MODELS Mercury/Mariner (4-Stroke) Starting Serial Numbers 0R and Above

Transcription

1 MODELS Merury/Mriner (4-Stroke) Strting Seril Numers 0R nd Aove Printed in U.S.A. 2000, Merury Mrine R1 MAY 2000

2 Notie Throughout this pulition, Dngers, Wrnings nd Cutions (ompnied y the Interntionl HAZARD Symol ) re used to lert the mehni to speil instrutions onerning prtiulr servie or opertion tht my e hzrdous if performed inorretly or relessly. OBSERVE THEM CAREFULLY! These Sfety Alerts lone nnot eliminte the hzrds tht they signl. Strit ompline to these speil instrutions when performing the servie, plus Common Sense opertion, re mjor ident prevention mesures. DANGER DANGER - Immedite hzrds whih WILL result in severe personl injury or deth. WARNING WARNING - Hzrds or unsfe prties whih COULD result in severe personl injury or deth. CAUTION Hzrds or unsfe prties whih ould result in minor personl injury or produt or property dmge. Notie to Users of This Mnul This servie mnul hs een written nd pulished y the Servie Deprtment of Merury Mrine to id our delers mehnis nd ompny servie personnel when serviing the produts desried herein. It is ssumed tht these personnel re fmilir with the serviing proedures of these produts, or like or similr produts mnuftured nd mrketed y Merury Mrine, tht they hve een trined in the reommended serviing proedures of these produts whih inludes the use of mehnis ommon hnd tools nd the speil Merury Mrine or reommended tools from other suppliers. We ould not possily know of nd dvise the servie trde of ll oneivle proedures y whih servie might e performed nd of the possile hzrds nd/or results of eh method. We hve not undertken ny suh wide evlution. Therefore, nyone who uses servie proedure nd/or tool, whih is not reommended y the mnufturer, first must ompletely stisfy himself tht neither his nor the produts sfety will e endngered y the servie proedure seleted. All informtion, illustrtions nd speifitions ontined in this mnul re sed on the ltest produt informtion ville t the time of pulition. As required, revisions to this mnul will e sent to ll delers ontrted y us to sell nd/or servie these produts. It should e kept in mind, while working on the produt, tht the eletril system nd ignition system re ple of violent nd dmging short iruits or severe eletril shoks. When performing ny work where eletril terminls ould possily e grounded or touhed y the mehni, the ttery les should e disonneted t the ttery. Any time the intke or exhust openings re exposed during servie they should e overed to protet ginst identl entrne of foreign mteril whih ould enter the ylinders nd use extensive internl dmge when the engine is strted R1 MAY 2000 Pge i

3 It is importnt to note, during ny mintenne proedure replement fsteners must hve the sme mesurements nd strength s those removed. Numers on the heds of the metri olts nd on the surfes of metri nuts indite their strength. Amerin olts use rdil lines for this purpose, while most Amerin nuts do not hve strength mrkings. Mismthed or inorret fsteners n result in dmge or mlfuntion, or possily personl injury. Therefore, fsteners removed should e sved for reuse in the sme lotions whenever possile. Where the fsteners re not stisftory for re-use, re should e tken to selet replement tht mthes the originl. Clenliness nd Cre of Outord Motor Pge Numering A mrine power produt is omintion of mny mhined, honed, polished nd lpped surfes with tolernes tht re mesured in the ten thousnds of n inh/mm. When ny produt omponent is servied, re nd lenliness re importnt. Throughout this mnul, it should e understood tht proper lening, nd protetion of mhined surfes nd frition res is prt of the repir proedure. This is onsidered stndrd shop prtie even if not speifilly stted. Whenever omponents re removed for servie, they should e retined in order. At the time of instlltion, they should e instlled in the sme lotions nd with the sme mting surfes s when removed. Personnel should not work on or under n outord whih is suspended. Outords should e tthed to work stnds, or lowered to ground s soon s possile. We reserve the right to mke hnges to this mnul without prior notifition. Refer to deler servie ulletins for other pertinent informtion onerning the produts desried in this mnul. Two numer groups pper t the ottom of eh pge. The exmple elow is self-explntory. EXAMPLE: R1 JANUARY 1998 Pge - 6A-7 Revision No. 1 Month of Printing Yer of Printing Setion Numer Prt of Setion Letter Pge Numer Pge ii R1 MAY 2000

4 Servie Mnul Outline Setion 1 - Importnt Informtion A - Speifitions B - Mintenne C - Generl Informtion D - Outord Instlltion Setion 2 - Eletril A - Ignition B - Chrging & Strting System C - Timing, Synhronizing & Adjusting D - Wiring Digrms Setion 3 - Fuel System A - Fuel Pump B - Cruretor C - Emissions Setion 4 - Powerhed A - Cylinder Hed B - Cylinder Blok/Crnkse Setion 5 - Mid-Setion A - Clmp/Swivel Brkets & Drive Shft Housing Setion 6 - Lower Unit Setion 7 - Atthments/Control Linkge A - Shift Linkge B - Tiller Hndle Setion 8 - Mnul Strter Setion 9 - Color Digrms Importnt Informtion Eletril Fuel System Powerhed Mid-Setion Lower Unit Atthment/Control Linkge Mnul Strter Color Digrms R1 MAY 2000 Pge iii

5 Tle of Contents IMPORTANT INFORMATION Setion 1A - Speifitions SPECIFICATIONS 1 A Speifitions A-1 Propeller Informtion Chrts A-8 Speifitions HORSEPOWER (kw) OUTBOARD WEIGHT FUEL OIL Model 4 Model 5 Model 6 Short Shft Long Shft RECOMMENDED GASOLINE Model 4/5/6 (4-Stroke) ENGINE OIL CAPACITY ENGINE OIL SAE SAE F C 25W-40 10W hp (2.9 kw) 5 hp (3.7 kw) 6 hp (4.4 kw) 55 ls. (25.0 kg) 57 ls. (26.0 kg) Automotive Unleded with Minimum Pump Posted Otne Rting of 87 Either 15 fl oz. or 450 ml. SAE 10W-30 visosity oil is reommended for use in ll tempertures. SAE 25W-40 visosity oil my e used t tempertures ove 40 F (4 C). Use Quiksilver 4-Cyle Mrine Oil with the proper visosity for the expeted temperture in your re (see rnge thermometer on left). If not ville, use premium qulity 4-yle engine oil, ertified to meet or exeed nyone of the following Amerin Petroleum Institute (API) servie lssifitions SH, SG, SF, CF-4, CE, CD, CDll. CHARGING SYSTEM Redings 68 F (20 C). STARTING SYSTEM Alterntor (Optionl) Type: Lighting Coil Lighting Coil Resistne Bttery Chrging Retifier (Optionl) Mnul Strt 12 Volt 60 Wtt (Non Regulted Lighting Coil) Ω (YEL/RED - YEL/RED) 2 Amperes (Retified) Reoil Strter R1 MAY 2000 Pge 1A-1

6 SPECIFICATIONS IGNITION SYSTEM Redings 68 F (20 C). CARBURETOR Type Sprk Plug: Type Gp Hex Size Torque Firing Order Ignition Timing: (Fixed) Cpitor Chrge Coil Resistne Trigger Coil Resistne Ignition Coil Resistne: Primry Seondry (W/o Boots) Sprk Plug Boot Engine Speed Limiter Oil Pressure Swith (Red Light) Idle rpm (Out Of Ger) Idle rpm (In Forwrd Ger) Wide Open Throttle rpm (WOT) 4/5 (1999 & 2000) 4/5/6 (2001 & Newer) Pilot (Idle Mixture) Srew 4/5/6 (1999 & 2000) Europen Models Only 2001 & Newer All Other Models Non-Adjustle Venturi Bore Dimeter 4/5 6 Min Jet Size 4/5 (1999 & 2000) 4 (2001 & Newer) 5 (2001 & Newer) 6 (2000 & Newer) 4 (Bodensee) 5 (Bodensee) 6 (Bodensee) Pilot Jet 4 (1999 & 2000) 5 (1999 & 2000) 4/5 (2001 & Newer) 6 (2000 & Newer) 4/5 (Bodensee) 6 (Bodensee) Flot Height Cpitor Dishrge Ignition NGK DCPR6E in. (0.9 mm) 5/8 in. (16 mm) 13 l-ft. (17.5 Nm) 1 25 ± 1 B.T.D.C Ω (WHT - BLK/RED) Ω (RED/WHT - BLK) Ω Ω Ω 6300 ± 200 RPM Continuity Below 3.5 psi ± 0.7 psi (24.5 ± 5 kp) 1300 ± 50 rpm 1100 ± 50 rpm ± 1/2 Turns Out 2-1/8 ± 1/2 Turns Out 1-1/2 ± 1/2 Turns Out 2-3/4 ± 1/2 Turns Out 13.5 mm 15 mm #70 #58 #65 #75 #55 #62 #68 #40 #42 #38 #45 #38 # in. (9-10 mm) Pge 1A R1 MAY 2000

7 FUEL SYSTEM CYLINDER BLOCK Fuel Pump Type Fuel Pump: Pressure Plunger Stroke Diphrgm Stroke Fuel Tnk Cpity Type Displement Numer of Cylinders SPECIFICATIONS Externl (Plunger/Diphrgm) psi (17-35 kp) in. (1.5 mm) in. (1.5 mm) 3.2 US Gllons 4 Stroke Cyle Over Hed Vlve 7.5 u. in. (123 ) 1 STROKE Length 1.77 in. (45 mm) CYLINDER BORE PISTON PISTON CLEARANCE RINGS COMPRESSION RATIO Dimeter Stndrd Oversize in. (0.50 mm) Tper/Out of Round Mximum Bore Type Piston Type O.D. t Skirt Stndrd Oversize in. (0.50 mm) Piston to Cylinder Clerne Piston Clerne Limit Ring End Gp (Instlled) Top Middle Bottom (Oil Ring) Side Clerne: Top Middle Bottom (Oil Ring) Compression Rtio With Deompression 4/5 (1999 & 2000) 4/5 (2001 & Newer) 6 (2000 & Newer) in. (59.00 mm) in. (59.50 mm) in. (0.076 mm) Steel Aluminum in. ( mm) in. ( mm) in. ( mm) in. (0.15 mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) 8.5:1 42 psi ± 14 psi (0.29 ± 0.1 MP) 9.5:1 42 psi ± 14 psi (0.29 ± 0.1 MP) PISTON PIN CONNECTING ROD Outer Dimeter Dimeter of Piston Pin Hole Clerne etween Piston Pin nd Piston Pin Hole Oil Clerne (Big End) Side Clerne (Big End) Smll End Inside Dimeter in. (16.00 mm) in. ( mm) in. (0.002 mm mm) in. ( mm) in. ( mm) in. (16.01 mm) R1 MAY 2000 Pge 1A-3

8 SPECIFICATIONS CRANKSHAFT Crnkshft Runout Dimeter of Crnk Pin (A) Outer Dimeter of Crnkshft in Oil Pn Bering (B) A B Less thn in. (0.05 mm) in. ( mm) in. ( mm) CAMSHAFT Cmshft Dimensions Intke/Exhust A 4 (1999 & 2000) 5 (1999 & 2000) 6 (2000) 4/5/6 (2001 & Newer) Bering Dimeter B A in. (25.24 mm) in. (26.59 mm) in. (28.33 mm) in. (28.33 mm) in. (13.98 mm) B Inside Dimeter of Oil Pn Bering: Crnkshft A Cmshft B B A in. (25.01 mm) in. (14.01 mm) OIL PAN Crnkshft to Oil Pn Bering Clerne Cmshft to Oil Pn Bering Clerne in. ( mm) in. ( mm) Pge 1A R1 MAY 2000

9 SPECIFICATIONS Free Length (Intke/Exhust) Tilt Limit (Intke/Exhust) 4/5 (1999) 4/5/6 (2000 & Newer) = in. (32.0 mm) = in. (1.12 mm) = in. (35.0 mm) = in. (1.12 mm) VALVE SPRING Compressed Pressure (Instlled) Intke/Exhust: Closed Height in. (24.4 mm) 4/5 (1999 & 2000) 6 (2000) 4/5/6 (2001 & Newer) Open Height in. (17.4 mm) 4/5 (1999 & 2000) 6 (2000) 4/5/6 (2001 & Newer) Diretion of Winding (Intke/Exhust) Wrp Limit * 17 lf. (7.7 kgf) 24 lf. (10.8 kgf) 24 lf. (10.8 kgf) 31 lf. (14.0 kgf) 39.4 lf. (17.9 kgf) 39.4 lf. (17.9 kgf) Right Hnd in. (0.03 mm) CYLINDER HEAD * Lines indite stright edge mesurement Vlve Dimensions B C D A Hed Dimeter Fe Width Set Width Mrgin Thikness R1 MAY 2000 Pge 1A-5

10 SPECIFICATIONS VALVES Vlve/Vlve Set/Vlve Guides: Vlve Clerne (old) Intke Exhust Vlve Dimensions: A Hed Dimeter Intke Exhust B Fe Width Intke Exhust C Set Width Intke Exhust D Mrgin Thikness Intke Exhust Stem Outside Dimeter Intke Exhust Guide Inside Dimeter Intke Exhust Stem To Guide Clerne Intke Exhust Stem Run-out Limit (mx.) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. (2.6 mm) in. (2.6 mm) in. (0.8 mm) in. (0.8 mm) in. (0.7 mm) in. (1.2 mm) in. (5.48 mm) in. (5.44 mm) in. (5.5 mm) in. (5.5 mm) in. ( mm) in. ( mm) in. (0.016 mm) THERMOSTAT Vlve Opening Temperture Full Open Temperture Vlve Lift (Minimum) 122 F F (50 C - 54 C) 145 F F (63 C - 67 C) 0.12 in. (3 mm) Pge 1A R1 MAY 2000

11 LUBRICATION SYSTEM Pump Type Engine Oil Pressure* (Wrm rpm Engine Oil Pn Cpity Oil Pump Clerne: Inner Rotor to Outer Rotor A Outer Rotor to Body B Rotor to Body (Side) C Height of Outer Rotor D Relief Vlve Operting Pressure* D Trohoid SPECIFICATIONS 4.0 psi (0.03 MP) Minimum 21.0 psi (0.15 MP) Minimum 0.95 pt (450 ml) in. (0.15 mm) or Less in. ( mm) in. ( mm) in. (5.99 mm) psi ( kg/m 2 ) kp A C B MID-SECTION GEAR HOUSING (2.15:1) Trnsom Height - Short Shft - Long Shft Steering Pivot Rnge Tilt Pin Positions Totl Tilt Angle Tilt Angle Shllow Wter Tilt Angle Allowle Trnsom Thikness Ger Rtio Gerse Cpity Lurint Type Forwrd Ger Numer of Teeth Pinion Ger Numer of Teeth Pinion Height Forwrd Ger Bklsh Wter Pressure 1300 rpm (Idle) 5000 rpm 17 in. (38 m) 22 in. (51 m) in. (55 mm) 2.15:1 6.5 fl oz (195 ml) Quiksilver Ger Lue-Premium Blend 28 Spirl/Bevel 13 Spirl/Bevel Floting No Adjustment psi (16-25 kp) 8-15 psi ( kp) * Oil pressure speifitions listed were otined with oil t 165 F (75 C) Wter pressure redings will vry with thermostt opertion R1 MAY 2000 Pge 1A-7

12 SPECIFICATIONS Propeller Informtion Chrts Merury/Mriner 4 (4-Stroke) Wide Open Throttle RPM : Reommended Trnsom Heights : 15, 20 Right Hnd Rottion Stndrd Ger Redution : 2.15:1 Approx. Gross Bot Wgt. (ls) Approx. Bot Length Speed Rnge (mph) Dimeter Pith No. of Bldes Mteril Propeller Prt Numer 8-3/8 9 3 Alum Up to 400 Up to T1 8-3/8 8 3 Alum /8 7 3 Alum * 8-3/8 6 3 Alum /8 6 3 Alum Silot A1 Merury/Mriner 5 (4-Stroke) Wide Open Throttle RPM : Reommended Trnsom Heights : 15, 20 Right Hnd Rottion Stndrd Ger Redution : 2.15:1 Approx. Gross Bot Wgt. (ls) Approx. Bot Length Speed Rnge (mph) Dimeter Pith No. of Bldes Mteril Propeller Prt Numer 8-3/8 9 3 Alum Up to 500 Up to T1 8-3/8 8 3 Alum * 8-3/8 7 3 Alum /8 6 3 Alum /8 6 3 Alum Silot A1 Merury/Mriner 6 (4-Stroke) Wide Open Throttle RPM : Reommended Trnsom Heights : 15, 20 Right Hnd Rottion Stndrd Ger Redution : 2.15:1 Approx. Gross Bot Wgt. (ls) Approx. Bot Length Speed Rnge (mph) Dimeter Pith No. of Bldes Mteril Propeller Prt Numer 8-3/8 9 3 Alum Up to 500 Up to T1 8-3/8 8 3 Alum * 8-3/8 7 3 Alum /8 6 3 Alum /8 6 3 Alum Silot A1 *Stndrd propeller shipped with outord. Pge 1A R1 MAY 2000

13 Tle of Contents IMPORTANT INFORMATION Setion 1B - Mintenne MAINTENANCE 1 B Tle of Contents B-1 Speifitions B-1 Ger Cse Lurint Cpity B-1 Speil Tools B-1 Quiksilver Lurint/Selnt B-2 Inspetion nd Mintenne Shedule B-3 Before Eh Use B-3 After Eh Use B-3 Every 100 Hours of Use or One Yerly, Whihever Ours First B-3 Flushing The Cooling System B-4 Fuel System B-4 Fuel Line Inspetion B-4 Engine Fuel Filter B-4 Corrosion Control Anode B-5 Sprk Plug Inspetion B-5 Lurition Points B-6 Chnging Engine Oil B-8 Engine Oil Cpity B-8 Oil Chnging Proedure B-8 Oil Filling B-8 Ger Cse Lurition B-9 Ger Cse Lurint Cpity B-9 Drining Ger Cse B-9 Cheking Lurint Level nd Refilling Ger Cse B-10 Storge Preprtions B-10 Fuel System B-10 Proteting Externl Engine Components B-10 Proteting Internl Engine Components B-11 Ger Cse B-11 Positioning Outord for Storge B-11 Speifitions Ger Cse Lurint Cpity Ger Cse Rtio Cpity Speil Tools 1. Grese Gun A1 2.15:1 6.6 fl oz. (195.0 ml) R1 MAY 2000 Pge 1B-1

14 MAINTENANCE Quiksilver Lurint/Selnt 1. Quiksilver Anti-Corrosion Grese P/N A C Mrine Lurint with Teflon P/N A1 3. SAE 10-30W Motor Oil P/N A1 4. Quiksilver Ger Lurint P/N A24 Pge 1B R1 MAY 2000

15 Inspetion nd Mintenne Shedule MAINTENANCE Before Eh Use After Eh Use 1. Chek engine oil level. 2. Visully inspet the fuel system for deteriortion or leks. 3. Chek outord for tightness on trnsom. 4. Chek propeller ldes for dmge. 1. Flush out the outord ooling 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 se with fresh wter if operting in slt wter. Every 100 Hours of Use or One Yerly, Whihever Ours First 1. Lurite ll lurition points. Lurite more frequently when used in slt wter. 2. Chnge engine oil. The oil should e hnged more often when the engine is operted under dverse onditions suh s extended trolling. 3. Inspet nd len sprk plugs. 4. Chek fuel line filter for ontminnts. 5. Chek orrosion ontrol node. Chek more frequently when used in slt wter. 6. Drin nd reple ger se lurint. 7. Lurite splines on the drive shft. 8. Chek tightness of olts, nuts, nd other fsteners. 9. Reple wter pump impeller. These items should e servied y n uthorized deler R1 MAY 2000 Pge 1B-3

16 MAINTENANCE Flushing The Cooling System Flush the internl wter pssges of the outord with fresh wter fter eh use in slt, polluted, or muddy wter. This will help prevent uildup of deposits from logging the internl wter pssges. NOTE: Do not run the engine while flushing the ooling system. 1. Remove plug nd gsket nd thred-in hose oupling. 2. Atth wter hose to the hose oupling. Turn on the wter gently nd flush the ooling system for 3 to 5 minutes. 3. Remove the thred-in hose oupling nd reinstll plug nd gsket. Fuel System Fuel Line Inspetion Engine Fuel Filter -Plug nd Gsket - Hose Coupling WARNING Avoid serious injury or deth from gsoline fire or explosion. Crefully follow ll fuel system servie instrutions. Alwys stop the engine nd DO NOT smoke or llow open flmes or sprks in the re while serviing ny prt of the fuel system. Before serviing ny prt of the fuel system, stop engine nd disonnet the ttery. Drin the fuel system ompletely. Use n pproved ontiner to ollet nd store fuel. Wipe up ny spillge immeditely. Mteril used to ontin spillge must e disposed of in n pproved reeptle. Any fuel system servie must e performed in well ventilted re. Inspet ny ompleted servie work for sign of fuel lekge. Visully inspet the fuel line nd primer ul for rks, swelling, leks, hrdness or other signs of deteriortion or dmge. If ny of these onditions is found, the fuel line or primer ul must e repled. Inspet the fuel line filter. If the filter ppers to e ontminted, remove nd reple. Pge 1B R1 MAY 2000

17 Corrosion Control Anode MAINTENANCE Your outord hs orrosion ontrol node instlled to the ger se. An node helps protet the outord ginst glvni orrosion y srifiing its metl to e slowly eroded insted of the outord metls. The node requires periodi inspetion espeilly in slt wter whih will elerte the erosion. To mintin this orrosion protetion, lwys reple the node efore it is ompletely eroded. Never pint or pply protetive oting on the node s this will redue effetiveness of the node. -Anode Sprk Plug Inspetion Inspet sprk plugs t the reommended intervls. 1. Remove the sprk plug leds y twisting the ruer oots slightly nd pull off. 2. Remove the sprk plugs to inspet nd len. Reple sprk plug if eletrode is worn or the insultor is rough, rked, roken, listered or fouled. 3. Set the sprk plug gp. See Speifition Chrt in Generl Informtion Setion. 4. Before reinstlling sprk plugs, len wy dirt on the sprk plug sets. Instll plugs finger tight, nd tighten 1/4 turn or torque to 13 l-ft (17.5 Nm) R1 MAY 2000 Pge 1B-5

18 MAINTENANCE Lurition Points Lurite Points 1 thru 5 with Quiksilver 2-4-C with Teflon Mrine Lurint or Speil Lurint Co-Pilot Lurite threds. 2. Swivel Brket Lurite fitting. 3. Trnsom Clmp Srews Lurite threds. NOTE: Luriting points 4 nd 5 require disssemly of the produt. These points should e lurited t lest one yer y n uthorized deler. 4. Tiller Hndle Ruer Bushing Lurite internl dimeter. 5. Shift Hndle Detent Lurite detent. Pge 1B R1 MAY 2000

19 Lurite Point 6 with Light Weight Oil 6. Tilt Pivot. MAINTENANCE Lurite Point 7 with Quiksilver Anti-Corrosion Grese or 2-4-C with Teflon Mrine Lurint. 7. Propeller Shft Refer to Propeller Replement for removl nd instlltion of the propeller. Cot the entire propeller shft with lurint to prevent the propeller hu from orroding to the shft R1 MAY 2000 Pge 1B-7

20 MAINTENANCE Chnging Engine Oil ENGINE OIL CAPACITY 15 fl oz. (450 ml) OIL CHANGING PROCEDURE 1. Ple outord in n upright slightly tilted position. 2. Turn the steering on the outord to gin ess to the drin plug. Remove drin plug nd drin engine oil into n pproprite ontiner. Lurite the sel on the drin plug with oil nd reinstll. OIL FILLING -Drin Plug IMPORTANT: Inspet oil for signs of ontmintion. Oil ontminted with wter will hve milky olor to it; oil ontminted with fuel will smell strongly of fuel. If ontminted oil is notied, hve the engine heked y your deler. IMPORTANT: Do not overfill. Be sure tht the outord is upright (not tilted) when heking oil. Remove the oil fill p nd refill with 15 fl oz. (450 ml) of oil. Reinstll the oil fill p. Idle engine for five minutes nd hek for leks. Stop engine nd hek oil level on dipstik. Add oil if neessry. Pge 1B R1 MAY 2000

21 Ger Cse Lurition MAINTENANCE Ger Cse Lurint Cpity Drining Ger Cse Ger Cse Rtio Cpity 2.15:1 6.6 fl oz. (195 ml) When dding or hnging ger se lurint, visully hek for the presene of wter in the lurint. If wter is present, it my hve settled to the ottom nd will drin out prior to the lurint, or it my e mixed with the lurint, giving it milky olored pperne. If wter is notied, hve the ger se heked y your deler. Wter in the lurint my result in premture ering filure or, in freezing tempertures, will turn to ie nd dmge the ger se. Also exmine the ger se lurint for metl prtiles. A smll mount of metl filings or fine metl prtiles indites norml ger wer. An exessive mount of metl filings or lrger prtiles (hips) my indite norml ger wer nd should e heked y n uthorized deler. 1. Ple outord in vertil operting position. 2. Ple drin pn elow outord. 3. Remove fill/drin plug nd vent plug nd drin lurint. -Fill/Drin Plug - Vent Plug R1 MAY 2000 Pge 1B-9

22 MAINTENANCE Cheking Lurint Level nd Refilling Ger se 1. Ple outord in vertil operting position. 2. Remove vent plug. 3. Ple lurint tue into the fill hole nd dd lurint until it ppers t the vent hole. 4. Stop dding lurint. Instll the vent plug nd seling wsher efore removing the lurint tue. 5. Remove lurint tue nd reinstll lened fill/drin plug nd seling wsher. Storge Preprtions Fuel System d -Vent Plug/Seling Wsher - Lurint Tue -Vent Hole d- Fill/Drin Plug nd Seling Wsher IMPORTANT: Gsoline ontining lohol (ethnol or methnol) n use formtion of id during storge nd n dmge the fuel system. If the gsoline eing used ontins lohol, it is dvisle to drin s muh 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 injetion systems) with treted (stilized) fuel to help prevent formtion of vrnish nd gum. Proeed with following instrutions. 1. Portle Fuel Tnk Pour the required mount of Quiksilver Gsoline Stilizer (follow instrutions on ontiner) into fuel tnk. Tip fuel tnk k nd forth to mix stilizer with the fuel. 2. Permnently Instlled Fuel Tnk Pour the required mount of Quiksilver Gsoline Stilizer (follow instrutions on ontiner) into seprte ontiner nd mix with pproximtely one qurt (one liter) of gsoline. Pour this mixture into fuel tnk. 3. Ple the outord in wter or onnet flushing tthment for irulting ooling wter. Run the engine for ten minutes to llow treted fuel to fill the fuel system. Proteting Externl Engine Components 1. Lurite ll outord omponents listed in the Inspetion nd Mintenne Shedule. 2. Touh up ny pint niks. 3. Spry Quiksilver Corrosion Gurd on externl metl surfes (exept orrosion ontrol nodes). Pge 1B R1 MAY 2000

23 Proteting Internl Engine Components Ger Cse MAINTENANCE NOTE: Before performing Steps 1 nd 2, mke sure the fuel system hs een prepred for storge. 1. Chnge the engine oil. 2. Ple the outord in wter or onnet flushing tthment for irulting ooling wter. Strt the engine nd let it run in neutrl to wrm up. 3. With engine running t fst idle, stop the fuel flow y disonneting the remote fuel line. When engine egins to stll, quikly spry Quiksilver Storge Sel into ruretor until engine stops from lk of fuel. 4. Remove the sprk plugs nd injet five seond spry of Quiksilver Storge Sel round the inside of eh ylinder. 5. Rotte the flywheel mnully severl times to distriute the storge sel in the ylinders. Reinstll sprk plugs. Drin nd refill the ger se lurint (refer to mintenne proedure). Positioning Outord for Storge 1. Crry, trnsport or store the outord only in these two positions. These positions will prevent oil from drining out of the rnkse.. Upright. Tiller Side Down 2. Never rry, store or trnsport the outord in these positions. Engine dmge ould result from oil drining out of the rnkse. CAUTION If outord is on ot nd is stored tilted up in freezing temperture, trpped ooling wter or rin wter tht my hve entered the propeller exhust outlet in the ger se ould freeze nd use dmge to the outord R1 MAY 2000 Pge 1B-11

24 Tle of Contents IMPORTANT INFORMATION Setion 1C - GENERAL INFORMATION GENERAL INFORMATION 1 C Seril Numer Lotion C-2 Conditions Affeting Performne C-2 Wether C-2 Bot C-3 Engine C-5 Following Complete Sumersion C-6 Sumerged While Running C-6 Slt Wter Sumersion C-6 Fresh Wter Sumersion C-6 Propeller Seletion C-7 Propeller Removl/Instlltion C-8 Compression Chek C-10 Cylinder Lekge Testing C-11 Anlysis C-11 Pinting Proedures C-12 Clening & Pinting Aluminum Propellers & Ger Housings C-12 Del Applition C-13 Del Removl C-13 Instrutions for Wet Applition C R1 MAY 2000 Pge 1C-1

25 GENERAL INFORMATION Seril Numer Lotion The Outord seril numer is loted on the lower strord side of the engine lok. A seril numer is lso loted on the top side of the swivel rket. OGXXXXXX 19XX XXXX -Seril Numer -Model Yer -Model Desription d-yer Mnuftured e -Certified Europe Insigni Conditions Affeting Performne Wether e XX d Rted hp Summer hp Horsepower Loss Due to Atmosphere Conditions Seondry Loss Due to Propeller Beoming To Lrge for Summer Horsepower RPM Drop Due to Wether ENGINE RPM Rted RPM It is known ft tht wether onditions exert profound effet on power output of internl omustion engines. Therefore, estlished horsepower rtings refer to the power tht the engine will produe t its rted rpm under speifi omintion of wether onditions. 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 omputtion of horsepower from dt otined on the dynmometer, orreting ll vlues to the power tht the engine will produe t se level, t 30% reltive humidity t 77 F (25 C) temperture nd rometri pressure of inhes of merury. Pge 1C R1 MAY 2000

26 Bot GENERAL INFORMATION Summer Conditions of high temperture, low rometri pressure nd high humidity ll omine to redue the engine power. This, in turn, is refleted in deresed ot speeds--s muh s 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some ses. (Refer to previous hrt.) Nothing will regin this speed for the oter, ut the oming of ool, dry wether. In pointing out the prtil onsequenes of wether effets, n engine--running on hot, humid summer dy--my enounter loss of s muh s 14% of the horsepower it would produe on dry, risk spring or fll dy. The horsepower, tht ny internl omustion engine produes, depends upon the density of the ir tht it onsumes nd, in turn, this density is dependent upon the temperture of the ir, its rometri pressure nd wter vpor (or humidity) ontent. Aompnying this wether-inspired loss of power is seond ut more sutle loss. At rigging time in erly spring, the engine ws equipped with propeller tht llowed the engine to turn within its reommended rpm rnge t full throttle. With the oming of the summer wether nd the onsequent drop in ville horsepower, this propeller will, in effet, eome too lrge. Consequently, the engine opertes t less thn its reommended rpm. Due to the horsepower/rpm hrteristis of n engine, this will result in further loss of horsepower t the propeller with nother derese in ot speed. This seondry loss, however, n e regined y swithing to smller pith propeller tht llows the engine to gin run t reommended rpm. For oters to relize optimum engine performne under hnging wether onditions, it is essentil tht the engine hve the proper propeller to llow it to operte t or ner the top end of the reommended 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 ft tht the engine lso will e operting in n rpm rnge tht disourges dmging detontion. This, of ourse, enhnes overll reliility nd durility of the engine. WEIGHT DISTRIBUTION 1. Proper positioning of the weight inside the ot (persons nd ger) hs signifint effet on the ot s performne, for exmple:. Shifting weight to the rer (stern). (1.) Generlly inreses top speed. (2.) If in exess, n use the ot to porpoise. (3.) Cn mke the ow oune exessively in hoppy wter. (4.) Will inrese the dnger of the following - wve splshing into the ot when oming off plne.. Shifting weight to the front (ow).. Adjusting tilt pin to hieve est performne nd hndling. (1.) Improves ese of plning off. (2.) Generlly improves rough wter ride. (3.) If exessive, n mke the ot veer left nd right (ow steer). BOTTOM For mximum speed, ot ottom should e nerly flt plne where it ontts the wter nd prtiulrly stright nd smooth in fore-nd-ft diretion R1 MAY 2000 Pge 1C-3

27 GENERAL INFORMATION 1. Hook: Exists when ottom is onve in fore-nd-ft diretion when viewed from the side. When ot is plning, hook uses more lift on ottom ner trnsom nd llows ow to drop, thus gretly inresing wetted surfe nd reduing ot speed. Hook frequently is used y supporting ot too fr hed of trnsom while huling on triler or during storge. 2. Roker: The reverse of hook nd muh less ommon. Roker exists if ottom is onvex in fore-nd-ft diretion when viewed from the side, nd ot hs strong tendeny to porpoise. 3. Surfe Roughness: Moss, rnles, et., on ot or orrosion of outord s ger housing inrese skin frition nd use speed loss. Clen surfes when neessry. WATER ABSORPTION It is impertive tht ll through hull fsteners e oted with qulity mrine seler t time of instlltion. Wter intrusion into the trnsom ore nd/or inner hull will result in dditionl ot weight (redued ot performne), hull dey nd eventul struturl filure. CAVITATION Cvittion is used y wter vpor ules forming either from shrp edge or ngle on the ger se, from n irregulrity in the propeller lde itself or from improper engine instlltion (too high). These vpor ules flow k nd ollpse when striking the surfe of the propeller lde resulting in the erosion of the propeller lde surfe. If llowed to ontinue, eventul lde filure (rekge) will our. Pge 1C R1 MAY 2000

28 Engine DETONATION GENERAL INFORMATION Detontion in 4-yle engine resemles the pinging herd in n utomoile engine. It n e otherwise desried s tin-like rttling or plinking sound. Detontion is n explosion of n unurned portion of the fuel/ir hrge fter the sprk plug hs fired. Detontion retes severe shok wves in the engine, nd these shok wves often find or rete wekness: The dome of piston, ylinder hed/gsket, piston rings or piston ring lnds, piston pin nd erings. A few of the most ommon uses of detontion in mrine 4-yle pplition re s follows: Over-dvned ignition timing. Use of low otne gsoline. Propeller pith too high (engine rpm elow reommended mximum rnge). Len fuel mixture t or ner wide-open-throttle. Sprk plugs (het rnge too hot - inorret reh - ross-firing). Indequte engine ooling (deteriorted ooling system). Comustion hmer/piston deposits (result in higher ompression rtio). Detontion usully n e prevented if: 1. The engine is orretly set up. 2. Diligent mintenne is pplied to omt the detontion uses. Dmged Piston Resulting from Detontion R1 MAY 2000 Pge 1C-5

29 GENERAL INFORMATION Following Complete Sumersion Sumerged While Running (Speil Instrutions) When n engine is sumerged while running, the possiility of internl engine dmge is gretly inresed. If, fter engine is reovered nd with sprk plugs removed, engine fils to turn over freely when turning flywheel, the possiility of internl dmge (ent onneting rod nd/or ent rnkshft) exists. If this is the se, the powerhed must e disssemled. Slt Wter Sumersion (Speil Instrutions) Due to the orrosive effet of slt wter on internl engine omponents, omplete disssemly is neessry efore ny ttempt is mde to strt the engine. Fresh Wter Sumersion (Speil Instrutions) 1. Reover engine s quikly s possile. 2. Remove owling. 3. Flush exterior of outord with fresh wter to remove mud, weeds, et. DO NOT ttempt to strt engine if snd hs entered powerhed, s powerhed will e severely dmged. Disssemle powerhed if neessry to len omponents. 4. Drin engine oil. Do not refill engine oil t this time. 5. Drin ruretor nd len fuel pump ssemly. 6. Remove sprk plug nd get s muh wter s possile out of powerhed. Most wter n e eliminted y pling engine in horizontl position (with sprk plug holes down) nd rotting flywheel. 7. Pour lohol into ruretor throt (lohol will sored wter). Agin rotte flywheel. 8. Turn engine over nd pour lohol into sprk plug opening nd rotte flywheel. 9. Turn engine over (ple sprk plug openings down) nd pour engine oil into throt of ruretor while rotting flywheel to distriute oil throughout rnkse. 10. Agin turn engine over nd pour pproximtely one tespoon of engine oil into sprk plug opening. Agin rotte flywheel to distriute oil in ylinder. 11. Dry ll wiring nd eletril omponents using ompressed ir. 12. Reinstll sprk plug. 13. Refill engine rnkse with fresh oil. 14. Attempt to strt engine, using fresh fuel soure. If engine strts, it should e run for t lest one hour to eliminte ny wter in engine. 15. If engine fils to strt, determine use (fuel, eletril or mehnil). Engine should e run within 2 hours fter reovery of outord from wter, or serious internl dmge my our. If unle to strt engine in this period, disssemle engine nd len ll prts. Apply oil s soon s possile. Pge 1C R1 MAY 2000

30 Propeller Seletion GENERAL INFORMATION For in-depth informtion on mrine propellers nd ot performne - written y mrine engineers - see your Authorized Deler for the illustrted Wht You Should Know Aout Quiksilver Propellers...nd Bot Performne Informtion (Prt No ). For est ll round performne from your outord/ot omintion, selet propeller tht llows the engine to operte in the upper hlf of the reommended full throttle rpm rnge with the ot normlly loded (refer to Speifitions). This rpm rnge llows for etter elertion while mintining mximum ot speed. If hnging onditions use the rpm to drop elow the reommended rnge (suh s wrmer, more humid wether, opertion t higher elevtions, inresed ot lod or dirty ot ottom/ger se) propeller hnge or lening my e required to mintin performne nd ensure the outord s durility. Chek full-throttle rpm using n urte thometer with the engine trimmed out to lned-steering ondition (steering effort equl in oth diretions) without using the propeller to rek loose. Refer to Quiksilver Aessory Guide for omplete list of ville propellers. 1. Selet propeller tht will llow the engine to operte t or ner the top of the reommended full throttle rpm rnge (listed in Speifitions, preeding) with norml lod. Mximum engine speed (rpm) for propeller seletion exists when ot speed is mximum nd trim is minimum for tht speed. (High rpm, used y n exessive trim ngle, should not e used in determining orret propeller.) Normlly, there is rpm hnge etween propeller pithes. 2. If full throttle opertion is elow the reommended rnge, the propeller MUST BE hnged to one with lower pith to prevent loss of performne nd possile engine dmge. 3. After initil propeller instlltion, the following ommon onditions my require tht the propeller e hnged to lower pith:. Wrmer wether nd gret humidity will use n rpm loss.. Operting in higher elevtion uses n rpm loss.. Operting with dmged propeller or dirty ot ottom or ger housing will use n rpm loss. d. Opertion with n inresed lod (dditionl pssengers, equipment, pulling skiers, et.) R1 MAY 2000 Pge 1C-7

31 GENERAL INFORMATION Propeller Removl/Instlltion WARNING If the propeller shft is rotted while the engine is in ger, there is the possiility tht the engine will rnk over nd strt. To prevent this type of identl engine strting nd possile serious injury used from eing struk y rotting propeller, lwys shift outord to neutrl position nd remove sprk plug leds when you re serviing the propeller 1. Remove the sprk plug leds to prevent engine from strting. 2. Shift outord to neutrl position. N 3. Strighten nd remove otter pin. -Cotter Pin 4. Ple lok of wood etween ger se nd propeller to hold propeller nd remove propeller nut. -Blok of Wood -Propeller Nut Pge 1C R1 MAY 2000

32 GENERAL INFORMATION 5. Pull propeller stright off shft. If propeller is seized to the shft nd nnot e removed, hve the propeller removed y n uthorized deler. -Propeller -Propeller Nut 6. Cot the propeller shft with Quiksilver Anti-Corrosion Grese or 2-4-C Mrine Lurint with Teflon. IMPORTANT: To prevent the propeller hu from orroding nd seizing to the propeller shft, espeilly in slt wter, lwys pply ot of the reommended lurint to the entire propeller shft t the reommended mintenne intervls nd lso eh time the propeller is removed. 7. Instll front thrust wsher, propeller, rer thrust hu nd propeller nut onto the shft. 8. Ple lok of wood etween ger se nd propeller to prevent rottion nd tighten propeller nut. Seure propeller nut to the shft with otter pin. e d -Front Thrust Wsher -Propeller -Rer Thrust Hu d-propeller Nut e -Cotter Pin R1 MAY 2000 Pge 1C-9

33 GENERAL INFORMATION Compression Chek 1. Remove sprk plugs. 2. Instll ompression guge in sprk plug hole. 3. Hold throttle plte t W.O.T. 4. Crnk the engine over until the ompression reding peks on the guge. Reord the reding. 5. Chek nd reord ompression of ylinder. A reding elow 36 psi might indite totl engine wer prolem. Mximum (psi)* Minimum (psi)* *Compression listed ove is with deompression ssemly in opertion. Mximum (psi)* Minimum (psi)* *Compression listed ove is with deompression ssemly not in opertion. (Roker rm on exhust side is removed) 6. Compression hek is importnt euse n engine with low ompression nnot e tuned suessfully to give pek performne. It is essentil, therefore, tht improper ompression e orreted efore proeeding with n engine tuneup. 7. Cylinder soring: If powerhed shows ny indition of overheting, suh s disolored or sorhed pint, visully inspet ylinder for soring or other dmge s outlined in Setion 4 Powerhed. Pge 1C R1 MAY 2000

34 Cylinder Lekge Testing GENERAL INFORMATION NOTE: Cylinder lekge testing*, long with ompression testing, n help the mehni pinpoint the soure of mehnil filure y guging the mount of lekge in n engine ylinder. Refer to the mnuftures tester instrutions for proper testing proedures. * Courtesy of Snp-On-Tools Anlysis Cylinder Lekge Tester (Snp-On-Tools MT324) NOTE: Sprk plug hole is 12 mm dimeter. Use Snp-On Tool MT26-18 dpter with vlve ore removed. Due to stndrd engine tolernes nd engine wer, no ylinder will mintin 0% of lekge. It is importnt only tht ylinders hve somewht onsistent reding etween them. Differenes of 15 to 30% indite exessive lekge. Lrger engines tend to hve lrger perentge of ylinder lekge thn smller engines. If exessive lekge is present, first hek tht the piston is t top ded enter of it s ompression stroke. Lekge will nturlly our if the exhust or intke vlve is open. To determine the use of high perentge leks, you must lote where the ir is esping from. Listen for ir esping thru the ruretor intke, djent sprk plug holes, exhust pipe, rnkse fill plug. Use the following tle to id in loting the soure of ylinder lekge: Air Esping From: Cruretor Exhust System Crnkse Fill Plug Cylinder Indites Possile Defetive: Intke Vlve Exhust Vlve Piston or Rings Hed Gsket R1 MAY 2000 Pge 1C-11

35 GENERAL INFORMATION Pinting Proedures Clening & Pinting Aluminum Propellers & Ger Housings PROPELLERS WARNING Avoid serious injury from flying deris. Avoid serious injury from irorne prtiles. Use eye nd rething protetion with proper ventiltion. 1. Snd the entire re to e pinted with 3M 120 Reglite Polyut or orse Soth-Brite, dis or elts. 2. Fether edges of ll roken pint edges. Try not to snd through the primer. 3. Clen the surfe 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 Quiksilver s Light Gry Primer. 5. Allow minimum of 1 hour dry time nd no more thn 1 week efore pplying the finish ot. 6. Apply the finish ot using Quiksilver s EDP Propeller Blk. GEAR HOUSINGS The following proedures should e used in refinishing ger housings. This proedure will provide the most durle pint system ville in the field. The mterils reommended re of high qulity nd pproximte mrine requirements. The following proedure will provide repint jo tht ompres with properly pplied ftory pint finish. It is reommended tht the listed mterils e purhsed from lol Ditzler Automotive Finish Supply Outlet. The minimum pkge quntity of eh mteril shown following is suffiient to refinish severl ger housings. Proedure: 1. Wsh ger housing with muriti id se lener to remove ny type of mrine growth, nd rinse with wter, if neessry. 2. Wsh ger housing with sop nd wter, then rinse. 3. Snd listered re with 3M 180 grit sndpper or P180 Gold Film Dis 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 surfes 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 surfe nor will the oting e suffiiently thik to resist future pint listering. 6. Mix epoxy hromte primer (DP-40) with equl prt tlyst (DP-401) per mnufturers instrutions, llowing proper indution period for permetion of the epoxy primer nd tlyst. 7. Allow minimum of one hour drying time nd no more thn one week efore top oting ssemlies. 8. Use Ditzler Urethne DU9000 for Merury Blk, DU34334 for Mriner Grey, nd DU35466 for Fore Chrol, nd DU33414M for Se Ry White. Ctlyze ll four olors with Ditzler DU5 tlyst mixed 1:1 rtio. Redue with solvents per Ditzler lel. Pge 1C R1 MAY 2000

36 Del Applition Del Removl CAUTION GENERAL INFORMATION Be sure to omply with instrutions on the lel for ventiltion nd respirtors. Using spry gun, pply one hlf to one mil even film thikness. Let dry, flsh off for five minutes nd pply nother even ot of one hlf to one mil film thikness. This urethne pint will dry to the touh in mtter of hours, ut will remin sensitive to srthes nd rsions for few dys. 9. The type of spry gun used will determine the proper redution rtio of the pint. IMPORTANT: Do not pint srifiil zin trim t or zin node. 10. Cut out rdord plug for trim t poket to keep pint off of mting surfe to mintin good ontinuity iruitry etween trim t nd ger housing. 1. Mrk del lotion efore removl to ssure proper lignment of new del. 2. Crefully soften del nd del dhesive with het gun or het lower while removing old del. 3. Clen del ontt re with 1:1 mixture of isopropyl lohol nd wter. 4. Thoroughly dry del ontt re nd hek for ompletely lened surfe. Instrutions for Wet Applition NOTE: The following del instlltion instrutions re provided for Wet instlltion. All dels should e pplied wet. TOOLS REQUIRED 1. Plsti Squeegee* 2. Stik Pin 3. Dish Wshing Liquid/Detergent without mmoni** Joy nd Drift re known to e omptile for this proess. ** Automotive Body Filler Squeegee ** Do not use sop tht ontins petroleum sed solvents. SERVICE TIP: Plement of dels using the Wet pplition will llow time to position del. Red entire instlltion instrutions on this tehnique efore proeeding. TEMPERATURE IMPORTANT: Instlltion of vinyl dels should not e ttempted while in diret sunlight. Air nd surfe temperture should e etween 60 F (15 C) nd 100 F (38 C) for est pplition. SURFACE PREPARATION IMPORTANT: Do not use sop or ny petroleum sed solvents to len pplition surfe. Clen entire pplition surfe with mild dish wshing liquid nd wter. Rinse surfe thoroughly with len wter. DECAL APPLICATION 1. Mix 1 / 2 oune (16 ml) of dish wshing liquid in one gllon (4 l) of ool wter to use s wetting solution R1 MAY 2000 Pge 1C-13

37 GENERAL INFORMATION NOTE: Leve protetive msking, if present, on the fe of del until finl steps of del instlltion. This will ensure tht the vinyl del keeps it s shpe during instlltion. 2. Ple the del fe down on len work surfe nd remove the pper king from dhesive side of del. 3. Using spry ottle, flood the entire dhesive side of the del with the pre-mixed wetting solution. 4. Flood re where the del will e positioned with wetting solution. 5. Position pre-wetted del on wetted surfe nd slide into position. 6. Strting t the enter of the del, lightly squeegee out the ir ules nd wetting solution with overlpping strokes to the outer edge of the del. Continue going over the del surfe until ll wrinkles re gone nd dhesive onds to the owl surfe. 7. Wipe del surfe with soft pper towel or loth. 8. Wit minutes. 9. Strting t one orner, refully nd slowly pull the msking off the del surfe t 180 ngle. NOTE: To remove ny remining ules, piere the del t one end of the ule with stik pin nd press out the entrpped ir or wetting solution with your thum (moving towrd the punture). Pge 1C R1 MAY 2000

38 Tle of Contents IMPORTANT INFORMATION Setion 1D - Outord Motor Instlltion OUTBOARD MOTOR INSTALLATION 1 D Notie to Instller nd Owner D-2 Bot Horsepower Cpity D-2 Seleting Aessories For The Outord D-2 Instlling Outord D-3 Fstening Seurity Line D-4 Tilt Pin Adjustment D-4 Setting The Operting Angle Of Your Outord. 1D-4 Engine Over-Speed Protetion System D-5 Instlltion Drwings D R1 MAY 2000 Pge 1D-1

39 OUTBOARD MOTOR INSTALLATION Notie 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 speil sfety instrutions tht should e followed. DANGER DANGER Immedite hzrds whih WILL result in severe personl injury or deth. WARNING WARNING Hzrds or unsfe prties whih COULD result in severe personl injury or deth. CAUTION CAUTION Hzrds or unsfe prties whih ould result in minor injury or produt or property dmge. Bot Horsepower Cpity U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX Do not overpower or overlod your ot. Most ots will rry required pity plte inditing the mximum eptle power nd lod s determined y the mnufturer following ertin federl guidelines. If in dout, ontt your deler or the ot mnufturer. WARNING Using n outord tht exeeds the mximum horsepower limit of ot n: 1. use loss of ot ontrol 2. ple too muh weight t the trnsom ltering the designed flottion hrteristis of the ot or 3. use the ot to rek prt prtiulrly round the trnsom re. Overpowering ot n result in serious injury, deth, or ot dmge. Seleting Aessories For The Outord Genuine Merury Mrine Quiksilver Aessories hve een speifilly designed nd tested for your outord. Merury Mrine Quiksilver essories re ville from Merury Mrine delers. Some essories not mnuftured or sold y Merury Mrine re not designed to e sfely used with your outord or outord operting system. Aquire nd red the instlltion, opertion, nd mintenne mnuls for ll your seleted essories. Pge 1D R1 MAY 2000

40 Instlling Outord OUTBOARD MOTOR INSTALLATION 1. Mesure the trnsom height of your ot. The ot ottom should e ligned or e within 1 in. (25 mm) ove the nti-ventiltion plte of the outord. -Anti-Ventiltion Plte 1-2 in. (25-50 mm) 2. Ple outord on enter line of trnsom. 3. Tighten trnsom lmp hndles R1 MAY 2000 Pge 1D-3

41 OUTBOARD MOTOR INSTALLATION Fstening Seurity Line Tilt Pin Adjustment WARNING If the length of seurity line eing used is long enough to llow the outord to disengge off the ot trnsom ut is too short to not llow the outord to sumerge ehind the ot nd stop running, the outord ould ontinue running nd propel itself k into the ot with the propeller rotting under power. This exposes the oupnts to serious injury or deth. The primry purpose for instlling seurity line is to prevent loss of the outord if the outord eomes dethed from the ot trnsom. An effetive seurity line should e of working strength of t lest five times the weight of the outord. The seurity line should e tthed etween the ot nd outord following one of these steps. Step 1. The length of the seurity line should e short enough nd ffixed in mnner to prevent the outord from rising up nd disengging off the ot trnsom. Step 2. The length of the seurity line should e long enough nd ffixed in mnner to permit dethed outord to sumerge ompletely ehind the ot nd stop running ut not too short tht ould llow the outord to ontinue running nd propel itself k into the ot. Setting The Operting Angle Of Your Outord 1. The vertil operting ngle of your outord is djusted y hnging the position of the tilt pin in the djustment holes provided. Proper djustment llows the ot to run stle, hieve optimum performne, nd minimize steering effort. -Tilt Pin 2. The tilt pin should e djusted so the outord is positioned to run perpendiulr to the wter when the ot is running t full speed. This llows the ot to e driven prllel to the wter. 3. Arrnge pssengers nd lod in the ot so the weight is distriuted evenly. Pge 1D R1 MAY 2000