Mercury 40hp 4cyl Service Instruction

 

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Mercury 40hp 4cyl Service Instruction

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Service Manual Outline Section 1 - Important Information Section 2 - Electrical & Ignition A - Ignition System B - Battery, Charging System & Starting System C - Timing, Synchronizing & Adjustment D - Wiring Diagrams Section 3 - Fuel System & Carburetion Section 4 - Powerhead Section 5 - Mid-Section A - Clamp/Swivel Bracket & Drive Shaft Housing B - Power Trim (Design I) C - Power Trim (Design II) D - Power Trim (Design III) E - Power Trim (Design IV) F - Manual Tilt System (Design I, II, III) G - Manual Tilt System (Design IV) Section 6 - Lower Unit A - Lower Unit B - Jet Drive Section 7 - Outboard Motor Installation/Attachments A - Outboard Motor Installation/Attachments B - Tiller Handle and Co-Pilot C - Rewind Starter Section 8 - Oil Injection System Important Information Electrical & Ignition Fuel System & Carburetion Powerhead Mid-Section Lower Unit Outboard Motor Installation/ Attachments Oil Injection System 1 2 3 4 5 6 7 8 90-814676R1 DECEMBER 1996 iii

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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 in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. 90-814676R1 DECEMBER 1996 i

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Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch./mm. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual. ii 90-814676R1 DECEMBER 1996

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IMPORTANT INFORMATION 1 50332 GENERAL INFORMATION and SPECIFICATIONS

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Table of Contents Page Propeller Information . . . . . . . . . . . . . . . . . . . . . . 1-1 How to Use this Manual . . . . . . . . . . . . . . . . . . . . 1-1 General Specifications . . . . . . . . . . . . . . . . . . . . . 1-2 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . 1-3 Trim “In” Angle Adjustment . . . . . . . . . . . . . . . . . 1-4 Power Trim System (Models with Power Trim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General Information . . . . . . . . . . . . . . . . . . . . . 1-4 Checking Trim System Fluid Level . . . . . . . . 1-5 Trimming (Models with Power Trim) . . . . . . . . . . 1-5 Trimming Outboard “Out” (“Up”) Characteristics . . . . . . . . . . . . . . . . . . . . . . . 1-5 Trimming Outboard “In” (’Down”) Characteristics . . . . . . . . . . . . . . . . . . . . . . . 1-5 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . 1-6 Boat Performance . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Test Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Boat Test Chart (Example) . . . . . . . . . . . . . . . 1-7 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Ride-Guide Steering Cable and Pivot Points Lubrication . . . . . . . . . . . . . . . . . . . . 1-9 Gear Housing Lubrication . . . . . . . . . . . . . . . 1-10 Salt Water Corrosion - Gear Housing Bearing Carrier and Cover Nut . . . . . . . . 1-10 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . 1-11 Flushing Outboard Cooling System . . . . . . . . . 1-11 Following Complete Submersion . . . . . . . . . . . 1-12 Salt Water Submersion (Special Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Submerged While Running (Special Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Submerged Engine (Fresh Water) (Plus Special Instructions) . . . . . . . . . . . . . . . . . 1-12 Out-of-Season Outboard Storage . . . . . . . . . . 1-13 Out-of-Season Battery Storage . . . . . . . . . . . . 1-13 How Weather Affects Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Conditions Affecting Operation . . . . . . . . . . . . . 1-15 Detonation: Causes and Prevention . . . . . . . . 1-15 Compression Check . . . . . . . . . . . . . . . . . . . . . . 1-16 Painting Procedure . . . . . . . . . . . . . . . . . . . . . . . 1-17 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1-0 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996

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Propeller Information For in-depth information on marine propellers and boat performance - written by marine engineers - see your Authorized Dealer for the illustrated “What You Should Know About Quicksilver Propellers and Boat Performance Information” (Part No. 90-86144). How to Use this Manual The manual is divided into SECTIONS (shown, right) which represents major components and systems. Some SECTIONS are further divided into PARTS. Each PART has a title page. A “Table of Contents” for the particular PART is printed on the back of the title page. SECTIONS and PARTS are listed on the “Service Manual Outline” sheet which immediately follows the cover of this book. Section 1 2 3 4 5 6 7 8 Section Heading Important Information Electrical and Ignition Fuel System and Carburetion Powerhead Mid-Section Lower Unit Outboard Installation/Attachments Oil Injection System 90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-1

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General Specifications Model Horsepower Engine Type Full Throttle RPM Range Idle RPM Range (in Forward Gear) Piston Displacement Cylinder Bore Standard Stroke Ignition Type Firing Order Recommended Spark Plug Gear Selection Gear Ratio Gear Housing Lubricant Capacity Outboard Weight (ELPTO) Carburetion Recommended Gasoline Remote Fuel Tank Capacity: - U.S. Gallons - Imperial Gallons - Liters Recommended Oil Gasoline/Oil Ratio Oil Tank Capacity* Maximum Operation at Full Throttle* Oil Remaining when Warning Buzzer Sounds* Approximate Running Time Remaining at Wide Open Throttle when Buzzer Sounds* Recommended Battery Rating *Specification for Oil Injected Model 40 40 4 Cylinder, In-Line, Two-Stroke 5000-5500 600-700 44 cu. in. (721cc) 2.565 in. (65.151mm) 2.125 in. (53.975mm) Thunderbolt Capacitor Discharge 1-3-2-4 NGK BUHW-2 Forward - Neutral - Reverse 2:1 12.5 fl. oz. (370ml) 192 lbs. (87kg) 2 Carburetors, Center Bowl Any leaded or unleaded (lead-free) gasoline, with a minimum posted octane rating of 86 (research octane number 90) 6.6 5.5 25 Quicksilver 2-Cycle Outboard Oil 50:1 0.935 gal. (3.54 Liters) 7 Hours 7.5 fl. oz. 30 Minutes Minimum Reserve Capacity rating of 100 Minutes and Cold Cranking Amperage of 350 Amperes 1-2 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996

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Propeller Selection 1. Select a propeller that will allow the engine to operate at or near the top of the recommended full throttle RPM range (listed in “Specifications,” preceding) with a normal load. Maximum engine speed (RPM) for propeller selection exists when boat speed is maximum and trim is minimum for that speed. (High RPM, caused by an excessive trim angle, should not be used in determining correct propeller.) Normally, there is a 150-350 RPM change between propeller pitches. 2. If full throttle operation is below the recommended range, the propeller MUST BE changed to a lower pitch to prevent loss of performance and possible engine damage. 3. For better acceleration, such as is needed in water skiing, propping up to 500 RPM above the recommended range is advised. Continuous operation above the recommended maximum RPM, however, is not permissible. 4. After initial propeller installation, the following common conditions may require that the propeller be changed to a lower pitch: a. Warmer weather and great humidity will cause an RPM loss. b. Operating in a higher elevation causes an RPM loss. c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss. d. Operation with an increased load (additional passengers, equipment, pulling skiers, etc.). Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. Coat the propeller shaft with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon. IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. Flo-Torq I Drive Hub Propellers cb a a - Forward Thrust Hub b - Propeller Nut Retainer c - Propeller Nut Flo-Torq II Drive Hub Propellers ed c ba a - Forward Thrust Hub b - Replaceable Drive Sleeve c - Rear Thrust Hub d - Propeller Nut Retainer e - Propeller Nut 1. Tighten propeller nut to 55 lb.ft. (75 N·m). Bend tabs against nut. a b b a - Propeller Nut - Torque To 55 lb. ft. (75 N·m) b - Bend Tabs Against Nut 90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-3

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Trim “In” Angle Adjustment WARNING Operating some boats with outboard trimmed to the full “in” trim angle [not using trim adjustment bolt (a)] at planing speed will cause undesirable and/or unsafe steering conditions. Each boat must be water tested for handling characteristics after outboard installation and after any trim adjustments. IMPORTANT: Some boat/outboard combinations, that do not use the trim adjustment pin (a) and are trimmed to the full “in” trim angle, will not experience any undesirable and/or unsafe steering conditions during planing speed. Thus, not using trim adjustment pin may be desired. However, some boats with outboard trimmed to the full “In” trim angle at planing speeds will cause undesirable and/or unsafe steering conditions. If these steering conditions are experienced, under no circumstances should the outboard be operated without the trim adjustment pin and without the pin adjusted in the proper holes to prevent unsafe handling characteristics. Water test the boat not using the trim adjustment pin. If undesirable and/or unsafe steering conditions are experienced (boat runs with nose down), install trim adjustment pin in proper hole to prevent unsafe handling characteristics. Power Trim System (Models with Power Trim) General Information The power trim system is filled at the manufacturer and is ready for use. Trim outboard through entire trailering range several times to remove any air from the system. The trim system is pressurized and is not externally vented. The outboard can be raised or lowered manually by loosening the manual release valve 2 to 3 turns counterclockwise. The trim “out” angle of this outboard is not adjustable. The trim system has an internal valve which will automatically stop the outward trim travel at 200 when engine RPM is approximately 2000 RPM or higher; outboard also has to be in water and in gear. The outboard can be operated beyond the 200 trim limit for operating outboard in shallow water if engine RPM is kept below approximately 2000 RPM. 50158 1-4 - IMPORTANT INFORMATION 50157 50146 a - Fill Screw (System is Pressurized, DO NOT Open Unless Outboard is Tilted to Full Up Position) b - Manual Tilt Release Valve Location 90-814676R1 DECEMBER 1996

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Checking Trim System Fluid Level IMPORTANT: This trim system is pressurized. Remove fill screw when outboard is trimmed to the full “up” position. Retighten fill screw securely. 1. Trim outboard to full “up” position. Engage tilt lock level (a). Trim system fluid can only be checked when outboard is in this position. Trimming (Models with Power Trim) NOTE: Because varying hull designs react differently in various degrees of rough water, it is recommended to experiment with trim positions to determine whether trimming up or down will improve the ride in rough water. When trimming your outboard from a mid-trim position (trim tab in neutral straight fore-and-aft position), you can expect the following results: 50157 2. Remove fill screw and check fluid level. Fluid level should be to bottom of threads in fill hole (b). 3. If necessary, add Quicksilver Power Trim & Steering Fluid or; Automatic Transmission Fluid (ATF) Type F, FA or Dexron 11 fluid to trim system. 4. Reinstall fill screw. Trimming Outboard “Out” (“Up”) Characteristics WARNING Excessive trim “out” also may reduce the stability of some high speed hulls. To correct instability at high speed, reduce the power GRADUALLY and trim the outboard “In” slightly before resuming high speed operation. (Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability.) 1. Will lift bow of boat, generally increasing top speed. 2. Transfers steering torque harder to left on standard or slightly elevated transom installation (single outboard). 3. Increases clearance over submerged objects. 4. In excess, can cause porpoising and/or ventilation. 5. If trimmed out beyond the water pickup, reduced water supply can cause serious overheating. b Trimming Outboard “In” (“Down”) Characteristics WARNING Excessive speed at minimum trim “in” may cause undesirable and/or unsafe steering conditions. Each boat should be tested for handling characteristics after any adjustment is made to the trim angle (trim adjustment pin relocation). 1. Will help planing off, particularly with a heavy load. 2. Usually improves ride in choppy water. 90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-5

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3. In excess, can cause boat to veer to the left or right (bow steer). 4. Transfers steering torque harder to right (or less to the left) on single outboard installations. 5. Improves planing speed acceleration. Trim Tab Adjustment 1. Check trim tab position as follows: a. Operate boat at the speed at which it would normally be operated. b. If the boat pulls to the right (starboard), the trailing edge of trim tab must be moved to the right. If the boat pulls to the left (port), the trailing edge of trim tab must be moved to the left. 2. If necessary, adjust trim tab as follows: a. Shift outboard control into neutral and turn ignition key to “Off” position. b. Remove plug from rear of drive shaft housing and loosen bolt and trim tab. c. If boat pulls to the left, adjust trailing edge of trim tab to the left. If boat pulls to the right, adjust trailing edge of trim tab to the right. d. Tighten trim tab bolt securely and replace plug. e. Operate boat per “Check trim tab position as follows,” preceding, to check trim tab setting. If necessary, readjust trim tab. a - Anti-Ventilation Plate b - Adjustable Trim Tab c - Plug 22750 Boat Performance Test Instructions WARNING A tight grip on the steering wheel/tiller handle is always advisable and is required when accelerating, decelerating or when trimming the boat. On models with Power Trim, upon reaching cruising speed, the outboard should be trimmed to obtain a balanced steering condition. While trimming, steering loads will vary and will pull in one direction until a balanced condition has been attained. If the outboard is trimmed past the balanced steering condition, the steering wheel/tiller handle then will have a tendency to pull in the opposite direction. Excessive trimming past the balanced steering position will result in increased steering loads and, in most boat applications, a decrease in performance. CAUTION When trimming boat with dual outboards, both outboards should be at approximately the same tilt angle and be tilted out (up) simultaneously (to prevent boat from pitching side-to-side) until desired boat attitude is achieved. Outboards can then be trimmed individually to precisely adjust boat trim angle and pitch. 1. With boat in water, trim the outboard(s) (trim button in remote control handle) so that the decal on the side of cowl is horizontal. This is a typical average setting that should give reasonable acceleration and top speed. 2. Go for a short familiarization ride at various throttle and trim settings BEFORE starting testing. NOTE: Instruments should be read with eye directly in front to eliminate any error in reading the instruments. 3. When making either top speed or acceleration runs, best accuracy will be obtained by running with or against any wind. Side winds require driving in a constant turn to keep the boat moving straight ahead. If winds are 10 MPH (16 km/hr) or greater, it is suggested that all acceleration runs be made downwind. 1-6 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996

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4. The top speed WOT (wide-open-throttle) test should be done with the boat normally loaded (to duplicate actual running conditions). Operate boat in gear at WOT and check RPM. Engine RPM must be within the recommended full throttle RPM range (listed in the Operation and Maintenance Manual). NOTE: When performing an acceleration test, it is recommended that a stop watch be used to improve testing accuracy. A wrist watch with a second hand may also be substituted. 5. An acceleration test can also be performed if desired. Start the test with boat motionless in the water and outboard in neutral. A stop watch should be started as the throttle is quickly pushed to WOT (wide-open-throttle). Stop the watch as the speedometer needle sweeps past 20 MPH (32 km/hr). Several runs should be made to assure a good average. 6. Prop “break loose” (sudden higher RPM), if not excessive, in some cases can be beneficial during acceleration. If undesirable “break loose” occurs, it can be decreased by trimming the outboard further under. If it remains excessive with all similar propellers, the outboard must be lowered. 7. It is suggested that all applicable data be recorded on a chart (such as that illustrated, following) and retained for future reference. 8. After several propellers of different pitch and/or design have been tried, select one that best serves the general purpose of the boat. The selected propeller should enable the engine to operate within its recommended full throttle RPM range, without excessive propeller “break loose” during acceleration or turns. A second propeller that would make both a suitable spare or a special purpose alternate might also be desirable. NOTE: A higher pitch often gives best top speed, but the next lower pitch gives adequate top speed with much better acceleration. Boat Test Chart (Example) * WOT is wide-open-throttle 90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-7

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Lubrication Points Item No. Description Type of Lubricant Fresh Water Frequency Salt Water Frequency Throttle/Shift 1 Linkage Pivot Points 2 Upper Shift Shaft 3 Tilt Lock Lever 4 Swivel Pin 5 Ride Guide Steering Cable Quicksilver 2-4-C Marine Lubricant Every 60 Days Every 30 Days 6 Tilt Tube 7 Steering Link Rod Pivot Points SAE 30W Motor Oil Every 60 Days Every 30 Days Quicksilver - Special Lubricant 101 8 Propeller Shaft - Anti-Corrosion Grease - 2-4-C Marine Lubricant Once in Season Every 60 Days 9 Starter Motor Pinion Gear SAE 10W Motor Oil Once in Season Every 60 Days Quicksilver Gear Housing - Special Lubricant L Bearing Carrier 101 and Cover Nut - 2-4-C Marine Lubricant After first 20 hours, then once in season Check and fill after first 10 days, then every 30 days Check and fill after first 10 days, then every 30 days j Gear Housing Quicksilver Gear Lube 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 Engine Z Crankshaft Splines to Drive Shaft Splines Quicksilver 2-4-C Marine Lubricant Once in Season Once in Season L Refer to lubrication instructions outlined in “Salt Water Corrosion - Gear Housing Bearing Carrier and Cover Nut” of this section (see “Table of Contents”). j Refer to “Gear Housing Lubrication” of this section (see “Table of Contents”). Z Refer to “Gear Housing Removal and Installation” (Section 5). 1 - Throttle/Shift Linage Pivot Pint Lubrication 2 - Upper Shift Shaft Lubrication 50195 54634 1-8 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996

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8 3 - Tilt Lock Lever Grease Fitting 4 - Swivel Pin Grease Fittings 50157 Ride-Guide Steering Cable and Pivot Points Lubrication WARNING Core of steering cable (transom end) must be fully retracted into cable housing before lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur. With core of Ride-Guide Steering cable (transom end) fully retracted, lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with Quicksilver 2-4-C Marine Lubricant. Lubricate all pivot points with SAE 30W engine oil. 57 8 - Propeller Shaft Lubrication 9 9 - Starter Motor Pinion Gear Lubrication 26474 12579 6 5 - Ride-Guide Steering Grease Fitting 6 - Tilt Tube Grease Fitting 7 - Steering Link Rod Pivot Point Lubrication 90-814676R1 DECEMBER 1996 50334 IMPORTANT INFORMATION - 1-9

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Gear Housing Lubrication NOTE: Refer to “Specifications,” for gear housing lubricant capacity. WARNING If gear housing is installed on outboard, to avoid accidental starting, disconnect (and isolate) spark plug leads from spark plugs before working near the propeller. CAUTION Do not use automotive grease in the gear housing. Use only Quicksilver Gear Lube or Quicksilver Super-Duty Lower Unit Lubricant. 1. Tilt outboard so that lubricant in gear housing will drain toward front of housing, out fill hole and into clean container. IMPORTANT: Inspect fill and VENT plug washers for damage. Use new washer as needed. 2. Remove lubricant fill plug and washer. Note amount of metal particles on magnetic fill plug. 3. Remove VENT plug with washer and allow sufficient time for all lubricant to drain. 5. Note color of gear lubricant. White or cream color indicates presence of water in lubricant. Gear lubricant which has been 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. 6. Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals, seal surfaces, O-rings, water pump gaskets as well as gear housing components for damage. IMPORTANT: Never add lubricant to gear housing without first removing VENT plug, as trapped air will prevent housing from being filled. Fill gear housing only when outboard is in operating position. 7. With outboard in operating position, insert lubricant tube into fill hole. 8. Fill gear housing with lubricant, until excess starts to flow from VENT hole. 9. At this point, drain approximately one fluid ounce (30ml) from gear housing to permit expansion of lubricant. 10. Install VENT plug and washer. 11. Remove lubricant tube and install cleaned magnetic fill plug with washer. a b a - Lubricant VENT Plug b - Lubricant Fill Plug/Washer 4. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance). Presence of fine metal particles (resembling powder) on the drain plug bar magnet indicates normal wear. The presence of metal chips on the drain plug bar magnet indicates the need for gear housing disassembly and components inspection. Salt Water Corrosion - Gear Housing Bearing Carrier and Cover Nut Salt water corrosion buildup can be sufficient to split a gear housing and destroy an entire lower unit. To protect against such damage, therefore, it is recommended that the gear housing bearing carrier and gear housing cover nut be lubricated on a regular basis, as follows: Service first at the 20-hour inspection, then on an annual basis. Remove the cover nut and entire bearing carrier to adequately clean corrosive deposits and dried-up lubricant from both ends of the bearing carrier, as well as the gear housing internal threads and cover nut external threads. Apply a liberal amount of Quicksilver Special Lubricant 101; or 2-4-C Marine Lubricant to the 2 ends of the bearing carrier and to the gear housing and cover nut threads, then reassemble and retorque. Refer to gear housing disassembly and reassembly (Section 5). 1-10 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996

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