MID-SECTION. Table of Contents. Power Trim Specifications. Section 5B Power Trim Design I (Showa)

Transcription

1 MID-SECTION Setion 5B Power Trim Design I (Show) Tle of Contents POWER TRIM - DESIGN I Power Trim Speifitions B-1 Speil Tools B-2 Power Trim Components B-4 Power Trim Motor B-6 Power Trim - Generl Informtion B-7 Desription B-7 Trimming Chrteristis B-7 Trilering Outord B-8 Tilting Outord Mnully B-8 Trim In Angle Adjustment B-9 Striker Plte Replement B-9 Anode Plte B-10 Trim Inditor Guge B-10 Chek, Fill nd Purge - Power Trim System.. 5B-10 Trouleshooting B-12 Power Trim System with Relys nd 2 Wire Trim Motor B-14 Eletril System Trouleshooting B-15 Generl Cheks B-15 Trouleshooting the Down Ciruit B-15 Trouleshooting the Up Ciruit B-16 Trouleshooting the Down nd Up Ciruits (All Ciruits Inopertive) B-17 Power Trim Assemly Removl nd Instlltion. 5B-18 Removl B-18 Power Trim Speifitions Instlltion B-21 Testing Power Trim System With Test Guge Kit ( A6) B-23 UP Pressure Chek B-23 DOWN Pressure Chek B-26 Hydruli Repir B-28 Trim Rod End Cp Sel B-29 Tilt Rm B-30 Disssemly B-31 Srper Sel Replement B-34 Motor nd Eletril Tests/Repir B-38 Trim Pump Motor Test B-38 Motor Disssemly B-38 Armture Tests B-39 Motor Repir B-40 Ressemly B-44 Ressemly - Motor nd Pump B-46 Priming Power Trim System B-47 Trim Sender Test B-47 Trim Inditor Guge Needle Adjustment.... 5B-48 Trim Inditor Wiring Digrms B-49 5 B POWER TRIM Design I (Show) Trim UP Trim DOWN Lek Down Design I & II 1300 PSI (91kg/m 2 ) Mximum Pressure 500 PSI (35kg/m 2 ) Minimum Pressure Mximum Aeptle Amount of Lek Down in 24 hours is 1 in. (25.4 mm) R1 JUNE 2000 Pge 5B-1

2 Speil Tools 1. Alignment Tool Trim Rod Removl Tool A Trim Rod Guide Removl Tool A1 4. Power Trim Test Guge Kit A Pge 5B R1 JUNE 2000

3 5. Adptor Fitting A2 nd A3 POWER TRIM - DESIGN I 6. Spnner Wrenh Multi-Meter DVA Tester A1 or DMT 2000 Digitl Thometer Multi-meter A1 -Multi-Meter DVA Tester A1 -DMT 2000 Digitl Thometer Multi-meter A R1 JUNE 2000 Pge 5B-3

4 Power Trim Components Lotite 271 ( ) 94 Anti-Corrosion Grese ( A6) GM Silione Seler ( ) 110 Power Trim & Steering Fluid ( A12) Pge 5B R1 JUNE 2000

5 Power Trim Components TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 POWER TRIM ASSEMBLY Complete 1 1 MANIFOLD ASSEMBLY 2 9 PIPE PLUG 3 1 TILT CYLINDER ASSEMBLY 4 1 PISTON ROD 5 1 GUIDE KIT 6 1 REPAIR KIT 7 1 CHECK VALVE KIT 8 2 GUIDE ASSEMBLY 1 PISTON/ROD ASSEMBLY (PORT) 9 1 PISTON/ROD ASSEMBLY (STBD.) 10 1 TRIM FILTER ASSEMBLY 11 1 VALVE ASSEMBLY 12 1 E RING 13 1 O RING KIT 14 1 PUMP 15 1 PLUG ASSEMBLY 16 4 SCREW 17 4 WASHER 18 1 COVER 19 1 DRIVE SHAFT TRIM MOTOR 20 1 (Brekdown on Power Trim Motor) SHAFT ASSEMBLY 23 2 PIPE PLUG 24 1 GROOVE PIN 25 1 GROOVE PIN 26 1 SHAFT 27 1 ANODE ASSEMBLY 28 2 SCREW (M6 x 1 x 25) WASHER 30 6 SCREW (M10 x 1.5 x 30) WASHER 32 1 DECAL-Cution power trim 33 1 SCREW (10-16 x 3/5 IN.) 34 1 C WASHER 35 2 CLAMP 36 1 TUBING 37 1 STA-STRAP 38 2 FILTER SCREENS 2 SCREW (LONG) SCREW (SHORT) 80 9 NOTE: Lurite ll o-rings with ATF Dexron III or Power Trim nd Steering Fluid R1 JUNE 2000 Pge 5B-5

6 Power Trim Motor TORQUE REF. NO. QTY. DESCRIPTION l.in. l.ft. N m 1 POWER TRIM MOTOR 1 1 BRUSH AND SEAL KIT 2 1 ARMATURE KIT 3 1 END FRAME (Complete) Pge 5B R1 JUNE 2000

7 Power Trim - Generl Informtion POWER TRIM - DESIGN I Desription Trimming Chrteristis The Power Trim System onsists of n eletri motor, pressurized fluid reservoir, pump, tilt ylinder, nd two trim rms. The remote ontrol (or trim pnel) hs swithes tht trim the outord Up or Down nd tilt the engine for Trilering. The outord n e trimmed nd tilted under power or when the outord is not running. NOTE: Beuse hull designs ret differently in vrying wter onditions, vrying the trim position will often improve the ride nd ot hndling. When trimming from mid-trim position (with outord trim t in stright fore nd ft position), expet the following: TRIMMING OUTBOARD UP (OUT): WARNING Exessive trim Out my redue the stility of some high speed hulls. To orret instility, redue the power grdully nd trim the outord In slightly efore resuming high speed opertion. A rpid redution in power will result in sudden hnge of steering torque nd my use dditionl ot instility. Will lift ot ow, inresing top speed. Trnsfers steering torque hrder to port (left) on instlltions elow 23 in. (584.2 mm) trnsom height. Inreses gerse lerne over sumerged ojets. Exess trim n use porpoising nd/or ventiltion. WARNING Exessive outord trim ngle will result in insuffiient wter supply using wter pump nd/or powerhed overheting dmge. Insure wter level is ove wter intke holes whenever outord is running. The Up iruit tutes the up rely (under outord owl) nd loses the motor iruit. The eletri motor drives the pump, foring fluid thru pssgewys into the up side of the trim ylinders. The trim ylinders position the outord t the desired trim ngle in the 20 degree mximum trim rnge. The system will not llow the outord to e trimmed ove the 20 degree trim rnge s long s the engine RPM is ove pproximtely 2000 RPM. The outord n e trimmed ove the 20 degree mximum trim ngle (for shllow wter opertion, et.), y keeping the engine RPM elow If the RPM inreses over 2000, propeller thrust (if propeller is deep enough) will use the trim system to return the outord to the 20 degree mximum trim position R1 JUNE 2000 Pge 5B-7

8 TRIMMING OUTBOARD DOWN (IN): Trilering Outord WARNING Exessive speed t minimum trim In my result in undesirle nd/or unsfe steering onditions. Test for hndling hrteristis fter ny djustment is mde to the trim ngle (nd tilt pin lotion). Aids plning, prtiulrly with hevy lods. Improves ride in hoppy wter onditions. Exess trim In n use ow steer (ot veers to left or right). Trnsfers steering torque to strord (right). Improves elertion to plning speed. The Down iruit tutes the down rely (under engine owl) nd loses the motor iruit. The eletri motor drives the pump in the opposite diretion s the up iruit, foring fluid thru pssgewys into the down side of the tilt rm. The tilt rm moves the engine down to the desired position. The Up iruit first moves the trim ylinders; when the trim ylinders extend fully, the tilt rm extends to tilt the outord to the full up position for trilering. Before the ot is trilered, the opertor should hek for lerne etween the outord skeg nd pvement to prevent dmge to skeg from striking pvement. If the outord must e tilted for lerne etween skeg nd pvement, devie suh s Trnsom Sver should e instlled to prevent stress to ot trnsom from outord weight while the ot/outord re eing trilered. Tilting Outord Mnully WARNING Before opening the mnul relese vlve, insure ll persons re ler of outord s outord will drop to full Down when vlve is opened. The outord n e rised or lowered mnully y opening the mnul relese vlve 3 to 4 turns ounterlokwise. Close mnul relese vlve to hold outord t the desired tilt position. -Mnul Relese Vlve Pge 5B R1 JUNE 2000

9 Trim In Angle Adjustment POWER TRIM - DESIGN I WARNING Bot opertion with outord trimmed to the full In trim ngle [not using the trim ngle djustment olt ()] t plning speed my result in undesirle nd/or unsfe steering onditions. A wter test for hndling/steering onditions is required fter ny trim ngle djustments. IMPORTANT: Some ot/motor omintions not using the trim ngle djustment pin () nd trimmed to the full In trim ngle position my not exhiit ny undesirle nd/or unsfe hndling nd/or steering hrteristis t plning speed. If so, not using the trim ngle djustment olt my e dvntgeous to elertion nd plning. A wter test is required to determine if these hrteristis pply to prtiulr ot/motor omintion. -Trim Angle Adjustment Bolt Striker Plte Replement Visully inspet striker pltes nd reple if worn exessively. -Striker Plte (2) -Lokwsher -Loknut. Torque to 80 l. in. (9 Nm) R1 JUNE 2000 Pge 5B-9

10 Anode Plte Anode plte is self-srifiing lloy plte tht is onsumed grdully y orrosion while providing protetion to the midsetion nd power trim from glvni orrosion. Reple node plte when it is 50% onsumed. -Anode Plte Trim Inditor Guge IMPORTANT: Do not pint or ple protetive oting on node plte, or orrosion protetion funtion will e lost. A Quiksilver Trim Inditor Guge essory kit is ville for the power trim sender (if not previously instlled). Chek, Fill nd Purge - Power Trim System TO CHECK: CAUTION Tilt outord to full Up position nd engge tilt lok lever efore heking fluid level. System is pressurized. Extend trim nd tilt rms fully to depressurize system. Remove fill plug nd O-ring. System is full when oil level is present t filler hole. Tighten fill plug seurely. NOTE: Automti Trnsmission Fluid (ATF) Type F, FA, Dexron II or Dexron III my e used. -Tilt Lok Lever Pge 5B R1 JUNE 2000

11 TO FILL: POWER TRIM - DESIGN I IMPORTANT: This trim system is pressurized. Remove Fill plug only when outord is tilted to the full Up position or the trim/tilt rms re fully extended. Retighten Fill plug efore tilting outord down or retrting tilt/trim rms. Remove Fill plug nd O-ring. System is full when oil level is present t fill hole. Tighten Fill plug seurely Fill Plug nd O-ring (remove to fill system, tighten seurely) -Oil Cn (fill system with Quiksilver Power Trim nd Steering Fluid) -Tilt Lok Lever (engge to support engine in Up position) TO PURGE: IMPORTANT: Fill plug nd O-ring must e tightened seurely efore purging system. IMPORTANT: Run Trim System in short jogs until pump is primed nd trim system moves. If trim motor is run without priming pump, driveshft filure ould result. Cyle outord through entire trim/tilt rnge 4 times. Chek fluid level fter purging system. Push down on outord when trim rms re slightly extended. If rms retrt more thn 1/8 in. (3.2 mm), ir is present in system. Cyle system gin nd hek fluid level R1 JUNE 2000 Pge 5B-11

12 Trouleshooting IMPORTANT: Determine if Eletril or Hydruli prolem exists. IMPORTANT: Aeptle power trim lek down should not exeed 1 in. (25.4 mm) (when mesured t the tilt rm) in 24 hour period. HYDRAULIC SYSTEM TROUBLESHOOTING IMPORTANT: Mke one orretion t time. Chek opertion of trim system efore proeeding to the next hek. CONDITION OF TRIM SYSTEM PROBLEM A. Trim motor runs; trim system does not move up or down. 1, 2, 5, 10 B. Does not trim full down. Up trim OK. 2, 3, 4 C. Does not trim full up. Down trim OK. 1, 6 D. Prtil or Jerky down/up. 1, 3 E. Thump noise when shifting. 2, 3, 6, 7 F. Does not trim under lod. 5,8, 9,10 G. Does not hold trim position under lod. 2, 5, 6 H. Tril out when king off from high speed. 3, 4 I. Leks down nd does not hold trim. 2, 5, 7 J. Trim motor working hrd nd trims slow up nd down. 8, 9 K. Trims up very slow. 1, 2, 8, 9 L. Strts to trim up from full down position when IN trim utton is depressed. 3, 4 M. Trim position will not hold in reverse. 3, 4 PROBLEM 1. Low oil level. 2. Pump ssemly fulty. 3. Tilt rm piston ll not seted (displed, dirt, nikel set). 4. Tilt rm piston O-ring leking or ut. 5. Mnul relese vlve leking (hek ondition of O-rings) (Vlve not fully losed). 6. Lower hek vlve not seting in port side trim rm. 7. Upper hek vlve not seting in port side trim rm. 8. Chek ondition of ttery Reple motor ssemly Broken motor/pump drive shft Externl Mounted Hydruli System Pge 5B R1 JUNE 2000

13 ELECTRICAL SYSTEM TROUBLESHOOTING POWER TRIM - DESIGN I CONDITION OF TRIM SYSTEM PROBLEM A. Trim motor does not run when trim utton is depressed. 1, 2, 4, 5, 6, 7, 8 B. Trim system trims opposite of uttons. 3 C. Cowl mounted trim uttons do not tivte trim system. 2, 4, 5, 6, 7 PROBLEM 1. Bttery low or dishrged. 2. Open iruit in trim wiring. 3. Wiring reversed in remote ontrol, owl swith or trim leds. 4. Wire hrness orroded through. 5. Internl motor prolem (rushes, shorted rmture). 6. Blown fuse(s). 7. Trim swith filure. 8. Verify relys re funtioning orretly. POWER TRIM RELAY TEST PROCEDURE The trim motor rely system used on permnent mgnet trim systems onnet eh of the two wires from the trim motor to either ground or positive in order to llow the motor to run in oth diretions. If the motor will not run in the UP diretion, it ould e either the UP rely is not mking ontt to 12 volts OR the DOWN rely is not mking ontt to ground. The opposite is true if the system will not run DOWN. When the system is not energized, oth relys should onnet the hevy motor leds to ground. To test whih rely is fulty if the trim system does not operte in one diretion: 1. Disonnet the hevy guge pump wires from the trim ontrol rely. 2. Chek for ontinuity etween the hevy leds from the trim relys to ground. Ohmmeter Leds Between Resistne (Ohms) Sle Reding* (x ) GREEN nd Ground 0 Full Continuity (Rx1) BLUE nd Ground 0 Full Continuity (Rx1) Reple the rely tht does not hve ontinuity. 3. Connet voltmeter to the hevy BLUE led nd to ground. You should hve 12 volts on the BLUE led when the UP swith is pushed. You should should lso hve 12 volts on the GREEN led when the DOWN swith is pushed. Reple the rely tht does not swith the led to positive R1 JUNE 2000 Pge 5B-13

14 Power Trim System with Relys nd 2 Wire Trim Motor UP Rely DOWN Rely BLK = Blk BLU = Blue GRN = Green RED = Red WHT = White Pge 5B R1 JUNE 2000

15 Eletril System Trouleshooting Generl Cheks POWER TRIM - DESIGN I Before trouleshooting the Power Trim eletril system, hek the following: 1. Chek for disonneted wires. 2. Mke ertin ll onnetions re tight nd orrosion free. 3. Chek tht plug-in onnetors re fully engged. 4. Mke ertin ttery is fully hrged. Refer to the preeding four wiring digrms for onnetion points when trouleshooting the eletril systems (Connetion points re speified y numer.) Trouleshooting the Down Ciruit Connet Voltmeter red led to Point 1 nd lk led to ground. Depress the Down trim utton. Bttery Voltge Indited: Connet Voltmeter red led to Point 3. No Voltge Indited: Connet Voltmeter red led to Point 4 nd lk led to ground. Depress Down trim utton. If ttery voltge is indited, wire is open etween Points 4 nd 1. Bttery Voltge Indited: Connet Voltmeter red led to Point 2. Depress Down trim utton. Bttery Voltge Indited: Test UP rely. Refer to pge 5B-13 for rely test proedure. No Voltge Indited: There is n open iruit etween Point 3 nd positive (+) ttery terminl. Chek for loose or orroded onnetions. Chek wires for open. No Voltge Indited: Rely Swith is defetive. Rely good: Pump motor wiring is defetive. Pump motor is defetive. No Voltge Indited: Connet Voltmeter red led to Point 5. If ttery voltge is indited, trim swith is fulty. If no ttery voltge, hek for loose or orroded onnetion t Point 5 or open iruit in wire supplying urrent to Point R1 JUNE 2000 Pge 5B-15

16 Trouleshooting the Up Ciruit Connet Voltmeter red led to Point 8 nd lk led to ground. Depress the Up trim utton. Bttery Voltge Indited: Connet Voltmeter red led to Point 9. No Voltge Indited: Connet Voltmeter red led to Point 7 nd lk led to ground. Depress Up trim utton. If ttery voltge is indited, wire is open etween Points 7 nd 8. Bttery Voltge Indited: Connet Voltmeter red led to Point 6. Depress Up trim utton. Bttery Voltge Indited: Test DOWN rely. Refer to pge 5B-13 for rely test proedure. No Voltge Indited: There is n open iruit etween Point 9 nd positive (+) ttery terminl. Chek for loose or orroded onnetions. Chek wires for open. No Voltge Indited: Rely Swith is defetive. Rely good: Pump motor wiring is defetive. Pump motor is defetive. No Voltge Indited: Connet Voltmeter red led to Point 5. If ttery voltge is indited, trim swith is fulty. If no ttery voltge, hek for loose or orroded onnetion t Point 5 or open iruit in wire supplying urrent to Point 5. Pge 5B R1 JUNE 2000

17 Trouleshooting the Down nd Up Ciruits (All Ciruits Inopertive) POWER TRIM - DESIGN I Chek in-line fuse (under owl) to see if fuse is lown. Blown Fuse: Corret prolem tht used fuse to low. Reple fuse. Fuse Not Blown: Connet Voltmeter red led to Point 3 nd lk led to ground. Bttery voltge should e indited. No Voltge Indited: Chek ttery leds for poor onnetions or open iruits. Chek ttery hrge. Bttery Voltge Indited: Connet Voltmeter red led to Point 8 nd lk led to ground. Depress Up trim utton nd hek for ttery voltge. No Voltge Indited: Connet red Voltmeter led to Point 5, nd lk led to ground. Bttery Voltge Indited: Chek lk ground wires for poor onnetion or poor ground, Point 10. Pump motor is fulty. Refer to Motor nd Eletril Tests/ Repir, following. No Voltge Indited: Chek tht voltge is eing supplied to ontrol y performing the following heks: DO NOT strt engine. Turn ignition swith to Run position. Chek for voltge t ny instrument, using Voltmeter. Bttery Voltge Indited: Trim swith is fulty or there is n open iruit in wires (green-white, lue-white) etween trim uttons nd trim pump. Chek trim swith. Chek ll trim hrness onnetors for loose or orroded onnetions. Chek for pinhed or severed wires. No Voltge Indited: Red wire is open etween Point 3 nd red terminl on k of the ignition swith. Chek for loose or orroded onnetions. Chek for open in wire. Bttery Voltge Indited: There is n open iruit in wire etween Point 5 nd Red terminl on the k of the ignition swith R1 JUNE 2000 Pge 5B-17

18 Power Trim Assemly Removl nd Instlltion Removl 1. Remove lmps on trnsom rket to free power trim wiring. 2. Rise outord to full Up position nd engge tilt lok lever. -Clmps -Tilt Lok Lever WARNING Filure to support outord s shown ould result in personl injury nd/or dmge to outord or ot Tilt Lok Lever -Support Tool -Retining Clips IMPORTANT: Support outord s shown ove to prevent engine from tipping when power trim retining pin is removed. Pge 5B R1 JUNE 2000

19 SUPPORT TOOL 3/8 in. dimeter metl rod ( used shift shft works well) 14 POWER TRIM - DESIGN I 2 -Drill holes for retining lips METRIC CONVERSION 14 in. = m. 2 in. = 50.8 mm 3/8 in. = 9.5 mm. 1/4 in. = 6.35 mm. 1/4 CAUTION Disonnet ttery les t ttery efore removing power trim wires from solenoids. 3. Disonnet power trim wires t solenoids (BLUE, GREEN, nd BLACK) or if rely style, disonnet (BLUE nd GREEN) ullet onnetor hrness. 4. Open filler p nd relese ny remining pressure in the system. IMPORTANT: Outords equipped with thru-the-tilt-tue steering - remove steering link rm from end of steering le nd le retining nut from tilt tue. -Filler Cp -Retining Nut R1 JUNE 2000 Pge 5B-19

20 IMPORTANT: Cross pin () should not e reused. Reple with new ross pin. 5. Drive out ross pin, push out upper swivel pin, nd remove 3 olts nd wshers in port lmp rket Cross Pin -Upper Swivel Pin -Port Trnsom Brket Bolts nd Wshers (3). Remove to Relese Trim System from Outord. 6. Remove 3 olts nd wshers nd in strord trnsom rket. d Trnsom Mount Bolts (2) -Tilt Tue Nut (flush with end of thred) -Srews (3) d-wshers (3) 7. Remove outord trnsom mounting olts nd loosen tilt tue nut until nut is flush with end of tilt tue thred. Remove system from outord. Pge 5B R1 JUNE 2000

21 Instlltion POWER TRIM - DESIGN I 1. Pint ny exposed metl surfes to prevent orrosion. 2. Apply Lotite 271 to srews. Instll trim system, strord trnsom rket, nd tilt tue nut. 3. Use 12 volt power soure to extend tilt rm up to lign upper swivel shft hole nd end of rm. Connet trim motor wires [BLUE wire to POSITIVE (+), BLACK wire to NEGATIVE ( )]. If rm extends too fr, retrt rm y onneting GREEN wire to POS- ITIVE (+). 4. Instll Upper Swivel Pin with slotted end to left (port) side of engine. e d f Srew (6) Torque to 40 l. ft. (54.0 N m) -Lokwsher (6) Instll one per srew -Tilt Tue Nut d-upper Swivel Pin e -Slotted end f -Cross hole (in line with slotted end) IMPORTANT: Cross pin should not e reused. Instll new pin. 5. Position slot on end of swivel shft in line with hole in tilt rm end. Insert punh into tilt rm hole to lign ross hole in upper swivel shft. Tp new ross pin in until flush. d -Upper Swivel Shft (Slot is in line with ross hole) -Chmfered End of Hole (Fes wy from trnsom) -Retining Pin d-tilt Rm End R1 JUNE 2000 Pge 5B-21

22 6. Connet trim motor wires to relys. Refer to Wiring Digrms in this mnul. Route trim wires s speified in this mnul. NOTE: The 2 power leds going to the trim motor should e enpsulted with onduit tuing. If tuing hs not een previously instlled, order nd ut to pproprite length. -Conduit Tuing Apply mrine seler to shnks of mount olts nd instll trnsom mount olts. IMPORTANT: Do not use n impt driver to tighten trnsom mount olts. Apply mrine seler to threds of mount olts. Seure with flt wshers nd loknuts. Be sure instlltion is wtertight. 8. Tighten tilt tue nut seurely. IMPORTANT: Outords equipped with thru-the-tilt-tue steering: Tighten steering le retining nut seurely to tilt tue. -Steering Cle Retining Nut Apply Quiksilver Liquid Neoprene ( ) on ll eletril onnetions. Pge 5B R1 JUNE 2000

23 WARNING POWER TRIM - DESIGN I Eletril wires pssing through owl openings must e proteted from hfing or eing ut. Follow the reommended proedures outlined in Setion 1D of this Mnul. Filure to protet wires s desried ould result in eletril system filure nd/or injury to oupnts of ot. Testing Power Trim System With Test Guge Kit ( A6) UP Pressure Chek IMPORTANT: This test will not lote prolems in the trim system. The test will show if the system is orret fter repir. If minimum pressures re not otinle, the trim system requires dditionl repir. IMPORTANT: Insure ttery is fully hrged efore performing tests. 1. Tilt outord to full Up position nd engge tilt lok lever. 2. Slowly remove Fill plug to leed pressure from reservoir. 3. Remove irlip seuring mnul relese vlve nd unsrew relese vlve from trim ssemly. NOTE: A smll mount of trim fluid my drip from mnul relese vlve hole. Ple suitle ontiner under trim ssemly to ollet ny lekge. NOTE: Assemle test dptor y using O-ring instlltion tool to position smll O-ring onto dptor 1st, then instll medium O-ring nd lstly lrge O-ring. Thred rss fitting into test dptor seurely using teflon tpe on threds. g f -Test Adptor ( A2) -O-ring Instlltion Tool -Smll O-ring (Instll 1st) d-medium O-ring (Instll 2nd) e -Lrge O-ring (Instll Lst) f -Brss Fitting g-apply Teflon Tpe e d R1 JUNE 2000 Pge 5B-23

24 4. Instll test dptor A2 into mnul relese vlve hole. -Test Adptor ( A2) Thred hose from Test Guge Kit ( A6) into rss fitting on dptor. e d -Brss Fitting -Test Guge Assemly -Tilt Pin (Position in Hole Shown) d-hose e -Hose (Not Used) 6. Reinstll fill plug. 7. Run trim UP. 8. Disengge tilt lok lever Pge 5B R1 JUNE 2000

25 CAUTION POWER TRIM - DESIGN I Filure to instll spre tilt pin (or hrdened olts nd nuts) in hole shown ould result in trnsom rket filure nd possile injury. 9. Move outord IN until hole in swivel rket er ligns with the 3rd tilt hole in trnsom rket. Lok engine in trim rnge y instlling 3/8 in. (9.5 mm) dimeter tilt pin or two 3/8 in. (9.5 mm) hrdened olts nd nuts thru the trnsom rkets nd swivel rket in the hole shown Tilt Pin Hole (Instll Spre Tilt Pin or Hrdened Bolts nd Nuts) 10. Open vlve () nd lose vlve () Run trim UP. The minimum pressure should e 1300 P.S.I. (91 kg/m 2 ). 12. Run trim DOWN to relese pressure nd remove spre tilt pin or olts nd nuts. 13. Tilt outord full UP nd engge tilt lok lever. 14. Slowly remove Fill plug to leed pressure. 15. Remove test guge hose nd dpter. 16. Reinstll Mnul Relese Vlve nd seure vlve with irlip. 17. Retighten Fill plug. NOTE: If pressure is less thn 1300 PSI (91 kg/m 2 ), trouleshoot system per instrutions on pge 5B R1 JUNE 2000 Pge 5B-25

26 DOWN Pressure Chek IMPORTANT: Insure ttery is fully hrged efore performing tests. 1. Tilt outord to full Up position nd engge tilt lok lever. 2. Slowly remove Fill plug to leed pressure from reservoir. 3. Remove irlip seuring mnul relese vlve nd unsrew relese vlve from trim ssemly. NOTE: A smll mount of trim fluid my drip from mnul relese vlve hole. Ple suitle ontiner under trim ssemly to ollet ny lekge. NOTE: Assemle test dptor y using O-ring instlltion tool to position smll O-ring onto dptor 1st, then instll medium O-ring nd lstly lrge O-ring. Thred rss fitting into test dptor seurely using teflon tpe on threds. g 3 f e d -Test Adptor ( A3) -O-ring Instlltion Tool -Smll O-ring (Instll 1st) d-medium O-ring (Instll 2nd) e -Lrge O-ring (Instll Lst) f -Brss Fitting g-apply Teflon Tpe 4. Instll test dptor A3 into mnul relese vlve hole. -Test Adptor ( A3) Pge 5B R1 JUNE 2000

27 5. Thred hose from Test Guge Kit ( A6) into rss fitting on dptor. e d -Brss Fitting -Test Guge Assemly -Tilt Pin (Position in Hole Shown) d-hose e -Hose (Not Used) f -OPEN Vlve g-close Vlve f g Reinstll fill plug. 7. Run trim UP. 8. Disengge tilt lok lever. 9. Open vlve (f) nd lose vlve (g). 10. Run trim DOWN. Minimum pressure should e 500 P.S.I. (35 kg/m 2 ). 11. Tilt outord full UP nd engge tilt lok lever. 12. Slowly remove Fill plug to leed pressure. 13. Remove test guge hose nd dptor. 14. Reinstll mnul relese vlve nd seure vlve with irlip. 15. Retighten Fill plug. NOTE: If pressure is less thn 500 PSI (35 kg/m 2 ), trouleshoot system per instrutions on Pge 5B R1 JUNE 2000 Pge 5B-27

28 Hydruli Repir TRIM ROD REMOVAL AND REPAIR NOTE: Power Trim does not hve to e removed from outord to remove trim rods. 1. Tilt outord to full UP position nd engge tilt lok lever. 2. Slowly remove Fill plug to leed reservoir pressure. 3. Turn Mnul Relese Vlve 3 to 4 turns (ounterlokwise) to leed remining pressure. 4. Remove trim rod ylinder ps. NOTE: Ple len pn under trim system to th fluid. d Trim Rod Cylinder Cp -Turn Counterlokwise to Remove -Removl Tool ( A1) d-spnner Wrenh ( ) 5. Instll trim rod removl tool nd pull trim rod from ylinder. -Trim Rod Removl Tool ( A1) Pge 5B R1 JUNE 2000

29 CLEANING AND INSPECTION - TRIM RODS AND CAPS CAUTION POWER TRIM - DESIGN I Do not remove hek vlve (). Chek vlve is preset to operte t speifi pressure. Removl nd instlltion of hek vlve ould result in improper operting pressure nd possile system dmge. NOTE: Chek vlve is in port side trim rod only. NOTE: Certin models my hve trim limit reduers instlled on the trim rod to limit trim out ngle. Eh reduer limits the mount of totl trim y 2. A mximum of 5 reduers my e instlled on eh trim rod. 1. Inspet hek vlve nd hek vlve sreen for deris; if deris nnot e removed, reple trim rod ssemly. Clen trim rod with prts lener nd dry with ompressed ir. Trim Rod End Cp Sel Chek Vlve -Chek Vlve Sreen -Trim Limit Reduers [Trim Redution Kit (858915A1)] 1. Inspet trim p end sel nd reple if dmged or if sel does not keep trim rod len. -Sel (remove s shown) 2. Instll new sel with sel lip up. TRIM ROD INSTALLATION IMPORTANT: Components must e free of dirt nd lint. Any deris in the system n use system to mlfuntion NOTE: Instll trim rod with hek vlve in the port (left) ylinder. 1. Apply ATF Dexron III or Quiksilver Power Trim nd Steering Fluid on ll O-rings nd sels efore instlltion R1 JUNE 2000 Pge 5B-29

30 2. Instll trim rods nd ps. Use instlltion tool ( A1) or spnner wrenh ( ) to tighten ps seurely. Tilt Rm Trim Rods -Cylinder End Cps -Rod End Rollers (lurite with Quiksilver Anti-Corrosion Grese or Speil Lurint 101) REMOVAL - TILT ROD ASSEMBLY ONLY NOTE: Tilt Rod Assemly n e removed from ylinder without removing entire power trim system from outord. TILT RAM COMPONENTS Housing - Tilt Rm 2 -O-ring* (5) 3 -Memory Piston** 4 -Wsher 5 -Piston Assemly 6 -End Cp Oil Sel 8 -Bolt (Design 1) 9 -Nut (Design 2) 10 - Tilt Rod (Design 1) 11 - Tilt Rod (Design 2) *O-ring Repir Kit Aville, P.N A1 (Inludes item 7, Oil Sel) **Memory piston (3) for tilt rods (j nd k) re different nd must e used with orret tilt rod/ylinder ssemly. Memory piston for Design 1 tilt rod is flt, Design 2 is dished to ler nut nd thred. Pge 5B R1 JUNE 2000

31 TILT RAM REMOVAL - POWER TRIM SYSTEM REMOVED FROM OUTBOARD CAUTION Insure trim system is depressurized prior to tilt rm removl. 1. Remove ross pin. 2. Remove lower swivel pin. POWER TRIM - DESIGN I Cross Pin (Remove s shown) -Lower Swivel Pin (Remove s shown) Disssemly 1. Seure tilt rm in soft jwed vise. Remove tilt rod nd p Cp (Turn Counterlokwise to Remove) -Spnner Wrenh ( ) -Tilt Rod - Pull to Remove R1 JUNE 2000 Pge 5B-31

32 2. Clmp tilt rod in soft jwed vise. Remove olt or nut s pplile to disssemle rod ssemly. Remove O-ring Bolt (Design 1) or Stud/Nut (Design 2) -O-Ring IMPORTANT: Note Design 1 nd 2 on pge 5B-30. Design 1 tilt rod ssemly reples either tilt rod ssemly. Either design will fit s (reple) ylinder ssemly omplete. Design 2 will NOT fit ylinder originlly using Design 1 tilt rod ssemly. Memory Pistons for Design 1 nd 2 differ lso nd must e used only on the ylinder the piston ws removed from. 3. Remove wsher, hek vlve ssemlies, nd piston. NOTE: Chek vlve held in y roll pin n e lened ut not removed. -Wsher -Chek Vlve Assemly (7) -Piston Pge 5B R1 JUNE 2000

33 4. Remove end p from tilt rod. 5. Remove llen plug. IMPORTANT: Remove plug from sme side s holes in shft. DO NOT REMOVE End Cp -Allen Plug -Hole In Shft Lurite shft with Quiksilver Power Trim nd Steering Fluid. Insert shft into ylinder Tp shft into ylinder until shft is positioned s shown WARNING Memory Piston Cup my e expelled t high veloity when ir pressure is pplied. Filure to ple ylinder s shown elow ould result in personl injury R1 JUNE 2000 Pge 5B-33

34 8. Ple ylinder s shown. Hold down on ylinder nd injet ir into shft opening. -Shop Cloth -Solid Surfe -Air Nozzle 9. Remove shft fter Memory Piston Cup hs een expelled. Reple llen plug removed in Step 5 nd tighten seurely. CLEANING AND INSPECTION Srper Sel Replement Inspet ll internl prts for dmge or wer. Clen nd reple prts s neessry. 2. Inspet tilt rod for srthes. Reple srper sel in rod end p if tilt rod is srthed or worn. 3. Slight srthes or tool mrks less thn in. (0.1 mm) deep in ylinder re eptle. 1. Remove omponents from end p. d e -Cp -O-ring (2) -Srper Sel d-wsher e -Retining Ring Pge 5B R1 JUNE 2000

35 REASSEMBLY POWER TRIM - DESIGN I IMPORTANT: Components must e len for ressemly. Any deris in the system n use the system to mlfuntion. NOTE: Refer to Tilt Rm Components for proper O-ring sizes. 1. Apply ATF Dexron III or Quiksilver Power Trim nd Steering Fluid on O-rings prior to ressemly. 2. Instll O-ring on Memory Piston Cup nd instll in ylinder. -O-ring -Memory Piston Cup (Design 1 shown) Assemle end p. 4. Instll end p. d f e End Cp -O-ring (2) -Srper sel d-wsher e -Retining Ring f -End Cp R1 JUNE 2000 Pge 5B-35

36 5. Instll omponents on rod. e d Piston -O-ring -Chek Vlve Assemly (7) d-wsher e -Bolt or Loknut. (Tighten seurely) Clmp ylinder in soft jwed vise nd instll tilt rod ssemly. Use spnner wrenh nd tighten end p seurely Cylinder -Tilt Rod Assemly -End Cp (Tighten Seurely.) Use Spnner Wrenh. Pge 5B R1 JUNE 2000

37 TILT RAM ASSEMBLY INSTALLATION POWER TRIM - DESIGN I 1. Lurite lignment tool ( ) nd shft. Use ATF Dexron III or Quiksilver Power Trim nd Steering Fluid. -Alignment Tool ( ) -Shft Align tilt rm nd housing using lignment tool. 3. Instll shft Alignment Tool ( ) -Shft -Groove d-hole [Groove () will Align with this Hole] d Drive pin in until flush. -Pin (Drive Aginst Knurled End) R1 JUNE 2000 Pge 5B-37

38 Motor nd Eletril Tests/Repir Trim Pump Motor Test WARNING Do not perform this test ner flmmle mterils, s sprk my our while mking eletril onnetions. 1. Connet 12 volt power supply to motor wires; one motor led to POSITIVE (+) ttery terminl nd the other motor led to the NEGATIVE ( ) ttery terminl. Motor should run. Reverse motor leds etween ttery terminls. Motor should run Motor Disssemly 2. If motor does not run, disssemle nd hek omponents. 1. Remove 2 srews. -Srew (2) Pge 5B R1 JUNE 2000

39 2. Remove n nd rmture from end p. Use re not to drop rmture. -Cn -Armture -End Cp Armture Tests TEST FOR SHORTS Chek rmture on Growler per the Growler mnufturer s instrutions. Reple rmture if short is indited. TEST FOR GROUND 1. Use n Ohmmeter (Rx1 sle). Connet one led on rmture shft nd other led on ommuttor. If ontinuity is indited, rmture is grounded. Reple rmture R1 JUNE 2000 Pge 5B-39

40 CHECKING AND CLEANING COMMUTATOR 1. If ommuttor is worn it my e turned on n rmture onditioner or lthe. 2. Clen ommuttor with OO sndpper. -Commuttor FIELD TESTS IMPORTANT: Commuttor end of rmture must e instlled in rushes when performing the following tests. Motor Repir REMOVAL Ohmmeter Leds Between Resistne (Ohms) Sle Reding* (x ) BLUE nd BLACK Motor Wires 0 (Rx1) BLACK Motor Wire, nd Frme (Motor Housing) No Continuity (Rx1) BLUE Motor Wire nd Frme No Continuity (Rx1) *If speified redings re not otined, hek for: defetive rmture dirty or worn rushes dirty or worn ommuttor If defetive omponents re found, repir or reple omponent(s) nd retest. NOTE: Power Trim System does not hve to e removed from outord to repir/reple motor. DISASSEMBLY Refer to Motor Disssemly on pge 5B-38 to disssemle motor from pump. Pge 5B R1 JUNE 2000

41 CLEANING AND INSPECTION POWER TRIM - DESIGN I Inspet O-rings nd reple if neessry. Crefully inspet power ord for uts or ters whih will llow wter to enter motor. Reple ord if ut or torn. Clen, inspet, nd test motor omponents. Refer to Brush Replement, Armture Test, nd Field Tests for inspetion nd test proedures. e -Frme -Armture -Shim d-brush Crd Assemly e -O-rings d BRUSH REPLACEMENT 1. Brush replement is required if rushes re pitted, hipped, or if distne () etween the rush pigtil nd end of rush holder slot is 1/16 in. or less. Chek distne with rmture instlled. -1/16 in R1 JUNE 2000 Pge 5B-41

42 2. To reple rush rd, disonnet spde terminl. 3. Cut rimped rush led. 4. Remove 2 srews seuring rush rd to end p. -Spde Terminl -Crimped Brush Led -Srews 5. Instll new rush rd (BRUSH nd SEAL KIT A1). 6. Crimp metl onnetor onto motor led nd new rush led. 7. Connet spde onnetor motor led to rush rd onnetor. 8. Seure rush rd to end p with 2 srews nd lokwshers. 9. Inspet O-ring for uts nd risions. Reple O-ring s required (BRUSH nd SEAL KIT A1). d e -Brush Crd -Metl Connetor -Spde Connetor d-srews nd Lokwshers e -O-ring Pge 5B R1 JUNE 2000

43 END CAP INSPECTION POWER TRIM - DESIGN I 1. Inspet sel nd O-ring for uts nd risions. If replement is required, instll BRUSH nd SEAL KIT A1. 2. Inspet ushing for wer. If ushing ppers to e exessively worn grooves, srthes, et. instll END FRAME ASSEMBLY (COMPLETE) A Sel (Apply 2-4-C w/teflon to sel lips) -O-ring -Bushing If trim motor is overheted, thermoswith loted under rush rd will open. Normlly, this swith will reset itself within 1 minute. -Thermoswith R1 JUNE 2000 Pge 5B-43

44 Ressemly IMPORTANT: Components must e len. Any deris in power trim system n use system to mlfuntion. 1. Instll rmture into end p/rush rd ssemly. d Armture -Shim -End Cp Assemly d-armture (Spred rushes to instll rmture into end p) 2. Instll O-rings in end p. -O-rings Pge 5B R1 JUNE 2000

45 IMPORTANT: Atth Vise Grip pliers to rmture shft efore instlling frme ssemly. The Vise Grip pliers will prevent the rmture from eing drwn out of the rush rd ssemly y the frme mgnets while instlling the frme ssemly. 3. Instll Vise Grip pliers on rmture shft. 4. Crefully instll n over rmture. 5. Position hrness retiner hole over t in end p. 6. Seure frme ssemly to end p with 2 srews. h i f e i g d -Vise Grip Pliers -Armture Shft -O-ring d-end Cp e -Hrness Retiner f -Retiner Hole g-o-ring h-cn i -Srews R1 JUNE 2000 Pge 5B-45

46 Ressemly - Motor nd Pump NOTE: Drive shft is loose prt nd my fll out of position. 1. Instll pump onto power trim mnifold. Insure O-rings re in proper lotions. Seure with two (2) srews. Torque srews to 80 l. in. (9 N m). IMPORTANT: Instll pump with lotion flt fing towrds strord trnsom rket. d Pump (Flt Towrds Strord Trnsom Brket) -Flt - Fes Strord Trnsom Brket) -O-rings (4) d-drive Shft (Instll in Center Hole in Pump) 2. Fill pump with ATF Dexron III or Quiksilver Power Trim nd Steering Fluid prior to instlling motor. 3. Instll motor, seure with two (2) srews. Route wiring; refer to Wiring Digrms in this servie mnul. Pge 5B R1 JUNE 2000

47 NOTE: Verify motor nd drive shft re ligned. POWER TRIM - DESIGN I Motor -O-ring -Srew (2) Tighten seurely Complete ressemly of Power Trim System s outlined in Instlltion on pge 5B-21. Priming Power Trim System Trim Sender Test 1. Fill system with Quiksilver Power Trim nd Steering Fluid or Automti Trnsmission Fluid (ATF) Type F,FA, Dexron II or Dexron III. Refer to Fill, Chek, nd Purge on pge 5B-10. IMPORTANT: Run Trim System in short jogs until pump motor primes nd trim system moves. If trim motor is run without priming pump, drive shft filure ould result. 1. Chek trim sender lk led for proper ground. 2. Trim outord to full DOWN position. 3. Ple ignition swith to ON position. 4. Disonnet BRN/WHT trim sender wire from trim sender hrness. 5. Connet Ohmmeter (Rx1 sle) leds etween outord ground nd Point 1 (trim sender end). 6. Depress UP utton. Ohmmeter needle should move s the outord is trimmed up. If needle does not move, trim sender is defetive. 1 -Trim sender R1 JUNE 2000 Pge 5B-47

48 Trim Inditor Guge Needle Adjustment 1. Turn ignition key to RUN position. 2. Tilt outord to full IN position. Needle of trim inditor guge should e in full IN position. 3. If not, tilt outord to full OUT position to gin ess to trim sender nd engge tilt lok lever. 4. Loosen trim sender srews nd reposition trim sender. 5. Tighten trim sender srews. d e -Trim Sender -Srews, Loosen to Rotte Sender -Turn Sender Counterlokwise to rise needle reding d-turn Sender Clokwise to Lower Needle Reding e -Tilt lok lever Pge 5B R1 JUNE 2000

49 Trim Inditor Wiring Digrms POWER TRIM - DESIGN I Wiring Digrm - For ots equipped with Quiksilver Commnder Series side mount remote ontrol. d e Wiring Digrm - For ots equipped with Quiksilver Ignition/Choke nd Min Hrness Assemly. f g d e -Trim Inditor -Remote Control -Trim Sender d-engine Ground e -To Engine f -Ignition Swith g-power Trim Hrness R1 JUNE 2000 Pge 5B-49