter bolts (4) d - Flat washers (4)

b - Flat washers(4) e - Marine sealer - apply to shanks
c - Locknuts (4) of bolts, not threads
Page 1D-6 90-889785 APRIL 2003

Electrical, Fuel Hose, and Control Cables

IMPORTANT: Warning Horn Requirement – The remote control or key switch as-
sembly must be wired with a warning horn. This warning horn is used with the en-
gine warning system.
Front Cover Assembly
REMOVAL
Pull up the cowl seal and remove the cover from the bottom cowl.
a
a
b
ob00388
a - Screws (2)
b - Cover
INSTALLATION
IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables,
fuel hose, and oil hoses routed between clamp and engine attachment point, to re-
lieve stress and prevent hoses from being kinked or pinched.
1. Route the fuel hose, wiring, and cables through the front cover opening.
2. Place the neoprene wrap around the wiring, hoses, and control cables as shown. Re-
install the cover and cowl seal. Torque screws to 7.3 Nm (65 lb. in.).
b
b
a c
ob59598
ob00388
a - Neoprene wrap c - Cover

b - Screws (2)
90-889785 APRIL 2003 Page 1D-7

Remote Wiring Harness

1. Connect wiring. Push the retainer over the ends of the connectors. This will hold the
connectors together. Place the harness connection and retainer into the cable holder
located in the bottom cowl has shown.
ob00654
BLU = Blue BLU/WHT BLU/WHT

BRN = BROWN GRN/WHT GRN/WHT a
GRN = GREEN TAN TAN b
WHT = WHITE
BRN/WHT BRN/WHT c
a - Power trim connections

b - Wire connection for analog water temp gauge – not supported by this engine
c - Connection for non-SmartCraft analog trim gauge
d - Retainer - push over connector ends
e - Cable holder
Page 1D-8 90-889785 APRIL 2003

Battery Cable Connections

SINGLE OUTBOARD
(+)
(–) c
a - Red sleeve (positive)

b - Black sleeve (negative)
c - Starting battery
DUAL OUTBOARDS
Connect a common ground cable (wire size same as engine battery cables) between neg-
ative (–) terminals on starting batteries.
(–)
(–)
a - Ground cable (same wire size as engine battery cable) – connect between neg-
ative (–) terminals
90-889785 APRIL 2003 Page 1D-9

Fuel Hose Connection

PORTABLE FUEL TANK
Select a suitable location in boat within engine fuel line length limitations and secure tank
in place.
PERMANENT FUEL TANK

These should be installed in accordance with industry and federal safety standards which
include recommendations applicable to grounding, anti-siphon protection, ventilation,
etc.
FUEL HOSE SIZE

Minimum fuel line inside diameter (I.D.) is 8 mm (5/16 in.), with separate fuel line/fuel tank
pickup for each engine.
FUEL HOSE CONNECTION

Fasten remote fuel hose to fitting with hose clamp.
b a
ob00388
a - Fuel hose
b - Hose clamp – secure remote fuel hose
Page 1D-10 90-889785 APRIL 2003

Shift Cable Installation

Install cables into the remote control following the instructions provided with the remote
control.
NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move
when the remote control handle is moved out of neutral.
1. Position remote control into neutral.
N
2. Shift outboard into neutral.

3. Measure the distance between pin and center of barrel pocket.
ob00528
F N R
a - Distance between pin and center of barrel pocket
b - Pin
c - Barrel pocket
90-889785 APRIL 2003 Page 1D-11

4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain
distance taken in Step 3.
b
a
ob00528
a - Shift cable end

b - Cable barrel
5. Place cable barrel into pocket. Fasten cable with locknut and flat washer.
c
b
a
ob00528
a - Place barrel into barrel pocket

b - Locknut – tighten locknut then back off locknut 1/4 turn.
c - Flat washer
6. Check shift cable adjustments as follows:
a. Shift remote control into forward. The propeller shaft should be locked in gear. If
not, adjust the barrel closer to the cable end.
b. Shift remote control into neutral. The propeller shaft should turn freely without
drag. If not, adjust the barrel away from the cable end. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propeller shaft should
be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps
a through c.
d. Shift remote control back to neutral. The propeller shaft should turn freely without
drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d.
Page 1D-12 90-889785 APRIL 2003

Throttle Cable Installation

Install cables into the remote control following the instructions provided with the remote
control.
N
2. Install throttle cable to the throttle arm with washer and locknut.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm
against the idle stop.
4. Place cable barrel into retainer.
5. Lock the retainer and cables in place with the cable latch.
a b
d
ob00529
e
a - Flat washer c - Barrel retainer

b - Locknut – tighten then d - Cable barrel
back off 1/4 turn e - Cable latch
90-889785 APRIL 2003 Page 1D-13

Filling Fuel System

For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel,
the fuel system should to be filled as follows:
1. Squeeze the fuel line primer bulb until it feels firm.

2. Turn the ignition key switch to the ON position for three seconds. This operates the
electric fuel pump.
3. Turn the ignition key switch back to the OFF position, and squeeze the primer bulb
again until it feels firm. Turn the ignition key switch to the ON position again for three
seconds. Continue this procedure until the fuel line primer bulb stays firm.
Filling The Oil Injection Tank

NOTE: The oil tank capacity is 4.72 liters (5 qt.).
1. Open the cowl cap. Turn the oil fill cap to the left and remove.
a
b
a - Cowl cap b - Oil fill cap
2. Use the chain on the fill cap to check oil level. First ball marker (a) is 0.94 liters (1 quart)
low and second ball marker (b) is 1.89 liters (2 quart) low.
3. Slowly fill the oil tank with the specified oil. Do Not overfill – add only enough oil to bring
the oil level up to the bottom of the fill neck (a).
4. Install oil filler cap and re-tighten. Reinstall the cowl cap.
a d
c
b
a - 0.94 liters (1 quart) low marker

b - 1.89 liters (2 quart) low marker
c - Full line
d - Oil fill cap
Page 1D-14 90-889785 APRIL 2003

Priming the Oil Injection Pump

Before starting engine for the first time, prime the oil injection pump. Priming will re-
move any air that may be in the pump, oil supply hose, or internal passages.
a b
a - Oil injection pump

b - Oil supply hose
CAUTION
To prevent damage to the fuel pumps, fill the engine fuel system with fuel. Other-
wise the fuel pumps will run without fuel during the priming process.
Prime the oil injection pump as follows:
1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
it feels firm.
2. Turn the ignition key switch to the ON position.
3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F
NOTE: It may take a few minutes for the pump to complete the priming process.
90-889785 APRIL 2003 Page 1D-15

Propeller Installation
WARNING
If the propeller shaft is rotated while the engine is in gear, there is the possibility
that the engine will crank over and start. To prevent this type of accidental engine
starting and possible serious injury caused from being struck by a rotating pro-
peller, always shift outboard to neutral position and remove spark plug leads
when you are servicing the propeller.
IMPORTANT: Propellers used on this product require the Mercury Marine Flo-Torq
lll type hub (835257A9) or equivalent.
Flo-Torq lll Drive Hub Propellers
e c b a
d
Flo-Torq III Drive Hub Propeller

a - Forward thrust hub
b - Replaceable drive sleeve
c - Rear thrust hub
d - Propeller nut retainer
e - Propeller nut
4. Tighten propeller nut to specified torque. Bend tabs against nut.
a - Propeller nut
b - Bend tabs into grooves
TORQUE
REF.
REF
a 1 NUT 55 75
Page 1D-16 90-889785 APRIL 2003

Trim-In Stop Adjustment

Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further in or under. This greater
trim under capability is desirable to improve acceleration, reduce the angle and time
spend in a bow high boat attitude during planing off, and in some cases, may be necessary
to plane off a boat with aft live wells, given the variety of available propellers and height
range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position
to avoid a bow-down planing condition called plowing. Plowing can cause bow steering
or over steering and inefficiently consumes horsepower. In this condition, if attempting a
turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may
result.
In rare circumstances, the owner may decide to limit the trim under. This can be accom-
plished by purchasing a stainless steel tilt pin and inserting it through whatever pin hole
is desired. The non-stainless steel shipping bolt should not be used in this application oth-
er than on a temporary basis.
WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim
position as soon as boat is on plane to avoid possible ejection due to boat spin-
out. Do not attempt to turn boat when engine is trimmed extremely under or in.
a - Tilt pin (17-49930A1)
90-889785 APRIL 2003 Page 1D-17

Paddle Wheel Speed Sensor Installation (If Equipped)

Parts Provided
b f
j a
h f
e
i
c g
d
a - Paddle wheel
b - Bracket
c - Flat washer (2)
d - #10 - 3/4 in. (19 mm) screw (2)
e - Cable cap
f - # 6 - 1/2 in. (12 mm) screw (4)
g - Clamp (2)
h - Connector
i - Wire retainer
j - Spare pin yoke
Selecting Location
Single engine installation – Mount on paddle wheel on the transom where the propeller
blade is rotating upward. [usually the right (starboard) side] to minimize cavitation. If feasi-
ble, mount at least 50 mm (2 in.) beyond the swing radius of the propeller.
Dual engine installation – Mount the paddle wheel between the engines as close to the
center line (keel) of the boat as possible. On slower, heavier displacement boats, howev-
er, positioning it farther from the keel is acceptable.
NOTE: Do not mount the paddle wheel directly behind any strakes, ribs, intakes or outlets
for live wells or any protrusion that may cause turbulence or cavitation.
50mm
(2 in.)
Page 1D-18 90-889785 APRIL 2003

Transom Angle Requirements

Standard 13° to 20° transoms – No special adjustments required.
Stepped or undercut transom with 3° angles – A small shim of tapered plastic, metal
or wood must be fabricated and installed as shown. Mount the paddle wheel on the step
for best performance.
a OK b
OK
d
c NO c OK
a - 13° Transom angle c - Stepped transom

b - 20° Transom angle d - Shim
Installing Bracket
1. Cut out the template at the end of this installation manual. At the location you’ve
selected, tape the template to the transom. Make sure the black dotted line on the
template is aligned with the transom’s bottom edge, as shown.
2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep where indicated on the template.
To prevent drilling too deeply, wrap masking tape around the drill 22 mm (7/8 in.) from
the point.
NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill Then drill
a hole approximately 15 mm (1/16 in.) deep to prevent surface cracks.
3. To prevent water seepage into the transom, apply a marine sealant (such as RTV 587
Silicone Sealer) to the two #10 screws provided. Using the washers provided, attach
and tighten the bracket to the hull, making sure the bracket is flush with the underside
of the hull.
4. Fill any gap between the housing and the transom with a caulking material, as shown.
Using a putty knife, smooth the surface to ensure proper water flow.
a
d
50 mm
(2 in.)
b c
a - Template c - Flat washer (2)
b - #10 Screw (2) d - Caulking
90-889785 APRIL 2003 Page 1D-19

Routing the Cable

NOTE: You can choose to drill a hole through the transom for routing the cable, or you
can route the cable over the transom or through a drain hole above the water line.
NOTE: There are two ways to route the cable: 1) Drill a hole through the transom for rout-
ing the cable, or 2) Route the cable over the transom or through a drain hole above the
water line.
When drilling a hole through the transom, follow these instructions:
1. Select a transom location for the hole above the water line that does not interfere with
other cables and controls.
2. Drill a 15 mm (5/8 in.) diameter hole.
3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV 587
Silicone Sealer) or a comparable marine sealant after you routed the cable through.
NOTE: The hole for the first clamp should be 1 in. (25 mm) above the paddle wheel. The
hole for the second clamp should be positioned halfway between the first clamp and the
cap covering the transom hole you drilled for the cable.
4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm
(1/2 in.) deep.
5. Apply RTV Silicone Sealer or a comparable marine sealant to the screw threads and
Install the cable clamps and the cable feed-through cap.
If you choose not to drill a hole through the transom:
NOTE: If you prefer not to drill a hole, route the cable over the transom or through a drain
hole that is above the water line.
25.4 mm
(1 in.)
a - 1st clamp
b - Middle clamp
c - Cable cap
d - Drain hole
Page 1D-20 90-889785 APRIL 2003

Paddle Wheel Removal and Installation

Removal – squeeze open (unlock) the tabs and pull up on the paddle wheel.
Installation – slide the pins into the slots in the bracket and snap the tabs into place.
a - Pins
b - Tabs
Wire connections
IMPORTANT: Before making wire connections, make sure wires are routed through
the transom.
NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with
the tabs inside the connector.
1. Have the wiring routed through the transom.
2. Push each wire terminal into its respective location in the connector. Push wires in un-
til they snap into place.
3. Secure wires into connector with the wire retainer.
WHITE
YELLOW
BLUE
BLACK
a b
b
a - Connector
b - Wire retainer
90-889785 APRIL 2003 Page 1D-21

IGNITION
ELECTRICAL
Section 2A – Ignition
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Shift Interrupt Switch . . . . . . . . . . . . . . . . . . 2A-22
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Guardian Protection System . . . . . . . . . . . . . . . 2A-23 A
Electrical Components . . . . . . . . . . . . . . . . . . . 2A-4 Guardian System Operation with Gauges . 2A-23
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-8 Guardian System Activation . . . . . . . . . . . . 2A-23
Ignition Component Description . . . . . . . . . . . 2A-9 Warning System . . . . . . . . . . . . . . . . . . . . . . . 2A-24
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-25
Propulsion Control Module (PCM) . . . . . . 2A-10 Troubleshooting without Digital Diagnostic
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-11 Troubleshooting with the Digital Diagnostic
Ignition Spark Plug Leads . . . . . . . . . . . . . 2A-13 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-26
Crank Position Sensor . . . . . . . . . . . . . . . . 2A-14 Digital Diagnostic Cartridges . . . . . . . . . . . 2A-26
Throttle Position Sensor (TPS) . . . . . . . . . 2A-14 DDT Functions – Optimax Models Software
Throttle Position Sensor (TPS) Version 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-15 DDT Functions – Optimax Models Software
Charging System Alternator . . . . . . . . . . . . 2A-16 Version 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-29
Temperature Sensor . . . . . . . . . . . . . . . . . . 2A-17 Ignition Components Removal and Installation 2A-36
Manifold Absolute Pressure (MAP) Propulsion Control Module (PCM) . . . . . . . 2A-36
Sensor and Air Temperature Sensor . . . . 2A-19 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-37
Direct Injectors . . . . . . . . . . . . . . . . . . . . . . . 2A-20 Crank Position Sensor . . . . . . . . . . . . . . . . . 2A-38
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 2A-21 Throttle Position Sensor . . . . . . . . . . . . . . . . 2A-39
Disconnecting Harness Connectors MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-40
from Ignition Coils and/or Injectors . . . . . . 2A-21 Air Temperature Sensor . . . . . . . . . . . . . . . . 2A-41
Specifications
IGNITION Type Digital Inductive
SYSTEM Firing Order 1-2-3
@ Idle 0.17 - 1.05 vdc
@ W.O.T 3.76 - 4.64 vdc
Air Gap 0.635 mm – 1.01 mm
(0.025 in. – 0.040 in.)
90-889785 APRIL 2003 Page 2A-1

IGNITION
Special Tools
Digital Diagnostic Terminal (DDT) 91-823686A2
Software Cartridge 91-880118A2
DDT Reference Manual 90-881204--2
Page 2A-2 90-889785 APRIL 2003

IGNITION
Adaptor Harness 84-822560A5
Spark Gap Tester 91-850439T
Timing Light 91-99379
DMT 2000 Digital Tachometer Multimeter 91-854009A1
90-889785 APRIL 2003 Page 2A-3

IGNITION
Electrical Components

Description
25 Liquid Neoprene 92-25711-3 92-25711-3
NOTE: Coat all eyelet wiring terminals with Liquid Neoprene.

NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with Dielectric Grease.
Page 2A-4 90-889785 APRIL 2003

IGNITION
Electrical Components (Continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 ELECTRICAL PLATE
2 3 IGNITION COIL
3 3 HI-TENSION LEADS
4 3 SPARK PLUG (PZFR6H) 20 27
5 6 SCREW (M6 x 30) 60 6.8
6 3 CLIP
7 1 SCREW (M6 x 20)
8 1 PRESSURE SENSOR
9 1 CLIP
10 1 FITTING
11 1 TUBING 20.3 cm (8 in.)
12 3 SCREW (M6 x 14) 60 6.8
13 4 WASHER
14 1 CABLE (BRAIDED)
15 2 CLIP
16 1 PCM
17 8 SCREW (M6 x 25) 35 4
18 3 WASHER
19 3 GROMMET
20 3 BUSHING
21 3 TRIM RELAY
22 3 BRACKET
23 3 GROMMET
24 3 BUSHING
25 2 PIN
26 1 SPACER
27 1 NUT (M6)
28 1 CLIP
29 1 START SOLENOID
30 2 GROMMET
31 2 BUSHING
32 2 NUT (10-32)(BRASS) 8 0.9
33 1 CAP NUT
34 1 CABLE (YELLOW/RED)
35 2 LOCKWASHER
36 2 NUT (0.312-18)(STAINLESS STEEL) 50 5.5
37 1 CABLE 10.1 cm (4 in.)
38 1 BOOT (YELLOW)
39 1 TRIM HARNESS
40 1 FUSE HARNESS (W/100 AMP FUSE)
41 1 STARTER HARNESS
42 1 BOOT (RED)
43 1 ENGINE HARNESS
90-889785 APRIL 2003 Page 2A-5

IGNITION

Description
25 Liquid Neoprene 92-25711-3 92-25711-3
NOTE: Coat all eyelet wiring terminals with Liquid Neoprene.

NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with Dielectric Grease.
Page 2A-6 90-889785 APRIL 2003
IGNITION

TORQUE
REF.
REF
44 1 FUSE COVER
45 1 MINI FUSE
46 4 MINI FUSE (20 AMP-YELLOW)
47 1 BATTERY CABLE
48 3 GROMMET
49 3 BUSHING
50 3 WASHER
51 3 SCREW (M8 x 35) 20 27
52 1 COVER
53 2 GROMMET
54 1 CABLE ASSEMBLY (BLACK) 30.5 cm (12 in.)
90-889785 APRIL 2003 Page 2A-7

IGNITION
Theory of Operation
When the ignition key is turned to the RUN position, battery voltage is applied to the elec-
trical system through the main power relay. If the Propulsion Control Module (PCM) does
not sense engine rotation from the starter motor within a certain time period, the relay is
turned off. Engine rotation will again engage the relay. When the main power relay is
closed, system voltage is supplied through the dedicated 20 ampere ignition fuse to the
positive terminal of all 3 ignition coils. Each coil contains an internal driver circuit. The driv-
er circuit switches the primary current on for a given time period (dwell), and then switches
it off causing the collapse of the coil’s magnetic field which creates a spark. The Crank
Position Sensor reads the encoder tooth pattern on the flywheel which allows the PCM
to monitor the position of the crankshaft while the engine is running. At the proper time
for ignition spark, the PCM sends a digital signal to the coil driver commanding the driver
to dwell and then provide spark. When the engine is operating at lower RPM, this process
is repeated in quick succession to provide a multi-strike spark for each combustion event.
The number of strikes per event is varied depending on RPM and load requirements. The
spark plug features an extended protrusion into the combustion chamber and platinum
tips on both the center and ground electrode.
Page 2A-8 90-889785 APRIL 2003

IGNITION
Ignition Component Description

Fuses
Wiring circuits on the outboard are protected from overload by fuses. If the silver band is
broken, the fuse is blown. If a fuse is blown, locate and correct the cause of the overload.
If the cause is not found, the fuse may blow again. Always replace blown fuse with a new
fuse with the same rating.
The fuses and circuits are identified as follows:
a b
d c
ob00398
a - SmartCraft Data Bus Circuit – SFE 5 Ampere Fuse.

b - Accessories – SFE 20 Ampere Fuse.
c - Ignition Coil Circuit – SFE 20 Ampere Fuse.
d - Electric Fuel Pump/PCM Driver Power/Oil Pump Circuit – SFE 20 Ampere
Fuse.
90-889785 APRIL 2003 Page 2A-9

IGNITION
Propulsion Control Module (PCM)

The PCM requires 8 VDC minimum to operate. If the PCM should fail, the engine will stop
running.
The inputs to the PCM can be monitored and tested by the Digital Diagnostic Terminal
91-823686A2 using adaptor harness 84-822560A5.
The PCM performs the following functions:
• Calculates the precise fuel and ignition timing requirements based on engine speed,
throttle position, manifold pressure and coolant temperature.
• Controls fuel injectors for each cylinder, direct injectors for each cylinder and ignition
for each cylinder.
• Controls all alarm horn and warning lamp functions.
• Supplies tachometer signal to gauge.
• Controls RPM limit function.
• Monitors shift interrupt switch.
• Records engine running information.
ob00398
a - Propulsion control module
Page 2A-10 90-889785 APRIL 2003

IGNITION
Flywheel
The 54 teeth under the flywheel ring gear provide engine rpm and crankshaft position in-
formation to the PCM through the crank position sensor.
ob00521
a - Flywheel
Ignition Coils
Inductive type ignition coils are used. A 12 volt DC current is supplied to the coils at all
times from the boat battery. For a predetermined length of time (dwell), the primary circuit
of the coil is completed by closing the electrical circuit within the coil driver. When the coil
driver circuit opens, the primary field of the coil collapses inducing high voltage in the sec-
ondary windings which produces up to 40000 volts at the spark plugs.
ob59576
a - Ignition coils
90-889785 APRIL 2003 Page 2A-11

IGNITION
Ignition Coil Ohms Test
58903
BLACK METER LEAD

Secondary EST EST Low Secondary Primary Battery +
Tower PIN A PIN B Low Ground Pin E
Pin C Pin D
Secondary X No No 850 – 1200 No No
Tower Continuity Continuity ohm Continuity Continuity
EST No X 8500 – No 29000 – 11000 –
PIN A Continuity 12000 Continuity 39000 21000
ohm ohm ohm
EST Low No 8500 – X No 39000 – 21000 –
RED PIN B Continuity 12000 Continuity 49000 31000
METER ohm ohm ohm
LEAD Secondary 850 – 1200 No No X No No
Low ohm Continuity Continuity Continuity Continuity
Pin C
Primary No 20000 – 39000 – No X 13000 –
Ground Continuity 30000 49000 Continuity 23000
Pin D ohm ohm ohm
Battery + No 11000 – 21000 – No 13000 – X
Pin E Continuity 21000 31000 Continuity 23000
ohm ohm ohm
EST = Electronic Spark Trigger

EST Low = Return ground path for the trigger signal to the ECM
Page 2A-12 90-889785 APRIL 2003

IGNITION
Ignition Spark Plug Leads

Spark plug leads are directional. The boot with the support webbing is to be installed on
the spark plug only. The other boot has a slightly larger internal diameter and there are
ribs inside the boot to help with retention when installed on the ignition coil tower.
c
a d
b ob59535
a - Spark plug lead

b - Support webbing – spark plug boot
c - Ignition coil boot
d - Retention ribs

The crank position sensor senses 54 teeth located on flywheel under ring gear. It supplies
the PCM with crank position information and engine speed. If sensor should fail, the en-
gine will stop running.
a ob00522
a - Crank position sensor
Crank Position Sensor Specifications
Air Gap 0.635 mm – 1.01 mm
(0.025 in. – 0.040 in.)
90-889785 APRIL 2003 Page 2A-13

IGNITION
Throttle Position Sensor (TPS)

The TPS transmits throttle angle information to the PCM which varies the injector pulse
width accordingly. Should the sensor fail, the dash mounted CHECK ENGINE light will
light and the warning horn will sound. RPM will be reduced by the PCM. TPS settings are
not adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal
through the PCM. Voltage change should be smooth from idle to wide open throttle. If volt-
age change is erratic, TPS is defective.
ob59583
a - Throttle position sensor
Model 75/90/115 Throttle Position Sensor Specifications

Idle 0.17 – 1.05 VDC
Wide Open Throttle 3.76 – 4.64 VDC
Page 2A-14 90-889785 APRIL 2003

IGNITION
Throttle Position Sensor (TPS) Troubleshooting

If the throttle position sensor(s) are out of the intended operating range when the engine
is started, the Propulsion Control Module (PCM) will sense that the Throttle Position Sen-
sor (TPS) has failed. The warning horn will sound, check engine light will illuminate, DDT
will indicate failed TPS, and the engine will go into RPM reduction. When the engine is
started, the throttle arm on the engine must be against the idle stop screw.
• Check throttle cable adjustment. The throttle stop screw on the throttle arm must be
against the throttle stop on the cylinder block when the engine is started. Pre-load the
throttle cable barrel 1 or 2 turns if necessary.
• Verify driver is not pushing on throttle (if foot throttle is used) or advancing the throttle
only on the control box.
• Check throttle cam to roller adjustment. If the roller is not down in the pocket/valley
area on the cam, there is a tendency for the roller to ride up or down on the cam which
may cause the TPS values to change.
• Heat or pressure test the TPS.
HEAT TEST
With engine at idle, heat the TPS (with a hot air gun) below the electrical connection until
warm to the touch. Watch for any one or a combination of the following symptoms:
• RPM change
• Momentary warning horn signal
• TPS voltage value change (1/2 volt) on DDT
NOTE: Excessive heat will damage TPS.
PRESSURE TEST
IMPORTANT: When testing TPS voltage, do not move the drive mechanism (rotor/
wiper).
1. Connect DDT and rotate the key to the ON position.
2. Set DDT to read TPS voltage. Expand the screen to show Now/Min/Max.
NOTE: Test accuracy is improved when TPS is at its lowest voltage reading.
3. Clear the minimum/maximum values on the DDT – press the 0 button.
4. Watch the DDT readings while pressing below the electrical connection point on the
TPS cover.
a - Press on cover below electrical connection
5. Voltage reading should change:

• Less than a couple of digits (i.e. 1.90 v to 1.92 v)
• Less than 10 millivolts (i.e. 0.293 v to 0.285 v)
6. Replace any TPS that fails either test.
90-889785 APRIL 2003 Page 2A-15

IGNITION
Charging System Alternator

The battery charging system is contained within the belt driven alternator, including the
regulator. At cranking speeds, electrical power for the engine is provided by the boat bat-
tery - minimum recommended size is 750 CCA, or 1,000 MCA, cold cranking amperes
or 105 (Minimum) Ampere Hours. Above 550 RPM, all electrical power is provided by the
alternator. Should engine rpm drop below 550 RPM, the alternator is not capable of pro-
viding sufficient output and the battery becomes the primary source of electrical power.
Alternator output (when hot) to the battery @ 2000 RPM is approximately 32 - 38 am-
peres.
ob00397
a - Alternator
Page 2A-16 90-889785 APRIL 2003

IGNITION
Temperature Sensor
Two (2) temperature sensors are used to provide cylinder head temperature information
to the PCM. One sensor is mounted in the engine cylinder head and one in the air com-
pressor cylinder head. The PCM uses this information to increase injector pulse width for
cold starts and to retard timing in the event of an overheat condition.
ob59591
ob00523
a - Cylinder temperature sensor

b - Air compressor temperature sensor
90-889785 APRIL 2003 Page 2A-17

IGNITION
An ohms test of the temperature sensor would be as follows:

MODEL 75/90/115 – Disconnect temperature sensor harness and check continuity with
digital or analog ohmmeter test leads between both connector pins. With engine at tem-
perature (F!) indicated, ohm readings should be as indicated ±10%. There should be no
continuity between each connector pin and ground.
MODEL 75/90/115
F! C! OHMS
257 125 340
248 120 390
239 115 450
230 110 517
221 105 592
212 100 680
203 95 787
194 90 915
185 85 1070
176 80 1255
167 75 1480
158 70 1752
149 65 2083
140 60 2488
131 55 2986
122 50 3603
113 45 4370
104 40 5327
95 35 6530
86 30 8056
77 25 10000
68 20 12493
59 15 15714
50 10 19903
41 5 25396
32 0 32654
14 –10 55319
5 –15 72940
Page 2A-18 90-889785 APRIL 2003

IGNITION
Manifold Absolute Pressure (MAP) Sensor

The MAP sensor is mounted on top of the air plenum. The ECM regulates fuel flow, in part,
based on manifold absolute pressure.
ob59575
a - MAP sensor
Air Temperature Sensor

The air temperature sensor is mounted on top of the air plenum. The PCM regulates fuel
flow, in part, based on manifold air temperature. As air temperature increases, the PCM
decreases fuel flow.
a
ob59574
a - Air temperature sensor
90-889785 APRIL 2003 Page 2A-19

IGNITION
Direct Injectors
Three direct injectors (1 per cylinder) are used to inject a fuel/air mix into cylinders. Injec-
tors are mounted between fuel rail and cylinder block.
ob59586
a - Direct injectors
Direct Injector Ohm Test (Injector Lead Disconnected)

Connect meter leads between each in-
1 - 1.6 !
jector terminal pin.
Connect 1 meter lead to either injector
pin while touching the other meter lead to No continuity
the injector metal case.
Page 2A-20 90-889785 APRIL 2003

IGNITION
Fuel Injectors
Three fuel injectors (1 per cylinder) are used to provide fuel from the fuel rail to the direct
injectors. The fuel injectors are mounted in the fuel rail.
ob59592
a - Fuel injectors
Fuel Injector Ohm Test (Injector Lead Disconnected)

Connect meter leads between each in-
1.7 - 1.9 !
jector terminal pin.
90-889785 APRIL 2003 Page 2A-21

IGNITION
Disconnecting Harness Connectors from Fuel Injectors

1. Push wire clip center down to disconnect.
ob54871
a - Wire clip
Shift Interrupt Switch

The shift switch is mounted on the exhaust adaptor plate and is activated by a cam/notch
in the upper shift shaft. The switch has a closed circuit when the engine is in gear (forward
or reverse) and an open circuit when the engine is in neutral. The switch is monitored by
the PCM. The PCM will change fueling, timing and RPM limit according to whether the en-
gine is in gear or in neutral.
a ob59573
a - Shift interrupt switch
The switch function can be monitored by the DDT. The DDT will display “ON” when out-
board is in neutral and “OFF” when in gear.
The switch is open (no continuity) when outboard is in neutral and closed (continuity)
when outboard is in gear.
If shift operation is difficult, shift interrupt switch function can be checked by the DDT or
an ohmmeter – for open or closed operation and for a continuity check of the switch har-
ness for shorts or open wiring.
Page 2A-22 90-889785 APRIL 2003

IGNITION
Guardian Protection System

The guardian protection system monitors critical engine functions and will reduce engine
power accordingly in an attempt to keep the engine running within safe operating parame-
ters.
IMPORTANT: The Guardian System cannot guarantee that powerhead damage will
not occur when adverse operating conditions are encountered. The Guardian Sys-
tem is designed to warn the boat operator that the engine is operating under ad-
verse conditions and reduce power by limiting maximum RPM in an attempt to
avoid or reduce the possibility of engine damage. The boat operator is ultimately
responsible for proper engine operation.
Guardian System Operation with Gauges
SmartCraft Gauge System will sound warning horn and display the
warning message.
Guardian System Activation

Condition Result
Engine Overheat Engine power level can be reduced to any percent-
age down to a fast idle speed, if overheat condition
persists.
Air Compressor Overheat Warning horn is activated but there is no power re-
duction.
Block Water Pressure Low Engine power level can be reduced to any percent-
age down to a fast idle, if condition persists.
Throttle Position Sensor Failure If the throttle position sensor fails or becomes discon-
nected, power will be limited to a maximum of
approximately 4500 RPM. When the TPS is in the fail
mode, the ECM will use the MAP sensor for a refer-
ence to determine fuel calibration.
Temperature Sensor (cylinder head and air com- If a temperature sensor should fail or become discon-
pressor) Failure nected, power will be limited to a maximum of
approximately 4500 RPM.
Battery Voltage (too high or too low) Battery voltage greater than 16 volts or less than 10
volts will result in engine output power being reduced.
The higher or lower the voltage is outside of these
parameters, the greater the percentage of power re-
duction. In an extreme case, power could be reduced
to a fast idle speed.
Oil Pump Failure If the oil pump fails or an open circuit occurs between
the pump and the PCM, engine power will be re-
duced to a fast idle.
ENGINE OVER-SPEED PROTECTION SYSTEM

The system is activated when the engine speed exceeds the maximum allowable RPM.
Anytime the engine over-speed system is activated, the warning horn begins to sound continu-
ously. The system will automatically reduce the engine speed to within the allowable limit.
NOTE: Engine speed should never reach the maximum limit to activate the system unless the
propeller is ventilating, an incorrect propeller is being used, or the propeller is faulty.
90-889785 APRIL 2003 Page 2A-23

IGNITION
Warning System
WARNING HORN SIGNALS
When the key switch is turned to the “ON” position, the horn will turn on for a moment as
a test to tell you the horn is working.
The warning horn will emit either a continuous beep or intermittent short beeps. This will
alert the operator and help identify the following listed situations (see chart below). For
visual display of the specific engine functions and for additional engine data, refer to
SmartCraft Product information.
Warning Horn
Function Sound Description
Start Up One Beep Normal System Test
Low Oil Four Beeps every 2 Minutes Oil level is low in the oil tank.
Water In Fuel Four Beeps every 2 Minutes Water in the fuel filter chamber
reached the full level.
Cooling System Problem Continuous Engine Guardian System is acti-
vated. Power limit will very with
level of overheat.
Oil Level is Critically Low Continuous Engine Guardian System is acti-
vated. Power limit will allow a fast
idle.
Oil Pump Failure Continuous Engine Guardian System is acti-
vated. Power limit will allow a fast
idle.
Engine Overspeed Continuous The warning horn is activated any
time engine speed exceeds the
maximum allowable RPM. The
system will limit the engine speed
to within the allowable range.
Sensor out of Range Continuous Engine Guardian System is acti-
vated. Power limit may activate at
full throttle speed.
Intermittent Beep Engine Guardian System is acti-
vated. Power limit may restrict en-
gine speed to idle.
Engine Running Cold at Slow One Beep Engine is not reaching correct tem-
Speed perature while operating below
1000 RPM.
Page 2A-24 90-889785 APRIL 2003

IGNITION
Troubleshooting
The PCM is designed such that if a sensor fails, the PCM will compensate, so that the
engine does not go into an over-rich condition.
Disconnecting a sensor for troubleshooting purposes may have no noticeable effect.
Troubleshooting Without Digital Diagnostic Terminal

Troubleshooting without the DDT is limited to checking resistance on some of the sen-
sors.
Typical failures usually do not involve the PCM. Connectors, set-up, and mechanical wear
are most likely at fault.
• Verify spark plug wires are securely installed (pushed on) on the coil tower.
• The engine may not run or may not run above idle with the wrong spark plugs installed.
• Swap ignition coils to see if the problem follows the coil or stays with the particular
cylinder.
NOTE: PCMs are capable of performing a cylinder misfire test to isolate problem cylin-
ders. Once a suspect cylinder is located, an output load test on the ignition coil, fuel injec-
tor and direct injector may be initiated through use of the DDT.
• Any sensor or connection can be disconnected and reconnected while the engine is
operating without damaging the PCM. Disconnecting the crank position sensor will
stop the engine.
IMPORTANT: Any sensor that is disconnected while the engine is running will be
recorded as a Fault in the PCM Fault History. Use the DDT to view and clear the fault
history when troubleshooting/repair is completed.
• If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input
to the PCM.
• If problem is speed related or intermittent, it is probably connector or contact related.
Inspect connectors for corrosion, loose wires or loose pins. Secure connector seating;
use dielectric compound.
• Inspect the harness for obvious damage: pinched wires, chaffing.
• Secure grounds and all connections involving ring terminals (coat with Liquid Neo-
prene).
• Check fuel pump connections and fuel pump pressure.
• Check air compressor pressure.
90-889785 APRIL 2003 Page 2A-25

IGNITION
Troubleshooting with the Digital Diagnostic Terminal

The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to
help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.
a
c d
b
a - Digital Diagnostic Terminal (91-823686A2)

b - Software Cartridge (91-880118-1 or A2)
c - DDT Reference Manual (90-881204)
d - Adapter Harness (84-822560A5)
Attach the diagnostic cable to the PCM diagnostic connector and plug in the software car-
tridge. You will be able to monitor sensors and PCM data values including status switches.
The PCM program can help diagnose intermittent engine problems. It will record the state
of the engine sensors and switches for a period of time and then can be played back to
review the recorded information.
Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic proce-
dures.
Digital Diagnostic Cartridges
P/N 880110 1 - Software version 1.1 has improvements that allow you to see engine tim-
ing on 2002 model V-6 EFI outboards and diagnostics for M/C models that use the Opti-
max outboard style advanced PCM. The 1.1 version supersedes to 1.2 version.
P/N 880118A2 - Software version 1.2 has improvements for EFI 4 stroke outboard ignition
coil diagnostics.
Page 2A-26 90-889785 APRIL 2003

CHARGING & STARTING SYSTEM
ELECTRICAL
Section 2B – Charging & Starting System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-17 B
Battery Cable Size . . . . . . . . . . . . . . . . . . . . . . 2B-5 Alternator Belt Tension Adjustment . . . . . . . . 2B-18
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 2B-5 Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Recommended Battery . . . . . . . . . . . . . . . . . . . 2B-6 Starter Motor Amperes Draw . . . . . . . . . . . 2B-19
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Starter System Components . . . . . . . . . . . 2B-19
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Charging a Discharged Battery . . . . . . . . . . . . 2B-6 Starter Motor (Solenoid Driven Bendix) . . . . . 2B-20
Winter Storage of Batteries . . . . . . . . . . . . . . . 2B-7 Troubleshooting the Solenoid Driven Bendix
Flywheel Removal and Installation . . . . . . . . . 2B-8 Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Starter Circuit Troubleshooting Flow Chart
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 (Solenoid Driven Bendix) . . . . . . . . . . . . . . . . . 2B-23
Flywheel/Alternator . . . . . . . . . . . . . . . . . . . . . . 2B-10 Starter Removal and Installation
System Components . . . . . . . . . . . . . . . . . . . . 2B-12 (Solenoid Driven Bendix) . . . . . . . . . . . . . . . . . 2B-25
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-25
Alternator Description . . . . . . . . . . . . . . . . . . . . 2B-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26
Diagnosis of Alternator System on Engine . . 2B-13 Disassembly
Alternator System Circuitry Test . . . . . . . . . . . 2B-14 (Solenoid Driven Bendix Starter) . . . . . . . . . . 2B-27
Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Cleaning and Inspection . . . . . . . . . . . . . . . . . . 2B-30
Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . 2B-14 Reassembly (Solenoid Driven Bendix Starter) 2B-31
Output Load Test . . . . . . . . . . . . . . . . . . . . . 2B-15 Commander 2000 Key Switch Test . . . . . . . . 2B-35
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-16
90-889785 APRIL 2003 Page 2B-1

Specifications
CHARGING Alternator Output (Regulated) 32 - 38 Amperes @ 2000 RPM @ Battery

SYSTEM 52 - 60 Amperes @ 2000 RPM @
Alternator
Brush Length Std Exposed Length: 10.5 mm (0.413 in.)
Min. Exposed Length: 1.5 mm (0.059 in.)
Voltage Output 13.5 to 15.1 Volts
Regulator Current Draw* 0.585 mA (Ign. Switch Off)
150.0 mA (Ign. Switch On)
STARTING Starter Draw (Under Load) 150 Amperes
SYSTEM Starter Draw (No Load) 60 Amperes
Minimum Brush Length 65.4 mm (0.25 in.)
*Battery Rating 1000 (Minimum) Marine Cranking Amps
750 (Minimum) Cold Cranking Amps
NOTE: All model alternator specifications require an amperage draw of less than 1.0 mA
with the ignition key in the “OFF” position and an amperage draw of not more than 350.0
mA with ignition key in the “ON” position.
Page 2B-2 90-889785 APRIL 2003

Special Tools
Volt/Ohm Meter 91-99750A1
Flywheel Holder 91-52344
Protector Cap (Used with Puller 91-73687A1) 91-24161
90-889785 APRIL 2003 Page 2B-3

Flywheel Puller 91-73687A1 or
Flywheel Puller 91-849154T1
Page 2B-4 90-889785 APRIL 2003

Battery Cable Size

If standard (original) battery cables are replaced with longer cables, the wire gauge size
must increase. See chart below for correct wire gauge size.
b
a - Wire Gauge Size b - Battery Cable Length
Battery Cable Wire Gauge Size
Mercury/Mariner Outboards
Battery Cable Length
8 ft. 9 ft. 10ft. 11ft. 12ft. 13ft. 14ft. 15ft. 16ft. 17ft. 18ft. 19ft. 20ft. 21ft. 22ft. 23ft. 24ft.
2.4m 2.7m 3.0m 3.4m 3.7m 4.0m 4.3m 4.6m 4.9m 5.2m 5.5m 5.8m 6.1m 6.4m 6.7m 7.0m 7.3m
Models Wire Gage Size No. SAE

6-25 Hp #8* #8 #6 #6 #6 #6 #4 #4 #4 #4 #4 #4 #4 #4 #2 #2 #2
30-115 #6* #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Hp
125-250 #6* #6 #4 #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2
Hp (ex-
cept
DFI)
DFI #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0
Models
* = Standard (original) Cable Length and wire gauge size.
Replacement Parts
WARNING
Electrical, ignition and fuel system components on your Mercury/Mariner out-
board are designed and manufactured to comply with U. S. Coast Guard Rules
and Regulations to minimize risks of fire and explosions. Use of replacement
electrical, ignition or fuel system components, which do not comply with these
rules and regulations, could result in a fire or explosion hazard and should be
avoided.
CAUTION
Deep-cycle batteries are not suitable for use as engine starting batteries or for
use as accessory batteries that are connected to high output engine charging
systems. Deep-cycle battery life may be shortened by high output engine charg-
ing systems. Refer to individual battery maker instructions for specific battery
charging procedures and applications.
90-889785 APRIL 2003 Page 2B-5

Recommended Battery
A 12 volt marine battery with a minimum Cold Cranking amperage rating of 750 amperes
or 1000 (minimum) Marine Cranking amperes or 105 ampere hours should be used.
Battery
Precautions
CAUTION
If battery acid comes in contact with skin or eyes, wash skin immediately with a
mild soap. Flush eyes with water immediately and see a doctor.
When charging batteries, an explosive gas mixture forms in each cell. Part of this gas es-
capes through holes in vent plugs and may form an explosive atmosphere around battery
if ventilation is poor. This explosive gas may remain in or around battery for several hours
after it has been charged. Sparks or flames can ignite this gas and cause an internal ex-
plosion which may shatter the battery.
The following precautions should be observed to prevent an explosion.
1. DO NOT smoke near batteries being charged or which have been charged very re-
cently.
2. DO NOT break live circuits at terminals of batteries because a spark usually occurs
at the point where a live circuit is broken. Always be careful when connecting or dis-
connecting cable clamps on chargers. Poor connections are a common cause of elec-
trical arcs which cause explosions.
3. DO NOT reverse polarity of battery terminal to cable connections.
NOTE: There is a 100 ampere fusible link between the alternator and the slave solenoid.
This fusible link is designed to protect the alternator from damage due to incorrect battery
connection polarity. If battery cables are reversed, the fusible link may open circuit and
must be replaced. With the fusible link open, the engine can be started but the run time
will be limited due to the rapid discharge of the boat battery.
Charging a Discharged Battery

WARNING
Hydrogen and oxygen gases are produced during normal battery operation or
charging. Sparks or flame can cause this mixture to ignite and explode, if they are
brought near the vent openings. Sulphuric acid in battery can cause serious
burns, if spilled on skin or in eyes. Flush or wash away immediately with clear
water.
The following basic rule applies to any battery charging situation:
1. Any battery may be charged at any rate (in amperes) or as long as spewing of electro-
lyte (from violent gassing) does not occur and for as long as electrolyte temperature
does not exceed 52° C (125° F). If spewing of electrolyte occurs, or if electrolyte tem-
perature exceeds 52° C (125° F), charging rate (in amperes) must be reduced or tem-
porarily halted to avoid damage to the battery.
Page 2B-6 90-889785 APRIL 2003

2. Battery is fully charged when, over a 2-hour period at a low charging rate (in amperes),
all cells are gassing freely (not spewing liquid electrolyte), and no change in specific
gravity occurs. Full charge specific gravity is 1.260-1.275, corrected for electrolyte
temperature with electrolyte level at 4.8 mm (3/16 in.) over plate, unless electrolyte
loss has occurred (from age or over-filling) in which case specific gravity reading will
be lower. For most satisfactory charging, lower charging rates in amperes are recom-
mended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be
reached, battery is not in optimum condition and will not provide optimum perform-
ance; however, it may continue to provide additional service, if it has performed satis-
factorily in the past.
4. To check battery voltage while cranking engine with electric starting motor, place RED
(+) lead of tester on POSITIVE (+) battery terminal and BLACK (–) lead of tester on
NEGATIVE (–) battery terminal. If the voltage drops below 9-1/2 volts while cranking,
the battery is weak and should be recharged or replaced.
Winter Storage of Batteries

Battery companies are not responsible for battery damage either in winter storage or in
dealer stock if the following instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sul-
fate and dirt from top surface by running water over top of battery. Be sure, however,
that vent caps are tight beforehand, and blow off all excess water thoroughly with com-
pressed air. Check water level, making sure that plates are covered.
2. When adding distilled water to battery, be extremely careful not to fill more than 4.8
mm (3/16 in.) above perforated baffles inside battery. Battery solution or electrolyte
expands from heat caused by charging. Overfilling battery will cause electrolyte to
overflow [if filled beyond 4.8 mm (3/16 in.) above baffles].
3. Grease terminal bolts well with 2-4-C with Teflon and store battery in a COOL-DRY
place. Remove battery from storage every 30-45 days, check water level and put on
charge for 5 or 6 hours at 6 amperes. DO NOT FAST CHARGE.
4. If specific gravity drops below 1.240, check battery for reason and recharge. When
gravity reaches 1.260, discontinue charging. To check specific gravity, use a hydrom-
eter, which can be purchased locally.
5. Repeat preceding charging procedure every 30-45 days, as long as battery is in stor-
age, for best possible maintenance during inactive periods to ensure a good service-
able battery in spring. When ready to place battery back in service, remove excess
grease from terminals (a small amount is desirable on terminals at all times), recharge
again as necessary and reinstall battery.
90-889785 APRIL 2003 Page 2B-7

Flywheel Removal and Installation

Removal
1. Remove flywheel cover from engine.
WARNING
Engine could possibly start when turning flywheel during removal and installa-
tion; therefore, disconnect (and isolate) spark plug leads from spark plugs to pre-
vent engine from starting.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and
washer.
ob59578
a - Flywheel Holder (91-52344)
4. Install a Crankshaft Protector Cap (91-24161) on end of crankshaft, then install Fly-
wheel Puller (91-73687A2) into flywheel.
Page 2B-8 90-889785 APRIL 2003

5. Hold flywheel tool with wrench while tightening bolt down on protector cap. Tighten
bolt until flywheel comes free.
ob5957
a - Flywheel Puller (91-73687A2)
NOTE: Neither heat or hammer should be used on flywheel to aid in removal as damage
to flywheel may result.
6. Remove flywheel. Inspect flywheel for cracks or damage.
Installation
IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry.
1. Install flywheel.
2. Install flywheel washer and nut.
3. Hold flywheel with Flywheel Holder (91-52344). Torque nut to specification.
ob58579
a - Flywheel Holder (91-52344)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
a 1 NUT 120 163
90-889785 APRIL 2003 Page 2B-9

Flywheel/Alternator
Page 2B-10 90-889785 APRIL 2003

Flywheel/Alternator (Continued)
TORQUE
REF.
REF
1 1 FLYWHEEL
2 1 DAMPER
3 3 SCREW 25 33.9
4 1 BELT
5 1 ALTERNATOR
6 2 SCREW (M10 x 50) 25 33.9
7 1 WASHER
8 1 CABLE
9 1 NUT (M6) 50 5.7
10 1 BRACKET–ALTERNATOR
11 1 PIN 45 5.1
12 3 MOUNT
13 3 SCREW (M10 x 45) 25 33.9
14 6 WASHER
15 1 PLUG
16 1 WASHER
17 1 NUT 120 163
90-889785 APRIL 2003 Page 2B-11

System Components
The battery charging system consists of the alternator, battery, ignition switch, starter so-
lenoid and the wiring which connects these components.
c
BLK = Black
BLK BLU = Blue
BRN = Brown
BLK GRY = Gray
GRN = Green
YEL/RED
aa ORN = Orange
PNK = Pink
PUR = Purple
RED = Red
d TAN = Tan
e WHT = White
YEL = Yellow
RED
f
RED
LT = Light
RED
RED
DRK = Dark
RED
BLK RED
RED
BLK
RED PPL
RED RED
RED RED
bb
ob58911
a - Alternator d - Starter solenoid
b - Battery e - 100 ampere fuse
c - 20 ampere fuse f - Flat plug
Precautions
The following precautions must be observed when working on the alternator system. Fail-
ure to observe these precautions may result in serious damage to the alternator system.
1. Do not attempt to polarize the alternator.
2. Do not short across or ground any of the terminals on the alternator, except as specifi-
cally instructed.
3. Never disconnect the alternator output lead, regulator harness or battery cables when
the alternator is being driven by the engine.
4. Always remove NEGATIVE (–) battery cable from battery before working on alternator
system.
5. When installing battery, be sure to connect the NEGATIVE (–) (GROUNDED) battery
cable to NEGATIVE (–) battery terminal and the POSITIVE (+) battery cable to POSI-
TIVE (+) battery terminal.
6. When using a charger or booster battery, connect it in parallel with existing battery
(POSITIVE to POSITIVE; NEGATIVE to NEGATIVE).
Page 2B-12 90-889785 APRIL 2003

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

1. If problem is an undercharged battery, verify condition has not been caused by exces-
sive accessory current draw or by accessories which have accidentally been left on.
2. Check physical condition and state of charge of battery. Battery must be at least 75%
(1.230 specific gravity) of fully charged to obtain valid results in the following tests. If
not, charge battery before testing system.
3. Inspect entire alternator system wiring for defects. Check all connections for tightness
and cleanliness, particularly battery cable clamps and battery terminals.
IMPORTANT: RED output lead from alternator must be tight. A darkened RED
sleeve indicates lead was loose and becoming hot. There is a 100 ampere fusible
link in the output lead between the alternator and the slave solenoid. This fusible
link is designed to protect the alternator from damage due to incorrect battery con-
nection polarity. If battery cables are reversed, the fusible link may open circuit and
must be replaced. With the fusible link open, the alternator will not produce any am-
perage.
90-889785 APRIL 2003 Page 2B-13

4. Check alternator drive belt for cracks and fraying. Replace if necessary. Check belt
tension. Adjust if necessary, as outlined under Drive Belt Replacement and Adjust-
ment.
Alternator System Circuitry Test

Using a 0-20 volt DC voltmeter, perform the following tests:
Output Circuit
1. Connect POSITIVE (+) voltmeter lead to alternator terminal B (output terminal). Con-
nect NEGATIVE (–) lead to case ground on alternator.
2. Shake alternator wiring harness. Meter should indicate battery voltage and should not
vary. If proper reading is not obtained, check for loose or dirty connections or dam-
aged wiring.
ob59580
a - Terminal B
Sensing Circuit
1. Unplug RED and PURPLE lead connector from alternator.
2. Connect POSITIVE (+) voltmeter lead to RED lead and NEGATIVE (–) voltmeter lead
to ground.
Page 2B-14 90-889785 APRIL 2003

3. Voltmeter should indicate battery voltage. If correct voltage is not present, check
sensing circuit (RED lead) for loose or dirty connections or damaged wiring.
ob58458
ob59581
a - Sense lead (RED)

Output Load Test
NOTE: Battery must be fully charged and no accessories turned on while performing the
output load test.
1. With engine shutoff, install ammeter (capable of reading 60+ amperes) in series be-
tween TERMINAL B on alternator and POSITIVE (+) of battery. If using a clamp-on
ammeter, place clamp over output lead of alternator.
ob59580
a - Terminal B
2. Start engine and allow to warm up. Advance RPM to 2000.

3. Trim engine to the full down position and while loading trim pump in the full down posi-
tion, observe the ammeter. Output of the alternator should be 45 amperes minimum.
Voltage at the battery should be between 12.5 and 14.5 volts. If proper output is not
obtained, replace alternator.
NOTE: If the battery is not fully charged or is defective, voltage will be considerably lower
than 12.5 volts and the amperage will be correspondingly lower.
90-889785 APRIL 2003 Page 2B-15

Repair
Removal
1. Remove top cowling.
2. Disconnect battery cables from battery.
3. Disconnect wiring harness from alternator.
4. Use a breaker bar to release belt tensioner and remove alternator belt.
5. Remove 2 screws securing alternator.
ob00397
a - Attaching screws
b - Harnesses (hidden)
c - Belt tensioner (3/8 Drive)
Page 2B-16 90-889785 APRIL 2003

Installation
1. Secure alternator to engine block with 2 attaching screws. Torque screws to
specification.
2. Install alternator belt in grooves of flywheel, alternator and compressor pulley.
3. Reconnect electrical harness to alternator.
ob00397
a - Screws (M10 x 50)

b - Tensioner
c - Harnesses
TORQUE
QTY DESCRIPTION lb-in lb-ft Nm.
2 SCREW (M10 x 50) 25 33.9
90-889785 APRIL 2003 Page 2B-17

Alternator Belt Tension Adjustment

Correct alternator belt tension is maintained by a belt tensioner assembly.
ob00397
a - Belt tensioner assembly
Page 2B-18 90-889785 APRIL 2003

Starter System
Starter Motor Amperes Draw
STARTER MOTOR NO LOAD NORMAL
PART NO. AMP. DRAW AMP. DRAW
50-853329-1 60 AMPS 150 AMPS
Starter System Components

1. Battery
2. Starter Solenoid
3. Neutral Start Switch
4. Starter Motor
5. Ignition Switch
6. Slave Solenoid
Description
The battery supplies electricity to activate the starter motor. When the ignition is turned
to the “START” position, the slave solenoid is energized. The slave solenoid completes
the circuit between the battery and the starter solenoid which activates the starter.
The neutral start switch opens the starter circuit when the shift control lever is not in neu-
tral thus preventing accidental starting when the engine is in gear.
CAUTION
The starter motor may be damaged if operated continuously. DO NOT operate
continuously for more than 30 seconds. Allow a 2 minute cooling period between
starting attempts.
90-889785 APRIL 2003 Page 2B-19

Starter Motor (Solenoid Driven Bendix)

1
3
2
5
4
12 14
13
9
10
11
26
23 15
24
16 18
24
25
17
21 19
20
21
22
ob58430
22
Page 2B-20 90-889785 APRIL 2003

Starter Motor(Solenoid Driven Bendix)(Continued)

TORQUE
REF.
REF
1 2 THRU BOLT 110 12.5
2 2 SCREWS 30 3.4
3 1 END CAP
4 1 BUSHING
5 1 BRUSH PLATE ASSEMBLY
6 1 ARMATURE
7 1 FIELD FRAME
8 1 SOLENOID
9 1 SHIELD
10 1 CUSHION
11 3 PLANETARY GEARS
12 1 PLUG
13 1 DISC
14 1 SHIFT FORK
15 1 GEAR/CLUTCH ASSEMBLY
16 1 BEARING
17 1 HOUSING
18 3 SCREW 40 4.5
19 1 DRIVE GEAR
20 1 SNAP RING
21 2 MOUNTING COLLAR
22 2 STOP
23 2 NUT (M8) 55 6
24 2 WASHER
25 1 NUT 20 2.3
26 1 NUT (M5) 10 0.8
90-889785 APRIL 2003 Page 2B-21

Troubleshooting the Solenoid Driven Bendix Starter Circuit

Before beginning the troubleshooting flow chart, verify the following conditions:
1. Confirm that battery is fully charged.
2. Check that control lever is in NEUTRAL position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 20 amp fuse.
Location of Test Points (called out in flow chart) are numbered below.
#*
a
$
%
#
h c
"
!
g
f
&
'
( )
d
e
ob58431
a - To alternator
b - Starter
c - Starter solenoid
d - Neutral start switch – located in control box
e - Ignition switch
f - 20 ampere fuse
g - Slave solenoid
h - Battery
Page 2B-22 90-889785 APRIL 2003

Starter Circuit Troubleshooting Flow Chart (Solenoid

Driven Bendix)
Starter Motor Does Not Turn
TEST 1
With ignition key in “START” position, check for battery
voltage at TEST POINT 1.
Voltage indicated and solenoid clicks No voltage indicated Voltage indicated and solenoid does not click
Go to TEST 2 Check for starter motor ground at Test Point 10

Voltage indicated at Test Point 9
is 9.5 volts or greater.
Good ground Bad ground – clean cable ends

Voltage indicated at Test Point 9 or replace ground cable
is less than 9.5 volts.
Defective starter solenoid

Defective starter motor Defective starter solenoid
SAFETY WARNING: Disconnect BLACK with RED sleeve (starter motor)

cable from slave solenoid test point 7 BEFORE making tests 1 through 7 to
prevent unexpected engine cranking.
TEST 2
Use an ohmmeter (Rx1 scale) and connect meter leads
between NEGATIVE (–) battery post and common power-
head ground.
No Continuity Indicated – There is an open circuit in the Continuity Indicated

BLACK NEGATIVE (–) battery cable between the NEGATIVE (–) Proceed to TEST 3
battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.
Test 3
a. Disconnect BLACK ground wire from Test Point 3.
No voltage reading: b. Connect voltmeter between common engine ground and Test Point 3.
proceed to TEST 4. c. Turn ignition key to “START” position.
TEST 4 12 Volt Reading*

a. Reconnect BLACK ground wire. Check BLACK ground wire for poor connection
b. Connect voltmeter between common engine ground and Test Point 4. or open circuit.
Reconnect ground wire to starter solenoid.
c. Turn ignition key to Start position. Proceed to TEST 8.
90-889785 APRIL 2003 Page 2B-23

No voltage reading: 12 Volt Reading

proceed to TEST 5 Defective starter solenoid
TEST 5
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 5. Neutral start switch is open or YELLOW/RED
No voltage reading: wire is open between Test Points 5 and 4.
proceed to TEST 6 b. Turn ignition key to “START” position.
TEST 6
Connect voltmeter between common 12 Volt Reading*
No voltage reading:
engine ground and Test Point 6 Defective ignition switch.
proceed to TEST 7
TEST 7
Check for voltage between common engine ground and Test Point 7.
No voltage reading: 12 Volt Reading*

Check BLACK cable with RED Check fuse in RED wire between Test Points
sleeve between battery(+) 6 and 7.
POSITIVE terminal and Test Point 8 Check for open RED wire between Test
and Test Point 7. Points 6 and 7.
TEST 8
a. Connect voltmeter between common engine ground and Test Point 2.
b. Turn ignition key to “START” position.
No voltage reading: 12 Volt Reading*

Defective slave solenoid Should hear solenoid click: proceed to TEST 9
TEST 9
a. Reconnect BLACK cable (with RED sleeve) to slave solenoid Test
Point 7.
b. Connect voltmeter between common engine ground and Test Point 7.
c. Turn ignition key to “START” position.
No voltage reading:
Check BLACK cable (with RED sleeve) for
poor connection or open circuit.
*Battery Voltage
Page 2B-24 90-889785 APRIL 2003

Starter Removal and Installation (Solenoid Driven Bendix)

Removal
CAUTION
Disconnect battery leads from battery before removing starter.
1. Disconnect battery cables from battery.
2. Disconnect wires from starter solenoid terminals.
3. Remove starter trunion mounting bolts and remove starter from engine.
a
d
b
c
a
ob00410
a - Mounting bolts
b - Solenoid leads
c - Nut under boot
d - Starter solenoid
90-889785 APRIL 2003 Page 2B-25

Installation
1. Secure starter to engine with 4 bolts. Use right top bolt to attach BLACK (NEGATIVE).
Torque four attaching screws to 24.4 Nm (18 lb-ft).
2. Secure YELLOW and RED lead to stator solenoid. Torque nut to specification.
3. Secure BLACK cable (with RED sleeve) to POSITIVE (+) terminal on starter solenoid.
Torque nut to specification.
a
f
d c
e
a
b
ob00410
a - Screws (4)
b - BLACK cable (with RED sleeve)
c - YELLOW and RED lead
d - Nut (M5)
e - Nut (M8) (under boot)
f - Starter solenoid
TORQUE
REF.
REF
a 4 SCREW (M8 x 40) 18 24.4
d 1 NUT (M5) 10 .8
e 2 NUT (M8) 55 6
Page 2B-26 90-889785 APRIL 2003

Disassembly (Solenoid Driven Bendix Starter)

1. Remove brush lead from solenoid and thru-bolts from end frame.
e
b
a
c
ob58434
a - Brush lead d - Brush plate screws

b - Thru-bolts e - End frame
c - Starter solenoid
2. Remove armature and field frame from drive housing.

NOTE: Permanent magnets inside field frame will be holding armature in place.
d
e
ob58430
a - End frame and bearing

b - Screws (2) (Internal Torx – Snap On E6 Socket)
c - Brush holder
d - Armature
e - Field frame
90-889785 APRIL 2003 Page 2B-27

3. Remove shield and cushion from drive housing.
ob58432
a - Shield
b - Cushion
c - Drive housing
4. Remove 3 screws retaining starter solenoid. Remove solenoid from drive housing.
5. Remove snap ring and gear from starter shaft.
b
d
ob58436
a - Drive housing
b - Starter solenoid
c - Screws (3) (internal torx– Snap On E6 Socket)
d - Snap ring
e - Pinion gear
Page 2B-28 90-889785 APRIL 2003

6. Remove planetary gear and clutch assembly from drive housing.

7. Remove solenoid arm, metal disc and plug from drive housing.
d
c
a
ob58437
a - Planetary gear and d - Metal disc
clutch assembly e - Solenoid arm
b - Drive housing
c - Plug
8. Inspect drive housing needle bearing for roughness. If bearing is worn or damaged,
bearing can be removed by using an appropriate mandrel to drive/press bearing from
drive housing.
NOTE: If bearing has spun in drive housing bore, drive housing must be replaced.
ob58439
a - Needle bearing
b - Drive housing
90-889785 APRIL 2003 Page 2B-29

Cleaning and Inspection

IMPORTANT: Do not use grease dissolving solvents to clean electrical compo-
nents, planetary gears or drive clutch. Solvent will damage insulation and wash the
lubricant out of the clutch drive and gears. Use clean rags and compressed air to
clean components.
1. Test over-running clutch action of drive. Pinion should turn freely in over-running di-
rection and must not slip in cranking direction.
2. Inspect pinion teeth for wear.
3. Inspect spring for tension and drive collar for wear.
4. Check that bearings roll freely. If any roughness is felt, replace bearing.
5. Inspect planetary gear assembly. Gears must mesh easily and roll freely with no bind-
ing.
Page 2B-30 90-889785 APRIL 2003

Reassembly (Solenoid Driven Bendix Starter)

1. Install solenoid arm with planetary gear and clutch assembly into drive housing.
b
ob58438
a - Solenoid arm
b - Planetary gear and clutch assembly
c - Drive housing
2. Install metal disc and plug into drive housing.
a
b
ob58433
a - Metal disc
b - Plug
90-889785 APRIL 2003 Page 2B-31

3. Attach solenoid arm to starter solenoid. Install starter solenoid in drive housing and
secure with 3 screws. Torque screws to specification.
4. Install drive gear and secure with snap ring.
5. Reinstall rubber bumpers on housing.
c
e
a
ob58436
a - Drive housing d - Drive gear
b - Starter solenoid e - Snap ring
c - Screw (3) f - Bumpers
TORQUE
REF.
REF
c 3 SCREW 40 4.5
6. Install cushion and shield in drive housing.

c
ob58432
a - Shield
b - Cushion
c - Drive housing
Page 2B-32 90-889785 APRIL 2003

7. Install field frame over armature.

8. While holding brushes back, slide brush plate onto armature while aligning brush lead
grommet with slot in field frame.
9. Secure end plate to brush assembly with 2 screws. Torque screws to specification.
NOTE: Prior to installing field frame assembly into drive housing, align slot in field frame
with plug in drive housing.
g
b
d
c
f
ob58435
a - Armature e - End plate
b - Field frame grommet slot f - Screws
c - Brush plate g - Field frame plug slot
d - Brush lead grommet
TORQUE
REF.
REF
f 2 SCREWS 30 3.4
90-889785 APRIL 2003 Page 2B-33

10. Install field frame and end frame in drive housing.

11. Install through bolts and brush lead. Torque through bolts to specification. Torque
brush nut to specification.
b
d c
f
a
ob58434
a - End frame
b - Field frame
c - Drive housing
d - Through bolts
e - Brush lead
f - Brush nut
TORQUE
REF.
REF
d 2 THRU-BOLT 110 12.5
f 1 NUT 55 6
Page 2B-34 90-889785 APRIL 2003

Commander 2000 Key Switch Test

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

POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK
OFF
RUN
START
CHOKE*
90-889785 APRIL 2003 Page 2B-35

TIMING, SYNCHRONIZING & ADJUSTING
ELECTRICAL
Section 2C – Timing, Synchronizing & Adjusting
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Throttle Linkage Adjustment . . . . . . . . . . . . . . 2C-5
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Throttle Position Sensor (TPS) Adjustment . 2C-10 C
Crank Position Sensor . . . . . . . . . . . . . . . . . . . 2C-4 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Alternator Belt Tension Adjustment . . . . . . . . 2C-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4
Specifications
Full Throttle RPM (75/90/115) 5000 - 5750

Idle RPM (In Gear) (75/90/115) 625 - 675
Firing Order 1-2-3
@ Idle 0.17 - 1.05 VDC
@ W.O.T 3.76 - 4.64 VDC
90-889785 APRIL 2003 Page 2C-1

Special Tools
DMT 2000 Digital Tachometer Multimeter 91-854009T1
Digital Diagnostic Tool (DDT) 91-823686A2
Software Cartridge 91-880118, 91-880118--1, 91-880118A2
Page 2C-2 90-889785 APRIL 2003

DDT Reference Manual 91-881204, 91-881204--1, 91-881204--2
ECM Harness 84-822560A5
Extension Cable [3.05 m (10 ft.)] 84-825003A1
90-889785 APRIL 2003 Page 2C-3


NOTE: Crank position sensor is not adjustable.
Removal
1. Remove flywheel cover.
2. Disconnect sensor harness connector.
3. Remove 2 screws securing sensor to engine block.
a c
b
ob00522
a - Crank position sensor

b - Harness connector
c - Screws
Installation
1. Secure sensor to block with 2 screws.
2. Reconnect sensor harness connector.
TORQUE
REF.
REF
c 2 SCREWS 45 5.1
Page 2C-4 90-889785 APRIL 2003

Throttle Linkage Adjustment

IMPORTANT: The throttle cam end of the throttle cables should not under normal
service conditions require adjustment, as they are preset at factory. However, prior
to making any adjustments to the throttle linkage, verify that each of the throttle
cable sheaves extend a distance of 1.11 mm ! 0.10 mm (0.44 in. ! 0.040 in.) below
their attaching plate. If the distance is not correct, adjust throttle cables according-
ly. If the cables need to be adjusted, torque the jam nuts to specification.
b
c
ob000838
a - Attaching plate
b - Jam nuts
c - 1.11 mm ± 0.10 mm (0.44 in. ± 0.040 in.)
TORQUE
REF.
REF
b 4 JAM NUTS 65 7.3
90-889785 APRIL 2003 Page 2C-5

1. With throttle arm against idle stop, adjust lower throttle cable to remove excess slack
from lower throttle cable.
2. While holding throttle arm against idle stop, adjust upper throttle cable to remove ex-
cess cable slack.
IMPORTANT: Too much tension on upper throttle cable will prevent throttle arm
from returning freely against idle stop.
ob00712
a - Throttle arm
b - Idle stop
c - Lower throttle cable
d - Upper throttle cable
Page 2C-6 90-889785 APRIL 2003

IMPORTANT: Throttle shutter opening at idle should not under normal service con-
ditions require adjustment, as this opening is preset at factory. However, it may be
checked to verify that the opening is 0.40 mm (0.016 in.) between the throttle shut-
ter and the throttle bore. If the measurement is not correct, adjust the throttle shut-
ter stop screw accordingly.
ob00418
a - Throttle shutter opening 0.40 mm (0.016 in.)

b - Throttle shutter stop screw
90-889785 APRIL 2003 Page 2C-7

3. Holding the throttle arm against the idle stop, verify that the throttle roller is in the
throttle cam pocket and that the roller rotates freely without binding against the cam.
If the roller is not positioned correctly, adjust the roller arm adjustment screw to obtain
correct alignment.
IMPORTANT: The throttle roller to cam interface is preset at factory and under nor-
mal service conditions should not require any adjustment.
e ob59630
ob00712
a - Throttle roller
b - Throttle cam pocket
c - Adjustment screw
d - Throttle arm
e - Idle stop
Page 2C-8 90-889785 APRIL 2003

4. Holding the throttle arm against the wide open throttle stop, there should be a 0.508
mm – 1.016 mm (0.020 in. – 0.040 in.) gap between the throttle shutter arm and the
throttle shutter stop. If gap is not within specifications, Adjust wide open throttle stop
screw accordingly.
e
c
f d
b
a
ob59632 ob59631
a - Throttle arm
b - Wide open throttle stop
c - Throttle shutter arm
d - Throttle shutter stop
e - Gap – 0.508 mm – 1.016 mm (0.020 in. – 0.040 in.)
f - Wide open throttle stop screw
90-889785 APRIL 2003 Page 2C-9

Throttle Position Sensor (TPS) Adjustment

The Throttle Position Sensor is not adjustable. TPS settings can be monitored with the
Digital Diagnostic Terminal through the PCM. If TPS settings are not within specifications,
refer to Section 2A, Throttle Position Sensor.
ob59583
a - Throttle position sensor
Idle Speed
Engine idle speed is not adjustable. The parameters affecting idle speed can be checked
and monitored by the DDT. Refer to the DDT Reference Manual for complete details.
Page 2C-10 90-889785 APRIL 2003

Alternator Belt Tension Adjustment

Correct alternator belt tension is maintained by a belt tensioner assembly.
ob00397
a - Belt tensioner
90-889785 APRIL 2003 Page 2C-11

WIRING DIAGRAMS
ELECTRICAL
Section 2D – Wiring Diagrams
Table of Contents
2
Power Trim Wiring Diagram . . . . . . . . . . . . . . 2D-2 Instrument/Lanyard Stop Switch Wiring
D
Instrument Wiring Connections . . . . . . . . . . . . 2D-3 Diagram (Dual Outboard) . . . . . . . . . . . . . . . . . 2D-10
Commander 3000 Classic Panel Oil Level Gauge Wiring Diagram . . . . . . . . . . 2D-12
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5 QSI Gauge Wiring Diagrams . . . . . . . . . . . . . . 2D-13
Commander 3000 Panel Remote Control . . . 2D-6 Tachometer Wiring Diagram . . . . . . . . . . . 2D-13
MPC 4000 Mechanical Panel Control . . . . . . 2D-7 Oil Level Gauge Wiring . . . . . . . . . . . . . . . . 2D-14
Instrument/Lanyard Stop Switch Engine Synchronizer Wiring Diagram . . . 2D-15
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-17
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9
90-889785 APRIL 2003 Page 2D-1

WIRING DIAGRAMS
Power Trim Wiring Diagram
cc
bb
aa
dd
m
m
ll
ee
ff
gg
kk
j h
i
a - Tachometer connector h - Trim pump and motor

b - Key switch assembly i - DOWN solenoid
c - Trim switch j - UP solenoid
d - Trim sender k - Bottom cowl switch
e - Start solenoid l - 20 ampere fuse
f - To battery m - Engine harness
g - To alternator n - Remote control harness
Page 2D-2 90-889785 APRIL 2003

WIRING DIAGRAMS
Instrument Wiring Connections

NOTE: Instrument wiring harness leads not used must be taped back to the harness.
Wire Color Where To

BLK = BLACK Ground
TAN/WHT = TAN/WHITE Oil light
TAN/BLK = TAN/BLACK Temperature light
TAN = TAN Temperature gauge
PUR = PURPLE Ignition 12 volt
GRY = GRAY Tachometer
BRN/WHT = BROWN/WHITE Trim gauge
TAN/BLU = TAN/BLUE Visual warning kit (optional)
d e
f
aa bb
cc
ob51820
Figure 1 – Without Light Switch

a - Tachometer receptacle - from control box or ignition/choke switch
b - Tachometer wiring harness
c - Lead to optional visual warning kit (taped back to harness)
d - Speedometer
e - Tachometer
f - Volt meter
90-889785 APRIL 2003 Page 2D-3

WIRING DIAGRAMS
NOTE: Instrument wiring harness leads not used must be taped back to the harness.
Wire Color Where To

BLK = BLACK Ground
TAN/WHT = TAN/WHITE Oil light
TAN/BLK = TAN/BLACK Temperature light
TAN = TAN Temperature gauge
PUR = PURPLE Ignition 12 volt
GRY = GRAY Tachometer
BRN/WHT = BROWN/WHITE Trim gauge
TAN/BLU = TAN/BLUE Visual warning kit (optional)
To 12V
d g
f
e
a
b
c
ob51819
Figure 2 – With Light Switch

a - Tachometer receptacle - from control box or ignition/choke switch
b - Tachometer wiring harness
c - Lead to optional visual warning kit (taped back to harness)
d - Light switch
e - Speedometer
f - Tachometer
g - Volt meter
Page 2D-4 90-889785 APRIL 2003

WIRING DIAGRAMS
Commander 3000 Classic Panel Remote Control

BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LIT = LIGHT
DRK = DARK
< F R >
RED
PUR
GRN
aa
a - Neutral interlock switch
90-889785 APRIL 2003 Page 2D-5

WIRING DIAGRAMS
Commander 3000 Panel Remote Control
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LIT = LIGHT
DRK = DARK
RED
PUR
GRN
aa
Page 2D-6 90-889785 APRIL 2003

WIRING DIAGRAMS
MPC 4000 Mechanical Panel Control

BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LIT = LIGHT
DRK = DARK
d
RED/PUR
BLU/WHT
GRN/WHT aa
ob58629

b - Solder connections covered with shrink tube
c - Emergency stop switch harness
d - Trim harness
90-889785 APRIL 2003 Page 2D-7

WIRING DIAGRAMS
Instrument/Lanyard Stop Switch Wiring Diagram

BLK=BLACK f
BLU=BLUE
BRN=BROWN
GRN=GREEN
GRY=GRAY
PUR=PURPLE dd
RED=RED
TAN=TAN
WHT=WHITE ee
YEL=YELLOW
cc aa
bb
jj
j
g
h
ob52204
a - Ignition/choke switch
b - Lanyard stop switch
c - Lead not used on outboard installations
d - Retainer
e - Tachometer
f - Trim indicator gauge (optional)
g - Remote control
h - Power trim harness connector
i - Connect wires together with screw and nut (2 places); apply Liquid Neoprene
to connections and slide rubber sleeve over each connection.
j - Lead to optional visual warning kit
IMPORTANT: On installations where gauge options will not be used, tape back any
unused wiring harness leads.
Page 2D-8 90-889785 APRIL 2003

WIRING DIAGRAMS
Instrument/Lanyard Stop Switch Wiring Diagram (Dual

Outboard)
d j dd
cc b
BLK=BLACK k
BLU=BLUE BATT GND
d
BRN=BROWN
GRN=GREEN SENDER
GRY=GRAY
PUR=PURPLE ee
RED=RED aa
TAN=TAN
WHT=WHITE
YEL=YELLOW
ff
n
g m
ob52205 PORT INSTALLATION
a - Ignition/choke switch
b - Lanyard stop switch
c - Lead not used on outboard installations
d - Retainer
e - Tachometer
f - Trim indicator gauge
g - Remote control
IMPORTANT: On installations where gauge options will not be used, tape back and
isolate unused wiring harness leads
Page 2D-10 90-889785 APRIL 2003

WIRING DIAGRAMS
BATT GND
h
SENDER
aa
ee
i
ff
STARBOARD INSTALLATION ob52206
h - Synchronizer gauge
i - Synchronizer module
j - Lanyard switch – isolation diode
k - Y harness
l - Power trim harness connector
m - Connect wires together with screw and nut (4 places); apply liquid neoprene
to connections and slide rubber sleeve over each connection.
n - Lead to visual warning kit
90-889785 APRIL 2003 Page 2D-11

WIRING DIAGRAMS
Oil Level Gauge Wiring Diagram

ee
d ff
cc
gg
bb
aa
q
rr
pp ss h
oo t
nn
jj
m
m l
k ii
a - To 12 volt source
b - PURPLE wire – connect to trim indicator gauge “I” or POSITIVE (+) 12 volt
source that is turned “ON” and “OFF” with ignition switch
c - Oil level gauge
d - BLACK wire – connects to NEGATIVE ground
e - To ground
f - Black wire – from gauge to oil clip connector
g - LIGHT/BLUE sender lead to gauge
h - Wiring harness (LIGHT/BLUE and BLACK)
i - Screw (10-16 x 5/8 in.)
j - Spring
k - Oil clip connector
l - Adaptor housing
m - Screw (10-16 x 1/4 in.)
n - Spring
o - Screw (10-16 x 5/8 in.)
p - BLACK wire
q - Oil level sender unit
r - Oil pick-up tube
s - WHITE lead – from oil level sender
t - Screw (10-16 x 5/8 in.)
Page 2D-12 90-889785 APRIL 2003

WIRING DIAGRAMS
QSI Gauge Wiring Diagrams

Tachometer Wiring Diagram
Tachometer dial on back side of case must be set to position number 4.
WIRING DIAGRAM A
Use this wiring diagram when using a separate light switch for instrument lighting.
b
c
a d
ob51106
a - Connect to + 12 volt
b - +12 volt light switch wire
c - Position light bulb to the switched position
d - Connect to NEGATIVE (–) ground
WIRING DIAGRAM B
Use this wiring diagram when instrument lighting is wired directly to the ignition key switch.
(Instrument lights are on when ignition key switch is turned on.)
a b
ob51106
a - Connect to +12 volt

b - Position light bulb to the unswitched position
c - Connect to NEGATIVE (–) ground
90-889785 APRIL 2003 Page 2D-13

WIRING DIAGRAMS
Oil Level Gauge Wiring

LIGHT BULB POSITION A
Use this position when using a separate light switch for instrument lighting.
b
ob51109
a - +12 volt light switch wire

b - Position light bulb to the switched position
LIGHT BULB POSITION B

Use this position when instrument lighting is wired directly to the ignition key switch. (In-
strument lights are on when ignition key switch is turned on.)
a
ob51112
a - Position light bulb to the unswitched position

b - Sender
Page 2D-14 90-889785 APRIL 2003

WIRING DIAGRAMS
SENDER WIRING
a
bb
ob51108
a - Connect to +12 volt

b - Connect to NEGATIVE (–) ground
Engine Synchronizer Wiring Diagram

LIGHT BULB POSITION A
Use this position when using a separate light switch for instrument lighting.
b
SEND
ob51105
a - +12 volt light switch wire

b - Position light bulb to the unswitched position
90-889785 APRIL 2003 Page 2D-15

WIRING DIAGRAMS
LIGHT BULB POSITION B

Use this position when instrument lighting is wired directly to the ignition key switch. (In-
strument lights are on when ignition key switch is turned on.)
a
ob51106
a - Position light bulb to the switched position

b - Sender
Synchronizer wiring can be accomplished two different ways as an option to the user.
Wiring Diagram – Gauge needle to point toward slow running engine
a cc
bb
GRY=GRAY
WHT=WHITE
BLK=BLACK dd
PUR=PURPLE
ob51107
a - Tachometer starboard engine

b - Synchronizer gauge
c - Tachometer port engine
d - Synchronizer module
Page 2D-16 90-889785 APRIL 2003

WIRING DIAGRAMS
Wiring Diagram – Gauge needle to point toward fast running engine

a cc
bb
GRY=GRAY
WHT=WHITE
BLK=BLACK d
PUR=PURPLE ob51107
a - Tachometer starboard engine

b - Synchronizer gauge
c - Tachometer port engine
d - Synchronizer module
Maintenance
Clean gauge by washing with fresh water to remove sand and salt deposits. Wipe off with
a soft cloth moistened with water. The gauge may be scored or damaged if wiped with
abrasive material (sand, saline or detergent compounds, etc.) or washed with solvents
such as trichloroethylene, turpentine, etc.
90-889785 APRIL 2003 Page 2D-17

PULSE CRANKCASE DRIVEN FUEL PUMP
FUEL SYSTEM
Section 3A – Pulse Crankcase Driven Fuel Pump
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Checking Fuel Pump Lift (Vacuum) . . . . . . . . 3A-4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Vacuum Test Troubleshooting . . . . . . . . . . 3A-4
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Testing Fuel Pump . . . . . . . . . . . . . . . . . . . . 3A-5
Fuel Pump Description/Operation . . . . . . . . .
Checking for Restricted Fuel Flow Caused
3A-3 Fuel Pump Removal/Disassembly . . . . . . . . .
Cleaning/Inspection . . . . . . . . . . . . . . . . . . .
3A-6
3A-7 3
by Anti-Siphon Valves . . . . . . . . . . . . . . . . . . . . 3A-3 Reassembly/lnstallation . . . . . . . . . . . . . . . 3A-7
A
Specifications
Model 75/90/115
FUEL Fuel Pressure
SYSTEM Crankcase Pump
– @ Idle Normal – 13.7 - 20.5 kPa (2-3 psi)
– @ WOT Normal – 41.0 - 54.8 kPa (8-10 psi)

Maximum – 68.5 kPa (10 psi)
Minimum –4 psi (27.4 kPa)
NOTE: Electric fuel pump pressure, if used in conjunction with engine mechanical fuel
pump, must be limited to no more than 27.4 kPa (4 psi).
Special Tools
Fuel Pressure/Vacuum Gauge 0 – 103.4 kPa (0-15 Obtain Locally

psi)
ob57721
90-889785 APRIL 2003 Page 3A-1

Fuel Pump
TORQUE
REF.
REF
– 1 FUEL PUMP ASSEMBLY
1 1 FUEL PUMP
2 1 DIAPHRAGM KIT
3 2 GASKET–BOOST
4 2 DIAPHRAGM
5 1 GASKET–PULSE
6 1 SPRING
7 1 CAP
8 1 RETAINER
9 1 SPRING
10 1 CAP
11 1 BASE
12 1 PLATE
13 1 ELBOW (45 DEGREE)
15 2 SCREW–FUEL PUMP (M5 x 40) 60 6.8
16 2 SCREW–PUMP TO CRANKCASE (M6 x 50) 60 6.8
17 1 ELBOW
18 3 O–RING (WB#326–028)
19 1 GASKET
Page 3A-2 90-889785 APRIL 2003

Fuel Pump Description/Operation

The fuel pump is a crankcase-pressure-operated, diaphragm type pump. Crankcase pul-
sating pressure (created by the up and down movement of piston) is transferred to fuel
pump by way of a passage (hole) between crankcase and fuel pump.
When piston is in an upward motion, a vacuum is created in the crankcase, thus pulling
in on the fuel pump diaphragm. The inlet check valve (in fuel pump) is opened and fuel
(from fuel tank) is drawn into fuel pump.
Downward motion of the piston forces the mixture out of the crankcase into the cylinder.
This motion also forces out on the fuel pump diaphragm, which, in turn, closes the inlet
check valve (to keep fuel from returning to fuel tank) and opens the outlet check valve,
thus forcing fuel to the VST.
Checking for Restricted Fuel Flow Caused by Anti-Siphon

Valves
While anti-siphon valves may be helpful from a safety stand-point, they clog with debris,
they may be too small, or they may have too heavy a spring. Summarizing, the pressure
drop across these valves can, and often does, create operational problems and/or power
head damage by restricting fuel to the fuel pump and VST. Some symptoms of restricted
(lean) fuel flow, which could be caused by use of an anti-siphon valve, are:
1 - Loss of fuel pump pressure
2 - Loss of power
3 - High speed surging
4 - Preignition/detonation (piston dome erosion)
5 - Outboard cuts out or hesitates upon acceleration
6 - Outboard runs rough
7 - Outboard quits and cannot be restarted
8 - Outboard will not start
9 - Vapor lock
Since any type of anti-siphon device must be located between the outboard fuel inlet and
fuel tank outlet, a simple method of checking [if such a device (or bad fuel) is a problem
source] is to operate the outboard with a separate fuel supply which is known to be good,
such as a remote fuel tank.
If, after using a separate fuel supply, it is found that the anti-siphon valve is the cause of
the problem, there are 2 solutions to the problem; either 1) replace the anti-siphon valve
with one that has lighter spring tension or 2) replace it with a solenoid-operated fuel shut
off valve.
90-889785 APRIL 2003 Page 3A-3

Checking Fuel Pump Lift (Vacuum)

The square fuel pump is designed to lift fuel (vertically) about 1524 mm (60 in.) if there
are no other restrictions in the system using a fuel hose that is 7.9 mm (5/16 in.) minimum
diameter. As restrictions are added, such as filters, fittings, valves etc., the amount of fuel
pump lift decreases.
Fuel pump vacuum and air bubbles in the fuel supply can be checked with a vacuum
gauge, a t-fitting and a clear piece of fuel hose. Connect the clear hose between the inlet
fitting on the pulse driven fuel pump and the vacuum gauge t-fitting. Keep the t-fitting and
the gauge as close as possible to the pump for the most accurate readings. Connect the
fuel line from the fuel tank to the remaining connection on the t-fitting.
ob57771
a - Clear hose
b - T-fitting
c - Vacuum gauge
Vacuum Test Troubleshooting

This test is normally performed at an idle speed. As engine rpm increases, there will be
a slight increase in vacuum. The increase should not exceed specification
Normal Reading Below 2.5 in. of mercury
Reading above 2.5 in. of mercury Restriction within the fuel system –
• Restricted anti-siphon valve
• Restriction within the primer bulb
• Kinked or collapsed fuel hose
• Plugged water separating fuel filter (in the
boat)
• Restriction in fuel line thru-hull fitting
• Restriction in fuel tank switching valves
• Plugged fuel tank pick-up screen
Page 3A-4 90-889785 APRIL 2003

Testing Fuel Pump

Install clear fuel hose between fuel pump and VST. Run engine, and inspect fuel passing
thru hose for air bubbles.
Problem: Air Bubbles in Fuel Line

Low fuel in tank. Fill tank with fuel.
Loose fuel line connection. Check and tighten all connectors.
Fuel pump fitting loose. Tighten fitting.
A hole or cut in fuel line. Check condition of all fuel lines and replace.
Fuel pump anchor screw loose. Tighten all screws evenly and securely.
Fuel pump filter cover anchor screw loose. Tighten screws securely.
Fuel pump filter gasket worn out. Replace gasket.
Fuel pump gasket worn out. Rebuild fuel pump.
Fuel vaporizing Fuel with high reed vapor pressure (winter grade
fuel) may vaporize (form bubbles) when used in
hot/warm weather. Use fuel with a lower reed va-
por pressure (summer grade fuel).
Problem: Lack of Fuel Pump Pressure
An anti-siphon valve. See Checking for Restricted Fuel Flow preced-
ing.
Air in fuel line. See Air Bubbles in Fuel Line, above.
A dirty or clogged fuel filter. Clean or replace fuel filter.
The fuel pickup in fuel tank is clogged or dirty. Clean or replace pickup.
Worn out fuel pump diaphragm. Rebuild fuel pump.
Worn out check valve in fuel pump. Rebuild fuel pump.
A leaky check valve gasket. Rebuild fuel pump.
Pulse hole plugged. Remove fuel pump and clean out holes.
Hole in pulse hose. Replace pulse hose.
Loose pulse hose. Tighten connection.
Fuel hose internal diameter too small. Use 5/16 I.D. fuel hose.
Primer bulb check valve not opening. Replace primer bulb.
Excessive fuel lift required. Fuel lift exceeds 2.5 in. of vacuum (mercury).
90-889785 APRIL 2003 Page 3A-5

Fuel Pump Removal/Disassembly

IMPORTANT: Fuel pump diaphragm and gaskets should not be re-used once fuel
pump is disassembled.
1. Disconnect fuel hose from tank to fuel pump.
2. Disconnect pulse hose.
3. Remove 2 mounting screws.
4. Remove fuel pump.
c d
ob00884
a - Fuel hose c - Mounting screws
b - Pulse hoses d - Fuel pump
5. Disassemble fuel pump.
Page 3A-6 90-889785 APRIL 2003

Cleaning/Inspection
1. Clean fuel pump housing, check valves, pulse chamber and pump base in solvent and
dry all but check valves with compressed air.
2. Inspect each check valve for splits, chips and for proper sealing against pump hous-
ing.
3. Inspect boost springs for weakness or breakage.
4. Inspect fuel pump housing, pulse chamber and base for cracks or rough gasket sur-
face and replace if any are found.
5. Inspect fitting on fuel pump housing for loosening or any signs of fuel or air leaks. Re-
place or tighten fitting if a leak is found.
Reassembly/lnstallation
ASSEMBLY
NOTE: The new repair kits contain check valves made of a plastic material, impervious
to damage from additives. When repairing the fuel pump discard old rubber and small
plastic check valve disks, and install one new plastic disk under each retainer. Caution
must be taken not to push the check valve retainer to tightly against the check valve, this
may cause valve to deform.
b
CORRECT INCORRECT ob57861
a - Check valve retainer

b - Check valve (plastic)
1. Insert retainer through plastic check valve.

b
ob23601
a - Retainer
b - Plastic check valve
90-889785 APRIL 2003 Page 3A-7

2. Install check valves and retainers into fuel pump body.
3. With retainer installed in pump body, break retainer rod from retainer by bending side-
ways.
aa
bb
ob23601
a - Rod
b - Retainer cap
4. Reinstall rod into retainer cap and, use a small hammer and punch to tap rod down
into retainer until flush with top of retainer.
aa
bb
ob23601
a - Rod
b - Retainer cap
Page 3A-8 90-889785 APRIL 2003

5. Place boost spring into pump body and place cap onto boost spring.
cc
aa
bb
ob50161
a - Boost spring
b - Pump body
c - Cap
6. Assemble remainder of components as shown and install retaining screws through

to align.
90-889785 APRIL 2003 Page 3A-9

7. Install pump onto engine. Torque attaching screws to specification.

8. Install hoses onto proper fittings and secure with cable ties.
9. Run engine and check for leaks.
c d
ob00884
a - Fuel hose c - Mounting screws
b - Pulse hoses d - Fuel pump
TORQUE
REF.
REF
a 2 SCREWS 60 6.8
Page 3A-10 90-889785 APRIL 2003

DIRECT FUEL INJECTION
FUEL SYSTEM
Section 3B – Direct Fuel Injection
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Throttle Plate Assembly Removal . . . . . . . 3B-33
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3 Throttle Plate Assembly Installation . . . . . 3B-33
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-6 Reed Block Assembly Removal . . . . . . . . 3B-34
Reed Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3B-8
3B-10
Reed Block Assembly Installation . . . . . . .
Vapor Separator Tank Disassembly . . . . .
3B-34
3B-37 3
Vapor Separator Components . . . . . . . . . . . . .
Fuel Rail Components . . . . . . . . . . . . . . . . . . .
3B-12
3B-14
Fuel Flow Director Components . . . . . . . .
Vapor Separator Tank Reassembly . . . . .
3B-40
3B-41
B
Vapor Separator/Fuel Rail Mounting . . . . . . . 3B-16 Air Plenum Installation . . . . . . . . . . . . . . . . 3B-46
Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-18 Vapor Separator Installation . . . . . . . . . . . 3B-46
Air Compressor Components . . . . . . . . . . . . . 3B-20 Fuel Rail Removal . . . . . . . . . . . . . . . . . . . . 3B-48
DFI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-22 Fuel Pressure Regulator . . . . . . . . . . . . . . 3B-54
Air Induction Through Crankcase . . . . . . . 3B-22 Air Pressure Regulator . . . . . . . . . . . . . . . . 3B-59
Air Compressor System . . . . . . . . . . . . . . . 3B-22 Air Regulator Troubleshooting . . . . . . . . . . 3B-60
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-22 Fuel Rail Cleaning . . . . . . . . . . . . . . . . . . . . 3B-64
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Direct Injector Removal . . . . . . . . . . . . . . . 3B-64
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Direct Injector Leak Test . . . . . . . . . . . . . . . 3B-67
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23 Fuel Rail and Direct Injector Installation . 3B-68
Testing Electric Fuel Pump Pressure Output 3B-24 Air Compressor . . . . . . . . . . . . . . . . . . . . . . 3B-69
Low Pressure Electric Fuel Pump . . . . . . . 3B-24 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-73
High Pressure Electric Fuel Pump . . . . . . 3B-25 Air Compressor Disassembly/Reassembly 3B-74
Fuel Management Assembly Removal . . . . . 3B-26 Air Compressor End Cap/Crankshaft
Air Temperature Sensor Removal . . . . . . 3B-31 Removal and Reassembly . . . . . . . . . . . . . 3B-76
Air Temperature Sensor Installation . . . . . 3B-31 Air Compressor Flow Diagram . . . . . . . . . 3B-81
MAP Sensor Removal . . . . . . . . . . . . . . . . 3B-32 Air Compressor Pressure Test . . . . . . . . . 3B-82
MAP Sensor Installation . . . . . . . . . . . . . . . 3B-32 Fuel Injector Test . . . . . . . . . . . . . . . . . . . . . 3B-84
90-889785 APRIL 2003 Page 3B-1

Specifications
Fuel System Specifications
Fuel Pressure 744.6 ± 13.8 kPa (108 ± 2 psi)
Air Pressure 648.1 ± 13.8 kPa (94 ± 2 psi)
Fuel/Air Differential 96.5 kPa ± 6.9 kPa (14.0 ± 1.0 psi)
High and Low Pressure Fuel Pump Amperage 10-14 Amps
Draw
Low Pressure Electric Fuel Pump Output 137.9 kPa - 206.8 kPa (20-30 psi)
Fuel Injector Ohm Resistance 1.8 ± 0.1Ω
Direct Injector Ohm Resistance 1.3 ± 0.3Ω
Air Compressor Specifications

Compressor Output @ Idle – 655 kPa (95 psi)
mum 0.025 mm (0.001 in.)
Bore Type Cast Iron
(2.0453 ± .0004 in.)
Dimen-
sion “A”
at Right
Angle
(90°) to
Piston Pin
0.300 in.
Piston Ring End Gap

Top Ring 0.15 - 0.30 mm
(0.0059 - 0.0118 in.)
(0.0059 - 0.0118 in.)
(0.0039 - 0.014 in.)
Page 3B-2 90-889785 APRIL 2003

Special Tools
Duel Fuel/Air Pressure Gauge 1103.2 kPa (160 psi) 91-852087A1/A2/A3
Adaptors to convert pressure gauge 91-852087A1/A2 91-803804A2

to an A3
a b c d e
NOTE: 2 Adaptors 91-803804A2 are required to convert a pressure gauge set.

a - 1/2 in. to 1/4 in. Adapter – if required
b - Female quick disconnect
c - Male quick disconnect
d - Screw on Schrader
e - O-ring 25-803803
Seal/Teflon Ring Installation Tool 91-851980--3
56015
90-889785 APRIL 2003 Page 3B-3

Seal/Teflon Ring Sizing Tool 91-851980-2
ob56014
DMT 2000 Digital Tachometer Multi-meter 91-854009T1
Direct Injector Removal Tool 91-883521
Page 3B-4 90-889785 APRIL 2003

Clamp Tool Kit 91-803146A2
ob57316
a - Clamp tool 91-803146T
Gearcase Leakage Tester FT-8950
ob57714
Regulator Installation Tool 91-889431
ob59361
90-889785 APRIL 2003 Page 3B-5

Throttle Body
Page 3B-6 90-889785 APRIL 2003

Throttle Body (Continued)

TORQUE
REF.
REF
1 1 THROTTLE BODY ASSEMBLY
2 1 PLATE
3 4 SCREW 100 11.3
4 1 GROMMET
5 1 GROMMET
6 1 CLAMP
7 1 SCREW
8 1 WASHER
9 1 WASHER
10 1 BUSHING
11 1 THROTTLE LEVER KIT
12 1 THROTTLE ROLLER ASSEMBLY
13 1 LOCKWASHER
14 1 WASHER
15 1 WASHER
16 1 SCREW
17 1 ROLLER
18 1 BRACKET
19 3 SCREW (M6 x 16) 105 11.9
20 2 CABLE
21 1 CAM
22 1 SPACER
23 1 WASHER
24 1 SCREW (M6x 40) 95 10.7
25 1 COUPLER
26 1 TPI
27 3 SCREW 24 2.7
28 1 CLAMP – Oetiker
29 2 CONDUIT [33 cm (13 in.)]
90-889785 APRIL 2003 Page 3B-7

Reed Block
25
14

Description
Ref. # ber Number
2 Cycle Premium Out-
14 92-802813A1 92-802813Q1
board Oil
25 Liquid Neoprene 92-25711-3 92-25711-3
Page 3B-8 90-889785 APRIL 2003

Reed Block (Continued)

TORQUE
REF.
REF
1 1 SHIFT RAIL
2 2 TAB WASHER
3 2 SCREW (M8 x 25) 18 24.4
4 1 SLIDE
5 1 NUT
6 1 WASHER
Drive tight; but joint
7 1 NUT
must be free to pivot
8 1 GASKET
9 1 LOWER END CAP ASSEMBLY
10 1 CHECK VALVE
11 1 OIL SEAL
12 1 O-RING
13 3 SCREW (M10 x 25)
14 1 REED ADAPTOR PLATE
15 1 GASKET
16 1 FITTING
17 1 COVER
18 1 GASKET
19 9 SCREW (M8 x 45) 18 24.4
20 15 SCREW (M8 x 35) 18 24.4
21 3 REED BLOCK
22 3 GASKET
23 6 SCREW (M6 x 20) 90 10.2
24 1 MAP SENSOR
25 1 BRACKET
26 1 SCREW (M6 x 16) 90 10.2
27 1 TEMPERATURE SENSOR 13 1.4
28 1 O-RING
29 1 NEGATIVE BATTERY CABLE
30 2 SCREW (M8 x 14) 18 24.4
31 4 WASHER
32 1 CLAMP
90-889785 APRIL 2003 Page 3B-9

Fuel System
NOTE: A = To Crankcase
NOTE: B = To Vent Fitting
Page 3B-10 90-889785 APRIL 2003

Fuel System (Continued)

TORQUE
REF.
REF
1 1 HOSE – VENT
2 AR CABLE TIE (8 in.)
3 1 HOSE ASSEMBLY
4 1 HOSE ASSEMBLY
5 1 SCHRADER VALVE
6 1 O–RING
7 1 CLIP
8 1 SCREW (M6 x 12) 90 10.2
9 1 TUBING (10-1/2 in.)
10 1 FITTING
11 1 TUBING (28 in.)
12 1 TUBING (4-1/2 in.)
13 1 CLAMP (15.3)
14 1 HOSE
15 1 SEAL
90-889785 APRIL 2003 Page 3B-11

Vapor Separator Components
Page 3B-12 90-889785 APRIL 2003

Vapor Separator Components (Continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 COVER KIT
2 1 SEAT
3 1 BAFFLE PLATE
4 2 SCREW 22 2.5
5 1 GASKET
6 1 FITTING 75 8.5
7 1 O-RING
8 1 FITTING 50 5.5
9 1 PLUG 45 5
10 1 FUEL FILTER
11 1 FLOAT KIT
12 1 FLOAT PIN
13 1 FUEL PUMP–HIGH PRESSURE
14 1 SLEEVE
15 1 O-RING
16 1 SEAL
17 1 RETAINER
18 11 SCREW 40 4.5
19 1 BOOST PUMP
20 1 GROMMET
21 1 O-RING
22 1 SEAL
23 1 BOWL KIT
24 1 WIRE
25 1 CHECK VALVE
26 2 FITTING
27 1 INLET VALVE KIT
28 2 DRAIN SCREW 15 1.7
29 2 O-RING
30 1 WATER SENSOR
31 1 ELBOW (90 DEGREE) Note
32 2 O-RING
33 1 INSERT
NOTE: Install elbow fitting in to VST 5 turns minimum – 7 turns maximum.
A – Torque retainer screws to 2.5 Nm (22 lb. in.)
90-889785 APRIL 2003 Page 3B-13

Fuel Rail Components
Page 3B-14 90-889785 APRIL 2003

Fuel Rail Components (Continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL RAIL ASSEMBLY
2 1 FUEL PLUG
3 2 SEAL
4 2 CLAMP
5 9 SCREW (M5 x 10) 70 8
6 1 O-RING
7 1 FITTING
8 1 BRACKET
9 3 INJECTOR
10 1 O-RING KIT
11 1 O-RING KIT
12 3 RETAINER
13 2 VALVE KIT - SCHRADER
14 2 CAP
15 1 O-RING KIT
16 2 CLAMP
17 1 ELBOW
18 1 AIR PLUG
19 1 FITTING
20 1 O-RING
21 2 CLAMP
22 1 O-RING KIT
23 1 O-RING (16 per kit)
90-889785 APRIL 2003 Page 3B-15

Vapor Separator/Fuel Rail Mounting

Description
Ref. # ber Number
4 Stroke 10W30 Out-
110 92-802833A1 92-802833Q1
board Oil
Page 3B-16 90-889785 APRIL 2003

Vapor Separator/Fuel Rail Mounting (Continued)

TORQUE
REF.
REF
1 2 STUD (M10 x 91) Drive Tight
2 2 NUT 33 44.7
3 3 AIR INJECTOR
4 3 CUPPED WASHER
5 2 SPACER
6 3 GROMMET
7 3 WASHER
8 2 SCREW (M8 x 60) 18 24.4
9 1 SCREW (M8 x 35) 18 24.4
10 1 BUSHING
90-889785 APRIL 2003 Page 3B-17

Air Hoses
Page 3B-18 90-889785 APRIL 2003

Air Hoses (Continued)

TORQUE
REF.
REF
1 1 TUBING [20.3 cm (8 in.)]
2 2 CLAMP (15.3)
3 1 HOSE
4 1 HOSE ASSEMBLY
5 2 CABLE TIE [20.3 cm (8 in.)]
6 1 AIR MUFFLER
7 1 HOSE [11.4 cm (4-1/2 in.)]
90-889785 APRIL 2003 Page 3B-19

Air Compressor Components
14
14
14
14
9
9
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
#
Loctite 271
7 92-809819 92-809819
Threadlocker
9 92-809822 92-809822
Sealant
2 Cycle Premium Outboard
14 92-802813A1 92-802813Q1
Oil
Page 3B-20 90-889785 APRIL 2003

Air Compressor Components (Continued)

TORQUE
REF.
REF
1 1 AIR COMPRESSOR
2 1 END CAP
3 1 O–RING
4 1 CONNECTING ROD
5 1 PISTON ASSEMBLY (WITH RINGS)
6 2 LOCK RING
7 1 REED PLATE ASSEMBLY
8 1 GASKET
9 1 GASKET
10 1 COMPRESSOR HEAD
11 1 ELBOW (45 Degree)
12 4 SCREW (M8 x 1.25) 20 27.1
13 2 ELBOW
14 1 FITTING 25 33.9
15 1 O–RING
17 1 O–RING
18 3 CHECK VALVE 58 6.6
19 1 PIN 45 5.1
20 1 ELBOW
21 5 CABLE TIE
22 1 HOSE
23 1 CHECK VALVE
24 1 SCREW (M6 x 20) 100 11.3
25 1 PULLEY
26 3 SCREW (M6 x 12) 100 11.3
27 1 TENSIONER ARM
28 1 PULLEY
29 1 SCREW (M10 x 25) 18.8 25.4
30 1 BEARING
31 1 BUSHING
32 2 TUBING [45.7 cm (18 in.)]
33 1 SPRING
34 1 SCREW (M10 x 45) 16.7 22.6
35 1 WASHER
36 1 TUBING [55.8 cm (22 in.)]
37 6 CABLE TIE [20.3 cm (8 in.)]
38 3 SCREW (M8 x 90) 18 24.4
90-889785 APRIL 2003 Page 3B-21

DFI Operation
Air Induction Through Crankcase
Combustion air enters the cowl through holes located in the top aft end of the cowl. The
cowl liner directs this air to the bottom of the powerhead. This limits the exposure of salt
air to the components inside the engine cowl.
Once inside the cowl the air enters the plenum through the throttle shutter which is located
in the plenum assembly. The air then continues through the reed valves and into the
crankcase. The throttle shutter is actuated by the throttle shaft. Mounted on a separate
shaft is a throttle position sensor (TPS). This sensor tells the propulsion control unit (PCM)
the position of the throttle.
Air Compressor System
Air from inside the engine cowl is drawn into the compressor through an air filter in the
air attenuator. This attenuator acts like a muffler to quiet compressor noise and contains
a filter to prevent the ingestion of debris into the compressor. The compressor is driven
by a belt from a pulley mounted on the flywheel and is automatically self-adjusted using
a single idler pulley. This air compressor is a single cylinder unit containing a connecting
rod, piston, rings, bearings, reed valves, and a crankshaft. The compressor is water
cooled to lower the temperature of the air charge and is lubricated by oil from the engine
oil pump assembly. As the compressor piston moves downward inside the cylinder, air
is pulled through the filter, reed valves and into the cylinder. After the compressor piston
changes direction, the intake reeds close and the exhaust reeds open allowing com-
pressed air into the hose leading to the air/fuel rails.
The air/fuel rails contain two passages; one for fuel, the second for air. The air passage
is common between all the cylinders included in the rail. A hose connects the rail air pas-
sage to the air compressor. An air pressure regulator will limit the amount of pressure de-
veloped inside the air passages to approximately 96.5 kPa (14 psi) below the pressure
of the fuel inside the fuel passages [i.e. 648.1 kPa (94 psi) air vs 744.6 kPa (108 psi) fuel].
Air exiting the pressure regulator is discharged through a muffler into the lower cowling.
Fuel
Fuel for the engine is stored in a typical fuel tank. A primer bulb is installed into the fuel
line to allow priming of the fuel system. A vapor separator mounted diaphragm fuel pump
draws fuel through the fuel line, primer bulb and fuel pump assembly. The pump then
pushes the fuel through a water separating fuel filter. This filter removes any contaminates
and water before the fuel reaches the vapor separator. Fuel vapors are vented through
the bottom cowling into the atmosphere. The electric fuel pump is capable of developing
fuel pressures in excess of 744.6 kPa (108 psi). Fuel inside the rail must remain pressur-
ized at exactly 96.5 kPa (14 psi) over the air rail pressure or the PCM (map) calibrations
will be incorrect. Fuel from the vapor separator is supplied to the top of the fuel rail. Fuel
is stored inside the rail until an injector opens. A fuel pressure regulator controls pressure
in the fuel rail, and allows excess fuel to return into the vapor separator. The fuel regulator
not only regulates fuel pressure but also regulates it at 96.5 kPa (14 psi) higher than what-
ever the air rail pressure is. The fuel regulator diaphragm is held closed with a spring that
requires 96.5 kPa (14 psi) to force the diaphragm off the diaphragm seat. The back side
of the diaphragm is exposed to air rail pressure. As the air rail pressure increases, the fuel
pressure needed to open the regulator will equally increase. Example: If there is 344.7
kPa (50 psi) of air pressure on the air rail side of the diaphragm, 441.3 kPa (64 psi) of fuel
pressure will be required to open the regulator. The fuel rail is water cooled.
Page 3B-22 90-889785 APRIL 2003

Oil
Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil is stored
inside an engine mounted reservoir.
A remote oil tank is available as an option. Crankcase pressure will force oil from the remote
oil tank into the oil reservoir on the front of the powerhead.
Oil will flow from the oil reservoir into the oil pump. The oil pump is a solenoid design. It is acti-
vated by the PCM and includes 7 pistons with corresponding discharge ports. The oil pump
is mounted on the electrical plate. Each cylinder is lubricated by one of the discharge ports. The
oil is discharged into the crankcase. The seventh passage connects to the hose that leads to
the air compressor for lubrication. Excess oil from the compressor returns into the cylinder
bores.
The PCM will change the discharge rate of the oil pump, depending upon engine demand. The
PCM will also pulse the pump on initial start up to fill the oil passages eliminating the need to
bleed the oil system. The PCM provides additional oil for break-in, as determined by its internal
clock. The oil ratio varies with engine RPM and load.
Electrical
The electrical system consists of the PCM, crank position sensor (flywheel speed & crankshaft
position), throttle position sensor (TPS), MAP sensor, engine temperature sensor, ignition coils
and injectors (fuel & direct). The engine requires a battery to start (i.e. the ignition and injection
will not occur if the battery is dead). The system will run off of the alternator.
Operation
The operation of the system happens in milliseconds (ms). Exact timing is critical for engine
performance. As the crankshaft rotates, air is drawn into the crankcase through the throttle
shutter, into the plenum and through the reed valves. As the piston nears bottom dead center,
air from the crankcase is forced through the transfer system into the cylinder. As the crankshaft
continues to rotate the exhaust and intake ports close. With these ports closed, fuel can be
injected into the cylinder. The PCM will receive a signal from the throttle position sensor (TPS),
engine temperature sensor (TS) and the crank position sensor (flywheel speed and position
sensor). With this information, the PCM refers to the fuel calibration (maps) to determine when
to activate (open and close) the injectors and fire the ignition coils. With the piston in the correct
position, the PCM opens the fuel injector, 744.6 kPa (108 psi) fuel is discharged into a ma-
chined cavity inside the air chamber of the air/fuel rail. This mixes the fuel with the air charge.
Next the direct injector will open, discharging the air/fuel mixture into the combustion chamber.
The direct injector directs the mixture at the bowl located in top of the piston. The piston’s bowl
directs the air/fuel mixture into the center of the combustion chamber. This air fuel mixture is
then ignited by the spark plug.
Compressor Notes: To aid in starting when the air rail pressure is low and before the compres-
sor has time to build pressure, some direct injectors are held open by the PCM. This allows
the compression from inside the cylinders to pressurize the air rail faster (1 or 2 strokes, or 60°
of crankshaft rotation).
Idle Notes: Idle quality is controlled by fuel volume and fuel timing. The throttle shutter will be
open at idle speed. The shift switch is mounted on the exhaust adaptor plate and is activated
by a cam/notch in the upper shift shaft. The switch has a closed circuit when the engine is in
gear (forward or reverse) and an open circuit when the engine is in neutral. The switch is moni-
tored by the PCM. The PCM will change fueling, timing and RPM limit according to whether
the engine is in gear or in neutral.
The TPS signals the PCM to change the fuel and spark without movement of the throttle
shutters. The throttle cam is manufactured to allow the TPS sensor shaft to move before
opening the throttle shutter.
90-889785 APRIL 2003 Page 3B-23

Testing Electric Fuel Pump Pressure Output

Low Pressure Electric Fuel Pump
1. Connect Dual Fuel/Air Pressure Gauge [91-852087A1/A2/A3] to Schrader valve on
VST. Gauge should indicate 137.9 – 206.8 kPa (20 – 30 psi).
ob57416
ob59586
a - Low pressure electric fuel pump Schrader valve
Page 3B-24 90-889785 APRIL 2003

High Pressure Electric Fuel Pump

1. Install Pressure Gauge Assembly 91-852087A1/A2/A3 to fuel rail pressure test valve.
NOTE: After 15 seconds of cranking engine with starter motor, fuel pressure gauge
should indicate 744.6 ± 13.8 kPa (108 ± 2 psi).
91-852087A1/A2/A3
ob59607
a - Fuel pressure gauge [should indicate 744.6 ± 13.8 kPa (108 ± 2 psi)]
b - Fuel pressure test valve (bottom of fuel rail)
90-889785 APRIL 2003 Page 3B-25

Fuel Management Assembly Removal

CAUTION
Fuel system must be bled off prior to removal of fuel system components.
WARNING
Drain fuel from vapor separator tank (VST) into a suitable container. Even though
VST has been drained, fuel may still remain in fuel rails and hoses. Normal pre-
cautionary procedures should be adhered to while working with the fuel system.
Avoid sparks, smoking and open flame while in the presence of liquid fuel or fuel
vapors.
NOTE: Use Fuel/Air Pressure Gauge 91-16850--1 or 91-852087A1/A2/A3 to de-pressur-
ize air hose first and then fuel hose.
1. De-pressurize fuel system.
a b
d
ob59594
a - Air pressure gauge d - Fuel pressure port (Design 1)
b - Fuel pressure gauge e - Fuel pressure port (Design 2)
c - Air pressure port
Page 3B-26 90-889785 APRIL 2003

2. Cut cable tie securing VST vent hose.

3. Place suitable container underneath vapor separator drain fittings. Turn respective
release screw to allow fuel to drain from fitting. Use rubber hose connecting drain fit-
tings to direct fuel into suitable container. After fuel is drained from VST, close off each
release screw and reattach hose to each drain fitting.
4. Disconnect water separator sensor connector.
b b
e
c
d ob00526
a - Cable ties d - Rubber hose

b - Release screws e - Drain fittings
c - Water separator sensor lead
5. Disconnect electric fuel pump harness connector.
ob59610
a - Electric fuel pump connector
90-889785 APRIL 2003 Page 3B-27

6. Remove the inlet fuel hose from the pulse fuel pump.
7. Remove pulse fuel pump vacuum hoses (2 each).
8. Remove the fuel outlet hose and fuel return hose on vapor separator tank (VST).
9. Remove 3 mounting bolts and remove separator.
e d
c
e
ob00883
a - Fuel inlet hose to pulse c - Fuel return hose

pump d - Mounting bolts
b - Fuel outlet hose (dis- e - Pulse pump vacuum
connect at fuel rail) hoses
Page 3B-28 90-889785 APRIL 2003

10. Remove throttle arm screw and throttle cable platform screw.
11. Disconnect MAP sensor, air temperature sensor and throttle position sensor harness
connectors.
ob00712 c
ob00694
a - Throttle arm screw d - Air temperature sensor connector

b - Throttle cable platform screw e - Throttle position sensor connector
c - MAP sensor connector
90-889785 APRIL 2003 Page 3B-29

12. Remove 9 screws securing air plenum and remove plenum/throttle body assembly.
a a
a
a
a a
a
a
ob00707
a - Screws
Page 3B-30 90-889785 APRIL 2003

Air Temperature Sensor Removal

1. Disconnect sensor harness.
2. Unscrew sensor from air plenum.
a
ob59574
a - Air temperature sensor harness connector

b - Air temperature sensor
Air Temperature Sensor Installation

1. Screw sensor into air plenum.
2. Reconnect sensor harness.
TORQUE
REF.
REF
b 1 TEMPERATURE SENSOR 13 1.4
90-889785 APRIL 2003 Page 3B-31

MAP Sensor Removal

1. Disconnect wiring harness.
2. Remove screw securing MAP sensor retainer and remove sensor.
c
ob59575
a - MAP sensor
b - Screw
c - Harness connector
MAP Sensor Installation

1. Install sensor into air plenum.
2. Reconnect sensor harness connector.
TORQUE
REF.
REF
b 1 SCREW (M6 x 16) 90 10.2
Page 3B-32 90-889785 APRIL 2003

Throttle Plate Assembly Removal

NOTE: The throttle plate assembly is calibrated and preset for proper running character-
istics and emissions at the factory. Other than complete assembly removal from the air
plenum, no further disassembly should be made.
1. Remove 4 bolts securing throttle plate assembly to air plenum and remove assembly.
ob00356
a - Screws (4) b - Throttle plate assembly
Throttle Plate Assembly Installation

1. Secure throttle plate assembly to air plenum with 4 screws.
TORQUE
REF.
REF
a 4 SCREW 100 11.3
90-889785 APRIL 2003 Page 3B-33

Reed Block Assembly Removal

1. Remove 9 screws securing cover to reed block adaptor plate.
2. Remove 15 screws securing reed block adaptor plate to crankcase cover.
3. Remove 2 screws securing each reed block to adaptor plate.
d
c
g
a
a - Screws (9 each) (M8 x 45)

b - Cover
c - Adaptor Plate
d - Screws (6 each) (M6 x 20)
e - Crankcase Cover
f - Reed Block (3 each)
g - Screws (15 each) (M8 x 35)
Reed Block Assembly Installation

NOTE: Replace all gaskets for lasting repair.
1. Secure each reed block with 2 screws to adaptor plate.
TORQUE
REF.
REF
d 6 SCREW (M6 x 20) 90 10.2
Page 3B-34 90-889785 APRIL 2003

2. Secure adaptor plate to crankcase cover with 15 screws. Torque screws in following
sequence.
!*
( )
' &
a
%
# $
" !
!!
!" !#
!% !$
ob00792
TORQUE
REF.
REF
a 15 SCREW (M8 x 35) 18 24.4
90-889785 APRIL 2003 Page 3B-35

3. Reinstall cover with 9 screws. Torque screws in following sequence.
8 7
a 3
4
2
5 6
ob00820
TORQUE
REF.
REF
a 9 SCREW (M8 x 45) 18 24.4
Page 3B-36 90-889785 APRIL 2003

Vapor Separator Tank Disassembly

1. Remove 2 screws securing pulse fuel pump to VST and remove pump. Refer to Sec-
tion 3A for disassembly, inspection and reassembly of pulse fuel pump.
ob59376
a - Pulse fuel pump b - Screws
2. Remove fuel/water separator filter from VST. Inspect filter O-rings for cuts or abrai-
sions. Replace O-rings as required. Inspect filter element for debris. Remove debris
or replace element as required.
a
c
ob59372
ob59375
a - Fuel/water separator b - O-rings

filter c - Filter element
90-889785 APRIL 2003 Page 3B-37

3. Remove water sensor from VST and inspect for debris or corrosion. Clean or replace
as required. Inspect sensor O-ring for cuts or abrasions. Replace as required.
a
ob59370
ob59371
a - Water sensor
b - O-ring
4. Remove 9 screws securing VST cover and remove cover. Inspect cover sealing ring
for cuts or abraisions. Replace as required.
ob59374
ob59378
a - Screws (9)
b - Sealing ring
Page 3B-38 90-889785 APRIL 2003

5. Loosen screw securing float assembly and remove float. Inspect float for deterioration
or fuel retention. Replace float as required. Inspect float needle and seat for wear, de-
bris or corrosion. Replace needle and seat as required.
b
c
a ob59342
a - Float c - Float needle

b - Screw
6. Remove 2 screws securing low pressure fuel pump.

7. Remove low and high pressure pumps from VST. Disconnect electrical connectors
from each pump. Inspect O-rings on each pump and on harness for cuts or abraisions.
Replace as required.
a b
c
ob59378
e e
b
d
d
e
c
ob59377
a - Screws d - Electrical connectors

b - Low pressure pump e - O-rings
c - High pressure pump
90-889785 APRIL 2003 Page 3B-39

Fuel Flow Director Components

COMPONENTS
a
c
ob00815
a - Fuel director insert

b - Seal
c - Seal
ASSEMBLY VIEW
d b
e
c
ob00816
a - High pressure fuel pump

b - Seal
c - Fuel director insert
d - Check valve
e - Seal (install on fitting)
Page 3B-40 90-889785 APRIL 2003

Vapor Separator Tank Reassembly

1. Apply light oil to fuel pump elbow O-rings to aid installation into vapor separator.
2. Align gasket between fuel pump and VST. Secure fuel pump to VST with 2 screws.
3. Retorque assembly screws.
a
c
b
e
c
ob59376
a - Elbow d - Attaching screws

b - Fuel pump e - Gasket (hidden)
c - Assembly screws
TORQUE
REF.
REF
c/d 4 SCREW 60 6.8
4. Apply light oil to water sensor O-ring and reinstall sensor in VST.
ob59370
ob59371
a - Water sensor
b - O-ring
90-889785 APRIL 2003 Page 3B-41

NOTE: If the fuel pump harness must be replaced, the new harness must be routed
through the VST casting before installing the RED and BLACK wire pins into the harness
connector. To ensure correct electrical polarity, the RED wire pin must be installed into
the (A) pin receptacle and the BLACK wire pin must be installed into the (B) pin receptacle.
After both pins are installed and locked into the connector, slide the pin retainer over the
harness and lock in place on the connector.
c d
b
e
a
ob59373
f
a - (A) pin receptacle

b - Pin retainer
c - RED wire
d - BLACK wire
e - (B) pin receptacle
f - Connector
Page 3B-42 90-889785 APRIL 2003

5. Apply light oil to electric fuel pump O-rings and pump harness O-rings.
6. Attach electrical harnesses to each fuel pump. Secure high pressure pump harness
to pump with cable tie.
a a
b
c
a
ob59377
a - O-rings
b - Electrical harness
c - Cable tie
7. Install both fuel pumps into VST. Secure low pressure pump with retainer and 2
screws.
a
b c d
ob59378
a - Screws
b - Retainer
c - Low pressure pump
d - High pressure pump
TORQUE
REF.
REF
a 2 SCREW 22 2.5
90-889785 APRIL 2003 Page 3B-43

8. Secure float, needle and pivot pin assembly to separator cover with screw.
d
b
c a ob59382
a - Float c - Pivot pin

b - Needle d - Screw
TORQUE
REF.
REF
d 1 SCREW 10 1
9. Install cover sealing ring on VST. Secure cover to VST with 9 screws.
ob59378
a
b
ob59374
a - Sealing ring
b - Screws
TORQUE
REF.
REF
b 9 SCREW 37 4.2
Page 3B-44 90-889785 APRIL 2003

10. Apply 2-4-C with Teflon to fuel/water separator filter O-rings. Thread filter into VST
cover until filter seats.
95 b
ob59372
ob59375
a - Fuel/Water separator filter

b - O-rings

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
90-889785 APRIL 2003 Page 3B-45

Air Plenum Installation

Secure plenum to crankcase with 9 screws. Torque bolts in sequence shown.
& %
a
"
! b
$
#
' (
ob00707
a - Air plenum b - Screws
TORQUE
REF.
REF
b 9 SCREW (M8 x 45) 18 24.4
Vapor Separator Installation

1. Secure vapor separator to air plenum with 3 bolts.
2. Reconnect pulse fuel pump vacuum hose.
3. Connect fuel inlet hose to pulse pump.
IMPORTANT: Only use tool 91-803146T (or Snap-On equivalent YA3080) to crimp
full circle clamps. Using a different tool could result in a crimp that is too loose, or
too tight. Do not use screw type metal hose clamp as it may damage hose.
4. Secure fuel outlet hose with 15.3 mm full circle clamp (54-856880) using crimping tool
91-803146T.
Page 3B-46 90-889785 APRIL 2003

5. Connect fuel return hose to vapor separator. Secure hose with retainer and screw
b
a
d
e
d
ob00882
a - Screws e - Retainer
b - Pulse pump vacuum hoses f - Screw
c - Inlet fuel hose g - Outlet fuel hose
d - Fuel return hose
TORQUE
REF.
REF
a 3 SCREW (M8 x 60) 18 24.4
f 1 SCREW (M6 x 12) 90 10.2
90-889785 APRIL 2003 Page 3B-47

Fuel Rail Removal

CAUTION
NOTE: Use Fuel/Air Pressure Gauge 91-16850--1 or 91-852087A1/A2 to de-pressurize
air hose first and then fuel hose.
2. Remove fuel injector harness from each injector by compressing spring clip with flat
tip screw driver while pulling on connector.
c
e d
f
57798
ob54871
b
ob59586
a - Fuel pressure port d - Harness connector

(bottom of fuel rail)(De- e - Spring clip
sign 1) f - Fuel pressure port (Design 2)
b - Air pressure port
c - Fuel injector
Page 3B-48 90-889785 APRIL 2003

NOTE: Always remove fuel/air hose and fitting together by removing fitting retainer rather
than cutting clamps.
IMPORTANT: If air hose is removed from barbed fitting, replace hose, as interior
surface of hose will be damaged during removal.
3. Remove allen screws securing air and fuel hose retainers.
4. Remove fuel, water and air hoses from fuel rail.
b
a c
ob59609
ob59592
d
ob59605
a - Fuel hose
b - Water hose
c - Fuel hose retainer allen screws
d - Air hose retainer allen screws (bottom of rail)
e - Air hose
90-889785 APRIL 2003 Page 3B-49

NOTE: It is recommended that direct injectors remain in the cylinder head (if they are not
to be replaced) while removing the fuel rail. The direct injectors have a teflon seal which
may expand if the injector is removed from the head. This expansion may cause rein-
stallation difficulty or require the replacement of the seal.
5. Remove 2 nuts securing fuel rail.
ob59602
a - Nuts
6. As fuel rail is removed, use a flat tip screw driver to hold direct injectors in cylinder
head.
b a
b ob59601
a - Fuel rail b - Direct injectors
NOTE: The fuel rail contains 3 fuel injectors, 1 fuel fuel regulator, and 1 air regulator.
Page 3B-50 90-889785 APRIL 2003

NOTE: Each fuel/air inlet or outlet hose adaptor has 2 O-ring seals. These O-rings should
be inspected for cuts or abraisions and replaced as required when fuel rail is disas-
sembled for cleaning.
a
b
a
e
c a
g
d
k
h ob00774
a - Fuel injector
b - Fuel regulator
c - Air regulator
d - Coolant outlet to tell-tale
e - Excess fuel return to VST
f - Water inlet for cooling fuel rail
g - Excess air to muffler
h - 751.5 kPa (109 psi) fuel
i - 655 kPa (95 psi) air
j - Air pressure Schrader valve
k - Fuel pressure Schrader valve (Design 1)
l - Fuel pressure Schrader valve (Design 2)
90-889785 APRIL 2003 Page 3B-51

FUEL INJECTOR REMOVAL

1. Remove 2 screws securing injector.
NOTE: Use a cotter pin extractor tool in pry holes to remove injectors.
2. Gently pry up on injector to loosen O-ring adhesion and remove injector.
ob57970 ob57967
a - Screws
b - Pry holes
3. Inspect fuel injector orifices for foreign debris, O-rings for cuts or abraisions, and plas-
tic components for heat damage. Replace components as required.
4. An ohm test of the fuel injector may be made by connecting test leads to injector termi-
nals. Ohm reading should be 1.8 ± 0.1 ohm.
aa
cc
bb
ob56124 ob56002
a - Fuel injector
b - Fuel nozzle
c - O-rings
Page 3B-52 90-889785 APRIL 2003

FUEL INJECTOR INSTALLATION

NOTE: Apply anti-seize grease (obtain locally) or 2-4-C with Teflon to fuel injector attach-
ing screw threads.
1. Insert fuel injector into fuel rail with connector pins facing (inwards) towards center of
engine.
NOTE: Turn injector back and forth slightly to seat injector O-rings in fuel rail while secur-
ing injector with retainer and 2 screws.
95
95
ob57970
a - Injector b 9 0 c - Screws
b - Retainer

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
c 2 SCREW 70 8
90-889785 APRIL 2003 Page 3B-53

Fuel Pressure Regulator

The fuel regulator is located on the port fuel rail.
ob59587
a - Fuel pressure regulator
The fuel pump is capable of delivering more fuel than the engine can consume. Excess
fuel flows through the fuel pressure regulator, interconnecting passages/hoses, fuel cool-
er, and back to the vapor separator tank. This constant flow of fuel means that the fuel
system is always supplied with cool fuel, thereby preventing the formation of fuel vapor
bubbles and minimizing the chances of vapor lock.
The fuel pressure regulator is calibrated to raise the fuel pressure to 96.5 kPa (14 psi)
above the air pressure.
The fuel regulator is mounted on the fuel rail, near the top. This regulator relies on both
air and spring pressure to control the fuel pressure. Inside the regulator assembly is a 14
lb. spring, this spring holds the diaphragm against the diaphragm seat. The contact be-
tween the diaphragm and diaphragm seat closes the passage between the incoming fuel
[from the electric fuel pump] and the fuel return passage.
When the engine is not running (no air pressure on the spring side of the diaphragm) the
fuel pressure required to move the diaphragm is 96.5 kPa (14 psi).
When the engine is running, air pressure from the air compressor 648.1 kPa (94 psi) is
routed through the air passages, to the spring side of the fuel pressure regulator dia-
phragm.
The air pressure 648.1 kPa (94 psi) and spring pressure 96.5 kPa (14 psi) combine to reg-
ulate system fuel pressure to 744.6 kPa (108 psi) - or 96.5 kPa (14 psi) higher than the
air pressure in the DFI system fuel/air rails.
Page 3B-54 90-889785 APRIL 2003

FUEL PRESSURE REGULATOR CUTAWAY

Regulator Closed Regulator Open
1! 1!
"2 "2
#3 #3
$4 $4
13
!# !#
%5 %5
12
!" &6 !" &6
'7 '7
11
!! 11
!!
(8 (8
10
!* !*
10
)9 )9
1 - Top cover 8 - Air rail

2 - Expansion plug 9 - Air passage (from air compressor)
3 - O-ring 10 - Fuel return passage (to vapor separator)
4 - Spring retainer 11 - Fuel inlet passage (from electric fuel pump)
5 - Spring 12 - Diaphragm assembly
6 - O-ring 13 - Calibration screw (do not turn)
7 - Diaphragm seat
90-889785 APRIL 2003 Page 3B-55

FUEL REGULATOR REMOVAL

1. Remove 4 screws securing regulator and remove regulator.
2. Inspect regulator diaphragm for cuts or tears.
3. Inspect regulator housing O-ring for cuts and abraisions. Replace components as re-
quired.
d
e f
c
a
a
b ob57968 ob57969
a - Screws d - Spring
b - Fuel regulator e - Cup
c - Diaphragm f - O-Ring
Page 3B-56 90-889785 APRIL 2003

FUEL REGULATOR INSTALLATION

NOTE: Apply a light coat of 2-4-C with Teflon to diaphragm surface and O-ring to aid in
the retention of diaphragm and O-ring on fuel rail during reassembly.
a
e
b e
c
d
ob57968
95 95
ob57975
a - Diaphragm d - Cup
b - O-ring e - Screws
c - Spring

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
1. Position diaphragm on fuel rail.

2. Position O-ring on fuel rail.
3. Position spring and cup onto diaphragm.
NOTE: Apply anti-seize grease (obtain locally) or 2-4-C with Teflon to regulator attaching
screw threads.
4. Place cover over spring/cup/diaphragm assembly. Place the alignment pins from the
special tool (91-889431) through two of the regulator cover mounting holes and
thread them into the corresponding threaded holes in the fuel rail.
a
a
ob00205
a - Alignment Pins
90-889785 APRIL 2003 Page 3B-57

5. Push the regulator cover against the fuel rail. While holding the cover down install two
cover retaining screws through the open holes in the cover. Thread the two screws
down until the head of the screw makes contact with the cover. Do not torque screws
at this time.
a
ob00204
a - Screw
6. Remove the alignment pins and install the two remaining screws.
" #
a a
$ !
ob56126
a - Screws
TORQUE
REF.
REF
1st torque 5.6 Nm
(50 lb. in.); 2nd
e 4 SCREW
torque 7.9 Nm (70
lb. in.)
Page 3B-58 90-889785 APRIL 2003

Air Pressure Regulator

The air pressure regulator is located on the fuel rail.
ob59585
a - Air pressure regulator
The air pressure regulator is designed to limit the air pressure inside the rails to
approximately 648.1 kPa (94 psi).
The air regulator uses a spring (pressure) to control the air pressure. This spring
648.1 kPa (94 psi) holds the diaphragm against the diaphragm seat. The contact area
blocks (closes) the air inlet passage from the excess air, return passage. As the air
pressure rises (below the diaphragm), it must reach a pressure equal to or greater
than the spring pressure holding the diaphragm closed. Once this pressure is
achieved, the spring compresses, allowing the diaphragm to move. The diaphragm
moves away from the diaphragm seat, allowing air to exit through the diaphragm seat,
into the excess air passage leading to the air plenum.
90-889785 APRIL 2003 Page 3B-59

Air Regulator Troubleshooting

Correct air pressure and volume is critical to proper operation. Although air pressure
gauge may show correct pressure, it does not confirm good volume. Air pressure should
be measured at the air schrader valve located near the middle of the fuel rail assembly.
Is air pressure within [641.2 – 668.8 kPa (93 – 97 psi)] range at neutral idle position?
No Yes
Momentarily pinch off air discharge hose. Momentarily pinch off air discharge hose.
Does pressure rise very quickly to approximately Does pressure rise very quickly to approximately
744.6 kPa (108 psi) or higher? 744.6 kPa (108 psi) or higher?
No Yes No Yes
Obstruction at compressor inlet or Air regulator OK.

Compressor output low.
outlet or failed compressor.
Check compressor.
Air compressor output and volume OK. Air compressor output and volume OK.
Air regulator faulty. Inspect regulator Regulator OK.
diaphragm, spring and cup.
Regulator Closed Regulator Open

!1 "2 1! "
2
!" #3 !" #
3
12 12
$4 $4
%5 %
5
!!
11 !!
&6 &6
!*
10 !*
10
'7 '7
)
9 9)
(8 (
8
1 - Top cover 7 - Air rail

2 - Expansion plug 8 - Air passage (from air compressor)
3 - Spring retainer 9 - Excess air passage (to exhaust adaptor)
4 - Vent 10 - Fuel inlet passage (from electric fuel pump)
5 - Spring 11 - Diaphragm assembly
6 - Diaphragm seat 12 - Calibration screw (do not turn)
Page 3B-60 90-889785 APRIL 2003

AIR REGULATOR REMOVAL

NOTE: Due to the stiffness of the regulator spring, it is recommended that Regulator
Installation Tool 91-889431 be utilized when removing the air regulator cover. Clean area
area around regulator prior to disassembly to keep debris out of fuel system.
1. Remove two opposing screws from regulator cover and install regulator installation
tool.
ob59360
2. With installation tool applying pressure to regulator cover, remove remaining cover
screws.
ob59357
3. Loosen installation tool and remove cover.
ob59356
90-889785 APRIL 2003 Page 3B-61

4. Inspect regulator diaphragm for cuts or tears. Replace as required.
d b
a a
ob57974
a - Screws d - Spring
b - Air regulator cover e - Cup
c - Diaphragm
AIR REGULATOR INSTALLATION
NOTE: Apply a light coat of 2-4-C with Teflon to diaphragm surface to aid in the retention
of diaphragm on fuel rail during reassembly.
1. Remove fuel rail from engine and place rail in a horizontal position when assembling
air regulator to rail to prevent damage to diaphragm.
NOTE: Mount fuel rail in vice to keep rail stable while reassembling.
2. Position diaphragm, spring and cup onto fuel rail with fuel rail in horizontal position.
NOTE: Apply anti-seize grease (obtain locally) or 2-4-C with Teflon to regulator attaching
screw threads.
NOTE: Due to the stiffness of the regulator spring, it is recommended that Regulator
Installation Tool 91-889431 be utilized when installing the air regulator cover.
a
a - Cup
b - Spring
c - Diaphragm
Page 3B-62 90-889785 APRIL 2003

3. Position cover over diaphragm spring and install Regulator Installation Tool
91-889431.
ob59356
a - Regulator Installation Tool (91-889431)
4. Gently apply pressure to cover with installation tool until cover is just seated against
fuel rail. Do not over tighten center screw during installation or damage to regulator
cover may occur.
ob59357
5. Install two retaining screws. Remove installation tool. Install remaining two screws.
95
a
95 a
ob59360
a - Screws
NOTE: After installation of rail on engine, verify function of regulator with pressure gauge
and check for air leaks using soapy water.

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
a 4 SCREW 70 8
90-889785 APRIL 2003 Page 3B-63

Fuel Rail Cleaning

After all fuel injectors, air regulator, fuel regulator, inlet hoses and outlet hoses have been
removed, the fuel rails may be flushed out with a suitable parts cleaning solvent. Use com-
pressed air to remove any remaining solvent.
IMPORTANT: If mechanical failure should occur in the air compressor or direct in-
jector assemblies, the fuel rail and attached hoses should be removed and flushed
with a suitable parts cleaning solvent to remove any metal debris.
Direct Injector Removal
1. Remove harness connectors from direct injectors.
2. Remove direct injector from cylinder head using
91-883521
ob00783
a - Direct Injector (3 each)
b - Direct Injector Removal Tool 91-883521
Page 3B-64 90-889785 APRIL 2003

3. Inspect injector teflon sealing ring (white) for signs of combustion blowby (teflon ring
will be streaked brownish black). If blowby is present, replace teflon sealing ring. If
blowby is not present, sealing ring may be reused.
4. Inspect O-rings and teflon ring for cuts or abraisions. Replace components as re-
quired.
5. If teflon seal requires replacement, use Teflon Seal Installation Tool to slide new seal
onto injector. Following installation of teflon ring, the Teflon Ring Sizing Tool can be
used to compress the teflon seal to aid in the installation of the injector into the cylinder
head.
c d e e
a f
b
ob57983 91-851980-1
a - Teflon sealing ring d - Seal Installation Tool (91-851980--3)

b - O-ring e - O-ring
c - Teflon seal f - Teflon Ring Sizing Tool (91-851980-2)
90-889785 APRIL 2003 Page 3B-65

NOTE: It is recommended that a digital ohm meter be used due to it’s improved accuracy
when measuring small ohm readings inherit with direct injectors.
6. An ohm test of the direct injector may be made by connecting test leads to injector
terminals. Ohm reading should be 1.3 ± 0.3 ohm.
7. An ohm test to determine if direct injector windings are shorted to ground can be made
by connecting one ohm lead to either injector pin while touching the other ohm lead
to the injector metal case. There should be no continuity. If there is continuity, the inter-
nal windings are shorted and the injector must be replaced.
a
b
ob00051
ob00052
a - Direct injector ohm test (1.3 ± 0.3 ohm)

b - Direct injector short to ground ohm test (no continuity)
Page 3B-66 90-889785 APRIL 2003

Direct Injector Leak Test

1. Attach Gearcase Leakage Tool to discharge side of injector.
b
a
ob57714
a - Gearcase Leakage Tool (FT-8950)

b - Direct injector
2. Pump up leakage tool to indicate 172.4 - 206.8 kPa (25 - 30 psi).

3. Direct injector should not leak down more than 3.5 kPa (1/2 psi) in 1 minute.
4. If injector does not meet the above specifications, replace injector.
NOTE: If cylinder block is going to be replaced, remove cup washers from each direct in-
jector port by prying out with a flat tip screwdriver. Reinstall washers with retainers into
new cylinder block. Washers provide tension between direct injectors, cylinder head and
fuel rails.
ob59600
a - Cup washer
b - Retainer
90-889785 APRIL 2003 Page 3B-67

Fuel Rail and Direct Injector Installation

1. Use Teflon Ring Sizing Tool (91-851980-1) to compress new teflon sealing rings prior
to installation of injector into cylinder head.
2. Carefully slide fuel rail over mounting studs and onto direct injectors.
IMPORTANT: ALL fuel and air hoses attached to the fuel rails MUST be secured with
stainless steel hose clamps.
3. Secure each fuel rail with 2 nuts.
4. Reinstall direct injector harness connectors.
a
b
ob59608
a - Nuts
b - Direct injector harness connectors
TORQUE
REF.
REF
a 2 NUT 33 44.7
Page 3B-68 90-889785 APRIL 2003

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

Compressor Output @ Idle – 648.1 kPa (94 psi)
mum 0.025 mm (0.001 in.)
Bore Type Cast Iron
(2.0453 ± .0004 in.)
Dimen-
sion “A”
at Right
Angle
(90°) to
Piston Pin
0.300 in.
Piston Ring End Gap

Top Ring 0.15 - 0.30 mm
(0.0059 - 0.0118 in.)
(0.0059 - 0.0118 in.)
(0.0039 - 0.014 in.)
90-889785 APRIL 2003 Page 3B-69

COMPRESSOR REMOVAL
1. Disconnect battery cables from battery terminals.
4. Use 3/8 inch drive on belt tensioner arm to relieve belt tension. Remove belt.
ob00397
a - Belt tensioner
b - 3/8 in. drive
Page 3B-70 90-889785 APRIL 2003

CAUTION
If engine has been recently run, air pressure outlet hose fittings may be extremely
hot. Allow components to cool off before beginning disassembly.
NOTE: Remove 2 screws securing retainer plate to remove air pressure outlet hose. In-
spect O-rings on air pressure hose fitting for cuts or abraisions. Replace O-rings as re-
quired.
5. Remove air pressure outlet hose.
ob59605
a - Air pressure outlet hose

b - Screws
6. Remove air compressor water outlet hose.

7. Disconnect air compressor temperature sensor connector.
8. Disconnect compressor air inlet hose.
b c
ob59611 ob00523
a - Compressor water outlet hose

b - Compressor temperature sensor connector
c - Compressor air inlet hose
90-889785 APRIL 2003 Page 3B-71

9. Disconnect air compressor oil inlet hose.

10. Disconnect water outlet hose (to fuel rail).
11. Disconnect excess oil return hoses.
b
c
d
ob00784
a - Air compressor oil inlet hose
b - Water inlet hose
c - Excess oil return hoses
d - Oil return check valves (3)
12. Remove 3 screws securing air compressor to outboard and remove compressor.
a
ob00772
a - Screws
Page 3B-72 90-889785 APRIL 2003

Air Compressor Disassembly/Reassembly

IMPORTANT: If an internal failure of the air compressor has occurred, all air
hoses, excess oil return hose check valves, fuel rails and injectors should be
disassembled and inspected for metal debris. Failure to remove all metal debris
will result in poor performance and/or powerhead failure.
NOTE: If cylinder bore is scored, air compressor must be replaced as an assembly.
NOTE: Piston Installation – use a metal hose clamp for piston ring compressor. Stagger
piston ring openings.
NOTE: The piston and rings are not sold separately. They must be replaced as an assem-
bly. The connecting rod and bearings are not sold separately. They must be replaced as
an assembly. End cap bearing and seal are not sold separately. End cap must be replaced
as an assembly.
7 a
c
c b
7 7
14
14
e
14
14
f
9
9
9
g
i
h
a - Screw (pulley) f - Reed plate (inspect for broken or chipped

b - Screw (tensioner) reeds/stops) maximum reed stand-open –
c - Screw (end cap) 0.254 mm (0.010 in.)
d - End cap assembly (inspect bearing g - Screw (4 each)
for roughness) h - Temperature sensor
e - O-ring (inspect for cuts or abrai- i - Fitting (outlet)
sions)
Page 3B-74 90-889785 APRIL 2003

Tube Ref. Quicksilver Part Num-

Description Mercury Part Number
# ber
Loctite 271 – Thread
7 92-809819 92-809819
Locker
9 92-809822 92-809822
Sealant
14 92-802813A1 92-802813Q1
board Oil
TORQUE
REF.
REF
a 3 SCREW 100 11.3
b 1 SCREW 16.7 22.6
c 1 SCREW 100 11.3
d 3 SCREW 18 24.4
h 4 SCREW 20 27.1
i 1 TEMPERATURE SENSOR 13 1.4
j 1 FITTING 25 33.9
90-889785 APRIL 2003 Page 3B-75

Air Compressor End Cap/Crankshaft Removal and Reassembly

DISASSEMBLY
2. Use 3/8-inch drive on belt tensioner arm to relieve belt tension, and remove belt.
3. Remove the 3 bolts that retain the pulley to the pulley flange.
ob00397
a - Pulley retaining bolts (3)

b - Tensioner
c - 3/8 in. square drive
Page 3B-76 90-889785 APRIL 2003

4. Remove the 4 bolts that retain the end cap to the compressor body.
ob57809
a - End cap retaining bolts (4)
5. While rotating the pulley flange alternately clockwise and counterclockwise about 1/8
to 1/4 turn, pull outward on the pulley flange. Continue rotating until the end cap as-
sembly has been removed from the compressor body.
90-889785 APRIL 2003 Page 3B-77

REASSEMBLY
1. Lubricate end cap O-ring and O-ring contact area in compressor body with two cycle
oil.
2. Slide the new end cap assembly into the compressor body, keeping the connecting
rod journal lined up with the open end of the connecting rod, until the crankshaft just
enters the open end of the connecting rod.
a - Connecting rod open end

b - Crankshaft connecting rod journal
3. While rotating the pulley flange clockwise and counterclockwise, push the end cap
into the compressor. Continue rotating the flange until the end cap is all the way down
against the compressor body.
4. To confirm that the connecting rod journal has properly engaged with the connecting
rod, rotate the flange until you feel resistance from the piston trying to compress air
in the cylinder.
Page 3B-78 90-889785 APRIL 2003

5. Apply Loctite 271 to the threads of the end cap retaining screws and torque to specifi-
cation.
a 7
ob57809
a - End cap retaining screws (4)

# ber
7 92-809819 92-809819
Locker
TORQUE
REF.
REF
a 4 SCREW 100 11.3
90-889785 APRIL 2003 Page 3B-79

6. Apply Loctite 271 to the pulley retaining screws. Torque screws to specification.
7
a
ob00397
a - Screws
# ber
7 92-809819 92-809819
Locker
TORQUE
REF.
REF
a 3 SCREW 190 21.5
7. Install compressor/alternator belt.

8. Run engine to confirm that compressor is functioning correctly.
Page 3B-80 90-889785 APRIL 2003

Air Compressor Flow Diagram

j
l
k
m p
f
g
e
c d
n
i
o
ob59589
a
a - Excess air return to adaptor plate
b - Air muffler
c - Water outlet from fuel rail
d - Air regulator – 648.1 ± 13.8 kPa (94 ± 2 psi)
e - Fuel regulator – 744.6 ± 13.8 kPa (108 ± 2 psi)
f - Fuel rail
g - Fuel inlet to fuel rail – 744.6 ± 13.8 kPa (108 ± 2 psi)
h - Excess fuel return to VST
i - Air pressure test valve (hidden)
j - Water inlet hose to air compressor
k - High pressure air to fuel rail – 648.1 ± 13.8 kPa (94 ± 2 psi)
l - Air compressor
m - Compressor air inlet
n - Air filter
o - Air inlet
p - Oil tank/air attenuator
90-889785 APRIL 2003 Page 3B-81

Air Compressor Pressure Test

1. Install Pressure Gauge Assembly 91-852087A1/A2/A3 to fuel rail pressure test
valves.
NOTE: After 15 seconds of cranking engine with starter motor, air pressure gauge should
indicate 648.1 ± 13.8 kPa (94 ± 2 psi) and fuel pressure gauge should indicate 744.6 ±
13.8 kPa (108 ± 2 psi).
a b
d
ob59594
a - Air pressure gauge – should indicate 648.1 ± 13.8 kPa (94 ± 2 psi)
b - Fuel pressure gauge – should indicate 744.6 ± 13.8 kPa (108 ± 2 psi)
c - Air pressure test valve
d - Fuel pressure test valve (Design 1)
e - Fuel pressure test valve (Design 2)
Fuel/Air pressures within the above listed ranges are important, but the difference be-
tween the two pressures is even more important. There should be a 96.5 ± 6.9 kPa (14
± 1 psi) difference. If the pressure difference is outside this range, confirm gauge accura-
cy. Reversing the dual pressure gauge connections is a good way to confirm gauge accu-
racy.
Page 3B-82 90-889785 APRIL 2003

NOTE: Proper pressure does not necessarily confirm good fuel/air volumes.
To confirm good air volume, momentarily pinch off the air discharge hose on the port side
of the engine. Pressure should rise very quickly to about 827.4 kPa (120 psi) or higher.
0b59595
a - Air discharge hose pinched off to raise pressure
If air pressure does not rise quickly to 827.4 kPa (120 psi), the following items should be
checked:
! Dirty air compressor air filter.
! Leaking air hoses.
! Broken air compressor reed valves.
! Scuffed air compressor piston.
! Defective direct injector.
To confirm good fuel volume, momentarily pinch off the fuel return hose on the port side
of the engine. Pressure should rise very quickly to about 827.4 kPa (120 psi) or higher.
0b59596
a - Fuel discharge hose pinched off to raise pressure
If fuel pressure does not rise quickly to 827.4 kPa (120 psi), the following items should
be checked:
!Proper fuel level in vapor separator tank.
! Check low pressure fuel pump output.
90-889785 APRIL 2003 Page 3B-83

Fuel Injector Test

If a fuel injector, fuel pressure regulator or injector O-ring is leaking, fuel will enter the air
pressure side of the rail. Fuel in the air side of the rail will cause spark plug fouling. A sim-
ple test is to connect a pressure gauge to the fuel pressure test port and turn the ignition
key to the “ON” position.
NOTE: Prior to making this test, prime the fuel system using the primer bulb in the fuel
supply hose to confirm that the Vapor Separating Tank (VST) is filled with fuel.
• The electric fuel pumps should run for about 2 – 3 seconds.
• The fuel pressure should rise to about 227.5 – 296.5 kPa (33 – 43 psi) at the fuel
rail when the pumps are running.
• Fuel pressure at the boost pump Schrader valve on the VST should be 137.9 –
206.8 kPa (20 – 30 psi).
• When the pumps stop, the pressure should level off to about 68.9 – 137.9 kPa (10
– 20 psi) and hold.
• If the pressure drops below 68.9 kPa (10 psi) quickly, it is an indication of a fuel
leak.
If a fuel leak is suspected, proceed as follows:
• Remove the fuel rail retainer nuts.
• Remove the water outlet hose.
• Slide the rail away from the cylinder block (keep the direct injectors in place in the
cylinder block).
• Turn the ignition key to the “ON” position to pressurize the system and look for fuel
leaks at the injector openings.
• Replace any leaking injectors.
ob59486
a - Fuel rail pulled back from cylinder block

b - Fuel injector openings
Page 3B-84 90-889785 APRIL 2003

FUEL PRESSURE AND AIR PRESSURE TROUBLESHOOTING CHART
PROBLEM CORRECTIVE ACTION

Fuel pressure and air pressure are both low 1. Inspect air compressor air intake for blockage.
2. Inspect air compressor for scuffing of cylinder
wall. Inspect for broken reeds and/or reed stops.
3. Air Regulator – inspect diaphragm for cuts or
tears on diaphragm and rail.
Fuel pressure low or fuel pressure drops while 1. Each time key is turned to the “RUN” position,
running (air pressure remains normal) both electric pumps should operate for 2 se-
conds. If they do not run, check 20 ampere fuse
and wire connections.
2. If pumps run but have no fuel output, check va-
por separator (remove drain plug) for fuel.
3. If no fuel present in vapor separator, check fuel/
water separator for debris. Check crankcase
mounted fuel pump for output.
4. High and low pressure pumps are on the same
electrical circuit. Amperage draw for both com-
bined should be 10 – 14 amperes. If amperage
is low, check for insufficient fuel to pumps or an
open circuit in one or both pumps. If amperage
is high, check low pressure pump output. It
should be 137.9 – 206.8 kPa (20 – 30 psi). If
pressure is low, replace low pressure pump. If
pressure is correct, replace high pressure pump.
5. Fuel Regulator – inspect diaphragm for cuts or
tears.
Fuel pressure high and air pressure is normal 1. Debris blocking fuel regulator hole.
2. Faulty pressure gauge
Fuel and air pressure higher than normal 1. Debris blocking air regulator passage.
2. Air dump hoses (rail to muffler) blocked/plugged.
3. Air muffler plugged.
90-889785 APRIL 2003 Page 3B-85

OIL INJECTION
FUEL SYSTEM
Section 3C – Oil Injection
Table of Contents
Oil System Operation . . . . . . . . . . . . . . . . . . . . 3C-2 Priming Procedure – Method 1 . . . . . . . . . 3C-10
Oil Pump Output . . . . . . . . . . . . . . . . . . . . . 3C-2 Oil Hose Connection . . . . . . . . . . . . . . . . . . 3C-11
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-3 Remote Oil Tank (1257-8742A25)
Oiling System . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oiling System (Continued) . . . . . . . . . . . . . . . .
3C-4
3C-5
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling the Oil Tank . . . . . . . . . . . . . . . . . . . .
3C-12
3C-13 3
Oil Pump Removal and Installation . . . . .
Engine Oil Tank . . . . . . . . . . . . . . . . . . . . . .
3C-6
3C-7
Purging Air From the Remote Oil Hose . .
Oil System Troubleshooting . . . . . . . . . . . . . .
3C-13
3C-14
C
Priming the Oil Pump . . . . . . . . . . . . . . . . . 3C-9 Low Oil Warning System is Activated . . . 3C-14
90-889785 APRIL 2003 Page 3C-1

OIL INJECTION
Oil System Operation

Oil in this engine is not mixed with the fuel before entering the combustion chamber. Oil
is stored inside the oil reservoir on the front of the engine. If an optional remote oil tank,
which is mounted in the boat, is used, crankcase pressure forces oil from the remote oil
tank into the engine oil reservoir. The engine oil reservoir feeds oil to the oil pump. The
oil pump is PCM driven and controls oil distribution to the crankcase and air compressor.
The oil pump has seven oil discharge ports. Six of the oil discharge ports inject oil into the
crankcase through hoses, one hose for each cylinder. The last oil discharge port dis-
charges oil into the air compressor for lubrication. Unused oil from the air compressor re-
turns to the cylinder bores.
NOTE: If optional remote oil tank (installed in boat) is to be used, it is recommended that
the engine mounted oil tank be completely filled prior to initial operation. The remote oil
tank will not be able to displace any air in the engine mounted oil tank if the tank is not
full. Low oil level in the engine mounted tank may cause activation of the low oil warning
system.
The PCM is programmed to automatically increase the oil supply to the engine during the
initial engine break-in period. The oil ratio is doubled during the first 120 minutes of opera-
tion whenever engine speed exceeds 2500 RPM and is under load; below 2500 RPM the
oil pump provides oil at the normal ratio. After the engine break-in period, the oil ratio will
return to normal – 300 - 400:1 at idle to 60:1 at WOT.
NOTE: On some light boat applications after the break-in is completed and the engine is
being run at cruising speed – between 4000 and 5000 RPM – the fuel to oil ratio may be
as high as 40:1. This results from a reduced throttle opening with a corresponding reduc-
tion in fuel consumption.
Oil Pump Output

Using the DDT to activate auto prime, the oil pump should discharge 110 ml (cc) ± 8 ml
(cc) during the auto prime time period.
To check the oil pump output:
• Verify the on-board oil reservoir is full.
• Release any pressure (loosen cap) from the remote oil tank in the boat.
• With engine not running, use the DDT to activate the auto prime.
• Using a ml or cc graduated container, record the amount of oil needed to refill the on-
board oil reservoir.
• Retighten cap on the remote oil tank in the boat.
Page 3C-2 90-889785 APRIL 2003

OIL INJECTION
Oiling System
15
Page 3C-4 90-889785 APRIL 2003

OIL INJECTION
Oiling System (Continued)

TORQUE
REF.
REF
1 1 OIL LINE [ 63.5 CM (25 IN.)] [3 MM (1/8 IN.) I.D.]
2 1 OIL LINE [17.8 CM (7 IN.)]
3 3 OIL LINE [34.3 CM (13-1/2 IN.)]
4 2 OIL LINE [50.8 CM (20 IN.)]
5 1 TUBING [8.3 CM (3-1/4 IN.)]
6 1 TUBING [17.8 CM (7 IN.)]
7 1 OIL FILTER
8 AR CABLE TIE [10.2 CM (4 IN.)]
9 AR CABLE TIE [20.3 CM (8 IN.)]
10 1 CONDUIT [15.3 CM (6 IN.)]
11 AR CABLE TIE [14 CM (5-1/2 IN.)]
12 1 OIL PUMP
13 3 SCREW (M8 x 20) 18 24.4
14 2 HOSE
15 3 CHECK VALVE
90-889785 APRIL 2003 Page 3C-5

OIL INJECTION
Oil Pump Removal and Installation

REMOVAL
1. Disconnect the wiring harness from the pump.
2. Disconnect the oil hoses.
3. Remove three screws and remove pump.
c
ob59582
a - Wiring harness
b - Screws
c - Oil pump
INSTALLATION
1. Secure pump with 3 screws. Torque screws to specifications.
TORQUE
REF.
REF
b 3 SCREW (M8 x 20) 18 24.4
2. Reconnect the oil hoses. Refer to Oiling System, preceding, for correct location. Fas-
ten hoses to pump fittings with cable ties.
3. Connect the wiring harness.
4. Refill the oil system. Refer to Priming the Oil Pump.
Page 3C-6 90-889785 APRIL 2003

OIL INJECTION
Engine Oil Tank

REMOVAL
1. Disconnect air compressor air intake hose.
2. Disconnect the oil hose. Plug the hose to prevent spillage.
3. Disconnect low oil sensor connector.
4. Remove 2 screws securing oil tank to powerhead and remove tank.
d
a
ob00412
a - Air compressor air intake hose
b - Oil hose
c - Low oil sensor connector
d - Screws
90-889785 APRIL 2003 Page 3C-7

OIL INJECTION
INSTALLATION
1. Position oil tank assembly onto engine aligning throttle body seal with air intake
flange.
2. Fasten the oil hose with cable ties.
3. Connect low oil sensor harness.
4. Secure oil tank assembly with 2 screws. Torque screws to specifications.
5. Refill the oil system. Refer to Priming the Oil Pump.
e
a d
ob00412 ob00409
ob59627
a - Oil tank d - Screws

b - Oil hose e - Air compressor air in-
c - Sensor harness take hose
TORQUE
REF.
REF
d 2 SCREW (M8 x 35) 18 24.4
Page 3C-8 90-889785 APRIL 2003

OIL INJECTION
Priming the Oil Pump

There are three methods for priming the oil pump:
METHOD 1 – SHIFT SWITCH ACTIVATION PRIME
This method does three things:
a. Fills the oil pump, oil supply hose feeding pump and oil hoses going to the crank-
case and air compressor.
b. Activates break-in oil ratio.
c. Initiates a new 120 minute engine break-in cycle.
Refer to Priming Procedure Method 1, following.
METHOD 2 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – RESET BREAK-IN
This method is the same as Method 1, except the run history and fault history are erased
from the ECM.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part No. 91-822608-4 or -5.
METHOD 3 – (DDT) DIGITAL DIAGNOSTIC TERMINAL – OIL PUMP PRIME
This method fills the oil pump, oil supply hose feeding pump, and oil hoses going to the
crankcase and air compressor.
Refer to procedure in the Technician Reference Manual provided with the Digital Diagnos-
tic Software Cartridge Part No. 91-822608-4 or -5.
Conditions Requiring Priming the Oil Pump

Condition Priming Procedure
New engine Use Method 1 or 2
Rebuilt Powerhead Use Method 1 or 2
New Powerhead Use Method 1 or 2
Oil system ran out of oil Use Method 3
Oil drained from oil supply hose feeding pump Use Method 3
Oil pump removed Use Method 3
Oil injection hoses drained Use Method 3
90-889785 APRIL 2003 Page 3C-9

OIL INJECTION
Priming Procedure – Method 1

METHOD 1 – SHIFT SWITCH ACTIVATION PRIME PROCEDURE
Before starting engine for the first time, prime the oil pump. Priming will remove any
air that may be in the pump, oil supply hose, or internal passages.
ob00412
a - Oil injection pump b - Oil supply hose
CAUTION
To prevent damage to the fuel pumps, fill the engine fuel system with fuel. Other-
wise the fuel pumps will run without fuel during the priming process.
Prime the oil injection pump as follows:
1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until
firm.
2. Turn the ignition key switch to the “ON” position.
3. Within the first 10 seconds after the key switch has been turned on, move the remote
control handle from neutral into forward gear 3 to 5 times. This will automatically start
the priming process.
N
F
NOTE: It may take a few minutes for the pump to complete the priming process.
Page 3C-10 90-889785 APRIL 2003

OIL INJECTION
Oil Hose Connection

NOTE: The oil hose between oil reservoir and oil pump contains a directional filter, which
is designed to trap any debris in the oil before it reaches the engine oil pump. The filter
is marked with an arrow denoting direction of flow of oil and should be installed according-
ly.
ob59597
a - Oil filter
90-889785 APRIL 2003 Page 3C-11

OIL INJECTION
Remote Oil Tank (1257-8742A25) (Optional)

INSTALLATION INSTRUCTIONS
1. Remove duckbill valve from on-board oil tank.
2. Install screw into tank port.
3. Remove cable tie and plastic cap from on-board oil tank 90° elbow.
a
c
ob00034
a - Duckbill valve location c - Plastic cap
b - Screw (10-96610M)
4. Attach molded 90° hose to on-board oil tank elbow. Secure with cable tie.
5. Install 5/16 in. barbed end of tee fitting into hose end. Secure with cable tie.
6. Secure molded hose along side of on-board oil tank with 2 cable ties.
NOTE: DO NOT over-tighten cable ties.
c
a
c
b ob00033
a - Molded 90° hose (32-884402)

b - Check valve fitting (Tee) (22-42425--2)
c - Cable tie
Page 3C-12 90-889785 APRIL 2003

OIL INJECTION
7. Remove pipe plug from engine. Install check valve.

8. Remove plugs from oil line hose ends.
9. Cut 300 mm (12 in.) of blue-striped hose section from oil line.
10. Attach oil line to check valve on engine. Secure hose with cable tie.
11. Attach blue striped hose end to tee fitting. Secure hose with cable tie.
c
d b
ob00035
a - Check valve (21-43278--3) c - Cable tie

b - Blue striped hose end d - Pulse/pressure hose
12. Find a suitable location for remote oil tank.

13. Fasten hold down bracket to floor using clamps.
14. Secure remote oil tank in place with bungy cord.
15. Attach oil line to remote oil tank. Blue striped hose section should be attached to top
fitting of oil tank adapter.
Filling the Oil Tank
1. Fill remote oil tank and engine mounted oil reservoir with the recommended oil listed
in the Operation and Maintenance Manual. Tighten fill caps.
a - Fill cap
Purging Air From the Remote Oil Hose

NOTE: Before starting engine, make sure the oil pump has been primed.
With the engine mounted oil reservoir filled, there is ample oil for normal engine operation
while the remote oil tank hose is bled of air during engine operation. No special proce-
dures are required to eliminate air if the engine mounted oil reservoir is full.
90-889785 APRIL 2003 Page 3C-13

OIL INJECTION
Oil System Troubleshooting

Low Oil Warning System is Activated
Problem Problem Problem Problem
Low oil level in engine Low oil level in engine Oil level is not low in Oil leaks out of
oil reservoir but not low oil reservoir and also engine oil reservoir exhaust
in (optional) remote oil (optional) remote oil
tank tank Disconnect BLUE
Note: Oil level in engine wires going to the
low oil float switch in Pulse hose and
oil reservoir should be oil supply hose
up to the fill cap Refill both oil tanks. the engine oil reser-
voir. Check switch are reversed
for continuity
Boat oil tank is
Fill cap is leaking air on re- Caps on remote tank must be mounted higher
mote tank sealed and installed tight than pulse hose
fitting on engine
and oil tank is
Remote oil hoses blocked or Check hoses for a kink or over-filled
punctured leakage
Restricted oil outlet filter in re-

Remove filter and clean
mote oil tank
Restricted oil inlet filter in oil

hose before engine oil reser- Replace oil filter
voir
Air leak in upper portion on

Replace tube
the oil pickup tube
Faulty pressure check valve.

Replace check valve
Located in engine at end of
(black without blue stripe) re-
mote oil hose
No Continuity
Remove engine oil reservoir. Verify oil fill cap is
closed tight and oil outlet hose is plugged/closed.
Turn reservoir upside down. Check continuity on Continuity
switch. Note: Oil reservoir must be partly empty to Check for open wire between
allow sensor float to go to top of stem when turned oil float switch and ECM
up side down.
No Continuity Continuity
Oil Float switch is faulty. Re- Float in oil tank is faulty. Re-
place switch place oil tank
Page 3C-14 90-889785 APRIL 2003

EMISSIONS
FUEL SYSTEM
Section 3D – Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . . . . . . 3D-1 Emissions Information . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
What Are Emissions? . . . . . . . . . . . . . . . . . . . . . . 3D-1 Manufacturer’s Responsibility: . . . . . . . . . . . . . . 3D-4
Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 Dealer Responsibility: . . . . . . . . . . . . . . . . . . . . . . 3D-5
Carbon Monoxide – CO . . . . . . . . . . . . . . . . . . . . 3D-1
Oxides of Nitrogen – NOx . . . . . . . . . . . . . . . . . . 3D-2
Owner Responsibility: . . . . . . . . . . . . . . . . . . . . . . 3D-5
EPA Emission Regulations: . . . . . . . . . . . . . . . . . 3D-5 3
Controlling Emissions . . . . . . . . . . . . . . . . . . . . . . 3D-2
Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . . . . 3D-2
Decal Location: . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6
Manufacturer’s Certification Label . . . . . . . . . . . . . . 3D-6
D
Outboard Hydrocarbon Emissions Reductions . . . 3D-2 Service Replacement Certification Label . . . . . . . . 3D-7
Stratified vs Homogenized Charge . . . . . . . . . . . . . 3D-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7
Homogenized Charge . . . . . . . . . . . . . . . . . . . . . . 3D-3 Date Code Identification . . . . . . . . . . . . . . . . . . . . 3D-7
Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7
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 United States.
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 com-
bustion. 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
contains mainly hydrogen and carbon. These four elements combine chemically during
combustion. If combustion were complete, the mixture of air and gasoline would result in
these emissions: water, carbon dioxide and nitrogen, which are not harmful to the environ-
ment. However, combustion is not usually complete. Also, potentially harmful gases can
be formed during and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful
gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards
become more stringent each year. Standards are set primarily with regard to three emis-
sions: hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).
Hydrocarbons – HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned
during combustion in combination with oxygen. But they are not totally consumed. Some
pass through the combustion chamber and exit the exhaust system as unburned gases
known as hydrocarbons.
Carbon Monoxide – CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxy-
gen during the combustion process. If the carbon in the gasoline could combine with
enough oxygen (one carbon atom with two oxygen atoms), it would come out of the en-
gine in the form of carbon dioxide [CO2]. CO2 is a harmless gas. However, carbon often
combines with insufficient 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.
90-889785 APRIL 2003 Page 3D-1

EMISSIONS
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
chambers 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
engine. The first method is to control the air/fuel ratio that goes into the combustion cham-
ber. The second is to control the time when this air/fuel mixture enters the combustion
chamber. Timing is important, to prevent any unburned mixture from escaping out of the
exhaust port.
Stoichiometric (14.7:1) Air/Fuel Ratio
In the search to control pollutants and reduce exhaust emissions, engineers have discov-
ered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio
of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1
provides the best control of all three elements in the exhaust under almost all conditions.
The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio.
At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer
than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves
might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1.
However, there is also NOx to consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combus-
tion temperatures raise the NOx content of the exhaust. However, enrichening the air/fuel
ratio to decrease combustion temperatures or 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
Page 3D-2 90-889785 APRIL 2003

EMISSIONS
Stratified vs Homogenized Charge

DFI engines use a stratified charge inside the combustion chamber to aid in reducing
emissions. All other models use a homogenized charge. The difference between the two
is:
Homogenized Charge
A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder.
This mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional
mixing occurs as the fuel is forced through the transfer system into the cylinder.
The homogenized charge is easy to ignite when the air/fuel ratio is approximately 14.7:1.
90-889785 APRIL 2003 Page 3D-3

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 a fuel/air mixture in the form of a bubble into the cylinder. Sur-
rounding this bubble is air supplied by the transfer system. As the bubble is ignited and
burns, the surrounding air provides almost complete combustion before the exhaust port
opens.
A stratified charge is hard to ignite. The fuel/air bubble is not evenly mixed at 14.7:1 and
is not easily ignited.
Emissions Information
Manufacturer’s Responsibility:
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family and certi-
fy these engines with the United States Environmental Protection Agency [EPA]. A certifi-
cation decal/emissions control information label, showing emission levels and engine
specifications directly related to emissions, must be placed on each engine at the time
of manufacture.
Page 3D-4 90-889785 APRIL 2003

EMISSIONS
Dealer Responsibility:
When performing service on all 1998 and later outboards that carry a certification, atten-
tion 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. Also included would be factory authorized:
• Installation of performance style gear housings by Mercury Marine.
• Service replacement parts modified, changed or superceded by Mercury Marine.
Owner Responsibility:
The owner/operator is required to have engine maintenance performed to maintain emis-
sion levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horse-
power or allow emissions levels to exceed their predetermined factory specifications.
Single engine exceptions may be allowed with permission from the EPA for racing and
testing.
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
contingent on certain adjustments being set to factory standards. For this reason, the fac-
tory procedure for servicing the product must be strictly followed and, whenever practica-
ble, 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
90-889785 APRIL 2003 Page 3D-5

EMISSIONS
CERTIFICATION LABEL:
The certification label must be placed on each engine at the time of manufacture and must
be replaced in the same location if damaged or removed. Shown below is a typical certifi-
cation label and is not representative of any one model. Label shown below is not to scale;
(shown at twice the normal size).
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
i IDLE SPEED (IN GEAR): 625–675 RPM FAMILY: 4M9XM01.52C0 a
h 115 HP 1521.8 cc FEL: 16.6 g/kW-hr b
g
TIMING (IN DEGREES): NOT ADJUSTABLE c
f Spark Plug: NGK PZFR6H

JULY 2003 d
Gap: 0.8 mm 〈0.030 in.)
Cold Valve Clearance (mm) Intake: N/A

Exhaust: N/A e
a - Family Example e - Valve Clearance (Four Stroke en-

b - FEL: Represents (Mercury Marine) gines only)
statement of the maximum emis- f - Date of Manufacture
sions output for the engine family g - Cubic Centimeter
c - Timing specifications when adjust- h - Engine Horsepower rating
able i - Idle Speed (In Gear)
d - Recommended spark plug for best
engine performance
4 M9X M 01.5 2 C 0
0=Unspecified
Technology type 3=Ultra Clean California
Model Year Regulation 1=OB Old Tech Rated Eng.
4=2004 M=Marine 2=OB New Tech Application
3=Sport Jet C=2 Stroke
Manufacturer 4=Opti Jet
Mercury Marine 4 Places for Displacement E=EFI Sport Jet
G=4 Stroke
Decimal Point = Liter H=Hi-Perf.
No Point = Cubic Inch J=Sport Jet
Decal Location:
Model Service Part No. Location on Engine
2003 Merc/Mar 1.5 L DFI (75 37-891765A-04 Vapor Separator
H.P.)
H.P.)
2003 Merc/Mar 1.5 DFI (115 37-891765A-04 Vapor Separator
H.P.)
Page 3D-6 90-889785 APRIL 2003

EMISSIONS
Service Replacement Certification Label

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine
outboards have a visible and legible emission certification label. If this label is mis-
sing or damaged, contact Mercury Marine Service for replacement if appropriate.
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label
over the old label. Use a suitable solvent to remove any traces of the old label adhesive
from the display location.
Date Code Identification
Cut and remove a V notch through the month of engine manufacture before installing the
new label. The month of manufacture can be found on the old label. If the label is missing
or the date code illegible, contact Mercury Marine Technical Service for assistance.
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
IDLE SPEED (IN GEAR): 625–675 RPM FAMILY: 4M9XM01.52C0
115 HP 1523.5 cc FEL: 16.6 g/kW-hr
TIMING (IN DEGREES): NOT ADJUSTABLE
Spark Plug: NGK PZFR6H
Gap: 0.8 mm (0.030 in.)
Cold Valve Clearance (mm) Intake: NA
Exhaust: NA
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
a
a - V Notch b - Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.
Decal Location:
Model Service Part No. Location on Engine
H.P.)
H.P.)
H.P.)
90-889785 APRIL 2003 Page 3D-7

POWERHEAD
POWERHEAD
Section 4A
Table of Contents
Powerhead Specifications . . . . . . . . . . . . . . . . 4A-2 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-61
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Crankshaft (and End Cap) Bearings . . . . 4A-62
Powerhead Repair Stand . . . . . . . . . . . . . . 4A-5 Reed Block Assembly . . . . . . . . . . . . . . . . . 4A-63
Compression Tester Tools . . . . . . . . . . . . . 4A-5 End Bearing Bleed System . . . . . . . . . . . . 4A-63
Cylinder Block and Crankcase . . . . . . . . . . . . 4A-6 Connecting Rods . . . . . . . . . . . . . . . . . . . . . 4A-63
Poppet/Thermostat Mounting . . . . . . . . . . . . . 4A-8 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . 4A-65
Crankshaft, Pistons and Connecting Rods . . 4A-10 Powerhead Reassembly and Installation . . . 4A-66
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-12 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-66
Crankcase Cover Screws . . . . . . . . . . . . . .
Reed Block Adaptor Plate Screws . . . . . .
4A-12
4A-13
Piston and Connecting Rod Reassembly
Piston and Piston Ring . . . . . . . . . . . . . . . .
4A-71
4A-72
4
Reed Block Screws . . . . . . . . . . . . . . . . . . . 4A-14 Piston Reassembly to Crankshaft . . . . . . . 4A-75 A
Air Plenum Assembly Plate Bolts . . . . . . . 4A-15 Crankshaft Assembly Installation
General Information . . . . . . . . . . . . . . . . . . . . . 4A-16 into Cylinder Block . . . . . . . . . . . . . . . . . . . . 4A-79
Powerhead Removal from Crankcase Cover Installation . . . . . . . . . . . 4A-81
Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . 4A-16 Assembly of Reed Blocks/ Adaptor
Removing Engine Components . . . . . . . . . . . 4A-23 Plate and Air Plenum . . . . . . . . . . . . . . . . . 4A-84
Removing Engine Components Thermostat/Poppet Valve Installation . . . . 4A-88
Individually . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-23 Reinstalling Engine Components . . . . . . . . . . 4A-90
Removing Engine Components Throttle Lever and Linkage . . . . . . . . . . . . . . . 4A-91
as an Assembly . . . . . . . . . . . . . . . . . . . . . . 4A-24 Powerhead Installation on
Powerhead Disassembly . . . . . . . . . . . . . . . . . 4A-43 Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . 4A-92
Water Pressure Relief Valve Components 4A-55 Shift Cable Installation . . . . . . . . . . . . . . . . 4A-97
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4A-56 Throttle Cable Installation . . . . . . . . . . . . . 4A-99
Cylinder Block and Crankcase Cover . . . 4A-56 Break-ln Procedure . . . . . . . . . . . . . . . . . . . . . . 4A-102
Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . 4A-58 Engine Break-in Procedure . . . . . . . . . . . . 4A-102
Pistons and Piston Rings . . . . . . . . . . . . . . 4A-59
90-889785 APRIL 2003 Page 4A-1

POWERHEAD
Powerhead Specifications
CYLINDER Type 3 Cylinder, Two Cycle, Direct Injected

BLOCK Displacement 1523.5 cc (92.9 cu. in.) In-line
Thermostat 61°C (142°F)
Water Pressure
Idle 27.6 – 48.3 kPa (4 – 7 psi)
Poppet Valve Opening 48.3 – 62.1 kPa (7 – 9 psi)
W.O.T. 75.8 – 96.5 kPa (11 – 14 psi)
STROKE Length (All Models) 76.2mm (3.00 in.)
CYLINDER Diameter (Std) 92.1131 mm (3.6265 in.)
BORE Diameter 0.038 mm (0.015 in.) Over- 92.4941 mm (3.6415 in.)
size
Diameter 0.076 mm (0.030 in.) Over- 92.875 mm (3.6565 in.)
size
Taper/Out of Round/Wear Maximum 0.076 mm (0.003 in.)
Bore Type Cast Iron
Compression 620 – 758 kPa (90 – 110 psi)♦
CRANKSHAFT Maximum Runout 0.0508 mm (0.002 in.)
PISTON Piston Type Aluminum
Diameter Standard 91.9226 mm ± 0.0127 mm (3.619 in. ±
.0005 in.)
size (3.634 in. ± 0.0005 in.)

size (3.649 in. ± 0.0005 in.)
PISTON
DIAMETER 91.9226 mm ± .0127 mm
(3.619 in. ± .0005 in.)Using a microme-
Dimension
“A” at Right ter, measure dimension “A” at location
Angle (90°) shown. Dimension “A” should be 3.619
to Piston Pin in. ± .0005 for a STANDARD size piston
(new) Dimension “A” will be 0.001 -
1.0 in. 0.0015 less if coating is worn off piston
25.4 mm
(used)
REEDS Reed Stand 0pen (Max.) 0.50 mm (0.020 in.)
♦When performing cylinder compression test, place lanyard switch in the OFF position to pre-
vent operation of direct injectors or remove fuse controlling fuel and direct injectors.
Page 4A-2 90-889785 APRIL 2003

POWERHEAD
Special Tools
Lifting Eye 91-90455T1
Powerhead Stand 91-812549T
Piston Ring Expander 91-24697
Lockring Removal Tool 91-52952A1
Piston Pin Tool 91-92973A1
90-889785 APRIL 2003 Page 4A-3

POWERHEAD
Universal Puller Plate 91-37241
Snap Ring Pliers 91-24283
Lockring Installation Tool 91-93004A2
Piston Ring Compressor 91-823237
Direct Injector Removal Tool 91-883521
Page 4A-4 90-889785 APRIL 2003

POWERHEAD
Compression Tester with Adaptor Snap-On P/N EEPV303A* and Snap-On P/N
MT26-J200R*
a - Compression Tester (EEPV303A)*

b - Adaptor (MT26-J200R)*
Remote Starter Switch 91-52024A1
Powerhead Repair Stand

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

A compression tester and necessary adaptor may be purchased from:
*Snap-On Tools Company
2801 - 80th Street
Kenosha, Wisconsin 53143
Phone 414.656.5200
90-889785 APRIL 2003 Page 4A-5

POWERHEAD
Cylinder Block and Crankcase
12

Description
Ref. # ber Number
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
Page 4A-6 90-889785 APRIL 2003

POWERHEAD
Cylinder Block and Crankcase (continued)

TORQUE
REF.
REF
1 1 CYLINDER BLOCK
2 1 DOWEL PIN
3 3 CENTER MAIN PIN
4 8 SCREW (M10 x 80) 28 37.9
5 2 BRACKET
6 4 SCREW (M8 x 40) 18 24.4
7 1 PIPE PLUG (1/4-18)
8 3 PIPE PLUG
9 12 SCREW (M8 x 35) 18 24.4
11 3 CHECK VALVE
12 3 CHECK VALVE
14 1 CHECK VALVE
15 3 WATER DEFLECTOR
16 8 PIPE PLUG
17 1 FITTING
18 8 STUD (M10 x 136)
19 8 WASHER
27 Nm (20 lb. ft. )
20 8 NUT (M10) and rotate 90 de-
grees
21 3 CHECK VALVE
22 2 SEAL
23 1 OIL RESERVOIR BRACKET
24 2 SCREW (M8 x 20) 18 24.4
25 1 CRANK POSITION SENSOR
26 2 SCREW (M5 x 16) 45 5.1
27 1 COVER–FLYWHEEL
28 3 GROMMET
29 1 COUPLING INSERT (SALTWATER)
30 1 COUPLING BODY (SALTWATER)
31 1 CAP (SALTWATER)
32 1 TUBING (43 IN.) (SALTWATER)
33 AR CABLE TIE (SALTWATER)
34 1 FITTING (SALTWATER)
90-889785 APRIL 2003 Page 4A-7

POWERHEAD
Poppet/Thermostat Mounting
11
Page 4A-8 90-889785 APRIL 2003

POWERHEAD
Poppet/Thermostat Mounting (continued)

TORQUE
REF.
REF
1 1 POPPET
2 1 DIAPHRAGM
3 1 WASHER
4 1 SCREW (10-16 x 3/4) Drive tight
5 1 SPRING
6 1 COVER–THERMOSTAT POPPET
7 4 SCREW (M8 x 35) 18 24.4
8 1 GASKET
9 1 GASKET
10 1 THERMOSTAT 61.7° C (143° F)
11 1 J–CLAMP
12 1 SCREW (M6 x 12) 144 12 16.2
14 1 O–RING
90-889785 APRIL 2003 Page 4A-9

POWERHEAD
Crankshaft, Pistons and Connecting Rods

Description
Ref. # ber Number
Needle Bearing
4 92-802868A1 N/A
Assembly Lubricant
14 92-802813A1 92-802813Q1
board Oil
Page 4A-10 90-889785 APRIL 2003

POWERHEAD
Crankshaft, Pistons and Connecting Rods (continued)

TORQUE
REF.
REF
1 1 CRANKSHAFT ASSEMBLY
2 1 RETAINING RING
3 1 BALL BEARING (LOWER)
4 1 KEY
5 1 WEAR SLEEVE
6 1 O-RING
7 2 RING–SEAL
8 2 BEARING
9 4 NEEDLE BEARING
10 3 PISTON ASSEMBLY
11 3 PISTON PIN
12 6 LOCK RING
13 6 PISTON RING ASSEMBLY
14 3 CONNECTING ROD ASSEMBLY
15 6 THRUST WASHER
16 102 NEEDLE BEARING
Apply light oil to
threads and bolt
face: 1st torque - 15
lb-in (1.7 Nm.)
2nd torque - 30 lb-ft
17 6 SCREW
(40.6 Nm.)
Turn bolt an addi-
tional 90 degrees af-
ter 2nd torque is at-
tained.
18 6 BEARING ASSEMBLY
19 48 ROLLER BEARING
20 1 ROLLER BEARING ASSEMBLY (UPPER)
21 1 OIL SEAL
90-889785 APRIL 2003 Page 4A-11

POWERHEAD
Torque Sequence
Crankcase Cover Screws
a
2 1
"!
$#
"* ")
4 3
"( "'
"& "%
6 5
"$ ""
"# !
b 8 7
ob00785
TORQUE
REF.
REF
a 8 SCREW (M10 x 80) 28 37.9
b 12 SCREW (M8 x 35) 18 24.4
Page 4A-12 90-889785 APRIL 2003

POWERHEAD
Reed Block Adaptor Plate Screws
"#
* !
) (
a
'
% &
$ "
""
"$ "%
"' "&
ob00792
TORQUE
REF.
REF
a 15 SCREW (M8 x 35) 18 24.4
90-889785 APRIL 2003 Page 4A-13

POWERHEAD
Reed Block Screws
a a
a a
a a
0b00776
TORQUE
REF.
REF
a 6 SCREW (M6 x 20) 90 10.2
Page 4A-14 90-889785 APRIL 2003

POWERHEAD
Air Plenum Assembly Plate Bolts
8 7
a 3
4
2
5 6
ob00820
TORQUE
REF.
REF
a 9 SCREW (M8 x 45) 18 24.4
90-889785 APRIL 2003 Page 4A-15

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 disassembly
was stopped. Refer to Table of Contents, preceding. Usually, complete disassembly of
powerhead will be required.
If major powerhead repairs are to be performed, remove powerhead from drive shaft
housing. Removal of powerhead is required for inspection of cylinder walls and pistons
but not for minor repairs on components such as ignition system, fuel injection, reed
blocks and checking operation of thermostats.
Powerhead Removal from Drive Shaft Housing

1. Disconnect battery cables from battery terminals.
2. Disconnect fuel tank hose from outboard.
4. Remove two screws which secure remote control harness clamp and remove clamp.
a
a
ob00388
a - Screws
b - Clamp
Page 4A-16 90-889785 APRIL 2003

POWERHEAD
5. Slide outboard shift lever into neutral position.

6. Open latch and remove throttle cable and shift cable from control cable anchor brack-
et. Remove attaching nuts.
7. Remove shift arm attaching nut.
a b
d
e f
ob00529
a - Flat washer d - Cable barrel
b - Locknut e - Barrel retainer latch
c - Barrel retainer f - Shift arm attaching nut
8. Disconnect input fuel line.
b a
ob00388
a - Fuel line
b - Clamp
90-889785 APRIL 2003 Page 4A-17

POWERHEAD
9. Disconnect optional remote oil tank hose connections, if equipped.
c
d b
ob00035
a - Check valve c - Cable tie

b - Blue striped hose end d - Pulse/pressure hose
10. Disconnect remote control harness from powerhead harness connector and wires as
shown.
ob00654
a - Remote control harness
Page 4A-18 90-889785 APRIL 2003

POWERHEAD
11. Disconnect air compressor air intake hose.

12. Disconnect the oil hose. Plug the hose to prevent spillage.
13. Disconnect low oil sensor connector.
14. Remove 2 screws securing oil tank to powerhead and remove tank.
d
a
ob00412
a - Air compressor air intake hose
b - Oil hose
c - Low oil sensor connector
d - Screws
90-889785 APRIL 2003 Page 4A-19

POWERHEAD
15. Disconnect tilt switch connector.
ob00652
a - Tilt switch connector
16. Remove 4 screws holding cowl halves together.

17. Loosen 1 screw holding front cowl halves together.
18. Remove 2 nuts attaching cowl halves to driveshaft housing.
NOTE: The tell-tale hose, air compressor dump hose and I.V.S.T. vent hose all pass
through openings in the cowl halves and will be disconnected when the cowl halves are
removed.
a - Screws (4) M6 x 40 mm
b - Screw (1) M6 x 16 mm
c - Nuts (2) M8
d - Boot – idle relief
Page 4A-20 90-889785 APRIL 2003

POWERHEAD
19. Disconnect SmartCraft harness connector.
ob00525
a - SmartCraft harness connector
20. Disconnect BLUE and GREEN trim harness leads.

21. Disconnect RED and BLACK neutral switch harness leads.
a
ob00398
a - BLUE and GREEN trim harness leads

b - RED and BLACK neutral switch harness leads
90-889785 APRIL 2003 Page 4A-21

POWERHEAD
22. Remove eight nuts, six washers and two support plates from powerhead base.
a a
ob00832
a - Nuts and washers

b - Nuts and support plates
c - Support plate
d - Protrusion faces down
23. Remove plastic cap from center of flywheel and install Lifting Eye into flywheel at least
five full turns. Using a hoist, lift powerhead assembly from drive shaft housing.
ob00413
a - Lifting Eye (91-90455T1)
Page 4A-22 90-889785 APRIL 2003

POWERHEAD
Removing Engine Components

NOTE: Engine components can be removed individually or in some cases as an
assembly.
Removing Engine Components Individually
Section 2 Starter Motor
Starter Motor
*Propulsion Control Module
*Ignition Coil
*Starter Solenoid
Alternator
Flywheel
Section 3
Fuel Pump/Internal Vapor Separator Tank
On-Board Oil Tank
Oil Pump
Section 4
Throttle/Shift Control Platform
Throttle/Shift Cable Installation and Adjustment
*All ignition and electrical components should remain attached to electrical plate.
Plate with components can be removed as an assembly.
90-889785 APRIL 2003 Page 4A-23

POWERHEAD
Removing Engine Components as an Assembly

VAPOR SEPARATOR TANK (VST) AND FUEL RAIL REMOVAL
CAUTION
WARNING
Drain fuel from vapor separator tank (VST) into a suitable container. Even though
VST has been drained, fuel may still remain in fuel rails and hoses. Normal pre-
cautionary procedures should be adhered to while working with the fuel system.
Avoid sparks, smoking and open flame while in the presence of liquid fuel or fuel
vapors.
NOTE: Use Fuel/Air Pressure Gauge 91-16850--1 or 91-852087A1/A2 to de-pressurize
air hose first and then fuel hose.
a b
d
ob59594
a - Air pressure gauge d - Fuel pressure port (Design 1)
b - Fuel pressure gauge e - Fuel pressure port (Design 2)
c - Air pressure port
Page 4A-24 90-889785 APRIL 2003

POWERHEAD
2. Cut cable tie securing VST vent hose.

3. Place suitable container underneath vapor separator drain fittings. Turn respective
release screw to allow fuel to drain from fitting. Use rubber hose connecting drain fit-
tings to direct fuel into suitable container. After fuel is drained from VST, close off each
release screw and reattach hose to each drain fitting.
4. Disconnect water separator sensor connector.
5. Remove two electrical harnesses from alternator.
a
f
b b
e
c
d ob00526
a - Cable tie d - Rubber hose

b - Release screws e - Drain fittings
c - Water sensor lead f - Alternator harnesses
6. Disconnect electric fuel pump harness connector.
ob59610
a - Electric fuel pump connector
90-889785 APRIL 2003 Page 4A-25

POWERHEAD
7. Remove pulse fuel pump vacuum hoses (2 each).

8. Remove the fuel outlet hose and fuel return hose on vapor separator tank (VST).
9. Remove 3 mounting bolts and remove separator.
e d
c
ob00883
a - Fuel inlet hose to pulse c - Fuel return hose

pump d - Mounting bolts
b - Fuel outlet hose (discon- e - Pulse pump vacuum
nect at fuel rail) hoses
Page 4A-26 90-889785 APRIL 2003

POWERHEAD
10. Remove throttle arm screw and throttle cable platform screw.
11. Disconnect MAP sensor, air temperature sensor and throttle position sensor harness
connectors.
ob00712
c
ob00694
a - Throttle arm screw d - Air temperature sensor connector

b - Throttle cable platform screw e - Throttle position sensor connector
c - MAP sensor connector
90-889785 APRIL 2003 Page 4A-27

POWERHEAD
12. Remove 9 screws securing air plenum and remove plenum/throttle body assembly.
a a
a
a
a a
a
a
ob00707
a - Screws
Page 4A-28 90-889785 APRIL 2003

POWERHEAD
FUEL RAIL REMOVAL

13. Remove spark plug leads.
14. Remove cable tie securing fuel injector harness.
15. Remove fuel injector harness from each injector by compressing spring clip with flat
tip screw driver while pulling on connector.
c e
ob54871
ob59586
a - Spark plug leads

b - Cable tie
c - Spring clip
d - Fuel injector
e - Harness connector
90-889785 APRIL 2003 Page 4A-29

POWERHEAD
NOTE: Always remove fuel/air hose and fitting together by removing fitting retainer rather
than cutting clamps.
IMPORTANT: If air hose is removed from barbed fitting, replace hose, as interior
surface of hose will be damaged during removal.
16. Remove allen screws securing air and fuel hose retainers.
17. Remove fuel, water and air hoses from fuel rail.
b
a c
ob59609
ob59592
d
ob59605
a - Fuel hose
b - Water hose
c - Fuel hose retainer allen screws
d - Air hose retainer allen screws
e - Air hose
Page 4A-30 90-889785 APRIL 2003

POWERHEAD
NOTE: It is recommended that direct injectors remain in the cylinder head (if they are not
to be replaced) while removing the fuel rail. The direct injectors have a teflon seal which
may expand if the injector is removed from the head. This expansion may cause rein-
stallation difficulty or require the replacement of the seal.
18. Disconnect direct injector connectors.
ob59586
a - Direct injector connectors
19. Remove 2 nuts securing fuel rail.
ob59602
a - Nuts
90-889785 APRIL 2003 Page 4A-31

POWERHEAD
20. As fuel rail is removed, use a flat tip screw driver to hold direct injectors in cylinder
head.
b a
b
ob59601
a - Fuel rail
b - Direct injectors
Page 4A-32 90-889785 APRIL 2003

POWERHEAD
21. Remove alternator ground lead.

22. Disconnect water pressure sensor connector.
23. Disconnect block temperature sensor connector.
c
b
ob59612
a - Alternator ground lead

b - Water pressure sensor connector
c - Block temperature sensor connector
90-889785 APRIL 2003 Page 4A-33

POWERHEAD
24. Disconnect oil pump harness.

25. Remove three screws securing oil pump to electrical plate and swing oil pump away
from electrical plate.
a
b
ob59582
a - Oil pump harness

b - Screws
Page 4A-34 90-889785 APRIL 2003

POWERHEAD
ELECTRICAL PLATE AND HARNESS REMOVAL

26. Disconnect air compressor temperature sensor harness.
27. Disconnect crank position sensor harness.
28. Remove electrical leads from starter solenoid.
29. Remove electrical plate ground lead.
30. Remove battery negative cable.
d e
ob00693
a - Air compressor temperature sensor harness

b - Crank position sensor harness
c - Electrical leads
d - Electrical plate ground lead
e - Battery negative cable
90-889785 APRIL 2003 Page 4A-35

POWERHEAD
ELECTRICAL PLATE AND HARNESS REMOVAL (CONTINUED)

31. Disconnect shift switch bullet connectors.
32. Disconnect power trim bullet connectors.
33. Remove three screws securing electrical plate.
b
c
ob00693
a - Shift limit switch bullet connectors

b - Power trim bullet connectors
c - Screws
Page 4A-36 90-889785 APRIL 2003

POWERHEAD
34. Remove block temperature sensor.

35. Remove water pressure sensor.
36. Remove direct injectors using Direct Injector Removal Tool.
ob00783
ob00713
a - Block temperature sensor

b - Water pressure sensor
c - Direct injector
d - Direct Injector Removal Tool (91-883521)
90-889785 APRIL 2003 Page 4A-37

POWERHEAD
STARTER MOTOR REMOVAL

37. Remove four screws securing starter and remove starter.
ob00768
a - Screws
b - Starter
Page 4A-38 90-889785 APRIL 2003

POWERHEAD
OIL PUMP AND OIL HOSE/BLEED HOSE REMOVAL

38. Remove oil pump and associated hoses from cylinder block.
ob00769
a - Oil pump
90-889785 APRIL 2003 Page 4A-39

POWERHEAD
ALTERNATOR AND AIR COMPRESSOR REMOVAL

39. Disconnect air compressor oil inlet hose.
40. Disconnect water outlet hose (to fuel rail).
41. Disconnect excess oil return hoses.
b
c
d
ob00784
a - Oil inlet hose c - Excess oil return hoses
b - Water inlet hose d - Check valves (3)
42. Use a breaker bar to release belt tensioner and remove alternator belt.
43. Remove 3 screws securing air compressor to outboard and remove compressor.
44. Remove 2 screws securing alternator and remove alternator.
ob00397
a - Alternator screws c - Compressor screws

b - Belt tensioner (3/8 Drive)
Page 4A-40 90-889785 APRIL 2003

POWERHEAD
THROTTLE AND SHIFT PLATFORM REMOVAL

45. Remove two screws securing throttle and shift platform to block.
46. Remove air compressor water supply hose. Remove water supply hose filter and re-
move any debris from filter.
a ob00706
a - Screw and locking tab washer

b - Filter
c - Air compressor water supply hose
90-889785 APRIL 2003 Page 4A-41

POWERHEAD
OIL LINE ROUTING
Page 4A-42 90-889785 APRIL 2003

POWERHEAD
Powerhead Disassembly
1. Place powerhead in repair stand or on a bench.
2. Remove four screws securing thermostat cover.
3. Remove thermostat, poppet valve and gasket.
a b
ob59619
ob00713
a - Thermostat cover
b - Thermostat
c - Poppet Valve
d - Screws
90-889785 APRIL 2003 Page 4A-43

POWERHEAD
4. Remove reed block adaptor plate from crankcase half.
a b
ob00792
a - Crankcase half c - Screws (15)

b - Reed block (3) d - Adaptor plate
Page 4A-44 90-889785 APRIL 2003

POWERHEAD
5. Inspect reeds as outlined in Cleaning and Inspection.
0b00776
a - Reeds
LOWER END CAP

1. Remove bolts securing end cap.
ob00789
a - Crankcase attaching end cap bolts
90-889785 APRIL 2003 Page 4A-45

POWERHEAD
2. Remove bolts which secure crankcase cover to cylinder block and remove cover.
ob00785
a - Crankcase cover
3. Remove lower end cap from crankshaft.

4. Remove and discard O-ring seal from end cap.
5. Remove oil seals from end cap by driving seals out with a punch and hammer.
a
ob00790
a - O-ring
b - Seal
Page 4A-46 90-889785 APRIL 2003

POWERHEAD
CRANKCASE COVER REMOVED

1. Crankshaft and pistons can be removed as an assembly. Use Powerhead Stand
(91-81549T) to mount crankshaft assembly.
91-812549T
ob00825
2. Using an awl or electric pencil, scribe the cylinder identification number on each con-
necting rod, piston and rod cap as shown. Reassemble connecting rods in same cylin-
der.
! !
ob59616
a - Scribe identification number
90-889785 APRIL 2003 Page 4A-47

POWERHEAD
IMPORTANT: Do not reuse connecting rod screws. Discard screws after removal.
3. Use a 3/8 in. 12 point socket to remove connecting rod screws, then remove rod cap,
roller bearings and bearing cage from connecting rod.
ob00797
a - Connecting rod screws
4. After removal, reassemble each piston and connecting rod assembly.
CAUTION
Each connecting rod and end cap are a matched machined set and must never
be mismatched.
5. Inspect pistons as outlined in Cleaning and Inspection, following.
6. Use Piston Ring Expander to remove piston rings. Always install new piston rings.
91-24697
ob55967
a - Piston Ring Expander (91-24697)
Page 4A-48 90-889785 APRIL 2003

POWERHEAD
7. Using Lockring Removal Tool, remove piston pin lockrings from both ends of piston
pin. Never re-use piston pin lockrings.
91-52952A1
ob55969
a - Lockring
b - Lockring Removal Tool (91-52952A1)
IMPORTANT: Warming the piston dome using a torch lamp will ease removal and
installation of piston pin.
8. Support piston and tap out piston pin using Piston Pin Tool as shown.
91-92973A1
ob55957
a - Piston pin
b - Piston Pin Tool (91-92973A1)
90-889785 APRIL 2003 Page 4A-49

POWERHEAD
9. Remove piston pin needle bearings (34 per piston) and locating washers (2 per pis-
ton) as shown.
IMPORTANT: It is recommend that new needle bearings be used at reassembly for
lasting repair. However, if needle bearings must be re-used, keep each set of bear-
ings identified for reassembly on same connecting rod.
ob55958
a - Needle bearing locating washers
10. Inspect upper crankshaft bearing for rust, pits, discoloration and roughness.
11. Replace upper crankshaft seal for lasting repair.
NOTE: If roller bearing is damaged, replace roller bearing assembly.
a
b
ob00799
a - Upper crankshaft bearing

b - Seal
Page 4A-50 90-889785 APRIL 2003

POWERHEAD
12. Remove center main bearing retaining rings as shown.
b
a
ob00827
ob00826
a - Retaining ring
b - Center main bearings
90-889785 APRIL 2003 Page 4A-51

POWERHEAD
13. Remove center main bearing race halves and bearings from crankshaft.
IMPORTANT: Keep same bearing races and roller bearings together.
ob00828
a - Bearing race halves

b - Roller bearings
c - Center main bearing
Page 4A-52 90-889785 APRIL 2003

POWERHEAD
14. Remove crankshaft sealing rings if broken or damaged.

IMPORTANT: DO NOT remove crankshaft sealing rings from crankshaft, unless re-
placement of a sealing ring is necessary. Usually, crankshaft sealing rings do not
require replacement, unless broken.
CAUTION
Safety glasses should be worn when removing or installing crankshaft sealing
rings.
ob59617
a - Sealing ring
15. Inspect crankshaft ball bearing as outlined in Cleaning and Inspection, following.
IMPORTANT: DO NOT remove crankshaft ball bearing, unless replacement is re-
quired.
16. Remove lower ball bearing from crankshaft as follows:
a. Remove retaining ring using a pair of snap ring pliers.
b
a
ob59622
a - Crankshaft ball bearing
b - Pliers
c - Retaining ring
90-889785 APRIL 2003 Page 4A-53

POWERHEAD
b. Press crankshaft out of lower ball bearing as shown.
aa
bb
91-812549A1 c
91-37241
dd
ob51081
a - Press
b - Powerhead Stand (91-812549A1)
c - Crankshaft ball bearing
d - Universal Puller Plate (91-37241)
Page 4A-54 90-889785 APRIL 2003

POWERHEAD
Water Pressure Relief Valve Components

1. Remove and inspect water pressure relief valve components for debris or damage.
Replace components as required.
11
TORQUE
REF.
REF
1 1 POPPET
2 1 DIAPHRAGM
3 1 WASHER
5 1 SPRING
7 4 SCREW (M8 x 35) 18 24.4
8 1 GASKET
9 11 GASKET
10 1 THERMOSTAT 61.7° C (143° F)
11 1 J–CLAMP
12 1 SCREW (M6 x 12) 90 10.2
13 1 TEMPERATURE SENSOR 144 12 16.3
14 1 O–RING
90-889785 APRIL 2003 Page 4A-55

POWERHEAD
Cleaning and Inspection

Cylinder Block and Crankcase Cover
IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored as-
sembly and never should be mismatched by using a different crankcase cover or
cylinder block.
CAUTION
If crankcase cover or cylinder block is to be submerged in a very strong cleaning
solution, it will be necessary to remove the crankcase cover/cylinder block bleed
system from crankcase cover/cylinder block to prevent damage to hoses and
check valves.
Page 4A-56 90-889785 APRIL 2003

POWERHEAD
1. Thoroughly clean cylinder block and crankcase cover. Be sure that all sealant and old
gaskets are removed from matching surfaces. Be sure that carbon deposits are re-
moved from exhaust ports.
2. Inspect cylinder block and crankcase cover for cracks or fractures.
3. Check gasket surfaces for nicks, deep grooves, cracks and distortion that could cause
compression leakages.
4. Check all water and oil passages in cylinder block and crankcase cover to be sure that
they are not obstructed and that plugs and locating pins are in place and tight.
a a
a
b b b
ob00779
a - Oil ports
b - Center main bearing locating pins
5. Remove 3 allen screws to gain access to water dam plugs. Remove plugs and inspect
for damage from high engine temperatures due to lack of water. Replace plugs as re-
quired.
NOTE: If water dam plugs are missing or damaged, engine may overheat as plugs are
necessary to maintain proper coolant flow around cylinder bores.
a
b
a
ob00831
a - Allen screw
90-889785 APRIL 2003 Page 4A-57

POWERHEAD
Cylinder Bores
1. Inspect cylinder bores for scoring, scuffing or a transfer of aluminum from piston to
cylinder wall. Scoring or scuffing, if not too severe, can normally be removed by hon-
ing. If a transfer of aluminum has occurred, an acidic solution containing muriatic acid
(i.e. TIDY BOWL CLEANER) should be applied to the areas of the cylinder bore where
transfer of aluminum has occurred. After the acidic solution has removed the trans-
ferred aluminum, thoroughly flush the cylinder bore to remove any remaining acid.
Cylinder walls may now be honed to remove any glaze and to aid in the seating of new
piston rings.
HONING PROCEDURE
1. When cylinders are to be honed, follow the hone manufacturer’s recommendations
for use of the hone and cleaning and lubrication during honing.
2. For best results, a continuous flow of honing oil should be pumped into the work area.
If pumping oil is not practical, use an oil can. Apply oil generously and frequently on
both stones and work area.
CAUTION
When honing cylinder block, remove hone frequently and check condition of cyl-
inder walls. DO NOT hone any more than absolutely necessary, as hone can re-
move cylinder wall material rapidly.
3. Start stroking at smallest diameter. Maintain firm stone pressure against cylinder wall
to assure fast stock removal and accurate results.
4. Localize stroking in the smallest diameter until drill speed is constant throughout
length of bore. Expand stones, as necessary, to compensate for stock removal and
stone wear. Stroke at a rate of 30 complete cycles per minute to produce best
cross-hatch pattern. Use honing oil generously.
5. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff
bristle brush and rinse thoroughly with hot water. A good cleaning is essential. If any
of the abrasive material is allowed to remain in the cylinder bore, it will cause rapid
wear of new piston rings and cylinder bore in addition to bearings. After cleaning,
bores should be swabbed several times with engine oil and a clean cloth, then wiped
with a clean, dry cloth. Cylinders should not be cleaned with kerosene or gasoline.
Clean remainder of cylinder block to remove excess material spread during honing
operation.
NOTE: Hone all cylinder walls just enough to de-glaze walls.
Page 4A-58 90-889785 APRIL 2003

POWERHEAD
6. Measure cylinder bore diameter (with a snap gauge micrometer) of each cylinder, as
shown below. Check for tapered, out of round (egg-shaped) and oversize bore.
ob00782
Model Cylinder Block Finish Hone
75/90/115 92.1131 mm (3.6265 in.)
0.38 mm (0.015 in.) Oversize 92.4941 mm (3.6415 in.)
0.76 mm (0.030 in.) Oversize 92.8751 mm (3.6565 in.)
7. If a cylinder bore is tapered, out of round or worn more than .0.076 mm (0.003 in) from
standard Cylinder Block Finish Hone diameter (refer to chart, preceding), it will be
necessary to re-bore that cylinder to 0.381 mm (0.015 in.) oversize or 0.762 mm
(0.030 in.) oversize and install an oversize piston and piston rings during reassembly.
NOTE: The weight of an oversize piston is approximately the same as a standard size
piston; therefore, it is not necessary to re-bore all cylinders in a block just because one
cylinder requires re-boring.
8. After honing and thoroughly cleaning cylinder bores, apply light oil to cylinder walls
to prevent rusting.
Pistons and Piston Rings

IMPORTANT: If engine was submerged while engine was running, piston pin and/or
connecting rod may be bent. If piston pin is bent, piston must be replaced. (Piston
pins are not sold separately because of matched fit into piston.) If piston pin is
bent, connecting rod must be checked for straightness (refer to Connecting Rods,
following, for checking straightness).
1. Inspect pistons for scoring and excessive piston skirt wear.
2. Check tightness of piston ring locating pins. Locating pins must be tight.
3. Thoroughly clean pistons. Carefully remove carbon deposits from pistons, with a soft
wire brush or carbon remove solution. Do not burr or round off machined edges.
4. Inspect piston ring grooves for wear and carbon accumulation. If necessary, scrape
carbon from piston ring grooves being careful not to scratch sides of grooves. Re-
fer to procedure following for cleaning piston ring grooves.
90-889785 APRIL 2003 Page 4A-59

POWERHEAD
CLEANING PISTON RING GROOVES

Keystone (tapered) ring grooves
CAUTION
Care must be taken not to scratch the side surfaces of the ring groove. Scratching
the side surface of the ring groove will damage the ring groove.
1. Use a bristle brush and carbon remover solution to remove carbon from side surfaces.
2. A tool can be made for cleaning the inner diameter of the tapered ring grooves. The
tool can be made from a broken tapered piston ring with the side taper removed to
enable the inside edge of the ring to reach the inner diameter of the groove. Carefully
scrape carbon from inner diameter of ring grooves. Care must be taken not to damage
the grooves by scratching the side surfaces of the grooves.
Piston with two half keystone (half tapered) rings
Enlarged View of
a Piston Ring Grooves
a - Ring Grooves
MEASURING PISTON ROUNDNESS

Piston has a barrel profile shape and is not a true diameter.
1. Using a micrometer, measure dimension at location shown. Dimension (a) should be
91.9734 ± 0.0127 mm (3.6210 in. ± 0.0005 in.) for a STANDARD size piston.
a
25.4 mm
(1.0 in.)
ob00793
a - Dimension at right angle (90°) to piston pin
Piston Dimension (a)
Standard Piston 91.9734 mm ± .0127 mm
(3.6210 in. ± .0005 in.)
0.015 in. Oversize Piston 92.354 mm ± .0127 mm
(3.636 in. ± .0005 in.)
0.030 in. Oversize Piston 92.735 mm ± .0127 mm
(3.651 in. ± .0005 in.)
Page 4A-60 90-889785 APRIL 2003

POWERHEAD
Crankshaft
1. Inspect crankshaft to drive shaft splines for wear. Replace crankshaft if necessary.
2. Check crankshaft for straightness. Maximum runout is 0.0508 mm (0.002 in.). Re-
place as necessary.
3. Inspect crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted or
scratched. Replace as necessary.
4. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven
wear and/or overheating. Refer to Connecting Rods.
5. If necessary, clean crankshaft surfaces with crocus cloth.
c
c
ob00822
a - Crankshaft journals
b - Crocus cloth
c - Work cloth back and forth
WARNING
DO NOT spin-dry crankshaft ball bearing with compressed air.
6. Thoroughly clean (with solvent) and dry crankshaft and crankshaft ball bearing. Re-
check surfaces of crankshaft. Replace crankshaft, if surfaces cannot be properly
cleaned up. If crankshaft will be re-used, lubricate surfaces of crankshaft with light oil
to prevent rust. DO NOT lubricate crankshaft ball bearing at this time.
90-889785 APRIL 2003 Page 4A-61

POWERHEAD
Crankshaft (and End Cap) Bearings

IMPORTANT: When overhauling powerhead assembly, it is recommended that all
crankshaft bearings – upper/lower, center main, connecting rod and wrist pin bear-
ings – be replaced to ensure optimum powerhead performance and longevity.
1. After cleaning crankshaft, grasp outer race of crankshaft ball bearing (installed on low-
er end of crankshaft) and attempt to work race back and forth. There should not be
excessive play.
2. Lubricate ball bearing with light oil. Rotate outer bearing race. Bearing should have
smooth action and no rust stains. If ball bearing sounds or feels rough or has catches,
remove and discard bearing. (Refer to Powerhead Removal and Disassembly -
Crankshaft Removal and Disassembly.)
ob00823
a - Lower crankshaft ball bearing
3. Thoroughly clean (with solvent) and dry crankshaft center main roller bearings. Lubri-
cate bearings with 2-Cycle Outboard Oil.
CAUTION
DO NOT intermix halves of upper and lower crankshaft center main roller bear-
ings. Replace bearings in pairs only.
4. Thoroughly inspect center main roller bearings. Replace bearings if they are rusted,
fractured, worn, galled or badly discolored.
a ob00798
a - Center main roller bearing
5. Clean (with solvent) and dry crankshaft roller bearing that is installed in upper end cap.
Lubricate bearing with light oil.
6. Thoroughly inspect upper crank shaft roller bearing. If roller bearing is rusted, frac-
tured, worn, galled, badly discolored or loose inside of end cap replace end cap and
roller bearing as an assembly.
a - Upper roller bearing
Page 4A-62 90-889785 APRIL 2003

POWERHEAD
Reed Block Assembly

IMPORTANT: DO NOT remove reeds from reed blocks, unless replacement is nec-
essary. DO NOT turn used reeds over for re-use. Replace reeds in sets only.
1. Thoroughly clean gasket surfaces of reed blocks and reed block housing. Check for
deep grooves, cracks and distortion that could cause leakage. Replace parts as nec-
essary.
2. Inspect reed block neoprene surface for wear, cuts or abraisions. Replace reed block
as required.
3. Check for chipped and broken reeds.
ob56023
NOTE: Allowable reed opening is 0.51 mm (0.020 in.) or less. Replace reeds if any reed
is standing open more than 0.51 mm (0.020 in.).
End Bearing Bleed System
1. Check rubber bleed hoses. Replace any hose that is cracked, cut or deteriorating.
2. Check operation of lower end cap check valve. If valve is working properly, air can be
drawn through check valve one way only. If air can pass through a check valve both
ways, valve is not working properly and must be replaced.
Connecting Rods
1. Check connecting rods for alignment by placing rods on a surface plate. If light can
be seen under any portion of machined surfaces, if rod has a slight wobble on plate,
or if a 0.051 mm (0.002 in.) feeler gauge can be inserted between any machined sur-
face and surface plate, rod is bent and must be discarded.
2. Overheating: Overheating is visible as a bluish bearing surface color that is caused
by inadequate lubrication or excessive RPM.
3. Rust: Rust formation on bearing surfaces causes uneven pitting of surface.
a ob51853
a - Pitting
90-889785 APRIL 2003 Page 4A-63

POWERHEAD
4. Water Marks: When bearing surfaces are subjected to water contamination, a bear-
ing surface etching occurs. This etching resembles the size of the bearing.
ob51853
5. Spalling: Spalling is the loss of bearing surface, and it resembles flaking or chipping.
Spalling will be most evident on the thrust portion of the connecting rod in line with the
“I” beam. General bearing surface deterioration could be caused by or accelerated
by improper lubrication.
a
a ob51853
a - Spalling
6. Chatter Marks: Chatter marks are the result of a combination of low speed - low load
- cold water temperature operation, aggravated by inadequate lubrication and/or im-
proper fuel. Under these conditions, the crankshaft journal is hammered by the con-
necting rod. As ignition occurs in the cylinder, the piston pushes the connecting rod
with tremendous force, and this force is transferred to the connecting rod journal.
Since there is little or no load on the crankshaft, it bounces away from the connecting
rod. The crankshaft then remains immobile for a split second until the piston travel
causes the connecting rod to catch up to the waiting crankshaft journal, then hammers
it. The repetition of this action causes a rough bearing surface which resembles a tiny
washboard. In some instances, the connecting rod crank pin bore becomes highly pol-
ished. During operation, the engine will emit a whirr and/or chirp sound when it is ac-
celerated rapidly from idle speed to approximately 1500 RPM, then quickly returned
to idle. If the preceding conditions are found, replace both the crankshaft and connect-
ing rod.
a
a ob51853
a - Chatter marks between arrows
Page 4A-64 90-889785 APRIL 2003

POWERHEAD
7. Uneven Wear: Uneven wear could be caused by a bent connecting rod.
aa ob51853
a - Uneven wear between arrows
8. If necessary, clean connecting rod bearing surfaces, as follows:

a. Be sure that etched marks on connecting rod (crankshaft end) are perfectly
aligned with etched marks on connecting rod cap. Tighten connecting rod cap at-
taching bolts securely.
CAUTION
Crocus cloth MUST BE USED to clean bearing surface at crankshaft end of con-
necting rod. DO NOT use any other type of abrasive cloth.
b. Clean CRANKSHAFT END of connecting rod by using CROCUS CLOTH
placed in a slotted 9.5 mm (3/8 in.) diameter shaft, as shown. Chuck shaft in a drill
press and operation press at high speed while keeping connecting rod at a 90°
angle to slotted shaft.
IMPORTANT: Clean connecting rod just enough to clean up bearing surfaces. DO
NOT continue to clean after marks are removed from bearing surfaces.
ob51083
c. Clean PISTON PIN END of connecting rod, using same method as in Step b,
preceding, but using 320 grit carborundum cloth instead of crocus cloth.
d. Thoroughly wash connecting rods to remove abrasive grit. Recheck bearing sur-
faces of connecting rods. Replace any connecting rod that cannot be properly
cleaned up. Lubricate bearing surfaces of connecting rods (which will be re-used)
with light oil to prevent rust.
Thermostats 61°C (142°F)

1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks
and corrosion damage that could cause leakage. Replace parts as necessary.
2. Remove and discard gasket from thermostat.
3. Wash thermostat with clean water.
4. Using a thermostat tester, similar to the one shown, test thermostat as follows:
a. Open thermostat valve, then insert a thread between valve and thermostat body.
Allow valve to close against thread.
90-889785 APRIL 2003 Page 4A-65

POWERHEAD
b. Suspend thermostat (from thread) and thermometer inside tester so that neither
touches the container. Bottom of thermometer must be even with bottom of ther-
mostat to obtain correct temperature of thermostat opening.
c. Fill thermostat tester with water to cover thermostat.
d. Plug tester into electrical outlet.
e. Observe temperature at which thermostat begins to open. (Thermostat will drop
off thread, that was installed in Step a, when it starts to open.) Thermostat must
begin to open when temperature reaches 60°-62° C (140°-144° F).
f. Continue to heat water until thermostat is completely open.
g. Unplug thermostat tester.
h. Replace thermostat if it fails to open at the specified temperature, or if it does not
fully open.
NOTE: BE SURE that water in thermostat tester is allowed to cool sufficiently [below
43° C (110° F)] before testing another thermostat.
ob51087
Powerhead Reassembly and Installation

General
Before proceeding with powerhead reassembly, be sure that all parts to be re-used have
been carefully cleaned and thoroughly inspected, as outlined in Cleaning and Inspec-
tion, 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. All new powerhead gaskets MUST BE installed during reassembly.
During reassembly, lubricate parts with 2-Cycle Outboard Oil whenever light oil is speci-
fied. Quicksilver/Mercury part numbers of lubricants, sealers and locking compounds and
tools are listed in Section 1A.
A torque wrench is essential for correct reassembly of powerhead. DO NOT attempt to
reassemble powerhead without using a torque wrench. Attaching bolts for covers, hous-
ings and cylinder heads MUST BE torqued by tightening bolts in 3 progressive steps (fol-
lowing specified torque sequence) until specified torque is reached.
EXAMPLE: If cylinder head attaching bolts require a torque of 41 Nm (30 Ib. ft.), a) tighten
all bolts to 13.5 Nm (10 Ib. ft.), following specified torque sequence, b) tighten all bolts
to 27 Nm (20 Ib. ft.), following torque sequence, then finally c) tighten all bolts to 41 Nm
(30 Ib. ft.), following torque sequence.
Page 4A-66 90-889785 APRIL 2003

POWERHEAD
IMPORTANT: Always support crankshaft journal when pressing on new bearing.

1. If removed, press lower crankshaft ball bearing onto crankshaft as shown. Be sure
bearing is pressed firmly against shoulder.
2. Reinstall retaining ring using a suitable pair of snap ring pliers.
c
aa b
e
f
ob59622
ob00851
a - Crankshaft d - Press
b - Crankshaft ball bearing e - Crankshaft journal
c - Suitable mandrel f - Retaining ring
3. If removed, spread new crankshaft sealing rings just enough to slide over crankshaft
journal.
ob59617
a - Crankshaft sealing ring
4. Lubricate center main crankshaft roller bearings and races with light oil.
14
a b
ob52318
a - Install so hole is toward DRIVE SHAFT end of crankshaft

b - Verify retaining ring bridges the separating lines of the bearing race

Description
Ref. # ber Number
14 92-802813A1 92-802813Q1
board Oil
90-889785 APRIL 2003 Page 4A-67

POWERHEAD
5. Place center main crankshaft roller bearings on upper and lower main bearing jour-
nals as shown.
6. Install center main bearing races as shown.
7. Secure center main bearing races together with retaining rings. Make sure retaining
ring bridges the separating lines of the bearing race.
ob00828
ob00826
b
a - Flywheel end c - Center main bearing races
b - Drive shaft end
Page 4A-68 90-889785 APRIL 2003

POWERHEAD
8. Install oil seal into lower end cap as follows:

a. Press oil seal (lip facing up) into lower end cap until firmly seated as shown.
b. Lubricate oil seal lips with 2-4-C with Teflon.
c. Lubricate O-ring seal surface on end cap with 2 cycle oil. Install O-ring over lower
end cap.
a 95
ob00790
14 b
a - Oil seal b - O-ring

Description
Ref. # ber Number
14 92-802813A1 92-802813Q1
board Oil
95 2-4-C with Teflon 92-802859A1 92-802859Q1
90-889785 APRIL 2003 Page 4A-69

POWERHEAD
9. Install upper bearing and oil seal onto crankshaft. Seal lip faces toward bearing
(down).
10. Lubricate oil seal lip with 2-4-C with Teflon.
11. Lubricate bearing with outboard oil.
14
95
a
ob00799
a - Oil seal
b - Bearing carrier

Description
Ref. # ber Number
14 92-802813A1 92-802813Q1
board Oil
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 4A-70 90-889785 APRIL 2003

POWERHEAD
Piston and Connecting Rod Reassembly

IMPORTANT: If reusing piston, rod and bearing assemblies, always reassemble the
correct rod and bearings with original piston they were assembled with. Moving
components establish a wear pattern and for lasting repair, this wear pattern loca-
tion should be maintained.
1. Place needle bearings on a clean piece of paper and lubricate with 2-4-C with Teflon.
NOTE: There are 34 needle bearings per piston.
2. Place sleeve into connecting rod and install needle bearings around sleeve as shown.
3. Place locating washers on connecting rod.
4. Carefully position piston over end of rod. Make sure locating washers remain in place.
a
b
a
ob55960
a - Sleeve (part of tool assembly 91-92973A1)
b - Locating washers
5. Insert Piston Pin Tool and push sleeve out of piston. Keep piston pin tool in piston.
6. Use a mallet and tap piston pin into piston and push piston pin tool out.
b c
ob55961 ob55962
a - Piston Pin Tool c - Piston pin
(91-74607A1) d - Piston pin tool
b - Sleeve
90-889785 APRIL 2003 Page 4A-71

POWERHEAD
7. Install new piston pin lockrings (one each end of piston pin) with Lockring Installation
Tool.
8. Make sure lockrings are properly seated in lockring grooves.
a
aa
ob51086 ob55963
a - Lockring Installation Tool (91-93004A2)

b - Lockring
Piston and Piston Ring

Pistons have two half keystone (half tapered) rings.
0.078 in. (1.98 mm)
aa bb
0.078 in. (1.98 mm)
ob00793
a - Half keystone (half tapered) piston ring

b - Enlarged view of piston ring grooves
Page 4A-72 90-889785 APRIL 2003

POWERHEAD
1. Before installing new piston rings, check gap between ring ends by placing each ring
in its respective cylinder, then pushing ring about 12.7 mm (1/2 in.) into cylinder using
piston to assure proper position.
2. Check end gap of each new piston ring with a feeler gauge. End gap must be within
0.25 mm to 0.46 mm (0.010 in. to 0.018 in.). If end gap is greater, check other piston
rings in cylinder bore, until rings (within tolerance) are found.
IMPORTANT: Piston ring side with letter must be facing up.
c
b
ob00830
a - Piston ring
b - Feeler gauge
c - Ring end gap
IMPORTANT: The top side of the ring is marked 1T The “T” represents the top side
of of the ring.
ob58126
ob59615
a - 1T top side of ring
90-889785 APRIL 2003 Page 4A-73

POWERHEAD
3. Use Piston Ring Expander and install piston rings (1T up) on each piston. Spread
rings just enough to slip over piston.
4. Check piston rings to be sure that they fit freely in ring groove.
5. Lubricate piston, rings and cylinder wall with 2-Cycle Outboard Oil.
ob52319
a - Piston Ring Expander (91-24697)
b - Letter side UP on piston ring
6. Rotate each piston ring so end of ring is aligned with locating pin as shown.
ob00795
a - Locating pin
Page 4A-74 90-889785 APRIL 2003

POWERHEAD
Piston Reassembly to Crankshaft

IMPORTANT: If reusing piston assemblies, always reassemble the correct piston
assembly to its original location on the crankshaft. Moving components establish
a wear pattern and for lasting repair, this wear pattern location should be main-
tained.
NOTE: Pistons are marked for correct orientation during reassembly. On the piston face,
the letters UP must face towards the flywheel end of the crankshaft. When installing the
piston assembly to the crankshaft, a raised vertical line is located inside the piston on the
connecting rod boss. This line must face up. This is a verification for the mechanic that
the piston assembly is being installed/oriented to the crankshaft correctly.
ob00794
a - Raised line – faces up toward flywheel end of crankshaft
1. Apply a light coat of 2-4-C with Teflon to the connecting rod journal of the crankshaft.
2. Apply a light coat of 2-4-C with Teflon to the connecting rod bearing cages.
3. Install connecting rod bearings into their respective cages.
4. Place cage with bearings onto their respective crankshaft journal.
5. Install the piston and rod assembly to their respective crankshaft journal.
NOTE: Always reassemble connecting rod assemblies with new connecting rod screws.
6. Place connecting rod cap on connecting rod. Apply light oil to threads and face of con-
necting rod screws. Thread connecting rod screws finger tight while checking for cor-
rect alignment of the rod cap as shown.
90-889785 APRIL 2003 Page 4A-75

POWERHEAD
IMPORTANT: Connecting rod and connecting rod caps are matched halves. Do not
torque screws before completing the following procedure.
• Run a pencil lightly over ground area.
• If pencil stops at fracture point, loosen screws, retighten, and check again.
NOTE: If you still feel the fracture point, discard the rod.
CONNECTING ROD CAP ALIGNMENT
Check each connecting rod cap for correct alignment. If not aligned, a ridge can be seen
or felt at the separating line as shown below. Correct any misalignment.
a c
b d
ob52381
a - Side view incorrect – cap on backwards
b - End view incorrect – cap on backwards
c - Side view correct
d - End view correct
Page 4A-76 90-889785 APRIL 2003

POWERHEAD
7. Tighten connecting rod screws (using a 3/18 in. - 12 point socket). First torque to 1.7
Nm (15 lb. in.) then 41 Nm (30 lb. ft.). Turn each screw an additional 90° after 2nd
torque is attained. Recheck alignment between rod cap and rod as shown.
a b 4
14 ob00797
a - Connecting rod screws

b - Bearing cage assembly
c - Raised line – faces up towards flywheel end of crankshaft

Description
Ref. # ber Number
Needle Bearing
4 92-802868A1 N/A
Assembly Lubricant
14 92-802813A1 92-802813Q1
board Oil
TORQUE
REF.
REF
Apply light oil to
threads and bolt
face: 1st torque - 15
lb-in (1.7 Nm.)
2nd torque - 30 lb-ft
a 6 SCREW
(40.6 Nm.)
Turn bolt an addi-
tional 90 degrees af-
ter 2nd torque is at-
tained.
90-889785 APRIL 2003 Page 4A-77

POWERHEAD
IMPORTANT: Piston must be correctly installed and positioned as shown.

8. Verify word UP on each piston faces toward flywheel end of crankshaft.
ob00829
a - UP on each piston faces toward flywheel end of crankshaft.
Page 4A-78 90-889785 APRIL 2003

POWERHEAD
Crankshaft Assembly Installation into Cylinder Block

NOTE: Cylinder block piston bores are tapered to aid in the installation of the crankshaft/
piston rod assembly without the use of piston ring compressors. Two cycle oil should be
applied to the cylinder bores and piston ring assemblies to ease installation. Verify locat-
ing pins for each piston ring is centered before attempting to install crankshaft assembly
into cylinder block.
1. Carefully ease crankshaft assembly into cylinder block. It may be necessary to use
a flat sided tool such as small screw driver to compress individual piston rings when
initially starting piston assemblies into cylinder block.
IMPORTANT: Do not force crankshaft assembly into cylinder block. If assembly is
not sliding into cylinder block, remove crankshaft assembly and verify piston lo-
cating pins are centered with piston ring gaps.
2. After crankshaft assembly is in cylinder block, verify locating pins in cylinder block
align with locating holes in center main bearings. Do not hammer on crankshaft to
align center main bearings with locating pins as cylinder block webbing where locating
pin is installed may crack or bearing race may crack.
b
a a
14
ob00825
a - Center main bearing locating pins (hidden)

b - Piston ring locating pins

Description
Ref. # ber Number
14 92-802813A1 92-802813Q1
board Oil
90-889785 APRIL 2003 Page 4A-79

POWERHEAD
3. After crankshaft assembly is seated properly in cylinder block, use an awl or scribe
to push on connecting rod bearing races. Races should rotate smoothly. If races do
not rotate, connecting rod cap is not properly aligned. Cap must be loosened and re-
torqued. If proper alignment cannot be achieved, Remove crankshaft assembly and
discard connecting rod.
ob00821
a - Awl or scribe
4. Lubricate lower crankshaft end (oil seal area) with light oil, then install lower end cap.
Secure end cap to cylinder block with attaching bolts. DO NOT tighten end cap screws
at this time.
a
ob00833
a - Lower end cap
Page 4A-80 90-889785 APRIL 2003

POWERHEAD
Crankcase Cover Installation

1. Thoroughly remove all oil from mating surfaces of crankcase cover and cylinder block
with Loctite Primer 203 included in Master Gasket Kit.
2. Apply a thin, even coat of Loctite Master Gasket on mating surfaces of crankcase cov-
er.
b b
a
c ob00781
a - Crankcase cover c - Loctite Master Gasket

b - Remove all oil
3. Install new cylinder block seal. Do not reuse old seal.
a
ob00824
a - Crankcase seal
90-889785 APRIL 2003 Page 4A-81

POWERHEAD
4. Place crankcase cover in position on cylinder block. Turn the 8 center main bolts in
a LITTLE at a time, (following torque sequence) compressing crankshaft seal rings
until crankshaft cover has been drawn down to cylinder block. Tighten eight bolts
evenly in three progressive steps (following torque sequence).
5. Install remaining crankcase cover flange bolts.
a
2 1
"!
$#
"* ")
4 3
"( "'
"& "%
6 5
"$ ""
"# !
b 8 7
ob00785
TORQUE
REF.
REF
a 8 SCREW (M10 x 80) 28 37.9
b 12 SCREW (M8 x 35) 18 24.4
Page 4A-82 90-889785 APRIL 2003

POWERHEAD
6. Tighten end cap screws to specified torque.
ob00789
TORQUE
REF.
REF
a 3 SCREW (M10 x 25) 18 24.4
90-889785 APRIL 2003 Page 4A-83

POWERHEAD
Assembly of Reed Blocks/ Adaptor Plate and Air Plenum

NOTE: Air plenum gasket is beaded on 1 side. Bead side of the gasket faces the air
plenum.
g
a
a - Screws (9 each) (M8 x 45)

b - Cover
c - Adaptor plate
d - Screws (6 each) (M6 x 20)
e - Crankcase cover
f - Reed block (3 each)
g - Screws (15 each) (M8 x 35)
Page 4A-84 90-889785 APRIL 2003

POWERHEAD
1. Install reed blocks to reed block adaptor plate
a a
a a
a a
0b00776
TORQUE
REF.
REF
a 6 SCREW (M6 x 20) 90 10.2
90-889785 APRIL 2003 Page 4A-85

POWERHEAD
2. Install reed block adaptor plate to crankcase cover following torque sequence.
"#
* !
) (
a
'
% &
$ "
""
"$ "%
"' "&
ob00792
TORQUE
REF.
REF
a 15 SCREW (M8 x 35) 18 24.4
Page 4A-86 90-889785 APRIL 2003

POWERHEAD
3. Install air plenum torquing screws in following sequence.
8 7
a 3
4
2
5 6
ob00820
TORQUE
REF.
REF
a 9 SCREW (M8 x 45) 18 24.4
90-889785 APRIL 2003 Page 4A-87

POWERHEAD
Thermostat/Poppet Valve Installation

1. If removed, install water pressure relief valve components as shown. Torque bolts to
specifications.
11
TORQUE
REF.
REF
1 1 POPPET
2 1 DIAPHRAGM
3 1 WASHER
5 1 SPRING
7 4 SCREW (M8 x 35) 18 24.4
8 1 GASKET
9 11 GASKET
10 1 THERMOSTAT 61.7° C (143° F)
11 1 J–CLAMP
12 1 SCREW (M6 x 12) 90 10.2
14 1 O–RING
Page 4A-88 90-889785 APRIL 2003

POWERHEAD
2. Install block temperature sensor and water pressure sensor into cylinder block.
ob00713
a - Block temperature sensor

b - Water pressure sensor
c - Fitting
TORQUE
REF.
REF
a 1 TEMPERATURE SENSOR 144 12 16.3
c 1 FITTING 13 1.4
90-889785 APRIL 2003 Page 4A-89

POWERHEAD
Reinstalling Engine Components

NOTE: Components can be reinstalled individually or as an assembly. If reinstalling
components individually, refer to the following sections. If reinstalling components as an
assembly, refer to Removing Engine Components as an Assembly, and reinstall in
reverse sequence.
Section 2
Starter Motor
Electronic Control Module
Ignition Coil
Starter Solenoid
Alternator
Flywheel
Section 3
Fuel Pump
On-Board Oil Tank
Oil Pump
Section 4
Throttle/Shift Control Platform
Throttle/Shift Cable Installation and Adjustment
Page 4A-90 90-889785 APRIL 2003

POWERHEAD
Throttle Lever and Linkage
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
! 1 THROTTLE LEVER
2 1 BUMPER 20 27
3 1 BUSHING
4 1 INSERT
Tighten securely but
5 1 SCREW (M10 x 45) arm must be free to
pivot
6 1 BRACKET LEVER ARM ASSEMBLY
7 1 SCREW (M6 x 35)
8 1 NUT
9 1 NYLON CAP
10 1 SCREW (M6 x 16) 90 10.2
11 1 WASHER
12 1 NUT
90-889785 APRIL 2003 Page 4A-91

POWERHEAD
Powerhead Installation on Drive Shaft Housing

1. Install Lifting Eye (91-90455T1) into flywheel.
WARNING
BE SURE that Lifting Eye is threaded into flywheel as far as possible BEFORE lift-
ing powerhead.
2. Using a hoist, lift powerhead high enough to allow removal of powerhead from repair
stand. Remove powerhead from repair stand, being careful not to damage drive shaft
housing gasket surface of powerhead.
3. Place a new gasket around powerhead studs and into position on base of powerhead.
IMPORTANT: DO NOT apply lubricant to top of drive shaft as this will prevent drive
shaft from fully engaging into crankshaft.
4. Apply a small amount of 2-4-C with Teflon onto drive shaft splines.
5. Use hoist to lower powerhead onto driveshaft housing. It may be necessary to turn
flywheel (aligning crankshaft splines with drive shaft splines) so that powerhead will
be fully installed.
ob00413
a - Lifting Eye (91-90455)
Page 4A-92 90-889785 APRIL 2003

POWERHEAD
6. Install 6 flat washers 8 locknuts and 2 support plates which secure powerhead to ex-
haust extension plate/drive shaft housing. Torque locknuts in following sequence to
specification.
a a
ob00832
a - Nuts and washers c - Support plate
b - Nuts and support plates d - Protrusion faces down
& '
% #
( !
" $
ob00886
TORQUE
REF.
REF
Torque to 27 Nm (20
a/b 8 NUT (M10) lb. ft. ) and rotate 90
degrees
7. Disconnect hoist from Lifting Eye and remove Lifting Eye from flywheel.
8. Reinstall plastic cap into center of flywheel cover.
90-889785 APRIL 2003 Page 4A-93

POWERHEAD
9. Reconnect SmartCraft harness connector.

10. Secure shift lever with attaching nut. Drive nut tight.
ob00525
a - SmartCraft harness connector

b - Attaching nut
11. Reconnect BLUE and GREEN trim harness leads.
12. Reconnect RED and BLACK neutral switch harness leads.
a
ob00398
a - BLUE and GREEN trim harness leads

b - RED and BLACK neutral switch harness leads
Page 4A-94 90-889785 APRIL 2003

POWERHEAD
13. Check for proper placement of idle relief boot between cowl halves. Verify engine wir-
ing, water hoses and trim wires are not pinched during bottom cowl installation.
14. Secure cowl halves together with screws and nuts.
15. Reinstall screw holding front cowl halves together.
a - Screws (4) M6 x 40
b - Screw (1) M6 x 16
c - Nuts (2) M8
d - Boot – idle relief
TORQUE
REF.
REF
a 4 SCREW (M6 x 40) 65 7.3
b 2 SCREW (M6 x 16) 65 7.3
c 2 NUT (M8) 15 20.3
90-889785 APRIL 2003 Page 4A-95

POWERHEAD
16. Position oil tank assembly onto engine aligning throttle body seal with air intake
flange.
17. Fasten the oil hose with cable ties.
18. Connect low oil sensor harness.
19. Secure oil tank assembly with 2 screws. Torque screws to specifications.
20. Refill the oil system. Refer to Priming the Oil Pump, Section 3C.
e
a d
ob00412 ob00409
ob59627
a - Oil tank d - Screws

b - Oil hose e - Air compressor air intake
c - Sensor harness hose
TORQUE
REF.
REF
d 2 SCREW (M8 x 35) 18 24.4
Page 4A-96 90-889785 APRIL 2003

POWERHEAD
Shift Cable Installation

NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move
when the remote control handle is moved out of neutral.
N
2. Shift outboard into neutral.

3. Measure the distance between pin and center of barrel pocket.
ob00528
F N R
a - Distance between pin and center of barrel pocket
b - Pin
c - Barrel pocket
90-889785 APRIL 2003 Page 4A-97

POWERHEAD
4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain
distance taken in Step 3.
b
a
ob00528
a - Shift cable end

b - Cable barrel
5. Place cable barrel into pocket. Fasten cable with locknut and flat washer.
c
b
a
ob00528
a - Place barrel into barrel pocket

b - Locknut – tighten locknut then back off locknut 1/4 turn.
c - Flat washer
6. Check shift cable adjustments as follows:
a. Shift remote control into forward. The propeller shaft should be locked in gear. If
not, adjust the barrel closer to the cable end.
b. Shift remote control into neutral. The propeller shaft should turn freely without
drag. If not, adjust the barrel away from the cable end. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propeller shaft should
be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps
a through c.
d. Shift remote control back to neutral. The propeller shaft should turn freely without
drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d.
Page 4A-98 90-889785 APRIL 2003

POWERHEAD
Throttle Cable Installation

N
2. Install throttle cable to the throttle arm with washer and locknut.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm
against the idle stop.
4. Place cable barrel into retainer.
5. Lock the retainer and cables in place with the cable latch.
a b
d
ob00529
e
a - Flat washer c - Barrel retainer

b - Locknut – tighten then d - Cable barrel
back off 1/4 turn e - Cable latch
90-889785 APRIL 2003 Page 4A-99

POWERHEAD
6. Route the fuel hose, wiring, and cables through the front cover opening.
7. Place the neoprene wrap around the wiring, hoses, and control cables as shown. Re-
install the cover and cowl seal.
a
ob59598
a - Neoprene wrap
b - Screws (2)
8. Connect wiring. Push the retainer over the ends of the connectors. This will hold the
connectors together. Place the harness connection and retainer into the cable holder
located in the bottom cowl has shown.
d
e
ob00654
BLU = BLUE BLU/WHT BLU/WHT

BRN = BROWN GRN/WHT GRN/WHT a
GRN = GREEN TAN TAN b
WHT = WHITE
BRN/WHT BRN/WHT c
a - Power trim connections

b - Wire connection for analog water temp gauge – not supported by this engine
c - Connection for non-SmartCraft analog trim gauge
d - Retainer - push over connector ends
e - Cable holder
Page 4A-100 90-889785 APRIL 2003

POWERHEAD
9. Reinstall cable cover and cowl seal. Torque screws to specification.
b b
ob00388
a - Cover b - Screws
TORQUE
REF.
REF
b 2 SCREW (M6 x 16) 65 7.3
90-889785 APRIL 2003 Page 4A-101

POWERHEAD
Break-ln Procedure
CAUTION
Severe damage to the engine can result by not complying with the Engine
Break-in Procedure.
FUEL REQUIREMENTS
Do not use pre-mixed gas and oil in this engine. Use straight gasoline during engine
break-in and after engine break-in. The ECM is programmed to signal the oil pump to
provide additional oil (50:1 ratio) during the first 120 minutes of operation. The ECM will
monitor this period through its own internal clock. At the end of this period, the ECM will
signal the oil pump to go to a standard ratio of 300 – 400:1 @ idle and 60:1 @ W.O.T.
INITIATING ENGINE BREAK-IN SEQUENCE (PRIMING OIL PUMP)

Refer to Section 3C for proper procedures.
Engine Break-in Procedure (All Models)

FIRST HOUR
• Allow engine to warm up for 30 – 60 seconds.
• Avoid continuous operation at idle speed for more than 10 minutes.
• Run engine for the majority of time between 3000 and 4500 RPM; approximately 3/4
throttle.
• Vary engine speed; change engine speed approximately every 2 minutes.
• Avoid trimming outboard out (up) beyond a vertical trim position during operation.
• Short bursts of full throttle for periods up to 10 seconds are acceptable.
NEXT 3 HOURS
• Change engine speed every 10 minutes.
Page 4A-102 90-889785 APRIL 2003

COOLING
POWERHEAD
Section 4B - Cooling
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Water Pressure Check . . . . . . . . . . . . . . . . . . . . . . . 4B-10
Temperature Sensor Location . . . . . . . . . . . . . . . . . . 4B-3 Cooling Water Strainer . . . . . . . . . . . . . . . . . . . . . . . 4B-10
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Water Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 4B-11
1.5 Liter Optimax Water Flow . . . . . . . . . . . . . . . . . . 4B-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B-5
4B-6
Water Pump Cleaning and Inspection . . . . . . . . . . 4B-12
Problem Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-13
4
B
Specifications
Water Pressure
Idle 20.6 - 41.3 kPa
(3 - 6 psi)
Poppet Valve Opening 48.3 - 62.1 kPa
(7 - 9 psi)
W.O.T. 75.8 - 96.5 kPa
(11 - 14 psi)
Thermostat . . . . . . . . . . . 61°C (142°F)
Temperature Sensor
Temperature Sensor(s)
Between BLACK and each TAN/BLACK wire. No
Continuity
Between each lead and ground No
Continuity
Temperature Sensor Specifications
Cylinder Head
Horn Activation Horn activation and speed reduction is variable
Speed Reduction – refer to Guardian Sys- depending on engine RPM and load
tem in Section 2A
Air Compressor
Horn Activation 90°C (194°F)
90-889785 APRIL 2003 Page 4B-1

COOLING
Special Tools
Water Pressure Gauge 91-79250A2
Page 4B-2 90-889785 APRIL 2003

COOLING
Temperature Sensor Location
ob59591
ob00523
a - Cylinder block temperature sensor

b - Air compressor temperature sensor
90-889785 APRIL 2003 Page 4B-3

COOLING
Temperature Sensor
Two temperature sensors are used to provide temperature information to the PCM. A sen-
sor is mounted above cylinder #1. One sensor is also mounted in the air compressor cylin-
der head. The PCM uses this information to increase injector pulse width for cold starts
and to retard timing in the event of an over heat condition.
Disconnect temperature sensor harness and check continuity with digital or analog ohm-
meter test leads between both connector pins. With engine at temperature (F!) indicated,
ohm readings should be as indicated ±10%. There should be no continuity between each
connector pin and ground.
NOTE: The Digital Diagnostic Terminal (DDT) can be used to monitor temperature read-
ings from both temperature sensors.
Model 75/90/115
F C !
257 125 340
248 120 390
239 115 450
230 110 517
221 105 592
212 100 680
203 95 787
194 90 915
185 85 1070
176 80 1255
167 75 1480
158 70 1752
149 65 2083
140 60 2488
131 55 2986
122 50 3603
113 45 4370
104 40 5327
95 35 6530
86 30 8056
77 25 10000
68 20 12493
59 15 15714
50 10 19903
41 5 25396
32 0 32654
14 –10 55319
5 –15 72940
Page 4B-4 90-889785 APRIL 2003

COOLING
1.5 Liter Optimax Water Flow

Description
Cooling water enters the cooling system through the lower unit water inlets. The pump
assembly forces water through the water tube and exhaust adapter plate passages filling
the chamber next to the exhaust passage. Water exits this chamber in three locations.
• Water exits through the strainer screen which leads to the air compressor, fuel rail
and tell-tale.
• Some water exits at the top of this chamber through a passage way leading to an
area around the cylinders.
• The main flow of water exits at the bottom of the chamber into passageways
around the cylinders.
Water then flows past the cylinders to the top of the block. Water deflectors direct water
up the port side of the of the cylinders and down the starboard side. The water then enters
the cylinder dome area flowing the bottom to the top of the cylinder block. Water exiting
the block is controlled by the poppet valve and thermostat.
Thermostat – controls water flow at lower engine RPM. When the correct temperature is
reached, the thermostat opens.
Poppet valve – water pressure will build up in the system as engine RPM increases. When
the pressure reaches the correct level, the poppet valve is forced open.
Water exits the block through a passage way at the port rear corner of the cylinder block.
The water then passes through the adapter plate into the drive shaft housing forming a
wall of water between the exhaust tube and the inside of the drive shaft housing. Water
exits the drive shaft housing around the anode on the lower unit.
90-889785 APRIL 2003 Page 4B-5

1.5 Liter OptiMax Water Flow Diagram 1 -
Water outlet
2 -
Water inlet
3 -
Water pump
4 -
Wall of water – If water level height is insufficient, water pump may draw in air
resulting in an overheated engine
5 - Water tube
6 - Water dump down exhaust pipe
7 - Exhaust adaptor plate
8 - Cylinder block – halves separated for illustration
9 - Cylinder block combustion chamber – halves separated for illustration
10- Thermostat 61° C (142° F) – If stuck closed, engine will overheat at idle
11- Poppet valve – controls water flow at high rpm.
Note: If poppet valve is stuck open at low rpm, the engine will not reach proper
operating temperature (run cold) and will run rough at idle.
12- Exhaust cover – separated for illustration
13- Strainer screen for air compressor and fuel rail water supply – if restricted,
compressor will overheat and tell-tale will be weak
14- Air compressor – water outlet from air compressor connects to fuel rail coolant inlet
15- Fuel rail – fuel cooler is built into fuel rail
16- Tell-tale outlet on bottom cowl
17- Powerhead flush
18- Thermostat water dump
19- Poppet valve opening
20- Rubber water defectors (3) – if missing, may result in uneven cooling of cylinders and
scuffed pistons
ob00839
COOLING
Troubleshooting
Thermostat Test 61°C (142°F)
1. Inspect thermostat covers and cylinder head covers (thermostat opening) for cracks and
corrosion damage that could cause leakage. Replace parts as necessary.
2. Remove and discard gasket from each thermostat.
3. Wash thermostats with clean water.
4. Using a thermostat tester, similar to the one shown, test each thermostat as follows:
a. Open thermostat valve, then insert a thread between valve and thermostat body. Al-
low valve to close against thread.
b. Suspend thermostat (from thread) and thermometer inside tester so that neither
touches the container. Bottom of thermometer must be even with bottom of thermo-
stat to obtain correct temperature of thermostat opening.
c. Fill thermostat tester with water to cover thermostat.
d. Plug tester into electrical outlet.
e. Observe temperature at which thermostat begins to open. (Thermostat will drop off
thread, that was installed in Step “a”, when it starts to open.) Thermostat must begin
to open when temperature reaches 60°-62° C (140°-144° F).
f. Continue to heat water until thermostat is completely open.
g. Unplug thermostat tester.
h. Replace thermostat if it fails to open at the specified temperature, or if it does not fully
open.
NOTE: BE SURE that water in thermostat tester is allowed to cool sufficiently [below 43.3°
C (110°F)] before testing another thermostat.
ob51087
IMPORTANT: DO NOT operate engine without thermostats installed.
90-889785 APRIL 2003 Page 4B-9

COOLING
Water Pressure Check

Water pressure may be checked by one of three methods;
• Use a Digital Diagnostic Terminal (DDT) 91-823686A2
• On engines equipped with SmartCraft gauges, water pressure is an available readout.
• Temporarily connect a dash style analog water pressure gauge into the water pressure sen-
sor GRAY tube. A tee fitting (875207) and short piece of GRAY tubing (859785-68) would be
required to make this connection.
WARNING
Shut off engine and refer to troubleshooting chart if water pressure is not within
specification. DO NOT exceed 3000 RPM in neutral.
Idle 20.6 - 41.3 kPa

(3 - 6 psi)
Poppet Valve Opening 48.3 - 62.1 kPa
(7 - 9 psi)
W.O.T. 75.8 - 96.5 kPa
(11 - 14 psi)
Cooling Water Strainer

The cooling water strainer filters cooling water flowing to the air compressor.
1. Disconnect water hose from the strainer plug.
2. Remove and clean strainer.
3. Apply Loctite Pipe Sealant with Teflon to strainer threads and reinstall strainer. Recon-
nect water hose and secure with cable tie.
ob00526
a - Water strainer
Page 4B-10 90-889785 APRIL 2003

COOLING
Water Pressure Sensor
ob59612
a - Water pressure sensor
The water pressure sensor is monitored by the PCM at 1200 RPM and above. Should the
low water pressure continue for more than 5 seconds, a speed reduction circuit* within the
PCM will be activated.
*The Guardian System will limit rpm if temperatures are high regardless of system pressure.
Water pressure low for more than 2 seconds Warning horn activated
Water pressure low for more than 5 seconds Warning horn activated
Maximum engine rpm limited
90-889785 APRIL 2003 Page 4B-11

COOLING
Water Pump Cleaning and Inspection

1. Inspect the water tube coupling for wear or damage. If necessary replace the worn or
damaged components especially the two O-rings on the inside, one at the top and one
at the bottom.
b
b ob70613
a - Water tube coupling
b - O-rings
2. Inspect the water pump impeller for wear on the end, top and bottom of the impeller
blades. Replace the impeller if this condition is found.
3. Inspect for proper bonding between the hub and the impeller. Replace the impeller if im-
proper bonding is found.
b
a
ob70500
a - Hub
b - Impeller
4. Inspect the impeller blades to see if they are cracked, burnt, hard or deformed. Replace
the impeller if the blades are in this condition.
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate. The depth of the groove will not affect wa-
ter pump output.
5. Replace cover and/or face plate if grooves (other than impeller sealing bead groove) are
more than 0.030 in. (0.76 mm) deep.
a
b
ob70609
a - Water pump face plate
b - Water pump cover
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
IMPORTANT: It is recommended that the water pump impeller be replaced whenever
the gearcase is removed for maintenance. However, if it is necessary to re-use the
impeller, DO NOT install in reverse to original rotation as premature impeller failure
will occur.
Page 4B-12 90-889785 APRIL 2003
COOLING
Problem Diagnosis
NOTE: The Guardian System will limit power if temperatures are high regardless of system
pressures.
Condition Recommended Range Possible Cause

Pressure below specification @ idle 20.6 - 41.3 kPa (3 - 6 psi) •Poppet valve spring defective
(weak, broken, missing)
•Defective poppet valve seal
•Severe internal leak
•Thermostat stuck open
•Low output water pump
•Inlet restriction
Compressor overheats and weak or •Strainer screen for air compressor
no tell-tale water supply is restricted
Pressure above 44.8 kPa (6-1/2 psi) 20.6 - 41.3 kPa (3 - 6 psi) •Plugged tell-tale
@ idle •Strainer screen for air compressor
water supply is plugged
Pressure does not drop between 48.3 - 62.1 kPa (7 - 9 psi) between •Wrong poppet valve spring
1200 - 2100 RPM indicating poppet 1200 - 2100 RPM •Low output water pump
valve has opened •Inlet restriction
•Poppet valve vent hole plugged or
restricted
Poppet valve flutter/water pressure 48.3 - 62.1 kPa (7 - 9 psi) between •Poppet valve spring defective
drop does not start prior to 1500 1200 - 2100 RPM (weak, broken, strong, missing)
RPM •Broken diaphragm in poppet valve
•Defective poppet valve seal
Poppet valve flutter/water pressure 48.3 - 62.1 kPa (7 - 9 psi) between •Wrong poppet valve spring
drop does not stop prior to 1800 1200 - 2100 RPM •Low output water pump
RPM •Inlet restriction
•Broken diaphragm in poppet valve
•Defective valve seal
Pressure exceeds specification @ 75.8 - 96.5 kPa (11 - 14 psi) •Restriction on discharge side of
W.O.T. Note: A modified propeller or low cooling system
pitch propeller is required to check •Engine mounted high or trimmed
water pressure @ W.O.T. if boat is too far out resulting in formation of
stationary. Boat must be in the water steam pockets in cooling system
and secured to a dock or trailer and •If boat is being run on open water,
run in forward gear. DO NOT perform ram effect of water on coolant inlets
check using a flush device. @ high speeds may increase water
pressure above specifications
Pressure is below specification @ 75.8 - 96.5 kPa (11 - 14 psi) •Inlet restriction
W.O.T. •Engine mounted too high on tran-
som
•Engine trimmed out too far
•Configuration of boat bottom inter-
fering with adequate flow of water to
coolant inlets
Pressure higher than normal @ Maximum pressure – 158.6 kPa (23 •Outlet water passages restricted.
W.O.T., but engine still indicates psi) •Steam pocket has formed at top of
overheat condition powerhead due to lack of cooling wa-
ter
90-889785 APRIL 2003 Page 4B-13

CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING
MID-SECTION
Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Bottom Cowl Removal . . . . . . . . . . . . . . . . . . . 5A-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Bottom Cowl Installation . . . . . . . . . . . . . . . . . . 5A-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Drive Shaft Housing and
Swivel Bracket and Steering Arm . . . . . . . . . . 5A-2 Dyna-Float Suspension . . . . . . . . . . . . . . . . . . 5A-14
Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Removal and Disassembly . . . . . . . . . . . . . . . 5A-14
Exhaust Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Shift Linkage Assembly . . . . . . . . . . . . . . . . . 5A-15
Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . 5A-8 Reassembly and Installation . . . . . . . . . . . . . 5A-20
Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10
Specifications
5
Recommended Transom Height:
Short Shaft 51 cm (20 in.)
A
Long Shaft 64 cm (25 in.)
MID-SECTION
Steering Pivot Range 60°
Full Tilt Up Angle 71°
Allowable Transom Thickness (Max) 76.2 mm (3 in.)
Special Tools
Drive Shaft Bushing Installer Tool 91-875215
90-889785 APRIL 2003 Page 5A-1

Swivel Bracket and Steering Arm
B A

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 5A-2 90-889785 APRIL 2003

Swivel Bracket and Steering Arm (continued)

TORQUE
REF.
REF
1 1 SWIVEL BRACKET
2 1 OIL SEAL (LOWER)
3 2 BUSHING
4 1 O-RING
5 1 SPACER
6 2 GREASE FITTING 40 4.5
7 2 BUSHING
8 2 SCREW (1/4-28 X 1/2 IN.) 100 11.5
9 1 SWIVEL PIN/STEERING ARM
10 1 STEERING LINK ASSEMBLY
11 1 SCREW (3/8-28 X 1/2 IN.) 20 27
12 2 NUT Note A and B
13 2 WASHER
14 2 BUMPER
15 1 BOTTOM YOKE
16 1 RETAINING RING
17 1 THRUST WASHER
18 1 DECAL-SERIAL OVERLAMINATE
19 1 DECAL–SERIAL NUMBER
NOTE: A – Torque nut to 13.5 Nm (120 lb. in.)and then back off 1/4 turn.
NOTE: B – Torque nut to 27 Nm (20 lb. ft. ).
90-889785 APRIL 2003 Page 5A-3

Transom Bracket

Description
Ref. # ber Number
High Performance Gear 92-802854A1 92-802854Q1
87
Lube
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 5A-4 90-889785 APRIL 2003

Transom Bracket (continued)

TORQUE
REF.
REF
1 1 TRANSOM BRACKET (STARBOARD)
2 1 TRANSOM BRACKET (PORT)
3 1 GREASE FITTING (PORT) 40 4.5
4 1 TILT TUBE
5 1 O-RING
6 2 WAVE WASHER
7 1 NUT See Note
8 1 NUT See Note
9 4 BOLT (1/2-24 X 4.5 IN.)
10 4 WASHER
11 4 WASHER
12 4 NUT
13 1 SPRING
14 1 TILT LOCK LEVER
15 2 BUSHING
16 1 SPRING
17 1 KNOB
18 1 GROOVE PIN
19 1 PIN
20 1 ANCHOR BRACKET
21 6 SCREW (M10 X 30 MM) 40 54
22 6 WASHER
23 1 NUT 40 54
24 1 ANODE ASSEMBLY
25 2 SCREW (M6 X 25 MM) 60 7
26 2 WASHER
27 2 CLAMP
28 1 C–WASHER
29 1 SCREW (10–16 x 5/8)
NOTE: Ref. #7’s - Tighten nut until bottomed on shoulder of tilt tube
NOTE: Ref. #8’s - Drive nut until assembly is drawn together; but must be free to pivot
90-889785 APRIL 2003 Page 5A-5

Exhaust Plate
Page 5A-6 90-889785 APRIL 2003

Exhaust Plate (continued)

TORQUE
REF.
REF
1 1 EXHAUST PLATE
2 5 DOWEL PIN
3 1 RETAINER
4 2 MOUNT
5 4 SCREW (M8 x 35) 20 27.1
6 2 BOLT (M12 x 175)
7 1 NUT (M12) 45 61
8 1 SPACER
9 1 COUPLING
10 1 GASKET
11 1 EXHAUST TUBE
12 6 SCREW (M8 x 35) 20 27.1
13 1 SEAL–EXHAUST TUBE
14 1 GROMMET
15 1 WATER TUBE
16 1 CLAMP
17 1 SEAL (UPPER)
18 2 SCREW (M8 x 45) 15 20.3
19 1 CLAMP
20 1 GROMMET
21 1 BUSHING
22 1 SHIFT SHAFT
23 1 SHIFT LINK See Note
24 2 BUSHING
25 1 NUT (M6) 50 5.6
26 2 SCREW (M8 x 35) 15 20.3
27 1 SCREW (M8 x 70) 15 20.3
28 1 SWITCH
29 1 SCREW (M3.5 x 20) 20 2.2
90-889785 APRIL 2003 Page 5A-7

Drive Shaft Housing
NOTE: A – To swivel bracket
Page 5A-8 90-889785 APRIL 2003

Drive Shaft Housing (continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in. lb-ft Nm
1 1 DRIVE SHAFT HOUSING ASSEMBLY
2 1 STUD (M10 x 100)
3 4 STUD (M10 x 63)
4 5 WASHER
5 5 NUT (10) 40 54.2
6 1 SPEEDOMETER PICK-UP ASSEMBLY
7 1 CONNECTOR (90 DEGREES)
8 1 CONNECTOR (STRAIGHT)
9 2 MOUNT
10 2 BOLT (M12 x 154)
11 2 WASHER
12 2 NUT (M12) 50 67.8
13 2 GROUND WIRE ASSEMBLY
14 1 SCREW (1/4–20 x 3/8) Drive tight
15 2 CLAMP
16 4 PLASTIC–GROMMET
17 4 SCREW (M8 x 25) 20 27.1
18 2 COVER
19 4 SCREW (12–24 x 0.62) Drive tight
20 2 WASHER
21 2 WASHER (NEOPRENE)
22 1 SPACER
23 2 DOWEL PINS
90-889785 APRIL 2003 Page 5A-9

Bottom Cowl
Page 5A-10 90-889785 APRIL 2003

Bottom Cowl (continued)

TORQUE
REF.
REF
1 1 STARBOARD BOTTOM COWL
2 1 SEAL (41 IN.)
3 1 SOUND BLANKET (STARBOARD)
4 1 PORT BOTTOM COWL
5 1 SEAL (41 IN.)
6 1 SOUND BLANKET (PORT)
7 2 CHECK VALVE DRAIN
8 1 COWL LATCH LEVER
9 2 BUSHING
10 1 FITTING–VENT
11 1 CAM–LATCH
12 1 WASHER
13 1 SCREW (M6 x 16) 90 10.2
14 1 RETAINER
15 2 SCREW (M6 x 16) 65 7.3
16 1 PIN
17 1 SPRING
18 4 SCREW (M6 x 40) 65 7.3
19 1 BRACKET– CABLE RETAINER
20 1 LATCH
21 2 DRIVE SCREW
22 1 CUP
23 2 SCREW (M8 x 50) 15 20.3
24 2 NUT (M8) 15 20.3
25 2 WASHER
26 2 STUD Drive tight
27 2 GROMMET
28 2 BUSHING
29 1 SEAL–LOWER COWL
30 1 SWITCH
31 1 TELL–TALE FITTING
32 1 RETAINER–CABLE
33 1 BOOT–IDLE RELIEF
34 1 CLAMP–UPPER
35 1 CLAMP–LOWER
36 2 SCREW (M6 x 16) 65 7.3
37 1 FOAM
38 2 CABLE TIE (11-1/2 IN.)
90-889785 APRIL 2003 Page 5A-11

Bottom Cowl Removal

1. Disconnect tilt switch connector.
ob00652
2. Remove 4 screws holding cowl halves together.

3. Loosen 1 screw holding front cowl halves together.
4. Remove 2 screws holding upper clamp.
a - Screws (4) M6 x 40 mm d - Screws (2) M6 x 16 mm

b - Screw (1) M6 x 16 mm e - Boot – idle relief
c - Nuts (2) M8
Page 5A-12 90-889785 APRIL 2003

Bottom Cowl Installation

1. Check for proper placement of idle relief boot between cowl halves. Verify engine wiring,
water hoses and trim wires are not pinched during bottom cowl installation.
2. Secure cowl halves together with screws and nuts.
3. Reinstall upper clamp and secure with 2 screws.
4. Reinstall screw holding front cowl halves together.
a - Screws (4) M6 x 40 d - Screws (2) M6 x 16

b - Screw (1) M6 x 16 e - Boot – idle relief
c - Nuts (2) M8
TORQUE
REF.
REF
a 4 SCREW (M6 x 40) 65 7.3
b 2 SCREW (M6 x 16) 65 7.3
c 2 NUT (M8) 15 20.3
d 2 SCREW (M6 x 16) 65 7.3
90-889785 APRIL 2003 Page 5A-13

5. Connect tilt switch connector.
ob00652
Drive Shaft Housing and Dyna-Float Suspension

NOTE: Refer to Section 4A for powerhead removal.
NOTE: Refer to Section 6A for lower unit removal.
Removal and Disassembly
1. Remove shift shaft from drive shaft housing by pulling straight up on shaft.
2. Remove power trim wiring harness from exhaust adaptor plate.
3. Remove four screws securing upper mount cover to adaptor plate. Remove cover.
ob00811
a - Shift shaft c - Screws

b - Wiring harness
Page 5A-14 90-889785 APRIL 2003

SHIFT LINKAGE ASSEMBLY
d e
f
d
g
b
a - Spacer e - Nut (M6)

b - Coupling f - Shift link
c - Clamp g - Shift shaft
d - Bushing (2) h - Bushing
TORQUE
REF.
REF
e 1 NUT (M6) Drive tight; but joint
must be free to pivot
90-889785 APRIL 2003 Page 5A-15

4. Remove screws securing lower mount cover to drive shaft housing and remove cover.
ob00813
a - Screws
b - Cover
5. Remove screws securing lower mount retainers to drive shaft housing. Remove retain-
ers.
a
b c
ob59623
a ob00835
a - Screws
b - Port retainer
c - Starboard retainer
d - Ground strap
Page 5A-16 90-889785 APRIL 2003

6. Remove lower mount nuts.
ob00852
a - Lower mount nut (port)
7. Remove upper mount nuts and retainer.
b
a
ob00837
a - Nuts
b - Retainer
c - Bolts
90-889785 APRIL 2003 Page 5A-17

8. Pull drive shaft housing assembly away from swivel bracket.

9. Remove upper and lower mounts from drive shaft housing.
10. Remove three screws securing adaptor plate to drive shaft housing.
ob00807
a - Screws
b - Adaptor Plate
11. Use a mallet and drift to break gasket adhesion between adaptor plate and drive shaft
housing. Remove adaptor plate from drive shaft housing.
ob59621
a - Adaptor plate
b - Drift
c - Protrusion
Page 5A-18 90-889785 APRIL 2003

12. Remove two screws securing water tube and remove tube.
13. Remove six screws securing exhaust pipe and remove pipe. Remove old gasket materi-
al from adaptor plate. Inspect water tube seal for heat damage. Replace as required.
d e
d
b
ob00812
a - Water tube d - Screws

b - Screws e - Water tube seal
c - Exhaust pipe
90-889785 APRIL 2003 Page 5A-19

Reassembly and Installation

1. Inspect exhaust pipe seal and water tube grommet for cuts, tears or heat damage. Re-
place as required.
2. Apply 2-4-C with Teflon onto the outside surface of the exhaust pipe seal or the drive
shaft housing surface where the exhaust pipe seal contacts.
3. Apply 2-4-C with Teflon onto the inside surface of the water tube grommet in drive shaft
housing.
95
95
ob00791
a - Exhaust pipe contact surface

b - Water tube grommet

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 5A-20 90-889785 APRIL 2003

4. Install new gasket on adaptor plate. Secure exhaust pipe to adaptor plate with six
screws.
5. Secure water tube to adaptor plate with two screws.
c c
e
ob00812
a - Gasket
b - Exhaust pipe
c - Screws
d - Water tube
e - Screws
TORQUE
REF.
REF
c 6 SCREW (M8 x 35) 20 27.1
e 2 SCREW (M8 x 45) 15 20.3
90-889785 APRIL 2003 Page 5A-21

6. Install adaptor plate assembly into drive shaft housing.

7. Secure adaptor plate with three screws.
ob00807
a - Screws (M8 x 35)
b - Screw (M8 x 70)
c - Adaptor plate
TORQUE
REF.
REF
a 2 SCREW (M8 x 35) 15 20.3
b 1 SCREW (M8 x 70) 15 20.3
Page 5A-22 90-889785 APRIL 2003

8. Install lower mounts with bolt, flat washer and rubber washer into drive shaft housing.
9. Secure mounts (both sides) with retainer plates and screws.
a
e
d c b
ob00834
a - Bolt e - Screws
b - Flat washer f - Ground cable – port
c - Rubber washer side only
d - Retainer plate
TORQUE
REF.
REF
e 4 SCREW (M8 x 25) 20 27.1
10. Install upper mounts into adaptor plate.

NOTE: Install mounts with arrow pointing towards swivel bracket.
b a
ob00810
a - Mounts
b - Arrow
90-889785 APRIL 2003 Page 5A-23

11. Secure mounts with clamp. Torque screws in sequence shown.
# a
b
"
ob00809
a - Clamp
b - Screws
TORQUE
REF.
REF
b 4 SCREW (M8 x 35) 20 27
12. Position leather mount bumpers onto swivel bracket.
ob00814
a - Mount bumpers
Page 5A-24 90-889785 APRIL 2003

13. Slide drive shaft housing assembly onto swivel bracket.

14. Install upper mount retainer and nuts.
ob00808
a - Retainer
b - Nuts
TORQUE
REF.
REF
b 2 NUT (M12) 45 61
90-889785 APRIL 2003 Page 5A-25

15. Install lower mount nuts.
ob59624
a - Nuts
b - Ground strap (port side)
TORQUE
REF.
REF
a 2 NUT (M12) 50 67.8
16. Install mount covers. Secure covers with two screws.
ob00813
a - Cover
b - Screws
TORQUE
REF.
REF
b 2 SCREW (12–24 x 0.62) Drive tight
Page 5A-26 90-889785 APRIL 2003

17. Install shift shaft and trim harness.
ob00811
a - Shift shaft
b - Trim harness
90-889785 APRIL 2003 Page 5A-27

POWER TRIM
MID-SECTION
Section 5B - Power Trim
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 5B-1 UP Pressure Check . . . . . . . . . . . . . . . . . . . 5B-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 DOWN Pressure Check . . . . . . . . . . . . . . . 5B-37
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5 Power Trim Disassembly . . . . . . . . . . . . . . . . . 5B-39
Power Trim Components . . . . . . . . . . . . . . . . . 5B-6 Trim Motor Removal . . . . . . . . . . . . . . . . . . 5B-39
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 5B-8 Pump and Components Removal . . . . . . . 5B-40
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Manifold Removal . . . . . . . . . . . . . . . . . . . . 5B-41
Trimming Characteristics . . . . . . . . . . . . . . 5B-8 Shock Rod Removal . . . . . . . . . . . . . . . . . . 5B-41
Trailering Outboard . . . . . . . . . . . . . . . . . . . 5B-9 Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5B-42
Tilting Outboard Up and Down Manually . 5B-9 Memory Piston Removal . . . . . . . . . . . . . . 5B-45
Power Trim Flow Diagrams . . . . . . . . . . . . . . . 5B-10 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 5B-46
Trim Up Circuit . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Trim Motor Electrical Tests . . . . . . . . . . . . . 5B-46
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-47
Trim Limit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . .
5B-13
5B-14
O-Ring and Seal Placement . . . . . . . . . . .
O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . .
5B-47
5B-48
5
Trim Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16 O-Ring Description and Sizes . . . . . . . . . . . . . 5B-49 B
Shock Function Up . . . . . . . . . . . . . . . . . . . 5B-18 Power Trim Reassembly . . . . . . . . . . . . . . . . . 5B-50
Shock Function Return . . . . . . . . . . . . . . . . 5B-20 Shock Rod Reassembly . . . . . . . . . . . . . . . 5B-50
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Shock Rod Installation . . . . . . . . . . . . . . . . 5B-52
Reverse Operation . . . . . . . . . . . . . . . . . . . 5B-23 Trim Limit Assembly Installation . . . . . . . . 5B-53
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24 Manual Release Valve Installation . . . . . . 5B-53
Preliminary Checks . . . . . . . . . . . . . . . . . . . 5B-24 Manifold Installation . . . . . . . . . . . . . . . . . . 5B-54
Hydraulic System Troubleshooting Oil Pump Installation . . . . . . . . . . . . . . . . . . 5B-55
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-25 Pressure Operated Assembly Installation 5B-56
Troubleshooting the Power Trim Reservoir/Motor Installation . . . . . . . . . . . . 5B-57
Electrical System . . . . . . . . . . . . . . . . . . . . . 5B-29 Bleeding Power Trim Unit . . . . . . . . . . . . . 5B-58
Power Trim System Removal . . . . . . . . . . . . . 5B-31 Installation of Power Trim System . . . . . . . . . 5B-59
Testing Power Trim System with Test
Gauge Kit (91-52915A6) . . . . . . . . . . . . . . 5B-34
90-889785 APRIL 2003 Page 5B-1

POWER TRIM
Special Tools
Spanner Wrench 91-74951
Lock Ring Pliers SRP-4 (Snap On*)
Expanding Rod CG 41-11 (Snap On*)
Collet CG 41-12 (Snap On*)
*Address
Snap-On Tools Company
2801 - 80th Street
Kenosha, Wisconsin 53143
Phone 414.656.5200
Page 5B-2 90-889785 APRIL 2003

POWER TRIM
Heat Lamp 91-63209
Power Trim Test Gauge Kit 91-52915A6
73835
Adaptor Fitting 91-82278A2 and 91-82278A3
54458
90-889785 APRIL 2003 Page 5B-3

POWER TRIM
Multimeter DVA Tester or DMT 2000 Digital 91-99750A1 or 91-854009A1

Tachometer Multimeter
a b
a - Multi-Meter DVA Tester 91-99750A1

b - DMT 2000 Digital Tachometer Multi-meter 91-854009A1
Page 5B-4 90-889785 APRIL 2003

POWER TRIM
Notes:
90-889785 APRIL 2003 Page 5B-5

POWER TRIM
Power Trim Components
16
A
18
20
21
19
2
3 B
2
11
7 8 12
D
4 E
13
5 15
10 5 10
10 6
5
C 10
5
10 10
16 10
10 14
9
17 15 10
D
NOTE: Lubricate all O-rings using Power Trim and Steering Fluid. If not available, use automotive (ATF)
NOTE: It is recommended that all O-rings be replaced when servicing tilt system.
Page 5B-6 90-889785 APRIL 2003

POWER TRIM
Power Trim Components (continued)

TORQUE
REF.
REF
– 1 POWER TRIM PUMP
1 1 SHOCK ROD KIT
2 1 O-RING REBUILD KIT
3 1 MEMORY PISTON ASSEMBLY
4 1 CYLINDER ASSEMBLY
5 1 TRIM LIMIT VALVE KIT
6 1 PUMP ASSEMBLY
7 1 MOTOR KIT
8 1 RESERVOIR PLUG
9 1 MANUAL RELEASE ASSEMBLY
10 1 MANIFOLD KIT
11 1 SCREW KIT (MOTOR)
12 1 CABLE
13 1 DRIVE SHAFT
14 1 FILTER KIT
15 1 P.O. CHECK ASSEMBLY KIT
– 1 O-RING KIT (COMPLETE TRIM)
16 2 GROOVE PIN
17 1 ANCHOR PIN
18 1 SHAFT
19 2 CLAMP
20 1 SCREW
21 1 C WASHER
TORQUE
REF.
REF
A 1 CYLINDER CAP 45 61
B 4 SCREWS 80 9
C 4 SCREWS 70 7.9
D 2 PLUGS 120 13.5
E 2 SCREWS 100 11
F 1 SHOCK PISTON 90 122
90-889785 APRIL 2003 Page 5B-7

POWER TRIM
Theory of Operation
The Power Trim system consists of an electric motor, pressurized fluid reservoir, pump and
trim cylinder.
The remote control (or trim panel) is equipped with a switch that is used for trimming the
outboard up or down, and for tilting the outboard for shallow water operation (at slow speed)
or for trailering. The outboard can be trimmed up or down while engine is under power or
when engine is not running.
Adjustments
Trimming Characteristics
NOTE: Because varying hull designs react differently in various degrees of rough water, it
is recommended to experiment with trim positions to determine whether trimming up or
down will improve the ride in rough water.
When trimming your outboard from a mid-trim position (trim tab in neutral, straight fore and
aft, position), you can expect the following results:
TRIMMING OUTBOARD UP (OUT)
WARNING
Excessive trim out may reduce the stability of some high speed hulls. To correct
instability at high speed, reduce the power gradually and trim the motor IN slightly
before resuming high speed operation. (Rapid reduction in power will cause a sud-
den change of steering torque and may cause additional momentary boat instabili-
ty.)
• Will lift bow of boat, generally increasing top speed.
• Transfers steering torque harder to left on installations below 585 mm (23 in.) transom
height.
• Increases clearance over submerged objects.
• In excess, can cause porpoising and/or ventilation.
• In excess, can cause insufficient water supply to water pump resulting in serious water
pump and/or powerhead overheating damage.
WARNING
Excessive engine trim angle will result in insufficient water supply to water pump
causing water pump and/or powerhead overheating damage. Make sure that water
level is above gear housing water intake holes whenever engine is running.
Operating UP circuit will actuate the up relay (located under engine cowl) and close the elec-
tric motor circuit. The electric motor will drive the pump, thus forcing automatic transmission
fluid through internal passageways into the up side of the trim cylinder.
The trim cylinder/trim rod will position the engine at the desired trim angle within the 20 de-
gree maximum trim range. The power trim system is designed so the engine cannot be
trimmed beyond the 20 degree maximum trim angle as long as engine rpm is above approxi-
mately 2000 rpm.
Page 5B-8 90-889785 APRIL 2003

POWER TRIM
The engine can be raised beyond the 20 degree maximum trim angle for shallow water op-
eration, etc., by keeping the engine rpm below 2000 rpm. If engine rpm increases above
2000 rpm, the thrust created by the propeller (if deep enough in the water) will cause the
trim system to automatically lower the engine back to the 20 degree maximum trim angle.
TRIMMING OUTBOARD DOWN (IN)
WARNING
Excessive speed at minimum trim IN may cause undesirable and/or unsafe steering
conditions. Each boat should be tested for handling characteristics after any ad-
justment is made to the tilt angle (tilt pin relocation).
• Will help planing off, particularly with a heavy load.
• Usually improves ride in choppy water.
• In excess, can cause boat to veer to the left or right (bow steer).
• Transfers steering torque harder to right (or less to the left).
• Improves planing speed acceleration (by moving tilt pin one hole closer to transom).
Operating DOWN circuit will actuate the down relay (located under engine cowl) and close
the electric motor circuit (motor will run in opposite direction of the UP circuit). The electric
motor will drive the pump, thus forcing automatic transmission fluid through internal pas-
sageways into the down side of the trim cylinder. The trim rod will move the engine down-
ward to the desired angle.
Trailering Outboard
WARNING
Excessive engine trim angle will result in insufficient water supply to water pump
causing water pump and/or powerhead overheating damage. Make sure that water
level is above gear housing water intake holes whenever engine is running.
While operating UP circuit, the cylinder rod will continue to tilt the outboard to a full up posi-
tion for trailering.
Tilting Outboard Up and Down Manually
WARNING
Before loosening the manual release valve, make sure all persons are clear of en-
gine, as engine will drop to full down position when valve is loosened.
With power trim installed, the outboard can be raised or lowered manually by opening the
manual release valve 3 to 4 turns (counterclockwise).
a - Manual release valve
90-889785 APRIL 2003 Page 5B-9

POWER TRIM
Power Trim Flow Diagrams

Trim Up Circuit
a b
w
h d i j k
l
# v
u e
m
f n
t
g
g
o
p
Reservoir Oil
! s r q " Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-10 90-889785 APRIL 2003

POWER TRIM
Trim Up (continued)
When the trim switch is activated in the up position, the electric motor ”c” begins to rotate
the oil pump gears ”j”, the oil pump draws a small amount of oil through the filter ”g” and
through the up circuit suction port ”i”. The oil pump gear ”j” rotation forces oil into the pas-
sages for the up circuit. Oil, under pressure, will slide the shuttle valve ”m” against the down
circuit pressure operated valve ”f”. The shuttle valve will mechanically open the down pres-
sure operated valve, allowing oil from the down cavity of the trim cylinder, to flow into the
oil pump. This returning oil, from the down cavity, will supply most of the oil required for the
up circuit. Oil in the up circuit is blocked from returning into the reservoir by the ball inside
the down circuit suction port ”k”. The pressure of the oil will force the up circuit pressure oper-
ated valve ”n” to open, allowing the oil to enter the passages inside the manifold ”q” leading
to the trim cylinder ”w” up cavity. Oil is blocked from all other passages by the closed manual
release valve ”p”. Oil under pressure will enter the trim cylinder below the memory piston
”t”. With an increasing amount of oil entering the cylinder, the memory piston contacts the
shock piston ”u” and forces the trim rod ”a” up and out, raising the outboard motor. Oil on
the top of the shock piston exits through a passage running down along the side of the cylin-
der and enters the manifold passages. The oil is drawn back into the pump ”j” through the
open down circuit pressure operated valve ”f” and enters the pump as supply for the up cir-
cuit.
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
e - Down circuit pressure relief valve
f - Down circuit pressure operated valve
g - Filter (2 shown for clarity)
h - Shock return valve
i - Up circuit suction port
j - Oil pump gears
k - Down circuit suction port
l - Oil fill cap
m - Shuttle valve
n - Up circuit pressure operated valve
o - Manifold reverse suction valve
p - Manual release valve
q - Manifold
r - Tilt relief valve
s - Tilt relief piston
t - Memory piston
u - Shock piston
v - Impact relief valve
w - Cylinder
1 - Up pressure -18,200 kPa (2640 PSI) (F75–F115) minimum
2 - Tilt relief pressure - 3725-6825 kPa (540-990 PSI) (F75-F115)
3 - Impact relief pressure - 8065-9375 kPa (1170-1360 PSI)(F75-F115)
90-889785 APRIL 2003 Page 5B-11

POWER TRIM
Tilt Up
a b
# v h
u d i j k
l
t
e
f m
n
g
g
Reservoir Oil
! s r q "
Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-12 90-889785 APRIL 2003

POWER TRIM
Tilt Up (continued)
In the up mode, as the trim rod ”a” extends from the cylinder ”w”, the memory piston ”t” clears
or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and,
if required, causes the tilt relief piston ”s” to open the tilt pressure relief valve ”r”. This valve
lowers the amount of pressure available to lift the outboard motor. With the engine in forward
gear, and at high engine rpm, the oil pressure available will not be able to overcome the pro-
peller thrust, limiting the trim range to below the pressure relief orifice. Up pressure flows
into the trim relief passage, and returns back into the reservoir. When the engine rpm’s fall
or if engine is not in forward gear, the oil pressure is available to extend the trim rod ”a” up
into the tilt range.
Trim Limit
When the weight of the outboard and propeller thrust reach sufficient levels, the pressure
inside the trim cylinder ”w” will increase to the pressure required to move the tilt relief piston
”s”. The tilt relief piston’s pin opens the tilt relief valve ”r”. Up pressure flows into the trim relief
passage, and returns back into the reservoir. If the outboard engine is positioned in the tilt
range (beyond full trim position) when the tilt relief valve opens, it will move back down to
the full trim position (trim limit).
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
j - Oil pump gears
l - Oil fill cap
m - Shuttle valve
q - Manifold
t - Memory piston
u - Shock piston
w - Cylinder
1 - Up pressure -18,200 kPa (2640 PSI) (F75–F115) minimum
90-889785 APRIL 2003 Page 5B-13

POWER TRIM
Maximum Tilt
a b
# v h
u
t
c
d i j k l
e
f
g m n
o
p
Reservoir Oil
! s r q "
Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-14 90-889785 APRIL 2003

POWER TRIM
Maximum Tilt (continued)

With the cylinder at maximum travel, due to no ram movement, the pressure inside of the
trim cylinder will increase to the pressure setting of the tilt relief valve ”r”. Pressure forces
the tilt relief actuator ”s” to move and unseat the tilt relief valve ”r” allowing oil to return to
the reservoir through passages in the manifold ”q”. Oil flow will continue until the up button
is released.
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
j - Oil pump gears
l - Oil fill cap
m - Shuttle valve
q - Manifold
t - Memory piston
u - Shock piston
w - Cylinder
1 - Up pressure- 2640 PSI (18,200 kPa) (F75–F115) minimum
90-889785 APRIL 2003 Page 5B-15

POWER TRIM
Trim Down
b
a
#
d i j k l
" v h e
m
f n
u
g
g
t
o
p
Reservoir Oil
s r q !
Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-16 90-889785 APRIL 2003

POWER TRIM
Trim Down (continued)

When the trim switch is activated in the down position, the electric motor ”c” will rotate the
oil pump gears ”j” in the opposite direction. With the oil pump gears rotating backwards, the
flow of oil is reversed. Oil is drawn through the filter ”g”, through the down circuit suction port
”k” and into the oil pump gears ”j”. The pump forces pressurized oil into the down passages.
Oil will slide the shuttle valve ”m” into the up circuit pressure operated valve ”n”. The shuttle
valve will mechanically open the up circuit pressure operated valve and allow oil, from the
up cavity of the trim cylinder ”w”, to return into the oil pump. This returning oil, from the up
cavity, will supply the oil required for the down circuit. The oil is blocked from returning into
the reservoir by the ball ”i” inside the up circuit suction port. Oil, under pressure, opens the
down circuit pressure operated valve ”f” and enters the down passages inside of the man-
ifold ”q”. The manifold passage connects into the trim cylinder passage leading to the top
of the cylinder. The cavity, inside the cylinder, above the shock piston ”u” is the down cavity.
As the down cavity fills with oil, the trim rod ”a” retracts into the cylinder, lowering the out-
board motor. Oil from the up cavity exits the cylinder and is drawn back into the pump
through the open up circuit pressure operated valve ”n”. When the trim rod reached full trav-
el, the oil pressure inside the down circuit will rise until the down circuit pressure relief valve
”e” opens, bypassing oil back into the reservoir. When the trim button is released, the pump
stops supplying oil, both of the pressure operated valves ”f & n” will close and; if open, the
down circuit pressure relief valve ”e” will close. The closed valves will lock the fluid on either
side of the shock piston ”u” & memory piston ”t”, holding the outboard motor in position.
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
j - Oil pump gears
l - Oil fill cap
m - Shuttle valve
q - Manifold
t - Memory piston
u - Shock piston
w - Cylinder
2 - Impact relief pressure - 8065-9375 kPa (1170-1360 PSI) (F75-F115)
3 - Down pressure - 3480-5860 kPa (505-850 PSI) (F75-F115)
90-889785 APRIL 2003 Page 5B-17

POWER TRIM
Shock Function Up
b
a
h
" v
u
d i j k l
t
e
m
f n
g
g
s r q ! Reservoir Oil
Return Oil
Oil Under Pressure
Page 5B-18 90-889785 APRIL 2003

POWER TRIM
Shock Function Up (continued)

Oil inside the down cavity is locked in a static position by the closed down circuit pressure
operated valve ”f”, the manual release valve ”p” and the manifold reverse suction valve ”o”.
If the outboard strikes an underwater object while in forward gear, the trim rod ”a” will try to
rapidly extend from the cylinder ”w”, the pressure increases inside the trim cylinder down
cavity and connecting passages. When the pressure increases to the level required, the im-
pact relief valves ”v”, located inside the shock piston ”u”, will open and allow the fluid to pass
through the shock piston. As the fluid passes through the piston, the trim rod ”a” will extend
from the trim cylinder. The memory piston ”t” is held in position by vacuum, created by the
oil in the up cavity being locked in a static position. Therefore; oil passing through the shock
piston is trapped between the memory piston ”t” and shock piston ”u”.
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
j - Oil pump gears
l - Oil fill cap
m - Shuttle valve
q - Manifold
t - Memory piston
u - Shock piston
w - Cylinder
90-889785 APRIL 2003 Page 5B-19

POWER TRIM
Shock Function Return
a b
v h
" u
d i j k l
t
e
f m
n
g
g
o
p
Return Oil
Oil Under Pressure
Page 5B-20 90-889785 APRIL 2003

POWER TRIM
Shock Function Return (continued)

After the engine clears the under water object, the weight of the engine will increase the oil
pressure between the memory piston ”t” and shock piston ”u” to the level required to open
the shock return valve ”h”, inside the shock piston, allowing the oil to bleed back through
the shock piston into the down cavity. If required, additional oil will enter the down cavity
through the manifold reverse suction valve ”o”. This will return the engine back against the
memory piston ”t” and into the original running position.
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
j - Oil pump gears
l - Oil fill cap
m - Shuttle valve
q - Manifold
t - Memory piston
u - Shock piston
w - Cylinder
90-889785 APRIL 2003 Page 5B-21

POWER TRIM
Manual Tilt
a b
" v h
d i j k l
u
t
e
f m
g n
g
Return Oil
Filtered Oil
Page 5B-22 90-889785 APRIL 2003

POWER TRIM
Manual Tilt
To manually tilt the outboard engine, the owner will need to back out the manual release
valve ”p” 3-4 turns. With the valve backed out, the internal passages inside the manifold are
connected together. These passages connect both the cylinder down and up cavities to-
gether, along with the reservoir, allowing the engine to be raised or lowered. Trim rod ”a”
movement will continue until the manual release valve ”p” is closed, locking the fluid inside
of the cylinder and manifold. If the outboard motor is to be raised manually, turn the manual
release (tilt) valve counterclockwise to the full out position. When in the full (out) position,
oil in the trim cylinder can flow freely from the up side to the down side or from the down side
to the up side. The oil return line into the reservoir is also open, allowing free oil flow to either
side of the tilt cylinder to accommodate the differential oil capacities between the tilt cylinder
up side and down side cavities
When trimming the outboard in either the up or down position, with the manual tilt valve open
or leaking, little or no movement will occur. Oil pressure from the pump will move to both,
the up cavity and through the manual tilt valve into the down cavity, each cavity would have
equal pressure resulting in little or no movement.
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or
throttling back rapidly, oil in the trim system must be locked in a static position. This is accom-
plished with the up and down pilot check valves. Thus, not allowing oil in the system to move
in either direction.
a - Trim rod
b - End cap
c - Electric motor
d - Reservoir oil
j - Oil pump gears
l - Oil fill cap
m - Shuttle valve
q - Manifold
t - Memory piston
u - Shock piston
w - Cylinder
90-889785 APRIL 2003 Page 5B-23

POWER TRIM
Troubleshooting
Support outboard with tilt lock pin when servicing power trim system.
IMPORTANT: After debris or failed components have been found, it is recommended
that unit be disassembled completely and ALL O-rings be replaced. Check valve
components and castings must be cleaned using engine cleaner and compressed air
or replaced prior to reassembly.
IMPORTANT: Power trim system is pressurized. Outboard must be in the full UP
position (trim rod fully extended) prior to fill/drain plug or manual release valve re-
moval.
Refer to instructions following if disassembly is required when servicing.
Follow preliminary checks before proceeding to troubleshooting flow diagrams (following).
Preliminary Checks
IMPORTANT: Operate Power Trim system after each check to see if problem has been
corrected. If problem has not been corrected proceed to next check.
1. Check that manual release valve is tightened to full right (clockwise) position.
2. Check trim pump fluid level with outboard in full UP position and fill if necessary. Refer
to Bleeding Power Trim Unit.
3. Check for external leaks in Power Trim system. Replace defective part if leak is found.
4. Outboard not holding tilted position (falls down to trim position) indicates debris or defec-
tive components in trim assembly. Clean or replace components as required.
Page 5B-24 90-889785 APRIL 2003

POWER TRIM
Hydraulic System Troubleshooting Flow Chart
OUTBOARD WILL NOT HOLD TILTED

POSITION DURING REVERSE AND/OR
TRAILS OUT DURING HIGH SPEED
DECELERATION.
Manual release Manual release valve and

Inspect manual release valve.
valve and O-ring O-rings appear to be O.K. -
damaged. Clean and reinstall manual
release valve.
Trim will not hold

Replace manual re- reverse thrust. Trim system holds re-
lease valve and O-rings. verse thrust. Testing
complete.
Trim system holds re- Remove and inspect pis-

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

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly. Trim system holds
reverse thrust. Test-
ing complete.
Trim will not hold
reverse thrust.
Trim system holds re-
complete.
continued on next page
90-889785 APRIL 2003 Page 5B-25

POWER TRIM

continued
Remove suction seat as-

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

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

assembly. Trim will not hold
reverse thrust. Trim system holds
ing complete.
Trim system holds
ing complete.
Replace trim system.
Page 5B-26 90-889785 APRIL 2003

POWER TRIM
TRIM SYSTEM LEAKS DOWN

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

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

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

Replace tilt relief valving.
down. not leak down. Test-
ing complete.
Trim system does Remove PO check valve

not leak down. Test- assembly, inspect O-
ing complete. rings and seals for dam-
age.
Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly.
Trim system leaks down. Trim system does
not leak down.
Testing complete.
Trim system does
continued on next page
ing complete.
90-889785 APRIL 2003 Page 5B-27

POWER TRIM

continued
Inspect memory pis-

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

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

ing complete. Replace trim system.
Page 5B-28 90-889785 APRIL 2003

POWER TRIM
Troubleshooting the Power Trim Electrical System

UP
a DN
b
UP
DN
GRN/WHT
c
BLU/WHT
GRN/WHT or GRN
BLU/WHT or PUR
RED
RED
e c
A
20 (A) RED
d
B
– +
B
30 (A)
RED
BLK LT.BLU
g
RED/PUR
BLU
i RED GRN
LT.BLU
BLU
LT.GRN
RED LT.BLU
RED
h
#
GRN
BLK
$ "
BLK LT.GRN LT. BLU/WHT
LT.BLU/WHT
j
f GRN/WHT
RED/PUR GRN/WHT
UP
DN k !
a - Trim switch (remote control mounted) g - Up relay

b - Trim switch (panel mounted) h - Down relay
c - Fuses (20A, 30A) i - Solenoid - start
d - Remote control wiring plug connector j - Trim pump motor
e - Battery k - Cowl switch
f - Block screw
90-889785 APRIL 2003 Page 5B-29

POWER TRIM
Troubleshooting the Power Trim Electrical System

Refer to wiring diagram on preceding page for location of wire connections.
Problem Possible Cause Remedy
Trim switch UP is inopera- 1. Open wire between wire connection (1) 1. Check for an open connection or cut
tive, but the cowl switch UP and trim switch. wire.
does operate. 2. Faulty trim switch. 2. Replace.
Cowl switch UP is inopera- 1. Open wire between Wire Connection (2) 1. Check for an open connection or cut
tive, but the trim switch UP and Solenoid. wire.
does operate. 2. Faulty cowl switch. 2. Replace.
Trim switch UP and cowl 1. Open wire between wire connection (1) 1. Check for an open connection.
switch UP are both inopera- and the UP relay.
tive. 2. Open BLACK wire between ground and 2. Check for an open connection.
UP relay.
3. Open RED wire between solenoid and 3. Check for an open connection.
UP relay.
4. Faulty UP relay. 4. Replace.
Trim switch DOWN is inop- 1. Open wire between wire connection (3) 1. Check for an open connection or cut
erative, but the cowl switch and trim switch. wire.
DOWN does operate. 2. Faulty trim switch. 2. Replace.
Cowl switch DOWN is inop- 1. Open wire between wire connection (2) 1. Check for a open connection or cut
erative, but the trim switch and solenoid. wire.
DOWN does operate. 2. Faulty cowl switch. 2. Replace
Trim switch DOWN and cowl 1. Open wire between wire connection (3) 1. Check for an open connection.
switch DOWN are both inop- and the UP relay.
erative. 2. Open BLACK wire between ground and 2. Check for an open connection.
DOWN relay.
3. Open RED wire between solenoid and 3. Check for an open connection.
DOWN relay.
4. Faulty DOWN relay 4. Replace.
Trim switch UP and DOWN 1. 20 AMP fuse blown. 1. Replace fuse. Locate the cause of
are both inoperative, but the the blown fuse. Check electrical wiring
cowl switch does operate. for a shorted circuit.
2. Faulty trim switch. 2. Replace.
3. Wire is open between fuse holder and 3. Check for a open connection or cut
solenoid. wire.
4. Wire is open between fuse holder and 4. Check for a loose or corroded con-
trim switch. nection.
Trim switch and cowl switch 1. One of the trim pump motor wires is 1. Check wire connections (4) for loose
are both inoperative. open between the motor and the relays. or corroded condition.
2. Faulty trim pump motor. 2. If voltage is present at connections
(4) when the appropriate trim button is
pressed, then motor is faulty. Replace
motor.
Trim system operates (motor 1. The trim or cowl switch is shorted. 1. Replace.
runs) without pressing the
switches.
Page 5B-30 90-889785 APRIL 2003

POWER TRIM
Power Trim System Removal

1. Tilt outboard to the full up position and support with tilt lock pin.
2. Disconnect the power trim wire harness and remove J-clips.
c b
ob53949 ob55264
a - Tilt lock pin

b - J-clips
c - Harness
3. Remove the trilobe pin.

4. Drive out the upper pivot pin.
a - Trilobe pin
b - Upper pivot pin
90-889785 APRIL 2003 Page 5B-31

POWER TRIM
5. Use suitable punch to remove lower cross pin.
a - Lower cross pin
6. Use suitable punch to drive out lower pivot pin.

7. Remove the sacrificial anode.
a
b
a - Lower pivot pin

b - Sacrificial anode
Page 5B-32 90-889785 APRIL 2003

POWER TRIM
8. Tilt power trim assembly (top first) out from clamp bracket and remove assembly.
ob53944
WARNING
Electrical wires passing through cowl openings must be protected from chafing or
being cut. Follow the recommended procedures outlined in Section 1D of this
Manual. Failure to protect wires as described could result in electrical system fail-
ure and/or injury to occupants of boat.
90-889785 APRIL 2003 Page 5B-33

POWER TRIM
Testing Power Trim System with Test Gauge Kit (91-52915A6)

IMPORTANT: This test will not locate problems in the trim system. The test will show
if the system is correct after a repair. If minimum pressures are not obtainable, the
trim system requires additional repair.
UP Pressure Check
IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full UP position and engage tilt lock lever.
2. Slowly remove fill plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim as-
sembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring onto
adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test
adaptor securely using teflon tape on threads.
gg
f a c
ee d c bb ob54457
a - Test Adaptor (91-822778A1)

b - O-ring Installation Tool
c - Small O-ring (install 1st)
d - Medium O-ring (install 2nd)
e - Large O-ring (install Last)
f - Brass fitting
g - Apply teflon tape
Page 5B-34 90-889785 APRIL 2003

POWER TRIM
4. Install test adaptor into manual release valve hole.
5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
a d
b ob54459
a - Brass fitting
b - Test Gauge Assembly
c - Tilt pin (position in hole shown)
d - Hose
e - Hose (not used)
6. Reinstall fill plug.

7. Run trim UP.
8. Disengage tilt lock lever.
90-889785 APRIL 2003 Page 5B-35

POWER TRIM
CAUTION
Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could re-
sult in transom bracket failure and possible injury.
9. Move outboard IN until hole in swivel bracket ear aligns with the 3rd tilt hole in transom
bracket. Lock engine in trim range by installing a 9.5 mm (3/8 in.) diameter tilt pin or two
9.5 mm (3/8 in.) hardened bolts and nuts through the transom brackets and swivel
bracket in the hole shown.
ob54460
a - Tilt pin hole (install spare tilt pin or hardened bolts and nuts)
10. Open valve (a) and close valve (b).
a bb
ob51374
11. Run trim UP. The minimum pressure should be 2640 psi (18,200 kPa).
12. Run trim DOWN to release pressure and remove spare tilt pin or bolts and nuts.
13. Tilt outboard full UP and engage tilt lock lever.
14. Slowly remove fill plug to bleed pressure.
15. Remove test gauge hose and adapter.
16. Reinstall manual release valve and secure valve with circlip.
17. Retighten fill plug.
NOTE: If pressure is less than 2640 psi (18,200 kPa), troubleshoot system per instructions
in Troubleshooting, preceding.
Page 5B-36 90-889785 APRIL 2003

POWER TRIM
DOWN Pressure Check

IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full UP position and engage tilt lock lever.
2. Slowly remove fill plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim as-
sembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring onto
adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test
adaptor securely using teflon tape on threads.
g
f a e d c b !"#$$#%

b - O-ring Installation Tool
c - Small O-ring (install 1st)
d - Medium O-ring (install 2nd)
e - Large O-ring (install Last)
f - Brass fitting
g - Apply teflon tape
4. Install test adaptor into manual release valve hole.
a
90-889785 APRIL 2003 Page 5B-37

POWER TRIM
5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
a d
b
ob54459
a - Brass fitting
b - Test Gauge Assembly
c - Tilt pin (position in hole shown)
d - Hose
e - Hose (not used)
f - OPEN valve
g - CLOSE valve
6. Reinstall fill plug.

7. Run trim UP.
8. Disengage tilt lock lever.
9. Open valve (f) and close valve (g).
10. Run trim DOWN. Minimum pressure should be 3480 kPa (505 psi).
11. Tilt outboard full UP and engage tilt lock lever.
12. Slowly remove fill plug to bleed pressure.
13. Remove test gauge hose and adaptor.
14. Reinstall manual release valve and secure valve with circlip.
15. Retighten fill plug.
NOTE: If pressure is less than 3480 kPa (505 psi), troubleshoot system per instructions in
Troubleshooting, preceding.
Page 5B-38 90-889785 APRIL 2003

POWER TRIM
Power Trim Disassembly

IMPORTANT: Power trim system is pressurized. Trim rod must be in the full UP posi-
tion (fully extended) prior to fill/drain plug, or manual release valve removal.
1. Remove reservoir cap.
2. Remove manual release valve assembly to drain oil.
ob55263
a - Reservoir cap
b - Manual release valve
Trim Motor Removal

1. Secure power trim assembly in a soft jaw vise.
2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler.
a - Screw (4)
b - Reservoir
c - Reservoir seal
d - Coupler
e - Manifold assembly
90-889785 APRIL 2003 Page 5B-39

POWER TRIM
Pump and Components Removal

1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet
(both sides). Use special tool CG 41-11 and special tool CG 41-12 with 5/16 in. end to
remove spool.
a
b
c
d
e
d
c
b
a
a - Plug (2)
b - Spring (2)
c - Check valve/poppet (2)
d - Seat (2)
e - Spool
IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found
on poppet replace poppet.
2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump.
Remove suction seat assembly.
a
d
b
a - Debris under valve tip

b - Rubber seat
c - Screws (3)
d - Filter seal
e - Filter
f - Suction seat assembly
Page 5B-40 90-889785 APRIL 2003

POWER TRIM
Manifold Removal
1. Remove two (2) screws to remove manifold from cylinder.
2. Remove tilt relief components.
a
e
ob51146
ob51008
a - Screws (2)
b - Spring
c - Poppet
d - Spool housing
e - Trim limit spool
Shock Rod Removal

1. Unscrew end cap assembly from cylinder using spanner wrench (1/4 in. x 5/16 in.
long pegs).
2. Remove shock rod assembly from cylinder.
90-889785 APRIL 2003 Page 5B-41

POWER TRIM
Shock Rod Disassembly

NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper
ring. If shock rod requires any other repair, replace shock rod assembly.
b
b
a
a - End cap
b - O-ring (2)
c - Wiper ring
1. Place shock rod assembly on clean work surface.

2. Remove three (3) screws and remove plate from shock rod piston.
ob51143
a - Screw (3)
b - Plate
c - Shock rod piston
Page 5B-42 90-889785 APRIL 2003

GEAR HOUSING
LOWER UNIT
Section 6A - Gear Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Forward Gear Bearing Race . . . . . . . . . . . 6A-36
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-37
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Bearing Carrier Reassembly . . . . . . . . . . . 6A-40
Gear Housing (Drive Shaft) . . . . . . . . . . . . . . . 6A-10 Forward Gear Reassembly . . . . . . . . . . . . 6A-44
Gear Housing (Prop Shaft) . . . . . . . . . . . . . . . 6A-12 Propeller Shaft Reassembly . . . . . . . . . . . 6A-46
General Service Recommendations . . . . . . . 6A-14 Drive Shaft Wear Sleeve Installation . . . . 6A-47
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Lower Drive Shaft Bearing Race
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-49
Draining and Inspecting Gear Lubricant . . . . 6A-15 Oil Sleeve Installation . . . . . . . . . . . . . . . . . 6A-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Drive Shaft Upper Bearing Installation . . . 6A-50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Forward Gear, Lower Bearing, Pinion
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Gear, and Drive Shaft Installation . . . . . . . 6A-52
Bearing Carrier and Propeller Shaft . . . . . 6A-20 Pinion Gear Depth and Forward
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . 6A-53
Pinion Gear, Drive Shaft, and Bearing Carrier and Propeller
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Shaft Installation . . . . . . . . . . . . . . . . . . . . . 6A-58
Upper Drive Shaft Bearing . . . . . . . . . . . . .
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-30
6A-31
Water Pump Reassembly and Installation
Gear Housing Pressure Test . . . . . . . . . . .
6A-60
6A-64
6
Lower Drive Shaft Bearing Race . . . . . . . .
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-32
6A-33
Filling Gear Housing With Lubricant . . . . . . .
Gearcase Installation . . . . . . . . . . . . . . . . . . . .
6A-65
6A-66
A
Forward Gear Bearing Race . . . . . . . . . . . 6A-35 Trim Tab Adjustment and Replacement . . 6A-70
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36
90-889785 APRIL 2003 Page 6A-1

GEAR HOUSING
Specifications
Gear Ratio 2.33:1
Gearcase Capacity 665 ml (22.5 fl oz)
Lubricant Type Premium Gear
Lubricant
Forward Gear
Pinion Gear
75/90 Pinion Height 0.64 mm (0.025 in.)
GEAR HOUSING Pinion Gear Locating Tool 91-12349A2
(2.33:1) Flat Number #8
Disc Number #3
Backlash Indicating Tool 91-19660--1
Mark Number #1
Water Pressure
@ 625–675 rpm (idle) 27.6-48.3 kPa (3-6 psi)
@ 5000–5750 rpm (WOT) 75.8-96.5 kPa (11-14 psi)
Leak Test 69-83 kPa (10-12 psi)
for 5 minutes
Gear Ratio 2.07:1
Gearcase Capacity 665 ml (22.5 fl oz)
Lubricant Type Premium Gear
Lubricant
Forward Gear
Pinion Gear
115 Pinion Height 0.64 mm (0.025 in.)
GEAR HOUSING Pinion Gear Locating Tool 91-12349A2
(2.07:1) Flat Number #2
Disc Number #3
Backlash Indicating Tool 91-19660--1
Mark Number #1
Water Pressure
@ 625–675 rpm (idle) 20.6-41.3 kPa (3-6 psi)
@ 5000–5750 rpm (WOT) 75.8-96.5 kPa (11-14 psi)
Leak Test 69-83 kPa (10-12 psi)
for 5 minutes
Page 6A-2 90-889785 APRIL 2003

GEAR HOUSING
Special Tools
Pinion Gear Locating Tool 91-12349A2
Disc 3 Disc1
Disc 2
55079
Bearing Installation Tool 91-13945
Oil Seal Driver 91-13949
Bearing Race Tool 91-14308T01
a - P/N 91-13778T1, No Stamp
90-889785 APRIL 2003 Page 6A-3

GEAR HOUSING
Bearing Installation Tool 91-14309T01
a
a - P/N 91-13780, Stamped 91-13780
Bearing Race Tool 91-14308T02
a b
a - P/N 91-889622A01, Stamped 91-889622
b - P/N 91-13778T1, No Stamp
Bearing Cup Driver 91-14309T02
a b
a - P/N 91-889623, Stamped 91-889623

b - P/N 91-13780, Stamped 91-13780
NOTE: Threaded Rod (91-31229) and Nut (11-24156) are from Bearing Removal and
Installation Kit 91-31229A7
Lower Drive Shaft Bearing Race Tool Application Chart
Model Gear Ratio Pinion Gear Bearing Race Tool Bearing Cup
P/N (Teeth) Driver
115 2.07:1 43-881259 91-889622A01 91-889623
(14) (Stamped 91-889622) (Stamped 91-889623)
75/90 2.33:1 91-889622A01 91-889623
(12) (Stamped 91-889622) (Stamped 91-889623)
NOTE: Bearing Race Tool 91-889622A01 should be combined with Bearing Race Tool
91-14308T01 to create a 91-18308T02 which will supersede and replace the 91-14308T01.
NOTE: Bearing Cup Driver 91-889623 should be combined with Bearing Cup Driver
91-14309T01 to create a 91-18309T02 which will supersede and replace the 91-14309T01.
Page 6A-4 90-889785 APRIL 2003

GEAR HOUSING
Wear Sleeve Installation Tool 91-14310A1
Bearing Preload Tool 91-14311A2
Mandrel 91-15755
73815
Backlash Indicator Tool 91-19660--1 [2.07:1 Gear Ratio (14/29)]
19660-1
Mandrel 91-31106
90-889785 APRIL 2003 Page 6A-5

GEAR HOUSING
Oil Seal Driver 91-31108
Threaded Rod and Nut 91-31229* and 91-24156
Slide Hammer 91-34569A1
Mandrel 91-36569
Universal Puller Plate 91-37241
Driver Rod 91-37323*
74184
* From Bearing Removal and Installation Kit (91-31229A7)
Page 6A-6 90-889785 APRIL 2003

GEAR HOUSING
Mandrel 91-37350
Puller Jaws 91-46086A1
Drive Shaft Holding Tool 91-56775
Dial Indicator 91-58222A1
Backlash Indicator Tool [2.33:1 Gear Ratio (12/28)] 91-78473
Puller Bolt 91-85716
90-889785 APRIL 2003 Page 6A-7

GEAR HOUSING
Dial Indicator Adaptor Kit 91-83155
Bearing Puller Assembly 91-83165M
Bearing Installation Tool 91-856875A1
56783
Bearing Installation Tool 91-877321A1
Page 6A-8 90-889785 APRIL 2003

GEAR HOUSING
Gear Housing (Drive Shaft)

32
31 107.95MM(4.25 IN.)
7
TORPEDO DIA.
29 21
95
22 7
34 95
33
28
30
35 20
24
7
7 40 41
23
26 7
27 38
25 95
95 39
7 95
11
10 37
14 95 36
12 19 95
14 Tooth Pinion Gear 18

87
8 3
9
6
12
1
13
7 2
17
15
16 5
4
7
5
4
5
4

Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
High Performance 92-802854A1 92-802854Q1
87
Gear Lube
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 6A-10 90-889785 APRIL 2003

GEAR HOUSING
Gear Housing (Drive Shaft)(Continued)

TORQUE
REF.
REF
– 1 GEAR HOUSING
1 1 GEAR HOUSING ASSEMBLY
2 1 DOWEL PIN (FRONT)
3 1 OILER TUBE
4 3 DRAIN SCREW 60 7
5 3 WASHER-Sealing
6 1 DOWEL PIN (REAR)
7 1 TRIM TAB
8 1 SCREW (.437-14 x 1.25) 22 30
9 1 WASHER
10 1 CARRIER
11 1 NEEDLE BEARING
12 2 ANODE
13 1 NUT
14 1 SCREW (M6 x 40) 60 7
PINION GEAR ([12 TEETH] 2.33:1 S/N-0T599000 AND ABOVE)
15 1
PINION GEAR ([14 TEETH] 2.07:1 S/N-0T598999 AND BELOW)
16 1 NUT 70 95
17 1 SHIFT CAM
18 1 TAPERED ROLLER BEARING
19 AR SHIM ASSEMBLY (SIZES 006 THRU 048)
20 1 DRIVE SHAFT ASSEMBLY
21 1 WEAR SLEEVE ASSEMBLY
22 1 RING SEAL
23 1 COVER ASSEMBLY
24 1 GASKET
25 1 GASKET
26 1 OIL SEAL (UPPER)
27 1 OIL SEAL (LOWER)
28 1 GASKET
29 1 WATER PUMP ASSEMBLY
30 1 FACE PLATE
31 4 SCREW (M6x30) 60 7
32 1 SEAL
33 1 KEY
34 1 IMPELLER
35 6 SCREW 60 7
36 1 SHIFT SHAFT ASSEMBLY
37 1 E-RING
38 1 BUSHING ASSEMBLY
39 1 O-RING
40 1 OIL SEAL
41 2 SCREW (M6 x 25) 60 7
42 1 SEAL
90-889785 APRIL 2003 Page 6A-11

GEAR HOUSING
Gear Housing (Prop Shaft)

95
69 107.95MM(4.25 IN.)
70 1
50 TORPEDO DIA.
44
48
4947
45
46 42 87
43
67 68
95 75
57 68
95 95 74
55
72
54
73
53
52
51
7 7
65
66
64
95
87
71
60
59
58
56
95 61
95 62 63

Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
87
High Performance 92-802854A1 92-802854Q1
Gear Lube
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 6A-12 90-889785 APRIL 2003

GEAR HOUSING
Gear Housing (Prop Shaft)(Continued)

TORQUE
REF.
REF
1 1 GEAR HOUSING ASSEMBLY
43 1 TAPERED ROLLER BEARING ASSEMBLY
44 1 CUP
FORWARD GEAR ([28 TEETH] 2.33:1, S/N-0T599000 AND ABOVE)
45 1
FORWARD GEAR ([29 TEETH] 2.07:1, S/N-0T598999 AND BELOW)
46 1 ROLLER BEARING
47 1 RETAINING RING
48 1 CAM FOLLOWER ASSEMBLY
49 3 BALL
50 1 SLIDE
51 1 SPRING
52 1 CLUTCH
53 1 CROSS PIN
54 1 SPRING
55 1 PROPELLER SHAFT
REVERSE GEAR ([28 TEETH] 2.33:1, S/N-0T599000 AND ABOVE)
56 1
REVERSE GEAR ([29 TEETH] 2.07:1, S/N-0T598999 AND BELOW)
57 1 BEARING CARRIER ASSEMBLY
58 1 O-RING
59 1 ROLLER BEARING
60 1 OIL SEAL (INNER)
61 1 OIL SEAL (OUTER)
62 1 ROLLER BEARING
63 1 THRUST WASHER
64 1 THRUST BEARING
65 2 STUD 100 135
66 2 WASHER
67 2 NUT 22 30
68 AR SHIM ASSEMBLY (SIZES 006 THRU 038)
69 2 THREAD INSERT
70 1 DECAL
71 1 DECAL-PROP OPERATION
72 1 THRUST HUB ASSEMBLY
73 1 PROPELLER NUT ASSEMBLY SERVICE ITEMS
74 1 TAB WASHER
75 4 SCREW 40 54
76 4 WASHER
90-889785 APRIL 2003 Page 6A-13

GEAR HOUSING
General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part, therefore,
it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more components.
Service procedure order in this section is a normal disassembly/reassembly sequence.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
When compressed air is used to dry a part, verify that no water is present in air line.
Bearings
All bearings must be cleaned and inspected. Clean bearings with solvent and dry with com-
pressed air. Air should be directed at the bearing so that it passes through the bearing. DO
NOT spin bearing with compressed air, as this may cause bearing to score from lack of lu-
brication. After cleaning, lubricate bearings with Premium Gear Lubricant. DO NOT lubri-
cate tapered bearing cups until after inspection.
Inspect ball bearings for roughness, catches and bearing race side wear. Work inner bear-
ing race in-and-out, while holding outer race, to check for side wear. When inspecting ta-
pered bearings, determine condition of rollers and inner bearing race by inspecting bearing
cup for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and race as a set.
Inspect gear housing for bearing races that have spun in their respective bores. If races
have spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded particles, un-
even wear and/or discoloration from overheating. The shaft and bearing must be replaced
if such a condition exists.
Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to ap-
pearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal
case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply
2-4-C with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C with Teflon to external
surfaces of bearing carrier.
Page 6A-14 90-889785 APRIL 2003

GEAR HOUSING
Draining and Inspecting Gear Lubricant

WARNING
If gear housing is installed on engine, to avoid accidental starting, disconnect (and
isolate) spark plug leads from spark plugs before working near the propeller.
1. With gear housing in normal running position, place a clean pan under housing and re-
move the two vent screws and one fill/drain screw (with gaskets).
c b
ob53922
a - Fill/Drain screw
b - Oil level screw
c - Vent screw
2. Inspect gear lubricant for metal particles (lubricant will have a metal flake appearance).
Drain lubricant into a clean pan/container. Presence of fine metal particles (resembling
powder) in the gear lubricant indicates normal wear. The presence of metal chips in the
gear lubricant indicates the need for gear housing disassembly and component inspec-
tion.
3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lu-
bricant. Gear lubricant which has been drained from a gearcase recently in operation
will have a yellowish color due to lubricant agitation/aeration. Gear lubricant which is
mixed with assembly lubricant (Special Lubricant 101 or 2-4-C with Teflon) will also be
creamy white in color. This is normal and should not be confused with the presence of
water. If water is suspected to be present in gearcase, a pressure check of gearcase
should be made (with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of
pressure for 5 minutes without leaking down. Pouring a portion of the gear lubricant into
a glass jar and allowing the lubricant to settle will allow any water in the lubricant to sepa-
rate and settle to the bottom of the jar.
4. Presence of water in gear lubricant indicates the need for disassembly and inspection
of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing compo-
nents for damage. If gearcase is rebuilt, gearcase should be pressure checked before
filling with lubricant.
90-889785 APRIL 2003 Page 6A-15

GEAR HOUSING
Removal
WARNING
To prevent accidental engine starting, remove (and isolate) spark plug leads from
spark plugs before removing gear housing.
1. Remove (and isolate) spark plug leads from spark plugs.
2. Shift engine into forward gear.
3. Tilt engine to full UP position.
4. Remove 4 fasteners.
5. Remove locknut and washer.
6. Remove gear housing.
a
b
ob53992
a - Fasteners (2 each side)

b - Locknut and washer
Page 6A-16 90-889785 APRIL 2003

GEAR HOUSING
Disassembly
Water Pump
NOTE: If water tube seal stayed on water tube (inside of drive shaft housing) when gear
housing was removed, pull water tube seal from water tube.
NOTE: Newer models will not have the isolators installed on the water pump.
1. Replace water tube seal, if damaged.
2. Remove 4 screws (2 on each side of water pump housing).
3. Remove cover.
a
c
ob19212
a - Water tube seal

b - Screw (4)
c - Cover
IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover (Step 4) and plate (Step 8), as the depth of the groove
will not affect water pump output.
4. Replace cover if thickness of steel at the discharge slots is 1.50 mm (0.060 in.) or less,
or if grooves (other than impeller sealing bead groove) in cover roof are more than 0.75 mm
(0.030 in.) deep.
5. Lift impeller, drive key, and gasket from drive shaft.
c b
ob19220
a - Impeller
b - Drive key
c - Gasket
90-889785 APRIL 2003 Page 6A-17

GEAR HOUSING
6. Inspect impeller. Replace impeller if any of the following conditions exist:

• Impeller blades are cracked, torn, or worn.
• Impeller is glazed or melted (caused by operation without sufficient water supply).
• Rubber portion of impeller is not bonded to impeller hub.
7. Remove plate and gasket.
8. Replace plate if grooves (other than impeller sealing bead groove) in plate are more than
0.75 mm (0.030 in.) deep.
c a
ob19219
a - Plate
b - Gasket
c - Impeller sealing groove
9. Remove screws and washers.
ob19217
a - Screws and washers (6 each)
Page 6A-18 90-889785 APRIL 2003

GEAR HOUSING
10. Remove water pump base using flat screwdrivers to lightly pry up on base.
a
ob19226
a - Water pump base
11. Remove (and discard) seals (It may be beneficial to clamp the water pump base in
a vise while removing seals).
ob19195
a - Seals
12. Remove gasket.
ob19218
a - Gasket
90-889785 APRIL 2003 Page 6A-19

GEAR HOUSING
Bearing Carrier and Propeller Shaft

1. Remove fasteners.
a ob51117
a - Fasteners
2. With propeller shaft horizontal, pull carrier (using tool shown) to break seal with gear
housing.
3. Remove bearing carrier/propeller shaft components as an assembly by pulling back on
the propeller shaft. Take care not to lose cam follower or 3 metal balls in end of propeller
shaft.
4. Remove propeller shaft from bearing carrier.
b
e a
c
d ob51116
a - Bearing carrier
b - Puller jaws (91-46086A1)
c - Puller bolt (91-85716)
d - Thrust hub
e - Propeller shaft
Page 6A-20 90-889785 APRIL 2003

GEAR HOUSING
5. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust
bearing and thrust washer if rusted or damaged.
6. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or
chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be in-
spected for damage.
ob19202
a - Reverse gear
b - Thrust bearing
c - Thrust washer
7. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If the bear-
ing needs to be replaced remove it using Slide Hammer (91-34569A1).
a
ob19205 91-34569A1
a - Radial bearing
90-889785 APRIL 2003 Page 6A-21

GEAR HOUSING
8. If bearing is rusted or does not roll freely, replace bearing. If replacement is necessary,
remove bearing and oil seals using Mandrel* and Driver Rod*. Discard oil seals.
*From Bearing Removal and Installation Kit (91-31229A7).
c
91-37323
91-36569
ob58205
a - Bearing
b - Mandrel (91-36569)
c - Driver Rod (91-37323)
9. Remove propeller shaft seals (if not removed previously) and bearing carrier O-ring.
ob51263
a - O-ring
Page 6A-22 90-889785 APRIL 2003

GEAR HOUSING
Propeller Shaft
INSPECTION
1. Clean propeller shaft assembly with solvent and dry with compressed air.
2. Inspect bearing carrier oil seal surfaces for grooves. Run fingernail across seal surface
to check for groove. Replace shaft if groove is found.
3. Visually check bearing surfaces of propeller shaft for pitting, grooves, scoring, uneven
wear or discoloration (bluish color) from overheating. Replace shaft and corresponding
needle bearing if any of the above conditions are found. (Bearing carrier needle bearing
contacts propeller shaft just in front of oil seal surface. Forward gear bearing contacts
propeller shaft in front of sliding clutch splines.)
4. Inspect propeller shaft splines for wear and/or corrosion damage.
5. Check propeller shaft for straightness. Use either method, following:
a. Place propeller shaft on balance wheels. Rotate propeller shaft and observe propel-
ler end of shaft for wobble. Replace shaft if any wobble is observed.
bb b
aa
cc
ob51872
a - Balance wheels
b - Bearing surfaces
c - Watch for wobble
b. Position propeller shaft roller bearing surfaces on V-blocks. Mount a dial indicator
at front edge of propeller splines. Rotate propeller shaft. Dial indicator movement of
more than 0.228 mm (0.009 in.) (or noticeable wobble) is reason for replacement.
b b
c a
ob51872
a - V-blocks
b - Bearing surfaces
c - Measure with dial Indicator at this point
90-889785 APRIL 2003 Page 6A-23

GEAR HOUSING
6. Replace propeller shaft if any of the following exist:

• Splines are twisted or worn.
• Bearing surfaces of propeller shaft are pitted or worn.
• Oil seal surface is grooved.
• Shaft has a noticeable wobble or is bent more than 0.228 mm (0.009 in.). Prop shaft
trueness should be measured with a dial indicator with prop shaft on V-blocks.
7. Inspect sliding clutch. Check reverse gear and forward gear clutch jaws. Rounded jaws
indicate one or more of the following:
a. Improper shift cable adjustment.
b. Improper shift habits of operator (shift from NEUTRAL to REVERSE gear too slow-
ly).
c. Engine idle speed too high (while shifting).
a aa
ob51865
a - Clutch jaws
8. Check condition of cam follower. If it shows wear (pitting, scoring or rough surface), re-
place cam follower and shift cam.
Page 6A-24 90-889785 APRIL 2003

GEAR HOUSING
DISASSEMBLY
1. Remove spring.
ob51876
a - Spring
2. Apply constant pressure to cam follower in order to prevent it and internal components
from ejecting out of the propeller shaft during removal of the cross pin from the clutch.
ob51800
a
a - Cross pin
b - Cam follower
90-889785 APRIL 2003 Page 6A-25

GEAR HOUSING
3. Remove components from propeller shaft.

4. Replace cam follower if worn or pitted.
5. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or
more of the following:
• Improper shift cable adjustment.
• Engine idle speed too high while shifting.
• Shifting from neutral to reverse (or forward) too slowly.
a f c
ob51265
b e d
a - Cam follower
b - Metal balls (3)
c - Guide block
d - Spring
e - Sliding clutch
f - Jaws
Page 6A-26 90-889785 APRIL 2003

GEAR HOUSING
Pinion Gear, Drive Shaft, and Forward Gear

1. Hold drive shaft using Drive Shaft Holding Tool Remove (and discard) pinion nut.
Model Drive Shaft Holding Tool

40/50 Bigfoot (4-Stroke) 91-56775
50/60 Bigfoot (4-Stroke) 91-817070A1
75/90/115 EFI (4-Stroke) 91-804776A1
60 Bigfoot (2-Stroke) 91-56775
75/90/100/115/125 (2-Stroke) 91-56775
2. Remove drive shaft, pinion gear, pinion bearing and forward gear.
3. Replace pinion gear if it is chipped or worn.
4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing
does not roll freely. To remove race, refer to Lower Drive Shaft Bearing Race, follow-
ing.
5. Replace forward gear if gear teeth or clutch teeth are chipped or worn.
a
c
d
b
f
ob19175
a - Drive Shaft Holding Tool

b - Pinion nut
c - Drive shaft
d - Pinion gear
e - Pinion bearing
f - Forward gear
90-889785 APRIL 2003 Page 6A-27

GEAR HOUSING
6. Replace forward gear needle bearing if it is rusted or does not roll freely.
7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and ham-
mer to remove bearing.
ob57905 b
ob19203
a - Retaining rIng
b - Forward gear needle bearing
8. Replace forward gear bearing and race if either are rusted, pitted or damaged, or if bear-
ing does not roll freely. Remove bearing from gear using Universal Puller Plate and man-
drel. To remove race, refer to Forward Gear Bearing Race, following.
a c
b 91-37241
ob51119
a - Forward gear bearing

b - Universal Puller Plate (91-37241)
c - Mandrel
Page 6A-28 90-889785 APRIL 2003

GEAR HOUSING
9. Replace drive shaft if splines are worn or twisted.

10. If bearing surface is damaged, replace drive shaft and corresponding bearing.
IMPORTANT: Do not tighten vise against drive shaft.
11. If wear sleeve is deeply grooved allowing water to enter gearcase, remove (and discard)
sleeve using Universal Puller Plate and mallet.
91-37241
c d
b
a ob19710
a - Crankshaft/drive shaft splines

b - Bearing surface
c - Wear sleeve
d - Universal Puller Plate (91-37241)
e - Mallet
12. Remove (and discard) rubber ring.

a
ob19152
a - Rubber ring
90-889785 APRIL 2003 Page 6A-29

GEAR HOUSING
Upper Drive Shaft Bearing

1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will
not roll freely. Remove bearing and then sleeve using Puller Assembly with suitable
jaws.
OR
c
91-83165M
a
b ob19177
a - Upper drive shaft bearing

b - Sleeve
c - Puller Assembly (91-83165M)
IMPORTANT: Upper drive shaft bearing/sleeve must be removed prior to oil sleeve
removal. Refer to Upper Drive Shaft Bearing, preceding.
Page 6A-30 90-889785 APRIL 2003

GEAR HOUSING
Oil Sleeve
1. Remove oil sleeve (if necessary) using Puller Assembly with suitable jaws.
b
a
91-83165M
ob19122
a - Oil sleeve
b - Puller Assembly (91-83165M)
90-889785 APRIL 2003 Page 6A-31

GEAR HOUSING
Lower Drive Shaft Bearing Race
IMPORTANT: Upper drive shaft bearing/sleeve and oil sleeve do not have to be re-
moved for lower drive shaft bearing race removal.
IMPORTANT: Retain shims for reassembly.
1. Remove race and shims using Bearing Race Tool.
NOTE: See Special Tools list in this section for bearing race tool application chart.
91-14308T01
91-14308T02
ob19171
a - Bearing race
b - Shim
c - Bearing Race Tool (91-14308T01 or 91-14308T02)
Page 6A-32 90-889785 APRIL 2003

GEAR HOUSING
Shift Shaft
1. Remove shift shaft coupler and nylon spacer.
ob53925
a - Shift shaft coupler

b - Spacer
2. Remove screws.
ob53926
a - Screws M6 x 25
NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing.
3. Remove shift shaft bushing and shift shaft.
a b
ob53927
a - Bushing
b - Shift shaft
90-889785 APRIL 2003 Page 6A-33

GEAR HOUSING
4. Remove shift cam from housing.

5. Replace shift cam if worn.
ob51117
a - Shift cam
6. Remove shift shaft bushing and clip from shift shaft.

7. Replace shift shaft if splines are worn or shaft is twisted.
8. Remove and discard O-ring.
a
d c e d
b
ob53928
a - Bushing
b - Clip
c - Shift shaft
d - Splines
e - O-ring
Page 6A-34 90-889785 APRIL 2003

GEAR HOUSING
9. Remove (and discard) seal. (Lightly clamp the bushing in a vise when removing seal.)
a
ob53929
a - Seal
Forward Gear Bearing Race

IMPORTANT: Retain shims for reassembly. If shims are damaged, replace with new
shims of equal thickness.
1. Remove race and shims using Slide Hammer.
91-34569A1
b c
ob27653
a - Race
b - Shims
c - Slide Hammer (91-34569A1)
90-889785 APRIL 2003 Page 6A-35

GEAR HOUSING
Reassembly
Forward Gear Bearing Race
NOTE: Propshaft should be vertical when installing bearing race.
1. Place shims (retained from disassembly) into housing. If shims were lost, or a new gear
housing is being assembled, start with 0.254 mm (0.010 in.) shim.
2. Assemble components as shown using mandrel. Apply 2-4-C with Teflon to O.D. of race.
Drive race into housing by striking propeller shaft end with lead hammer.
NOTE: Install a nut on the end of the propeller shaft to prevent damage to the propeller shaft
threads while performing step 2.
e d
91-31106
95
b
ob19179
a - Shims d - Disassembled propeller shaft

b - Race e - Assembled bearing carrier
c - Mandrel (91-31106)

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 6A-36 90-889785 APRIL 2003

GEAR HOUSING
Shift Shaft
1. Apply Loctite 271 on O.D. of new seal.
2. Press seal into shift shaft bushing until seal is seated against shoulder.
3. Install new O-ring.
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
c a
7
d b
ob53930
95
a - Seal
b - Bushing
c - Surface
d - O-ring

Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
95 2-4-C with Teflon 92-802859A1 92-802859Q1
5. Assemble components as shown.

a b
c ob53928
a - Shift shaft
b - E-clip
c - Shift shaft bushing
90-889785 APRIL 2003 Page 6A-37

GEAR HOUSING
6. Install shift cam. Align hole in shift cam with shift shaft pilot bore in gear housing.
ob51117
a - Shift cam (marked with part number only)

b - Shift shaft pilot bore
7. Install shift shaft assembly; insert splines into shift cam.
ob53932
a - Shift shaft assembly

b - Splines
Page 6A-38 90-889785 APRIL 2003

GEAR HOUSING
8. Apply Loctite 271 to bottom half of threads on each screw. Install screws and tighten to
specified torque.
ob53926
a - Screw (2)

Description
Ref. # ber Number
Loctite 271 – Thread 92-809819 92-809819
7
Locker
TORQUE
REF.
REF
a 2 SCREW (M6 x 25) 60 7
90-889785 APRIL 2003 Page 6A-39

GEAR HOUSING
Bearing Carrier Reassembly

1. Lubricate O.D. of bearing and bearing carrier bore with 2-4-C with Teflon.
2. Protect lip on forward side of bearing carrier, using Bearing Installation Tool (91-13945).
3. Press propeller shaft needle bearing (number side toward Mandrel [91-15755]) into car-
rier, until bearing bottoms out.
95
91-15755
91-13945
ob21042
a - Bearing Installation Tool (91-13945)

b - Mandrel (91-15755)
c - Suitable driver rod

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 6A-40 90-889785 APRIL 2003

GEAR HOUSING
4. Place smaller diameter seal on longer shoulder of Oil Seal Driver with seal lip away from
shoulder.
5. Protect lip on front side of bearing carrier using Bearing Installation Tool. Apply Loctite
271 on O.D. of seal. Press seal into carrier until tool bottoms.
a 7
91-31108
91-13945
ob21040
a - Seal c - Bearing Installation Tool

b - Oil Seal Driver (91-13945)
(91-31108)

Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
6. Place larger diameter seal on shorter shoulder of Oil Seal Driver with seal lip toward
shoulder.
7. Protect lip on front side of bearing carrier using Bearing Installation Tool. Apply Loctite
271 on O.D. of new seal. Press seal into carrier until tool bottoms.
a
b
91-31108 7
91-13945 ob21041
a - Seal c - Bearing Installation Tool

b - Oil Seal Driver (91-13945)
(91-31108)
Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
90-889785 APRIL 2003 Page 6A-41

GEAR HOUSING
8. Install O-ring. Lubricate O-ring with 2-4-C with Teflon. Lubricate seal lips with 2-4-C with
Teflon.
9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light
coating of 2-4-C with Teflon.
10. Press bearing into carrier until tool bottoms.
95
c
a
91-13945 ob19163
a - O-ring c - Bearing Installation Tool

b - Bearing, numbered side (91-13945)
toward tool

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
11. Install thrust washer. Coat thrust washer with Premium Gear Lubricant.
82
ob19167
a - Thrust washer

Description
Ref. # ber Number
Premium Gear Lubri- 92-802846A1 92-802846Q1
82
cant
Page 6A-42 90-889785 APRIL 2003

GEAR HOUSING
12. Install thrust bearing. Coat thrust bearing with Premium Gear Lubricant.
a
82
ob19168
a - Thrust bearing

Description
Ref. # ber Number
82
cant
13. Apply Premium Gear Lubricant to bearing surface of reverse gear and install reverse
gear.
82
ob19202
a - Reverse gear
b - Bearing surface

Description
Ref. # ber Number
82
cant
90-889785 APRIL 2003 Page 6A-43

GEAR HOUSING
Forward Gear Reassembly

1. Apply 2-4-C with Teflon to the I.D. of the bearing. Press bearing onto gear using suitable
mandrel (press only on inner race of bearing). Because the gear hub is longer than the
bearing, a tube type mandrel should be used to install the bearing. This will allow the
bearing to bottom out on the gear.
a
95
b
ob51869
a - Mandrel (91-37350)
b - Bearing

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, fol-
lowing, for tool end selection.
Model Installation End Bearing Position

Tool Stamped
6 Jaw Reverse 91-856875A 1 6 Flush with surface
Clutch
FORWARD GEAR NEEDLE BEARING INSTALLATION

6 Jaw Reverse Clutch
c
a ob56784
a - Stamped “6”
b - Numbered end of needle bearing
c - 6 Jaw reverse clutch
Page 6A-44 90-889785 APRIL 2003

GEAR HOUSING
3. Apply Premium Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing. Press
needle bearing into forward gear (using forward gear bearing installer tool) until tool bot-
toms out on gear.
a
82
b
91-877321A1
a - Forward Gear Bearing Installer (91-877321A1)

b - Needle Bearing, Numbered Side Toward Installer Tool

Description
Ref. # ber Number
82
cant
4. Install retaining ring into groove of forward gear by starting at one end of retaining ring
and working it around until seated in groove.
a
ob57905
a - Retaining ring
b - Groove in forward gear
90-889785 APRIL 2003 Page 6A-45

GEAR HOUSING
Propeller Shaft Reassembly

1. Install components into propeller shaft in sequence shown.
NOTE: When installing the clutch make sure the ratcheting clutch teeth (angled) are toward
forward gear, and non-ratcheting (square on both sides) are toward reverse gear.
e f g b
ob51265
d c a
Assembly Sequence
a - Spring
b - Guide block
c - Clutch
d - 3 metal balls
e - Cam follower
f - Forward clutch teeth
g - Reverse clutch teeth
2. Align the hole in the clutch with the hole in the guide block, install cross pin.
b
a
ob51800
a - Apply pressure in this direction

b - Cross pin
Page 6A-46 90-889785 APRIL 2003

GEAR HOUSING
3. Install spring. DO NOT allow spring coils to overlap each other.
ob51876
a - Spring
Drive Shaft Wear Sleeve Installation

1. Install new rubber ring.
2. Apply a light coat of Loctite 271 on outside diameter of rubber ring.
a
ob19152
7
a - Ring

Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
3. Insert sleeve into holder*.

*Component of Wear Sleeve Installation Tool (91-14310A1).
a
a
91-14310A1
ob19169
a - Sleeve
b - Holder
90-889785 APRIL 2003 Page 6A-47

GEAR HOUSING
4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool. Continue pressing
until the upper and lower part of the tool make surface to surface contact.
91-14310A1
a
b d
ob19166
a - Drive shaft
b - Wear Sleeve Installation Tool (91-14310A1)
c - Upper part of tool (Surface C)
d - Lower part of tool (Surface D)
5. Remove excess Loctite from assembled shaft.
Page 6A-48 90-889785 APRIL 2003

GEAR HOUSING
Lower Drive Shaft Bearing Race Installation

1. Lubricate O.D. of bearing race with 2-4-C with Teflon.
2. Install shims and bearing race into housing. If shims were lost or a new gear housing
is being assembled, start with 0.635 mm (0.025 in.) shims.
NOTE: Verify shims are not cocked when drawing up race. Once shims and bearing cup
are in place, position gearcase assembly so the drive shaft is vertical. This will aid in prevent-
ing the bearing cup from becoming cocked in the bore.
f e
a
91-14309T01
b 91-14309T02
95
c
ob58207
a - Shims; retained from disassembly

b - Bearing race
c - Mandrel* (13780 or 91-889623)
d - Mandrel* (13781)
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309T01 or 91-14309T02)
**From Bearing Removal and Installation Kit (91-31229A7)

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
90-889785 APRIL 2003 Page 6A-49

GEAR HOUSING
Oil Sleeve Installation

1. Install oil sleeve with tab positioned as shown.
ob53934
a - Oil sleeve b - Tab
Drive Shaft Upper Bearing Installation

1. Lubricate I.D. of bearing sleeve and O.D. of bearing with 2-4-C with Teflon.
2. Press bearing into sleeve using mandrel from Bearing Cup Driver.
b 91-13781
95
c
d
ob19164
a - Mandrel* (91-13781)
b - Bearing - numbered side toward mandrel
c - Bearing sleeve
d - Tapered end
*From Bearing Cup Driver (91-14309T02 or 91-14309T01)

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 6A-50 90-889785 APRIL 2003

GEAR HOUSING
3. Install bearing/sleeve into housing.

IMPORTANT: Oil sleeve must be installed prior to upper drive shaft bearing installa-
tion.
IMPORTANT: Lower drive shaft bearing cup pilots the mandrel (13780 or 91-889623)
during installation of the upper drive shaft bearing/sleeve. Lower bearing cup must be
installed prior to installing upper bearing/sleeve.
f
c
a e
b
91-14309T01
91-14309T02
d ob58206
a - Bearing/Sleeve d - Mandrel* (13780 or 91-889623)

b - Tapered End Of Sleeve e - Threaded Rod** (91-31229)
c - Mandrel* (13781) f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309T01 or 91-14309T02)

**From Bearing Removal and Installation Kit (91-31229A7)
90-889785 APRIL 2003 Page 6A-51

GEAR HOUSING
Forward Gear, Lower Bearing, Pinion Gear, and Drive Shaft Installation
1. Install components per assembly sequence shown.
a. Forward Gear/bearing and lower drive shaft tapered roller bearing: Work Premium
Gear Lubricant into bearing rollers.
b. Pinion nut (New): Clean nut and drive shaft threads with Loctite Primer or suitable
de-greaser. Apply Loctite 271 to threads (not necessary if using a new nut with
drylock patch on threads) during final assembly (after pinion gear depth and for-
ward gear backlash have been set), tighten to specified torque.
e
d
b
82
c
f
a
7
ob19175
Assembly Sequence:
a - Forward Gear/bearing d - Drive shaft
b - Lower drive shaft tapered roller e - Drive shaft holding tool
bearing f - Pinion nut (New)
c - Pinion gear
Model Drive Shaft Holding Tool

75/90/115 91-56775

Description
Ref. # Number Number
Loctite 271 – Thread 92-809819 92-809819
7
Locker
82
cant
117 Loctite 7649 Primer N 92-809824 92-809824
TORQUE
REF.
REF
f 1 NUT 70 95
Page 6A-52 90-889785 APRIL 2003

GEAR HOUSING
Pinion Gear Depth and Forward Gear Backlash

DETERMINING PINION GEAR DEPTH
NOTE: Read entire procedure before attempting any change in shim thickness.
IMPORTANT: Forward gear assembly pilots the end of the pinion gauge and must be
installed in gear housing when checking pinion gear depth. Without it an inaccurate
measurement will be obtained.
1. Clean the gear housing bearing carrier shoulder and diameter.
2. With gear housing positioned up right (drive shaft vertical), install Bearing Preload Tool
(91-14311A2) over drive shaft in sequence shown.
g
h h
e c
f b
a
d
a - Adaptor: Bearing surfaces clean and free of nicks

b - Thrust bearing: Oiled and able to move freely
c - Thrust washer: Clean and free of nicks and bends
d - Spring
e - Nut: Threaded all the way onto bolt
f - Bolt: Held snug against spring
g - Sleeve: Holes in sleeve must align with set screws
h - Set screw (2): Tightened against drive shaft, bolt should not slide on drive shaft.
3. Measure distance between top of nut and bottom of bolt head.

4. Increase distance by 25.4 mm (1 in.).
5. Rotate drive shaft 5 to 10 revolutions. This should properly seat drive shaft tapered roller
bearing.
a
c
ob19884
a - 25.4 mm (1 in.) c - Bolt head

b - Nut
90-889785 APRIL 2003 Page 6A-53

GEAR HOUSING
6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown Do not tighten collar retain-
ing screw at this time. Install gauging block with numbers away from split collar.
b d e
a c f
a - Arbor d - Split collar

b - Gauging block e - Collar retaining screw
c - Screw (2) f - Snap ring
7. Insert tool into forward gear assembly Position gauging block under pinion gear as
shown.
ob22067
a - Gauging block
8. Remove tool, taking care not to change gauging block position, and tighten collar retain-
ing bolt.
9. Insert tool into forward gear assembly Position proper numbered flat (from chart) of
gauging block – under pinion gear.
MODEL GEAR RATIO (PINION USE FLAT LOCATING DISC

GEAR TEETH/REVERSE NO. NO.
GEAR TEETH)
75/90 2.33:1 (12/28) 8 3
115 2.07:1 (14/29) 2 3
Page 6A-54 90-889785 APRIL 2003

GEAR HOUSING
10. Install locating disc against bearing carrier shoulder in gear housing.
11. Position access hole as shown.
a
Disc 3
ob24643
a - Locating disc b - Access hole
12. Determine pinion gear depth by inserting a feeler gauge through access hole in locating
disc.
13. The correct clearance between gauging block and pinion gear is 0.64 mm (0.025 in.).
14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to Deter-
mining Forward Gear Backlash, following.
15. If clearance is more than 0.064 mm (0.025 in.) add shims behind the bearing race. If
clearance is less than 0.064 mm (0.025 in.) remove shims from behind the bearing race.
When reinstalling pinion nut, apply Loctite 271 Thread Locker on threads of nut.
NOTE: Clean drive shaft and pinion nut threads with Loctite Primer or suitable de-greaser
before applying Loctite.
d c
a
7 b
ob24643
a - Feeler gauge
b - Gauging block
c - Pinion gear
d - Bearing race

Description
Ref. # ber Number
Loctite 271 – Thread 92-809819 92-809819
7
Locker
117 Loctite 7649 Primer N 92-809824 92-809824
90-889785 APRIL 2003 Page 6A-55

GEAR HOUSING
DETERMINING FORWARD GEAR BACKLASH

NOTE: Read entire procedure before attempting any change in shim thickness.
1. Obtain correct pinion gear depth; refer to Determining Pinion Gear Depth, preceding.
2. Install Bearing Preload Tool (91-14311A2) on drive shaft Refer to Determining Pinion
Gear Depth, preceding.
3. Install components as shown.
4. While holding the drive shaft (to prevent from turning), torque the puller bolt to specifica-
tion.
5. Rotate drive shaft 5-10 revolutions. This should properly seat the forward gear tapered
roller bearing. Repeat step 4.
d a b
c
ob53936
a - Propeller shaft
b - Bearing carrier (Assembled)
c - Puller jaws (91-46086A1)
d - Puller bolt (91-85716)
TORQUE
REF.
REF
d 1 PULLER BOLT 45 5
Page 6A-56 90-889785 APRIL 2003

GEAR HOUSING
6. Install components as shown.

e f
d
c
b c ob51117
a - Threaded rod (obtain locally) d - Dial Indicator Adaptor Kit

b - Washers (91-83155)
c - Nuts e - Dial Indicator (91-58222A1)
f - Backlash Indicator Tool
7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indi-
cator Tool. Make sure the dial indicator is perpendicular (⊥) to the indicator tool or an
inaccurate reading will be obtained.
ALIGN POINTER
MODEL INDICATOR TOOL WITH MARK
75/90 91-78473 4
115 91-19660--1 1
90-889785 APRIL 2003 Page 6A-57

GEAR HOUSING
8. Grasp the drive shaft pre-load tool bolt head and lightly turn drive shaft back and forth
(no movement should be noticed at propeller shaft).
9. Dial Indicator registers amount of backlash, which must be between specification shown
in chart.
MODEL DIAL INDICATOR MINIMUM READING MAXIMUM

75/90 0.30 mm (0.012 in.) 0.48 mm (0.019 in.)
115 0.38 mm (0.013 in.) 0.55 mm (0.019 in.)
10. If backlash is less than the minimum specification, remove shims from in front of forward
gear bearing race. If backlash is more than the maximum specification, add shims in
front of forward gear bearing race. When reinstalling pinion nut, apply Loctite 271 on
threads of nut.
NOTE: By adding or subtracting 0.025 mm (0.001 in.) shim, the backlash will change
approximately 0.025 mm (0.001 in.).
Bearing Carrier and Propeller Shaft Installation

1. Insert propeller shaft assembly into bearing carrier.
2. Before installing bearing carrier assembly into gear housing, obtain locally a 152 mm
(6 in.) long by 32 – 38 mm (1.25 in. – 1.50 in.) diameter piece of PVC pipe. Install the
PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly
with the propeller nut and tab washer. This holds the reverse gear and thrust bearing
tight against the bearing carrier preventing possible bearing damage during installation.
a b c d
ob21043
e
a - Bearing carrier assembly d - Prop shaft
b - PVC pipe e - Tab washer
c - Propeller nut
Page 6A-58 90-889785 APRIL 2003

GEAR HOUSING
3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with
2-4-C with Teflon.
4. Install bearing carrier and propeller shaft into housing with the word TOP (located on
flange) toward top of housing.
a b
95
ob21044
a - O-ring
b - TOP

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
NOTE: Use thick 2.29 mm (0.090 in.) washers (12-855941) under fasteners if not previously
installed.
Washer Thickness Fastener Torque

2.29 mm (0.090 in.) 30 Nm (22 lb-ft)
1.52 mm (0.060 in.) 34 Nm (25 lb-ft)
b
a
a - Washers
b - Fasteners (If using screws, apply Loctite 271 on threads)
90-889785 APRIL 2003 Page 6A-59

GEAR HOUSING
Water Pump Reassembly and Installation

1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver with seal
lip away from shoulder.
2. Apply Loctite 271 on O.D. of seal. Press seal into water pump base until tool bottoms.
91-13949
7
b
ob51553
a - Seal - Lip faces UP (when water pump base is installed on gearcase)
b - Spring - Faces UP (when water pump base is installed on gearcase)
c - Oil Seal Driver (91-13949)
d - Longer shoulder side of oil seal driver
e - Shorter shoulder side of oil seal driver

Description
Ref. # ber Number
Loctite 271 – Thread 92-809819 92-809819
7
Locker
Page 6A-60 90-889785 APRIL 2003

GEAR HOUSING
3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver with seal
lip toward shoulder.
4. Apply Loctite 271 on O.D. of seal; press seal into water pump base until tool bottoms.
5. Lubricate lip of each seal with 2-4-C with Teflon.
91-13949
95
b
7
ob51553
a - Seal - Lip Faces DOWN (when water pump base is installed on gearcase)
b - Spring - Faces DOWN (when water pump base is installed on gearcase)
c - Oil Seal Driver (91-13949)
d - Longer shoulder side of oil seal driver
e - Shorter shoulder side of oil seal driver

Description
Ref. # ber Number
7
Loctite 271 – Thread 92-809819 92-809819
Locker
95 2-4-C with Teflon 92-802859A1 92-802859Q1
6. Install gasket.
ob19218
a - Gasket
90-889785 APRIL 2003 Page 6A-61

GEAR HOUSING
IMPORTANT: To prevent cutting the seal lips remove any burrs or sharp edges from
the drive shaft splines before installing water pump base assembly.
7. Install components as shown. Apply Loctite 271 Thread Locker on bottom half of threads
and tighten to specified torque in sequence shown.
a & ! $
b
"
%
#
ob19217
a - Water pump base
b - Screws (6) M6 x 25 and washers (6)

Description
Ref. # ber Number
Loctite 271 – Thread 92-809819 92-809819
7
Locker
TORQUE
REF.
REF
b 6 SCREW (M6 x 25) 60 7
8. Install gasket and plate.

b
ob19219
a - Gasket
b - Plate
Page 6A-62 90-889785 APRIL 2003

GEAR HOUSING
IMPORTANT: If the old impeller is re-used it must be installed in original (clockwise)

direction of rotation.
9. Install gasket, drive key and impeller.
c
b
a
ob19220
a - Gasket
b - Drive key
c - Impeller
10. Lubricate I.D. of cover with 2-4-C with Teflon.

11. Rotate drive shaft clockwise and push impeller housing down (over impeller) until it con-
tacts water pump base.
12. Apply Loctite 271 to bottom threads of cover screws. Install cover screws and tighten
to specified torque.
95 a b
ob19212
a - Impeller Housing
b - Screw (4)

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
b 4 SCREW (M6x30) 60 7
NOTE: It is recommended that the gearcase be pressure tested for leaks after reassembly
and BEFORE gear lubricant is added. Gearcase should hold 70-80 kPa (10-12 psi) for 5
minutes.
90-889785 APRIL 2003 Page 6A-63

GEAR HOUSING
Gear Housing Pressure Test

1. Remove vent plug and install pressure test gauge.
2. Pressurize housing to 70-80 kPa (10-12 psi) and observe gauge for 5 minutes.
3. Rotate drive shaft, prop shaft and shift shaft while housing is pressurized to check for
leaks.
4. If pressure drop is noted, immerse housing in water.

5. Re-pressurize to 70-80 kPa (10-12 psi) and check for air bubbles.
6. Replace leaking seals as necessary. Retest housing.
NOTE: Gearcase should hold 70-80 kPa (10-12 psi) for 5 minutes.
7. Remove tester from housing and install vent plug and sealing washer.
Page 6A-64 90-889785 APRIL 2003

GEAR HOUSING
Filling Gear Housing With Lubricant

NOTE: Gear housing lubricant capacity is 710 ml (24 fl oz).
WARNING
If gear housing is installed on engine, to avoid accidental starting, disconnect (and
isolate) spark plug leads from spark plugs before working near the propeller.
CAUTION
Do not use automotive gear lubricant in the gear housing. Use only Premium Gear
Lubricant.
1. Remove any gasket material from Fill/Drain and Vent screws and gear housing.
2. Install new sealing washer on Fill/Drain and Vent screws.
IMPORTANT: Never apply lubricant to gear housing without first removing vent
screws or gear housing cannot be filled because of trapped air. Fill gear housing only
when drive shaft is in a vertical position.
3. Remove lubricant Fill/Drain screw and sealing washer from gear housing.
4. Insert lubricant tube into Fill hole, then remove Vent screws and sealing washer.
5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent screw
hole.
6. Install this Vent screw and sealing washer only and continue filling until excess starts
to flow out of second Vent screw hole.
7. Rotate drive shaft clockwise approximately 10 revolutions. Let gearcase sit for at least
one minute to allow any trapped air to settle out, then top off lubricant level.
a c
ob53922
a - Vent screw
b - Fill/Drain screw
c - Oil level vent screw
TORQUE
REF.
REF
a/b/c 3 DRAIN SCREW 60 7
90-889785 APRIL 2003 Page 6A-65

GEAR HOUSING
8. Replace second lubricant vent screw and sealing washer.

IMPORTANT: Do not lose more than 30cc (1 oz) of gear lubricant while reinstalling
FILL/DRAIN screw.
9. Remove lubricant tube from Fill/Drain hole; install Fill/Drain screw and sealing washer.
Gearcase Installation
IMPORTANT: Do not install a 75/90/115 2-stroke gearcase assembly on a 75/90/115
Optimax engine. The driveshaft on the Optimax gearcase is 15.87 mm (0.625 in.) lon-
ger than the 2-stroke gearcase driveshaft. Installation of the 2-stroke gearcase on the
Optimax engine will result in crankshaft failure.
15.87 mm
(0.625 in.)
ob00806
WARNING
Disconnect (and isolate) spark plug leads from spark plugs before installing gear
housing onto drive shaft housing. Failure to follow this warning could result in acci-
dental engine starting and possible injury.
1. Position outboard shift linkage into forward gear position.
NOTE: Front of shift block MUST extend 3.2 mm (1/8 in.) past front of rail.
a b
ob19879
a - Shift block
b - Rail
Page 6A-66 90-889785 APRIL 2003

GEAR HOUSING
2. Tilt engine to full up position and engage tilt lock lever.

3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direc-
tion.
4. Install water tube seal Apply 2-4-C with Teflon to I.D. of seal.
5. Apply a bead of RTV 587 Silicone Sealer as shown.
NOTE: For ease of gear housing installation, install water tube seal (labyrinth end) onto
water tube in drive shaft housing. Tapered end of water tube seal goes onto water pump.
95
116
b
ob53938
a - Water tube seal

b - RTV 587 Silicone Sealer

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
116
RTV 587 Silicone 92-809825 92-809825
Sealer
90-889785 APRIL 2003 Page 6A-67

GEAR HOUSING
CAUTION
Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clear-
ance space, will not allow drive shaft to fully engage with crankshaft. Subsequently,
tightening the gear housing fasteners (while lubricant is on top of drive shaft) will
load the drive shaft/crankshaft and damage either or both the power head and gear
housing. Top of drive shaft is to be wiped free of lubricant.
6. Apply a light coat of 2-4-C with Teflon onto drive shaft splines.
7. Apply a light coat of 2-4-C with Teflon on gearcase shift shaft splines and upper shift
shaft splines. Do not use lubricant on ends of shift shafts.
8. Install components as shown in appropriate photo.
ALL MODELS EXCEPT 75 W/MECHANICAL REVERSE LOCK
ob53698
a - Nylon spacer
b - Shift shaft coupler
75 W/MECHANICAL REVERSE LOCK

NOTE: Flat MUST BE positioned toward front of gear housing.
a b
ob53925
a - Nylon spacer
b - Shift shaft coupler
c - Flat
Page 6A-68 90-889785 APRIL 2003

GEAR HOUSING
9. Shift gear housing into forward gear position. In forward gear the gear housing will ratch-
et when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft
is rotated counterclockwise.
NOTE: During installation of gear housing, it may be necessary to move the shift block (lo-
cated under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines.
10. Apply Loctite 271 on threads of gear housing retaining screws.
11. Position gear housing so that the drive shaft is protruding into drive shaft housing.
12. Move gear housing up toward drive shaft housing, while aligning upper shift shaft
splines with shift shaft coupler splines, water tube with water tube seal, and crankshaft
splines with drive shaft splines.
13. Install 4 fasteners and washers (two each side). Install locknut and washer.
14. Torque screws and locknut (or nuts only if applicable) to specified torque.
7
b a
ob53922
a - Fasteners and washers (2 Each Side)

b - Locknut and washer

Description
Ref. # ber Number
Loctite 271 – Thread 92-809819 92-809819
77
Locker
TORQUE
REF.
REF
a 4 SCREW 40 54
15. Check shift operation as follows:
• Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is
turned clockwise. Resistance should be felt when propeller shaft is turned counter-
clockwise.
• Place shift lever in neutral. Propeller shaft should rotate freely in either direction.
• While rotating propeller shaft, place shift lever in reverse gear. Resistance should be
felt when propeller shaft is rotated in either direction.
IMPORTANT: If shift operation is not as described above, the gear housing must be
removed and the cause of the problem corrected.
90-889785 APRIL 2003 Page 6A-69

GEAR HOUSING
Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is now painted and does NOT aid in protecting the drive
shaft housing and gear housing from galvanic corrosion (corrosion and pitting of
metal surfaces). Side anodes now provide protection. Do not paint or place protec-
tive coating on the side anodes, or corrosion protection function will be lost.
TRIM TAB REPLACEMENT
1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before
removal Install new trim tab in same location.
TRIM TAB ADJUSTMENT
NOTE: The trim tab provides a means to offset (balance) some of the steering load that is
caused by propeller torque at higher operating speeds.
NOTE: Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges
in gearcase before attempting to move tab. DO NOT strike trim tab with a hard object to
make adjustments.
1. Shift engine control into NEUTRAL and turn ignition key to OFF position.
2. If at higher speeds the boat turns more easily to the left, loosen screw, move the trim
tab (trailing edge) to the left (when viewed from behind). Tighten retaining screw to spe-
cified torque.
3. If the boat turns more easily to the right, loosen screw, move the trim tab (trailing edge)
to the right (when viewed from behind) turn trim tab (trailing edge) to the right . Tighten
retaining screw to specified torque.
c
b a ob53931
a - Trim tab
b - Anti-ventilation plate
c - Retaining screw and washer
TORQUE
REF.
REF
c 1 SCREW (7/16–14 x 1.25) 22 30
Page 6A-70 90-889785 APRIL 2003

POWER TRIM
3. Remove check ball components from shock rod piston.

4. Remove O-ring from shock rod piston.
c
b
a
d
ob51147
a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring
CAUTION
When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs
to avoid damage to shock piston.
5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp
(91-63209).
6. Loosen shock rod piston using spanner wrench (1/4 in. x 5/16 in. long pegs).
7. Allow shock rod piston to cool. Remove from shock rod.
a
b
ob51146 ob51146
a - Spanner Wrench
b - Shock rod piston
90-889785 APRIL 2003 Page 5B-43

POWER TRIM
8. Inspect check valve for debris. Clean debris from check valve if found. If debris cannot
be cleaned from check valve, replace shock piston as an assembly.
9. Clean shock and components with compressed air.
10. Remove inner O-ring from shock rod piston.
a b
ob51199
a - Shock piston
b - O-ring
11. Remove cylinder end cap assembly from shock rod.

12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper.
13. Place end cap on clean work surface.
14. Remove rod wiper, inner O-ring, and outer O-ring.
c
b
ob51145
a - Rod wiper
b - Inner O-ring
c - Outer O-ring
Page 5B-44 90-889785 APRIL 2003

POWER TRIM
Memory Piston Removal

1. Remove memory piston from cylinder using one of two methods:
a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool.
SRP-4 (Snap-On)
b. Blowing compressed air into manual release valve hole using air nozzle.
WARNING
Memory piston cup may be expelled at a high velocity when air pressure is applied.
Failure to place cylinder as shown below could result in personal injury.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston.
2. Remove O-ring from memory piston.
a d
e
ob55466 ob51144
a - Adaptor/air hose
b - Memory piston exit
c - Shop rag
d - O-ring
e - Memory piston
90-889785 APRIL 2003 Page 5B-45

POWER TRIM
Cleaning/Inspection/Repair
IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in
Power Trim system could cause system to malfunction.
Clean shock rod and components with parts cleaner and dry with compressed air.
It is recommended that all O-rings in trim system be replaced. Use O-Ring Kit 25-809880A1.
Lubricate all O-rings with Power Trim & Steering Fluid. If not available, use automotive (ATF)
Trim Motor Electrical Tests
1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor.
IMPORTANT: Trim motor is not serviceable. If motor fails to run, replace motor as-
sembly.
Page 5B-46 90-889785 APRIL 2003

POWER TRIM
Reassembly
O-Ring and Seal Placement
O-rings and seals are part of O-ring kit 25-809880A1.
!
"
&
!!
!'
(
$
#$ #'
21
!# ##
#! #"
#%
$
#( #&
#' #*
#)
$
(
90-889785 APRIL 2003 Page 5B-47

POWER TRIM
O-Ring Sizes
!2
#1
$9
"3
)7
!! %
#"
13
&
#( #) #! 14
#%
!' #&
*
#*
Cutaway View of O-Ring
#$
( Width
#' 21
!#
O.D. I.D.
##
O-RINGS SHOWN ARE ACTUAL SIZE
Page 5B-48 90-889785 APRIL 2003

POWER TRIM
O-Ring Description and Sizes

O-Ring Description O-ring I.D. O-ring O.D. O-ring Width
1 Wiper ring (412585)
2 Cyl. cap, inner1 17.04 mm (0.671 in.) 24.10 mm (0.949 in.) 3.53 mm (0.139 in.)
3 Cyl. cap 47.34 mm (1.864 in.) 50.90 mm (2.004 in.) 1.78 mm (0.07 in.)
4 Shock piston 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)
5 Piston screw05797) 17.17 mm (0.676 in.) 20.726 mm (.816 in.) 1.78 mm (0.07 in.)
6 Reservoir plug01271) 13.94 mm (0.549 in.) 19.17 mm (0.755 in.) 2.616 mm (0.103 in.)
7 Motor seal12599)
8 (2) P.O. check plug06484) 12.42 mm (0.489 in.) 15.97 mm (0.629 in.) 1.78 mm (0.07 in.)
9 (3) Poppet assy.4585)
10 (2) P.O. check seat07328) 9.25 mm (0.364 in.) 12.80 mm (0.504 in.) 1.78 mm (0.07 in.)
11 (2) Pump port 3.683 mm (0.145 in.) 7.239 mm (0.285 in.) 1.78 mm (0.07 in.)
12 Suction seat 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
13 Filter seal12607)
14 Filter12590)
15 Manual release406483) 2.90 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
18 Spool09051) 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
19 (3) Spool housing09005) 7.645 mm (0.301 in.) 11.20 mm (0.441 in.) 1.78 mm (0.07 in.)
20 Trim limit spool06483) 2.895 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
21 (2) Manifold405387) 5.283 mm (0.208 in.) 8.839 mm (0.348 in.) 1.78 mm (0.07 in.)
22 Memory piston412579) 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)
90-889785 APRIL 2003 Page 5B-49

POWER TRIM
Power Trim Reassembly

IMPORTANT: Lubricate all O-rings with Power Trim & Steering Fluid. If not available,
use automotive (ATF) automatic transmission fluid.
Shock Rod Reassembly
1. Install lubricated O-rings to end cap.
2. Install rod wiper.
3. Install lubricated O-rings to shock piston.
c
b
e f
ob51145 d ob51199
a - Rod wiper
b - Inner O-ring
c - Outer O-ring
d - Shock piston
e - O-ring
f - O-ring
4. Clamp shock rod in soft jawed vise.

5. Position cylinder end cap onto rod as shown.
ob51146
CAUTION
When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in.
(6.4mm x 8mm) long pegs to avoid damage to shock rod piston.
6. Apply Loctite 271 Thread Locker to threads on shock rod.
7. Install shock rod piston.
Page 5B-50 90-889785 APRIL 2003

POWER TRIM
8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs).
If a torquing type spanner tool is used to tighten shock piston, then torque to specified
torque.
b a
ob51146
a - Shock rod piston b - Spanner Wrench
TORQUE
QTY DESCRIPTION lb-in. lb-ft Nm
1 SHOCK PISTON 90 122
9. Remove shock rod assembly from vise.

10. Install ball, seat, and spring (five sets) to shock rod piston.
11. Secure components with plate. Tighten screws to specified torque.
e
d
c
a
b ob51147
a - Screw (3)
b - Plate
c - Spring (5)
d - Seat (5)
e - Ball (5)
TORQUE
3 SCREW 35 4
90-889785 APRIL 2003 Page 5B-51

POWER TRIM
Shock Rod Installation

1. Place trim cylinder in soft jawed vice.
2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston
all the way to bottom.
3. Fill cylinder 76.2 mm (3 in.) from top of cylinder using Power Trim and Steering Fluid.
If not available, use automotive (ATF) automatic transmission fluid.
4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage.
Fill remaining cylinder to just below the cylinder threads.
b
c
a - Memory piston
b - O-ring
c - Oil blow off ball passage
CAUTION
End cap must not make contact with shock rod piston when tightening. Shock rod
piston must be positioned in cylinder deep enough to avoid contact.
5. Tighten end cap securely using spanner wrench (1/4 in. x 5/16 in. long pegs). If a torqu-
ing type spanner tool is used to tighten end cap, then torque to specified torque.
TORQUE
1 END CAP 45 61
Page 5B-52 90-889785 APRIL 2003

POWER TRIM
Trim Limit Assembly Installation

1. Lubricate all O-rings with Power Trim and Steering Fluid. Install spring, poppet, spool
housing and trim limit spool into manifold.
NOTE: There are three different size springs used in this manifold. The heavy spring is used
on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The
light spring is used on 30-60 hp outboards.
or or a
d
ob51008
a - Spring
b - Poppet
c - Spool housing
d - Trim limit spool
Manual Release Valve Installation

1. Install E clip (if removed) and lubricate O-rings on manual release valve.
2. Install manual release valve assembly into manifold.
b
a - Manifold
c - E Clip
90-889785 APRIL 2003 Page 5B-53

POWER TRIM
Manifold Installation
1. Install dowel pin and two (2) lubricated O-rings into trim cylinder.
a - O-ring (2)
b - Dowel pin
2. Align the trim cylinder and pump/reservoir assembly together.

3. Install the two (2) long screws and torque to specified torque.
c
b
ob51146
a - Trim cylinder assembly

b - Reservoir/Manifold assembly
c - Screw (2)
TORQUE
2 SCREW 100 11.5
Page 5B-54 90-889785 APRIL 2003

POWER TRIM
Oil Pump Installation

1. Install spring, ball, lubricated O-ring and plastic seat to manifold.
2. Check to see that O-rings are placed on bottom of pump.
3. Install filter and filter seal under pump. Install pump onto manifold. Tighten screws to
specified torque.
a - Screw (3)
b - Suction seat assembly
TORQUE
3 SCREW 70 8
90-889785 APRIL 2003 Page 5B-55

POWER TRIM
Pressure Operated Assembly Installation

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found
on poppet, replace poppet.
a
b
a - Debris under valve tip

b - Rubber seat
1. Lubricate O-rings.
2. Install spool, seat with O-ring, check valve/poppet, spring and plug with O-ring into
pump. Repeat for other side. Tighten plugs to specified torque.
a
b
c
d
e
d
c
b
a
a - Plug (2)
b - Spring (2)
c - Check valve/poppet (2)
d - Seat (2)
e - Spool
TORQUE
2 PLUG 120 13.5
Page 5B-56 90-889785 APRIL 2003

POWER TRIM
Reservoir/Motor Installation
1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and
place reservoir onto pump/manifold assembly. Install ground strap under screw shown.
Tighten screws to specified torque.
e f
a - Screw (4)
b - Reservoir
c - Reservoir seal
d - Coupler
e - Manifold assembly
f - Ground strap
TORQUE
4 SCREW 80 9
2. Fill reservoir to bottom of fill hole using Power Trim and Steering Fluid. If not available,
use automotive (ATF) automatic transmission fluid.
90-889785 APRIL 2003 Page 5B-57

POWER TRIM
Bleeding Power Trim Unit

1. Secure power trim unit in soft jawed vise.
2. Add power trim fluid until it is even with the bottom of the fill hole. Reinstall plug.
3. Close the manual release valve. (Turn full clockwise).
ob55263
a - Reservoir plug/fill Hole

4. Cycle system full up and down 3 times or until fluid level remains at proper level.
Connect power trim wire to 12 volt source.
Direction
⇑ Up ⇓ Down
Blue + Positive Blue – Negative
Green – Negative Green + Positive
5. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until
fluid level stays even with the bottom of the fill hole.
Page 5B-58 90-889785 APRIL 2003

POWER TRIM
Installation of Power Trim System

1. Apply 2-4-C with Teflon to lower pivot pin bore and pivot pin surface.
2. Position trim cylinder assembly (BOTTOM FIRST) between clamp brackets and route
trim pump electrical harness through access hole in starboard clamp bracket.
3. Start lower pivot pin into pivot pin bore and position lower cross pin (RETAINED) in its
respective hole.
4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assem-
bly until pivot pin is flush with outside surface.
95
b c a ob53965
a - Trim cylinder assembly c - Lower cross pin

b - Lower pivot pin

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
5. Using a suitable punch, drive lower cross pin into its respective bore until seated.
6. Install sacrificial aluminum anode to reservoir bracket placing ground strap to anode, as
shown.
c
a
ob53967
b
a - Lower cross pin c - Ground strap
b - Sacrificial anode
90-889785 APRIL 2003 Page 5B-59

POWER TRIM
7. Apply 2-4-C with Teflon to surface of upper pivot pin, pivot pin bore and trim ram bore.
NOTE: Install trim ram with cross hole located as shown. If trim ram is installed reversed,
the trim sender (if installed) will not operate.
f b
95
c
a
95
e
a - Pivot pin
b - Trim ram bore
c - Install trim ram as shown
d - Engine side
e - Transom side
f - Cross hole

Description
Ref. # ber Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 5B-60 90-889785 APRIL 2003

POWER TRIM
8. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram
until pivot pin is flush with swivel bracket.
ob53966
a - Pivot pin
b - Swivel bracket
c - Trim ram
9. Drive upper retaining pin in until seated.
ob52941
a - Retaining pin
90-889785 APRIL 2003 Page 5B-61

POWER TRIM
10. Secure trim harness with clamps.
a
ob55264
a - Clamps
11. Recheck fluid level.

12. Power trim may now be operated to lower outboard to desired position. Trim system is
self purging.
13. Reconnect power trim leads to relays under ignition cover.
14. Reinstall spark plug leads to spark plugs.
15. Reinstall cowls.
16. Connect battery leads to battery terminals.
Page 5B-62 90-889785 APRIL 2003

ATTACHMENTS / CONTROL LINKAGE

Section 7
Table of Contents
Ride Guide Steering Cable/Attaching Kit Parallel Routed Steering Cables and
Installation (92876A1) . . . . . . . . . . . . . . . . . . . . 7-2 Attaching Kit Installation . . . . . . . . . . . . . . . 7-15
Single Cable . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Maintenance Instructions . . . . . . . . . . . . . . 7-4 Opposite Side Routed Steering Cables
Ride Guide Steering Cable/Attaching Kit and Attaching Kit Installation . . . . . . . . . . . 7-26
Installation (92876A3) . . . . . . . . . . . . . . . . . . . . 7-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . 7-37
Dual Cable - Single Outboard . . . . . . . . . . 7-5 Ride Guide Steering Attachment
Super Ride-Guide Steering Kit Installation 7-6 Extension Couplers . . . . . . . . . . . . . . . . . . . 7-37
Steering Cable Mounting Tube Installation 7-7 Maintenance Instructions . . . . . . . . . . . . . . 7-38
Installing Steering Cables . . . . . . . . . . . . . 7-8 Transom Mounted Ride Guide Attaching
Coupler Installation . . . . . . . . . . . . . . . . . . . 7-9 Kit Installation (73770A1) . . . . . . . . . . . . . . . . . 7-40
Installing Link Rod . . . . . . . . . . . . . . . . . . . . 7-10 Attaching Kit Installation . . . . . . . . . . . . . . . 7-40
Maintenance Instructions . . . . . . . . . . . . . . 7-13 Maintenance Instructions . . . . . . . . . . . . . . 7-45
Ride Guide Steering Cable/Attaching Kit Clevis Attaching Kit Installation (A-70599A5) 7-46
Installation (92876A6) . . . . . . . . . . . . . . . . . . . . 7-14 Installation Instructions . . . . . . . . . . . . . . . . 7-46
Dual Cable - Dual Outboard . . . . . . . . . . . 7-14 Maintenance Instructions . . . . . . . . . . . . . . 7-47
Installation Requirements . . . . . . . . . . . . . . 7-14
90-889785 APRIL 2003 Page 7-1

Ride Guide Steering Cable/Attaching Kit Installation

(92876A1)
Single Cable
Refer to Quicksilver Accessories Guide to determine correct length of steering
cable and remote control cables.
IMPORTANT: Steering cable and remote control cables must be the correct length.
Sharp bends on too-short cables result in kinks and too-long cables require unnec-
essary bends and/or loops. Both conditions place extra stress on the cables and
will reduce the performance of the steering system.
INSTALLING RIDE GUIDE CABLE TO OUTBOARD TILT TUBE
IMPORTANT: Before installing steering cable in tilt tube, lubricate entire cable end
with 2-4-C with Teflon.
NOTE: Ride Guide steering cable is lubricated at the factory and requires no additional
lubrication at initial installation.
1. Lubricate seal inside of outboard tilt tube and entire cable end with 2-4-C with Teflon.
2. Insert steering cable end through outboard tilt tube and secure steering cable to tilt
tube with steering cable attaching nut, as shown. Torque nut to specification.
95 aa
c 95
b
ob28160
ob57833
a - Seal
b - Cable end
c - Nut

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
c 1 NUT 35 47.5
Page 7-2 90-889785 APRIL 2003

STEERING LINK ROD INSTALLATION

IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt “a” (Part Number 10-849838) and
self locking-nuts “b” and “c” (Part Number 11-826709113). These locknuts must
never be replaced with common nuts (non-locking) as they will work loose and vi-
brate off freeing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown
overboard exposing them to serious injury or death.
3. Assemble steering link rod to steering cable with two flat washers “d” and nylon insert
locknut “b” (Part Number 11-826709113). Tighten locknut “b” until it seats, then back
nut off 1/4 turn.
4. Production Outboards - Assemble steering link rod to engine with special washer
head bolt “a” (Part Number 10-849838) and nylon insert locknut “c” (Part Number
11-826709113). First torque bolt “a” to 27 Nm (20 lb. ft.), then torque locknut “c” to 27
Nm (20 lb. ft.).
High Performance Outboards - An access hole is provided through the bottom cowl
to ease installation of the link rod connecting bolt. Remove the back plug for installa-
tion and reinstall after installation.
aa
bb
c ob57834
a - Washer head bolt

b - Lock nut
c - Lock nut
d - Washer
TORQUE
REF.
REF
a 1 WASHER HEAD BOLT 20 27
Tighten nut until it
b 1 LOCK NUT seats and then back
off 1/4 turn
c 1 LOCK NUT 20 27
WARNING
After installation is complete (and before operating outboard), check that boat
will turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) and
at all tilt angles to assure interference-free movement.
90-889785 APRIL 2003 Page 7-3

Maintenance Instructions
Maintenance inspection is owner’s responsibility and must be performed at intervals spe-
cified, following:
Normal Service - Every 50 hrs. of operation or 60 days (whichever comes first)
Severe Service* - Every 25 hrs. of operation or 30 days (whichever comes first)
*Operation in a salt water area is considered Severe Service.
1. Carefully check steering system components for wear. Replace worn parts.
2. Check steering system fasteners to be sure that they are torqued to correct specifica-
tions.
NOTE: Ride-Guide Steering Cables are lubricated at the factory and require no additional
WARNING
Core of each steering cable (transom end) must be fully retracted into cable hous-
ing before lubricating cable. If cable is lubricated while extended, hydraulic lock
of cable could occur.
3. With core of Ride-Guide Steering Cable (transom end) fully retracted, lubricate tran-
som end of steering cables through grease fittings “a” with 2-4-C with Teflon. Lubricate
exposed portion of cable end “b” with 2-4-C with Teflon.
4. Lubricate pivot point “c” of steering link rod and ball joint “d” of link rod with SAE 10W30
weight oil.
5. Inspection and lubrication of steering head assembly (rotary or straight rack) should
be performed once each year (by your Authorized Dealer) or whenever steering
mount and/or steering head are disassembled, or if steering effort has increased. Lu-
bricate with 2-4-C with Teflon.
110
95 d
110
a b
a c
ob57833
a - Grease fitting c - Pivot point
b - Cable end d - Ball joint

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
Page 7-4 90-889785 APRIL 2003


(92876A3)
Dual Cable - Single Outboard
WARNING
Quicksilver Super Ride-Guide Steering (dual cables) must be used with this at-
taching kit. Failure to adhere to this requirement could result in steering system
failure.
Refer to Mercury Precision Parts/Quicksilver Accessories Guide to determine cor-
rect length of steering cables and remote control cables.
IMPORTANT: Steering cables and remote control cables must be the correct
length. Sharp bends on too-short cables result in kinks and too-long cables require
unnecessary bends and/or loops. Both conditions place extra stress on the cables
and will reduce the performance of the steering system.
CAUTION
With this kit installed, the upper (outboard) mounting bolts must be installed so
that hex head end of bolts is on the inside of boat transom, as illustrated. Failure
to install upper mounting bolts, as shown in illustration, could result in interfer-
ence between steering cable nut and ends of mounting bolts when outboard is
tilted up.
CAUTION
Marine sealer must be used on shanks bolts to make a water-tight installation.
IMPORTANT: DO NOT use an impact driver when tightening transom bolts.
1. Apply marine sealer to shanks of mounting bolts (not threads) and secure outboard
to transom with four bolts, flat washers and locknuts, as shown. Be sure that installa-
tion is water tight.
2. Install upper bolts so that hex head end of bolts is on the inside of boat transom.
d
b
151
a
c
a - 1/2 in. diameter bolts (4) c - Locknuts (4)
b - Flat washers(4) d - Flat washers(4)

Description
151 Marine Sealer Obtain Locally Obtain Locally
90-889785 APRIL 2003 Page 7-5

Super Ride-Guide Steering Kit Installation

IMPORTANT: Both gear racks or rotary steering heads must be installed so that
both steering cables will be routed together on the same side of the boat and will
push-and-pull together.
1. Install Super Ride-Guide Steering Kit in accordance with instructions included with
Super Ride-Guide Kit.
2. Make sure that both gear racks or rotary steering heads are installed so that both
steering cables are routed together down starboard side of boat and will push and pull
together.
aa
b bb c
c
b
a - Gear rack
b - Steering cables
c - Rotary steering heads
Page 7-6 90-889785 APRIL 2003

Steering Cable Mounting Tube Installation

IMPORTANT: Spacers must be installed between outboard swivel bracket and
mounting bracket for steering cable mounting tube to provide proper spacing be-
tween steering cables.
1. Secure mounting bracket for steering cable mounting tube onto swivel bracket of out-
board.
b
aa
cc
dd
ob28163
cc
a - Mounting bracket for steering cable mounting tube
b - Spacer (2)
c - Locking retainer (2)
d - Bolts (4) - 22 mm (7/8 in.) long
TORQUE
REF.
REF
d 4 BOLT 100 11.5
WARNING
Locking retainer corner tabs, must be bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube to outboard swivel
bracket to prevent bolts from turning out.
2. Install steering cable mounting tube into mounting bracket with two adjusting nuts and
two locking tab washers. Verify longer threaded end of tube is toward starboard side
of boat.
3. Temporarily adjust tube so that longer threaded end of tube extends out the same dis-
tance as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d
bb
cc a ob51891
a - Steering cable mounting tube (end of tube with longer threads toward star-
board side of boat)
b - Mounting bracket
c - Locking tab washers (2)
d - Adjustment nuts (flats of nuts facing toward locking tab washer)
90-889785 APRIL 2003 Page 7-7

Installing Steering Cables

IMPORTANT: Lubricate inside of outboard tilt tube, inside of steering cable mount-
ing tube and rubber O-ring seal (located in outboard tilt tube) with 2-4-C with Teflon
before installing steering cables.
1. Lubricate inside of outboard tilt tube and inside of steering cable mounting tube with
2-4-C with Teflon. Verify rubber O-ring seal (located in outboard tilt tube) is lubricated.
aa
ob51890
a - O-ring seal
2. Insert steering cable ends through outboard tilt tube and cable mounting tube. Thread
steering cable attaching nuts on to tubes hand tight.
NOTE: Torque steering cable attaching nuts only after final steering adjustments have
been made.
d b a
c
ob51891
a - Steering cable ends c - Cable mounting tube
b - Tilt tube d - Attaching nuts
3. Place a mark on steering cable mounting tube 16 mm (5/8 in.) from end of mounting
tube. Slide plastic spacer, O-ring and cap over steering cable.
16 mm(5/8 in.)
a
c d e ob51890
a - Mark d - O-ring
b - Cable mounting tube e - Cap
c - Plastic spacer
4. Thread cap onto steering cable mounting tube, up to mark.
a b ob51890
a - Cap b - Mark
Page 7-8 90-889785 APRIL 2003

Coupler Installation
WARNING
Locknuts must be used with bolts to secure steering cables to coupler. Failure
to adhere to this requirement could result in steering system failure.
Slide coupler onto steering cable ends and secure each steering cable to coupler with bolt
and locknut as shown. Tighten to specification.
b c
aa bb
ob51888
a - Coupler
b - Bolt
c - Locknut
TORQUE
REF.
REF
b 2 BOLT 20 27
90-889785 APRIL 2003 Page 7-9

Installing Link Rod

WARNING
Steering link rod must be secured between outboard steering arm and steering
coupler, using special washer head bolt (10-849838) and two nylon insert lock-
nuts (11-826709113), as shown. Both special washer head bolt and nylon insert
locknuts must be tightened as specified.
1. Lubricate hole in steering coupler, with 2-4-C with Teflon. Assemble steering link rod
to steering coupler, using two flat washers (one each side of coupler) and nylon insert
locknut. Tighten locknut until it seats – do not exceed 13.5 Nm (120 Ib. in.) of torque,
then back nut off 1/4 turn.
2. Lubricate ball joint in steering link rod with SAE 10W30 motor oil. Secure link rod to
outboard steering arm, using special washer head bolt provided and nylon insert lock-
nut as shown. Torque special bolt to 27 Nm (20 Ib. ft.), then torque locknut to 27 Nm
(20 Ib. ft.).
110 e
b
cc
ff 95
a d
ob28172
a - Steering coupler
b - Steering link rod
c - Flat washer (2)
e - Special washer head bolt (10-849838)
f - Nylon insert locknut (11-826709113)

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
TORQUE
REF.
REF
Torque until it seats
– Do not exceed
d 1 NYLON INSERT LOCKNUT
13.5 Nm (120 lb. in.)
then back off 1/4 turn
e 1 WASHER HEAD BOLT 20 27
f 1 NYLON INSERT LOCKNUT 20 27
Page 7-10 90-889785 APRIL 2003

STEERING SYSTEM TENSION ADJUSTMENT

IMPORTANT: After this dual steering cable attachment kit is installed, there must
be proper tension in forward mounted steering cable for this attachment kit to oper-
ate properly. Not enough tension will cause slack (or play) in steering system. Too
much tension will cause steering cables to bind. Perform the following steps to ad-
just for correct tension.
1. Loosen adjustment nuts and pull steering cable mounting tube (by hand) away from
end of steering cable (to remove slack in steering system).
2. Tighten adjustment nuts against mounting bracket and check system for slack (play.)
If steering system is too tight, readjust tube toward end of steering cable or, if too much
slack (play) exists in system, readjust tube away from end of steering cable.
3. Tighten nuts against mounting bracket and readjust, if necessary.
b
cc a dd
ob51887
a - Steering cable mounting tube
b - Adjustment nuts
c - Adjust tube in this direction to remove slack from steering system
d - Adjust tube in this direction to reduce tension from steering system
90-889785 APRIL 2003 Page 7-11

4. After steering system tension is adjusted correctly, tighten adjustment nuts against
mounting bracket, to a torque of 47.5 Nm (35 Ib. ft.) and bend a tab lock washer
against flat on each adjustment nut.
c c a ob51887
b - Adjustment nuts
c - Tab lock washer (bend against flat on each adjustment nut)
TORQUE
REF.
REF
b 2 ADJUSTMENT NUTS 35 47.5
5. Tighten steering cable attaching nuts on each steering cable to specification.
b
b
aa
ob51889
a - Cable attaching nut
b - V groove
TORQUE
REF.
REF
a 2 CABLE ATTACHING NUTS 35 47.5
NOTE: Cable attaching nuts with a V groove around the outer circumference of the nut
are self-locking and do not require locking sleeves.
WARNING
After installation is complete and before operating outboard, check that boat will
turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) at
all tilt angles to assure interference free movement.
Page 7-12 90-889785 APRIL 2003

cified, following:

tions.
WARNING
could occur.
som end of steering cables through grease fittings with 2-4-C with Teflon. Lubricate
exposed portion of cable ends with 2-4-C with Teflon.
4. Lubricate pivot point of steering link rod and ball joint of link rod/steering coupler with
SAE 10W30 motor oil.
be performed once each year (by your Authorized Dealer), whenever steering mount
and/or steering head are disassembled, or if steering effort has increased. Lubricate
with 2-4-C with Teflon.
95 110
110 d
b
c
95
aa a ob28170
95
a - Grease fittings c - Pivot point

b - Cable ends d - Ball joint

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
90-889785 APRIL 2003 Page 7-13


(92876A6)
Dual Cable - Dual Outboard
WARNING
Quicksilver Super Ride-Guide Steering (dual cables) must be used with this at-
taching kit. Failure to adhere to this requirement could result in steering system
failure.
Refer to Mercury Precision Parts/Quicksilver Accessories Guide to determine cor-
rect length of steering cable and remote control cables.
IMPORTANT: Steering cable and remote control cables must be the correct length.
Sharp bends on too-short cables result in kinks and too-long cables require unnec-
essary bends and/or loops. Both conditions place extra stress on the cables and
reduce the performance of the steering system.
Installation Requirements
IMPORTANT: The distance from each outboard’s centerline to the side of transom
opening MUST BE a minimum of 406 mm (16 in.).
This kit contains all necessary parts to connect both outboards to Ride-Guide Steering
Cables for 597 mm – 699 mm (23-1/2 in. – 27-1/2 in.) outboard centerline spacing. If out-
board centerline distance is other then specified, refer to end of this instruction manual
for optional extension couplers.
DETERMINE ROUTING OF STEERING CABLES
Use 1 or 2, following, to route steering cables:
1. Parallel cable routing: Cables routed together down starboard side of boat. Refer
to Parallel Routed Steering Cables and Attaching Kit Installation immediately fol-
lowing.
2. Opposite side cable routing: One cable routed down starboard side of boat and one
cable routed down port side of boat. Refer to Opposite Side Routed Steering
Cables and Attaching Kit Installation.
CAUTION
With this kit installed, the upper (outboard) mounting bolts must be installed so
that hex head end of bolts is on the inside of boat transom, as illustrated. Failure
to install upper mounting bolts, as shown in illustration, could result in interfer-
ence between steering cable nut and ends of mounting bolts when outboard is
tilted up.
Install upper bolts so that hex head end of bolts is on the inside of boat transom.
Page 7-14 90-889785 APRIL 2003

Parallel Routed Steering Cables and Attaching Kit Installation

BOTH STEERING CABLES ROUTED TOGETHER DOWN STARBOARD SIDE OF BOAT
SUPER RIDE-GUIDE STEERING KIT INSTALLATION
IMPORTANT: Steering cable must be installed into tilt tube of port outboard before
outboard is mounted on boat transom.
IMPORTANT: Both gear racks or rotary steering heads must be installed so that
both steering cables will be routed together on the same side of the boat and will
push and pull together.
a
b b a
a - Straight rack (left); rotary steering (right)
b - Steering cables (install so that both cables will push and pull together)
90-889785 APRIL 2003 Page 7-15

STEERING CABLE INSTALLATION STARBOARD OUTBOARD

IMPORTANT: Mounting bracket for steering cable mounting tube must be secured
to outboard swivel bracket, using 16 mm (5/8 in.) long bolts supplied with this dual
cable - dual outboard attaching kit.
WARNING
Locking retainer corner tabs, must be bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube to outboard swivel
bracket, to prevent bolts from turning out.
1. Secure mounting bracket for steering cable mounting tube onto swivel bracket of star-
board outboard.
cc
cc
b
b
a ob28164
b - Locking retainers (2)
c - Bolts (4) - 16 mm (5/8 in.) long
TORQUE
REF.
REF
c 4 BOLTS 100 11.5
two locking tab washers. Be sure longer threaded end of tube is toward starboard side
of boat.
3. Temporarily adjust tube, so that longer threaded end of tube extends out the same
distance as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d
bb
cc a
ob51891
a - Steering cable mounting tube (end of tube with longer threads toward star-
board side of boat)
Page 7-16 90-889785 APRIL 2003

IMPORTANT: Lubricate inside of steering cable mounting tube with 2-4-C with Te-
flon before installing steering cable.
4. Lubricate inside of steering cable mounting tube (starboard outboard) with 2-4-C with
Teflon.
5. Insert steering cable end through cable mounting tube and thread steering cable at-
taching nut onto tube hand tight.
NOTE: Torque steering cable attaching nut only after final steering adjustments have
been made.
a
c b 95
ob51887
a - Cable end c - Attaching nut
b - Mounting tube

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
16 mm (5/8 in.)
bb
a c d e ob51890
a - Mark d - O-ring
b - Mounting tube e - Cap
c - Plastic spacer
a b ob51890
a - Mark b - Cap
90-889785 APRIL 2003 Page 7-17

STEERING CABLE INSTALLATION - PORT OUTBOARD

IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-
cated inside tilt tube with 2-4-C with Teflon before installing steering cable.
1. Lubricate inside of port outboard’s tilt tube and rubber O-ring seal with 2-4-C with Te-
flon.
aa 95
ob51890
a - O-ring seal

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
2. Insert steering cable end through tilt tube of port outboard and thread steering cable
attaching nut onto tilt tube hand tight.
been made.
a
c b
ob51887
b - Tilt tube
TORQUE
REF.
REF
c 1 CABLE ATTACHING NUT 35 47.5
Page 7-18 90-889785 APRIL 2003

WARNING
Steering link rods must be secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
Lubricate holes in ends of steering cables with 2-4-C with Teflon. Assemble steering link
rods to steering cable ends of each outboard, using flat washers and nylon insert locknuts.
Tighten locknuts until they seat – do not exceed 13.5 Nm (120 Ib. in.) of torque, then back
nut off 1/4 turn.
Lubricate ball joints in steering link rods with SAE 10W30 motor oil. Secure link rods to out-
board steering arms, using special washer head bolts (10-849838) and nylon insert lock-
nuts. Torque special bolts to 27 Nm (20 Ib. ft.) then torque locknuts to 27 Nm (20 Ib. ft.).
110
ee cc
95 e
f a
b a ob50061
dd
c c
e e
a a
d b d b
f f ob28166
a - Flat washer (2 each d - Nylon insert locknut

link rod) e - Steering link rod
b - Nylon insert locknut f - Steering cable end
c - Special washer head
bolt (10-849838)

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
TORQUE
REF.
REF
– Do not exceed
b 1 NYLON INSERT LOCKNUT
13.5 Nm (120 lb. in.)
c 1 WASHER HEAD BOLT 20 27
d 1 NYLON INSERT LOCKNUT 20 27
90-889785 APRIL 2003 Page 7-19

STEERING ARM EXTENSION BRACKET INSTALLATION
WARNING
Locking retainer corner tabs must be bent up and against flats on each bolt that
secures extension bracket to outboard steering arm to prevent bolts from turning
out.
1. Secure a steering arm extension bracket to each outboard’s steering arm.
b
d
dd
aa
c
c cc
ob51889
a - Steering arm (port outboard shown)
b - Extension bracket
c - Locking retainer (2 each bracket)
d - Bolts (2 each bracket) 31.8 mm (1-1/4 in.) long
TORQUE
REF.
REF
d 2 BOLTS 23 31
STEERING COUPLER ASSEMBLY AND INSTALLATION

1. Position outboards so that they are facing straight forward. Distance between
threaded hole centers of steering arm extensions must be equal to distance between
propeller shaft centerlines.
2. Lubricate inside of rubber sleeves with 2-4-C with Teflon and slide sleeves on steering
coupler.
3. Work rubber bushings onto threaded ends of steering eyes.
4. Thread jam nut on starboard steering eye.
5. Thread steering eyes equally into coupler, so that distance between hole centers of
steering eye ball joints is equal to distance between threaded hole centers of steering
arm extensions. Exposed threads of steering eyes must be of equal length and
threads must not extend out from coupler more than 70 mm (2-3/4 in.).
95
c d e b a b d c
ob50061
a - Coupler d - Rubber bushing
b - Rubber sleeve e - Jam nut
c - Steering eye

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
Page 7-20 90-889785 APRIL 2003

WARNING
Both steering eyes must be threaded into coupler 19 mm (3/4 in.) minimum.
Thread length of steering eye is 89 mm (3-1/2 in.), so exposed thread must not
extend out of coupler more than 70 mm (2-3/4 in.). Failure to adhere to this re-
quirement could result in steering system failure.
6. Lubricate ball joint in steering eyes, with SAE 10W30 motor oil.
7. Assemble steering coupler between outboard steering arm extension brackets, using
special washer head bolts (10-849838) provided and nylon insert locknuts as shown.
IMPORTANT: With assembled steering coupler installed, and before tightening
special washer head bolts/locknuts, check outboard alignment . Distance between
centers of special washer head bolts must be equal to distance between propeller
shaft center lines for proper steering. If adjustment is necessary, temporarily re-
move special washer head bolt/locknut from one steering eye and turn eye in or out
to correct alignment.
8. Torque special washer head bolts to 27 Nm (20 Ib. ft.), then torque locknuts to 27 Nm
(20 Ib. ft.).
WARNING
Both steering eyes must be threaded into coupler 19 mm (3/4 in.) minimum, and
jam nut must be tightened against coupler to prevent coupler from turning.
Torque jam nut to 27 Nm (20 Ib. ft.).
9. Tighten jam nut against coupler. Torque jam nut to 27 Nm (20 Ib. ft.).
Page 7-22 90-889785 APRIL 2003

10. Spray Corrosion Guard on exposed threads of steering eyes and position rubber
bushings and rubber sleeves to cover exposed threads of steering eyes.
f a f
ob28167
110
g 110
g
ff
cc
gg hh
dd 120 bb 120
dd
c
hh h
f
f cc ee a ob50061
a - Coupler
b - Rubber sleeve
c - Steering eye
d - Rubber bushing
e - Jam nut - torque against coupler
f - Special washer head bolt (10-849838)
g - Nylon insert locknut (11-826709113)
h - Steering arm extension bracket

Description
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
TORQUE
REF.
REF
e 1 JAM NUT 20 27
f 1 WASHER HEAD BOLT 20 27
g 1 NYLON INSERT LOCKNUT 20 27
90-889785 APRIL 2003 Page 7-23

STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES)

IMPORTANT: For proper operation of this dual cable - dual outboard steering instal-
lation, there must be proper tension in the steering system. Not enough tension will
cause slack (play) in steering system. Too much tension will cause steering cables
to bind. Perform the following steps to correctly adjust tension.
2. Tighten adjustment nuts against mounting bracket and check system for slack (play).
a b
cc dd
ob51887
b - Adjustment nuts
mounting bracket, to a torque to specification and bend a tab lock washer against a
flat on each nut.
bb
c c a ob51887
b - Adjustment nuts
c - Tab lock washer – bend against flat on each adjustment nut
TORQUE
REF.
REF
Page 7-24 90-889785 APRIL 2003

5. Tighten steering cable attaching nuts of each steering cable to a torque of 47.5 Nm
(35 Ib. ft.).
a
a
ob51887
a - Cable attaching nut
TORQUE
REF.
REF
a 2 CABLE ATTACHING NUTS 35 47.5
WARNING
After installation is complete (and before operating outboard), check that boat
Adjust trim tabs of both outboards, as outlined in Trim Tab Adjustment, following.
90-889785 APRIL 2003 Page 7-25

Opposite Side Routed Steering Cables and Attaching Kit Installation

ONE CABLE ROUTED DOWN STARBOARD SIDE OF BOAT AND ONE CABLE ROUTED
DOWN PORT SIDE OF BOAT
SUPER RIDE-GUIDE STEERING KIT INSTALLATION
IMPORTANT: Steering cable must be installed into tilt tube of port outboard before
outboard is mounted on boat transom.
STEERING CABLE INSTALLATION - STARBOARD OUTBOARD
IMPORTANT: Mounting bracket for steering cable mounting tube MUST BE secured
to outboard swivel bracket, using 16 mm (5/8 in.) long bolts supplied with this dual
cable - dual outboard attaching kit.
WARNING
Locking retainer corner tabs must be bent up and against flats on each bolt that
secures mounting bracket for steering cable mounting tube, to prevent bolts
from turning out.
1. Secure mounting bracket for steering cable mounting tube, onto swivel bracket of
starboard outboard.
dd d
c
c
b aa ob28164

b - J clip - supplied with outboard
c - Locking retainers (2)
d - Bolts (4) - 16 mm (5/8 in. ) long
TORQUE
REF.
REF
c 4 BOLTS 100 11.5
two locking tab washers. Verify longer threaded end of tube is toward center of boat
transom.
Page 7-26 90-889785 APRIL 2003

3. Temporarily adjust tube, so that longer threaded end of tube extends out the same
distance as the outboard tilt tube. Do not tighten adjustment nuts at this time.
d
bb
a c ob51891
a - Steering cable mounting tube (end of tube with longer threads toward center
of boat transom)
IMPORTANT: Lubricate inside of steering mounting tube with 2-4-C with Teflon be-
fore installing steering cable.
4. Insert steering cable end (steering cable routed down port side of boat) through cable
mounting tube and thread steering cable attaching nut onto tube hand tight.
been made.
a
95
bb cc ob51887
b - Mounting tube

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
90-889785 APRIL 2003 Page 7-27

5/8 in. (16 mm)
aa
e d c b ob51890
a - Mark d - O-ring
b - Mounting tube e - Cap
c - Plastic spacer
a ob51888
a - Mark b - Cap
Page 7-28 90-889785 APRIL 2003

STEERING CABLE INSTALLATION - PORT OUTBOARD

IMPORTANT: Lubricate inside of port outboard’s tilt tube and rubber O-ring seal lo-
cated inside tilt tube with 2-4-C with Teflon, before installing steering cable.
1. Lubricate inside of port outboard’s tilt tube and rubber O-ring seal with 2-4-C with Te-
flon.
aa 95
ob51890
a - O-ring seal

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
2. Insert steering cable end (steering cable routed down starboard side of boat) through
3. tilt tube of port outboard and thread steering cable attaching nut onto tilt tube hand
tight.
been made.
c a
b
ob51887
a - Steering cable end c - Attaching nut
b - Tilt tube
TORQUE
REF.
REF
90-889785 APRIL 2003 Page 7-29

WARNING
Steering link rods must be secured between outboard steering arm and steering
cable end, using special washer head bolt (10-849838) and two nylon insert lock-
Lubricate holes in ends of steering cables, with 2-4-C with Teflon. Assemble steering link
rods to steering cable ends of each outboard, using flat washers and nylon insert locknuts.
Tighten locknuts until they seat – do not exceed 13.5 Nm (120 lb. in.) of torque, then back
nut off 1/4 turn.
Lubricate ball joints in steering link rods with SAE 10W30 motor oil. Secure link rods to
outboard steering arms, using special washer head bolts provided and nylon insert lock-
nuts as shown. Torque special bolts to 27 Nm (20 lb. ft.) then torque locknuts to 27 Nm
(20 Ib. ft.).
ee 110
cc
ee
f a 95
d ob50061
aa
bb
ee cc cc
ee
aa
aa
d d
f b
b ff ob28165
a - Flat washer (2 each link rod)
b - Nylon insert locknut (11-826709113)
c - Special washer head bolt (10-849838)
e - Steering link rod
f - Steering cable end
Page 7-30 90-889785 APRIL 2003


Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
TORQUE
REF.
REF
– Do not exceed
b 1 NYLON INSERT LOCKNUT
13.5 Nm (120 lb. in.)
c 1 WASHER HEAD BOLT 20 27
d 1 NYLON INSERT LOCKNUT 20 27
90-889785 APRIL 2003 Page 7-31

STEERING ARM EXTENSION BRACKET INSTALLATION
WARNING
Locking retainer corner tabs, MUST BE bent up and against flats on each bolt that
secures extension bracket to outboard steering arm, to prevent bolts from turn-
ing out.
1. Secure a steering arm extension bracket to each outboard’s steering arm.

b
d dd
aa
c c
ob51889
a - Steering arm (port outboard shown)
b - Extension bracket
c - Locking retainer (2 each bracket)
d - Bolts (2 each bracket) 31.8 mm (1-1/4 in.) long
TORQUE
REF.
REF
d 2 BOLTS 23 31
Page 7-32 90-889785 APRIL 2003

STEERING COUPLER ASSEMBLY AND INSTALLATION
WARNING
Both steering eyes must be threaded into coupler 19 mm (3/4 in.) minimum.
Thread length of steering eye is 89 mm (3-1/2 in.), so exposed thread must not
extend out of coupler more than 70 mm (2-3/4 in.). Failure to adhere to this re-
quirement could result in steering system failure.
1. Position outboards so that they are facing straight forward. Distance between
threaded hole centers of steering arm extensions must be equal to distance between
propeller shaft centerlines.
2. Lubricate inside of rubber sleeves with 2-4-C with Teflon and slide sleeves on steering
coupler.
3. Work rubber bushings onto threaded ends of steering eyes.
4. Thread jam nut on starboard steering eye.
5. Thread steering eyes equally into coupler, so that distance between hole centers of
steering eye ball joints is equal to distance between threaded hole centers of steering
arm extensions. Exposed threads of steering eyes must be of equal length and
threads must not extend out from coupler more than 2-3/4 in. (70 mm).
95
c d e b a b d c
ob50061
a - Coupler d - Rubber bushing

b - Rubber sleeve e - Jam nut
c - Steering eye

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
6. Lubricate ball joint in steering eyes with SAE 10W30 motor oil.
7. Assemble steering coupler between outboard steering arm extension brackets, using
special washer head bolts (10-849838) provided and nylon insert locknuts, as shown.
IMPORTANT: With assembled steering coupler installed and before tightening spe-
cial washer head bolts/locknuts, check outboard alignment. Distance between
centers of special washer head bolts must be equal to distance between propeller
shaft center lines for proper steering. If adjustment is necessary, temporarily re-
move special washer head bolt/locknut from one steering eye and turn eye in or out
to correct alignment.
8. Torque special washer head bolts to 27 Nm (20 Ib. ft.), then torque locknuts to 27 Nm
(20 Ib. ft.).
90-889785 APRIL 2003 Page 7-33

WARNING
Both steering eyes MUST BE threaded into coupler 19 mm (3/4 in.) minimum, and
jam nut must be tightened against coupler to prevent coupler from turning.
Torque jam nut to 27 Nm (20 Ib. ft.).
9. Tighten jam nut against coupler. Torque jam nut to 27 Nm (20 Ib. ft.).
10. Spray Corrosion Guard on exposed threads of steering eyes and position rubber
bushings and rubber sleeves to cover exposed threads of steering eyes.
ff ff
aa
ob28174
gg gg
110
ff
110
cc
g h ob50061
120 120
dd b d
cc
hh
h
ff
ff
c e a ob50061
a - Coupler f - Special washer head bolt

b - Rubber sleeve (10-848838) - torque to 27 Nm (20
c - Steering eye lb.ft.)
d - Rubber bushing g - Nylon insert locknut - torque to 27 Nm
e - Jam nut - torque (against cou- (20 lb. ft.)
pler) to 27 Nm (20 lb. ft.) h - Steering arm extension bracket

Description
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
TORQUE
REF.
REF
e 1 JAM NUT 20 27
f 1 WASHER HEAD BOLT 20 27
g 1 NYLON INSERT LOCKNUT 20 27
Page 7-34 90-889785 APRIL 2003

STEERING SYSTEM TENSION ADJUSTMENT (PARALLEL ROUTED STEERING CABLES)

IMPORTANT: For proper operation of this dual cable - dual outboard steering instal-
lation, there must be proper tension in the steering system. Not enough tension will
cause slack (play) in steering system. Too much tension will cause steering cables
to bind. Perform the following steps to correctly adjust tension.
2. Tighten adjustment nuts against mounting bracket and check system for slack (play).
aa
b
ob51887
d c
b - Adjustment nuts
mounting bracket to specification and bend a tab lock washer against a flat on each
nut.
c c a ob51887
b - Adjustment nuts
c - Tab lock washer (bend against flat on each adjustment nut)
TORQUE
REF
REF.
5. Tighten steering cable attaching nuts on each steering cable to a torque of 47.5 Nm
(35 Ib. ft.).
NOTE: Cable attaching nuts with a V groove around outer circumference are self-locking
and do not require locking sleeves.
90-889785 APRIL 2003 Page 7-35

been made.
a ob51887
a - Attaching nut
TORQUE
REF.
REF
WARNING
After installation is complete and before operating outboard, check that boat will
turn right when steering wheel is turned right and that boat will turn left when
all tilt angles to assure interference-free movement.
6. Adjust trim tabs of both outboards, as outlined in Trim Tab Adjustment, following.
Page 7-36 90-889785 APRIL 2003

Trim Tab Adjustment

DUAL OUTBOARD - COUNTER ROTATION
INSTALLATION
1. Shift outboard into neutral and make sure ignition key is at off position.
2. Remove plastic cap from rear of driveshaft housing and loosen bolt and trim tab.
3. Position trim tabs of both outboards straight to rear of outboard, so that tabs are
aligned with gear housing centerline.
4. Tighten both trim tab bolts securely and replace plastic caps. No further adjustment
will be required.
DUAL OUTBOARD - NON COUNTER ROTATION INSTALLATION
1. Check trim tab position as follows:
IMPORTANT: Initial trim tab setting for both outboards should be straight to rear
of outboard, so that tabs are aligned with gear housing center line. Refer to follow-
ing.
a. Operate boat at normal cruise throttle setting and adjust trim to optimum setting.
b. If boat pulls to the right (starboard), trailing edge of trim tab must be moved to the
right (when viewing outboard from behind). If boat pulls to the left (port), trailing
edge of trim tab must be moved to the left.
2. If necessary, adjust trim tab as follows:
a. Shift outboard into neutral and make sure ignition key is at off position.
b. Remove plastic cap from rear of drive shaft housing and loosen bolt and trim tab.
IMPORTANT: Trim tabs MUST BE set in the same position on both outboards.
c. If boat pulls to the right, adjust trailing edges of both trim tabs to the right. If boat
pulls to the left, adjust trailing edges of both trim tabs to the left.
d. Tighten both trim tab bolts securely and replace plastic caps.
e. Operate boat. Readjust trim tabs, if necessary.
Ride Guide Steering Attachment Extension Couplers
Listed below are typical couplers available. Refer to the current Mercury Precision
Parts/Quicksilver Accessory Guide for specific coupler lengths and part numbers.
Outboard Center Line Distance Required Coupler Between Steering Eyes
572 mm – 622 mm 305 mm (12 in.) Coupler
(22-1/2 in. – 24-1/2 in.)
597 mm – 699 mm 381 mm (15 in.) Coupler (Supplied with this kit)
(23-1/2 in. – 27-1/2 in.)
673 mm 755 mm 457 mm (18 in.) Coupler
(26-1/2 in. – 30-1/2 in.)
763 mm – 864 mm 229 mm (9 in.) Coupler and 305 mm (12 in.)
Coupler
(30 in. – 34 in.) (Connected together with coupler link rod)
838 mm – 940 mm 305 mm (12 in.) Coupler and 305 mm (12 in.)
Coupler
(33 in. – 37 in.) (Connected together with coupler link rod)
90-889785 APRIL 2003 Page 7-37

WARNING
When 2 couplers are connected together with coupler link rod, a lock washer
must be used on each side of coupler link rod, and link rod must be torqued to
27 Nm (20 Ib. ft.) into end of each coupler.
aa aa
b
cc ob51890
a - Couplers connected together

b - Lock washers
c - Coupler link rod
TORQUE
REF.
REF
c 1 COUPLER LINK ROD 20 27
cified, following:
tions.
WARNING
of cable could occur.
som end of steering cables through grease fittings with 2-4-C with Teflon. Lubricate
exposed portion of cable ends with 2-4-C with Teflon.
4. Lubricate pivot points of steering link rods and ball joints of link rods/steering coupler
with SAE 10W30 motor oil.
Page 7-38 90-889785 APRIL 2003

be performed once each year (by your Authorized Dealer) or whenever steering
mount and/or steering head are disassembled, or if steering effort has increased. Lu-
bricate with 2-4-C with Teflon.
d d
d
95 110
110 110 110
a c cc
b a b
a
a
95 95
95 95
95
ob28168
Lubrication Points for Parallel Cable Routing Installations
d
d
110 110
110 110
cc
cc
a
b a aa a bb
95
95 95 95
95 95
ob28175
Lubrication Points for Opposite Side Cable Routing Installations

a - Grease fitting c - Pivot points
b - Cable ends d - Ball joints

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
90-889785 APRIL 2003 Page 7-39

Transom Mounted Ride Guide Attaching Kit Installation

(73770A1)
Attaching Kit Installation
1. Lubricate both holes in pivot block (Figure 1) with 2-4-C with Teflon.
2. Place pivot block on pivot spacer and secure to transom bracket with 9.5 mm x 63.5
mm (3/8 in. x 2-1/2 in.) bolt, flat washer and locknut, as shown in Figure 1. Torque lock-
nut to specification.
aa b i hh
95
f
k c gg
95
d
l
j ee
Figure 1
a - Ride-Guide cable
b - Ride-Guide yoke
c - Pivot block
d - Pivot spacer
e - 381 mm (15 in.) (centerline of attaching kit pivot to centerline of outboard)
f - Pivot attaching locknut
g - Outboard steering arm
h - Clevis kit
i - Ride-Guide cable attaching locknut
j - Bolt – 9.5 mm x 63.5 mm (3/8 in. x 2-1/2 in.)
k - Flat washer
l - Transom bracket

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
f 1 PIVOT ATTACHING LOCKNUT 20 27
i 1 RIDE GUIDE CABLE ATTACHING LOCKNUT 10 13.5
Page 7-40 90-889785 APRIL 2003

3. Place Ride-Guide yoke on pivot block and secure with 11.1 mm x 44.5 mm (7/16
in. x 1-3/4 in.) bolt and locknut, as shown in Figures 1 and 2. Torque locknut to
13.5 Nm (10 Ib. ft.), then back off 1/4-turn.
g ff
bb
cc
ee
Figure 2
a - Transom backing plate
b - Bolt – 7.9 mm x 82.5 mm (5/16 in. x 3-1/4 in.)
c - Locknut
d - Ride-Guide yoke attaching locknut
e - 60.3 mm (2-3/8 in.) maximum transom thickness
f - Bolt – 11.1 mm x 44.5 mm (7/16 in. x 1-3/4 in.)
g - Ride-Guide yoke
TORQUE
REF
REF.
c 3 LOCKNUT 10 13.5
Torque to 13.5 Nm
d 1 RIDE GUIDE YOKE ATTACHING LOCKNUT (10 lb. ft. ) and then
back off 1/4 turn
90-889785 APRIL 2003 Page 7-41

4. Install one cable tube jam nut onto steering cable tube. Place tab washer over
Ride-Guide yoke, then insert cable tube through tab washer and yoke. Install second
cable tube jam nut onto cable tube but do not tighten at this time. (Figure 3)
5. Position transom attaching kit on transom as shown:
a. Determine centerline of outboard, then measure 38.1 cm (15 in.) over from this
centerline and draw a vertical line on transom. (Figure 1)
b. Position attaching kit on transom so that transom bracket is centered on the
38.1 mm (15 in.) measure (Figure 1), at the height where the center of the Ride-
Guide yoke is even with, or not more than 12.7 mm (1/2 in.) above top edge
of transom. (Figure 3)
f h j
aa e
e
f b
i
k
c
g
b
dd
Figure 3
a - Ride-Guide yoke g - After jam nuts are torqued to speci-
b - 0 mm to 12.8 mm (0 in. to 1/2 in.) fication, bend locking tabs against
(center of Ride-Guide yoke to top of nuts
transom h - Cable guide tube
c - Top of transom i - Ride-Guide cable attaching nut
d - Transom bracket j - Clevis kit
e - Cable tube jam nuts k - Clevis attaching locknut
f - Tab washer
TORQUE
REF
REF.
e 2 CABLE TUBE JAM NUTS 35 47.5
i 1 RIDE GUIDE CABLE ATTACHING NUT 35 47.5
k 1 CLEVIS ATTACHING LOCKNUT 20 27
Page 7-42 90-889785 APRIL 2003

NOTE: When drilling through transom, be sure that holes are drilled perpendicular to tran-
som.
6. With attaching kit positioned as outlined preceding, use 3 holes in transom bracket
as a guide and drill three 8.7 mm (11/32 in.) holes through transom.
7. Use a marine-type sealer on three 7.9 mm x 82.6 mm (5/16 in. x 3-1/4 in.) bolts. Se-
cure attaching kit to transom, using transom backing plate, 3 bolts (with sealer) and
3 locknuts, installed as shown in Figure 2. Torque locknuts to specification.
a
a - Locknuts
TORQUE
REF.
REF
a 3 LOCKNUTS 10 13.5
90-889785 APRIL 2003 Page 7-43

STEERING CABLE INSTALLATION

1. Lubricate steering cable end with 2-4-C with Teflon.
2. Install steering cable through steering cable tube, and secure with cable attaching nut.
(Figure 3) Do not tighten cable attaching nut at this time.
3. Attach Ride-Guide cable to outboard steering arm, using the proper Clevis Kit. Instal-
lation instructions for clevis are with Clevis Kit.
4. Adjust 2 large jam nuts on cable tube of attaching kit, so that steering wheel is in nor-
mal straight-driving position with outboard in straight-running position. Torque each
jam nut to specification, then bend a side of tab washer against flat of each jam nut.
(Figure 3)
5. Torque Ride-Guide cable attaching nut (which secures cable to guide tube) to specifi-
cation.
WARNING
After installation is completed (and before operating outboard), check that boat
95
a - Ride Guide cable attaching nut

b - Cable tube jam nuts

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
a 1 RIDE GUIDE CABLE ATTACHING NUT 35 47.5
b 2 CABLE TUBE JAM NUTS 35 47.5
Page 7-44 90-889785 APRIL 2003

Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, following:
CAUTION
Core of steering cable must be fully retracted into cable housing when lubricating
cable. If cable is lubricated while extended, hydraulic lock of cable could occur.
1. Lubricate outboard end of Ride-Guide steering cable (through grease fitting - if
equipped - next to cable attaching nut) with 2-4-C with Teflon.
NOTE: Ride-Guide steering cable is lubricated at the factory and requires no additional
2. Lubricate all steering system pivot points (and exposed portion of steering cable core)
with 2-4-C with Teflon. Lubricate at intervals specified preceding.
3. Carefully check steering system components for wear (at intervals specified, preced-
ing). Replace worn parts.
4. Check steering system fasteners (at intervals specified, preceding) to be sure that
they are torqued to correct specifications. (Figures 1, 2 and 3)
90-889785 APRIL 2003 Page 7-45

Clevis Attaching Kit Installation (A-70599A5)

NOTE: This kit is used to attach Ride-Guide cable to outboard steering arm ONLY when
Transom Mounted Ride-Guide Attaching Kit is being used. If Ride-Guide cable is in-
stalled through outboard tilt tube, then steering link rod must be used.
Installation Instructions
1. Install clevis to steering cable as shown.
2. Lubricate 9.5 mm x 34.9 mm (3/8 in. x 1-3/8 in.) bolt (area without threads) with 2-4-C
with Teflon, then secure clevis to steering cable with this bolt and a locknut. Torque
locknut to specification.
3. Lubricate spacer (supplied with this kit) with 2-4-C with Teflon.
4. Attach clevis to top of outboard steering arm with a 9.5 mm x 31.8 mm (3/8 in. x 1-1/4
in.) bolt, thin washer, spacer, thick washer (thick washer must be installed between
clevis and steering arm) and locknut, as shown. Torque bolt to specification, then
torque locknut to specification.
a 95
e
b
f
g
h
i
j
c d
a - Clevis
b - Steering cable
c - Bolt – 9.5 mm x 34.9 mm (3/8 in. x 1-3/8 in.)
d - Clevis to steering cable locknut
e - Bolt – 9.5 mm x 31.8 mm (3/8 in. x 1-1/4 in.)
f - Thin washer – 1.6 mm (1/16 in.) thick
g - Spacer
h - Thick washer – 3.2 mm (1/8 in.) thick
i - Engine steering arm
j - Clevis to engine locknut

Description
95 2-4-C with Teflon 92-802859A1 92-802859Q1
TORQUE
REF.
REF
d 1 LOCKNUT 10 13.5
e 1 BOLT [9.5 mm x 31.8 mm (3/8 in. x 1-1/4 in.)] 20 27
j 1 LOCKNUT 20 27
Page 7-46 90-889785 APRIL 2003

Lubrication and maintenance inspection is owner’s responsibility and must be performed
at intervals specified, following:
1. Carefully check steering system components (at intervals specified, preceding) for
wear. Replace worn parts.
2. Check steering system fasteners (at intervals specified, preceding) to be sure that
they are torqued to correct specifications.
3. Lubricate clevis pivot points with a drop of light oil. Lubricate at intervals specified, pre-
ceding.
90-889785 APRIL 2003 Page 7-47

COLOR DIAGRAMS
COLOR DIAGRAMS
Table of Contents
1.5 Liter OptiMax Wiring Diagram . . . . . . . . . Page 8-3 1.5 Liter OptiMax Water Flow Diagram . . . . . Page 8-9
Typical SmartCraft (Non CAN) Installation . . Page 8-5 1.5 Liter OptiMax Fuel & Air Flow Diagram . Page 8-11
Typical SmartCraft Control Area Network
(CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8-7
90-889785 APRIL 2003 Page 8-1

COLOR DIAGRAMS
1.5 LITER OPTIMAX

WIRING DIAGRAM
90-889785 APRIL 2003 Page 8-3

1.5 Liter OptiMax Wiring Diagram
1. PCM 35. Engine harness
2. Ignition coils 36. Data buss (10 pin) control area network (CAN)
3. Fuel injectors 37. DDT test port
4. Direct injectors 38. SmartCraft harness (8 pin)
5. Oil pump
6. MAP sensor
7. Block pressure sensor
8. Water sensor
9. Shift switch
10. Air temperature sensor
11. Throttle position sensor (TPS)
12. Crank Position Sensor
13. SmartCraft circuit 5 ampere fuse
14. Electric fuel pump/fuel and direct injectors/oil
pump/PCM 20 ampere fuse
15. Power trim/power to trim switch 20 ampere fuse
16. Ignition coil 20 ampere fuse
17. Low oil switch
18. Compressor temperature sensor
19. Slave solenoid
20. Starter solenoid
21. Starter motor
22. 100 ampere fuse
23. 60 ampere alternator
24. Block temperature sensor
25. Main power relay
26. To remote control trim switch
27. Cowl mounted trim switch
28. Trim down relay
29. Trim up relay
30. To trim pump
31. To 12 volt battery
32. High pressure fuel pump #1 (inside vapor sepa-
rator)
33. Low pressure fuel pump #2 (inside vapor sepa-
rator)
34. Accessory power
1.5 Liter OptiMax Wiring Diagram 12 17
2 18
T6 T5
5 7 21
3 4 23 24 27
8 BLK
28 29
1 C28 13 15 19
C16 1 C29 9 10 11 25
1 BLK/WHT 6
BLK
2 C26 20
26
BLK/WHT
2 C27
14 16
YEL/RED
C17
LT BLU/WHT
3 C24
GRN/WHT
T2
2 BLK 3 C25
C18 C12
BLK/GRN
BLK/WHT
RED
RED/BLU
C13 C8
RED/BLU
S10 C20
RED
RED/BLU
YEL/RED
RED/BLU
RED/BLU
C22
ORN/WHT
C19 C21 C23
RED/WHT
C14 BLK BLK
BRN/PNK
RED/BLU
BRN/WHT
RED/PNK
C10
PUR
ORN/PNK
RED
3
LT BLU/BLK
BLK
RED/WHT
BLK
RED/PUR
RED
BLK
BLK/ORN
RED/BLU
C33
22
GRN
C11
PUR/YEL
LT BLU/WHT
TAN
BLU
S13 30
PUR/YEL
BLK/ORN
LT BLU/WHT
GRN
YEL
C31 J6 J7
BLK/ORN
WHT
BLK/ORN
WHT/GRN
1 S11 RED
1
PUR/YEL
9 17
RED
2 RED
A
TAN/GRN
RED/WHT
BLK/ORN
3 RED
4 T20 T21
31
RED/BLK
RED
TAN/PUR
BLK
5 BRN/WHT
BLK
6 BRN/PNK
7
8 GRN/RED RED/WHT
9 RED/WHT S9
10 RED/BLU T7
11 RED/PNK BLK
12 RED/BLU RED/BLU BLK
S12
13 S6 RED/PUR RED/PUR
14 T1 RED/BLU
15 BLK/WHT RED/PUR RED/PUR C32
BLK/ORN
S5 S1
LT BLU
16 BLK/WHT J3
17
18 YEL/PUR
19
RED/YEL RED/YEL
20
21 BLK/ORN
22 BLK/ORN BLK
23 BLK/ORN
8 16 24 24 BLK/WHT BLK/ORN S7 RED
BLK
RED/BLU
PUR/YEL S4
1 9 17 1 BLK/GRN
GRN/BRN
PUR/YEL
2 PUR/YEL
B 3 GRN/BLU
4 YEL/PUR
5 WHT
6
7 LT BLU/BLK S2 BLK
8
9 BLK
1 10
11
GRN/ORG
TAN/LT BLU 33 32
12 GRY
13 RED
14
15 RED/BLK
16 LT BLU J2
17
18
RED/BLU
RED/BLU PUR/YEL
PUR 34
19 C1
20 BLK/YEL
21 ORN/WHT PUR
22 ORN/PNK TAN/LT BLU
8 16 24
4
3 5
23
24
BLK/YEL
PUR/BLK GRY 2 6 35
J1 P1 8
YEL/RED 1 7
RED/PUR
1 PUR PUR S3
2 C6
1 12 22 3
4
YEL
WHT/GRN DK BLU
C
5 WHT/ORN WHT
6 LT BLU/WHT
7
8 BRN/WHT
PUR 36
9 S14 C4 C5 BLK
10 RED/BLK RED/BLK
11 WHT BLK
12 PUR
13 TAN/ORN
14 TAN C2
15 TAN/GRN WHT/BLU
16
17 GRN
DK BLU/WHT 37
18 WHT/BLU
19
20 GRN/BLU C30
21 DK BLU WHT/ORN
22 BLK/ORN PNK/BLK
23 PUR/YEL TAN/ORN
24
25 LT BLU/BLK
BRN/WHT
LT BLU/BLK
38
PNK/BLK BLK/ORN
26
27 TAN/PUR PUR/BLK
ob00778
28 DK BLU/WHT
29
11 21 32 30
31
32
COLOR DIAGRAMS
TYPICAL
SMARTCRAFT (NON CAN)
INSTALLATION
90-889785 APRIL 2003 Page 8-5

Typical SmartCraft (Non CAN) Installation
1. 8-Pin Digital Sensor Harness Extension Connection to Engine Wiring Harness
2. Digital Speedometer Sensor
3. Digital Trim Sender
4. 6-Pin Digital Sensor Harness
5. Connection for Analog Temperature Sender
6. Connections to Trim Relays
7. Connection to SmartCraft Data Link (ECM) Two Wire Harness
8. Remote Control Harness Connects to Engine Harness
9. Digital Connections for Fuel Sender
10. Digital Connections to Oil Sender
11. 4-Pin Digital Sensor Harness Connection to Paddle Wheel
12. Paddle Wheel/Lake/Sea Water Temperature Sender
13. Analog Temperature Gauge Connection
14. Warning Horn
15. Tachometer Harness
16. SmartCraft Tachometer Harness
17. Ignition Key Switch
18. Connections for Neutral Start Switch
19. Connections for Power Trim Switch
20. Connections for Lanyard Stop Switch
21. Mechanical Panel Control (MPC) 4000
22. Connection to 12 Volt Power Supply of Engine being Monitored
23. Connection for Optional Visual Warning Light
24. SmartCraft Tachometer
25. Connection Between SmartCraft Tachometer Harness and SmartCraft Tachometer
26. Connection Between SmartCraft Tachometer Harness and SmartCraft Speedometer Harness
27. Connection for Optional GPS
28. Connection Between SmartCraft Speedometer Harness and SmartCraft Speedometer
29. SmartCraft Speedometer
30. Connection for Ambient Air Temperature Sensor
31. Ambient Air Temperature Sensor
32. Connection for Second SmartCraft Tachometer (Dual Outboard Application)
33. SmartCraft Tachometer Harness (Dual Outboard Application)
34. SmartCraft Tachometer (Dual Outboard Application)
35. Connection for Optional Visual Warning Light (Dual Outboard Application)
36. Connection to 12 Volt Power Supply of Second Engine being Monitored (Dual Outboard Application)
37. Connection to Second Remote Control Tachometer Harness (Dual Outboard Application)
38. Digital Trim Sender Harness
31
Typical SmartCraft (Non CAN) Installation
34 29 24
27
35
23 22
36
30 21
3
28 25
33
2
18
19
37
26 20
30
32
17
8
7
6
5 C B
13
D E A
16
15
4 11
1 12
14
9
10 ob00703
COLOR DIAGRAMS
TYPICAL
SMARTCRAFT (CAN)
INSTALLATION
90-889785 APRIL 2003 Page 8-7

Typical SmartCraft (CAN) Installation
1. 8-Pin Digital Sensor Harness Extension, Connect to 8-Pin SmartCraft Harness on Engine
2. Digital Speedometer Sensor
3. Digital Trim Sender
4. 6-Pin Digital Sensor Harness
5. Connection for Analog Temperature Sender
6. Connections to Trim Relays
7. Connection for Analog Trim Sender
8. Remote Control Harness Connects to Engine Harness
9. 10-Pin Control Area Network (CAN) Harness, Connect to Data Buss 10-Pin CAN Harness on Engine
10. Resistors within CAN Harness (120Ω 1/4W 5%)
11. Connections for Auxiliary Warning Horn for Depth Sensor
12. 10-Pin Control Area Network (CAN) Connection to System Monitor
13. System Monitor
14. System Link Series Connections
15. 3-1/4 in. System Link Gauges (Tachometer and Speedometer)
16. 2-1/4 in. Dia. System Link Gauges (Fuel, Temperature, Trim, etc.)
17. Series Connection for Additional System Link Gauges
18. 4000 Series Mechanical Panel Control (MPC 4000)
19. Connections for Lanyard Stop Switch
20. Connections for Power Trim Switch
21. Connections for Neutral Start Safety Switch
22. Ignition Key Switch
23. Analog Tachometer Harness (Not Used on CAN Installation)
24. Warning Horn
25. Analog Temperature Gauge Connection
26. Paddle Wheel/Lake/Sea Water Temperature Sender
27. 4-Pin Digital Sensor Harness Connection to Paddle Wheel
28. Digital Connections to Oil Sender
29. Digital Connections for Fuel Sender
30. Digital Trim Sender Harness
Typical SmartCraft (CAN) Installation
13
17
14 14 14
16 16
12
15 15
14
18
3
10
11
2
21
20
30 9 19
10 22
7
6
5 25 C B
23
D E A
4 27
1
26 24
29 28 ob00396
COLOR DIAGRAMS
1.5 LITER OPTIMAX

WATER FLOW DIAGRAM
90-889785 APRIL 2003 Page 8-9

1.5 Liter OptiMax Water Flow Diagram
1. Water outlet
2. Water inlet
3. Water pump
4. Wall of water – If water level height is insufficient, water pump may draw in air resulting in an overheated
engine
5. Water tube
6. Water dump down exhaust pipe
7. Exhaust adaptor plate
8. Cylinder block – halves separated for illustration
9. Cylinder block combustion chamber – halves separated for illustration
10. Thermostat 61° C (142° F) – If stuck closed, engine will overheat at idle. If stuck open, engine will run
cold at idle.
11. Poppet valve – controls water flow at high RPM. If poppet valve is stuck open at low RPM, the engine
will not reach proper operating temperature (run cold) and will run rough at idle
12. Exhaust cover – separated for illustration
13. Strainer screen for air compressor water supply – If restricted, compressor will overheat and tell-tale
will be weak
14. Air compressor – water outlet from air compressor connects to fuel rail coolant inlet
15. Fuel rail – fuel cooler is built into fuel rail
16. Tell-tale outlet on bottom cowl
17. Powerhead flush
18. Thermostat water dump
19. Poppet valve opening
20. Rubber water deflectors (3) – If missing may result in uneven cooling of cylinders and scuffed pistons.
1.5 Liter OptiMax Water Flow Diagram
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1.5 LITER OPTIMAX

FUEL & AIR FLOW DIAGRAM
90-889785 APRIL 2003 Page 8-11

1.5 Liter OptiMax Fuel and Air Flow Diagram
1.Engine pulse fuel pump
2.Fuel/Water separator filter
3.Vapor separator tank vent hose
4.Air compressor inlet coolant hose
5.Fuel outlet from high pressure electric fuel pump – 744.6 kPa (108 psi)
6.High pressure air outlet – 648.1 kPa (94 psi)
7.Air compressor
8.Air compressor inlet air filter
9.Cooling water routed from air compressor to fuel rail
10.Direct injector discharges the air/fuel mixture into the combustion chamber
11.Schrader valve for testing fuel pressure (design 2 location) – 744.6 kPa (108 psi)
12.Schrader valve for testing air pressure – 648.1 kPa (94 psi)
13.Water outlet to tell-tale
14.Schrader valve for testing fuel pressure (design 1 location) – 744.6 kPa (108 psi)
15.Fuel injector is opened by the PCM, 744.6 kPa (108 psi) fuel is discharged into a machined cavity inside the
air chamber of the air/fuel rail. This mixes fuel with the air charge.
16.Fuel pressure regulator
17.Air pressure regulator
18.Excess high pressure air muffler
19.Bleed off from air pressure regulator; routed to the outside through bottom cowl
20.Bleed off from fuel pressure regulator; routed back to vapor separator tank.
21.Low pressure electric fuel pump Schrader valve
22.High pressure electric fuel pump
23.172 kPa (25 psi) relief valve
24.Vapor separator tank float needle
25.Vapor separator tank float
26.Low pressure electric fuel pump
27.Fuel Director
28.Vapor separator tank drain screw
29.Vapor separator tank drain fitting
30.Fuel/Water Drain Fitting
31.Fuel/Water Drain Screw
32.Fuel/Water sensor
33.Fuel Inlet from primer bulb
1.5 Liter OptiMax Fuel and Air Flow Diagram
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Optimax 75 90 115 DFI-2004 and Up

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Optimax 75 90 115 DFI-2004 and Up

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75 90 115 Optimax.

qxd 4/16/2003 9:06 AM Page 1

Starting Model Year 2004

www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com

Notice to Users of This Manual

90-889785 APRIL 2003 Page i

Cleanliness and Care of Outboard Motor

90-859769 R1 JULY 2003 - 6A-7

Month of Printing Section Number

Year of Printing Part of Section Letter

90-889785 APRIL 2003 Page iii

Idle RPM (In Gear) (75/90/115) 625 – 675

90-889785 APRIL 2003 Page 1A-1

Model 75/90/115 DFI

REEDS Reed Stand 0pen (Max.) 0.50 mm (0.020 in.)

Page 1A-2 90-889785 APRIL 2003

Model 75/90/115 DFI

Forward Gear Backlash 0.012-0.019 in. (0.30-0.48mm)

Forward Gear Backlash 0.33-0.48 mm (0.013-0.019 in.)

90-889785 APRIL 2003 Page 1A-3

Model 75/90/115 DFI

Fuel Line Pressure @ Injectors 744.6 ± 13.8 kPa (108 ± 2 psi)*

Low Pressure Electric Fuel Pump 1 - 2 Amperes

Fuel Pump Ohm Resistance 1.0 – 1.8 Ω

Page 1A-4 90-889785 APRIL 2003

Model 75/90/115 DFI

90-889785 APRIL 2003 Page 1A-5

Model 75/90/115 DFI

Piston Ring End Gap

Page 1A-6 90-889785 APRIL 2003

Propeller Information Charts

Approx. Approx. Speed

90-889785 APRIL 2003 Page 1A-7

Propeller Information Charts

Approx. Approx. Speed

Page 1A-8 90-889785 APRIL 2003

Approx. Approx. Speed

90-889785 APRIL 2003 Page 1A-9

Mercury/Quicksilver Lubricants, Sealants, and Adhesives

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

27 Bellows Adhesive N/A 92-86166Q1

Page 1A-10 90-889785 APRIL 2003

Tube Mercury Part Quicksilver Part

90-889785 APRIL 2003 Page 1A-11

Tube Mercury Part Quicksilver Part

Page 1A-12 90-889785 APRIL 2003

FUEL Fuel Gasoline with Oil Injection

90-889785 APRIL 2003 Page 1B-1

Grease Gun 91-37299Q2

Flushing Attachment 44357Q2

Mercury/Quicksilver Lubricants and Sealants

Page 1B-2 90-889785 APRIL 2003

Inspection and Maintenance Schedule

After Each Use

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

90-889785 APRIL 2003 Page 1B-3

Page 1B-4 90-889785 APRIL 2003

Fuel Line Inspection

90-889785 APRIL 2003 Page 1B-5

Draining Water from Fuel Filter Chamber

Page 1B-6 90-889785 APRIL 2003

Corrosion Control Anode

90-889785 APRIL 2003 Page 1B-7