Mercury 40 FourStroke, 30 FourStroke Service Manual

Download

30/40

FourStroke

Starting Model Year 1999

Starting Serial Number 0G760300

Starting Model Year 1999

90-857046R1 NOVEMBER 2001

30/40 FourStroke

Notice

Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol

cerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY!

These “Safe t y A l e rts” 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.

) are used to alert the mechanic to special instructions con-

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 injury 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 products, 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 includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended 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.

90-857046R1 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 metric 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. Mismatched 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 whenever 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 manual, 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.

Page ii 90-857046R1 NOVEMBER 2001

Service Manual Outline

Section 1 - Important Information

A - Specifications B - Maintenance C - General Information D - Outboard Motor Installation

Section 2 - Electrical

A - Ignition B - Charging & Starting System C - Timing,Synchronizing & Adjusting D - Wiring Diagrams

Section 3 - Fuel System

A - Fuel Pump B - Carburetor C - Emissions

Section 4 - Powerhead

A - Cylinder Head B - Cylinder Block/Crankcase C - Lubrication

Section 5 - Mid-Section

A - Clamp/Swivel Bracket & Drive Shaft Housing B - Power Trim C - Manual Tilt Assist

Section 6 - Gear Housing

A - Non-Bigfoot Gear Housing B - Bigfoot Gear Housing

Section 7 - Attachments/Control Linkage

A - Throttle/Shift Linkage B - Tiller Handle

Section 8 - Manual Starter Section 9 - Color Diagrams

Important Information

Electrical

Fuel System

Powerhead

Mid-Section

Gear Housing

Attachments/ Control Linkage

Manual Starter

Color Diagrams

1 2 3 4 5 6 7 8

90-857046R1 NOVEMBER 2001 Page iii

SPECIFICATIONS

IMPORTANT INFORMATION

Section 1A - Specifications

Table of Contents

Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Information Charts 1A-8. . . . . . . . . . . . . .

Specifications

Models 30/40 EFI (4-Stroke)

HORSEPOWER

(kW)

OUTBOARD

WEIGHT

FUEL

Model 30 Model 40

Electric

30/40 MH 30/40 ELPT 40 ELPT BIGFOOT

RECOMMENDED GASOLINE Automotive Unleaded

OIL FILTER OIL FILTER WRENCH ENGINE OIL CAPACITY ENGINE OIL

SAE

25W-40

F°

C°

SAE 10W-30

Mercury/Quicksilver Lubricants and Sealants 1A-11

Torque Chart 1A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

30 hp (22.4 Kw) @ 5750 rpm 40 hp (29.8 Kw) @ 5750 rpm

204 lb (93 kg) 224 lb (112.7 kg) 235 lb (106.6 kg)

with a Minimum Pump Posted

Octane Rating of 87

p/n 35-822626A2 p/n 91-802653Q1

Either 3 Quarts or 3 Liters

SAE 10W-30 viscosity oil is recom-

mended for use in all temperatures.

SAE 25W-40 viscosity oil may be used at

temperatures above 40° F (4° C).

OIL

+100

+80 +60

+40 +20

+38

+27 +16

+4 –7

–18

Use 4-Stroke Outboard Oil with the proper viscosity for the expected temperature in

your area (see range thermometer on

left). If not available, use a premium

quality 4-stroke engine oil, certified to meet or exceed anyone of the following American Petroleum Institute (API) ser-

vice classifications SH, SG, SF, CF-4,

CE, CD, CDll.

90-857046R1 NOVEMBER 2001 Page 1A-1

SPECIFICATIONS

IGNITION

SYSTEM

Readings taken @

68°F (20°C).

CHARGING

SYSTEM

Readings taken @

68°F (20°C).

STARTING

SYSTEM

Type Spark Plug:

Type Gap Hex Size Torque

Hole Size Firing Order Ignition Timing:

@ Idle (800 rpm)

@ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance:

Primary

Secondary (W/o Boots) ECM Engine Speed Limiter

Soft Reduction (Retards Timing)

Spark Cut-Out Reduction (Percent-

ages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure

Speed Control Engine Temperature Sensor

Alternator Type:

6 Amp Manual Lighting Coil Output Lighting Coil Resistance 15 Amp. Electric Alternator Output

Battery Charging Coil Resistance Power Bobbin Resistance

(For Electrothermal Valve)

Quicksilver Tachometer Setting Manual Start

Electric Start:

Starter Type Output Ampere Draw Under:

(Load) (No Load)

Capacitor Discharge Ignition

NGK DPR6EA-9

0.035 in. (0.9 mm) 18 mm

150 lb-in. (17 Nm)

12mm

1-2-3

10° A.T.D.C 28° B.T.D.C

660 - 710 Ω (GRN/WHT - WHT/GRN)

300 - 350 Ω (RED - WHT)

0.08 - 0.7 Ω (BLK - BLK/WHT)

3.5 - 4.7 kΩ (BLK - High Tension) 6200 rpm 6250 rpm

Approximately 2000 rpm

See Graph Section 2A-Ignition

Single Phase (12 Pole)

6 Amps

0.9 - 1.1 Ohms (YEL-YEL)

12.6 V-15 Amps. (185 Watts) (Rectified/Regulated)

0.22 - 0.24 Ohms (YEL-YEL)

6.7-7.1 Ohms (YEL/BLK-YEL/BLK) “6P” or “4”

Recoil Start

Bendix

1.1 kW

174.0 Amps

23.7 Amps

Battery Rating

Minimum Requirement For operation below 32° F (0° C)

BATTERY

Ampere-Hours (Ah) Minimum

For operation above 32° F (0° C) For operation below 32° F (0° C)

IMPORTANT: Use resistive spark plugs only.

Page 1A-2 90-857046R1 NOVEMBER 2001

465 Marine Cranking Amps (MCA)

or 350 Cold Cranking Amps (CCA)

1000 Marine Cranking Amps (MCA) or

775 Cold Cranking Amps (CCA)

105

SPECIFICATIONS

ENRICHMENT

CONTROL

SYSTEM

Readings taken @

68°F (20°C).

FUEL

SYSTEM

CARBURETOR

Auto Enrichener Resistance Electrothermal Ram Projection

Fuel Pump Type Fuel Pump:

Pressure Fuel Tank Capacity

Idle rpm (Out Of Gear) Idle rpm (In Forward Gear) Wide Open Throttle rpm (WOT)

Range Main Jet Size Pilot Jet Idle Jet Float Height

15 - 25 Ohms (YEL/BLK - YEL/BLK)

0.3 in. (7mm) after 5 min. of power

Mechanical Water Cooled

(Plunger/Diaphragm)

3-6 psi

Accessory

900 ± 25 rpm

800 ± 25 rpm

5500–6000

#98 #38 #42

0.47-0.63 in. (12.0-16.0 mm)

CYLINDER

BLOCK

Type Displacement Number of Cylinders

4 Stroke – Over Head Camshaft

45.6 cu. in. (747 cc) 3

STROKE Length 2.953 in. (75 mm)

Diameter

2.5591 in. (65 mm)

2.5689 in. (65.25 mm)

2.5787 in. (65.5 mm)

0.003 in. (0.08 mm) Cast Iron

Aluminum

CYLINDER

BORE

Standard Oversize-0.010 in. (0.25 mm)

Oversize-0.020 in. (0.50 mm) Taper/Out of Round Maximum Bore Type

Piston Type O.D. at Skirt

PISTON

Standard

Oversize-0.010 in. (0.25 mm)

Oversize-0.020 in. (0.50 mm) Piston to Cylinder Clearance 0.0014 - .0026 in. (0.035 - 0.065 mm)

2.5570 - 2.5578 in. (64.950 - 64.965 mm)

2.5669 - 2.5675 in. (65.2 - 65.215 mm)

2.5768 - 2.5774 in. (65.450 - 65.465 mm)

CLEARANCE

Ring End Gap (Installed)

0.006 - 0.012 in. (0.15 - 0.03 mm)

0.012 - 0.020 in. (0.30 - 0.50 mm)

0.008 - 0.028 in. (0.20 - 0.70 mm)

RINGS

Top

Middle

Bottom (Oil Ring) Side Clearance:

Top

Middle

0.0008 - 0.0024 in. (0.02 - 0.06 mm)

90-857046R1 NOVEMBER 2001 Page 1A-3

SPECIFICATIONS

Compression Ratio

COMPRESSION

RATIO

PISTON PIN Piston Pin Diameter 0.6285 - 0.6287 in. (15.965 - 15.970 mm)

CONNECTING

ROD

CRANKSHAFT

CAMSHAFT

Cylinder Compression* (Electric Models Only, Cold Engine @ W.O.T.)

Oil Clearance (Big End) Small End Inside Diameter

Main Bearing Clearance Crankshaft Run-out

Camshaft Dimensions

Intake “A” Exhaust “A” Intake “B” Exhaust “B”

Run-out Limit Camshaft Bearing Diameter “b”

0.0008 - 0.0020 in. (0.020 - 0.052 mm)

0.6293 - 0.6298 in. (15.985 - 15.998 mm)

0.0005 - 0.0017 in. (0.012 - 0.044 mm)

1.214 - 1.222 in. (30.83 - 31.03 mm)

1.020 - 1.028 in. (25.90 - 26.10 mm)

180 - 210 psi (Peak)

0.0018 in. (0.046 mm)

0.0039 in. (0.1 mm)

1.4541 - 1.4549 in.

(36.935 - 36.955 mm)

9.7:1

VALVE SPRING

Free Length “a” Tilt Limit “b”

Compressed Pressure (Installed)

Intake

Exhaust Tilt Limit (Intake & Exhaust) Dir. of Winding (Intake & Exhaust)

1.491-1.569 in. (37.85-39.85 mm) Less than 0.060 in. (1.7 mm)

19.8 - 22.0 lbs. (9.0 - 10.0 kg)

0.043 in. (1.1 mm) Left Hand

Page 1A-4 90-857046R1 NOVEMBER 2001

SPECIFICATIONS

CYLINDER HEAD

VALVES

Warp Limit

* Lines indicate straight edge measurement

Camshaft Bore Inside Diameter “a”

56900

Valve/Valve Seat/Valve Guides: Valve Clearance (cold)

Intake

Exhaust Valve Dimensions: “A” Head Diameter

Intake

Exhaust “B” Face Width

Intake

Exhaust “C” Seat Width

Intake

Exhaust “D” Margin Thickness

Intake

Exhaust Stem Outside Diameter

Intake

Exhaust Guide Inside Diameter

Intake

Exhaust Stem To Guide Clearance

Intake

Exhaust Stem Run-out Limit (max.)

0.004 in. (0.1 mm)

56899

1.4567 - 1.4577 in.

(37.000 - 37.025 mm)

0.006 - 0.010 in. (0.15 - 0.25 mm)

0.010 - 0.014 in. (0.25 - 0.35 mm)

1.256 - 1.264 in. (31.9 - 32.1 mm)

1.020 - 1.028 in. (25.9 - 26.1 mm)

0.079 - 0.124 in. (2.00 - 3.14 mm)

0.035 - 0.043 in. (0.9 - 1.1 mm)

0.020 - 0.035 in. (0.5 - 0.9 mm)

0.2156 - 0.2161 in. (5.475 - 5.490 mm)

0.2150 - 0.2156 in. (5.460 - 5.475 mm)

0.2165 - 0.2170 in. (5.500 - 5.512 mm)

0.0004 - 0.0015 in. (0.010 - 0.037 mm)

0.0010 - 0.0020 in. (0.025 - 0.052 mm)

0.0006 in. (0.016 mm)

90-857046R1 NOVEMBER 2001 Page 1A-5

SPECIFICATIONS

Valve Dimensions

Head Diameter Face Width

ROCKER SHAFT

ROCKER ARM

THERMOSTAT

LUBRICATION

SYSTEM

“B”

“C”

“A”

Seat Width

Margin Thickness

Outside Diameter 0.6288 - 0.6296 in.

(15.971 - 15.991 mm)

Inside Diameter of Bore 0.6299 - 0.6306 in.

(16.000 - 16.018 mm)

Valve Opening Temperature Full Open Temperature Valve Lift (Minimum)

Pump Type

136° F - 143° F (58° C - 62° C)

158° F (70° C)

0.12 in. (3mm) Trochoid

Engine Oil Pressure (Warm Engine)

@ 3000 rpm

Engine Oil Pan Capacity

30-40 psi (207-278 kPa)

Either 3 Qts. or 3 Liters

Oil Pump:

S/N OT427437 & Up (Electric) S/N OT426439 & Up (Manual) Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c”

0.0045 - 0.009 in. (0.11 - 0.23 mm)

0.005 in. (0.12 mm)

0.0015 - 0.003 in. (0.04 - 0.08 mm)

Oil Pump:

S/N OT427436 & Below (Electric) S/N OT426438 & Below (Manual) Outer Rotor to Housing “a” Inner Rotor to Outer Rotor “b” Rotor to Housing “c”

0.0035 - 0.006 in. (0.09 - 0.15 mm)

0.005 in. (0.12 mm)

0.001 - 0.003 in. (0.03 - 0.08 mm)

“D”

Transom Height:

Short Shaft Long Shaft

Steering Pivot Range:

MID-SECTION

Tiller

Remote Tilt Pin Positions Full Tilt Up Angle Allowable Transom Thickness

Page 1A-6 90-857046R1 NOVEMBER 2001

15 in. (38 cm) 20 in. (51 cm)

90° 60°

5 + Shallow Water

69°

2-3/4 in. (69.8 mm)

SPECIFICATIONS

GEAR HOUSING

(2.00:1)

GEAR HOUSING

BIGFOOT

(2.3:1)

Gear Ratio Gearcase Capacity Lubricant Type Forward Gear

Number of Teeth

Pinion Gear

Number of Teeth Pinion Height Forward Gear Backlash Water Pressure (Warm Engine)

@ 800 rpm

@ 6000 rpm (WOT) Leak Test Pressure

Gear Ratio Gearcase Capacity Lubricant Type Forward Gear

Number of Teeth Pinion Gear

Number of Teeth Pinion Height

Pinion Gear Locating Tool

Flat Number Disc Number

Forward Gear Backlash

Backlash Indicating Tool

Mark Number

Water Pressure

@ 800 rpm (Idle)

@ 6000 rpm (WOT) Leak Test Pressure

2.00:1

14.9 fl oz (440 mL)

Premium Blend Gear Lube

26 Spiral/Bevel 13 Spiral/Bevel

0.025 in. (0.64 mm) No Adjustment

2–4 psi (14-28 kPa)

12-17 psi (69-103 kPa)

10-12 psi (68-83 kPa)

for 5 Minutes

2.31:1

24 fl oz (710 mL)

Premium Blend Gear Lube

30 Spiral/Bevel 13 Spiral/Bevel

0.025 in. (0.64 mm)

91-12349A2

#8 #3

0.012-0.019 in. (0.30-0.48 mm) 91-78473

2-7 psi (14-41 kPa)

12-17 psi (83-172 kPa)

10-12 psi (69-83 kPa)

for 5 Minutes

90-857046R1 NOVEMBER 2001 Page 1A-7

SPECIFICATIONS

Propeller Information Charts

Mercury/Mariner 30 (4-Stroke) 2.00:1 Non-Bigfoot

Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.00:1

Approx.

No. of

Diameter

10” 19” 3 Alum Up to 600 Up to 14’ 45-53 48-73146A40 10” 17” 3 Alum Up to 700 Up to 14’ 39-46 48-73144A40 10” 16” 3 Steel 600-800 Up to 14’ 36-42 48-91818A5

10” 16” 3 Alum 600-800 Up to 14’ 36-42 48-73142A40 10-1/8” 15” 3 Steel 700-900 13-14’ 33-39 48-76232A5 10-1/8” 15” 3 Alum 700-900 13-14’ 33-39 48-73140A40 10-1/4” 14” 3 Steel 800-1000 14-15’ 30-36 48-76230A5 10-1/4” 14” 3 Alum 800-1000 14-15’ 30-36 48-73138A40 10-3/8” 13” 3 Steel 900-1100 14-16’ 27-33 48-76228A5 10-3/8” 13” 3 Alum 900-1100 14-16’ 27-33 48-73136A40 10-5/8” 12” 3 Steel 1000-1200 15-17’ 24-29 48-79792A5 10-5/8” 12” 3 Alum 1000-1200 15-17’ 24-29 48-73134A40 11-5/8” 11” 3 Steel 1100-1400 15-17’ 21-26 48-823478A5 10-7/8” 11” 3 Alum 1100-1400 15-17’ 21-26 48-85632A40 11-5/8” 10-1/2” 3 Alum 1300-1700 15-18’ 19-24 48-827312A10

Pitch

Blades

Material

Gross Boat

Wgt. (lbs)

Approx.

Boat

Length

Speed

Range

(mph)

Propeller

Part Number

11-1/4” 10” 3 Alum 1400-1900 16’ + 18-22 48-73132A40 12-1/4” 9” 3 Steel 2000+ pontoon 15-19 48-97868A10 12-1/4” 9” 3 Alum 2000+ pontoon 15-19 48-87818A10 12-1/2” 8” 3 Alum 2400+ pontoon/

houseboat

12-1/2” 8” Cup 3 Alum pontoon 48-42738A12

Page 1A-8 90-857046R1 NOVEMBER 2001

1-17 48-42738A10

Mercury/Mariner 40 (4-Stroke) 2.00:1 Non-Bigfoot

Wide Open Throttle RPM : 5500-6000 Recommended Transom Heights : 15”, 20”, 22.5” Right Hand Rotation Standard Gear Reduction : 2.00:1

SPECIFICATIONS

Diameter Pitch

No. of

Blades

Material

Approx.

Gross Boat

Wgt. (lbs)

Approx.

Boat

Length

Speed Range

(mph)

Propeller

Part Number

10” 19” 3 Alum Up to 800 Up to 14’ 45-53 48-73146A40 10” 17” 3 Alum Up to 1000 Up to 15’ 39-46 48-73144A40 10” 16” 3 Steel 900-1100 Up to 15’ 36-42 48-91818A5

10” 16” 3 Alum 900-1100 Up to 15’ 36-42 48-73142A40 10-1/8” 15” 3 Steel 1000-1200 13-15’ 33-39 48-76232A5 10-1/8” 15” 3 Alum 1000-1200 13-15’ 33-39 48-73140A40 10-1/4” 14” 3 Steel 1100-1300 14-16’ 30-36 48-76230A5 10-1/4” 14” 3 Alum 1100-1300 14-16’ 30-36 48-73138A40 10-3/8” 13” 3 Steel 1200-1500 14-17’ 27-33 48-76228A5 10-3/8” 13” 3 Alum 1200-1500 14-17’ 27-33 48-73136A40 10-5/8” 12” 3 Steel 1400-1700 15-17’ 24-29 48-79792A5 10-5/8” 12” 3 Alum 1400-1700 15-17’ 24-29 48-73134A40 11-5/8” 11” 3 Steel 1600-2000 16-18’ 21-26 48-823478A5 10-7/8” 11” 3 Alum 1600-2000 16-18’ 21-26 48-85632A40 11-5/8” 10-1/2” 3 Alum 1800-2400 16’ + 19-24 48-827312A10 11-1/4” 10” 3 Alum 2000-2600 17’ + 18-22 48-73132A40 12-1/4” 9” 3 Steel 2300+ pontoon 15-19 48-97868A10 12-1/4” 9” 3 Alum 2300+ pontoon 15-19 48-87818A10 12-1/2” 8” 3 Alum 2700+ Pontoon/

1-17 48-42738A10

houseboat

12-1/2” 8” Cup 3 Alum pontoon 48-42738A12

90-857046R1 NOVEMBER 2001 Page 1A-9

SPECIFICATIONS

Mercury/Mariner 40 (4-Stroke) 2.3:1 Bigfoot

Special soft rubber hub propellers designed to reduce clutch rattle

Wide Open Throttle rpm: 5500-6000 Recommended Transom Heights : 20”, 25” Right Hand Rotation Standard Gear Reduction : 2.31:1

IMPORT ANT: These specially designed rubber hub propellers are rated for 60 horsepower MAXIMUM.

Approx.

No. of

Diameter

13-3/4” 15” 3 Alum 1200-1500 14-16’ 27-32 48-77342A33

14” 13” 3 Alum 1500-2000 16-18’ 22-27 48-77340A33 14” 11” 3 Alum 2000-3000 pontoon 17-21 48-77338A33 14” 10” 3 Alum 2500+ pontoon/work 14-19 48-854342A33 14” 9” 3 Alum 3500+ houseboat/

Pitch

Blades

Material

Gross Boat

Wgt. (lbs)

Approx.

Boat

Length

work

Speed Range

(mph)

1-15 48-854340A33

Propeller

Part Number

Page 1A-10 90-857046R1 NOVEMBER 2001

Mercury/Quicksilver Lubricants and Sealants

SPECIFICATIONS

Description

Needle Bearing Assy. Lubricant [8 oz. (226.8 grams)] tube

Dielectric Grease [8 oz. (226.8 grams)] can

Loctite 271 – Thread Locker (10 ml) tube

Loctite 567 PST Pipe Sealant (50 ml) tube

Loctite Master Gasket Kit 2 Cycle Premium Outboard Oil

[1 Gallon (3.7 liter)] Perfect Seal

[16 oz. (0.45 kg)] can

Mercury Part Number

92-802868A1

92-823506-1

92-809819

92-809822

92-12564-2

92-802815A1

92-34227-1

Quicksilver Part Number

N/A

92-823506-1

92-809819

92-809822

92-12564-2

92-802815Q1

92-34227-1

Liquid Neoprene [8 oz. (226.8 grams)] can

Cyanacrylate Adhesive Bellows Adhesive Loctite 680 Retaining Compound

(10 ml) tube Loctite 222 Thread Locker

(10 ml) tube 3M Permabond #3M08155 Loctite 242 Thread Locker

(10 ml) tube Loctite 609 Loctite 405

92-25711-3

Obtain Locally

N/A

92-809833

92-809818

Obtain Locally

92-809821

Obtain Locally Obtain Locally

92-25711-3

Obtain Locally

92-86166Q1

92-809833

92-809818

Obtain Locally

92-809821

Obtain Locally Obtain Locally

90-857046R1 NOVEMBER 2001 Page 1A-11

SPECIFICATIONS

Description

RTV 587 Silicone Sealer [3 oz. (85.05 grams)]

Loctite 262 Premium Gear Lubricant

[1 Quart (0.94 liter)] Loctite 7649 Primer

[4.5 oz (127.57 grams)] Anti-Corrosion Grease

[8 oz. (226.8 grams)] tube 2-4-C with Teflon

[8 oz. (226.8 grams)] tube Loctite Quick Tite

Mercury Part Number

92-809825

Obtain Locally

92-802846A1

92-809824

92-802867A1

92-802859A1

Obtain Locally

Quicksilver Part Number

92-809825

Obtain Locally

92-802846Q1

92-809824

92-802867Q1

92-802859Q1

Obtain Locally Isopropyl Alcohol Hot Glue Special Lubricant 101

[8 oz. (226.8 grams)] tube 4 Stroke 10W30 Outboard Oil

[1 Quart (0.94 liter)] 4 Cycle 25W40 Engine Oil

[1 Quart (0.94 liter)] Power Trim & Steering Fluid

[8 oz. (226.8 grams)] Engine Coupler Spline Grease

[14 oz. (0.39 kg)] cartridge Power Tune Engine Cleaner

[13 oz. (384 ml)] spray can

Obtain Locally Obtain Locally

92-802865A1

92-802833A1

92-802837A1

92-802880A1

92-802869A1

92-802878

Obtain Locally

92-802865Q1

92-802833Q1

92-802837Q1

92-802880Q1

92-802869Q1

92-802878Q57

Fuel System Treatment & Stabilizer [12 oz. (355 ml)] plastic bottle

Page 1A-12 90-857046R1 NOVEMBER 2001

92-802875A1

92-802875Q1

Torque Chart

SPECIFICATIONS

Fastener Location

Diameter x

Length (mm)

Torque

lb-in. lb-ft..

Ignition

Coil Mounting Nuts M5 30 3.5 Coil Mount Plate Screw (Rear) M6 x 25 60 7 Coil Mount Plate Screw M6 x 30 75 8.5 Coil Plate Ground Screw M6 x 10 60 7 Spark Plug 12 mm 150 17

Charging & Starting System

Flywheel Cover Screws M6 x 25 75 8.5 Flywheel Nut N/A 116 157 Stator Screws (Electric) M5 x 30 85 9.5 Stator Screws (Manual) M5 x 25 85 9.5 Voltage Regulator Screws M6 x 40 75 8.5 Starter Motor Mount Bolts M8 x 45 21.5 29.5 Starter Cable Nut 1/4-20 60 7 Starter Motor Thru Bolts N/A 70 8 Battery Cable (+) Nut M6 60 7 Solenoid Plate Screw M6 x 14 45 5 Harness Retainer Screws M6 x 14 45 5 Wire Clamp Screw (Top of Block) M5 x 12 45 5

Cylinder Head

Cylinder Head Bolts (*) M9 x 95 34.5 47 Cylinder Head Bolts (*) M6 x 25 106 12 Baffle Plate Screws M4 x 10 Drive Tight Valve Cover Screws M6 x 20 70 8 Valve Adjusting Nuts M6 120 13.5 Rocker Arm Shaft Screws M8 x 23 160 13 18 Driven Gear Screw M10 x 40 28 38

Cylinder Block/Crankcase

Crankcase Cover Bolts - Center (*) M8 x 82 22 30 Crankcase Cover Bolts - Outer (*) M6 x 35 106 12 Exhaust Cover Screws M6 x 35 106 12 Connecting Rod Bolts (*) Special 150 17 Oil Filter N/A 70 8 Oil Filter Nipple N/A 29.5 40 Powerhead Mounting Bolts (*) M8 x 110 33 44.5 Lifting Eye Screw M8 x 35 29 39.5 Oil Pressure Switch N/A 75 8.5 Oil Galley Plug 1/8-27 Pipe Plug 80 9 Oil Galley Plug 3/4-14 Pipe Plug 30 40.5 Oil Galley Plug 1/2-14 Pipe Plug 30 40.5

*NOTE:

90-857046R1 NOVEMBER 2001 Page 1A-13

Two Step Torque - See appropriate section of component for details.

SPECIFICATIONS

Fastener Location

Diameter x

Length (mm)

Torque

lb-in. lb-ft.

Lubrication

Oil Pump Mounting Screws M6 x 40 70 8 Oil Pump Cover Screws M6 x 16 70 8

Mid-Section

Top Cowl Latch Screw/Nut M4 x 14 Drive Tight Top Rear Cowl Latch Screw/Nut M6 x 16 90 10 Bottom Cowl Screws M6 x 30 60 7 Bottom Cowl Screws M6 x 60 60 7 Rear Cowl Latch Screw (Bottom) M6 x 16 60 7 Oil Drain Plug N/A 17.5 23.5 Gear Housing Mounting Stud M10 144 12 16 Adaptor Plate Mounting Screw M8 x 45 33 44.5 Co-Pilot Plate Bolt (Shoulder) 1/4-20 x 0.68 70 8 Steering Bracket Bolts M10 x 30 32.5 44 Steering Link Rod Bolt Special 20 27 Steering Link Rod Nut 3/8-24 Torque to 120 lb-in. then

back off 1/4 turn. Upper Mount Bolts M6 x 20 130 14.5 Upper Mount Bolts M12 x 154 24 32.5 Upper Mount Nuts M12 24 32.5 Lower Mount Bolts M10 x 105 32.5 44 Lower Mount Nuts M12 32.5 44 Ground Screws 10-16 x 0.38 Drive Tight Tilt Lever Bolt (Shoulder) 3/8-16 x 0.62 18 25 Tilt Stop Bolt M10 x 40 Tilt Tube Nut 3/414 Torque to 32 lb-ft., then back

off 1/4 turn. Anchor Bracket Screws M8 x 30 25 34 Anchor Bracket Screws M8 x 35 25 34 Anode Screws M6 x 25 60 7 Adaptor Plate (Socket Head) Screw M6 x 55 150 17 Oil Pressure Relief Valve N/A 34 46 Oil Pickup/Gasket Screw M6 x 20 75 8.5 Oil Gallery Plug 1/214 Pipe Plug 24 33

Power Trim

Shock Rod Piston N/A 90 122 Piston Spring Plate Screws N/A 35 4 Cylinder End Cap N/A 45 61 Trim Cylinder/Reservoir Screws N/A 100 11 Pump to Manifold Screws N/A 70 8 Check Valve Plug N/A 120 13 Reservoir Screws N/A 80 9

Page 1A-14 90-857046R1 NOVEMBER 2001

SPECIFICATIONS

Fastener Location

Diameter x

Length (mm)

Torque

lb-in. lb-ft.

Manual Tilt Assist

Plug, Velocity Valve N/A 75 8.5 Plug, Plunger (2) N/A 75 8.5 Shock Rod Piston N/A 90 122 Piston Spring Plate Screws N/A 35 4 Cylinder End Cap N/A 45 61 Tilt Cylinder/Reservoir Screws N/A 100 11 Accumulator N/A 35 47

Non-Bigfoot Gear Housing

Pinion Nut N/A 50 68 Bearing Carrier Screws M8 x 25 19 25.5 Vent, Fill/Drain Screw NA 60 7 Water Pump Cover Screws M6 x 16 60 7 Gear Housing Mounting Screws M10 x 45 40 54 Gear Housing Mounting Nut M10 40 54 Trim Tab Screw M8 x 20 23 31.5 Propeller Nut N/A 55 74.5

Bigfoot Gear Housing

Bearing Carrier Nut M8 25 34 Water Pump Base Screws M6 x 25 60 7 Water Pump Cover Screws M6 x 30 60 7 Vent, Fill/Drain, Oil Level Screw N/A 60 7 Gear Housing Mounting Bolts M10 x 45 40 54 Gear Housing Mounting Nut M10 40 54 Trim Tab Screw 7/16 x 1-1/4 in 22 30 Anode Screw M6 x 40 60 7 Propeller Nut

Throttle/Shift Linkage

Throttle/Shift Lever Screw M8 x 70 100 11.5 Throttle Cam Mounting Screw M6 x 40 75 8.5 Throttle Cam Screw 10-16 x 5/8 in. Drive Tight Remote Control Cable Anchor Bracket Screws M6 x 16 75 8.5 Shift Spring Screw M5 x 16 45 5 Neutral Start Switch Screws M3 x 20 20 2.5 Shift Link Nut (Bigfoot) M6

Tiller Handle

Tiller Mounting Bracket Screws M10 x 90 35 47.5 Shift Handle Screw M8 x 150 100 11 Tiller Tube Retainer Screw M5 x 16 35 4 Tiller Mount Cover Screws M8 x 25 135 15 Pulley Case Screws Self Tapping 10-16 x 1/2 20 2.5

90-857046R1 NOVEMBER 2001 Page 1A-15

MAINTENANCE

IMPORTANT INFORMATION

Section 1B - Maintenance

Table of Contents

Table of Contents 1B-1. . . . . . . . . . . . . . . . . . . . . . .

Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury/Quicksilver Lubricants and Sealants 1B-2

Inspection And Maintenance Schedule 1B-3. . . . .

Before Each Use 1B-3. . . . . . . . . . . . . . . . . . . . .

After Each Use 1B-3. . . . . . . . . . . . . . . . . . . . . . .

Every 100 Hours of Use or Once yearly 1B-3. Every 300 Hours of Use or Three Years 1B-4.

Before Periods of Storage 1B-4. . . . . . . . . . . . .

Flushing the Cooling System 1B-4. . . . . . . . . . . . . .

Steering Link Rod Fasteners 1B-5. . . . . . . . . . . . . .

Corrosion Control Anode 1B-6. . . . . . . . . . . . . . . . .

Spark Plug Inspection and Replacement 1B-7. . .

Battery Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement - Electric Start Models 1B-8. .

Timing Belt Inspection 1B-8. . . . . . . . . . . . . . . . . . .

Lubrication Points 1B-9. . . . . . . . . . . . . . . . . . . . . . .

Checking Power Trim Fluid 1B-10. . . . . . . . . . . . . . .

Fuel System 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Line Inspection 1B-11. . . . . . . . . . . . . . . . . .

Changing Engine Oil 1B-12. . . . . . . . . . . . . . . . . . . . .

Oil Changing Procedure 1B-12. . . . . . . . . . . . . . .

Changing Oil Filter 1B-13. . . . . . . . . . . . . . . . . . . .

Checking and Adding Engine Oil 1B-13. . . . . . .

Changing Gear Case Lubricant 1B-14. . . . . . . . . . .

3-1/4 In. (83mm) Diameter Gear Case 1B-14. . 4-1/4 In. (108mm) Diameter Gear Case 1B-15.

Storage Preparation 1B-17. . . . . . . . . . . . . . . . . . . . .

Fuel System 1B-17. . . . . . . . . . . . . . . . . . . . . . . . .

Protecting External Outboard

Components 1B-17. . . . . . . . . . . . . . . . . . . . . . . . .

Protecting Internal Engine Components 1B-17.

Gear Case 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning Outboard for Storage 1B-18. . . . . . .

Battery Storage 1B-18. . . . . . . . . . . . . . . . . . . . . .

90-857046R1 NOVEMBER 2001 Page 1B-1

MAINTENANCE

Special Tools

1. Crankcase Oil Pump P/N 90265A5

2. Oil Filter Wrench P/N 91-802653Q1

3. Flushing Attachment P/N 44357A2

Mercury/Quicksilver Lubricants and Sealants

NOTE: See section 1A for lubricants and sealants chart.

Page 1B-2 90-857046R1 NOVEMBER 2001

Inspection And Maintenance Schedule

To keep your outboard in the best operating condition, it is important that your outboard receive 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 correct 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.

MAINTENANCE

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.

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 r oom t emperature. I f q uestionable, i nspect t hermostat a s o utlined 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 and adjust valve clearance, if necessary.

11. Check power trim fluid.

12. Inspect battery.

13. Check control cable adjustments.

14. Inspect timing belt.

90-857046R1 NOVEMBER 2001 Page 1B-3

MAINTENANCE

15. Remove engine deposits with Power Tune Engine Cleaner.

16. Check tightness of bolts, nuts, and other fasteners.

Every 300 Hours of Use or Three Years, Whichever Occurs First

1. Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).

Before Periods of Storage

1. Refer to Storage procedure (this section).

Flushing the Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt, polluted or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages.

IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.

NOTE: You can have the outboard tilted or in the vertical operating position during flushing.

WARNING

To avoid possible injury when flushing, remove the propeller. Refer to Propeller Replacement.

1. Place the outboard in either the operating position (vertical) or in a tilted position.

2. Remove propeller (refer to Propeller Replacement).

3. Thread a water hose into the rear fitting. Partially open the water tap (1/2 maximum). Do not open the water tap all the way, as this allows a high pressure flow of water.

a-Water Hose Threaded into Rear Fitting

IMPORTANT: Do not run engine above idle when flushing.

4. Shift outboard into neutral. Start the engine and flush the cooling system for at least 5 minutes. Keep engine speed at idle.

5. Stop the engine. Turn off the water and remove hose. Reinstall the propeller.

Page 1B-4 90-857046R1 NOVEMBER 2001

Steering Link Rod Fasteners

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 overboard exposing them to serious injury or death.

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt (“a” – Part Number 10-823919) and self locking nylon insert locknuts (“b” & “c” – Part Number 11-826709113). 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.

MAINTENANCE

WARNING

a-Special Washer Head Bolt (10-823919) b-Nylon Insert Locknut (11-826709113) c-Nylon Insert Locknut (11-826709113) d-Flat Washers e-Spacer (12-71970)

f-Link Rod Mount Hole

1. Assemble steering link rod to steering cable with two flat washers (d) and nylon insert

locknut (“c” – Part Number 11-826709113). Tighten locknut (c) until it seats, then back nut off 1/4 turn.

2. Assemble steering link rod to engine with special washer head bolt (“a” – Part Number

10-823919), locknut (“b” – Part Number 11-826709113) and spacer (“e” – 12-71970). First torque bolt (a) to 20 lb. ft. (27 Nm), then torque locknut (b) to 20 lb. ft. (27 Nm).

90-857046R1 NOVEMBER 2001 Page 1B-5

MAINTENANCE

Corrosion Control Anode

Your outboard has control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.

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 completely eroded. Never paint or apply a protective coating on the anode as this will reduce effectiveness of the anode.

1. An anode is installed on the bottom of the transom bracket assembly. On the 3-1/4 in. (83 mm) diameter gear case the trim tab is also an anode. The 4-1/4 in. (108 mm) diameter (Bigfoot) gear case has three anodes. One of the anodes is the trim tab and two anodes (one on each side) are located on the side of the housing.

a-Bottom Anode b-Trim Tab c-Side Anodes (Big Foot Models Only)

MANUAL START MODELS S/N OT426439 AND BELOW ELECTRIC START MODELS S/N OT427437 AND BELOW

2. Three anodes are installed in the engine block. Remove the three ignition coils for clearance. Remove anodes at locations shown. Install each anode with rubber seal and cover. Tighten screws to 70 lb-in. (8 Nm) torque. Reinstall the ignition coils. Tighten coil screws to 70 lb-in. (8 Nm) torque

a-Anodes-Engine Block b-Ignition Coils

Page 1B-6 90-857046R1 NOVEMBER 2001

c-Rubber Seal d-Cover

Spark Plug Inspection and Replacement

Inspect spark plugs at the recommended intervals.

WARNING

Avoid ser i ous injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. T o avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.

1. Remove the spark plug leads by twisting the rubber boots slightly and pulling 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.

IMPORTANT: Use resistive spark plugs only.

MAINTENANCE

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 12.5 lb-ft (17 Nm).

Battery Inspection

The battery should be inspected at periodic intervals to ensure proper engine starting capability.

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.

90-857046R1 NOVEMBER 2001 Page 1B-7

MAINTENANCE

Fuse Replacement – Electric Start Models

IMPORTANT: Always carry spare 20 AMP Fuses.

The electric starting circuit is protected from overload by a 20 Amp. fuse. 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. Disconnect fuse holder , and remove fuse. Look at the silver colored band inside the fuse. If band is broken replace the fuse. Replace fuse with a new fuse with the same amperage rating.

a-Fuse Holder and 20 Amp. Fuse b-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

Page 1B-8 90-857046R1 NOVEMBER 2001

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 corroding and seizing to the shaft.

Lubricate Points 2 thru 6 with 2 -4-C Marine Lubricant with Teflon or Special Lubricant 101.

2. Swivel Bracket – Lubricate through fitting.

MAINTENANCE

3. Tilt Support Lever – Lubricate through fitting.

4. Tilt Tube – Lubricate through fitting.

90-857046R1 NOVEMBER 2001 Page 1B-9

MAINTENANCE

WARNING

The end o f t he s teering c able must be fully r etracted i nto the outboard t ilt t ube b efore adding lubricant. Adding lubricant t o steering cable w hen f ully e xtended c ould c ause steering cable to become hydraulically l ocked. A h ydraulically l ocked s teering c able will cause loss of steering control, possibly resulting in serious injury or death.

5. Steering Cable Grease Fitting (5) (If equipped) - Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting.

Lubricate Pivot Points with light weight oil.

6. This grease fitting (6) is for lubricating the threaded rod for the co-pilot.

a-Steering Cable End b-Pivot Points

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) automatic transmission fluid.

a-Fill Cap

Page 1B-10 90-857046R1 NOVEMBER 2001

Fuel System

Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuel system service instructions. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system.

Before servicing any part of the fuel system, stop engine and disconnect the battery . Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. Inspect any completed service work for signs of fuel leakage.

Fuel Filter

IMPORT ANT: Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter.

Inspect the fuel line filter. If the filter appears to be contaminated, remove and replace.

MAINTENANCE

WARNING

a-Filter

Fuel Line Inspection

Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of det e r i o r a t i o n o r damage. If any of these conditions are found, the fuel line or primer bulb must be replaced.

90-857046R1 NOVEMBER 2001 Page 1B-11

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.

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

Page 1B-12 90-857046R1 NOVEMBER 2001

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.

a-Oil Filter

Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Be sure that the outboard is upright (not tilted) when checking oil.

MAINTENANCE

91-802653Q1

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.

a-Dipstick b-Oil Fill Cap c-Full Mark d-Add Mark

Engine Oil Capacity

90-857046R1 NOVEMBER 2001 Page 1B-13

3 U.S. Quarts or (3.0 Liters)

MAINTENANCE

Changing Gear Case Lubricant

3-1/4 In. (83mm) 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.

Examine the drained gear case lubricant for metal particles. A small amount of fine metal particles indicates normal gear wear . An excessive 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. Drain lubricant.

a-Fill/drain Plug b-Vent Plug

CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE

Gear Case Lubricant Capacity

14.9 fl oz (440 ml)

1. Place outboard in a vertical operating position. Remove vent plug (a).

2. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent hole (c).

IMPORTANT: Replace sealing washers if damaged.

3. Stop adding lubricant. Install the vent plug and sealing washer (a) before removing the lubricant tube.

4. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer (d).

Page 1B-14 90-857046R1 NOVEMBER 2001

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

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. Drain lubricant.

MAINTENANCE

a-Fill/drain Plug b-Rear Vent Plug c-Front Vent Plug

90-857046R1 NOVEMBER 2001 Page 1B-15

MAINTENANCE

CHECKING LUBRICANT LEVEL AND FILLING GEAR CASE

Gear Case Lubricant Capacity

24 fl oz (710 ml)

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 lubricant tube.

6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

a-Front Vent Plug b-Rear Vent Plug c-Front Vent Hole d-Rear Vent Hole e-Fill/Drain Plug and Sealing Washer

Page 1B-16 90-857046R1 NOVEMBER 2001

Storage Preparation

The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water.

The following storage procedures should be followed to prepare your outboard for out-ofseason storage or prolonged storage (two months or longer).

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.

Fuel System

IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation 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 tank and engine fuel system 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 Gasoline Stabilizer (follow instructions

on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.

MAINTENANCE

CAUTION

2. Permanently Installed Fuel Tank – Pour the required amount of Gasoline Stabilizer (fol-

low 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 15 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).

90-857046R1 NOVEMBER 2001 Page 1B-17

MAINTENANCE

Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of outboard.

If outboard is stored tilted up in freezing temperature, trapped cooling water, or rain water that 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.

CAUTION

Page 1B-18 90-857046R1 NOVEMBER 2001

GENERAL INFORMATION

IMPORTANT INFORMATION

Section 1C - GENERAL INFORMATION

Table of Contents

Serial Number Location 1C-2. . . . . . . . . . . . . . . . . .

Conditions Affecting Performance 1C-2. . . . . . . . .

Weather 1C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boat 1C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 1C-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Following Complete Submersion 1C-6. . . . . . . . . .

Submerged While Running 1C-6. . . . . . . . . . . . . .

Salt Water Submersion 1C-6. . . . . . . . . . . . . . .

Fresh Water Submersion 1C-6. . . . . . . . . . . . .

Model 30/40 (4-Stroke) Powerhead Views

Front View 1C-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Starboard View 1C-8. . . . . . . . . . . . . . . . . . . . . .

Port View 1C-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top View 1C-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aft View 1C-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Selection 1C-12. . . . . . . . . . . . . . . . . . . . . .

Propeller Removal/Installation 1C-13. . . . . . . . . . . .

3-1/4 In. (83mm) Diameter Gear Case 1C-13. .

4-1/4 In. (108mm) Diameter Gear Case 1C-14.

Power Trim System 1C-15. . . . . . . . . . . . . . . . . . . . . .

General Information 1C-15. . . . . . . . . . . . . . . . . .

Power Trim Operation 1C-15. . . . . . . . . . . . . . . . .

Trim “In” Angle Adjustment 1C-16. . . . . . . . . . . .

Trim Tab Adjustment 1C-17. . . . . . . . . . . . . . . . . . . . .

Compression Check 1C-18. . . . . . . . . . . . . . . . . . . . .

Cylinder Leakage Testing 1C-19. . . . . . . . . . . . . . . . .

Analysis 1C-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pressure Measurement 1C-20. . . . . . . . . . . .

Painting Procedures 1C-21. . . . . . . . . . . . . . . . . . . . .

Cleaning & Painting Aluminum

Propellers & Gear Housings 1C-21. . . . . . . . . . .

Decal Removal/Application 1C-22. . . . . . . . . . . . . . .

Removal 1C-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for “Wet” Application 1C-22. . . . . . .

90-857046R1 NOVEMBER 2001 Page 1C-1

GENERAL INFORMATION

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 top side of the swivel bracket.

a-Serial Number b-Model Year c-Model Description d-Year Manufactured e-Certified Europe Insignia

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

OGXXXXXX

19XX XXXX

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 Organization) 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 power that the engine will produce at sea level, at 30% relative humidity, at a temperature of 77° F (25° C) and a barometric pressure of 29.61 inches of mercury.

Page 1C-2 90-857046R1 NOVEMBER 2001

ENGINE RPM

RPM Drop Due to Weather

Rated RPM

GENERAL INFORMATION

Summer conditions of high temperature, low barometric pressure and high humidity all combine 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 engine 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 rigging 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 ef fect, become too large. Consequently, the engine operates at less than its recommended rpm.

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, however, 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 detonation. 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 effect on the boat’s performance, for example:

a. Shifting weight to the rear (stern).

b. Shifting weight to the front (bow).

c. Adjusting tilt pin to achieve best performance and handling.

(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.

and/or

(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).

90-857046R1 NOVEMBER 2001 Page 1C-3

GENERAL INFORMATION

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

2. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is con-

3. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear

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.

CAVITATION

Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on the gear case, from an irregularity in the propeller blade itself or from improper engine installation (too high). 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.

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 trailer or during storage.

vex in fore-and-aft direction when viewed from the side, and boat has strong tendency to porpoise.

housing increase skin friction and cause speed loss. Clean surfaces when necessary.

Page 1C-4 90-857046R1 NOVEMBER 2001

Engine

DETONATION

GENERAL INFORMATION

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 bearings.

A few of the most common causes of detonation in a marine 4-cycle application are as follows:

• 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

90-857046R1 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 disassembly 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 t ime a nd c heck f or p resence o f w ater i n o il. I f w ater i s p resent ( milky a ppearance) drain and refill as previously mentioned.

6. Pour alcohol into carburetor 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 p lug o penings d own) a nd p our e ngine o il i nto i ntake m anifold plug holes (plugs removed) 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 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 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 90-857046R1 NOVEMBER 2001

Model 30/40 (4-Stroke) Powerhead Front View

GENERAL INFORMATION

59244

a-Remote Control and Engine Harness Connection b-Fuse – 20 Amp. c-Negative Battery Cable d-DDT Test Port e-Fuel Connection

f-Battery Cables g-Throttle and Shift Cables h-Remote Control Harness

i-ECM j-Intake Manifold

90-857046R1 NOVEMBER 2001 Page 1C-7

GENERAL INFORMATION

Model 30/40 (4-Stroke) Powerhead Starboard View

59245

a-Lifting Eye b-Engine Harness Connection to Remote Control Harness c-Intake Manifold d-Shift Arm (Non Bigfoot) e-Shift Linkage

f-Throttle Cam

g-Throttle Lever

Page 1C-8 90-857046R1 NOVEMBER 2001

Model 30/40 (4-Stroke) Powerhead Port View

GENERAL INFORMATION

a-Starter Motor b-Negative Battery Cable c-Access Port, Water Pressure/Temperature Sender Accessory d-Thermostat Housing e-Voltage Regulator

f-Ignition Coils g-Oil Dip Stick h-Engine Coolant Temperature (ECT) Sender

i-Oil Filter

j-Oil Pressure Port k-Positive Battery Cable

59247

90-857046R1 NOVEMBER 2001 Page 1C-9

GENERAL INFORMATION

Model 30/40 (4-Stroke) Powerhead Top View

a-Cam Shaft Timing Gear b-Timing Belt c-Crank Position Sensor d-Flywheel e-Remote Control and Engine Harness Connection

f-Enrichener Valve

59251

Page 1C-10 90-857046R1 NOVEMBER 2001

Model 30/40 (4-Stroke) Powerhead Aft View

GENERAL INFORMATION

a-Valve Cover b-Crankcase Breather Hose c-Oil Fill Plug d-Fuel Pump (Water Cooled)

59250

90-857046R1 NOVEMBER 2001 Page 1C-11

GENERAL INFORMATION

Propeller Selection

For in-depth information on marine propellers and boat performance - written by marine engineers - 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 all ows 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 acceleration while maintaining maximum boat speed.

If changing conditions cause the rpm to drop below the recommended range (such as warmer, 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 balanced-steering condition (steering effort equal in both directions) without causing the propeller 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 maximum 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 90-857046R1 NOVEMBER 2001

Propeller Removal/Installation

3-1/4 In. (83mm) Diameter Gear Case

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 starting 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 (N) position.

2. Remove the spark plug leads to prevent engine from starting.

GENERAL INFORMATION

WARNING

3. Straighten the bent tabs (a) on the propeller nut retainer.

4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. Pull propeller straight off shaft.

5. Coat the p ropeller shaft w ith Anti-Corrosion G rease or 2-4-C Marine L ubricant with Teflon.

IMPORT ANT: T o 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.

Flo-Torque I Drive Hub Propellers

6. Flo-Torque I Drive Hub Propellers nut retainer (c) and propeller nut (d) onto the shaft.

7. Place propeller nut retainer over pins. Place a block of wood between gear case and propeller and tighten propeller nut to 55 lb. ft. (75 N·m), aligning flat sides of the propeller nut with tabs on the propeller nut retainer.

– Install forward thrust hub (a), propeller (b), propeller

8. Secure propeller nut by bending tabs up and against the flats on the propeller nut.

9. Reinstall spark plug leads.

90-857046R1 NOVEMBER 2001 Page 1C-13

GENERAL INFORMATION

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

1. Shift outboard to neutral (N) position.

2. Remove the spark plug leads to prevent engine from starting.

3. Straighten the bent tabs (a) on the propeller nut retainer.

4. Place a block of wood between gear case and propeller to hold propeller and remove propeller nut. Pull propeller straight off shaft.

WARNING

5. Coat the p ropeller shaft with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.

Flo-Torque I Drive Hub Propellers

6. Flo-Torq I Drive Hub Propellers – Install thrust washer (a), propeller (b), continuity washer (c), thrust hub (d), propeller nut retainer (e), and propeller nut (f) onto the shaft.

7. Flo-Torq II Drive Hub Propellers (b), propeller (c), thrust hub (d), propeller nut retainer (e) and propeller nut (f) onto the shaft.

– Install forward thrust hub (a), replaceable drive sleeve

Flo-Torque II Drive Hub Propellers

8. Place a block of wood between gear case and propeller and torque propeller nut to 55 lb. ft. (75 N·m).

9. Secure propeller nut by bending three of the tabs into the thrust hub grooves.

10. Reinstall spark plug leads.

Page 1C-14 90-857046R1 NOVEMBER 2001

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 t o remove any a ir from the

system. 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 results. 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.

Avoid possible serious injury or death. When the outboard is trimmed in or out beyond a neutral steering condition, a pull on the steering wheel or tiller handle in either 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.

GENERAL INFORMATION

WARNING

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.

Avoid possible serious injury or death. Adjust outboard to an intermediate trim position 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.

WARNING

2. Generally increase top speed.

3. Increase clearance over submerged objects or a shallow bottom.

90-857046R1 NOVEMBER 2001 Page 1C-15

GENERAL INFORMATION

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 greater trim “under” capability is desirable to improve acceleration, reduce 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 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 result.

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

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

Page 1C-16 90-857046R1 NOVEMBER 2001

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 l eft, m ove t he t railing e dge o f t rim t ab t o t he l eft. If t he b oat t urns more easily t o t he r ight m ove t he t railing e dge o f t rim t ab t o t he r i ght. R etighten b olt a nd r etest.

GENERAL INFORMATION

a- Trim Tab

90-857046R1 NOVEMBER 2001 Page 1C-17

GENERAL INFORMATION

Compression Check

Compression/Cylinder Leakage Tests Must be performed with the ignition/injection system disabled. T o do this, the lanyard stop switch MUST BE placed to the “OFF” position.

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. Remove all spark plugs.

3. Lubricate threads in cylinder head and on compression gauge. Install compression gauge in spark plug hole.

CAUTION

110

EEPV303A / MT26-18P/N

110

a-Compression Gauge (EEPV303A - Snap-on) b-Adaptor (MT26-18 - Snap-on)

4. Hold throttle plate at W.O.T. and crank the engine over until the compression reading peaks on the gauge. Record the reading.

5. 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)

135 psi (950 Kpa, 9.5 kg/cm2)

Example of compression test differences:

Maximum (psi) Minimum (psi)

4-Stroke Outboard Oil

180 162 150 127.5

6. Remove compression gauge. Install spark plugs.

NOTE: Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine tuneup.

Page 1C-18 90-857046R1 NOVEMBER 2001

Cylinder Leakage Testing

Compression/Cylinder Leakage Tests Must be performed with the ignition/injection system disabled. T o do this, the lanyard stop switch MUST BE placed to the “OFF” position.

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.

GENERAL INFORMATION

CAUTION

* Courtesy of Snap-On-Tools

Analysis

Cylinder Leakage Tester (Snap-On-Tools EEPV309A)

NOTE: Spark plug hole is a 12 mm diameter. Use Snap-On Tool MT26-18 adapter with valve core removed.

Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. 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 it’s compression 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 through the carburetor, adjacent spark plug holes, exhaust pipe, crankcase fill plug. Use the following table to aid in locating the source of cylinder leakage:

Air Escaping From:

Carburetor Intake Valve

Exhaust System Exhaust Valve

Crankcase Fill Plug Piston or Rings

Indicates Possible

Defective:

90-857046R1 NOVEMBER 2001 Page 1C-19

Cylinder Head Gasket

GENERAL INFORMATION

Water Pressure Measurement

1. Warm up engine.

2. Remove plug.

3. Attach 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

91-79250A2

22-89772

22 20 18 16 14 12 10

8 6

Pump Pressure (psi)

4 2

0123456

rpm x 1000

a-Plug

Page 1C-20 90-857046R1 NOVEMBER 2001

Painting Procedures

Cleaning & Painting Aluminum Propellers & Gear Housings

WARNING

Avoid serious injury from flying debris. Avoid serious injury from airborne particles. 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 h our d ry t ime a nd no more than 1 w eek b efore a pplying t he f inish c oat.

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 provide a repaint job that compares with a properly applied factory paint finish. It is recommended that t h e l i s t e d m a t e r i a l s b e 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.

GENERAL INFORMATION

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.

IMPORT ANT: 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 manufacturers

instructions, allowing proper i nduction period f or p ermeation o f the e poxy p rimer a nd 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 colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.

90-857046R1 NOVEMBER 2001 Page 1C-21

GENERAL INFORMATION

Be sure to comply with instructions on the label for ventilation and respirators. Using 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 maintain good continuity circuitry between trim tab and gear housing.

Decal Removal/Application

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.

CAUTION

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.**

** Automotive Body Filler Squeegee ** Do not use a soap that contains petroleum based solvents.

SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding.

TEMPERATURE

IMPORT ANT: Installation of vinyl decals should not be attempted while in direct sunlight. Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application.

SURFACE PREPARATION

IMPORT ANT: 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 thoroughly with clean water.

Page 1C-22 90-857046R1 NOVEMBER 2001

DECAL APPLICATION

1. Mix

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 it’s shape during installation.

2. Place the decal face down on a clean work surface and remove the paper backing from

3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wet-

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

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

GENERAL INFORMATION

/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as

wetting solution.

“adhesive side” of decal.

ting solution.

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.

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).

90-857046R1 NOVEMBER 2001 Page 1C-23

OUTBOARD MOTOR INSTALLATION

IMPORTANT INFORMATION

Section 1D - Outboard Motor Installation

Table of Contents

Electric Fuel Pump 1D-1. . . . . . . . . . . . . . . . . . . . . .

Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . . .

Start in Gear Protection 1D-2. . . . . . . . . . . . . . . . . .

Selecting Accessories For The Outboard 1D-2. . .

Installation Specifications 1D-2. . . . . . . . . . . . . . . . .

Lifting Outboard 1D-3. . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable Seal 1D-4. . . . . . . . . . . . . . . . . . . . .

Steering Link Rod 1D-4. . . . . . . . . . . . . . . . . . . . . . .

Installing Outboard

Thumb Screw Models 1D-5. . . . . . . . . . . . . . . . .

Non Thumb Screw Models 1D-6. . . . . . . . . . . . .

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.

Wiring Harness 1D-7. . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cable Connections 1D-8. . . . . . . . . . . . . . .

Shift and Throttle Cable Installation 1D-9. . . . . . . .

Trim-In Stop Adjustment Power Trim Models 1D-13

Trim Tab Adjustment 1D-13. . . . . . . . . . . . . . . . . . . . .

Instrument/Lanyard Stop Switch

Wiring Diagram (Dual Outboard) 1D-14. . . . . . . . .

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.

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.

WARNING

90-857046R1 NOVEMBER 2001 Page 1D-1

OUTBOARD MOTOR INSTALLATION

Start in Gear Protection

The remote control c onnected t o t he o utboard m ust b e e quipped w ith a s tart-in-gear p rotection 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, Operation, and Maintenance manuals for all selected accessories.

Installation Specifications

Transom Opening “A” (Minimum)

Single Engine (Remote) 19 in. (483 mm) Single Engine (Tiller) 30 in. (762 mm) Dual Engines 40 in. (1016 mm)

Engine Center Line For Dual Engines “B” (Minimum)

Page 1D-2 90-857046R1 NOVEMBER 2001

26 in. (660mm)

Lifting Outboard

Use lifting eye on engine.

Steering Cable

STARBOARD SIDE ROUTED CABLE

OUTBOARD MOTOR INSTALLATION

1. Lubricate the entire cable end.

2. Insert steering cable into tilt tube.

3. Torque nut to 35 lb. ft. (47.5 Nm).

2-4-C with Teflon

90-857046R1 NOVEMBER 2001 Page 1D-3

OUTBOARD MOTOR INSTALLATION

Steering Cable Seal

1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install seal components.

2. Thread cap to the mark.

a- 1/4 in. (6.4 mm) Mark b- Plastic Spacer c- O-Ring Seal d- Cap

Steering Link Rod

1. Install steering link rod per illustration.

1/4 in. (6.4mm)

a- Special Bolt (10-823919) Torque to 20 lb. ft. (27.1 N·m) b- Nylon Insert Locknut (11-826709113) Torque to 20 lb. ft. (27.1 N·m) c- Spacer (12-71970) d- Flat Washer (2) e- Nylon Insert Locknut (11-826709113) Tighten Locknut Until it Seats, Then Back

Nut Off 1/4 Turn

f-Use Middle Hole – Steer Outboard to the Side to Gain Hole Access

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special bolt (“a” - Part Number 10-823919) and self locking nuts (“b” & “ e ” - P a r t Number 11-826709113). 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.

Page 1D-4 90-857046R1 NOVEMBER 2001

WARNING

Installing Outboard – Thumb Screw Models

WARNING

Outboard must be fastened to boat transom one of two ways: 1. permanently fastened to transom with thumb screws, and mounting bolts (provided), or 2. secured to the transom using the optional outboard mounting kit (shown below). Should the outboard strike an underwater object or be steered into a sharp turn, failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could result in outboard ejecting suddenly off boat transom causing serious injury, death, boat damage, or loss of outboard.

IMPORTANT: Optional outboard mounting kits shown, must be used if outboard will not be permanently fastened to the transom with mounting bolts.

OUTBOARD MOTOR INSTALLATION

a- Outboard Mounting Kit Part No. 812432A4

1. Center outboard on the transom. Install the outboard so that the anti-ventilation plate

is in line or within 1 in. (25 mm) below the bottom of the boat.

0 - 1 in. (0 - 25mm)

a- Anti-Ventilation Plate

2. Fasten outboard with provided mounting hardware shown.

a- 1/2 in. Diameter Bolts (2) b- Flat Washers c- Locknuts

90-857046R1 NOVEMBER 2001 Page 1D-5

d- Marine Sealer - Apply to Shanks of

Bolts, Not Threads

e- Thumb Screws - Tighten Securely

OUTBOARD MOTOR INSTALLATION

Installing Outboard – Non Thumb Screw Models

1. Attach (tape) engine mounting template to boat transom.

2. Mark and drill four 17/32 in. (13.5mm) mounting holes.

3. Install the outboard so that the anti-ventilation plate is in-line or within 1 in. (25 mm) below the bottom of the boat.

0 - 1 in. (0 - 25mm)

a- Anti-Ventilation Plate

4. Fasten outboard with provided mounting hardware shown.

a- 1/2 in. Diameter Bolts (2) b- Flat Washers c- Locknuts d- Marine Sealer - Apply to Shanks of Bolts, Not Threads

Page 1D-6 90-857046R1 NOVEMBER 2001

Wiring Harness

IMPORT ANT: W arning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system.

1. Route wiring harness into bottom cowl.

a-Wiring Harness

OUTBOARD MOTOR INSTALLATION

2. Connect wiring. Push the wiring harness connectors together inside the rubber sleeve.

Push the retainer over the exposed ends of the connectors. This will hold the connectors together.

TAN

BRN/WHT

BLU/WHT

GRN/WHT

BLU/WHT

GRN/WHT

a- Power Trim Connections b- Rubber Sleeve – Place Harness Connectors Inside c- Retainer – Push Over Connector Ends

90-857046R1 NOVEMBER 2001 Page 1D-7

OUTBOARD MOTOR INSTALLATION

Battery Cable Connections

SINGLE OUTBOARD

(+)

DUAL OUTBOARDS

Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries.

(–)

a- Red Sleeve (Positive) b- Black Sleeve (Negative) c- Starting Battery

(–)

d- Ground Cable (Same Wire Size As Engine Battery Cable) - Connect Between

Negative (–) Terminals

Page 1D-8 90-857046R1 NOVEMBER 2001

(–)

Shift and Throttle Cable Installation

Install cables into the remote control following the instructions provided with the remote control.

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.

Shift Cable Installation

1. Position remote control into neutral.

2. Shift outboard into neutral.

OUTBOARD MOTOR INSTALLATION

3. Measure the distance (a) between pin and center of lower hole.

a- Distance Between Pin And Center of Lower Hole b- Pin c- Lower Hole

4. Fit shift cable through rubber grommet.

90-857046R1 NOVEMBER 2001 Page 1D-9

OUTBOARD MOTOR INSTALLATION

5. Push in on the cable end until resistance is felt.

6. While pushing in on the cable end, adjust the cable barrel (b) to attain the measured distance (a) taken in Step 3.

a- Adjust Cable Barrel To Attain The Measured Distance Taken In Step 3 b- Cable Barrel

7. Place cable barrel into the barrel holder. Fasten cable with retainer.

a- Place Barrel Into Barrel Holder b- Retainer

8. Check shift cable adjustments as follows: a. Shift remot e c o n t r o l i n t o f o r w a r d . 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 thru 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 thru d.

Page 1D-10 90-857046R1 NOVEMBER 2001

Throttle Cable Installation

1. Position remote control into neutral.

2. Fit throttle cable through rubber grommet.

3. Install throttle cable with retainer pin. Lock retainer pin in place.

OUTBOARD MOTOR INSTALLATION

4. Place throttle cable onto the throttle lever pin. Lock in place with retainer.

a-Throttle Cable b-Retainer

90-857046R1 NOVEMBER 2001 Page 1D-11

OUTBOARD MOTOR INSTALLATION

5. Adjust cable barrel until the center of the roller lines up with the alignment mark on the cam.

a-Cable Barrel b-Alignment Mark c-Roller

6. Fasten control cables with the cable latch.

Page 1D-12 90-857046R1 NOVEMBER 2001

OUTBOARD MOTOR INSTALLATION

Trim-In Stop Adjustment – Power Trim Models

a- Tilt Pin

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-ventilation plate is raised 2 inches (50mm) or more above the boat bottom.

90-857046R1 NOVEMBER 2001 Page 1D-13

OUTBOARD MOTOR INSTALLATION

Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)

BLK = Black BLU = Blue

BRN = Brown

GRY = Gray GRN = Green ORN = Orange

PNK = Pink

PUR = Purple

RED = Red

TAN = Tan

WHT = White

YEL = Yellow

LIT = Light

DRK = Dark

BATT

GND

SENDER

PORT INSTALLATION

a-Ignition/Choke Switch b-Lanyard Stop Switch c-Lead Not Used on Outboard Installations d-Retainer e-Tachometer

f-Trim Indicator Gauge g-Temperature Gauge h-Remote Control

i-Synchronizer Gauge

j-Synchronizer Box

52716

Page 1D-14 90-857046R1 NOVEMBER 2001

OUTBOARD MOTOR INSTALLATION

IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused wiring harness leads.

BATT

SENDER

GND

k-Lanyard/Diode

l-“Y” Harness

m-Power Trim Harness Connector

90-857046R1 NOVEMBER 2001 Page 1D-15

STARBOARD INSTALLATION

5265

n-Connect Wires Together with Screw and Hex

Nut (4 Places);Apply Quicksilver Liquid Neoprene to Connections and Slide Rubber Sleeve over Each Connection.

o-Lead to Visual Warning Kit

Table of Contents

IGNITION

ELECTRICAL

Section 2A - Ignition

Specifications 2A-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 2A-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel 2A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Components 2A-8. . . . . . . . . . . . . . . . . . .

Ignition Description 2A-10. . . . . . . . . . . . . . . . . . . . . .

Ignition Component Description 2A-10. . . . . . . . . . .

Electronic Control Module (ECM) 2A-10. . . . . . .

Crank Position Sensor 2A-11. . . . . . . . . . . . . . . .

Stator Assembly 2A-11. . . . . . . . . . . . . . . . . . . . . .

Flywheel Assembly 2A-12. . . . . . . . . . . . . . . . . . .

Ignition Coils 2A-12. . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Test Procedures 2A-12. . . . . . . . . . . . . . . . . .

Direct Voltage Adapter (DVA) 2A-12. . . . . . . . . .

Ignition Troubleshooting 2A-13. . . . . . . . . . . . . . . . . .

Ignition Diagnostic Procedures 2A-14. . . . . . . . . . . .

Recommended Test 2A-15. . . . . . . . . . . . . . . . . .

Troubleshooting with the

Digital Diagnostical Terminal 2A-17. . . . . . . . . . . . . .

Using the Digital Diagnostical

Terminal (DDT) 2A-17. . . . . . . . . . . . . . . . . . . . . . .

Component Resistance Tests 2A-18. . . . . . . . . . . . .

Spark Plug Cap Removal 2A-19. . . . . . . . . . . . . .

Spark Plug Cap Resistor Test-P/N VDFP 2A-20 Spark Plug Cap Resistor Test

P/N VDO5FP 2A-20. . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant Temperature

(ECT) Sensor 2A-21. . . . . . . . . . . . . . . . . . . . . . . .

Flywheel Removal/Installation 2A-22. . . . . . . . . . . . .

Removal 2A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 2A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .

Stator Removal/Installation 2A-25. . . . . . . . . . . . . . .

Timing Belt 2A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 2A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 2A-27. . . . . . . . . . . . . . . . . . . . . . . . . . .

ECM Removal/Installation 2A-28. . . . . . . . . . . . . . . .

Ignition Coil Removal/Installation 2A-29. . . . . . . . . .

Voltage Regulator Removal/Installation 2A-30. . . .

Crank Position Sensor Removal/Installation 2A-31 Engine Coolant Temperature

(ECT) Sensor Removal/Installation 2A-32. . . . . . . .

90-857046R1 NOVEMBER 2001 Page 2A-1

IGNITION

Specifications

IGNITION

SYSTEM

Readings taken @

68°F (20°C).

CHARGING

SYSTEM

Readings taken @

68°F (20°C).

Type Spark Plug:

Type Gap Hex Size Torque

Hole Size Firing Order Ignition Timing:

@ Idle (800 rpm)

@ WOT (6000 rpm) Charge Coil Resistance Crank Position Sensor Resistance Ignition Coil Resistance:

Primary

Secondary (W/o Boots) ECM Engine Speed Limiter

Soft Reduction (Retards Timing)

Spark Cut-Out Reduction (Percent-

ages of ignition spark are Cut-Out) ECM Overheat/Low Oil Pressure

Speed Control Engine Temperature Sensor

Alternator Type:

6 Amp. Manual Lighting Coil Output Lighting Coil Resistance 15 Amp. Electric Alternator Output

Battery Charging Coil Resistance

Power Bobbin Resistance

(For Electrothermal Valve)

Quicksilver Tachometer Setting

Capacitor Discharge Ignition

NGK DPR6EA-9

0.035 in. (0.9 mm) 18 mm

150 lb-in. (17 Nm)

12mm

1-2-3

10° A.T.D.C 28° B.T.D.C

660 - 710 Ω (GRN/WHT - WHT/GRN)

300 - 350 Ω (RED - WHT)

0.08 - 0.7 Ω (BLK - BLK/WHT)

3.5 - 4.7 kΩ (BLK - High Tension) 6200 rpm 6250 rpm

Approximately 2000 rpm

See Graph Section 2A-Ignition

Single Phase (12 Pole)

6 Amps.

0.9 - 1.1 Ohms (YEL-YEL)

12.6 V-15 Amps. (185 Watts) (Rectified/Regulated)

0.22 - 0.24 Ohms (YEL-YEL)

6.7-7.1 Ohms (YEL/BLK-YEL/BLK) “6P” or “4”

IMPORTANT: Use resistive spark plugs only.

Page 2A-2 90-857046R1 NOVEMBER 2001

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

90-857046R1 NOVEMBER 2001 Page 2A-3

IGNITION

5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

6. Digital Diagnostic Tester 91-823686A2

7. Cartridge 91-822608--5

8. DDT Reference Manual 90-881204--2

Page 2A-4 90-857046R1 NOVEMBER 2001

9. DDT Cable 10’ (3.05m) Extension 84-825003A1

10. DDT Test Harness 84-822560A7

IGNITION

11. DDT Test Harness 84-822560A10

90-857046R1 NOVEMBER 2001 Page 2A-5

IGNITION

FLYWHEEL

110

Page 2A-6 90-857046R1 NOVEMBER 2001

Loctite 222

4-Stroke Outboard Oil

IGNITION

REF

FLYWHEEL

QTY. DESCRIPTION lb. in. lb. ft. N·m

NO.

1 1 FLYWHEEL COVER ELECTRIC 2 4

3 1 DECAL-EPA Information 4 1 FLYWHEEL (ELECTRIC) 5 1 FLYWHEEL (MANUAL) 6 1 DECAL-Warning Spinning flywheel 7 1 DECAL-Timing Marks 8 1 DECAL-Warning-Neutral 9 1 NUT 116 157

10 1 WASHER 11

12 1 STATOR (OG 960499 and Below) 13 1 STATOR (OG 960500 and Up) 14 1 LOAD RING

SCREW (M6 x 25) 45 5.0

3 SCREW (M5 x 25) (MANUAL) 85 9.5 3 SCREW (M5 x 30) (ELECTRIC) 85 9.5

TORQUE

90-857046R1 NOVEMBER 2001 Page 2A-7

IGNITION

ELECTRICAL COMPONENTS

Dielectric Grease

Loctite Pipe Sealant With Teflon

1 4

Page 2A-8 90-857046R1 NOVEMBER 2001

IGNITION

REF

ELECTRICAL COMPONENTS

QTY. DESCRIPTION lb. in. lb. ft. N·m

NO.

1 1 SOLENOID ASSEMBLY 2 2

3 2 GROMMET 4 2 NUT (8-32) (ELECTRIC) 25 3.0 5 3 NUT (1/4-20) 60 7.0 6 1 BATTERY CABLE (POSITIVE) 7 1 INSULATOR BOOT 8 1 CABLE 9 1 BATTERY CABLE (NEGATIVE)

10 1 STARTER MOTOR (See breakdown on Starter Motor) 11

12 13 1 J CLIP (ELECTRIC)

14 1 PRESSURE SWITCH 75 8.5 15 1 SENSOR-Crank Position 16 2 SCREW (M5 x 16) 45 5.0 17 3 SCREW (M6 x 25) 75 8.5 18 3 WASHER 19 1 PLATE 20 3 BUSHING 21 3 GROMMET 22 1 ECM 23 3 BUSHING 24 3 SCREW (M6 x 40) 45 5.0 25 3 SPARK PLUG (NGK DPR6EA-9) 12.5 17

26 27 3 IGNITION COIL

28 3 SCREW (M6 x 20) 75 8.5 29

30 1 FUSE (SFE 20 AMP) (ELECTRIC) 31 1 COVER (ELECTRIC) 32 1 CLAMP (ELECTRIC) 33 2 SCREW (M6 x 16) (ELECTRIC) 34 1 HARNESS-EXTENSION (ELECTRIC HANDLE) 35 AR STA-STRAP 36 1 J CLIP (MANUAL) 37 1 VOLTAGE REGULATOR (S/N OG960499 and Below) 38 1 VOLTAGE REGULATOR (S/N OG960500 and Up) 39 1 J-CLIP

40 41 1 SCREW (M6 x 10)

42 1 PLUG 43 1 SCREW (M6 x 16)

3 SCREW (M8 x 45) (ELECTRIC) 21.5 29.5 1 SCREW (M8 x 25) (MANUAL) 21.5 29.5 2 SCREW (M6 x 30) (ELECTRIC) 75 8.5 1 SCREW (M6 x 16) (MANUAL) 75 8.5

1 DECAL-Coil Identification (1#) 1 DECAL-Coil Identification (2#) 1 DECAL-Coil Identification (3#)

1 ENGINE WIRING HARNESS (MANUAL) 1 ENGINE WIRING HARNESS (ELECTRIC)

2 SCREW (M6 x 40) ELECTRIC 105 12.0 1 SCREW (MANUAL)

BUSHING

TORQUE

90-857046R1 NOVEMBER 2001 Page 2A-9

IGNITION

Ignition Description

The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick voltage buildup and strong spark required for high power and high performance engines. The CDI 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 capacitor charging coil. This power is rectified by diodes so that direct current voltage is utilized by the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor. Once capacitor 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.

The electronic control module (ECM) activates the ignition driver in the ECM which allows the capacitor to discharge, causing the spark to occur. Ignition timing is regulated by the ECM which receives status input from a variety of sensors. These sensors include the crank position sensor, engine temperature and oil pressure sender.

The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient amplitude causes the spark plugs to fire.

Ignition Component Description

Electronic Control Module (ECM)

Under normal operating conditions the ECM unit controls the following:

1. Controls ignition spark timing by monitoring the crank position sensor, the engine temperature sensor, and the oil pressure sensor.

2. Maintains normal idle timing (see specification).

3. Engine stall. a. The stall saver feature will advance the ignition timing to 15° BTDC if engine falls

below 615 RPM.

4. Advances spark timing quickly to 28° BTDC under hard acceleration conditions.

5. Limits RPM of the engine in the event of a over speed condition (cavitation, no load on propeller, and/or under propped), as listed in the following steps:

a. Soft Reduction: Ignition timing is gradually retarded to keep engine RPM below

6200.

b. Spark Cut-Out Reduction: Percentages of ignition spark will be cut-out according to

the degree of over speed RPM reached.

Page 2A-10 90-857046R1 NOVEMBER 2001

IGNITION

RPM % Spark Cut-Out

6250 11% 6281 33% 6313 66%

6. Over Heat Protection: Limits engine RPM to 2000 if the engine temperature exceeds

192.2° F (89° C). The ECM will sound the over heat warning horn (a continuous tone) and turn on the optional Over Heat Warning lamp. Over heat warning will subside if the engine temperature drops below 183.2° F (84° C) and engine RPM is momentarily dropped below 1000 RPM as a reset condition. The ECM incorporates a 20 second warning system delay to compensate for a warm restart (heat soak) condition.

7. Low Oil Pressure Protection: Limits the engine RPM to 2000 if oil pressure drops below

2.25 +/– 0.75 psi. The ECM will sound the low oil pressure warning horn (intermittent 1 second on - 1 second off) and turn on the optional Low Oil Pressure Warning lamp. Low oil pressure warning will reset by shutting the engine off and restarting at a normal oil pressure. The ECM incorporates a 10 second warning system delay to allow engine to achieve operating oil pressure.

NOTE: The ECM controls all timing operations. There are no timing adjustment required on this engine.

Crank Position Sensor

Contains a permanent magnet and is positioned 0.030 ± 0.010″ (0.762 ± 0.254mm) from the flywheel teeth. The timed passing of the flywheel teeth through the sensor’s magnetic field enables the ECM to determine engine RPM and crankshaft angle.

Stator Assembly

a-S/N OG960499 and Below b-S/N OG960500 and Up

The stator assembly located under the flywheel contains the Ignition, auto enrichener, and battery charge coils. All of these coils make up the stator assembly.

As the flywheel permanent magnets pass the respective stator coil windings, an AC pulse current is produced at each coil winding when magnet polarity changes. (South to North), (North to South) etc.

90-857046R1 NOVEMBER 2001 Page 2A-11

IGNITION

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.

Ignition Coils

a-S/N OG960499 and Below b-S/N OG960500 and Up

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. Each ignition coil will produce a high voltage spark at each crankshaft revolution, producing a spark at each cylinder at the proper time (pre-determined by the ECM). Ignition coil maximum output is approximately 40,000 volts.

Ignition Test Procedures

Direct Voltage Adapter (DVA)

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.

Failure to c omply with t he f ollowing i tems m ay r esult i n d amage t o t he i gnition s ystem.

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 CDI or Ignition Coils not grounded.

Page 2A-12 90-857046R1 NOVEMBER 2001

CAUTION

T o p rotect a gainst m eter a nd/or c omponent d amage, o bserve t he f ollowing p r ecautions:

• 400 VDC* test position (or higher) MUST BE used for all tests.

• INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+) recep-

tacle of meter

• DO NOT CHANGE meter selector switch position while engine is running and/or be-

ing “cranked”.

• ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” en-

gine with CDI or Ignition Coils ungrounded may damage components.

* If u sing a m eter w ith a b uilt-in D V A, the D VA/400 or DVA/500 VDC test p osition s hould b e used.

NOTE: Test leads are not supplied with the Direct Voltage Adapter (p/n 91-89045). 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.

Ignition Troubleshooting

IGNITION

CAUTION

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.

Tool: Multimeter/DVA Tester 91-99750A1 or DMT 2000 Multi-Meter with Direct Voltage Adaptor (p/n 91-89045).

Component

Test

Coil

Primary

Stator Charge

Coil

Stator Charge

Coil

Selector

Sw.

Position

400 DVA*

400 DVA* Green/White (2) Ground 250 - 330 (1)

400 DVA* White/Green Lead (2) Ground 250 - 330 (1)

DVA Lead

Red

Coil (–) Black (B)

(2) **

Lead

DVA Lead

Black

Coil (+) Orange

(O) Lead

(2) **

Voltage Read-

@300-3000 RPM

250 - 320 (1)

ing

(1)

*If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position. ** Reverse Polarity

NOTE: If using DMT 2000 turn the selector switch to DC volts. Allow the meter to auto-range.

(1) Readings may vary at cranking speed or at idle speed. (2) Back probe the electrical lead bullet connector in order to make connection.

90-857046R1 NOVEMBER 2001 Page 2A-13

IGNITION

Multimeter Ohm Checks

Tested Part Multimeter Wires Connected To: Meter Scale Meter Reading

Stator Charge Coil

Power Bobbin

Charge Coil

Stator Battery Charge

Coil (6 Amp.)

Stator Battery Charge

Coil (15 Amp.)

Crank Position Sensor

Ignition Coil Primary

(with wires

disconnected)

Ignition Coil

Secondary

(test with coil leads

disconnected)

Red

Black

Red

Black

Red

Black

Red

Black

Red

Black

Red

Black

Red

Black

Green/White (2) White/Green (1)

Yel/Blk Yel/Blk

Yel Yel

Red (1)

White (2)

Black/White

Black (B)

High Tension Lead

Black (B)

R x 1 Ω 660 - 710

R x 1 Ω 6.7-7.1

R x 1 Ω 0.9-1.1

R x 1 Ω 0.22-0.24

R x 1 Ω 300 - 350

R x 1 Ω 0.18 - 0.24

R x 1k Ω 2.72 - 3.68

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 recommended 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 resistance test to validate suspected component failure.

Page 2A-14 90-857046R1 NOVEMBER 2001

*Recommended Test

(1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair

IGNITION

PROBLEM/CONDITION

Probable Cause *Perform

No Spark Condition (All Cylinders) Crank Position Sensor

Stator (ECM) Stop Circuit Short to Ground:

a - stop circuit lead b - lanyard stop switch c - tiller handle stop button (if supplied) d - remote control harness

Ignition Coil

a - primary Circuit Shorted to Ground Spark Plugs Open Ground Condition:

a - ignition coil

b - stator ground

c - (ECM)

No Spark Condition (One Cylinder) High Tension Lead

Spark Plug Cap (Resistor) Spark Plug

Weak Spark Condition Ground Connection at:

a - Ignition Coil Primary Leads

b - Stator

c - (ECM) Primary Coil Supply Leads High Resistance To Ground at:

a - stop/lanyard switch (water/corrosion) Weak Charge Coil Ignition Coil/High Tension Lead(s) Spark Plug(s) Spark Plug Cap (Resistor) Spark Plug Cap Leak (ECM) Failure

Test No.

1-2

3 2

2 2 2 2 2 3

2 3 3

2 2 3

2 1-2 1-3

Timing Fluctuates

NOTE: It is considered normal

for the timing to fluctuate approxi-

mately 1

- 2° within the desig-

nated timing window.

Timing Will Not Advance Low Oil Pressure/Engine Over Heating:

90-857046R1 NOVEMBER 2001 Page 2A-15

Loss Of Oil Pressure/Over Heating:

a - timing retards and fluctuates, rpm

will drop below 2000 rpm Flywheel Key Sheared (ECM) Unit

a - timing retards and fluctuates, rpm

will remain below 2000 rpm (ECM)

4 4

4 3

IGNITION

*Recommended Test (cont.)

(1) DVA TEST (Direct Voltage Adapter) (2) OHM TEST (Resistance Testing) (3) Replace Component and Retest (4) Mechanical Test/Repair

PROBLEM/CONDITION

Probable Cause *Perform

Engine Misfires At High RPM

Low Oil Pressure/Engine Over Heating:

a - timing retards and fluctuates, rpm

will remain below 2000 rpm Ignition Coil/High Tension Lead(s) Spark Plug Cap(s) Spark Plug(s) (ECM) Unit Ground Connection:

a - (ECM) b - ignition coil c - stator

Engine Hard To Start Cold Debris In Carburetor Enrichener Circuit

Weak Spark Condition Throttle Plate in Open Position

Engine Hard To Start Hot Weak Spark Condition

Vapor Lock

Engine Will Not Run Over 2000 RPM Low Oil Pressure/Engine Over Heating:

a - timing retards and fluctuates, rpm

will remain below 2000 rpm Stator Ignition Coil/High Tension Lead(s) (ECM) Spark Plug(s)

Test No.

4 2

2 3 3

3 2 2

4 1 4

4 4

1-2

2 3 3

Engine Occasionally Misfires Charge Coil

Ignition Coil/High Tension Lead(s) Spark Plug Cap(s) Spark Plug(s) Ground Connection at:

a - ignition coil b - (ECM) c - stator

High Resistance To Ground at:

a - stop/lanyard switch (water/corro-

sion)

(ECM)

Engine Surges Over 6200 RPM While Under Load

Boat Under Propped Propeller Hub Spun

NOTE: The engine (ECM)

will retard timing and reduce RPM above 6200 RPM.

1-2

2 2 3

2 3 2

2 3

4 4

Page 2A-16 90-857046R1 NOVEMBER 2001

Troubleshooting with the Digital Diagnostical Terminal

The ECM is designed such that if a sensor fails the ECM will compensate so that the engine does not go into an over-rich condition. Because of this, disconnecting a sensor for troubleshooting purposes may have no noticeable effect.

Using the Digital Diagnostical Terminal (DDT)

IMPORT ANT: Any sensor that is disconnected while the engine is running will be recorded as a fault in the ECM Fault History. Use the DDT to view and clear the fault history when troubleshooting/repair is completed.

IGNITION

a-Digital Diagnostic Terminal (91-823686A2) b-Software Cartridge (91-822608--6) c-DDT Reference Manual (90-825159--3) d-DDT Cable 10ft. (3.05m) Extension (84-825003A1) e-DDT Test Harness (84-822560A7)

f-DDT Test Harness (84-822560A10)

The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.

Attach the diagnostic cable to the ECM diagnostic connector and plug in the software cartridge. You will be able to monitor sensors and ECM data values including status switches. The ECM program can help diagnose intermittent engine problems. It will record the state of the engine sensors and switches for a period of time and then can be played back to review the recorded information.

Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic procedures.

90-857046R1 NOVEMBER 2001 Page 2A-17

IGNITION

Component Resistance Tests

When performing resistance tests, all component leads must be disconnected. Readings may very slightly due to temperature changes.

NOTE: Refer to section 1C General Information (powerhead reference views) for location of sensors.

NOTE: If using DMT 2000 turn the selector switch to NOTE: Readings listed are taken at 68

STATOR (IGNITION CHARGE COIL)

F (20° C).

Ω.

Allow the meter to auto-range.

a-S/N OG960499 and Below b-S/N OG960500 and Up

METER TEST LEADS

RED BLACK

GRN/WHT WHT/GRN

METER SCALE READING

RX1 660 - 710

STATOR AUTO ENRICHENER (POWER BOBBIN CHARGE COIL)

a-S/N OG960499 and Below b-S/N OG960500 and Up

(

METER TEST LEADS

RED BLACK

YEL/BLK YEL/BLK

Page 2A-18 90-857046R1 NOVEMBER 2001

METER SCALE READING

(

RX1 6.7 - 7.1

IGNITION COIL (PRIMARY)

IGNITION

a-S/N OG960499 and Below b-S/N OG960500 and Up

METER TEST LEADS

RED BLACK

BLK/WHT BLACK

Spark Plug Cap Removal

NOTE: High tension cables must have spark plug cap removed before testing. Cap contains

5k ohm resistor.

IMPORTANT: To remove spark plug cap from high tension leads, turn cap counterclockwise while applying slight outward pressure. DO NOT PULL HARD or lead may be damaged. To install cap, turn cap clockwise threading cap onto high tension lead.

METER SCALE READING

RX1 0.18 - 0.24

(

IGNITION COIL (SECONDARY)

a-S/N OG960499 and Below b-S/N OG960500 and Up

METER TEST LEADS

RED BLACK

HIGH TENSION LEAD BLK

METER SCALE READING

(

RX1K 2.72 - 3.68

90-857046R1 NOVEMBER 2001 Page 2A-19

IGNITION

RX1K

3.5

RX1

300

350

Spark Plug Cap Resistor Test-P/N VDFP

METER TEST LEADS METER SCALE READING

RED BLACK

WIRE END PLUG END

Spark Plug Cap Resistor Test-P/N VDO5FP

(

METER TEST LEADS METER SCALE READING

RED BLACK

WIRE END PLUG END

CRANK POSITION SENSOR

METER TEST LEADS METER

RED BLACK

RED WHT

SCALE

(

- 5.

READING

(

Page 2A-20 90-857046R1 NOVEMBER 2001

Engine Coolant Temperature (ECT) Sensor

1. Place the engine coolant 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. If the reading is out of specification, replace the sensor.

270 255 240

225



210 195 180 165 150 135 120 105

90 75 60 45

Test Water Temperature(

30 15

02468101214161820222426283032

IGNITION

Temperature Sensor

90-857046R1 NOVEMBER 2001 Page 2A-21

Resistance (k)

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, always remove spark plug leads from spark plugs.

Removal

1. Remove flywheel cover (manual start models refer to section 8).

a-Screw (4) M6 x 25 b-Flywheel Cover

Page 2A-22 90-857046R1 NOVEMBER 2001

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

3. Remove nut and washer.

IGNITION

91-83163M

a-Flywheel Holder (91-83163M) b-Breaker Bar with 30 mm Socket c-Nut d-Washer

4. Loosen flywheel using puller (91-83164M). Remove flywheel and key.

a-Flywheel Puller (91-83164M) b-Flywheel c-Key

90-857046R1 NOVEMBER 2001 Page 2A-23

91-83164M

IGNITION

Installation

1. Place flywheel key into slot.

2. Install flywheel. Apply oil to threads on crankshaft.

3. Install washer and nut.

4. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque.

a-Key b-Flywheel c-Washer d-Nut e-Torque Wrench (with 30mm socket)

f-Flywheel Holder (91-83163M)

91-83163M

Page 2A-24 90-857046R1 NOVEMBER 2001

Flywheel Nut Torque

116 lb. ft. (157 N·m)

Stator Removal and Installation

1. Remove stator harness from j-clips (s/n OG960499 and below).

2. Remove cable tie from bundled wire connectors (s/n OG960499 and below).

3. Disconnect stator wires.

4. Remove stator mounting screws.

5. Reverse steps for installation (refer to wiring diagram Section 2D for correct stator wire connections).

IGNITION

Loctite “222”

a-Stator b-J-Clips c-Cable Tie d-Screws (3) M5 x 30 (Electric) or M5 x 25 (Manual) e-Voltage Regulator/Rectifier (s/n og960499 and below)

f-Voltage Regulator/Rectifier (s/n og960500 and up)

Stator Screw Torque

85 lb. in. (9.5 N·m)

90-857046R1 NOVEMBER 2001 Page 2A-25

Mercury 40 FourStroke, 30 FourStroke Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual