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MODELS 2.5 3.32.2 3.0 MODELS 2.5 3.32.2 3.0 Printed in U.S.A. © 1992, Brunswick Corporation 90-44477--1 1192 Notice Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “Common Sense” operation, are major accident prevention measures. ! DANGER DANGER -Immediate hazards which WILL result in severe personal injury or death. ! WARNING WARNING -Hazards or unsafe practices which COULD result in severe personal 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 ing 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 is 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. 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. Customary bolts use radial lines for this purpose, while most customary 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. 90-44477--1 1192 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. 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. Before raising or removing and outboard engine from a boat, the following precautions should be adhered to: (1) Check that flywheel is secured to end of crankshaft with a locknut and lifting eye is threaded into flywheel a minimum of 5 turns. (2) Connect a hoist of suitable strength to the lifting eye. In addition, 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 described in this manual. Service Manual Outline Section 1 -General Information & Specifications Section 2 -Electrical & Ignition Section 3 -Fuel System & Carburetion Section 4 -Powerhead Section 5 -Mid-Section Section 5A -Gear Housing (Non-Shifting) Section 5B -Gear Housing (Shiftable-F/N) Section 6 -Rewind Starter Assembly 90-44477--1 1192 GENERAL INFORMATION AND SPECIFICATIONS 1 50966 Table of Contents Page Motors Parts Identification . . . . . . . . . . . . . . . . . . . . . . . 1-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Gear Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Mid-Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Standard Bolts and Nuts. . . . . . . . . . . . . . . . . . . 1-3 Outboard Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Transom Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Mounting Outboard on Transom . . . . . . . . . . . . . . . 1-4 Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Gasoline Recommendations . . . . . . . . . . . . . . . . . . 1-4 Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . 1-4 Fuel Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Correct Fuel Mixing Procedure . . . . . . . . . . . . . . . 1-4 Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Adjustments and Maintenance . . . . . . . . . . . . . . . . . . . 1-5 Cowl Removal and Installation . . . . . . . . . . . . . . . . 1-5 Model 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Models 2.5/3.0 (1990). . . . . . . . . . . . . . . . . . . . . 1-6 Models 2.5/3.0/3.3 (1991 and later) . . . . . . . . . 1-6 Throttle Lever Friction Adjustment . . . . . . . . . . . . . 1-6 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . 1-6 Servicing Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Gear Housing Lubrication . . . . . . . . . . . . . . . . . . . . 1-7 Propeller and Drive Pin. . . . . . . . . . . . . . . . . . . . . . . 1-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Points of Lubrication - All Models . . . . . . . . . . . . . . 1-8 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Flushing Outboard. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Following Complete Submersion . . . . . . . . . . . . . 1-10 Salt Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . 1-10 Submerged While Running (Special Instructions) . . . . . . . . . . . . . . . . . 1-10 Fresh Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . 1-10 Out-of-Season Outboard Storage . . . . . . . . . . . . . . . 1-10 How Weather Affects Engine Performance . . . . . . . 1-11 Conditions Affecting Operation . . . . . . . . . . . . . . . . . . 1-11 Detonation: Causes and Prevention . . . . . . . . . . . . . 1-12 Compression Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Propeller Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . 1-13 90-44477--1 1192 Motors Parts Identification 1 -Air Vent Knob 2 -Fuel Tank Cap 3 -Cowl 4 -Cowl Latch (Model 2.5/3.0/3.3) 5 -Fuel Cock Knob 6 -Spark Plug Access Door 7 -“Tell-Tale” Outlet 8 -Driveshaft Housing 9 -Exhaust Relief Outlet 10-Anti-Ventilation Plate 11-Exhaust Outlet 12-Anodic Plate 13-Cotter Pin 14-Propeller 50649 15-Skeg 16-Starter Handle 17-Control Panel 18-Tiller Handle 19-Lift Handle 20-Tilt Lock Pin 21-Clamp Screw (2) 22-Clamp Bracket (2) 23-Tilt Angle Adjustment Pin 24-OIL LEVEL Plug 25-Cooling Water Intake 26-Gear Housing 27-OIL FILL Plug 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-1 General Specifications NOTE: Other specifications (torque, etc) are listed in the respective sections. Dimensions Overall Length w/Tiller Handle . . . . . 23-1/4 in.(591mm) Overall Width . . . . . . . . . . . . . . . . . . . . . 8-1/2 in.(215mm) Overall Height (Short Shaft) . . . . . . . . . . 38 in. (965mm) Recommended Boat Transom Height . . 15 in. (381mm) Weight (Short Shaft) . . . . . . . . . . . . . . 27.5 lb. (12.5kgs) Powerhead Horsepower (Model 2.2). . . . . . . . . . . 2.2 @ 5000 RPM Kilowatts*. . . . . . . . . . . . . . . . . . . . 1.6 @ 5000 RPM Horsepower (Model 2.5). . . . . . . . . . . 2.5 @ 5000 RPM Kilowatts*. . . . . . . . . . . . . . . . . . . . 1.9 @ 5000 RPM Horsepower (Model 3.0). . . . . . . . . . . 3.0 @ 5000 RPM Kilowatts*. . . . . . . . . . . . . . . . . . . . 2.2 @ 5000 RPM Horsepower (Model 3.3). . . . . . . . . . . 3.3 @ 5000 RPM Kilowatts*. . . . . . . . . . . . . . . . . . . . 2.5 @ 5000 RPM RPM Range at Full Throttle Model 2.2. . . . . . . . . . . . . . . . . . . . . . . . . 4200 - 5200 Model 2.5. . . . . . . . . . . . . . . . . . . . . . . . . 4000 - 5000 Model 3.0. . . . . . . . . . . . . . . . . . . . . . . . . 4500 - 5500 Model 3.3. . . . . . . . . . . . . . . . . . . . . . . . . 4500 - 5500 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-Stroke Cycle Number of Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Displacement . . . . . . . . . . . . . . . . . . . . 4.6 cu. in. (74.6cc) Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.85 in. (47mm) Dia. 0.5mm Oversized . . . . . . . . 1.869 in. (47.5mm) Out of Round (Max.) . . . . . . . . . 0.002 in. (0.05mm) Taper (Max.) . . . . . . . . . . . . . . . . 0.002 in. (0.05mm) Crankshaft Runout (Max.). . . . . . . . . . . . . . . 0.001 in. (0.05mm) Connecting Rod Deflection . . . 0.022 in. to 0.056 in. (0.6mm to 1.5mm) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.69 in. (43mm) Intake System . . . . . . . . . . . . . . . . . . . . . . . . . Reed Valve Reed Block Reed Stop Opening . . . . . . . . . 0.236 in. to 0.244 in. (6mm to 6.2mm) Scavenging System . . . . . . . . . . . . . . . . . . Loop Charge Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T hru-Prop Lubrication System . . . . . . Pre-Mixed Gasoline and Oil Cooling System . . . . . . . . . . . . . . . . . . . . . . Water-Cooled Starting System . . . . . . . . . . . . . . . . . . . . . . Manual Start *Measured at the propeller shaft in accordance with ICOMIA 28 Fuel System Carburetor . . . . . . . . . . . . . . . Center Bowl Gravity Feed Float Level (All Models) . . . . . . . 0.090 in. (from gasket) (2.0mm) Ref. Section 3 Main Jet (Model 2.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . #96 Main Jet (Model 2.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . #92 Main Jet (Model 3.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . #92 Main Jet (Model 3.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . #94 Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 - 1000 Fuel . . . . . . . . . . . . . . . . . . . . Pre-Mixed Gasoline and Oil Recommended Gasoline . . . . . . . Automotive Leaded or Lead-Free Gasoline Recommended Oil . . . . . . . . . . . . . . Quicksilver 2-Cycle Outboard Oil Gasoline/Oil Ratio . . . . . . . . . . . 50:1 (Including Break-In) Integral Fuel Tank Capacity U.S. Gallons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.375 Imperial Gallons . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 Liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Ignition System Ignition Type (Models 2.0/2.5/3.0) . . Flywheel Magneto Spark Plug (All Models) . . . . . . . . . . . NGK BPR6HS-10 or Champion RL87YC Spark Plug Gap . . . . . . . . . . . . . . . . . . 0.040 in. (1.0mm) Breaker Point Gap. . . . . . . . . . . . . . . . . . . 0.012 - 0.016 in. (0.3mm - 0.4mm) Primary Ignition Coil Test . . . . . . . . . . . . . . . . . . 1.5 Ohms Condenser Capacity . . . . . . . . . . . . . . . 0.22mF - 0.28mF Secondary Ignition Coil Test Primary Winding Resistance . . . . 0.81 - 1.09 Ohms Secondary Winding Resistance . . 4250 -5750 Ohms Ignition Type [1993 Models (2.5/3.3)] . . . . . . . Capacitor Discharge Test Specifications . . . . . . . . . . . . . . . Refer to DVA Chart 1-2 - GENERAL INFORMATION and SPECIFICATIONS 90-44477--1 1192 Gear Housing Gear Ratio (Model 2.2). . . . . . . . . . . . . . . . . . . . . . 1.85:1 Gear Ratio (Models 2.5/3.0/ 3.3) . . . . . . . . . . . . . 2.18:1 Gear Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spiral Bevel Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . Sliding Dog Propeller Drive System . . . . . . . . . . . . . Drive (Shear) Pin Lubricant Type . . . . . . . . . . . . . . . . . . . Quicksilver Gear Lube Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . 3 oz. (90ml) Mid-Section Steering Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360° Tilt Pin Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Full Tilt-Up Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75° Allowable Transom Thickness . . . . . 1.18 in. - 2.165 in. (30mm - 55mm) Torque Specifications 1. All torque values are for clean, dry, corrosion free threads, except where locking compounds are specified. Refer to appropriate section of this manual. 2. Cover and housing screws MUST BE torqued by tightening in 3 progressive steps (following specified torque sequence) until specified torque is reached. Refer to appropriate section of this manual. 3. When retightening powerhead and gear housing mounting bolts, first back them out one turn, and then retorque to specification. 4. To retighten spark plug, start engine and warm-up to operating temperature. Stop engine and allow to cool, then retorque plug to specification. 5. Propeller MUST BE secured with cotter pin. Powerhead Flywheel Nut . . . . . . . . . . . . . . . . . . . . . 30 lb. ft. (4.1 N·m) Crankcase Cover to Cylinder Block Bolts. . . . . . . . . . . . 50 lb. in. (5.6 N·m) Cylinder Head Bolts . . . . . . . . . . . . . . . 85 lb. in. (9.6 N·m) Spark Plug . . . . . . . . . . . . . . . . . . . . . . 20 lb. ft. (27.1 N·m) STANDARD BOLTS AND NUTS TORQUE SPECIFICATION N·M LB. IN. LB. FT. Outboard Installation ! WARNING DO NOT OVERPOWER - Most boats are rated and certified for the maximum horsepower capabilities of the boat. Refer to the boat “Certification Plate” for the maximum horsepower limit. If in doubt, contact your dealer. Transom Height 1. This outboard is designed to provide optimum performance when mounted at the recommended transom height. If the transom is too high, the propeller may operate too close to the water surface introducing air over the propeller blades, causing a lost of thrust (particularly when attempting to plane off or during a turn). If the transom is too low, a performance loss is created by excessive lower unit drag and water spray (additionally, under clearance may also present a problem). 2. Conventional installations generally locate the gear housing anti-ventilation plate parallel to and approximately 1 in. - 2 in. (30mm - 50mm) below the boat bottom. a -Anti-Ventilation Plateb -Recommended Boat Transom Height - 15 in. (381mm) 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-3 Mounting Outboard on Transom ! WARNING Before operating the outboard, it MUST BE PROPERLY SECURED to the boat transom. Failure to adhere to the outboard mounting instructions, following, may result in loss of the outboard, damage to boat and/or outboard and injury to occupants of the boat. 1. Center outboard on boat transom at recommended transom height (see “Transom Height,” preceding) and secure outboard to transom with clamp screws. To avoid damage to transom and to prevent clamp screws from working loose during operation, make certain that clamp screws are tightened securely and equally. Clamp screws should be checked for tightness periodically. IMPORTANT: During use, a periodic check of the clamp screws is recommended to ensure that the outboard remains secure on the transom. Fuel Recommendations Gasoline Recommendations ! WARNING Use CARE when transporting fuel container, whether in a boat or car. DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazzard. Any gasoline that will satisfactorily operate an automobile engine is suitable for your outboard motor. IMPORTANT: While the use of REGULAR LEADED gasoline is entirely satisfactory, LEAD FREE or LOW LEAD regular gasolines are PREFERRED as they generally provide an “extra margin” of spark plug life. Some fuel distributors pre-mix gasoline and oil for 2-cycle engines. Such fuels, if known to be of of recommended quality, are acceptable. If in doubt, check with your local dealer. ! CAUTION DO NOT USE white gasolines or fuels intended for stoves and lanterns. Use of improper gasolines and/or oils can cause serious damage to your outboard motor. Oil Recommendations Mix recommended gasoline with Quicksilver 2-Cycle Outboard Oil in ratio shown in the following chart. If Quicksilver 2-Cycle Oil is not available, substitute a high quality 2-cycle oil intended for outboard use and meets NMMA rating TCWII E, as shown on oil container. NMMA rating TC-WII™ is the Boating Industry Association’s designation for approved, 2-cycle water-cooled outboard oils. Use at oil manufacturer’s recommended gasoline-oil mixture as shown on the label. (NOT TO EXCEED 50:1 RATIO.) ! CAUTION The use of other than recommended gasoline and Quicksilver 2-Cycle Outboard Oil or an acceptable oil may cause piston scoring, bearing failure or both. DO NOT, under any circumstances, use multi-grade or other highly detergent automobile oils or oils which contain metallic additives. IMPORTANT: When checking fuel level and/or filling the motor fuel tank ALWAYS check the fuel tank cap to verify that the seal is properly seated inside the cap. Tighten fuel tank cap securely. FUEL MIXTURE Use a 50:1 gasoline-oil ratio for “break-in” and all normal operation of your outboard motor. (See chart, following.) U.S. Measure Imperial Measure Metric Measure Quicksilver 2-Cycle Oil 16 U.S. oz. to each 6 gallons of gasoline 15 Imp. oz. to each 5 Imp. gallons gasoline 400cc to each 20 liters of gasoline Other Acceptable Oils Use at manufacturer’s recommended gasoline/oil ratio, not to exceed 50:1 IMPORTANT: Using less than the recommended proportion of oil may result in very serious damage from lack of sufficient lubrication. Using more than the recommendations will cause spark plug fouling, erratic carburetion, excessive smoking and faster-than-normal carbon accumulation. Correct Fuel Mixing Procedure ! WARNING Observe fire prevention rules, particularly the matter of smoking. Mix fuel outdoors or in a well-ventilated location. 1-4 - GENERAL INFORMATION and SPECIFICATIONS 90-44477--1 1192 Mix fuel in a separate container. Measure accurately the required amounts of oil and gasoline. Pour a small amount of gasoline into container and add a small amount of oil (about the same amount as gasoline). Mix thoroughly by shaking or stirring vigorously; then add balance of oil and gasoline, mix again and pour into fuel tank. Cleanliness is important in mixing fuel. Be consistent; prepare each batch of fuel exactly the same as previous amounts (to avoid readjustment of carburetor low speed mixture screw). IMPORTANT: Always use fresh gasoline. Gasoline forms gum and varnish deposits and when kept in a tank for a length of time, may cause trouble. ! WARNING Use care to prevent spilling fuel when filling the motor fuel tank. DO NOT OVERFILL. If tank is overfilled, fuel may spill into the cowling and if gasoline vapors are present, an errant spark could cause an explosion or fire. If fuel is spilled, remove cowling and clean up as much of the spill as possible. Allow a minimum of 5 minutes for ventilation/evaporation of fuel and/or vapors BEFORE ATTEMPTING TO START ENGINE. Tilt Angle Adjustment The angle of the motor can be adjusted by changing the position of the tilt angle adjustment pin in the holes provided in the clamp brackets. 50652 a -Tilt Angle Adjustment Pin Adjusting Tilt Angle of the Motor - 2.5/3.0 Model 2.2/3.3 -Reposition tilt screw/nut as in (a) above. The angle of the motor is important for obtaining the best performance of the motor. The tilt angle should be adjusted so that the motor anti-ventilation plate is parallel to the water surface when at full speed. Wrong! Bow Up Wrong! Bow Down Right! Plane or Even Keel Outboard Motor Angle Positions Adjustments and Maintenance ! WARNING DO NOT attempt to remove or install cowl while engine is running. Cowl Removal and Installation MODEL 2.2 Remove spark plug access cover. Remove 10 screws to remove cowling. Replace 10 screws and access cover to reinstall cowl. MODELS 2.5/3.0 (1990) 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-5 Remove gas tank cap and retainer from tank. Push in on inner portion of cowl latches to disengage latches and lift top cowl off. To replace cowl, position cowl over engine and push down until latches engage. Replace gas tank cap and tighten securely. 50915 MODELS 2.5/3.0/3.3 (1991 AND LATER) Lift up on latches to remove cowl. Replace cowl by engaging latches over top cowl latch recess. 50965 Throttle Lever Friction Adjustment Turn the screw attached to the throttle lever end. To increase, turn screw clockwise. To decrease, turn screw counterclockwise. Idle Speed Adjustment With engine running, position throttle lever to slowest speed. Adjust the idle speed screw to obtain recommended idle speed (see “Specifications” on page 1-1). 1-6 - GENERAL INFORMATION and SPECIFICATIONS 90-44477--1 1192 Servicing Spark Plug 1. Open access cover on outboard motor. 2. Disconnect spark plug lead and remove spark plug using socket provided in tool kit. 50651 IMPORTANT: Use same type of spark plug that is specified on page 1-1. Set spark plug gap at 0.040 in. (1mm). 3. Install new spark plug. Start threads 1 or 2 turns with fingers to avoid danger of cross-threading. 4. Seat plug finger-tight on gasket; an additional 1/4 turn with a wrench generally will be sufficient to tighten. Do not overtighten. 5. Inspect spark plug lead. If insulation is damaged or deteriorated, install new lead. 6. Connect spark plug lead. Reinstall access cover. Gear Housing Lubrication ! CAUTION If any water drains from the filler hole, if lubricant appears milky brown, or if large amounts of lubricant must be added to fill the gear housing, it should be checked promptly by your servicing dealer. Periodically lubricate (see “Lubrication Chart”) the gear housing assembly with Quicksilver Gear Lubricant. IMPORTANT: DO NOT use automotive grease in the gear housing assembly. Use only Quicksilver Gear Lubricant. a -Lubricant Fill Plug b -Lubricant Vent Plug 1. Remove lubricant fill plug and washer from gear housing. 2. Insert lubricant tube into fill hole, then remove lubricant vent plug and washer. IMPORTANT: Never add lubricant to gear housing without removing lubricant vent plug or gear housing cannot be completely filled. 3. Fill gear housing until excess starts to flow out of vent plug hole. 4. Replace vent plug and washer. 5. Remove lubricant tube from filler hole and install fill plug and washer. 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-7 Propeller and Drive Pin ! WARNING BEFORE attempting to remove or install the propeller, remove spark plug lead from spark plug to prevent engine from starting accidentally. If the propeller hits an obstacle underwater, the drive pin is designed to break instantly protecting the propeller and other parts from damage. Use only genuine Quicksilver replacement parts. REMOVAL 1. Using the pliers provided, straighten the cotter pin and pull it out of propeller. 2. Remove propeller from shaft. 3. Remove drive pin. 1 2 3 INSTALLATION 1. To aid in future removal of the propeller, liberally coat the propeller shaft with one of the following Quicksilver lubricants: – Special Lubricant 101 – Anti-Corrosion Grease – 2-4-C Marine Lubricant 2. Reinstall drive pin. 3. Align the groove in propeller with drive pin and slide propeller onto propeller shaft. 4. Secure propeller to shaft with cotter pin. Bend ends of cotter pin. Points of Lubrication - All Models Item Description Type of Lubricant Fresh Water Frequency Salt Water Frequency 1 Throttle Linkage (All Pivot Points) A Every 60 Days Every 30 Days 2 Tilt Lock Pin A Every 60 Days Every 30 Days 3 Til t Pivot A Every 60 Days Every 30 Days 4 Clamp Screws A Every 60 Days Every 30 Days 5 Swivel Bracket/ Swivel Pin A Every 60 Days Every 30 Days 6 Co-Pilot Screw A Every 60 Days Every 30 Days Check and Fill After 1st 10 Days, then Every 30 Days Check and Fill After 1st 10 Days, then Every 30 Days 7 Gear Housing B Drain and Refill After 1st 25 Hours, then After every 100 Hours, or Once a Year Before Storing Drain and Refill After 1st 25 Hours, then After every 100 Hours, or Once a Year Before Storing 8 Propeller Shaft A Once a Season Every 60 Days Type of Lubricants A= Quicksilver 2-4-C Lubricant B= Quicksilver Gear Lubricant 1-8 - GENERAL INFORMATION and SPECIFICATIONS 90-44477--1 1192 Periodic Inspection Conduct a periodic, systematic inspection to uncover and correct a failure before it can cause inconvenience or mechanical damage. Inspection interval is based on average operating conditions in utility service. Under severe conditions, the interval should be shortened. Inspection includes: 1. Clean entire unit thoroughly, including all accessible powerhead parts. 2. Check entire unit for loose, damaged or missing parts. Tighten or replace as required. 3. Lubricate gear housing as instructed previously. 4. Lubricate other points as indicated, preceding. 5. Service spark plug. Inspect spark plug lead and electrical leads for damage or deterioration, as explained in Section 2A, “Ignition System.” 6. Inspect fuel hoses for damage or deterioration and service fuel filters as indicated in Section 3A, “Fuel System.” 7. Remove propeller and inspect. Dress nicks and burrs with a file. Do not remove more metal than necessary. Inspect for cracks, damage or bent blades. If condition is doubtful, refer to authorized Quicksilver Repair Station facilities. Before reinstalling propeller, apply Quicksilver Special Lubricant 101, Anti-Corrosion Grease or 2-4-C Marine Lubricant to the propeller shaft. 8. Inspect the outboard surface finish for damage or corrosion. Thoroughly clean damaged or corroded areas and apply matching paint (Quicksilver Spray Paints). 9. Check remote controls and steering. Verify all connections and fittings are in good condition, properly secured and correctly adjusted. Flushing Outboard NOTE: Outboard can be flushed by running engine in a fresh water test tank. 1. Mount outboard in a test tank. 2. Start engine. DO NOT exceed half throttle speed. IMPORTANT: While and after flushing, keep outboard in upright position until all water has drained from driveshaft housing and exhaust ports. 3. Flush or service engine as required. Be sure adequate cooling water is provided. a. Water must be discharged thru “tell-tale.” IMPORTANT: Prevent engine overheating. If water flow is insufficient, stop engine and determine cause before continuing. b. Flush until discharged water is clear. In saltwater areas, run outboard 3 to 5 minutes. Zinc Anode A zinc anode is a self-sacrificing component that will be consumed gradually by corrosion while it protects an aluminum drive from the damaging effects of galvanic corrosion. Inspect the zinc anode regularly and replace when anode has been approximately 50% consumed. IMPORTANT: DO NOT paint or place protective coating on zinc anodes (or the “contact surface” on the drive), or their corrosion protection is lost. Check the zinc anode (a) and replace it when necessary. 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-9 Following Complete Submersion Submerged engine treatment is divided into 3 distinct problem areas. The most critical is submersion in salt water; the second is submersion while running. 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. 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 rotate 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. 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. Pour alcohol into carburetor throat (alcohol will absorb water). Again rotate flywheel. 6. Turn engine over and pour alcohol into spark plug openings and again rotate flywheel. 7. Turn engine over (place spark plug openings down) and pour engine oil into throats of carburetors while rotating flywheel to distribute oil throughout crankcase. 8. 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. 9. Remove and clean carburetors and fuel pump assembly. 10. Reinstall spark plugs, carburetors and fuel pump. 11. 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. 12. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should be run within 2 hours after recovery of outboard from water, as serious internal damage may occur. If unable to start engine in this period, disassemble engine and clean all parts and apply oil as soon as possible. Out-of-Season Outboard Storage ! WARNING As a safety precaution, when boat is in storage, remove positive (+) battery cable. This will eliminate possibility of accidental starting of engine and resultant overheating and damage to engine from lack of water. In preparing an outboard for out-of-season storage, 2 precautions must be considered: 1) The engine must be protected from physical damage and 2) the engine must be protected from rust, corrosion and dirt. 1. Remove cowling from engine. 2. Place outboard in water or install Quicksilver Flushing Attachment over water intake by following instructions outlined in “Flushing Cooling System” (see “Table of Contents”). 3. Start engine and allow to warm up. Disconnect fuel line. When engine starts to stall quickly spray Quicksilver Storage Seal into each carburetor throat. Continue to spray until engine dies from lack of fuel. 4. Remove spark plugs and inject a 5 second spray of Quicksilver Storage Seal around the inside of each cylinder. Manually turn engine over several times to distribute Storage Seal throughout cylinders. Reinstall spark plugs. 5. If engine fuel filter appears to be contaminated, remove and replace. Refer to Section 3 “Fuel System and Carburetion.” 6. Drain and refill lower unit with Quicksilver Gear Lube, as explained in “Gear Housing Lubrication” (see “Table of Contents”). 7. Clean outboard thoroughly, including all accessible powerhead parts, and spray with Corrosion and Rust Preventive. 8. Refer to lubrication chart in this section (see “Table of Contents”) and lubricate all lubrication points. 9. Remove propeller. Apply Quicksilver Special Lubricant 101, Anti-Corrosion Grease or 2-4-C Marine Lubricant to propeller shaft and reinstall propeller. Refer to “Propeller Installation” (see “Table of Contents”). IMPORTANT: When storing outboard for the winter, be sure that all water drain holes in gear housing are open and free so that all water will drain out. If a speedometer is installed in the boat, disconnect the pickup tube 1-10 - GENERAL INFORMATION and SPECIFICATIONS 90-44477--1 1192 and allow it to drain. Reconnect the tube after draining. Trapped water may freeze and expand, thus cracking gear housing and/or water pump housing. Check and refill gear housing with Quicksilver Gear Lube before storage to protect against possible water leakage into gear housing which is caused by loose lubricant vent plug or loose grease fill plug. Inspect gaskets under lubricant vent and fill plugs, replacing any damaged gaskets, before reinstalling plugs. How Weather Affects Engine Performance 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, correcting all values to the power that the engine will produce at sea level, at 30% relative humidity at 77° F (25° C) temperature and a barometric pressure of 29.61 inches of mercury. 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 effect, 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. Conditions Affecting Operation 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) (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. 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-11 b. Shifting weight to the front (bow) (1.) Improves ease of planing off. (2.) Generally improves rough water ride. (3.) If excessive, can make the boat veer left and right (bow steer). 2. Boat 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-andaft direction. a. Hook: Exists when bottom is concave in fore-andaft direction when viewed from the side. When boat is planing, “hook” causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed. “Hook” frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage. b. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom is convex in fore- and-aft direction when viewed from the side, and boat has strong tendency to porpoise. c. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboard’s gear housing increase skin friction and cause speed loss. Clean surfaces when necessary. 3. Gear Housing: If unit is left in the water, marine vegetation may accumulate over a period of time in certain types of water. This growth must be removed from unit before operation, as it may clog the water inlet holes in the gear housing and cause the engine to overheat. Detonation: Causes and Prevention Detonation in a 2-cycle engine somewhat resembles the “pinging” heard in an automobile engine. It can be otherwise described as a tin-link “rattling” or “plinking” sound. Detonation generally is thought of as spontaneous ignition, but it is best described as a noisy explosion in an unburned portion of the fuel/air charge after the spark plug has fired. Detonation creates severe, untimely, shock waves in the engine, and these shock waves often find or create a weakness: The dome of a piston, piston rings or piston ring lands, piston pin and roller bearings. While there are many causes for detonation in a 2-cycle engine, emphasis is placed on those causes which are most common in marine 2-cycle application. A few, which are not commonly understood, are: 1. Over-advanced ignition timing. 2. Use of low octane gasoline. 3. Propeller pitch too high (engine RPM below recommended maximum range). 4. Lean fuel mixture at or near wide-open-throttle. 5. Spark plugs (heat range too hot - incorrect reach -cross-firing). 6. Inadequate engine cooling (deteriorated cooling system). 7. Combustion chamber/piston deposits (result in higher compression ratio). Detonation usually can be prevented, provided that 1) the engine is correctly set up and 2) diligent maintenance is applied to combat the detonation causes, listed, preceding. Damaged Piston Resulting from Detonation Compression Check NOTE: Engine should be at normal operating temperature (run approximately 5 minutes) prior to checking compression to achieve accurate readings. 1. Remove spark plug. 2. Install compression gauge in spark plug hole. 3. Hold throttle at W.O.T. 4. Check and record compression. The compression reading should be at least 90 psi (620.5 kPa). A lower compression indicates that cylinder is in some way defective, such as worn or sticking piston rings and/or scored piston and cylinder. 1-12 - GENERAL INFORMATION and SPECIFICATIONS 90-44477--1 1192 5. 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. 6. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or scorched paint, remove cylinder head and inspect cylinder visually for possible scoring. It is possible for a cylinder to be scored slightly and still have comparatively good compression. Propeller Chart Dia. Pitch No. Blades & Material Model Propeller Part No. 7-3/8 7-3/8 7-3/8 7-3/8 6. 6. 4-1/2. 4-1/2. 3-Aluminum 3-Plastic 3-Plastic 3-Aluminum 2.5/3.0/3.3 2.5/3.0/3.3 2.2 2.2 48-815084 48-815083 (A) 48-17294 48-95294-1 (A) (A) Standard Propeller Furnished with Engine Recommended Transom Height: Standard 15 in. (381mm) Serial Number Location 1. Serial number is on top of swivel bracket on all models. 2. Serial number is also found on the starboard side of the cylinder block on the 2.5/3.0/3.3. a -Swivel Bracket Location b -Cylinder Block Location 50966 90-44477--1 1192 GENERAL INFORMATION and SPECIFICATIONS - 1-13 IGNITION SYSTEM 2 Table of Contents Page Magneto Ignition System (Models - 2.2/2.5/3.0 - 1992 and Earlier). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Stop Switch Test (All Models) . . . . . . . . . . . . . . . . . . . . 2-2 Magneto Ignition System . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Breaker Points Cleaning and Inspection . . . . . . . . 2-2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Abnormal Point Wear . . . . . . . . . . . . . . . . . . . . . 2-2 Burning of Points . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Primary Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . 2-2 Secondary Ignition Coil Test . . . . . . . . . . . . . . . . . . 2-3 Condenser Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Capacitor Discharge Ignition System (Models - 2.5/3.3 - 1993) . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Capacitor Discharge Ignition Tests (1993 Model - 2.5/3.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Capacitor Charging/Trigger Coil Test . . . . . . . . . . . 2-5 Secondary Ignition Coil Test . . . . . . . . . . . . . . . . . . 2-5 CD Module Test (Diode Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Flywheel Removal and Installation (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Flywheel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Secondary Coil Removal and Installation (Magneto Ignition) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Ignition Primary Coil (Magneto Ignition) . . . . . . . . 2-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Breaker Point Assembly and Condenser . . . . . . . 2-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Breaker Point Adjustment . . . . . . . . . . . . . . . . . . . . 2-8 Capacitor Discharge Ignition . . . . . . . . . . . . . . . . . . . . . 2-9 Capacitor Charging/Trigger Coil . . . . . . . . . . . . . . . 2-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Secondary Ignition Coil . . . . . . . . . . . . . . . . . . . . . . 2-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Capacitor Discharge (CD) Module . . . . . . . . . . . . 2-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 90-44477--1 1192 Magneto Ignition System (Models - 2.2/2.5/3.0 - 1992 and Earlier) Description When the breaker points are closed, a magnetic field is built up in the primary coil (located below flywheel) as the flywheel permanent magnets pass the coil. When breaker points open, the magnetic field of the primary coil collapses, discharging voltage into the primary winding of the secondary coil. At this time the condenser also discharges its stored voltage into the primary circuit. This current creates an extremely high voltage in the secondary coil that will jump the spark plug gap. PRIMARY COIL STOP SWITCH CONDENSER BREAKER POINTS SECONDARY COIL SPARK PLUG 90-44477--1 1192 IGNITION SYSTEM 2-1 Stop Switch Test (All Models) 1. Disconnect stop switch leads. 2. Use ohmmeter and connect leads to switch leads. 3. Meter should show “continuity” with switch depressed. 4. If meter shows other than in step 3, replace switch. Magneto Ignition System Breaker Points Cleaning and Inspection CLEANING 1. Dirty contact points should be dressed with a clean, fine- cut contact file. File should not be used on other metals and should not be allowed to become greasy or dirty. Normal point condition is overall grey color. NOTE: DO NOT use emery cloth to clean contact points. 2. After use, contact surfaces may not appear bright and smooth. This is not necessarily an indication that points are not functioning satisfactorily. Do not attempt to remove all roughness nor dress point surfaces down smooth. Remove scale and dirt only. 3. Badly burned or pitted contact points should be replaced. ABNORMAL POINT WEAR 1. Under normal operating conditions, contact points will provide many hundreds-of-hours of service. 2. Points, which have been operated for a period of time, develop a rough surface. 3. If the roughness between points match enough that a large contact area is maintained, the points will continue to provide satisfactory service until most of the tungsten is worn off. 4. If points burn or pit they must be replaced. Ignition system must be inspected to determine the cause of failure. If cause is not corrected, new points will quickly burn or pit. BURNING OF POINTS 1. Contact point burning results from high voltage, presence of oil or other foreign material, defective condenser and improper point adjustment. 2. Oil or crankcase vapors on point surfaces cause points to burn rapidly. The presence of oil will produce a smudgy line under contact points. 3. If contact point opening is too small, points will be closed for too much operating time. Average current flow thru points will be too high resulting in rapid burning. Arcing will occur between points and result in low secondary voltage and engine miss. 4. High series resistance in condenser circuit will prevent normal condenser action, so contact points will burn rapidly. This resistance may be caused by a loose condenser mounting or lead connection or by poor connections inside condenser. Primary Ignition Coil Test Breaker Points Must Be Open When Testing Coil Test Meter Range Ohm Reading Connect (+) Ohmmeter Lead to Coil BLACK/ WHITE Lead and (–) Lead to Coil Ground x 1 1.5 Ohms 17359 2-2 IGNITION SYSTEM 90-44477--1 1192 Secondary Ignition Coil Test IMPORTANT: Ohmmeter test can only detect certain faults in the secondary ignition coil. Replace ignition coil if ohmmeter reading listed in chart are not as specified. If coil tests OK, and coil is still suspected of being faulty, use a magneto analyzer to thoroughly check coil. Follow coil test outlined in analyzer manual. Test Meter Range Ohm Reading Primary Winding Test Connect (+) Ohmmeter Lead to Coil BLACK/WHITE Lead x 1 .81 to 1.09 Ohms and (–) Lead to Coil Ground Secondary Winding Test Connect (+) Ohmmeter Lead to Spark Plug Lead Terminal and (–) Lead to Coil Ground x 100 4.250 to 5.750 Ohms Testing Primary Winding 17356 Testing Secondary Winding Condenser Test Check condenser using a magneto analyzer. Perform condenser tests outlined in analyzer manual. When checking condenser capacity, reading should be 0.22 to 0.28 microfarads. 90-44477--1 1192 IGNITION SYSTEM 2-3 CD MODULE STOP SWITCH CAPACITOR CHARGING/ TRIGGER COIL IGNITION COIL SPARK PLUG BLK/WHT BRN WHT ORN BLK/WHT BRN WHT ORN Tested Part Ignition Coil PRI Capacitor Charging Coil/ Trigger Coil Stop Circuit Multimeter Wires RED BLACK RED BLACK RED BLACK Connected To GROUND ORANGE GROUND BLACK WHITE BLACK/WHITE Selector Position 400 VDC 400 VDC 400 VDC Reading at 300 - 2000 RPM 100 - 320 120 - 320 120 - 320 Capacitor Discharge Ignition System (Models - 2.5/3.3 1993) Description The flywheel contains 4 magnets. As a north/south polarity magnet passes the capacitor charging/trigger coil, (located under flywheel), a magnetic field is built up within the windings and voltage is sent to the capacitor discharge (CD) module to be stored. As a south/north polarity magnet passes the capacitor charging/trigger coil, a triggering voltage is sent to the CD module. A bias/trigger circuit within the CD module controls the release of this voltage to the secondary ignition coil. The secondary coil increases this voltage through its primary and secondary windings. The secondary coil fires the spark plug at both the top of the piston stroke and the bottom of the stroke (or every 180° of crankshaft rotation). TOOL: MULTIMETER/DVA TESTER 91-99750 There is no timing advance or timing adjustment in this system. If engine will not idle down to trolling speed (runs excessively fast with throttle closed), the bias circuit within the CD module may have failed. Replace the CD module. If engine will not start (no spark at spark plug), use the DVA chart, following, to determine the serviceabilty of each ignition component. 2-4 IGNITION SYSTEM 90-44477--1 1192 Capacitor Discharge Ignition Tests (1993 Model - 2.5/3.3) Capacitor Charging/Trigger Coil Test CHECK METER RANGE OHM READING Connect (+) Ohm Lead to WHITE Lead. Connect (–) Ohm Lead to GROUND. R x 100 300-400 Secondary Ignition Coil Test CHECK METER RANGE OHM READING PRIMARY WINDING TEST Connect (+) Ohm Lead to ORANGE Lead. Connect (–) Ohm Lead SECONDARY WINDING TEST Connect (+) Ohm Lead to Spark Plug Lead. Connect (–) Ohm Lead to Ground. to GROUND. R x 1 R x 1K Less Than 1 Ohm 3000-4000 CD Module Test (Diode Test) CHECK METER RANGE OHM READING Connect (+) Ohm Lead to WHITE Lead. Connect (–) Ohm Lead to ORANGE Lead. Connect (+) Ohm Lead to ORANGE Lead. Connect (–) Ohm Lead to WHITE Lead. . R x 1K R x 1K Continuity No Continuity 90-44477--1 1192 IGNITION SYSTEM 2-5 2-6 IGNITION SYSTEM 90-44477--1 1192 Flywheel Removal and Installation (All Models) Flywheel Removal 1. Remove rewind housing. 2. Remove rope cup. 3. Hold flywheel using Flywheel Holder 91-83163M. 4. Remove flywheel using Flywheel Puller 91-83164M. Flywheel Installation 1. Hold flywheel using Flywheel Holder 91-83163M and torque flywheel nut to 30 lb. ft. (40.6 N·m). 2. Reinstall rope guide using 3 bolts. Torque bolts securely. 3. Reinstall rewind housing. 17002 a a - Flywheel Holder (91-83163M) 16999 a a - Flywheel Puller (91-83164M) 17424 a a - Rope Cup Installed 17423 a a - Torqueing Flywheel Nut [30 lb. ft. (40.6 N·m)] 90-44477--1 1192 IGNITION SYSTEM 2-7 Secondary Coil Removal and Installation (Magneto Ignition) Remove and install secondary coil as shown. IMPORTANT: Coil must be grounded to engine thru the mounting bolts. 17361 a a - Secondary Coil Ignition Primary Coil (Magneto Ignition) REMOVAL 1. Remove flywheel as outlined in “Flywheel Removal and Installation,” preceding. 2. Remove stator plate. 3. Remove 2 screws and clamp. Remove coil from stator plate. 17000 d c b b a e a - Stator Plate b - Screws (2) c - Clamp d - Coil e - Ground Wire INSTALLATION 1. Install primary coil to stator plate with 2 screws as shown. Verify ground wire (soldered terminal lug to coil winding) is fastened with coil mounting screw. 2. Route wire lead below breaker points and fasten to bottom side of stator plate with clamp. 3. Apply a drop of Loctite 271 to threads of stator plate mounting screws and reinstall stator plate. 17357 a b a - Ground Wire b - Clamp 2-8 IGNITION SYSTEM 90-44477--1 1192 Breaker Point Assembly and Condenser REMOVAL 1. Remove screw, retaining clip and disconnect wire. 2. Remove breaker point assembly from plate. 3. Remove screw and lift condenser from plate. INSTALLATION 1. Position condenser at location shown and secure with screw and lockwasher. 2. Verify felt pad is in place and moistened with oil. 3. Install breaker points and connect wires as shown. 17000 g f e d c b a a - Screw b - Retaining Clip c - Wire d - Breaker Point e - Screw f - Condenser g - Felt Pad Breaker Point Adjustment 1. Reinstall flywheel as outlined in “Flywheel Installation.” 2. Rotate flywheel to position high point on cam against the rubbing block of the breaker point assembly. 3. Check point gap using a feeler gauge. Point gap should be 0.012 in. to 0.016 in. (0.3mm to 0.4mm). 4. If necessary, loosen adjustment screw and reposition breaker point base to obtain correct point gap. 5. Verify that felt pad is making light contact with cam. Felt Pad should be Moistened with Oil and Making Light Contact with Cam Cam High Point on Cam Rubbing Block .012 in. to .014 in. (.3mm to .4mm) Point Gap Base Adjustment Screw 16987 Checking Breaker Point Gap Capacitor Discharge Ignition Capacitor Charging/Trigger Coil REMOVAL 1. Remove top cowling. 2. Remove lower PORT side cowling. a a 52053 a -Screws 3.Remove recoil assembly. a 52052 a -Bolts 4.Remove flywheel as outlined in “Flywheel Removal and Installation,” preceding. 5. Remove 2 screws, clamp and disconnect bullet connector. Remove charge/trigger coil from stator. 52053 c d b a a -Screws b -Clamp c -Bullet Connector d -Coil INSTALLATION 1. Secure charge/trigger coil to stator plate with 2 screws. 2. Secure coil wire lead with clamp to stator. 3. Reconnect coil bullet connector. 4. Reinstall flywheel. Refer to “Flywheel Removal and Installation,” preceding. 5. Reinstall recoil starter. 6. Reinstall PORT side lower cowl. 7. Reinstall top cowl. 90-44477--1 1192 IGNITION SYSTEM 2-9 Secondary Ignition Coil REMOVAL 1. Remove top cowl. 2. Remove PORT side lower cowl. 3. Disconnect spark plug lead from spark plug. 4. Disconnect ORANGE bullet connector. 5. Remove bolt securing coil to block and remove coil. d c a b 52054 a -Coil b -Spark Plug Lead c -Orange Lead d -Bolt INSTALLATION 1. Position coil on block with BLACK/WHITE ground lead between coil and block. Secure both coil and ground lead with attaching bolt. 2. Connect ORANGE lead to bullet connector. 3. Connect spark plug lead to spark plug. 4. Reinstall PORT side lower cowl. 5. Reinstall top cowl. Capacitor Discharge (CD) Module REMOVAL 1. Remove top cowl. 2. Remove PORT side lower cowl. 3. Disconnect WHITE bullet connector. Disconnect ORANGE bullet connector. Disconnect BROWN lead from BLACK/WHITE bullet connector. Disconnect BLACK ground lead from secondary ignition coil attaching bolt. 4. Remove bolt securing module to block. 52054 a b c d e f a -WHITE Lead b -ORANGE Lead c -BROWN Lead d -BLACK Lead e -Bolt f -Capacitor Discharge Module INSTALLATION 1. Secure CD module to block with attaching bolt. 2. Fasten BLACK ground lead to block with secondary ignition coil attaching bolt. 3. Reconnect WHITE bullet connector. Reconnect ORANGE bullet connector. Reconnect BROWN lead to BLACK/WHITE bullet connector. 4. Reinstall PORT side lower cowl. 5. Reinstall top cowl. 2-10 IGNITION SYSTEM 90-44477--1 1192 FUEL SYSTEM AND CARBURETION 17350 3 Table of Contents Page Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Carburetor Components. . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Throttle Jet Needle Adjustment. . . . . . . . . . . . . . . . . . . 3-3 Float Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Carburetor Removal/Installation . . . . . . . . . . . . . . . . . . 3-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Carburetor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Carburetor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 90-44477--1 1192 Troubleshooting Problems, which sometimes are thought to be caused by the fuel system, may be something completely different. Trouble with items 1-2-3-4, listed on the right, also may give the impression that a problem exists in the fuel system. Problem: Engine Will Not Start or Starts Hard When Cold Engine Idles Rough and Stalls Possible Cause Corrective Action Improperly mixed fuel; contaminants (water, dirt, etc.) in fuel Fuel tank air vent closed or restricted Restricted fuel line or fuel shut-off valve Carburetor flooding Restricted fuel strainer Idle speed screw out-of-adjustment Improper carburetor float setting Engine runs lean Engine runs rich Check fuel in fuel tank and replace if necessary Check air vent in filler cap. Air vent must be fully open and free from restrictions Check and replace or clean fuel line or fuel shut-off valve See following Check and clean fuel strainer Refer to “Carburetor Adjustment” in this section Reset float to correct level See following See following Problem: Engine Runs Too Rich Possible Cause Corrective Action Choke not opening Clogged pilot air passage or pilot jet Fuel level too high Carburetor floods Check operation of choke Clean, then blow out with compressed air Reset float to correct level See following Problem: Engine Runs Too Lean Possible Cause Corrective Action Carburetor loose on reed block housing Air drawn in from mixing chamber cover Fuel level too low Clogged main jet or needle jet Tighten locknuts securely Tighten cover Reset float level to correct level Check and clean, if necessary Problem: Engine Floods 1. Spark Plug 2. Ignition Spark Voltage 3. Cylinder Compression 4. Reed Valves Engine Hesitates upon Acceleration Engine Runs Uneven or Surges Possible Cause Corrective Action Dirt or foreign particles are preventing inlet needle from seating Worn inlet needle or weak inlet needle spring Punctured or deformed float Incorrect float setting Flush out inlet seat and clean inlet needle Remove and replace with new inlet needle and seat assembly Replace with new float Reset float to correct level 90-44477--1 1192 FUEL SYSEM and CARBURETION 3-1 Carburetor Components 4039 33 37 34 35 36 38 2 3 4 5 6 7 8 21 31 29 30 25 24 4039 15 16 13 1411 1718 19 17 11 12 2026 23 22 27 20 41 9 10 1 -Screw 2 -Throttle Cable 3 -Retainer Nut 4 -Bracket 5 -Mixing Chamber Cover 6 -Spring 7 -Retainer 8 -E-Clip 9 -Jet Needle 10-Throttle Valve 11-Main Nozzle 12-Gasket 13-Float 14-Float Bowl 15-Hinge Pin 16-Float Hinge 17-Main Jet 18-Screw 19-Gasket 20-Inlet Needle 21-Seat 22-Idle Speed Screw 23-Spring 24-Choke Lever 25-Screw 26-Choke Plate 27-Washer 28-Nut 29-Clamp 30-Screw 31-Gasket 32-Screw 33-Throttle Lever 34-Screw 35-Lock washer 36-Gasket 37-Lever Support 38-Collar 39-Knob 40-Screw 41-Cover 3-2 FUEL SYSTEM and CARBURETION 90-44477--1 1192 Idle Speed Adjustment Start the engine. After engine has been warmed up, position throttle lever at the lowest speed position. Adjust idle speed screw to obtain recommended idle speed (900 1000 RPM). 16815 Throttle Jet Needle Adjustment This carburetor is equipped with a throttle valve that utilizes a tapered jet needle to vary the fuel flow as the carburetor is opened. Normally the “E” ring is in the second groove. Locating the “E” ring closer to the end of the jet will “lean” the mixture. Further leaning requires a change of the main jet. The first indication of an overly rich mixture will be a decrease in RPM as the carburetor is opened beyond 2/3 throttle. Change jet needle adjustment as follows: 1. Remove carburetor from engine as outlined in “Carburetor Removal”. 2. Remove and disassemble throttle valve assembly. 3. Change “E” ring groove and reassemble throttle valve assembly and carburetor as instructed in “Carburetor Reassembly,” following. 4. Reinstall carburetor as outlined in “Carburetor Installation”. IMPORTANT: Lowering the “E” ring on the jet needle results in a richer fuel mixture. Raising the “E” ring on the jet needle results in a leaner fuel mixture. It is preferable to adjust fuel mixture a little rich rather than too lean. “E” Ring Position Groove Jet Needle “E” Ring Grooves Standard Main Jet #92 - for CDI Ign. Models Standard Main Jet #94 - for MAGNETO Ign. Models Float Level Adjustment Adjust float hinge as shown. a a -Models with MAGNETO Ignition: 0.090 in. (2.0mm) from top of gasket. Models with CAPACITOR DISCHARGE Ignition: 0.118 in. (3.0mm) from top of gasket. 90-44477--1 1192 FUEL SYSEM and CARBURETION 3-3 3-4 FUEL SYSTEM and CARBURETION 90-44477--1 1192 Carburetor Removal/Installation Removal 1. Remove knobs from throttle and choke levers. 2. Remove 2 screws and lift intake front cover from carburetor. 3. Close fuel shut-off valve and remove fuel line from carburetor. 4. Loosen clamp screw and remove carburetor. 16991 a a - Clamp screw Installation 1. Place seal into carburetor. 2. Slide carburetor onto crankcase cover and secure by tightening clamp screw. 3. Connect fuel line to carburetor. 4. Reinstall front cover and install knobs on throttle and choke levers. 16998 a a - Seal 16992 c b b - Clamp Screw c - Fuel Line Carburetor Disassembly 1. Remove 2 screws and lift float bowl from carburetor. a b a -Screws b -Float Bowl 2.Remove float from carburetor. 17350 a 17345 a -Float 3. Remove float hinge and float pin. a b a -Float Hinge b -Float Pin 4. Model 2.2 - 3.0 - Remove inlet needle, main jet, screw in main nozzle and float bowl gasket . 17349 a b c d a -Inlet Needle d -Gasket b -Main Jet c -Main Nozzle Model 2.5 - 3.3 -Remove main jet and main nozzle a -Main Jet b -Main Nozzle 90-44477--1 1192 FUEL SYSEM and CARBURETION 3-5 3-6 FUEL SYSTEM and CARBURETION 90-44477--1 1192 5. Remove throttle lever from bracket. 6. Loosen retainer several turns and then unscrew mixing chamber cover. 7. Lift throttle valve assembly from carburetor. 17344 a b c a - Bracket b - Retainer c - Mixing Chamber Cover 17330 Removing Throttle Valve Assembly 8. Compress spring and unhook throttle cable from throttle valve. 17347 b a c a - Spring b - Throttle Cable c - Throttle Valve 9. Remove jet needle and jet retainer from throttle valve. 17336 a b a - Jet Needle b - Jet Retainer 90-44477--1 1192 FUEL SYSEM and CARBURETION 3-7 Cleaning and Inspection 1. Carefully inspect carburetor body casting for cracks, stripped threads, plugged or restricted passages and passage plugs that show signs of leakage. 2. Thoroughly clean all carburetor parts with a mild cleaning solution (that will not damage rubber or plastic) to remove dirt, gum and varnish which may have acculmulated. 3. After washing parts, blow parts dry with compressed air. Blow air thru all passages, orifices and nozzles. 4. Inspect float hinge in the float pin area for wear and both float chambers for leaks. 5. Inspect inlet needle for wear. If worn, replace with new inlet needle. Carburetor Reassembly 1. Reassemble throttle valve components as follows: a. If “E” ring is removed from jet needle, refer to “Throttle Jet Needle Adjustment,” preceeding, to determine correct “E” ring slot. 17346 a a - “E” Ring b. Place jet needle in throttle valve. 17333 a a - Jet Needle c. Place needle retainer in throttle valve over “E” ring. Align retainer slot with slot in throttle valve. 17334 a a - Needle Retainer d. Assemble throttle components as shown. Place spring over throttle cable. Compress spring; then slide anchor thru slot and into pocket in bottom of throttle valve. 17338 a b a - Spring b - Anchor 17337 a a - Pocket 3-8 FUEL SYSTEM and CARBURETION 90-44477--1 1192 Throttle Valve Assembled 17331 2. Position throttle valve so slot slides over alignment pin. Slide throttle valve assembly into carburetor. 3. Tighten cover. 17341 a b a - Slot b - Cover 4. Reinstall throttle lever as shown. Position bracket so throttle lever just clears front of carburetor and then tighten retainer nut. 17332 g f e d c b a a - Throttle Lever b - Bracket c - Retainer Nut d - Screw e - Lockwasher f - Lever Support g - Fiber Washer 5. Model 2.2 - 3.0 - Install main nozzle and main jet. 6. Install float bowl gasket. 7. Install inlet needle. 17349 a b c d a - Main Nozzle b - Main Jet c - Bowl Gasket d - Inlet Needle 8. Model 2.5 - 3.3 - Install main nozzle and main jet. Main jet holds main nozzle in place. a -Main Nozzle b -Main Jet 9. Install float hinge and float pin. a b 17348 a -Float Hinge b -Float Pin 10. Check float hinge adjustment as shown. a a -Models with MAGNETO Ignition: 0.090 in. (2.0mm) from top of gasket. Models with CAPACITOR DISCHARGE Ignition: 0.118 in. (3.0mm) from top of gasket. 11. Install float as shown. a a -Float 90-44477--1 1192 FUEL SYSEM and CARBURETION 3-9 12. Install fuel bowl with 2 screws. a b a -Screws b -Bowl 13. Install seal into carburetor. 14. Reinstall idle speed adjustment screw. 17350 17332 a b a -Seal b -Idle Speed Screw 3-10 FUEL SYSTEM and CARBURETION 90-44477--1 1192 POWERHEAD 16990 4 Table of Contents Page Powerhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Powerhead Components . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Powerhead Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Cylinder Block and Crankcase Cover . . . . . . . . . . 4-5 Cylinder Bore (Cleaning and Inspection) . . . . . 4-5 Honing Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Determining Piston Clearance. . . . . . . . . . . . . . 4-7 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Reed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Crankshaft Ball Bearings and Piston Needle Bearings . . . . . . . . . . . . . . . . . . . . . . 4-8 Crankshaft Ball Bearings . . . . . . . . . . . . . . . . . . 4-8 Piston Roller Bearing . . . . . . . . . . . . . . . . . . . . . 4-8 Powerhead Reassembly and Installation . . . . . . . . . . 4-9 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Powerhead Reassembly . . . . . . . . . . . . . . . . . . . . . 4-9 Powerhead Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Break-in Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 90-44477--1 1192 Powerhead Specifications Block Type . . . . . . . . . . . . . . . . . . . . . . . Two-Stoke Cycle Displacement . . . . . . . . . . . . . . . 4.6 cu. in. (74.6cc) Cylinder Bore Dia. Standard . . . . . . . . . . . . . . . 1.850 in. (47.05mm) Dia. 0.5mm Oversized . . . . . . . . 1.869 in. (47.55mm) Out of Round (Max.) . . . . . . . . . 0.002 in. (0.05mm) Taper (Max.) . . . . . . . . . . . . . . . . 0.002 in. (0.05mm) TOP CENTER BOTTOM Piston Clearance . . . . . . . . . . . . . . . . . . 0.002 in. to 0.005 in. (.06mm to .15mm) Piston Ring End Gap . . . . . . . . . . . . . . . . . . . 0.006 in. to 0.012 in. (.18mm to .33mm) Side Clearance. . . . . . . . . . . . . . 0003 in. to .0010 in. (.01mm to .05mm) Crankshaft Runout (Max.). . . . . . . . . . . . . . . 0.001 in. (0.05mm) Connecting Deflection . . . . . . . . 0.022 in. to 0.056 in. (0.6mm to 1.5mm) 1,2 - Check Runout Here 3 - “Vee” Blocks 1 2 3 3 Reed Block Reed Stop Opening . . . . . . . . . . 0.236 in. to 0.244 in. (6mm to 6.2mm) Reed Stop Opening .236 in. to .244 in. (6.0mm to 6.2mm) Special Tools Description Part No. Piston Ring Expander 91-24697 Universal Puller Plate 91-37241 Flywheel Holder 91-83163M Flywheel Puller 91-83164M Torque Specifications Flywheel Nut 30 lb. ft. (40.6 N·m) Cylinder Head Bolts 85 lb. in. (9.6 N·m) Crankcase Cover Bolts 50 lb. in. (5.6 N·m) Lower End Cap Bolts 50 lb. in. (5.6 N·m) Spark Plug 20 lb. ft. (27.1 N·m) 90-44477--1 1192 POWERHEAD 4-1 1 -Cylinder Block 2 -Alignment Pin (2) 3 -Bolt (4) 4 -Bolt (2) 5 -Gasket 6 -Cover 7 -Bolt (4) 8 -Wave Washer 9 -Fitting 10-Hose 11-End Cap 12-Bolt (2) 13-Washer (2) 14-Seal (2) 15-Gasket 16-Reed Valve 17-Reed Stop 18-Screw (2) 19-Clamp (Wires) 20-Crankshaft 21-Roller Bearing 22-Ball Bearing 23-Ball Bearing 24-Flywheel Key 25-Retainer 26-Retainer 27-Seal b b E B C E E E E E 6 5 33 c 72 a8 1 10 9 2 18 1716 19 15 11 13 12 b 24 20 23 26 28 32 31 3032 29 22 25 27 14 4 3 21 Powerhead Components 1 -Cylinder Block 2 -Alignment Pin (2) 3 -Bolt (4) 4 -Bolt (2) 5 -Gasket 6 -Cover 7 -Bolt (4) 8 -Wave Washer 9 -Fitting 10-Hose 11-End Cap 12-Bolt (2) 13-Washer (2) 14-Seal (2) 15-Gasket 16-Reed Valve 17-Reed Stop 18-Screw (2) 19-Clamp (Wires) 20-Crankshaft 21-Roller Bearing 22-Ball Bearing 23-Ball Bearing 24-Flywheel Key 25-Retainer 26-Retainer 27-Seal b b E B C E E E E E 6 5 33 c 72 a8 1 10 9 2 18 1716 19 15 11 13 12 b 24 20 23 26 28 32 31 3032 29 22 25 27 14 4 3 21 Powerhead Components 28-Seal 29-Piston 30-Piston Ring 31-Piston Pin 32-Clip 33-Spark Plug Quicksilver Lubrication/Sealant Application Points B Torque Specifications Loctite “271” (92-32609-1) a 85 lb. in. (10 N·m) C E Needle Bearing Assy. Lub. (92-42649A1) b c 50 lb. in. (6 N·m) 20 lb. ft. (27.1 N·m) 2 Cycle Outboard Oil (92-13249A24) 4-2 POWERHEAD 90-44477--1 1192 90-44477--1 1192 POWERHEAD 4-3 Engine Removal 1. Remove cowling from engine. 2. Remove spark plug lead from spark plug. 3. Remove rewind starter, flywheel, magneto base assembly and ignition coil as described on Section 2. 4. Drain fuel from engine mounted fuel tank. 5. Remove fuel tank, fuel shut-off valve and carburetor from engine as described in Section3. 6. Remove 6 bolts securing powerhead to driveshaft housing. 7. Lift up on powerhead to break gasket between powerhead and driveshaft housing. Remove powerhead from driveshaft housing. 16995 a a - Bolts (6) Powerhead Disassembly 1. Remove lower end cap. 2. Remove cylinder head. 17019 a b a - End Cap b - Cylinder Head 3. Remove 6 bolts and remove crankcase cover. 17016 a a b a - Bolts (6) b - Crankcase Cover 4. Remove 2 screws and remove reed stop and reed. 17015 a b c a -Screws (2) b -Reed c -Reed Stop 5. Remove crankshaft assembly from cylinder block. IMPORTANT: DO NOT remove ball bearings from crankshaft unless replacement is necessary. 6. Inspect crankshaft ball bearings as outlined in “Cleaning and Inspection,” following. 17422 7. If necessary, remove ball bearings from crankshaft as shown. 17766 a b c a -Press b -Universal Puller Plate (91-37241) c -Ball Bearing ! WARNING Eye protection must be worn when removing piston pin lockrings from piston. 8. Inspect piston as outlined in “Cleaning and Inspection,” following. 9. Remove piston ring from piston with Piston Ring Expander (91-24697). 10. Remove piston from connecting rod by removing piston pin “G” lockrings from both ends as shown and pushing pin out of piston. 17004 a a -Lockring 4-4 POWERHEAD 90-44477--1 1192 11. Inspect connecting rod needle bearing as outlined in “Cleaning and Inspecting,” following. NOTE: Connecting rod is not removable from crankshaft. b b ac d 17021 a -Needle Bearing b -Piston Pin Lockrings c -Piston Pin d -Connecting Rod Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT: Crankcase cover and cylinder block are a matched, line-bored assembly and never should be mismatched by using a different crankcase cover or cylinder block. ! CAUTION If crankcase cover or cylinder block is to be submerged in a very strong solution, it will be necessary to remove the bleed system from the crankcase cover/ cylinder block assembly to prevent damage to hose and check valve. 1. Thoroughly clean cylinder block and crankcase cover. Remove all sealant and old gasket material from mating surfaces. Remove all carbon deposits from exhaust ports and cylinder dome. 2. Inspect cylinder block and crankcase cover for cracks or fractures. 3. Inspect gasket surfaces for nicks, grooves, cracks and distortion that could cause compression leakages. 4. Inspect all water and fuel passages in cylinder block and crankcase cover for obstructions. 5. Verify all fittings and plugs are tight. CYLINDER BORE (CLEANING AND INSPECTION) NOTE: Cylinder sleeve is part of the cylinder block and cannot be replaced. 1. a. If the piston is scored and has transferred aluminum to the cylinder wall, remove all loose aluminum deposits from cylinder wall with a stiff bristle brush. b. If any aluminum deposits remain, apply a small amount of muriatic acid (or liquid toilet bowl cleaner) to deposits. Do not allow muriatic acid (or liquid toilet bowl cleaner) to contact aluminum portion of cylinder block. c. Leave acid on aluminum deposit for 1 to 2 minutes and then wash cylinder thoroughly with hot water and detergent. d. Steps “b” and “c” may require repeating several times before all the aluminum deposits are gone. 2. Inspect cylinder bore for scoring. Minor cylinder wall scoring usually can be “cleaned up” by honing. Refer to “Honing Procedure,” following. HONING PROCEDURE IMPORTANT: If cylinder wall is not scored, hone cylinder just enough to deglaze wall. 3. a. Hone cylinder following the hone manufacturer’s recommendations for use of the hone and cleaning and lubrication during honing. b. For best results, a continuous flow of honing oil should be pumped into the work area. If pumping oil is not practical, use an oil can. Apply oil generously and frequently to stones and cylinder wall. ! CAUTION When honing cylinder block, remove hone frequently and check condition of cylinder wall. DO NOT hone any more than absolutely necessary, as hone can remove cylinder wall material rapidly. c. Start stroking at smallest diameter. Maintain firm stone pressure against cylinder wall to assure fast stock removal and accurate results. d. Localize stroking in the smallest diameter until drill speed is constant throughout length of bore. Expand stones, as necessary, to compensate for stock removal and stone wear. Stroke at a rate of 30 complete cycles-per-minute to produce best cross-hatch pattern. Use honing oil generously. e. Thoroughly clean cylinder bore with hot water and detergent. Scrub well with stiff bristle brush and rinse thoroughly with hot water. It is essential that a good cleaning be performed. If any of the abrasive material is allowed to remain in the cylinder bore, it will cause rapid wear of new piston rings 90-44477--1 1192 POWERHEAD 4-5 and cylinder bore, in addition to bearings. After cleaning, bore should be swabbed several times with engine oil and a clean cloth, then wiped with a clean, dry cloth. Cylinder should not be cleaned with kerosene or gasoline. Clean remainder of cylinder block to remove excess material spread during honing operation. 4. Measuring Cylinder Bore NOTE: A .020 in. (5mm) oversized piston is available to enable reboring of standard cylinder bore. a. Using an inside micrometer, take two measurements at top, center and bottom of cylinder as shown. b. If cylinder is tapered, out of round or worn more than .002 in. (.05mm) from standard cylinder bore, the cylinder can be rebored for oversized piston. CYLINDER BORE Standard Bore Wear Limit 1.850 in. (46.99mm) 1.852 in. (47.04mm) or greater Oversize Bore Wear Limit 1.869 in. (47.47mm) 1.871 in. (47.52mm) or greater Piston NOTE: To obtain maximum engine performance, it is recommended that piston rings be replaced during engine tear down. IMPORTANT: If engine was submerged while engine was running, piston pin and/or connecting rod may be bent. If piston pin is bent, piston must be replaced. (Piston pins are not sold separately because of matched fit into piston.) If piston pin is bent, connecting rod must be checked for straightness (refer to “Connecting Rods,” following, on how to check straightness). Cleaning Piston Ring Groove 17764 1. Check piston for scoring, cracks, metal damage and cracked or worn piston bosses. If any of these conditions are found, replace piston. 2. Inspect piston ring groove for wear, burns, distortion or loose piston ring locating pins. 3. Clean piston dome, ring groove and piston skirt. Use the recessed end of a broken piston ring to clean carbon deposits from ring groove. DO NOT use an automotive type ring groove cleaner as this type tool could loosen piston ring locating pins. 4. Clean carbon deposits from top of piston with a soft wire brush, carbon removal solution or sand blasting. When wire brushing top of piston, DO NOT burr or round machined edges. Clean (polish) piston skirt with crocus cloth. 4-6 POWERHEAD 90-44477--1 1192 DETERMINING PISTON CLEARANCE 1. Measure the outside diameter of the piston at the piston skirt and at right angle to the piston pin. Obtain maximum piston diameter. 2. Measure cylinder bore and obtain minimum bore diameter. 3. Subtract the maximum piston measurement from the minimum cylinder bore measurement. This equals your piston clearance. Minimum Bore Measurement – Maximum Piston Measurement = Piston Clearance Piston Clearance .002 in. to .005 in. ( .051mm to .127mm) If piston clearance exceeds the specification, replace cylinder block or replace piston so that clearance is within the specification. Piston Rings Measure piston ring end gap as follows: a. Insert one ring into cylinder bore. Push ring approximately 1/2 in. (12.7mm) into cylinder using piston to position ring at right angle to the bore. b. Measure gap between piston ring ends using a feeler gauge. c. If end gap of ring exceeds specification, replace ring. If gap is less than specifications then you can file some material from piston ring ends. Piston Ring End Gap .006 in. to .012 in. (0.152mm to 0.304mm) Measure side clearance of piston ring grooves as follows: Use a feeler gauge and check clearance between piston ring and groove as shown. Clearance should be within specification. Clearance between Piston Ring and Ring Groove .0003 in. to .0010 in. (.0076mm to .0254mm) 90-44477--1 1192 POWERHEAD 4-7 Crankshaft Check (off-centering) of crankshaft using “vee” blocks and a dial indicator as follows. 1. Position crankshaft in “vee” blocks as shown. 2. Rotate crankshaft. Movement of dial indicators must not exceed .001 in. (.025mm). If over .001 in. (.025mm), replace crankshaft assembly. 1,2 - Check Runout Here 3 - “Vee” Blocks 1 2 3 3 Check connecting rod deflection as follows: 1. Check the connecting rod deflection at the small end of the rod to determine the amount of wear of the crank pin and the bearing at the crank pin end. 2. If deflection of connecting rod exceeds tolerance, replace crankshaft assembly. Connecting Rod Deflection .022 in. to .056 in. (.558mm to 1.422mm) Check Deflection Here Reed Valve 1. Inspect reed petals for signs of fatigue, cracks or chips. The reed petals should fit flush or nearly flush against the seat. 2. Check for wear (indentation on face of seat). If reeds have made indentations in the seat, the crankcase cover/cylinder block will have to be replaced. 3. Check reed stop opening as shown. Replace reed stop if opening is not within specification. .236 in. to .244 in. (6.0mm to 6.2mm) Reed Stop Opening Crankshaft Ball Bearings and Piston Needle Bearings CRANKSHAFT BALL BEARINGS Grasp outer race of crankshaft ball bearing and work race back-and-forth. There should not be excessive play. Lubricate crankshaft ball bearings with light oil. Rotate outer bearing race. Bearing should have smooth action and no rust stains. If bearing sounds or feels “rough” or “catches,” replace bearing. PISTON ROLLER BEARING Thoroughly inspect piston roller bearing. If bearing is rusted, fractured, worn, galled or badly discolored, replace bearing. 4-8 POWERHEAD 90-44477--1 1192 Powerhead Reassembly and Installation General Before proceeding with powerhead reassembly, verify that all parts to be re-used have been carefully cleaned and thoroughly inspected, as outlined in “Cleaning and Inspection,” preceeding. Parts, which have not been properly cleaned (or which are questionable), can severely damage an otherwise good powerhead within the first few minutes of operation. All new powerhead gaskets MUST BE installed with Quicksilver Outboard Oil whenever “light oil” is speciified or use Quicksilver Needle Bearing Assembly Lubricant where “grease” is specified. Mercury part numbers of lubricants, sealers and locking compound can be found on the exploded view of specific assemblies, if applicable. A torque wrench is essential for correct reassembly of powerhead. DO NOT attempt to reassemble powerhead without using a torque wrench. Attaching bolts for covers MUST be torqued by tightening bolts in 3 progressive steps (following specified torque sequence) until correct torque is reached. If removed, reinstall crankshaft ball bearings as follows: IMPORTANT: Ball bearings must be installed so that alignment pins will be toward bottom of crankshaft as shown. 17003 a a -Alignment Pins Using a press and suitable side mandrel, press bearings onto crankshaft. Press only on inner race of bearing. Verify bearings are seated firmly against shoulder. 90-44477--1 1192 Powerhead Reassembly 1. Place needle bearing into connecting rod. 17021 b b ac d a a -Needle Bearing b -Piston Pin “G” Lockrings c -Piston Pin d -Connecting Rod IMPORTANT: Install piston so arrow (on piston dome) is facing down toward exhaust port. Piston a -Install Piston so Arrow is Facing Down Toward Exhaust Port POWERHEAD 4-9 2. Secure piston pin in piston with new “G” lockrings. Verify lockrings are seated in grooves. 17004 a -Lockrings 17004 a 3. Install piston using Piston Ring Expander Tool (91-24697) as shown. IMPORTANT: Piston ring must be installed so that the grooved end of the piston ring is toward top side of piston as shown. a 17009 a -Piston Ring 4. Lubricate lips on oil seals with 2-4-C Marine Lubricant. 5. Install oil seals on crankshaft so that lips are positioned as shown. a b a -Position of Top Seal b -Position of Bottom Seal 6.Install bearing retainers into cylinder block aa a -Bearing Retainers 4-10 POWERHEAD 90-44477--1 1192 7 7. Install crankshaft assembly into cylinder block as follows: a. Lubricate piston ring, piston and cylinder wall with light oil. b. Align ends of piston ring with locating pin as shown. NOTE: Ring Compressor is not used to install piston into cylinder. c. Keeping crankshaft horizontal, push piston into cylinder. 8. Gently push crankshaft down into position. Rotate bearings so that alignment pins are positioned into notches. 9. Position oil seals against retainers. a 17028 a -Alignment Pins 10. Check piston ring for spring tension thru exhaust port by pressing with a screwdriver as shown. If no tension exists (ring fails to return to position) it is likely that the ring was broken during installation and must be replaced. 17763 11. Apply Loctite 271 to threads on screws and install reed valve and reed stop as shown. a b c a b c 17015 a -Screws b -Reed Valve c -Reed Stop 90-44477--1 1192 POWERHEAD 4-11 4-12 POWERHEAD 90-44477--1 1192 12. Thoroughly clean mating surface of crankcase cover and cylinder block with solvent to remove oil. 13. Apply a continuous bead of Loctite Master Gasket on cylinder block, as shown. ! CAUTION Before applying Loctite Master Gasket to cylinder block, verify that mating surface of crankcase cover and cylinder block are clean and free of oil. Loctite must be applied in a continuous bead along the inside of mounting bolt holes. If a void should occur when applying a bead of Loctite, either remove the entire bead with a rag or apply an additional bead parallel to the void and overlapping the previously applied bead. Assemble crankcase cover to cylinder block without lateral movement. 14. Place crankcase cover in position on cylinder block and fasten with 6 bolts. Tighten bolts evenly and torque to 50 lb. in. (5.6 N·m). 17016 a a a - Bolt (6) [Torque to 50 lb. in. (5.6 N·m)] 15. Install cylinder head with gasket. Torque bolts to 85 lb. in. (9.6 N·m). a - Cylinder Head [Torque to 85 lb. in. (9.6 N·m)] b - Gasket 16. Install lower end cap with 2 bolts. Torque bolts to 50 lb. in. (5.6 N·m). 17019 a a - End Cap 17. Rotate crankshaft several times to assure free operation (no binds and/or catches). Powerhead Installation 1. Reinstall powerhead and new gasket to driveshaft. 2. Apply Perfect Seal to threads of powerhead mounting bolts and secure powerhead to driveshaft housing. Torque bolts to 50 lb. in. (5.6 N·m). 3. Install electrical components, flywheel and rewind starter to engine as described in Section 2. 4. Install carburetor, fuel shut-off valve and fuel tank as described in Section 3. ! CAUTION When engine is started, check that water pump is operating. Operation of water pump is indicated by water discharging from “tell-tale.” 5. While test running engine, check powerhead cylinder block, cylinder block cover and exhaust cover for water leaks. Inspect fuel system for any fuel leaks. If leaks are detected, correct problem before returning outboard to service. ! CAUTION To avoid possible engine damage, “Break-in Procedure,” following, MUST BE completed BEFORE operating engine at full throttle continuously. 16990 Break-in Procedure 1. Mix gasoline and oil at the normal 50:1 ratio. 2. Operate motor at varied throttle settings for the first hour (1 hour). AVOID both wide-open-throttle operation and prolonged idle in cold water areas during this period. 3. After the first hour of operation, the motor is ready for normal operation and may be run at any speed. DO NOT EXCEED the full throttle RPM range. 90-44477--1 1192 POWERHEAD 4-13 MID-SECTION 5 Table of Contents Page Mid-Section Components (Design 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Mid-Section Components (Design 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Shift Linkage Components (Shiftable Gearcase) . . . . . . . . . . . . . . . . . . . . . . . 5-3 90-44477--1 1192 15 17 18 19 20 21 22 23 24 251516 21 17 26 27 28 29 30 32 A A A A K Quicksilver Lubrication/Sealant 2-4-C Marine Lubricant (92-90018A12) a b 15 17 18 19 20 21 22 23 24 251516 21 17 26 27 28 29 30 32 A A A A K Quicksilver Lubrication/Sealant 2-4-C Marine Lubricant (92-90018A12) a b Mid-Section Components (Design 1) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13 31 A A K K b b b 1 -Housing 2 -Bolt 3 -Lockwasher 4 -Washer 5 -Carrying Handle 6 -Bolt (2) 7 -Nut (2) 8 -Bolt and Washer (6) 9 -Gasket 10-Steering Handle 11-Bolt 12-Plate 13-Damper 14-Grip 15-Bracket 16-Bolt 17-Washer 18-Nut 19-Bracket 20-Bolt 21-Washer 22-Nut 23-Thumb Screw Assembly (2) 24-Washer (2) 25-Swivel Bracket 26-Bolt (4) 27-Bushing 28-Screw 29-Spring 30-Pad 31-Nut 32-Washer Torque Specifications b a 120 lb. in. (13.5 N·m) 50 lb. in. (5.6 N·m) Application Points A K Perfect Seal (92-34227-1) 90-44477--1 1192 MID-SECTION 5-1 Quicksilver Lubrication /Sealant Torque Specifications Mid-Section Components Quicksilver Lubrication /Sealant Torque Specifications Mid-Section Components (Design 2) 1 -Housing 2 -Bolt (6) 3 -Gasket 4 -Dowel Pin (2) 5 -Handle 6 -Bolt (3) 7 -Nut (3) 8 -Grommet 9 -Grip 10-Handle 11-Bolt 12-Washer (2) 13-Damper, Rubber (2) 14-Spacer 15-Bracket (2) 16-Bolt 17-Washer 18-Nut 19-Bracket 20-Rod 21-Washer (2) 22-Nut (2) 23-Thumb Screw (2) 24-Washer (2) 25-Swivel Bracket 26-Bolt (4) 27-Bushing (2) 28-Screw 29-Spring 30-Friction Pad 31-Washer 32-Pin 33-Thrust Rod 34-Spring 35-Tilt Stopper 36-Knob 37-Extension Housing 38-Bushing 39-Stud 40-Nut 41-Lockwasher (2) 42-Washer (2) Application Points A K 120 lb. in. (13.5 N·m) 2-4-C Marine Lubricant (92-90018A12) b a 50 lb. in. (5.6 N·m) Perfect Seal (92-34227-1) 5-2 - MID-SECTION 90-44477--1 1192 Shift Linkage Components (Shiftable Gearcase) 1 -Shift Lever 2 -O-ring 3 -Detent 4 -Spring 5 -Shift Rod Lever 6 -Screw 7 -Cover 8 -Gasket 9 -Bolt (2) 10-Washer (2) 11-Nut (2) 12-Cam 13-Cam Rod 14-Pin 15-O-ring 16-Bushing 17-O-ring 18-Joint 19-Shift Rod 20-Bolt 21-Washer 22-Washer A A A Quicksilver Lubrication/Sealant Application Points A 2-4-C Marine Lubricant (92-90018A12) 90-44477--1 1192 MID-SECTION 5-3 GEAR HOUSING (NON-SHIFTING) 5 A Table of Contents Page Gear Housing (Non-Shiftable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1 Gear Housing Components (Non-Shiftable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Gear Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Propeller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Draining and Inspecting Gear Housing Lubricant . . . . . . . . . . . . . . . . . 5A-3 Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . 5A-4 Disassembly of Water Pump Housing . . . . . . . . . 5A-5 Pinion Gear and Driveshaft Removal . . . . . . . . . . 5A-5 Propeller Shaft Removal . . . . . . . . . . . . . . . . . . . . 5A-6 Propeller Shaft Bearing Removal . . . . . . . . . . . . . 5A-6 Removal of Seals . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-7 Removal of Driveshaft Bearings . . . . . . . . . . . . . . 5A-7 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8 Propeller Shaft Bearing Installation . . . . . . . . . . . 5A-8 Installation of Driveshaft Bearings . . . . . . . . . . . . 5A-8 Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9 Propeller Shaft Installation . . . . . . . . . . . . . . . . . . . 5A-9 Pinion Gear and Driveshaft Installation . . . . . . . . 5A-9 Gear Backlash Check . . . . . . . . . . . . . . . . . . . . . . 5A-10 Assembling Water Pump Housing . . . . . . . . . . . 5A-10 Water Pump Installation . . . . . . . . . . . . . . . . . . . . 5A-10 Filling Gear Housing with Lubricant . . . . . . . . . . 5A-11 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . 5A-12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12 90-44477--1 1192 Gear Housing (Non-Shifting) Specifications Gear Ratio Model 2.2/2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.85:1 Models 3.0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18:1 Gear Type Gear Type . . . . . . . . . . . . . . . . . . . . . . . . Spiral Bevel Propeller Drive System Propeller Drive System . . . . . . . . Drive (Shear) Pin Lubricant Capacity Lubricant Capacity. . . . . . . . . . . . . . . 3 fl. oz. (90ml) Gear Case Pressure Test Pressure Test (without lube in case) . . . . 10-12 psi Special Tools Description Part No. Plate 91-29310 SNAP-ON TOOL Expander Rod CG-40-4 Collet 7/16 CG-40-9 Expander Rod CG-41-11 Collet 3/8 CG-41-13 Washer 12-37429 Slide Hammer 91-34569A1 90-44477--1 1192 GEAR HOUSING 5A-1 Gear Housing Components (Non-Shiftable) 1 -Housing 2 -Ball Bearing 3 -Sleeve 4 -Ball Bearing 5 -Snap Ring 6 -Anode 7 -Screw 8 -Plug (2) 9 -Gasket (2) 10-Ball Bearing 11-Ball Bearing 12-Seal 13-Water Pump Housing 14-O–ring 15-Impeller 16-Cover 17-Screw (2) 18-Washer (2) 19-Seal 20-Water Tube 21-Grommet 22-Seal 23-Drive Shaft (Upper) 24-Drive Shaft (Lower) 25-Tube 26-Propeller Shaft 27-Shim(S) 28-Pinion Gear 29-Snap Ring 30-Drive Pin, Impeller 31-Shear Pin 32-Propeller 33-Cotter Pin A A A A A K bb F F F 25 23 8 9 8 9 6 7 10 27 26 11 12 33 32 17 18 16 15 13 14 30 31 29 28 2 3 4 5 19 24 20 L 21 K A A Quicksilver Lubrication /Sealant Application Points 50 lb. in. (5.6 N·m) Torque Specifications 2-4-C Marine Lubricant (92-90018A12) Super Duty Gear Lubricant (92-13783A24) Perfect Seal (92-34227-1) Bellows Adhesive (92-86166) 5A-2 GEAR HOUSING 90-44477--1 1192 b A K L F Gear Housing Removal NOTE: Gear housing does NOT have to be removed from driveshaft housing to repair water pump. ! WARNING To prevent accidental engine starting, remove (and isolate) spark plug lead from spark plug BEFORE removing gear housing from driveshaft housing. 1. Remove spark plug lead from spark plug. 2. Close fuel shut-off valve. 3. Tilt engine to full “UP” position. 4. Remove 2 bolts and pull gear housing from driveshaft housing. 17391 a -Bolts a a Disassembly NOTE: When performing partial repairs, follow the disassembly procedure to the point where desired component( s) can be replaced, then proceed to reassembly of the component. 1. Pull tube and upper driveshaft from gear housing. a b 17385 a -Tube b -Driveshaft PROPELLER REMOVAL ! WARNING Before turning propeller or attempting to remove propeller, remove (and isolate) spark plug lead from spark plug to prevent engine from starting accidentally. 2. Remove cotter pin and pull propeller off from shaft. 3. Remove shear pin. a -Cotter Pin b -Shaft c -Shear Pin DRAINING AND INSPECTING GEAR HOUSING LUBRICANT 4. Place gear housing over a clean pan and remove screws (with gaskets). OIL LEVEL OIL a a -Screws with Gaskets a. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal particles (resembling powder) indicates normal wear. Presence of larger particles (or a large quantity of fine particles) indicates need for gear housing disassembly and component inspection. 90-44477--1 1192 GEAR HOUSING 5A-3 b. Note the color of gear lubricant. White or cream color indicates presence of water in lubricant. c. Check drain pan for water separation from lubricant. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-ring and gear housing components. WATER PUMP REMOVAL 5. Remove bolts (with washers). a 17008 a -Bolts 6. Lift cover from shaft. 7. Inspect surface of cover that contacts impeller. Replace if worn. a 17389 a -Cover 8. Using a screwdriver, remove impeller from shaft. Replace impeller if: a. Blades are cracked, worn or glazed. b. Rubber portion of impeller is NOT bonded to inner hub. b a a -Screwdriver b -Impeller 9.Remove drive pin from shaft. a 5A-4 GEAR HOUSING 90-44477--1 1192 a -Drive Pin a -Drive Pin 10. Inspect surface of water pump housing that contacts impeller. Remove (and replace) if worn. To remove, pull housing from shaft. 17024 a a -Water Pump Housing DISASSEMBLY OF WATER PUMP HOUSING IMPORTANT: DO NOT remove bearing unless necessary as removal process will damage bearing. If bearing must be replaced, replace prop shaft seal also. 11. Inspect bearing. If bearing does NOT roll freely or is rusted, replace bearing. 12. Pull bearing from housing using SNAP-ON TOOL: Collet 7/16 CG 40-9 Expander Rod CG 40-4 with Slide Hammer 91-34569A1. 13. Remove and discard O-ring. a b 17025 a -Bearing b -O-ring 14. Remove and discard seal from housing using a punch and hammer, as shown. 17377 a a -Seal PINION GEAR AND DRIVESHAFT REMOVAL 15. Remove clip from end of driveshaft using a screwdriv- er. a a -Clip 90-44477--1 1192 GEAR HOUSING 5A-5 16. Pull driveshaft out of housing being careful not to drop pinion gear. 17. Remove pinion gear from housing. 18. Replace shaft if: a. Shaft seal surface is deeply grooved, allowing water to enter gear housing. b. Shaft splines are twisted or worn. 19. Replace gear if it is chipped or worn. a 17005 a -Shaft a 17026 a -Pinion Gear PROPELLER SHAFT REMOVAL 20. Pull propeller shaft and shims from housing. 21. Replace shaft if: a. Gear is chipped or worn. b. Shaft seal surface is deeply grooved, allowing water to enter gear housing. c. Shear pin hole (or impeller drive pin hole) is worn. 17006 b a a -Shaft b -Shims PROPELLER SHAFT BEARING REMOVAL IMPORTANT: DO NOT remove bearing unless necessary as removal process will damage bearing. 22. Inspect bearing. If bearing does NOT roll freely or is rusted, replace bearing. 23. Pull bearing using SNAP-ON TOOL: Expander Rod CG-41-11 Collet 3/8 CG-41-13 with Slide Hammer 91-34569A1./ a -Bearing a 5A-6 GEAR HOUSING 90-44477--1 1192 REMOVAL OF SEALS 28. Lift sleeve from housing. 24. Remove (and discard) seals using screwdriver. 17010 a -Seals 17380 REMOVAL OF DRIVESHAFT BEARINGS IMPORTANT: DO NOT remove bearings unless necessary as removal process may damage bearings. 25. Remove snap ring. 26. Inspect bearing. If bearing does NOT roll freely or is rusted, replace bearing. 27. Pull bearing using SNAP-ON TOOL: Expander Rod CG-40-4 Collet 7/16 CG-40-9 with Slide Hammer 91-34569A1. a 17011 a -Bearing 17375 a -Snap Ring b -Bearing a a a -Sleeve 29. Inspect bearing. If bearing does NOT roll freely or is rusted, replace bearing. Drive bearing out of housing using a 3/4 in. socket and driver rod. a b 90-44477--1 1192 GEAR HOUSING 5A-7 Reassembly PROPELLER SHAFT BEARING INSTALLATION NOTE: Drive on numbered side of bearing. 1. Apply oil on O.D. of bearing. 2. Drive bearing into housing using propeller shaft/forward gear assembly, with washer 12-37429 between forward gear and bearing, until bearing bottoms-out. Install bearing carrier in gear housing to maintain alignment of prop shaft while seating bearing. a 17315 a -Bearing INSTALLATION OF DRIVESHAFT BEARINGS 3. Apply oil on O.D. of bearing. 4. Pull bearing into housing by holding rod so that it will not rotate. Tighten upper nut against plate. Pull bearing up into bore until bearing is flush with housing.. a bc d e b 17384 a -3/8 in. (9.5mm) O.D. Threaded Rod b -Nut c -Metal Plate (91-29310) d -Bearing (Numbered Side “UP”) e -1 in. (25.4mm) O.D. x 3/8 IN. (9.5MM) I.D. Mandrel (or Washer) 5. Place sleeve into housing. a a -SleeveNOTE: Drive on numbered side of bearing. 6.Apply oil on O.D. of bearing. 7.Drive bearing into housing until bearing bottoms-out, using a 13/16 in. socket and driver rod. 8.Install snap ring into groove. a b a -Bearing b -Snap Ring 5A-8 GEAR HOUSING 90-44477--1 1192 SEAL INSTALLATION SEAL INSTALLATION 9. Apply Quicksilver Bellows Adhesive to O.D. of seal. 10. Push new seals (“a” and “b”) into housing, as shown. 11. Apply Quicksilver 2-4-C Marine Lubricant on I.D. of seals. ab 17010 a -Seal b -Seal PROPELLER SHAFT INSTALLATION 12. Place propeller shaft and shims into housing. 17006 b a a -Shaft b -Shims PINION GEAR AND DRIVESHAFT INSTALLATION 13. Insert driveshaft, as shown. 14. Install pinion gear onto driveshaft, as shown. 15. Install clip into groove in driveshaft. a a -Shaft a b a -Pinion Gear b -Clip 90-44477--1 1192 GEAR HOUSING 5A-9 GEAR BACKLASH CHECK 16. Pull up on driveshaft and hold so that it will not rotate. While pushing in on propeller shaft, rotate shaft back and forth. There should be play between gears (a clicking sound should be heard as the shaft is rotated back and forth. NOTE: The amount of play between the gears is not critical, but no play between the gears is unacceptable. If there is no play between the gears, check that bearings are completely seated in housing. If bearings are seated properly, remove shim(s)* until play is obtained between gears. *Shim Kit (15-95292) contains 3 shims (.002 in., .004 in. and .008 in.) [.05mm, .10mm and .20mm] 17381 ASSEMBLING WATER PUMP HOUSING 17. Install new seal into housing using a suitable mandrel (or socket) and driver rod. a -Seal b -Spring NOTE: Press on numbered side of bearing. 18. Press bearing into housing using 13/16 in. socket until bearing bottoms-out. 19. Install new O-ring. 20. Apply Quicksilver 2-4-C Marine Lubricant on O-ring and I.D. of seal. 17025 a b c a -Bearing b -O-ring c -Seal WATER PUMP INSTALLATION 21. Install water pump housing, as shown. 17024 a 5A-10 GEAR HOUSING 90-44477--1 1192 a -Pump Housing a -Pump Housing 22. Install drive pin. 17013 a -Drive Pin IMPORTANT: Rotate impeller in a clockwise direction during installation. 23. Install impeller on drive pin. 17386 a -Impeller a a 24. Apply Quicksilver Perfect Seal on threads of bolts. Install components as shown. 25. Torque bolts to 50 lb. in. (5.6 N·m). a b c c 17374 a -Cover b -Bolt [Torque to 50 lb. in. (5.6 N·m)] c -Washer FILLING GEAR HOUSING WITH LUBRICANT 26. Place gear housing in a vertical position. 27. Remove lubricant screws with gaskets. 28. Slowly fill gear housing with Quicksilver Super Duty Lower Unit Lubricant until lubricant flows out OIL LEVEL hole and no air bubbles are visible. 29. Remove grease tube from OIL hole and quickly install screw (with gasket) OIL LEVEL OIL a b 17390 a -OIL (Fill) Screw b -OIL LEVEL Screw 90-44477--1 1192 GEAR HOUSING 5A-11 PROPELLER INSTALLATION ! WARNING BEFORE turning propeller or attempting to install propeller, remove (and isolate) spark lead from spark plug to prevent engine from starting accidentally. 30. Remove (and isolate) spark plug lead from spark plug. 31. Coat the shaft with one of the following Quicksilver products: a. Special Lubricant 101 b. 2-4-C Marine Lubricant c. Perfect Seal 32. Insert shear pin. 33. Install propeller onto shear pin. 34. Install cotter pin and bend ends. a b a -Shear Pin b -Cotter Pin Installation ! WARNING To prevent accidental engine starting, remove (and isolate) spark plug lead from spark plug BEFORE installing gear housing onto driveshaft housing. 1. Remove (and isolate) spark plug lead from spark plug. 2. Close fuel shut-off valve. 3. Tilt engine to full “UP” position. 4. Apply Quicksilver 2-4-C Marine Lubricant to end of tube O.D. 5. Insert tube into driveshaft housing and push tube into lower crankshaft seal. 17379 a 17376 b a a -Shaft b -Tube a -Tube 6. Apply Quicksilver 2-4-C Marine Lubricant on I.D. of upper driveshaft at both ends. 7. Insert shaft into tube. Push shaft onto end of crankshaft. 5A-12 GEAR HOUSING 90-44477--1 1192 8. Apply Quicksilver 2-4-C Marine Lubricant on I.D. of seals. Align components as shown. While pushing up on gear housing, rotate propeller (clockwise) to engage lower driveshaft into upper driveshaft. b a c 17388 a -Water Tube b -Seal c -Tube 9. Secure gear housing as shown. Torque bolts to 50 lb. in. (5.6 N·m) 17391 a b c a b c a -Bolt [Torque to 50 lb. in. (5.6 N·m)] b -Lockwasher c -Washer 90-44477--1 1192 GEAR HOUSING 5A-13 GEAR HOUSING (SHIFTABLE - F/N) OIL LEVEL OIL 28110 5 B Table of Contents Page Gear Housing (Shiftable - F/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 Gear Housing Assembly Components . . . . . . . . . . . 5B-2 Draining and Inspecting Gear Housing . . . . . . . . . . . 5B-3 Propeller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Gear Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Gear Housing Disassembly . . . . . . . . . . . . . . . . . . . . . 5B-4 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Bearing Carrier and Propeller Shaft . . . . . . . . . . . 5B-6 Propeller Shaft Disassembly . . . . . . . . . . . . . . . . . 5B-8 Driveshaft, Pinion Gear and Forward Gear . . . . . 5B-8 Upper Driveshaft Bearing. . . . . . . . . . . . . . . . . . . . 5B-9 Lower Driveshaft Bearing/Forward Gear Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Gear Housing Reassembly . . . . . . . . . . . . . . . . . . . . 5B-10 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Installation of Lower Driveshaft Bearing . . . . . . 5B-11 Installation of Forward Gear Bearing . . . . . . . . . 5B-11 Installation of Forward Gear . . . . . . . . . . . . . . . . 5B-11 Installation of Driveshaft . . . . . . . . . . . . . . . . . . . . 5B-12 Bearing Carrier Reassembly . . . . . . . . . . . . . . . . 5B-13 Shift Shaft Installation . . . . . . . . . . . . . . . . . . . . . . 5B-13 Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . 5B-14 Propeller Shaft Installation . . . . . . . . . . . . . . . . . . 5B-14 Bearing Carrier Installation . . . . . . . . . . . . . . . . . 5B-14 Water Pump Installation . . . . . . . . . . . . . . . . . . . . 5B-15 Gear Housing Installation. . . . . . . . . . . . . . . . . . . . . . 5B-16 Filling Gear Housing with Lubricant . . . . . . . . . . 5B-16 Gear Housing Installation . . . . . . . . . . . . . . . . . . . 5B-16 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . 5B-17 90-44477--1 1192 Gear Housing (Shiftable - F/N) Specifications Gear Ratio Model 2.5/3.3 . . . . . . . . . . . . . . . . 2.18:1 Gear Type . . . . . . . . . . . . . . . . . . . . . . Spiral Bevel Clutch Type . . . . . . . . . . . . . . . . . . . . . Sliding Dog Propeller Drive System . . . . . . . . . . Drive (Shear) Pin Lubricant Capacity . . . . . . . . . . . . . . 2.5 fl. oz. (74 ml) Special Tools Description Part No. Mandrel Kit 91-31229A5 Mandrel 37312 Mandrel 38628 Driver 91-37323 SNAP-ON TOOL Expanding Rod CG-40-4 Collet 7/16 CG-40-9 Bearing Puller 91-27780 Slide Hammer 91-34569A1 Universal Puller Plate 91-37241 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-1 Gear Housing Assembly Components (Shiftable – Forward and Neutral) 44 43 42 40 41 39 38 37 36 29 30 31 32 33 35 34 28 1 -Housing 2 -Ball Bearing 3 -Bolt (2) 4 -Lock Washer (2) 5 -Washer 6 -Plug (2) 7 -Gasket (2) 8 -Bolt 9 -Anode 10-Pinion Gear 11-Spacer 12-Drive Shaft 13-Ball Bearing 14-Impeller Key 15-Gasket 16-Seal 17-Pump Base 18-Gasket 19-Guide Plate 20-Gasket 21-Impeller 22-Insert 23-Housing 24-Grommet 25-Bolt (4) 26-Washer (4) 27-Water Tube 28-Grommet 29-Ball Bearing 30-Shim 31-Gear 32-Cam Follower 33-Spring 34-Propeller Shaft 35-Clutch 36-Ball Bearing 37-Seal 38-O-ring 39-Housing 40-Bolt (2) 41-Washer (2) 42-Propeller 43-Shear Pin 44-Cotter Pin Quicksilver Lubrication/Sealant Application Points Torque Specifications 2-4-C Marine Lubricant (92-90018A12) Super Duty Gear Lubricant (92-13783A24) Perfect Seal (92-34227A24) Bellows Adhesive (92-86166) b a 50 lb. in. (5.6 N·m) A F K L A A A A A A F F F F L K K b a 70 lb. in. (7.9 N·m) 5B-2 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 Draining and Inspecting Gear Housing ! WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug lead from spark plug before working near the propeller. 1. With gear housing in normal running position, place a clean pan under housing and remove “OIL” fill screw with gasket and “OIL LEVEL” screw with gasket. a. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of metal flakes indicates the need for gear housing disassembly and component inspection. b. Note color of gear lubricant. White or cream color indicates presence of water. Gear lubricant drained from a gearcase recently in operation will have a yellowish color due to lubricant agitation/ aeration. This is normal and should not be confused with the presence of water. OIL LEVEL OIL a b 28110 a -“OIL LEVEL” Screw with Gasket b -“OIL” Fill Screw with Gasket Propeller Removal ! WARNING Before turning propeller or attempting to remove propeller, remove (and isolate) spark plug lead from spark plug to prevent engine from starting accidentally. 1. Remove cotter pin and pull propeller off from shaft. 2. Remove drive (shear) pin. a -Cotter Pin b -Drive (Shear) Pin Gear Housing Removal 1. Close fuel shut-off valve. ! WARNING To prevent accidental engine starting, remove (and isolate) spark plug lead from spark plug BEFORE removing gear housing from driveshaft housing. 2. Place gear shift lever in NEUTRAL position. 3. Tilt engine to full “UP” position. 4. a -Cover 28111 a b Remove shift linkage access cover. a 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-3 5. Loosen (DO NOT remove) linkage bolt. 28113 a a -Bolt 6.Remove 2 bolts (with flatwashers and lockwashers). Pull gear housing from driveshaft housing. a a -Bolts Gear Housing Disassembly Water Pump 1. Remove 4 bolts (with flatwashers and lockwashers) securing water pump housing. 28114 a -Pry Points 28115 a a b a -Bolts b -Housing 2.Use padding to protect gearcase surface while apply- ing pressure against housing pry points. a a 5B-4 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 3. Remove impeller and drive key from driveshaft. Replace impeller if: a. Impeller blades are cracked, torn or worn. b. Impeller is glazed or melted (caused by insufficient water supply. c. Rubber portion of impeller is not bonded to impeller hub. a b 28117 a -Impeller b -Drive Key IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting cover insert and base plate. The depth of the groove will not affect water pump output. If other grooves (from sand or debris) are present, insert and/ or base plate should be replaced. 4. Remove plate and gasket. b a 28118 a -Base Plate b -Gasket IMPORTANT: If water pump repair procedures ONLY are to be performed, hold driveshaft DOWN while prying/ lifting up on pump base to prevent driveshaft from disconnecting from pinion gear. If driveshaft separates from pinion, gearcase must be disassembled to realign driveshaft with pinion gear. 5. Pad gearcase and pry up on pump base to remove base. c b a 28119 a -Pry Point b -Pump Base c -Pad 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-5 6. Shift shaft O-rings are located in both the upper pump housing and lower pump base. If sealing capabilities of O-rings are questionable, replace O-rings. c ba 28121 a -Upper Housing b -O-ring c -Carrier O-ring a b 28122 a -Pump Base b -O-ring 7. If pump base seal is damaged, remove seal with a punch being careful not to damage base. Apply 2-4-C Marine Lubricant to cavity between new seal lips. Press new seal into pump base with a 11/16 or 16mm socket. a b a -Seal b -Socket Bearing Carrier and Propeller Shaft 1. Drain lubricant; refer to “Draining and Inspecting Gear Lubricant”. 2. Remove 2 bolts (with flat washers). a a -Bolts 5B-6 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 3. Tap on either side of carrier with leather mallet to break adhesion between carrier and gearcase. Remove carrier and propeller shaft. a b 28125 a -Carrier b -Propeller Shaft 4. Inspect carrier ball bearing for serviceability. If bearing is rusted or does not roll freely, replace bearing. If bearing must be replaced, use slide hammer (91-34569A1) with the following SNAP-ON TOOLS: a. Expanding Rod CG 40-4 b. Collet 7/16 CG 40-9 b c d a 28126 a -Bearing b -Collet (CG 41-13) c -Expanding Rod (CG 41-11) d -Slide Hammer (91-34569A1) NOTE: Propeller shaft seal cannot be replaced without removing carrier bearing. Removal of bearing most likely will damage bearing. DO NOT remove bearing unless neces sary and at that time replace shaft seal also. Remove seal with screwdriver or punch. a a -Seal 5. Remove carrier O-ring and inspect for cuts and abraisions. a a -O-ring 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-7 Propeller Shaft Disassembly 1. Remove cam follower and inspect both ends for wear. If worn or pitted, replace follower. 2. Compress spring with awl or small screwdriver and remove clutch. Replace clutch if teeth are rounded or chipped or if wear is evident from cam follower or spring. Rounded jaws indicate the following: a. Improper shift cable adjustment. b. Engine idle speed too high while shifting. c. Shifting too slowly. a b c 28129 a -Cam Follower b -Clutch c -Spring 3. Replace propeller shaft if: a. Oil seal surface is grooved. b. Shaft has a noticeable “wobble” or is bent more than .006 in. (.152mm). Check with a dial indicator and V-block. 29130 c b a a -V-Blocks b -Bearing Surfaces c -Check with Dial Indicator Here Driveshaft, Pinion Gear and Forward Gear 1. Remove driveshaft and sleeve from gear housing. a b a -Driveshaft b -Sleeve 2. Remove base gasket and shift cam from gear housing. a b a -Gasket b -Shift Cam 5B-8 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 3. Inspect shift cam face for roughness or gauling from cam follower. If cam face is worn, replace shift cam assembly. a 28133 a -Cam Face 4. Remove forward gear and shim. a. Inspect forward gear clutch teeth for wear. b. Inspect bronze bearing for wear. c. Inspect forward gear and pinion gear for chips or excessive wear. e d cb a 28134 a -Forward Gear b -Clutch Teeth c -Shim d -Bronze Bearing e -Pinion Gear Upper Driveshaft Bearing 1. Inspect upper driveshaft ball bearing for rust or rough movement. If necessary, replace bearing. Use a Protector Cap (91-24161) to protect driveshaft while pressing bearing off while utilizing a Universal Puller Plate (91-37241). b c a a -Bearingb -Protector Cap (91-24161) c -Universal Puller Plate (91-37241) 2.Inspect driveshaft where water pump seals ride. If fin- gernail can catch in grooves, driveshaft should be re- placed. a a -Seal Surface 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-9 Lower Driveshaft Bearing/Forward Gear Bearing. IMPORTANT: DO NOT remove FORWARD gear ball bearing or lower driveshaft ball bearing from gearcase unless replacement is necessary. Removal process may damage bearing. IMPORTANT: If FORWARD gear bearing and lower driveshaft bearing are removed from gearcase, inspect gearcase for signs of bearing race spinning in their respective bores. This usually occurs as a result of bearing seizure from lack of lubricant or water intrusion. If such signs are apparent, gearcase must be replaced. 1. Inspect lower driveshaft ball bearing for roughness. If necessary, remove bearing by driving bearing downward with a 3/4 in. socket. a b 28137 a -Bearing b -3/4 in. Socket 2. Inspect FORWARD gear ball bearing for roughness. If necessary, remove bearing using Bearing Puller (91-27780). a b 28138 a -Bearing b -Bearing Puller (91-27780) Gear Housing Reassembly Propeller Shaft 1. Compress clutch spring and reinsert clutch into propeller shaft. 2. Apply a small amount of Quicksilver Needle Bearing Assembly Lubricant to the clutch end of cam follower. This will aid in retaining cam follower in propeller shaft during installlation of shaft in gear housing. a b c a -Clutch Spring b -Clutch c -Cam Follower 5B-10 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 Installation of Lower Driveshaft Bearing 1. Lubricate O.D. of lower bearing race with Quicksilver Needle Bearing Assembly Lubricant. Place bearing into driveshaft bore (NUMBER SIDE UP). using a 3/4 in. socket, carefully tap bearing (CHECK ALIGNMENT FREQUENTLY) into position [approximately 1/8 in. (3.17 mm)] from bottom of bore. IMPORTANT: If lower driveshaft bearing is not positioned low enough in driveshaft bore, water pump base will preload upper and lower driveshaft bearings resulting in premature failure of both bearings. a b c 28140 a -3/4 in. Socket b -Bearing c -1/8 in. (3.17mm) Installation of Forward Gear Bearing NOTE: Drive on NUMBER SIDE of bearing. 1. Lubricate O.D. of bearing with Quicksilver Needle Bearing Assembly Lubricant. Position bearing in gear case. Seat bearing in case using Mandrel (38628) and Driver (91-37323) from Mandrel Kit (91-31229A5). a b c a -Bearing b -Mandrel (38628) c -Driver (91-37323) Installation of Forward Gear 1. Lubricate forward gear bronze propeller shaft bearing and roller bearing surface with Quicksilver Gear Lubricant. 2. Place forward gear with shim (retained) into forward bearing. c b a a -Forward Bearing b -Shim c -Forward Gear 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-11 Installation of Driveshaft 1. Lubricate I.D. of new upper driveshaft bearing with Quicksilver Needle Bearing Assembly Lubricant. In order to position bearing at the proper height on drive- shaft, fabricate a driver tool to the following dimensions: cb a 28143 a -3-5/8 in. (92.07mm) b -3/4 in. (19.05mm) c -13/32 in. (10.31mm) 2. Place driveshaft (crankshaft end) on a padded surface. Place bearing on pinion end of shaft and using fabricated driver tool, tap bearing down driveshaft until tool is flush with pinion end of shaft. a bc 28144 a -Tool b -Bearing c -3-5/8 in. (92.07mm) 3. Place sleeve into housing. a 28145 a -Sleeve 4. Slide driveshaft assembly through sleeve into housing while installing Pinion gear onto lower driveshaft splines. a b 28146 a -Driveshaft b -Pinion Gear 5B-12 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 Bearing Carrier Reassembly 1. Apply 2-4-C Marine Lubricant into space between new seal lips. Press new seal (FLAT SIDE DOWN) into carrier with 13/16 in. socket. ab 28147 a -Seal (FLAT SIDE DOWN) b -13/16 in. (Socket) 2. Apply Quicksilver Needle Bearing Assembly Lubricant to O. D. of new carrier bearing. 3. Press new ball bearing (NUMBER SIDE UP) into carrier until bearing seats using press or Driver (91-37323) and Mandrel (37312) from Mandrel Kit (91-31229A5). a b 28148 a -Bearing b -Mandrel (37312) 4. Install carrier O-ring. Apply 2-4-C Marine Lubricant to O-ring surface. a a -O-ring Shift Shaft Installation 1. Install shift shaft in gear housing. Apply a light coat of 2-4-C Marine Lubricant to shaft to lubricate O-ring in pump base. 2. Install water pump base and new base gasket. 128150 a b c a -Shift Shaft b -Pump Base c -Base Gasket 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-13 Forward Gear Backlash NOTE: The amount of backlash is not critical; NO BACKLASH IS CRITICAL. Check Forward gear backlash as follows: a. Apply DOWN pressure on driveshaft. b. Push UP on Pinion gear (gear floats on driveshaft) c. Rock Forward gear back-and-forth. A light clicking sound [approximately 0.002 in. to 0.006 in.(0.050mm to 0.152mm) freeplay] should be heard. If excessive freeplay exists [over .012 in. (0.30mm)], gear case components should be inspected for wear. If NO freeplay exists, either Forward gear or Forward gear bearing are not seated properly in gearcase or lower driveshaft bearing (above Pinion gear) is positioned TOO LOW in driveshaft housing. Propeller Shaft Installation NOTE: Verify shift cam is aligned properly in gearcase. 1. Install propeller shaft assembly into Forward gear/ bearing. a 28151 a -Propeller Shaft Bearing Carrier Installation 1. Slide bearing carrier assembly over propeller shaft. Secure carrier to gearcase with 2 bolts and flat washers. Torque bolts to 50 lb. in. (5.6 N·m). a b a -Carrier b -Bolts with Washers [Torque to 50 lb. in. (5.6 N.m)] Water Pump Installation 1. Install new top base gasket, base plate (if required) and pump cover gasket. 28153 c b a a -Base Gasket b -Base Plate c -Pump Cover Gasket 5B-14 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 2. Install drive key and impeller onto driveshaft. If reusing old impeller, DO NOT reverse impeller vanes or premature failure of vanes will occur. a b 28154 a -Drive Key b -Impeller NOTE: Reapply a light coat of 2-4-C Marine Lubricant to shift shaft to lubricate O-ring in pump housing. 3. Apply a light coat of 2-4-C Marine Lubricant to inside of pump cover insert. Slide pump cover assembly down over driveshaft. Rotate driveshaft CLOCKWISE as pump cover is pressed down over impeller. 28155 a b a -Pump Coverb -Driveshaft (Turn CLOCKWISE) 4. Secure pump cover to gearcase with 4 bolts, flatwashers and lockwashers. Torque bolts to 70 lb. in. (7.9 N·m). 5. Lubricate I. D. of water tube seal with a light coat of 2-4-C Marine Lubricant. 28156 a a b a -Bolts [Torque to 70 lb. in. (7.9 N·m)] b -Seal Gear Housing Installation Filling Gear Housing with Lubricant NOTE: Gear housing lubricant capacity is approximately 2.5 fl. oz. (74ml). ! WARNING If gear housing is installed on outboard, disconnect (and isolate) spark plug lead from spark plug before working near propeller. ! CAUTION DO NOT use automotive grease in the gear housing. Use only Quicksilver Gear Lubricant. 1. Remove any gasket material from “OIL” fill and “OIL LEVEL” screws and gear housing. Install new gaskets on “OIL” and “OIL LEVEL” plugs. IMPORTANT: DO NOT add lubricant without removing “OIL LEVEL” screw. Gear housing cannot be filled because of trapped air. Fill gear housing when driveshaft is in the vertical position. 2. Remove “OIL” fill screw and gasket. 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-15 3. Insert lubricant tube in “OIL” fill hole, then remove “OIL LEVEL” screw and gasket. Gear Housing Installation ! WARNING Disconnect (and isolate) spark plug leads before installing gear housing onto driveshaft housing to prevent accidental starting. 1. Place shift lever in NEUTRAL position. 2. Tilt engine to full “UP” position. 3. Shift gear housing into NEUTRAL. Propeller will rotate freely in either position. ! CAUTION DO NOT lubricate top of driveshaft. Excess lubricant will not allow driveshaft to fully engage crankshaft. Tightening the gear housing fasteners (if excess lubricant is on top of driveshaft) will load the driveshaft/ crankshaft and may damage either or both powerhead and gear housing. Verify top of driveshaft is free of lubricant. 4. Apply a light coat of 2-4-C Marine Lubricant to drive- shaft splines. 5. Position driveshaft into driveshaft housing. Move gear housing upwards into driveshaft housing while aligning shift shaft, water tube and driveshaft splines. NOTE: If driveshaft splines will not align with crankshaft splines, rotate flywheel slightly while pushing gear housing into driveshaft housing. 6. Secure gearcase to driveshaft housing with 2 bolts, flat washers and lockwashers. Torque bolts to 50 lb. in. (5.6 N·m). 28157 a -Bolts (with flat washers and lockwashers) [Torque to 50 lb. in. (5.6 N·m)] a 7. Tighten bolt clamping upper and lower shift shafts. With outboard in NEUTRAL, propeller shaft should turn freely. If propeller shaft DOES NOT turn freely in NEUTRAL, loosen clamping bolt and verify shift lever and gearcase are both in NEUTRAL. Retighten bolt. Reinstall access cover. a -Bolt b -Access Cover 8. Verify correct shift operation. Propeller shaft should turn freely in either direction in NEUTRAL. In FORWARD, propeller shaft should turn approximately 90° in either direction before stopping. If shift operation is not as described, remove gearcase and inspect shift cam and clutch for proper assembly. 9. Inspect sacrificial anode on bottom of anti-ventilation plate for erosion. If 50% (or more) consumed, replace anode. DO NOT paint or apply a protective coating to the anode or corrosion protection will be lost. a -Anode 28158 a b a 5B-16 - GEAR HOUSING (SHIFTABLE) 90-44477--1 1192 Propeller Installation ! WARNING Disconnect and isolate spark plug lead when working near the propeller to prevent outboard from starting. 1. Insert shear pin into propeller shaft. 2. Slide propeller onto shaft and align with shear pin. 3. Secure propeller to shaft with new cotter pin. 90-44477--1 1192 GEAR HOUSING (SHIFTABLE) - 5B-17 REWIND STARTER ASSEMBLY 17761 6 Table of Contents Page Rewind Starter Assembly . . . . . . . . . . . . . . . . . . . . 6-1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 90-44477--1 1192 Mariner/Mercury – 2.5/3.0/3.3 Rewind Starter Assembly NOTE: Disassembly and Reassembly Instructions Apply to All Models – 2.2/2.5/3.0/3.3 Mercury 2.2 27645 17761 27646 17328 90-44477--1 1192 REWIND STARTER ASSEMBLY 6-1 Disassembly 1. Remove 3 bolts that secure rewind starter to engine. a 17761 a -Bolts (3) ! WARNING When disassembling rewind starter, SAFTEY GLASSES must be worn in case rewind spring uncoils out of housing. 2. Untie knot in end of starter rope and remove starter handle. Hold sheave and allow rope to slowly retract into starter housing, thus relaxing rewind spring tension. a 17328 a -Handle 3. Remove retaining clip, spacer and friction plate. a b c d a -Return Spring b -Spring Cover c -Friction Spring d -Ratchet a b c 17318 a -Retaining Clip b -Spacer c -Friction Plate 4.Remove return spring, spring cover, friction spring and ratchet. 6-2 REWIND STARTER ASSEMBLY 90-44477--1 1192 5. Carefully lift sheave up approximately 1/2 in. (12.7mm) and rotate sheave back and forth until rewind spring disengages from bottom of sheave. a a -Sheave 6.Lift sheave from rewind housing. Remove starter rope from sheave by untying knot. 17317 a b 17322 a -Sheave b -Knot 7. If necessary, remove rewind spring by holding rewind housing (spring facing down) on the floor and gently tap on the top of the housing. The rewind spring will fall from the confines of the spring brackets and unwind within the rewind housing. 17316 a a -Rewind Spring 90-44477--1 1192 REWIND STARTER ASSEMBLY 6-3 Reassembly 1. Apply Quicksilver 2-4-C Marine Lubricant to inside rewind spring surface of the starter housing. 2. Hook end of spring over catch and coil rewind spring in starter housing. 17323 a -Knot 17316 a a -Catch 3.Tie a knot in starter rope and pass rope through hole in sheave. 4.Push knot and end of rope into recess. a 5. Wind starter rope counterclockwise on sheave. a a -Starter Rope 6. Apply a thin coat of 2-4-C Marine Lubricant to outer surface of rewind spring. 7. Install sheave into rewind housing. The inner spring hook must catch into slot of the sheave. a b a -Spring Hook b -Slot 6-4 REWIND STARTER ASSEMBLY 90-44477--1 1192 8. Place ratchet on sheave in direction shown. a a -Ratchet 9. Place spring and cap on center shaft. 17326 b a 17327 a -Spring b -Cap 10. Hook end of return spring in slot of friction plate in direction shown. 11. Insert other end of return spring into hole and install spring and friction plate together over center shaft. a b c d a -Return Spring b -Friction Plate c -Return Spring d -Hole 12. Place spacer over center shaft. 13. Install “E” clip into groove. a b a -Spacer b -“E” Clip 90-44477--1 1192 REWIND STARTER ASSEMBLY 6-5 14. Apply rewind spring tension to sheave by placing starter rope in notch and turning sheave 3 turns counterclockwise from its relaxed position. a 17329 a -Notch 15. Route starter rope through rope guide in starter housing and handle and tie a knot in rope. 1 -Leave a Reserve Length of 1/4 in. to 1/2 in. (6.3mm to 12.7mm) at rope end 17328 16. Reinstall rewind housing on engine. 17761 6-6 REWIND STARTER ASSEMBLY 90-44477--1 1192