SERVICE MANUAL. MODELS Mercury/Mariner 20 JET MARATHON 25 SEAPRO. With Serial Numbers

Transcription

1 SERVICE MANUAL MODELS Mercury/Mriner 20 JET MARATHON 25 SEAPRO With Seril Numers United Sttes Belgium G nd Aove nd Aove Printed in U.S.A. 1998, Mercury Mrine R2 JUNE 1998

2 Notice Throughout this puliction, Dngers, Wrnings nd Cutions (ccompnied y the Interntionl HAZARD Symol ) re used to lert the mechnic to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. OBSERVE THEM CAREFULLY! These Sfety Alerts lone cnnot eliminte the hzrds tht they signl. Strict complince to these specil instructions when performing the service, plus Common Sense opertion, re mjor ccident prevention mesures. DANGER DANGER - Immedite hzrds which WILL result in severe personl injury or deth. WARNING WARNING - Hzrds or unsfe prctices which COULD result in severe personl injury or deth. CAUTION Hzrds or unsfe prctices which could result in minor personl injury or product or property dmge. Notice to Users of This Mnul This service mnul hs een written nd pulished y the Service Deprtment of Mercury Mrine to id our delers mechnics nd compny service personnel when servicing the products descried herein. It is ssumed tht these personnel re fmilir with the servicing procedures of these products, or like or similr products mnufctured nd mrketed y Mercury Mrine, tht they hve een trined in the recommended servicing procedures of these products which includes the use of mechnics common hnd tools nd the specil Mercury Mrine or recommended tools from other suppliers. We could not possily know of nd dvise the service trde of ll conceivle procedures y which service might e performed nd of the possile hzrds nd/or results of ech method. We hve not undertken ny such wide evlution. Therefore, nyone who uses service procedure nd/or tool, which is not recommended y the mnufcturer, first must completely stisfy himself tht neither his nor the products sfety will e endngered y the service procedure selected. All informtion, illustrtions nd specifictions contined in this mnul re sed on the ltest product informtion ville t the time of puliction. As required, revisions to this mnul will e sent to ll delers contrcted y us to sell nd/or service these products. It should e kept in mind, while working on the product, tht the electricl system nd ignition system re cple of violent nd dmging short circuits or severe electricl shocks. When performing ny work where electricl terminls could possily e grounded or touched y the mechnic, the ttery cles should e disconnected t the ttery. Any time the intke or exhust openings re exposed during service they should e covered to protect ginst ccidentl entrnce of foreign mteril which could enter the cylinders nd cuse extensive internl dmge when the engine is strted R2 JUNE 1998 Pge i

3 It is importnt to note, during ny mintennce procedure replcement fsteners must hve the sme mesurements nd strength s those removed. Numers on the heds of the metric olts nd on the surfces of metric nuts indicte their strength. Americn olts use rdil lines for this purpose, while most Americn nuts do not hve strength mrkings. Mismtched or incorrect fsteners cn result in dmge or mlfunction, or possily personl injury. Therefore, fsteners removed should e sved for reuse in the sme loctions whenever possile. Where the fsteners re not stisfctory for re-use, cre should e tken to select replcement tht mtches the originl. Clenliness nd Cre of Outord Motor Pge Numering A mrine power product is comintion of mny mchined, honed, polished nd lpped surfces with tolernces tht re mesured in the ten thousnds of n inch/mm. When ny product component is serviced, cre nd clenliness re importnt. Throughout this mnul, it should e understood tht proper clening, nd protection of mchined surfces nd friction res is prt of the repir procedure. This is considered stndrd shop prctice even if not specificlly stted. Whenever components re removed for service, they should e retined in order. At the time of instlltion, they should e instlled in the sme loctions nd with the sme mting surfces s when removed. Personnel should not work on or under n outord which is suspended. Outords should e ttched to work stnds, or lowered to ground s soon s possile. We reserve the right to mke chnges to this mnul without prior notifiction. Refer to deler service ulletins for other pertinent informtion concerning the products descried in this mnul. Two numer groups pper t the ottom of ech pge. The exmple elow is self-explntory. EXAMPLE: R2 JUNE A-7 Revision No. 2 Month of Printing Yer of Printing Section Numer Prt of Section Letter Pge Numer Pge ii R2 JUNE 1998

4 Service Mnul Outline Section 1 - Importnt Informtion A - Specifictions B - Mintennce C - Generl Informtion D - Outord Instlltion Section 2 - Electricl A - Ignition B - Chrging & Strting System C - Timing, Synchronizing & Adjusting D - Wiring Digrms Section 3 - Fuel System A - Cruretor/Fuel Pump B - Emissions Section 4 - Powerhed Section 5 - Mid-Section Section 6 - Lower Unit A - Ger Housing B - Jet Drive Section 7 - Attchments/Control Linkge A - Throttle/Shift Linkge B - Tiller Hndle C - Side Shift Section 8 - Mnul Strter Importnt Informtion Electricl Fuel System Powerhed Mid-Section Lower Unit Attchment/Control Linkge Mnul Strter R2 JUNE 1998 Pge iii

5 Tle of Contents IMPORTANT INFORMATION Section 1A - Specifictions SPECIFICATIONS 1 A Mster Specifictions A R2 JUNE 1998 Pge 1A-1

6 SPECIFICATIONS Mster Specifictions HORSEPOWER (KW) OUTBOARD WEIGHT CYLINDER BLOCK Model 20 Jet Model 20 Model in. (38 cm) 20 in. (51 cm) 20 Jet Type Displcement Model 15XD/20 Jet /20/25 20 (14.9) 20 ( (18.7) 114 ls - 52 kg 117 ls - 53 kg 124 ls - 56 kg Two Cylinder - Two Cycle 24.4 cu. in. (400 cc) STROKE Length in. (60 mm) CYLINDER BORE CRANK SHAFT CONNECTING ROD PISTON PISTON DIA. Dimeter (Stndrd) Tper/Out of Round Mximum* Bore Type: S/N 0G nd Below S/N 0G nd Aove Top Min Bering Journl Center Min Bering Journl Bottom Min Bering Journl Connecting Rod Journl End Ply Piston Pin End (I.D.) Crnkpin End (I.D.) Piston Type O.D. t Skirt (Stndrd) Ring End Gp Dimension A t Right Angle (90 ) to Piston Pin 0.50 in. (12.7 mm) in. (65.01 mm) in. (0.08 mm)* Chrome Mercosil in. (31.77 mm) in. (25.40 mm) in. (28.58 mm) in. (22.43 mm) ( mm) in. (22.78 mm) in. (30.38 mm) Aluminum ( ) (.28 mm -.64 mm) in. ±.0005 in. (64.98 mm ±.0127 mm)using micrometer, mesure dimension A t loction shown. Dimension A should e in. ±.0005 for STANDARD size piston (new) Dimension A will e less if coting is worn off piston (used) *Models S/N 0G nd Below: NOTE: The cylinder ores re chrome nd cnnot e e reored or efficiently honed. Check ech cylinder ore for n out-of-round egg shped cylinder. A mximum of in. (0076mm) is llowle. *Models S/N 0G nd Aove: NOTE: The cylinder lock is Mercosil nd the cylinders cn e reored to in. oversized. Check ech cylinder ore for n out-of-round egg shped cylinder. A mximum of in. (0.076mm) is llowed. Pge 1A R2 JUNE 1998

7 Mster Specifictions SPECIFICATIONS GEAR HOUSING MID SECTION FUEL SYSTEM Forwrd - Neutrl - Reverse Ger Rtio Gercse Cpcity Luricnt Type Forwrd Ger - No. of Teeth-Type Pinion Ger - No. of Teeth-Type Pinion Foreword Ger Bcklsh Reverse Ger Bcklsh Wter RPM Wter Pressure With 120 Thermostt Trnsom Height - Short Shft - Long Shft Fuel Pump Type Recommended Gsoline Fuel Tnk Cpcity Operting Fuel/Oil Rtio Full Shift 2.25:1 8.8 fl.oz. (260 ml) Quicksilver Ger Lue Premium Blend Not Adjustle Not Adjustle Not Adjustle RPM 0-6 PSI (SPORADIC) 2000 RPM 15 in. (38 cm) 20 in. (51 cm) Integrl Automotive Unleded with Minimum Pump Posted Octne Rting of U.S. Gllons 50:1 OIL Recommended Oil 50:1) NMMA TC-W II or TC-W III 2-Cycle Outord Oil STARTING SYSTEM CHARGING SYSTEM Mnul Strt Rope Length Electric Strt Ampere Drw (crnking) Alterntor Output BLACK Sttor - 2 Mgnet Flywheel (8 Pole)(4 Pulses) RED Sttor - 4 Mgnet Flywheel (10 Pole)(5 Pulses) Recoil 66 in. (1676 mm) 12 Volt 55 mperes 4 Amp. ( RPM 6 mp ( RPM BATTERY Bttery Rting 465 Mrine Crnking Amps (MCA) or 350 Cold Crnking Amps (CCA) R2 JUNE 1998 Pge 1A-3

8 SPECIFICATIONS IGNITION SYSTEM Redings 68 F (20 C). Type Sprk Plug Type (NGK) Sprk Plug Gp Sprk Plug Hex Firing Order 20 Jet / 2 THRU / / 2 THRU 1996 Electronic Sprk Advnce 750 ± 50 RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) Setup Timing Sttor High Speed Winding Sttor Low Speed Winding Diode Test Ignition Coil Resistnce: Primry Secondry (w/o Boots) 20 Jet 1999 nd Newer 20/ /98 Models Mechnicl Sprk Advnce 750 ± 50 RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) Sttor High Speed Winding Sttor Low Speed Winding Diode Test Ignition Coil Resistnce: Primry Secondry (w/o Boots) Trigger Cpcitor Dischrge Ignition NGK BP8H-N in. (1.0 mm) 18 mm ± 2 B.T.D.C (Not Adjustle) 1400 RPM ± 250 RPM 25 RPM ± 200 R.P.M. (Set-up timing of 28 B.T.D.C. will e retrded to R.P.M.) Ω (RED BLK) Ω (BLUE BLACK) Ω (RED BLUE) 0 Ω Ω 6 ±1 B.T.D.C 1500 RPM ± 200 RPM 25 RPM Ω (BLK/WHT - GRD) Ω (BLK/YEL - GRD) Ω (BLK/YEL - BLK/ WHT) Ω Ω Ω JET DRIVE Impeller Liner Clernce in. (0.8 mm) * Use NGK BPZ8H-N-10 Where Rdio Frequency Interference (RFI) Suppression is Required. Pge 1A R2 JUNE 1998

9 Mster Specifictions SPECIFICATIONS CARBURETOR SPECIFI- CATIONS TIMING SPECIFI- CATIONS Idle RPM (In Forwrd Ger) Wide Open Throttle (WOT) RPM Idle Mixture Screw Adjustment (Preset-Turns Out) Jet 25/25 Sepro/25 Mrthon Flot Level Min Jet Size / 2 thru (WMC-44) -25/20 Jet (WMC-45) -25 Sepro/Mrthon (WMC-46) -25 Sepro/Mrthon (WMC-46A) 1997 nd Newer -20 Jet (WMC-45) -20 (WMC-52) -25 (WMC-53) -25 Sepro/Mrthon (WMC-54) 20 Jet / 2 THRU / / 2 THRU 1996 Electronic Sprk Advnce 750 ± 50 RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) Setup Timing 20/ AND NEWER 20 Jet 1999 AND NEWER Mechnicl Sprk Advnce 750 ± 50 RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) 750 ± ± 1/4 Turn 1-1/2 ± 1/2 Turn 1-1/4 ± 1/4 Turn 1.0 in. (25.4 mm) in. (1.12 mm) in. (1.93 mm) in. (1.93 mm) in. (2.03 mm) in. (1.93 mm) in. (1.12 mm) in. (1.93 mm) in. (2.03 mm) 4 ± 2 B.T.D.C (Not Adjustle) 1400 RPM ± 250 RPM 25 RPM ± 200 R.P.M. (Set-up timing of 28 B.T.D.C. will e retrded to R.P.M.) 6 ±1 B.T.D.C 1500 RPM ± 200 RPM 25 RPM R2 JUNE 1998 Pge 1A-5

10 Tle of Contents IMPORTANT INFORMATION Section 1B - Mintennce MAINTENANCE 1 B Tle of Contents B-1 Specifictions B-1 Ger Cse Luricnt Cpcity B-1 Specil Tools B-1 Quicksilver Luricnt/Selnt B-2 Inspection nd Mintennce Schedule B-3 Before Ech Use B-3 After Ech Use B-3 Every 100 Hours of Use or Once Yerly, Whichever Occurs First B-3 Every 300 Hours of Use or Three Yers B-3 Flushing The Cooling System B-4 Fuel System B-5 Fuel Line Inspection B-5 Engine Fuel Filter B-5 Corrosion Control Anode B-6 Sprk Plug Inspection B-7 Bttery Inspection B-7 Fuse Replcement -- Electric Strt Remote Control Models B-8 Luriction Points B-8 Ger Cse Luriction B-10 Ger Cse Luricnt Cpcity B-10 Drining Ger Cse B-10 Drining Ger Cse B-11 Checking Luricnt Level nd Refilling Ger Cse B-11 Storge Preprtions B-12 Fuel System B-12 Protecting Externl Engine Components.... 1B-12 Protecting Internl Engine Components B-12 Ger Cse B-13 Positioning Outord for Storge B-13 Bttery Storge B-13 Specifictions Ger Cse Luricnt Cpcity Specil Tools Ger Cse Rtio Cpcity 2.25:1 8.8 fl. oz. (260.0ml) 1. Flushing Attchment 44357A2 2. Grese Gun A R2 JUNE 1998 Pge 1B-1

11 MAINTENANCE Quicksilver Luricnt/Selnt 1. Quicksilver Anti-Corrosion Grese P/N A C Mrine Luricnt with Teflon P/N A12 3. SAE 30W Motor Oil P/N Quicksilver Ger Luricnt P/N A24 Pge 1B R2 JUNE 1998

12 Inspection nd Mintennce Schedule MAINTENANCE Before Ech Use After Ech Use 1. Check tht lnyrd stop switch stops the engine. 2. Visully inspect the fuel system for deteriortion or leks. 3. Check outord for tightness on trnsom. 4. Check steering system for inding or loose components. 5. Visully check steering link rod fsteners for proper tightness. 6. Check propeller ldes for dmge. 1. Flush out the outord cooling system if operting in slt or polluted wter. 2. Wsh off ll slt deposits nd flush out the exhust outlet of the propeller nd ger cse with fresh wter if operting in slt wter. Every 100 Hours of Use or Once Yerly, Whichever Occurs First 1. Luricte ll luriction points. Luricte more frequently when used in slt wter. 2. Inspect nd clen sprk plugs. 3. Check fuel line filter for contminnts. 4. Check cruretor djustments, if required. 5. Check corrosion control nodes. Check more frequently when used in slt wter. 6. Drin nd replce ger cse luricnt. 7. Luricte splines on the drive shft.* 8. Electric strt models -- Inspect ttery. 9. Remote control models -- Check control cle djustments. * 10. Remove engine deposits with Quicksilver Power Tune Engine Clener. 11. Check tightness of olts, nuts, nd other fsteners. 12. Clen fuel tnk pick up filter. Every 300 Hours of Use or Three Yers 1. Replce wter pump impeller (more often if overheting occurs or reduced wter pressure is noted).* * These items should e serviced y n uthorized deler R2 JUNE 1998 Pge 1B-3

13 MAINTENANCE Flushing The Cooling System Flush the internl wter pssges of the outord with fresh wter fter ech use in slt, polluted, or muddy wter. This will help prevent uildup of deposits from clogging the internl wter pssges. Use Quicksilver ccessory (or equivlent) flushing ttchment. WARNING To void possile injury when flushing, remove the propeller. Refer to Propeller Replcement. 1. Remove propeller (refer to Propeller Replcement). Instll the flushing ttchment so the ruer cups fit tightly over the cooling wter intke holes. CAUTION Never strt or run your outord (even momentrily) without wter circulting through the cooling wter intke in the ger cse to prevent dmge to the wter pump (running dry) or overheting of the engine. 2. Attch wter hose to the flushing ttchment. Turn on the wter nd djust the flow so wter is leking round the ruer cups to ensure the engine receives n dequte supply of cooling wter. 3. Strt the engine nd run it t idle speed in neutrl shift position. Pge 1B R2 JUNE 1998

14 MAINTENANCE 4. Adjust wter flow (if necessry) so excess wter continues leking out from round the ruer cups to ensure the engine is receiving n dequte supply of cooling wter. Fuel System Fuel Line Inspection Engine Fuel Filter REMOVAL 5. Check for stedy strem of wter flowing out of the wter pump indictor hole. Continue flushing the outord for 3 to 5 minutes, crefully monitoring wter supply t ll times. 6. Stop the engine, turn off the wter, nd remove the flushing ttchment. Reinstll the propeller. WARNING Avoid serious injury or deth from gsoline fire or explosion. Crefully follow ll fuel system service instructions. Alwys stop the engine nd DO NOT smoke or llow open flmes or sprks in the re while servicing ny prt of the fuel system. Before servicing ny prt of the fuel system, stop engine nd disconnect the ttery. Drin the fuel system completely. Use n pproved continer to collect nd store fuel. Wipe up ny spillge immeditely. Mteril used to contin spillge must e disposed of in n pproved receptcle. Any fuel system service must e performed in well ventilted re. Inspect ny completed service work for sign of fuel lekge. Visully inspect the fuel line nd primer ul for crcks, swelling, leks, hrdness or other signs of deteriortion or dmge. If ny of these conditions is found, the fuel line or primer ul must e replced. Inspect the sight owl for wter ccumultion nd inspect the filter element for sediment. Clen filter s follows. 1. Hold onto the cover to prevent it from turning. 2. Turn off the sight owl. 3. Pull out the filter element nd wsh it with clening solvent R2 JUNE 1998 Pge 1B-5

15 MAINTENANCE INSTALLATION 1. Push the filter element (with open end towrd cover) into cover. 2. Plce the O-ring sel into the sight owl nd screw the sight owl hnd tight into the cover. 1 3/ Visully inspect for fuel lekge round the sight owl y squeezing the primer ul until firm, forcing fuel into the sight owl. Corrosion Control Anode Your outord hs corrosion control node instlled to the ger cse. An node helps protect the outord ginst glvnic corrosion y scrificing its metl to e slowly eroded insted of the outord metls. The node requires periodic inspection especilly in slt wter which will ccelerte the erosion. To mintin this corrosion protection, lwys replce the node efore it is completely eroded. Never pint or pply protective coting on the node s this will reduce effectiveness of the node. - Anode Pge 1B R2 JUNE 1998

16 Sprk Plug Inspection MAINTENANCE Inspect sprk plugs t the recommended intervls. 1. Remove the sprk plug leds y twisting the ruer oots slightly nd pull off. 2. Remove the sprk plugs to inspect nd clen. Replce sprk plug if electrode is worn or the insultor is rough, crcked, roken, listered or fouled. 3. Set the sprk plug gp. See Specifiction Chrt in Generl Informtion Section. Bttery Inspection 4. Before reinstlling sprk plugs, clen wy dirt on the sprk plug sets. Instll plugs finger tight, nd tighten 1/4 turn or torque to 20 l. ft. (27.1 N m). The ttery should e inspected t periodic intervls to ensure proper engine strting cpility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your ttery. 1. Turn off the engine efore servicing the ttery. 2. Add wter s necessry to keep the ttery full. 3. Mke sure the ttery is secure ginst movement. 4. Bttery cle terminls should e clen, tight, nd correctly instlled. Positive to positive nd negtive to negtive. 5. Mke sure the ttery is equipped with nonconductive shield to prevent ccidentl shorting of ttery terminls R2 JUNE 1998 Pge 1B-7

17 MAINTENANCE Fuse Replcement - Electric Strt Remote Control Models The electric strting circuit is protected from overlod y SFE 20 AMP fuse. If the fuse is lown, the electric strter motor will not operte. Try to locte nd correct the cuse of the overlod. If the cuse is not found, the fuse my low gin. Replce the fuse with fuse of the sme rting. Luriction Points Replce with new SFE 20 AMP fuse. Luricte Points 1 thru 6 with Quicksilver 2-4-C Mrine Luricnt with Teflon or Specil Luricnt Steering Friction Adjustment Shft (Tiller Hndle Models) -- Luricte fitting. 2. Swivel Brcket -- Luricte fitting Trnsom Clmp Screws -- Luricte threds. Pge 1B R2 JUNE 1998

18 MAINTENANCE 4. Tilt Tue -- Luricte fittings. 5. Luricte the throttle nd shft cles, moving components nd pivot loctions. WARNING The end of the steering cle must e fully retrcted into the outord tilt tue efore dding luricnt. Adding luricnt to steering cle when fully extended could cuse steering cle to ecome hydruliclly locked. An hydruliclly locked steering cle will cuse loss of steering control, possily resulting in serious injury or deth. 6. Steering Cle Grese Fitting (If Equipped) -- Rotte steering wheel to fully retrct the steering cle end () into the outord tilt tue. Luricte through fitting (). Luricte points 7 With Light Weight Oil 7. Steering Link Rod Pivot Points -- Luricte points R2 JUNE 1998 Pge 1B-9

19 MAINTENANCE Luricte Point 8 with Quicksilver Anti-Corrosion Grese or 2-4-C Mrine Luricnt with Teflon. 8. Propeller Shft -- Refer to Propeller Replcement for removl nd instlltion of the propeller. Cot the entire propeller shft with luricnt to prevent the propeller hu from corroding to the shft. 8 Ger Cse Luriction Ger Cse Luricnt Cpcity Drining Ger Cse Ger Cse Rtio Cpcity 2.25:1 8.8 fl. oz. (260.0ml) When dding or chnging ger cse luricnt, visully check for the presence of wter in the luricnt. If wter is present, it my hve settled to the ottom nd will drin out prior to the luricnt, or it my e mixed with the luricnt, giving it milky colored ppernce. If wter is noticed, hve the ger cse checked y your deler. Wter in the luricnt my result in premture ering filure or, in freezing tempertures, will turn to ice nd dmge the ger cse. Whenever you remove the fill/drin plug, exmine the mgnetic end for metl prticles. A smll mount of metl filings or fine metl prticles indictes norml ger wer. An excessive mount of metl filings or lrger prticles (chips) my indicte norml ger wer nd should e checked y n uthorized deler. Pge 1B R2 JUNE 1998

20 Drining Ger Cse 1. Plce outord in verticl operting position. 2. Plce drin pn elow outord. 3. Remove fill/drin plug () nd vent plug () nd drin luricnt. MAINTENANCE Checking Luricnt Level nd Refilling Ger Cse 1. Plce outord in verticl operting position. 2. Remove vent plug from vent hole (). 3. Plce luricnt tue into the fill hole () nd dd luricnt until it ppers t the vent hole (). 4. Stop dding luricnt. Instll the vent plug nd seling wsher efore removing the luricnt tue R2 JUNE 1998 Pge 1B-11

21 MAINTENANCE 5. Remove luricnt tue nd reinstll clened fill/drin plug nd seling wsher. Storge Preprtions Fuel System IMPORTANT: Gsoline contining lcohol (ethnol or methnol) cn cuse formtion of cid during storge nd cn dmge the fuel system. If the gsoline eing used contins lcohol, It is dvisle to drin s much of the remining gsoline s possile from the fuel tnk, remote fuel line, nd engine fuel system. Fill the fuel system (tnk, hoses, fuel pumps, nd fuel injection systems) with treted (stilized) fuel to help prevent formtion of vrnish nd gum. Proceed with following instructions. 1. Portle Fuel Tnk -- Pour the required mount of Quicksilver Gsoline Stilizer (follow instructions on continer) into fuel tnk. Tip fuel tnk ck nd forth to mix stilizer with the fuel. 2. Permnently Instlled Fuel Tnk -- Pour the required mount of Quicksilver Gsoline Stilizer (follow instructions on continer) into seprte continer nd mix with pproximtely one qurt (one liter) of gsoline. Pour this mixture into fuel tnk. 3. Plce the outord in wter or connect flushing ttchment for circulting cooling wter. Run the engine for ten minutes to llow treted fuel to fill the fuel system. Protecting Externl Engine Components 1. Luricte ll outord components listed in the Inspection nd Mintennce Schedule. 2. Touch up ny pint nicks. 3. Spry Quicksilver Corrosion Gurd on externl metl surfces (except corrosion control nodes). Protecting Internl Engine Components NOTE: Before performing Steps 1 nd 2, mke sure the fuel system hs een prepred for storge. 1. Plce the outord in wter or connect flushing ttchment for circulting cooling wter. Strt the engine nd let it run in neutrl to wrm up. 2. With engine running t fst idle, stop the fuel flow y disconnecting the remote fuel line. When engine egins to stll, quickly spry Quicksilver Storge Sel into cruretor until engine stops from lck of fuel. 3. Remove the sprk plugs nd inject five second spry of Quicksilver Storge Sel round the inside of ech cylinder. Pge 1B R2 JUNE 1998

22 Ger Cse MAINTENANCE 4. Rotte the flywheel mnully severl times to distriute the storge sel in the cylinders. Reinstll sprk plugs. Drin nd refill the ger cse luricnt (refer to mintennce procedure). Positioning Outord for Storge Bttery Storge Store outord in n upright position to llow wter to drin out of outord. CAUTION If outord is stored tilted up in freezing temperture, trpped cooling wter or rin wter tht my hve entered the propeller exhust outlet in the ger cse could freeze nd cuse dmge to the outord. 1. Follow the ttery mnufcturers instructions for storge nd rechrging. 2. Remove the ttery from the ot nd check wter level. Rechrge if necessry. 3. Store the ttery in cool, dry plce. 4. Periodiclly check the wter level nd rechrge the ttery during storge R2 JUNE 1998 Pge 1B-13

23 Tle of Contents IMPORTANT INFORMATION Section 1C - Generl Informtion GENERAL INFORMATION 1 C Tle of Contents C-1 Seril Numer Loction C-1 Conditions Affecting Performnce C-2 Wether C-2 Bot C-3 Engine C-4 Following Complete Sumersion C-5 Sumerged While Running (Specil Instructions) C-5 Slt Wter Sumersion (Specil Instructions). 1C-5 Fresh Wter Sumersion (Specil Instructions) 1C-5 Propeller Selection C-6 Propeller Removl/Instlltion C-7 Compression Check C-9 Pinting Procedures C-10 Clening & Pinting Aluminum Propellers & Ger Housings C-10 Decl Appliction C-11 Decl Removl C-11 Instructions for Wet Appliction C-11 Seril Numer Loction The Outord seril numer is locted on the lower strord side of the engine lock. A seril numer is lso locted on the strord side of the swivel rcket. OGXXXXXX 19XX XXXX c - Seril Numer - Model Yer c - Model Description d - Yer Mnufctured e - Certified Europe Insigni e XX d R2 JUNE 1998 Pge 1C-1

24 GENERAL INFORMATION Conditions Affecting Performnce Wether It is known fct tht wether conditions exert profound effect on power output of internl comustion engines. Therefore, estlished horsepower rtings refer to the power tht the engine will produce t its rted RPM under specific comintion of wether conditions. Corportions interntionlly hve settled on doption of I.S.O. (Interntionl Stndrds Orgniztion) engine test stndrds, s set forth in I.S.O stndrdizing the computtion of horsepower from dt otined on the dynmometer, correcting ll vlues to the power tht the engine will produce t se level, t 30% reltive humidity t 77 F (25 C) temperture nd rometric pressure of inches of mercury. Summer Conditions of high temperture, low rometric pressure nd high humidity ll comine to reduce the engine power. This, in turn, is reflected in decresed ot speeds-- s much s 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cses. (Refer to previous chrt.) Nothing will regin this speed for the oter, ut the coming of cool, dry wether. In pointing out the prcticl consequences of wether effects, n engine--running on hot, humid summer dy--my encounter loss of s much s 14% of the horsepower it would produce on dry, risk spring or fll dy. The horsepower, tht ny internl comustion engine produces, depends upon the density of the ir tht it consumes nd, in turn, this density is dependent upon the temperture of the ir, its rometric pressure nd wter vpor (or humidity) content. Accompnying this wether-inspired loss of power is second ut more sutle loss. At rigging time in erly spring, the engine ws equipped with propeller tht llowed the engine to turn within its recommended RPM rnge t full throttle. With the coming of the summer wether nd the consequent drop in ville horsepower, this propeller will, in effect, ecome too lrge. Consequently, the engine opertes t less thn its recommended RPM. Pge 1C R2 JUNE 1998

25 Bot GENERAL INFORMATION Due to the horsepower/rpm chrcteristics of n engine, this will result in further loss of horsepower t the propeller with nother decrese in ot speed. This secondry loss, however, cn e regined y switching to smller pitch propeller tht llows the engine to gin run t recommended RPM. For oters to relize optimum engine performnce under chnging wether conditions, it is essentil tht the engine hve the proper propeller to llow it to operte t or ner the top end of the recommended mximum RPM rnge t wide-open-throttle with norml ot lod. Not only does this llow the engine to develop full power, ut eqully importnt is the fct tht the engine lso will e operting in n RPM rnge tht discourges dmging detontion. This, of course, enhnces overll reliility nd durility of the engine. WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the ot (persons nd ger) hs significnt effect on the ot s performnce, for exmple:. Shifting weight to the rer (stern) (1.) Generlly increses top speed. (2.) If in excess, cn cuse the ot to porpoise. (3.) Cn mke the ow ounce excessively in choppy wter. (4.) Will increse the dnger of the following - wve splshing into the ot when coming off plne.. Shifting weight to the front (ow) (1.) Improves ese of plning off. (2.) Generlly improves rough wter ride. (3.) If excessive, cn mke the ot veer left nd right (ow steer). BOTTOM For mximum speed, ot ottom should e nerly flt plne where it contcts the wter nd prticulrly stright nd smooth in fore-nd-ft direction. 1. Hook: Exists when ottom is concve in fore-nd-ft direction when viewed from the side. When ot is plning, hook cuses more lift on ottom ner trnsom nd llows ow to drop, thus gretly incresing wetted surfce nd reducing ot speed. Hook frequently is cused y supporting ot too fr hed of trnsom while huling on triler or during storge. 2. Rocker: The reverse of hook nd much less common. Rocker exists if ottom is convex in fore-nd-ft direction when viewed from the side, nd ot hs strong tendency to porpoise. 3. Surfce Roughness: Moss, rncles, etc., on ot or corrosion of outord s ger housing increse skin friction nd cuse speed loss. Clen surfces when necessry. WATER ABSORPTION It is impertive tht ll through hull fsteners e coted with qulity mrine seler t time of instlltion. Wter intrusion into the trnsom core nd/or inner hull will result in dditionl ot weight (reduced ot performnce), hull decy nd eventul structurl filure R2 JUNE 1998 Pge 1C-3

26 GENERAL INFORMATION CAVITATION Engine DETONATION Cvittion is cused y wter vpor ules forming either from shrp edge or ngle on the ger cse or from n irregulrity in the propeller lde itself. These vpor ules flow ck nd collpse when striking the surfce of the propeller lde resulting in the erosion of the propeller lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Detontion in 2-cycle engine resemles the pinging herd in n utomoile engine. It cn e otherwise descried s tin-like rttling or plinking sound. Detontion is n explosion of n unurned portion of the fuel/ir chrge fter the sprk plug hs fired. Detontion cretes severe shock wves in the engine, nd these shock wves often find or crete wekness: The dome of piston, cylinder hed/gsket, piston rings or piston ring lnds, piston pin nd roller erings. A few of the most common cuses of detontion in mrine 2-cycle ppliction re s follows: Over-dvnced ignition timing. Use of low octne gsoline. Propeller pitch too high (engine RPM elow recommended mximum rnge). Len fuel mixture t or ner wide-open-throttle. Sprk plugs (het rnge too hot - incorrect rech - cross-firing). Indequte engine cooling (deteriorted cooling system). Comustion chmer/piston deposits (result in higher compression rtio). Detontion usully cn e prevented if: 1. The engine is correctly set up. 2. Diligent mintennce is pplied to comt the detontion cuses. Dmged Piston Resulting from Detontion Pge 1C R2 JUNE 1998

27 Following Complete Sumersion GENERAL INFORMATION Sumerged While Running (Specil Instructions) When n engine is sumerged while running, the possiility of internl engine dmge is gretly incresed. If, fter engine is recovered nd with sprk plugs removed, engine fils to turn over freely when turning flywheel, the possiility of internl dmge (ent connecting rod nd/or ent crnkshft) exists. If this is the cse, the powerhed must e disssemled. Slt Wter Sumersion (Specil Instructions) Due to the corrosive effect of slt wter on internl engine components, complete disssemly is necessry efore ny ttempt is mde to strt the engine. Fresh Wter Sumersion (Specil Instructions) Propeller Selection 1. Recover engine s quickly s possile. 2. Remove cowling. 3. Flush exterior of outord with fresh wter to remove mud, weeds, etc. DO NOT ttempt to strt engine if snd hs entered powerhed, s powerhed will e severely dmged. Disssemle powerhed if necessry to clen components. 4. Remove sprk plugs nd get s much wter s possile out of powerhed. Most wter cn e eliminted y plcing engine in horizontl position (with sprk plug holes down) nd rotting flywheel. 5. Pour lcohol into cruretor throts (lcohol will sored wter). Agin rotte flywheel. 6. Turn engine over nd pour lcohol into sprk plug openings nd rotte flywheel. 7. Turn engine over (plce sprk plug openings down) nd pour engine oil into throt of cruretors while rotting flywheel to distriute oil throughout crnkcse. 8. Agin turn engine over nd pour pproximtely one tespoon of engine oil into ech sprk plug opening. Agin rotte flywheel to distriute oil in cylinders. 9. Remove nd clen cruretors nd fuel pump ssemly. 10. Dry ll wiring nd electricl components using compressed ir. 11. Disssemle the engine strter motor nd dry the rush contcts, rmture nd other corrodile prts. 12. Reinstll sprk plugs, cruretors nd fuel pump. 13. Attempt to strt engine, using fresh fuel source. If engine strts, it should e run for t lest one hour to eliminte ny wter in engine. 14. If engine fils to strt, determine cuse (fuel, electricl or mechnicl). Engine should e run within 2 hours fter recovery of outord from wter, or serious internl dmge my occur. If unle to strt engine in this period, disssemle engine nd clen ll prts. Apply oil s soon s possile. For in-depth informtion on mrine propellers nd ot performnce - written y mrine engineers - see your Authorized Deler for the illustrted Wht You Should Know Aout Quicksilver Propellers... nd Bot Performnce Informtion (Prt No ) R2 JUNE 1998 Pge 1C-5

28 GENERAL INFORMATION For est ll round performnce from your outord/ot comintion, select propeller tht llows the engine to operte in the upper hlf of the recommended full throttle RPM rnge with the ot normlly loded (refer to Specifictions). This RPM rnge llows for etter ccelertion while mintining mximum ot speed. If chnging conditions cuse the RPM to drop elow the recommended rnge (such s wrmer, more humid wether, opertion t higher elevtions, incresed ot lod or dirty ot ottom/ger cse) propeller chnge or clening my e required to mintin performnce nd ensure the outord s durility. Check full-throttle RPM using n ccurte tchometer with the engine trimmed out to lnced-steering condition (steering effort equl in oth directions) without cusing the propeller to rek loose. Refer to Quicksilver Accessory Guide for complete list of ville propellers. 1. Select propeller tht will llow the engine to operte t or ner the top of the recommended full throttle RPM rnge (listed in Specifictions, preceding) with norml lod. Mximum engine speed (RPM) for propeller selection exists when ot speed is mximum nd trim is minimum for tht speed. (High RPM, cused y n excessive trim ngle, should not e used in determining correct propeller.) Normlly, there is RPM chnge etween propeller pitches. 2. If full throttle opertion is elow the recommended rnge, the propeller MUST BE chnged to one with lower pitch to prevent loss of performnce nd possile engine dmge. 3. After initil propeller instlltion, the following common conditions my require tht the propeller e chnged to lower pitch:. Wrmer wether nd gret humidity will cuse n RPM loss.. Operting in higher elevtion cuses n RPM loss. c. Operting with dmged propeller or dirty ot ottom or ger housing will cuse n RPM loss. d. Opertion with n incresed lod (dditionl pssengers, equipment, pulling skiers, etc.). Pge 1C R2 JUNE 1998

29 Propeller Removl/Instlltion GENERAL INFORMATION WARNING If the propeller shft is rotted while the engine is in ger, there is the possiility tht the engine will crnk over nd strt. To prevent this type of ccidentl engine strting nd possile serious injury cused from eing struck y rotting propeller, lwys shift outord to neutrl position nd remove sprk plug leds when you re servicing the propeller 1. Shift outord to neutrl position. N N 2. Remove the sprk plug leds to prevent engine from strting. 3. Plce lock of wood etween ger cse nd propeller to hold propeller nd remove propeller nut. 4. Pull propeller stright off shft. If propeller is seized to the shft nd cnnot e removed, hve the propeller removed y n uthorized deler R2 JUNE 1998 Pge 1C-7

30 GENERAL INFORMATION 5. Cot the propeller shft with Quicksilver Anti-Corrosion Grese or 2-4-C Mrine Luricnt with Teflon. IMPORTANT: To prevent the propeller hu from corroding nd seizing to the propeller shft, especilly in slt wter, lwys pply cot of the recommended luricnt to the entire propeller shft t the recommended mintennce intervls nd lso ech time the propeller is removed. 6. Flo-Torque I Drive Hu Propellers Instll forwrd thrust hu, propeller, rer thrust hu nd propeller nut onto the shft. d c - Forwrd Thrust Hu - Propeller c - Rer Thrust Hu d - Propeller Nut 7. Flo-Torque II Drive Hu Propellers Instll forwrd thrust hu, replcele drive sleeve propeller, rer thrust hu nd propeller nut onto the shft. e d c - Forwrd Thrust Hu - Replcele Drive Sleeve c - Propeller d - Rer Thrust Hu e - Propeller Nut Pge 1C R2 JUNE 1998

31 GENERAL INFORMATION 8. Plce lock of wood etween ger cse nd propeller nd tighten propeller nut. Compression Check 1. Remove sprk plugs. 2. Instll compression guge in sprk plug hole. 3. Hold throttle plte t W.O.T. 4. Crnk the engine over until the compression reding peks on the guge. Record the reding. 5. Check nd record compression of ech cylinder. The highest nd lowest reding recorded should not differ y more thn 15% (see exmple chrt elow). A reding elow 120 psi might indicte totl engine wer prolem. Exmple of compression test differences Mximum (psi) Minimum (psi) Compression check is importnt ecuse n engine with low or uneven compression cnnot e tuned successfully to give pek performnce. It is essentil, therefore, tht improper compression e corrected efore proceeding with n engine tuneup. 7. Cylinder scoring: If powerhed shows ny indiction of overheting, such s discolored or scorched pint, visully inspect cylinders for scoring or other dmge s outlined in Section 4 Powerhed R2 JUNE 1998 Pge 1C-9

32 GENERAL INFORMATION Pinting Procedures Clening & Pinting Aluminum Propellers & Ger Housings PROPELLERS WARNING Avoid serious injury from flying deris. Avoid serious injury from irorne prticles. Use eye nd rething protection with proper ventiltion. 1. Snd the entire re to e pinted with 3M 120 Reglite Polycut or corse Scotch- Brite, disc or elts. 2. Fether edges of ll roken pint edges. Try not to snd through the primer. 3. Clen the surfce to e pinted using PPG Industries DX330 Wx nd Grese Remover or equivlent (Xylene or M.E.K.). 4. If re metl hs een exposed, use Quicksilver s Light Gry Primer. 5. Allow minimum of 1 hour dry time nd no more thn 1 week efore pplying the finish cot. 6. Apply the finish cot using Quicksilver s EDP Propeller Blck. GEAR HOUSINGS The following procedures should e used in refinishing ger housings. This procedure will provide the most durle pint system ville in the field. The mterils recommended re of high qulity nd pproximte mrine requirements. The following procedure will provide repint jo tht compres with properly pplied fctory pint finish. It is recommended tht the listed mterils e purchsed from locl Ditzler Automotive Finish Supply Outlet. The minimum pckge quntity of ech mteril shown following is sufficient to refinish severl ger housings. Procedure: 1. Wsh ger housing with muritic cid se clener to remove ny type of mrine growth, nd rinse with wter, if necessry. 2. Wsh ger housing with sop nd wter, then rinse. 3. Snd listered re with 3M 180 grit sndpper or P180 Gold Film Disc to remove pint listers only. Fether edge ll roken pint edges. 4. Clen ger housing thoroughly with (DX-330) wx nd grese remover. 5. Spot repir surfces where re metl is exposed with (DX-503) lodine tretment. IMPORTANT: Do not use ny type of erosol spry pints s the pint will not properly dhere to the surfce nor will the coting e sufficiently thick to resist future pint listering. 6. Mix epoxy chromte primer (DP-40) with equl prt ctlyst (DP-401) per mnufcturers instructions, llowing proper induction period for permetion of the epoxy primer nd ctlyst. 7. Allow minimum of one hour drying time nd no more thn one week efore top coting ssemlies. 8. Use Ditzler Urethne DU9000 for Mercury Blck, DU34334 for Mriner Grey, nd DU35466 for Force Chrcol, nd DU33414M for Se Ry White. Ctlyze ll three colors with Ditzler DU5 ctlyst mixed 1:1 rtio. Reduce with solvents per Ditzler lel. Pge 1C R2 JUNE 1998

33 Decl Appliction Decl Removl CAUTION GENERAL INFORMATION Be sure to comply with instructions on the lel for ventiltion nd respirtors. Using spry gun, pply one hlf to one mil even film thickness. Let dry, flsh off for five minutes nd pply nother even cot of one hlf to one mil film thickness. This urethne pint will dry to the touch in mtter of hours, ut will remin sensitive to scrtches nd rsions for few dys. 9. The type of spry gun used will determine the proper reduction rtio of the pint. IMPORTANT: Do not pint scrificil zinc trim t or zinc node. 10. Cut out crdord plug for trim t pocket to keep pint off of mting surfce to mintin good continuity circuitry etween trim t nd ger housing. 1. Mrk decl loction efore removl to ssure proper lignment of new decl. 2. Crefully soften decl nd decl dhesive with het gun or het lower while removing old decl. 3. Clen decl contct re with 1:1 mixture of isopropyl lcohol nd wter. 4. Thoroughly dry decl contct re nd check for completely clened surfce. Instructions for Wet Appliction NOTE: The following decl instlltion instructions re provided for Wet instlltion. All decls should e pplied wet. TOOLS REQUIRED 1. Plstic Squeegee* 2. Stick Pin 3. Dish Wshing Liquid/Detergent without mmoni** Joy nd Drift re known to e comptile for this process. ** Automotive Body Filler Squeegee ** Do not use sop tht contins petroleum sed solvents. SERVICE TIP: Plcement of decls using the Wet ppliction will llow time to position decl. Red entire instlltion instructions on this technique efore proceeding. TEMPERATURE IMPORTANT: Instlltion of vinyl decls should not e ttempted while in direct sunlight. Air nd surfce temperture should e etween 60 F (15 C) nd 100 F (38 C) for est ppliction. SURFACE PREPARATION IMPORTANT: Do not use sop or ny petroleum sed solvents to clen ppliction surfce. Clen entire ppliction surfce with mild dish wshing liquid nd wter. Rinse surfce thoroughly with clen wter R2 JUNE 1998 Pge 1C-11

34 GENERAL INFORMATION DECAL APPLICATION 1. Mix 1 / 2 ounce (16 ml) of dish wshing liquid in one gllon (4 l) of cool wter to use s wetting solution. NOTE: Leve protective msking, if present, on the fce of decl until finl steps of decl instlltion. This will ensure tht the vinyl decl keeps it s shpe during instlltion. 2. Plce the decl fce down on clen work surfce nd remove the pper cking from dhesive side of decl. 3. Using spry ottle, flood the entire dhesive side of the decl with the pre-mixed wetting solution. 4. Flood re where the decl will e positioned with wetting solution. 5. Position pre-wetted decl on wetted surfce nd slide into position. 6. Strting t the center of the decl, lightly squeegee out the ir ules nd wetting solution with overlpping strokes to the outer edge of the decl. Continue going over the decl surfce until ll wrinkles re gone nd dhesive onds to the cowl surfce. 7. Wipe decl surfce with soft pper towel or cloth. 8. Wit minutes. 9. Strting t one corner, crefully nd slowly pull the msking off the decl surfce t 180 ngle. NOTE: To remove ny remining ules, pierce the decl t one end of the ule with stick pin nd press out the entrpped ir or wetting solution with your thum (moving towrd the puncture). Pge 1C R2 JUNE 1998

35 Tle of Contents IMPORTANT INFORMATION Section 1D - Outord Motor Instlltion OUTBOARD MOTOR INSTALLATION 1 D Tle of Contents D-1 Notice to Instller nd Owner D-1 Bot Horsepower Cpcity D-1 Outord Remote Control D-1 Selecting Accessories For The Outord D-2 Selecting Steering Cles nd Remote Control Cles D-2 Instlling Outord D-3 Steering Cle nd Steering Link Rod Instlltion 1D-4 Instlling Ride Guide Steering Cle to the Outord D-4 Steering Cle Sel D-4 Steering Link Rod Instlltion D-5 Remote Control Instlltion D-6 Shift nd Throttle Cle Instlltion to the Outord D-6 Shift Cle Instlltion D-6 Throttle Cle Instlltion D-7 Remote Wiring Hrness Connection to Engine... 1D-8 Bttery Cle Connections D-10 Propeller Instlltion D-11 Tilt Pin Adjustment D-11 Plcing Tilt Pin in Lower Holes D-11 Plcing Tilt Pin in Upper Holes D-12 Trim T Adjustment D-12 Notice to Instller nd Owner This mnul s well s sfety lels posted on the outord use the following sfety lerts to drw your ttention to specil sfety instructions tht should e followed. DANGER DANGER -- Immedite hzrds which WILL result in severe personl injury or deth. WARNING WARNING -- Hzrds or unsfe prctices which COULD result in severe personl injury or deth. CAUTION CAUTION -- Hzrds or unsfe prctices which could result in minor injury or product or property dmge. Bot Horsepower Cpcity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY XXX XXX XXX Do not overpower or overlod your ot. Most ots will crry required cpcity plte indicting the mximum cceptle power nd lod s determined y the mnufcturer following certin federl guidelines. If in dout, contct your deler or the ot mnufcturer R2 JUNE 1998 Pge 1D-1

36 OUTBOARD MOTOR INSTALLATION WARNING Using n outord tht exceeds the mximum horsepower limit of ot cn: 1. cuse loss of ot control 2. plce too much weight t the trnsom ltering the designed flottion chrcteristics of the ot or 3. cuse the ot to rek prt prticulrly round the trnsom re. Overpowering ot cn result in serious injury, deth, or ot dmge. Outord Remote Control The remote control connected to your outord must e equipped with strt-in-ger protection device. This prevents the engine from strting when the outord is in ger. WARNING Avoid serious injury or deth from sudden unexpected ccelertion when strting your engine. The design of this outord requires tht the remote control used with it must hve uilt in strt-in-ger protection device. Selecting Accessories For The Outord Genuine Mercury Mrine Quicksilver Accessories hve een specificlly designed nd tested for your outord. Mercury Mrine Quicksilver ccessories re ville from Mercury Mrine delers. Some ccessories not mnufctured or sold y Mercury Mrine re not designed to e sfely used with your outord or outord operting system. Acquire nd red the instlltion, opertion, nd mintennce mnuls for ll your selected ccessories. Selecting Steering Cles nd Remote Control Cles Instll steering mount nd steering wheel in ccordnce with instlltion instructions tht ccompny ech. IMPORTANT: Steering cle must e correct length. Shrp ends on too-short of cle result in kinks; too-long of cle require unnecessry ends nd/or loops. Both conditions plce extr stress on the cle. Refer to Quicksilver Accessories Guide to determine correct length of steering cle. Pge 1D R2 JUNE 1998

37 Instlling Outord OUTBOARD MOTOR INSTALLATION 1. Mesure the trnsom height of your ot. The ot ottom should e ligned or e within 1 in. (25mm) ove the nti-ventiltion plte () of the outord. - Anti-Ventiltion Plte 0-1in. (0-25mm) 2. Plce outord on center line of trnsom. 3. Tighten trnsom clmp hndles. 4. To prevent loss of outord overord, fsten outord y drilling two 5/16 in. (7.9 mm) holes through the trnsom using trnsom clmp holes s templte. Fsten with two olts, flt wshers nd locknuts. Use mrine wterproofing seler in holes nd round olts to mke the instlltion wter tight. - Bolts (2) - Flt Wshers (2) c - Locknuts (2) c R2 JUNE 1998 Pge 1D-3

38 OUTBOARD MOTOR INSTALLATION Steering Cle nd Steering Link Rod Instlltion Instlling Ride Guide Steering Cle to the Outord IMPORTANT: Before instlling steering cle into tilt tue, luricte entire cle end with Quicksilver 2-4-C w/teflon Mrine Luricnt ( A12). 1. Luricte the entire cle end. - Quicksilver 2-4-C Mrine Luricnt with Teflon 2. Insert steering cle end thru outord tilt tue nd secure steering cle to tilt tue with steering cle ttching nut s shown. Torque nut to 35 l. ft. (47.5 N m). Steering Cle Sel - Cle End - Attching Nut [Torque to 35 l. ft. (47.5 N m)]. 3. Plce mrk on tilt tue 5/8 in. (15.9mm) from port end of tue. Slide plstic spcer, o-ring nd cp over steering cle end, to tilt tue on engine. 1/4 in. (6.4mm ) c d - Mrk - Spcer c - O-ring d - Cp Pge 1D R2 JUNE 1998

39 OUTBOARD MOTOR INSTALLATION 4. Thred cp up to the 1/4 in. (6.4mm) mrk. - Cp Steering Link Rod Instlltion IMPORTANT: The steering link rod tht connects the steering cle to the engine must e fstened using specil wsher hed olt ( -Prt Numer )nd self locking nuts ( & c - Prt Numer ). These locknuts must never e replced with common nuts (non locking) s they will work loose nd virte off freeing the link rod to disengge. WARNING Disenggement of steering link rod cn result in the ot tking full, sudden, shrp turn. This potentilly violent ction cn cuse occupnts to e thrown overord exposing them to serious injury or deth. 1. Assemle steering link rod to steering cle with two flt wshers (d) nd nylon insert locknut ( -- Prt Numer ). Tighten locknut () until it sets, then ck nut off 1/4 turn. 2. Assemle steering link rod to engine with specil wsher hed olt ( -- Prt Numer ) nd nylon insert locknut ( c -- Prt Numer ). First torque olt () to 20 l. ft. (27.1 N m), then torque locknut (c) to 20 l. ft. (27.1 N m). c d - Bolt ( ) - Lock Nut ( ) c - Lock Nut ( ) d - Wshers (2 ech) R2 JUNE 1998 Pge 1D-5

40 OUTBOARD MOTOR INSTALLATION WARNING After instlltion is complete (nd efore operting outord), check tht ot will turn right when steering wheel is turned right nd tht ot will turn left when steering wheel is turned left. Check steering thru full rnge (left nd right) nd t ll tilt ngles to ssure interference-free movement. Remote Control Instlltion Refer to Quicksilver Accessory Guide for pproprite electric or mnul remote control. Use instructions provided with control for proper instlltion. Shift nd Throttle Cle Instlltion to the Outord Shift Cle Instlltion Instll the shift cle nd throttle cle into the remote control nd mount the remote control following instructions which re provided with the remote control. NOTE: Instll the shift cle efore the throttle cle. The shift cle is the first cleto move when the remote control hndle is moved into ger. 1. Move the remote control hndle into full reverse position. 2. Plce the engine shift lever () into reverse position (towrd rer) while rotting propeller. The propeller shft will not rotte in either direction when in reverse position. 3. Open up the cle retiner cover () nd remove the rrel holder nd front ruer grommet. 4. Instll the shift cle (c) onto the shift lever pin (d). lock in plce with retiner ltch (e). 5. Adjust the shift cle rrel so it will fit into the ottom hole of the rrel holder (f)nd tht the rrel holder will slide freely into the retining pocket without pre-loding the shift cle. f e d c - Shift Lever - Cle Retiner Cover c - Shift Cle d - Shift Lever Pin e - Retiner Ltch f - Brrel Holder 6. Check shift cle djustments s follows: Pge 1D R2 JUNE 1998

41 Throttle Cle Instlltion OUTBOARD MOTOR INSTALLATION. With remote control shifted into forwrd the propeller shft should lock solidly in ger. If it does not, djust the cle rrel closer to the engine shift lever.. Shift remote control into neutrl. The propeller shft should turn freely without drg. If not, djust the rrel wy from the engine shift lever. Repet steps nd. c. Shift remote control into reverse while turning the propeller shft. The propeller shft should lock solidly in ger. If not, djust the rrel wy from the engine shift lever. Repet steps thru c. d. Return remote control hndle to neutrl. The propeller shft should turn freely without drg. If not, djust the rrel closer to the engine shift lever. Repet steps thru d. NOTE: Attch Shift cle to engine prior to ttching throttle cle. 1. Position the remote control hndle forwrd, to wide-open-throttle position. 2. Instll the throttle cle () onto the throttle pin (). lock in plce with retiner ltch (c). 3. Move throttle lever (g) until t (e) contcts throttle stop (f). Adjust the rrel on the throttle cle so tht the rrel will fit into the rrel holder (d). 4. Slip the rrel into the rrel holder nd plce the rrel holder into the retining pocket. 5. Check the throttle cle djustment s follows.. Move the remote control hndle ck to neutrl few times nd then return the hndle ck to forwrd wide-open-position.. Recheck to mke sure t (e) is contcting throttle stop (f). f e d g - Throttle Cle - Throttle Pin c - Retiner Ltch d - Brrel Holder e - T f - Throttle Stop g - Throttle Lever c R2 JUNE 1998 Pge 1D-7

42 OUTBOARD MOTOR INSTALLATION 6. Plce the ruer sel ( side with holes towrds front)) onto the control cles nd instll control cles, rrel holder nd ruer sel into the cle holder s shown. 7. Lock the rrel holder in plce with the cle retiner ltch. - Ruer Sel - Cle Retiner Ltch Remote Wiring Hrness Connection to Engine 1. Remove wire retiner from the ottom cowl. - Wire Retiner Pge 1D R2 JUNE 1998

43 OUTBOARD MOTOR INSTALLATION 2. Position the remote wiring hrness nd ttery cles thru the ottom cowl ruer grommet s shown. 3. Plug the remote wiring hrness into the engine wiring hrness connector. 4. Secure the connection together using retiner. - Ruer Grommet - Remote Wiring Hrness c - Engine Hrness Connector d - Retiner c d 5. Fsten the remote wiring hrness nd ttery cles into the ottom cowl ruer grommet with retiner. - Retiner R2 JUNE 1998 Pge 1D-9

44 OUTBOARD MOTOR INSTALLATION Bttery Cle Connections SINGLE OUTBOARD (+) c DUAL OUTBOARD ( -) - RED Sleeve (POSITIVE) - BLACK Sleeve (NEGATIVE) c - Strting Bttery 1. Connect common ground cle (wire size sme s engine ttery cles) etween negtive (--) terminls on strting tteries. ( -) ( -) Propeller Instlltion - Ground Cle (Sme Wire Size As Engine Bttery Cle -- Connect Between Negtive (--) Terminls WARNING If the propeller shft is rotted while the engine is in ger, there is the possiility tht the engine will crnk over nd strt. To prevent this type of ccidentl engine strting nd possile serious injury cused from eing struck y rotting propeller, lwys shift outord to neutrl position nd remove sprk plug leds when you re servicing the propeller. Pge 1D R2 JUNE 1998

45 Flo-Torq I Drive Hu Propellers d c OUTBOARD MOTOR INSTALLATION - Forwrd Thrust Hu - Propeller c - Rer Thrust Hu d - Propeller Nut -- Tighten Flo-Torq II Drive Hu Propellers e d c Tilt Pin Adjustment - Forwrd Thrust Hu - Replcele Drive Sleeve c - Propeller d - Rer Thrust Hu e - Propeller Nut -- Tighten Plcing Tilt Pin in Lower Holes 1. Lower the ow. 2. Result in quicker plning off, especilly with hevy lod or stern hevy ot. 3. Generlly improve the ride in choppy wter. 4. Increse steering torque or pull to the right (with the norml right hnd rottion propeller). 5. In excess, lower the ow of some ots to point t which they egin to plow with their ow in the wter while on plne. This cn result in n unexpected turn in either direction clled ow steering or over-steering if ny turn is ttempted or if significnt wve is encountered R2 JUNE 1998 Pge 1D-11

46 OUTBOARD MOTOR INSTALLATION Plcing Tilt Pin in Upper Holes 1. Lift the ow out of the wter. 2. Generlly increse top speed. Trim T Adjustment 3. Increse clernce over sumerged ojects or shllow ottom. 4. Increse steering torque or pull to the left t norml instlltion height (with the norml right hnd rottion propeller). 5. In excess, cuse ot porpoising (ouncing) or propeller ventiltion. Propeller steering torque my cuse ot to pull in one direction. This steering torque results from outord not eing djusted so the propeller shft is prllel to the wter surfce. The trim t cn help compenste for this steering torque nd cn e djusted within limits to reduce ny unequl steering effort. NOTE: Trim t djustment will hve little effect reducing steering torque if the outord is instlled with the nti-ventiltion plte pproximtely 2 inches (50mm) or more ove the ot ottom. Operte ot t norml cruising speed, with the outord set t the desired trnsom ngle djustment. Turn ot left nd right nd note the direction the ot turns more esily. If djustment is necessry, loosen trim t olt nd mke smll djustments t time. If the ot turns more esily to the left, move the triling edge of trim t to the left. If the ot turns more esily to the right move the triling edge of trim t to the right. Retighten olt nd retest. Pge 1D R2 JUNE 1998

47 Tle of Contents Specifictions A-2 Specil Tools A-3 Ignition/Electricl Components A-4 Ignition Description A-6 Electronic Sprk Advnce A-7 Mechnicl Sprk Advnce A-7 15XD RPM Limiter A-7 Ignition Component Description A-7 Trigger Coil A-7 Sttor A-8 Flywheel A-8 Ignition Coil A-9 ELECTRICAL Section 2A - Ignition IGNITION Ignition Switch Box A-9 Electronic Sprk Advnce A-11 Ignition Test Procedures A-12 Direct Voltge Adpter (DVA) A-12 Ignition Trouleshooting A-13 Ignition Dignostic Procedures A-13 Ignition Trouleshooting A-15 Electronic Sprk Advnce A-15 Tool: Multimeter/DVA Tester A A-15 Ignition Trouleshooting A-16 Mechnicl Sprk Advnce A-16 Ignition Trouleshooting (RED Sttor) A-17 2 A R2 JUNE 1998 Pge 2A-1

48 IGNITION Specifictions IGNITION SYSTEM Redings 68 F (20 C). Type Sprk Plug Type (NGK) Sprk Plug Gp Sprk Plug Hex Firing Order 20 Jet / 2 THRU / / 2 THRU 1996 Electronic Sprk Advnce RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) Setup Timing Sttor High Speed Winding Sttor Low Speed Winding Diode Test Ignition Coil Resistnce: Primry Secondry (w/o Boots) 20 Jet 1999 nd Newer 20/ /98 Models Mechnicl Sprk Advnce RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) Sttor High Speed Winding Sttor Low Speed Winding Diode Test Ignition Coil Resistnce: Primry Secondry (w/o Boots) Trigger Cpcitor Dischrge Ignition NGK BP8H-N in. (1.0 mm) 18 mm B.T.D.C (Not Adjustle) 1400 RPM 250 RPM 25 RPM R.P.M. (Set-up timing of 28 B.T.D.C. will e retrded to R.P.M.) W (RED -- BLK) W (BLUE -- BLACK) W (RED -- BLUE) 0 W W 6 1 B.T.D.C 1500 RPM 200 RPM 25 RPM W (BLK/WHT - GRD) W (BLK/YEL - GRD) W (BLK/YEL - BLK/WHT) W W W Pge 2A R2 JUNE 1998

49 Specil Tools IGNITION 1. DMT 2000 Digitl Tchometer Multi-meter P/N A1 2. Flywheel Holder P/N A1. 3. Flywheel Puller P/N M. 4. Flywheel Holder Sprk Gp Bord R2 JUNE 1998 Pge 2A-3

50 IGNITION Ignition/Electricl Components 6 Dielectric Grese ( ) 7 Loctite 271 ( ) 25 Liquid Neoprene ( ) A=ALTERNATOR VERSION ONLY Pge 2A R2 JUNE 1998

51 IGNITION Ignition/Electricl Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 COVER--ignition coil 2 3 SCREW--ignition coil cover (M5x.8x55) STATOR ASSEMBLY (20/25--USA-S/N-0G & BELOW) 1 (BEL-S/N & BELOW) 3 STATOR ASSEMBLY (20/25--USA-S/N-0G & UP) 1 (BEL-S/N & UP) 1 STATOR ASSEMBLY (JET 20) 4 2 SCREW--sttor ttching (M5x.8x25) SCREW--sttor ttching (M5x12) CLIP 7 1 SCREW--clip to crnkcse (#10-16x1/2 IN.) Drive Tight 8 1 C-WASHER--clip screw 1 SWITCH BOX (JET 20)(S# USA-0G & UP) 1 SWITCH BOX (JET 20)(S#USA-0G & BELOW) 9 SWITCH BOX (20/25--USA-S/N-0G & BELOW) 1 BEL-S/N & BELOW) SWITCH BOX (20/25--USA-S/N-0G thru 0G589999) 1 (BEL-S/N thru ) 10 SWITCH BOX (20/25--USA-S/N-0G & UP) 1 (BEL-S/N & UP) 11 2 SCREW (M5 x 20) 12 3 SCREW (M5x.8x35 hex wsher hed) Drive Tight 13 1 SCREW--ground wire Drive Tight 14 1 CLIP 15 1 TRIGGER ASSEMBLY 16 1 TERMINAL BLOCK 17 2 SCREW--terminl lock (#10-16x5/8 IN.) COMMERCIAL 18 2 SCREW--terminl lock (#10-16x3/8 IN.) 19 1 STATOR ASSEMBLY--uxiliry 20 3 SCREW (M5x.8x30 hex hed) AR STA-STRAP HI-TENSION CABLE SET 24 1 HI-TENSION CABLE (Prt of Ref. #22) 25 2 BOOT ASSEMBLY--sprk plug 26 AR STA-STRAP 27 2 IGNITION COIL ASSEMBLY 28 4 NUT--coil terminl (1#10-32 Brss) CABLE ASSEMBLY (Blck) 2 SPARK PLUG (NGK #BP8H-N-10) SPARK PLUG (NGK #BPZ8H-N-10) (CAN/BELG.) R2 JUNE 1998 Pge 2A-5

52 IGNITION Ignition Description The ignition system is n lterntor driven cpcitor dischrge system. Mjor components of the ignition system re the flywheel, sttor, trigger coil, switch ox, 2 ignition coils nd 2 sprk plugs. The flywheel hs permnent mgnets mounted in oth the outer rim nd the center hu. The BLACK sttor ssemly is mounted elow the flywheel nd hs low speed (LS) nd high speed (HS) cpcitor chrging coil. Low speed coil provides primry voltge to the switch ox from idle to pproximtely 2500 RPM. The high speed coil provides primry voltge from 2000 RPM to the mximum RPM the outord is cple of chieving. The RED sttor ssemly is mounted elow the flywheel nd hs only one cpcitor chrging coil. As the flywheel rottes, the mgnets mounted in the flywheel outer rim pss the chrging coils creting voltge. This voltge chrges the cpcitor locted in the switch ox. As the flywheel continues to rotte, the mgnets in the center hu pss the trigger coil creting AC voltge. This voltge turns on one of the two electronic switches (SCR) in the switch ox. A positive voltge pulse turns on the SCR switch ssocited with cylinder #1; negtive voltge pulse turns on the SCR switch ssocited with cylinder #2. The SCR switch dischrges the stored cpcitor voltge into the primry side of the respective ignition coil. The ignition coil multiplies this voltge to vlue high enough to jump the sprk plug gp volts for stndrd coils; volts for high energy coils. This sequence occurs once per engine revolution for ech cylinder Sprk timing on electroniclly dvnced models is controlled internlly y the switch ox with fixed trigger. Sprk timing on mechniclly dvnced models is chnged (dvnced/retrded) y rotting the trigger coil which chnges the trigger coil position in reltion to the mgnets in the center hu of the flywheel. The stop switch (or ignition switch) shorts the output of the sttor to ground to stop the engine on ll models. Pge 2A R2 JUNE 1998

53 Electronic Sprk Advnce 20/25 OUTBOARDS SERIAL NUMBER: USA 0G THRU 0G BELGIUM THRU JET OUTBOARDS USA 0G THRU 0G BELGIUM THRU IGNITION The sprk timing is controlled y n electronic circuit within the engine switch ox. The trigger ssemly is positioned for mximum dvnce. (Refer to Set-Up Timing/Adjustment Procedure) The electronic timing feture of the switch ox retrds the timing on strt up nd t idle RPM. As the engine RPM increses the timing will dvnce. Mximum timing will occur t pproximtely 2500 RPM. Mechnicl Sprk Advnce RPM Limiter 20/25 OUTBOARDS SERIAL NUMBER: USA 0G AND ABOVE BELGIUM AND ABOVE 20 JET OUTBOARDS SERIAL NUMBER USA 0G AND ABOVE BELGIUM AND ABOVE The sprk timing is chnged (dvnced/retrded) y rotting the trigger coil, which chnges the trigger coil position in reltion to the mgnets in the center hu of the flywheel. The stop switch (or ignition switch) shorts the output of the sttor to ground to stop the engine. The 20 JET RED sttor ignition module contins RPM limiter circuit which interrupts one cylinder when RPM exceeds RPM. Ignition Component Description Trigger Coil A single wound coil locted under the flywheel. The trigger is chrged y the center hu flywheel mgnet nd sends pulse voltge to n (SCR) switch locted in the ignition switch ox. - Trigger Coil ELECTRONIC SPARK ADVANCE The trigger is mounted in fixed timing position R2 JUNE 1998 Pge 2A

54 IGNITION MECHANICAL SPARK ADVANCE Sprk timing is chnged (dvnced/retrded) y rotting the trigger coil, which chnges the trigger coil position in reltion to the mgnets in the center hu of the flywheel. Sttor The ignition sttor locted under the flywheel contins two sttor windings. One low speed winding nd one high speed winding. As the outer flywheel mgnets pss the sttor windings, current is produced tht chrges cpcitor in the ignition switch ox. Electronic Sprk Advnce Sttor Flywheel - Low Speed Winding - High Speed Winding e c e d Center Hu Mgnet - Outer Mgnet c - BLACK Sttor Flywheel (2 Mgnets) d - RED Sttor Flywheel (4 Mgnets) e - Spcers The flywheel ssemly (BLACK sttor) contins two outer mgnets (8 Pole) (4 Pulse), nd one center hu mgnet. The outer mgnets re needed for ttery chrge coil nd ignition chrge coils. The inner hu mgnet is for trigger coil. The flywheel ssemly (RED sttor) contins four outer mgnets (10 Pole) (5 Pulse), nd one center hu mgnet. The outer mgnets re needed for ttery chrge coil nd ignition chrge coils. The inner hu mgnet is for trigger coil. NOTE: Commercil nd service flywheels will hve 2 dditionl spcers nd retining ring used only with the RED sttor. Pge 2A R2 JUNE 1998

55 Ignition Coil IGNITION The primry (+) side of the ignition coil receives voltge dischrged from cpcitor in the ignition switch ox. The voltge is multiplied y the coil until it cn jump the sprk plug gp. Ignition coil mximum output pproximtely volts. - Positive (+) Primry Terminl - Negtive Terminl Ignition Switch Box ELECTRONIC SPARK ADVANCE (BLACK STATOR) The ignition switch ox receives n AC current from the low nd high speed sttor ssemly. This current is rectified nd chnged to DC current where it will e stored in the internl cpcitor. A voltge pulse from the trigger ssemly (in firing order) turns on respective SCR switch which dischrges the cpcitor stored voltge nd sends it to the ignition coil. The switch ox contins n electricl circuit tht controls the ignition sprk timing. The switch ox senses the engine R.P.M. y counting trigger pulses nd djusts the engine timing ccordingly. No idle timing djustment is required. Refer to the Timing/Synchronizing/Adjusting section of this mnul. c d e f g h i j - #1 Coil Primry Led (Green/Yellow) - #2 Coil Primry Led (Green/White) c - Ground Led d - Sttor Connector e - Sttor Led (RED) High Speed f - Sttor Ground Led (BLACK) g - Sttor Led (Blue) Low Speed h - Engine Stop Led (BLACK/YELLOW) i - Trigger Led (BROWN/WHITE) j - Trigger Led (BROWN/YELLOW) R2 JUNE 1998 Pge 2A-9

56 IGNITION MECHANICAL SPARK ADVANCE (BLACK STATOR) The ignition switch ox receives n AC current from the low nd high speed sttor ssemly. This current is rectified nd chnged to DC current where it will e stored in the internl cpcitor. A voltge pulse from the trigger ssemly (in firing order) turns on respective SCR switch which dischrges the cpcitor stored voltge nd sends it to the ignition coil. c e d f g h - #1 Coil Primry Led (Green/Yellow) - #2 Coil Primry Led (Green/White) c - Ground Led d - Engine Stop Led (BLACK/YELLOW) e - Trigger Led (BROWN/YELLOW) f - Sttor Led (BLACK/WHITE) High Speed g - Trigger Led (BROWN/WHITE) h - Sttor Led(BLACK/YELLOW) Low Speed MECHANICAL AND ELECTRONIC SPARK ADVANCE (RED STATOR) The mechnicl nd electronic sprk dvnce mechnism/circuitry operte the sme with the RED sttor s they do with the BLACK sttor. The only difference is tht the RED sttor hs only 1 chrging coil wheres the BLACK sttor hs 2 chrging coils; 1 high speed coil nd 1 low speed coil. Pge 2A R2 JUNE 1998

57 Electronic Sprk Advnce IGNITION Set-Up Timing RPM 5500 RPM 25 B.T.D.C R.P.M RPM 15 B.T.D.C R.P.M. Approx. 3-5 B.T.D.C Engine Speed - RPM R2 JUNE 1998 Pge 2A-11

58 IGNITION Ignition Test Procedures Direct Voltge Adpter (DVA) WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components nd/or metl test proes while engine is running nd/or eing crnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, ech individul sprk plug led should e grounded to engine. WARNING When testing or servicing the ignition system, high voltge is present. DO NOT TOUCH OR DISCONNECT ny ignition prts while engine is running, while key switch is on or while ttery cles re connected. CAUTION Filure to comply with the following items my result in dmge to the ignition system. 1. DO NOT reverse ttery cle connections. The ttery negtive cle is (-) ground. 2. DO NOT sprk ttery terminls with ttery cle connections to check polrity. 3. DO NOT disconnect ttery cles while engine is running. 4. DO NOT crnk engine with CDI or Ignition Coils not grounded. CAUTION To protect ginst meter nd/or component dmge, oserve the following precutions: 400 VDC* test position (or higher) MUST BE used for ll tests. INSURE the Positive (+) led/terminl of DVA is connected to the Positive (+) receptcle of meter. DO NOT CHANGE meter selector switch position while engine is running nd/or eing crnked. ALL COMPONENTS MUST BE GROUNDED during tests. Running or crnking engine with CDI or Ignition Coils ungrounded my dmge components. * If using meter with uilt-in DVA, the DVA/400 or DVA/500 VDC test position should e used. NOTE: Test leds re not supplied with the Direct Voltge Adpter. Use test leds supplied with multi meter. Test procedures nd specifictions re provided for checking primry ignition voltge while the engine is running nd/or eing crnked with ll hrnesses connected. Pge 2A R2 JUNE 1998

59 Ignition Trouleshooting IGNITION WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components nd/or metl test proes while engine is running nd/or eing crnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, ech individul sprk plug led should e grounded to engine. WARNING When testing or servicing the ignition system, high voltge is present. DO NOT TOUCH OR DISCONNECT ny ignition prts while engine is running. Ignition Dignostic Procedures TROUBLESHOOTING TIP: With engine running, use inductive timing light to check sprk dvnce of ech cylinder s throttle is opened nd closed. If timing dvnces nd retrds smoothly on ech cylinder, ignition system is MOST LIKELY functioning properly IMPORTANT: If outord ppers to hve n ignition system filure, it is recommended tht efore eginning in-depth trouleshooting:. Ensure tht the engine is mechniclly sound condition. (Fuel System, Cylinder Compression etc.).. Check ll engine ground leds for loose or corroded connections. c. Disconnect nd reconnect ignition hrness connectors to verify proper continuity. PROBLEM CORRECTION 1. No Sprk or Wek Sprk on Both Cylinders No Sprk -- Trigger, Sttor, Ignition Switch Box or Bd Ground Connection from Switch Box to Block Wek Sprk -- Sttor 2. No Sprk or Wek Sprk on 1 Cylinder Ignition Switch Box or Coil 3. Timing Fluctutes -- Note: It is norml for timing to fluctute Idle. -- If engine RPM exceeds 5800, switch ox will retrd timing from 25 BTDC to 15 BTDC --If engine RPM drops elow 600, idle stilizer in switch ox will dvnce timing to s high s 10 crnk ing speed of 300 RPM. 4. Timing will not Advnce -- Note: If timing will not dvnce on only 1 cylinder, check wiring for shorted trigger wire Shorted Trigger Wire or Ignition Switch Box Defective Switch Box 5. Engine High RPM Defective Coil Defective Switch Box R2 JUNE 1998 Pge 2A-13

60 IGNITION 6. Engine Hrd to Strt when Cold Defective Trigger Assemly Defective Ignition Switch Box 7. Engine Low RPM ut Runs High RPM Defective Hrness or (loose connections) Defective Switch Box Defective Sttor 8. Engine Strts Hrd when Hot Defective Switch Box or Trigger 9. Engine Occsionlly Misfires Replce Stndrd Sprk Plug with Inductor Plug Bd Ground Connection from Switch Box to Block Pge 2A R2 JUNE 1998

61 Ignition Trouleshooting IGNITION Electronic Sprk Advnce WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components nd/or metl test proes while engine is running nd/or eing crnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, ech individul sprk plug led should e grounded to engine. WARNING When testing or servicing the ignition system, high voltge is present. DO NOT TOUCH OR DISCONNECT ny ignition prts while engine is running, while key switch is on. Tool: Multimeter/DVA Tester A1 Test 1 Test 2 Test 3 Test 4 Component Test Coil Primry Sw. Box - Stop Circuit Sttor - Low Speed Sttor - High Speed Selector Sw. Position 400 DVA* 400 DVA* 400 DVA* 400 DVA* DVA Led Red Coil (+) Terminl Blck/Yellow Sw. Box Terminl Blue Sw. (2) Box Terminl Red Sw. (2) Box Terminl DVA Led Blck Coil (--) Terminl Voltge Reding RPM Voltge RPM (1) Ground Ground Ground (1)Redings my vry t crnking speed or t idle. (2)Bck proe the electricl connector in order to mke connection. Test 5 Test 6 Tested Prt Sttor Trigger Multimeter Ohm Checks Multimeter Wires RED BLACK RED BLACK RED BLACK RED BLACK Connected To: Meter Scle Meter Reding RED BLACK BLUE BLACK RED BLUE BROWN/WHITE *If using meter tht requires DVA dpter, plce selector switch to the 400 VDC position. BROWN/YEL- LOW R x 1 W R x 100 W R x 100 W R x 100 W R2 JUNE 1998 Pge 2A-15

62 IGNITION Test 7 Ignition Coils ( + ) wire disconnected) RED BLACK RED BLACK (+) Terminl (--) Terminl Sprk Plug Tower (+) Terminl R x 1 W 0 R x 100 W NOTE: Copper is n excellent conductor, however resistnce my notly vry etween low ndhigh temperture. Therefore, resonledifferences cne cceptedetween resistnce redings nd specifictions. The ove redings re for cold (room temperture) engine. Resistnce will increse if the engine is wrm. Ignition Trouleshooting Mechnicl Sprk Advnce TOOL : MULTIMETER/DVA TESTER Tested Prt Sttor (BLACK/ YELLOW nd BLACK/WHITE wires disconnected from switch oxes) Trigger (BROWN/ YELLOW nd BROWN wires disconnected from switch oxes) Multimeter Wires RED BLACK RED BLACK RED BLACK RED BLACK Connected To BLACK/WHITE GROUND BLACK/YELLOW GROUND BLACK/YELLOW BLACK/WHITE BROWN/YELLOW BROWN Scle Resistnce (ohms) R x R x 100 R x R x Tested Prt Multimeter Connected To Scle Ignition Coils (ll wires disconnected) RED BLACK RED BLACK + Terminl -- Terminl Sprk Plug Tower -- Terminl R x 1 R x 1000 Resistnce (ohms) Tested Prt Multimeter Wires Connected To Selector Position Reding At RPM RED -- Terminl Switch Box Primry Coil 400 VDC BLACK + Terminl Switch Box Stop Circuit Sttor Low Speed RED BLACK GROUND BLACK/YELLOW 400 VDC Reding At RPM Sttor High Speed RED BLACK GROUND BLACK/WHITE 400 VDC Pge 2A R2 JUNE 1998

63 Ignition Trouleshooting (RED Sttor) IGNITION TOOL : MULTIMETER/DVA TESTER Tested Prt Multimeter Wires Connected To Scle Resistnce (ohms) Sttor (GREEN/ WHITE nd WHITE/GREEN wires disconnected from switch oxes) RED BLACK GREEN/WHITE WHITE/GREEN R x Trigger (BROWN/ YELLOW nd BROWN/WHITE wires disconnected from switch oxes) RED BLACK BROWN/YELLOW BROWN/WHITE R x Tested Prt Multimeter Connected To Scle Ignition Coils (ll wires disconnected) RED BLACK RED BLACK + Terminl -- Terminl Sprk Plug Tower -- Terminl R x 1 R x 1000 Resistnce (ohms) Tested Prt Multimeter Wires Connected To Selector Position Reding At RPM RED -- Terminl Switch Box Primry Coil 400 VDC BLACK + Terminl Reding At RPM Switch Box Stop Circuit RED BLACK BLACK/YELLOW GROUND 400 VDC RED GREEN/WHITE 400 VDC Sttor Voltge BLACK RED GROUND WHITE/GREEN 400 VDC BLACK GROUND NOTE: Copper is n excellent conductor, ut resistnce my notly vry etween low nd high temperture. Therefore, resonle differences cn e ccepted etween resistnce redings nd specifictions R2 JUNE 1998 Pge 2A-17

64 BATTERY CHARGING AND STARTING SYSTEMS ELECTRICAL Section 2B - Bttery Chrging nd Strting Systems Tle of Contents Specifictions B-1 Electric Strt Components B-2 Bttery B-4 Precutions B-4 Recommended Bttery B-4 Operting Engine Without Bttery B-4 Specific Grvity Redings B-4 Electrolyte Level B-5 Chrging A Dischrged Bttery B-6 Winter Storge of Btteries B-6 Voltge Regultor Test B-7 Lmps Burn Out When Engine RPM is Incresed B-7 Lmps Burn Dim t Wide-Open-Throttle B-7 Bttery Chrging System B-7 Description B-7 Alterntor Amperes Output B-8 Bttery Chrging System Trouleshooting B-9 Alterntor Test B-9 Rectifier Test B-10 Strting System B-11 Strter Motor Amperes Drw B-11 Strting System Components B-11 Description B-11 Trouleshooting the Strting Circuit B-11 Commnder 2000 Key Switch Test B-14 Emergency Stop Switch (Lnyrd Type) B-15 Push Button Stop Switch B-15 Strter Motor B-16 Disssemly B-16 Clening nd Inspection B-17 Testing Motor Armture B-18 Strter Motor Ressemly B-19 Strter Solenoid Test B-21 Flywheel Ring Ger B-22 Instlltion B-22 Neutrl Strt Switch (Electric Strt Tiller Hndle Shift Models) B-23 Tiller Hndle Strt Button B-24 Choke Solenoid B-25 Instlltion B-25 Bttery Cles/Engine Wiring Hrness (Remote Electric Strt Models) B-26 Bttery Cles (Tiller Hndle Push Button Electric Strt Models) B-29 Instlltion B-29 Plug Hrness (Bttery Chrging Kit) B-31 Instlltion B-31 Emergency Stop Switch (Lnyrd Type) B-31 Instlltion B-31 2 B Specifictions BATTERY Bttery Rting 465 Mrine Crnking Amps (MCA) or 350 Cold Crnking Amps (CCA) CHARGING SYSTEM Alterntor Output BLACK Sttor - 2 Mgnet Flywheel (8 Pole - 4 Pulse) 4 Amp. ( RPM STARTING SYSTEM RED Sttor - 4 Mgnet Flywheel (10 Pole - 5 Pulse)) Mnul Strt Electric Strt Ampere Drw (Under Lod) (No Lod) 6 mp ( RPM Recoil 12 Volt 55 mperes 15 Amperes R2 JUNE 1998 Pge 2B-1

65 BATTERY CHARGING AND STARTING SYSTEMS Electric Strt Components A B A Cycle Outord Oil ( A24) 25 Liquid Neoprene ( ) A=LOCAL ELECTRIC ONLY B=SERVICE ONLY Pge 2B R2 JUNE 1998

66 BATTERY CHARGING AND STARTING SYSTEMS Electric Strt Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 RECTIFIER 2 2 SCREW (#10-16x5/8 IN.) Drive Tight 3 2 NUT (#10-32 Brss) NUT (#10-32 Brss) CABLE ASSEMBLY (Red) 6 1 STARTER SOLENOID ASSEMBLY 7 2 BUSHING 8 2 GROMMET 9 1 WIRE ASSEMBLY--yellow 10 2 SCREW (M6x1x25 hex hed cp) NUT (#8-32 Brss) NUT (1/4-20) INSULATOR--solenoid 14 1 NUT (1/4-20) RETAINER--hrness connector 16 1 J-CLIP 17 1 SCREW (M6x30 hex hed cp) WIRING HARNESS ASSEMBLY--engine 19 1 FUSE 20 1 STARTER MOTOR ASSEMBLY 21 1 THRU BOLT 22 1 END CAP (W/BRUSHES) 23 1 ARMATURE 24 1 DRIVE CAP 25 1 DRIVE 26 1 DRIVE KIT 27 2 SCREW (M8x1.25x55 hex wsher) CLIP 29 1 START SWITCH ASSEMBLY 30 1 HOUSING--switch 31 1 BATTERY WIRE ASSEMBLY--lck 32 1 BATTERY WIRE ASSEMBLY--red R2 JUNE 1998 Pge 2B-3

67 BATTERY CHARGING AND STARTING SYSTEMS Bttery Precutions Recommended Bttery When chrging tteries, n explosive gs mixture forms in ech cell. A portion of this gs escpes thru holes in vent plugs nd my form n explosive tmosphere round ttery if ventiltion is poor. This explosive gs my remin in or round ttery for severl hours fter it hs een chrged. Sprks or flmes cn ignite this gs nd cuse n internl explosion which my shtter the ttery. The following precutions should e oserved to prevent n explosion. 1. DO NOT smoke ner tteries eing chrged or which hve een chrged very recently. 2. DO NOT rek live circuits t terminls of tteries ecuse sprk usully occurs t the point where live circuit is roken. Alwys e creful when connecting or disconnecting cle clmps on chrgers. Poor connections re common cuse of electricl rcs which cuse explosions. 3. DO NOT reverse polrity of ttery cles on ttery terminls. CAUTION If ttery cid comes into contct with skin or eyes, wsh skin immeditely with mild sop. Flush eyes with wter immeditely nd see doctor. A 12 volt ttery with Mrine Crnking Amperge rting minimum of 465 mperes or or Cold Crnking Amperge of 400. Operting Engine Without Bttery Specific Grvity Redings If desired (or in n emergency), engines equipped with n lterntor cn e strted nd operted without ttery (either disconnected or removed) if WARNING, elow, is followed. WARNING Before operting engine with ttery leds disconnected from ttery, disconnect sttor leds (Yellow) from rectifier. Insulte (tpe) sttor led ring terminls. Use hydrometer to mesure specific grvity of electrolyte in ech cell. - Hydrometer Pge 2B R2 JUNE 1998

68 BATTERY CHARGING AND STARTING SYSTEMS Hydrometer mesures percentge of sulfuric cid in ttery electrolyte in terms of specific grvity. As ttery drops from chrged to dischrged condition, cid leves the solution nd chemiclly comines with the pltes, cusing decrese in specific grvity of electrolyte. An indiction of concentrtion of electrolyte is otined with hydrometer. When using hydrometer, oserve the following points: 1. Hydrometer must e clen (inside nd out) to insure n ccurte reding. 2. Never tke hydrometer redings immeditely fter wter hs een dded. Wter must e thoroughly mixed with electrolyte y chrging for t lest 15 minutes t rte high enough to cuse vigorous gssing. 3. If hydrometer hs uilt-in thermometer, drw liquid in severl times to ensure correct temperture efore tking reding. 4. Hold hydrometer verticlly nd drw in just enough liquid from ttery cell so tht flot is free-floting. Hold hydrometer t eye level so tht flot is verticl nd free of outer tue, then tke reding t surfce of liquid. Disregrd curvture where liquid rises ginst flot stem due to cpillry ction. 5. Avoid dropping electrolyte on ot or clothing, s it is extremely corrosive. Wsh off immeditely with king sod solution. Specific grvity of electrolyte vries not only with percentge of cid in liquid ut lso with temperture.as temperture drops, electrolyte contrcts, so tht specific grvity increses. Unless these vritions in specific grvity re tken into ccount, specific grvity otined y hydrometer my not give true indiction of concentrtion of cid in electrolyte. A fully chrged ttery will hve specific grvity reding of pproximtely t n electrolyte temperture of 80 F (27 C). If electrolyte temperture is ove or elow 80 F, dditions or sutrctions must e mde in order to otin hydrometer reding corrected to 80 F stndrd. For every 10 F (3.3 C) ove 80 F, dd 4 specific grvity points (.004) to hydrometer reding. Exmple: A hydrometer reding of t 110 F (43 C) would e corrected to 80 F, indicting fully chrged ttery. For every 10 elow 80 F, sutrct 4 points (.004) from the reding. Exmple: A hydrometer reding of t 0 F (-18 C) would e corrected to 80 F, indicting prtilly chrged ttery. SPECIFIC GRAVITY CELL COMPARISON TEST Electrolyte Level This test my e used when n instrumentl tester is not ville. To perform this test, mesure specific grvity of ech cell, regrdless of stte of chrge, nd interpretresults s follows: If specific grvity redings show difference etween highest nd lowest cell of.050 (50 points) or more, ttery is defective nd should e replced. Check electrolyte level in ttery regulrly. A ttery in use in hot wether should e checked more frequently ecuse of more rpid loss of wter. If electrolyte level is found to e low, then distilled wter should e dded to ech cell until liquid level rises pproximtely 3/16 (4.8mm) over plte. DO NOT OVERFILL, ecuse this will cuse loss of electrolyte nd result in poor performnce, short life nd excessive corrosion. CAUTION During service, only distilled wter should e dded to the ttery, not electrolyte R2 JUNE 1998 Pge 2B-5

69 BATTERY CHARGING AND STARTING SYSTEMS Chrging A Dischrged Bttery The following sic rules pply to ny ttery chrging sitution: 1. Any ttery my e chrged t ny rte (in mperes) s long s spilling of electrolyte (from violent gssing) does not occur nd s long s electrolyte temperture does not exceed 125 F (52 C). If spewing of electrolyte occurs, or if electrolyte temperture exceeds 125 F, chrging rte (in mperes) must e reduced or temporrily hlted to void dmge to the ttery. 2. Bttery is fully chrged when, over 2-hour period t low chrging rte (in mperes), ll cells re gssing freely (not spewing liquid electrolyte), nd no chnge in specific grvity occurs. Full chrge specific grvity is , corrected for electrolyte temperture with electrolyte level t 3/16 (4.8mm) over plte. For most stisfctory chrging, lower chrging rtes in mperes re recommended. 3. If, fter prolonged chrging, specific grvity of t lest on ll cells cnnot e reched, ttery is not in optimum condition nd will not provide optimum performnce; however, it my continue to provide dditionl service, if it hs performed stisfctorily in the pst. 4. To check ttery voltge while crnking engine with electric strter motor, plce RED (+) led of tester on POSITIVE (+) ttery terminl nd BLACK (--) led of tester on NEGATIVE (--) ttery terminl. If the voltge drops elow 9-1/2 volts while crnking, the ttery is wek nd should e rechrged or replced. Winter Storge of Btteries Bttery compnies re not responsile for ttery dmge, either in winter storge or in deler stock, if the following instructions re not oserved: 1. Remove ttery from its instlltion s soon s possile nd remove ll grese, sulfte nd dirt from top surfce y running wter over top of ttery. Be sure, however, tht vent cps re tight eforehnd nd low off ll excess wter thoroughly with compressed ir. Check wter level, mking sure tht pltes re covered. 2. When dding distilled wter to ttery, e extremely creful not to fill more thn 3/16 (4.8mm) over plte inside ttery. Bttery solution or electrolyte expnds from het cused y chrging. Overfilling ttery will cuse electrolyte to overflow (if filled eyond 3/16 over plte). 3. Grese terminl olts well with Quicksilver 2-4-C Mrine Luricnt, nd store ttery in COOL-DRY plce. Remove ttery from storge every dys, check wter level (dd wter if necessry), nd put on chrge for 5 or 6 hours t 6 mperes. DO NOT FAST CHARGE. 4. If specific grvity drops elow 1.240, check ttery for reson, nd then rechrge. When grvity reches 1.260, discontinue chrging. To check specific grvity, use hydrometer, which cn e purchsed loclly. 5. Repet preceding chrging procedure every dys, s long s ttery is in storge. When redy to plce ttery ck in service, remove excess grese from terminls ( smll mount is desirle on terminls t ll times), rechrge gin s necessry nd re-instll ttery. WARNING Hydrogen nd oxygen gses re produced during norml ttery opertion or chrging. Sprks or flme cn cuse this mixture to ignite nd explode, if they re rought ner the ttery. Sulfuric cid in ttery cn cuse serious urns, if spilled on skin or in eyes. Flush or wsh wy immeditely with cler wter. Pge 2B R2 JUNE 1998

70 Voltge Regultor Test BATTERY CHARGING AND STARTING SYSTEMS Lmps Burn Out When Engine RPM is Incresed The voltge regultor is defective. Replce regultor. Lmps Burn Dim t Wide-Open-Throttle 1. Run engine t mid-rnge (pproximtely 3000 RPM) with 3 numer 94 lmps connected to voltge regultor output leds. Note lmp rightness. 2. Disconnect the leds t one terminl of regultor. Connect the leds together using screw nd nut. Isolte (tpe) connection. 3. Run engine t mid-rnge (pproximtely 3000 RPM) nd note lmp rightness. If lmps re considerly righter thn with leds connected to regultor, the regultor is defective. If lmps re NOT considerly righter, check the lterntor (refer to Alterntor Test, following. Bttery Chrging System Description The ttery chrging system components re the lterntor, rectifier nd ttery. Alternting current (generted in lterntor coils) flows to the rectifier which chnges AC current to direct current (DC) for chrging the ttery. c - Alterntor - Rectifier c - Bttery The chrging system my e dmged y:. Reversed ttery cles.. Running the engine with ttery cles disconnected nd lterntor leds connected to rectifier. c. An open circuit -- such s roken wire or loose connection R2 JUNE 1998 Pge 2B-7

71 BATTERY CHARGING AND STARTING SYSTEMS Alterntor Amperes Output Amperge output cn e mesured y instlling 10 mpere (minimum) mp meter in series etween the rectifier nd the ttery or y clmping n inductive type mp meter (10 mp minimum) over the RED output led from the rectifier to the ttery. BLACK Sttor (2 Mgnet Flywheel) RPM AMPERES (Approximte) Idle RED Sttor (4 Mgnet Flywheel) RPM AMPERES (Approximte) Idle Pge 2B R2 JUNE 1998

72 Bttery Chrging System Trouleshooting Alterntor Test BATTERY CHARGING AND STARTING SYSTEMS A fult in the ttery chrging system usully will cuse the ttery to ecome underchrged. Check ttery electrolyte level, nd chrge ttery. See Electrolyte Level, nd Chrging Dischrged Bttery. If ttery will NOT ccept stisfctory chrge, replce ttery. If ttery ccepts stisfctory chrge, determine the cuse of the chrging system prolem s follows. 1. Check for correct ttery polrity [RED cle to POSITIVE (+) ttery terminl]. If polrity ws incorrect, check for dmged rectifier. See RECTIFIER TEST. 2. Check for loose or corroded ttery connections. 3. Visully inspect wiring etween sttor nd ttery for cuts, chfing; nd disconnected, loose or corroded connection. 4. Excessive electricl lod (from too mny ccessories) will cuse ttery to run down. If visul inspection determines tht ttery connections nd wiring re OK, perform the following sttor nd rectifier tests. *NOTE: Alterntor cn e tested without removing from engine. DC resistnce of these windings generlly is less thn 1 ohm. A reding tht resemles short is cceptle. 1. Disconnect GRAY nd YELLOW lterntor leds from terminls on either rectifier, voltge regultor or isoltor lock. 2. Use n ohmmeter nd perform tests s shown in following chrt. 3. If meter redings re other thn specified, replce lterntor ssemly. Test Leds Resistnce Scle RED to YELLOW BLACK to GRAY 0.65 R x 1 RED to either GRAY or YELLOW BLACK to GROUND NO CONTINUITY R x R2 JUNE 1998 Pge 2B-9

73 BATTERY CHARGING AND STARTING SYSTEMS Rectifier Test WARNING Disconnect ttery leds from ttery efore testing rectifier. *NOTE: Rectifier cn e tested without removing from engine. d c f e Rectifier Test (continued) Connect RED meter led to ground, BLACK led lterntely to terminls nd c. Continuity Indicted Connect BLACK meter led to ground, RED led lterntely to terminls nd c. No Continuity Indicted Connect BLACK meter led to ground, RED led lterntely to terminls nd c. No Continuity Indicted Connect BLACK meter led to terminl, RED led lterntely to terminls nd c. Continuity Indicted. Replce Rectifier. No Continuity Indicted. Replce Rectifier. Continuity Indicted Connect BLACK meter led to terminl, RED led lterntely to terminls nd c. Continuity Indicted Connect RED meter led to terminl, BLACK led lterntely to terminls nd c. No Continuity Indicted. Replce Rectifier. Continuity Indicted. Replce Rectifier. No Continuity Indicted Connect RED meter led to terminl, BLACK led lterntely to terminls nd c. No Continuity Indicted. Rectifier tests O.K. Continuity Indicted. Replce Rectifier. No Continuity Indicted. Replce Rectifier. Continuity Indicted. Rectifier Tests O.K. Pge 2B R2 JUNE 1998

74 Strting System BATTERY CHARGING AND STARTING SYSTEMS STARTER MOTOR AMPERES DRAW STARTER MOTOR PART NO. NO LOAD AMP. DRAW NORMAL AMP. DRAW A1 15 AMPS 55 AMPS Strter Motor Teeth 10 STARTING SYSTEM COMPONENTS The strting system consists of the following components. 1. Bttery 2. Strter Solenoid 3. Neutrl Strt Switch 4. Strter Motor Description 5. Ignition Switch The function of the strting system is to crnk the engine. The ttery supplies electricl energy to crnk the strter motor. When the ignition switch is turned to START position, the strter solenoid is ctivted nd completes the strting circuit etween the ttery nd strter. The neutrl strt switch opens the strt circuit when the shift control lever is not in neutrl. This prevents ccidentl strting when engine is in ger. CAUTION The strter motor my e dmged if operted continuously. DO NOT operte continuously for more thn 30 seconds. Allow 2 minute cooling period etween strting ttempts. Trouleshooting the Strting Circuit Before eginning the strting circuit trouleshooting flow chrt, following, check first for the following conditions: 1. Mke sure tht ttery is fully chrged. 2. Check tht control lever is in NEUTRAL position. 3. Check terminls for corrosion nd loose connections. 4. Check cles nd wiring for fryed nd worn insultion. 5. Check in-line fuse in RED wire; see digrm SEC 2D. The following STARTING CIRCUIT TROUBLESHOOTING FLOW CHART is designed s n id to trouleshooting the strting circuit. This flow chrt will ccurtely locte ny existing mlfunction. Loction of TEST POINTS (clled out in the chrt) re numered in digrm elow. IMPORTANT: Remote Control Electric Strt Models hve 20 Ampere fuse locted under the cowl next to the strter solenoid. This fuse protects the remote control hrness. If this fuse is open, the strter will e inopertive. The cuse of the lown fuse ( short) should e found nd corrected R2 JUNE 1998 Pge 2B-11

75 BATTERY CHARGING AND STARTING SYSTEMS Strting Circuit Trouleshooting Flow Chrt 5 To Rectifier Strter Motor Does Not Turn SAFETY WARNING: Disconnect BLACK (w/yellow sleeve) cle from strter solenoid test point 1 BEFORE mking tests to prevent unexpected engine crnking. TEST 1 Use n ohmmeter (R x 1 scle) nd connect meter leds etween NEGATIVE (-) ttery post nd common powerhed ground. No Continuity Indicted There is n open circuit in the BLACK NEGATIVE (-) ttery cle etween the NEGATIVE (-) ttery post nd the powerhed. Check cle for loose or corroded connections. Check cle for open. Continuity Indicted Proceed to TEST 2, on next pge. Pge 2B R2 JUNE 1998

76 BATTERY CHARGING AND STARTING SYSTEMS No voltge reding; proceed to TEST 3. TEST 2. Connect voltmeter etween common engine ground nd Test Point 2.. Push strt switch. * Bttery Voltge TEST 3. Connect voltmeter etween common engine ground nd Test Point 3.. Push Strt Switch. 12 Volt Reding* Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to strter solenoid; proceed to TEST 7. No voltge reding; proceed to TEST Volt Reding Defective strter solenoid. Electric Strt Tiller Hndle Model Neutrl strt switch on lower engine cowl is open or BLACK or WHITE switch leds re disconnected or dmged. Proceed to TEST 7. No voltge reding; proceed to TEST 5. TEST 4. Connect voltmeter etween common engine ground nd Test Point 4.. Push Strt Switch. 12 Volt Reding* Neutrl strt switch is open, or YELLOW/RED wire is open etween Test Points 4 nd 3. No voltge reding; proceed to TEST 6. TEST 5 Connect voltmeter etween common engine ground nd Test Point Volt Reding* Defective ignition switch. TEST 6 Connect voltmeter etween common engine ground nd Test Point 6. No voltge reding; check RED wire etween ttery (+) positive terminl nd Test Point Volt Reding* Check fuse in RED wire etween test points 5 nd 6. Check for open RED wire etween test points 5 nd 6. TEST 7. Connect voltmeter etween common engine ground nd Test Point 1.. Push Strt Switch. No voltge reding; Defective 12 Volt Reding* strter solenoid. Should her solenoid click; proceed to TEST 8. TEST 8. Reconnect BLACK (strter motor) cle to strter solenoid Test Point 1.. Connect voltmeter etween common engine ground nd Test Point 7 c. Push Strt Switch. No voltge reding; check BLACK cle for poor connection or open circuit. 12 Volt Reding* Check BLACK ground cle t strter for loose or corroded connection, or open circuit. If cle is O.K., check strter motor R2 JUNE 1998 Pge 2B-13

77 BATTERY CHARGING AND STARTING SYSTEMS Commnder 2000 Key Switch Test 1. Disconnect remote control wiring hrness nd instrument pnel connector. 2. Set ohmmeter on R x 1 scle for the following tests: KEY POSITION CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: BLK BLK/YEL RED YEL/RED PUR YEL/BLK OFF RUN START CHOKE* *NOTE: Key switch must e positioned to RUN or START nd key pushed in to ctute choke for this test. 3. If meter redings re other thn specified in the preceding tests, verify tht switch nd not wiring is fulty. If wiring checks ok, replce switch. Pge 2B R2 JUNE 1998

78 Emergency Stop Switch (Lnyrd Type) BATTERY CHARGING AND STARTING SYSTEMS IMPORTANT: Refer to Section 2D Wiring Digrms for wiring connections. 1. Disconnect emergency stop switch leds from engine wiring. 2. Use n ohmmeter nd perform the following tests. OFF CONTINUITY (1 Ohm or Less) RUN NO CONTINUITY ( ) Push Button Stop Switch If meter redings re other thn specified, replce emergency stop switch. IMPORTANT: Refer to Section 2D Wiring Digrms for wiring connections. 1. Disconnect push utton stop switch leds from engine wiring. 2. Use n ohmmeter nd perform the following tests. CONTINUITY (I Ohm or Less) NO CONTINUITY ( ) If meter redings re other thn specified, replce push utton stop switch R2 JUNE 1998 Pge 2B-15

79 BATTERY CHARGING AND STARTING SYSTEMS Strter Motor Disssemly 1. Remove 2 thru olts from strter. - Bolts 2. Lightly tp on end of shft nd lower end cp with ruer mllet. Do not loose rush springs. c Lower End Cp - Wshers c - Bolts 3. Tp on drive end cp to loosen. Remove end cp nd rmture from strter housing. 4. If removl of prts tht re instlled on rmture is necessry, hold rmture with Strp Wrench ( A1) nd remove locknut (nd discrd) from end of shft. - Strp Wrench ( A1) - Locknut (discrd) Pge 2B R2 JUNE 1998

80 5. Remove prts from shft. c d e f g h BATTERY CHARGING AND STARTING SYSTEMS - Locknut - Spcer c - Spring d - Drive Assemly e - Drive End Cp f - Armture Shft g - Helix Threds h - Wsher Clening nd Inspection If rushes re pitted, chipped or worn to less thn 3/16 in. (4.8mm), replce rushes. IMPORTANT: DO NOT clen the strter drive ssemly or rmture shft while strter motor is instlled on outord. The clening solution will drin dirt into motor housing. 2. If the motor drive ssemly does not fully engge with flywheel, the drive ssemly my e inding on the helix threds on the rmture shft due to dirt or wer. Locte cuse of inding nd correct efore ressemling. 3. Clen drive components with clening solution nd inspect prts for wer. 4. Clen commuttor with No. 00 sndpper. Remove ny oil from commuttor. If commuttor surfce is pitted, rough or worn unevenly, resurfce on lthe. 5. Resurfce commuttor on lthe s follows:. Use lthe to turn down the commuttor surfce. DO NOT turn down the commuttor surfce excessively.. Clen copper prticles from slots etween commuttor rs. c. Snd the commuttor lightly with No. 00 snd pper to remove urrs. Thoroughly clen the rmture fter resurfcing nd snding R2 JUNE 1998 Pge 2B-17

81 BATTERY CHARGING AND STARTING SYSTEMS Testing Motor Armture TESTING ARMATURE FOR SHORTS 1. Plce rmture in growler nd switch growler on. 2. Hold hck sw lde over rmture core while rotting rmture. 3. If sw lde virtes, rmture is shorted. Retest fter clening etween commuttor rs. If sw lde still virtes, replce rmture. c - Hck Sw Blde - Armture Core c - Commuttor TESTING ARMATURE FOR GROUND Use n ohmmeter (R x 100) to check for no continuity etween commuttor nd rmture core or commuttor nd shft. 2. If continuity exists, rmture is grounded nd must e replced. c - Commuttor - Armture Core c - Shft Pge 2B R2 JUNE 1998

82 Strter Motor Ressemly 1. Reinstll rush ssemly. BATTERY CHARGING AND STARTING SYSTEMS e d c Brush - End Cp c - Fier Wsher d - Metl Wsher e - Nut 2. Apply drop of SAE 10W oil to to helix threds on rmture shft. DO NOT over luricte Helix Threds 3. Apply drop of SAE 10W oil to ushings in drive end cp nd lower end cp. DO NOT over luricte 4. Reinstll components on rmture shft. Use new locknut nd tighten securely. c d e f g h - Locknut - Spcer c - Spring d - Drive Assemly e - Drive End Cp f - Armture Shft g - Helix Threds h - Wsher R2 JUNE 1998 Pge 2B-19

83 BATTERY CHARGING AND STARTING SYSTEMS 5. Position rmture into strter frme so tht commuttor end of rmture is t end of strter frme where permnent mgnets re recessed 1-5/16 in. (33.3mm). Align mrks s shown. 1-5/16 in Alignment Mrks - Bottom Edge of Permnent Mgnets 6. Instll springs nd rushes into rush holders. Spred rushes nd hold in plce with strip of spring steel. 7. Push in on drive end of shft so tht commuttor will extend out of strter frme. - Brushes - Spring Steel c - Commuttor c Pge 2B R2 JUNE 1998

84 8. Instll lower end cp onto strter frme. BATTERY CHARGING AND STARTING SYSTEMS c - Alignment Mrk; Must Align with Slot - Slot c - Lower End Cp Strter Solenoid Test Test strter solenoid s follows: Disconnect ll leds from solenoid terminls. 2. Use n ohmmeter, set to (R x 1 scle) nd connect etween solenoid terminls 3 nd Connect 12-volt supply etween solenoid terminls 1 nd 2. Solenoid should click nd meter should red zero ohms. 4. If meter does not red zero ohms (full continuity), replce solenoid Ohmmeter Leds - 12-Volt Supply R2 JUNE 1998 Pge 2B-21

85 BATTERY CHARGING AND STARTING SYSTEMS Flywheel Ring Ger Instlltion IMPORTANT: Before instlling ring ger on flywheel, inspect gernd flywheelfor pint runs which will prevent ring ger from lying flt ginst flywheel. 1. Inspect (nd remove) ny pint runs on ring ger nd/or mounting surfce on flywheel. 2. Plce ger on flywheel with countersink side of mounting holes towrd the outside. 3. Apply Loctite 271 to threds of 4 ger mounting screws nd secure ger to flywheel. Torque screws to 100 l. in. (11.3 N m). c - Ring Ger - Flywheel c - Screws [Torque to 100 l. in. (11.3 N )] Pge 2B R2 JUNE 1998

86 BATTERY CHARGING AND STARTING SYSTEMS Neutrl Strt Switch (Electric Strt Tiller Hndle Shift Models) 1. Mount neutrl strt switch onto control pltform with 2 olts nd plte. 2. Torque mounting olts to 5 l. in. (0.6 N m). c Neutrl Strt Switch - Plte c - Bolts [Torque to 5 l in. (0.6 N m)] 3. Route switch hrness over lock. Secure hrness to sttor hrness with st-strp. 4. Route hrness ehind rectifier. Attch BLACK led to solenoid mount olt. Attch Blck led with YELLOW sleeve to terminl 1 of strter solenoid. c d e - Switch Hrness - BLACK Led c - BLACK Led with YELLOW Sleeve d - Terminl 1 e - St-strp R2 JUNE 1998 Pge 2B-23

87 BATTERY CHARGING AND STARTING SYSTEMS Tiller Hndle Strt Button 1. The tiller hndle strt utton ssemly is secured to the tiller hndle y 2 semi-loops which snp fit onto the tiller throttle shft. To remove the utton ssemly, pry the ssemly wy from the tiller hndle with flt tip screw driver. 2. The strter utton hrness is routed into the lower cowl through the fuel connector ccess hole. d c Strt Button Assemly - Semi-Loops c - Hrness d - Fuel Connector 3. The strter utton hrness is routed down the PORT side of lower engine to cowl. 4. The RED hrness led is connected to the POSITIVE (+) terminl of the rectifier. Torque ttching nut to 25 l. in. (2.8 N m). 5. The YELLOW/RED hrness led ttches to the #2 terminl of the strter terminl. Torque ttching nut to 15 l. in. (1.7 N m) RED Led [Torque nut to 25 l. in. (2.8 N m)] - YELLOW/RED Led [Torque nut to 15 l. in. (1.7 N m)] Pge 2B R2 JUNE 1998

88 Choke Solenoid BATTERY CHARGING AND STARTING SYSTEMS Instlltion IMPORTANT: New gsket MUST e positioned s shown when eing instlled. 1. Instll new gsket with solenoid plte ssemly. 2. Secure ssemly with 2 screws. Torque screws to 18 l. in. (2.0 N m). c Gsket - Solenoid Plte c - Screws [Torque to 18 l. in. (2.0 N m)] R2 JUNE 1998 Pge 2B-25

89 BATTERY CHARGING AND STARTING SYSTEMS Bttery Cles/Engine Wiring Hrness (Remote Electric Strt Models) 1. Slide ttery cles through sleeve Bttery Cles - Sleeve 2. Thred ttery cle/sleeve through wire retiner of engine wiring hrness. Verify 1 in. (25.4mm) of sleeve remins to the outside of wire retiner. 1 in. (25.4mm) c - Sleeve - Retiner c - Hrness Pge 2B R2 JUNE 1998

90 3. Remove cruretor s outlined in Section 3. BATTERY CHARGING AND STARTING SYSTEMS 4. Thred engine wiring hrness first nd then ttery cle/sleeve through opening in ottom cowl. c Hrness - Bttery Cle/Sleeve c - Opening 5. Route engine wiring hrness nd ttery cle/sleeve (under cruretor loction) round to PORT side of cylinder lock R2 JUNE 1998 Pge 2B-27

91 BATTERY CHARGING AND STARTING SYSTEMS 6. Push wire retiner into opening of ottom cowl nd secure with clip Clip 7. Secure hrness nd ttery cle/sleeve with st-strp just inside ottom cowl. 8. Reinstll cruretor s outlined in Sec 3A. - St-strp 9. Secure fuse holder in J-clip Fuse Holder - J-clip Pge 2B R2 JUNE 1998

92 BATTERY CHARGING AND STARTING SYSTEMS 10. Plug remote control hrness connector into engine wiring hrness connector nd secure with hrness connector retiner. - Remote Control Hrness - Engine Hrness c - Retiner c Bttery Cles (Tiller Hndle Push Button Electric Strt Models) Instlltion 1. Fsten hrness clmp to ottom cowl with nut, wsher nd olt. d c - Clmp - Nut c - Wsher d - Bolt R2 JUNE 1998 Pge 2B-29

93 BATTERY CHARGING AND STARTING SYSTEMS 2. Slide ttery cles through sleeve. 3. Slide hrness clmp over ttery cle sleeve nd position cles into ottom cowl. 4. Position hrness clmp onto clmp rcket in ottom cowl. Tighten clmp securely Clmp - Brcket 5. Slide ttery cle grommet over ttery cles nd instll grommet into opening in strord ottom cowl. - Grommet - Cles Pge 2B R2 JUNE 1998

94 Plug Hrness (Bttery Chrging Kit) BATTERY CHARGING AND STARTING SYSTEMS Instlltion 1. Instll plug hrness through fuel fitting opening in ottom cowl. 2. Route hrness long PORT side of engine to rectifier. - Hrness 3. Refer to Section 2D for wiring connections Emergency Stop Switch (Lnyrd Type) Instlltion 1. Route emergency stop switch wiring through opening in STARBOARD ottom cowl Stop Switch 2. Secure stop switch into opening in ottom cowl using clip. - Clip 3. Refer to Section 2D for wiring connections R2 JUNE 1998 Pge 2B-31

95 Tle of Contents ELECTRICAL Section 2C - Timing/Synchronizing/Adjusting Specifictions C-1 Specil Tools C-2 Timing/Synchronizing/ Adjusting-Tiller Hndle & Side Shift Models C-3 Side Shift Models: Adjusting Tiller Hndle Cles C-4 Tiller Shift Models: Adjusting Link Rod C-5 Strting Procedure C-6 Timing Checking nd Adjustment C-6 Adjusting Idle Speed C-8 TIMING/SYNCHRONIZING/ADJUSTING 20 Jet/20/25 Models (Non Mrthon/SePro) 2C-10 Timing/Synchronizing/Adjusting - Remote Control Models C-10 Shift nd Throttle Cle Instlltion to the Outord C-13 Shift Cle Instlltion C-14 Throttle Cle Instlltion C-15 Strting Procedure C-16 Adjusting Idle Speed C-17 2 C Specifictions TIMING SPECIFI- CATIONS 20 Jet / 2 THRU / / 2 THRU 1996 Electronic Sprk Advnce 750 ± 50 RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) Setup Timing 20 Jet 1999 AND NEWER 20/ AND NEWER Mechnicl Sprk Advnce 750 ± 50 RPM (In Forwrd Ger) Fst Idle Speed Mximum BTDC (Running) 4 ± 2 B.T.D.C (Not Adjustle) 1400 RPM ± 250 RPM 25 RPM ± 200 R.P.M. (Set-up timing of 28 B.T.D.C. will e retrded to R.P.M.) 6 ±1 B.T.D.C 1500 RPM ± 200 RPM 25 RPM R2 JUNE 1998 Pge 2C-1

96 TIMING/SYNCHRONIZING/ADJUSTING Specil Tools 1. DMT 2000 Service Tchometer A1* 2. Timing Light * *My e otined loclly. Pge 2C R2 JUNE 1998

97 Timing/Synchronizing/Adjusting Tiller Hndle & Side Shift Models TIMING/SYNCHRONIZING/ADJUSTING NOTE: Timing/Synchronizing djustments re the sme for tiller nd side shift models unless otherwise specified. 1. Check ll electricl connections to ensure they re tight nd secure (including ttery connections on electric strt models). 2. Shift outord to Neutrl, (on side shift model plce throttle twist grip to Slow ). 3. Push choke/primer ll the wy In. On models equipped with primer, turn kno to full Counterclockwise position. 4. Check the tiller hndle cles for proper djustment. If necessry, djust cles nd remove ny slck. 5. With the outord plced in Neutrl, ck the idle speed screw off the cm follower. c - Idle Speed Screw - Cm Follower c - Side Shift Model Shown R N F R2 JUNE 1998 Pge 2C-3

98 TIMING/SYNCHRONIZING/ADJUSTING 6. Turn idle speed screw In until the cm follower just mkes contct with throttle cm then turn In one dditionl turn to slightly open throttle plte. d N F R c Cm Follower - Idle Speed Screw c - Throttle Cm d - Side Shift Model Shown NOTE: The throttle return spring on cm follower plte should just contct the fuel pump housing t wide open throttle position. (Do not llow the throttle spring to ct s throttle stop). 7. Plce throttle twist grip to Full Throttle position. Verify tht the throttle plte cn chieve wide open throttle. If djustment is necessry, djust tiller cles or throttle link rod s shown. Side Shift Models: Adjusting Tiller Hndle Cles c c R N F Cm Follower Plte - Fuel Pump Housing c - Throttle Cles Pge 2C R2 JUNE 1998

99 Tiller Shift Models: Adjusting Link Rod TIMING/SYNCHRONIZING/ADJUSTING c Contct Point (spring to just contct fuel pump housing) - Throttle Return Spring c - Throttle Link Rod 8. Remove ccess plug from cruretor ir intke cover. 9. Turn idle mixture screw in (clockwise) until LIGHTLY seted then ck out to n initil setting (See Specifictions Chrt) - Access Plug - Idle Mixture Screw (Behind Access Plug) R2 JUNE 1998 Pge 2C WARNING Keep cler of propeller while crnking nd running the outord motor 10. With the outord in wter, connect fuel line to engine, squeeze ul until firm, nd check for cruretor flooding. 11. Check choke opertion, mking sure choke shutter opens nd closes ll the wy. IMPORTANT: (Locl Electric Strt Models Only) Check the neutrl strt micro switch for proper opertion. Try to strt the engine in the Forwrd, Neutrl, nd Reverse ger with the electric strt utton. The engine must strt in Neutrl Only.

100 TIMING/SYNCHRONIZING/ADJUSTING Strting Procedure 15XD/25 SEAPRO/MARATHON MODELS ONLY NOTE: Outords equipped with thermostt will hve Spordic tell til wter dischrge. Pull choke to full OUT position nd strt the engine. Immeditely fter the engine strts, push the choke kno to Full In position. Check for wter t the tell tle nd t the idle relief holes. (Tell tle pressure to e per Generl Specifictions). 20 JET/20/25 MODELS NOTE: Outords equipped with thermostt will hve Spordic tell til wter dischrge. Turn primer enrichener kno fully clockwise nd pull to the Full Out position two (2) times, witing pproximtely five (5) seconds etween pulls, leving the kno out fter the second pull. Strt the engine. Immeditely fter the engine strts, push the primer kno to Full In position nd check for wter t the tell til nd idle relief holes. Allow the engine to wrm up then turn the primer kno to the Full Counterclockwise position. (Tell tle pressure to e per Generl Specifictions). WARNING To prevent personl injury or possile deth, from loss of lnce or stility while servicing the motor, DO NOT ttempt to check or djust timing while ot is in motion. Filure to follow one of the recommended servicing procedures my result in the person flling overord or cusing personl injury from fll in ot. Timing Checking nd Adjustment IMPORTANT: When checking the set-up timing with the engine running, one of the following test procedures must e followed. Check mximum timing per the set-up specifiction while running the outord: IN TEST TANK IN BACK-IN TEST TANK ON DYNAMOMETER WHILE STILL SECURED ON BOAT TRAILER Bcked in the Wter Pge 2C R2 JUNE 1998

101 TIMING/SYNCHRONIZING/ADJUSTING ELECTRONIC SPARK ADVANCE MODELS 20/ / 2 THRU 1996 AND 20 JET / 2 THRU Using pproved test procedure, plce the outord in Forwrd ger nd check set-up timing. (If not within specifictions, djustment will e required). BTDC Timing Mrk - Side Shift Model Shown WARNING To prevent personl injury from spinning flywheel, Do Not ttempt to djust the trigger link rod (Mximum Timing Adjustment) with engine running. ADJUSTING SET-UP TIMING With the engine OFF, snp the trigger link rod socket off ll stud nd: Extend rod length to Advnce timing Shorten rod length to Retrd timing Snp link rod onto ll stud, re-strt the engine nd check set-up timing specifiction. - Trigger Link Rod (Set-up Timing Adjustment) - Side Shift Model Shown R2 JUNE 1998 Pge 2C-7

102 TIMING/SYNCHRONIZING/ADJUSTING MECHANICAL SPARK ADVANCE MODELS 20 JET/20/ AND NEWER 1. Using pproved test procedure, plce the outord in Forwrd ger nd check the mximum nd idle timing. (If not within specifictions, djustment will e required) MAX IDLE BTDC c e d - Timing Mrk - Mximum Timing Jm Nut c - Mximum Timing Screw d - Idle Timing Jm Nut e - Idle Timing Screw ADJUSTING MAXIMUM TIMING 1. Loosen mximum timing jm nut nd turn mximum timing djustment screw in/out to otin specified timing. NOTE: Turning screw out will dvnce timing. Turning screw in will retrd timing. ADJUSTING IDLE TIMING 1. Loosen idle timing jm nut nd turn idle timing djustment screw in/out to otin specified timing. Adjusting Idle Speed NOTE: Turning screw in will dvnce timing. Turning screw out will retrd timing. NOTE: Outords equipped with thermostt will hve Spordic tell til wter dischrge. 1. Strt the outord. After the outord strts, push the primer kno to the Full In position, nd immeditely check for wter t the tell til nd idle relief holes. After llowing the engine to wrm up, turn the primer kno to Full Counterclockwise position. (Tell til pressure should e per Generl Specifiction). 2. Run engine t 3500 R.P.M. nd check stop utton function, nd lnyrd stop switch function. Pge 2C R2 JUNE 1998

103 3. Adjust idle speed screw in Forwrd ger to specifiction. TIMING/SYNCHRONIZING/ADJUSTING R N F Side Shift Model Shown - Idle Speed Screw - Side Shift Model Shown NOTE: When setting idle mixture, DO NOT djust lener thn necessry to ttin resonly smooth idling. When in dout, set to the slightly rich side of highest R.P.M.. 4. Adjust cruretor for est performnce, fter clering the engine. With engine running t idle speed in Forwrd ger, turn mixture screw In (clockwise) until engine strts to loose R.P.M., fire unevenly, nd or misfires. Bck out 1/4 turn or more. (See Generl Specifictions for minimum nd mximum djustment). 5. Check for too len of mixture on ccelertion. (Engine will hesitte or stll on ccelertion). Redjust mixture if necessry. Instll ccess plug Idle Mixture Screw (Behind Access Plug) - Access Plug 6. Redjust idle speed screw in Forwrd ger to specifiction R2 JUNE 1998 Pge 2C-9

104 TIMING/SYNCHRONIZING/ADJUSTING 20 Jet/20/25 Models (Non Mrthon/SePro) 1. With the engine in Neutrl, nd the primer enrichener pushed to the Full In nd Full Clockwise position, djust the fst idle speed screw per specifiction Fst Idle Speed Screw - Primer Enrichener 2. Check the primer enrichener circuit y pulling the primer enrichener kno to the full out position. The engine speed should drop minimum of 300 R.P.M. nd remin running for pproximtely five (5) seconds efore stlling. Timing/Synchronizing/Adjusting - Remote Control Models 1. Check ll electricl connections to ensure they re tight nd secure (including ttery connections on electric strt models). 2. Push primer enrichener to Full In position nd turn the primer kno to Full Counterclockwise position. Pge 2C R2 JUNE 1998

105 TIMING/SYNCHRONIZING/ADJUSTING 3. Mnully pull throttle lever to Full Aft position until the stop t on the throttle rm contcts the stop t on the shift pltform. c - Stop T - Shift Pltform Stop T c - Throttle Lever 4. Bck the idle speed screw off of cm follower Idle Speed Screw - Cm Follower R2 JUNE 1998 Pge 2C-11

106 TIMING/SYNCHRONIZING/ADJUSTING 5. Turn idle speed screw In until the cm follower just mkes contct with throttle cm then turn In one dditionl turn to slightly open throttle plte. c - Idle Speed Screw - Cm Follower c - Throttle Cm NOTE: The throttle return spring on cm follower plte should just contct the fuel pump housing t wide open throttle position. If not, djust the throttle link rod. (Do not llow the throttle spring to ct s throttle stop). - Contct Point (spring to just contct fuel pump housing) - Throttle Return Spring Pge 2C R2 JUNE 1998

107 TIMING/SYNCHRONIZING/ADJUSTING 6. Mnully push throttle lever forwrd until it contcts the throttle stop on shift pltform. Verify tht the throttle plte cn chieve wide open throttle nd tht no prelod exists on the throttle return spring ehind the cm follower plte. (Adjust throttle link rod if necessry) c d Throttle Stop - Throttle Lever c - Return Spring (do not llow to ct s throttle stop) d - Throttle Link Rod Shift nd Throttle Cle Instlltion To The Outord Instll the shift cle nd throttle cle into the remote control nd mount the remote control following instructions which re provided with the remote control. NOTE: Instll the shift cle efore the throttle cle. The shift cle is the first cle to move when the remote control hndle is moved into ger R2 JUNE 1998 Pge 2C-13

108 TIMING/SYNCHRONIZING/ADJUSTING Shift Cle Instlltion 1. Move the remote control hndle into full reverse position. 2. Plce the engine shift lever into reverse position (towrd rer) while rotting propeller. The propeller shft will not rotte in either direction when in reverse position. 3. Open up the cle retiner cover nd remove the rrel holder nd front ruer grommet. 4. Instll the shift cle onto the shift lever pin. lock in plce with retiner ltch. 5. Adjust the shift cle rrel so it will fit into the ottom hole of the rrel holder (f)nd tht the rrel holder will slide freely into the retining pocket without pre-loding the shift cle. f e d c - Shift Lever - Cle Retiner Cover c - Shift Cle d - Shift Lever Pin e - Retiner Ltch 6. Check shift cle djustments s follows:. With remote control shifted into forwrd the propeller shft should lock solidly in ger. If it does not, djust the cle rrel closer to the engine shift lever.. Shift remote control into neutrl. The propeller shft should turn freely without drg. If not, djust the rrel wy from the engine shift lever. Repet steps nd. c. Shift remote control into reverse while turning the propeller shft. The propeller shft should lock solidly in ger. If not, djust the rrel wy from the engine shift lever. Repet steps thru c. d. Return remote control hndle to neutrl. The propeller shft should turn freely without drg. If not, djust the rrel closer to the engine shift lever. Repet steps thru d. Pge 2C R2 JUNE 1998

109 Throttle Cle Instlltion NOTE: Attch Shift cle to engine prior to ttching throttle cle. TIMING/SYNCHRONIZING/ADJUSTING 1. Position the remote control hndle forwrd, to wide-open-throttle position. 2. Instll the throttle cle onto the throttle pin. lock in plce with retiner ltch. 3. Move throttle lever until t contcts throttle stop. Adjust the rrel on the throttle cle so tht the rrel will fit into the rrel holder. 4. Slip the rrel into the rrel holder nd plce the rrel holder into the retining pocket. 5. Check the throttle cle djustment s follows.. Move the remote control hndle ck to neutrl few times nd then return the hndle ck to forwrd wide-open-position.. Recheck to mke sure t is contcting throttle stop. f e d g c - Throttle Cle - Throttle Pin c - Retiner Ltch d - Brrel Holder e-t f - Throttle Stop g - Throttle Lever R2 JUNE 1998 Pge 2C-15

110 TIMING/SYNCHRONIZING/ADJUSTING 6. Plce the ruer sel ( side with holes towrds front)) onto the control cles nd instll control cles, rrel holder nd ruer sel into the cle holder s shown. 7. Lock the rrel holder in plce with the cle retiner ltch. - Ruer Sel - Retiner Ltch Strting Procedure ELECTRIC START REMOTE CONTROL MODELS NOTE: Strting cold engine will usully require the use of the choke/enrichener to strt the engine. The choke/enrichener is operted y pushing in on the ignition key while strting the engine. It my lso e helpful to prime the engine 1 to 3 times using the mnul primer kno on the outord. IMPORTANT: DO NOT lift fst idle lever up when strting cold engine. Leve the lever in the down position until the engine strts. 1. Turn ignition key to the START position. If the engine is cold, push In on key to enrich the engine. If the engine fils to strt in ten seconds, return key to ON position, wit 30 seconds nd try gin. 2. If engine egins to stll, re-ctivte the choke/enrichener until engine is running smoothly. NOTE: Strting Flooded Engine Lift the fst idle lever to full up. Without using the choke/ enrichener, continue to crnk the engine for strting. 3. After the engine hs strted, slowly lift up the fst idle lever to increse idle speed until engine is wrmed up. Return fst idle lever to full down position. NOTE: Outords equipped with thermostt will hve Spordic tell til wter dischrge. 4. Immeditely fter the engine strts, check for wter t the tell til nd t idle relief holes. (Tell til pressure should e per specifiction). Pge 2C R2 JUNE 1998

111 TIMING/SYNCHRONIZING/ADJUSTING MANUAL START REMOTE CONTROL MODELS 1. Turn primer enrichener kno fully Clockwise nd Pull to Full Out position two (2) times, witing pproximtely five (5) seconds etween pulls, leving the kno out fter second pull. Adjusting Idle Speed NOTE: Outords equipped with thermostt will hve Spordic tell til wter dischrge. 2. Strt the outord. After the outord strts, push the primer kno to the Full In position, nd immeditely check for wter t the tell til nd idle relief holes. After llowing the engine to wrm up, turn the primer kno to Full Counterclockwise position. (Tell til pressure should e per Generl Specifiction). 1. Remove ccess plug from cruretor ir intke cover. 2. Turn idle mixture screw in (clockwise) until LIGHTLY seted then ck out to n initil setting (See Specifictions Chrt). - Access Plug - Idle Mixture Screw (Behind Access Plug) WARNING Keep cler of propeller while crnking nd running the outord motor. 3. With outord in the wter, connect fuel line to engine, squeeze ul until firm, nd check for cruretor flooding. 4. Turn the ignition key switch, on the remote control ox, to on position nd depress the ignition key. This will ctivte the choke solenoid on the cruretor to enrich the fuel circuit R2 JUNE 1998 Pge 2C-17

112 Tle of Contents Mnul Strt Models (Electronic Advnce) Model 20/25 (19941/2 THRU 1997) Model 20 Jet (19941/2 THRU 1998) D-2 Electric Strt Models with Tiller Hndle Strt Button (Electronic Advnce) Model 20/25 (19941/2 THRU 1997) D-3 Electric Models Equipped with Remote Control (Electronic Advnce) Model 20/25 (19941/2 THRU 1997) D-4 Mnul Strt Models (Mechnicl Advnce) Model 20/25 (1998) D-5 Electric Strt Models with Tiller Hndle Strt Button (Mechnicl Advnce) Model 20/25 (1998) D-6 Electric Models Equipped with Remote Control (Mechnicl Advnce) Model 20/25 (1998) D-7 ELECTRICAL Section 2D - Wiring Digrms WIRING DIAGRAMS Mnul Strt Ignition Wiring Digrm(RED Sttor) Model 20 Jet/20/25 (1999 nd NEWER) D-8 Mnul Strt Wiring Digrm (RED Sttor) Model 20/25 (1999 nd NEWER)(Work Model)... 2D-9 Electric Strt Models with Tiller Hndle Strt Button (RED Sttor) Model 20/25 (1999 nd NEWER). 2D-10 Electric Models Equipped with Remote Control (RED Sttor) Model 20/25 (1999 nd NEWER) D-11 Optionl Electricl Accessories Wiring Digrms 2D-12 Commnder Remote Control (Electric Strt)... 2D-13 Commnder 2000 Remote Control (Mnul)... 2D-14 Commnder 2000 Remote Control (Electric Strt) D-15 Commnder 3000 Pnel Mount Control D-16 2 D R2 JUNE 1998 Pge 2D-1

113 WIRING DIAGRAMS Mnul Strt Models (Electronic Advnce) Model 20/25 ( / 2 THRU 1997) Model 20 Jet ( / 2 THRU 1998) c i h d g f - Chrging Coils - Sttor c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Emergency Stop Switch f - Stop Switch g - Switch Box h - Trigger i. - Terminl Block e BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW Pge 2D R2 JUNE 1998

114 Electric Strt Models with Tiller Hndle Strt Button (Electronic Advnce) Model 20/25 ( / 2 THRU 1997) WIRING DIAGRAMS j i c h n d m l k (+) g f e BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Emergency Stop Switch f - Stop Switch g - Rectifier h - Switch Box i. - Chrging Coils j. - Strter Motor k - Strter Solenoid l. - Strt Button m - 12 VDC Bttery n - Neutrl Strt Switch R2 JUNE 1998 Pge 2D-3

115 WIRING DIAGRAMS Electric Models Equipped with Remote Control (Electronic Advnce) Model 20/25 ( / 2 THRU 1997) h g m i f c l j e (+) d k BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Rectifier f - Switch Box g - Chrging Coils h - Strter Motor i. - Strter Solenoid j. - Fuse Holder (20 Ampere Fuse) k - Remote Control Hrness l VDC Bttery m - Neutrl Strt Switch Pge 2D R2 JUNE 1998

116 Mnul Strt Models (Mechnicl Advnce) Model 20/25 (1998) WIRING DIAGRAMS d c f e g BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Switch Box d - Ignition Coil Top Cylinder e - Ignition Coil Bottom Cylinder f - Stop Switch g - Emergency Stop Switch R2 JUNE 1998 Pge 2D-5

117 WIRING DIAGRAMS Electric Strt Models with Tiller Hndle Strt Button (Mechnicl Advnce) Model 20/25 (1998) h n c g m i f l e d - Chrging Coils - Sttor c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Rectifier f - Switch Box g - Trigger h - Strter Motor i. - Strter Solenoid j. - Emergency Stop Switch k - Stop Switch l. - Strt Switch m - 12 VDC Bttery n - Neutrl Strt Switch k j BLK = Blck BRN = Brown GRY = Gry GRN = Green RED = Red WHT = White YEL = Yellow Pge 2D R2 JUNE 1998

118 Electric Models Equipped with Remote Control (Mechnicl Advnce) Model 20/25 (1998) WIRING DIAGRAMS h m c g j i f l e d k BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Chrging Coils - Sttor c - Ignition Coil Top Cylinder d - Ignition Coil Bottom Cylinder e - Rectifier f - Switch Box g - Trigger h - Strter Motor i. - Strter Solenoid j. - Fuse Holder (20 Ampere Fuse) k - Remote Control Wiring Hrness l VDC Bttery m - Choke Solenoid R2 JUNE 1998 Pge 2D-7

119 WIRING DIAGRAMS Mnul Strt Ignition Wiring Digrm(RED Sttor) Model 20 Jet/20/25 (1999 nd NEWER) BLK Z1 BLK c d #2 GRN BLK BLK Z1 Z1 GRN/WHT WHT/GRN GRN/WHT WHT/GRN BRN/YEL BRN/WHT GRN/YEL Z1 #1 Z1 Z1 Z1 Z1 J1 J2 J3 J4 BLK/YEL Z1 J5 BLK/YEL J7 J6 BLK/YEL BLK/YEL BLK T4 T5 e BRN/YEL BRN/WHT g BLK f BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Emergency Stop Switch g - Stop Switch Pge 2D R2 JUNE 1998

120 Mnul Strt Wiring Digrm (RED Sttor) Model 20/25 (1999 nd NEWER)(Work Model) WIRING DIAGRAMS BLK BLK c d #2 GRN BLK BLK e i GRY YEL GRN/WHT WHT/GRN J1 J2 BRN/YEL BRN/WHT J3 J4 GRN/YEL #1 GRN/WHT Z1 Z1 Z1 Z1 WHT/GRN BRN/YEL BRN/WHT h BLK/YEL Z1 J5 g BLK/YEL BLK J7 J6 BLK/YEL BLK/YEL BLK f BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Stop Switch g - Emergency Stop Switch h - Terminl Strip i - Chrging Coils R2 JUNE 1998 Pge 2D-9

121 WIRING DIAGRAMS Electric Strt Models with Tiller Hndle Strt Button (RED Sttor) Model 20/25 (1999 nd NEWER) n BLK BLK c d GRN BLK BLK #2 l j i GRY YEL GRN/WHT WHT/GRN GRN/YEL GRN/WHT WHT/GRN J1 J2 BRN/YEL BRN/WHT Z1 Z1 BRN/YEL BRN/WHT #1 BLK YEL J3 J4 Z1 Z1 e BLK RED RED YEL/RED BLK BLK RED g h BLK/YEL BLK BLK BLK/YEL Z1 J5 J7 J6 BLK/YEL BLK/YEL BLK f + YEL/RED RED k m BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Emergency Stop Switch g - Push Button Stop Switch h - Rectifier i. - Chrging Coils j. - Neutrl Strt Switch k - Push Button Strt Switch l. - Strt Solenoid m - 12 VDC Bttery n - Strter Motor Pge 2D R2 JUNE 1998

122 Electric Models Equipped with Remote Control (RED Sttor) Model 20/25 (1999 nd NEWER) WIRING DIAGRAMS m BLK BLK c d GRN BLK BLK #2 BLK YEL + k BLK BLK BLK RED BLK YEL/RED j GRY RED GRY YEL i h GRN/WHT WHT/GRN J1 J2 Z1 Z1 GRN/WHT WHT/GRN BRN/YEL BRN/WHT J3 J4 Z1 Z1 BRN/YEL BRN/WHT BLK/YEL Z1 J5 RED e J7 J6 YEL/BLK BLK GRN/YEL BLK/YEL BLK GRY YEL/BLK YEL/RED f g #1 l BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Sttor - Trigger c - Switch Box d - Ignition Coil Bottom Cylinder e - Ignition Coil Top Cylinder f - Choke Solenoid g - Remote Control Hrness h - Fuse Holder (20 Ampere Fuse) i. - Rectifier j. - Chrging Coils k - Strter Solenoid l VDC Bttery m - Strter Motor R2 JUNE 1998 Pge 2D-11

123 WIRING DIAGRAMS Optionl Electricl Accessories Wiring Digrms d e c f - Mnul Strt Model with Lighting Coil nd Unregulted AC Voltge - Terminl Block c - Mnul Strt Model with Bttery Chrging Kit d - Rectifier e - Mnul Strt Model with Voltge Regultor f - Voltge Regultor Pge 2D R2 JUNE 1998

124 Commnder Remote Control (Electric Strt) WIRING DIAGRAMS d e c BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Ignition/Choke Switch - Emergency Stop Switch c - Neutrl Strt Switch d - Tchometer/Accessories Hrness Connector e - Remote Control Hrness Connector R2 JUNE 1998 Pge 2D-13

125 WIRING DIAGRAMS Commnder 2000 Remote Control (Mnul) BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW c - RUN OFF Switch - Emergency Stop Switch c - Stop Switch Hrness Pge 2D R2 JUNE 1998

126 Commnder 2000 Remote Control (Electric Strt) WIRING DIAGRAMS BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW d e c Ignition/Choke Switch - Emergency Stop Switch c - Neutrl Strt Switch d - Tchometer/Accessories Hrness Connector e - Wiring Hrness Connector R2 JUNE 1998 Pge 2D-15

127 WIRING DIAGRAMS Commnder 3000 Pnel Mount Control BLK = BLACK BRN = BROWN GRY = GRAY GRN = GREEN RED = RED WHT = WHITE YEL = YELLOW - Neutrl Interlock Switch - Emergency Stop Switch Pge 2D R2 JUNE 1998

128 Tle of Contents FUEL SYSTEM Section 3A - Cruretor/Fuel Pump CARBURETOR/FUEL PUMP Specifictions A-1 Specil Tools A-1 Cruretor (20/25/JET 20) A-2 Cruretor (Sepro/Mrthon 15/25 & Super 15). 3A-4 Cruretor Adjustments A-6 Low Speed Mixture Screw A-6 Min Jet A-6 High Altitude Jet Chrt A-7 Cruretor Flot Adjustment A-8 Cruretor Adjustments A-9 Fuel System Trouleshooting A-15 Generl Informtion A-15 Specifictions Cruretor Removl A-18 Cruretor Instlltion A-19 Fuel Pump A-22 Removl nd Disssemly A-22 Clening nd Inspection A-22 Ressemly nd Instlltion A-22 Primer System A-23 Symptoms of defective primer system A-23 Servicing Sight Bowl Fuel Filter A-24 3 A CARBURETOR SPECIFI- CATIONS Idle RPM (In Forwrd Ger) Wide Open Throttle (WOT) RPM Idle Mixture Screw Adjustment (Preset-Turns Out) Jet 25/25 Sepro/25 Mrthon Flot Level Min Jet Size / 2 thru (WMC-44) -25/20 Jet (WMC-45) -25 Sepro/Mrthon (WMC-46) -25 Sepro/Mrthon (WMC-46A) 1997 nd Newer -20 Jet (WMC-45) -20 (WMC-52) -25 (WMC-53) -25 Sepro/Mrthon (WMC-54) 750 ± ± 1/4 Turn 1-1/2 ± 1/2 Turn 1-1/4 ± 1/4 Turn 1.0 in. (25.4 mm) in. (1.12 mm) in. (1.93 mm) in. (1.93 mm) in. (2.03 mm) in. (1.93 mm) in. (1.12 mm) in. (1.93 mm) in. (2.03 mm) Specil Tools 1. Cruretor Scle R2 JUNE 1998 Pge 3A-1

129 CARBURETOR/FUEL PUMP Cruretor (20/25/JET 20) = CONTENTS OF PRIMER/INJECTOR KIT, PART NO A1, REFERENCE NO. 26 Pge 3A R2 JUNE 1998

130 CARBURETOR/FUEL PUMP Cruretor (20/25/JET 20) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 CARBURETOR (WMC-52-20HP) 1 CARBURETOR (WMC-53-25HP) 1 1 CARBURETOR (WMC-44-20HP) 1 CARBURETOR (WMC-45-25HP)(JET 20) 1 THROTTLE VALVE (20HP) 2 1 THROTTLE VALVE (25HP/JET 20) 1 THROTTLE SHAFT (20-WMC-44) 3 1 THROTTLE SHAFT (25-WMC-45)(JET 20) THROTTLE SHAFT(20/25HP)(WMC52/52A/53/53A) 4 1 FUEL BOWL 5 1 FLOAT 6 1 VALVE inlet needle 1 JET min fuel ( HP) 7 1 JET min fuel ( HP/JET 20) 8 1 PLUG jet retiner COVER diphrgm 10 4 SCREW diphrgm cover BODY fuel pump 12 5 SCREW fuel pump cover COVER fuel pump 14 1 COVER fuel pump (JET 20) 15 1 PLUG GASKET/DIAPHRAGM KIT 17 1 REPAIR PARTS KIT 18 1 PLATE cover (MANUAL) 19 1 ELECTRIC CHOKE (ELECTRIC) 20 2 SCREW cover plte GASKET cruretor 22 1 DIAPHRAGM/GASKET 23 1 GASKET 24 1 FLOAT PIN 25 1 FLOAT LEVER 26 1 PRIMER/INJECTOR SERVICE KIT (See illustrtion for contents) 27 1 SCREW 28 1 NUT R2 JUNE 1998 Pge 3A-3

131 CARBURETOR/FUEL PUMP Cruretor (Sepro/Mrthon 15/25 & Super 15) Pge 3A R2 JUNE 1998

132 CARBURETOR/FUEL PUMP Cruretor (Sepro/Mrthon 15/25 & Super 15) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 CARBURETOR (WMC-54) 1 1 CARBURETOR (WMC-46A) 1 CARBURETOR (WMC-56) 1 THROTTLE VALVE (WMC 46/46A/54/54A) 2 1 THROTTLE VALVE (WMC-56/56A) 3 1 THROTTLE SHAFT 4 1 FUEL BOWL 5 1 FLOAT 6 1 VALVE inlet needle 1 JET min fuel (.076) (WMC 46) 7 1 JET min fuel (.080) (WMC 46A/54/54A) 1 JET min fuel (.046) (WMC 56/56A) 8 1 PLUG jet retiner CHOKE SHAFT 10 1 CHOKE LEVER 11 1 BODY fuel pump 12 5 SCREW fuel pump cover COVER pump (WMC-54/54A/56/56A) 14 1 COVER fuel pump (WMC-46/46A) 15 1 CHOKE VALVE 16 1 GASKET/DIAPHRAGM KIT 17 1 REPAIR PARTS KIT 18 1 PLATE cover 19 1 SCREW owl drin SCREW cover plte GASKET cruretor 22 1 DIAPHRAGM/GASKET 23 1 GASKET 24 1 FLOAT PIN 25 1 FLOAT LEVER 26 1 CHOKE LINK 27 1 SCREW 28 1 NUT R2 JUNE 1998 Pge 3A-5

133 CARBURETOR/FUEL PUMP Cruretor Adjustments Cruretor Numer Stmped t Top of Cruretor Mounting Flnge Cruretor Numer WMC - 43 Commercil Model H.P. Min Jet Size Bowl Vent Jet Bck Drg Jet Flot Setting None None 1.0 in. (25.4 mm) WMC None None 1.0 in. (25.4 mm) WMC None None 1.0 in. (25.4 mm) WMC - 53 WMC - 53A WMC - 54 Commercil Low Speed Mixture Screw None None 1.0 in. (25.4 mm) None None 1.0 in. (25.4 mm) Pre-Set Idle Mixture Screw (Open) 1-1/2 Turns 1-1/2 Turns 1-1/2 Turns 1-1/2 Turns 1-1/2 Turns Rich Len Min Jet -Low Speed Mixture Screw -Min Jet Altitude ft. (0-1524m) ft. ( m) ( m) High Altitude High Speed Jetting Min Jet SePro/Mrthon.044 in.*.076 in.*.080 in.*.042 in..074 in..078 in..040 in..072 in..076 in. *Stndrd Min Jet Pge 3A R2 JUNE 1998

134 High Altitude Jet Chrt Feet Meter Jet Size CARBURETOR/FUEL PUMP Fctory instlled min fuel jets re normlly dequte for proper performnce up to pproximtely 5000 feet (1524m) ove se level. Between 2000 feet (609.6m) nd 5000 feet (1524m) the reduction of the min fuel jet(s) my result in improved performnce nd fuel economy. Aove 5000 feet, however, it is recommended tht min jet size e reduced s shown per 1000 feet (304.8m) in the following chrt. RETURN TO LOWER ELEVA- TION: Cruretor jet chnges must e reversed to void len fuel condition when used t low elevtion R2 JUNE 1998 Pge 3A-7

135 CARBURETOR/FUEL PUMP Cruretor Flot Adjustment 1 in. (25.4 mm) -Cruretor Scle ( ) -Mesured from ottom of flot c d -Flot -Flot Hinge c -Flot Pin d-bend Flot Arm Here to Adjust Flot Level e -Needle e Pge 3A R2 JUNE 1998

136 Cruretor Adjustments CARBURETOR/FUEL PUMP 1. Plce outord in wter. 2. Check tiller hndle cle djustment for full throttle movement in oth Forwrd nd Reverse gers. Adjust jm nuts for proper trvel nd to eliminte ny slck. -Jm Nuts INITIAL CARBURETOR ADJUSTMENTS Idle Speed Screw (Models So Equipped) 1. Shift outord to Neutrl nd plce throttle twist grip to Slow. 2. Push primer/fst idle kno completely in nd rotte kno fully counterclockwise R2 JUNE 1998 Pge 3A-9

137 CARBURETOR/FUEL PUMP 3. Bck idle speed screw off of cm follower. 4. Turn idle speed screw inwrd (clockwise) until it just touches cm follower, then inwrd n dditionl 1/2 turn to slightly open throttle plte. -Idle Speed Screw -Cm Follower Pge 3A R2 JUNE 1998

138 LOW SPEED MIXTURE SCREW CARBURETOR/FUEL PUMP 1. Remove ccess plug from cruretor ir intke cover (models so equipped) Access Plug -Intke Cover 2. Turn low speed mixture screw slowly inwrd (clockwise) until it sets lightly, then ck screw out (counterclockwise) 1 1/2 to 1 3/8 turns(turning mixture screw in tight will dmge needle nd set). 3. Do not instll ccess plug t this time. -Low Speed Mixture Screw R2 JUNE 1998 Pge 3A-11

139 CARBURETOR/FUEL PUMP IDLE WIRE ADJUSTMENT 1. Push primer/fst idle kno completely in nd rotte fully counterclockwise. 2. Shift engine to Neutrl Adjust screw () to remove ll clernce etween idle wire () nd trigger Screw -Idle Wire 4. Check fst idle speed y turning primer kno to full clockwise position. Fst idle speed should e RPM. Pge 3A R2 JUNE 1998

140 IDLE ADJUSTMENT CARBURETOR/FUEL PUMP Low speed Mixture Adjustment 1. Strt engine nd llow to wrm up (run for severl minutes). Throttle engine ck to idle for out one minute to llow RPM to stilize. 2. Push primer/fst idle kno completely in nd rotte kno fully counterclockwise With engine running t idling speed while in Forwrd ger, turn low speed mixture screw counterclockwise until engine strts to lod up or fire unevenly from over rich mixture. 4. Slowly turn low speed mixture screw clockwise until cylinders fire evenly nd engine picks up speed Low Speed Mixture Screw 5. Continue turning mixture screw clockwise until too len mixture is otined nd engine slows down nd misfires. 6. Set low speed mixture screw hlfwy etween rich nd len. 7. DO NOT djust lener thn necessry to ttin resonly smooth idling. When in dout, set mixture slightly richer rther thn too len. 8. Check for freedom from 4 cycling etween idle nd 2000 RPM (in Forwrd ger). 9. Instll ccess plug into opening in cruretor ir intke cover R2 JUNE 1998 Pge 3A-13

141 CARBURETOR/FUEL PUMP IDLE SPEED ADJUSTMENT (MODELS EQUIPPED WITH IDLE SCREW) 1. With engine running t idle in Forwrd ger, mke sure primer/fst idle kno is pushed completely in nd rotte fully counterclockwise to stop. 2. Adjust idle speed screw () to otin recommended idle speed (see specifictions). -Idle Speed Screw IDLE SPEED ADJUSTMENT (MODELS NOT EQUIPPED WITH AN IDLE SPEED SCREW) For models not equipped with n idle speed screw, the cruretor hs een clirted t the fctory to mintin n idle speed of 650 ± 75 RPM in Forwrd ger. Pge 3A R2 JUNE 1998

142 Fuel System Trouleshooting CARBURETOR/FUEL PUMP Generl Informtion Prolems tht re thought to e cused y the fuel system my, in relity, e something completely different. Items, tht re shown in the list on the right, could give the impression tht there is prolem in the fuel system. 1. Propeller 2. Sprk Plugs 3. Ignition Timing 4. Ignition Sprk Voltge 5. Cylinder Compression 6. Reed Vlves Typicl symptoms nd solutions in trouleshooting fuel system re shown elow: Prolem: Engine Turns Over ut Will Not Strt or Strts Hrd When Cold Prolem: Engine Idles Rough nd Stlls. Prolem: Engine Runs Uneven or Surges. Prolem: Engine Will Not Accelerte. Possile Cuse Corrective Action Improper strting procedure used. Review strting procedure s outlined in Opertion nd Mintennce Mnul. Fuel tnk empty or too low. Improperly mixed fuel. Contminnts (wter,dirt, etc.) in fuel. Fuel tnk ir vent closed or restricted. Pinched, cut, restricted fuel line or loose fuel line connection. Dirty or restricted fuel filter. Choke solenoid or enrichment vlve not operting. Needle nd set in cruretor tht is either stuck open (flooding) or closed (no fuel). Improper cruretor jet, restricted jet or idle mixture screw out of djustment. Improper flot level. Low fuel pump pressure. Defective nti-siphon vlve. Check fuel in tnk nd replce or dd whichever is necessry. Check ir vent on fuel tnk. Air vent must e open ll-the-wy nd free from ny contminnts. Inspect ll fuel lines nd replce s needed. Tighten fuel line connections. Inspect nd replce or clen ll fuel filters. Inspect solenoid or vlve nd wiring. Replce s required. Refer to cruretor disssemly in this section. Refer to cruretor djustments in this section. Refer to cruretor djustments in this section. Disssemle nd inspect fuel pump components. Inspect vlve nd/or test engine without vlve in fuel system R2 JUNE 1998 Pge 3A-15

143 CARBURETOR/FUEL PUMP Possile Cuse Improperly mixed fuel. Contminnts(wter, dirt, etc.) in fuel. Fuel tnk ir vent closed or restricted. A pinched, cut or restricted fuel line. Also loose fuel line connection. Dirty or restricted fuel filter. Low fuel pump pressure. Defective nti-siphon vlve. Needle nd set in cruretor tht is either stuck open or closed. Improper cruretor jet, restricted jet or idle mixture screw out of djustment. Improper flot level. Cruretor loose on intke mnifold. Reed lock loose or gsket defective. Improperly routed or restricted leed hose(s). Dmged fuel pump diphrgm. Cruretor mixing chmer cover leking ir. Off idle holes plugged. Min nozzle or idle nozzle ir leed holes plugged. Dmged reeds. Fuel pick-up outlet tue in fuel tnk crcked. Wrong sprk plug or improper sprk plug gp Improper sprk timing. Corrective Action Check fuel in tnk nd replce if necessry. Check ir vent on tnk. Vent must e open ll-thewy nd free from ny contminnts. Inspect ll fuel lines nd replce s needed. Inspect nd tighten ll fuel line connections. Inspect nd replce or clen ll fuel filters. Disssemle nd inspect fuel pump components. Inspect vlve nd/or test engine without vlve in fuel system. Refer to cruretor djustments in this section. Refer to cruretor djustments in this section. Refer to cruretor djustments in this section. Check tightness of cruretor nuts. Using pressure oil cn, pply 2-cycle oil round reed lock housing/crnkcse housing mtching surfces nd cruretor se. If engine RPM chnges, tighten olts/nuts or replce gskets s required. Refer to leed hose routing in Powerhed section. Disssemle nd inspect fuel pump components. Tighten screws or replce gsket. Blow with compressed ir. Blow with compressed ir. Refer to Section 4 for reed inspection. Replce Instll correct plug or redjust gp. Reset timing to correct specifictions. Pge 3A R2 JUNE 1998

144 CARBURETOR/FUEL PUMP Prolem: Engine Floods Possile Cuse Dirt or deris re preventing inlet needle from seting. Worn inlet needle. Punctured flot Incorrect flot setting Corrective Action Flush out inlet set nd clen inlet needle. Replce Replce. Reset flot. Prolem: Engine Runs Too Rich Possile Cuse Fuel level too high. Cruretor floods. Idle nozzle ir holes plugged. Restricted ir flow. Min fuel jet loose. Corrective Action Reset flot to correct level. See preceding Engine Floods. Blow out with compressed ir. Inspect cowl ir inlet nd cruretor for ostructions. Retighten jet. Prolem: Fuel Blowck Out of Cruretor Prolem: Unle to Reduce Engine RPM to Slow Idle Possile Cuse Corrective Action Chipped or roken reeds on reed lock. Replce reeds. Prolem: Rough Idle Possile Cuse Corrective Action Excessive prelod on reeds. Replce reeds. Prolem: Engine Runs Too Len Possile Cuse Cruretor is loose. Air leks pst mixing chmer cover. Fuel level is too low. Clogged high speed jet. Restricted fuel flow to cruretor. Incorrect high speed jet. Idle mixture set too len. Air lekge into fuel system. Anti-siphon vlve restricting fuel flow. Corrective Action Tighten olts securely. Tighten cover or replce gsket. Reset flot level. Inspect jet for vrnish or deris nd clen. Check fuel lines nd filter(s) for restricted flow. Refer to min jet chrt nd replce with proper jet. Adjust to run richer (turn idle mix screw counterclockwise). Inspect fuel line connections, hose clmps, fuel pump nd fuel outlet tue (locted in fuel tnk) for loose fittings. Inspect vlve nd/or test engine without vlve in fuel system R2 JUNE 1998 Pge 3A-17

145 CARBURETOR/FUEL PUMP Cruretor Removl NOTE: Air intke cover hs een removed for visul clrity. 1. Loosen primer cm retining screw. 2. Remove retining clip Screw -Retining Clip 3. Push down on primer rm nd pull primer kno, ezel nd slide lock out of ottom cowl. 4. Remove link wire from fst idle lever. 5. Disconnect fuel line from cruretor. 6. Remove cruretor mounting nuts. 7. Lift cruretor from engine. e c d -Primer Arm -Primer Kno c -Bezel d-slide Block e -Link Wire Pge 3A R2 JUNE 1998

146 Cruretor Instlltion CARBURETOR/FUEL PUMP 1. Instll cruretor with new gsket onto mounting studs. Strt ttching nuts ut do not tighten Gsket -Nuts 2. Instll primer ssemly onto cruretor. Position lignment hole on ssemly over post on ottom of cruretor. -Alignment Hole -Post R2 JUNE 1998 Pge 3A-19

147 CARBURETOR/FUEL PUMP 3. Instll ir cover onto cruretor nd secure with 2 screws. 4. Tighten cruretor ttching nuts. -Screws -Nuts 5. Secure fuel line to cr with st-strp. 6. Reconnect link wire to fst idle lever c -Fuel Line -St-strp c -Link Wire Pge 3A R2 JUNE 1998

148 CARBURETOR/FUEL PUMP 7. Push down on primer rm nd insert primer kno, ezel nd slide lock into primer ssemly. c d Primer Arm -Primer Kno c -Bezel d-slide Block 8. Tighten screw to secure slide lock in plce. 9. Align notch in ck side of ezel with t on ottom cowl nd secure ezel in plce with retining clip. -Screw -Retining Clip R2 JUNE 1998 Pge 3A-21

149 CARBURETOR/FUEL PUMP Fuel Pump Removl nd Disssemly Clening nd Inspection IMPORTANT: Fuel pump check vlve diphrgm nd gsket should NOT e re-used once the fuel pump is disssemled. 1. Remove 5 screws securing fuel pump ssemly to cruretor. 2. Seprte fuel pump components. 1. Clen nd dry ll prts thoroughly. 2. Inspect pump ody nd se on cruretor for nicks, crcks or rough gsket surfce. 3. Inspect pump check vlve diphrgm. Diphrgm MUST BE flt nd free from holes nd imperfections. 4. Pump ody surfce elow check vlves MUST BE flt so tht check vlve will set. Ressemly nd Instlltion 1. Inspect ll prts for serviceility. 2. Ressemle fuel pump. 3. Secure fuel pump ssemly to cruretor with 5 screws. Torque screws to 18 l. in. (3.2 N m). k j e c d i h g -Gsket -Pump Body c -Spring d-cp e -Gsket f -Diphrgm g-pump Cover h-lock Wsher (5) i -Screw (5) [Torque screws to 18 l. in. (3.2 N m)] j -Idle Timing Screw k -Nut f Pge 3A R2 JUNE 1998

150 Primer System CARBURETOR/FUEL PUMP The primer system provides extr fuel to the outord whenever the primer kno is pulled out. The primer system components should e inspected crefully for serviceility. The diphrgm nd gskets should e inspected for cuts or rsions. Replce ccordingly. The primer check ll nd springs should e inspected for deris or vrnish which restrict free movement. SYMPTOMS OF A DEFECTIVE PRIMER SYSTEM 1. Outord is hrd to strt.. Diphrgm is cut.. Primer check ll is stuck in the closed position. c. Primer pssge is plugged with deris or vrnish. 2. Outord smokes excessively t idle.. Primer check ll is not seted due to deris, vrnish or dmged check ll spring. c d f e h i j k -Sel -Screw (4) [Torque to 14 l. in. (1.6 N m)] c -Cover d-diphrgm e -Gsket f -Spring g-primer Bowl h-check Bll i -Spring j -Gsket k -Plug g R2 JUNE 1998 Pge 3A-23

151 CARBURETOR/FUEL PUMP Servicing Sight Bowl Fuel Filter WARNING Exercise extreme cution when clening fuel filter elements. Gsoline is extremely flmmle nd highly explosive under certin conditions. Alwys stop the engine nd DO NOT smoke or llow open flmes in the re while clening fuel filter elements. CAUTION DO NOT turn or cock fuel filter ssemly when removing or instlling. PULL STRAIGHT DOWN when removing ssemly. PUSH STRAIGHT UP when instlling ssemly. Turning or cocking fuel filter my rek fuel line connection on filter. The sight owl fuel filter removes dirt nd wter from the fuel. Check the sight owl frequently nd clen the filter s required. 1. Verify tht the sight owl ruer seling ring is properly positioned in the owl. 2. Reinstll element in filter cover. 3. Thred sight owl onto filter cover. 4. Tighten owl securely y hnd Fuel Line 2 -St-strp (4) 3 -Cover 4 -Filter 5 -Ruer Seling Wsher 6 -Sight Bowl 7 -Fuel Line Connector Pge 3A R2 JUNE 1998

152 Tle of Contents FUEL SYSTEM Section 3B - Emissions EMISSIONS Tle of Contents C-1 Exhust Emissions Stndrds C-1 Wht Are Emissions? C-1 Hydrocrons HC C-1 Cron Monoxide CO C-1 Oxides of Nitrogen - NOx C-1 Controlling Emissions C-2 Stoichiometric (14.7:1) Air/Fuel Rtio C-2 Outord Hydrocron Emissions Reductions... 3C-3 Strtified VS Homogenized Chrge C-4 Homogenized Chrge C-4 Exhust Emissions Stndrds Strtified Chrge C-5 Emissions Informtion C-5 Mnufcturer s Responsiility C-5 Deler Responsiility C-6 Owner Responsiility C-6 EPA Emission Regultions C-6 Decl Loction C-7 3 B Wht Are Emissions? Hydrocrons HC Cron Monoxide CO Through the Environmentl Protection Agency (EPA), the federl government hs estlished exhust emissions stndrds for ll new mrine engines sold in the U.S. Emissions re wht comes out of the exhust system in the exhust gs when the engine is running. They re formed s result of the process of comustion or incomplete comustion. To understnd exhust gs emissions, rememer tht oth ir nd fuel re mde of severl elements. Air contins oxygen nd nitrogen mong other elements; gsolene contins minly hydrogen nd cron. These four elements comine chemiclly during comustion. If comustion were complete, the mixture of ir nd gsoline would result in these emissions: wter, cron dioxide nd nitrogen, which re not hrmful to the environment. But comustion is not usully complete. Also, potentilly hrmful gses cn e formed during nd fter comustion. All mrine engines must reduce the emission of certin pollutnts, or potentilly hrmful gses, in the exhust to conform with levels legislted y the EPA. Emissions stndrds ecome more stringent ech yer. Stndrds re set primrily with regrd to three emissions: hydrocrons (HC), cron monoxide (CO) nd oxides of nitrogen (NOx). Gsoline is hydrocron fuel. The two elements of hydrogen nd cron re urned during comustion in comintion with oxygen. But they re not totlly consumed. Some pss through the comustion chmer nd exit the exhust system s unurned gses known s hydrocrons. Cron is one of the elements tht mke up the fuel urned in the engine long with oxygen during the comustion process. If the cron in the gsoline could comine with enough oxygen (one cron tom with two oxygen toms), it would come out of the engine in the form of cron dioxide (CO 2 ). CO 2 is hrmless gs. But cron often comines with insufficient oxygen (one cron tom with one oxygen tom). This forms cron monoxide, CO. Cron monoxide is the product of incomplete comustion nd is dngerous, potentilly lethl gs R2 JUNE 1998 Pge 3B-1

153 EMISSIONS Oxides of Nitrogen - NOx Controlling Emissions NOx is slightly different yproduct of comustion. Nitrogen is one of the elements tht mkes up the ir going into the engine. Under extremely high tempertures it comines with oxygen to form oxides of nitrogen (NOx). This hppens in the engine s comustion chmers when tempertures re too high. NOx itself is not hrmful, ut when exposed to sunlight it comines with unurned hydrocrons to crete the visile ir pollutnt known s smog. Smog is serious prolem in Cliforni s well s mny other hevily populted res of the United Sttes. There re two principle methods of reducing emissions from two-stroke-cycle mrine engine. The first method is to control the ir/fuel rtio tht goes into the comustion chmer. The second is to control the time when this ir/fuel mixture enters the comustion chmer. Timing is importnt, to prevent ny unurned mixture from escping out of the exhust port. Stoichiometric (14.7:1) Air/Fuel Rtio In the serch to control pollutnts nd reduce exhust emissions, engineers hve discovered tht they cn e reduced effectively if gsoline engine opertes t n ir/fuel rtio of 14.7:1. The technicl term for this idel rtio is stoichiometric. An ir/fuel rtio of 14.7:1 provides the est control of ll three elements in the exhust under lmost ll conditions. The HC nd CO content of the exhust gs is influenced significntly y the ir/fuel rtio. At n ir/fuel rtio lener thn 14.7:1, HC nd CO levels re low, ut with rtio richer thn 14.7:1 they rise rpidly. It would seem tht controlling HC nd CO y themselves might not e such difficult tsk; the ir/fuel rtio only needs to e kept lener thn 14.7:1. However, there is lso NOx to consider. As the ir/fuel rtio ecomes lener, comustion tempertures increse. Higher comustion tempertures rise the NOx content of the exhust. But, enrichening the ir/fuel rtio to decrese comustion tempertures nd reduce NOx lso increses HC nd CO, s well s lowering fuel economy. So the solution to controlling NOx - s well s HC nd CO - is to keep the ir/fuel rtio s close to 14.7:1 s possile. Pge 3B R2 JUNE 1998

154 OUTBOARD HYDROCARBON EMISSIONS REDUCTIONS 8 1/3% PER YEAR OVER 9 MODEL YEARS EMISSIONS R2 JUNE 1998 Pge 3B-3

155 EMISSIONS STRATIFIED VS HOMOGENIZED CHARGE Homogenized Chrge DFI engines use strtified chrge inside the comustion chmer to id in reducing emissions. All other models use homogenized chrge. The difference etween the two is: A homogenized chrge hs the fuel/ir prticles mixed evenly throughout the cylinder. This mixing occurs inside the cruretor venturi, reed locks nd crnkcse. Additionl mixing occurs s the fuel is forced through the trnsfer system into the cylinder. The homogenized chrge is esy to ignite s the ir/fuel rtio is pproximtely 14.7:1. Pge 3B R2 JUNE 1998

156 Strtified Chrge EMISSIONS A strtified chrge engine only pulls ir through the trnsfer system. The fuel required for comustion is forced into the cylinder through n injector plced in the top of the cylinder (hed). The injector sprys fuel/ir mixture in the form of ule into the cylinder. Surrounding this ule is ir supplied y the trnsfer system. As the ule is ignited nd urns, the surrounding ir provides lmost complete comustion efore the exhust port opens. A strtified chrge is hrd to ignite, the fuel/ir ule is not evenly mixed t 14.7:1 nd not esily ignited. Emissions Informtion Mnufcturer s Responsiility: Beginning with 1998 model yer engines, mnufcturers of ll mrine propulsion engines must determine the exhust emission levels for ech engine horsepower fmily nd certify these engines with the United Sttes Environmentl Protection Agency (EPA). A certifiction decl/emissions control informtion lel, showing emission levels nd engine specifictions directly relted to emissions, must e plced on ech engine t the time of mnufcture R2 JUNE 1998 Pge 3B-5

157 EMISSIONS Deler Responsiility: Owner Responsiility: When performing service on ll 1998 nd lter outords tht crry certifiction, ttention must e given to ny djustments tht re mde tht ffect emission levels. Adjustments must e kept within pulished fctory specifictions. Replcement or repir of ny emission relted component must e executed in mnner tht mintins emission levels within the prescried certifiction stndrds. Delers re not to modify the engine in ny mnner tht would lter the horsepower or llow emission levels to exceed their predetermined fctory specifictions. Exceptions include mnufcturers prescried chnges, such s tht for ltitude djustments. The owner/opertor is required to hve engine mintennce performed to mintin emission levels within prescried certifiction stndrds. The owner/opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow emissions levels to exceed their predetermined fctory specifictions. Single engine exceptions my e llowed with permission from the EPA for rcing nd testing. EPA Emission Regultions: All new 1998 nd lter outords mnufctured y Mercury Mrine re certified to the United Sttes Environmentl Protection Agency s conforming to the requirements of the regultions for the control of ir pollution from new outord motors. This certifiction is contingent on certin djustments eing set to fctory stndrds. For this reson, the fctory procedure for servicing the product must e strictly followed nd, whenever prcticle, returned to the originl intent of the design. The responsiilities listed ove re generl nd in no wy complete listing of the rules nd regultions pertining to the EPA lws on exhust emissions for mrine products. For more detiled informtion on this suject, you my contct the following loctions: VIA U.S. POSTAL SERVICE: Office of Moile Sources Engine Progrms nd Complince Division Engine Complince Progrms Group (6403J) 401 M St. NW Wshington, DC VIA EXPRESS or COURIER MAIL: Office of Moile Sources Engine Progrms nd Complince Division Engine Complince Progrms Group (6403J) 501 3rd St. NW Wshington, DC EPA INTERNET WEB SITE: CERTIFICATION LABEL: The certifiction lel must e plced on ech engine t the time of mnufcture nd must e replced in the sme loction if dmged or removed. Shown elow is typicl certifiction lel nd is not representtive of ny one model. Lel shown elow is not to scle; (shown t twice the norml size). Pge 3B R2 JUNE 1998

158 k Emission Control Informtion This engine conforms to 1999 Model Yer U.S. EPA regultions for mrine SI engines. Refer to Owners Mnul for required mintennce. Fmily: WM9XM cc Idle Speed (in ger): 750 RPM 1999 PART # Timing: Idle: 6 BTDC WOT: 25 BTDC Stndrd Sprk Plug: NGK BP8H-N-10 Gp:.040 EMISSIONS c d e f j FEL: GM/KW-HR Vlve Clernce (Cold) mm Intke: N/A Exhust: N/A HP g h i JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC - Sprk Ignition (SI) - Cuic Centimeter c - Model yer of engine nd production decl prt numer d - Idle Speed (In Ger) e - Timing specifictions when djustle f - Recommended sprk plug for est engine performnce g - Vlve Clernce (Four Stroke engines only) h - Engine Horsepower rting i - Month of production (Boxing month will punched) j - FEL: Represents (Mercury Mrine) sttement of the mximum emissions output for the engine fmily k - Fmily exmple W M9X M Model Yer W=1998 X=1999 Mnufcturer Mercury Mrine Regultion M=Mrine Displcement Liter Cuic Inch Appliction 1=PWC 2=OB Unspecified Technology type 1=Existing 2=New Decl Loction: Model Production Prt No. Service Prt No. Loction on Engine 1998 Merc/Mr 12,24 ci Inside Top Cowl (20-25 H.P.) 1999 Merc/Mr 12,24 ci (20-25 H.P.) Inside Top Cowl R2 JUNE 1998 Pge 3B-7

159 Tle of Contents POWERHEAD Section 4 - Powerhed POWERHEAD Specifictions Specil Tools Cylinder Block nd Covers Crnkshft, Pistons nd Flywheel Torque Sequence Powerhed Removl Powerhed Disssemly Cylinder Block Crnkshft Powerhed Clening nd Inspection Cylinder Block nd Crnkcse Cover Exhust Mnifold nd Exhust Cover Cylinder Bore Crnkshft Sels Berings Connecting Rod Pistons Reed Block Bleed System Thermostt Powerhed Ressemly Generl Informtion Crnkshft Cylinder Block Powerhed Instlltion Set-Up nd Test-Run Procedures Brek-In Procedure R2 JUNE 1998 Pge 4-1

160 POWERHEAD Specifictions HORSEPOWER (KW) CYLINDER BLOCK Model 20 Jet Model 20 Model 25 Type Displcement 20 (14.9) 20 ( (18.7) Two Cylinder - Two Cycle 24.4 cu. in. (400 cc) STROKE Length in. (60 mm) CYLINDER BORE CRANK SHAFT CONNECTING ROD PISTON PISTON DIA. Dimeter (Stndrd) Tper/Out of Round Mximum* Bore Type: S/N 0G nd Below S/N 0G nd Aove Top Min Bering Journl Center Min Bering Journl Bottom Min Bering Journl Connecting Rod Journl End Ply Piston Pin End (I.D.) Crnkpin End (I.D.) Piston Type O.D. t Skirt (Stndrd) Ring End Gp Dimension A t Right Angle (90 ) to Piston Pin 0.50 in. (12.7 mm) in. (65.01 mm) in. (0.08 mm)* Chrome Mercosil in. (31.77 mm) in. (25.40 mm) in. (28.58 mm) in. (22.43 mm) ( mm) in. (22.78 mm) in. (30.38 mm) Aluminum ( ) (.28 mm -.64 mm) in in. (64.98 mm.0127 mm)using micrometer, mesure dimension A t loction shown. Dimension A should e in for STANDARD size piston (new) Dimension A will e less if coting is worn off piston (used) *Models S/N 0G nd Below: NOTE: The cylinder ores re chrome nd cnnot e e reored or efficiently honed. Check ech cylinder ore for n out-of-round egg shped cylinder. A mximum of in. (0076mm) is llowle. *Models S/N 0G nd Aove: NOTE: The cylinder lock is Mercosil nd the cylinders cn e reored to in. oversized. Check ech cylinder ore for n out-of-round egg shped cylinder. A mximum of in. (0.076mm) is llowed. Pge R2 JUNE 1998

161 Specil Tools POWERHEAD 1. Powerhed Stnd A1 2. Piston Pin Tool A2 3. Piston Ring Expnder Torque Wrench ( l. ft.) * 5. Torque Wrench ( l. in.) * R2 JUNE 1998 Pge 4-3

162 POWERHEAD 6. Flywheel Puller M - Bolts 10mm (3) M 7. Compression Tester Pge R2 JUNE 1998

163 Cylinder Block nd Covers POWERHEAD A Loctite 271 ( ) 9 Loctite PST Pipe Selnt ( ) 12 Loctite Mster Gsket ( ) C With Teflon ( A12) SIDE SHIFT AND TILLER SHIFT ONLY R2 JUNE 1998 Pge 4-5

164 POWERHEAD Cylinder Block nd Covers TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 CYLINDER BLOCK 2 1 STUD (M6x1x32) Drive Tight 3 2 ELBOW (45 deg.) 4 1 STUD (M6x1x50) (Commercil) Drive Tight 5 1 DOWEL PIN 6 5 SCREW (60 MM) STUD (M6x1x32) Drive Tight 8 2 STUD Drive Tight 9 1 SCREW 10 1 NUT 11 1 GASKET 12 1 REED BLOCK 13 1 GASKET 14 1 PLATE--cr dptor 15 2 CHECK VALVE 16 3 SCREW (M5x.8x20) TUBING (13-1/4 IN.) 18 2 O-RING 19 2 COVER 20 4 SCREW (M5x.8x16) BALL--threded SCREW (M5x.8x16) COVER 24 2 O-RING 25 1 GASKET 26 1 COVER CASTING 27 1 COVER ASSEMBLY 28 1 PIPE PLUG (BRASS) Drive Tight 29 5 SCREW (30 MM) FITTING 31 1 HOSE--tell tle (8 IN.) 32 1 ELBOW Drive Tight 33 2 SCREW (M6x1x40) COVER 35 1 GASKET 36 1 GASKET 37 1 THERMOSTAT 38 1 PLUG--seril numer Stke Tight 39 2 O-RING 40 2 COVER 41 1 STRAP 42 4 SCREW (M5x.8x16) GASKET--exhust mnifold 44 1 EXHAUST MANIFOLD 45 1 GASKET--exhust mnifold cover 46 1 COVER--exhust mnifold 47 9 SCREW (M6 x 1 x 40) Pge R2 JUNE 1998

165 Crnkshft, Pistons nd Flywheel POWERHEAD A Loctite 271 ( ) 14 2 Cycle Outord Oil ( A24) C With Teflon ( A12) A=ELECTRIC START MODELS ONLY R2 JUNE 1998 Pge 4-7

166 POWERHEAD Crnkshft, Pistons nd Flywheel TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 DECAL--wrning (NOT A SERVICE PART) 2 1 DECAL--wrning (NOT A SERVICE PART) 3 1 SCREW--flywheel to crnkshft WASHER--flywheel screw 5 1 FLYWHEEL 6 1 RING GEAR--flywheel ELECTRIC 7 4 SCREW (M5x.8x13) OIL SEAL--crnkshft-upper (Qty. of 2 used on Electric RC) 9 1 ROLLER BEARING--upper 10 1 KEY--flywheel drive 11 1 CRANKSHAFT ASSEMBLY 12 1 WEAR SLEEVE KIT 13 1 O-RING (Prt of Ref. #12) 14 1 OIL SEAL--crnkshft - lower 15 1 ROLLER BEARING--lower 16 2 CONNECTING ROD ASSEMBLY 17 4 SCREW ROLLER BEARING ASSEMBLY ROLLER (Prt of Ref. #18) NEEDLE BEARING--piston end 21 4 BEARING--thrust 22 2 PISTON AND PIN ASSEMBLY 23 4 LOCK RING--piston pin USA-S/N 0G & BELOW 24 1 PISTON RING BEL & BELOW 25 2 PISTON RING (Prt of Ref. #24) 2 PISTON AND PIN ASSEMBLY (STD.) 22 2 PISTON AND PIN ASSEMBLY (.030 O/S) 23 4 LOCK RING--piston pin USA-S/N 0G & UP PISTON RING (Prt of Ref. #24) 26 1 BEARING ASSEMBLY--center min 27 1 BEARING 28 1 BEARING 29 1 THRUST WASHER 30 1 THRUST WASHER 31 1 NEEDLE ROLLER 32 1 THRUST WASHER 33 1 NEEDLE ROLLER 34 1 BEARING 35 1 THRUST WASHER 1 PISTON RING ASSEMBLY (STD. BEL & UP 1 PISTON RING ASSEMBLY (.030 O/S) Pge R2 JUNE 1998

167 Torque Sequence POWERHEAD 1. Exhust Cover [140 l. in. (15.8 N m)] Crnkcse Cover [30.0 l. ft. (41.1 N m)] Cylinder Block Cover [140 l. in. (15.8 N m)] R2 JUNE 1998 Pge 4-9

168 POWERHEAD Powerhed Removl 1. Remove the following components/ssemlies referring to the listed service mnul sections: Component/Assemly Section Rewind Strter 8 Flywheel nd Ignition/Electricl Components Throttle/Shift Mechnism Cruretor 2. Disconnect tell-tle hose from ottom cowl. 2A/B 7A/B/C 3A - Tell-tle Hose 3. Remove 4 olts Bolts (2 ech side) Pge R2 JUNE 1998

169 4. Remove 6 olts securing powerhed. POWERHEAD Bolts (3 ech side) 5. Rock powerhed to rek gsket nd lift powerhed from drive shft housing. 6. Plce powerhed on ench or powerhed stnd ( A1) mounted in vise Powerhed Stnd ( A1) R2 JUNE 1998 Pge 4-11

170 POWERHEAD Powerhed Disssemly Cylinder Block 1. Remove 3 olts nd remove intke mnifold/reed lock Bolts - Intke Mnifold/Reed Block IMPORTANT: Reed lock cn e inspected without disssemling. If inspection of reed lock indictes tht replcement of prt is necessry, entire reed lock ssemly must e replced s individul prts re not sold seprtely. 2. Inspect sel for cuts or risions. If sel is dmged, entire reed lock ssemly must e replced. 3. Inspect reeds for crcks or chips. c Sel - Reeds c - Reed Vlve Opening -- Mximum Opening in. (0.178mm) Pge R2 JUNE 1998

171 4. Remove 2 olts nd remove thermostt cover. POWERHEAD - Bolts (2) - Cover 5. Remove thermostt (if equipped). 6. Remove 5 olts nd remove cylinder lock cover c - Bolts - Cover c - Thermostt (if equipped) R2 JUNE 1998 Pge 4-13

172 POWERHEAD 7. Remove 9 olts nd seprte exhust cover nd exhust mnifold from cylinder lock. c Bolts (9) - Exhust Cover c - Exhust Mnifold NOTE: If engine is suspected of hving een overheted or sprk plugs re gryish colored ( sign of possile wter intrusion), inspect exhust mnifold for wrpge or for proper plcement nd integrity of gskets which will llow wter to enter cylinders through exhust ports. 8. Remove 10 olts nd 4 trnsfer covers -- Strord Side - Trnsfer Covers Pge R2 JUNE 1998

173 9. Remove 4 olts nd 2 trnsfer covers -- Port Side. POWERHEAD - Trnsfer Covers 10. Remove 6 olts which secure crnkcse cover to cylinder lock Bolts (6) R2 JUNE 1998 Pge 4-15

174 POWERHEAD 11. Use soft mllet to rek sel etween crnkcse cover nd cylinder lock Lift crnkcse cover from lock Pge R2 JUNE 1998

175 Crnkshft 1. Remove cylinder lock from crnkshft ssemly. POWERHEAD Slide upper nd lower roller erings nd sels off of crnkshft. Discrd sels. c - Crnkshft Sel (Upper) - Bering c - Crnkshft Sel (Lower) R2 JUNE 1998 Pge 4-17

176 POWERHEAD CENTER MAIN BEARING REMOVAL 1. Remove retining ring from groove of center min ering rce Retining Ring 2. Remove center min ering rces nd center min ering hlves. Remove min ering thrust wshers. - Bering Hlves - Thrust Wshers Pge R2 JUNE 1998

177 PISTON AND ROD DISASSEMBLY POWERHEAD CAUTION Eye protection MUST BE worn while removing piston pin lockrings. IMPORTANT: Identify upper (#1) nd lower (#2) pistons nd connecting rods. Store piston pin, piston pin needle erings, locting wshers, connecting rod erings, rod cps nd olts together with corresponding piston nd connecting rod for ressemly. 1. Using Piston Ring Expnder ( ), remove (nd discrd) piston rings. - Ring Expnder ( ) 2. Remove (nd discrd) piston pin lockrings Lockrings (discrd) IMPORTANT: It is recommended tht the piston nd rod ssemly e removed from the crnkshft efore removing the piston pin to prevent possile ending of the connecting rod. IMPORTANT: It is recommended tht new needle erings e instlled in connecting rod to ssure lsting repir. If needle erings must e reused, they should e ressemled on the sme crnkpin throw nd on the sme connecting rod R2 JUNE 1998 Pge 4-19

178 POWERHEAD IMPORTANT: Keep the sme connecting rod, cp, cge nd roller erings (if reused) together nd instll them in their originl loction on the crnkshft. 3. Remove (nd discrd) rod olts nd remove piston nd rod ssemly from crnkshft Rod Bolts (discrd) 4. While supporting piston, use Piston Pin Tool A2 nd soft fced mllet to drive piston pin from piston. - Piston Pin Tool ( A2) - Piston Pin Pge R2 JUNE 1998

179 POWERHEAD IMPORTANT: Piston pin needle erings nd locting wshers will fll out when piston is removed from connecting rod. 5. Slide piston pin tool from piston nd remove piston, needle erings nd locting wshers. - Needle Berings - Locting Wshers 6. Remove (nd discrd) coupling sel using: Snp On* Expnding Rod (CG 40-4) Snp On Collet (CG 40-A6) Slide Hmmer ( A1) *Purchse from: Snp On Tools Corportion th Street Kenosh, WI CG 40-4 CG 40-A c d - Coupling Sel - Collet (CG 40-15) c - Expnding Rod (CG 40-4) d - Slide Hmmer ( A1) R2 JUNE 1998 Pge 4-21

180 POWERHEAD Powerhed Clening nd Inspection Cylinder Block nd Crnkcse Cover IMPORTANT: Crnkcse cover nd cylinder lock re mtched, line-ored ssemly nd must e replced s set. 1. Thoroughly clen cylinder lock nd crnkcse cover with Quicksilver Power Tune Engine Clener ( A12). Verify tht ll selnt nd old gskets re removed from mting surfces. Remove ll cron deposits from exhust ports, decompression ports nd cylinder dome. 2. Inspect cylinder lock nd crnkcse cover for crcks or frctures. 3. Check gsket surfces for nicks, deep grooves, crcks nd distortion. 4. Inspect ll wter nd fuel pssges in cylinder lock nd crnkcse cover for ostructions. 5. Verify tht ll fittings nd plugs re tight. If the center min ering lignment pin is loose, cylinder lock nd crnkcse cover must e replced. - Alignment Pin Pge R2 JUNE 1998

181 POWERHEAD - Decompression Ports Exhust Mnifold nd Exhust Cover Cylinder Bore R2 JUNE 1998 Pge Remove ll cron deposits nd gsket mteril from exhust mnifold nd cover. 2. Inspect for grooves, crcks or distortion tht could cuse lekge. Replce prts s required. CHROME BORE - ALL MODELS S/N OG AND BELOW Cylinder ores which re chrome cnnot e ored or efficiently honed. Honing chrome cylinder ore is not necessry nor is it recommended. Do not mistke cylinder ore porosity (pitting) for cylinder dmge. Porosity in chrome lined cylinder is norml nd is not detrimentl to engine opertion or performnce. 1. If chrome surfce is flking, or if groove or ny other mrk penetrtes the chrome surfcing to the luminum portion of the cylinder wll, the cylinder lock must e replced. 2. To determine if groove or mrk on the cylinder wll penetrtes the chrome surfcing to the luminum cylinder wll, pply smll mount of diluted muritic cid (TIDY BOWL CLEANER) to the groove or mrk. If the groove or mrk egins to fizz, the luminum wll is exposed nd the cylinder lock nd crnkcse cover must e replced. 3. If piston is scored nd trnsferred luminum to the cylinder wlls, remove the luminum from the wll s follows:. Remove ll loose luminum deposits from cylinder wlls with stiff ristle rush.. Apply smll mount of diluted muritic cid (TIDY BOWL CLEANER) onto luminum deposits. A fizzing ction will pper indicting tht luminum is eing dissolved. c. Leve the cid solution on the luminum deposit for 1 to 2 minutes, then wsh cylinder thoroughly with hot wter nd detergent. d. Steps nd c my require repeting severl times efore ll luminum deposits re gone. e. After clening luminum deposits from cylinder ores, pply light oil to ech cylinder ore with clen cloth.

182 POWERHEAD 4. Check ech cylinder ore for n out-of -round egged shped cylinder. A mximum of in. (0.076mm) is llowle. If out-of-round is more thn in. (0.076 mm), cylinder lock nd crnkcse cover must e replced. MERCOSIL BORE - ALL MODELS S/N OG AND ABOVE MEASURING CYLINDER BORE 1. Inspect cylinder ores for scoring, scuffing or trnsfer of luminum from piston to cylinder wll. Scoring or scuffing, if NOT TOO SEVERE, cn normlly e removed y honing. If trnsfer of luminum hs occurred, diluted muritic cid such s TIDY BOWL CLEANER should e pplied to the res of the cylinder ore where trnsfer of luminum hs occurred. After the cidic solution hs removed the trnsferred luminum, thoroughly wsh the cylinder ore(s) with hot wter nd detergent to remove ny remining cid. Cylinder wlls my now e honed to remove ny glze nd to id in the seting of new piston rings. 2. The cylinder lock is Mercosil nd if necessry cn e reored to in. (0.762 mm) oversized. 3. Check ech cylinder ore for n out-of -round egged shped cylinder. A mximum of in. (0.076 mm) is llowle. If out-of-round is more thn in. (0.076 mm), cylinder lock nd crnkcse cover must e replced. 1. Mesure ring trveled re of cylinder ore t 3 depths, (6 plces) y positioning mesuring instrument in-line with nd t right ngle (90 ) to piston pin centerline. 2. If cylinder ore is tpered, egg shped or out-of-round y more thn in. (0.076 mm), replce cylinder lock. TOP CENTER BOTTOM Pge R2 JUNE 1998

183 POWERHEAD STANDARD CYLINDER BORE DIAMETER 20/25/20 JET BORE TYPE STANDARD BORE DIAMETER ALL MODELS S/N OG AND BELOW ALL MODELS S/N OG AND ABOVE HONING PROCEDURE The cylinder ores re chrome nd cnnot e reored or efficiently honed. Check ech cylinder ore for n out-of -round egged shped cylinder. A mximum of in. (0.076 mm) is llowle. The cylinder lock is Mercosil nd the cylinders cn e reored to in. (0.762 mm) oversized. Check ech cylinder ore for n out-of-round egged shped cylinder. A mximum of in. (0.076 mm) is llowle in. (65.01 mm) in. (65.01 mm). When cylinders re to e honed, follow the hone mnufcturer s recommendtions for use of the hone nd clening nd luriction during honing.. For est results, continuous flow of honing oil should e pumped into the work re. If pumping oil is not prcticl, use n oil cn. Apply oil generously nd frequently on oth stones nd work re. CAUTION When honing cylinder lock, remove hone frequently nd check condition of cylinder wlls. DO NOT hone ny more thn solutely necessry, s hone cn remove cylinder wll mteril rpidly. c. Strt stroking t smllest dimeter. Mintin firm stone pressure ginst cylinder wll to ssure fst stock removl nd ccurte results. d. Loclize stroking in the smllest dimeter until drill speed is constnt throughout length of ore. Expnd stones, s necessry, to compenste for stock removl nd stone wer. Stroke t rte of 30 complete cycles per minute to produce est cross-htch pttern. Use honing oil generously. e. Thoroughly clen cylinder ores with hot wter nd detergent. Scru well with stiff ristle rush nd rinse thoroughly with hot wter. A good clening is essentil. If ny of the rsive mteril is llowed to remin in the cylinder ore, it will cuse rpid wer of new piston rings nd cylinder ore in ddition to erings. After clening, ores should e swed severl times with engine oil nd clen cloth, then wiped with clen, dry cloth. Cylinders should not e clened with kerosene or gsoline. Clen reminder of cylinder lock to remove excess mteril spred during honing opertion. 3. Hone ll cylinder wlls just enough to de-glze wlls. 4. Mesure cylinder ore dimeter (with snp guge micrometer) t top, middle nd ottom of ech cylinder. Check for tpered, out-of-round (egg-shped) nd oversize ore. IMPORTANT: Ports must e deurred fter honing R2 JUNE 1998 Pge 4-25

184 POWERHEAD Crnkshft 1. Inspect crnkshft to drive shft splines for wer. 2. Check crnkshft for strightness -- runout in. (0.076 mm). 3. Inspect crnkshft oil sel surfces. Seling surfces must not e grooved, pitted or scrtched. If top crnkshft seling surfce is severely worn, replce crnkshft. If ottom crnkshft seling surfce is worn, replce crnkshft coupling sel. 4. Check ll crnkshft ering surfces for rust, wter mrks, chtter mrks, uneven wer nd/or overheting (lued). 5. If necessry, clen up crnkshft ering surfces with crocus cloth. - Crocus Cloth 6. Thoroughly clen crnkshft with solvent nd dry with compressed ir Recheck surfces of crnkshft nd replce crnkshft if surfces cn not e properly clened up. 8. If crnkshft will e reused, pply light oil to prevent rust. Pge R2 JUNE 1998

185 Sels POWERHEAD It is recommended tht ll sels e replced s stndrd reuilding procedure. NOTE: Both top nd ottom crnkshft sels fce down when instlled on crnkshft. Berings ROLLER BEARINGS - Top Crnkshft Sel - Bottom Crnkshft Sel Clen roller ering with solvent nd dry with compressed ir. 2. Inspect roller ering for rust, frcturing, wer, glling oroverheting (lued). Alwys replce erings s set if replcement is necessry. 3. Apply light oil to erings fter inspection to prevent rust. NOTE: Use 2-4-C with Teflon to hold erings in plce while ressemling roller erings to crnkshft Cycle Outord Oil ( A24) R2 JUNE 1998 Pge 4-27

186 POWERHEAD Connecting Rod 1. Check connecting rods for lignment y plcing rods on surfce plte. If light cn e seen under ny portion of mchined surfces, if rod hs slight wole on plte, or if in. (0.051 mm) feeler guge cn e inserted etween ny mchined surfce nd surfce plte, rod is ent nd must e discrded. c Feeler Guge - Surfce Plte c - Even Downwrd Pressure 2. Overheting: Overheting is visile s luish ering surfce color tht is cused y indequte luriction or excessive RPM. 3. Rust: Rust formtion on ering surfces cuses uneven pitting of surfce(s). - Pitting Pge R2 JUNE 1998

187 POWERHEAD 4. Wter Mrks: When ering surfces re sujected to wter contmintion, ering surfce etching occurs. This etching resemles the size of the ering Splling: Splling is the loss of ering surfce, nd it resemles flking or chipping. Splling will e most evident on the thrust portion of the connecting rod in line with the I em. Generl ering surfce deteriortion could e cused y or ccelerted y improper luriction Splling 6. Chtter Mrks: Chtter mrks re the result of comintion of low speed - low lod - cold wter temperture opertion, ggrvted y indequte luriction nd/or improper fuel. Under these conditions, the crnkshft journl is hmmered y the connecting rod. As ignition occurs in the cylinder, the piston pushes the connecting rod with tremendous force, nd this force is trnsferred to the connecting rod journl. Since there is little or no lod on the crnkshft, it ounces wy from the connecting rod. The crnkshft then remins immoile for split second until the piston trvel cuses the connecting rod to ctch up to the witing crnkshft journl, then hmmers it. The repetition of this ction cuses rough ering surfce(s) which resemles tiny wshord. In some instnces, the connecting rod crnk pin ore ecomes highly polished. During opertion, the engine will emit whirr nd/or chirp sound when it is ccelerted rpidly from idle speed to pproximtely 1500 RPM, then quickly returned to idle. If the preceding conditions re found, replce oth the crnkshft nd connecting rod(s). - Chtter Mrks Between Arrows R2 JUNE 1998 Pge 4-29

188 POWERHEAD 7. Uneven Wer: Uneven wer could e cused y ent connecting rod. - Uneven Wer CAUTION Crocus cloth MUST BE USED to clen ering surfce t CRANKSHAFT END OF CONNECTING ROD. 320 grit Crorundum cloth MUST BE USED to clen ering surfce t PISTON PIN END OF CONNECTING ROD. VERIFY CAP TO ROD ALIGNMENT BEFORE TORQUING ROD BOLTS. DO NOT continue to clen connecting rod ering surfces fter mrks hve een removed. NOTE: Wsh rod to remove rsive grit nd pply light oil to ering surfces to prevent rust. c 100 l. in. (11.3 N m) - To Drill Motor - Use 320 Crorundum c - Crocus Cloth Pge R2 JUNE 1998

189 Pistons POWERHEAD IMPORTANT: If engine ws sumerged while engine ws running, piston nd/or connecting rod my e ent. If piston pin is ent, piston must e replced. If piston pin is ent, connecting rod must e checked for strightness. 1. Inspect pistons for scoring nd excessive piston skirt wer. 2. Check tightness of piston ring locting pins. Locting pins must e tight. - Locting Pins Thoroughly clen pistons. Crefully remove cron deposits from pistons, with soft wire rush or cron remove solution. Do not urr or round off mchined edges. Inspect piston ring grooves for wer nd cron ccumultion. If necessry, scrpe cron from piston ring grooves eing creful not to scrtch sides of grooves. Refer to procedure following for clening piston ring grooves. CLEANING PISTON RING GROOVES Keystone (tpered) ring grooves CAUTION Cre must e tken not to scrtch the side surfces of the ring groove. Scrtching the side surfce of the ring groove will dmge the ring groove. 1. Use ristle rush nd cron remover solution to remove cron from side surfces. 2. A tool cn e mde for clening the inner dimeter of the tpered ring grooves. For the top ring groove, tool cn e mde from roken tpered piston ring with the side tper removed to enle the inside edge of the ring to rech the inner dimeter of the groove. For the ottom ring groove, tool cn e mde from roken rectngulr ring. Crefully scrpe cron from inner dimeter of ring grooves. Cre must e tken not to dmge the grooves y scrtching the side surfces of the grooves. Piston with 1 hlf keystone (hlf tpered) nd 1 rectngulr ring R2 JUNE 1998 Pge 4-31

190 POWERHEAD MEASURING PISTON 1. Mesure piston skirt t right ngle (90 ) to piston pin centerline in. (12.7mm) Stndrd Piston Dimeter /25/20 JET in in. (64.98 mm mm) PISTON CLEARANCE MINIMUM BORE MEASUREMENT -- MAXIMUM PISTON MEASUREMENT = PISTON CLEARANCE PISTON CLEARANCE in in. (0.076 mm mm) Reed Block IMPORTANT: DO NOT remove reeds from reed lock except for inspection purposes only. DO NOT turn used reeds over for reuse. If reed lock component is dmged, the entire reed lock ssemly must e replced. Individul components re not sold seprtely. 1. Thoroughly clen reeds nd reed lock. 2. Check for wer (indenttions), crcks or grooves on seling surfces of reed lock tht could cuse lekge. 3. Check for chipped or roken reeds. 4. Inspect reed lock sel for swelling or looseness. Replce reed lock ssemly if necessry. 5. If reeds hve een removed, retorque screws to 25 l. in. (2.8 N m). Check reeds s outlined in Reed Opening nd Reed Stop Opening following Pge R2 JUNE 1998

191 REED OPENING POWERHEAD 1. Check reeds for prelod nd stnd open conditions. Stnd open should not exceed in. (0.178 mm). Replce reed lock ssemly if necessry. c d e Bleed System - Reed - Reed Stop c - Lock Wsher d - Screw e - Reed Block f - Sel (Vulcnized to Reed Block) NOTE: Reed Stop Opening is not djustle. 1. Inspect leed hoses for deteriortion. Replce hoses s required. f 2. Inspect leed vlves in lower crnkcse cover for proper function. Vlve should flow fuel only one wy -- from ottom of crnkcse cover to intke trnsfer port cover side of ech cylinder. If check ll in vlve is stuck open or closed, replce check vlve Fitting (2) 2 - Bleed Check Vlves(2) 3 - Strord Bleed Line (To Bottom 90 Fitting) 4 - Port Bleed Line (To Top 90 Fitting) 5 - Bleed hoses must e routed thru slot R2 JUNE 1998 Pge 4-33

192 POWERHEAD Thermostt Wsh thermostt with clen wter. Using thermostt tester, similr to the one shown, test thermostt s follows: Open thermostt vlve, then insert thred etween vlve nd thermostt ody. Allow vlve to close ginst thred. Suspend thermostt (from thred) nd thermometer inside tester so tht neither touches the continer. Bottom of thermometer must e even with ottom of thermostt to otin correct thermostt opening. Fill thermostt tester with wter to cover thermostt. Plug tester into electricl outlet Oserve temperture t which thermostt egins to open. Thermostt will drop off thred when it strts to open. Thermostt must egin to open when temperture reches 5 F (3 C) ove designted stmping on ottom of thermostt. Continue to het wter until thermostt is completely open. Unplug tester unit. Replce thermostt, if it fils to open t the specified temperture, or if it does not fully open Pge R2 JUNE 1998

193 Powerhed Ressemly POWERHEAD Generl Informtion Before proceeding with powerhed ressemly, e sure tht ll prts to e reused hve een crefully clened nd thoroughly inspected, s outlined in Clening nd Inspection. Prts, which hve not een properly clened (or which re questionle), cn severely dmge n otherwise perfectly good powerhed within few minutes of opertion. All new powerhed gskets must e instlled during ssemly. During ressemly, luricte prts with Quicksilver 2-Cycle Outord Oil whenever 2-cycle oil is specified, nd Quicksilver 2-4-C w/teflon Mrine Luricnt whenever grese is specified. CAUTION Any GREASE used for erings INSIDE the powerhed MUST BE gsoline solule. Use only Quicksilver 2-4-C w/teflon Mrine Luricnt or Quicksilver Needle Bering Assemly Luricnt. The use of ny other grese my result in powerhed dmge. Crnkshft A torque wrench is essentil for correct ressemly of powerhed. Do not ttempt to ressemle powerhed without using torque wrench. NOTE: Three designs of crnkshft sels hve een used. Design 3 is the current ppliction. c Design 1 -- O-ring fits in groove on driveshft - Design 2 -- O-ring fits inside of crrier c - Design lip sel permnently instlled inside of crrier R2 JUNE 1998 Pge 4-35

194 POWERHEAD 1. If removed, reinstll new crnkshft crrier s follows:. Apply thin cot of Loctite 271 to crrier surfce on crnkshft.. Squre the crrier with crnkshft nd using 7/8 in. deep well socket nd hmmer, crefully set crrier onto crnkshft. 7 7 Loctite 271 ( ) Crrier - 7/8 in. deep well socket 2. Apply 2-4-C w/teflon to crnkshft roller erings nd thrust wshers to hold components in plce on crnkshft while ressemling. 3. Instll roller erings nd thrust wshers onto crnkshft C With Teflon ( A12) - Rce Hlves with Roller Berings - Thrust Wshers Pge R2 JUNE 1998

195 POWERHEAD NOTE: Bering rce hlves retiner ring groove fces towrd flywheel end of crnkshft. 4. Reinstll ering rce hlves. Secure hlves with retiner ring. NOTE: Instll retiner ring so tht ring ridges oth frcture lines of ering rce. - Rce Hlves - Retiner Ring R2 JUNE 1998 Pge 4-37

196 POWERHEAD 5. Check center min thrust wshers for wer s follows:. Push thrust wshers nd center min ering towrd either end of crnkshft.. Use feeler guge nd check clernce etween crnkshftnd thrustwshers. c. If clernce etween crnkshft nd thrust wshers is greter thn in. (0.762 mm), replce thrust wshers Thrust Wshers - Feeler Guge NOTE: It is recommended tht the piston pin nd piston e instlled on the connecting rod prior to instlling the connecting rod on the crnkshft to void possile ending of the rod during piston pin instlltion. IMPORTANT: When replcing needle erings, replce ll needles s set. Do not use old nd new needles together. 6. Instll piston onto connecting rod s follows:. Luricte sleeve of Piston Pin Tool ( A2) with 2-4-C w/teflon Mrine Luricnt ( A12).. Hold lower locting wsher nd sleeve onto piston pin ore of connecting rod nd instll needle ering set of 27. c C With Teflon ( A12) - Sleeve - Locting Wsher c - Needle Berings (27) Pge R2 JUNE 1998

197 POWERHEAD NOTE: If the tip of n wl cn e inserted etween the needle erings, one or more needles re missing nd must e replced. c. Instll upper locting wsher Locting Wsher d. Slide piston onto connecting rod, centering piston pin ore over sleeve. e. Slide piston tool up thru piston pin ore nd remove sleeve. - Sleeve - Piston Pin Tool ( A2) R2 JUNE 1998 Pge 4-39

198 POWERHEAD f. Apply light oil to piston pin nd plce piston pin onto tool Cycle Outord Oil ( A24) Piston Pin - Piston Pin Tool ( A2) g. Support ottom of piston nd hold piston pin tool up ginst piston pin. h. Drive piston pin into piston pin ore (with soft fce mllet) until pin is flush with piston. - Piston Pin Tool ( A2) - Piston Pin Pge R2 JUNE 1998

199 POWERHEAD i. Move piston pin tool to top of piston pin ore nd center piston pin in piston. - Piston Pin Tool ( A2) 7. Instll new lockrings into grooves in oth ends of piston pin ore Lockring R2 JUNE 1998 Pge 4-41

200 POWERHEAD 8. Instll connecting rods onto crnkshft s follows:. Apply 2-4-C w/teflon Mrine Luricnt to connecting rod ig-end erings. IMPORTANT: Replce roller ering hlves s set. DO NOT use old nd new hlves together.. Plce oth hlves of connecting rod ig-end roller ering onto crnk pin C With Teflon ( A12) Roller Bering CAUTION The word UP (cst on the outside of piston) must e towrd flywheel end of crnkshft when instlling piston/rod ssemly onto crnkshft. Filure to orient piston/rod ssemly correctly on crnkshft will result in piston rings ctching in ports cusing powerhed dmge. If UP is not present on top of piston, rised ri on wrist pin oss must fce up towrds flywheel end of crnkshft. OR Pge R2 JUNE 1998

201 POWERHEAD IMPORTANT: Clen connecting rod olts with solvent nd dry with compressed ir. Inspect threds for dmge. If threds re not dmged, olts my e reused. Apply light oil to threds prior to instlltion. c. Oserve connecting rod/cp frcture line for correct lignment. Secure connecting rod (with v-notch of rod towrd flywheel end of crnkshft) onto crnkshft with rod cp nd olts. Torque olts to 150 l. in. (16.9 N m). 14 c e d e 14 2 Cycle Outord Oil ( A24) - Frcture Line - Connecting Rod c - V-Notch (Towrd Flywheel) d - Rod Cp e - Bolts -- Torque to 150 l. in. (16.9 N m) R2 JUNE 1998 Pge 4-43

202 POWERHEAD d. Correct piston instlltion: Intke Side - Exhust Side 9. Instll new piston rings using Piston Ring Expnder ( ). Instll RECTANGU- LAR ring first in ottom ring groove. Instll HALF-KEYSTONE ring in top ring groove. Align piston rings with ech respective ring groove locting pin. d c - Piston Ring Expnder ( ) - Rectngulr Ring c - Hlf-Keystone Ring d - Locting Pin Pge R2 JUNE 1998

203 POWERHEAD 10. Apply outord oil to upper nd lower roller erings nd instll erings on crnkshft. Numered side of ering should fce UP or OUT on erings. 11. Instll new upper nd lower crnkshft sels. Both sel lips fce down. Apply 2-4-C w/teflon to sel lips c d Cycle Outord Oil ( A24) C With Teflon ( A12) - Upper Crnkshft Sel - Upper Crnkshft Bering (Numers/letters fce up/out) c - Lower Crnkshft Bering (Numers/letters fce down/out) d - Lower Crnkshft Sel R2 JUNE 1998 Pge 4-45

204 POWERHEAD Cylinder Block CAUTION Piston rings must e properly positioned with locting pin etween piston ring end gps. Improperly positioned piston rings will rek during instlltion. 1. Luricte piston rings, piston nd cylinder wll with light oil. 2. Keeping crnkshft horizontl, guide pistons into cylinder ores. 3. Align hole in center min ering rce with pin of cylinder lock. c c Hole - Pin (Hidden) c - Align Pin In Slot 4. Position lignment oss of upper crnkshft roller ering into notch in cylinder lock. 5. Gently push sels inwrd to set. 6. Check ech piston ring for spring tension thru trnsfer nd exhust ports y pressing with screwdriver. If no spring tension exists (ring fils to return to position), it is likely tht the piston ring ws roken during ssemly [replce roken piston ring(s)]. Use cution not to urr piston rings while inspecting Pge R2 JUNE 1998

205 POWERHEAD 7. Clen crnkcse seling surfces ccording to Loctite Mster Gsket instructions. Apply continuous ed of Loctite selnt long the inside of the mounting olt holes of crnkcse cover Selnt 8. Plce crnkcse cover onto cylinder lock nd secure with 6 olts. Torque olts to 30.0 l. ft. (40.7 N m) in numered torque sequence Bolts -- Torque to 16.7 l. ft. (22.7 N m) R2 JUNE 1998 Pge 4-47

206 POWERHEAD 9. Rotte crnkshft severl times to ssure free opertion. 10. If disssemled, ssemle reed lock s follows:. Torque reed stop screws to 25 l. in. (2.8 N m). Luricte sel with 2-4-C w/teflon nd instll reed lock onto cylinder lock. c C With Teflon ( A12) Screws [Torque to 25 l. in. (2.8 N m)] - Sel c - Reed Vlve Opening -- Mximum Opening in. (0.178 mm) 11. Secure cruretor dptor plte with new gsket to cylinder lock with 3 olts. Torque olts to 80 l. in. (9.0 N m). - Adptor Plte - Bolts -- Torque to 80 l. in. (9.0 N m) Pge R2 JUNE 1998

207 12. Route upper nd lower leed hoses to their respective fittings s shown. POWERHEAD 13. Instll strord trnsfer port covers with new sels. Torque ttching olts to 40 l. in. (9.0 N m). c Upper Bleed Hose - Lower Bleed Hose c - Trnsfer Port Covers 14. Instll trnsfer port covers with new sels. Torque ttching olts to 40 l. in. (4.5 N m). - Trnsfer Port Covers - Bolts -- Torque to 40 l. in. (4.5 N m) R2 JUNE 1998 Pge 4-49

208 POWERHEAD 15. Instll exhust mnifold nd exhust cover with new gskets. Torque olts to 140 l. in. (15.8 N m) in torque sequence shown Exhust Mnifold - Exhust Cover 16. Instll cylinder lock cover with thermostt nd new gskets. Torque olts to 140 l. in. (15.8 N m) in torque sequence shown. NOTE: If tell-tle elow fitting is removed/replced t thermostt cover, pply Loctite PST Pipe Selnt to threds of elow fitting prior to instlltion c d 9 Loctite PST Pipe Selnt ( ) 6 7 e - Cylinder Block Cover - Thermostt (Under Cover) c - Gsket d - Elow e - Bolts -- Torque to 140 l. in. (15.8 N m) Pge R2 JUNE 1998

209 Powerhed Instlltion POWERHEAD 1. Verify powerhed se surfce nd driveshft housing mting surfces re free of old gsket mteril. 2. Instll powerhed with new gsket onto driveshft housing. NOTE: It my e necessry to rotte propeller shft slightly to lign crnkshft splines with driveshft splines. 3. Secure powerhed to driveshft with 6 olts. Torque olts to 20 l. ft. (27.1 N m). - Bolts [Torque to 20 l. ft. (27.1 N m)] 4. Reinstll trim cover. Torque olts to 85 l. in. (9.6 N N m) Bolts -- Torque to 85. l. in. (9.6 N m) R2 JUNE 1998 Pge 4-51

210 POWERHEAD 5. Instll tell-tle hose nd ttch hose to fitting on ottom cowl. Pge R2 JUNE Tell-Tle Hose 6. Instll the following components/ssemlies referring to the listed service mnul sections. Component/Assemly Cruretor Throttle/Shift Mechnism Electricl/Ignition Components nd Flywheel Section 3A 7A/B/C 2A/B Rewind Strter 8 Set-Up nd Test-Run Procedures Brek-In Procedure CAUTION When engine is strted, IMMEDIATELY check for fuel leks nd wter leks. Check for wter pump opertion y wter eing dischrged from tell-tle. 1. Following powerhed repirs, refer to Section 2C Timing/Synchronizing/Adjusting nd perform set-up procedures. 2. While test running engine, check powerhed ssemly for leks nd/or unusul noises. Mke ny repirs BEFORE returning engine to service. CAUTION To void possile engine dmge, rek-in procedure MUST BE completed BE- FORE operting engine continuously t full throttle. Filure to rek-in engine in properly will result in engine filure or shortened powerhed life. IMPORTANT: Advise the owner tht the rek-in procedure must e followed EX- ACTLY when returning n overhuled engine to service. 1. Mix gsoline nd oil t the norml 50:1 rtio. 2. Operte engine t vried throttle settings for the first hour (1 hour). AVOID oth wideopen-throttle opertion nd prolonged idle in cold wter res during this period. 3. After the first hour of opertion, the engine is my e run t ny speed. DO NOT EX- CEED the full throttle RPM rnge listed in Specifictions, preceding.

211 Tle of Contents MIDSECTION Section 5 - CLAMP nd SWIVEL BRACKET CLAMP AND SWIVEL BRACKET Clmp Brcket Assemly A-2 Swivel Brcket Assemly A-4 Drive Shft Housing Assemly A-6 Drive Shft Housing Disssemly/Ressemly.. 5A R2 JUNE 1998 Pge 5-1

212 CLAMP AND SWIVEL BRACKET Clmp Brcket Assemly C With Teflon ( A12) Pge R2 JUNE 1998

213 CLAMP AND SWIVEL BRACKET Clmp Brcket Assemly TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 CLAMP BRACKET (STBD.) (BLACK) 1 1 CLAMP BRACKET (STBD.) (GRAY) 1 CLAMP BRACKET (STBD.) (TRACKER GRAPHITE GRAY) 1 CLAMP BRACKET (PORT) (BLACK) 2 1 CLAMP BRACKET (PORT) (GRAY) 1 CLAMP BRACKET (PORT) (TRACKER GRAPHITE GRAY) 3 2 THUMB SCREW ASSEMBLY 4 2 RIVET 5 2 HANDLE 6 2 SCREW--wsher ttching WASHER--thum screw 8 1 NUT (1/4-28) NUT (7/8-14) SCREW (M6x1x40) HANDLE--crrying 12 1 SPACER 13 1 WASHER--tilt tue (NYLON) 14 1 TILT TUBE 15 1 WASHER--tilt tue (NYLON) 16 1 DECAL--co-pilot 17 1 TILT PIN ASSEMBLY 18 1 SPRING 19 1 SCREW (M6x1x40) NUT (7/8-14) CLIP--sfety 22 2 BOLT--clmp rcket to trnsom 23 2 WASHER--clmp rcket olt 24 2 NUT--clmp rcket olt 25 1 NUT (1/4-28) SCREW (1/4-28x1 IN.) LEVER--tilt stop - strord side 28 1 NUT (1/4-28) SPRING--tilt stop lever screw 30 1 SCREW (1/4-28x1-3/4 IN.) SCREW (1/4-28x1-3/4 IN.) WAVE WASHER--tilt stop strp screw 33 1 NUT (1/4-28) STRAP--tilt stop - port side 35 1 SCREW (1/4-28x1 IN.) R2 JUNE 1998 Pge 5-3

214 CLAMP AND SWIVEL BRACKET Swivel Brcket Assemly B A NO TAG B Loctite 271 ( ) Anti-Corrosion Grese ( A6) C With Teflon ( A12) A=REMOTE CONTROL MODELS ONLY B=TILLER HANDLE MODELS ONLY Pge R2 JUNE 1998

215 CLAMP AND SWIVEL BRACKET Swivel Brcket Assemly TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 ROD--reverse hook 2 1 NUT HANDLE 4 1 WASHER 5 1 BRAKE PLATE 6 1 BRAKE DISC 7 1 SWIVEL HEAD PLATE (Included W/Ref. #36) 8 1 BRAKE DISC 9 2 SCREW (M6x1x14) (Included W/Ref. #36) ROD 11 1 SWIVEL BRACKET 12 1 GREASE FITTING GREASE FITTING GREASE FITTING BUSHING KIT 16 1 O-RING 17 1 BUSHING 18 1 BUSHING 19 1 WASHER 20 1 HOOK ASSEMBLY--reverse lock 21 1 SPRING (REMOTE CONTROL MODELS) 22 1 SPRING (ALL OTHER MODELS) 23 1 SPRING 24 1 RING--retining 25 1 PIN 26 1 TROLL BRACKET 27 1 SPRING 28 1 LEVER--control 29 1 RING--retining 30 2 COVER--lower mount 31 2 SCREW (M8x100) SCREW (M8x60) WASHER 34 3 NUT BUMPER--front 36 2 MOUNT--lower 37 1 SWIVEL HEAD 38 2 SCREW--upper mount (M8x1.25x133) MOUNT--upper 40 2 WASHER--ruer - upper mount screw 41 2 WASHER--upper mount screw 42 2 NUT--upper mount screw SCREW ( x1.25) STEERING LINK ASSEMBLY 45 1 WASHER 46 1 NUT 1 BRACKET--ride guide (BLACK) 47 2 SCREW (M10x1.5x25) LOCKWASHER 49 1 WASHER 50 1 NUT R2 JUNE 1998 Pge 5-5

216 CLAMP AND SWIVEL BRACKET Drive Shft Housing Assemly A Loctite 271 ( ) A=SERVICE ONLY Pge R2 JUNE 1998

217 CLAMP AND SWIVEL BRACKET Drive Shft Housing Assemly TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 SEAL--dptor plte 2 1 ADAPTOR PLATE ASSEMBLY 3 1 GASKET--dptor plte 4 2 SCREW (M6x1x20) BRACKET--upper mount 6 1 EXHAUST TUBE (Prt of Ref. #2) 7 1 HOUSING ASSEMBLY--wter tue 8 1 SPACER--wter tue 9 1 SEAL--wter tue 10 2 SCREW (M5x.8x16) WATER TUBE (SHORT SHAFT) 11 1 WATER TUBE (LONG SHAFT) 1 HOUSING ASSEMBLY (SHORT SHAFT) BLACK 1 HOUSING ASSEMBLY (LONG SHAFT) 12 1 HOUSING ASSEMBLY (SHORT SHAFT) GRAY 1 HOUSING ASSEMBLY (LONG SHAFT) 1 HOUSING ASSEMBLY (LONG) (TRACKER GRAPHITE GRAY) 13 1 GASKET--drive shft housing 14 1 GASKET--idle relief cover 15 1 COVER--idle relief 16 1 SCREW--cover (1/4-20x1-1/4 IN.) Drive Tight 17 6 SCREW--drive shft housing to lock (M8 x 70) WASHER--drive shft housing screw 19 4 SCREW (M6x1x20) TRIM COVER (BLACK) 20 1 TRIM COVER (GRAY) 1 TRIM COVER (TRACKER GRAPHITE GRAY) Drive Shft Housing Disssemly/Ressemly Servicing components such s steering rm, drive shft housing, exhust ssemly nd swivel rcket will usully require powerhed nd/or ger housing removl. Refer to SECTION 4 for powerhed removl nd SECTION 6 for ger housing removl. The trnsom rcket, lower mount rcket, tilt tue nd lower engine mounts cn e serviced without powerhed/ger housing removl. However, OUTBOARD MUST BE SUP- PORTED BEFORE SERVICING COMPONENTS. IMPORTANT: All gskets should e replced when removing powerhed nd/or disssemling drive shft housing. Corresponding gsket mting surfces should e clened of ny gsket mteril efore instlling new gskets R2 JUNE 1998 Pge 5-7

218 Tle of Contents LOWER UNIT Section 6A - Ger Housing GEAR HOUSING Specifictions A-1 Quicksilver Luricnts nd Service Aids... 6A-2 Specil Tools A-2 Ger Housing (Drive Shft) A-6 Ger Housing (Propeller Shft) A-8 Generl Service Recommendtions A-10 Drining nd Inspecting Ger Luricnt.... 6A-11 Ger Housing Removl A-12 Disssemly A-14 Bering Crrier A-14 Propeller Shft A-15 Wter Pump A-16 Shift Shft A-18 Drive Shft nd Pinion Ger A-18 Upper Drive Shft nd Bering/Sels... 6A-19 Lower Drive Shft Bering/Cup A-20 Forwrd Ger Rce A-20 Clening nd Inspection A-21 Ger Housing/Bering Crrier Cstings. 6A-21 Bll Berings A-21 Needle Bering A-21 Specifictions Cm Follower A-22 Clutch A-22 Propeller shft A-22 Shift Shft A-23 Reverse And Forwrd Ger A-23 Pinion Ger A-25 Driveshft A-25 Bering Crrier A-26 Ressemly A-26 Drive Shft Bering nd Sels A-26 Shift Shft A-28 Forwrd Ger Instlltion A-29 Pinion nd Driveshft A-31 Propeller Shft A-31 Bering Crrier A-33 Bering Crrier/Propeller Shft Instlltion 6A-34 Wter Pump A-35 Ger Housing Instlltion A-36 Trim T Adjustment nd Replcement. 6A-41 Filling Ger Housing with Luricnt A-42 6 A GEAR HOUSING BIGFOOT (2.42:1) Ger Rtio Gercse Cpcity Luricnt Type Forwrd Ger Numer of Teeth Pinion Ger Numer of Teeth Pinion Height Forwrd Ger Bcklsh Wter Pressure (With 950 rpm 5000 rpm (WOT) 2.42:1 7.8 fl oz (230 ml) Quicksilver Ger Lue-Premium Blend 29 Spirl/Bevel 12 Spirl/Bevel No Adjustment No Adjustment 1-4 psi (7-28 kp) 6-9 psi (41-62 kp) NOTE: Before filling ger cse, pply psi of ir pressure t the vent hole. Pressure should not drop for 5 minutes while lterntely pplying 2-3 pound force to the top of the shift shft in the fore nd ft direction R2 JUNE 1998 Pge 6A-1

219 GEAR HOUSING Quicksilver Luricnts nd Service Aids Prt No. Description Loctite A1 2-4-C w/teflon Loctite Primer A1 Super Duty Ger Luricnt Specil Tools 1. Universl Puller Plte Lekge Tester FT Bering Puller & Instlltion Tool A7. Nut Wsher (2) c. Plte d. Threded Rod Pge 6A R2 JUNE 1998

220 e. Mndrel GEAR HOUSING 4. Bering Puller Tool Slide Hmmer A1 6. Bering Crrier Tool Bering Cup Puller Bushing Removl Tool R2 JUNE 1998 Pge 6A-3

221 GEAR HOUSING 9. Driveshft Sel Instlltion Tool Bering Crrier Prop Shft Sel Instlltion Tool Bering Crrier Prop Shft Bering Instlltion Tool Pge 6A R2 JUNE 1998

222 Notes: GEAR HOUSING R2 JUNE 1998 Pge 6A-5

223 GEAR HOUSING Ger Housing (Drive Shft) Loctite 271 ( ) 13 Super Duty Ger Luricnt ( A1) Loctite Primer 7649 ( ) C w/teflon ( A1) Pge 6A R2 JUNE 1998

224 GEAR HOUSING Ger Housing (Drive Shft) TORQUE REF. NO. QTY. DESCRIPTION l-in. l-ft Nm 1 1 GEAR HOUSING ASSEMBLY 2 1 SLEEVE 3 2 SEAL--ger housing 4 1 ROLLER BEARING--upper 5 2 DOWEL PIN (.187 x.53) 6 1 SCREW (.375 x.25) WASHER--seling 8 1 SCREEN--wter inlet-port 9 1 SCREW (M5 x 40) DRAIN SCREW--mgnetic WASHER 12 1 SCREEN--strord 13 1 NUT (M5) 14 1 ROLLER BEARING ASSEMBLY 15 1 CUP 16 1 PINION GEAR (12-29) 17 1 NUT GASKET 19 1 FACE PLATE 20 1 WASHER 21 1 KEY 22 1 lmpeller 23 1 WASHER 24 1 O-RING 25 1 WATER PUMP ASSEMBLY 26 1 INSERT 27 1 SEAL 28 1 RING 29 4 BOLT (M6 x 16) SHIFT SHAFT 31 1 NUT (M6) Tighten Securely 32 1 COUPLER Tighten Securely 33 1 SHIFT SHAFT (UPPER) 34 1 DRIVE SHAFT 35 1 BOOT 36 1 RETAINER 37 1 O-RING 38 1 O-RING 39 1 WASHER 40 1 SPRING 41 1 WASHER 42 1 ROLL PIN 43 1 SHIFT CAM 44 1 DRIVE PIN R2 JUNE 1998 Pge 6A-7

225 GEAR HOUSING Ger Housing (Propeller Shft) Loctite 271 ( ) Super Duty Ger Luricnt ( A1) Anti-Corrosion Grese ( A1) C w/teflon ( A1) Pge 6A R2 JUNE 1998

226 GEAR HOUSING Ger Housing (Propeller Shft) TORQUE REF. NO. QTY. DESCRIPTION l-in. l-ft Nm 1 1 GEAR HOUSING ASSEMBLY 45 1 TRIM TAB 46 1 BOLT (M8x30) WASHER 48 1 TAPERED ROLLER BEARING 49 1 CUP 50 1 FORWARD GEAR (12-29) 51 1 BUSHING 52 1 CAM FOLLOWER 53 1 SPRING 54 1 CLUTCH 55 1 CROSS PIN 56 1 SPRING 57 1 PROPELLER SHAFT 58 1 REVERSE GEAR (12-29) 59 1 BEARING CARRIER ASSEMBLY ROLLER BEARING 61 1 OIL SEAL (INNER) 62 1 OIL SEAL (OUTER) 63 1 O-RING 64 1 PLATE 65 3 BOLT (M5x16) BOLT (M10 x 35) WASHER 68 1 THRUST HUB ASSEMBLY 69 1 PROPELLER 70 1 PROP NUT R2 JUNE 1998 Pge 6A-9

227 GEAR HOUSING Generl Service Recommendtions There my e more thn one wy to disssemle or ressemle prticulr prt(s), therefore, it is recommended tht the entire procedure e red prior to repir. IMPORTANT: Red the following efore ttempting ny repirs. In mny cses, disssemly of su-ssemly my not e necessry until clening nd inspection revels tht disssemly is required for replcement of one or more components. Service procedure order in this section is norml disssemly-ressemly sequence. Threded prts re right hnd (RH), unless otherwise indicted. When holding, pressing or driving is required, use soft metl vise jw protectors or wood for protection of prts. Use suitle mndrel (one tht will contct only the ering rce) when pressing or driving erings. Whenever compressed ir is used to dry prt, verify tht no wter is present in ir line. BEARINGS SEALS All erings must e clened nd inspected. Clen erings with solvent nd dry with compressed ir. Air should e directed t the ering so tht it psses through the ering. DO NOT spin ering with compressed ir s this my cuse ering to score from lck of luriction. After clening, luricte erings with Quicksilver Ger Luricnt. DO NOT luricte tpered ering cups until fter inspection. Inspect ll erings for roughness, ctches nd ering rce side wer. Work inner ering rce in-nd-out, while holding outer rce, to check for side wer. When inspecting tpered erings, determine condition of rollers nd inner ering rce y inspecting ering cup for pitting, scoring, grooves, uneven wer, imedded prticles nd/or discolortion from over-heting. Alwys replce tpered ering nd rce s set. Inspect ger housing for ering rces tht hve spun in their respective ores. If rce(s) hve spun, ger housing must e replced. Roller ering condition is determined y inspecting the surfce of the shft tht the roller ering supports. Check shft surfce for pitting scoring, grooving, imedded prticles, uneven wer nd/or discolortion from overheting. The shft nd ering must e replced if such condition exists. As norml procedure, ll O-rings nd oil sels SHOULD BE REPLACED without regrd to ppernce. To prevent lekge round sels, pply Loctite 271 to outer dimeter of ll metl cse sels. When using Loctite on sels or threds, surfces must e clen nd dry. Apply 2-4-C w/teflon on ll O-rings nd on I.D. of oil sels. Apply 2-4-C w/teflon to ering crrier threds nd pilot dimeters. Pge 6A R2 JUNE 1998

228 Drining nd Inspecting Ger Luricnt GEAR HOUSING WARNING If ger housing is instlled on outord, disconnect (nd isolte) sprk plug leds from sprk plugs efore working ner the propeller. 1. With ger housing in norml running position, plce clen pn under housing nd remove vent plug nd fill/drin plug (with gskets). -Vent Plug/Wsher -Drin Plug/Wsher 2. Inspect ger luricnt for metl prticles (luricnt will hve metl flke ppernce). Presence of fine metl prticles (resemling powder) on the drin plug mgnet indictes norml wer. Metl chips on the mgnet indicte the need for ger housing disssemly nd component inspection. 3. Note color of ger luricnt. White or crem color indictes presence of wter. 4. Presence of wter indictes the need for disssemly nd inspection of oil sels, O- rings, gskets nd components for dmge. Pressure check prior to disssemly to determine lek re R2 JUNE 1998 Pge 6A-11

229 GEAR HOUSING Ger Housing Removl WARNING To prevent ccidentl engine strting, remove (nd isolte) sprk plug leds from sprk plugs BEFORE removing ger housing. 1. Tilt outord to full UP position. 9.9/15 Bigfoot (4 Stroke) 2. Remove reverse hook guide ssemly from lower shift shft. 3. Loosen jm nut nd disconnect coupler. Remove jm nut to llow removl of gercse. c -Reverse Hook Guide -Jm Nut c-coupler 20/25 (2 Stroke) 4. Unltch nd remove retiner to free shift shft for removl of gercse Retiner Pge 6A R2 JUNE 1998

230 GEAR HOUSING NOTE: A flt wsher is locted on the shift shft ner the top of the shft. This wsher my slide off shift shft when ger cse is removed. Do not lose wsher s wsher is necessry for ressemly Flt Wsher 5. Remove four screws nd remove ger housing Screws (4) NOTE: If wter tue should pull out of driveshft housing, remove tue from wter pump nd insert tue ck into driveshft housing to id in ressemly R2 JUNE 1998 Pge 6A-13

231 GEAR HOUSING Disssemly Bering Crrier IMPORTANT: It is recommended tht, during complete disssemly of ger housing, ll O-rings nd oil sels e replced, regrdless of their ppernce. 1. Remove 3 screws which secure the O-ring retiner plte nd O-ring to the ering crrier. Remove the O-ring retiner plte nd O-ring from ger housing. 2. Remove ering crrier using Specil Tool (LEFT HAND THREAD). d c d Screws (3) -O-Ring Retiner Plte c-o-ring d-bering Crrier 3. While holding onto propeller shft nd ering crrier, pull propeller shft from propeller shft cvity, s shown. NOTE: Cm follower is free to slide out of propeller shft. 4. Remove reverse ger nd ering crrier from propeller shft. 5. Seprte reverse ger from ering crrier. c d Cm Follower -Propeller Shft Assemly c-reverse Ger d-bering Crrier Pge 6A R2 JUNE 1998

232 GEAR HOUSING NOTE: When using screwdriver to remove crrier sels, e creful not to scr crrier sel surfce. If crrier sel surfce is dmged, replce crrier. 6. Secure ering crrier in vise. Using screwdriver, pry out oth sels from ering crrier Propeller Shft -Oil Sels 1. Insert thin lde screwdriver or wl under first coil (from front) of cross-pin retiner spring. 2. Rotte propeller shft to unwind spring from sliding clutch. -Awl -Cross Pin Retining Ring 3. Insert flt end of cm follower into front end of propeller shft. 4. Position cm follower ginst solid surfce R2 JUNE 1998 Pge 6A-15

233 GEAR HOUSING WARNING Use cution when removing cm follower. As the cross-pin is remove the cm follower cn shoot out of the propeller shft s high speed projectile. 5. Push ginst cm follower. Use punch or wl to push cross-pin out of sliding clutch. 6. Relese pressure ginst cm follower. -Cm Follower -Cross Pin 7. Remove cm follower, spring nd sliding clutch from propeller shft. c Wter Pump -Cm Follower -Spring c-clutch 1. Slide centrifugl slinger off drive shft. 2. Remove four (4) screws securing wter pump to ger housing s shown in illustrtion. -Centrifugl Slinger -Wter Pump Mounting Screws 3. Remove cover, nylon wshers (ove nd elow impeller), impeller nd drive key from drive shft. 4. It is recommended tht impeller e replced whenever ger cse is eing serviced. NOTE: If impeller is not going to e replced, DO NOT instll impeller in reverse rottion to its originl stte s vnes hve tken set. Vnes will crck nd rek shortly fter outord is returned to service. Pge 6A R2 JUNE 1998

234 5. Remove fce plte nd se gsket. 6. Remove shift shft from housing. GEAR HOUSING c d f h g e Cover -Nylon Wsher c-impeller d-nylon Wsher e-key f-shift Shft g-fce Plte h-bse Gsket NOTE: Replce impeller if: Impeller ldes re crcked, torn or worn. Impeller is glzed or melted. Ruer portion of impeller is not onded to impeller hu R2 JUNE 1998 Pge 6A-17

235 GEAR HOUSING Shift Shft 1. Pull shift shft ssemly from ger housing. 2. Remove nd replce outer O-ring from shift shft retiner. g -Shift Shft -Boot c-retiner d-o-ring (outer) e-o-ring (inner) f-wsher d e f c h k i j g-spring h-wsher i-roll Pin j-driver Pin k-shift Cm Drive Shft nd Pinion Ger 1. Clmp driveshft in soft jw vise nd remove pinion nut or olt tht secures pinion to driveshft. Pull driveshft out of ger housing. Remove pinion nd tpered roller ering. NOTE: 9.9/15 Bigfoot (4 Stroke) uses nut to secure pinion ger. 20/25 (2 Stroke) uses olt to secure pinion ger. c -Pinion Nut/Bolt -Pinion c-tpered Roller Bering Pge 6A R2 JUNE 1998

236 Upper Drive Shft nd Bering/Sels GEAR HOUSING 1. Using Wter Pump Crtridge Puller ( ), s shown, remove the driveshft oil sels from ger housing Oil Sels -Wter Pump Crtridge Puller 2. Using suitle mndrel drive upper drive shft ering through gercse sleeve to the ottom of gercse. 3. Do not remove gercse sleeve (not shown). -Upper Driveshft Bering -Mndrel R2 JUNE 1998 Pge 6A-19

237 GEAR HOUSING Lower Drive Shft Bering/Cup g 1. Fsten ering cup puller on threded rod s shown. 2. Tighten hex nut nd drw the ering cup puller up into ering cup until lip on tool snps over the top side of ering cge. Remove threded rod ssemly. 3. Insert tpered end of rod ( ) into ering cup puller nd tp ering cup out of driveshft ore. c f e h c d -Bering Cup -Bering Cup Puller ( ) c-flt Wshers 2 ( ) d-hex Nut 0.625x18 ( ) e-threded Rod 0.625x18-16 Long ( ) f-plte ( ) g-hex Nut 0.625x18 ( ) h-tpered Rod ( ) Forwrd Ger Rce 1. Use slide hmmer to remove forwrd ger tpered ering rce s shown A1 -Slide Hmmer -Tpered Bering Rce Pge 6A R2 JUNE 1998

238 Clening nd Inspection GEAR HOUSING Ger Housing/Bering Crrier Cstings Bll Berings 1. Thoroughly clen ger housing/ering crrier cstings. Be sure ll old gsket mteril is removed from mting surfces nd tht cron deposits hve een removed from exhust pssges. 2. Inspect cstings for crcks or frctures. 3. Check seling surfces for nicks, deep grooves nd distortion which could cuse leks. 4. Check wter pssges for ostructions. CAUTION DO NOT spin-dry ll erings with compressed ir. 1. Clen ering in solvent nd dry with compressed ir. 2. Bering should e free of rust stins. 3. Attempt to work inner ering rce in-nd-out. There should not e excessive ply. 4. Luricte ll ering with Quicksilver Ger Lue. Rotte inner ering rce. Bering should hve smooth ction. If ll ering sounds or feels rough or hs ctches, remove nd discrd ering. Refer to Bering Crrier following. Needle Bering Clen needle erings in solvent nd dry with compressed ir. 2. Replce ering if needles re rusted, frctured, worn, glled dly, discolored, or if re of shft tht ering contcts is worn or pitted. Refer to Drive Shft following R2 JUNE 1998 Pge 6A-21

239 GEAR HOUSING Cm Follower 1. Inspect cm follower for wer or glling. If wer is present, inspect corresponding shift cm for wer. Replce if worn Clutch 1. Replce clutch if jws re rounded or chipped. Rounded jws my e cused y the following: Improper shift cle djustment or linkge. Engine idle speed too high while shifting. Shifting too slowly from NEUTRAL into FORWARD or REVERSE Propeller shft 1. Check propeller shft for strightness. 2. Inspect ushing/ering surfces of propeller shft for pitting or wer. Replce shft nd corresponding ushing/ering if wer or pitting is oserved. 3. Replce propeller shft if ny of the following exist: Splines re twisted or worn. Oil sel surfce is grooved. Shft hs noticele wole or is ent more thn in. (0.15 mm). c Bushing/Bering Surfces -Oil Sel Surfce c-mesure Here for Wole (When mesuring shft for wole, use v-locks nd support t ushing surfce) Pge 6A R2 JUNE 1998

240 Shift Shft 1. Inspect shift shft retiner for crcks nd replce if necessry. 2. Inspect shift cm fce for wer. Replce if worn. GEAR HOUSING Shift Cm -Shift Shft Retiner Reverse And Forwrd Ger 1. Inspect ger teeth for pitting, uneven wer, scoring, etc. Replce ger if ny dmge is found. 2. Inspect ger clutch jws. Replce ger if jws re rounded or chipped Ger Teeth -Clutch Teeth R2 JUNE 1998 Pge 6A-23

241 GEAR HOUSING 3. Inspect FORWARD ger tpered ering nd rce for rust, roughness, pitting, splling or excessive wer (looseness). NOTE: DO NOT remove tpered ering from FORWARD ger unless replcement is necessry s removl process will dmge ering. 4. If ering must e replced, remove ering from ger using Universl Puller Plte ( ) nd suitle mndrel (5/8 in. socket). IMPORTANT: If FORWARD ger tpered ering or rce requires replcement, replce ering nd rce s set. c Bering -Universl Puller Plte ( ) c-mndrel (5/8 in. Socket) If inspection determines tht replcement of forwrd ger ushing is required, remove ushing from forwrd ger using one of two wys. 6. Using Punch: Secure forwrd ger in vise. Be sure to use soft jw vise nd do not clmp onto tpered ering. Use punch nd hmmer, remove ushing from the clutch jw (teeth) side of ger. 7. Using Press: Press ushing from ger using Bushing Removl Tool e c c d Forwrd Ger -Vise Protector c-bushing d-punch e-bushing Removl Tool ( ) Pge 6A R2 JUNE 1998

242 Pinion Ger GEAR HOUSING 1. Inspect pinion ger teeth for rekge, rust, chipping or excessive wer. 2. If pinion ger teeth re dmged, inspect FORWARD nd REVERSE ger for dmge. 3. Replce gers s required Driveshft -Pinion Ger IMPORTANT: If upper drive shft ushing or lower drive shft needle ering rce pper to e spinning in their respective ores, the ger housing should e replced. 1. Replce drive shft if the following exist: Splines re twisted or worn. Oil sel surfce is grooved. Bering/Bushing journl surfces re pitted or worn. Replce corresponding ering s well. c Bering/Bushing Surfce -Bering/Bushing Surfce c-sel Surfce R2 JUNE 1998 Pge 6A-25

243 GEAR HOUSING Bering Crrier 1. If inspection of ering re on propeller shftdetermines thtreplcement ofering inside of ering crrier is required, remove ering from ering crrier. 2. Secure ering crrier in vise, DO NOT clmp onto threded portion of ering crrier. 3. Remove ering from ering crrier with punch or suitle mndrel/socket nd hmmer. Ressemly -Bering -Punch Drive Shft Bering nd Sels Instll upper driveshft ering into driveshft ore of ger housing sleeve. Apply light cot of 2-4-C w/teflon to upper driveshft ering retiner ore s follows: Plce upper driveshft ering over ering retiner ering ore with lettered side of ering fce up. Using suitle mndrel, press ering into ger housing sleeve until the ering is just elow the oil hole to depth of 1.00 in. (25.4 mm) s shown in. (25.4 mm) c -Upper Driveshft Bering -Mndrel c-oil Hole Pge 6A R2 JUNE 1998

244 GEAR HOUSING 2. Instll lower driveshft ering cup into driveshft ore of ger housing s follows: Assemle ering cup s shown. Drw ering cup up to shoulder of gercse housing using cup puller ( ) s shown e f c d c f -Bering Cup -Bering Cup Puller ( ) c-flt Wshers 2 ( ) d-threded Rod 0.625x18-16 in. long ( ) e-plte ( ) f-hex Nut 0.625x18 (2) ( ) 3. Instll new driveshft oil sels into driveshft ore of ger housing s follows: Apply Loctite 271 to outer dimeter of driveshft oil sels. With lip of sel fcing down, press the first oil sel into driveshft ore until sel is just elow the top of driveshft ore. With lip of sel fcing up, nd using Instlltion tool , press the second oil sel into driveshft ore until sel is 3/16 (4.7 mm) elow top of driveshft ore. Wipe off excess Loctite. 7 3/16 (4.7 mm) c 7 7 Loctite 271 ( ) d e f Upper Driveshft Bering -Mndrel c-sels (2) d-oil Sel with Lip of Sel Fcing Up e-oil Sel with Lip of Sel Fcing Down f-instlltion Tool ( ) R2 JUNE 1998 Pge 6A-27

245 GEAR HOUSING Shift Shft 1. Instll shift shft ssemly into ger housing ssemly. c d e f g k h i j -Shift Shft Assemly -Boot c-retiner d-o-ring (outer) e-o-ring (inner) f-wsher g-spring h-wsher i-roll Pin j-driver Pin k-shift Cm Pge 6A R2 JUNE 1998

246 Forwrd Ger Instlltion 1. Instll forwrd ger ering rce into ger housing. GEAR HOUSING 2. Apply light cot of Super Duty Ger Luricnt to forwrd ger ering rce ore in propeller shft cvity. 3. Position tpered ering rce squrely over ering ore in front portion of propeller shft cvity. 4. Plce mndrel ( ) from Bering Instlltion Kit ( A7) over tpered ering rce. 5. Plce propeller shft into hole in center of mndrel. 6. Instll ering crrier ssemly over propeller shft nd thred it in 4 or 5 turns. 7. Thred suitle nut onto propeller shft to protect propeller shft threds. (DO NOT use propeller nut.) 8. Use mllet to drive propeller shft ginst mndrel until tpered ering rce is firmly seted in ering rce ore. d c Super Duty Ger Luricnt ( A1) -Forwrd Ger Bering Rce -Mndrel ( ) c-propeller Shft d-bering Crrier R2 JUNE 1998 Pge 6A-29

247 GEAR HOUSING 9. Remove nut from propeller shft, then remove ering crrier, propeller shft nd mndrel from propeller shft cvity. 10. Apply light cot of oil on tpered ering rce. 11. Plce forwrd ger on press with ger teeth down. 12. Apply light cot of oil to I.D. of forwrd ger tpered ering. 13. Position forwrd ger tpered ering over ger. 14. Press on inner rce of ering until ering is firmly seted ginst forwrd ger. 15. Apply light cot of Ger Lue to ore in center of forwrd ger. 16. Using suitle mndrel, press forwrd ger ushing into forwrd ger until ushing is flush with the ck of ger. c d 95 e C w/teflon ( A1) -Press -Mndrel c-bering d-forwrd Ger e-bushing 17. Apply light cot of oil on forwrd ger tpered ering, then position forwrd ger ssemly in ger housing. Pge 6A R2 JUNE 1998

248 Pinion nd Driveshft 1. Plce lower drive shft tpered roller ering into ering cup. GEAR HOUSING 2. Plce pinion ger into ger housing with teeth of pinion meshed with teeth of forwrd ger. 3. Insert driveshft into ger housing while holding pinion in plce with other hnd. Rotte driveshft ck nd forth to lign splines on driveshft with splines in pinion ger. 4. Secure pinion ger to driveshft. Apply Loctite 271 to pinion nut or olt. Refer to tle for Fstener Type nd Torque. Model Fstener Type Torque 9.9/15 Bigfoot (4-Stroke) Pinion Nut 15 l-ft (20.3 Nm) 20/25 (2-Stroke) Pinion Bolt 13.3 l-ft (18.0 Nm) 7 Loctite 271 ( ) c Propeller Shft -Tpered Roller Bering -Pinion Ger c-fstener 1. Position sliding clutch over propeller shft spline with cross-pin holes ligned with slots in propeller shft. c -Short End -Cross Pin Hole c-slot 2. Apply smll mount of light oil onto sliding clutch spring nd insert spring into propeller shft R2 JUNE 1998 Pge 6A-31

249 GEAR HOUSING 3. Insert flt end of cm follower into propeller shft. -Spring -Flt End of Cm Follower 4. Plce cm follower ginst solid oject nd push ginst cm follower to compress spring. 5. Insert punch thru the cross-pin holes in sliding clutch (etween cm follower nd spring). 6. Apply light cot of oil on cross-pin nd instll cross-pin into sliding clutch y pushing punch out of clutch with cross-pin, s shown. (Relese pressure on cm follower nd remove follower from propeller shft.) c C w/teflon ( A1) -Punch -Cross Pin c-cm Follower 7. Instll cross-pin retiner spring. -Cross Pin Retiner Spring 8. Plce d of 2-4-C w/teflon into end of propeller shft nd instll cm follower (flt end first). Pge 6A R2 JUNE 1998

250 GEAR HOUSING Bering Crrier 1. Apply smll mount of oil into ering ore in ering crrier. 2. Position ering crrier on press (with the threded side down). 3. Plce propeller shft ering into ft end of ering crrier with lettered end of ering up. 4. Use instlltion tool ( ) to press ering into ering crrier until the instlltion tool ottoms out, or using suitle mndrel press ering to depth of 1-9/64 in. (28.9 mm) from end of ering crrier housing. c 1-9/64 in. (28.9 mm) Suitle Mndrel -Propeller Shft Bering c-lettered end of Bering 7 Loctite 271 ( ) 5. Apply Loctite Type 271 to outer dimeter of inner propeller shft sel. Use instlltion tool ( ) to press inner sel into ering crrier (lip of sel is fcing inwrd) to depth of 7/8 in. (22.2 mm) from end of ering crrier housing. 6. Apply 2-4-C w/teflon etween sels. 7. Apply Loctite Type 271 to outside dimeter of the outer propeller shft sel. Rotte instlltion tool nd press outer sel into ering crrier (lip of sel is fcing outwrd) to depth of 13/32 in. (10.3 mm) from end of ering crrier housing C w/teflon ( A1) 7/8 in. (22.2 mm) 13/32 in. (10.3 mm) Inner Propeller Shft Sel -Outer Propeller Shft Sel R2 JUNE 1998 Pge 6A-33

251 GEAR HOUSING Bering Crrier/Propeller Shft Instlltion 1. Apply smll mount of 2-4-C w/teflon etween lips of propeller shft oil sels. Apply 2-4-C w/teflon to threds, O-ring groove nd pilot dimeter. 2. Slide reverse ger into ering crrier ssemly. Slide ering crrier ssemly over propeller shft nd thred it into propeller shft cvity s-fr-s possile y hnd (LEFT HAND THREAD). 3. Torque ering crrier using Specil Tool Torque to 80 l-ft (108.5 Nm) Reverse Ger -Bering Crrier Assemly 4. Instll O-ring nd O-ring retiner plte on ering crrier. 5. Secure O-ring retiner plte to ering crrier with 3 screws. NOTE: Orientte O-ring to prevent pinching it. 6. Torque screws to 65 l-in. (7.2 Nm). d -O-Ring -O-Ring Retiner Plte c-screws (3) Torque to 65 l-in. (7.2 Nm) d-bering Crrier c Pge 6A R2 JUNE 1998

252 Wter Pump GEAR HOUSING 1. Slide new fce plte gsket nd fce plte over driveshft nd position them on ger housing. 2. Instll nylon wsher over driveshft nd set it flt ginst fce plte. 3. Plce impeller drive key on flt of driveshft. 4. Slide new impeller over driveshft. Align impeller keywy with drive key, then push impeller over drive key nd ginst fce plte. If reusing impeller (not recommended) note orienttion of vne set. 5. Instll nylon wsher nd set it flt ginst impeller. 6. Instll new O-ring in wter pump cover. Instll cover ssemly over driveshft nd down ginst impeller. c -Nylon Wsher -Fce Plte c-drive Key 7. While pushing down on wter pump cover ssemly, rotte driveshft clockwise to instll impeller cover nd set cover ginst fce plte. 8. Align mounting holes in gsket, fce plte nd wter pump cover with mounting holes in ger housing. Instll four (4) screws pplying Loctite 271 nd torque to 60 l-in. (6.8 Nm). 9. Slide centrifugl slinger down drive shft. 7 7 Loctite 271 ( ) -Centrifugl Slinger -Screws (4) Torque to 60 l-in. (6.8 Nm) R2 JUNE 1998 Pge 6A-35

253 GEAR HOUSING Ger Housing Instlltion 9.9/15 Bigfoot (4 - Stroke) WARNING To prevent ccidentl engine strting remove (nd isolte) sprk plug leds from sprk plugs efore instlling ger housing IMPORTANT: If wter tue hs een removed, follow instlltion procedure in Section 5. Wter tue loction is criticl for proper lignment to wter pump. 1. Tilt outord to full UP position. 2. Plce shift hndle (tiller models) or shift lever (remote control models) into neutrl. 3. Plce ger housing into neutrl y pushing down on the lower shift shft (from forwrd ger) to neutrl detent. (Propeller will rotte freely in either direction). 4. Cot splines of drive shft with 2-4-C w/teflon. 5. Guide ger housing onto drive shft housing to ligning the following: Keep mting surfces of ger housing/drive shft housing prllel. NOTE: It my e necessry to rotte the flywheel to id enggement of drive shft splines to crnkshft splines. Insert drive shft into the opening in the upper prt of the drive shft housing to lign with crnkshft splines. Guide lower shift shft thru ruer sel/opening in lower drive shft housing nd up thru loop of reverse lock link rod. Position wter tue guide onto wter tue. c -Reverse Lock Link Rod -Lower Shift Shft c-jm Nut Pge 6A R2 JUNE 1998

254 GEAR HOUSING 6. Secure ger housing to drive shft house with four (4) screws. Torque screws to 40 l-ft (54.2 Nm) Screws (4) Torque to 40 l-ft (54.2 Nm) 7. Thred (retined) jm nut onto lower shift to expose five (5) threds ove the nut. 8. Reconnect shift shft coupling nd tighten jm nut ginst coupler. 9. Shift to forwrd ger. 10. Assemle reverse hook guide round lower shift shft nd tighten olt/nut to llow djustment d c -Jm Nut -Coupling c-reverse Hook Guide d-lower Shift Shft R2 JUNE 1998 Pge 6A-37

255 GEAR HOUSING 11. Lift nd hold reverse lock hook in the full up position. 12. Slide reverse hook guide up shift shft to mke contct with loop of reverse lock link rod. DO NOT end link rod. Tighten guide olt/nut to torque of 50 l-in. (5.7 Nm). c -Reverse Hook Guide -Bolt/Nut - Torque to 50 l-in. (5.7 Nm) c-reverse Lock Hook Link Rod d-reverse Lock Hook 13. Lower outord to the norml operting position. 14. Check reverse lock opertion s follows: Forwrd Ger - Reverse lock fully relesed. Outord will tilt up. Neutrl - Reverse lock engged. Outord will not tilt up. d Reverse Ger - Reverse lock fully engged. Outord will not tilt up. 15. Shift outord into reverse nd verify tht free ply exists etween lowerloop ofreverse lock link rod nd shift shft coupling jm. 16. If no free ply exists, turn coupling up shift shft mximum of 1-1/2 turns nd re-tighten jm nut ginst coupling. Pge 6A R2 JUNE 1998

256 20/25 (2 Stroke) GEAR HOUSING 17. While turning drive shft in clockwise direction, pull up lightly on shift shft until ger housing is in forwrd ger (propeller shft turns clockwise). 18. Instll flt wsher (retined) onto shift shft Wsher IMPORTANT: Verify wter tue (inside drive shft housing) is connected to the wter tue sel in the dptor plte. 19. Position twist grip on tiller hndle so tht outord is in forwrd ger. NOTE: It is not necessry to grese the drive shft splines prior to instlltion of ger housing ssemly. Splines receive internl engine luriction during norml engine opertion. 20. Position ger housing so tht drive shft nd shift shft extend up into drive shft housing. 21. Move ger housing up towrd drive shft housing while keeping mchined surfces prllel. 22. Guide shift shft thru loop in the reverse lock rod. 23. Guide wter tue into ruer sel in wter pump cover. 24. Guide drive shft into crnkshft. NOTE: It my e necessry to rotte the flywheel to id enggement of drive shft splines to crnk shft splines R2 JUNE 1998 Pge 6A-39

257 GEAR HOUSING 25. Secure shift rod to horizontl shift shft with retiner Retiner 26. Check shift opertion s follows: Plce shift lever in FORWARD. Ger housing should rtchet when propeller shft is turned clockwise nd resistnce should e felt when propeller is turned counterclockwise. Plce shift lever in NEUTRAL. Resistnce should NOT e felt when propeller shft is rotted in either direction. Plce shift lever in REVERSE. Resistnce should e felt when propeller shft is rotted in either direction. If shift opertion is not s descried, recheck the coupler instlltion procedure. Pge 6A R2 JUNE 1998

258 Trim T Adjustment nd Replcement GEAR HOUSING IMPORTANT: The trim t mde of specil lloy to id in protecting the drive shft housing nd ger housing from glvnic corrosion (corrosion nd pitting of metl surfces). Do not pint or plce protective coting on the trim t, or trim t corrosion protection function will e lost. Replce trim t if 50% (or more) corroded. Mrk loction of old trim t on nti-ventiltion plce efore removl; instll new trim t in sme loction. 1. Check trim t position. 2. Operte ot t the speed t which it would normlly e operted. 3. If the ot pulls to the right (strord), the triling edge of trim t must e moved to the right. If the ot pulls to the left (port). the triling edge of trim t must e moved to the left. 4. If necessry, djust trim t. 5. Shift engine control into NEUTRAL nd turn ignition key to OFF position. NOTE: Loosen trim t olt sufficiently to llow trim t to disengge from locking ridges in ger cse efore ttempting to move t. DO NOT strike trim t with hrd oject to mke djustments. 6. Repet steps 2-4 s required to reduce steering torque Trim T -Retining Bolt R2 JUNE 1998 Pge 6A-41

259 GEAR HOUSING Filling Ger Housing with Luricnt 1. Plce outord in verticl operting position. 2. Remove vent plug from vent hole. 3. Plce luricnt tue into the fill hole nd dd luricnt until it ppers t the vent hole. -Vent Hole -Luricnt Tue 4. Instll the vent plug nd seling wsher efore removing the luricnt tue. 5. Remove luricnt tue nd reinstll clened fill/drin plug nd seling wsher. -Vent Plug -Fill Plug 6. Apply lierl cot of 2-4-C w/teflon ( A12) to propeller shft splines C w/teflon ( A1) 7. Instll thrust hu cp on thrust hu. Pge 6A R2 JUNE 1998

260 Tle of Contents LOWER UNIT Section 6B - Jet Drive JET DRIVE Jet Pump Assemly (S/N 0G & Below)... 6B-2 Jet Linkge (S/N 0G & Below) B-4 Jet Wter Pump Components B-5 Jet Pump Assemly (S/N 0G & Up) B-6 Jet Linkge (S/N 0G & Up) B-8 Selecting Bot tht Is Best Suited for Jet Power 6B-10 Engine Horsepower Selection B-10 Trnsom Height of the Bot B-11 Locte Centerline of the Outord B-11 Outord Mounting Height B-11 Wter Testing B-13 Checking for Cvittion B-13 Shift Link Rod Adjustment B-15 Checking Shift Link Rod Adjustment B-15 Adjusting Shift Link Rod B-15 Luricting the Drive Shft Bering B-16 Impeller Removl nd Instlltion B-17 Steering Pull Adjustment B-20 Impeller Clernce Adjustment B-20 Specifictions Worn (Dull) Impeller B-21 Liner Replcement B-22 Jet Drive Removl nd Instlltion B-23 Removl B-23 Instlltion B-23 Wter Pump Removl nd Instlltion B-24 Removl B-24 Instlltion B-24 Bering Crrier Removl nd Instlltion B-25 Removl B-25 Instlltion B-25 Instlling Drive Shft Bering B-25 Single Bering System (Smll Dimeter Bering) B-25 Single Bering System (Lrge Dimeter Bering) B-26 Instlling Drive Shft B-27 Instlling Upper Sel Housing B-28 Single Bering System B-28 6 B JET DRIVE Impeller Liner Clernce in. (0.8 mm) R2 JUNE 1998 Pge 6B-1

261 JET DRIVE Jet Pump Assemly (S/N 0G & Below) Loctite 271 ( ) C With Teflon ( A12) Pge 6B R2 JUNE 1998

262 JET DRIVE Jet Pump Assemly (S/N 0G & Below) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m -- 1 JET PUMP ASSEMBLY (BLACK) -- 1 JET PUMP ASSEMBLY (GRAY) 1 1 HOUSING--pump 2 1 HOSE--lue 3 1 IMPELLER 4 1 HOUSING--intke 5 1 LINER 6 1 DRIVESHAFT 7 1 SLEEVE 8 1 NUT 9 1 ADAPTOR 10 1 BASE--pump 11 4 SCREW (10-32 x 1) SCREW ( x 1-1/4) SCREW ( x 2) SCREW 15 1 KEY--impeller 16 8 SHIM--impeller 17 1 TAB WASHER 18 6 SCREW ( x 3/4) SCREW (10-24 x 5/8) R2 JUNE 1998 Pge 6B-3

263 JET DRIVE Jet Linkge (S/N 0G & Below) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 COTTER PIN 2 1 ROD END 3 1 BUSHING 4 2 WASHER 5 2 NUT (1/4-28) 6 1 SHIFT ROD 7 2 NUT 8 1 ROD END 9 1 SPACER 10 1 SCREW (1/4-20 x 3/4) 11 1 WASHER 12 2 WASHER 13 1 BUSHING 14 1 LEVER ASSEMBLY 15 1 SCREW 16 1 KNOB 17 1 SCREW ( x 1/2) 18 1 SPRING 19 1 SHAFT 20 1 SCREW (1/4-20 x 1-1/4) 21 1 LEVER MOUNT Pge 6B R2 JUNE 1998

264 JET DRIVE Jet Wter Pump Components Loctite 271 ( ) C With Teflon ( A12) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 FACE PLATE 2 1 WASHER-impeller 3 1 KEY-Impeller Drive 4 1 IMPELLER 5 1 WASHER-impeller 6 1 O RING-wter pump 7 1 WATER PUMP ASSEMBLY 8 1 INSERT 9 1 SEAL-wter tue 10 1 RING-driveshft - ruer 11 4 SCREW (M6 x 16) SCREW (M5 x 16) BUSHING (Use with M5 X 16 REF. #11) R2 JUNE 1998 Pge 6B-5

265 JET DRIVE Jet Pump Assemly (S/N 0G & Up) Loctite 271 ( ) C With Teflon ( A12) Pge 6B R2 JUNE 1998

266 JET DRIVE Jet Pump Assemly (S/N 0G & Up) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m -- 1 JET PUMP ASSEMBLY 1 1 HOUSING--pump 2 1 HOSE--lue 3 1 IMPELLER 4 1 HOUSING--intke 5 1 LINER 6 1 DRIVESHAFT 7 1 SLEEVE 8 1 NUT Drive Tight 9 1 ADAPTOR 10 1 BASE--pump 11 4 SCREW (10-32 x 1) SCREW ( x 1-1/4) SCREW ( x 2) WASHER 15 4 SCREW (M10 x 35) KEY--impeller 17 8 SHIM--impeller 18 1 TAB WASHER 19 6 SCREW ( x 3/4) SCREW (10-24 x 5/8) R2 JUNE 1998 Pge 6B-7

267 JET DRIVE Jet Linkge (S/N 0G & Up) Loctite 271 ( ) Pge 6B R2 JUNE 1998

268 JET DRIVE Jet Linkge (S/N 0G & Up) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 NUT 2 1 LOCKWASHER 1 SHIFT HANDLE (Use without Ref. #4) 3 1 SHIFT HANDLE (Use with Ref. #4) 4 1 SPACER--sleeve 5 1 ROD END 6 2 SPRING 7 2 WASHER 8 2 COTTER PIN 9 2 NUT SHIFT LEVER 11 1 SCREW (10-32 x 3/4) 12 1 SCREW (10-32 x 2-1/2) SHIFT ROD 14 1 ROD END 15 1 TILT LATCH ROD R2 JUNE 1998 Pge 6B-9

269 JET DRIVE Selecting A Bot Tht Is Best Suited For Jet Power To otin the est performnce from the jet drive, the ot should hve the following fetures: 1. The ot should e s light s possile. 2. The ot should hve hull nd trnsom tht is designed for use with jet drive. 3. The ot should e t lest 13 feet in length. Engine Horsepower Selection A ot operting t slow speed requires considerly more depth thn one which is plning on the surfce of the wter. It is importnt therefore to use sufficient horsepower nd not to overlod your ot eyond its ility to plne. See the following tle. The following tle is sed on experience otined with sled-type ots using outord jets. The gross weights shown includes the outord, ot, people, nd ll the ger crried. For given horsepower loding eyond these weights will give less thn good performnce. HP Gross Weight - Ls. Pge 6B R2 JUNE 1998

270 Trnsom Height of the Bot JET DRIVE Outords with jet drives will e mounted pproximtely 7 inches higher on the trnsom thn propeller driven outords. This requires outords tht hve 15 in. shft length to e instlled on ots hving 22 in. trnsom height nd outords tht hve 20 in. shft length to e instlled on ots hving 27 in. trnsom height. If the ot trnsom is of insufficient height, nd the outord cnnot e instlled to the recommended height, contct the ot mnufcturer for recommended procedure to uild up the ot trnsom. Locte Centerline Of The Outord Locte (nd mrk with pencil) the verticl centerline () of ot trnsom. A B C D - Centerline of Trnsom Outord Mounting Height The initil outord mounting height setting will work good for most pplictions, however, ecuse of different ot/hulls designs, the setting should e rechecked y test-running the ot. Refer to Wter Testing. Instlling the outord too high on the trnsom will llow the wter intke to suck in ir nd cuse cvittion. (Cvittion will cuse the engine to overspeed in spurts nd reduce thrust). This condition should e voided y proper height setting. Instlling the outord too low on the trnsom will llow excessive drg. SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH V BOTTOM HULLS 1. Mesure the width of the leding edge on the wter intke housing. Mke horizontl line () on the trnsom up from the V ottom the sme length s the widthof thewter intke housing () - Horizontl Line - Width of Wter Intke Housing R2 JUNE 1998 Pge 6B-11

271 JET DRIVE 2. Plce (center) the outord on the ot trnsom so tht the trnsom rckets re resting on top of the trnsom. Temporrily fsten the outord to the trnsom using two C-clmps. 3. Position the outord in verticl position. 4. Line up stright edge long the ottom of the ot with the horizontl line mde in Step 1 nd mesure the distnce etween the horizontl line nd top front edge of the wter intke housing. - Stright Edge - Top Front Edge of Wter Intke Housing 5. Rise The outord up on the trnsom the distnce mesured in Step 4. Use stright edge nd recheck the mounting height. The top edge of the wter intke housing should e lined up with the horizontl line mde in Step Fsten outord to the trnsom t this height. Pge 6B R2 JUNE 1998

272 SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH FLAT BOTTOM HULLS JET DRIVE 1. Plce (center) the outord on the ot trnsom so tht the trnsom rckets re resting on top of the trnsom. Temporrily fsten the outord to the trnsom using two C-clmps. 2. Position the outord in verticl position. 3. Plce stright edge long the ottom of the ot s shown nd mesure the distnce etween the ottom of the ot nd top front edge of the wter intke housing. - Stright Edge - Top Front Edge of Wter Intke Housing 4. Rise the outord up on the trnsom the distnce mesured in Step 3. Use stright edge nd recheck the mounting height. The top edge of the wter intke housing should e in line with the ottom of the ot s shown. Wter Testing Checking for Cvittion 5. Fsten outord to the trnsom t this height. Mking the initil outord height setting should e close to the optimum setting for the outord. However ecuse of the hull design of some ots, ostructions or imperfections in the hull hed of the wter intke my require this setting to chnge in order to prevent cvittion t running speeds. When operting the ot, the outord drive shft should e verticl when plning or tilted towrd the ot in order to provide scooping ngle on the wter intke. Tilting the outord out eyond verticl position reduces the scoop ngle nd cn cuse impeller slippge nd cvittion. If the ngle of the ot trnsom does not llow the drive shft to e positioned verticlly, Wedge kit should e instlled ehind the trnsom rckets to increse the tilt-in ngle. NOTE: Slight cvittion in shrp turns nd rough wter is cceptle ut excessive cvittion is hrmful to the outord nd should e voided R2 JUNE 1998 Pge 6B-13

273 JET DRIVE Test run the ot. If cvittion occurs (ir enters the pump cusing loss of thrust, engine over-speeds errticlly), the first thing to try is lowering the outord height 1/4 in. This cn e ccomplished y elongting the drilled mounting holes in the ot trnsom y 1/4 in. If cvittion still exists fter lowering the outord 1/4 in. (6.35 mm), it mye helpful to seek dvice from the ot mnufcturer. A numer of other options re ville to further reduce cvittion. 1. Wter intke fin kit () -- Aville from the Specilty Mfg. Co. for jet models 30 thru 140. The purpose of these fins is to rm more wter into the intke nd shield the forwrd sides of the intke from the entrnce of ir. This kit will help reduce cvittion when running with the wind in chop. - Intke Fin Kit Wter Intke Fin Kit Prt No.1186 for jet models 45 thru 140 nd Prt No for jet model 30 is ville from: Specilty Mfg. Co Edison Ave. Sn Lendro, CA Rough Wter Plte () -- Using this type of plte my e helpful in reducing cvittion when running in windy rough wter conditions where ir is sucked-in the wter intke when jumping wves. Instll 1/32 in. (0.794 mm) metl plte tht extends from the hull ottom to the top of the wter intke housing. This plte tends to reduce ir intke s well s reduce spry. - Rough Wter Plte Pge 6B R2 JUNE 1998

274 Shift Link Rod Adjustment JET DRIVE WARNING The shift link rod must e djusted to lock the reverse gte ginst unexpected enggement (cused y wter pressure hitting the gte) while operting the ot in forwrd. Activtion of the reverse gte will cuse sudden unexpected stopping of the ot. Sudden stopping my cuse occupnts to e thrown within the ot or even out of the ot. This ction my result in serious injury or deth. Checking Shift Link Rod Adjustment Adjusting Shift Link Rod Check the shift link rod () djustment in forwrd shift position. The correct djustment will position the shift cm () fr enough on the roller (c) in order to lock the the reverse gte (d) into forwrd position. You should not e le to forcily push up the reverse gte towrd neutrl. Pull on the reverse gte y hnd to verify this. 1. Plce the shift hndle into full forwrd shift position. 2. Adjust the length of the shift link rod () so tht roller (c) is t the full end of trvel (ottom) in the shift cm (c) when the shift hndle is in full forwrd. c d - Shift Link Rod - Shift Cm c - Roller d - Reverse Gte R2 JUNE 1998 Pge 6B-15

275 JET DRIVE Luricting the Drive Shft Bering Recommended Luriction - Use Quicksilver 2-4-C w/teflon, or Luriplte 630-AA Grese. IMPORTANT: It is importnt tht you do not use generl-ll-purpose grese for this ering. The luricnt we recommend is wter resistnt grese of the proper consistency for this ppliction. If you use sustitute grese, e sure tht it is wter resistnt nd of the sme consistency. Frequency of luriction - We recommend luricting the drive shft ering fter ech dy s use nd fter every 10 hours of opertion. After every 30 hours of opertion, pump in extr grese to purge out ny moisture. Luricting Procedure - Pull vent hose off the grese fitting. Pump in grese through the grese fitting until excess grese strts to exit the vent hose. - Vent Hose - Grese Exiting Vent Hose Reconnect the vent hose onto the grese fitting fter gresing. After 30 hours of opertion, pump in extr grese to purge out ny moisture. Visully inspecting the purged grese t this time will give you n indiction of conditions inside the ering housing. A grdul increse in moisture content, indictes sel wer. If the grese egins to turn drk, dirty gry, the drive shft ering nd sels should e inspected nd replced if necessry. Some discolortion of the grese is norml during the rek-in period on new set of sels. Pge 6B R2 JUNE 1998

276 Impeller Removl nd Instlltion JET DRIVE REMOVAL 1. Shift outord to NEUTRAL (N) position. 2. Remove sprk plug leds to prevent engine from strting. 3. Remove the wter intke housing tht is fstened with six screws. 4. Strighten the ent ts on the impeller nut retiner nd remove the impeller nut. 5. Pull impeller stright off the shft. If the impeller is tight, use hmmer nd lock of wood to rotte the impeller (clockwise) on the shft until the keywy is directly ove the flt on the shft. This will free the jmmed key nd llow removl. - T - Nut R2 JUNE 1998 Pge 6B-17

277 JET DRIVE INSTALLATION 1. Grese the drive shft, sher key, nd impeller ore. Plce the plstic sleeve () inside the impeller () nd instll impeller, sher key (c), shims (d) nut retiner (e), nd impeller nut (f). Turn the nut tight on the shft to remove ny ply etween the impeller nd shft. If the ts on the retiner do not line up with the flts on the nut, remove the nut nd turn the retiner over nd re-tighten the nut gin. c d e f - Plstic Sleeve - Impeller c - Sher Key d - Shims e - Nut Retiner f - Impeller Nut 2. Temporrily reinstll the wter intke housing in order to check for impeller clernce. The clernce etween the impeller nd liner should e in. (0.8 mm). Shim wshers cn e trnsferred to either side of the impeller to rise or lower the impeller to the correct clernce setting. The wter intke housing cn e shifted side wys smll mount in order to center the liner..03 in. (.8mm) Pge 6B R2 JUNE 1998

278 JET DRIVE 3. After setting the impeller height, tighten the impeller nut snug with wrench. Secure impeller nut y ending ts () ginst the flts on the impeller nut. - Ts 4. Reinstll the wter intke housing with six olts. Check clernce round the impeller to mke sure the wter intke housing is centered nd not ruing ginst the liner. Torque mounting olts to 100 l. in. (11.3 N m). NOTE: If the outord is used in slt wter, pply Quicksilver Anti-Corrosion Grese round the entire mounting flnge on the wter intke housing nd lso to the threds on the six mounting olts R2 JUNE 1998 Pge 6B-19

279 JET DRIVE Steering Pull Adjustment The steering on some ots will hve the tendency to pull towrds strord. This pulling condition cn e corrected y using pliers nd ending the ends of the exhust fins () 1/16 in. (1.5 mm) towrd the strord side of the outord. - Exhust Fins Impeller Clernce Adjustment 1. The impeller should e djusted so there is pproximtely in. (0.8 mm) clernce etween the impeller edge nd liner. Operting the jet drive in wters tht contin snd nd grvel cn cuse wer to the impeller ldes, nd the clernce will strt to exceed in. (0.8 mm). As the ldes wer, shims () locted in the stck outside of the impeller cn e trnsferred ehind the impeller. This will move the impeller further down into the tpered liner to reduce the clernce. 2. Check the impeller clernce y sliding feeler guge through the intke grte nd mesure the clernce etween the impeller edge nd liner. If djustment is required, refer to Impeller Removl nd Instlltion. - Shims.03 in. (.8mm) Pge 6B R2 JUNE 1998

280 Worn (Dull) Impeller JET DRIVE The intke of grvel through the pump cn round off nd wer the leding edges on the impeller. Some conditions you my experience from worn impeller re (1) noticele performnce loss, especilly on ccelertion, (2) difficultly getting the ot on plne, or (3) n increse in engine RPM t wide open throttle. Check the impeller ldes occsionlly for dmge. Use flt file to reshrpen the leding edges s shown. d c - Do not shrpen or lter the top side lifting ngle - Leding Edge c - Shrpen to 1/32 in. (0.8mm) rdius y removing mteril from ottom side only d - Enlrged View R2 JUNE 1998 Pge 6B-21

281 JET DRIVE Liner Replcement 1. Mrk the liner mounting olts for ressemly into the sme holes. Remove the olts. 2. Remove the liner. If the liner is tight, tp on the inner edge of the liner with long drift punch through the intke grte. NOTE: Apply grese to the liner mounting olt threds efore ssemly. 3. Position the liner into the wter intke housing. Line up one of the liner olts nd lightly thred it in. It my e necessry to tp or press the liner into the wter intke housing to locte the liner for instlltion of the remining olts. Torque olts to 100 ls. in. (11.3 N m). 4. Grind off the ends of ny olts tht my extend eyond the inner liner surfce. Pge 6B R2 JUNE 1998

282 Jet Drive Removl nd Instlltion JET DRIVE Removl Instlltion 1. Remove wter intke nd impeller. Refer to Impeller Removl nd Instlltion preceding. 2. Disconnect the shift linkge. Remove 5 olts (shown) securing jet drive to drive shft housing nd remove jet drive. 1. Instll jet drive with olts shown Loctite 271 ( ) - Bolts (4) -- Apply Loctite 271 to Threds nd Torque to 25 l. ft. (34.0 N m) - Bolt (1) -- Apply Loctite 271 to Threds nd Torque to 23.0 l. ft. (31.0 N m) R2 JUNE 1998 Pge 6B-23

283 JET DRIVE Wter Pump Removl nd Instlltion Removl Instlltion 1. Remove wter pump ssemly s shown. IMPORTANT: If impeller eing instlled hs een previously used nd vnes hve tken set, do not instll the impeller with the vnes reversed from their previous set s vne rekge will occur shortly fter unit is returned to service. NOTE: Apply light cot of 2-4-C w/teflon to inside of pump cover to ese instlltion of cover over impeller. 1. Ressemle wter pump ssemly s shown. Rotte drive shft CLOCKWISE while pressing wter pump ody down over impeller. c d 95 e f g h i j k l C With Teflon ( A12) m - Bolt nd flt wsher (4) -- Apply Loctite 271 to threds - Bushing (4) -- Used on erlier type wter pumps c - Ruer Ring d - Sel -- Wter Tue e - Pump Assemly f - O-Ring g - Wsher h - Impeller i - Key j - Wsher k - Fce Plte l - Screw (4) -- Apply Loctite 271. Torque to 35 l. in. (4.0 N m) m - Bse Pge 6B R2 JUNE 1998

284 Bering Crrier Removl nd Instlltion JET DRIVE Removl Instlltion 1. Remove wter pump ssemly nd wter pump se. 2. Remove 2 screws securing ering crrier to jet drive. Remove ering crrier. Reinstll ering crrier s shown. - Screws (2) Apply Loctite 271 to Threds, Torque to 30 l. in. (3.4 N m) Instlling Drive Shft Bering Single Bering System (Smll Dimeter Bering) 1. If removed, instll the ering thrust ring () into the groove on the drive shft. 2. Instll collr () onto the drive shft. Instll thrust wsher (c) (gry Teflon coting side fcing the ll ering). Press the new ll ering (d) onto the drive shft, pressing ginst the inner rce only. Press collr () over the thrust ring (), locking it in its groove. Instll snp ring (e) into drive shft groove elow the ering. c c d e d e R2 JUNE 1998 Pge 6B-25

285 JET DRIVE Single Bering System (Lrge Dimeter Bering) 1. If removed, instll the ering thrust ring into the groove on the drive shft. 2. Instll collr onto the drive shft. Press the new ll ering onto the drive shft, pressing ginst the inner rce only. Press collr over the thrust ring (), locking it in its groove. Instll snp ring into drive shft groove elow the ering. c d c d - Bering Thrust Ring - Collr c - Bll Bering d - Snp Ring Pge 6B R2 JUNE 1998

286 Instlling Drive Shft JET DRIVE 1. Luricte the sels nd inside ore of the ering crrier (). 2. Plce the drive shft ( impeller end fcing up) into vise. 3. Het the ering crrier () until it feels wrm to the touch. 4. Plce the ering crrier () onto the drive shft. Squre up the inner ore with the ll ering(s) nd push the ering crrier down until it ottoms-out ginst the ering. It my e necessry to lightly tp ering crrier onto the ering(s) using ruer hmmer. NOTE: Only light pressing force is needed to press on the ering crrier. It my e necessry to lightly tp the ering crrier onto the ering(s) using ruer hmmer. - Bering Crrier - Drive Shft R2 JUNE 1998 Pge 6B-27

287 JET DRIVE Instlling Upper Sel Housing Single Bering System 1. Grese the upper O-ring sels nd inside ore of the ering crrier to ese entry of the sel housing. 2. Lrge Dimeter Bering Type Only: Instll thrust wsher (d) -- [GRAY teflon coting side of thrust wsher FACES ll ering] -- on top of ering. 3. Instll spcer on top of the thrust wsher. 4. Instll the upper sel housing () eing creful not to dmge the O-ring sels s they pss the snp ring groove. Only finger pressure should e necessry to push in the housing. 5. Instll the eveled snp ring (), eveled side fcing up into the ring groove. Mke sure the snp ring is fully seted into groove. 6. Instll the ering crrier into the jet drive nd fill with grese, using grese gun. If using hnd lever gun, pump very slowly so s to not uild up internl grese pressure nd dmge the sels or housing. Smll Dimeter Bering Type c Lrge Dimeter Bering Type c d Pge 6B R2 JUNE 1998

288 Tle of Contents CONTROLS Section 7A - Throttle/Shift Linkge THROTTLE/SHIFT LINKAGE Throttle nd Shift Linkge (Tiller Hndle Shift)... 7A-2 Control Cles (Tiller Hndle Shift) A-4 Removl/Instlltion A-4 Control Pltform A-4 Removl/Disssemly A-4 Ressemly/Instlltion A-7 Throttle Cm/Control Lever A-10 Removl A-10 Throttle Cm/Control Lever A-10 Ressemly A-10 Instlltion A-12 Neutrl Interlock Control Lever A-13 Ressemly/Instlltion A-13 Horizontl Shift Shft A-14 Removl A-14 Instlltion A-15 7 A R2 JUNE 1998 Pge 7A-1

289 THROTTLE/SHIFT LINKAGE Throttle nd Shift Linkge (Tiller Hndle Shift) A C With Teflon ( A12) A=LOCAL ELECTRIC ONLY Pge 7A R2 JUNE 1998

290 THROTTLE/SHIFT LINKAGE Throttle nd Shift Linkge (Tiller Hndle Shift) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 SWITCH--interlock 2 2 SCREW (M3.5x0.6x16 hex wsh) LINK interlock 4 1 LEVER--interlock control 5 1 SCREW (M6x1x25 hex hd cp) PLAIN WASHER (62x.255x.03) 7 1 BUSHING 8 1 LEVER--ckplte 9 1 LEVER--horizontl shift shft (PORT) 10 1 SHIFT SHAFT (HORIZONTAL) 11 1 SHIFT LINK ASSEMBLY 12 1 SOCKET 13 1 NUT 14 1 THROTTLE LINK ASSEMBLY 15 2 SOCKET 16 1 NUT 17 1 LINK--sprk djustment S/N 18 2 SOCKET USA -0G & BELOW 19 1 NUT BEL & BELOW 20 1 THROTTLE CAM ASSEMBLY S/# 21 1 LEVER--ger shift USA -0G & BELOW 22 1 PRIMARY LEVER BEL & BELOW 23 1 WASHER (.62x.255x.03) (Use w/ref #20) 20 1 THROTTLE CAM ASSEMBLY S/N 21 1 LEVER--ger shift USA -0G thru 0G PRIMARY LEVER BEL thru WASHER (Use w/ref #20) 24 1 WASHER 25 1 WAVE WASHER 26 1 THROTTLE CAM S/N 27 1 SPRING USA-0G & UP 28 1 SPARK ARM BEL & UP 29 1 TIMING LINK 30 1 SECONDARY GEAR 31 1 PRIMARY GEAR 32 1 BUSHING 33 1 BALL--detent 34 1 SPRING 35 1 SCREW (M6x1x20 hex hd cp) SCREW (M6x1x25 hex hd cp) BUSHING 38 1 WASHER (.62x.255x.03) 39 1 SCREW (M6x1x30) WASHER (.62x.255x.03) 41 1 BUSHING 42 1 CONTROL PLATFORM 43 3 SCREW (M5x1x16 hex wsher hd) PLATE 45 1 STRAP 46 1 SCREW R2 JUNE 1998 Pge 7A-3

291 THROTTLE/SHIFT LINKAGE Control Cles (Tiller Hndle Shift) Removl/Instlltion Control Pltform Removl/Disssemly Refer to Section 7B for removl nd instlltion instructions 1. Disconnect control cles from nchor rcket nd pulley s outlined in Section 7B. 2. Disconnect throttle link rod from ll joint of primry throttle lever. e c d Cles - Brcket c - Pulley d - Link Rod e - Throttle Lever Pge 7A R2 JUNE 1998

292 3. Disconnect shift link rod from ll joint of ger shift lever. THROTTLE/SHIFT LINKAGE c - Shift Link Rod - Ger Shift Lever c - Shift Lever 4. Remove 3 olts nd control pltform Bolts - Control Pltform R2 JUNE 1998 Pge 7A-5

293 THROTTLE/SHIFT LINKAGE 5. Remove nuts nd flt wshers. - Nuts - Flt Wshers 6. Disssemle control pltform c e d f g j i h e e Bolts (2) -- Torque to 120 l. in. (13.6 N m) - Fltwshers (2) c - Primry Ger d - Bushing (Long) e - Mount Bolts -- Torque to 120 l. in. (13.6 N m) f - Control Pltform g - Bushing (Short) h - Detent Spring i - Detent Bll j - Secondry Ger Pge 7A R2 JUNE 1998

294 Ressemly/Instlltion THROTTLE/SHIFT LINKAGE 1. Instll short ushing nd long ushing on control pltform. 2. Instll detent spring nd detent ll into recess of control pltform. 3. Luricte ushings nd re of pltform trveled y gers with 2-4-C w/teflon. c C With Teflon ( A12) Short Bushing - Long Bushing c - Pltform 4. Instll secondry ger over short ushing nd detent ll nd spring s shown. 5. Secure secondry ger with olt nd flt wsher. Torque olt to 120 l. in. (13.6 N m). 6. Luricte ger teeth with 2-4-C w/teflon C With Teflon ( A12) Secondry Ger - Bolt nd Flt Wsher -- Torque to 120 l. in. (13.6 N m) R2 JUNE 1998 Pge 7A-7

295 THROTTLE/SHIFT LINKAGE 7. Instll primry ger over long ushing s shown. 8. Secure primry ger with olt nd flt wsher. Torque olt to 120 l. in. (13.6 N m). 9. Luricte ger teeth with 2-4-C w/teflon C With Teflon ( A12) Primry Ger - Bolt nd Flt Wsher -- Torque to 120 l. in. (13.6 N m) 10. Secure ssemled control pltform onto cylinder lock using 3 olts. Torque olts to 120 l. in. (13.6 N m). - Pltform - Bolts -- Torque to 120 l. in. (13.6 N m) Pge 7A R2 JUNE 1998

296 THROTTLE/SHIFT LINKAGE 11. Adjust shift link rod to length of 5-1/2 in. (13.9 cm) s mesured etween ll joint centerlines. 12. Connect shift link rod etween joints of secondry lever nd shift shft lever. c Shift Link Rod -- Adjust to length of 5-1/2 in. (13.9 cm) - Shift Shft Lever c - Secondry Lever 13. Adjust throttle link rod to length of 5-1/4 in. (13.3 cm) s mesured etween ll joint centerlines. 14. Connect throttle link rod etween ll joints of primry ger nd throttle cm. e d c f - Throttle Link Rod -- Adjust to length of 5-1/4 in. (13.3 cm) - Primry Ger c - Throttle Cm d - Pulley e - Anchor Brcket f - Control Cles R2 JUNE 1998 Pge 7A-9

297 THROTTLE/SHIFT LINKAGE Throttle Cm/Control Lever Removl 1. Refer to Section 7B for removl of throttle cles. 2. Remove olt nd flt wsher securing cm/lever to powerhed. c - Bolt - Wsher c - Cm/Lever Throttle Cm/Control Lever Ressemly 1. Position spring over hu of throttle cm. Spring ends must strddle t. - Hu - Spring Ends c - T c Pge 7A R2 JUNE 1998

298 THROTTLE/SHIFT LINKAGE 2. Luricte ushing with 2-4-C w/teflon nd instll ushing nd wve wsher C With Teflon ( A12) Bushing - Wve Wsher 3. Instll control lever onto throttle cm ssemly so tht t of control lever is positioned etween ends of spring. c c Control Lever - T c - Ends of Spring R2 JUNE 1998 Pge 7A-11

299 THROTTLE/SHIFT LINKAGE Instlltion 1. Secure throttle cm/control lever ssemly onto mounting oss of crnkcse cover with olt. Torque olt to 120 l. in. (13.6 N m). 2. Connect timing link etween ll joints of control lever nd trigger ssemly. e d c Throttle Cm - Control Lever c - Flt Wsher d - Bolt -- Torque olt to 120 l. in. (13.6 N m) e - Timing Link 3. Adjust throttle link rod to length of 5-1/4 in. (13.3cm) s mesured etween ll joint center lines. 4. Connect throttle link rod etween ll joints of throttle cm nd primry throttle lever. c - Throttle Link Rod -- Adjust to length of 5-1/4 in. (13.3cm) - Throttle Cm c - Primry Ger Pge 7A R2 JUNE 1998

300 Neutrl Interlock Control Lever THROTTLE/SHIFT LINKAGE Ressemly/Instlltion 1. Luricte ushing with 2-4-C w/teflon nd instll ushing C With Teflon ( A12) Bushing 2. Secure interlock lever components with olt onto mounting oss of crnkcse cover. d c - Interlock lever - Flt wsher c - Bolt -- Torque to 120 l. in. (13.6 N m) d - Neutrl Interlock Wire R2 JUNE 1998 Pge 7A-13

301 THROTTLE/SHIFT LINKAGE Horizontl Shift Shft Removl 1. Remove nut securing ccess cover to port side of ottom cowl. Remove cover. - Nut - Access Cover 2. Lift up nd remove lever securing horizontl shift shft Lever Pge 7A R2 JUNE 1998

302 3. Pull out nd remove horizontl shift shft. THROTTLE/SHIFT LINKAGE Instlltion - Horizontl Shift Shft Instll horizontl shift shft/shift lever ssemly into opening in STARBOARD side of crnkcse cover. - Horizontl Shift Shft - Shift Lever R2 JUNE 1998 Pge 7A-15

303 THROTTLE/SHIFT LINKAGE 2. Secure end of shift shft to yoke of horizontl shift shft with lever Lever 3. Reinstll ccess cover nd secure with nut nd olt. Torque nut to 50 l. in. (5.6 N m) Access Cover - Nut -- Torque to 50 l. in. (5.6 N m) 4. Refer to Control Pltform/Throttle Cm/Control Lever previous nd reinstll pltform, shift link nd throttle cm. Pge 7A R2 JUNE 1998

304 Tle of Contents CONTROLS Section 7B - Tiller Hndle TILLER HANDLE Tiller Hndle Assemly B-2 Control Cles B-4 Removl B-4 Tiller Hndle Removl/Disssemly B-5 Removl B-5 Instlltion B-7 Control Cles B-10 Instlltion B-10 7 B R2 JUNE 1998 Pge 7B-1

305 TILLER HANDLE Tiller Hndle Assemly Loctite 271 ( ) C With Teflon ( A12) Pge 7B R2 JUNE 1998

306 TILLER HANDLE Tiller Hndle Assemly TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m -- 1 TILLER HANDLE (BLACK) TILLER HANDLE -- 1 TILLER HANDLE (GRAY) SHIFT -- 1 TILLER HANDLE (BLACK) SIDE SHIFT -- 1 TILLER HANDLE (GRAY) 1 COVER KIT (TILLER HANDLE SHIFT) 1 1 COVER KIT (SIDE SHIFT) 2 1 PULLEY 3 1 CASE 4 1 SCREW (#10-16x1/2 IN.) Drive Tight 1 THROTTLE CABLE (TILLER HANDLE SHIFT) 5 1 THROTTLE CABLE (SIDE SHIFT) 1 THROTTLE CABLE (TILLER HANDLE SHIFT) 6 1 THROTTLE CABLE (SIDE SHIFT) 7 1 SLEEVE--throttle cle 1 ARM--steering hndle (BLACK) 8 1 ARM--steering hndle (GRAY) 2 SCREW (M5x1x16) SCREW (M6x1x20) 10 1 SCREW (M5x.5x16) KNOB--throttle friction As Required 12 1 SPRING 13 1 LOCK--throttle friction 14 1 SCREW (M6x1x25) 15 1 TILLER TUBE 1 DECAL (TILLER HANDLE SHIFT) 16 1 DECAL (SIDE SHIFT) 1 THROTTLE HANDLE (TILLER HANDLE SHIFT) 17 1 THROTTLE HANDLE (SIDE SHIFT) 18 1 GRIP--throttle hndle 19 1 STOP SWITCH 20 1 RETAINER 1 PLATE--tiller hndle (Use with 6MM screw REF. #9) 21 1 PLATE--tiller hndle (Use with 5MM screw REF. #9) 22 1 BUSHING 23 2 SCREW (M10x1.5x80) BRACKET (BLACK) 24 1 BRACKET (GRAY) 25 1 BUSHING 26 1 WASHER 27 1 WAVE WASHER 28 1 WASHER 29 1 WASHER R2 JUNE 1998 Pge 7B-3

307 TILLER HANDLE Control Cles Removl 1. Plce tiller hndle twist grip in NEUTRAL position. 2. Remove throttle link rod from throttle cm nd primry throttle lever. c - Link Rod - Throttle Cm c - Primry Throttle Lever 3. Loosen jm nuts which secure control cles to nchor rcket. 4. Unwrp nd remove control cles from pulley of primry ger NOTE: If not replcing control cles, mrk top cle with piece of tpe to id in ressemly. - Jm Nuts - Primry Ger Pge 7B R2 JUNE 1998

308 5. Remove nut securing ccess cover nd remove cover TILLER HANDLE - Nut - Access Cover 6. Disconnect stop utton wires -- BLACK/YELLOW nd BLACK BLACK/YELLOW - BLACK R2 JUNE 1998 Pge 7B-5

309 TILLER HANDLE Tiller Hndle Removl/Disssemly Removl 1. Remove 2 olts securing tiller hndle to nchor rcket nd remove tiller hndle ssemly Bolts 2. Remove ushing, fltwshers (2). wve wsher nd tiller hndle wsher. Remove retiner nd olt. c d e f - Bushing - Flt Wsher (2) c - Wve Wsher d - Tiller Hndle Wsher e - Retiner f - Bolt Pge 7B R2 JUNE 1998

310 3. Slide tiller tue out of pulley cse. TILLER HANDLE Tiller Tue - Pulley Cse 4. Remove pulley cse ssemly from tiller hndle nd remove cover olt Pulley Cse Assemly - Cover Bolt 5. Remove cover nd lift pulley ssemly from cse. Replce cles s required. - Cover - Pulley Assemly R2 JUNE 1998 Pge 7B-7

311 TILLER HANDLE Instlltion 1. Wrp cles round pulley. Top cle wrps nd locks in top groove. Bottom cle wrps nd locks in ottom groove. 2. Plce pulley nd cle ssemly into pulley cse. c Pulley - Top Cle c - Bottom Cle 3. Instll pulley cover nd secure cover with olt Cover - Bolt (Drive Tight) 4. Instll pulley ssemly into tiller hndle nd slide tiller tue into pulley. - Pulley Assemly - Tiller Tue Pge 7B R2 JUNE 1998

312 TILLER HANDLE 5. Secure tiller tue in hndle with retiner nd olt. Torque olt to 50 l. in. (5.6 N m). 6. Instll tiller wsher (t ligns with slot in hndle), plin wsher, wve wsher, plin wsher nd flnged ushing over cle/hrness ssemly. h d f g f c e - Retiner - Bolt -- Torque to 50 l. in. (5.6 N m) c - Tiller Wsher d - T e - Slot f - Plin Wsher g - Wve Wsher h - Flnged Bushing 7. Slide tiller hndle ssemly into nchor rcket Route stop utton hrness through fuel connector opening in ottom cowl. 9. Route control cles through opening in ottom cowl. 10. Align ts of inner nd outer flnged ushings with slots in nchor rcket. c - Stop Button Hrness - Control Cles c - Ts R2 JUNE 1998 Pge 7B-9

313 TILLER HANDLE 11. Pull on cle ends to remove slck nd secure tiller hndle to nchor rcket with plte nd 2 olts. Torque olts to 80 l. in. (9.0 N m). Control Cles - Plte - Bolts -- Torque to 80 l. in. (9.0 N m) Instlltion 1. Rotte tiller hndle twist grip to REVERSE ger position. 2. Route extended cle over top of primry ger pulley nd secure cle into inner groove of pulley. Plce cle jcket into top notch of cle nchor rcket. d c - Extended Cle - Inner Groove c - Cle Jcket d - Top Notch Pge 7B R2 JUNE 1998

314 3. Rotte tiller hndle to FORWARD ger position. TILLER HANDLE 4. Route remining cle elow primry ger pulley nd secure cle into outer groove of pulley. Plce cle jcket into lower notch of cle nchor rcket. 5. Rotte tiller hndle twist grip to NEUTRAL. 6. Rotte tiller hndle twist grip to SLOW position. 7. Adjust jm nuts to remove slck from throttle cles while llowing full trvel of throttle linkge/cruretor throttle shutter. e d c Cle - Outer Groove c - Cle Jcket d - Lower Notch e - Jm Nuts 8. Reinstll ccess cover. Secure cover with nut nd olt. Torque nut to 50 l. in. (5.6 N m). - Access Cover - Nut -- Torque to 50 l. in. (5.6 N m) R2 JUNE 1998 Pge 7B-11

315 Tle of Contents CONTROLS Section 7C - Side Shift SIDE SHIFT Throttle And Shift Linkge (Side Shift) C-2 Throttle Cles (Side Shift Models) C-4 Removl/Instlltion C-4 Throttle Cm/Control Lever C-4 Removl C-4 Throttle Cm/Control Lever C-5 Ressemly C-5 Instlltion C-6 Neutrl Interlock Control Lever C-8 Ressemly/Instlltion C-8 Horizontl Shift Shft C-9 Ressemly/Instlltion C-9 7 C R2 JUNE 1998 Pge 7C-1

316 SIDE SHIFT Throttle And Shift Linkge (Side Shift) C With Teflon ( A12) Pge 7C R2 JUNE 1998

317 SIDE SHIFT Throttle nd Shift Linkge (Side Shift) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 LINK--interlock 1 LEVER (20/25) (JET 20 - S/N-G & UP) 2 1 LEVER (JET 20 - S/N-G & BELOW) 3 1 SCREW (M6x1x25) WASHER 5 1 BUSHING 6 1 LEVER--ckplte 7 1 SPRING--detent NOT USED ON JET SPRING PLATE S/N G & BELOW 9 2 SCREW (M5x0.8x16) LEVER--horizontl shift shft (PORT) 11 1 SHIFT SHAFT (HORIZONTAL) 12 1 SHIFT HANDLE 13 1 SCREW (M5 x 20) WASHER 15 1 THROTTLE CAM 16 1 WASHER 17 1 SPARK ADJUST LINK 20 JET 18 2 SOCKET 19 1 NUT 20 1 ANCHOR BRACKET--cle 15 1 THROTTLE CAM 20/ WASHER 17 1 SPARK ADJUST LINK S/N 18 2 SOCKET USA-0G & BELOW 19 1 NUT BEL & BELOW 1 ANCHOR BRACKET--cle 20 1 ANCHOR BRACKET--cle 21 1 WASHER 22 1 WAVE WASHER 23 1 THROTTLE CAM 20/25 S/N 24 1 SPRING USA-0G & UP 25 SPARK ARM BEL & UP 26 TIMING LINK 27 1 SCREW (M6x1x 25) BUSHING 29 3 SCREW (M5x1x16) R2 JUNE 1998 Pge 7C-3

318 SIDE SHIFT Throttle Cles (Side Shift Models) Removl/Instlltion Refer to Section 7B for removl nd instlltion instructions Throttle Cm/Control Lever Removl 1. Refer to Section 7B for removl of throttle cles. 2. Remove olt nd flt wsher securing cm/lever to powerhed. d c - Throttle Cm - Control Lever c - Flt Wsher d - Bolt Pge 7C R2 JUNE 1998

319 Throttle Cm/Control Lever SIDE SHIFT Ressemly 1. Position spring ssemly over hu of throttle cm. c Inner Spring Ends - Hu c - T 2. Luricte ushing with 2-4-C w/teflon nd instll ushing nd wve wsher C With Teflon ( A12) Bushing - Wve Wsher R2 JUNE 1998 Pge 7C-5

320 SIDE SHIFT 3. Instll control lever onto throttle cm ssemly so tht t of control lever is positioned etween ends of inner spring. c Instlltion - Control Lever - T c - Ends of Inner Spring c Secure throttle cm/control lever ssemly onto mounting oss of crnkcse cover with olt. Torque olt to 120 l. in. (13.6 N m). 2. Connect timing link etween ll joints of control lever nd trigger ssemly. e d c - Throttle Cm - Control Lever c - Flt Wsher d - Bolt -- Torque olt to 120 l. in. (13.6 N m) e - Timing Link Pge 7C R2 JUNE 1998

321 SIDE SHIFT 3. Connect throttle cles to throttle cm nd throttle cle nchor rcket s outlined in Throttle Cle -- Instlltion, preceding. c - Throttle Cles - Throttle Cm c - Brcket R2 JUNE 1998 Pge 7C-7

322 SIDE SHIFT Neutrl Interlock Control Lever Ressemly/Instlltion 1. Luricte ushing with 2-4-C w/teflon nd instll ushing C With Teflon ( A12) Bushing 2. Secure interlock lever components with olt onto mounting oss of crnkcse cover. d c - Interlock Lever - Flt Wsher c - Bolt -- Torque to 120 l. in. (13.6 N m) d - Neutrl Interlock Wire Pge 7C R2 JUNE 1998

323 Horizontl Shift Shft SIDE SHIFT Ressemly/Instlltion 1. Instll horizontl shift shft/shift lever ssemly into opening in STARBOARD side of crnkcse cover. - Horizontl Shift Shft - Shift Lever 2. Secure horizontl shift shft to shift rod with lever c - Lever - Horizontl Shift Shft c - Shift Rod R2 JUNE 1998 Pge 7C-9

324 SIDE SHIFT 3. Instll ruer grommet into opening in strord side of ottom cowl. 4. Secure shift hndle onto end of horizontl shift shft with screw nd flt wsher. Torque screw to 50 l. in. (5.6 N m). - Grommet - Shift Hndle c - Screw d - Wsher c d Pge 7C R2 JUNE 1998

325 MANUAL STARTER OUTBOARD MOTOR INSTALLATION/ATTACHMENTS Section 8 - Mnul Strter Tle of Contents Specifictions Strter Assemly (Mnul) Rewind Strter Assemly Removl Instlltion Strter Rope Replcement Disssemly Clening nd Inspection Ressemly Specifictions STARTING SYSTEM Mnul Strt Rope Length Recoil 66 in. (1676 mm) R2 JUNE 1998 Pge 8-1

326 MANUAL STARTER Strter Assemly (Mnul) A B A - 30 l. in. (3.5 N m) B l. in. (12.5 N m) 2 26 Cyncrylte Adhesive (purchse loclly) C With Teflon ( A12) Pge R2 JUNE 1998

327 MANUAL STARTER Strter Assemly (Mnul) TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m RECOIL STARTER ASSEMBLY -- 1 (USA-0G/BEL- & BELOW RECOIL STARTER ASSEMBLY -- 1 (USA-0G/BEL- & UP HOUSING--strter 1 (USA-0G/BEL- & BELOW 1 HOUSING--strter 1 (USA-0G/BEL- & UP 2 1 SCREW (1/4-20) RETAINING RING 4 1 PAD--felt 5 1 SPRING--strter 6 1 SHEAVE--strter 7 2 SPRING--cm 8 2 CAM 9 2 RETAINING RING--cm 10 1 CAM 11 1 SPRING--cm 12 1 ROPE--strter 13 1 HANDLE ASSEMBLY--strter rope 14 1 RETAINER 15 1 BUSHING--rope 16 1 SUPPORT--strter hndle 17 2 SCREW--support to strter housing (M5x35MM) 18 4 SPACER--support screw 19 1 SUPPORT 20 2 NUT--support screw LEVER--lock (LOWER) 22 1 ROLL PIN--lock lever 23 1 SPRING--upper lock lever 24 1 LEVER--lock (UPPER) 25 1 BUSHING SCREW (M6 x 35) 3 NON SEAPRO/MARATHON USA- 0G/BEL- & UP 26 2 SCREW (M6 x 20) NON SEAPRO/MARATHON 1 SCREW (M6 x 35) USA- 0G/BEL- & BELOW 27 3 WASHER (.62x.255x.03) COMMERCIAL 28 3 NUT (M6 Nylon Insert) ENGINES DECAL--high voltge 30 1 DECAL--servicing referrl 31 1 DECAL-Cution Strt in Ger (REMOTE CONTROL) 32 1 DECAL--emergency strt procedures R2 JUNE 1998 Pge 8-3

328 MANUAL STARTER Rewind Strter Assemly Removl CAUTION DO NOT turn or cock fuel filter ssemly when removing. Remove fuel filter y pulling stright down. Turning or cocking fuel filter my rek fuel line connection on filter. 1. Pry fuel filter from strter rope guide. DO NOT turn or cock filter; pull stright down. - Filter Guide 2. Unsnp interlock link rod from lower lock lever Link Rod - Lock Lever Pge R2 JUNE 1998

329 3. Remove 3 olts nd lift rewind strter from engine. MANUAL STARTER Instlltion - Bolts - Rewind Strter 1. Secure rewind strter to engine with 3 olts. Apply Loctite 242 to threds of 3 mounting olts. Torque olts to 110 l. in. (12.4 N m) Loctite 242 ( ) - Bolts -- Torque to 110 l. in. (12.4 N m) - Rewind Strter R2 JUNE 1998 Pge 8-5

330 MANUAL STARTER 2. Snp interlock link rod into lower lock lever. - Link Rod - Lock Lever CAUTION Push filter stright up when instlling. Turning or cocking filter my rek fuel line connection on filter. 3. Push ll of fuel filter into socket of rope guide. DO NOT turn or cock fuel filter. - Filter - Guide Pge R2 JUNE 1998

331 Strter Rope Replcement MANUAL STARTER 1. Remove rewind strter from engine, s outlined previously. NOTE: If strter is roken, remove ll remining rope from sheve. 2. Disengge strter interlock from strter sheve. 3. Pull strter rope hndle out from rewind strter out 1 ft. (30.5cm) nd tie knot t this point to prevent rope from eing pulled ck into rewind strter. NOTE: 1999 Model nd newer hve redesigned rope guide support which must e removed efore replcing strter rope Interlock - Rope Guide Support (1999 Model nd Newer) 4. Remove rope retiner from strter hndle nd rope Strter Hndle - Retiner R2 JUNE 1998 Pge 8-7

332 MANUAL STARTER 5. Instll strter hndle on new rope cut to length of 66 in. (1676 mm). Tie knot into end of rope. Plce knot into recess of rope retiner. Instll rope retiner into strter hndle. c Hndle - Knot c - Retiner CAUTION Strter sheve must e firmly held ginst spring tension to prevent spring from unwinding. 6. Pull strter rope from rewind strter until rope is fully unwound from strter sheve. - Rope - Sheve Pge R2 JUNE 1998

333 MANUAL STARTER 7. While holding sheve in this position, lift knot from recess nd pull ll remining rope from sheve. c Sheve - Knot c - Recess 8. Turn sheve COUNTERCLOCKWISE until stop, indicting spring is wound tight. 9. Slowly turn sheve CLOCKWISE (with spring tension) until knot recess is ligned with rope hole in strter housing. c - Sheve - Knot Recess c - Rope Hole R2 JUNE 1998 Pge 8-9

334 MANUAL STARTER 10. Push end of new rope through rope holes in strter housing nd strter sheve. Pull end of rope out of knot recess. c - Rope - Holes c - Knot Recess 11. Tie knot into end of rope nd pull knot ck into knot recess Knot - Knot Recess 12. Allow strter rope to e slowly rewound onto strter sheve. 13. Reinstll rope guide support, if pplicle Pge R2 JUNE 1998

335 Disssemly MANUAL STARTER WARNING When disssemling rewind strter, SAFETY GLASSES MUST BE WORN in cse spring should uncoil out of housing. 1. Remove strter rope s outlined previously. 2. With rope removed, llow sheve to slowly unwind to relese spring tension. 3. Remove olt securing cm nd sheve to housing Bolt - Sheve 4. Gently lift strter sheve from housing. 5. Rewind spring ssemly my e replced s required. DO NOT remove spring from retiner. Spring nd retiner re replced s n ssemly. - Sheve - Rewind Spring R2 JUNE 1998 Pge 8-11

336 MANUAL STARTER Clening nd Inspection Ressemly 1. Clen rewind spring ssemly with solvent nd dry with compressed ir. 2. Inspect rewind spring (without removing spring from retiner) for kinks, urrs or rekge. Replce ssemly if necessry. 3. Inspect cm tension spring for dmge. Replce s necessry. 4. Inspect strter sheve nd housing for nicks, grooves, crcks nd distortion especilly in re of rope trvel. Replce ssemly if necessry. 5. Inspect strter rope for wer nd replce if necessry. 1. Apply 2-4-C w/teflon ( A12) to rewind spring nd cm tension spring. 2. Instll rewind spring ssemly into recoil housing positioning end of spring in notch. c C With Teflon ( A12) - Rewind Spring - Notch c - Cm Tension Spring Pge R2 JUNE 1998