REMOVAL AND INSTALLATION 2 B MCM MODELS - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSION

Transcription

1 REMOVAL AND INSTALLATION 2 B MCM MODELS - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSION

2 Tle of Contents Pge Torque Speifitions B-1 Tools / Lurints / Selnts B-1 Removl B-2 Engine Removl B-2 Instlltion B-4 Engine Instlltion/Alignment B-4 Engine Connetions B-9 Throttle Connetions B-11 2B-0 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

3 Torque Speifitions Tools / Lurints / Selnts Fstener Lotion L. Ft. L. In. N m Bering Support (Tilstok) To Inner Trnsom Plte Drive Shft Rer Engine Mount Brket Drive Shft Shiel Extension Housing To Flywheel Housing Flywheel Housing Erly Style Power Steering Hose Fittings Lrge Smll Lter Style Power Steering Hose Fittings Remote Control Throttle Cle Seurely Cle Brrel Cle En Guie See Note Front n Rer Engine Mounts Hose Clmps Seurely Bttery Cles NOTE: Tighten, then k nut off one-hlf turn Desription Quiksilver Engine Alignment Tool Quiksilver Liqui Neoprene Quiksilver 2-4-C Mrine Lurint With Teflon Universl Protrtor Lotite Pipe Selnt With Teflon Prt Numer A A3 Otin Lolly BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-1

4 Removl IMPORTANT: It is not neessry to remove the engine to servie the rive shft n/or ering support (tilstok). Refer to instrutions s outline in Setion 8E - Drive Shft Repir or Bering Support Repir for serviing these items only. IMPORTANT: Stern rive unit oes not hve to e remove prior to engine removl. If stern rive is going to e remove, refer to pproprite Stern Drive Servie Mnul. 12. Remove top n then ottom rive shft shiels t engine en of extension rive shft. Engine Removl 1. Disonnet ttery les from ttery. 2. Remove instrument hrness onnetor plug from engine hrness reeptle fter loosening lmp.! WARNING Be reful when working on fuel system. Gsoline is extremely flmmle n highly explosive uner ertin onitions. Do not smoke or llow sprk or open flme in re. Wipe up ny spille fuel immeitely. 3. Using wrenh to stilize rss oupling t fuel filter inlet, loosen fuel line fitting, isonnet n suitly plug fuel line to prevent fuel in tnk from leking into ilge. 4. Disonnet throttle le from ruretor n retin loknuts n hrwre. 5. Disonnet ullet onnetors of trim sener wires (oming from trnsom ssemly) from engine hrness. NOTE: After wires re isonnete, e sure to loosen them from lmps or St-Strps retining them to engine or hoses. 6. Disonnet MerCthoe wires from MerCthoe ontroller if mounte on engine (some moels). 7. Disonnet sewter inlet hose from engine. 8. Disonnet exhust elow hoses (ellows). 9. Remove oth shift les from shift plte. Retin loknuts n hrwre. 10. Disonnet ny grouning wires n essories tht re onnete to engine. 11. Disonnet (n suitly plug) flui hoses from power steering ontrol vlve on trnsom. - Top Shiel - Bottom Shiel - 4 Srews / Nuts (2 Hien) - 3 Srews (Hien) Mrk extension rive shft U-joint yoke/output flnge onnetions t engine en (to ssist in ext sme positioning uring ressemly). Disonnet rive shft from output flnge. Engine En Shown - Mthing Prts On Flnge n Drive Shft Connetion - Extension Drive Shft U-Joint Yoke - Output Flnge B-2 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

5 Center lifting eye (lote on top of thermostt housing) is use for engine lignment only. DO NOT use to lift entire engine. DO NOT llow lifting sling to hook or ompress engine omponents or mge will our. IMPORTANT: To voi the nee for omplete relignment (fter engine repir), DO NOT MOVE FRONT AND REAR MOUNT ADJUSTMENT. Remove mounting olts from ot stringers. 14. Support engine with suitle sling through lifting eyes on engine n remove front n rer engine mounting olts from ot stringers. Retin hrwre. 15. Crefully remove engine. Mutli-Port Injetion engines MUST e lifte with lifting rm or mge to engine omponents will our Typil Mounting Shown - Suitle Sling - Engine Lifting Eyes - Mounting Bolts BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-3

6 Instlltion Engine Instlltion/Alignment ENGINE MOUNT ADJUSTMENT WAS NOT DISTURBED DURING SERVICE 5. As shown, tth engine output flnge to rive shft flnge extly s mrke uring isssemly. Torque fsteners to 50 l. ft. (68 N m). Center lifting eye (lote on top of thermostt housing) is use for engine lignment only. DO NOT use to lift entire engine. e DO NOT llow lifting sling to hook or ompress engine omponents or mge to them will our. Multi-Port Fuel Injetion engines MUST e lifte with lifting rm or mge to engine omponents will our. 1. Atth suitle sling to lifting eyes on engine n just so tht engine is level when suspene. (Refer to Removl setion for lotion of lifting eyes.) 2. Lift engine into pproximte position (in ot), using n overhe hoist. 3. Set engine on stringers. 4. Grese rive shft universl joints with Quiksilver 2-4-C Mrine Lurint With Teflon. Engine En Shown - Output Shft Flnge - Drive Shft - Srew 7/16-20 x 1-1/2 In. (38 mm) Long (4 Use) - Nut 7/16-20 (4 Use) e - Mthing Mrks Me Upon Disssemly - Aligne IMPORTANT: Filure to properly position output shft flnge my result in ering mge. 6. Relieve hoist tension from engine, then slie engine fore or ft s neee to otin 1/4 in. (6 mm) lerne etween flnge shouler n extension shft housing ering. When tthing shft in next step, BE SURE tht the pilot on rive shft flnges re engge in input shft n output shft flnges. Flnges MUST BE flush to eh other prior to tightening srews or srews my ome loose uring opertion. Filure to lign shft flnges with mthing mrks me on isssemly my use improperly ligne rive unit n extension rive shft U-joint enterlines resulting in severe virtion prolem. - Flnge Shouler - Bering - 1/4 In. (6 mm) B-4 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

7 7. Position engine for orret engine n rive shft lterl lignment s follows:. Mesure the length of () n () to the enters of olt holes. They MUST BE EQUAL. If they re not equl, slie the ft n forwr ens of the engine equl mounts in opposite iretions to otin equl lengths for () n ().. Rehek Step 6. If Step 6 is not s speifie, just n rehek Step 7. Continue this proess until oth Steps 6 n 7 re s speifie. Torque srews n nuts to 30 l. ft. (41 N m). These Dimensions Must Be Equl Shft Housing - Bottom Shiel - Srews (3 Use - Two Hien in This View) (Use Lotite 271) Engine En Shown 8. After engine hs een ligne orretly, fsten front n rer engine mounts to stringers. Tighten mounting olts seurely. 9. Apply Lotite 271 to thres of ottom rive shft shiel retining srews n instll ottom shiel on engine en s shown. Torque srews to 30 l. ft. (41 N m). Then instll top shiel s shown. - Top Shiel - Bottom Shiel - 4 Srews/Nuts (2 Hien) - 3 Srews (2 Hien) Engine En Shown Proee to Engine Connetions setion instrutions following BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-5

8 ENGINE MOUNT ADJUSTMENT WAS DISTURBED DURING SERVICE NOTE: A Universl Protrtor is reommene for mesuring the ngles in the following steps. IMPORTANT: In the following steps, the protrtor reings will e tken off of vertil n horizontl surfes; therefore, oth the 0 egree n the 90 egree mrks will e use. It shoul e kept in min tht these re referene mrks only n the ssigne numers shoul e ignore. It is only neessry to etermine the numer of egrees n to whih sie (left or right) of the referene mrks the initor neele rests. PRO- TRACTOR MUST BE VIEWED FROM THE SAME SIDE OF POWER PACKAGE THROUGHOUT IN- STALLATION. IMPORTANT: Be sure tht ot oes not move one reing hs een tken from input shft flnge, s this reing estlishes referene point for ligning rive shft n engine following. If ot is move, referene point my e ltere n susequently, improper rive shft n engine lignment my our. Alignment tool MUST BE in ple uring entire lignment proeure if rive unit is not instlle. - Initor Shft Flnge - Protrtor - Initor Neele Referene Mrks Refer to Setion 8E - Drive Shft Moels/Propeller Shft, n remove rive shft. 2. Position se of protrtor ginst input shft flnge, s shown. NOTE n RECORD the numer of egrees n to whih sie of the referene mrk the initor neele hs move in the following hrt. Reing from Step 1. egrees to the sie of referene mrk. NOTE: For ese of instlltion we reommen the use of hin leveler in the following steps. 3. Ajust engine mounts so tht n equl mount of up n own justment exists. 4. Atth suitle lifting hin to lifting eyes on engine n just so tht engine will e level when suspene, then ple engine into its pproximte position (in ot) using n overhe hoist. 5. Refer to Setion 8E - Drive Shft Moels/Propeller Shft, n instll rive shft while oserving preutions in Setion 8D, espeilly out ligning giml ering U-joint enterlines with extension rive shft U-joint enterlines t ering support input shft. DO NOT instll shiels t this time. 2B-6 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

9 Engine MUST BE ligne orretly to hieve proper engine opertion n to prevent mge to rive shft. If rive shft is run t n inorret ngle, mge to universl joint erings my result. 6. Position se of protrtor on rive shft; then rise or lower engine (s ot onstrution permits) until initor neele is 1 egree to 3 egrees on either sie of reing tken in Step 1. Reor this reing in the following hrt for lter use. Filure to properly position output shft flnge (s esrie following) my result in ering mge. 8. Relieve hoist tension from engine, then slie engine fore or ft s neee to otin 1/4 in. (6.4 mm) etween flnge shouler n extension shft housing ering, s shown. - Drive Shft - Protrtor - Output Shft Flnge Reing from Step 6. egrees to the sie of referene mrk Ajust stringer height so tht the stringers just ontt the engine mount ses. - Flnge Shouler - Bering - 1/4 In. (6 mm) Position engine for orret engine n rive shft lterl lignment s follows:. Mesure the length of () n () to the enters of olt holes. They MUST BE EQUAL. If they re not equl, slie the ft n forwr ens of the engine equl mounts in opposite iretions to otin equl lengths for () n () These Dimensions Must Be Equl. Rehek Step 8. If Step 8 is not s speifie, just n rehek Step 9. Continue this proess until oth Steps 8 n 9 re s speifie BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-7

10 10. After engine hs een ligne orretly, fsten front n rer engine mounts to stringers. Tighten seurely. 12. Position protrtor on rive shft n rehek ngle. Angle shoul e the sme s tht reore in Step 6. If not, rise or lower ll four engine mount justment nuts n equl mount until orret ngle is rehe. 13. Tighten ALL engine mount nuts seurely. Ben wsher t own on eh justment nut Typil Mounting Shown - Mounting Bolts 11. Position protrtor on strter housing over plte, s shown. Now, rise or lower front engine mount justing nuts s require so tht protrtor neele res extly the sme numer of egrees s tht reore in Step 1. - Loknut - Ajustment Nut - Turn Nut In This Diretion (Counterlokwise) To Rise Front Of Engine - Slotte Hole Towr Front Of Engine e - T Wsher e Thru-Prop Exhust Shown - Flywheel Housing - Strter Housing Cover Plte - Protrtor 2B-8 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

11 14. Apply Lotite 271 to thres of ottom rive shft shiel retining srews n instll ottom shiels on engine n trnsom en s shown. Torque srews to 30 l. ft. (41 N m). Then instll oth top shiels s shown. Torque srews n nuts to 30 l. ft. (41 N m). Engine Connetions IMPORTANT: When routing ll wire hrnesses n hoses, e sure they re route n seure to voi oming in ontt with hot spots on engine n voi ontt with moving prts. 1. Connet sewter inlet hose to sewter pump s shown. Tighten hose lmp seurely. e Top Shiel n Bottom Shiel t Trnsom En (Engine En Similr) - Top Shiel - Bottom Shiel - Bolt 3/8-16 x 7/8 In. (22.2 mm) - Nut 3/8-16 e - Srews (Use Lotite 271) Engines With Mehnil Fuel Pump / Sewter Pump - Sewter Inlet Hose Connetion - Mehnil Fuel Pump 15. Proee to Engine Connetions setion instrutions following. Engines Without Mehnil Fuel Pump - Sewter Inlet Hose - Hose To Cooler BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-9

12 2. Connet instrument hrness to engine hrness with hose lmp. Tighten lmp seurely.! WARNING Be reful when working on fuel system. Gsoline is extremely flmmle n highly explosive uner ertin onitions. Do not smoke or llow sprk or open flme in re. Wipe up ny spille fuel immeitely. FUEL SUPPLY CONNECTIONS! WARNING Engine Wiring Hrness - Instrumenttion Wiring Hrness Plug - Hose Clmp - Tighten Seurely 3. Connet two trim position sener les from giml housing to les from engine hrness. Avoi gsoline fire or explosion. Improper instlltion of rss fittings or plugs into fuel pump or fuel filter se n rk sting n/or use fuel lek. Apply #592 Lotite Pipe Selnt with Teflon to thres of rss fitting or plug. DO NOT USE TEFLON TAPE. Thre rss fitting or plug into fuel pump or fuel filter se until finger tight. Tighten fitting or plug n itionl 1-3/4 to 2-1/4 turns using wrenh. DO NOT OVER-TIGHTEN. Instll fuel line. To prevent over-tightening, hol rss fitting with suitle wrenh n tighten fuel line onnetors seurely. Chek for fuel leks. 4. Connet fuel line from fuel tnk(s) to engine. Mke ertin onnetions re seure. Chek for leks BROWN / WHITE (From Engine Hrness) - BLACK (From Engine Hrness) - BLACK (From Trnsom Assemly) - BLACK (From Trnsom Assemly) 2B-10 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

13 Throttle Connetions WEBER 4 BARREL CARBURETOR 5. Return remote ontrol throttle lever to ile position n hek to ensure tht throttle lever ontts ile spee justment srew. 1. Ple remote ontrol hnle(s) in neutrl, ile position. IMPORTANT: Be sure tht le is route in suh wy s to voi shrp ens n/or ontt with moving prts. DO NOT fsten ny items to throttle le. Outer le must e free to move when le is tute. 2. Instll le en guie on throttle lever, then push le rrel lightly towr throttle lever en. (This will ple slight prelo on le to voi slk in le when moving remote ontrol lever.) Ajust rrel on throttle le to lign with nhor stu. 3. Seure throttle le with hrwre (retine) s shown. Tighten le en guie nut until it ottoms out n then k off one full turn. Tighten le rrel seurely. DO NOT OVER- TIGHTEN, s le must pivot freely. Ile Position - Throttle Lever Contts () In ile Position - Ile Spee Ajustment Srew Cle En Guie - Atthing Hrwre (DO NOT Over-Tighten) - Cle Brrel - Anhor Stus Wie-Open-Throttle Position - Throttle Shft Lever Contts () At W.O.T. Position - Cruretor Boy Csting Ple remote ontrol throttle lever in the wie-open-throttle (W.O.T.) position. Chek to ensure tht throttle shutters (vlves) re ompletely open n throttle shft lever ontts ruretor oy sting BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-11

14 THROTTLE BODY INJECTION 1. Instll le en guie on throttle lever, then push le rrel en lightly towr throttle lever en. (This will ple slight prelo on shift le to voi slk in le when moving remote ontrol lever). Ajust rrel on throttle le to lign with hole in nhor plte. 2. Seure throttle le with hrwre s shown n tighten seurely. 3. Ple remote ontrol throttle level in the wie open throttle (W.O.T.) position. Chek to ensure tht throttle pltes re ompletely open. 4. Return remote ontrol throttle lever to ile position. MULTI-PORT INJECTION 1. Ple remote ontrol hnle(s) in neutrl ile position. IMPORTANT: Be sure tht le is route in suh wy to voi shrp ens n/or ontt with moving prts. DO NOT fsten ny items to throttle le. Outer le must e free to move when le is tute. 2. Remove flme rrestor Flme Arrestor (Erlier Style) - Loknuts 3. Instll le en guie on throttle lever, then push le rrel en lightly towr throttle lever en. (This will ple slight prelo on shift le to voi slk in le when moving remote ontrol lever). Ajust rrel on throttle le to lign with hole in nhor plte. Ensure hole in rrel positions le s shown. - Cle En Guie - Flt Wsher n Loknut - Tighten Until Bottoms Out, Then Bk Off One Hlf Turn - Cle Brrel - Flt Wsher n Loknut - Cle Brrel - Anhor Plte B-12 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

15 NOTE: If Bot is equippe with Quiksilver Zero Effort Controls, the throttle le mounting stu must e most forwr position on throttle lever. 6. Return remote ontrol throttle lever to ile position n hek to ensure tht throttle pltes re ompletely lose. g e Position For Zero Effort Controls 4. Seure throttle le with hrwre s shown n tighten seurely. 5. Ple remote ontrol throttle level in the wie open throttle (W.O.T.) position. Chek to ensure tht throttle pltes re ompletely open. f Cle En Guie - Cle Brrel - Bolt - Loknut e - Throttle Lever f - Flt Wsher n Lokwsher g - Throttle Pltes W.O.T. IDLE Throttle Lever - Positive Stop Srew - Throttle Stop Lever - Throttle Stop Srew BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-13

16 7. Reinstll flme rrestor n tighten loknuts seurely. Position rnkse vent hose ginst flme rrestor s shown. 10. Refer to pproprite Stern Drive Servie Mnul n instll n just rive unit n remote ontrol shift les, using hrwre retine. IMPORTANT: After flui hose instlltion in the following, lee power steering system s outline in SECTION 1B - Mintenne of this mnul, or refer to the pproprite Stern Drive Servie Mnul. - Crnkse Vent Hose IMPORTANT: Do not tth ny essory groun ( ) wires to trnsom plte groun point. Aessory groun wires shoul only e tthe to groun stu on engine. 8. Connet ny grouning wires or essories tht my hve een isonnete. 9. Moels with MerCthoe: Connet wires to MerCthoe ontroller ssemly s shown. Apply thin ot of Quiksilver Liqui Neoprene to ll onnetions. Route hoses extly s shown elow. This will help voi stress on the hose fittings n will help voi kinks in the hose. IMPORTANT: Mke hyruli onnetions s quikly s possile to prevent flui lekge. IMPORTANT: Be reful not to ross-thre or over-tighten fittings ORANGE Wire - From Eletroe On Trnsom Assemly - RED/PURPLE Wire - Connet (Other En) to Positive (+) Bttery Terminl - BLACK Wire - From Engine Hrness - BROWN Wire - From Eletroe on Trnsom Assemly IMPORTANT: Ajust shift les s outline in pproprite Stern Drive Servie Mnul. 2B-14 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS

17 11. Connet oth hyruli hose fittings.. Erly Style Control Vlves: Torque the lrge fitting to 23 l. ft. (31 N m). Torque the smll fitting to 100 l. in. (11 N m). 12. Connet ttery les to ttery y FIRST onneting positive (+) ttery le (usully RED) to positive (+) ttery terminl. Tighten lmp seurely. Then, onnet negtive ( ) ttery le (usully BLACK) to negtive ( ) ttery terminl. Tighten lmp seurely. NOTE: Spry terminls with ttery onnetion selnt to help retr orrosion Smll Fitting - Lrge Fitting. Lter Style Control Vlve: Torque oth fittings to 23 l. ft. (31 N m). Route hoses s shown for eh moel All Moels Exept 502 Multi-Port Injetion - Hose Fittings Multi-Port Injetion with Oil Cooler Return Lines on the Stror Sie of the Cooler - Hose Fittings BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS - 2B-15

18 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2B-16 - BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSIONS