115 HP 4T PDF

Srvc Man - ME 115 EFI FS 12/12/01 1:25 PM Page 1
115 FourStroke EFI

115
FourStroke
Electronic
Fuel Injection
90-881980R1 NOVEMBER 2001

Starting Model Year 2001
Starting Model Year 2001

Starting Serial Number 0T178500
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com
Frankston Road W6250 Pioneer Road (Parc Industriel de Petit-Rechain)
P.O. Box 80 Fond du Lac, WI 54936-1939 USA B-4822 Verviers/Belgium
Dandenong, Victoria 3175 Australia
English Version 90-881980R1
©December 2001, Mercury Marine. All rights reserved. Printed in U.S.A. Translated Version 90-887771R1
Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal in-
jury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual

This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these prod-
ucts, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which in-
cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-881980R1 NOVEMBER 2001 Page i

It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the met-
ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mis-
matched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations when-
ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
Cleanliness and Care of Outboard Motor

A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manu-
al, it should be understood that proper cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
Personnel should not work on or under an outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.
EXAMPLE:
90-826148R1 JANUARY 1996 Page 6A-7
Revision No. 1 Section Number
Month of Printing Part of Section Letter
Year of Printing Page Number
Page ii 90-881980R1 NOVEMBER 2001

Service Manual Outline
Section 1 - Important Information
Important Information
1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Motor Installation
Electrical
2
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
Electronic Fuel
Injection 3
Section 3 - Electronic Fuel Injection
A - Theory of Operation
B - Diagnostics & Troubleshooting
C - Service Procedures
Powerhead
4
D - Emissions
Section 4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
Mid-Section
5
C - Lubrication
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
Lower Unit
6
B - Power Trim
Section 6 - Lower Unit
A - Gear Housing
Section 7 - Attachments/Control Linkage
Attachments/
Control Linkage 7
A - Throttle/Shift Linkage
Section 8 - Color Diagrams Color Diagrams
8
9
90-881980R1 NOVEMBER 2001 Page iii

SPECIFICATIONS
IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants
Propeller Information Charts . . . . . . . . . . . . . . 1A-9 and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-12
Specifications
Models 115 EFI (4-Stroke)

Horsepower:
Model 115 115 hp (85.8 Kw) @ 5500 rpm
PERFORMANCE Wide Open Throttle (WOT) rpm
Range 5000 - 6000
OUTBOARD Electric
WEIGHT 115 EFI ELPT 386 lb (175 kg)
Recommended Gasoline Automotive Unleaded
FUEL with a Minimum Pump Posted
Octane Rating of 87
Oil Filter p/n 35-822626A2
Oil Filter Wrench p/n 91-802653Q1
Engine Oil Capacity Either 5 Quarts or 5 Liters
Engine Oil SAE 10W-30 viscosity oil is recom-
mended for use in all temperatures.
SAE SAE SAE 25W-40 viscosity oil may be used
F° C° 25W-40 10W-30 at temperatures above 40° F (4° C).
+100 +38 Use Mercury/Quicksilver 4-Cycle Ma-

+80 +27 rine Oil with the proper viscosity for the
OIL expected temperature in your area (see
+60 +16 range thermometer on left). If not avail-
+40 +4 able, use a premium quality 4-cycle en-
gine oil certified to meet or exceed any
+20 –7 one of the following American Petro-
–18 leum Institute (API) service classifica-
0
tions SH, SG, SF, CF-4, CE, CD, CDll.
90-881980R1 NOVEMBER 2001 Page 1A-1

SPECIFICATIONS
Type Microcomputer-ECM
Spark Plug:
Type NGK LFR6A-11
Gap 0.039 - 0.043 in. (1.0 - 1.1 mm)
Hex Size 5/8 in. (16 mm)
Torque 18 lb-ft (25 Nm)
Hole Size 14 mm
Firing Order 1-3-4-2
Ignition Timing:
@ Idle (750 rpm) in Neutral 4° A.T.D.C
@ WOT (6000 rpm) 20° B.T.D.C
Stator Coil Output - Peak Voltage:
@ 400 rpm (Cranking) 10 - 18 V
@ 750 rpm (Idle) 16 - 24 V
@ 1500 rpm 16 - 24 V
@ 3500 rpm 16 - 24 V
Stator Coil Resistance 0.2 - 0.8 Ω
Crank Position Sensor - Peak Voltage:
@ 400 rpm (Cranking) 3.0 -6.3 V
@ 750 rpm (Idle) 9 - 16 V
@ 1500 rpm 18 - 28 V
@ 3500 rpm 35 - 55 V
Crank Position Sensor Resistance 445 - 565 Ω
IGNITION ECM (Coil Primary) - Peak Voltage:
SYSTEM @ 400 rpm (Cranking) 180 - 320 V
Readings taken @ @ 750 rpm (Idle) 180 - 235 V
68°F (20°C). @ 1500 rpm 230 -290 V
@ 3500 rpm 280 - 340 V
Ignition Coil Resistance
Primary 1.8 - 2.6 Ω
Secondary (Between Boots)
Coil for Cylinders 1 & 4 18.97 - 35.23 kΩ
Engine Protection Controls:
Engine Speed Limiter
Spark Cut-Out to Cylinders
#1 or #4 6200 rpm
#1 and #4 6250 rpm
#1, #4, and #2 or #3 6350 rpm
#1, #2, #3, and #4 6450 rpm
Overheat/Low Oil Pressure Engine
Speed Control (Spark Cut-Out to
Cylinders #1 and #4). Gradually Lowers to 2000 rpm
Water Temperature Sensor:
Warning Horn/rpm Reduction. 194°F (90°C)
Reset Temperature and Closed
Throttle. 167°F (75°C)
Engine Oil Pressure Switch:
Warning Horn/rpm Reduction Continuity Below 21.78 psi (150 kPa)
Page 1A-2 90-881980R1 NOVEMBER 2001

SPECIFICATIONS
Reset Pressure and Closed

Throttle. No Continuity Above 21.78 psi (150 kPa)
Engine Water Temperature Sensor
IGNITION Resistance:
SYSTEM @ 41°F (5°C) 4.62 kΩ
Readings taken @ @ 68°F (20°C) 2.44 kΩ
68°F (20°C). @ 212°F (100°C) 0.19 kΩ
Throttle Position Sensor (TPS):
Input Voltage @ Idle (750 rpm) 5.0 ± 0.25 V
Output Voltage@ Idle (750 rpm) 0.718 - 0.746 V
Alternator Type: Three Phase Stator Coil (12 Pole)
Alternator Output 12.0 V; 25 Amps. (300 Watts)
(Rectified/Regulated)
Stator Coil - Peak Voltage:
CHARGING @ 750 rpm (Idle) 16 - 24 V
SYSTEM @ 1500 rpm 16 - 24 V
Readings taken @ @ 3500 rpm 16 - 24 V
68°F (20°C). Stator Coil Resistance 0.2 - 0.8 Ω
Rectifier/Regulator Output - Peak
Voltage:
@ 750 rpm (Idle) 12.5 - 15.5 V
@ 1500 rpm 13.0 - 16.0 V
@ 3500 rpm 13.0 - 16.0 V
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Sliding Gear
Model/Manufacturer S114-838A/Hitachi
Output 1.4 kW - 12 V
Rating 30 Seconds
Reduction Gear Ratio 7.85 (102:13)
Brush:
Length 0.610 in. (15.5 mm)
STARTING
Minimum Length 0.374 in. (9.5 mm)
SYSTEM
Commutator:
Diameter 1.113 in. (29.0 mm)
Minimum Diameter 1.100 in. (28.0 mm)
Undercut 0.020 in. (0.5 mm)
Undercut Limit 0.008 in. (0.2 mm)
Ampere Draw Under:
(Load) 165 Amps
(No Load) 80 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
BATTERY
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) 70 - 100
Fuel Pump Type External (Plunger/Diaphragm)
Fuel Pump:
FUEL Discharge (@ 3000 rpm) 17 gph (65 L/h)
SYSTEM Pressure (Maximum) 7 psi (49 kPa)
Plunger Stroke 0.23 - 0.36 in. (5.85 - 9.05 mm)
Fuel Tank Capacity Accessory

SPECIFICATIONS
Fuel Injection System Batch (1 & 4) - (2 & 3)

Idle rpm (In Neutral) Warm 750 ± 50 rpm
FUEL INJECTION
Idle rpm (In Forward Gear) Warm 700 ± 50 rpm
Fuel Pressure @ 1500rpm 41-44 psi (283-304 kPa)
Type In–Line, 4 Stroke – DOHC, 16 Valves
CYLINDER
Displacement 106.2 cid (1,741 cc)
BLOCK
Number of Cylinders 4
STROKE Length 3.496 in. (88.8 mm)
Diameter
Standard 3.110 - 3.111 in. (79.000 - 79.020 mm)
CYLINDER
Oversize-0.010 in. (0.25 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm)
BORE
Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Piston Type Aluminum
Measure Point (H) 0.51 in. (13 mm)
O.D. at Skirt (H)
Standard (D) 3.1074 - 3.1082 in. (78.928 - 78.949 mm)
PISTON Pin Boss Inside Diameter 0.7090 - 0.7093 in. (18.008 - 18.015 mm)
H
D
PISTON Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm)
CLEARANCE
Top Ring
Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm)
Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm)
End Gap (Installed) T 0.006 - 0.012 in. (0.15 - 0.30 mm)
Side Clearance 0.001 - 0.003 in. (0.03 - 0.08 mm)
Middle Ring
Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm)
Dimension “T” 0.118 - 0.126 in. (3.00 - 3.20 mm)
RINGS B 0.028 - 0.035 in. (0.70 - 0.90 mm)
End Gap (Installed)
Bottom (Oil Ring)
T
Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm)
Dimension “T” 0.094 in. (2.40 mm)
End Gap (Installed) 0.008 - 0.028 in. (0.20 - 0.70 mm)
Side Clearance B 0.001 - 0.006 in. (0.03 - 0.15 mm)
T
COMPRESSION Compression Ratio 9.7:1
RATIO Cylinder Compression (Minimum) 138 psi (950 kPa)
PISTON PIN Piston Pin Outside Diameter 0.7085 - 0.7087 in. (17.997 - 18.000 mm)

SPECIFICATIONS
Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm)
Big End Inside Diameter 1.7726 - 1.7734 in. (45.025 - 45.045 mm)
Oil Clearance (Big End) 0.0010 - 0.0012 in. (0.025 - 0.031 mm)
CONNECTING Big End Bearing Thickness
ROD Yellow 0.0591 - 0.0594 in. (1.502 -1.508 mm)
Green 0.0594 - 0.0596 in. (1.508 - 1.514 mm)
Blue 0.0596 - 0.0598 in. (1.514 - 1.520 mm)
Red 0.0598 - 0.0601 in. (1.520 - 1.526 mm)
Crankshaft Journal
Diameter 1.8891 - 1.8898 in.
(47.984 - 48.000 mm)
Crankshaft Pin
Diameter 1.6535 - 1.6528 in.
(42.000 - 41.982 mm)
CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm)
Crankshaft Run-out 0.001 in. (0.03 mm)
Crankcase Main Journal Inside

Diameter 2.1269 - 2.1276 in.
(54.023 - 54.042 mm)
Crankshaft Journal Oil Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm)
Upper Crankcase Main Journal
Bearing Thickness
Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm)
Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm)
Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm)
CRANKCASE Lower Crankcase Main Journal
Bearing Thickness
Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm)
Green 0.1188 - 0.1191 in. (3.017- 3.024 mm)
Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm)
Red 0.1193 - 0.1196 in. (3.031 - 3.038 mm)
No. 3 Main Journal Bearing Thickness
Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm)
Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm)
Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm)

SPECIFICATIONS
Camshaft Dimensions
Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm)
Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm)
Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm)
Exhaust “B” 1.178 - 1.184 in. (29.92 - 30.08 mm)
Valve Lift
Intake 0.287 in. (7.30 mm)
Exhaust B 0.275 in. (6.98 mm)
CAMSHAFT Run-out Limit 0.004 in. (0.1 mm)
Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm)
Camshaft Bearing Oil Clearance 0.0008-0.0024 in.(0.020-0.061 mm)
A
Free Length “a” 2.094 in. (53.20 mm)
Minimum Free Length 2.057 in. (52.25 mm)
Tilt Limit “b” Less than 0.10 in. (2.6 mm)
b
VALVE SPRING
a
Warp Limit 0.004 in. (0.1 mm)
CYLINDER HEAD
Camshaft Bearing Inside Diameter 0.984 - 0.985 in. (25.000 - 25.021 mm)
Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm)

SPECIFICATIONS
Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.007 - 0.009 in. (0.17 - 0.23 mm)
Exhaust 0.012 - 0.014 in. (0.31 - 0.37 mm)
Valve Face Angle

Intake 120°, 91°, 110°
Exhaust 140°, 91°, 110°
Valve Dimensions:
“A” Head Diameter
Intake 1.142 - 1.150 in. (29.00 - 29.20 mm)
Exhaust 0.945 - 0.953 in. (24.00 - 24.20 mm)
“B” Face Width
Intake 0.078 - 0.094 in. (1.98 - 2.40 mm)
Exhaust 0.089 - 0.106 in. (2.26 - 2.69 mm)
“C” Seat Width
Intake 0.062 - 0.076 in. (1.58 - 1.94 mm)
VALVES Exhaust 0.071 - 0.080 in. (1.80 - 2.02 mm)
“D” Margin Thickness
Intake 0.031 - 0.047 in. (0.80 - 1.20 mm)
Exhaust 0.039 - 0.055 in. (1.00 - 1.40 mm)
Stem Outside Diameter
Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm)
Exhaust 0.2346 - 0.2352 in. (5.960 - 5.975 mm)
Guide Inside Diameter
Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm)
Exhaust 0.2364 - 0.2369 in. (6.005 - 6.018 mm)
Stem To Guide Clearance
Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm)
Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm)
Stem Run-out Limit (max.) 0.001 in. (0.03 mm)
Valve Dimensions
“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness
Valve Lifter Outside diameter 1.1010 - 1.1016 in.

VALVE LIFTERS (27.965 - 27.980 mm)
Valve Lifter to Lifter Bore Clearance 0.0008 - 0.0022 in. (0.020 -0.056 mm)
Valve shim Thickness 0.0787 - 0.1299 in. (2.000 - 3.300 mm)
VALVE SHIM
(in 0.025 mm increments)
Valve Opening Temperature 122° F (50° C)
THERMOSTAT Full Open Temperature 140° F (60° C)
Valve Lift (Minimum) 0.17 in. (4.3 mm)

SPECIFICATIONS
Pump Type Trochoid with Relief Valve

Oil Pump Drive Drive shaft Spline
Discharge at 212°F (100°C) with
10W-30 Oil at 1000 rpm 1.56 gph (5.9 L/h)
LUBRICATION Engine Oil Pressure (Warm Engine)
SYSTEM @ 750 rpm 50.75 psi (350 kPa)
Engine Oil Pan Capacity Either 5 Qts. or 5 Liters
Relief Valve Opening Pressure 71 psi (490 kPa)
Oil Pump:
Non-Serviceable
Recommended Transom Height:
Short Shaft 20 in. (51 cm)
Long Shaft 25 in. (64 cm)
MID-SECTION
Steering Pivot Range 60°
Full Tilt Up Angle 71°
Allowable Transom Thickness (Max) 3 in. (76.2 mm)
Gear Ratio 2.07:1
Gearcase Capacity 24 fl oz (710 mL)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 29 Spiral/Bevel
Pinion Gear
GEAR HOUSING Pinion Height 0.025 in. (0.64 mm)
BIGFOOT Pinion Gear Locating Tool 91-12349A2
(2.07:1) Flat Number #2
Disc Number #3
Forward Gear Backlash 0.015-0.022 in. (0.38-0.55 mm)
Backlash Indicating Tool 91-19660--1
Mark Number #1
Water Pressure
@ 1000 rpm 5 psi (34.5 kPa)
@ 6000 rpm (WOT) 20.5 psi (141.5 kPa)

SPECIFICATIONS
Propeller Information Charts
Mercury/Mariner 115 EFI (4-Stroke) 2.07:1

Wide Open Throttle RPM : 5000-6000
Recommended Transom Heights : 20 in. (50.8 cm), 25 in. (63.5 cm)
Right Hand Rotation Standard
Gear Reduction : 2.07:1
Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13-1/2″ 26″ 3 Steel Up to 1700 Up to 17′ 51-67 48-16996A45
13-1/2″ 24″ 3 Steel Up to 2000 Up to 18′ 45-60 48-16994A45
12-1/2″ 23″ 3 Alum 1700-2400 16-18′ 43-57 48-77350A45
13-1/2″ 22″ 3 Steel 1800-2600 16-18′ 40-54 48-16992A45
12-3/4″ 21″ 3 Alum 2000-2800 16-19′ 38-51 48-77348A45
13-1/4″ 20″ 3 Steel 2100-3100 17-19′ 36-48 48-16990A45
13″ 19″ 3 Alum 2300-3400 17-19′ 33-45 48-77346A45
13″ 18″ 3 Steel 2500-3700 18-20′ 31-42 48-16988A45
13-1/4″ 17″ 3 Alum 2800-4100 18-21′ 29-39 48-77344A45
13-1/8″ 16″ 3 Steel 3100-4500 19-22′ 26-36 48-16986A45
13-1/4″ 16″ 3 Alum 3100-4500 19-22′ 26-36 48-85360A45
13-3/4″ 15″ 3 Alum 3400-5000 19-23′ 24-33 48-77342A45
13-3/8″ 14″ 3 Steel 3800-5700 21-25′ 22-30 48-17314A45
14″ 13″ 3 Alum 4200-6400 22-26′ 20-28 48-77340A45
14″ 12″ 3 Steel 5000+ pontoon 17-24 48-17312A45
14″ 11″ 3 Alum 6000+ pontoon/work 15-21 48-77338A45
14″ 10″ 3 Steel 8000+ houseboat/ 1-19 48-17310A45
work

SPECIFICATIONS
Mercury/Quicksilver Lubricants and Sealants

Description Mercury Part Number Quicksilver Part Number
Needle Bearing Assy. Lubricant
92-802868A1 N/A
[8 oz. (226.8 grams)] tube
Dielectric Grease
92-823506-1 92-823506-1
[8 oz. (226.8 grams)] can
Loctite 271 – Thread Locker
92-809819 92-809819
(10 ml) tube
Loctite 567 PST Pipe Sealant
92-809822 92-809822
(50 ml) tube
Loctite Master Gasket Kit 92-12564-2 92-12564-2
2 Cycle Premium Outboard Oil
92-802815A1 92-802815Q1
[1 Gallon (3.7 liter)]
Perfect Seal
92-34227-1 92-34227-1
[16 oz. (0.45 kg)] can
Liquid Neoprene
92-25711-3 92-25711-3
[8 oz. (226.8 grams)] can
Cyanacrylate Adhesive Obtain Locally Obtain Locally
Bellows Adhesive N/A 92-86166Q1
Loctite 680 Retaining Compound
92-809833 92-809833
(10 ml) tube
Loctite 222 Thread Locker
92-809818 92-809818
(10 ml) tube
3M Permabond #3M08155 Obtain Locally Obtain Locally
Loctite 242 Thread Locker
92-809821 92-809821
(10 ml) tube
Loctite 609 Obtain Locally Obtain Locally
Page 1A-10 90-881980R1 NOVEMBER 2001

SPECIFICATIONS
Description Mercury Part Number Quicksilver Part Number
RTV 587 Silicone Sealer

92-809825 92-809825
[3 oz. (85.05 grams)]
Premium Gear Lubricant

92-802846A1 92-802846Q1
[1 Quart (0.94 liter)]
Loctite 7649 Primer

92-809824 92-809824
[4.5 oz (127.57 grams)]
Anti-Corrosion Grease
92-802867A1 92-802867Q1
2-4-C with Teflon

92-802859A1 92-802859Q1
Loctite Quick Tite Obtain Locally Obtain Locally
Isopropyl Alcohol Obtain Locally Obtain Locally
Hot Glue Obtain Locally Obtain Locally
Special Lubricant 101

92-802865A1 92-802865Q1
4 Stroke 10W30 Outboard Oil

92-802833A1 92-802833Q1
4 Cycle 25W40 Engine Oil

92-802837A1 92-802837Q1
Power Trim & Steering Fluid

92-802880A1 92-802880Q1
[8 oz. (226.8 grams)]
Engine Coupler Spline Grease

92-802869A1 92-802869Q1
[14 oz. (0.39 kg)] cartridge
90-881980R1 NOVEMBER 2001 Page 1A-11

SPECIFICATIONS
Torque Specifications
Fastener Location DIameter x Torque
Length (mm) lb-in. lb-ft. Nm
ELECTRICAL
Flywheel
Cover Screw M6 x 20 70 8
Stator Screw M6 x 28 70 8
Flywheel Nut N/A 140 190
Belt Tensioner Screw N/A 29 40
Ignition Components
Crank Position Sensor Mounting Screw N/A 43 5
Voltage Regulator/Rectifier M6 x 25 70 8
Mounting Screw
ECM Mounting Screw M6 x 28 70 8
Coil Mounting Screw M6 x 25 70 8
Spark Plug Cover Screw M6 x 16 70 8
Water Temperature Sensor Screw M6 x 16 70 8
Charging and Starting System
Starter Through Screw M6 x 120 70 8
Starter Solenoid Screw M6 x 52 70 8
Solenoid - Spade Connector N/A 78 9
Terminal Nut
Solenoid - Red Wire Terminal Nut N/A 70 8
Starter Motor Mounting Screw M8 x 45 156 13 18
Positive Battery Terminal Nut N/A 70
Negative Battery Terminal Screw M6 x 20 70 8
ELECTRONIC FUEL INJECTION
Intake and Intake Silencer
Intake Silencer Mounting Screw M6 x 16 70 8
Intake Assembly Mounting Screw M8 x 40 156 13 18
Intake Bracket Mounting Screw M6 x 20 70 8
Throttle Body
Throttle Body Mounting Screw M8 x 70 56 13 18
Throttle Body Bracket Screw M6 x 25 70 8
Accelerator Cam Nut N/A 70 8
Throttle Control Lever Mounting Screw M6 x 30 70 8
Fuel Injection
Fuel Rail Joint Screw M5 x 16 43 5
Fuel Rail Mounting Screw M8 x 45 13 18
Fuel Rail/Fuel Cooler Mounting Screw M6 x 25 70 8
Vapor Separator Mounting Screw M6 x 30 70 8
Pressure Regulator Screw M6 x 12 70 8
Idle Air Control Assembly M8 x 60 156 13 18
Mounting Screw M8 x 24
Page 1A-12 90-881980R1 NOVEMBER 2001

SPECIFICATIONS

Manifold Absolute Pressure Sensor M5 x 15 43 5
Mounting Screw
Idle Air Control Mounting Screw M4 x 15 18 2
Throttle Position Sensor Tamper M4 x 12 18 2
Proof Screw
Bracket Tamper Proof Screw M5 x 12 40 5
Spark Plug Cover Screw M6 x 16 70 8
Fuel Filter Mounting Screw M6 x 16 70 8
Fuel Pump Mounting Screw M6 x 30 70 8
Fuel Pump Cover Screw M6 x 35 70 8
POWERHEAD
Cylinder Head
* Cylinder Head Screw M8 x 55 20 28
* Cylinder Head Screw M10 x 145 22 30
Head Cover Screws M6 x 30 70 8
Spark Plug Cover Screws M6 x 16 65 7.5
Anode Screw M6 x 20 70 8
Anode Cover Screw M8 x 25 156 13 18
Thermostat Screw M6 x 25 70 8
Camshaft/Oil Pump
* Camshaft Cap Screw N/A 150 17
Driven Sprocket Screw M10 x 35 44 60
Timing Belt Tensioner Screw M10 x 45 29.5 40
Cylinder Block/Crankcase
* Crankcase Cover Outer Screws M8 x 55 20 28
* Crankcase Cover Center Screws M8 135 14 19
* Exhaust Cover Screw M6 x 30 105 12
* Powerhead Mounting Nut N/A 35 47.5
* Powerhead Mounting Screw M8 x 35 20 27
* Connecting Rod Screw M8 x 38 132 11 15
Drive Sprocket Nut N/A 195 265
Powerhead/Oil Pump N/A
Powerhead Mounting Nut N/A 40 54.5
Powerhead Mounting Screw M8 x 35 20 27
Oil Pump Cover Screw M6 x 10 70 8
Oil Pick-up Tube Mounting Screw M6 x 20 100 11.5
Oil Pump Mounting Screw M6 x 45 85 9.5
NOTE: * = Must be tightened in sequence and/or multiple stages, and/or requires torque plus rotation.
See appropriate section of component for details.
90-881980R1 NOVEMBER 2001 Page 1A-13

SPECIFICATIONS

MID-SECTION
Bottom Cowl/Adaptor Plate
Bottom Cowl Screw M6 x 40 65 7.5
Grommet Cover Screw M6 x 20 65 7.5
Oil Drain Plug N/A 17.5 24
Lower Mounting Bolt M12 X 154 50 68
Upper Mounting Bolt M12 x 154 55 75
Adaptor Plate Screw M8 x 50 25 34
Oil Sump/Adaptor Plate M6 x 35 100 11.5
Check Valve N/A 15 1.5
Exhaust Tube Screw M6 x 60 100 11.5
Adaptor Plate Screw M6 x 36 100 11.5
Shift Linkage Bracket/Adaptor Screw M6 x 20 80 9
Drive Shaft Housing/Lower Unit Nut N/A 40 54
Lower Mount Clamp Screw N/A 17 23
Front Handle Assembly Bolt M6 x 75 65 7.5
Power Trim
Shock Rod Piston N/A 90 122
Shock Piston Screw N/A 35 4
End Cap N/A 45 61
Trim Motor/Manifold Assembly Screw N/A 80 9
Pump/Motor Assembly Screw N/A 70 8
Pump Plug N/A 120 13.5
Manifold Screw N/A 100 11
Clamp/Swivel Bracket
Grease Fitting N/A 40 3.5 4.5
Swivel Bracket Screw 1/4–28 x 1/2 in. 100 11.5
Link Arm Nut 3/8 in. 120 13.5
Link Arm Bolt 3/8-28 x 1/2 in. 20 27
Anchor Bracket Screw M10 x 30 40 54
Anchor Bracket Nut M10 40 54
Tilt Tube Nut (Port) N/A Drive Tight
* Tilt Tube Nut (Starboard) N/A *
Anode Assembly Screw M6 x 25 60 7
* Shift Link Nut N/A *
NOTE: * = Drive Nut until Assembly is drawn together; but must be free to pivot.
Page 1A-14 90-881980R1 NOVEMBER 2001

SPECIFICATIONS

LOWER UNIT
Gear Housing
Bearing Carrier Stud/Nut M8 x 48 225 25 34
Drive Shaft/Pinion Nut N/A 70 95
Water Pump Cover Screws M6 x 30 60 7
Water Pump Mounting Screw M6 x 25 60 7
Vent, Fill/Drain, Oil Level Screw N/A 60 7
Drive Shaft Housing/Lower Unit Nut N/A 40 54.2
Trim Tab Retaining Screw 7/16-14 x 1-1/4 22 30
in.
Propeller Nut N/A 55 75
Shift Shaft Bushing Assembly Screw M6 x 25 35 4
Anode Screw M6 x 40 60 7
CONTROL LINKAGE/
ATTACHMENTS
Throttle/Shift Linkage
Steering Cable Nut N/A 35 47.5
Throttle Lever Collar Nut N/A 70 8
Throttle Control Lever Mounting Bolt M6 x 30 70 8
Shift Bracket Screw M6 x 20 80 9
90-881980R1 NOVEMBER 2001 Page 1A-15

MAINTENANCE
Section 1B - Maintenance B
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Checking Power Trim Fluid . . . . . . . . . . . . . . . . . 1B-8
Inspection And Maintenance Schedule . . . . . . . 1B-2 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Before Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Oil Changing Procedure . . . . . . . . . . . . . . . . . 1B-9
After Each Use . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . 1B-10
Every 100 Hours of Use or Once yearly, Checking and Adding Engine Oil . . . . . . . . 1B-10
Whichever occurs first . . . . . . . . . . . . . . . . . . 1B-3 4-1/4 In. (108mm) Diameter Gear Case . . 1B-11
Every 300 Hours of Use or Three Years . . . 1B-3 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 1B-12
Every 400 Hours of Use or Four Years . . . . 1B-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Before Periods of Storage . . . . . . . . . . . . . . . 1B-3 Protecting External Outboard
Corrosion Control Anode . . . . . . . . . . . . . . . . . . . 1B-4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 1B-5 Protecting Internal Engine Components . . 1B-13
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Fuse Replacement – Electric Start Models . . . . 1B-6 Positioning Outboard for Storage . . . . . . . . 1B-13
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . 1B-6 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Special Tools
1. Flushing Attachment P/N 44357A2
2. Crankcase Oil Pump P/N 90265A5
3. Oil Filter Wrench P/N 91-802653Q1
90-881980R1 NOVEMBER 2001 Page 1B-1

MAINTENANCE
Inspection And Maintenance Schedule

To keep your outboard in the best operating condition, it is important that your outboard re-
ceive the periodic inspections and maintenance listed in the Inspection and Maintenance
Schedule. We urge you to keep it maintained properly to ensure the safety of you and your
passengers and retain its dependability.
WARNING
Neglected inspection and maintenance service of your outboard or attempting to
perform maintenance or repair on your outboard if you are not familiar with the cor-
rect service and safety procedures could cause personal injury, death, or product
failure.
Before Each Use
1. Check engine oil level.
2. Check that lanyard stop switch stops the engine.
3. Visually inspect the fuel system for deterioration or leaks.
4. Check outboard for tightness on transom.
5. Check steering system for binding or loose components.
6. Visually check steering link rod fasteners for proper tightness.
7. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. If operating in salt water, wash off all salt deposits and flush out the exhaust outlet of the
propeller and gear case with fresh water.
Page 1B-2 90-881980R1 NOVEMBER 2001

MAINTENANCE
Every 100 Hours of Use or Once yearly, Whichever occurs first

1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Change engine oil and replace the oil filter. The oil should be changed more often when
the engine is operated under adverse conditions such as extended trolling.
3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve
is completely closed at room temperature. If questionable, inspect thermostat as out-
lined in Section 4B “Thermostat”.
4. Inspect and clean spark plugs.
5. Check engine fuel filter for contaminants.
6. Check engine timing setup.
7. Check corrosion control anodes. Check more frequently when used in salt water.
8. Drain and replace gear case lubricant.
9. Lubricate splines on the drive shaft.
10. Check power trim fluid.
11. Inspect battery.
12. Check control cable adjustments.
13. Inspect timing belt.
14. Remove engine deposits with Power Tune Engine Cleaner.
15. Check tightness of screws, nuts, and other fasteners.
Every 300 Hours of Use or Three Years
1. Replace water pump impeller (more often if overheating occurs or reduced water pres-
sure is noted).
Every 400 Hours of Use or Four Years
1. Check and adjust valve clearance if necessary.
Before Periods of Storage
1. Refer to Storage procedure (this section).

MAINTENANCE
Corrosion Control Anode

Each anode requires periodic inspection especially in salt water which will accelerate the
erosion. To maintain this corrosion protection, always replace the anode before it is com-
pletely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
1. The gear case has two corrosion control anodes. Another anode is installed on the bot-
tom of the transom bracket assembly.
c
a
a - Bottom Anode c - Side Anodes
b - Trim Tab
2. Three anodes are installed in the engine block. Remove anodes at locations shown.
Install each anode with rubber seal and cover. Tighten screws to specified torque.
NOTE: Do not remove center screw (b) until cover had been removed from engine.
e
c d
a
b
Do Not Remove
a - Anode d - Anode
b - Screw e - Rubber Seal
c - Cover
Anode Screw Torque
70 lb-in. (8 Nm)

MAINTENANCE
Spark Plug Inspection

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

MAINTENANCE
Fuse Replacement – Electric Start Models

The electric starting circuit is protected by overload fuses. If the fuse is blown, the electric
starter motor will not operate. Try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again. Replace the fuse with a fuse of the same amperage
rating.
1. Open the electrical cover and pull fuse with fuse puller. Look at the silver colored band
inside the fuse. If band is broken replace the fuse. Replace fuse with a new fuse of the
same amperage rating.
e
b
a
a - Fuse Puller
b - Electrical Cover
c - Fuses - 20 Amp.
d - Fuses - 30 Amp.
e - Blown Fuse
Timing Belt Inspection

1. Inspect the timing belt and replace if any of the following conditions are found.
a. Cracks in the back of the belt or in the base of the belt teeth.
b. Excessive wear at the roots of the cogs.
c. Rubber portion swollen by oil.
d. Belt surfaces roughened.
e. Signs of wear on edges or outer surfaces of belt.
a - Timing Belt

MAINTENANCE
Lubrication Points
Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon
1. Propeller Shaft – Refer to Propeller Replacement for removal and installation of the pro-
peller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from cor-
roding and seizing to the shaft.
Lubricate Points 2 thru 4 with 2-4-C Marine Lubricant with Teflon or Special Lubricant
101.
2. Swivel Bracket – Lubricate through fitting.
3. Tilt Support Lever – Lubricate through fitting.
4. Tilt Tube-Lubricate through fitting.

MAINTENANCE
5. Steering Cable Grease Fitting (If equipped) – Rotate steering wheel to fully retract the
steering cable end into the outboard tilt tube. Lubricate through fitting.
Lubricate Point 5 with light weight oil.
a
b
5
a - Steering Cable End
b - Fitting
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube be-
fore adding lubricant. Adding lubricant to steering cable when fully extended could
cause steering cable to become hydraulically locked. An hydraulically locked steer-
ing cable will cause loss of steering control, possibly resulting in serious injury or
death.
Checking Power Trim Fluid

1. Tilt outboard to the full up position and engage the tilt support lock.
a - Tilt Support Lock

2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of
the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive (ATF) au-
tomatic transmission fluid.
a - Fill Cap

MAINTENANCE
Changing Engine Oil

Oil Changing Procedure
Pump Method
1. Place the outboard in an vertical upright position.
2. Remove dipstick and slide adaptor tube/pump down dipstick tube. Pump out the engine
oil into an appropriate container.
a
90265A5
a - Crankcase Oil Pump
Drain Plug Method

1. Tilt the outboard up to the trailer position.
2. Turn the steering on the outboard so that the drain hole is facing downward. Remove
drain plug and drain engine oil into an appropriate container. Lubricate the seal on the
drain plug with oil and reinstall.
a - Drain Hole

MAINTENANCE
Changing Oil Filter

1. Place a rag or towel below the oil filter to absorb any spilled oil.
2. Unscrew old filter by turning the filter counterclockwise.
3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease.
Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.
91-802653Q1
a - Oil Filter
Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when
checking oil.
1. Remove the oil fill cap and add oil to to proper operating level.
2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on dip-
stick. Oil must be between full mark and add mark. Add oil if necessary.
58653 58655
a - Dipstick c - Full Mark

b - Oil Fill Cap d - Add Mark
Engine Oil Capacity
5 U.S. Quarts or (5.0 Liters)
Page 1B-10 90-881980R1 NOVEMBER 2001

MAINTENANCE
4-1/4 In. (108mm) Diameter Gear Case

When adding or changing gear case lubricant, visually check for the presence of water in
the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer. Water in the lubricant may
result in premature bearing failure, or in freezing temperatures, will turn to ice and damage
the gear case.
Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A
small amount of metal filings or fine metal particles indicates normal gear wear. An exces-
sive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and
should be checked by an authorized dealer.
DRAINING GEAR CASE
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.
3. Remove vent plugs and fill/drain plug and drain lubricant.
c
b
a - Fill/drain Plug
b - Rear Vent Plug
c - Front Vent Plug
Gear Case Lubricant Capacity
24 fl oz (710 ml)
90-881980R1 NOVEMBER 2001 Page 1B-11

MAINTENANCE
CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE

1. Place outboard in a vertical operating position.
2. Remove the front vent plug and rear vent plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent
hole. At this time install the front vent plug and sealing washer.
4. Continue adding lubricant until it appears at the rear vent hole.
5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing lu-
bricant tube.
6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
c b
a - Front Vent Plug

b - Rear Vent Plug
c - Front Vent Hole
d - Rear Vent Hole
e - Fill/Drain Plug and Sealing Washer
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, cor-
rosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out-of-
season storage or prolonged storage (two months or longer).
CAUTION
Never start or run your outboard (even momentarily) without water circulating
through the cooling water intake in the gear case to prevent damage to the water
pump (running dry) or overheating of the engine.
Page 1B-12 90-881980R1 NOVEMBER 2001

MAINTENANCE
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a forma-
tion of acid during storage and can damage the fuel system. If the gasoline being
used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, and carburetor) with treated (stabilized) fuel to
help prevent formation of varnish and gum. Proceed with following instructions.
1. Portable Fuel Tank – Pour the required amount of Fuel System Treatment & Stabilizer
(follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabi-
lizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Fuel System Treatment
& Stabilizer (follow instructions on container) into a separate container and mix with
approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment for circulating cooling water.
Run the engine for ten minutes to allow treated fuel to fill the engine fuel system.
Protecting External Outboard Components
1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes).
Protecting Internal Engine Components
1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder.
2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.
3. Change the engine oil.
Gear Case
1. Drain and refill the gear case lubricant (refer to maintenance procedure).
Positioning Outboard for Storage
Store outboard in an upright (vertical) position to allow water to drain out of outboard.
CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or rain
water that may have entered the propeller exhaust outlet in the gear case could
freeze and cause damage to the outboard.
Battery Storage
1. Follow the battery manufacturer’s instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
90-881980R1 NOVEMBER 2001 Page 1B-13

GENERAL INFORMATION
Section 1C - General Information C
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Propeller Removal/Installation . . . . . . . . . . . . 1C-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Standard Models . . . . . . . . . . . . . . . . . . . . . 1C-13
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-2 Power Trim System . . . . . . . . . . . . . . . . . . . . . . 1C-15
Conditions Affecting Performance . . . . . . . . . 1C-3 General Information . . . . . . . . . . . . . . . . . . 1C-15
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Power Trim Operation . . . . . . . . . . . . . . . . . 1C-15
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Trim “In” Angle Adjustment . . . . . . . . . . . . 1C-16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 1C-17
Following Complete Submersion . . . . . . . . . . 1C-6 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-18
Submerged While Running . . . . . . . . . . . . 1C-6 Cylinder Leakage Testing . . . . . . . . . . . . . . . . . 1C-19
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-6 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Fresh Water Submersion . . . . . . . . . . . . . . 1C-6 Water Pressure Measurement . . . . . . . . . . . . 1C-21
Model 115 (4-Stroke) Powerhead Views Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-22
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Cleaning & Painting Aluminum Propellers
Starboard View . . . . . . . . . . . . . . . . . . . . . . 1C-8 & Gear Housings . . . . . . . . . . . . . . . . . . . . . 1C-22
Port View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Aft View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Instructions for “Wet” Application . . . . . . . 1C-23
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-12
90-881980 NOVEMBER 2001 Page 1C-1

GENERAL INFORMATION
Special Tools
1. Compression Gauge MT26J (Snap-on) Adaptor MT26J300 (Snap-on) (or equivalent).
2. Water Pressure Gauge 91-79250A2.
3. Adapter P/N 22-86306.
4. Connector P/N 22-89772.
Serial Number Location

The Outboard serial number is located on the lower starboard side of the engine block. A
serial number is also located on the starboard side of the swivel bracket.
a OGXXXXXX
19XX
b
XXXX
c
e
XX
d
a - Serial Number
b - Model Year
c - Model Description
d - Year Manufactured
e - Certified Europe Insignia
Page 1C-2 90-881980 NOVEMBER 2001

GENERAL INFORMATION
Conditions Affecting Performance

Weather
Rated hp
Horsepower Loss
Due to Atmosphere
Conditions
Summer hp
Secondary Loss Due to
Propeller Becoming To
Large for Summer
Horsepower
RPM Drop Due

to Weather
ENGINE RPM Rated RPM
It is a known fact that weather conditions exert a profound effect on power output of internal
combustion engines. Therefore, established horsepower ratings refer to the power that the
engine will produce at its rated rpm under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards Or-
ganization) engine test standards, as set forth in I.S.O. 3046, standardizing the computation
of horsepower from data obtained on the dynamometer. All values are corrected to the pow-
er that the engine will produce at sea level, at 30% relative humidity, at a 77° F (25° C) tem-
perature and a barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure and high humidity all com-
bine to reduce the engine power. This, in turn, is reflected in decreased boat speeds--as
much as 2 or 3 miles-per-hour (3 or 5 Km per-hour) in some cases. (Refer to previous chart.)
Nothing will regain this speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine--running on a hot,
humid summer day--may encounter a loss of as much as 14% of the horsepower it would
produce on a dry, brisk spring or fall day. The horsepower that any internal combustion en-
gine produces, depends upon the density of the air that it consumes, and in turn, this density
is dependent upon the temperature of the air, its barometric pressure and water vapor (or
humidity) content.
Accompanying this weather-inspired loss of power is a second but more subtle loss. At rig-
ging time in early spring, the engine was equipped with a propeller that allowed the engine
to turn within its recommended rpm range at full throttle. With the coming of the summer
weather and the consequent drop in available horsepower, this propeller will, in effect, be-
come too large. Consequently, the engine operates at less than its recommended rpm.
90-881980 NOVEMBER 2001 Page 1C-3

GENERAL INFORMATION
Due to the horsepower/rpm characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss, how-
ever, can be regained by switching to a smaller pitch propeller that allows the engine to again
run at recommended rpm.
For boaters to realize optimum engine performance under changing weather conditions, it
is essential that the engine have the proper propeller to allow it to operate at or near the top
end of the recommended maximum rpm range at wide-open-throttle with a normal boat
load.
Not only does this allow the engine to develop full power, but equally important is the fact
that the engine also will be operating in an rpm range that discourages damaging detona-
tion. This, of course, enhances overall reliability and durability of the engine.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant ef-
fect on the boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in choppy water.
(4.) Will increase the danger of the following - wave splashing into the boat when
coming off plane.
b. Shifting weight to the front (bow)
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer left and right (bow steer).
BOTTOM
For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water
and particularly straight and smooth in fore-and-aft direction.
1. Hook: Exists when bottom is concave in fore-and-aft direction when viewed from the
side. When boat is planing, “hook” causes more lift on bottom near transom and allows
bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook”
frequently is caused by supporting boat too far ahead of transom while hauling on a trail-
er or during storage.
2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is con-
vex in fore-and-aft direction when viewed from the side, and boat has strong tendency
to porpoise.
3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear
housing increase skin friction and cause speed loss. Clean surfaces when necessary.
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in additional
boat weight (reduced boat performance), hull decay and eventual structural failure.
Page 1C-4 90-881980 NOVEMBER 2001

GENERAL INFORMATION
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on
the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow
back and collapse when striking the surface of the propeller blade resulting in the erosion
of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will
occur.
Engine
DETONATION
Detonation in a 4-cycle engine resembles the “pinging” heard in an automobile engine. It
can be otherwise described as a tin-like “rattling” or “plinking” sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug
has fired. Detonation creates severe shock waves in the engine, and these shock waves
often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings
or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 4-cycle application are as fol-
lows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine rpm below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot - incorrect reach - cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
• Combustion chamber/piston deposits (result in higher compression ratio).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
51115
Damaged Piston Resulting from Detonation
90-881980 NOVEMBER 2001 Page 1C-5

GENERAL INFORMATION
Following Complete Submersion

Submerged While Running (Special Instructions)
When an engine is submerged while running, the possibility of internal engine damage is
greatly increased. If, after engine is recovered and with spark plugs removed, engine fails
to turn over freely when turning flywheel, the possibility of internal damage (bent connecting
rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled.
Salt Water Submersion (Special Instructions)
Due to the corrosive effect of salt water on internal engine components, complete disassem-
bly is necessary before any attempt is made to start the engine.
Fresh Water Submersion (Special Instructions)
1. Recover engine as quickly as possible.
2. Remove cowling.
3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt
to start engine if sand has entered powerhead, as powerhead will be severely damaged.
Disassemble powerhead if necessary to clean components.
4. Remove spark plugs and get as much water as possible out of powerhead. Most water
can be eliminated by placing engine in a horizontal position (with spark plug holes down)
and rotating flywheel.
5. Change engine oil and filter as outlined in Section 1B “Changing Engine Oil”. Run
outboard for short time and check for presence of water in oil. If water present (milky
appearance) drain and refill as previously mentioned.
6. Pour alcohol into throttle body throats (alcohol will absorb water). Again rotate flywheel.
7. Turn engine over and pour alcohol into spark plug openings and rotate flywheel.
8. Turn engine over (place spark plug openings down) and pour engine oil into throat of
throttle bodies while rotating flywheel to distribute oil throughout crankcase.
9. Again turn engine over and pour approximately one teaspoon of engine oil into each
spark plug opening. Again rotate flywheel to distribute oil in cylinders.
10. Remove and clean intake manifold assembly (fuel rail, vapor separator, idle air control,
and throttle body assembly) and fuel pump assembly.
11. Dry all wiring and electrical components using compressed air.
12. Disassemble the engine starter motor and dry the brush contacts, armature and other
corrodible parts.
13. Reinstall spark plugs, intake manifold assembly, and fuel pump.
14. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
15. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should
be run within 2 hours after recovery of outboard from water, or serious internal damage
may occur. If unable to start engine in this period, disassemble engine and clean all
parts. Apply oil as soon as possible.
Page 1C-6 90-881980 NOVEMBER 2001

GENERAL INFORMATION
Model 115 (4-Stroke) Powerhead Front View
c
e
a - ECM
b - Voltage Regulator/Rectifier
c - Air Temperature Sensor
d - Engine Wiring Harness Connector
e - Power Trim Relay
f - 20 Amp Fuse (2)
g - 30 Amp Fuse (2)
90-881980 NOVEMBER 2001 Page 1C-7

GENERAL INFORMATION
Model 115 (4-Stroke) Powerhead Starboard View

a b
l
c
d
k
f
m g
e
9
58566
a - Starter Motor j - Ignition Coil Cylinders #2 &#3
b - Lifting Eye k - Ignition Coil Cylinders #1 &#4
c - 30 Amp Fuse (2) l - Engine Water Temperature Sen-
d - 20 Amp Fuse (2) sor
e - Oil Dip Stick m - Access Port, Water Pressure/
f - Oil Filter Temperature
g - Anode Cover n - Adaptor (22-86306)
h - Tell-Tale
i - Water Pressure Control
Valve
Page 1C-8 90-881980 NOVEMBER 2001

GENERAL INFORMATION
Model 115 (4-Stroke) Powerhead Port View

a a
b
58567
a - Lifting Eye (2)

b - Throttle Position Sensor (TPS)
c - Fuel Cooler
d - Fuel Pump
e - Fuel Filter
f - Shift Position Switch
90-881980 NOVEMBER 2001 Page 1C-9

GENERAL INFORMATION
Model 115 (4-Stroke) Powerhead Top View
b
a a
57870
a - Camshaft Gear (2)

b - Timing Belt
c - Lifting Eye (2)
d - Flywheel
e - Timing Belt Tensioner
f - Thermostat Housing
Page 1C-10 90-881980 NOVEMBER 2001

GENERAL INFORMATION
Model 115 (4-Stroke) Powerhead Aft View
j
a
g
b
d
a - Spark Plug Cover
b - Ignition Coil Cylinders #1 & #4
c - Ignition Coil Cylinders #2 & #3
d - Tell-Tale
e - Fuel Filter
f - Fuel Pump
g - Electronic Fuel Injectors (4)
h - Fuel Rail
i - Fuel Regulator
j - Oil Fill Cap
90-881980 NOVEMBER 2001 Page 1C-11

GENERAL INFORMATION
Propeller Selection
For in-depth information on marine propellers and boat performance - written by marine en-
gineers - see your Authorized Dealer for the illustrated “What You Should Know About
Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144).
For best all around performance from your outboard/boat combination, select a propeller
that allows the engine to operate in the upper half of the recommended full throttle rpm range
with the boat normally loaded (refer to Specifications). This rpm range allows for better ac-
celeration while maintaining maximum boat speed.
If changing conditions cause the rpm to drop below the recommended range (such as warm-
er, more humid weather, operation at higher elevations, increased boat load or a dirty boat
bottom/gear case) a propeller change or cleaning may be required to maintain performance
and ensure the outboard’s durability.
Check full-throttle rpm using an accurate tachometer with the engine trimmed out to a bal-
anced-steering condition (steering effort equal in both directions) without causing the pro-
peller to “break loose”.
Refer to “Quicksilver Accessory Guide” for a complete list of available propellers.
1. Select a propeller that will allow the engine to operate at or near the top of the recom-
mended full throttle rpm range (listed in “Specifications,” preceding) with a normal load.
Maximum engine speed (rpm) for propeller selection exists when boat speed is maxi-
mum and trim is minimum for that speed. (High rpm, caused by an excessive trim angle,
should not be used in determining correct propeller.) Normally, there is a 150-350 rpm
change between propeller pitches.
2. If full throttle operation is below the recommended range, the propeller MUST BE
changed to one with a lower pitch to prevent loss of performance and possible engine
damage.
3. After initial propeller installation, the following common conditions may require that the
propeller be changed to a lower pitch:
a. Warmer weather and great humidity will cause an rpm loss.
b. Operating in a higher elevation causes an rpm loss.
c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause
an rpm loss.
d. Operation with an increased load (additional passengers, equipment, pulling skiers,
etc.).
Page 1C-12 90-881980 NOVEMBER 2001

GENERAL INFORMATION
Propeller Removal/Installation
Standard Models
WARNING
If the propeller shaft is rotated while the engine is in gear, there is the possibility that
the engine will crank over and start. To prevent this type of accidental engine start-
ing and possible serious injury caused from being struck by a rotating propeller,
always shift outboard to neutral position and remove spark plug leads when you
are servicing the propeller.
1. Shift outboard to neutral position.
2. Remove the spark plug leads to prevent engine from starting.
3. Straighten the bent tabs on the tab washer.
a
a - Tab Washer
90-881980 NOVEMBER 2001 Page 1C-13

GENERAL INFORMATION
4. Place a block of wood between gear case and propeller to hold propeller and remove
propeller nut.
5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed,
have the propeller removed by an authorized dealer.
6. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Te-
flon.
95
95 2-4-C Marine Lubricant with Teflon
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller
shaft, especially in salt water, always apply a coat of the recommended lubricant to
the entire propeller shaft at the recommended maintenance intervals and also each
time the propeller is removed.
7. Flo-Torque I Drive Hub Propellers
e d
f
c b a
a - Thrust Washer
b - Propeller
c - Continuity Washer
d - Thrust Hub
e - Propeller Nut Retainer
f - Propeller Nut
Page 1C-14 90-881980 NOVEMBER 2001

GENERAL INFORMATION
8. Flo-Torque II Drive Hub Propellers
f e
d b a
c
a - Forward Thrust Hub
b - Replaceable Drive Sleeve
c - Propeller
d - Rear Thrust Hub
e - Propeller Nut Retainer
f - Propeller Nut
9. Place a block of wood between gear case and propeller and torque propeller nut to 55
lb-ft (75 Nm), aligning flat sides of the propeller nut with tabs on the tab washer.
10. Secure propeller nut by bending three of the tabs into the thrust hub grooves.
a b
b
a
a b
a - Thrust Hub Grooves
b - Tabs
Propeller Nut Torque
55 lb-ft (75 Nm)
11. Reinstall spark plug leads.
Power Trim System

General Information
The power trim system is filled at the manufacturer and is ready for use.
Trim outboard through entire trim and tilt range several times to remove any air from the sys-
tem.
The trim system is pressurized and is not externally vented.
Power Trim Operation
With most boats, operating around the middle of the “trim” range will give satisfactory re-
sults. However, to take full advantage of the trimming capability there may be times when
you choose to trim your outboard all the way in or out. Along with an improvement in some
performance aspects comes a greater responsibility for the operator, and this is being aware
of some potential control hazards. The most significant control hazard is a pull or “torque”
that can be felt on the steering wheel or tiller handle. This steering torque results from the
outboard being trimmed so that the propeller shaft is not parallel to the water surface.
90-881980 NOVEMBER 2001 Page 1C-15

GENERAL INFORMATION
WARNING
Avoid possible serious injury or death. When the outboard is trimmed in or out be-
yond a neutral steering condition, a pull on the steering wheel or tiller handle in ei-
ther direction may result. Failure to keep a continuous firm grip on the steering
wheel or tiller handle when this condition exists can result in loss of boat control
as the outboard can turn freely. The boat can now “spin out” or go into a very tight
maximum turn which, if unexpected, can result in occupants being thrown within
the boat or out of the boat.
Consider the following lists carefully:
TRIMMING IN OR DOWN CAN:
1. Lower the bow.
2. Result in quicker planing off, especially with a heavy load or a stern heavy boat.
3. Generally improve the ride in choppy water.
4. Increase steering torque or pull to the right (with the normal right hand rotation propel-
ler).
5. In excess, lower the bow of some boats to a point where they begin to plow with their
bow in the water while on plane. This can result in an unexpected turn in either direction
called “bow steering” or “over steering” if any turn is attempted or if a significant wave
is encountered.
WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim po-
sition as soon as boat is on plane to avoid possible ejection due to boat spin-out.
Do not attempt to turn boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel or tiller handle.
TRIMMING OUT OR UP CAN:
1. Lift the bow higher out of the water.
2. Generally increase top speed.
3. Increase clearance over submerged objects or a shallow bottom.
4. Increase steering torque or pull to the left at a normal installation height (with the normal
right hand rotation propeller).
5. In excess, cause boat “porpoising” (bouncing) or propeller ventilation.
6. Cause engine overheating if any water intake holes are above the water line.
Trim “In” Angle Adjustment
Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further “in” or “under”. This great-
er trim “under” capability improves acceleration, reduces the angle and time spent in a bow
high boat position during planing off, and in some cases, may be necessary to plane off a
boat with aft live wells (given the variety of available propellers and height range of engine
installations).
However, once on plane, the engine should be trimmed to a more intermediate position to
a avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering”
or “over steering” and inefficiently consumes horsepower. In this condition, if attempting a
turn or encountering a diagonal, moderate wake, a more abrupt turn than intended may re-
sult.
Page 1C-16 90-881980 NOVEMBER 2001

GENERAL INFORMATION
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished
by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets
is desired.
WARNING
Do not attempt to turn boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel or tiller handle.
If an adjustment is required, purchase a stainless steel tilt pin (P/N 17-49930A1) and insert
it through whatever pin hole is desired. The non-stainless steel shipping bolt should not be
used in this application other than on a temporary basis.
a - Optional Tilt Pin
Trim Tab Adjustment

Propeller steering torque will cause your boat to pull in one direction. This steering torque
is a normal thing that results from your outboard not being trimmed so the propeller shaft
is parallel to the water surface. The trim tab can help to compensate for this steering torque
in many cases and can be adjusted within limits to reduce any unequal steering effort.
NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is
installed with the anti-ventilation plate approximately 2 inches (50mm) or more above the
boat bottom.
Operate your boat at normal cruising speed, trimmed to desired position. Turn your boat left
and right and note the direction the boat turns more easily.
If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the
boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat turns
more easily to the right move the trailing edge of trim tab to the right. Retighten bolt and
retest.
a - Trim Tab
90-881980 NOVEMBER 2001 Page 1C-17

GENERAL INFORMATION
Compression Check
CAUTION
Before removing the spark plugs, use compressed air to blow away dirt accumu-
lated in the spark plug well.
NOTE: Use Snap-on compression gauge with adaptor (or equivalent) MT26J-MT26J300.
Spark plug size is 14 mm.
IMPORTANT: Compression check should be done with throttle in WOT position.
1. Check valve clearance (refer to “Valve Clearance Adjustment” in section 4A), adjust
if out of specification.
2. Warm up the engine.
3. Remove all spark plugs.
4. Lubricate threads in cylinder head and on compression gauge. Install compression
gauge in spark plug hole.
110
110
b a
P/N MT26J/MT26J300
110 4-Stroke Outboard Oil

a - Compression Gauge (MT26J - Snap-on)
b - Adaptor (MT26J300 - Snap-on)
5. Hold throttle plate at W.O.T.

6. Crank the engine over until the compression reading peaks on the gauge. Record the
reading.
7. Check and record compression of each cylinder. The highest and lowest reading
recorded should not differ by more than 15% (see example chart below). A reading
below 120 psi might indicate a total engine wear problem.
Compression Pressure (Minimum)

138 psi (950 Kpa, 9.5 kg/cm2)
Example of compression test differences:
Maximum (psi) Minimum (psi)

180 162
150 127.5
Page 1C-18 90-881980 NOVEMBER 2001

GENERAL INFORMATION
8. Remove compression gauge.

9. Install spark plugs.
NOTE: Compression check is important because an engine with low or uneven compres-
sion cannot be tuned successfully to give peak performance. It is essential, therefore, that
improper compression be corrected before proceeding with an engine tuneup.
Cylinder Leakage Testing

NOTE: Cylinder leakage testing, along with compression testing, can help the mechanic
pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine
cylinder. Refer to the manufactures tester instructions for proper testing procedures.
NOTE: Cylinders #1 and #4 TDC positions should show TDC mark on flywheel with timing
marks (f). Cylinders #2 and #3 TDC positions should show TDC mark alone (g).
#1
P/N MT324
b
#2 f
e
g
c
#3
d
#4
a - TDC for Cylinder #1 e - Cylinder Leakage Tester

b - TDC for Cylinder #2 (Snap-On-Tools MT324)
c - TDC for Cylinder #3 f - Flywheel Position For Arrow Positions #1 & #4
d - TDC for Cylinder #4 g - Flywheel Position For Arrow Positions #2 & #3
NOTE: Spark plug hole is a 14 mm diameter. Use Snap-On Tool MT26J300 adapter with
valve core removed.
90-881980 NOVEMBER 2001 Page 1C-19

GENERAL INFORMATION
Analysis
Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leak-
age. It is important only that cylinders have somewhat consistent reading between them.
Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a larger
percentage of cylinder leakage than smaller engines.
If excessive leakage is present, first check that the piston is at top dead center of its com-
pression stroke. Leakage will naturally occur if the exhaust or intake valve is open.
To determine the cause of high percentage leaks, you must locate where the air is escaping
from. Listen for air escaping thru the carburetor intake, adjacent spark plug holes, exhaust
pipe, and crankcase fill plug. Use the following table to aid in locating the source of cylinder
leakage:
Air Escaping From: Indicates Possible Defective:

Throttle Bodies Intake Valve
Exhaust System Exhaust Valve
Crankcase Fill Plug Piston or Rings
Adjacent Cylinders Head Gasket
Page 1C-20 90-881980 NOVEMBER 2001

GENERAL INFORMATION
Water Pressure Measurement

1. Warm up engine.
2. Remove plug.
3. Attach adaptor, hose fitting and water pressure gauge to cylinder block.
NOTE: Water pressure measurements should be done on a warm engine with thermostat
operating 140°F (60°C).
Water Pump Pressure

24
22-86306 22-89772 22
20
Pump Pressure (psi)

91-79250A2 18
a 16
14
12
10
8
6
4
2
0
0 1 2 3 4 5 6
rpm x 1000
a - Plug
90-881980 NOVEMBER 2001 Page 1C-21

GENERAL INFORMATION
Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne par-
ticles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite,
disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover
or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black.
GEAR HOUSINGS
The following procedures should be used in refinishing gear housings. This procedure will
provide the most durable paint system available in the field. The materials recommended
are of high quality and approximate marine requirements. The following procedure will pro-
vide a repaint job that compares with a properly applied factory paint finish. It is recom-
mended that the listed materials be purchased from a local Ditzler Automotive Finish Supply
Outlet. The minimum package quantity of each material shown following is sufficient to
refinish several gear housings.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint
blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly
adhere to the surface nor will the coating be sufficiently thick to resist future paint
blistering.
6. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufactur-
ers instructions, allowing proper induction period for permeation of the epoxy primer and
catalyst.
7. Allow a minimum of one hour drying time and no more than one week before top coating
assemblies.
8. Use Ditzler Urethane DU9000 for Mercury Black, DU34334 for Mariner Grey, and
DU35466 for Force Charcoal, and DU33414M for Sea Ray White. Catalyze all four col-
ors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.
Page 1C-22 90-881980 NOVEMBER 2001

GENERAL INFORMATION
CAUTION
Be sure to comply with instructions on the label for ventilation and respirators. Us-
ing a spray gun, apply one half to one mil even film thickness. Let dry, flash off for
five minutes and apply another even coat of one half to one mil film thickness. This
urethane paint will dry to the touch in a matter of hours, but will remain sensitive
to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode.
10. Cut out a cardboard “plug” for trim tab pocket to keep paint off of mating surface to main-
tain good continuity circuitry between trim tab and gear housing.
Decal Application
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing
old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Instructions for “Wet” Application
NOTE: The following decal installation instructions are provided for a “Wet” installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing Liquid/Detergent without ammonia. Do not use a soap that contains
petroleum based solvents.
** Automotive Body Filler Squeegee
SERVICE TIP: Placement of decals using the “Wet” application will allow time to posi-
tion decal. Read entire installation instructions on this technique before proceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct sun-
light. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C)
for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean application
surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface thor-
oughly with clean water.
90-881980 NOVEMBER 2001 Page 1C-23

GENERAL INFORMATION
DECAL APPLICATION
1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as
wetting solution.
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal
installation. This will ensure that the vinyl decal keeps its shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing from
“adhesive side” of decal.
3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wet-
ting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position pre-wetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting
solution with overlapping strokes to the outer edge of the decal. Continue going over the
decal surface until all wrinkles are gone and adhesive bonds to the cowl surface.
7. Wipe decal surface with soft paper towel or cloth.
8. Wait 10 - 15 minutes.
9. Starting at one corner, “carefully and slowly” pull the masking off the decal surface at
a 180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with
stick pin and press out the entrapped air or wetting solution with your thumb (moving toward
the puncture).
Page 1C-24 90-881980 NOVEMBER 2001

OUTBOARD MOTOR INSTALLATION
Section 1D - Outboard Motor Installation D
Table of Contents
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Front Cowl Grommet . . . . . . . . . . . . . . . . . . . . 1D-7
Boat Horsepower Capacity . . . . . . . . . . . . . . . . . 1D-1 Remote Wiring Harness . . . . . . . . . . . . . . . . . 1D-7
Start in Gear Protection . . . . . . . . . . . . . . . . . . . . 1D-2 Battery Cable Connections . . . . . . . . . . . . . . 1D-8
Selecting Accessories For The Outboard . . . . . 1D-2 Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-9
Installation Specifications . . . . . . . . . . . . . . . . . . . 1D-2 Speedometer (Optional) Water Pick-up . . . . 1D-9
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Shift Cable Installation . . . . . . . . . . . . . . . . . 1D-10
Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Throttle Cable Installation . . . . . . . . . . . . . . 1D-12
Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Trim-In Stop Adjustment . . . . . . . . . . . . . . . . . . 1D-13
Installing Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . 1D-14
Electrical, Hoses, and Control Cables . . . . . . . . 1D-7 Installation Drawing . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Electric Fuel Pump

If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine.
If necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity

U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
Do not overpower or overload the boat. Most boats will carry a required capacity plate
indicating the maximum acceptable power and load as determined by the manufacturer
following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can:
1. cause loss of boat control 2. place too much weight at the transom, altering
the designed flotation characteristics of the boat or 3. cause the boat to break
apart, particularly around the transom area. Overpowering a boat can result in
serious injury, death, or boat damage.
90-881980R1 NOVEMBER 2001 Page 1D-1

Start in Gear Protection

The remote control connected to the outboard must be equipped with a start-in-gear protec-
tion device. This prevents the engine from starting in gear.
WARNING
Avoid serious injury or death from a sudden unexpected acceleration when starting
your engine. The design of this outboard requires that the remote control used with
it must have a built in start-in-gear protection device.
Selecting Accessories For The Outboard

Genuine Quicksilver Parts and Accessories have been specifically designed and tested for
this outboard.
Some accessories not manufactured or sold by Quicksilver are not designed to be safely
used with this outboard or outboard operating system. Acquire and read the Installation, Op-
eration, and Maintenance manuals for all selected accessories.
Installation Specifications
a
a b
a – Transom Opening – Minimum

Single Engine (Remote) – 19 in. (483 mm)
Single Engine (Tiller) – 30 in. (762 mm)
Dual Engines – 40 in. (1016 mm)
b – Engine Center Line For Dual Engine
26 in. (660mm) Minimum
Page 1D-2 90-881980R1 NOVEMBER 2001

Lifting Outboard
Use Flywheel Puller/Lifting Eye (91-83164M).
Steering Cable
STARBOARD SIDE ROUTED CABLE
1. Lubricate O-ring seal and entire cable end.
95
95 2-4-C with Teflon
2. Insert steering cable into tilt tube.
3. Tighten nut to specified torque.
Cable Nut Torque

35 lb-ft (47.5 Nm)

Steering Link Rod

Installation Note
NOTE: For ease of installation of special bolt (a) separate the front end of the bottom cowl.
1. Install steering link rod per illustration.
a - Special Bolt (10-90041)

b - Nylon Insert Locknut (11-34863)
c - Flat Washer (2)
d - Nylon Insert Locknut (11-34863)
Special Bolt Torque
20 lb. ft. (27.1 N·m)
b - Nylon Insert Locknut Torque
20 lb. ft. (27.1 N·m)
d - Nylon Insert Locknut Torque
Tighten Locknut Until it Seats, Then Back Nut Off 1/4 Turn
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special bolt (“a” - Part Number 10-90041) and self locking
nuts (“b” & “d” - Part Number 11-34863). These locknuts must never be replaced with
common nuts (non locking) as they will work loose and vibrate off, freeing the link
rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown over-
board exposing them to serious injury or death.

Installing Outboard
Determining Recommended Outboard Mounting Height
26 in.
(660mm)
25 in.
(635mm)
24 in.
(609mm)
b
(e)
23 in.
Outboard (584mm) c
Mounting
Height
(See NOTE 22 in.
e Below) (560mm)
21 in.
(533mm) a
d
20 in.
(508mm)
19 in.
(482mm)
10 20 30 40 50 60 70 80
NOTE: Add 5 in. (127mm) for XL mod-
els to the listed outboard mounting Maximum Boat Speed Anticipated
height.
IMPORTANT
NOTICE TO INSTALLER
1. The outboard should be mounted high enough on the transom so that the exhaust
relief hole will stay at least 1 in. (25.4 mm) above the water line when the engine is
running at idle speed. Having the exhaust relief hole above the water line will prevent
exhaust restriction. Exhaust restriction will result in poor performance at idle.
2. However, keep in mind that the mounting height (e) of the outboard must not exceed
25 in. (635 mm) for L models, 30 in. (762 mm) for XL models. Mounting the outboard
higher may cause damage to the gear case components.
a. This solid line is recommended to determine the out- c. This line may be preferred to determine outboard
board mounting height. mounting height dimension, if maximum speed is the
only objective.
IMPORTANT: Increasing the height of outboard gener-
ally will provide the following: 1) Less steering torque, d. This line may be preferred to determine outboard
2) more top speed, 3) greater boat stability, but, 4) will mounting height dimension for dual outboard installa-
cause more prop “break loose” which may be particu- tion.
larly noticeable when planing off or with heavy load.
e. Outboard mounting height (height of outboard transom
b. These broken lines represent the extremes of known brackets from bottom of boat transom). For heights over
successful outboard mounting height dimensions. 22 in. (560mm), a propeller, that is designed for surfac-
ing operation is usually preferred.

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

and install outboard to the nearest recommended mounting height.
4. Fasten outboard with provided mounting hardware shown.
NOTE: The addition of the four flat washers (d) is a manufacturing running change. Out-
boards built before the running change will not have the flat washers.
e 109
d
b
a
109 RTV 587 Silicone Sealer
a - 1/2 in. Diameter Bolts (4)

b - Flat Washers (4)
c - Locknuts (4)
d - Flat Washers (4)
e - Apply to Shanks of Bolts, Not Threads

Electrical, Hoses, and Control Cables

IMPORTANT: Warning Horn Requirement – The remote control or key switch assem-
bly must be wired with a warning horn. This warning horn is used with the engine
warning system.
Front Cowl Grommet
Pull up the cowl seal and remove the cover from the bottom cowl.
Route the hoses, wiring and cables through the correct openings in the rubber grommet as
shown.
c d
a e
b
i
h g f
a - Cover f - Battery Cables Opening

b - Rubber Grommet g - Shift Cable Opening
c - Fuel Hose Opening h - Speedometer Tube
d - Remote Wiring Harness i - Sta-Strap (Included in Parts Bag),
Opening Tie Around Grommet After Com-
e - Throttle Cable Opening ponents are Installed
Remote Wiring Harness
Route wiring harness through the rubber grommet. Connect wiring. Push the retainer over
the exposed ends of the connectors. This will hold the connectors together.
a
BLU/WHT
GRN/WHT
BRN/WHT
GRN/WHT
BLU/WHT
TAN
a - Power Trim Connections b - Retainer – Push Over Connector

Ends

Battery Cable Connections

SINGLE OUTBOARD
(+)
(–) c
a - Red Sleeve (Positive)

b - Black Sleeve (Negative)
c - Starting Battery
DUAL OUTBOARDS
Connect a common ground cable (wire size same as engine battery cables) between nega-
tive (–) terminals on starting batteries.
(–)
(–)
d - Ground Cable (Same Wire Size As Engine Battery Cable) – Connect Between
Negative (–) Terminals

Fuel Hose
PORTABLE FUEL TANK
Select a suitable location in boat within engine fuel line length limitations and secure tank
in place.
PERMANENT FUEL TANK
These should be installed in accordance with industry and federal safety standards which
include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.
FUEL HOSE SIZE
Minimum fuel line inside diameter (I.D.) is 5/16 in. (8mm), with separate fuel line/fuel tank
pickup for each engine.
FUEL HOSE CONNECTION
Fasten remote fuel hose to fitting with hose clamp.
Speedometer (Optional) Water Pick-up
This outboard is equipped with a speedometer water pick-up located in the leading edge
of the gear case. If this water pick-up is to be used, locate the hose coming out of the front
grommet. Cut off the end of the hose fitting and make the connection.
a
c
b
NOTE: If the speedometer water pick-up hose is not used, keep the hose routed out of the
rubber grommet.
a - Fuel Hose
b - Hose Clamp – Secure Remote Fuel Hose
c - Speedometer Water Pick-up Hose for Optional Speedometer
CAUTION
Prevent possible water leakage. Water pick up hose must be routed through grom-
met and outside of lower cowl at all times.

Shift Cable Installation

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

3. Measure the distance between pin and center of barrel pocket.
F N R
a - Distance Between Pin And Center of Barrel Pocket

b - Pin
c - Barrel Pocket
Page 1D-10 90-881980R1 NOVEMBER 2001

4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain dis-
tance (a) taken in Step 3.
e
d
d - Shift Cable End

e - Cable Barrel
5. Fit shift cable through rubber grommet.
6. Place cable barrel into pocket. Fasten cable with hairpin cotter.
f - Place Barrel Into Barrel Pocket

g - Hairpin Cotter
7. Check shift cable adjustments as follows:
a. Shift remote control into forward. The propeller shaft should be locked in gear. If not,
adjust the barrel closer to the cable end.
b. Shift remote control into neutral. The propeller shaft should turn freely without drag.
If not, adjust the barrel away from the cable end. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propeller shaft should
be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps a
through c.
d. Shift remote control back to neutral. The propeller shaft should turn freely without
drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d.
90-881980R1 NOVEMBER 2001 Page 1D-11

Throttle Cable Installation

Install cables into the remote control following the instructions provided with the remote con-
trol.
1. Position remote control into neutral.
N
2. Install throttle cable to the throttle arm with hairpin cotter.

3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against
the idle stop.
4. Place cable barrel into retainer and install.
5. Fit throttle cable through the rubber grommet.
6. Lock the retainer in place with the cable latch.
d
a
c b
a - Flat Washer
b - Hairpin Cotter
c - Barrel Retainer
d - Throttle Arm
e - Cable Latch
f - Throttle Cable Opening
Page 1D-12 90-881980R1 NOVEMBER 2001

Trim-In Stop Adjustment

Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further “in” or “under”. This great-
er trim “under” capability improves acceleration, reduces the angle and time spent in a bow
high boat during planing off, and in some cases, may be necessary to plane off a boat with
aft live wells (given the variety of available propellers and height range of engine installa-
tions).
However, once on plane, the engine should be trimmed to a more intermediate position to
avoid a bow-down planing condition called “plowing”. Plowing can cause “bow steering” or
“over steering” and inefficiently consumes horsepower. In this condition, if attempting a turn
or encountering a diagonal, moderate wake, a more abrupt turn than intended may result.
In rare circumstances, the owner may decide to limit the trim under. This can be accom-
plished by purchasing a stainless steel tilt pin (P/N 17-49930A1) and inserting it through
whatever pin hole is desired. The non-stainless steel shipping bolt should not be used in this
application other than on a temporary basis.
WARNING
Do not attempt to turn boat when engine is trimmed extremely under or in.
a - Stainless Steel Tilt Pin
90-881980R1 NOVEMBER 2001 Page 1D-13

Trim Tab Adjustment

The trim tab can be adjusted within limits to help compensate for steering torque.
Adjust trim tab as follows:
1. If boat tends to pull to the right, move the rear edge of the trim tab to the right.
2. If boat tends to pull to the left, move the rear edge of the trim tab to the left.
NOTE: Trim tab adjustment will have little effect reducing steering torque if the anti-ventila-
tion plate is raised 2 inches (50mm) or more above the boat bottom.
Page 1D-14 90-881980R1 NOVEMBER 2001

Installation Drawing
90-881980R1 NOVEMBER 2001 Page 1D-15

IGNITION
ELECTRICAL
Section 2A - Ignition
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Stator Coil Peak Voltage . . . . . . . . . . . . . . 2A-25
A
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Rectifier/Regulator Output - Peak Voltage 2A-26
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Throttle Position Sensor (TPS)
Electrical Components . . . . . . . . . . . . . . . . . . . 2A-8 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . 2A-27
Ignition Components . . . . . . . . . . . . . . . . . . . . . 2A-10 Throttle Position Sensor Output Voltage . 2A-28
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12 Throttle Position Sensor Adjustment . . . . 2A-28
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-14 Resistance Tests . . . . . . . . . . . . . . . . . . . . . . . . 2A-29
Ignition Component Description . . . . . . . . . . . 2A-15 Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-29
Electronic Control Module (ECM) . . . . . . . 2A-15 Crank Position Sensor (CPS) . . . . . . . . . . 2A-30
Ignition Timing Control During Engine Ignition Coil (Primary) . . . . . . . . . . . . . . . . . 2A-30
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Coil (Secondary) . . . . . . . . . . . . . . 2A-31
Normal Operation . . . . . . . . . . . . . . . . . . . . 2A-15 Ignition Spark Gap . . . . . . . . . . . . . . . . . . . . 2A-31
Protection Controls . . . . . . . . . . . . . . . . . . . 2A-16 Engine water Temperature Sensor . . . . . . 2A-32
Shift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 2A-33
Throttle Position Sensor (TPS) . . . . . . . . . 2A-17 Flywheel Removal and Installation . . . . . . . . . 2A-34
Engine Water Temperature Sensor . . . . . 2A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-34
Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-36
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-18 Stator Removal and Installation . . . . . . . . . . . 2A-37
Crank Position Sensors (CPS) . . . . . . . . . 2A-18 Timing Belt Removal and Installation . . . . . . . 2A-38
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-38
Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-39
Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-19 Crank Position Sensor Removal . . . . . . . . . . . 2A-40
Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-20 Crank Position Sensor Installation . . . . . . . . . 2A-40
Multimeter/DVA Tester or DMT 2000 Voltage Regulator/Rectifier Removal
Multimeter with Direct Voltage Adaptor . . 2A-20 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-41
Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-20 ECM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-43
Recommended Test . . . . . . . . . . . . . . . . . . 2A-21 ECM Installation . . . . . . . . . . . . . . . . . . . . . . . . 2A-44
Testing Ignition Components . . . . . . . . . . . . . . 2A-23 Ignition Coil Removal . . . . . . . . . . . . . . . . . . . . 2A-45
ECM Peak Voltage (Coil Primary) . . . . . . . 2A-23 Ignition Coil Installation . . . . . . . . . . . . . . . . . . 2A-46
Crank Position Sensor (CPS) Water Temperature Sensor Removal
Peak Voltage . . . . . . . . . . . . . . . . . . . . . . . . 2A-24 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-47

IGNITION
Specifications
Spark Plug:
Type NGK LFR6A-11
Gap 0.039 - 0.043 in. (1.0 - 1.1 mm)
Hole Size 14 mm
Ignition Timing:
@ Idle (850 rpm) 4° A.T.D.C
@ WOT (6000 rpm) 20° B.T.D.C
@ 750 rpm (Idle) 16 - 24 V
@ 1500 rpm 16 - 24 V
@ 3500 rpm 16 - 24 V
@ 400 rpm (Cranking) 3.0 -6.3 V
@ 750 rpm (Idle) 9 - 16 V
@ 1500 rpm 18 - 28 V
@ 3500 rpm 35 - 55 V
68°F (20°C). @ 1500 rpm 230 -290 V
@ 3500 rpm 280 - 340 V
Coil for Cylinders #1 & #4 18.97 - 35.23 kΩ
Coil for Cylinders #2 & #3 18.55 - 34.45 kΩ
#1 or #4 6200 rpm
#1 and #4 6250 rpm
#1, #4, and #2 or #3 6350 rpm
#1, #2, #3, and #4 6450 rpm

IGNITION

SYSTEM @ 41°F (5°C) 4.62 kΩ
68°F (20°C). @ 212°F (100°C) 0.19 kΩ
Special Tools
1. Flywheel Holder P/N 91-83163M
2. Flywheel Puller P/N 91-83164M
3. Timing Light P/N 91-99379

IGNITION
4. Direct Voltage Adapter P/N 91-89045 or P/N 91-89045--1
91-89045
91-89045-1
5. Spark Board P/N 91-850439T
6. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1
7. Crank Position Sensor Test Harness 91-881825
58677

IGNITION
8. Stator Coil Test Harness 91-881824
58676
9. Throttle Position Sensor Test Harness 91-881827
58678
10. ECM (Coil Primary) Test Harness 91-881826
58679

IGNITION
Flywheel
22
21 24
23
20
2
3
1
4
3
5
6
19
11 10
12
13 9
8
14
14
18 15
16
17

IGNITION
Flywheel
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb.ft. Nm
1 1 FLYWHEEL COVER
2 2 SCREW (M6 X 20 MM) 65 7.5
3 4 COLLAR
4 2 GROMMET
5 1 NUT (36 MM HEX) 140 190
6 1 WASHER
7 1 FLYWHEEL
– 1 STATOR KIT
8 2 CRANK POSITION SENSOR
9 1 STATOR
10 3 SCREW (M6 X 28 MM) 65 7.5
11 1 SCREW (M4 X 8 MM) 18 2
12 1 CLAMP
13 4 SCREW (M6 X 28 MM) 70 8
14 2 DOWEL PIN
15 1 ROTOR
16 1 KEY
17 1 TIMING PLATE
18 1 SCREW
19 1 DECAL - Warning Neutral
20 1 DECAL - Warning Spinning Flywheel
21 1 DECAL - Servicing Referral
22 1 DECAL - Engine Oil/Valve
23 1 DECAL – Emergency Starting
24 1 DECAL - EPA

IGNITION
Electrical Components
33 6
18
17
37
34 6 19
15
16
2
1 3
4
8 13
6 14 22
7 21
39
20
9
10
11
12
5
40 25
6 24
26 23
35 27
6
36
6 32
30
31
29
38 28
6 Dielectric Grease

IGNITION
Electrical Components
TORQUE
REF.
REF
1 1 COVER
2 1 WIRE HARNESS
3 4 FUSE (20A)
4 4 FUSE (30A)
5 1 FUSE PULLER
6 1 BRACKET
7 1 SCREW
8 1 RELAY
9 2 WASHER
10 2 LOCKWASHER
11 2 SCREW
12 2 BOOT
13 1 RELAY
14 1 SCREW
15 1 CLAMP
16 1 SCREW
17 1 BRACKET
18 1 CLAMP
19 1 CLAMP
20 5 SCREW (M6 X 28 MM) 70 8
21 5 DAMPER
22 5 BUSHING
23 1 RELAY ASSEMBLY
24 1 LEAD WIRE
25 2 CAP
26 2 SCREW (M6 X 10 MM) 70 8
27 1 SCREW (M6 X 14 MM) 70 8
28 1 SCREW (M6 X 28 MM) 70 8
29 1 BATTERY CABLE (POSITIVE)
30 1 BATTERY CABLE (NEGATIVE)
31 1 NUT (M8) 70 8
32 1 SCREW (M6 X 20 MM) 70 8
33 1 HARNESS - Adaptor/Trim
34 1 HARNESS - Trim Motor Adaptor
35 1 HARNESS - Adaptor Assy.-Remote
36 1 RETAINER
37 1 CONNECTOR
38 AR STA-STRAP
39 1 DECAL - Warning-High Voltage
40 1 DECAL - Warning-Start in Gear

IGNITION
Ignition Components
12
11 10
12 14
13 14
10
11
8
11
4
1
3
Page 2A-10 90-881980R1 NOVEMBER 2001

IGNITION
Ignition Components
TORQUE
REF.
REF
1 1 ENGINE CONTROL UNIT
2 4 SCREW (M6 X 28 MM) 70 8
3 4 GROMMET
4 4 BUSHING
5 1 RECTIFIER & REGULATOR ASSEMBLY
6 2 SCREW (M6 X 25 MM) 70 8
7 1 SCREW (M6 X 20 MM) 70 8
8 1 IGNITION COIL
9 1 IGNITION COIL
10 2 PLATE
11 2 STA-STRAP
12 4 SCREW (M6 X 25 MM) 70 8
13 2 CLAMP
14 2 CLAMP
90-881980R1 NOVEMBER 2001 Page 2A-11

IGNITION
Sensors
6
5
10
8
1 9
7
4 11
12
12 13
15
12
14
16 12
Page 2A-12 90-881980R1 NOVEMBER 2001

IGNITION
Sensors
TORQUE
REF.
REF
1 1 WATER TEMPERATURE SENSOR
2 1 RETAINER
3 2 SCREW (M6 X 16 MM) 70 8
4 1 GASKET
5 1 CLAMP
6 1 SCREW (M6 X 10 MM) 70 8
7 1 PLATE
8 1 SCREW (M6 X 10 MM) 70 8
9 1 PLATE
10 2 SCREW (M6 X 16 MM) 70 8
11 1 WIRE HARNESS
12 6 STA-STRAP
13 1 CLAMP
14 1 OIL PRESSURE SWITCH 70 8
15 1 LEAD WIRE
16 1 SCREW (M6 X 10 MM) 70 8
90-881980R1 NOVEMBER 2001 Page 2A-13

IGNITION
Theory of Operation
The ignition system uses a microcomputer-controlled CDI (Capacitor Discharge Ignition)
system. This system provides quick voltage buildup and strong spark required for high
power and high performance engines. The ECM ignition system does not incorporate
mechanically operated points, therefore making this CDI unit virtually maintenance free.
As the flywheel rotates, electrical power (alternating current) is produced by the stator coils.
This power is rectified by diodes so that direct current voltage is utilized by the ignition sys-
tem. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capaci-
tor voltage is charged to its potential, a gate signal is applied on the SCR and the residual
current is dissipated through the capacitor charging coils.
Ignition timing is regulated by the ECM which receives status input from three different sig-
nals. These signals include the crankshaft position, engine revolution and throttle position.
The voltage discharged to the primary winding of the ignition coil causes a surge of high volt-
age to be induced in the secondary winding of the ignition coil. This induced voltage of suffi-
cient amplitude causes the spark plugs to fire.
Page 2A-14 90-881980R1 NOVEMBER 2001

IGNITION
Ignition Component Description

Electronic Control Module (ECM)
Under normal operating conditions the microcomputer-controlled CDI system has two basic
modes of operation: Ignition Timing Control During Engine Start-up, and Normal Operation.
Ignition Timing Control During Engine Start Up
The ignition timing is mainly determined by signals from the throttle position sensor and the
crank position sensors. Corrections are controlled by the water temperature sensor, the oil
pressure switch, the shift position switch, the engine stop switch after engine start and the
main switch. During cranking, the ignition timing is 10° BTDC until the engine starts, then
it is retarded 1° per second until it reaches 4° ATDC. The ignition timing is normally con-
trolled between 4° ATDC and 26° BTDC. While the engine is warming up, the ignition timing
is fixed at 4° ATDC. At rapid acceleration or deceleration ignition timing changes according
to the throttle valve opening angle.
Normal Operation
This mode operates between 4° ATDC and 26° BTDC. The ignition timing is automatically
adjusted by the microcomputer. The microcomputer receives three signals (i.e., crankshaft
position, engine revolution, and throttle position) every 5ms (microseconds) and then
adjusts the ignition timing accordingly.
Two crank position sensors (CPS) send signals to the microcomputer which then deter-
mines the crankshaft position and engine revolution.
The throttle position sensor (TPS) also sends signals to the microcomputer which then
determines the throttle position. The microcomputer uses these three signals to determine
the proper ignition timing.
90-881980R1 NOVEMBER 2001 Page 2A-15

IGNITION
Protection Controls
This ignition system incorporates three protection controls that are described below.
OVER-REVOLUTION CONTROL
If the engine speed exceeds 6,200 rpm, the ignition of either cylinder #1 or #4 is cut. If the
engine speed exceeds 6,250 rpm, the ignition of both cylinders #1 and #4 is cut. If the engine
speed exceeds 6,350 rpm, the ignition of cylinders #1 and #4, and either cylinder #2 or #3
is cut. If the engine speed exceeds 6,450 rpm, the ignition of all four cylinders is cut.
OVERHEATING CONTROL
When the engine speed is less than 2,000 rpm, this control mode is delayed 60 seconds
after the engine is started. When the engine speed is 2,000 rpm or more, this control mode
is delayed 20 seconds after the engine is started. The engine is considered to be over-heat-
ing if its temperature increases from 167° F (75° C) to 185° F (85° C). If its temperature ex-
ceeds 194° F (90° C), this control mode begins. The warning buzzer sounds (constant tone),
and the ignition and injection are cut according to the misfiring rate, gradually reducing en-
gine speed to approximately 2000 rpm.
If the engine overheats, the ignition/injection of both cylinders #1 and #4 is cut. However the
ignition/injection of cylinders #2 and #3 is not cut. After the engine temperature decreases
to less than 167° F (75° C), the overheat warning can be cancelled by decreasing the throttle
opening angle to less than 2°, and turning the ignition key to the off position.
LOW OIL PRESSURE CONTROL
When the oil pressure switch turns on (oil pressure 21.75 psi (150 kPa) or below), this mode
starts. The warning buzzer sounds (constant tone) and the ignition/injection are cut accord-
ing to the misfiring rate, gradually reducing engine speed to approximately 2000 rpm.
If the engine’s oil pressure is low, the ignition/injection of both cylinders #1 and #4 is cut,
however the ignition/injection of cylinders #2 and #3 is not cut. Once the oil pressure in-
creases to 21.75 psi (150 kPa) or higher, the warning can be cancelled by decreasing the
throttle opening angle to less than 2°, and turning the ignition key to the “OFF” position.
Shift Switch
As the remote control handle is shifted from forward gear to neutral (idle position), the switch
is monitored by the ECM which will adjust engine idle rpm accordingly – NEUTRAL @ 750
± 50 rpm; – IN GEAR @ 700 ± 50 rpm..
a - Shift Switch
b - Bracket
c - Alternate Mounting Holes
Page 2A-16 90-881980R1 NOVEMBER 2001

IGNITION
Throttle Position Sensor (TPS)

If the TPS is faulty, the ignition timing will automatically be fixed at 10° BTDC.
a - Throttle Position Sensor

If the engine temperature sensor is faulty, the ignition timing will automatically be fixed at
10° BTDC.
a - Engine Temperature Sensor

Flywheel Assembly
The flywheel assembly contains six permanently charged magnet segments which are
bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a
south pole providing a 12 pole system.
90-881980R1 NOVEMBER 2001 Page 2A-17

IGNITION
Stator Assembly
The stator assembly, located under the flywheel, contains coil windings which provides
three-phase AC voltage to power the ignition, electronic engine controls, and battery charg-
ing.
As the flywheel permanent magnets pass the coil windings, an AC pulse current is produced
at each coil winding as the magnet polarity changes. (South to North), (North to South) etc.
Crank Position Sensors (CPS)
57673
a - Crank Position Sensors (CPS)
As the crankshaft rotates, the CPS’s (2) sense a passing tooth on the rotor (located on the
crankshaft, under the cam belt drive gear). The CPS’s send signals to the microcomputer
(located within the ECM), which then determines both the crankshaft position and engine
speed.
Ignition Coils
58566
a - Ignition Coils
The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the
ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can
jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft
revolution, producing a spark at each cylinder at the same time (Wasted Spark Ignition).
Ignition coil maximum output is approximately 40,000 volts.
Page 2A-18 90-881980R1 NOVEMBER 2001

IGNITION
Ignition Test Procedures

Direct Voltage Adapter (DVA)
WARNING
DANGER – HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components
and/or metal test probes while engine is running and/or being “cranked”. STAY
CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark
plug lead should be grounded to engine.
WARNING
When testing or servicing the ignition system, high voltage is present. DO NOT
TOUCH OR DISCONNECT any ignition parts while engine is running, while key
switch is on or while battery cables are connected.
CAUTION
Failure to comply with the following items may result in damage to the ignition sys-
tem.
1. DO NOT reverse battery cable connections. The battery negative cable is (–) ground.
2. DO NOT “spark” battery terminals with battery cable connections to check polarity.
3. DO NOT disconnect battery cables while engine is running.
4. DO NOT crank engine with ECM or Ignition Coils not grounded.
CAUTION
To protect against meter and/or component damage, observe the following precau-
tions:
• 400 VDC* test position (or higher) MUST BE used for all tests.
• INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+) receptacle
of meter.
• DO NOT CHANGE meter selector switch position while engine is running and/or being
“cranked”.
• ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” en-
gine with ECM or Ignition Coils ungrounded may damage components.
* If using a meter with a built-in DVA, the DVA/400 or DVA/500 VDC test position should be
used.
NOTE: If test leads are not supplied with the Direct Voltage Adapter, use test leads supplied
with multi meter.
Test procedures and specifications are provided for checking primary ignition voltage
while the engine is running and/or being “cranked” with all harnesses connected.
90-881980R1 NOVEMBER 2001 Page 2A-19

IGNITION
Ignition Troubleshooting
WARNING
DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components
and/or metal test probes while engine is running and/or being “cranked”. STAY
CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark
plug lead should be grounded to engine.
WARNING
When testing or servicing the ignition system, high voltage is present. DO NOT
TOUCH OR DISCONNECT any ignition parts while engine is running.
IMPORTANT: This ignition system requires proper battery voltage to obtain proper
spark voltage.
Tool: Multimeter/DVA Tester 91-99750A1 or DMT 2000 Multimeter with Direct
Voltage Adaptor (91-89045)
*If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position.
NOTE: Copper is an excellent conductor, however resistance may notably vary between
low and high temperature. Therefore, reasonable differences can be accepted between
resistance readings and specifications.
The above readings are for a cold (room temperature) engine. Resistance will increase if
the engine is warm.
Ignition Diagnostic Procedures

TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark
advance of each cylinder as throttle is opened and closed. If timing advances and retards
on each cylinder, ignition system is MOST LIKELY functioning properly.
IMPORTANT: If outboard appears to have an ignition system failure, it is recom-
mended that before beginning in-depth troubleshooting:
a. Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder
Compression etc.).
b. Check all engine ground leads for loose or corroded connections.
c. Disconnect and reconnect ignition harness connectors to verify proper continuity.
SUGGESTED TESTING PROCEDURES
NOTE: The following recommended tests and probable causes are not listed in any specific
order. The technician should use this table as a guide to help isolate and test the specific
problem/condition. Always perform the DVA tests first (if applicable), then perform resis-
tance test to validate suspected component failure.
Page 2A-20 90-881980R1 NOVEMBER 2001

IGNITION
*Recommended Test
(1) DVA TEST (Direct Voltage Adapter)
(2) OHM TEST (Resistance Testing)
(3) Replace Component and Retest
(4) Mechanical Test/Repair
(5) Battery Voltage Check
PROBLEM/CONDITION Probable Cause *Perform

Test No.
No Spark Condition (All Cylinders) Stator 1-2
(ECM) 3
Stop Circuit Short to Ground:
a - stop circuit lead 2
b - lanyard stop switch 2
c - tiller handle stop button (if supplied) 2
d- remote control harness 2
Ignition Coil 2
a - primary Circuit Shorted to Ground 2
Spark Plugs 3
Open Ground Condition:
a - ignition coil 2
b - stator ground 3
c - (ECM) 3
d - battery to ECM 5
Rectifier/Regulator 1-2
No Spark Condition High Tension Lead (Resistance Lead) 2
(One or two Cylinder) Spark Plug Cap (Resistor) 2
Spark Plug 3
Weak Spark Condition Ground Connection at:
a - Ignition Coil Primary Leads 2
b - Stator 2
c - (ECM) Primary Coil Supply Leads 3
High Resistance To Ground at:
a - stop/lanyard switch (water/corrosion) 2
Weak Charge Coil (Stator) 1-2
Ignition Coil/High Tension Lead(s) 1-2-3
Spark Plug(s) 2
Spark Plug Cap (Resistor) 3
Spark Plug Cap Leak 3
(ECM) Failure 3
Battery Voltage Condition 5
Rectifier/Regulator 1-2
Timing Fluctuates Loss Of Oil Pressure/Over Heating:
NOTE: It is considered normal for the a - timing retards and fluctuates, rpm 4
timing to fluctuate approximately 1° - 2° will drop below 2000 rpm
Flywheel Key Sheared 4
within the designated timing window.
(ECM) 3
Timing Will Not Advance Low Oil Pressure/Engine Over Heating:
a - timing retards and fluctuates, rpm 4
will remain below 2000 rpm
(ECM) 3
90-881980R1 NOVEMBER 2001 Page 2A-21

IGNITION
*Recommended Test (cont.)

(1) DVA TEST (Direct Voltage Adapter)
(2) OHM TEST (Resistance Testing)
(3) Replace Component and Retest
(4) Mechanical Test/Repair
(5) Battery Voltage Check
Engine Misfires At High RPM Low Oil Pressure/Engine Over Heating:

a - timing retards and fluctuates, rpm 4
will remain below 2000 rpm (Cyl. #1 & #4)
Ignition Coil/High Tension Lead(s) 2
Spark Plug Cap(s) 2
Spark Plug(s) 3
(ECM) 3
Ground Connection:
a - (ECM) 3
b - ignition coil 2
Engine Hard To Start Cold Debris In Fuel Injection Circuit 4
Weak Spark Condition 1
Throttle Plate in Open Position 4
Engine Hard To Start Hot Weak Spark Condition 4
Vapor Lock 4
Debris In Fuel Injectors 4
Engine Will Not Run Over 3000 RPM Low Oil Pressure/Engine Over Heating:
a - timing retards and fluctuates, rpm
will remain below 2000 rpm 4
Ignition Coil/High Tension Lead(s) 2
(ECM) 3
Spark Plug(s) 3
Engine Occasionally Misfires Ignition Coil/High Tension Lead(s) 2
Spark Plug Cap(s) 2
Spark Plug(s) 3
Ground Connection at:
a - ignition coil 2
b - (ECM) 3
High Resistance To Ground at:
a - stop/lanyard switch (water/corrosion) 2
(ECM) 3
Engine Surges Over Boat Under Propped 4
6200 RPM While Under Load Propeller Hub Spun 4
NOTE: The engine (ECM) will retard
timing and reduce rpm above 6200 rpm.
Page 2A-22 90-881980R1 NOVEMBER 2001

IGNITION
Testing Ignition Components

ECM Peak Voltage (Coil Primary)
1. Plug test harness between each coil harness (test both coils), and perform tests as spe-
cified in chart below.
• If the reading obtained is above specification on any of the tests - replace the ignition
coil.
• If the reading obtained is below specification on any of the tests - measure the stator coil
output peak voltage.
a
d e
91-881826
91-89045-1
b
58657
91-854009A1
a - Direct Voltage Adaptor (91-89045-1) d - To Ignition Coil Harness
b - DMT 2000 Multi - Meter e - To Engine Wiring Harness
(91-854009A1)
c - Ignition Coil Test Harness
(91-881826)
NOTE: Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness
(91-881826) while performing test.
METER TEST LEADS METER READING (V)

SCALE
RED BLACK
TEST HARNESS LEADS
#1 AND #4 CYL. #1 AND #4 CYL. DC VOLTS 180-320 V @ 400 RPM (CRANKING*)
BLK/WHT GROUND 180 235 V @ 750 RPM (IDLE)
180-235
#2 AND #3 CYL. #2 AND #3 CYL. 230-290 V @ 1500 RPM
BLK/WHT GROUND 280-340 V @ 3500 RPM
*Cranking specifications obtained with high tension spark plug leads removed from spark
plugs.
90-881980R1 NOVEMBER 2001 Page 2A-23

IGNITION
Crank Position Sensor (CPS) - Peak Voltage

1. Plug in the test harness and perform tests as specified in chart below.
• If the reading obtained is above specification on any of the tests - replace the ECM unit.
• If the reading obtained is below specification on any of the tests - replace the CPS.
a
d e
91-881825
91-89045-1
91-854009A1 58645
a - Direct Voltage Adaptor (91-89045-1) d - To Engine Wiring Harness
b - DMT 2000 Multi - Meter e - To CPS Harness
(91-854009A1)
c - CPS Test Harness (91-881825)
NOTE: Use direct voltage adaptor, DMT 2000 digital multi-meter and test harness
91-881825 while performing test.
METER TEST LEADS METER READING (V)

SCALE
RED BLACK
TEST HARNESS LEADS
#1 AND #4 CYL. #1 AND #4 CYL. DC VOLTS 3.0 - 6.3 V @ 400 RPM (CRANKING*)
WHT/RED BLK 9.0 - 16.0 V @ 750 RPM (IDLE)
#2 AND #3 CYL. #2 AND #3 CYL. 18.0 - 28.0 V @ 1500 RPM
WHT/BLK BLK 35.0 - 55.0 V @ 3500 RPM
plugs.
Page 2A-24 90-881980R1 NOVEMBER 2001

IGNITION
Stator Coil Peak Voltage

• If the reading obtained is above specification on any of the tests - measure the ECM unit
output peak voltage.
• If the reading obtained is below specification on any of the tests - replace the stator.
91-881824
91-89045-1 a
58658
91-854009A1
a - Direct Voltage Adaptor (91-89045-1)
b - DMT 2000 Multi - Meter (91-854009A1)
c - CPS Test Harness (91-881825)
NOTE: Use direct voltage adaptor 91-89045-1, DMT 2000 digital multi-meter 91-854009A1
and test harness (91-881824) while performing test.
METER TEST LEADS METER SCALE READING (V)

RED BLACK
TEST HARNESS LEADS
10-18 V @ 400 RPM (CRANKING)
GREEN 1 GREEN 2 DC VOLTS 16 - 24 V @ 750 RPM ((IDLE))
GREEN 1 GREEN 3 16 - 24 V @ 1500 RPM
16 - 24 V @ 3500 RPM
GREEN 2 GREEN 3
plugs.
91-881824
a b a b a b
GRN 1 GRN 2 GRN 1 GRN 3 GRN 2 GRN 3
BLACK
BLACK
BLACK
RED
RED
RED
58676
a - To Stator Harness b - To Voltage Regulator/Rectifier
90-881980R1 NOVEMBER 2001 Page 2A-25

IGNITION
Rectifier/Regulator Output - Peak Voltage

• If the reading obtained is excessively below specification - check the stator coil output
peak voltage.
a
91-881824
91-89045-1
91-854009A1 58658
a - Direct Voltage Adaptor (91-89045-1)

b - DMT 2000 Multi - Meter (91-854009A1)
c - Stator Test Harness (91-881824)
NOTE: Use direct voltage adaptor 91-89045-1, DMT 2000 digital multi-meter 91-854009A1
and test harness (91-881824) while performing test.

RED BLACK
DC VOLTS 12.5
12 5 - 15
15.5
5 V @ 750 RPM (IDLE)
TEST HARNESS LEADS
13.0 - 16.0 V @ 1500 RPM
RED BLACK 13.0 - 16.0 V @ 3500 RPM
91-881824
a b
RED BLK
BLACK
RED
58676
a - To Stator Harness b - To Voltage Regulator/Rectifier
Page 2A-26 90-881980R1 NOVEMBER 2001

IGNITION
Throttle Position Sensor (TPS) Input Voltage

1. Disconnect Throttle Position Sensor harness.
2. Connect TPS Test Harness (91-881827) between TPS and TPS harness.
3. If the reading obtained is out of specification - check ECM.
91-881827
91-854009A1
58659
NOTE: Use DMT 2000 digital multimeter (91-854009A1) and test harness (91-881827)
while performing test.
RED BLACK
TEST HARNESS LEADS
DC VOLTS 5 0 ± 0.25
5.0 0 25 V @ 750 RPM
ORANGE BLACK
90-881980R1 NOVEMBER 2001 Page 2A-27

IGNITION
Throttle Position Sensor Output Voltage

1. Disconnect Throttle Position Sensor (TPS) Harness.
2. Connect TPS Test Harness (91-881827) between TPS and TPS Harness.
3. Start engine and allow it to warm up for several minutes.
4. Measure the voltage at engine idle speed in forward gear.
5. If the reading obtained is out of specification – adjust the TPS position.
6. Slowly open and close the throttle valves. Voltage should change gradually. If not, re-
place TPS.
91-881827
91-854009A1
58659
NOTE: Use DMT 2000 digital multimeter (91-854009A1) and test harness (91-881827)
while performing test.

RED BLACK
TEST HARNESS LEADS
DC VOLTS 0.718 ± 0.746 V @ 750 RPM
PINK BLACK (IDLE)
Throttle Position Sensor Adjustment

The Throttle Position Sensor and throttle shaft are pre-set at factory during emission calibra-
tion.
No adjustments should normally be made to these components as emission performance
will be compromised.
However, should it be necessary to replace the Throttle Position Sensor or throttle body, the
new components should be adjusted to initial factory emission specifications. Refer to Sec-
tion 2C for proper procedure.
Page 2A-28 90-881980R1 NOVEMBER 2001

IGNITION
Resistance Tests
When performing resistance tests, all component leads must be disconnected. Readings
may very slightly due to temperature changes. Readings listed taken at 68° F (20° C).
Stator Coil
1. Plug test harness into stator harness and perform tests as specified in chart below.
• Out of specification – replace.
91-881824
NOTE: Use ohm meter and test harness 91-881824 while performing test.
METER TEST LEADS METER SCALE READING ()

RED BLACK
TEST HARNESS LEADS
GREEN 1 GREEN 2 RX1 0.2 - 0.8
GREEN 1 GREEN 3
GREEN 2 GREEN 3
91-881824
a a a
GRN 1 GRN 2 GRN 1 GRN 3 GRN 2 GRN 3
BLACK
BLACK
BLACK
RED
RED
RED
58676
a - To Stator Harness
90-881980R1 NOVEMBER 2001 Page 2A-29

IGNITION
Crank Position Sensor (CPS)

1. Plug test harness into crank position sensor harness and perform tests as specified in
chart below.
• Out of specification – replace
b
91-881825
58645
a - CPS Test Harness (91-881825) b - To CPS Harness

RED BLACK
TEST HARNESS LEADS
#1 AND #4 CYL. #1 AND #4 CYL. RX1 445 - 565
WHT/RED BLK
#2 AND #3 CYL. #2 AND #3 CYL.
WHT/BLK BLK
Ignition Coil (Primary)

1. Plug test harness into each ignition coil harness (test both coils), and perform tests as
specified in chart below.
• Out of specification – replace.
b
91-881826
58657
a - Ignition Coil Test Harness (91-881826) b - To Ignition Coil Harness

RED BLACK
TEST HARNESS LEADS
RX1 1.8 - 2.6
BLK/WHT RED/YEL
Page 2A-30 90-881980R1 NOVEMBER 2001

IGNITION
Ignition Coil (Secondary)

NOTE: DO NOT remove high tension spark plug leads/spark plug caps when performing
this test.
8240
METER TEST LEADS METER READING ()

SCALE
RED BLACK COIL FOR CYL. #1 & #4 – 18.97 - 35.23
HIGH TENSION HIGH TENSION RX1K
LEAD LEAD COIL FOR CYL. #2 & #3 – 18.55 - 34.45
Ignition Spark Gap

1. Remove the spark plugs from the engine. Connect the spark plug cap to the spark gap
tester (P/N 91-850439).
2. Set the spark gap length on the adjusting tool (Spark Gap 0.4 in. 11mm).
3. Crank the engine and observe the ignition system spark through the discharge window.
• Below specification - continue to check the ECM unit output.
90-881980R1 NOVEMBER 2001 Page 2A-31

IGNITION
Engine water Temperature Sensor

1. Place the engine cooling water temperature sensor in a container filled with water.
2. Place a thermometer in the water and slowly heat the water.
3. Measure the resistance when the specified temperature is reached.
• Out of specification - replace.
a BLK
BLK/YEL
8260
a - Engine Temperature Sensor

RED BLACK
RX1K 4.62
6 @ 41°F (5
(5°C)
C)
BLK/YELLOW BLK 2.44 @ 68°F (20°C)
0.19 @ 212°F (100°C)
260
245
230
215
200
Temperature (F)
185 Temperature Sensor

170
155
140
125
110
95
80
65
50
35
20
5
–10
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Resistance (k)
Page 2A-32 90-881980R1 NOVEMBER 2001

IGNITION
Oil Pressure Switch

• If the reading obtained is out of specification - replace.
METER TEST LEADS READING PRESSURE

RED BLACK
Contin ity and below
Continuity
SWITCH END SWITCH EDGE 21.78 psi (150 kPa)
90-881980R1 NOVEMBER 2001 Page 2A-33

IGNITION
Flywheel Removal and Installation

WARNING
Engine could possibly start when turning flywheel during removal and installation.
To prevent this type of accidental engine starting and possible serious injury, al-
ways remove spark plug leads from spark plugs.
Removal
1. Remove flywheel cover.
57601
a - Screws (2)
Page 2A-34 90-881980R1 NOVEMBER 2001

IGNITION
2. Loosen flywheel nut. Hold flywheel using flywheel holder (91-83163M).

3. Remove nut and washer.
c
91-83163M
d
b 57583
a - Flywheel Holder (91-83163M)

b - Breaker Bar with 36 mm Socket
c - Nut (36 mm Hex)
d - Washer
4. Loosen flywheel using puller (91-83164M). Remove flywheel and key.
b
a
91-83164M
57582
a - Flywheel Puller (91-83164M)

b - Flywheel
c - Key
90-881980R1 NOVEMBER 2001 Page 2A-35

IGNITION
Installation
1. Place flywheel key into slot.
2. Install flywheel.
3. Install washer and nut.
4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque.
d
110
c
b 91-83163M
a

a - Key
b - Flywheel
c - Washer
d - Nut (36 mm Hex)
e - Torque Wrench
f - Flywheel Holder (91-83163M)
Flywheel Nut Torque
140 lb-ft (190 Nm)
Page 2A-36 90-881980R1 NOVEMBER 2001

IGNITION
Stator Removal and Installation

1. Remove flywheel.
2. Remove electrical cover.
3. Disconnect stator coupler from rectifier/regulator.
4. Remove screw from j-clip.
5. Remove stator mounting screws (3).
6. Disconnect RED wire connector and remove ground lead.
7. Reverse steps for installation.
e
a
d 57586
58662
58665
a - Press Clips to Release d - J-clip

b - Electrical Cover e - Screws (3) M6 x 30 mm
c - Stator Coupler
Stator Screw Torque
70 lb-in. (8 Nm)
90-881980R1 NOVEMBER 2001 Page 2A-37

IGNITION
Timing Belt Removal and Installation

Removal
1. Remove flywheel (refer to flywheel removal section).
2. Remove stator (refer to stator removal on previous page).
3. Remove stator coil assembly base screws (4).
4. Remove timing belt tensioner spring.
5. Loosen timing belt tensioner screw.
6. Remove timing belt.
c
b
57550
57585
a - Base Screws (4)

b - Timing Belt Tensioner Spring
c - Timing Belt Tensioner Screw
Page 2A-38 90-881980R1 NOVEMBER 2001

IGNITION
Installation
1. Align marks on driven gears as shown.
2. Align mark on drive gear as shown.
3. Follow sequence in note below and install timing belt onto drive gear. Slide timing belt
onto driven sprockets.
4. Install belt tensioner spring.
5. Tighten belt tensioner screw.
NOTE: Install timing belt with parts name up.
NOTE: Install timing belt over drive gear first (1), then around driven gear (2) making sure
belt is tight from drive gear to driven gear. Continue to keep belt tight while installing belt
around other driven gear (3). Make sure timing marks are lined up on drive gear and driven
gears, then place belt around belt tensioner (4). Install spring and tighten screw.
3 a 2
b 4
1 e
d
57550
a - Timing Mark on Driven Gears

b - Timing Belt Tensioner Spring
c - Timing Belt Tensioner Screw
d - Timing Mark on Drive Gear
e - Parts Name Up On Timing Belt
Belt Tensioner Screw Torque
29 lb-ft (40 Nm)
90-881980R1 NOVEMBER 2001 Page 2A-39

IGNITION
Crank Position Sensor Removal

1. Remove stator (refer to stator removal on previous page).
2. Remove stator coil assembly base screws.
3. Remove j-clips and 2 screws per crank position sensor from under side of stator coil
base assembly.
b
b
a c d c
57673
57585
a - Stator Coil Base Screws (4)
b - J-clips (2)
c - Crank Position Sensor Screws (4)
d - Crank Position Sensors (2)
Crank Position Sensor Installation

1. Position crank position sensors on stator plate.
2. Route sensor harnesses through respective j-clip and retainer.
3. Secure sensors with screws. Tighten screws to the specified torque.
Crank Position Sensor Screw Torque

43 in-ft. (5 Nm)
Page 2A-40 90-881980R1 NOVEMBER 2001

IGNITION
Voltage Regulator/Rectifier Removal and Installation

1. Disconnect regulator harness.
2. Remove 2 screws securing regulator and remove regulator.
58665
a - Regulator Harness
b - Screws (2)
90-881980R1 NOVEMBER 2001 Page 2A-41

IGNITION
58665
a - Regulator Harness
b - Screws (2)
Voltage Regulator/Rectifier Mounting Screw Torque
70 lb-in. (8 Nm)
Page 2A-42 90-881980R1 NOVEMBER 2001

IGNITION
ECM Removal
1. Depress clips and remove electrical cover.
b
58662
a - Clips
b - Electrical Cover
2. Remove intake silencer retaining screw and remove silencer.
58663
a - Intake Silencer
b - Screw M6 x 20 mm
90-881980R1 NOVEMBER 2001 Page 2A-43

IGNITION
3. Disconnect ECM harness connectors.

4. Remove 4 screws securing ECM and remove ECM.
58570
a - Harness Connectors
b - Screws (4) M6 x 28 mm
ECM Installation
1. Secure ECM with 4 screws.
2. Connect harness connectors.
3. Reinstall electrical cover.
4. Reinstall intake silencer and secure with screw.
Intake Silencer and ECM Mounting Screw Torque

70 lb-in. (8 Nm)
Page 2A-44 90-881980R1 NOVEMBER 2001

IGNITION
Ignition Coil Removal

1. Remove 5 screws securing spark plug cover.
b
a
58654
a - Screws (5) M6 x 16 mm
b - Spark Plug Cover
2. Disconnect spark plug leads from spark plugs.

3. Disconnect coil harness connectors.
4. Remove ignition coil mounting screws and remove coils.
a
b
58661
a - Harness Connectors
90-881980R1 NOVEMBER 2001 Page 2A-45

IGNITION
Ignition Coil Installation

1. Secure coils with screws.
Ignition Coil Mounting Screw Torque

70 lb-in. (8 Nm)
2. Reconnect coil harnesses.

3. Reconnect spark plug leads.
4. Reinstall spark plug cover and secure cover with 5 screws (a).
b
a
58654
Spark Plug Cover Mounting Screw Torque

65 lb-in. (7.5 Nm)
Page 2A-46 90-881980R1 NOVEMBER 2001

IGNITION
Water Temperature Sensor Removal and Installation

1. Remove wiring harness connector.
2. Remove 2 screws to remove sensor from exhaust cover.
UP
b
c 58686
a - Gasket
b - Water Temperature sensor
c - Retainer
d - Screws (2) M6 x 16 mm
Temperature Sensor Mounting Screws Torque
70 lb-in. (8 Nm)
90-881980R1 NOVEMBER 2001 Page 2A-47

CHARGING & STARTING SYSTEM
ELECTRICAL
Section 2B - Charging & Starting System
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
B
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Starting System Components . . . . . . . . . . . . . 2B-18
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Starting System Schematic . . . . . . . . . . . . 2B-18
Recommended Battery . . . . . . . . . . . . . . . . 2B-6 Troubleshooting the Starting Circuit . . . . . . . . 2B-19
Operating Engine Without Battery . . . . . . 2B-6 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-19
Battery Charging System Troubleshooting 2B-6 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . 2B-20
Battery Charging System . . . . . . . . . . . . . . . . . 2B-7 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
Description (25 Ampere) . . . . . . . . . . . . . . 2B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-21
Wiring Diagram (25 Ampere) . . . . . . . . . . . 2B-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22
Alternator System Test . . . . . . . . . . . . . . . . . . . 2B-8 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-24
25 Ampere Stator . . . . . . . . . . . . . . . . . . . . 2B-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26
Stator Coil Resistance Test . . . . . . . . . . . . . . . 2B-9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Rectifier/Regulator Diode Test . . . . . . . . . . . . 2B-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-31
Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-10

Specifications
Alternator Type: Three Phase Stator Coil (12 Pole)
Alternator Output 12.0 V; 25 Amps. (300 Watts)
(Rectified/Regulated)
Stator Coil - Peak Voltage:
CHARGING @ 750 rpm (Idle) 16 - 24 V
SYSTEM @ 1500 rpm 16 - 24 V
Readings taken @ @ 3500 rpm 16 - 24 V
68°F (20°C). Stator Coil Resistance 0.2 - 0.8 Ω
Rectifier/Regulator Output - Peak
Voltage:
@ 750 rpm (Idle) 12.5 - 15.5 V
@ 1500 rpm 13.0 - 16.0 V
@ 3500 rpm 13.0 - 16.0 V
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Sliding Gear
Model/Manufacturer S114-838A/Hitachi
Output 1.4 kW - 12 V
Rating 30 Seconds
Reduction Gear Ratio 7.85 (102:13)
Brush:
Length 0.610 in. (15.5 mm)
STARTING
Minimum Length 0.374 in. (9.5 mm)
SYSTEM
Commutator:
Diameter 1.113 in. (29.0 mm)
Undercut 0.020 in. (0.5 mm)
Undercut Limit 0.008 in. (0.2 mm)
Ampere Draw Under:
(Load) 165 Amps
(No Load) 80 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
BATTERY
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) 70 - 100

Special Tools
1. Brush Holder P/N91-875216
3. Stator Coil Test Harness 91-881824
58676

STARTER MOTOR
110
22
21
20 22
26
19
1
2
10
23 11
4 5
12
5
25
24
14 5
9 3
95
11
13
26 11
15
6
16
7
95
17
29
28 18 8
27
30
31


STARTER MOTOR
TORQUE
REF.
REF
– 1 STARTER MOTOR
1 1 STATOR
2 1 ARMATURE
3 1 BRUSH HOLDER ASSEMBLY
4 1 BRUSH SET
5 4 BRUSH SPRING
6 1 BRACKET
7 2 SCREW (M4 X 16 MM) 18 2
8 2 SCREW (M6 X 120 MM) 70 8
9 1 GEAR ASSEMBLY
10 1 CLUTCH
11 1 WASHER KIT
12 1 BRACKET
13 1 RING GEAR
14 1 GASKET
15 1 BEARING
16 1 PINION SHAFT
17 3 IDLER GEAR
18 1 BRACKET
19 1 COVER
20 2 SCREW (M6 X 52 MM) 70 8
21 1 PINION
22 1 STOP SET
23 1 LEVER
24 1 COVER
25 1 STARTER RELAY
26 3 SCREW (M8 X 45 MM) 156 13 17.5
27 1 TERMINAL
28 1 LOCKWASHER
29 1 NUT
30 1 NUT
31 1 COVER

Battery
Recommended Battery
A 12 volt battery with a minimum rating of 465 marine cranking amps (MCA) or 350 cold
cranking amps (CCA). For operation below 32° F (0° C) a rating of 1000 Marine Cranking
Amps (MCA) or 775 Cold Cranking Amps (CCA) is recommended.
Operating Engine Without Battery
If desired (or in an emergency), engines equipped with an electric start and alternator can
be started and operated without a battery (either disconnected or removed) if “WARNING”,
below, is followed.
WARNING
Before operating engine with battery leads disconnected from battery, disconnect
the three wire (stator harness plug) from rectifier.
Battery Charging System Troubleshooting

CAUTION
The charging system may be damaged by: 1) reversed battery cables, 2) running the
engine with battery cables disconnected and stator leads connected to rectifier, 3)
an open circuit, such as a broken wire or loose connection.
A fault in the battery charging system usually will cause the battery to become under-
charged. Check battery electrolyte level, and charge battery.
If battery will NOT accept a satisfactory charge, replace battery.
If battery accepts a satisfactory charge, determine the cause of the charging system prob-
lem as follows.
1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If polar-
ity was incorrect, check for damaged rectifier. See “RECTIFIER TEST”.
2. Check for loose or corroded battery connections.
3. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected,
loose or corroded connection.
4. Excessive electrical load (from too many accessories) will cause battery to run down.
If visual inspection determines that battery connections and wiring are OK, perform the fol-
lowing stator and rectifier tests.

Battery Charging System

Description (25 Ampere)
The battery charging system components are the stator coils, rectifier/regulator and battery.
Alternating current (generated in the stator coils) flows to the rectifier/regulator, which
changes the alternating current to a regulated direct current for charging the battery.
Wiring Diagram (25 Ampere)
BLK WHT BLK WHT
a 2 WHT 1
WHT
RED RED WHT d
BLK
RED
e
RED
c 30 (A) 3
BLK = Black
BLU = Blue
BRN = Brown
GRY = Gray
GRN = Green
ORG = Orange
PNK = Pink
BLK BLK PUR = Purple
RED = Red
TAN = Tan
BLK (with RED Sleeve) WHT = White
YEL = Yellow
4 b
a - Rectifier/Regulator
b - 12V Battery
c - Fuse-30A
d - Stator Coil
e - Connector

Alternator System Test

25 Ampere Stator
1. Check battery voltage at battery with engine running.
2. If battery voltage is above 14.5-15.0 volts, replace voltage regulator/rectifier. Check con-
dition of battery as overcharging may have damaged battery.
3. If battery voltage is below 14.5 volts, charge battery. If battery can NOT be satisfactorily
charged, replace battery.
4. If battery accepts a satisfactory charge, check battery voltage while cranking engine. If
cranking voltage is not acceptable, replace battery.
5. If cranking voltage is acceptable, disconnect the RED (voltage rectifier/regulator) wire
bullet connector from the RED engine wiring harness.
6. Connect RED (+) ammeter lead to RED voltage rectifier/regulator wire and the BLACK
(–) ammeter lead to the RED engine wiring harness.
7. Secure starter wires away from flywheel.
8. With engine running at the indicated rpm, the ammeter should indicate the following ap-
propriate amperes:
24
22
20
18
Alternator current (Amps)
16
14
12
10
8
6
4
2
0
0 1 2 3 4 5 6
RPM x 1000
9. A reading of 22 amperes at 6000 rpm indicates the charging system is functioning prop-
erly.
10. If ammeter reads less than required amperes @ 6000 rpm, test the stator (refer to “Sta-
tor Coil Resistance Test”). If stator tests OK, replace rectifier/regulator.

Stator Coil Resistance Test

1. Plug test harness (91-881824) into stator harness and perform test as specified in chart
below.
91-881824
a
91-854009A1
GRN 1 GRN 2
BLACK
RED
58658
58676
a a
GRN 1 GRN 3 GRN 2 GRN 3

BLACK
BLACK
RED
RED
58676
a - To Stator Harness

RED BLACK
TEST HARNESS LEADS
GREEN 1 GREEN 2 RX1 0.2 - 0.8
GREEN 1 GREEN 3
GREEN 2 GREEN 3

Rectifier/Regulator Diode Test

Analog Meter
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
Install Stator Coil Test Harness 91-881824 onto voltage regulator/rectifier.
POSITIVE SIDE OF BRIDGE DIODE TEST 1:
1. Set Ohm meter to R X 10 scale.
2. Connect RED (+) meter lead to RED regulator lead.
3. Connect BLACK (–) meter lead to each of GREEN regulator test harness leads.
91-881824
91-99750A1
BLACK
RED
58658
58676
a - To Voltage Regulator/Rectifier
TEST RESULTS:
100 - 300 OHMS
Page 2B-10 90-881980R1 NOVEMBER 2001

DIODE TEST 2:
1. Set Ohm meter to R X 1k scale.
2. Connect BLACK (–) meter lead to RED regulator lead.
3. Connect RED (+) meter lead to each of GREEN regulator test harness leads.
91-881824
91-99750A1
BLACK
RED
58658
58676
TEST RESULTS:
∞ OHMS (No needle movement)
90-881980R1 NOVEMBER 2001 Page 2B-11

GROUND SIDE OF BRIDGE DIODE TEST 3:

1. Set Ohm meter to R X 1k scale.
2. Connect RED (+) meter lead to BLACK ground wire.
91-881824
91-99750A1
BLACK
RED
58658
58676
TEST RESULTS:
∞ OHMS (No needle movement)
Page 2B-12 90-881980R1 NOVEMBER 2001

DIODE TEST 4:
1. Set Ohm meter to R X 10 scale.
2. Connect BLACK (–) meter lead to BLACK ground lead.
91-881824
a
91-99750A1
BLACK
RED
58658
58676
TEST RESULTS:
100 - 300 OHMS
90-881980R1 NOVEMBER 2001 Page 2B-13

Digital Meter
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
Install Stator Coil Test Harness 91-881824 onto voltage regulator/rectifier.
POSITIVE SIDE OF BRIDGE DIODE TEST 1:
1. Set meter to .
2. Connect RED (+) meter lead to RED regulator lead.
91-881824
a
91-854009A1
BLACK
RED
58658
58676
TEST RESULTS:
No continuity - Ouch - OL
Page 2B-14 90-881980R1 NOVEMBER 2001

DIODE TEST 2:
1. Set meter to .
2. Connect BLACK (–) meter lead to RED regulator lead.
91-881824
a
91-854009A1
BLACK
RED
58658
58676
TEST RESULTS:
0.4 - 0.85 OHMS
90-881980R1 NOVEMBER 2001 Page 2B-15

GROUND SIDE OF BRIDGE DIODE TEST 3:

1. Set meter to .
2. Connect RED (+) meter lead to BLACK ground wire.
3. Connect BLACK (–) meter lead to one GREEN regulator test harness lead. Test. Con-
nect BLACK (–) meter lead to each of other GREEN leads.
91-881824
a
91-854009A1
BLACK
RED
58658
58676
TEST RESULTS:
0.4 - 0.85 OHMS
Page 2B-16 90-881980R1 NOVEMBER 2001

DIODE TEST 4:
1. Set meter to .
2. Connect BLACK (–) meter lead to BLACK ground lead.
3. Connect RED (+) meter lead to each of 3 GREEN regulator test harness leads.
91-881824
a
91-854009A1
BLACK
RED
58658
58676
TEST RESULTS:
No Continuity - Ouch - OL
90-881980R1 NOVEMBER 2001 Page 2B-17

Starting System Components

Description
The function of the starting system is to crank the engine. The battery supplies electrical
energy to crank the starter motor. When the ignition switch is turned to “START” position,
the starter solenoid is activated and completes the starting circuit between the battery and
starter.
The neutral start switch opens the start circuit when the shift control lever is not in neutral.
This prevents accidental starting when engine is in gear.
The starting system consists of the following components.
1. Battery
2. Starter Solenoid
3. Neutral Safety Switch
4. Starter Motor
5. Ignition Switch
CAUTION
The starter motor may be damaged if operated continuously. DO NOT operate con-
tinuously for more than 30 seconds. Allow a 2 minute cooling period between start-
ing attempts.
Starting System Schematic
a c
b
BRN
BRN
f
RED
BRN/WHT
BLK BLK (with RED Sleeve)
e
BLK
a - Starter Motor d - 12 Volt Battery

b - Starter Solenoid e - Starter Relay
c - Engine Wiring Harness f - 30 Ampere Fuse
Connector
Page 2B-18 90-881980R1 NOVEMBER 2001

Troubleshooting the Starting Circuit

Before beginning the starting circuit troubleshooting flow chart, following, check first for the
following conditions:
1. Make sure that battery is fully charged.
2. Check that control lever is in “NEUTRAL” position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check 30 Amp fuse.
6. Check starter relay.
7. Check shift position switch. Refer to Section 2A Ignition.
Starter Solenoid Test
1. Inspect starter solenoid for cracks, loose terminals or loose terminal lead connections.
2. Connect ohm meter between relay (magnetic switch) terminals as shown.
3. Connect the starter motor body to the negative (–) battery terminal.
4. Connect the BROWN/WHITE lead to the positive (+) battery terminal.
5. Check that there is continuity between the relay (magnetic switch) terminals.
6. Check that there is no continuity after the BROWN/ WHITE lead is removed.
NOTE: The pinion gear should be pushed out while the magnet switch is ON.
b
a
c
a - Relay Terminals
b - BROWN/WHITE Lead
c - Battery
90-881980R1 NOVEMBER 2001 Page 2B-19

Starter Relay
1. Inspect starter relay for cracks, loose terminals, or loose terminal lead connections.
2. Connect ohm meter between starter relay terminals as shown.
3. Connect BLACK wire lead of starter relay to negative (–) terminal of 12 volt battery.
4. Connect BROWN/WHITE wire lead of starter relay to positive (+) terminal of 12 volt bat-
tery.
5. Replace starter relay if no continuity is found.
+ –
– +
b
c
d
a
8360
a - Ohm Meter Test Lead - BLACK

b - Ohm Meter Test Lead - RED
c - Starter Relay Wire Lead - BROWN/WHITE
d - Starter Relay Wire Lead - BLACK
e - 12 Volt Battery
Page 2B-20 90-881980R1 NOVEMBER 2001

Starter Motor
Removal
WARNING
Always disconnect the battery and remove spark plug leads from spark plugs be-
fore working on motor.
1. Disconnect battery leads. Remove electrical component cover. Disconnect RED wires
from starter solenoid. Disconnect BLACK (negative) battery cable from starter. Discon-
nect BROWN/WHITE wire from slave solenoid.
2. Remove 3 screws. Remove starter.
d
a
b
58672
58566
b - Positive (RED) Starter Motor Lead (Battery)
c - Negative (BLACK) Starter Motor Lead
d - BROWN/WHITE
90-881980R1 NOVEMBER 2001 Page 2B-21

Disassembly
1. Place starter in vise.
2. Rotate pinion gear clip opening towards front. Using a screwdriver push down on pinion
gear. Using a hammer tap pinion gear stopper until pinion gear clip is protruded enough
to pry out with a small screwdriver.
a b
57637
a - Pinion Gear
b - Pinion Gear Stopper
3. Loosen nut to disconnect spade connector on start solenoid from starter motor.
4. Remove 2 screws to separate start solenoid from starter motor.
a - Spade Connector
Page 2B-22 90-881980R1 NOVEMBER 2001

5. Remove 2 through screws from commutator end cap to separate commutator from gear
end.
6. Remove 2 screws from end cap to separate end cap from commutator.
b a
a - Thru Screws (2) M6 x 120 mm

b - Commutator End Cap Screws (2) M4 x 14 mm
7. Pull commutator along with grommet and brush assembly from end cap.
8. Using a suitable punch, tap plate from brush holder assembly.
9. Pull brush assembly from commutator.
57621
a - Plate
10. For pinion gear disassembly refer to exploded view.
90-881980R1 NOVEMBER 2001 Page 2B-23

Cleaning and Inspection

1. Clean all motor parts.
2. Check pinion teeth for chips, cracks or excessive wear.
3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is ex-
cessive.
4. Check that the brush holder is not damaged or is not holding the brushes against the
commutator.
5. Replace brushes that are pitted or worn to less than 0.374 in. (9.5 mm) in length. Refer
to “BRUSH REPLACEMENT”, following.
6. Replace a damaged or excessively worn bushing in the end cap.
7. Check the armature conductor (commutator bar junction) for a firm connection. A poor
connection usually results in a burned commutator bar.
8. Measure commutator undercut.
a - Undercut
Commutator Undercut Limit
0.008 in. (0.2 mm)
9. Open-circuited armatures often can be saved where an open circuit is obvious and re-
pairable. The most likely place for an open circuit is at the commutator bars. Long crank-
ing periods overheat the starter motor so that solder in the connections melts. The poor
connections cause arcing and burning of the commutator bars.
10. Armature inspection.
• Clean with 600 grit sandpaper.
Page 2B-24 90-881980R1 NOVEMBER 2001

11. Measure commutator diameter.

Commutator Diameter Limit

1.10 in. (28.0 mm)
12. Repair bars, that are not too badly burned, by re-soldering the leads in bars (using rosin
flux solder) and turning down the commutator in a lathe to remove burned material, then
undercut the mica.
13. Clean out the copper or brush dust from slots between the commutator bars.
14. Check the armature for shorts and ground. See “TESTING”.
90-881980R1 NOVEMBER 2001 Page 2B-25

Testing
ARMATURE TEST FOR GROUND
1. Set ohmmeter to (R x 1 scale).
2. To test commutator segments, place leads as shown. Should have continuity. If not
replace.
3. To test armature core, place leads as shown. Should have no continuity. If continuity ex-
ists, replace armature.
4. To test armature shaft, place leads as shown. Should have no continuity. If continuity
exists, replace armature.
c
a
b
a - Commutator Test c - Armature Shaft Test

b - Armature Test
BRUSH HOLDER INSPECTION

1. Measure brush length. If out of specification, replace brushes.
Brush Length Limit

0.374 in. (9.5 mm)
2. Set ohmmeter to (R x 1 scale).

NOTE: Only positive brushes 1 and 2 can be replaced. If negative brushes need to be re-
placed, then the entire brush holder assembly must be replaced.
3. Place leads on one positive brush and one negative brush. Should have no continuity.
If so, replace brushes. Repeat this procedure on the other brushes. Should have no con-
tinuity. If so replace brushes.
1 b
a - Negative (–) Brushes b - Positive (+) Brushes
Page 2B-26 90-881980R1 NOVEMBER 2001

Reassembly
1. Using special tool (91-875216) slide brush assembly over tool as shown. Slide brush
holder assembly onto commutator.
2. Replace plate onto armature end shaft by tapping with a hammer.
b d
a
57647
57635
91-875216 c
a - Brush Holder Tool (91-875216)

b - Brush Assembly
c - Plate
d - Threaded Holes
3. Slide armature assembly into end cap.
4. Secure armature assembly with 2 screws.
NOTE: Make sure thrust plate is installed inside cover.
NOTE: Make sure plate is aligned with threaded holes as shown above. Use punch to align
holes.
95
a
b
c

a - Thrust Plate
b - End Cap
c - Screws (2) M4 x 16
5. Install armature stator cover over armature.
b
a
57900
a - Armature Stator Cover

b - End Cap
90-881980R1 NOVEMBER 2001 Page 2B-27

6. Install lever into pinion shaft as shown.

7. Insert pinion shaft into top cover making sure it is seated properly.
8. Install bracket cover as shown.
57901
c
a - Lever
b - Pinion Shaft
c - Bracket Cover
9. Align marks and insert armature shaft assembly into top cover.
10. Secure with 2 through screws. Torque screws to specified torque.
b
b
57902
57636
a - Alignment Marks
b - Through Screws (2) M6 x 120
Starter Through Screw Torque
70 lb-in. (8 Nm)
Page 2B-28 90-881980R1 NOVEMBER 2001

11. Install starter solenoid to starter making sure grommet is in place and lever spring is in
proper holes of dust cover plate.
12. Slide lever into starter solenoid assembly shaft hole while inserting spring below lever
as shown.
13. Secure solenoid with 2 screws. Tighten to specified torque.
f
a c e
f
b
d
57626
a - Spring e - Lever
b - Dust Cover Plate Holes f - Shaft Hole
c - Screw M4 x 20 g - Solenoid Screws (2) M6 x 52
d - Grommet
Starter Solenoid Screw Torque
70 lb-in. (8 Nm)
14. Connect spade connector on start solenoid.
a
b
a - Spade Connector
b - Nut
Terminal Nut Torque
78 lb-in. (9 Nm)
90-881980R1 NOVEMBER 2001 Page 2B-29

15. Lubricate helix threads and drive end cap bushing with SAE 10W oil.
16. Install the spring, pinion and pinion stopper onto starter shaft.
17. Place circlip into groove on shaft.
18. Press the pinion stopper over the circlip.
IMPORTANT: Make sure the circlip fits tightly into pinion stopper.
a b
c
b d
d
c
a - Circlip
b - Pinion Stopper
c - Pinion
d - Spring
Page 2B-30 90-881980R1 NOVEMBER 2001

Installation
1. Secure RED leads to starter solenoid with nut.
58671
a - Nut
Terminal Nut Torque
70 lb-in. (8 Nm)
2. Install terminal cover over nut.
58669
a - Cover
90-881980R1 NOVEMBER 2001 Page 2B-31

3. Secure starter motor to cylinder block with 3 screws.
58566
a - Screws
Starter Motor Mounting Screw Torque
13 lb-ft (18 Nm)
4. Secure BRN/WHT lead to slave solenoid.
58672
a - BRN/WHT Lead
b - Slave Solenoid
Page 2B-32 90-881980R1 NOVEMBER 2001

5. Connect RED positive battery cable to starter solenoid.
58566
a - Positive (RED) Battery Cable
b - Starter Solenoid
c - Negative (BLACK) Battery Cable
Positive Battery Terminal Nut Torque
70 lb-in. (8 Nm)
Negative Battery Terminal Screw Torque*
70 lb-in. (8 Nm)
6. Reinstall electrical cover.

7. Reconnect battery cables to battery.
* If removed.
90-881980R1 NOVEMBER 2001 Page 2B-33

TIMING, SYNCHRONIZING, & ADJUSTING
ELECTRICAL
Section 2C - Timing, Synchronizing, & Adjusting
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Throttle Shutter Synchronization . . . . . . . 2C-7
C
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Throttle Cam Adjustment . . . . . . . . . . . . . . 2C-11
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5 Throttle Position Sensor (TPS) and
Throttle Shaft Adjustment . . . . . . . . . . . . . . 2C-13
90-881980R1 NOVEMBER 2001 Page 2C-1

Specifications
Spark Plug:
Type NGK LFR6A-11
Gap 0.039 - 0.043 in. (1.0 - 1.1 mm)
Hole Size 14 mm
Ignition Timing:
@ Idle (750 rpm) 4° A.T.D.C
@ WOT (6000 rpm) 20° B.T.D.C
@ 750 rpm (Idle) 16 - 24 V
@ 1500 rpm 16 - 24 V
@ 3500 rpm 16 - 24 V
@ 400 rpm (Cranking) 3.0 -6.3 V
@ 750 rpm (Idle) 9 - 16 V
@ 1500 rpm 18 - 28 V
@ 3500 rpm 35 - 55 V
68°F (20°C). @ 1500 rpm 230 -290 V
@ 3500 rpm 280 - 340 V
#1 or #4 6200 rpm
#1 and #4 6250 rpm
#1, #4, and #2 or #3 6350 rpm
#1, #2, #3, and #4 6450 rpm
Page 2C-2 90-881980R1 NOVEMBER 2001


SYSTEM @ 41°F (5°C) 4.62 kΩ
68°F (20°C). @ 212°F (100°C) 0.19 kΩ
NOTE: The 115 four stroke ECM unit electronically controls the ignition timing, therefore
making the ignition timing non adjustable. When initially running the outboard, use a timing
light to verify that the ignition timing falls within the timing windows. If the ignition timing does
not stay within the timing windows, replace the ignition ECM unit and retest.

Special Tools
1. New Style Vacuummate Carburetor Tuner P/N 91-809871-1
2. Old Style Mercury Filled Carburetor Tuner P/N 91-809641A1

Filters (4) P/N 35-18206
4. Timing Light P/N 91-99379

Timing
WARNING
To prevent personal injury or possible death, from loss of balance or stability while
servicing the motor, DO NOT attempt to check timing while boat is in motion. Failure
to follow one of the recommended servicing procedures may result in the person
falling overboard or causing personal injury from fall in boat.
WARNING
To prevent personal injury from spinning flywheel, Do Not attempt to remove fly-
wheel cover or place hands on top of cover when checking ignition timing.
Ignition timing is not adjustable. The ECM unit electronically controls the ignition timing.
When initially running the outboard, use a timing light to verify that the ignition timing falls
within the timing windows as described within the following tests. If the ignition timing does
not stay within the timing windows, replace the ignition ECM unit and retest. (Refer to the
Ignition Diagnostic Procedures tests in Section 2A.)
IMPORTANT: When checking the timing with the engine running, one of the following
test procedures must be followed.
Check maximum timing per specification while running the outboard:
• IN A TEST TANK (with a cut down propeller).
• ON A DYNAMOMETER.
• ON A BOAT SECURED ON A TRAILER “Backed in Water” (with a cut down propeller).
1. Attach timing light to #1 spark plug lead.
2. Place the outboard in “Forward” gear and check timing at idle “Retarded.” (If not within
specification window, refer to Diagnostic Test Procedures Section 2A.)
58684
b
a - Timing Mark (4° ATDC) (Full Retarded)
b - Pointer

3. Slowly increase the engine rpm while watching the ignition timing marks. The timing
should increase to the maximum timing specification “Full Advance” at approximately
6000 RPM. (If not within specification window, refer to Diagnostic Test Procedures Sec-
tion 2A.)
20
b
a - Timing Mark (26° BTDC) (Full Advance)
b - Timing Pointer

Throttle Shutter Synchronization

NOTE: The cylinders are synchronized by adjusting the intake manifold vacuum on the in-
take manifold. Use Carburetor Tuner (91-809641A1) or Vacuummate Tuner (91-809871--1)
to measure the vacuum.
1. Remove four plugs from the intake manifold.
a
a
58673
a - Plugs (4)

2. Install intake manifold hose adaptor in each plug hole. Tighten securely.
3. Connect the Vacuummate to the hose adaptors.
4. If using Carburetor Tuner (91-809641A1), install filters to prevent mercury being drawn
into engine during an abrupt throttle change.
58682
a - Intake Manifold Hose Adaptor (4) From Vacuummate Carb. Tuner
b - Intake Manifold Hose Adaptor (4) From Mercury Filled Carb Tuner
c - Vacuummate Carb. Tuner (91-809871--1)
CAUTION
Do not run engine at high rpm or abruptly change throttle position when using the
old style liquid mercury filled carb. tuner (91-809641). The possibility exists of draw-
ing liquid mercury from the carb tuner into the engine during high rpm running or
an abrupt throttle change. Installing filters (4) (35-18206) in each line will help to pre-
vent liquid mercury from being drawn into engine during an accidental abrupt
throttle change.

5. With the outboard in water, start engine and allow to warm up until engine idles at 750
± 50 rpm in neutral.
6. Connect a tachometer onto the spark plug lead of cylinder #4.
7. Turn the synchronizing screw so that vacuum pressures on cylinders #3 and #4 are with-
in 3 cm Hg (40 mbar, 1.18 in Hg) of minimum and maximum vacuum pressures of cylin-
ders #1 and #2. It’s not important to be at any specific vacuum setting.
NOTE: The vacuum pressure of cylinders #3 and #4 will most likely never be exactly the
same as cylinders #1 and #2 due to mechanical tolerances and different operating efficien-
cies of individual cylinders.
58682
Example
If the vacuum reading of Cyl. #1 and #2 (base vacuum) is 30
cm, then adjust synchronization screw to achieve 30 cm for
cylinders #3 and #4.
32 cm
30 cm
28 cm
26 cm
Cyl. Cyl. Cyl. Cyl.
#1 #2 #3 #4
NOTE: Tighten screw to increase vacuum. Loosen screw to decrease vacuum.

58641
a - Synchronizing Screw
8. Rev engine a few times and then allow engine to idle for 15 seconds.
9. Check that vacuum reading of each cylinder did not change more than 30 mm Hg (40
mbar, 1.18 in Hg). Readjust if necessary.
10. Verify idle speed is 750 ± 50 rpm in neutral.
11. Stop engine, remove adaptors and reinstall plugs.
Page 2C-10 90-881980R1 NOVEMBER 2001

Throttle Cam Adjustment

Remove screws attaching sound attenuator. Remove attenuator to provide access to
throttle cam.
a
a
58681
a - Screws (9)
Check throttle pickup timing (using “Checking Steps” below, adjust if incorrectly set using
“Adjustment Steps” below).
CHECKING STEPS
1. Move throttle control lever to the full retard position (throttle arm against throttle stop at
idle).
2. Verify idle speed arm is against idle speed screw.
d
b
c
58576
a - Throttle Control Lever d - Idle Speed Arm

b - Throttle Stop e - Idle Speed Screw
c - Throttle Arm
90-881980R1 NOVEMBER 2001 Page 2C-11

3. Pointer on cam should align with center of cam follower while maintaining a 0.020 in.
(0.5 mm) gap between follower and cam.
58683
a - Pointer c - 0.020 in. (0.5 mm)
b - Cam Follower
ADJUSTMENT STEPS
1. If 0.020 in. (0.5 mm) gap does not exist, unsnap ball connector from ball on cam.
2. Thread connector in or out to obtain proper clearance. Tighten jam nut on connector.
NOTE: Proper clearance between cam follower and cam will take precedence to exact
alignment of pointer on cam to center of cam follower.
e
a
b
58683
a - Ball Connector d - Cam Follower
b - Throttle Cam e - Jam Nut
c - Pointer
Page 2C-12 90-881980R1 NOVEMBER 2001

3. Reinstall sound attenuator. Tighten screws to specified torque.
Sound Attenuator Screw Torque

70 lb-in. (8 Nm)
Throttle Position Sensor (TPS) and Throttle Shaft Adjustment

The Throttle Position Sensor and throttle shaft are pre-set at factory during emission calibra-
tion.
No adjustments should normally be made to these components as emission performance
will be compromised.
However, should it be necessary to replace the Throttle Position Sensor or throttle body, the
new components should be adjusted to initial factory emission specifications as follows:
1. Remove 9 screws attaching sound attenuator and remove attenuator.
2. Disconnect the Throttle Position Sensor harness.
3. Install TPS Test Harness (91-881827) between TPS and TPS harness.
b c
91-881827
58659
a - Throttle Position Sensor 58659
b - TPS Test Harness (91-881827)
c - TPS Harness
4. Turn ignition switch to the “RUN” position.

5. Connect DMT 2000 (91-854009A1) test leads to the TPS Test Harness – RED to PINK;
BLACK to BLACK.
90-881980R1 NOVEMBER 2001 Page 2C-13

6. Loosen synchronizing screw to allow cylinders #3 and #4 throttle shutter to open.

7. Loosen throttle plate screw to fully close cylinders #1 and #2 throttle shutter.
58641
a - Synchronizing Screw
b - Throttle Plate Screw
8. Adjust the position of Throttle Position Sensor until the (DC) output voltage is 0.7 ± 0.01
volts.
9. Operate the throttle shaft several times.
10. Record the value.
11. Slowly tighten the synchronizing screw until throttle shutters for cylinders #3 and #4 just
close.
12. Slowly tighten the throttle plate screw until a 0.032 ± 0.004 volt increase over the pre-
viously recorded value is observed.
13. Operate the throttle shaft several times.
Page 2C-14 90-881980R1 NOVEMBER 2001

14. With the throttle arm against the throttle stop, verify throttle cam mark is aligned with the
center of the cam follower while maintaining a 0.020 in. (0.5 mm) gap between follower
and cam. Check that output voltage has not changed.
NOTE: Proper clearance between cam follower and cam will take precedence to exact
alignment of pointer on cam to center of cam follower.
d f
c
58576 h
58683
a - Synchronizing Screw e - Cam Mark

b - Throttle Plate Screw f - Cam
c - Throttle Arm g - Cam Follower
d - Throttle Stop h - 0.020 in. (0.5 mm)
15. Reinstall sound attenuator. Tighten attaching screws to specified torque.
Sound Attenuator Screw Torque

70 lb-in. (8 Nm)
16. Start engine.

17. Check output voltage of Throttle Position Sensor. If TPS voltage is not within 0.718 –
0.746 volts, readjust TPS sensor.
18. Verify throttle shutters are synchronized. Refer to “Throttle Shutter Synchronization,”
preceding.
90-881980R1 NOVEMBER 2001 Page 2C-15

THEORY OF OPERATION

Section 3A - Theory of Operation
Table of Contents
Electronic Fuel Injection System . . . . . . . . . . . 3A-2 Rapid Deceleration . . . . . . . . . . . . . . . . . . . 3A-5
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5
Air Temperature Sensor . . . . . . . . . . . . . . .
Crank Position Sensor . . . . . . . . . . . . . . . .
3A-3
3A-3
Air Induction System . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-6
3A-7
3
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 3A-3 Pressure Regulator . . . . . . . . . . . . . . . . . . . 3A-8 A
Manifold Absolute Pressure Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . 3A-3 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . 3A-9
Throttle Position Sensor . . . . . . . . . . . . . . . 3A-3 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10
Water Temperature Sensor . . . . . . . . . . . . 3A-3 Electronic Control System . . . . . . . . . . . . . . . . 3A-10
Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . . . . 3A-4 Outline of Control System . . . . . . . . . . . . . 3A-11
Step-Motor-Type Actuator . . . . . . . . . . . . . 3A-4 Control and Function . . . . . . . . . . . . . . . . . . 3A-12
IAC Features . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Basic Injection Volume . . . . . . . . . . . . . . . . . . . 3A-13
Starting and Idling . . . . . . . . . . . . . . . . . . . . 3A-5 Features Of The Throttle Position Sensor . . 3A-13
Warming Up . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5

THEORY OF OPERATION
Electronic Fuel Injection System

The electronic fuel-injection system of the 115 EFI (4-Stroke) operates based on the com-
bination of the throttle opening angle and engine speed, as well as the combination of en-
gine speed, Manifold Absolute Pressure (MAP) and intake air temperature. When engine
speed is low, from fully closed to 10° open throttle, the fuel injection volume is determined
by the Manifold Absolute Pressure (MAP) and the engine speed map. From 7° open to fully
open (high speed), the fuel injection volume is determined by the throttle opening angle and
the engine speed map. Between 7° and 10° open, where the fuel injection volume depends
on a overlap of both MAP and throttle opening angle, the fuel injection volume is determined
more by the higher efficiency signal source (MAP vs throttle opening angle). The injection
volume is determined by the ECM using signals from the Manifold Absolute Pressure (MAP)
sensor, water temperature sensor, intake air temperature sensor, throttle position sensor,
and crank position sensors. A stoichiometric (optimal) air-fuel ratio can be achieved at all
speeds, including starting and warm-up, rapid acceleration and deceleration.
Idle Air Control
Engine
Sensors Control
Module
Crank Position
Air Sensors
Ignition
control
Throttle Position
Sensor Idle speed
control
Engine Temperature Fuel

Sensor control
Relay
control
Intake Air
Temperature Sensor
Manifold Absolute Pressure

(MAP) Sensor
Main Relay
Battery
:Electric Signal Fuel Filter Fuel

:Fuel Flow Electric
Fuel Pump
Fuel
Vapor Separator Pump Fuel Tank
Pressure Fuel cooler

Regulator

THEORY OF OPERATION
EFI SYSTEM CONT.

The injection system employs a 180° synchronous (batch) injection method which groups
cylinders #1 and #4, and cylinders #2 and #3. In order to make corrections according to the
engine conditions, an asynchronous injection is performed in all modes regardless of the
crank angle signal. In addition, the injector of the 115 EFI (4-Stroke) is equipped with a func-
tion that cleans the nozzle by operating it one time to prevent the injector needle from stick-
ing when the main switch is turned to ON.
Sensors
Air Temperature Sensor
Monitors the intake air temperature. Sends signals to the ECM which aid in determining the
optimal air-fuel ratio, fuel injection timing and fuel injection volume.
Crank Position Sensor
Provides the ECM with crank position information and engine speed which the ECM uses
in determining optimal air-fuel ratio, fuel injection volume, ignition timing, and ignition/injec-
tion cut-off/warning for over revolution control.
Oil Pressure Switch
Monitors engine oil pressure. Sends signals to the ECM which activates ignition/injection
cut-off/warning for low oil pressure.
Manifold Absolute Pressure (MAP) Sensor
Monitors the intake manifold pressure. Sends signals to the ECM which aid in determining
the optimal air-fuel ratio and fuel injection volume.
Throttle Position Sensor
Provides the ECM with throttle angle information which the ECM uses in determining opti-
mal air-fuel ratio, fuel injection timing and fuel injection volume.
Water Temperature Sensor
Monitors the engine temperature. Sends signals to the ECM which aid in determining the
optimal air-fuel ratio, fuel injection volume, and ignition/injection cut-off/warning for engine
overheat control.

THEORY OF OPERATION
Idle Air Control (IAC)

Step-Motor-Type Actuator
This system consists of a motor (constructed of a magnet-operated rotor and a stator coil),
a threaded portion (which converts the rotation into a linear movement of the valve), and
a valve. The electric current flowing through the stator coils is switched in steps. The regular
rotation and counter-rotation of the rotor raises or lowers the valve to adjust the amount of
air that flows through. The direction that the rotor rotates is determined by the electric flow
through the stator coils. The valve of this IAC can be opened from fully closed to fully open
in 120 steps.
Bearing Screw–type mechanism
Stator coil Rotor
Valve shaft
Valve
IAC Features
No. of steps Bypass air volume Difference
(g/sec) (g/sec) S1
0 0.47 + 0.3 Power
60 1.45 + 0.4
80 3 + 0.4
S3
120 9.8 + 1.0 S4
Power
Bypass air volume (g/sec)
S2
10
Condition 1
9
Bypass air volume (g/sec)
8
7
6
Condition Condition Condition Condition
5 Terminal
1 2 3 4
4 S1 ON ON
Condition 2
3 S2 ON ON
2 S3 ON ON
Condition 3
1 S4 ON ON
0 Condition 4
0 Open Close
50 100 150
No. of steps

THEORY OF OPERATION
Starting and Idling

The IAC controls an optimum idling engine speed depending on the cooling-water tempera-
ture and the condition of the engine. With the throttle valve fully closed, the air quantity in
the bypass is controlled by the step-motor-type actuator equipped in the IAC.
Warming Up
To warm up the engine, the IAC valve located in the bypass is opened and air is supplied
to the engine to increase the engine speed. After the engine is warmed up, the valve is
closed to decrease the engine speed and to maintain the specified idling speed.
Rapid Deceleration
When the throttle valve quickly returns to the fully closed position, the IAC valve will open
just before the throttle valve is fully closed and act as a dashpot to prevent the engine from
stalling.
Shut Off
The idle air control (IAC) is supplied current from the green EMC wire for a short period of
time at key shut off. During this time period the IAC is cycled to a predetermined setting for
the next start up. The fuel injectors are cycled once to provide extra fuel on the surfaces
for quicker restart.
(MAP) Sensor
Idle Air Control

(IAC)

THEORY OF OPERATION
Air Induction System

The air induction system consists of the throttle bodies, throttle valves, throttle position sen-
sor, intake air temperature sensor, Manifold Absolute Pressure (MAP) sensor, and the Idle
Air Control (IAC). The intake silencer attenuates the sound of the air drawn into the engine
to provide quite operation. The throttle valves are installed in two independent throttle bod-
ies (two sets of two throttle bodies).
Air From IAC
Air
Throttle Body

THEORY OF OPERATION
Fuel System
The fuel system consists of a low-pressure fuel pump, a high-pressure fuel pump, a fuel rail,
fuel injectors, a pressure regulator, and a fuel cooler. The low-pressure pump sends fuel to
the vapor separator tank, which is then pressurized to 43.5 psi (300 kPa) by the high-pres-
sure pump. The pressurized fuel then travels through the fuel rail where it is injected from
the fuel injectors into the intake manifold. Fuel not injected into the intake manifold goes
through the pressure regulator, the fuel cooler, and is then returned to the vapor separator
tank. The fuel pressure is maintained at 43.5 psi (300 kPa) between the high pressure fuel
pump and the fuel injectors by the pressure regulator. High fuel-injection pressure maxi-
mizes the atomization of the fuel, resulting in increased combustion efficiency.
Intake manifold
(MAP) sensor
Pressure regulator
Adaptor Plate
Filter
Air ventilation Low–pressure
E xhaust
fuel pump
Fuel filter
Fuel Filter Fuel rail

High–pressure
injector
fuel pump
Fuel cooler
Fuel tank
Filter
Vapor separator Float

THEORY OF OPERATION
Pressure Regulator
A pressure regulator is installed in the upper part of the fuel rail. The pressure regulator
maintains a stable fuel pressure according to the vacuum pressure in the intake manifold.
With a maintained fuel pressure, control of an accurate fuel injection volume is increased.
Intake Manifold Spring Chamber Spring
Diaphragm
Housing
Valve From Fuel Rail
Fuel Chamber
To fuel cooler
Fuel Cooler
The 115 EFI (4-Stroke) is equipped with a fuel cooler that uses the engine cooling water to
decrease the fuel temperature and reduce vapors. A brass pipe is used to prevent corrosion.
FUEL FUEL
WATER WATER

THEORY OF OPERATION
Vapor Separator
The vapor separator maintains a liquid fuel supply for the high pressure fuel pump located
in the vapor separator tank. Fuel delivered from the mechanical low pressure fuel pump is
supplied to the top port of the vapor separator and is controlled by the inlet needle/float. Low
pressure fuel returning from the pressure regulator, passes through the fuel cooler and is
supplied to the lower port of the vapor separator.
From the Low Pressure

Fuel Pump
To Fuel Rail
b
e
Return Fuel
From Pressure
Regulator
d
a - Check Valve
b - Vapor Separator
c - High Pressure Electric Fuel Pump
d - Filter
e - Fuel Float
f - Inlet Needle

THEORY OF OPERATION
Ignition System
The 115 EFI (4-Stroke) has a newly designed ignition system, which provides the longer dis-
charge duration required to burn the fuel injected into the cylinder in an extremely short peri-
od.
The ECM induces a high voltage in the ignition coil by allowing battery current to flow into
the ignition circuit and turning on and off the ECM’s ignition signals with the transistor.
Electronic Control System

The ECM of the 115 EFI (4-Stroke) controls the ignition timing, the fuel injection timing, the
fuel injection volume, and the IAC, maintaining the optimal air-fuel ratio in all operating con-
ditions. The ECM converts the signals from the input sensors and sends instructions to each
part of the fuel injection system.
Crank position sensor Fuel pump
Throttle position
Injectors
sensor
Water temperature IAC

sensor
Intake air temperature

ECM Ignition coils
sensor (Electronic
Overheat monitor
control
Manifold Absolute
Pressure (MAP) Sensor module) Oil pressure monitor
Oil Pressure Switch Buzzer
Stop switch
Tachometer
Shift position switch

Diagnostic system
Page 3A-10 90-881980R1 NOVEMBER 2001

THEORY OF OPERATION
Outline of Control System

ECM Sensors
Ignition Timing 0 Throttle opening angle/engine speed map Throttle position sensor
Control Crank position sensor
0 Engine temperature correction Water temperature sensor
0 Starting correction Water temperature sensor

Crank position sensor
0 Rapid acceleration correction Throttle position sensor

0 Ignition cutoff for decreased engine speed Crank position sensor

Water temperature sensor
Oil pressure sensor
0 Over–revolution prevention Crank position sensor

Shift position switch
0 Idle advancing when in neutral Shift position switch
0 Engine cutoff Stop switch

Main switch
0 Idling stabilizer Crank position switch
0 Safety control Sensors and switches
ECM Sensors
IAC Control 0 Starting correction Water temperature sensor
0 Engine heating control Water temperature sensor

Throttle position sensor
0 Rapid deceleration correction Throttle position sensor

0 Rapid deceleration preparation Throttle position sensor
0 Idling speed feedback Crank position sensor

0 Increased engine speed when in neutral Shift position switch
0 Variable idling speed control Throttle position sensor

0 Starting preparation Water temperature sensor

Power switch OFF
0 Idling stabilizer Crank position sensor
90-881980R1 NOVEMBER 2001 Page 3A-11

THEORY OF OPERATION
ECM Sensors
Fuel system 0 Throttle opening angle/engine speed map Manifold Absolute Pressure
Manifold air pressure/engine speed map (MAP) sensor
0 Manifold air pressure correction Manifold Absolute Pressure
(MAP) sensor
0 Voltage correction
0 Engine temperature correction Water temperature sensor
0 Intake air temperature correction Intake air temperature

sensor
0 Starting correction W ater temperature sensor

0 Rapid acceleration correction Throttle position sensor

0 Rapid deceleration correction Throttle position sensor

0 Fuel cutoff for decreased engine speed Crank position sensor

Oil pressure switch
0 Clogged injector prevention M ain switch turned on
0 Idling stabilizer Crank position sensor
Control and Function

Ignition Fuel Air/Fuel Function
Timing Injection Control
Timing
Crank Position Sensor Detects the crankshaft posi-
tion and engine speed
Throttle Position Sensor Detects the open degree of
the throttle valve
Water Temperature Sensor Detects engine temperature
Manifold Absolute Pressure Detects intake air pressure of
(MAP) Sensor the intake manifold
Intake Air Temperature Sen- Detects intake air tempera-
sor ture
Shift Position Switch Determines the shift position.
(Neutral: ON, Forward or Re-
verse: OFF)
Oil Pressure Switch Detects Oil Pressure
Page 3A-12 90-881980R1 NOVEMBER 2001

THEORY OF OPERATION
Basic Injection Volume

Basically, from fully closed to 10° open throttle (low speed), the fuel injection volume is deter-
mined by the intake air pressure and the engine speed map. From 7° open to fully open (high
speed), the fuel injection volume is determined by the throttle opening angle and the engine
speed map. Between 7° and 10° open, where the throttle valve is open and the intake air
pressure is gradually decreasing, the fuel injection volume is determined by the throttle
opening angle and the engine speed map. With a throttle valve opening angle of 8.5°, which
is between 7° and 10° open (intake air pressure and throttle opening angle), the fuel injection
volume is determined based more on the air detection accuracy.
(%)
100
Map percentage
Low speed High speed
0
Close Open
7 8.5 10
Throttle opening angle
Features Of The Throttle Position Sensor

The relationship between the throttle opening angle and the voltage is shown below.
107.5
Throttle opening angle (deg)
Throttle opening angle [0.1] = V 5 8 1250–175
− 17.5
0 0.7 5.0
Voltage
90-881980R1 NOVEMBER 2001 Page 3A-13

TROUBLESHOOTING AND DIAGNOSTICS

Section 3B - Troubleshooting and Diagnostics
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Injector Operation Test . . . . . . . . . . . . . . . . 3B-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Fail Safe Function Table . . . . . . . . . . . . . . . . . . 3B-6
Control and Function . . . . . . . . . . . . . . . . . . . .
EFI System Diagnostic Procedures . . . . . . . .
3B-3
3B-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Code Information . . . . . . . . . . .
3B-7
3B-7
3
Pressure Regulator Test . . . . . . . . . . . . . . . 3B-3 Diagnosis of Electronic Control System . . 3B-7 B
Mechanical Fuel Pump Test . . . . . . . . . . . . 3B-4 Diagnostic Code Chart . . . . . . . . . . . . . . . . 3B-10
Specifications
Fuel Pump:
FUEL INJECTION
Fuel Pressure @ Rail 41-44 psi (283-304 kPa)

Special Tools
1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3.
91-16850A7
91-852087A3
2. Mighty Vac vacuum gauge (obtain locally).
3. Malfunction Indicator Lamp 99056A1 or Diagnostic Lamp 91-8847931A1
99056A1
58680 91-884793A1 59129

Control and Function

Ignition Fuel Air/Fuel Function
Timing Injection Control
Timing
Crank Position Sensor Detects the crankshaft posi-
tion and engine speed
Throttle Position Sensor Detects the open degree of
the throttle valve
Water Temperature Sensor Detects engine temperature
Manifold Absolute Pressure Detects intake air pressure of
(MAP) Sensor the intake manifold
Intake Air Temperature Sen- Detects intake air tempera-
sor ture
Shift Position Switch Determines the shift position.
(Neutral: ON, Forward or Re-
verse: OFF)
Oil Pressure Switch Detects Oil Pressure
EFI System Diagnostic Procedures

Pressure Regulator Test
1. Install the fuel pressure gauge onto the pressure check valve (located on top of the fuel
rail).
2. Start the engine. Fuel pressure should be within specification.
c
91-16850A7
a - Fuel Pressure Gauge
b - Pressure Check Valve
c - Pressure Regulator

Mechanical Fuel Pump Test

NOTE: Do not over-pressurize the fuel pump. Excessive pressure may cause air to leak out.
1. Install the mighty vac onto the fuel pump as shown.
2. Test 1: Pressurize the fuel pump to 7psi (50 kPa). Fuel pump should hold this amount
of pressure. Perform this test on input and output side of fuel pump.
3. Test 2: Apply 4 in./mm Hg (14 kPa) vacuum to fuel pump. Fuel pump should hold this
amount of vacuum.
Test 1
a
b
Test 1
Test 2
a - Fuel Pump
b - Mighty Vac

Injector Operation Test

1. Start the engine. Fully close the throttle valves.
2. Hold the screwdriver so it is making contact with the fuel injector body. The fuel injector
should have a solenoid valve operating sound. Verify this on all injectors.
IMPORTANT: If no sound is coming from the injector then no fuel is being sprayed.
Verify the high pressure fuel pump is operating properly.
a - Screwdriver
b - Fuel Injector (4)
NOTE: Refer to section 2A for testing of the Throttle Position Sensor and Engine Tem-
perature Sensor.

Fail Safe Function Table

Symptoms FAIL SAFE FUNCTION
Ignition Fuel Injection IAC Engine Conditions
Abnormal signal Four cylinder igni- Cylinders with no Engine idling
from crank position tion is fixed at 40 input signal will be speed increases.
sensor ATDC stopped Top speeds can-
900 rpm
not be reached.
Abnormal signal When throttle When the throttle Engine idling
from throttle posi- opening angle is opening angle is speed increases.
tion sensor less than -100 or less than -100 or Top speeds can-
more than 1000: more than 1000: 900 rpm
not be reached.
Ignition is fixed at Injection is con-
100 BTDC trolled only by
the boost map
Abnormal signal When the intake When the intake Engine idling
from Manifold Ab- air pressure is less air pressure is less speed increases.
solute Pressure than 1.9 psi (100 than 1.9 psi (100 Top speeds can
(MAP) sensor mmHg) or more mmHg) or more 900 rpm
be reached.
than 17.4 psi (900 than 17.4 psi (900
mmHg): mmHg):
Ignition is fixed at Injection is con-
100 BTDC trolled with throttle
opening map
Abnormal signal When less than When less than Engine idling
from water temper- 0.1 V or more than 0.1 V or more than speed increases.
ature sensor 4.52 V are de- 4.52 V are de- Top speeds can
tected (substitutes tected (substitutes 900 rpm
be reached.
the intake air tem- the intake air tem-
perature sensor): perature sensor):
Ignition is fixed at Normal Operation
100 BTDC
Abnormal signal When less than When less than Engine idling
from intake air tem- 0.1 V or more than 0.1 V or more than speed increases.
perature sensor 4.52 V are de- 4.52 V are de- Top speed can be
tected (the intake tected (the intake 900 rpm
reached.
air temperature air temperature
sensor is fixed at sensor is fixed at
40): 40):
Ignition is fixed at Normal Operation
100 BTDC
Abnormal signal On is detected On is detected IAC is stopped Engine is stopped.
from engine stop Ignition is cut Ignition is cut
switch
Shift switch open 900 rpm Engine idling
speed increases.
Top speeds can
be reached.

Self-Diagnosis
Diagnosis Code Information
1. Normal condition (no defective part or irregular processing is found).
Single flash is given every 5 seconds.
a. Light on, 0.33 second
b. Light off, 5 seconds
2. Trouble code indication.

Example: The illustration indicates code number 23.
a. Light on, 0.33 second
b. Light off, 0.33 second
c. Light off, 1.65 seconds
d. Light off, 5 seconds.
Diagnosis of the Electronic Control System

1. Remove wire connector test plug cap.

2. Install Malfunction Indicator Lamp

a. Model Year 2001 and Prior
Install Malfunction Indicator Lamp (MIL) p/n 99056A1, or create your own test light.
(1.) Remove rubber plugs from engine harness bullet connectors.
(2.) Connect leads of the Malfunction Indicator Lamp (MIL) p/n 99056A1 to the en-
gine harness connectors.
RED/BLK
BLU/WHT
99056A1
NOTE: When performing this diagnosis, all of the electrical wires must be properly con-
nected.
BLU/WHT
RED/BLK

b. Model Year 2002 and Newer

Install Malfunction Indicator Lamp (MIL) p/n 91-884793A1.
NOTE: This new service tool must be used on 2002 model year product. The new tool con-
sists of the previous diagnostic lam 99056A1 and an additional harness with a 3 pin terminal
connector.
(1.) Remove rubber plug from engine harness bullet connector.
(2.) Connect the harness terminal to the diagnostic test terminal.
(3.) Connect the lamp wire bullet terminal to the blue/white wire bullet terminal on the
engine harness.
b
c d
59129
a - Lamp Wire
b - Lamp Wire
c - Green/Red Wire (Not Used)
d - Harness Terminal
59130
a - Harness terminal
b - Bullet terminal

3. Check diagnosis code(s) (reference chart)

a. Code 1 is indicated - normal
b. Code 13-29 indicated - Check the applicable parts.
c. Code 33-44 indicated - Microcomputer processing information.
CHECKING STEPS
1. Start the engine and let it idle.
2. Check the malfunction indicator lamp’s flash pattern to determine if there are any mal-
functions.
NOTE: The ignition key must be returned to the “OFF” position for 5 seconds to clear a cor-
rected failure code.
NOTE: When more than one problem is detected, the malfunction indicator lamp light
flashes in the pattern of the lowest numbered problem. After that problem is corrected and
the failure code is cleared, the lamp flashes in the pattern of the next lowest numbered prob-
lem. This continues until all of the problems are detected and corrected.
Diagnostic Code Chart
Code Symptoms
13 Incorrect crank position sensor
input signal
15 Incorrect engine cooling water tem-
perature sensor input signal
18 Incorrect throttle position sensor in-
put signal
19 Incorrect battery positive voltage
23 Incorrect intake air temperature
sensor input signal
28 Incorrect shift position switch
29 Incorrect manifold air pressure sen-
sor input signal (out of normal oper-
ating range)
(33) Ignition timing is being slightly cor-
rected (when starting a cold en-
gine)
(37) Intake passage air leakage
(44) Engine stop switch control operat-
ing
Page 3B-10 90-881980R1 NOVEMBER 2001

DIAGNOSIS/CORRECTION COMPLETED
1. Remove Malfunction Indicator Lamp (MIL).
2. Reinstall rubber plug(s) in engine harness bullet connector(s).
3. Reinstall connector test plug cap.
a - Plug Cap
90-881980R1 NOVEMBER 2001 Page 3B-11

SERVICE PROCEDURES

Section 3C - Service Procedures
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-32
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-32
Intake Silencer . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3C-4
3C-6
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly . . . . . . . . . . . . . . . .
3C-33
3C-33
3
Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . 3C-8 Vapor Separator . . . . . . . . . . . . . . . . . . . . . . . . 3C-34 C
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . 3C-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34
Intake Silencer Assembly . . . . . . . . . . . . . . . . . 3C-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-15 Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . 3C-39
Intake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 Idle Speed Control Assembly . . . . . . . . . . . . . 3C-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-19 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-40
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3C-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-24 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-42
Throttle Control Lever and Linkage . . . . . . . . 3C-25 Throttle Position Sensor . . . . . . . . . . . . . . . . . . 3C-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-25 Removal/Installation . . . . . . . . . . . . . . . . . . 3C-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-26 Low Pressure Fuel Line/Fuel Pump . . . . . . . . 3C-44
High Pressure Fuel Line . . . . . . . . . . . . . . . . . . 3C-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-44
Releasing Fuel Pressure in the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45
High-Pressure Fuel Line . . . . . . . . . . . . . . . 3C-27 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-28 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-29 Disassembly/Assembly . . . . . . . . . . . . . . . . 3C-47
Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-30 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-48
Removal/Installation . . . . . . . . . . . . . . . . . . 3C-30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-48
Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-50
Removal/Installation . . . . . . . . . . . . . . . . . . 3C-31

SERVICE PROCEDURES
Specifications
Fuel Pump:
FUEL INJECTION
Fuel Pressure @ Rail 43.5 psi (300 kPa)
Special Tools
1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3.
51796
91-16850A7
91-852087A3
2. Tamper proof screw torx bit set p/n 91-881828.

SERVICE PROCEDURES
Notes:

SERVICE PROCEDURES
INTAKE SILENCER
16
15 17
16
15
14
13
12
18
20
8 7
8
8 7 8
4
6 3
5 20
21
3
10
11
19
9
2
1

SERVICE PROCEDURES
INTAKE SILENCER
TORQUE
REF.
REF
1 1 INTAKE SILENCER
2 1 INTAKE AIR TEMPERATURE SENSOR
3 4 O-RING
4 6 BOLT (M6 X 16 MM) 70 7.9
5 2 BOLT (M8 X 20 MM) 13 18
6 1 BRACKET
7 2 BRACKET
8 8 BOLT (M6 X 20 MM) 70 7.9
9 1 INDUCTION SILENCER
10 1 MOUNTING BRACKET
11 1 SCREW (M6 X 20 MM) 70 7.9
12 2 PIN
13 1 GASKET
14 1 BREATHER PIPE
15 2 CLAMP
16 2 BOLT (M6 X 12 MM) 70 7.9
17 1 CLIP
18 1 CLAMP
19 2 BOLT (M6 X 105 MM) 70 7.9
20 5 BOLT (M8 X 40 MM) 13 18
21 1 SCREEN

SERVICE PROCEDURES
INTAKE
28 35
29
26 32
27
31
23 1
33
22 9
25
20
34
21 9
18
19 30
24 2
17
10
15
17 3
16
12 2
11
12
13
9
8 4
6 3
7
9
8

SERVICE PROCEDURES
INTAKE
TORQUE
REF.
REF
1 1 MANIFOLD
2 4 O-RING
3 4 DOWEL PIN
4 3 BOLT
5 1 THROTTLE BODY
6 1 SPRING
7 2 SCREW
8 6 BOLT (M8 X 70 MM) 13 18
9 9 WASHER
10 1 THROTTLE BODY
11 1 SCREW
12 2 SPRING
13 1 SCREW
14 2 SCREW
15 1 LINK JOINT
16 1 LINK JOINT
17 1 NUT
18 1 THROTTLE POSITION SENSOR
19 1 O-RING
20 2 SCREW (M5 X 15 MM) 43 5
21 2 WASHER
22 1 BRACKET
23 3 SCREW (TAMPERPROOF) 40 4.5
24 1 HOSE
– 1 CONTROL VALVE ASSEMBLY
25 1 BODY
26 1 CONTROL VALVE
27 1 O-RING
28 3 SCREW (M4 X 12 MM) 18 2
29 3 WASHER
30 1 FILTER
31 1 MAP SENSOR
32 2 SCREW (M5 X 6 MM) 43 5
33 1 BOLT (M6 X 24 MM) 70 7.9
34 2 BOLT (M6 X 60 MM) 70 7.9
35 1 WIRE HARNESS

SERVICE PROCEDURES
FUEL INJECTION NOZZLE
2
3
4
21
5
10
13 22
9 8
4 7
10
13 12
25
9 8 11 24 23
19
9 8 14
20 18
10 24 23
13 12
9 8 7
4 25
4 14 26
27
17 16
15
6

SERVICE PROCEDURES
FUEL INJECTION NOZZLE

TORQUE
REF.
REF
1 1 PRESSURE REGULATOR
2 2 SCREW (M6 X 12 MM) 70 7.9
3 2 LOCKWASHER
4 4 CLIP
5 1 HOSE
6 2 SCREW (M5 X 16 MM) 43 5
7 2 CLIP
8 4 BOLT
9 4 GASKET
10 3 COLLAR
11 1 COOLER
12 2 BOLT (M6 X 30 MM) 70 7.9
13 3 WASHER
14 2 CLAMP
15 1 HOSE
16 1 HOSE
17 1 CLAMP
18 1 FUEL RAIL
19 4 INJECTOR UNIT
20 1 O-RING
21 1 CAP
22 1 BOLT (M6 X 25 MM) 70 7.9
23 2 BOLT (M8 X 45 MM) 13 18
24 2 WASHER
25 2 COLLAR
26 1 NIPPLE
27 1 O-RING

SERVICE PROCEDURES
FUEL INJECTION PUMP
27
A = To fitting in exhaust plate
27
23
A 27
24
26 23
30 20
20
29 28
23
22 27 20
22 25 23
27
23 27
20
21
20 10
12 19 18
11 19
1
3 8
2
7 9
13
14
6
15 5 4
31
16
31
32
17
Page 3C-10 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
FUEL INJECTION PUMP

TORQUE
REF.
REF
– 1 VAPOR SEPARATOR
1 1 COVER
2 1 VALVE SEAT
3 1 O-RING
4 1 BODY
5 1 FLOAT
6 1 FLOAT PIN
7 1 NEEDLE VALVE
8 1 PLATE
9 1 SCREW (M3 X 8 MM)
10 7 SCREW (M4 X 16 MM) 18 2
11 1 GASKET
12 1 DAMPER
13 1 FUEL PUMP
14 1 FILTER
15 1 COVER
16 1 DRAIN SCREW
17 1 GASKET
18 1 HOSE KIT
19 2 CLIP
20 5 CLIP
21 1 HOSE
22 2 HOSE
23 5 TEE
24 1 HOSE
25 1 HOSE
26 1 HOSE
27 6 HOSE
28 1 HOSE
29 1 HOSE
30 1 HOSE
31 6 COLLAR
32 3 DAMPER
90-881980R1 NOVEMBER 2001 Page 3C-11

SERVICE PROCEDURES
FUEL PUMP
11
10
9
8
6
7
5
2
12
3
4
1 14
13
15
18
29
19
27 14
26 16
28
17
32 20
31 21
32
25 22
30 37 23
29 25 24
33
36
34
35
Page 3C-12 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
FUEL PUMP
TORQUE
REF.
REF
1 1 FUEL PUMP
2 1 BODY
3 1 SPRING
4 1 PLUNGER
5 1 SPRING
6 1 DIAPHRAGM
7 1 PIN
8 1 BODY
9 1 DIAPHRAGM
10 1 BODY
11 3 SCREW
12 3 NUT
13 1 O-RING
14 2 CLAMP
15 2 BOLT (M6 X 30 MM) 70 7.9
16 1 HOSE
17 1 BRACKET
18 1 BOLT (M6 X 16 MM) 70 7.9
19 1 NUT 70 7.9
20 1 FILTER ASSEMBLY
21 1 CUP
22 1 O-RING
23 1 FLOAT
24 1 ELEMENT
25 2 CLAMP
26 1 BRACKET
27 2 BOLT (M7 X 48 MM) 150 17
28 2 DOWEL PIN
29 2 WASHER
30 1 FUEL CHANGE LEVER
31 1 SHAFT
32 2 PIN
33 1 HOSE (55 IN.)
34 1 STA-STRAP
35 1 CONNECTOR
36 1 CAP
37 1 CONDUIT
90-881980R1 NOVEMBER 2001 Page 3C-13

SERVICE PROCEDURES
Intake Silencer Assembly

Removal
1. Remove access panel from port side bottom cowl.
a - Access Panel
2. Disconnect the air temperature sensor connector.
3. Remove the following breather hoses: cylinder head to intake silencer, idle air control
assembly to intake silencer.
4. Remove mounting screws from intake silencer and mounting screw from induction si-
lencer.
5. Remove intake silencer.
g b
e
f j
c
i
h a
a - Air Temperature Sensor g - Intake Silencer

b - Mounting Screw (6) M6 x 20 h - Induction Silencer
c - Mounting Screw (2) M6 x 105 i - Induction Silencer Mounting
d - Cylinder Head Breather Hose Screw(1) M6x20
e - Vapor Separator Vent Hose j - O-ring (4)
f - Idle Air Control Assembly Breather
Hose
Page 3C-14 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Installation
1. Connect idle air control assembly breather hose to intake silencer.
2. Install intake/induction silencer mounting screws and tighten to specified torque.
3. Connect vapor separator vent hose to adaptor plate fitting.
4. Connect cylinder head breather hose to intake silencer and secure the hose ends with
a plastic sta-strap.
5. Plug-in the air temperature sensor connector.
g b
e
f j
c
i
h a
a - Air Temperature Sensor g - Intake Silencer

b - Mounting Screw (6) M6 x 20 h - Induction Silencer
c - Mounting Screw (2) M6 x 105 i - Induction Silencer Mounting
d - Cylinder Head Breather Hose Screw(1) M6x20
e - Vapor Separator Vent Hose j - O-ring (4)
f - Idle Air Control Assembly
Breather Hose
Intake Silencer Mounting Screw Torque
70 lb-ft. (8 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-15

SERVICE PROCEDURES
Intake Assembly
Removal
1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal.
2. Remove lower cowl. Refer to Mid - Section segment of this manual.
3. Disconnect throttle and shift cables. Refer to Attachments/Control Linkage section of
this manual.
4. Disconnect the vapor separator vent hose from the adaptor plate fitting.
58565
58632
a - Vapor Separator Vent Hose
Page 3C-16 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
5. Disconnect the following wire connectors: throttle position sensor, idle air control har-
ness, MAP sensor and high pressure fuel pump.
6. Disconnect the upper and lower water hoses from the fuel cooler. Retain the metal hose
clamps for reassembly.
7. Disconnect the fuel pump hose (fuel pump to vapor separator).
b a
e
i
d
g
a - Throttle Position Sensor Connector

b - Idle Air Control Connector
c - MAP Sensor Connector
d - High Pressure Fuel Pump Connector
e - Fuel Cooler Upper Water Hose
f - Fuel Cooler Lower Water Hose
g - Metal Hose Clamp (2) (Retain)
h - Sta-strap (Discard)
i - Fuel Pump Hose (fuel pump to vapor separator)
90-881980R1 NOVEMBER 2001 Page 3C-17

SERVICE PROCEDURES
8. Disconnect the shift position switch and fuel injector connectors. Cut the sta-straps from
the injector harness. Place the injector harness out of the way (on the top of the engine).
a 58639
a - Shift Position Switch

b - Fuel Injector Connector (4)
c - Sta-strap (2) (Discard)
9. Remove the intake assembly mounting screws and the bracket mounting screws.
a
b
b
a
58640
a - Intake Assembly Mounting Screws (5)
b - Bracket Mounting Screws (4)
Page 3C-18 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Installation
1. Install the intake assembly and tighten mounting screws to specified torque.
2. Install the bracket mounting screws and tighten to specified torque.
a
b
b
a
58640
a - Intake Assembly Mounting Screws (5) M8 x 40
b - Bracket Mounting Screws (4) M6 x 20
Intake Assembly Mounting Screw Torque
13 lb-ft. (18 Nm)
Bracket Mounting Screw Torque

70 lb-in (8 Nm)
3. Install vapor separator vent hose onto adaptor plate fitting.
58565
58632
a - Vapor Separator Vent Hose
90-881980R1 NOVEMBER 2001 Page 3C-19

SERVICE PROCEDURES
4. Route the fuel injector harness as shown and secure with sta-straps in locations shown.
5. Plug in the fuel injector connectors and the shift position switch connector.
a 58639
a - Shift Position Switch Connector

b - Fuel Injector Connector (4)
c - Sta-strap (2) (New)
Page 3C-20 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
6. Plug in the following connectors: idle air control, throttle position sensor, MAP sensor,
high pressure fuel pump.
7. Connect the fuel cooler water hoses (upper and lower) and secure with metal hose
clamp (retained from disassembly).
8. Connect the fuel pump hose and secure with sta-strap.
9. Install throttle and shift cables. Refer to Attachments/Control Linkage section of this
manual.
10. Install lower cowl. Refer to Mid - Section segment of this manual.
11. Install intake silencer assembly. Refer to Intake Silencer Assembly Installation.
b a
e
i
d
g
a - Throttle Position Sensor Connector

b - Idle Air Control Connector
c - MAP Sensor Connector
d - High Pressure Fuel Pump Connector
e - Fuel Cooler Upper Water Hose
f - Fuel Cooler Lower Water Hose
g - Metal Hose Clamp (2) (Retained)
h - Sta-strap (New)
i - Fuel Pump Hose (fuel pump to vapor separator)
90-881980R1 NOVEMBER 2001 Page 3C-21

SERVICE PROCEDURES
Throttle Body
Removal
1. Remove the intake silencer assembly. Refer to Intake Silencer Assembly Removal.
2. Disconnect the throttle link rod from the throttle control lever by carefully prying the plastic
end off of the ball joint.
3. Remove bracket mounting screws.
58640
a - Bracket Mounting Screws (4) M6 x 25

b - Throttle Link Rod
c - Throttle Control Lever
Page 3C-22 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
4. Remove throttle body mounting screws.

5. Disconnect air lines (throttle body to idle air control). Retain metal hose clamps for
reassembly.
6. Remove the bracket mounting screws and remove the brackets from each throttle body
(if required).
NOTE: When removing the throttle body assemblies be careful not to lose the dowel pins
and o-rings.
NOTE: When separating the upper and lower throttle body assemblies be careful not to lose
the spring.
e g
b c
f
c a
a - Bracket Mounting Screw (4) M6 x 25

b - Air Lines (2) (throttle body to idle air control)
c - Throttle Body Mounting Screw (6) M8 x 70
d - Spring
e - Locating Pin (4)
f - O-ring (4)
90-881980R1 NOVEMBER 2001 Page 3C-23

SERVICE PROCEDURES
Installation
1. Assemble throttle body to intake manifold. Tighten screws to specified torque.
2. Assemble mounting brackets to throttle body. Tighten screws to specified torque.
3. Install spring between upper and lower throttle body as shown.
4. Connect air lines and secure with metal hose clamps.
5. Install intake silencer assembly. Refer to Intake Silencer Assembly Installation.
b c
g
f
c a
a - Bracket Mounting Screw (4) M6 x 25

b - Air Lines (2) (throttle body to idle air control)
c - Throttle Body Mounting Screw (6) M8 x 70
d - Spring
e - Locating Pin (4)
f - O-ring (4)
Throttle Body Mounting Screw Torque
13 lb-ft.. (18 Nm)
Bracket Screw Torque

70 lb-in (8 Nm)
Page 3C-24 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Throttle Control Lever and Linkage

Removal
1. Remove intake silencer assembly. Refer to Intake Silencer Assembly Removal.
2. Remove throttle control lever mounting screw.
3. Remove remaining components as shown.
4. Remove accelerator cam nut.
i
95
LT
g
d
c
d
c
f
95
e
4020
b
a
a - Mounting Screw (1) M6 x 30
b - Collar(2)
c - Wave Washer(2)
d - Washer(3)
e - Throttle Control Lever
f - Spring
g - Accelerator Cam Nut
h - Accelerator Cam
i - Stud Bolt
90-881980R1 NOVEMBER 2001 Page 3C-25

SERVICE PROCEDURES
Installation
1. Install spring so tab locks into notch as shown.
i
95
LT
g
d
c
d
c
f
95
j
58564 4020
b
a

b - Collar(2)
c - Wave Washer(2)
d - Washer(3)
f - Spring
g - Nut
h - Accelerator Cam
i - Stud Bolt
j - Spring Tab
2. Reassemble components as shown above. Tighten accelerator cam nut and mounting
screw to specified torque.
Accelerator Cam Nut Torque

70 lb-in (8 Nm)
Throttle Control Lever Mounting Screw Torque

70 lb-in (8 Nm)
Page 3C-26 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
High Pressure Fuel Line

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel may
spray out.
Releasing Fuel Pressure in the High-Pressure Fuel Line

1. Install the fuel pressure gauge onto the pressure check valve.
2. Place the drain hose into a container.
3. Open the valve and release the pressure.
a b
c
a
91-16850A7
a - Fuel Pressure Gauge
b - Valve
c - Drain Hose
90-881980R1 NOVEMBER 2001 Page 3C-27

SERVICE PROCEDURES
Removal
1. Remove intake assembly. Refer to Intake Assembly Removal.
2. Remove the vapor separator mounting screws.
3. Disconnect hoses as needed.
4. Remove fuel rail mounting screws.
5. Remove fuel cooler mounting screws.
d
c
l
j
f
k
a
g
b
i
h
m
e
a - Vapor Separator Mounting Screw (3) M6 x 30
b - Vapor Separator
c - Pressure Regulator Hose (to intake manifold fittings and idle air control filter)
d - Pressure Regulator
e - Fuel Rail Mounting Screw (2) M8 x 45
f - Fuel Rail Mounting Screw (1) M6 x 25
g - Fuel Rail
h - Fuel Cooler Mounting Screw (2) M6 x 25
i - Fuel Cooler
j - Flat Washer(3)
k - Collar(3)
l - Plastic Collar (3)
m - Plastic Collar (2) (stepped)
Page 3C-28 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Installation
1. Assemble vapor separator to intake manifold. Tighten screws to specified torque.
2. Assemble fuel cooler and fuel rail to intake manifold. Tighten screws to specified torque.
3. Attach hoses as shown.
4. Assemble intake manifold assembly to engine. Refer to Intake Assembly Installation.
d
c
l
j
f
k
a
g
b
i
h
m
e
b - Vapor Separator
c - Pressure Regulator Hose (to intake manifold fittings and idle air control filter)
d - Pressure Regulator
e - Fuel Rail Mounting Screw (2) M8 x 45
f - Fuel Rail Mounting Screw (1) M6 x 25
g - Fuel Rail
h - Fuel Cooler Mounting Screw (2) M6 x 25
i - Fuel Cooler
j - Flat Washer(3)
k - Collar(3)
l - Plastic Collar (3)
m - Plastic Collar (2) (stepped)
Vapor Separator Mounting Screw Torque
70 lb-in (8 Nm)
Fuel Rail Mounting Screw Torque (M8 x 45)

13 lb-ft. (18 Nm)
Fuel Rail/Fuel Cooler Mounting Screw Torque (M6 x 25)

70 lb-in (8 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-29

SERVICE PROCEDURES
Fuel Cooler
Removal/Installation
REMOVAL
1. Cut sta-straps and remove fuel cooler mounting screws.
NOTE: When removing the mounting screws, be careful not to lose the spacers between
fuel cooler base and intake manifold.
2. Disconnect the fuel cooler water and fuel hoses. Retain metal hose clamps.
INSTALLATION
1. Connect fuel cooler water and fuel hoses and secure with metal hose clamps (retained
from disassembly).
2. Install fuel cooler mounting screws and spacers. Tighten screws to specified torque.
3. Attach sta-straps as shown.
f
e
g
c
a d
c
g
f
e
58639
a - Fuel Cooler e - Water Hose

b - Sta-Strap (2) f - Fuel Hose
c - Mounting Screw (2)(M6 x 30) g - Metal Hose Clamp (4) (Retain)
d - Spacer (2)
Fuel Cooler Mounting Screw Torque
70 lb-in (8 Nm)
Page 3C-30 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Fuel Hoses
REMOVAL
2. Remove hoses as shown below. Retain metal hose clamps.
INSTALLATION
1. Reconnect hoses as shown below.
2. Secure fuel hoses with metal hose clamps (retained from disassembly).
3. Install intake assembly. Refer to Intake Assembly Installation.
c a
a
a
b
a
a
d
a - Metal Hose Clamp (6) (Retain)

b - Fuel Hose (Vapor Separator to Fuel Rail)
c - Fuel Hose (Pressure Regulator to Fuel Cooler)
d - Fuel Hose (Fuel Cooler to Vapor Separator)
90-881980R1 NOVEMBER 2001 Page 3C-31

SERVICE PROCEDURES
Fuel Injectors
REMOVAL
1. Remove fuel rail from intake manifold. Refer to High Pressure Fuel Line Removal.
2. Remove the fuel injectors from the fuel rail (twist while pulling out).
INSTALLATION
1. Lubricate the o-ring.
2. Install the fuel injector into the fuel rail.
3. Install the fuel rail assembly to the intake manifold. Refer to High Pressure Fuel Line
Installation.
b f
e
d
a
a - Fuel Injector
b - Fuel Rail
c - Intake Manifold
d - O-ring
e - Rubber Damper
f - Rubber Seal
Page 3C-32 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Fuel Rail
Disassembly/Assembly
DISASSEMBLY
1. Remove fuel rail from intake manifold. Refer to High Pressure Fuel Line Removal.
2. Remove fuel injectors from fuel rail. Refer to Fuel Injector Removal.
3. Remove fuel hoses. Refer to Fuel Hose Removal.
4. Remove pressure regulator. Refer to Pressure Regulator Removal.
5. Remove fuel rail joint screws. Remove fuel rail joint.
ASSEMBLY
1. Lubricate o-ring and install onto fuel rail joint.
2. Install fuel rail joint onto fuel rail and tighten screws to specified torque.
3. Install pressure regulator. Refer to Pressure Regulator Installation.
4. Install fuel hoses. Refer to Fuel Hose Installation.
5. Install fuel injectors onto fuel rail. Refer to Fuel Injector Installation.
6. Install fuel rail onto intake manifold. Refer to High Pressure Fuel Line Installation.
d
e
a - Cap
b - Fuel Rail
c - O-ring
d - Fuel Rail Joint
e - Fuel Rail Joint Screw (2) M5 x 10
Fuel Rail Joint Screw Torque
43 lb-in (5 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-33

SERVICE PROCEDURES
Vapor Separator
Removal
1. Remove the intake manifold assembly. Refer to Intake Assembly Removal.
2. Remove the following fuel lines: vapor separator to fuel cooler (reuse metal hose
clamps), vapor separator to fuel rail (discard the metal hose clamps from this hose).
a b 58639
a - Fuel Hose (vapor separator to fuel cooler)

b - Fuel Hose (vapor separator to fuel rail)
3. Remove the vapor separator mounting screws. Remove the vapor separator.

b - Vapor Separator
Installation
1. Assemble the vapor separator to the intake manifold as shown in the illustration above.
Tighten mounting screws to specified torque.
2. Connect the following fuel lines: vapor separator to fuel cooler (secure with metal hose
clamps retained from disassembly), vapor separator to fuel rail (install new metal hose
clamps on this hose).
3. Install the intake manifold assembly. Refer to Intake Assembly Installation.
Vapor Separator Mounting Screw Torque

70 lb-in (8 Nm)
Page 3C-34 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Disassembly
1. Remove top cover screws. Remove top cover assembly.
2. Remove high pressure fuel pump filter and holder. Inspect filter for debris and clean if
necessary.
a b
e
f c
a - Top Cover Screw (7) M4 x 16

b - Top Cover Assembly
c - High Pressure Fuel Pump Filter
d - Holder
e - O-ring
f - Float Chamber
3. Remove float pin by pressing on the round end, NOT THE SQUARE END. Drive the pin
out in the direction shown.
b
c
a
a - Float Pin
b - Square End
c - Round End
90-881980R1 NOVEMBER 2001 Page 3C-35

SERVICE PROCEDURES
4. Remove needle valve, screw and retainer.
CAUTION
When removing the collar do not grab the I.D. with a pliers or similar tool. Doing this
may cause damage to the bore and result in the needle valve sticking or not seating
properly.
5. Remove the collar if required.
6. Disconnect the high pressure fuel pump connector.
7. Remove the high pressure fuel pump (may have to twist while pulling out).
e c
d f
g
a
b
a - Needle Valve
b - Screw (1) M3 x 8
c - Retainer
d - Collar
e - O-ring
f - High Pressure Fuel Pump Connector
g - Rubber Grommet
h - High Pressure Fuel Pump
Page 3C-36 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Assembly
1. Lubricate o-ring on collar and install collar (if removed). Twist collar while pushing in.
2. Install retainer and tighten screw.
3. Install needle valve in collar.
4. Install float and float pin (round end of pin should be installed first). Float pin end
should be flush with surface.
5. Plug in high pressure fuel pump connector.
6. Install the rubber grommet into the top cover assembly. Install the high pressure fuel
pump barb end into the rubber grommet (apply lubricant if necessary).
j
e c k
d i
f
g
a
b
a - Needle Valve
b - Screw (1) M3 x 8
c - Retainer
d - Collar
e - O-ring
f - High Pressure Fuel Pump Connector
g - Rubber Grommet
h - High Pressure Fuel Pump
i - Float Pin
j - Square End
k - Round End
90-881980R1 NOVEMBER 2001 Page 3C-37

SERVICE PROCEDURES
7. Install high pressure fuel pump filter and holder.

8. Install top cover assembly into float chamber. Tabs on high pressure fuel pump filter
need to be aligned with notches at bottom of float chamber.
9. Install and tighten screws.
a b
f
g
d
a - Top Cover Screw (7) M4 x 16

b - Top Cover Assembly
c - High Pressure Fuel Pump
d - High Pressure Fuel Pump Filter
e - Holder
f - O-ring
g - Float Chamber
Page 3C-38 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Pressure Regulator
REMOVAL
1. Remove metal hose clamps (retain) and hoses.
2. Remove screws and pull pressure regulator from injector rail (twist while pulling).
INSTALLATION
1. Lubricate o-ring and install pressure regulator.
2. Tighten screws to specified torque.
3. Install hoses. Install hose clamp on hose (pressure regulator to fuel cooler).
b e
a
f
a - Metal Hose Clamp (Retain)

b - Hose (pressure regulator to fuel cooler)
c - Hose (intake manifold to pressure regulator)
d - Screw (2) M6 x 15
e - Pressure Regulator
f - O-ring
Pressure Regulator Screw Torque
70 lb-in (8 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-39

SERVICE PROCEDURES
Idle Speed Control Assembly

REMOVAL
2. Disconnect vacuum hose from filter.
3. Remove idle air control mounting screws.
4. Remove idle air control assembly.
5. Remove metal hose clamps (retain) and hoses as needed.
INSTALLATION
1. Install idle air control assembly. Tighten screws to specified torque.
2. Connect vacuum hose to filter.
3. Connect air hoses and secure with metal hose clamps (retained from disassembly).
a e j
g
c
f h
4150
a - Filter
b - Vacuum Hose (idle air control to intake manifold)
c - Idle Air Control Mounting Screw (2) M8 x 60
d - Idle Air Control Mounting Screw (1) M8 x 24
e - Idle Air Control Assembly
f - Hose (idle air control assembly to throttle body #2)
g - Hose (idle air control assembly to throttle body #1)
h - Metal Hose Clamp (4) (Retain)
i - Throttle Body #1
j - Throttle Body #2
Idle Air Control Assembly Mounting Screw Torque
156 lb-in (18 Nm)
Page 3C-40 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
DISASSEMBLY
1. Remove pressure sensor screws and pressure sensor (twist while pulling).
2. Remove idle air control screws. Remove air speed control from idle air control body.
3. Remove filter.
ASSEMBLY
1. Install filter.
2. Install idle air control to idle air control body.
3. Install the manifold absolute pressure (MAP) sensor and tighten screws to specified
torque.
a d
c
e
a - MAP Sensor Screws (2) M5 x 15

b - MAP Sensor
c - O-ring
d - Screw (3) M4 x 15
e - Idle Air Control
f - O-ring
g - Idle Air Control Body
h - Filter (24mm Hex)
Manifold Absolute Pressure Sensor Mounting Screw Torque
43 lb-in (5 Nm)
Idle Air Control Mounting Screw Torque

18 lb-in (2 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-41

SERVICE PROCEDURES
Intake Manifold
DISASSEMBLY
2. Remove throttle body, high pressure fuel line, vapor separator, fuel rail and idle air con-
trol assembly. Refer to appropriate segment in this section for removal instructions.
3. Remove components as as shown in illustration.
ASSEMBLY
1. Install components as shown in illustration.
2. Install throttle body, high pressure fuel line, vapor separator, fuel rail and idle speed con-
trol assembly. Refer to appropriate segment in this section for installation instructions.
b
a c
d
d
e
a - Hose (pressure regulator to intake manifold to idle speed control assembly)
b - Rubber Seal (4) (Fuel Injector)
c - Intake Manifold
d - Collar (6) (Vapor Separator Mount)
e - Grommet (3) (Vapor Separator Mount)
Page 3C-42 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES

REMOVAL
1. Disconnect throttle position sensor connector.
2. Remove the tamper proof screws for the bracket (covering the throttle position sensor)
and throttle position sensor using special tool p/n 91-881828.
INSTALLATION
1. Install throttle position sensor and torque tamper proof screws using special tool
91-882828.
2. Install the bracket and torque tamper proof screws using special tool 91-881828.
3. Connect throttle position sensor connector. Refer to section 2C Timing, Synchroniz-
ing and Adjusting for adjustment of the throttle position sensor.
i
h
g
f
91-881828 e
58685
d
c
b
a
58634
a - Throttle Position Sensor e - Bracket

b - Washer (2) f - Lock Washer (3)
c - Washer (2) g - Spool (3)
d - Tamper Proof Screw (2) M4 x 12 h - Washer (3) (Cupped)
(T20) i - Tamper Proof Screw (3) M5 x 12
(T25)
Throttle Position Sensor Tamper Proof Screw Torque
18 lb-in (2 Nm)
Bracket Tamper Proof Screw Torque

40 lb-in (5 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-43

SERVICE PROCEDURES
Low Pressure Fuel Line/Fuel Pump

Removal
1. Remove grommet retaining plate.
2. Cut sta-strap and remove fuel hose from grommet.
b
c
a - Grommet Retaining Plate

b - Screw (2) M6 x 28
c - Fuel Hose Opening
d - Rubber Grommet
e - Sta-Strap (Discard)
3. Remove spark plug cover.
4. Disconnect fuel hose from fuel pump and fuel filter.
5. Remove fuel pump. Remove fuel filter mounting bracket assembly.
h
g j
i
c b
d
f
a
k
b - Screw (5) M6 x 16
c - Sta-Strap (4) (Discard)
d - Fuel Hose (fuel pump to vapor separator)
e - Fuel Filter Mounting Bracket Assembly
f - Screw (1) M6 x 16
g - Fuel Pump
h - Screw (2) M6 x 30
i - O-ring
j - Low Pressure Fuel Line
k - Conduit
Page 3C-44 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Installation
1. Install fuel pump and fuel filter. Tighten mounting screws to specified torque.
2. Connect fuel hoses as shown. Secure with sta-straps.
3. Install spark plug cover. Tighten screws to specified torque.
h
g j
i
c b
d
f
a
k
b - Screw (5) M6 x 16
c - Sta-Strap (4) (New)
d - Fuel Hose (fuel pump to vapor separator)
e - Fuel Filter Mounting Bracket Assembly
f - Screw (1) M6 x 16
g - Fuel Pump
h - Screw (2) M6 x 30
i - O-ring
j - Low Pressure Fuel Line
k - Conduit
4. Route the fuel line through the opening in the rubber grommet and install sta-strap.
5. Install grommet retaining plate. Tighten screws to specified torque.
b
c
a - Grommet Retaining c - Fuel Hose Opening

Plate d - Rubber Grommet
b - Screw (2) M6 x 28 e - Sta-Strap (New)
M6 Mounting Screw Torque
70 lb-in (8 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-45

SERVICE PROCEDURES
DISASSEMBLY
1. Remove fuel hoses from fuel filter assembly and fuel pump as shown. Discard sta-
straps.
ASSEMBLY
2. Connect fuel hoses to fuel filter and fuel pump as shown. Secure with new sta-straps.
e
c
d f
b e
e
a - Fuel Filter Assembly

b - Fuel Hose (fuel supply to fuel filter)
c - Fuel Pump
d - Fuel Hose (fuel filter to fuel pump)
e - Sta-Straps (3)
f - Conduit
Page 3C-46 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
Fuel Filter
DISASSEMBLY
1. Remove fuel filter bracket.
2. Unscrew fuel filter cup and remove float, fuel filter element, and o-rings.
ASSEMBLY
1. Install fuel filter element onto fuel filter cap.
2. Install float into fuel filter cup. Line up notches in float with ribs on the inside of the fuel
filter cup.
3. Hand tighten fuel filter cup.
a
b
d
e
a - Nut
b - Fuel Filter Mounting Bracket
c - Fuel Filter Cap
d - O-ring
e - O-Ring
f - Fuel Filter Element
g - Float
h - Fuel Filter Cup
90-881980R1 NOVEMBER 2001 Page 3C-47

SERVICE PROCEDURES
Fuel Pump
Disassembly
1. Remove fuel pump assembly from engine.
2. Remove fuel pump cover.
3. Remove fuel pump body from fuel pump base assembly.
4. Disassemble as shown.
a LT e
d
c
58637
a - Fuel Pump Body

b - Fuel Pump Base Assembly
c - Fuel Pump Cover
d - Gasket
e - Screw (3) M6 x 35
5. Insert screwdriver in the plunger slot and rotate until the pin lines up with the groove.
b c
58636
a - Plunger
b - Groove
c - Fuel Pump Base Assembly
Page 3C-48 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
CAUTION
Plunger is spring loaded. Place the fuel pump assembly on a bench top (so plunger
is facing down) before pulling the pin completely out. Failure to do this could result
in injury due to objects flying through the air.
6. Insert screwdriver in back side of slot and push pin out. Grab pin with a needle nose and
pull completely out.
b
a
58635
a - Pin
b - Plunger
7. Disassemble components as shown.
g
a
b
d
e
c
f
a - Diaphragm
b - Spring
c - Fuel Pump Base
d - Spring
e - Plunger
f - Pin
g - Nut
90-881980R1 NOVEMBER 2001 Page 3C-49

SERVICE PROCEDURES
Assembly
1. Install components as shown.
b
d
e
c
f
a - Diaphragm
b - Spring
c - Fuel Pump Base
d - Spring
e - Plunger
f - Pin
2. Push down on the plunger until the groove lines up with the hole in the end of the dia-
phragm shaft. Insert pin.
b
c
a
58635
a - Pin
b - Plunger
c - Hole in Diaphragm Shaft
3. Rotate plunger back to original position (pin should be 90° from groove).
a
c
58636
a - Plunger
b - Groove
c - Fuel Pump Base Assembly
Page 3C-50 90-881980R1 NOVEMBER 2001

SERVICE PROCEDURES
4. Alignment marks on fuel pump body, base assembly and cover should be as shown be-
low. Assemble fuel pump body, cover, and new gasket to fuel pump base. Apply Loctite
242 (obtain locally) and tighten screws to specified torque.
66
c
a e
d
66 Loctite 242 Thread Locker 58637
a - Fuel Pump Body

b - Fuel Pump Base Assembly
c - Fuel Pump Cover
d - Gasket (NEW)
e - Screw (3) M6 x 35
f - Nut (3)
M6 Mounting Screw Torque
70 lb-in (8 Nm)
90-881980R1 NOVEMBER 2001 Page 3C-51

EMISSIONS
FUEL SYSTEM
Section 3D – Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . . . 3D-2 Stratified Charge . . . . . . . . . . . . . . . . . . . . . . . 3D-5
What Are Emissions? . . . . . . . . . . . . . . . . . . . 3D-2 Emissions Information . . . . . . . . . . . . . . . . . . . . . 3D-6
Hydrocarbons - HC . . . . . . . . . . . . . . . . . . . . . 3D-2 Manufacturer’s Responsibility . . . . . . . . . . . . 3D-6
Carbon Monoxide - CO . . . . . . . . . . . . . . . . . . 3D-2 Dealer Responsibility . . . . . . . . . . . . . . . . . . . 3D-6
Oxides of Nitrogen - NOx . . . . . . . . . . . . . . . .
Controlling Emissions . . . . . . . . . . . . . . . . . . .
3D-2
3D-2
Owner Responsibility . . . . . . . . . . . . . . . . . . .
EPA Emission Regulations . . . . . . . . . . . . . .
3D-6
3D-7
3
Stoichiometric (14.7:1) Air/Fuel Ratio . . . . . 3D-3 Manufacturer’s Certification Label . . . . . . . . . . . 3D-8 D
Outboard Hydrocarbon Service Replacement Certification Label . . . . . 3D-9
Emissions Reductions . . . . . . . . . . . . . . . . . . . . . 3D-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
8 1/3% # Per Year Over 9 Model Years . . . . 3D-3 Date Code Identification . . . . . . . . . . . . . . . . . 3D-9
Stratified Vs Homogenized Charge . . . . . . . . . . 3D-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
Homogenized Charge . . . . . . . . . . . . . . . . . . . 3D-4 Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9

EMISSIONS
Exhaust Emissions Standards

Through the Environmental Protection Agency (EPA), the federal government has estab-
lished exhaust emissions standards for all new marine engines sold in the U.S.
What Are Emissions?
Emissions are what comes out of the exhaust system in the exhaust gas when the engine
is running. They are formed as a result of the process of combustion or incomplete combus-
tion. To understand exhaust gas emissions, remember that both air and fuel are made of
several elements. Air contains oxygen and nitrogen among other elements; gasoline con-
tains mainly hydrogen and carbon. These four elements combine chemically during com-
bustion. If combustion were complete, the mixture of air and gasoline would result in these
emissions: water, carbon dioxide and nitrogen, which are not harmful to the environment.
But combustion is not usually complete. Also, potentially harmful gases can be formed dur-
ing and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful
gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards be-
come more stringent each year. Standards are set primarily with regard to three emissions:
hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).
Hydrocarbons – HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned dur-
ing combustion in combination with oxygen. But they are not totally consumed. Some pass
through the combustion chamber and exit the exhaust system as unburned gases known
as hydrocarbons.
Carbon Monoxide – CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxygen
during the combustion process. If the carbon in the gasoline could combine with enough
oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the
form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insuffi-
cient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide, CO.
Carbon monoxide is the product of incomplete combustion and is a dangerous, potentially
lethal gas.
Oxides of Nitrogen - NOx
NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that
makes up the air going into the engine. Under extremely high temperatures it combines with
oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion cham-
bers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight
it combines with unburned hydrocarbons to create the visible air pollutant known as smog.
Smog is a serious problem in California as well as many other heavily populated areas of
the United States.
Controlling Emissions
There are two principle methods of reducing emissions from a two-stroke-cycle marine en-
gine. The first method is to control the air/fuel ratio that goes into the combustion chamber.
The second is to control the time when this air/fuel mixture enters the combustion chamber.
Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.

EMISSIONS
Stoichiometric (14.7:1) Air/Fuel Ratio

In the search to control pollutants and reduce exhaust emissions, engineers have discov-
ered that they can be reduced effectively if a gasoline engine operates at an air/fuel ratio
of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of 14.7:1
provides the best control of all three elements in the exhaust under almost all conditions.
The HC and CO content of the exhaust gas is influenced significantly by the air/fuel ratio.
At an air/fuel ratio leaner than 14.7:1, HC and CO levels are low, but with a ratio richer than
14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves might not
be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However,
there is also NOx to consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combus-
tion temperatures raise the NOx content of the exhaust. But, enrichening the air/fuel ratio
to decrease combustion temperatures and reduce NOx also increases HC and CO, as well
as lowering fuel economy. So the solution to controlling NOx - as well as HC and CO - is to
keep the air/fuel ratio as close to 14.7:1 as possible.
OUTBOARD HYDROCARBON
EMISSIONS REDUCTIONS
8 1/3% PER YEAR OVER 9 MODEL YEARS
120
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08

EMISSIONS
STRATIFIED VS HOMOGENIZED CHARGE

At certain operating conditions, DFI engines use a stratified charge inside the combustion
chamber to aid in reducing emissions. All other models exclusively use a homogenized
charge. The difference between the two is:
Homogenized Charge
A homogenized charge has the air/fuel particles mixed evenly throughout the cylinder. This
mixing occurs inside the carburetor venturi, reed blocks, crankcase and/or combustion
chamber. Additional mixing occurs as the fuel is forced through the transfer system into the
cylinder. The homogenized charge has an air/fuel ratio of approximately 14.7:1 and is uni-
form throughout the cylinder.

EMISSIONS
Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel required for
combustion is forced into the cylinder through an injector placed in the top of the cylinder
(head). The injector sprays an air/fuel mixture in the form of a cloud into the cylinder. Sur-
rounding this cloud is air supplied by the transfer system. As the cloud is ignited and burns,
the surrounding air provides almost complete combustion before the exhaust port opens.
A stratified charge engine concentrates a rich mixture in the vicinity of the spark plug (air/fuel
ratio less than 14.7:1). Elsewhere, the mixture is very lean or is comprised of air only.

EMISSIONS
Emissions Information
Manufacturer’s Responsibility
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family and certify
these engines with the United States Environmental Protection Agency (EPA). A certifica-
tion decal/emissions control information label, showing emission levels and engine specifi-
cations directly related to emissions, must be placed on each engine at the time of manufac-
ture.
Dealer Responsibility
When performing service on all 1998 and later outboards that carry a certification, attention
must be given to any adjustments that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner
that maintains emission levels within the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow
emission levels to exceed their predetermined factory specifications.
Exceptions include manufacturers prescribed changes, such as that for altitude adjust-
ments.
Owner Responsibility
The owner/operator is required to have engine maintenance performed to maintain emis-
sion levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horse-
power or allow emissions levels to exceed their predetermined factory specifications.
Exceptions:
• Carburetor jets may be changed for high altitude use in accordance with factory recom-
mendations.
• Single engine exceptions may be allowed with permission from the EPA for racing and
testing.

EMISSIONS
EPA Emission Regulations

All new 1998 and later outboards manufactured by Mercury Marine are certified to the
United States Environmental Protection Agency as conforming to the requirements of the
regulations for the control of air pollution from new outboard motors. This certification is con-
tingent on certain adjustments being set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed and, whenever practicable, the
product returned to the original intent of the design.
The responsibilities listed above are general and in no way a complete listing of the rules
and regulations pertaining to the EPA laws on exhaust emissions for marine products. For
more detailed information on this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww

EMISSIONS
Manufacturer’s Certification Label

The certification label must be placed on each engine at the time of manufacture and must
be replaced in the same location if damaged or removed. Shown below is a typical certifica-
tion label and is not representative of any one model. Label shown below is not to scale;
(shown at twice the normal size).
Emission Control a
Information
This engine conforms to 2002 Model Year U.S. EPA regulations for Marine SI engines.
Refer to Owners Manual for required maintenance
j Family: 2M9XM01.72G0 Idle Speed (in neutral): 750 RPM b
i FEL: 16.6 GM/KW-HR 115 HP 1741 cc c
h Timing (in degrees): Not Adjustable CDI Controlled
d
Standard Spark Plug: NGK LFR6A-11
Gap: 0.043″ (1.1 mm)
OCTOBER
g e
Suppressor Spark Plug: NGK LFR6A-11 2002
Gap: 0.043″ (1.1 mm)
Intake: 0.17-0.23
f Valve Clearance (Cold) mm
Exhaust: 0.31-0.37
a - Spark Ignition (SI)

b - Idle Speed (In Gear)
c - Cubic Centimeter
d - Engine Horsepower rating
e - Month and Year of Production
f - Valve Clearance (Four Stroke engines only)
g - Recommended spark plug for best engine performance
h - Timing specifications when adjustable
i - FEL: Represents (Mercury Marine) statement of the maximum emissions output
for the engine family
j - Family example
2 M9X M01.7 2 G 0
Type of Product
0=All except; J=Sport Jet
E=EFI Sport Jet & EFI 4-strokes
Model Year Regulation 3=OptiMax 135
2=2002 M=Marine H=High Performance
Manufacturer Technology Cycle Type

Mercury Marine Type C=2 Stroke
1=OB Old Tech G=4 Stroke
2=OB New Tech
3=SportJet
4=OptiJet
4 Digits for Displacement
Decimal Point = Liters such as 01.7 = 1.7L, .935 = 935 cc
No Point = C.I. such as 0113 =113 Cubic Inches

EMISSIONS
Service Replacement Certification Label

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine out-
boards have a visible and legible emission certification label. If this label is missing
or damaged, replacement labels can be obtained from Mercury Marine.
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label over
the old label. Use a suitable solvent to remove any traces of the old label adhesive from the
display location.
Date Code Identification
Cut and remove a “V” notch through the month of engine manufacture before installing the
new label. The month of manufacture can be found on the old label. If the label is missing
or the date code illegible, contact Mercury Marine Technical Service for assistance.
Emission Control 1741 2002

Information cc PART # 37–859245
This engine conforms to 2002 Model Year Idle Speed (in neutral): 750 RPM
U.S. EPA regulations for marine SI engines.
Refer to Owners Manual Timing: Not Adjustable CDI
for required maintenance Controlled
Family: 2M9XM01.72G0 Spark Plug: NGK LFR6A-11
Gap: 0.043” (1.1 mm)
Valve Clearance (Cold) mm

FEL: 16.6 GM/KW-HR Intake: 0.17-0.23 Exhaust: 0.31-0.37
115 HP
4-Stroke
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
a
a - “V” Notch
b - Month of Manufacture
Installation
Install the label on a clean surface in the original factory location.
Decal Location
Model Service Part No. Location on Engine
2001 Merc/Mar 115 HP (4-Stroke) 37-881839A01 Top of Flywheel Cover
2002 Merc/Mar 115 HP (4-Stroke) 37-881839A02 Top of Flywheel Cover

CYLINDER HEAD
POWERHEAD
Section 4A - Cylinder Head
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . 4A-31
Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . . . 4A-8 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 4A-32
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . 4A-32
Cylinder Head Screws . . . . . . . . . . . . . . . . . 4A-12 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-35
Camshaft Caps Screws . . . . . . . . . . . . . . . . 4A-12 Cylinder Head Reassembly . . . . . . . . . . . . . . . . 4A-36
Adjustments
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . 4A-13
Cylinder Head Installation . . . . . . . . . . . . . . . . .
Following Cylinder Head Installation . . . . . . . .
4A-38
4A-39
4
Preparing Cylinder Head for Removal . . . . . . . 4A-23 Timing Belt Installation . . . . . . . . . . . . . . . . . 4A-41 A
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 4A-25 Extra Valve Clearance Work sheets . . . . . . . . . 4A-42
Cylinder Head Disassembly . . . . . . . . . . . . . . . 4A-26 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 4A-42
Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4A-28 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-42
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28

CYLINDER HEAD
Specifications
Camshaft Dimensions
Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm)
Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm)
Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm)
Exhaust “B” 1.178 - 1.184 in. (29.92 - 30.08 mm)
Valve Lift
Intake 0.287 in. (7.30 mm)
Exhaust B 0.275 in. (6.98 mm)
CAMSHAFT Run-out Limit 0.004 in. (0.1 mm)
Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm)
Camshaft Bearing Oil Clearance 0.0008-0.0024 in. (0.020-0.061 mm)
A
Free Length “a” 2.094 in. (53.20 mm)
Minimum Free Length 2.057 in. (52.25 mm)
Tilt Limit “b” Less than 0.10 in. (2.6 mm)
b
VALVE SPRING
a
Warp Limit 0.004 in. (0.1 mm)
CYLINDER HEAD
Camshaft Bearing Inside Diameter 0.984 - 0.985 in. (25.000 - 25.021 mm)
Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm)

CYLINDER HEAD
Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.007 - 0.009 in. (0.17 - 0.23 mm)
Exhaust 0.012 - 0.014 in. (0.31 - 0.34 mm)
Valve Face Angle

Intake 120°, 91°, 110°
Exhaust 140°, 91°, 110°
Valve Dimensions:
“A” Head Diameter
Intake 1.142 - 1.150 in. (29.0 - 29.2 mm)
Exhaust 0.945 - 0.953 in. (24.0 - 24.20 mm)
“B” Face Width
Intake 0.078 - 0.094 in. (1.98 - 2.40 mm)
Exhaust 0.089 - 0.106 in. (2.26 - 2.69 mm)
“C” Seat Width
Intake 0.062 - 0.076 in. (1.58 - 1.94 mm)
VALVES Exhaust 0.071 - 0.080 in. (1.80 - 0.02 mm)
“D” Margin Thickness
Intake 0.031 - 0.047 in. (0.80 - 1.20 mm)
Exhaust 0.039 - 0.055 in. (1.00 - 1.40 mm)
Stem Outside Diameter
Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm)
Exhaust 0.2346 - 0.2352 in. (5.960 - 5.975 mm)
Guide Inside Diameter
Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm)
Exhaust 0.2364 - 0.2369 in. (6.005 - 6.018 mm)
Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm)
Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm)
Stem Run-out Limit (max.) 0.001 in. (0.03 mm)
Valve Dimensions
“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness
Valve Lifter Outside diameter 1.1010 - 1.1016 in.

VALVE LIFTERS (27.965 - 27.980 mm)
Valve Lifter to Lifter Bore Clearance 0.0008 - 0.0022 in. (0.020 -0.056 mm)
Valve shim Thickness 0.0787 - 0.1299 in. (2.000 - 3.300 mm)
VALVE SHIM
(in 0.025 mm increments)
Valve Opening Temperature 122° F (50° C)
THERMOSTAT Full Open Temperature 140° F (60° C)
Valve Lift (Minimum) 0.17 in. (0.43 mm)

CYLINDER HEAD
Special Tools
1. Flywheel Holder P/N 91-83163M
2. Valve Guide Remover/Installer P/N 91-804774
3. Valve Guide Reamer P/N 91-804775
4. Valve Spring Compressor P/N 91-809494A1
5. Valve Seat Cutter Kit (Obtain Locally).

CYLINDER HEAD
Notes:

CYLINDER HEAD
Cylinder Head
27
26 22 28
29 30
7
109
110
25
24
23 26 31
21
20 110
19
110
110 12 3 2 7
4
5 18 17
2
10
11
9 8
16
15 7
14
13
95
7
6
110
3 1
7 Loctite 271 - Thread Locker 109 RTV 587 Silicone Sealer
95 2-4-C With Teflon 110 4 Cycle Oil

CYLINDER HEAD
Cylinder Head
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. Nm
1 1 CYLINDER HEAD
2 16 GUIDE PIN
3 4 PLUG
4 4 SCREW (M7 X 48 MM) See Note
5 4 DOWEL PIN
8 2 COLLAR
9 1 GASKET
10 4 SCREW
11 4 WASHER
13 2 ANODE
14 2 GROMMET
15 2 COVER
16 2 SCREW (M6 X 20 MM) 70 8
17 4 SCREW (M8 X 25 MM) 156 13 17.5
18 4 SPARK PLUG (NGK LFR 6A-11) 18 24.5
19 1 THERMOSTAT
20 1 THERMOSTAT COVER
21 2 SCREW (M6 X 25 MM)
22 1 CYLINDER HEAD COVER
23 1 BREATHER COVER
24 8 SCREW (M4 X 8 MM) 17 2
25 1 GASKET
26 2 GROMMET
28 1 OIL PLUG
29 1 O-RING
30 1 COVER
31 5 SCREW (M6 X 16 MM) 65 7.5
NOTE: Ref. #4 - 1st Torque 70 lb. in.; 2nd Torque 150 lb. in.
NOTE: Ref. #7 - 1st Torque 11 lb. ft.; 2nd Torque 22 lb. ft.., then turn +90 degrees
NOTE: Ref. #12 - 1st Torque 10 lb. ft.; 2nd Torque 20 lb. ft...
NOTE: Ref. #27 - Torque all screws to 70 lb. in.; then re-check and re-tighten to 70 lb. in.
as necessary

CYLINDER HEAD
Intake/Exhaust Valves
2
21 22
23
3 3
25 4
5
20
24
19
4
18
17
16
15 6
14 15
13
5
12
10
17
9 15 16 7
14
11 13
10
8
15

CYLINDER HEAD
TORQUE
REF.
REF
1 1 BELT
2 2 SCREW (M10 X 35 MM) 44.2 60
3 2 DRIVEN GEAR
4 2 OIL SEAL
5 2 DOWEL PIN
6 1 CAMSHAFT (EXHAUST)
7 1 CAMSHAFT (INTAKE)
8 8 INTAKE VALVE
9 8 EXHAUST VALVE
10 16 SEAT
11 8 SEAL
12 8 SEAL
13 16 SPRING
14 16 RETAINER
15 32 COTTER
16 16 VALVE LIFTER
17 AR ADJUSTING PAD (2.350 mm)
AR ADJUSTING PAD (2.375 mm)
CONTINUED ON NEXT PAGE

CYLINDER HEAD
2
21 22
23
3 3
25 4
5
20
24
19
4
18
17
16
15 6
14 15
13
5
12
10
17
9 15 16 7
14
11 13
10
8
15
Page 4A-10 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
TORQUE
REF.
REF
18 1 VALVE PLATE
19 1 KEY
20 1 TENSIONER ASSEMBLY
21 1 SCREW (M10 X 45 MM) 29.5 40
22 1 SPRING
23 1 HOSE
24 1 DRIVE GEAR
25 1 NUT (40 MM) 195.4 265
90-881980R1 NOVEMBER 2001 Page 4A-11

CYLINDER HEAD
Torque Sequence
Cylinder Head Screws
9 10 14
5 6 13
1 2
11
4 3 12
8 7 15
Cylinder Head Screw Torque-M8 x 55 mm

1st 120 lb-in. (14 Nm)
2nd 20 lb-ft (28 Nm)

1st 132 lb-in. (15 Nm)
3rd 90°
51 lb-ft (70 Nm)*
*Torque value given for reference only.
Camshaft Caps Screws

10 9 19 20
11
12
2
1 17
8 18
13
7
14
4
15
3
6 16
5
Camshaft Cap Screw Torque

1st 70 lb-in. (8 Nm)
2nd 150 lb-in. (17 Nm)
Page 4A-12 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
Adjustments
Valve Clearance
WARNING
Engine could possibly start when turning flywheel during adjustment. To prevent
this type of accidental engine starting and possible serious injury, always remove
spark plug leads from spark plugs.
NOTE: Valve clearance adjustment should be made on a cold engine at room temperature.
1. Remove flywheel cover and spark plug cap cover.
2. Disconnect spark plug leads and fuel hose.
a
c
b
d
e c
58654
a - Screws (2) M6 x 20
b - Flywheel Cover
d - Spark Plug Cap Cover
e - Fuel Hose
90-881980R1 NOVEMBER 2001 Page 4A-13

CYLINDER HEAD
3. Align timing marks on driven cams.

NOTE: Use flywheel holder (91-83163M) to rotate flywheel and align timing marks.
4. Loosen timing belt tensioner Screw and remove tensioner spring.
a
b
91-83163M
a - Timing Marks
b - Timing Belt Tensioner Screw M10 x 45
c - Tensioner Spring
5. Remove timing belt and driven sprockets.

6. Remove cylinder head cover and spark plugs.
a
d
b h
c
a - Driven Sprocket Screw (2) M10 x 35 e - Breather Hose

b - Washer (2) f - Screw (14) M6 x 30
c - Driven Sprocket (2) g - Cylinder Head Cover
d - Pin (2) h - Rubber Gasket
Page 4A-14 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
7. Re-install driven sprockets and timing belt.

NOTE: Make sure timing marks are still aligned.
d
a
b
c
a - Pin (2)
b - Washer (2)
c - Driven Sprocket (2)
d - Driven Sprocket Screw (2) M10 x 35
e - Timing Marks Aligned
Driven Sprocket Screw Torque
44 lb-ft (60 Nm)
8. Install tensioner spring and tighten timing belt tensioner.
a - Timing Belt Tensioner M10 x 45

b - Tensioner Spring
Timing Belt Tensioner Screw Torque
29 lb-ft (40 Nm)
90-881980R1 NOVEMBER 2001 Page 4A-15

CYLINDER HEAD
9. Measure intake and exhaust valve clearance using the Valve Clearance Measurement
Steps below.
VALVE CLEARANCE MEASUREMENT STEPS:
a. Turn flywheel clockwise until cylinder #1’s piston is at TDC.
b. Measure and record the intake valve clearance for cylinders #1 and #2.
c. Measure and record the exhaust valve clearance for cylinders #1 and #3.
d. Turn the flywheel 360° clockwise.
e. Measure and record the intake valve clearance for cylinders #3 and #4.
f. Measure and record the exhaust valve clearance for cylinders #2 and #4.
Intake cylinders #1 and #2 Intake cylinders #3 and #4

Exhaust cylinders #1 and #3 Exhaust cylinders #2 and #4
MEASUREMENT TABLE
INTAKE (cold) EXHAUST (cold)
0.007-0.009 in. (0.17-0.23 mm) 0.012-0.014 in. (0.31-0.37 mm)
CYL. Clearance Old New New CYL. Clearance Old New New
Pad Pad Clearance Pad Pad Clearance
#1 #1
#2 #2
#3 #3
#4 #4
#1
#2
#3
#4
Intake Exhaust
Page 4A-16 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
10. If Adjustment of intake or exhaust valve clearance is necessary (out of specification) fol-
low Changing Pad Thickness below. If no adjustment is necessary, skip to step #11
under Changing Pad Thickness.
CHANGING PAD THICKNESS
2. Loosen timing belt tensioner and remove tensioner spring.
NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts), keep individual
cylinder parts together.
a
b
a - Timing Marks
b - Timing Belt Tensioner M10 x 45
3. Remove timing Belt and driven sprockets.

4. Remove camshaft caps and camshafts.
IMPORTANT: Remove camshaft cap screws in reverse sequence (ex. #20 #1).
9
i 10 19 20
a g
e
d b 2 11 12
c
1
8 17 18
h 7
f 4 13 14
3
6 15 16
j
5
a - Driven Sprocket Screw (2) M10 x 35 f - Screw (16) M7 x 37

b - Washer (2) g - Camshaft Cap - Top (2)
c - Driven Sprocket (2) h - Camshaft Cap (8)
d - Pin (2) i - Oil Seal (2)
e - Screw (4) M7 x 48 j - Camshaft (2)
90-881980R1 NOVEMBER 2001 Page 4A-17

CYLINDER HEAD
5. Carefully pry up the valve pad and remove it.

6. Measure and record (in the Measurement Table) the thickness of the removed valve
pad with a micrometer.
c
a
b
a - Valve Pad
b - Screwdriver
c - Measure Valve Pad Thickness With a Micrometer
a. Select a proper replacement valve pad by calculating its thickness with the following
formula.
Removed Pad Thickness
+
Measured Valve Clearance
–
Specified Valve Clearance
= New Pad Thickness

NOTE: Measure the thickness of the new valve pads with a micrometer (thickness is not
indicated on the pad).
NOTE: Lubricate the valve pads with molybdenum disulfide before installing.
b. Insert the proper valve pad into the valve lifter.
A Molybdenum Disulfide Grease (Purchase Locally)
Page 4A-18 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
7. Install camshafts and camshaft caps

IMPORTANT: Install camshaft cap Screws in the proper sequence and torque.
e Intake 9 Exhaust
b 10 19 20
a
2 11 12
1
d 8 17 18
7
i
c 4 13 14
3
6 15 16
f g h
5

a - Screw (4) M7 x 48 e - Oil Seal (2)
b - Camshaft Cap Top (2) f - Camshaft - Intake
c - Screw (16) M7 x 37 g - Camshaft - Exhaust
d - Camshaft Cap (8) h - Pink Identification
i - Exhaust Cam Tang
2nd 150 lb-in. (17 Nm)
8. Install driven sprockets and timing belt.
a
d b
c
a - Driven Sprocket Screw (2) M10 x 35 c - Driven Sprocket (2)

b - Washer (2) d - Pin (2)
44 lb-ft (60 Nm)
90-881980R1 NOVEMBER 2001 Page 4A-19

CYLINDER HEAD
9. Tighten timing belt tensioner and install tensioner spring.
a - Timing Belt Tensioner M10 x 45

29 lb-ft (40 Nm)
10. Re-check valve clearance using Valve Clearance Measurement Steps.

NOTE: If any valve clearance is still out of specification, repeat all the valve clearance
adjustment steps until the specified clearance is obtained.
11. Loosen timing belt tensioner screw and remove tensioner spring.
12. Remove driven sprockets and timing belt.
Page 4A-20 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
13. Install cylinder head cover and driven sprockets.
109
109
h
a e
g
f
c
a - Rubber Gasket e - Pin (2)
b - Cylinder Head Cover f - Driven Sprocket (2)
c - Screw (14) M6 x 30 g - Washer (2)
d - Breather Hose h - Driven Sprocket Screw (2) M10 x 35
Cylinder Head Cover Screw Torque

70 lb-in. (8 Nm)

44 lb-ft (60 Nm)
90-881980R1 NOVEMBER 2001 Page 4A-21

CYLINDER HEAD
14. Install timing belt and spark plugs.

15. Install tensioner spring and tighten timing belt tensioner screw.
a - Timing Belt Tensioner Screw M10 x 45


29 lb-ft (40 Nm)
16. Connect fuel hoses and spark plug leads.

17. Install spark plug cap cover and flywheel cover.
c
e
d
b
c
a
c
58654
a - Fuel Hoses
b - Spark Plug Cap Cover
d - Flywheel Cover
e - Screws (2) M6 x 20
Spark Cover Screw Torque

65 lb. in. (7.5 Nm)
Page 4A-22 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
Preparing Cylinder Head for Removal

1. Remove flywheel cover and spark plug cap cover.
2. Disconnect fuel hoses and spark plug leads.
c
a
b d
e c
c
58654
b - Flywheel Cover
d - Spark Plug Cap Cover
e - Fuel Hoses

4. Loosen timing belt tensioner and remove tensioner spring.
91-83163M
c
a
b
a - Timing Marks
90-881980R1 NOVEMBER 2001 Page 4A-23

CYLINDER HEAD
5. Remove timing belt and driven sprockets.

6. Remove fuel pump/filter (refer to Section 3C) and cylinder head cover.
a
c
b h
d
e
a - Driven Sprocket Screw (2) e - Breather Hose

M10 x 35 f - Screw (14) M6 x 30
b - Washer (2) g - Cylinder Head Cover
c - Pin (2) h - Rubber Gasket
d - Driven Sprocket (2)
7. Remove camshaft caps and camshafts.

NOTE: Do not mix valve train parts (valve pads, camshaft caps, camshafts), keep individual
cylinder parts together.
IMPORTANT: Remove camshaft cap screws in reverse sequence (ex. #20 #1).
e
b Intake 9 Exhaust
a
10 19 20
2 11 12
1
8 17 18
d
7
4 13 14
c
3
6 15 16
f 5
a - Screw (4) M7 x 48 d - Camshaft Cap (8)

b - Camshaft Cap - Top (2) e - Oil Seal (2)
c - Screw (16) M7 x 37 f - Camshaft (2)
Page 4A-24 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
Cylinder Head Removal

1. Remove spark plugs and cylinder head assembly.
2. Remove gasket (discard) and dowel Pins.
IMPORTANT: Remove cylinder head screws in reverse order of torque sequence (ex.
#15 #1).
NOTE: Use Torx socket driver T55 for removal/installation of cylinder head screws.
e
f
9 10 14
b 5 6 13
1 2
11
4 3 12
a
8 7 15
c
d
a - Spark plugs
b - Screw (10) M10 x145
c - Screw (5) M8 x 55
d - Cylinder Head Assembly
e - Gasket (discard)
f - Dowel Pins (2)
90-881980R1 NOVEMBER 2001 Page 4A-25

CYLINDER HEAD
Cylinder Head Disassembly

1. Remove thermostat and anodes.
IMPORTANT: To prevent anode from falling into water jacket use the following proce-
dure for anode removal:
a. Remove anode cover screws “d”.
b. Remove anode assembly from cylinder block.
c. Remove anode screw “e”.
a
b
d
c
e
d
g
f
d
h
e
a - Screw (2) M6 x 25 e - Screw (2) M6 x 20
b - Thermostat Cover f - Anode Cover (2)
c - Thermostat g - O-Ring (2)
d - Screw (4) M8 x 25 h - Anode (2)
2. Remove valve pad and valve lifter.

NOTE: Keep valve pads and lifters organized to prevent them from being installed into the
wrong location during cylinder head reassembly.
a
e
b
c d
a - Pliers d - Valve Lifter

b - Valve Pad and Lifter e - Lifter Position Fixture
c - Valve Pad
Page 4A-26 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
3. Remove valve cotter, spring retainer, and spring.

NOTE: Use valve spring compressor (91-809494A1) for removal of valves. Compress valve
and remove valve cotters first.
4. Remove valve stem seal, spring seat, and valve guide* (see note below).
5. Remove valves (intake and exhaust).
NOTE: *Do not remove valve guide unless it is out of specification, refer to “Cleaning/In-
spection/Repair” in this section for measurement and removal procedures.
h
g
a c e
91-809494A1
d f
b
a - Valve Cotter e - Spring Seat

b - Spring Retainer f - Valve Guide
c - Valve Spring g - Exhaust Valve
d - Valve Stem Seal h - Intake Valve
90-881980R1 NOVEMBER 2001 Page 4A-27

CYLINDER HEAD
Cleaning/Inspection/Repair
Camshaft
1. Measure camshaft lobe dimensions “a” and “b”, replace the camshaft if out of specifica-
tion.
a
b
Cam Lobe Specifications

1.465 - 1.472 in.
Intake
(37.22 - 37.38 mm)
a
1.453 - 1.459 in.
Exhaust
(36.90 - 37.06 mm)
1.178 - 1.184 in.
Intake
(29.92 - 30.08 mm)
b
1.178 - 1.184 in.
Exhaust
(29.92 - 30.08 mm)
2. Measure camshaft journal diameter “a”, replace the camshaft if out of specification.
a
Camshaft Journal Diameter “a”

0.9827 - 0.9835 in. (24.96 - 24.98 mm)
Page 4A-28 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
3. Measure camshaft cap inside diameter “b”, replace cylinder head if out of specification.
Camshaft Cap Inside Diameter “b”

0.984 - 0.985 in. (25.000 - 25.021 mm)
Thermostat
1. Inspect thermostat, replace if damaged or valve does not open.
2. Measure valve opening temperature and valve lift “a” using the “Measurement Test”
below. Replace thermostat if out of specification.
MEASUREMENT TEST
1. Tie a piece of thread (or other non-conductive material) onto the thermostat.
2. Suspend the thermostat in water.
3. Heat water slowly while observing the thermostat.
a - Valve Lift Distance
Water Temperature Valve Lift

Below 122° F (50° C) 0 in. (0 mm)
Above 140° F (60° C) Minimum 0.17 in. (4.3 mm)
90-881980R1 NOVEMBER 2001 Page 4A-29

CYLINDER HEAD
Valves
1. Inspect valve for damage/warpage, replace if necessary.
2. Measure margin thickness “a”. Replace valve if out of specification.
Margin Thickness “a”

Intake Valve 0.031 - 0.047 in.
(0.80 - 1.20 mm)
Exhaust Valve 0.039 - 0.055 in.
(1.00 - 1.40 mm)
3. Measure the valve stem diameter. Replace valves if out of specification.
Valve Stem Diameter

0.2352 - 0.2358 in.
Intake Valve
(5.975 - 5.990 mm)
0.2346 - 0.2352 in.
Exhaust Valve
(5.960 - 5.975 mm)
Page 4A-30 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
4. Measure valve stem runout. Replace valves if out of specification.
Valve Stem Runout Limit (Max.)

Intake Valve
0.001 in. (0.03 mm)
Exhaust Valve
NOTE: Valve guides, valve seal, and valves should be replaced as a set.
Valve Springs
1. Check free length limit “a” of each spring. Replace valve springs if out of specification.
Valve Spring Free Length

2.094 in. (53.20 mm)
2. Measure valve spring tilt “a”. Replace valve springs if out of specification.
NOTE: Check each spring on a flat surface using a square. Rotate spring and check space
between the top coil and square.
Valve Spring Tilt Specification “a”

Less than 0.10 in. (2.6 mm)
90-881980R1 NOVEMBER 2001 Page 4A-31

CYLINDER HEAD
Cylinder Head
1. Inspect the cylinder head for mineral deposits/corrosion in the water passage ways,
clean any deposits/corrosion observed.
2. Inspect the cylinder head for carbon deposits In combustion chamber (use round scrap-
er to clean away deposits). Be careful not to scratch or remove material.
3. Measure cylinder head warpage. Replace cylinder head if out of specification.
NOTE: Use a straight edge and a thickness gauge to inspect cylinder head for warpage.
a - Straight Edge
b - Thickness Gauge
Cylinder Head Warpage Limit
0.004 in. (0.1 mm)
Valve Guides
1. Measure the valve guide bore “a”. If valve guide wear is out of specification, replace the
valve guide by following “Valve Guide Replacement” below.
Valve Guide Inside Diameter

0.2364 - 0.2369 in.
Intake Valve / Exhaust Valve
(6.005 - 6.018 mm)
Page 4A-32 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
VALVE GUIDE REPLACEMENT

NOTE: Heat the cylinder head in an oven to 390° F (200° C). This will help to ease guide
removal and installation and to maintain correct interference fit.
1. Remove the valve guide using a valve guide remover.
91-804774
a - Valve Guide Remover/Installer (91-804774)
2. Install the new valve guide to the specified position “a” using the valve guide remover/in-
staller.
NOTE: Before installing the valve guide, mark the installation depth “b” as shown.
91-804774
a
b
a - Valve Guide Depth Position “a”

b - Installation Depth Mark
c - Valve Guide Remover/Installer (91-804774)
Valve Guide Depth Position “a”
0.45 in. (11.5 mm)
90-881980R1 NOVEMBER 2001 Page 4A-33

CYLINDER HEAD
3. After installing the valve guide, bore the valve guide using a valve guide reamer to obtain
proper stem-to-guide clearance.
91-804775
a - Valve Guide Reamer (91-804775)

Intake 0.0006-0.0017 in. (0.015-0.043 mm)
Exhaust 0.0012-0.0023 in. (0.030-0.058 mm)
Page 4A-34 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
Valve Seats
VALVE SEAT RECONDITIONING
Clean the carbon deposits from the combustion chambers and valve seats and check for
pitting.
Several different types of equipment are available for reseating valve seats. Follow the
equipment manufacturer’s instructions.
Measure valve seat width “a”. Resurface the valve seat if not in specification.
Reface valve seat, use a 90° or 45° valve seat cutter.
NOTE: When twisting cutter, keep an even downward pressure to prevent chatter marks.
NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat
and valve face should be lapped.
Valve Seat Width Specification “a”

Intake Valve 0.062 - 0.076 in. (1.58 - 1.94 mm)
Exhaust Valve 0.071 - 0.080 in. (1.80 - 2.02 mm)
NOTE: If resurfacing the valve seats is required, resurface the valve seats to the specified
angles shown in chart following.
b
a
Obtain Locally
Valve Seat Area Valve Seat Cutter

a 90°
b 45°
90-881980R1 NOVEMBER 2001 Page 4A-35

CYLINDER HEAD
Cylinder Head Reassembly

1. Install valves (intake and exhaust).
2. Install spring seat and valve stem seal.
3. Install spring and spring retainer.
4. Compress valve springs using valve spring compressor and install valve cotters onto
their respective valves.
f
e
110
d
91-809494A1
c
a - Valves (Intake And Exhaust) d - Valve Spring

b - Spring Seat e - Spring Retainer
c - Valve Stem Seal f - Valve Cotter
5. Install valve pad and valve lifter into their original locations.
110
b c
a - Valve Pad and Lifter

b - Valve Pad
c - Valve Lifter
Page 4A-36 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
6. Install anode and thermostat.

IMPORTANT: To prevent anode from falling into water jacket use the “Anode Assem-
bly” procedure for anode installation:
Anode Assembly
a. Install anode screw “a” to secure anode to anode cover.
b. Install anode assembly in cylinder block.
c. Install anode cover screws “e”.
h
g
e
f
a
e 95
d
b
e
c
a
7 Loctite 271 7
a - Screw M6 x 20 e - Screw M8 x 25
b - Anode Cover (2) f - Thermostat
c - Anode (2) g - Thermostat Cover
d - O-Ring (2) h - Screw (2) M6 x 25
Anode Screw Torque

70 lb-in. (8 Nm)
Anode Cover Screw Torque

156 lb-in. (18 Nm)
Thermostat Screw Torque

70 lb-in. (8 Nm)
90-881980R1 NOVEMBER 2001 Page 4A-37

CYLINDER HEAD
Cylinder Head Installation

1. Install dowel Pins and Gasket (New).
2. Install cylinder head assembly and spark plugs.
IMPORTANT: Install cylinder head screws in torque sequence (ex. #1 #15) with
proper torque.
NOTE: Use Torx socket driver T55 for removal/installation of cylinder head screws.
b a
110 9 10 14
5 6 13
e
1 2
11
4 3 12
i
f 15
8 7
d
c
110 g
h
a - Dowel Pins (2) f - Spark plugs

b - Gasket (New) g - Cylinder Head
c - Cylinder Head Assembly h - Cylinder Block
d - Screw (5) M8 x 55 i - Specified Torque
e - Screw (10) M10 x 145

1st 120 lb-in. (14 Nm)

1st 132 lb-in. (15 Nm)
3rd 90°
51 lb-ft (70 Nm)*
*Torque value given for reference only.
Page 4A-38 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
Following Cylinder Head Installation

1. Install camshafts and camshaft caps.
109
110 109
110
b
c
d
10 9 19 20
a g
110 11
110
110 12
2
17
1
h 8 18
13
7
i 14
4
15
3
6 16
5

A Molybdenum Disulfide Grease (Obtain Locally)
a - Camshaft (2) e - Camshaft Cap (8)
b - Oil Seal (2) f - Screw (16) M7 x 37
c - Camshaft Cap (2) g - Exhaust Cam Tang
d - Screw (4) M7 x 48 h - Pink Identification
i - Pistons Turned 90° Past TDC
IMPORTANT: Install camshaft with tang and pink identifying mark on exhaust side of
cylinder head.
IMPORTANT: Before installing the intake and exhaust camshafts, turn the crankshaft
90° past TDC (either direction) to prevent bending of valves during cap installation.
90-881980R1 NOVEMBER 2001 Page 4A-39

CYLINDER HEAD
NOTE: Install the camshaft caps in the proper position and sequence as shown and with
the stamped numbers facing upside down.

2nd 150 lb-in. (17 Nm)
2. Install cylinder head cover and driven sprockets.
109 h
a e
g
f
c
a - Rubber Gasket
b - Cylinder Head Cover
c - Screw (14) M6 x 30
d - Breather Hose
e - Pin (2)
f - Driven Sprocket (2)
g - Washer (2)
h - Driven Sprocket Screw (2) M10 x 35
Cylinder Head Cover Screw Torque

70 lb-in. (8 Nm)

44 lb-ft (60 Nm)
Page 4A-40 90-881980R1 NOVEMBER 2001

CYLINDER HEAD
Timing Belt Installation

2. Align pointer with TDC mark on flywheel.
3. Install timing belt.
4. Install tensioner spring and secure timing belt tensioner screw.
a
b
91-83163M
a - Timing Marks
30 lb-ft (40 Nm)
5. Connect fuel hoses and spark plug leads.

NOTE: Secure fuel hoses with spring clips.
6. Install spark plug cap cover and flywheel cover.
c
e
b d
a c
a - Fuel Hoses d - Flywheel Cover

b - Spark Plug Cap Cover e - Screws (2) M6 x 20
90-881980R1 NOVEMBER 2001 Page 4A-41

CYLINDER HEAD
Extra Valve Clearance Work sheets

NOTE: Photocopy this page for extra valve clearance measurement work sheets.
Measurement
1. Turn flywheel clockwise until cylinder #1’s piston is at TDC.
2. Measure and record the intake valve clearance for cylinders #1 and #2.
3. Measure and record the exhaust valve clearance for cylinders #1 and #3.
4. Turn the flywheel 360° clockwise.
5. Measure and record the intake valve clearance for cylinders #3 and #4.
6. Measure and record the exhaust valve clearance for cylinders #2 and #4.
Adjustment
1. If clearance is out of specification, remove and measure the pad.
2. Add or subtract to that measurement a number to put the valve back into specification.
3. Use that measurement to select a new pad.
Removed Pad Thickness
+
Measured Valve Clearance
–
Specified Valve Clearance
= New Pad Thickness
Intake cylinders #1 and #2 Intake cylinders #3 and #4

Exhaust cylinders #1 and #3 Exhaust cylinders #2 and #4
MEASUREMENT TABLE
INTAKE (cold) EXHAUST (cold)
0.007-0.009 in. (0.17-0.23 mm) 0.012-0.014 in. (0.31-0.37 mm)
CYL. Clearance Old New New CYL. Clearance Old New New
Pad Pad Clearance Pad Pad Clearance
#1 #1
#2 #2
#3 #3
#4 #4
Page 4A-42 90-881980R1 NOVEMBER 2001

CYLINDER BLOCK/CRANKCASE
POWERHEAD
Section 4B - Cylinder Block/Crankcase
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 4B-23
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-23
Cylinder Block And Crankcase . . . . . . . . . . . . . . 4B-6 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24
Crankshaft, Pistons And Connecting Rods . . . . 4B-8 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-25
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4B-10 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-26
Crankcase Cover Screws . . . . . . . . . . . . . . . 4B-10 Crankcase and Bearings . . . . . . . . . . . . . . . 4B-26
Exhaust Cover Screws . . . . . . . . . . . . . . . . . 4B-11 Connecting Rod Oil Clearance . . . . . . . . . . 4B-31
Powerhead Mounting Screws/Nuts . . . . . . 4B-11
Preparing Powerhead for Removal . . . . . . . . . 4B-12
Powerhead Assembly . . . . . . . . . . . . . . . . . . . . .
Piston Ring/Piston Installation . . . . . . . . . . .
4B-35
4B-35
4
Powerhead Removal . . . . . . . . . . . . . . . . . . . . . 4B-15 Crankcase and Crankshaft Installation . . . 4B-36 B
Removing Powerhead Components . . . . . . . . 4B-16 Exhaust Cover Installation . . . . . . . . . . . . . . 4B-40
Ignition Components . . . . . . . . . . . . . . . . . . . 4B-16 Drive Sprocket Installation . . . . . . . . . . . . . . 4B-42
Charging and Starting System Installing Powerhead Components . . . . . . . . . 4B-43
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-16 Cylinder Head Installation . . . . . . . . . . . . . . 4B-43
Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-16 Harness and Battery Cable Removal . . . . . 4B-43
Harness and Battery Cable Removal . . . . . 4B-16 Fuel Components . . . . . . . . . . . . . . . . . . . . . 4B-43
Cylinder Head Removal . . . . . . . . . . . . . . . . 4B-16 Charging and Starting System
Powerhead Disassembly . . . . . . . . . . . . . . . . . . 4B-17 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-43
Drive Sprocket Removal . . . . . . . . . . . . . . . . 4B-17 Ignition Components . . . . . . . . . . . . . . . . . . . 4B-43
Exhaust Cover Removal . . . . . . . . . . . . . . . . 4B-18 Powerhead Installation . . . . . . . . . . . . . . . . . . . . 4B-44
Crankcase and Crankshaft Removal . . . . . 4B-20 Following Powerhead Installation . . . . . . . . . . . 4B-46
Piston Ring Removal . . . . . . . . . . . . . . . . . . 4B-22

Specifications
Type In–Line, 4 Stroke – DOHC, 16 Valves
CYLINDER Displacement 106.2 cid (1,741 cc)
BLOCK Number of Cylinders 4
STROKE Length 3.496 in. (88.8 mm)
Diameter
Standard 3.110 - 3.111 in. (79.000 - 79.020 mm)
CYLINDER Oversize-0.010 in. (0.25 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm)
BORE Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Piston Type Aluminum
Measure Point (H) 0.51 in. (13 mm)
O.D. at Skirt (H)
Standard (D) 3.1073 - 3.1082 in. (78.928 - 78.949 mm)
PISTON Pin Boss Inside Diameter 0.7090 - 0.7093 in. (18.008 - 18.015 mm)
H
D
PISTON Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm)
CLEARANCE
Top Ring
Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm)
Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm)
End Gap (Installed) T 0.006 - 0.012 in. (0.15 - 0.30 mm)
Middle Ring
Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm)
Dimension “T” 0.118 - 0.126 in. (3.00 - 3.20 mm)
RINGS B 0.028 - 0.035 in. (0.70 - 0.90 mm)
End Gap (Installed)
Bottom (Oil Ring)
T
Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm)
Dimension “T” 0.094 in. (2.40 mm)
End Gap (Installed) 0.008 - 0.028 in. (0.20 - 0.70 mm)
Side Clearance B 0.001 - 0.006 in. (0.03 - 0.15 mm)
T
COMPRESSION Compression Ratio 9.7:1
RATIO Cylinder Compression (Minimum) 138 psi (950 kPa)
PISTON PIN Piston Pin Outside Diameter 0.7085 - 0.7087 in. (17.997 - 18.000 mm)

Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm)
Big End Inside Diameter 1.7726 - 1.7734 in. (45.025 - 45.045 mm)
Oil Clearance (Big End) 0.0010 - 0.0012 in. (0.025 - 0.031 mm)
CONNECTING Big End Bearing Thickness
ROD Yellow 0.0591 - 0.0594 in. (1.502 -1.508 mm)
Green 0.0594 - 0.0596 in. (1.508 - 1.514 mm)
Blue 0.0596 - 0.0598 in. (1.514 - 1.520 mm)
Red 0.0598 - 0.0601 in. (1.520 - 1.526 mm)
Crankshaft Journal
Diameter 1.8891 - 1.8898 in.
(47.984 - 48.000 mm)
Crankshaft Pin
Diameter 1.6535 - 1.6528 in.
(42.000 - 41.982 mm)
CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm)
Crankshaft Run-out 0.001 in. (0.03 mm)
Crankcase Main Journal Inside

Diameter 2.1269 - 2.1276 in.
(54.023 - 54.042 mm)
Crankshaft Journal Oil Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm)
Upper Crankcase Main Journal
Bearing Thickness
Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm)
Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm)
Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm)
CRANKCASE Lower Crankcase Main Journal
Bearing Thickness
Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm)
Green 0.1188 - 0.1191 in. (3.017- 3.024 mm)
Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm)
Red 0.1193 - 0.1196 in. (3.031 - 3.038 mm)
No. 3 Main Journal Bearing Thickness
Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm)
Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm)
Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm)

Special Tools
1. Oil Filter Wrench (P/N 91-802653Q1)
2. Flywheel Holder (P/N 91-83163M)
3. Flywheel Puller/Lifting Eye (P/N 91-83164M)
4. Piston Ring Compressor (P/N FT2997)
5. Piston Ring Expander (P/N 91-24697)
6. Crankshaft Holder (P/N 91-804770A1)
7. 46 mm Socket (P/N 91-881847A1)

Notes:

Cylinder Block And Crankcase
28
13 29
27 15
26
25 30
24 31
23 14
21
22
16
20 17
19
18
8
7
2
11
7
8
12
110
10
9
35
5
32
1
33 34
3

Cylinder Block And Crankcase

TORQUE
REF.
REF
1 1 CYLINDER BLOCK
2 10 DOWEL PIN
3 1 GASKET
6 1 GROMMET
7 2 LIFTING EYE
8 4 SCREW (M6 X 20 MM) 70 8
9 1 PLUG (M14 X 12 MM)
10 1 GASKET
11 1 OIL FILTER
12 1 SCREW
13 1 OUTER EXHAUST COVER
14 1 GASKET
16 1 SCREW PLUG
17 1 GASKET
18 1 ANODE
19 1 GROMMET
20 1 COVER
21 1 SCREW (M6 X 16 MM) 70 8
22 2 SCREW (M8 X 25 MM) 156 13 17.5
23 1 GROMMET
24 1 PRESSURE CONTROL VALVE
25 1 SPRING
26 1 GASKET
27 1 COVER
28 3 SCREW (M6 X 20 MM) 70 8
29 1 CLIP
30 1 HOSE
31 1 CLAMP
32 6 STUD
33 6 WASHER
34 6 NUT 35 47.5
35 2 SCREW (M8 X 35 MM) 20 27
NOTE: Ref. #4 - 1st Torque 10 lb. ft.; 2nd Torque 20 lb. ft.
NOTE: Ref. #5 - 1st Torque 14 lb. ft., then torque +60 degrees

Crankshaft, Pistons And Connecting Rods
9
10
110
2 110
110
7
4 8
110
4
5
6
5
4
5
4
5 1
110
3
110
110 4 Cycle Oil

Crankshaft, Pistons And Connecting Rods

TORQUE
REF.
REF
1 1 CRANKSHAFT
2 1 OIL SEAL
3 1 OIL SEAL
4 4 BEARING (GREEN)
4 BEARING (BLUE)
4 BEARING (RED)
5 5 BEARING (YELLOW)
5 BEARING (GREEN)
5 BEARING (BLUE)
5 BEARING (RED)
6 1 BEARING (GREEN)
1 BEARING (BLUE)
1 BEARING (RED)
7 4 PISTON/CONNECTING ROD ASSEMBLY (STANDARD)
AR PISTON/CONNECTING ROD ASSEMBLY (.25 MM O/S)
9 4 PISTON RING SET (STANDARD)
AR PISTON RING SET (.25 MM O/S)
10 8 BEARING (YELLOW)
8 BEARING (GREEN)
8 BEARING (BLUE)
8 BEARING (RED)
NOTE: Ref. #8 - 1st Torque 132 lb. in./15 N-m; 2nd Torque +60 degrees

Torque Sequence
Crankcase Cover Screws
9 10
60° 19 20
b
b
15 16
5 6
a
11 12
1 2
1st Torque 2nd Torque
14 13
4 3
18 17
8 7
a - Center Screw (10) 1st Torque

b - Center Screw (10) 2nd Torque (60° Torque)
Crankcase Cover Screw Torque
Outer Screws Qty. 1st Torque: 120 lb-in. (14 Nm)
10 (M8 x 55 mm) 2nd Torque: 20 lb-ft (28 Nm)
1st Torque: 14 lb-ft. (19 Nm)
Center Screws Qty.
Qty
10 (M10 x 135 mm) 2nd Torque: 60°
37 lb-ft (50 Nm)*
*Torque value for reference only.
Page 4B-10 90-881980R1 NOVEMBER 2001

Exhaust Cover Screws

12 13
18
7 8
16
3 4
14
1
2
15 5
6
17
11 9
10
Exhaust Cover Screw Torque

1st Torque: 50 lb-in. (6 Nm)
2nd Torque: 105 lb-in. (12 Nm)
Powerhead Mounting Bolts/Nuts
6 7 8 4
1 2
3 5
Powerhead Mounting Nut Torque

35 lb-ft (47.5 Nm)
Powerhead Mounting Bolt Torque

20 lb-ft (27 Nm)
90-881980R1 NOVEMBER 2001 Page 4B-11

Preparing Powerhead for Removal

1. Remove top cowl.
2. Remove flywheel cover.
b - Flywheel Cover
3. Disconnect cowl switch power trim wires.
a
c
d b
58655
a - Green/White
b - Lt. Blue/White
c - Red
d - Cowl Switch
Page 4B-12 90-881980R1 NOVEMBER 2001

4. Remove cowl grommet.

5. Remove 2 screws from grommet cover. Remove grommet cover and grommet.
6. Remove 8 screws holding cowl halves together.
a
c
d
c
f
b e
h
b
a - Cowl Grommet
b - Cowl Screws (8) M6 x 40
d - Grommet Cover
e - Grommet
f - Cowl Latch
g - Grommet
h - Idle Exhaust Grommet
90-881980R1 NOVEMBER 2001 Page 4B-13

7. Remove dipstick and drain oil.

8. Disconnect shift switch harness.
9. Remove vapor separator vent hose.
10. Disconnect power trim pump wires.
11. Remove incoming fuel hose.
58681
b
a
58655
a - Dipstick
b - Shift Position Switch Harness
c - Vapor Separator Vent Hose
d - Power Trim Pump Wires (BLUE & GREEN)
e - Fuel Hose
Page 4B-14 90-881980R1 NOVEMBER 2001

Powerhead Removal
1. Remove nuts (6) and bolts (2) to free powerhead from drive shaft housing.
b
a
58654
c
a - Nuts (6)
b - Washers (6)
c - Bolts (2) M8 x 35
2. Lift powerhead from driveshaft housing using flywheel puller/lifting eye (91-83164M).
3. Place powerhead on suitable stand.
91-83164M
a - Flywheel Puller/Lifting Eye (91-83164M)
90-881980R1 NOVEMBER 2001 Page 4B-15

Removing Powerhead Components

Ignition Components
1. Refer to Section 2A for removal of the following ignition components.
a. Flywheel - must use Crankshaft Holder Tool (91-804770A1)
b. Stator
c. Timing belt
d. Ignition coils
e. ECM unit
f. Crank Position Sensors
g. Temperature sensor
Charging and Starting System Components

1. Refer to Section 2B for removal of the following ignition components.
a. Starter motor/relay
b. Voltage regulator/rectifier
Fuel Components
1. Refer to Section 3C for removal of the following components.
a. Fuel pump
b. EFI Assembly
Harness and Battery Cable Removal

1. Remove battery and harness cable assembly.
Cylinder Head Removal

1. See Section 4A for cylinder head removal.
Page 4B-16 90-881980R1 NOVEMBER 2001

Powerhead Disassembly
Drive Sprocket Removal
1. Remove nut.
NOTE: Use 46 mm socket with an internal depth of 76 mm (91-881847A1) to hold drive
sprocket nut. Use crankshaft holder tool (P/N 91-804770A1) to hold crankshaft.
e
a
91-881847A1 b
f
91-804770A1
a - Drive Sprocket Nut

b - Drive Sprocket
c - Crank Position Sensor Rotor
d - Key
e - 46 mm, 76 mm Deep Socket (91-881847A1)
f - Crankshaft Holder Tool (P/N 91-804770A1)
90-881980R1 NOVEMBER 2001 Page 4B-17

Exhaust Cover Removal

1. Remove oil filter.
2. Remove water hose, exhaust cover and gasket.
d
e
58574
91-802653Q1
c
a - Oil Filter
b - Water Hose
c - Screw (18) M6 x 30 mm
d - Exhaust Cover
e - Gasket (Discard)
Page 4B-18 90-881980R1 NOVEMBER 2001

3. Remove Pressure Control Valve (PCV) Cover.

4. Remove anode and engine temperature sensor.
IMPORTANT: If removing anode from outboard with exhaust plate installed use the
following procedure to prevent anode from falling into water jacket:
ANODE REMOVAL PROCEDURE
1. Remove anode cover screws “g”.
2. Remove anode assembly from cylinder block.
3. Remove anode screw “h” to separate anode from anode cover.
p
q n
m l
a
f
e
d
k
c
j
7 Loctite 271
i h g b 58686
7
a - Screw (3) M6 x 20 j - Anode

b - PCV Cover k - O-Ring
c - Spring l - Screw (2) M6 x 16
d - Pressure Control Valve (PCV) m - Engine Temperature Sensor
e - Grommet Retainer
f - Gasket (Discard) n - Engine Temperature Sensor
g - Screw (2) M8 x 25 o - Gasket (Discard)
h - Screw M6 x 20 p - J Clip
i - Anode Cover q - Screw
90-881980R1 NOVEMBER 2001 Page 4B-19

Crankcase and Crankshaft Removal

1. Remove crankcase and connecting rod caps.
IMPORTANT: Do not interchange connecting rod caps and bearing halves during dis-
assembly. Mark the cylinder number on the rod cap (1 through 4) with a paint pen or
scribe mark. Reinstall in their original locations.
NOTE: Use 5/16 in. 12 point socket for removal of connecting rod screws.
a
a - Screw (10) M8 x 55
b - Screw (10) M10 x 135
c - Crankcase
d - Connecting Rod Screw (Discard) (8) M8 x 38
e - Connecting Rod Cap (4)
2. Remove crankshaft and oil seals.
c
a - Crankshaft
b - Upper Oil Seal
c - Lower Oil Seal
Page 4B-20 90-881980R1 NOVEMBER 2001

IMPORTANT: Do not interchange main bearings. Re-install in their original locations.

3. Remove main bearing halves from the crankcase cover and cylinder block.
a
b
a - Main Bearing Halves-Crankcase Cover (5)
b - Main Bearing Halves-Cylinder Block (5)
IMPORTANT: Scribe (or use paint pen) the cylinder number (1 through 4) on the inside
of each piston/connecting rod assembly and connecting rod cap for re-assembly into
their original cylinders. Be sure to keep connecting rod bearings with the appropriate
piston/connecting rod assembly.
4. Remove piston/connecting rod assembly. Do not interchange bearings, end cap or pis-
ton assembly with other cylinders.
a
c
58563
a - Piston/Connecting Rod Assembly (4)

b - Connecting Rod Bearings (4)
c - Connecting Rod Cap (4)
90-881980R1 NOVEMBER 2001 Page 4B-21

Piston Ring Removal

1. Remove top and second ring.
2. Remove oil ring (bottom rail, top rail, and scraper).
NOTE: Use piston ring expander tool (91-24697) to prevent rings from breaking. If re-using
rings mark their location for re-installation.
91-24697
a
b
c
d
a - Top Ring
b - Second Ring
c - Oil Ring
d - Piston
Page 4B-22 90-881980R1 NOVEMBER 2001

Cylinder
MEASURING CYLINDER BORE
1. Measure the cylinder bore diameter at three locations in both X and Y axis.
2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be nec-
essary to re-bore the cylinder to accept the oversize piston.
NOTE: Measure at three locations (L1 , L2 , and L3 ) in both X and Y axis (D1-6 ).
L1 =0.8 in. (20 mm)
L2 =2.8 in. (70 mm)
L3 =4.7 in. (120 mm)
3. Measure bore diameter with a cylinder gauge, re-bore or replace if necessary.
L1
D1,2
L2
L3
D3,4
D5,6
Cylinder Bore Specifications

Bore Size Maximum Taper/Out-of-Round
Standard Bore
3.110-3.111 in. (79.000-79.020 mm) 0.003 in. (0.08 mm)
Oversize Bore-0.010 in. (0.25 mm)
3.120-3.121 in. (79.250-79.270 mm) 0.003 in. (0.08 mm)
NOTE: Taper=(Maximum of D1 or D2 )–(Minimum of D5 or D6 )
90-881980R1 NOVEMBER 2001 Page 4B-23

Piston
1. Inspect piston wall wear/damage, replace piston/connecting rod assembly if necessary.
2. Measure the piston at a point 0.51 in (13 mm) from the bottom, replace piston/connect-
ing rod assembly if out of specification.
a
b
a - Piston Diameter
b - 0.51 in. (13 mm)
Piston Diameter “a”
Piston Size Diameter
Standard 3.1074-3.1082 in. (78.928-78.949 mm)
Oversize-0.010 in. (0.25 mm) 3.1174-3.1182 in. (79.178-79.199 mm)
3. Measure piston to cylinder clearance. If out of specification examine piston and cylinder
bore further to determine repair/replacement.
a. Piston to Cylinder Clearance can be defined by:
MBM–MPM=PCC where:
MBM=Minimum Bore Measurement

MPM=Maximum Piston Measurement
PCC=Piston to Cylinder Clearance
Piston to Cylinder Clearance

0.0028-0.0031 in. (0.070-0.080 mm)
Page 4B-24 90-881980R1 NOVEMBER 2001

Piston Rings
PISTON RING SIDE CLEARANCE
1. Measure piston ring side clearance. Replace piston rings as a set if out of specification.
Piston Ring Side Clearance

Top 0.001-0.003 in. (0.020-0.080 mm)
Middle 0.001-0.003 in. (0.03-0.08 mm)
Oil 0.001-0.006 in. (0.03-0.15 mm)
PISTON RING END GAP CLEARANCE

1. Measure piston ring end gap clearance. Replace piston rings as a set if out of specifica-
tion.
NOTE: Ring should be level for measurement. Push ring into bore with crown of piston.
NOTE: Measure end gap clearance at a depth of 0.8 in. (20 mm).
a - Measurement Depth
Piston Ring End Gap
Top 0.006 - 0.012 in. (0.15 - 0.30 mm)
2nd 0.028 - 0.035 in. (0.70 - 0.90 mm)
Oil 0.008 - 0.028 in. (0.20 - 0.70 mm)
90-881980R1 NOVEMBER 2001 Page 4B-25

Crankshaft
1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bear-
ing surfaces are pitted, scored, or discolored.
2. Measure run-out. Replace crankshaft if out of specification.
3. Clean oil holes in crankshaft.
Crankshaft Run-out
0.001 in. (0.03 mm)
4. Measure crankshaft journal diameter and crankpin diameter, replace if out of specifica-
tion.
Crankshaft Journal Diameter Limit

1.8887 in. (47.972 mm)
Crankpin Diameter Limit
1.7311 in. (43.971 mm)
Crankcase and Bearings

1. Measure crankshaft main bearing clearance using the test below, replace the upper and
lower bearings as a set if out of specification (see Crankcase and Bearing Indication
Marks).
NOTE: Measure the main oil bearing clearance at room temperature 68° F (20° C).
Main Bearing Clearance

0.0009 - 0.0017 in. (0.024 - 0.044 mm)
Page 4B-26 90-881980R1 NOVEMBER 2001

CRANKSHAFT MAIN BEARING CLEARANCE MEASUREMENT

IMPORTANT: Do not interchange the main bearings. Re-install in their original posi-
tion.
1. Clean all the old sealing material from the split line on the crankcase cover and cylinder
block.
2. Clean all the oil from the following areas:
a. Main bearing surfaces on the cylinder block and crankcase cover.
b. Main bearings.
c. Crankshaft bearing surfaces.
3. Install main bearing halves into the cylinder block.
4. Install crankshaft.
a - Main Bearing Halves-Cylinder Block (5)
5. Place a piece of plastigauge onto each crankshaft bearing surface.

NOTE: Do not put plastigauge over the oil hole on the bearing surface of the crankshaft.
a - Plastigauge
90-881980R1 NOVEMBER 2001 Page 4B-27

6. Install main bearing halves into the crankcase.
a - Main Bearing Halves-Crankcase (5)
7. Install crankcase onto cylinder block.

8. Apply oil to the cover screws and torque cover screws in sequence and in two steps.
IMPORTANT: Do not move crankshaft until measurement has been completed.
9 10
19 20
b
15 16
5 6
110
11 12
1 2
110 14 13
4 3
a
18 17
8 7

a - Screw (10) M10x135mm
b - Screw (10) M8x55mm
10 (M8x55) 2nd Torque: 20 lb-ft. (28 Nm)
Center Screws Qty.
Qty
10 (M10x135) 2nd Torque: 60°
37 lb-ft. (50 Nm)*
Page 4B-28 90-881980R1 NOVEMBER 2001

SERVICE TIP
1. To obtain 60° rotation of crankcase cover screws (after initial torque has been set) put
a paint mark on corner point of the screw head and a second paint mark one corner point
clockwise on crankcase cover as shown. Rotate screw until paint marks align.
NOTE: When using this procedure for final assembly use different color paint on crankcase
cover to avoid confusion with previous paint marks.
a - Paint Mark On Screw Head

b - Paint Mark On Crankcase Cover
c - Screw Head
MAIN BEARING CLEARANCE
1. Remove the screws and crankcase.

2. Measure the width of the compressed plastigauge to check the main bearing clearance.
Replace bearings if clearance is not within specification (see Selecting New Main
Bearings following).
a - Compressed Plastigauge
Main Bearing Clearance
0.0009 - 0.0017 in. (0.024 - 0.044 mm)
90-881980R1 NOVEMBER 2001 Page 4B-29

SELECTING NEW MAIN BEARINGS

1. Subtract the crankshaft journal diameters (#1-#5) from the cylinder block journal diame-
ters (#1-#5).
2. Select a suitable bearing from the table below according to the calculated values.
NOTE: The cylinder block journal diameters (#1-#5) and the crankshaft journal diameters,
(#1-#5) can be determined by the stamped value as described below.
Crankshaft journal diameter = 47.900+(stamped value/1000)

Example:
If the stamped value of position #1 reads 92 then using the previous formula would yield a
crankshaft journal diameter of:
47.900+(92/1000) = 47.992
Cylinder block journal diameter = 54.000+(stamped value/1000)

Example:
If the stamped value of position #1 reads 32 then using the previous formula would yield a
cylinder block journal diameter of:
54.000+(32/1000) = 54.032
#1
#1
#2
#2
#3
#3
#4
#4
#5
#5
3. Refer to the following reference table to select the correct main bearings.
Crankshaft Bearing Selection Table

Cylinder Block journal Bearing Bearing
diameters–crankshaft (cylinder side) (crankcase side)
journal diameters (mm) (with oil groove) (w/o oil groove)
6.023-6.026 Green Yellow*
6.027-6.034 Blue Green*
6.035-6.042 Blue Blue
6.043-6.049 Red Blue*
6.050-6.058 Red Red
Page 4B-30 90-881980R1 NOVEMBER 2001

CAUTION
The (*) mark indicates that the color of the upper and lower bearings are different.
Install the main bearings in the middle of the cylinder block and crankcase journals
so they do not block the oil holes.
NOTE: Crankshaft bearing #3 is a thrust bearing.
NOTE: If the difference between the cylinder block journal diameter and crankshaft journal
diameter is more than the maximum value (6.058mm), replace the crankshaft, cylinder
block, or both.
Connecting Rod Oil Clearance
1. Measure the connecting rod oil clearance using the Connecting Rod Oil Clearance
Measurement steps below. Replace the upper and lower bearings as a set if out of
specification.

0.0010 - 0.0012 in. (0.025 - 0.031 mm)
CONNECTING ROD OIL CLEARANCE MEASUREMENT

IMPORTANT: Mark the original connecting rod screws to avoid confusion with new
screws.
CAUTION
The original connecting rod screws are to be used for measurement and adjustment
of the oil clearance only. Do not use the original connecting rod screws for reas-
sembly of the engine.
NOTE: Clean all the oil from the connecting rod bearing surfaces and connecting rod jour-
nals on the crankshaft.
CAUTION
Install the bearings in their original positions. Incorrect oil clearance measure-
ments can result in engine damage.
1. Install the upper half of the bearing into the connecting rod, and the lower half of the bear-
ing into the connecting rod cap.
2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft.
a - Plastigauge
90-881980R1 NOVEMBER 2001 Page 4B-31

3. Assemble the connecting rods onto their respective crankpins.

IMPORTANT: Make sure the dimple side “a” on the connecting rod faces toward the
flywheel side.
NOTE: Do not move the crankshaft until the big end oil clearance measurement has been
completed.
a 58563
a - Connecting Rod/Rod Cap Dimples
b - Connecting Rod/Piston Assembly
4. Apply engine oil onto the threads and seat of the original connecting rod screws.
5. Tighten the original connecting rod screws in alternating sequence and in two stages.
Connecting Rod Screw Torque

2nd Torque: 60°
6. Remove the connecting rod cap.

7. Measure the width of the compressed plastigauge on each crankpin to check the con-
necting rod oil clearance. Refer to Connecting Rod Oil Clearance Adjustment below
if oil clearance is not within specification.
0.0010 - 0.0012 in. (0.025 - 0.031 mm)
Page 4B-32 90-881980R1 NOVEMBER 2001

CONNECTING ROD OIL CLEARANCE ADJUSTMENT

NOTE: Measure big end oil clearance at room temperature 68° F (20° C).
1. Install new yellow bearings into the connecting rods and connecting rod caps.
NOTE: Yellow bearings are used as a “reference” bearing to help determine clearance.
2. Place a piece of Plastigauge onto the crank pin parallel to the crankshaft.
3. Assemble the connecting rod caps onto their respective crankpins.
IMPORTANT: Make sure the dimple side “a” on the connecting rod faces toward the
flywheel side.
NOTE: Do not move the crankshaft until the big end oil clearance measurement has been
completed.
a 58563
a - Connecting Rod/Rod Cap Dimples
b - Connecting Rod/Piston Assembly
90-881980R1 NOVEMBER 2001 Page 4B-33

4. Apply engine oil onto the threads and seat of the original connecting rod screws.
5. Tighten the original connecting rod screws in alternating sequence and in two stages.

2nd Torque: 60°
6. Remove the connecting rod cap.

7. Measure the width of the compressed plastigauge on each crankpin to check the con-
necting rod oil clearance.
8. Select a suitable bearing from the table below according to the measurement values.
Connecting Rod Bearing Selection Table
Measurement value with Upper Bearing Lower Bearing
new yellow bearing using (Piston) (Cap)
plastigauge (mm)
0.025-0.031 Yellow Yellow
0.032-0.039 Yellow Green*
0.040-0.046 Green Green
0.047-0.052 Green Blue*
0.053-0.058 Blue Blue
0.059-0.063 Blue Red*
CAUTION
The (*) mark indicates that the color of the upper and lower bearings are different.
NOTE: If the measurement value is more than the maximum value (0.063 mm), replace the
crankshaft, cylinder block, or both.
Page 4B-34 90-881980R1 NOVEMBER 2001

Powerhead Assembly
Piston Ring/Piston Installation
IMPORTANT: If re-using rings, install in their original locations.
IMPORTANT: Use caution when installing piston rings to avoid scratching piston.
1. Install the oil ring components as shown. Spread rings just enough to slip over piston.
2. Install the second and top compression rings (“T” side up). Spread rings just enough to
slip over piston.
3. Offset the piston ring end gaps.
110 e
110
f
c
a
d
b
h i
91-24697
j g
110 4-stroke Outboard Oil
a - Oil Ring Spacer

b - Bottom Rail
c - Top Rail
d - Second Compression Ring (“T” side up)
e - Top Compression Ring (“T” side up)
f - “T” Mark Should Face Piston Crown
g - End Gap – Lower Oil Ring Rail
h - End Gap – Upper Oil Ring Rail
i - End Gap – Second Compression Ring
j - End Gap – Top Compression Ring
90-881980R1 NOVEMBER 2001 Page 4B-35

NOTE: Cylinder bores must be clean before installing pistons. Clean with light honing as
necessary. After honing, clean cylinder bores with water and detergent. After cleaning, swab
cylinder bores several times with engine oil and a clean cloth, then wipe with a clean dry
cloth.
4. Lubricate pistons, rings, and cylinder walls with engine oil.
5. Install piston/connecting rod assembly using piston ring compressor tool.
NOTE: Install used pistons in their original locations (cylinders). Install piston with “UP” mark
on piston crown facing toward the flywheel end of block.
P/N FT2997
a - Piston Ring Compressor (FT2997)
Crankcase and Crankshaft Installation

IMPORTANT: Do not interchange main bearings, re-install in their original locations.
NOTE: Apply oil to bearings before installing.
NOTE: Bearing #3 is a thrust bearing.
1. Install main bearing halves on the crankcase cover and cylinder block.
110 110
a
b
a - Main Bearing Halves-Crankcase Cover (5)
b - Main Bearing Halves-Cylinder Block (with holes) (5)
c - #3 Thrust Bearing
Page 4B-36 90-881980R1 NOVEMBER 2001

2. Install crankshaft and oil seals.

NOTE: Apply oil to seals before installation.
b
110
110

a - Crankshaft
b - Upper Oil Seal
c - Lower Oil Seal
3. Lubricate connecting rod journals with engine oil.

NOTE: Apply oil to connecting rod Screws before installing.
4. Install connecting rod cap and new Screws onto their respective crankpins.
5. Tighten connecting rod screws in alternating sequence and in two stages.
NOTE: Use 5/16 in. 12 point socket for installation of connecting rod screws.
IMPORTANT: Assemble connecting rod caps in their original locations.
110
110 4-Stroke Outboard Oil b

a - Connecting Rod Cap (4)
b - Connecting Rod Screw (New) (8) M8 x 38
2nd Torque: 60°
90-881980R1 NOVEMBER 2001 Page 4B-37

6. Clean off all oil from the contacting surfaces of the crankcase cover and cylinder block.
IMPORTANT: Make sure the contacting surface of the crankcase cover and cylinder
block are clean before applying gasket sealant.
7. Apply a smooth even coat of Loctite Master Gasket Sealant to the contacting surfaces
on the crankcase cover. Use a small (paint type) roller to spread out the sealant for a
smooth even coverage. Instructions in gasket sealant kit must be followed exactly.
NOTE: Do not apply gasket sealant to the main bearings or the screw holes.
8. Oil screws and torque cover in sequence and in two steps.
9 10
110 19 20
c 15 16
5 6
11 12
1 2
a 12
14 13
4 3
d
b 18 17
8 7
110
e
12 Loctite Master Gasket Kit
a - Crankcase
b - Screw (10) M8 x 55
c - Screw (10) M10 x 135
d - Contact Surface of Crankcase
e - Use Roller To Apply A Smooth Even Coat
10 (M8 x 55 mm) 2nd Torque: 20 lb-ft (28 Nm)
Center Screws Qty.
Qty
10 (M10 x 135 mm) 2nd Torque: 60°
37 lb-ft (50 Nm)*
Page 4B-38 90-881980R1 NOVEMBER 2001

SERVICE TIP
1. To obtain 60° rotation of crankcase cover screws (after initial torque has been set) put
a paint mark on corner point of the screw head and a second paint mark one corner point
clockwise on crankcase cover as shown. Rotate screw until paint marks align.
NOTE: When using this procedure for final assembly use different color paint on crankcase
cover to avoid confusion with previous paint marks.
a - Paint Mark On Screw Head

b - Paint Mark On Crankcase Cover
90-881980R1 NOVEMBER 2001 Page 4B-39

Exhaust Cover Installation

1. Install gasket, exhaust cover, and water hose. Tighten exhaust cover screws to specified
torque and in sequence.
2. Install oil filter and oil return hose.
e
a
12 13
b
18
7 8
16
3 4
14
91-802653Q1
1 c
2
15 5
6
17
11 9
10
a - Gasket (New)
b - Exhaust Cover
c - Screw (18) M6 x 30
d - Water Hose
e - Oil Filter
Exhaust Cover Screw Torque
2nd Torque: 105 lb-in. (12 Nm)
Page 4B-40 90-881980R1 NOVEMBER 2001

ANODE INSTALLATION
1. Install Pressure Control Valve (PCV) Cover.
2. Install anode and engine temperature sensor.
IMPORTANT: To prevent anode from falling into water jacket use the following proce-
dure for anode installation:
• Install anode screw “h” securing cover to anode.
• Install anode assembly onto cylinder block.
• Install anode cover screws “g”.
p
q n
m l
e
d
a
f
k
c
j
7 Loctite 271 i g b
7 58686
h
a - Screw (3) M6 x 20 j - Anode
b - PCV Cover k - O-Ring
c - Spring l - Screw (2) M6 x 16
d - Pressure Control Valve (PCV) m - Engine Temperature Sensor
e - Grommet Retainer
f - Gasket (Discard) n - Engine Temperature Sensor
g - Screw (2) M8 x 25 o - Gasket (Discard)
h - Screw M6 x 20 p - J Clip
i - Anode Cover q - Screw
Temperature Sensor, PCV and Anode Screw Torque
70 lb-in. (8 Nm)
Anode Cover Screw Torque

156 lb-in. (18 Nm)
90-881980R1 NOVEMBER 2001 Page 4B-41

Drive Sprocket Installation

1. Install drive sprocket nut.
NOTE: Use 46 mm, 76mm deep socket (P/N 91-881847A1) to hold drive sprocket nut and
crankshaft holder tool (P/N 91-804776A1) to hold crankshaft.
e
d
c
91-881847A1
a
f
91-804776A1
a - Key
b - Crank Position Sensor Rotor
c - Drive Sprocket
d - Drive Sprocket Nut
e - 46 mm, 76mm Deep Socket (91-881847A1)
f - Crankshaft Holder Tool (P/N 91-804776A1)
Drive Sprocket Nut Torque
195 lb-ft (265 Nm)
Page 4B-42 90-881980R1 NOVEMBER 2001

Installing Powerhead Components

Cylinder Head Installation
1. See Section 4A for cylinder head installation.
Harness and Battery Cable Removal
1. Install battery and harness cable assembly.
Fuel Components
1. Refer to Section 3C for installation of the following components.
a. Fuel pump
b. EFI Assembly
Charging and Starting System Components
1. Refer to Section 2B for installation of the following ignition components.
a. Starter motor
b. Voltage rectifier/regulator
Ignition Components
1. Refer to Section 2A for installation of the following ignition components.
a. Flywheel - must use Crankshaft Holder Tool (91-804770A1)
b. Stator
c. Timing belt
d. Ignition coils
e. CDI unit
f. Crank Position Sensors
g. Temperature Sensor
90-881980R1 NOVEMBER 2001 Page 4B-43

Powerhead Installation
NOTE: Refer to Following Powerhead Installation for proper hose and adapter connec-
tions.
1. Lift powerhead using flywheel puller/lifting eye (91-83164M).
2. Install new powerhead gasket and dowel pins.
3. Place powerhead onto drive shaft housing.
b b
a
91-83164M
58575
a - Flywheel Puller/Lifting Eye (91-83164M)

b - Dowel Pins (2)
c - Powerhead Gasket (New)
Page 4B-44 90-881980R1 NOVEMBER 2001

4. Secure powerhead to drive shaft housing with nuts (6) and bolts (2). Torque in sequence.
b
a
6 7 8 4
1 2
c
3 5
d
58654
a - Nut (6)
b - Washer (6)
c - Bolts (2) M8 x 35
d - Torque Sequence
Powerhead Mounting Nut Torque
40 lb-ft (54.5 Nm)
Powerhead Mounting Bolt Torque

20 lb-ft (27 Nm)
90-881980R1 NOVEMBER 2001 Page 4B-45

Following Powerhead Installation

1. Connect vapor separator vent hose to adaptor plate fitting.
2. Connect shift switch harness.
3. Fill oil tank (refer to Section 1B-Maintenance) and install dipstick.
4. Connect power trim wires.
5. Connect incoming fuel hose.
b 58681
a
58655
a - Dipstick
b - Shift Position Switch Harness
c - Vapor Separator Vent Hose
d - Power Trim Pump Wires (BLUE & GREEN)
e - Fuel Hose
Page 4B-46 90-881980R1 NOVEMBER 2001

6. Install 8 screws holding cowl halves together.

7. Install grommet and grommet cover.
c
a
d
c
g f
b e
h
b
a - Cowl Grommet
b - Cowl Screws (8) M6 x 40
d - Grommet Cover
e - Grommet
f - Cowl Latch
g - Grommet
h - Idle Exhaust Grommet
Bottom Cowl Screw Torque
65 lb-in. (7.5 Nm)
Grommet Cover Screw Torque

65 lb-in. (7.5 Nm)
90-881980R1 NOVEMBER 2001 Page 4B-47

8. Connect trim wires.
a
c
d b
58655
a - Green/White
b - Lt. Blue/White
c - Red
d - Cowl Switch
9. Install flywheel cover.

10. Install top cowl.
a - Flywheel Cover
b - Screws (2) M6 x 20
Flywheel Cover Screw Torque
65 lb-in. (7.5 Nm)
Page 4B-48 90-881980R1 NOVEMBER 2001

LUBRICATION
POWERHEAD
Section 4C - Lubrication
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1 Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-7
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pickup Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-8
Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 4C-9
Oil Pressure Measurement . . . . . . . . . . . . . . . . . 4C-5 Oil Pickup Installation . . . . . . . . . . . . . . . . . . . . . 4C-10
Oil Pump Reference Drawing . . . . . . . . . . . . . . . 4C-6 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . 4C-11
Specifications 4
C
Pump Type Trochoid with Relief Valve
Oil Pump Drive Drive shaft Spline
Discharge at 212°F (100°C) with
10W-30 Oil at 1000 rpm 1.56 gph (5.9 L/h)
LUBRICATION Engine Oil Pressure (Warm Engine)
SYSTEM @ 750 rpm 50.75 psi (350 kPa)
Engine Oil Pan Capacity Either 5 Qts. or 5 Liters
Relief Valve Opening Pressure 71 psi (490 kPa)
Oil Pump:
Non-Serviceable

LUBRICATION
Oil Pump
13
91
12
11
18
9 8 10 16 21
7 95
20 17
16
5 15
6
14
3
4
3
10
4
2
1 91 Engine Coupler Spline Grease
95 2-4-C With Teflon
19

LUBRICATION
Oil Pump
TORQUE
REF.
REF
1 1 PIPE PLUG 25 34
2 1 PIPE PLUG 100 11.5
3 2 O-RING
4 2 DOWEL PIN
5 1 MOUNT
6 2 BOLT (M12 X 175 MM) 55 75
7 2 WASHER
8 2 WASHER
9 2 NUT
10 8 SCREW (M8 X 50 MM) 25 34
11 1 OIL PUMP
12 6 BOLT (M6 X 45 MM) 85 9.5
13 1 SEAL
14 1 SHIFT LINKAGE BRACKET
15 2 DRIVE SCREW
16 3 SCREW (M6 X 20 MM) 80 9
17 1 CUP
18 1 LATCH
19 1 SEAL
20 1 SWITCH
21 2 SCREW 20 2.5
NOTE: Torque Tolerance +/– 10%

LUBRICATION
LOW OIL PRESSURE PROTECTION

When the oil pressure switch turns on (oil pressure 21.75 psi (150 kPa) or below), this mode
starts. The warning buzzer sounds (constant tone) and the ignition/injection are cut accord-
ing to the misfiring rate, gradually reducing engine speed to approximately 2000 rpm.
If the engine’s oil pressure is low, the ignition/injection of both cylinders #1 and #4 is cut,
however the ignition/injection of cylinders #2 and #3 is not cut. Once the oil pressure can
be increased to 21.75 psi (150 kPa) or higher, the warning can be cancelled by decreasing
the throttle opening angle to less than 2°, and turning the ignition key to the “OFF” position.
Oil Flow Chart
Cylinder

LUBRICATION
Oil Pressure Measurement

1. Warm up engine.
2. Remove oil pressure switch.
3. Install oil pressure gauge.
NOTE: Use a pressure gauge with a range of 0-10 kg/cm 2 and an adaptor with a 1/8-28
BSPT thread.
a
a - Oil Pressure Gauge
4. Measure the oil pressure at idle. If out of specification, check oil pump, oil suction pipe,
and oil strainer.
Oil Pressure @ 750 rpm with warm engine - 149°F (65 °C)
50.75 psi (350 kPa)

LUBRICATION
Oil Pump Reference Drawing

NOTE: The oil pump is non-serviceable, the assembly drawing below is strictly for reference
purposes only.
NOTE: If removing pump cover follow torque sequence for removal and installation.
a
b
4 2
6 5
1 3
a - Screw (6) M6 x 10
b - Torque Sequence
Oil Pump Screw Torque
70 lb-in. (8 Nm)

LUBRICATION
Oil Pump Removal

NOTE: Powerhead must be removed to gain access to oil pump, refer to section 4B Power-
head Removal.
1. Remove oil pump from adaptor plate.
b c
d d
a - Seal
b - Oil Pump
c - Screw (6) M8 x 45
d - O-Rings (2)

LUBRICATION
Oil Pickup Removal

1. Adapter plate must be removed to gain access to the oil sump and pick-up, refer to Sec-
tion 5A for adaptor plate and oil sump removal.
2. Remove oil pick-up tube from adaptor plate.
d c
a
b
a - Screw (4) M6 x 20
b - Oil Pick-Up Tube
c - O-Ring
d - Gasket
e - Adaptor Plate

LUBRICATION
Cleaning and Inspection

1. Inspect pick up tube screen for debris, clean if necessary.
a
a - Pick-Up Tube Screen
2. Replace seals and gaskets.
3. Inspect oil pump, replace if gears are worn.
NOTE: Pump should be replaced if there is a problem with oil pressure relief valve.

LUBRICATION
Oil Pickup Installation

1. Install oil pick-up tube on adaptor plate, use proper torque sequence.
2. Refer to Section 5A for adaptor plate and oil sump installation.
b c
4
e 1
d
2 3
a - Adaptor Plate
b - Gasket (New)
c - O-Ring (New)
d - Oil Pick-Up Tube
e - Screw (4) M6 x 20
Oil Pick-up Tube Mounting Bolt Torque
100 lb-in. (11.5 Nm)
Page 4C-10 90-881980R1 NOVEMBER 2001

LUBRICATION
Oil Pump Installation

NOTE: Make sure dowel pins are inserted before securing oil pump to adaptor plate.
IMPORTANT: Oil pump must be primed before installation. Prime oil pump by filling
inlet hole with 4-stroke outboard oil and rotating gear several revolutions.
1. Install O-Rings.
2. Apply spline grease to coupling.
3. Install oil pump. Tighten screws to specified torque and in sequence.
c d
4 2
91
6 5
1
3 110
91 Engine Coupler Spline Grease

f
a - Dowel Pins (2) d - Screw (6) M6 x 45
b - O-Rings (2) e - Seal
c - Oil Pump f - Inlet Hole
Oil Pump Mounting Screw Torque
85 lb-in. (9.5 Nm)
90-881980R1 NOVEMBER 2001 Page 4C-11

CLAMP/SWIVEL BRACKETS & DRIVE SHAFT HOUSING
MID-SECTION
Section 5A - Clamp/Swivel Brackets & Drive Shaft Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Drive Shaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12
Swivel Bracket And Steering Arm . . . . . . . . . . . . 5A-2 Bottom Cowl Removal . . . . . . . . . . . . . . . . . . . . 5A-14
Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Bottom Cowl Installation . . . . . . . . . . . . . . . . . . . 5A-15
Exhaust Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Adaptor Plate Removal . . . . . . . . . . . . . . . . . . . 5A-16
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Adaptor Plate Reassembly . . . . . . . . . . . . . . . . 5A-21
Specifications
Recommended Transom Height:
Short Shaft 20 in. (51 cm) 5
MID-SECTION
Long Shaft
Steering Pivot Range
25 in. (64 cm)
60°
A
Full Tilt Up Angle 71°
Allowable Transom Thickness (Max) 3 in. (76.2 mm)
Special Tools
1. Drive Shaft Bushing Installer Tool (91-875215)

Swivel Bracket And Steering Arm

11 10
95
13
TORQUE NUT TO 120 LB-IN.

12 THEN BACK OFF 1/4 TURN
TORQUE NUT TO 20 LB-FT (27.1 NM)

9
95
16
95
2 3 1
8
6
7 95
95
17
95
3 4
5
95
Quicksilver Lubrication/Sealant
14 Application Points
15 95 2-4-C With Teflon

Swivel Bracket And Steering Arm

TORQUE
REF.
REF
1 1 SWIVEL BRACKET
2 1 OIL SEAL (LOWER)
3 2 BUSHING
4 1 O-RING
5 1 SPACER
6 2 GREASE FITTING 40 4.5
7 2 BUSHING
8 2 SCREW (1/4-28 X 1/2 IN.) 100 11.5
9 1 SWIVEL PIN/STEERING ARM
10 1 STEERING LINK ASSEMBLY
11 1 SCREW (3/8-28 X 1/2 IN.) 20 27
12 2 NUT See View
13 2 WASHER
14 1 BOTTOM YOKE
15 1 RETAINING RING
16 1 THRUST WASHER
17 1 DECAL-SERIAL OVERLAMINATE

Transom Bracket
87
95
7 Loctite 271 - Thread Locker
87 Premium Gear Lubricant

44
Transom Bracket
TORQUE
REF.
REF
1 1 TRANSOM BRACKET (STARBOARD)
2 1 TRANSOM BRACKET (PORT)
3 1 GREASE FITTING (PORT) 40 4.5
4 1 TILT TUBE
5 1 O-RING
6 2 WAVE WASHER
7 1 NUT See Note
8 1 NUT See Note
9 4 BOLT (1/2-24 X 4.5 IN.)
10 4 WASHER
11 4 WASHER
12 4 NUT
13 1 SPRING
14 1 TILT LOCK LEVER
15 2 BUSHING
16 1 SPRING
17 1 KNOB
18 1 GROOVE PIN
19 1 PIN
20 1 ANCHOR BRACKET
21 6 SCREW (M10 X 30 MM) 40 54
22 6 WASHER
23 1 NUT 40 54
24 1 ANODE ASSEMBLY
25 2 SCREW (M6 X 25 MM) 60 7
26 2 WASHER
NOTE: Ref. #7’s - Tighten Nut until Bottomed on Shoulder of Tilt Tube
NOTE: Ref. #8’s - Drive Nut until Assembly is drawn together; but must be free to pivot

Exhaust Plate
2 2
4 3
17 22
2 25
24 26
2
20
2
5
23
2 6
21
7
14
19
12 15
28 13
29
9 16
18
11
27
95
10
30

Exhaust Plate
TORQUE
REF.
REF
1 1 ADAPTOR PLATE ASSEMBLY
2 7 DOWEL PIN
3 1 FITTING 15 1.5
4 2 CHECK VALVE
5 1 GROMMET
6 1 GASKET
7 1 OIL SUMP
8 1 EXHAUST TUBE
9 1 O-RING
10 1 GROMMET
11 1 WATER TUBE
12 1 SEAL (UPPER)
13 1 OIL PICK-UP TUBE
14 1 O-RING
15 4 SCREW (M6 X 20 MM) 100 11.5
16 12 SCREW (M6 X 35 MM) 100 11.5
17 1 DIPSTICK
18 1 BUSHING
19 1 SHIFT SHAFT
20 1 SHIFT LINK
21 1 BUSHING
22 1 SHIFT SLIDER
23 1 NUT See Note
24 1 SPACER
25 1 COUPLING
26 2 HAIRPIN COTTER
27 1 SEAL
28 1 DRAIN PLUG
29 1 GASKET
30 4 SCREW (M6 X 60 MM) 100 11.5
NOTE: Ref. #23 - Drive Tight, but Joint must be free to Pivot

Oil Pump
13
91
12
11
18
9 8 10 16 21
7 95
20 17
16
5 15
6
14
3
4
3
10
4
2
1 91 Engine Coupler Spline Grease

19

Oil Pump
TORQUE
REF.
REF
1 1 PIPE PLUG 25 34
2 1 PIPE PLUG 100 11.3
3 2 O-RING
4 2 DOWEL PIN
5 1 MOUNT
6 2 BOLT (M12 X 175 MM) 55 75
7 2 WASHER
8 2 WASHER
9 2 NUT 45 61
10 8 SCREW (M8 X 50 MM) 25 34
11 1 OIL PUMP
12 6 SCREW (M6 X 45 MM) 85 9.5
13 1 SEAL
14 1 SHIFT LINKAGE BRACKET
15 2 DRIVE SCREW
16 3 SCREW (M6 X 20 MM) 80 9
17 1 RETAINER
18 1 LATCH
19 1 SEAL
20 1 SWITCH
21 2 SCREW 20 2.5
NOTE: TORQUE TOLERANCE +/– 10%

Drive Shaft Housing
36
36 Rubber Lubricant
Page 5A-10 90-881980R1 NOVEMBER 2001

Drive Shaft Housing

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in. lb-ft Nm
1 1 DRIVE SHAFT HOUSING ASSEMBLY
2 1 STUD (LONG)
4 STUD (X-LONG)
3 STUD (LONG)
STUD (X-LONG)
4 5 WASHER
5 5 NUT 40 54
6 1 SPEEDOMETER PICK-UP ASSEMBLY
7 1 CONNECTOR (90 Degrees)
8 1 CONNECTOR (STRAIGHT)
9 2 MOUNT
10 2 BOLT (M12 x 154 mm)
11 2 WASHER
12 2 NUT 50 68
13 2 GROUND WIRE ASSEMBLY
14 1 SCREW (1/4-20 x 3/8) Drive Tight
15 2 CLAMP
16 4 SCREW 17 23
17 4 CAP
18 1 BUSHING
19 1 PIN-ALIGNMENT
20 1 ELBOW
21 1 SPACER (X-LONG)
22 1 DOWEL PIN (X-LONG)(WHOLE)
1 DOWEL PIN (X-LONG)
90-881980R1 NOVEMBER 2001 Page 5A-11

Bottom Cowl
3
16
14
10
5 4
6
8 11
11
9
11 12 11
7 17
11
2
15
11
13
11
18 25
24
23
21
26 22
21 95
20
19
Page 5A-12 90-881980R1 NOVEMBER 2001

Bottom Cowl
TORQUE
REF.
REF
1 1 BOTTOM COWL ASSEMBLY (PORT)
2 1 BOTTOM COWL ASSEMBLY (STARBOARD)
3 2 SEAL KIT
4 1 INSERT
5 8 SCREW (M6 X 40 MM) 65 7.5
6 1 RETAINER
7 1 IDLE EXHAUST BOOT
8 1 GROMMET
9 1 TELLTALE FITTING
10 1 WASHER
11 6 STA-STRAP
12 1 HOSE (5 IN.)
13 1 HOSE (32 IN.)
14 1 HOSE (26 IN.)
15 1 TEE
16 2 SCREW (M6 X 20 MM) 65 7.5
17 1 GROMMET
18 1 SWITCH ASSEMBLY
19 1 SCREW (M6 X 75 MM)
20 1 FRONT HANDLE
21 2 BUSHING
22 1 O-RING
23 1 PAWL-FRONT HANDLE
24 1 WASHER
25 1 NUT 65 7.5
26 2 PLUG
90-881980R1 NOVEMBER 2001 Page 5A-13

Bottom Cowl Removal

1. Disconnect trim wires.
a
d c 58655
b
a - Green/White
b - Lt. Blue/White
c - Red
d - Cowl Switch
2. Remove 2 screws from grommet cover to free grommet.
3. Remove 8 screws holding cowl halves together.
a d
a - Cowl Screws (8) M6 x 40 mm

c - Cover
d - Grommet
Page 5A-14 90-881980R1 NOVEMBER 2001

Bottom Cowl Installation

1. Check for proper placement of boot and grommet between cowl halves. Make sure en-
gine wiring, water hoses and trim wires are not pinched during bottom cowl installation.
2. Place retainer between cowls.
3. Secure cowl halves together with screws.
4. Replace grommet, cover and screws.
g c
f
a d
a - Cowl Screws (8) M6 x 40 e - Boot

b - Screws (2) M6 x 20 f - Grommet
c - Cover g - Retainer
d - Grommet
5. Connect trim wires.
a
d b 58655
c
a - Green/White c - Red
b - Lt. Blue/White d - Cowl Switch
90-881980R1 NOVEMBER 2001 Page 5A-15

Adaptor Plate Removal

1. Remove the following components:
• Remove powerhead, refer to section 4B.
• Remove oil pump, refer to section 4C.
• Remove lower unit, refer to section 6.
2. Remove gearcase first.
3. Disconnect shift link from shift shaft and remove shift shaft.
4. Remove wire grommet from adaptor plate. Pull power trim wire and speedometer hose
out of grommet.
5. Pull water hose from adaptor plate.
b
c
a e
57668
57667
a - Shift Link
b - Nut
c - Power Trim Wire/Grommet/Speedometer Hose
d - Water Hose (drive shaft bushing)
e - Shift Shaft
Page 5A-16 90-881980R1 NOVEMBER 2001

6. Remove nuts and washers from lower mount bolts.

NOTE: Note placement of ground straps on port side mounting bolt.
c
a
57666
a - Ground Strap (port side)

b - Nut
c - Lower Mount Bolts (2) M12 x 154
7. Remove nuts and washers from upper mount bolts.
e d c
a
a
a
57669
a - Upper Mount Bolts (2) M12 x 154

b - Upper Mount
c - Washers (2)
d - Washers (2)
e - Nuts (2)
90-881980R1 NOVEMBER 2001 Page 5A-17

8. Pull speedometer hose down through swivel pin arm.

9. Separate driveshaft housing from lower mounting bolts by pulling backward.
e b
57664
d
a - Driveshaft Housing
b - Speedometer hose
c - Lower Mounting Bolt (2) M12 X 154
d - Washers (2)
e - Water Hose (Drive Shaft Bushing)
10. Remove drain plug on port side of driveshaft housing to drain remaining oil from sump.
57663
a - Drain Plug
Page 5A-18 90-881980R1 NOVEMBER 2001

11. Remove 4 screws from top/back of adaptor plate.

12. Remove adaptor plate from driveshaft housing.
13. Remove 4 screws to remove exhaust tube.

14. Remove 12 screws to remove oil sump.
c
b
a b
c c
b
b
c
c
57665
a - Exhaust Tube
b - Exhaust Tube Screws (4) M6 x 60
c - Adaptor Plate Screws (12) M6 x 35
90-881980R1 NOVEMBER 2001 Page 5A-19

DRIVE SHAFT BUSHING REMOVAL

1. Using a suitable punch, drive roll pin to inside of drive shaft housing.
2. Remove drive shaft bushing with suitable mandrel or socket.
57673
a - Roll Pin
b - Suitable Mandrel or Socket
c - Water Hose
Page 5A-20 90-881980R1 NOVEMBER 2001

Adaptor Plate Reassembly

NOTE: Use soapy water on drive shaft bushing for ease of installation.
1. Snap driveshaft bushing onto driveshaft bushing installer tool, and install into housing
until seated.
2. Insert roll pin into drive shaft housing until flush with outside of driveshaft housing.
b
57638
a
57639
c
91-875215
a - Driveshaft Installer Tool (91-875215)
b - Bushing
c - Roll Pin
3. Place oil sump onto adaptor plate and secure with 12 screws. Install exhaust tube to oil
sump and secure with 4 screws. Torque in sequence to specified torque.
c
13 16
7 11 c
b 1 9
a 4 b
c 5 6 c
b 3 2 b
10 8
12 c
14 15
57665
c
a - Exhaust Tube
b - Exhaust Tube Screws (4) M6 x 60
c - Adaptor Plate Screws (12) M6 x 35
Exhaust and Adaptor Plate Screw Torque
100 lb-in. (11.5 Nm)
90-881980R1 NOVEMBER 2001 Page 5A-21

4. Align water tube/grommet while installing adaptor plate onto drive shaft housing.
5. Install drain plug into housing and tighten to specified torque.
57663
57904
a - Water Tube/Grommet
b - Drain Plug
Drain Plug Torque
17.5 lb-ft (24 Nm)
6. Install 4 screws into adaptor plate (torque later).
Page 5A-22 90-881980R1 NOVEMBER 2001

7. Attach drive shaft housing assembly to transom bracket.

8. Install speedometer hose up through swivel pin bracket.
b
57664
a - Speedometer Hose
b - Washers (2)
9. Install nuts onto lower mount bolts. Torque to specified torque.

NOTE: Note placement of ground straps on port side mounting bolt.
a
c
a
b
57666
a - Ground Strap (port side)

b - Nut
c - Lower Mount Bolt (2) M12 x 154
Lower Mounting Bolts Torque
50 lb-ft (68 Nm)
90-881980R1 NOVEMBER 2001 Page 5A-23

10. Install nuts to upper mounting bolts. Torque to specified torque.

11. Torque adaptor plate bolts (4) to specified torque.
f
e
d
c
a a
b
57669
a - Upper Mount Bolts (2) M12 x 154

b - Adaptor Plate Bolts (4) M8 x 50
c - Upper Mount
d - Washer (2)
e - Washer (2)
f - Nut (2)
Upper Mounting Bolts Torque
55 lb-ft (75 Nm)
Adaptor Plate Bolts Torque
25 lb-ft (34 Nm)
Page 5A-24 90-881980R1 NOVEMBER 2001

12. Install shift shaft. Make sure engine is in neutral.
57668
a - Shift Shaft
13. Reconnect shift link to shift shaft.
14. Replace grommet. Pull power trim wire and speedometer hose up through grommet in
adaptor plate.
15. Pull water hose (drive shaft bushing) up through adaptor plate.
b c
d
e
a
a - Nut
b - Shift Shaft
c - Speedometer Hose
d - Power Trim Wire
e - Water Hose (drive shaft bushing)
16. Replace the following components:
• Replace oil pump, refer to section 4C.
• Replace lower unit, refer to section 6.
• Replace powerhead, refer to section 4B.
90-881980R1 NOVEMBER 2001 Page 5A-25

POWER TRIM
MID-SECTION
Section 5B - Power Trim
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim Disassembly . . . . . . . . . . . . . . . . . . 5B-37
Power Trim Components . . . . . . . . . . . . . . . . . . . 5B-4 Trim Motor Removal . . . . . . . . . . . . . . . . . . . 5B-37
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Pump and Components Removal . . . . . . . . 5B-38
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Manifold Removal . . . . . . . . . . . . . . . . . . . . . 5B-39
Trimming Characteristics . . . . . . . . . . . . . . . . 5B-6 Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5B-39
Trailering Outboard . . . . . . . . . . . . . . . . . . . . . 5B-7 Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5B-40
Tilting Outboard Up and Down Manually . . . 5B-7 Memory Piston Removal . . . . . . . . . . . . . . . 5B-43
Power Trim Flow Diagrams . . . . . . . . . . . . . . . . . 5B-8 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . . 5B-44
Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8 Trim Motor Electrical Tests . . . . . . . . . . . . . . 5B-44
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-45
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12 O-Ring and Seal Placement . . . . . . . . . . . . 5B-45
Trim Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-46
Shock Function Up . . . . . . . . . . . . . . . . . . . . 5B-16
Shock Function Return . . . . . . . . . . . . . . . . . 5B-18
O-ring Description and Sizes . . . . . . . . . . . . . . .
Power Trim Reassembly . . . . . . . . . . . . . . . . . .
5B-47
5B-48
5
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-20 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5B-48 B
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22 Shock Rod Installation . . . . . . . . . . . . . . . . . 5B-50
Preliminary Checks . . . . . . . . . . . . . . . . . . . . 5B-22 Trim Limit Assembly Installation . . . . . . . . . 5B-51
Hydraulic System Troubleshooting Manual Release Valve Installation . . . . . . . 5B-51
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Manifold Installation . . . . . . . . . . . . . . . . . . . 5B-52
Troubleshooting the Power Trim Oil Pump Installation . . . . . . . . . . . . . . . . . . . 5B-53
Electrical System . . . . . . . . . . . . . . . . . . . . . . 5B-27 Pressure Operated Assembly Installation . 5B-53
Power Trim System Removal . . . . . . . . . . . . . . 5B-29 Reservoir/Motor Installation . . . . . . . . . . . . . 5B-55
Testing Power Trim System With Bleeding Power Trim Unit . . . . . . . . . . . . . . 5B-56
Test Gauge Kit (91-52915A6) . . . . . . . . . . . . . 5C-32 Installation of Power Trim System . . . . . . . . . . 5B-57

POWER TRIM
Special Tools
1. Spanner Wrench P/N 91-74951
2. Lock-Ring Pliers P/N SRP-4 (Snap-On)
3. Expanding Rod P/N CG 41-11 (Snap- On)
4. Collet P/N CG 41-12 (Snap- On)

Address
Snap-On Tools Company
2801 - 80th Street
Kenosha, Wisconsin 53143
Phone 414.656.5200
5. Heat Lamp P/N 91-63209

POWER TRIM
6. Power Trim Test Gauge Kit 91-52915A6
73835
7. Adaptor Fitting 91-82278A2 and 91-82278A3
54458
8. Multi-Meter DVA Tester 91-99750A1 or DMT 2000 Digital Tachometer Multi-meter

91-854009A1
a b
a - Multi-Meter DVA Tester 91-99750A1

b - DMT 2000 Digital Tachometer Multi-meter 91-854009A1

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

POWER TRIM
Power Trim Components

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in. lb-ft Nm
– 1 POWER TRIM PUMP
1 1 SHOCK ROD KIT
2 1 O RING REBUILD KIT
3 1 MEMORY PISTON ASSEMBLY
4 1 CYLINDER ASSEMBLY
5 1 TRIM LIMIT VALVE KIT
6 1 PUMP ASSEMBLY
7 1 MOTOR KIT
8 1 RESERVOIR PLUG
9 1 MANUAL RELEASE ASSEMBLY
10 1 MANIFOLD KIT
11 1 SCREW KIT (MOTOR)
12 1 CABLE
13 1 DRIVE SHAFT
14 1 FILTER KIT
15 1 P.O. CHECK ASSEMBLY KIT
– 1 O RING KIT (COMPLETE TRIM)
16 2 GROOVE PIN
17 1 ANCHOR PIN
18 1 SHAFT
19 2 CLAMP
20 1 SCREW
21 1 C WASHER
A - Torque cylinder cap to 45 lb-ft (61 Nm)

B - Torque screws to 80 lb-in. (9.0 Nm)
C - Torque screws to 70 lb-in. (7.9 Nm)
D - Torque plugs to 120 lb-in. (13.5 Nm)
E - Torque screws to 100 lb-in. (11 Nm)
F - Torque shock piston to 90 lb-ft (122 Nm)

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

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

POWER TRIM
Power Trim Flow Diagrams - Trim Up Circuit
a b
w
h d i j k
l
3 v
u e
m
f n
t
g
g
Í Í
Í Í o
p
Reservoir Oil
1 s r q 2 Filtered Feed Oil
Return Oil
Oil Under Pressure

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

POWER TRIM
Tilt Up
a b
3 v h
u d i j k l
t
e
f m
n
g
g
Í Í
Í Í
o
Reservoir Oil
1 s r q 2
Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-10 90-881980R1 NOVEMBER 2001

POWER TRIM
Tilt Up
In the up mode, as the trim rod (a) extends from the cylinder (w), the memory piston (t) clears
or uncovers the pressure relief passage. Oil from the up cavity will enter this passage and,
if required, causes the tilt relief piston (s) to open the tilt pressure relief valve (r). This valve
lowers the amount of pressure available to lift the outboard motor. With the engine in forward
gear, and at high engine rpm, the oil pressure available will not be able to overcome the pro-
peller thrust, limiting the trim range to below the pressure relief orifice. Up pressure flows
into the trim relief passage, and returns back into the reservoir. When the engine rpm’s fall
or if engine is not in forward gear, the oil pressure is available to extend the trim rod (a) up
into the tilt range.
Trim Limit
When the weight of the outboard and propeller thrust reach sufficient levels, the pressure
inside the trim cylinder (w) will increase to the pressure required to move the tilt relief piston
(s). The tilt relief piston’s “pin” opens the tilt relief valve (r). Up pressure flows into the trim
relief passage, and returns back into the reservoir. If the outboard engine is positioned in
the “tilt” range (beyond full “trim” position) when the tilt relief valve opens, it will move back
down to the full “trim” position (trim limit).
a - Trim Rod
b - End Cap
c - Electric Motor
d - Reservoir Oil
j - Oil Pump Gears
l - Oil Fill Cap
m - Shuttle Valve
q - Manifold
t - Memory Piston
u - Shock Piston
w - Cylinder
90-881980R1 NOVEMBER 2001 Page 5B-11

POWER TRIM
Maximum Tilt
a b
3 v h
u
t
c
d i j k l
e
f
g m n
Í Í g
Í Í o
p
Reservoir Oil
1 s r q 2
Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-12 90-881980R1 NOVEMBER 2001

POWER TRIM
Maximum Tilt
With the cylinder at maximum travel, due to no ram movement, the pressure inside of the
trim cylinder will increase to the pressure setting of the tilt relief valve (r). Pressure forces
the tilt relief actuator (s) to move and unseat the tilt relief valve (r) allowing oil to return to
the reservoir through passages in the manifold (q). Oil flow will continue until the “up button”
is released.
a - Trim Rod
b - End Cap
c - Electric Motor
d - Reservoir Oil
j - Oil Pump Gears
l - Oil Fill Cap
m - Shuttle Valve
q - Manifold
t - Memory Piston
u - Shock Piston
w - Cylinder
90-881980R1 NOVEMBER 2001 Page 5B-13

POWER TRIM
Trim Down
b
a
3
d i j k l
2 v h e
m
f n
u
g
g
Í Í
t
Í Í
o
p
Reservoir Oil
s r q 1
Filtered Feed Oil
Return Oil
Oil Under Pressure
Page 5B-14 90-881980R1 NOVEMBER 2001

POWER TRIM
Trim Down
When the trim switch is activated in the down position, the electric motor (c) will rotate the
oil pump gears (j) in the opposite direction. With the oil pump gears rotating backwards, the
flow of oil is reversed. Oil is drawn through the filter (g), through the down circuit suction port
(k) and into the oil pump gears (j). The pump forces pressurized oil into the down passages.
Oil will slide the shuttle valve (m) into the up circuit pressure operated valve (n). The shuttle
valve will mechanically open the up circuit pressure operated valve and allow oil, from the
up cavity of the trim cylinder (w), to return into the oil pump. This returning oil, from the up
cavity, will supply the oil required for the down circuit. The oil is blocked from returning into
the reservoir by the ball (i) inside the up circuit suction port. Oil, under pressure, opens the
down circuit pressure operated valve (f) and enters the down passages inside of the man-
ifold (q). The manifold passage connects into the trim cylinder passage leading to the top
of the cylinder. The cavity, inside the cylinder, above the shock piston (u) is the down cavity.
As the down cavity fills with oil, the trim rod (a) retracts into the cylinder, lowering the out-
board motor. Oil from the up cavity exits the cylinder and is drawn back into the pump
through the open up circuit pressure operated valve (n). When the trim rod reached full trav-
el, the oil pressure inside the down circuit will rise until the down circuit pressure relief valve
(e) opens, bypassing oil back into the reservoir. When the trim button is released, the pump
stops supplying oil, both of the pressure operated valves (f & n) will close and; if open, the
down circuit pressure relief valve (e) will close. The closed valves will lock the fluid on either
side of the shock piston (u) & memory piston (t), holding the outboard motor in position.
a - Trim Rod
b - End Cap
c - Electric Motor
d - Reservoir Oil
j - Oil Pump Gears
l - Oil Fill Cap
m - Shuttle Valve
q - Manifold
t - Memory Piston
u - Shock Piston
w - Cylinder
2 - Impact Relief Pressure -1170-1360 PSI (8065-9375 kPa) (F75-F115)
3 - Down Pressure - 505-850 PSI (3480-5860 kPa) (F75-F115)
90-881980R1 NOVEMBER 2001 Page 5B-15

POWER TRIM
Shock Function Up
b
a
h
2 v
u
d i j k l
t
e
m
f n
g
g
Í Í
Í Í o
s r q 1 Reservoir Oil
Return Oil
Oil Under Pressure
Page 5B-16 90-881980R1 NOVEMBER 2001

POWER TRIM
Shock Function Up
Oil inside the down cavity is locked in a static position by the closed down circuit pressure
operated valve (f), the manual release valve (p) and the manifold reverse suction valve (o).
If the outboard strikes an underwater object while in forward gear, the trim rod (a) will try to
rapidly extend from the cylinder (w), the pressure increases inside the trim cylinder down
cavity and connecting passages. When the pressure increases to the level required, the im-
pact relief valves (v), located inside the shock piston (u), will open and allow the fluid to pass
through the shock piston. As the fluid passes through the piston, the trim rod (a) will extend
from the trim cylinder. The memory piston (t) is held in position by vacuum, created by the
oil in the up cavity being locked in a static position. Therefore; oil passing through the shock
piston is trapped between the memory piston (t) and shock piston (u).
a - Trim Rod
b - End Cap
c - Electric Motor
d - Reservoir Oil
j - Oil Pump Gears
l - Oil Fill Cap
m - Shuttle Valve
q - Manifold
t - Memory Piston
u - Shock Piston
w - Cylinder
90-881980R1 NOVEMBER 2001 Page 5B-17

POWER TRIM
Shock Function Return
a b
v h
2 u
d i j k l
t
e
f m
n
g
Í Í
g
Í Í o
p
Return Oil
Oil Under Pressure
Page 5B-18 90-881980R1 NOVEMBER 2001

POWER TRIM
Shock Function Return

After the engine clears the under water object, the weight of the engine will increase the oil
pressure between the memory piston (t) and shock piston (u) to the level required to open
the shock return valve (h), inside the shock piston, allowing the oil to bleed back through
the shock piston into the down cavity. If required, additional oil will enter the down cavity
through the manifold reverse suction valve (o). This will return the engine back against the
memory piston (t) and into the original running position.
a - Trim Rod
b - End Cap
c - Electric Motor
d - Reservoir Oil
j - Oil Pump Gears
l - Oil Fill Cap
m - Shuttle Valve
q - Manifold
t - Memory Piston
u - Shock Piston
w - Cylinder
90-881980R1 NOVEMBER 2001 Page 5B-19

POWER TRIM
Manual Tilt
a b
2 v h
d i j k l
u
t
e
f m
g n
Í Í
g
Í Í o
Return Oil
Filtered Oil
Page 5B-20 90-881980R1 NOVEMBER 2001

POWER TRIM
Manual Tilt
To manually tilt the outboard engine, the owner will need to back out the manual release
valve (p) 3-4 turns. With the valve backed out, the internal passages inside the manifold are
connected together. These passages connect both the cylinder down and up cavities to-
gether, along with the reservoir, allowing the engine to be raised or lowered. Trim rod (a)
movement will continue until the manual release valve (p) is closed, locking the fluid inside
of the cylinder and manifold.If the outboard motor is to be raised manually, turn the manual
release (tilt) valve counterclockwise to the full out position. When in the full (out) position,
oil in the trim cylinder can flow freely from the up side to the down side or from the down side
to the up side. The oil return line into the reservoir is also open, allowing free oil flow to either
side of the tilt cylinder to accommodate the differential oil capacities between the tilt cylinder
up side and down side cavities
When trimming the outboard in either the up or down position, with the manual tilt valve open
or leaking, little or no movement will occur. Oil pressure from the pump will move to both,
the up cavity and through the manual tilt valve into the down cavity, each cavity would have
equal pressure resulting in little or no movement.
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or
throttling back rapidly, oil in the trim system must be locked in a static position. This is accom-
plished with the up and down pilot check valves. Thus, not allowing oil in the system to move
in either direction.
a - Trim Rod
b - End Cap
c - Electric Motor
d - Reservoir Oil
j - Oil Pump Gears
l - Oil Fill Cap
m - Shuttle Valve
q - Manifold
t - Memory Piston
u - Shock Piston
w - Cylinder
90-881980R1 NOVEMBER 2001 Page 5B-21

POWER TRIM
Troubleshooting
Support outboard with tilt lock pin when servicing power trim system.
IMPORTANT: After debris or failed components have been found, it is recommended
that unit be disassembled completely and ALL o-rings be replaced. Check valve com-
ponents and castings must be cleaned using engine cleaner and compressed air or
replaced prior to reassembly.
IMPORTANT: Power trim system is pressurized. Outboard must be in the full “UP”
position (trim rod fully extended) prior to fill/drain plug or manual release valve re-
moval.
Refer to instructions following if disassembly is required when servicing.
Follow preliminary checks before proceeding to troubleshooting flow diagrams (following).
Preliminary Checks
IMPORTANT: Operate Power Trim system after each check to see if problem has been
corrected. If problem has not been corrected proceed to next check.
1. Check that manual release valve is tightened to full right (clockwise) position.
2. Check trim pump fluid level with outboard in full “UP” position and fill if necessary. Refer
to “Bleeding Power Trim Unit”.
3. Check for external leaks in Power Trim system. Replace defective part(s) if leak is found.
4. Outboard not holding tilted position (falls down to trim position) indicates debris or defec-
tive components in trim assembly. Clean or replace components as required.
Page 5B-22 90-881980R1 NOVEMBER 2001

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

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

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

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

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

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly. Trim system holds
reverse thrust. Test-
ing complete.
Trim will not hold
reverse thrust.
Trim system holds re-
complete.
continued on next page
90-881980R1 NOVEMBER 2001 Page 5B-23

POWER TRIM

continued
Remove suction seat as-

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

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

assembly. Trim will not hold
reverse thrust. Trim system holds
ing complete.
Trim system holds
ing complete.
Replace trim system.
Page 5B-24 90-881980R1 NOVEMBER 2001

POWER TRIM
TRIM SYSTEM LEAKS DOWN

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

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

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

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

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

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly.
Trim system leaks down. Trim system does
not leak down.
Testing complete.
Trim system does
continued on next page
ing complete.
90-881980R1 NOVEMBER 2001 Page 5B-25

POWER TRIM

continued
Inspect memory pis-

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

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

ing complete. Replace trim system.
Page 5B-26 90-881980R1 NOVEMBER 2001

POWER TRIM
Troubleshooting the Power Trim Electrical System

UP
a DN
b
UP
DN
GRN/WHT
c
BLU/WHT
GRN/WHT or GRN
BLU/WHT or PUR
RED
RED
e c
A
20 (A) RED
d
B
– +
B
30 (A)
RED
BLK LT.BLU
g
RED/PUR
BLU
i RED GRN
LT.BLU
BLU
LT.GRN
RED LT.BLU
RED
h
3
GRN
BLK
4 2
BLK LT.GRN LT. BLU/WHT
LT.BLU/WHT
j
f GRN/WHT
RED/PUR GRN/WHT
1
UP
DN k
a - Trim Switch (Remote Control Mounted) g - Up Relay

b - Trim Switch (Panel Mounted) h - Down Relay
c - Fuses (20A, 30A) i - Solenoid - Start
d - Remote Control Wiring Plug Connector j - Trim Pump Motor
e - Battery k - Cowl Switch
f - Block Screw
90-881980R1 NOVEMBER 2001 Page 5B-27

POWER TRIM
Troubleshooting the Power Trim Electrical System

Refer to wiring diagram on preceding page for location of wire connections.
Problem Possible Cause Remedy
Trim Switch “UP” is inopera- 1. Open wire between Wire Connection (1) 1. Check for an open connection or cut
tive, but the Cowl Switch and Trim Switch. wire.
“UP” does operate. 2. Faulty Trim Switch. 2. Replace.
Cowl Switch “UP” is inopera- 1. Open wire between Wire Connection (2) 1. Check for an open connection or cut
tive, but the Trim Switch “UP” and Solenoid. wire.
does operate. 2. Faulty Cowl Switch. 2. Replace.
Trim Switch “UP” and Cowl 1. Open wire between Wire Connection (1) 1. Check for an open connection.
Switch “UP” are both inop- and the “Up” Relay.
erative. 2. Open BLK wire between ground and 2. Check for an open connection.
“UP” Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
“UP” Relay.
4. Faulty “UP” Relay. 4. Replace.
Trim Switch “DOWN” is inop- 1. Open wire between Wire Connection (3) 1. Check for an open connection or cut
erative, but the Cowl Switch and Trim Switch. wire.
“DOWN” does operate. 2. Faulty Trim Switch. 2. Replace.
Cowl Switch “DOWN” is inop- 1. Open wire between Wire Connection (2) 1. Check for a open connection or cut
erative, but the Trim Switch and Solenoid. wire.
“DOWN” does operate. 2. Faulty Cowl Switch. 2. Replace
Trim Switch “DOWN” and 1. Open wire between Wire Connection (3) 1. Check for an open connection.
Cowl Switch “DOWN” are and the “UP” Relay.
both inoperative. 2. Open BLK wire between ground and 2. Check for an open connection.
“DOWN” Relay.
3. Open RED wire between Solenoid and 3. Check for an open connection.
“DOWN” Relay.
4. Faulty “DOWN” Relay 4. Replace.
Trim Switch “UP” and 1. 20 AMP Fuse blown. 1. Replace fuse. Locate the cause of
“DOWN” are both inopera- the blown fuse. Check electrical wiring
tive, but the Cowl Switch for a shorted circuit.
does operate. 2. Faulty trim switch. 2. Replace.
3. Wire is open between fuse holder and 3. Check for a open connection or cut
solenoid. wire.
4. Wire is open between fuse holder and 4. Check for a loose or corroded con-
trim switch. nection.
Trim Switch and Cowl Switch 1. One of the Trim Pump Motor wires is 1. Check wire connections (4) for loose
are both inoperative. open between the motor and the Relays. or corroded condition.
2. Faulty trim pump motor. 2. If voltage is present at connections
(4) when the appropriate trim button is
pressed, then motor is faulty. Replace
motor.
Trim system operates (motor 1. The Trim or Cowl switch is shorted. 1. Replace.
runs) without pressing the
switches.
Page 5B-28 90-881980R1 NOVEMBER 2001

POWER TRIM
Power Trim System Removal

1. Tilt outboard to the full up position and support with tilt lock pin.
2. Disconnect the power trim wire harness and remove J-Clips.
c b
53949 55264
a - Tilt Lock Pin

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

4. Drive out the upper pivot pin.
a - Trilobe Pin
b - Upper Pivot Pin
90-881980R1 NOVEMBER 2001 Page 5B-29

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

7. Remove the sacrificial anode.
a
b
a - Lower Pivot Pin

b - Sacrificial Anode
Page 5B-30 90-881980R1 NOVEMBER 2001

POWER TRIM
8. Tilt power trim assembly (top first) out from clamp bracket and remove assembly.
53944
WARNING
Electrical wires passing through cowl openings must be protected from chafing or
being cut. Follow the recommended procedures outlined in Section 1D of this
Manual. Failure to protect wires as described could result in electrical system fail-
ure and/or injury to occupants of boat.
90-881980R1 NOVEMBER 2001 Page 5B-31

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

IMPORTANT: This test will not locate problems in the trim system. The test will show
if the system is correct after a repair. If minimum pressures are not obtainable, the
trim system requires additional repair.
“UP” Pressure Check
IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full “Up” position and engage tilt lock lever.
2. Slowly remove “Fill” plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim as-
sembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring onto
adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test
adaptor securely using teflon tape on threads.
gg
f a c
ee d c bb 54457
a - Test Adaptor (91-822778A1)

b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
f - Brass Fitting
g - Apply Teflon Tape
Page 5B-32 90-881980R1 NOVEMBER 2001

POWER TRIM
4. Install test adaptor 91-822778A1 into manual release valve hole.
5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
a d
54459
b
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
6. Reinstall fill plug.

7. Run trim “UP”.
8. Disengage tilt lock lever.
90-881980R1 NOVEMBER 2001 Page 5B-33

POWER TRIM
CAUTION
Failure to install spare tilt pin (or hardened bolts and nuts) in hole shown could re-
sult in transom bracket failure and possible injury.
9. Move outboard “IN” until hole in swivel bracket “ear” aligns with the 3rd tilt hole in tran-
som bracket. Lock engine in trim range by installing a 3/8 in. (9.5 mm) diameter tilt pin
or two 3/8 in. (9.5 mm) hardened bolts and nuts through the transom brackets and swivel
bracket in the hole shown.
a
54460
a - Tilt Pin Hole (Install Spare Tilt Pin or Hardened Bolts and Nuts)
10. Open valve (a) and close valve (b).
a bb
51374
11. Run trim “UP”. The minimum pressure should be 2640 P.S.I. (18,200 kPa).
12. Run trim “DOWN” to release pressure and remove spare tilt pin or bolts and nuts.
13. Tilt outboard full “UP” and engage tilt lock lever.
14. Slowly remove “Fill” plug to bleed pressure.
15. Remove test gauge hose and adapter.
16. Reinstall Manual Release Valve and secure valve with circlip.
17. Retighten “Fill” plug.
NOTE: If pressure is less than 2640 P.S.I. ( 18,200 kPa), troubleshoot system per instructions
on pages 5B-22 to 28.
Page 5B-34 90-881980R1 NOVEMBER 2001

POWER TRIM
“DOWN” Pressure Check

IMPORTANT: Insure battery is fully charged before performing tests.
1. Tilt outboard to full “Up” position and engage tilt lock lever.
2. Slowly remove “Fill” plug to bleed pressure from reservoir.
3. Remove circlip securing manual release valve and unscrew release valve from trim as-
sembly.
NOTE: A small amount of trim fluid may drip from manual release valve hole. Place a suit-
able container under trim assembly to collect any leakage.
NOTE: Assemble test adaptor by using O-ring installation tool to position small O-ring onto
adaptor 1st, then install medium O-ring and lastly large O-ring. Thread brass fitting into test
adaptor securely using teflon tape on threads.
g
f a e d c b 54457

b - O-ring Installation Tool
c - Small O-ring (Install 1st)
d - Medium O-ring (Install 2nd)
e - Large O-ring (Install Last)
f - Brass Fitting
g - Apply Teflon Tape
4. Install test adaptor 91-822778A3 into manual release valve hole.
a
90-881980R1 NOVEMBER 2001 Page 5B-35

POWER TRIM
5. Thread hose from Test Gauge Kit (91-52915A6) into brass fitting on adaptor.
a d
54459
b
a - Brass Fitting
b - Test Gauge Assembly
c - Tilt Pin (Position in Hole Shown)
d - Hose
e - Hose (Not Used)
f - OPEN Valve
g - CLOSE Valve
6. Reinstall fill plug.

7. Run trim “UP”.
8. Disengage tilt lock lever.
9. Open valve (f) and close valve (g).
10. Run trim “DOWN”. Minimum pressure should be 505 P.S.I. (3480 kPa).
11. Tilt outboard full “UP” and engage tilt lock lever.
12. Slowly remove “Fill” plug to bleed pressure.
13. Remove test gauge hose and adaptor.
14. Reinstall manual release valve and secure valve with circlip.
15. Retighten “Fill” plug.
NOTE: If pressure is less than 505 PSI (3480 kPa), troubleshoot system per instructions on
pages 5B-22 to 28.
Page 5B-36 90-881980R1 NOVEMBER 2001

POWER TRIM
Power Trim Disassembly

IMPORTANT: Power trim system is pressurized. Trim rod must be in the full “UP”
position (fully extended) prior to fill/drain plug, or manual release valve removal.
1. Remove reservoir cap.
2. Remove manual release valve assembly to drain oil.
55263
a - Reservoir Cap
b - Manual Release Valve
Trim Motor Removal

1. Secure power trim assembly in a soft jaw vise.
2. Remove four (4) screws to remove motor/reservoir. Remove reservoir seal and coupler.
a - Screw (4)
b - Reservoir
c - Reservoir Seal
d - Coupler
e - Manifold Assembly
90-881980R1 NOVEMBER 2001 Page 5B-37

POWER TRIM
Pump and Components Removal

1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet
(both sides). Use special tool CG 41-11 and special tool CG 41-14 with 5/16″ end to re-
move spool.
a
b
c
d
e
d
c
b
a
a - Plug (2)
b - Spring (2)
c - Check Valve/Poppet (2)
d - Seat (2)
e - Spool
IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found
on poppet replace poppet.
2. Remove three (3) screws to remove pump. Remove filter and filter seal under pump.
Remove suction seat assembly.
a
d
b
a - Debris Under Valve Tip

b - Rubber Seat
c - Screws (3)
d - Filter Seal
e - Filter
f - Suction Seat Assembly
Page 5B-38 90-881980R1 NOVEMBER 2001

POWER TRIM
Manifold Removal
1. Remove two (2) screws to remove manifold from cylinder.
2. Remove tilt relief components.
a
e
51146 51008
a - Screws (2)
b - Spring
c - Poppet
d - Spool Housing
e - Trim Limit Spool
Shock Rod Removal

1. Unscrew end cap assembly from cylinder using spanner wrench [1/4 in. x 5/16 in.
(6.4 mm x 8 mm) long pegs].
2. Remove shock rod assembly from cylinder.
90-881980R1 NOVEMBER 2001 Page 5B-39

POWER TRIM
Shock Rod Disassembly

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

2. Remove three (3) screws and remove plate from shock rod piston.
51143
a - Screw (3)
b - Plate
c - Shock Rod Piston
Page 5B-40 90-881980R1 NOVEMBER 2001

POWER TRIM
3. Remove check ball components from shock rod piston.

4. Remove O-ring from shock rod piston.
c
b
a
d
51147
a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring
CAUTION
When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs
to avoid damage to shock piston.
5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp
(P/N 91-63209).
6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs].
7. Allow shock rod piston to cool. Remove from shock rod.
a
b
51146 51146
a - Spanner Wrench
b - Shock Rod Piston
90-881980R1 NOVEMBER 2001 Page 5B-41

POWER TRIM
8. Inspect check valve for debris. Clean debris from check valve if found. If debris cannot
be cleaned from check valve, replace shock piston as an assembly.
9. Clean shock and components with compressed air.
10. Remove inner O-ring from shock rod piston.
a b
51199
a - Shock Piston
b - O-ring
11. Remove cylinder end cap assembly from shock rod.

12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper.
13. Place end cap on clean work surface.
14. Remove rod wiper, inner O-ring, and outer O-ring.
c
b
51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
Page 5B-42 90-881980R1 NOVEMBER 2001

POWER TRIM
Memory Piston Removal

1. Remove memory piston from cylinder using one of two methods:
a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool.
SRP-4 (Snap-On)
b. Blowing compressed air into manual release valve hole using air nozzle.
WARNING
Memory piston cup may be expelled at a high velocity when air pressure is applied.
Failure to place cylinder as shown below could result in personal injury.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston.
2. Remove o-ring from memory piston.
a d
e
55466 51144
a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag
d - O-Ring
e - Memory Piston
90-881980R1 NOVEMBER 2001 Page 5B-43

POWER TRIM
IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in
Power Trim system could cause system to malfunction.
Clean shock rod and components with parts cleaner and dry with compressed air.
It is recommended that all o-rings in trim system be replaced. Use O-Ring Kit 25-809880A1.
Lubricate all o-rings with Power Trim & Steering Fluid. If not available, use automotive (ATF)
automatic transmission fluid.
Trim Motor Electrical Tests
1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor.
IMPORTANT: Trim Motor is not serviceable. If motor fails to run, replace motor assem-
bly.
Page 5B-44 90-881980R1 NOVEMBER 2001

POWER TRIM
Reassembly
O-Ring and Seal Placement
O-Rings and Seals are part of O-Ring Kit 25-809880A1
2
3
22
20
8
9
19 10
21
21 11
12 13
14
9
18 15
10 16
17
9
8
90-881980R1 NOVEMBER 2001 Page 5B-45

POWER TRIM
O-Ring Sizes
22
11
99
33
77
22 4
13
13
5
18 17 12 14
14
20 15
6
16
Cutaway View of O-Ring
19
8 Width
10 21
21
O.D. I.D.
11
O-RINGS SHOWN ARE ACTUAL SIZE
Page 5B-46 90-881980R1 NOVEMBER 2001

POWER TRIM
O-Ring Description and Sizes

O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width
1 Wiper Ring (412585)
2 Cyl. Cap, Inner12586) 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm)
3 Cyl. Cap8134) 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm)
4 Shock Piston2579) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
5 Piston Screw05797) 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm)
6 Reservoir Plug01271) 0.549 in. (13.94 mm) 0.755 in. (19.17 mm) 0.103 in. (2.616 mm)
7 Motor Seal12599)
8 (2) P.O. Check Plug06484) 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm)
9 (3) Poppet Assy.4585)
10 (2) P.O. Check Seat07328) 0.364 in. (9.25 mm) 0.504 in. (12.80 mm) 0.07 in. (1.78 mm)
11 (2) Pump Port 0.145 in. (3.683 mm) 0.285 in. (7.239 mm) 0.07 in. (1.78 mm)
12 Suction Seat 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm)
13 Filter Seal12607)
14 Filter12590)
15 Manual Release406483) 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
18 Spool09051) 0.239 in. (6.07 mm) 0.379 in. (9.626 mm) 0.07 in. (1.78 mm)
19 (3) Spool Housing09005) 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
20 Trim Limit Spool06483) 0.114 in. (2.895 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
21 (2) Manifold405387) 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm)
22 Memory Piston412579) 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
90-881980R1 NOVEMBER 2001 Page 5B-47

POWER TRIM
Power Trim Reassembly

IMPORTANT: Lubricate all O-rings with Power Trim & Steering Fluid. If not available,
use automotive (ATF) automatic transmission fluid.
Shock Rod Reassembly
1. Install lubricated O-rings to end cap.
2. Install rod wiper.
3. Install lubricated O-rings to shock piston.
c
b
e f
51145 d 51199
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
d - Shock Piston
e - O-ring
f - O-ring
4. Clamp shock rod in soft jawed vise.

5. Position cylinder end cap onto rod as shown.
51146
CAUTION
When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in.
(6.4mm x 8mm) long pegs to avoid damage to shock rod piston.
6. Apply Loctite 271 Thread Locker to threads on shock rod.
7. Install shock rod piston.
Page 5B-48 90-881980R1 NOVEMBER 2001

POWER TRIM
8. Tighten shock rod piston securely using spanner wrench (1/4 in. x 5/16 in. long pegs).
If a torquing type spanner tool is used to tighten shock piston, then torque to specified
torque.
b a
51146
a - Shock Rod Piston
b - Spanner Wrench
Shock Piston Torque
90 lb-ft (122 Nm)
9. Remove shock rod assembly from vise.

10. Install ball, seat, and spring (five sets) to shock rod piston.
11. Secure components with plate. Tighten screws to specified torque.
e
d
c
a
b 51147
a - Screw (3)
b - Plate
c - Spring (5)
d - Seat (5)
e - Ball (5)
Screw Torque
35 lb-in. (4 Nm)
90-881980R1 NOVEMBER 2001 Page 5B-49

POWER TRIM
Shock Rod Installation

1. Place trim cylinder in soft jawed vice.
2. Install lubricated O-ring to memory piston and place into cylinder. Push memory piston
all the way to bottom.
3. Fill cylinder three inches (76.2 mm) from top of cylinder using Power Trim and Steering
Fluid. If not available, use automotive (ATF) automatic transmission fluid.
4. Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage.
Fill remaining cylinder to just below the cylinder threads.
b
c
a - Memory Piston
b - O-ring
c - Oil Blow Off Ball Passage
CAUTION
End cap must not make contact with shock rod piston when tightening. Shock rod
piston must be positioned in cylinder deep enough to avoid contact.
5. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4 mm x 8 mm) long
pegs]. If a torquing type spanner tool is used to tighten end cap, then torque to specified
torque.
End Cap Torque

45 lb-ft (61 Nm)
Page 5B-50 90-881980R1 NOVEMBER 2001

POWER TRIM
Trim Limit Assembly Installation

1. Lubricate all O-rings. Install spring, poppet, spool housing and trim limit spool into man-
ifold.
NOTE: There are three different size springs used in this manifold. The heavy spring is used
on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The
light spring is used on 30-60 hp outboards.
or or a
d
51008
a - Spring
b - Poppet
c - Spool Housing
d - Trim Limit Spool
Manual Release Valve Installation

1. Install “E” clip (if removed) and lubricate O-rings to manual release valve.
2. Install manual release valve assembly into manifold.
b
a - Manifold
c - E Clip
90-881980R1 NOVEMBER 2001 Page 5B-51

POWER TRIM
Manifold Installation
1. Install dowel pin and two (2) lubricated O-rings into trim cylinder.
a - O-Ring (2)
b - Dowel Pin
2. Align the trim cylinder and pump/reservoir assembly together.

3. Install the two (2) long screws and torque to specified torque.
c
b
51146
a - Trim Cylinder Assembly
b - Reservoir/Manifold Assembly
c - Screw (2)
Screw Torque
100 lb-in. (11.5 Nm)
Page 5B-52 90-881980R1 NOVEMBER 2001

POWER TRIM
Oil Pump Installation

1. Install spring, ball, lubricated O-ring and plastic seat to manifold.
2. Check to see that O-rings are placed on bottom of pump.
3. Install filter and filter seal under pump. Install pump onto manifold. Tighten screws to
specified torque.
a - Screw (3)
b - Suction Seat Assembly
Screw Torque
70 lb-in. (8 Nm)
Pressure Operated Assembly Installation

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found
on poppet, replace poppet.
a
b
a - Debris Under Valve Tip

b - Rubber Seat
1. Lubricate O-rings.
90-881980R1 NOVEMBER 2001 Page 5B-53

POWER TRIM
2. Install spool, seat with O-ring, check valve/poppet, spring and plug with O-ring into
pump. Repeat for other side. Tighten plugs to specified torque.
a
b
c
d
e
d
c
b
a
a - Plug (2)
b - Spring (2)
c - Check Valve/Poppet (2)
d - Seat (2)
e - Spool
Plug Torque
120 lb-in. (13.5 Nm)
Page 5B-54 90-881980R1 NOVEMBER 2001

POWER TRIM
Reservoir/Motor Installation
1. Install coupler into top of pump. Make sure reservoir seal is in the reservoir groove and
place reservoir onto pump/manifold assembly. Install ground strap under screw shown.
Tighten screws to specified torque.
e f
a - Screw (4)
b - Reservoir
c - Reservoir Seal
d - Coupler
e - Manifold Assembly
f - Ground Strap
Reservoir/Motor Screw Torque
80 lb-in. (9 Nm)
2. Fill reservoir to bottom of fill hole using Power Trim and Steering Fluid. If not available,
use automotive (ATF) automatic transmission fluid.
90-881980R1 NOVEMBER 2001 Page 5B-55

POWER TRIM
Bleeding Power Trim Unit

1. Secure power trim unit in soft jawed vise.
2. Add power trim fluid until it is even with the bottom of the fill hole. Reinstall plug.
3. Close the manual release valve. (Turn full clockwise).
55263
a - Reservoir Plug/Fill Hole

4. Cycle system full up and down 3 times or until fluid level remains at proper level.
Connect power trim wire to 12 volt source.
Direction
⇑ Up ⇓ Down
Blue + Positive Blue – Negative
Green – Negative Green + Positive
5. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until
fluid level stays even with the bottom of the fill hole.
Page 5B-56 90-881980R1 NOVEMBER 2001

POWER TRIM
Installation of Power Trim System

1. Apply 2-4-C with Teflon to lower pivot pin bore and pivot pin surface.
2. Position trim cylinder assembly (BOTTOM FIRST) between clamp brackets and route
trim pump electrical harness through access hole in starboard clamp bracket.
3. Start lower pivot pin into pivot pin bore and position lower cross pin (RETAINED) in its
respective hole.
4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assem-
bly until pivot pin is flush with outside surface.
95
b c a
95 2-4-C with Teflon 53965
a - Trim Cylinder Assembly

b - Lower Pivot Pin
c - Lower Cross Pin
5. Using a suitable punch, drive lower cross pin into its respective bore until seated.
6. Install sacrificial aluminum anode to reservoir bracket placing ground strap to anode, as
shown.
c
a
b 53967
a - Lower Cross Pin

b - Sacrificial Anode
c - Ground Strap
90-881980R1 NOVEMBER 2001 Page 5B-57

POWER TRIM
7. Apply 2-4-C with Teflon to surface of upper pivot pin, pivot pin bore and trim ram bore.
NOTE: Install trim ram with cross hole located as shown. If trim ram is installed reversed,
the trim sender (if installed) will not operate.
f b
95
c
a
95
e

a - Pivot Pin
b - Trim Ram Bore
c - Install Trim Ram As Shown
d - Engine Side
e - Transom Side
f - Cross Hole
Page 5B-58 90-881980R1 NOVEMBER 2001

POWER TRIM
8. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram
until pivot pin is flush with swivel bracket.
53966
a - Pivot Pin
b - Swivel Bracket
c - Trim Ram
9. Drive upper retaining pin in until seated.
52941
a - Retaining Pin
90-881980R1 NOVEMBER 2001 Page 5B-59

POWER TRIM
10. Secure trim harness with clamps.
a
55264
a - Clamps
11. Recheck fluid level.

12. Power trim may now be operated to lower outboard to desired position. Trim system is
self purging.
13. Reconnect power trim leads to relays under ignition cover.
14. Reinstall spark plug leads to spark plugs.
15. Reinstall cowls.
16. Connect battery leads to battery terminals.
Page 5B-60 90-881980R1 NOVEMBER 2001

GEAR HOUSING
LOWER UNIT
Section 6
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Forward Gear Bearing Race . . . . . . . . . . . . . 6-30
Quicksilver Lubricants and Service Aids . . . . . . . 6-6 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Gear Housing (Drive Shaft) Bearing Carrier Reassembly . . . . . . . . . . . . . 6-33
(2.07:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Forward Gear Reassembly . . . . . . . . . . . . . . 6-37
Gear Housing (Prop Shaft) Propeller Shaft Reassembly . . . . . . . . . . . . . 6-39
(2.07:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . 6-10 Drive Shaft Wear Sleeve Installation . . . . . . 6-40
General Service Recommendations . . . . . . . . . 6-10 Lower Drive Shaft Bearing Race
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Oil Sleeve Installation . . . . . . . . . . . . . . . . . . . 6-43
Draining and Inspecting Gear Lubricant . . . . . . . 6-11 Upper Drive Shaft Bearing Installation . . . . . 6-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Forward Gear, Lower Drive Shaft Bearing,
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Pinion Gear, and Drive Shaft Installation . . . 6-45
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Pinion Gear Depth and Forward
Bearing Carrier and Propeller Shaft . . . . . . . 6-16 Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Pinion Gear, Drive Shaft, and Bearing Carrier and
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Propeller Shaft Installation . . . . . . . . . . . . . . . 6-51
Upper Drive Shaft Bearing . . . . . . . . . . . . . . . 6-24
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Water Pump Reassembly and Installation .
Gear Housing Pressure Test . . . . . . . . . . . . .
6-53
6-56
6
Lower Drive Shaft Bearing Race . . . . . . . . . . 6-26 Filling Gear Housing With Lubricant . . . . . . . . . 6-57
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Gearcase Installation . . . . . . . . . . . . . . . . . . . . . . 6-58
Forward Gear Bearing Race . . . . . . . . . . . . . 6-29 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 6-64
Trim Tab Adjustment and Replacement . . . . 6-29
Specifications
Gear Ratio 2.07:1
Gearcase Capacity 24.0 fl oz (710 mL)
Lubricant Type Premium Gear Lubricant
Forward Gear
Pinion Gear
Pinion Height 0.025 in. (0.64 mm)
GEAR HOUSING Pinion Gear Locating Tool 91-12349A2
BIGFOOT Flat Number #2
(2.07:1) Disc Number #3
Forward Gear Backlash 0.015 - 0.022 in. (0.38 - 0.55 mm)
Backlash Indicating Tool 91-19660--1
Mark Number #1
Water Pressure
@ 1000 rpm 5 psi (34.5 kPa)
@ 6000 rpm (WOT) 20.5 psi (141.5 kPa)
Leak Test Pressure 10-12 psi (69-83 kPa)
for 5 Minutes
90-881980R1 NOVEMBER 2001 Page 6-1

GEAR HOUSING
Special Tools
1. Pinion Gear Locating Tool (91-12349A2)
Disc 3 Disc1
Disc 2
55079
2. Bearing Installation Tool (91-13945)
3. Oil Seal Driver (91-13949)
4. Bearing Race Tool (91-14308A1)
5. Bearing Installation (91-14309A1)
6. Wear Sleeve Installation Tool (91-14310A1)
Page 6-2 90-881980R1 NOVEMBER 2001

GEAR HOUSING
7. Bearing Preload Tool (91-14311A2)
8. Mandrel (91-15755)*
73815
9. Backlash Indicator Tool (91-19660--1) 2.07:1 Gear Ratio (14/29)
19660-1
10. Mandrel (91-31106)
11. Oil Seal Driver (91-31108)
12. Treaded Rod (91-31229) and Nut (11-24156)*
* From Bearing Removal and Installation Kit (91-31229A7)
90-881980R1 NOVEMBER 2001 Page 6-3

GEAR HOUSING
13. Slide Hammer (91-34569A1)
14. Mandrel (91-36569)*
15. Universal Puller Plate (91-37241)
73652
16. Driver Rod (91-37323)*
74184
17. Mandrel (91-37350)
18. Puller Jaws (91-46086A1)
19. Driver Shaft Holding Tool (91-56775, 2-Stroke), (91-817070, 40/50 4-Stroke),
(91-817070A1, 50/60 4- Stroke), (91-804776A1, 75/90 4-Stroke)
Page 6-4 90-881980R1 NOVEMBER 2001

GEAR HOUSING
20. Dial Indicator (91-58222A1)
21. Backlash Indicator Tool (91-78473) 2.31:1 Gear Ratio (13/30)
22. Puller Bolt (91-85716)
23. Dial Indicator Adaptor Kit (91-83155)
24. Bearing Puller Assembly (91-83165M)
25. Bearing Installation Tool (91-856875A1)
56783
26. Bearing Installation Tool (91-877321A1)
90-881980R1 NOVEMBER 2001 Page 6-5

GEAR HOUSING
GEAR HOUSING (DRIVE SHAFT)(2.07:1 GEAR RATIO)

32
4.25 IN./107.95MM 33
TORPEDO DIA. 7
30
22
95
35 23
34 95
29 7
95
31
36 21
28
24 41 42
7
7
27
95
26 39
25 40
7
95
10
7 38
9
13 37
12
11
87
7 20
8 19
5 18
12
1
14
2
6
17
15
16 4
7 Loctite 271 THREAD LOCKER
3
87 Premium Gear Lubricant 4
7 3
4
3
Page 6-6 90-881980R1 NOVEMBER 2001

GEAR HOUSING
GEAR HOUSING (DRIVE SHAFT)(2.07:1 GEAR RATIO)

TORQUE
REF.
REF
1 1 GEAR HOUSING (BLACK)
2 1 DOWEL PIN (FRONT)
3 3 DRAIN SCREW 60 7
4 3 WASHER-SEALING
5 1 DOWEL PIN (REAR)
6 1 TRIM TAB
7 1 SCREW (7/16-14 X 1-1/4 IN.) 22 30
8 1 WASHER
9 1 CARRIER
10 1 NEEDLE BEARING
11 1 OILER TUBE
12 2 ANODE
13 1 SCREW (M6 X 40 MM)
14 1 NUT 60 7
15 1 PINION GEAR (14 TEETH)
16 1 NUT 70 95
17 1 SHIFT CAM
18 1 TAPERED ROLLER BEARING
19 1 CUP
20 1 SHIM ASSEMBLY (006 THRU 048)
21 1 DRIVE SHAFT ASSEMBLY
22 1 WEAR SLEEVE ASSEMBLY
23 1 SEAL RING
24 1 COVER ASSEMBLY
25 1 GASKET
26 1 OIL SEAL (LOWER)
27 1 OIL SEAL (UPPER)
28 1 GASKET
29 1 GASKET
30 1 WATER PUMP ASSEMBLY
31 1 FACE PLATE
32 4 SCREW (M6 X 30 MM) 60 7
33 1 SEAL
34 1 KEY
35 1 IMPELLER
36 6 SCREW (M6 X 25 MM) 60 7
37 1 SHIFT SHAFT ASSEMBLY
38 1 E-RING
39 1 BUSHING ASSEMBLY
40 1 O-RING
41 1 OIL SEAL
42 2 SCREW (M6 X 25 MM) 35 4
90-881980R1 NOVEMBER 2001 Page 6-7

GEAR HOUSING
GEAR HOUSING (PROP SHAFT)(2.07:1 GEAR RATIO)
87
87
7 Loctite 271 Thread Locker

Page 6-8 90-881980R1 NOVEMBER 2001

GEAR HOUSING
GEAR HOUSING (PROP SHAFT)(2.07:1 GEAR RATIO)

TORQUE
REF.
REF
1 1 GEAR HOUSING
2 1 TAPERED ROLLER BEARING
3 1 CUP
4 1 FORWARD GEAR (29 TEETH)
5 1 ROLLER BEARING
6 1 RETAINING RING
7 1 CAM FOLLOWER ASSEMBLY
8 3 BALL
9 1 SLIDE
10 1 SPRING
11 1 CLUTCH
12 1 CROSS PIN
13 1 SPRING
14 1 PROPELLER SHAFT
15 1 REVERSE GEAR (29 TEETH)
16 1 BEARING CARRIER ASSEMBLY
17 1 O-RING
18 1 ROLLER BEARING
19 1 OIL SEAL (INNER)
20 1 OIL SEAL (OUTER)
21 1 ROLLER BEARING
22 1 THRUST WASHER
23 1 THRUST BEARING
24 2 STUD (M8 X 48 MM)
25 2 WASHER
26 2 NUT 25 34
27 1 SHIM ASSEMBLY (006 THROUGH 038)
28 2 INSERT
29 1 DECAL-G/H PINION IDENTIFICATION
90-881980R1 NOVEMBER 2001 Page 6-9

GEAR HOUSING
General Service Recommendations

There may be more than one way to “disassemble” or “reassemble” a particular part(s),
therefore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: On Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more components.
Service procedure order in this section is a normal disassembly-reassembly sequence.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
When compressed air is used to dry a part, verify that no water is present in air line.
Bearings
All bearings must be cleaned and inspected. Clean bearings with solvent and dry with com-
pressed air. Air should be directed at the bearing so that it passes through the bearing. DO
NOT spin bearing with compressed air, as this may cause bearing to score from lack of lu-
brication. After cleaning, lubricate bearings with Premium Blend Gear Lubricant. DO NOT
lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing
race in-and-out, while holding outer race, to check for side wear. When inspecting tapered
bearings, determine condition of rollers and inner bearing race by inspecting bearing cup
for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and race as a set.
Inspect gear housing for bearing races that have spun in their respective bores. If race(s)
have spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, un-
even wear and/or discoloration from overheating. The shaft and bearing must be replaced
if such a condition exists.
Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to ap-
pearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all metal
case seals. When using Loctite on seals or threads, surfaces must be clean and dry. Apply
2-4-C with Teflon on all O-rings and on I.D. of oil seals. Apply 2-4-C with Teflon to external
surfaces of bearing carrier.
Page 6-10 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Draining and Inspecting Gear Lubricant

WARNING
If gear housing is installed on engine, to avoid accidental starting, disconnect (and
isolate) spark plug leads from spark plugs before working near the propeller.
1. With gear housing in normal running position, place a clean pan under housing and re-
move the two vent screws and one fill/drain screw (with gaskets).
c b
53922
a - Fill/Drain Screw
b - Oil Level Screw
c - Vent Screw
2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance).
Drain lube into a clean pan/container. Presence of fine metal particles (resembling pow-
der) in the gear lube indicates normal wear. The presence of metal chips in the gear lube
indicates the need for gear housing disassembly and component inspection.
3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lu-
bricant. Gear lubricant which has been drained from a gear case recently in operation
will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed
with assembly lubricant (Special Lube 101 or 2-4-C with Teflon) will also be creamy white
in color. This is normal and should not be confused with the presence of water. If water
is suspected to be present in gearcase, a pressure check of gearcase should be made
(with no lubricant in gearcase). Gearcase should hold 10 to 12 psi of pressure for 5 min-
utes without leaking down. Pouring a portion of the gear lubricant into a glass jar and
allowing the lubricant to settle will allow any water in the lube to separate and settle to
the bottom of the jar.
4. Presence of water in gear lubricant indicates the need for disassembly and inspection
of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing compo-
nents for damage. If gearcase is rebuilt, gearcase should be pressure checked before
filling with lubricant.
90-881980R1 NOVEMBER 2001 Page 6-11

GEAR HOUSING
Removal
WARNING
To prevent accidental engine starting, remove (and isolate) spark plug leads from
spark plugs before removing gear housing.
IMPORTANT: On 90 hp (4-Stroke) models, when removing or installing gearcase care-
fully guide driveshaft through drive shaft bushing to avoid scoring bushing surface.
1. Remove (and isolate) spark plug leads from spark plugs.
2. Shift engine into forward gear.
3. Tilt engine to full “Up” position.
4. Remove 4 fasteners.
5. Remove locknut and washer.
6. Remove gear housing.
a
b
53992
a - Fasteners (2 Each Side)

b - Locknut and Washer
Page 6-12 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Disassembly
Water Pump
NOTE: If water tube seal stayed on water tube (inside of drive shaft housing) when gear
housing was removed, pull water tube seal from water tube.
1. Replace water tube seal, if damaged.
2. Remove 4 screws, washers, and isolators.
3. Remove cover.
a
c
19212
a - Water Tube Seal

b - Screws (4 each)
c - Cover
IMPORTANT: On The circular groove formed by the impeller sealing bead should be
disregarded when inspecting cover (Step 5) and plate (Step 9), as the depth of the
groove will not affect water pump output.
4. Replace cover if thickness of steel at the discharge slots is 0.060 in. or less, or if
groove(s) (other than impeller sealing bead groove) in cover roof are more than 0.030
in. (0.762 mm) deep.
5. Lift impeller, drive key, and gasket from drive shaft.
b
c
19220
a - Impeller
b - Drive Key
c - Gasket
90-881980R1 NOVEMBER 2001 Page 6-13

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

• Impeller blade(s) are cracked, torn, or worn.
• Impeller is glazed or melted (caused by operation without sufficient water supply).
• Rubber portion of impeller is not bonded to impeller hub.
7. Remove plate and gasket.
8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more
than 0.030 in. (0.762 mm) deep.
c
a
19219
a - Plate
b - Gasket
c - Impeller Sealing Groove
9. Remove screws and washers.
19217
a - Screws and Washers (6 each)
Page 6-14 90-881980R1 NOVEMBER 2001

GEAR HOUSING
10. Remove water pump base using flat screwdrivers to lightly pry up on base.
19226
a - Water Pump Base
11. Remove (and discard) seals. (IT MAY BE BENEFICIAL TO CLAMP THE WATER
PUMP BASE IN A VISE WHILE REMOVING SEALS)
19195
a - Seals
12. Remove gasket.
19218
a - Gasket
90-881980R1 NOVEMBER 2001 Page 6-15

GEAR HOUSING
Bearing Carrier and Propeller Shaft

1. Remove fasteners.
a
51117
a - Fasteners
2. With propeller shaft horizontal, pull carrier to break seal with gear housing. Remove
bearing carrier/propeller shaft components as an assembly, taking care not to lose cam
follower or 3 metal balls in end of propeller shaft.
3. Remove propeller shaft from bearing carrier.
b
e
c a
d
51116
a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Screw (91-85716)
d - Thrust Hub
e - Propeller Shaft
Page 6-16 90-881980R1 NOVEMBER 2001

GEAR HOUSING
4. Lift reverse gear, thrust bearing and thrust washer from bearing carrier. Replace thrust
bearing and thrust washer if rusted or damaged.
5. Replace reverse gear if gear teeth or clutch teeth on reverse gear are rounded or
chipped. If reverse gear must be replaced, pinion gear and sliding clutch should be in-
spected for damage.
19202
a - Reverse Gear
b - Thrust Bearing
c - Thrust Washer
6. If reverse gear radial bearing is rusted or does not roll freely, replace bearing. If neces-
sary, remove bearing using Slide Hammer (91-34569A1).
a
91-34569A1
19205
a - Radial Bearing
90-881980R1 NOVEMBER 2001 Page 6-17

GEAR HOUSING
7. If bearing is rusted or does not roll freely, replace bearing. If necessary, remove bearing and
oil seals using Mandrel* (91-36569) and Driver Rod* (91-37323). Discard oil seals.
NOTE: *From Bearing Removal and Installation Kit (91-31229A7).
91-36569
c
b
a
91-37323
58205
a - Bearing
b - Mandrel (91-36569)
c - Driver Rod (91-37323)
8. Remove (if not removed with bearing in Step 9) propeller shaft seals and bearing carrier
O-ring.
51263
a - O-ring
Page 6-18 90-881980R1 NOVEMBER 2001

GEAR HOUSING
9. Remove spring.
51876
a - Spring
10. Apply constant pressure to cam follower in order to prevent it and internal components
from ejecting out of the propeller shaft during removal of the cross pin from the clutch.
51800
a
a - Cross Pin
b - Cam Follower
90-881980R1 NOVEMBER 2001 Page 6-19

GEAR HOUSING
11. Remove components from propeller shaft.

12. Replace cam follower if worn or pitted.
13. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one or
more of the following:
• Improper shift cable adjustment.
• Engine idle speed too high while shifting.
• Shifting from neutral to reverse (or forward) too slowly.
a f c
b e d 51265
a - Cam Follower
b - Metal Balls (3)
c - Guide Block
d - Spring
e - Sliding Clutch
f - Jaws
14. Replace propeller shaft if any of the following exist:

• Splines are twisted or worn.
• Bearing surfaces of propeller shaft are pitted or worn.
• Oil seal surface is grooved.
• Shaft has a noticeable “wobble” or is bent more than 0.009 in. (0.228 mm). Prop
shaft trueness should be measured with a dial indicator with prop shaft on V-blocks.
c b b
51877
a - V-Blocks
b - Bearing Surfaces
c - Measure with Dial Indicator at This Point
Page 6-20 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Pinion Gear, Drive Shaft, and Forward Gear

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

40/50 Bigfoot (4-Stroke) 91-56775
50/60 Bigfoot (4-Stroke) 91-817070A1
75/90/115 EFI (4-Stroke) 91-804776A1
60 Bigfoot (2-Stroke) 91-56775
75/90/100/115/125 (2-Stroke) 91-56775
2. Remove drive shaft, pinion gear, pinion bearing and forward gear.
3. Replace pinion gear if it is chipped or worn.
4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing
does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following.
5. Replace forward gear if gear teeth or clutch teeth are chipped or worn.
a c
d
b
f
19175
a - Drive Shaft Holding Tool
b - Pinion Nut
c - Drive Shaft
d - Pinion Gear
e - Pinion Bearing
f - Forward Gear
90-881980R1 NOVEMBER 2001 Page 6-21

GEAR HOUSING
6. Replace forward gear needle bearing if it is rusted or does not roll freely.
7. Use suitable tools (screwdriver and awl) to remove retaining ring. Use a punch and ham-
mer to remove bearing.
57905 b
19203
a - Retaining Ring
b - Forward Gear Needle Bearing
8. Replace forward gear bearing and race if either are rusted, pitted or damaged; or if bear-
ing does not roll freely. Remove bearing from gear using Universal Puller Plate
(91-37241) and mandrel. To remove race, refer to “Forward Gear Bearing Race,” follow-
ing.
a c
91-37241
b
51119
a - Forward Gear Bearing

b - Universal Puller Plate (91-37241)
c - Mandrel
Page 6-22 90-881980R1 NOVEMBER 2001

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

10. If bearing surface is damaged, replace drive shaft and corresponding bearing.
IMPORTANT: On Do not tighten vise against drive shaft.
11. If wear sleeve is deeply grooved allowing water to enter gear case, remove (and discard)
sleeve using Universal Puller Plate (91-37241) and mallet.
91-37241
d e
75/90/115
4-stroke
c
a 19710
a - Crankshaft/Driveshaft Splines
b - Oil Pump Drive Splines 75/90 4-Stroke Only
c - Bearing Surface
d - Wear Sleeve
e - Universal Puller Plate (91-37241)
f - Mallet
12. Remove (and discard) rubber ring.

a
19152
a - Rubber Ring
90-881980R1 NOVEMBER 2001 Page 6-23

GEAR HOUSING
Upper Drive Shaft Bearing

1. Replace upper drive shaft bearing and sleeve if either are rust stained, or if bearing will
not roll freely. Remove bearing and then sleeve using Puller Assembly (91-83165M) with
suitable jaws.
c OR
91-83165M
a
b 19177
a - Upper Drive Shaft Bearing

b - Sleeve
c - Puller Assembly (91-83165M)
IMPORTANT: On Upper drive shaft bearing/sleeve must be removed prior to oil sleeve
removal. Refer to “Upper Drive Shaft Bearing,” preceding.
Page 6-24 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Oil Sleeve
1. Remove oil sleeve (if necessary) using Puller Assembly (91-83165M) with suitable jaws.
91-83165M
19222
a - Oil Sleeve
b - Puller Assembly (91-83165M)
90-881980R1 NOVEMBER 2001 Page 6-25

GEAR HOUSING
Lower Drive Shaft Bearing Race
IMPORTANT: On Upper drive shaft bearing/sleeve and oil sleeve do not have to be
removed for lower drive shaft bearing race removal.
IMPORTANT: On Retain shim(s) for reassembly.
1. Remove race and shim(s) using bearing race tool (91-14308A1).
91-14308A1
19171
a - Race
b - Shim(s)
c - Bearing Race Tool (91-14308A1)
Page 6-26 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Shift Shaft
1. Remove shift shaft coupler and nylon spacer.
53925
75 (2-Stroke) Tiller Model Shown

a - Shift Shaft Coupler
b - Spacer
2. Remove screws.
53926
a - Screws
NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing.
3. Remove shift shaft bushing and shift shaft.
a b
53927
a - Bushing
b - Shift Shaft
90-881980R1 NOVEMBER 2001 Page 6-27

GEAR HOUSING
4. Remove shift cam from housing.

5. Replace shift cam if worn.
60 (2-Stroke) Bigfoot Shown
a
51117
a - Shift Cam
6. Remove shift shaft bushing and clip from shift shaft.

7. Replace shift shaft if splines are worn or shaft is twisted.
8. Remove (and discard) O-ring.
a d
d c e
b
53928
a - Bushing
b - Clip
c - Shift Shaft
d - Splines
e - O-ring
9. Remove (and discard) seal. (Lightly clamp the bushing in a vise when removing seal)
a
53929
a - Seal
Page 6-28 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Forward Gear Bearing Race

IMPORTANT: On Retain shim(s) for reassembly. If shims are damaged, replace with
new shims of equal thickness.
1. Remove race and shim(s) using Slide Hammer (91-34569A1).
91-34569A1
b c
27653
a - Race
b - Shim(s)
c - Slide Hammer (91-34569A1)
Trim Tab Adjustment and Replacement

IMPORTANT: On The trim tab is now painted and does NOT aid in protecting the drive
shaft housing and gear housing from galvanic corrosion (corrosion and pitting of
metal surfaces). Side anodes now provide protection. Do not paint or place protec-
tive coating on the side anodes, or corrosion protection function will be lost.
1. Replace trim tab if damaged. Mark location of old trim tab on anti-ventilation plate before
removal; install new trim tab in same location.
2. The trim tab provides a means to offset (balance) some of the steering load that is
caused by propeller torque at higher operating speeds. If at higher speeds the boat turns
more easily to the left, loosen screw, move the trim tab (trailing edge) to the left (when
viewed from behind); retighten screw. Turn trim tab (trailing edge) to the right if the boat
turns more easily to the right. Torque retaining screw to specified torque.
c
b a 53931
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Screw and Washer
Retaining Screw Torque
22 lb-ft (30 Nm)
90-881980R1 NOVEMBER 2001 Page 6-29

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

19179
a - Shim(s) d - Disassembled Propeller
b - Race Shaft
c - Mandrel (91-31106) e - Assembled Bearing Carrier
Shift Shaft
1. Apply Loctite 271 Thread Lockeron O.D. of new seal.
2. Press seal into shift shaft bushing until seal is seated against shoulder.
3. Install new O-ring.
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
c a
7
d b
95
a - Seal c - Surface
b - Bushing d - O-ring
Page 6-30 90-881980R1 NOVEMBER 2001

GEAR HOUSING
5. Assemble components as shown.

a b
c 53928
a - Shift Shaft
b - “E” Clip
c - Shift Shaft Bushing
6. Install shift cam; align hole in shift cam with shift shaft pilot bore in gear housing.
60 Bigfoot, 75/90/100/115/125 (2-Stroke)
51117
a - Shift Cam (marked with “UP” and part number)

b - Shift Shaft Pilot Bore
60 Bigfoot, 75/90/100/115/125 (2-Stroke) & 75/90/115EFI (4-Stroke)
51117
a - Shift Cam (marked with part number only)
90-881980R1 NOVEMBER 2001 Page 6-31

GEAR HOUSING
40/50 Bigfoot (4-Stroke), 50/60 Bigfoot(4-Stroke)
850307
51117
a - Shift Cam (Numbers Down)

7. Install shift shaft assembly; insert splines into shift cam.
b
53932
a - Shift Shaft Assembly

b - Splines
8. Apply Loctite 271 to bottom half of threads on each screw. Install screws and torque to
specified torque.
53926

a - Screws (2)
Screw Torque
60 lb-in. (7 Nm)
Page 6-32 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Bearing Carrier Reassembly

1. Lubricate O.D. of bearing and bearing carrier bore with 2-4-C with Teflon.
2. Protect lip on forward side of bearing carrier, using bearing installation tool (91-13945).
3. Press propeller shaft needle bearing (number side toward mandrel 91-15755) into carri-
er, until bearing bottoms out.
95
91-15755
a
91-13945

21042
a - Bearing Installation Tool (91-13945)

b - Mandrel (91-15755)
c - Suitable Driver Rod
90-881980R1 NOVEMBER 2001 Page 6-33

GEAR HOUSING
4. Place smaller diameter seal on longer shoulder of Oil Seal Driver (91-31108) with seal
lip away from shoulder.
5. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Ap-
ply Loctite 271 on O.D. of seal. Press seal into carrier until tool bottoms.
b a 7
91-31108
91-13945
a - Seal
b - Oil Seal Driver (91-31108)
c - Bearing Installation Tool (91-13945)
6. Place larger diameter seal on shorter shoulder of Oil Seal Driver (91-31108) with seal
lip toward shoulder.
7. Protect lip on front side of bearing carrier using Bearing Installation Tool (91-13945). Ap-
ply Loctite 271 Thread Locker on O.D. of new seal. Press seal into carrier until tool bot-
toms.
b
a
7
91-31108
a
c
91-13945 21041
a - Seal
b - Oil Seal Driver (91-31108)
Page 6-34 90-881980R1 NOVEMBER 2001

GEAR HOUSING
8. Install O-ring. Lubricate O-ring with 2-4-C with Teflon. Lubricate seal lips with 2-4-C with
Teflon.
9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light
coating of 2-4-C with Teflon.
10. Press bearing into carrier until tool bottoms.
95
91-13945
19163
a - O-ring
b - Bearing, Numbered Side Toward Tool
11. Install thrust washer. Coat thrust washer with Premium Gear Lubricant.
87
19167
a - Thrust Washer
90-881980R1 NOVEMBER 2001 Page 6-35

GEAR HOUSING
12. Install thrust bearing. Coat thrust bearing with Premium Gear Lubricant.
87
19168
a - Thrust Bearing
13. Apply Premium Gear Lubricant to bearing surface of reverse gear and install reverse
gear.
87
19202

a - Reverse Gear
b - Bearing Surface
Page 6-36 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Forward Gear Reassembly

1. Apply Quicksilver 2-4-C with Teflon grease to the I.D. of the bearing. Press bearing onto
gear using suitable mandrel (press only on inner race of bearing). Because the gear hub
is longer than the bearing, a tube type mandrel should be used to install the bearing. This
will allow the bearing to bottom out on the gear.
95
a
51869
a - Mandrel (91-37350)
b - Bearing; Lubricate I.D. with 2-4-C with Teflon
2. Inspect reverse gear end of clutch to determine the number of jaws. Refer to chart, fol-
lowing, for tool end selection.
Model Installation End Bearing Position

Tool Stamped
3 Jaw Reverse 91-856875A 1 3 0.155 in. (3.94mm)
Clutch below surface
6 Jaw Reverse 91-856875A 1 6 Flush with surface
Clutch
FORWARD GEAR NEEDLE BEARING INSTALLATION

3 Jaw Reverse Clutch
c b
56783
a - Stamped “3”
b - Numbered end of Needle Bearing
c - 3 Jaw Reverse Clutch
90-881980R1 NOVEMBER 2001 Page 6-37

GEAR HOUSING
6 Jaw Reverse Clutch
c
a 56784
a - Stamped “6”
b - Numbered end of Needle Bearing
c - 6 Jaw Reverse Clutch
3. Apply Premium Gear Lubricant to I.D. of forward gear, and O.D. of needle bearing. Press
needle bearing into forward gear (using forward gear bearing installer tool) until tool bot-
toms out on gear.
a
87
b
91-877321A1

a - Forward Gear Bearing Installer (91-877321A1)
b - Needle Bearing, Numbered Side Toward Installer Tool
4. Install retaining ring into groove of forward gear by starting at one end of retaining ring
and working it around until seated in groove.
a
57905
a - Retaining Ring
b - Groove in Forward Gear
Page 6-38 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Propeller Shaft Reassembly

1. Install components into propeller shaft in sequence shown.
NOTE: When installing the clutch make sure the ratcheting clutch teeth (angled) are toward
forward gear, and non-ratcheting (square on both sides) are toward reverse gear.
e f g b
d c a 51265
Assembly Sequence
a - Spring
b - Guide Block
c - Clutch
d - 3 Metal Balls
e - Cam Follower
f - Forward Clutch Teeth
g - Reverse Clutch Teeth
2. Align the hole in the clutch with the hole in the guide block, install cross pin.
b a
51800
a - Apply Pressure in This Direction
b - Cross Pin
90-881980R1 NOVEMBER 2001 Page 6-39

GEAR HOUSING
3. Install spring. DO NOT allow spring coils to overlap each other.
51876
a - Spring
Drive Shaft Wear Sleeve Installation

1. Install new rubber ring.
2. Apply a light coat of Loctite 271 Thread Locker on outside diameter of rubber ring.
a
19152

a - Ring
3. Insert sleeve into holder*.

*Component of Wear Sleeve Installation Tool (91-14310A1).
a
a
91-14310A1
19169
a - Sleeve
b - Holder
Page 6-40 90-881980R1 NOVEMBER 2001

GEAR HOUSING
4. Press sleeve onto drive shaft using Wear Sleeve Installation Tool (91-14310A1); contin-
ue pressing until the upper and lower part of the tool make surface to surface contact.
91-14310A1
b a
d
19166
a - Drive Shaft
b - Wear Sleeve Installation Tool (91-14310A1)
c - Upper part of tool (Surface C)
d - Lower part of tool (Surface D)
5. Remove excess Loctite from assembled shaft.
90-881980R1 NOVEMBER 2001 Page 6-41

GEAR HOUSING
Lower Drive Shaft Bearing Race Installation

1. Lubricate O.D. of bearing race with 2-4-C with Teflon.
2. Install shim(s) and bearing race into housing.
NOTE: Verify shim(s) are not cocked when drawing up race. Once shims and bearing cup
are in place, position gearcase assembly so the driveshaft is vertical. This will aid in prevent-
ing the bearing cup from becoming cocked in the bore.
f e
a
91-14309A1
b
95
c
a - Shim(s); Retained From Disassembly. If Shim(s) Were Lost or a New Gear

Housing is Being Assembled, Start With 0.025 in. (0.635 mm) Shim(s)
b - Bearing Race
c - Mandrel* (13780)
d - Mandrel* (13781)
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)
**From Bearing Removal and Installation Kit (91-31229A7)
Page 6-42 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Oil Sleeve Installation

1. Install oil sleeve with tab positioned as shown.
53934
a - Oil Sleeve
b - Tab
Upper Drive Shaft Bearing Installation

1. Lubricate I.D. of bearing sleeve and O.D. of bearing with 2-4-C with Teflon.
2. Press bearing into sleeve using mandrel from bearing installation tool (91-14309A1).
c 91-13781
95
a
2-4-C with Teflon 19164

95
a - Bearing Sleeve
b - Tapered End
c - Bearing; Numbered Side Toward Mandrel
d - Mandrel (91-13781); From Bearing Installation Tool (91-14309A1)
90-881980R1 NOVEMBER 2001 Page 6-43

GEAR HOUSING
3. Install bearing/sleeve into housing.

IMPORTANT: On Oil sleeve must be installed prior to upper driveshaft bearing instal-
lation.
IMPORTANT: On Lower driveshaft bearing cup pilots the mandrel (13780) during
installation of the upper driveshaft bearing/sleeve. Lower bearing cup must be
installed prior to installing upper bearing/sleeve.
f
c
a
e
91-14309A1
58206
a - Bearing/Sleeve
b - Tapered End Of Sleeve
c - Mandrel* (13781)
d - Mandrel* (13780)
e - Threaded Rod** (91-31229)
f - Nut** (11-24156)
*From Bearing Installation Tool (91-14309A1)
**From Bearing Removal and Installation Kit (91-31229A7)
Page 6-44 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Forward Gear, Lower Drive Shaft Bearing, Pinion Gear, and Drive Shaft
Installation
1. Install components per assembly sequence shown.
e d
b
87
c
f
a
7
Assembly Sequence:
a - Forward Gear/Bearing: Work Premium Blend gear lube into bearing rollers.
b - Lower Drive Shaft Tapered Roller Bearing: Work Premium Blend Gear Lube
into bearing rollers.
c - Pinion Gear
d - Drive Shaft
e - Drive Shaft Holding Tool
f - Pinion Nut (New): Clean nut and driveshaft threads with Loctite Primer or suit-
able de-greaser. Apply Loctite 271 Thread Locker to threads (not necessary if
using a new nut with drylock patch on threads) during final assembly (after
pinion gear depth and forward gear backlash have been set), tighten to speci-
fied torque.
Model Drive Shaft Holding Tool
40/50 Bigfoot (4-Stroke) 91-56775
50/60 Bigfoot (4-Stroke) 91-817070A1
75/90/115EFI (4-Stroke) 91-804776A1
60 Bigfoot/75/90/100/115/125
91-56775
(2-Stroke)
Pinion Nut Torque

70 lb-ft (95 Nm)
90-881980R1 NOVEMBER 2001 Page 6-45

GEAR HOUSING
Pinion Gear Depth and Forward Gear Backlash

DETERMINING PINION GEAR DEPTH
NOTE: Read entire procedure before attempting any change in shim thickness.
IMPORTANT: On Forward gear assembly pilots the end of the pinion gage and must
be installed in gear housing when checking pinion gear depth. Without it, an inaccu-
rate measurement will be obtained.
1. Clean the gear housing bearing carrier shoulder and diameter.
2. With gear housing positioned upright (drive shaft vertical), install Bearing Preload Tool
(91-14311A2) over drive shaft in sequence shown.
g
h h
e c
b
f
a
d
a - Adaptor: Bearing surfaces clean and free of nicks

b - Thrust Bearing: Oiled and able to move freely
c - Thrust Washer: Clean and free of nicks and bends
d - Spring
e - Nut: Threaded all-the-way onto screw
f - Screw: Held snug against spring
g - Sleeve: Holes in sleeve must align with set screws
h - Set Screw (2): Tightened against drive shaft, screw should not slide on drive
shaft.
3. Measure distance between top of nut and bottom of screw head.

4. Increase distance by 1 in. (25.4 mm).
5. Rotate drive shaft 5 to 10 revolutions. This should properly seat drive shaft tapered roller
bearing.
a
c
19884
a - 1 in. (25.4 mm) c - Screw Head
b - Nut
Page 6-46 90-881980R1 NOVEMBER 2001

GEAR HOUSING
6. Assemble Pinion Gear Locating Tool (91-12349A2) as shown; do not tighten collar retain-
ing screw at this time.
b d e
a c f
a - Arbor d - Split Collar

b - Gauging Block; Install With e - Screw; Collar Retaining
Numbers Away From Split Collar f - Snap Ring
c - Screw; Gauging Block Retaining
7. Insert tool into forward gear assembly; position gauging block under pinion gear as
shown.
22067
a - Gauging Block
8. Remove tool, taking care not to change gauging block position, and tighten collar retain-
ing screw.
9. Insert tool into forward gear assembly; position proper numbered flat (from chart) of
gauging block – under pinion gear.
MODEL GEAR RATIO (PINION GEAR USE FLAT NO. LOCATING DISC NO.
TEETH/REVERSE GEAR TEETH)
40/50 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3
50/60 Bigfoot (4-stroke) 2.31:1 (13/30) 8 3
75/90/115EFI (4-stroke) 2.07:1 (14/29) 2 3
60 Bigfoot/60 Seapro 2.31:1 (13/30) 8 3
60 Marathon
75-thru-90 2.31:1 (13/30) 8 3
(3 Cylinder)
100/115/125 2.07:1 (14/29) 2 3
(4 Cylinder)
90-881980R1 NOVEMBER 2001 Page 6-47

GEAR HOUSING
10. Install locating disc against bearing carrier shoulder in gear housing.
11. Position access hole as shown.
Disc 3
a
24643
a - Locating Disc
b - Access Hole
12. Determine pinion gear depth by inserting a feeler gauge through access hole in locating
disc.
13. The correct clearance between gauging block and pinion gear is 0.025 in. (0.64 mm).
14. If clearance is correct, leave Bearing Preload Tool on drive shaft and proceed to “Deter-
mining Forward Gear Backlash,” following.
15. If clearance is more than 0.025in. (.064mm) add shims behind the bearing race. If clear-
ance is less than 0.025in. (.064mm) remove shims from behind the bearing race. When
reinstalling pinion nut, apply Loctite 271 Thread Locker on threads of nut.
NOTE: Clean driveshaft and pinion nut threads with Loctite Primer or suitable de-greaser
before applying Loctite.
d c
a
7 b
24643
a - Feeler Gauge
b - Gauging Block
c - Pinion Gear
d - Bearing Race
Page 6-48 90-881980R1 NOVEMBER 2001

GEAR HOUSING
DETERMINING FORWARD GEAR BACKLASH

NOTE: Read entire procedure before attempting any change in shim thickness.
1. Obtain correct pinion gear depth; refer to “Determining Pinion Gear Depth,” preceding.
2. Install Bearing Preload Tool (91-14311A2) on drive shaft; refer to “Determining Pinion
Gear Depth,” preceding.
4. While holding the driveshaft, tighten the puller bolt to specified torque.
5. Rotate driveshaft 5-10 revolutions. This should properly seat the forward gear tapered
roller bearing. Repeat step 4.
d a b
c
53936
a - Propeller Shaft*
b - Bearing Carrier* (Assembled)
c - Puller Jaws (91-46086A1)
d - Puller Bolt (91-85716)
Puller Bolt Torque
45 lb-in. (5 Nm)
*Refer to “Bearing Carrier and Propeller Shaft Installation,” following.
90-881980R1 NOVEMBER 2001 Page 6-49

GEAR HOUSING
e f
d c
a g
b c 51117
a - Threaded Rod (Obtain Locally)
b - Washers
c - Nuts
d - Dial Indicator Adaptor Kit (91-83155)
e - Dial Indicator (91-58222A1)
f - Backlash Indicator Tool
g - Pre-Load Tool Screw Head
7. Position Dial Indicator on appropriate line (from chart below) marked on Backlash Indi-
cator Tool. Make sure the dial indicator is perpendicular (⊥) to the indicator tool or an
inaccurate reading will be obtained.
BACKLASH INDICATOR ALIGN POINTER OF DIAL

MODEL TOOL INDICATOR WITH MARK
40/50 Bigfoot (4-stroke) 91-78473 4
50/60 Bigfoot (4-stroke) 91-78473 4
75/90/115EFI (4-Stroke) 91-19660--1 1
60 Seapro/60 Marathon
4
60 Bigfoot 91-78473
75-thru-90
4
(3 Cylinder) 91-78473
100/115/125
1
(4 Cylinder) 91-19660--1
Page 6-50 90-881980R1 NOVEMBER 2001

GEAR HOUSING
8. Grasp the driveshaft pre-load tool bolt head and lightly turn drive shaft back-and-forth
(no movement should be noticed at propeller shaft).
9. Dial Indicator registers amount of backlash, which must be between specification shown
in chart.
MODEL DIAL INDICATOR MINIMUM READING MAXIMUM
40/50 Bigfoot 0.012 in. 0.019 in.
(4-Stroke) (0.30 mm) (.48 mm)
50/60 Bigfoot 0.012 in. 0.019 in.
(4-Stroke) (0.30 mm) (.48 mm)
75/90/115EFI 0.013 in. 0.019 in.
(4-Stroke) (0.38 mm) (.55 mm)
0.012 in. 0.019 in.
60 Bigfoot
(0.30 mm) (.48 mm)
75-thru-90 0.012 in. 0.019 in.
(3 Cylinder) (0.30 mm) (.48 mm)
100/115/125 0.013 in. 0.019 in.
(4 Cylinder) (0.38 mm) (0.55 mm)
10. If backlash is less than the minimum specification, remove shim(s) from in front of for-
ward gear bearing race. If backlash is more than the maximum specification, add
shim(s) in front of forward gear bearing race. When reinstalling pinion nut, apply Loctite
271 on threads of nut.
NOTE: By adding or subtracting 0.001 in. (0.025 mm) shim, the backlash will change
approximately 0.001 in.
Bearing Carrier and Propeller Shaft Installation

1. Insert propeller shaft assembly into bearing carrier.
2. Before installing bearing carrier assembly into gear housing, obtain locally a 6 in. (152.4
mm) long by 1-1/4 in. - 1-1/2 in. (31.7 - 38.1 mm) diameter piece of PVC pipe. Install the
PVC pipe over the prop shaft and secure the pipe against the bearing carrier assembly
with the propeller nut and tab washer. This holds the reverse gear and thrust bearing
tight against the bearing carrier preventing possible bearing damage during installation.
a b
c
d
e 21043
a - Bearing Carrier Assembly d - Prop Shaft
b - PVC Pipe e - Tab Washer
c - Propeller Nut
90-881980R1 NOVEMBER 2001 Page 6-51

GEAR HOUSING
3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with
2-4-C with Teflon.
4. Install bearing carrier and propeller shaft into housing with the word “TOP” (located on
flange) toward top of housing.
a
b
95
21044
a - O-ring b - TOP
NOTE: Use thick 0.090 in. (2.29mm) washers (12-855941) under fasteners if not previously
installed.
Washer Thickness Fastener Torque

0.090 in. (2.29mm) 22 lb-ft (29.8 Nm)
0.060 in. (1.53mm) 25 lb-ft (33.9 Nm)
b
a
a - Washers
b - Fasteners (If using Screws - Apply Loctite 271 Thread Locker on Threads)
Page 6-52 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Water Pump Reassembly and Installation

1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver (91-13949)
with seal lip away from shoulder.
2. Apply Loctite 271 Thread Locker on O.D. of seal; press seal into water pump base until
tool bottoms.
91-13949
7
a b
51553
a - Seal - Lip Faces Toward Power Head

b - Spring - Faces Toward Power Head (when base is installed on gearcase)
c - Oil Seal Driver (91-13949)
d - Longer Shoulder Side of Tool
e - Shorter Shoulder Side of Tool
90-881980R1 NOVEMBER 2001 Page 6-53

GEAR HOUSING
3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver (91-13949)
with seal lip toward shoulder.
4. Apply Loctite 271 Thread Locker on O.D. of seal; press seal into water pump base until
tool bottoms.
5. Lubricate lip of each seal with 2-4-C with Teflon.
91-13949
95
c
a b
7
a - Seal - Lip Faces Toward Gear Case

b - Spring - Faces Toward Gear Case
c - Oil Seal Driver (91-13949)
d - Longer Shoulder Side of Tool
e - Shorter Shoulder Side of Tool
6. Install gasket.
19218
a - Gasket
Page 6-54 90-881980R1 NOVEMBER 2001

GEAR HOUSING
IMPORTANT: On To prevent cutting the seal lips remove any burrs or sharp edges
from the driveshaft splines before installing water pump base assembly.
7. Install components as shown. Apply Loctite 271 Thread Locker on bottom half of threads
and tighten to specified torque in sequence shown.
a 3 1 5
b
2
6
4
a - Water Pump Base

b - Screws (6) M6 x 1 and Washers (6)
Screw Torque
60 lb-in. (7 Nm)
8. Install gasket and plate.

b
19219
a - Gasket
b - Plate
IMPORTANT: On If the old impeller is re-used it must be installed in original (clock-

wise) direction of rotation.
9. Install gasket, drive key and impeller.
b
a
19220
a - Gasket c - Impeller
b - Drive Key
90-881980R1 NOVEMBER 2001 Page 6-55

GEAR HOUSING
10. Lubricate I.D. of cover with 2-4-C with Teflon.

11. Rotate drive shaft clockwise and push impeller housing down (over impeller) until it con-
tacts water pump base.
12. Install cover screws and torque to specified torque.
95 a b
b
19212

a - Impeller Housing b - Screws (4); Apply Loctite 271 on Threads
Screw Torque
60 lb-in. (7 Nm)
NOTE: It is recommended that the gearcase be pressure tested for leaks after reassembly
and BEFORE gear lube is added. Gearcase should hold 10-12 psi (69-83 kPa) for 5 min-
utes.
Gear Housing Pressure Test

1. Remove vent plug and install pressure test gauge.
2. Pressurize housing to 10-12 psi (69-83 kPa) and observe gauge for 5 minutes.
3. Rotate drive shaft, prop shaft and move shift shaft while housing is pressurized to check
for leaks.
Page 6-56 90-881980R1 NOVEMBER 2001

GEAR HOUSING
4. If pressure drop is noted, immerse housing in water.

5. Re-pressurize to 10-12 psi (69-83 kPa) and check for air bubbles.
6. Replace leaking seals as necessary. Retest housing.
NOTE: Gearcase should hold 10-12 psi (69-83 kPa) for 5 minutes.
7. Remove tester from housing and install vent plug and sealing washer.
Filling Gear Housing With Lubricant

NOTE: Gear housing lubricant capacity is 24 fl oz (710 mL).
WARNING
If gear housing is installed on engine, to avoid accidental starting, disconnect (and
isolate) spark plug leads from spark plugs before working near the propeller.
CAUTION
Do not use automotive grease in the gear housing. Use only Premium Blend Gear
Lubricant.
1. Remove any gasket material from “Fill/Drain” and “Vent” screws and gear housing.
2. Install new sealing washer on “Fill/Drain” and “Vent” screws.
IMPORTANT: On Never apply lubricant to gear housing without first removing “Vent”
screws or gear housing cannot be filled because of trapped air. Fill gear housing only
when driveshaft is in a vertical position.
3. Remove lubricant “Fill/Drain” screw and sealing washer from gear housing.
4. Insert lubricant tube into “Fill” hole, then remove “Vent” screws and sealing washer.
5. Fill gear housing with lubricant until excess starts to flow out of one (first) “Vent” screw
hole.
6. Install this “Vent” screw and sealing washer only and continue filling until excess starts
to flow out of second “Vent” screw hole.
7. Rotate driveshaft clockwise approximately 10 revolutions. Let gearcase sit for at least
one minute to allow any trapped air to settle out, then top off lubricant level.
90-881980R1 NOVEMBER 2001 Page 6-57

GEAR HOUSING
a c
b
53922
a - Vent Screw - Tighten to specified torque

b - Fill/Drain Screw - Tighten to specified torque
c - Oil Level Vent Screw - Tighten to specified torque
Vent Screw, Fill/Drain Screw, Oil Level Vent Screw Torque
60 lb-in. (7 Nm)
8. Replace second lubricant “Vent” screw and sealing washer.

IMPORTANT: On Do not lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling “FILL/DRAIN” screw.
9. Remove lubricant tube from Fill/Drain hole; install Fill/Drain screw and sealing washer.
Gearcase Installation
WARNING
Disconnect (and isolate) spark plug leads from spark plugs before installing gear
housing onto drive shaft housing. Failure to follow this warning could result in acci-
dental engine starting and possible injury.
1. Position outboard shift linkage into forward gear position.
Models 40-60 Bigfoot (4-Stroke)
Remote Control Model Shown

a - Shift Lever
Page 6-58 90-881980R1 NOVEMBER 2001

GEAR HOUSING
Models 60 Bigfoot (2-Stroke)
a
a - Shift Block
Models 75/90/100/115/125 (2-Stroke)

a b
19879
a - Shift Block; Front of Block MUST Extend 1/8 in. (3.2 mm) Past Front of Rail.
b - Rail
Models 75/90/115EFI (4-Stroke)
F N R
a
a - Shift Block
2. Tilt engine to full up position and engage tilt lock lever.

3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direc-
tion.
90-881980R1 NOVEMBER 2001 Page 6-59

GEAR HOUSING
4. Install water tube seal; apply 2-4-C with Teflon to I.D. of seal.
5. Apply a bead of RTV Sealer as shown.
NOTE: For ease of gear housing installation, install water tube seal (labyrinth end) onto
water tube in drive shaft housing. Tapered end of water tube seal goes onto water pump.
95
b 85
85 RTV Silicone Sealer

a - Water Tube Seal b - RTV Sealer
CAUTION
Do not use lubricant on top of drive shaft. Excess lubricant, that is trapped in clear-
ance space, will not allow drive shaft to fully engage with crankshaft. Subsequently,
tightening the gear housing fasteners (while lubricant is on top of drive shaft) will
load the drive shaft/crankshaft and damage either or both the power head and gear
housing. Top of drive shaft is to be wiped free of lubricant.
6. Apply a light coat of 2-4-C with Teflon onto drive shaft splines.
7. Apply a light coat of 2-4-C with Teflon on gear case shift shaft splines and upper shift
shaft splines. Do not use lubricant on ends of shift shafts.
8. Install components as shown in appropriate photo.
ALL MODELS EXCEPT 75 (2-STROKE) W/MECHANICAL REVERSE LOCK
a - Nylon Spacer c - Bushing 40-60 Bigfoot 4-Stroke Only

b - Shift Shaft Coupler
Page 6-60 90-881980R1 NOVEMBER 2001

GEAR HOUSING
75 (2-STROKE) W/MECHANICAL REVERSE LOCK

a b
53925
a - Nylon Spacer
b - Shift Shaft Coupler
c - Flat; MUST BE Positioned Toward Front of Gear Housing
9. Shift gear housing into forward gear position. In forward gear the gear housing will ratch-
et when propeller shaft is turned clockwise. Resistance will be felt when propeller shaft
is rotated counterclockwise.
10. Apply Loctite 271 Thread Locker on threads of gear housing retaining screws.
90-881980R1 NOVEMBER 2001 Page 6-61

GEAR HOUSING
CAUTION
Use limited force when inserting the lower unit driveshaft into the oil pump. The oil
pump lower seal is exposed and the driveshaft is not piloted to the center of the oil
pump splines. Excessive force on contact by the driveshaft may damage the seal.
NOTE: During installation of gear housing, it may be necessary to move the shift block (lo-
cated under cowl) slightly to align upper shift shaft splines with shift shaft coupler splines.
NOTE: On 4-Stroke models. If, while performing Step 11, the drive shaft splines will not
align with the oil pump splines, place a propeller onto propeller shaft and turn it counterclock-
wise as the gear housing is being pushed toward drive shaft housing. Continue rotating the
propshaft until the driveshaft splines align with the crankshaft splines.
IMPORTANT: On 4-Stroke models, when removing or installing gearcase, carefully
guide driveshaft through driveshaft bushing to avoid scoring bushing surface.
5928
9
95
a b
a - Centerline of Oil Pump and Driveshaft Misaligned.

b - Centerline of Oil Pump and Driveshaft Aligned.
11. Position gear housing so that the driveshaft is protruding into driveshaft housing.
12. Move gear housing up toward driveshaft housing, while aligning upper shift shaft splines
with shift shaft coupler splines, water tube with water tube seal, and crankshaft splines/
oil pump splines with driveshaft splines.
Page 6-62 90-881980R1 NOVEMBER 2001

GEAR HOUSING
13. Install 4 fasteners and washers (two each side).

14. Install locknut and washer.
15. Torque screws and locknut (or nuts only if applicable) to specified torque.
7
b a
53922
a - Fasteners and Washers (2 Each Side)
b - Locknut and Washer
Screw or Nut Torque
40 lb-ft (54 Nm)
16. Check shift operation as follows:

• Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is
turned clockwise. Resistance should be felt when propeller shaft is turned counter-
clockwise.
• Place shift lever in neutral. Propeller shaft should rotate freely in either direction.
• While rotating propeller shaft, place shift lever in reverse gear. Resistance should be
felt when propeller shaft is rotated in either direction.
IMPORTANT: On If shift operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
90-881980R1 NOVEMBER 2001 Page 6-63

GEAR HOUSING
Trim Tab Adjustment

1. Check trim tab position as follows:
• Operate boat at the speed at which it normally would be operated.
• If the boat pulls to the right (STARBOARD), the trailing edge of trim tab must be
moved to the right. If the boat pulls to the left (PORT), the trailing edge of trim tab
must be moved to the left.
2. If necessary, adjust trim tab as follows:
• Shift engine control into NEUTRAL and turn ignition key to “OFF” position.
NOTE: Loosen trim tab screw sufficiently to allow trim tab to disengage from locking ridges
in gear case before attempting to move tab. DO NOT strike trim tab with a hard object to
make adjustments.
• If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the
right, adjust trailing edge of trim tab to the right.
3. Tighten trim tab retaining screw and washer to specified torque.
c
b a 53931
a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Screw and Washer
Retaining Screw Torque
22 lb-ft (30 Nm)
Page 6-64 90-881980R1 NOVEMBER 2001

THROTTLE/SHIFT LINKAGE
ATTACHMENTS/CONTROL LINKAGE
Section 7 - Throttle/Shift Linkage
Table of Contents
Throttle Lever and Linkage . . . . . . . . . . . . . . . 7-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Throttle Lever and Linkage Removal . . . . . . . 7-4 Shift Bracket Removal/Installation . . . . . . . . . 7-5
90-881980R1 NOVEMBER 2001 Page 7-1

Throttle Lever and Linkage
95
6
2 7
3
8
5
95
4
9
10
5
11
13
12
Page 7-2 90-881980R1 NOVEMBER 2001

Throttle Lever and Linkage

TORQUE
REF.
REF
1 1 THROTTLE LEVER
2 1 WASHER
3 1 WAVE WASHER
4 1 NUT 70 7.9
5 2 COLLAR
6 1 WASHER
7 1 SPRING
8 1 THROTTLE CONTROL LEVER
9 1 WASHER
10 1 WAVE WASHER
11 1 BOLT (M6 X 30 MM) 70 7.9
12 1 WASHER
13 1 COTTER PIN
90-881980R1 NOVEMBER 2001 Page 7-3

Throttle Lever and Linkage Removal

1. Remove intake silencer. Refer to Section 3C.
2. Remove throttle control lever mounting screw.
4. Remove accelerator cam nut.
i
95
LT
g
d
c
d
c
f
95
e
4020
b
a
b - Collar (2)
c - Wave Washer (2)
d - Washer (3)
f - Spring
g - Accelerator Cam Nut
h - Accelerator Cam
i - Stud Bolt
Installation
1. Reassemble components as shown above. Tighten screw to specified torque.
Throttle Control Lever Mounting Screw/Nut Torque

70 lb-in. (8 Nm)
Page 7-4 90-881980R1 NOVEMBER 2001

Shift Bracket Removal/Installation

1. Remove/install shift bracket as shown.
h g f
i d
c
b b
58568
e
a
a - Shift Bracket f - Switch

b - Screw (3) M6 x 20 g - Screw (2)
c - Retainer h - Cotter Pin
d - Latch i - Shift Slide
e - Shift Link
Shift Bracket Screw Torque
80 lb-in. (9 Nm)
NOTE: Refer to section “1D-Outboard Installation” for proper installation of shift and
throttle cables.
90-881980R1 NOVEMBER 2001 Page 7-5

COLOR DIAGRAMS
COLOR DIAGRAMS
Table of Contents
115 EFI (4-Stroke) 2002 Model Year 115 EFI (4-Stroke) 2001 Model Year
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-3 Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . Page 8-9
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . Page 8-5 Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . Page 8-11
Typical Gauges with Tach Signal Converter Page 8-7 Water Flow Diagram . . . . . . . . . . . . . . . . . . . . Page 8-13
90-881980R1 NOVEMBER 2001 Page 8-1

COLOR DIAGRAMS
Page 8-2 90-881980R1 NOVEMBER 2001

COLOR DIAGRAMS
115 4-STROKE EFI

COLOR WIRING DIAGRAM
2002 MODEL YEAR
90-881980R1 NOVEMBER 2001 Page 8-3

115 4-STROKE EFI WIRING DIAGRAM
2002 MODEL YEAR
1. Cowl Mounted Trim Switch
2. Starter and Solenoid
3. Starter Relay
4. Main Relay
5. Engine Water Temperature Sensor
6. Stator
7. Voltage Regulator/Rectifier
8. Ignition Coil 2 & 3
10. Not Used
11. Malfunction Indicator Lamp (MIL) Connections
12. Idle Air Control (IAC)
13. Fuel Pump
14. Injector 1
15. Injector 2
16. Injector 3
17. Injector 4
18. Oil Pressure Switch
19. Shift Position Switch
20. Manifold Absolute Pressure Sensor (MAP)
21. Throttle Position Sensor (TPS)
22. Engine Air Temperature Sensor
23. Crankshaft Position Sensor (CPS)
24. ECM
25. Remote Control Wiring From Boat
26. Adapter Harness
27. Engine Harness Connection
28. Trim Relay
29. To 12 Volt Battery
30. Main Relay Fuse 20 Amp
31. Trim System, Key Switch Fuse 20 Amp
32. Charging System Fuse 30 Amp
33. Starter Relay Fuse 30 Amp
S QT QU QV QW QY
T QS RQ RR
U
X Y QR
RP
V QP QQ QX
R
RS
SS
SR
Q QS
Q
SQ
SP
RT
QR RT
RX
RU SQ
SP SV
RY
RW RV
RU
UYRWU
COLOR DIAGRAMS
115 4-STROKE EFI

COLOR WIRING DIAGRAM
2001 MODEL YEAR
90-881980R1 NOVEMBER 2001 Page 8-5

115 4-STROKE EFI WIRING DIAGRAM
2001 MODEL YEAR
1. Cowl Mounted Trim Switch
2. Starter and Solenoid
3. Starter Relay
4. Main Relay
5. Engine Water Temperature Sensor
6. Stator
7. Voltage Regulator/Rectifier
10. Not Used
11. Malfunction Indicator Lamp (MIL) Connections
12. Plug Cap
13. Idle Air Control (IAC)
14. Fuel Pump
15. Injector 1
16. Injector 2
17. Injector 3
18. Injector 4
19. Oil Pressure Switch
20. Shift Position Switch
21. Manifold Absolute Pressure Sensor (MAP)
22. Throttle Position Sensor (TPS)
23. Engine Air Temperature Sensor
24. Crankshaft Position Sensor (CPS)
25. ECM
26. Remote Control Wiring From Boat
27. Adapter Harness
28. Engine Harness Connection
29. Trim Relay
30. To 12 Volt Battery
31. Main Relay Fuse 20 Amp
32. Trim System, Key Switch Fuse 20 Amp
33. Charging System Fuse 30 Amp
34. Starter Relay Fuse 30 Amp
QT QU QV QW QX
S T RP RR RS
U QS
X Y
RQ
V QP QY
R QR
RT
QQ
ST
SS
Q
SR
SQ
RU
RY
RX RW
SP
RV
UXVSP
COLOR DIAGRAMS
115 4-STROKE EFI

TYPICAL GAUGES
WITH TACH SIGNAL CONVERTER
2002 MODEL YEAR
90-881980R1 NOVEMBER 2001 Page 8-7

115 EFI (4-STROKE) TYPICAL GAUGES
WITH TACH SIGNAL CONVERTER 2002 MODEL YEAR
1. MPC 4000
2. Neutral Lock Button
3. Trim Switch
4. Throttle Only Button
5. Lanyard Stop Switch
6. Lanyard stop switch leads must be soldered and covered with shrink tube for a water proof connection.
If alternate method of connection is made (use of electrical butt connector) verify connection is secure
and seal for moisture proof connection.
7. Trim Harness Connection
8. Connect wires together with screw and hex nut (2 places); apply Quicksilver Liquid Neoprene to con-
nections and slide heat shrink tubing over each connection.
9. Key Switch
10. 5–Pin Tachometer Harness Connector
11. Warning Horn
12. Speedometer
13. Temperature Gauge
14. Trim Position Gauge
15. Tachometer
16. Light Switch Connection
17. Tachometer Signal Converter (required for correct tachometer operation)
18. To Warning Light ( if equipped)
19. To Trim Sender (if equipped)
20. To Engine Trim Harness Connections
21. To Temperature Sensor (if equipped)
22. Remote Control Harness Connection
Q
QS
R
S g
s i
QV
QU
ltN
calN
T
QT
grdN Up
Tp Vp
Xc
U QR Sp
g Vc
Rp
Tc
s i ignN sendN
W
X
QW
RR RQ
RP
c b
QY
d e a
QX
QP
QQ
COLOR DIAGRAMS
115 4-STROKE EFI

FUEL FLOW DIAGRAM
2002 MODEL YEAR
90-881980R1 NOVEMBER 2001 Page 8-9

115 4-STROKE EFI FUEL FLOW DIAGRAM
2002 MODEL YEAR
1. From Boat Fuel Tank
2. Fuel Filter Assembly
3. Fuel Pump
4. Vapor Separator Tank (VST) ”Low–pressure In”
5. Vapor Separator Tank (VST) ”High–pressure Out”
6. Fuel Rail
7. Filter
8. Fuel Injectors
9. Fuel Pressure Regulator
10. Fuel Return (to Fuel Cooler)
11. Fuel Pressure Regulator Vent (to Intake Manifold)
12. Fuel Cooler
13. Vapor Separator Tank (VST) ”Fuel Return”
14. Vapor Separator Tank (VST) Vent (to Adapter Plate)
15. Float Valve Assembly
16. Filter
17. High Pressure Fuel Pump
18. Check Valve
90-881980 DECEMBER 2001 Page 8-10

Y
T QT
U QQ
QQ
QU QX
QP
T
QP
QW
QS QV U
W ATER
FU EL
QR W
X
QS
W
X
R
W X
S
X
Q W
COLOR DIAGRAMS
115 4-STROKE EFI

OIL FLOW DIAGRAM
2002 MODEL YEAR
90-881980R1 NOVEMBER 2001 Page 8-11

115 4-STROKE EFI OIL FLOW DIAGRAM
2002 MODEL YEAR
1. Sump
2. Oil Pick-up
3. Adapter Plate
4. Oil Pump and Pressure Regulator
5. Cylinder Block with oil passages
6. Oil Filter
7. Crankshaft with oil passages
8. Cylinder Head with oil passages
9. Camshafts
10. Oil drains from head to block
11. Oil in block drains through adapter plate back to the sump.
5
8
7
6
11
10
1
COLOR DIAGRAMS
115 4-STROKE EFI

WATER FLOW DIAGRAM
2002 MODEL YEAR
90-881980R1 NOVEMBER 2001 Page 8-13

115 4-STROKE EFI WATER FLOW DIAGRAM
2002 MODEL YEAR
1. Water Inlet
2. Water Pump
3. Driveshaft Housing
4. Water Tube
5. Oil Sump
6. Adapter Plate
7. Cylinder Block
8. Cylinder Head
9. Thermostat
10. Water Jacket Cover and Pressure Relief Valve
11. Fuel Cooler
12. Tee Fitting
13. Tell-Tale
14. Driveshaft Bushing
Y
QP
QQ
QR
QT
QS
QT

115 HP 4T PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

115 HP 4T PDF

Uploaded by

Copyright:

Available Formats

Srvc Man - ME 115 EFI FS 12/12/01 1:25 PM Page 1

115 FourStroke EFI

90-881980R1 NOVEMBER 2001

Starting Model Year 2001

Notice to Users of This Manual

90-881980R1 NOVEMBER 2001 Page i

Cleanliness and Care of Outboard Motor

90-826148R1 JANUARY 1996 Page 6A-7

Revision No. 1 Section Number

Month of Printing Part of Section Letter

Year of Printing Page Number

Page ii 90-881980R1 NOVEMBER 2001

90-881980R1 NOVEMBER 2001 Page iii

Models 115 EFI (4-Stroke)

+100 +38 Use Mercury/Quicksilver 4-Cycle Ma-

90-881980R1 NOVEMBER 2001 Page 1A-1

Page 1A-2 90-881980R1 NOVEMBER 2001

Reset Pressure and Closed

90-881980R1 NOVEMBER 2001 Page 1A-3

Fuel Injection System Batch (1 & 4) - (2 & 3)

Page 1A-4 90-881980R1 NOVEMBER 2001

Crankcase Main Journal Inside

90-881980R1 NOVEMBER 2001 Page 1A-5

Warp Limit 0.004 in. (0.1 mm)

Page 1A-6 90-881980R1 NOVEMBER 2001

Valve/Valve Seat/Valve Guides:

Valve Face Angle

Valve Lifter Outside diameter 1.1010 - 1.1016 in.

90-881980R1 NOVEMBER 2001 Page 1A-7

Pump Type Trochoid with Relief Valve

Page 1A-8 90-881980R1 NOVEMBER 2001

Propeller Information Charts

Mercury/Mariner 115 EFI (4-Stroke) 2.07:1

Approx. Approx. Speed

90-881980R1 NOVEMBER 2001 Page 1A-9

Mercury/Quicksilver Lubricants and Sealants

Page 1A-10 90-881980R1 NOVEMBER 2001

Description Mercury Part Number Quicksilver Part Number

RTV 587 Silicone Sealer

Loctite 262 Obtain Locally Obtain Locally

Premium Gear Lubricant

Loctite 7649 Primer

2-4-C with Teflon

Loctite Quick Tite Obtain Locally Obtain Locally

Isopropyl Alcohol Obtain Locally Obtain Locally

Hot Glue Obtain Locally Obtain Locally

Special Lubricant 101

4 Stroke 10W30 Outboard Oil

4 Cycle 25W40 Engine Oil

Power Trim & Steering Fluid

Engine Coupler Spline Grease

90-881980R1 NOVEMBER 2001 Page 1A-11

Page 1A-12 90-881980R1 NOVEMBER 2001

Fastener Location DIameter x Torque

90-881980R1 NOVEMBER 2001 Page 1A-13

Fastener Location DIameter x Torque

Page 1A-14 90-881980R1 NOVEMBER 2001

Fastener Location DIameter x Torque

90-881980R1 NOVEMBER 2001 Page 1A-15

2. Crankcase Oil Pump P/N 90265A5

3. Oil Filter Wrench P/N 91-802653Q1

90-881980R1 NOVEMBER 2001 Page 1B-1

Inspection And Maintenance Schedule