Install bearing race and bearing retainer. Tick- ing should start after 2 cranking revolutions. Mount a dial indicator at front edge of propeller splines. Engine idle is rough 3. Use installation tool 91-44487A1 or spanner wrench 91-74951 to tighten caps securely. Hose Clamp Fuel Line Trim Solenoids 14. Hold flywheel tool with wrench while tightening bolt down on protector cap.
Thread a used pinion nut onto end of driveshaft. Bearing Removal and Installation Kit 91-31229A5. Replace bearings if they are rusted, fractured, worn, galled or badly discolored. Cross Pin Tool 91-86642 13. Use a bristle brush and carbon remover solution to remove carbon from side surfaces. The air flows through the in-line, one-way valve, and then to all of the carburetors. With carburetor turned upside down, and carb scale seated on inner edge, check float level from top of float to float bowl flange as shown.
Before start-up, the electrothermal ram needle is retracted the fuel enrichment valve is opened according to the temperature, allowing a high percentage of fuel to flow form the flat chamber into the venturi during start-up. Also, the diaphragm functions as a coasting enrichener during quick deceleration, preventing the engine form stalling. Remove 2 screws securing air plenum to reed plate assembly. Remove bolts which secure crankcase cover to cylinder block. Remove 3 bolts securing oil reservoir and lay reservoir off to one side.
Usually, crankshaft sealing rings do not require replacement, unless broken. Replace any hose that is cracked, cut or deteriorating. Remove and discard gasket from each thermostat. Secure air temperature sensor leads to fuel hose with sta-strap. Install tensioner spring and tighten timing belt tensioner. Use care not to drop armature. Remove cap and fill engine oil tank with oil.
Apply Quicksilver Super Duty Gear Lubricant to bearing carrier needle bearing. Start engine and allow to warm up. Place lubricant tube b into the fill hole and add lubricant until it appears at the vent hole c. As the throttle is closed, the throttle lever rotates back and the throttle lever link rod returns, causing the diaphragm in the dashpot to move back, As the diaphragm moves back, suction causes the air from the venturi of carburetor 4 to flow through a one-way valve in the carburetors and back to the dashpot. Fuel line to Water Separating Fuel Filter — 2-8 psi 14-55 kPa 4. Return remote control to neutral. Remove aft alternator bolt and pivot alternator forward.
Using an awl or electric pencil, scribe the cylinder identification number on each con- necting rod as shown. Scratching the side surface of the ring groove will damage the ring groove. Gently pry up on injector to loosen O-ring adhesion and remove injector. Cowl mounted trim buttons do not activate trim system. Wall of Water — If water level height is insufficient, water pump may draw in air resulting in an overheated engine 4. Measure and record the intake valve clearance for cylinders 1 and 2.
Improper shift habits of operator s shift from neutral to reverse gear or forward gear too slowly. Secure link rods to out- board steering arms, using special washer head bolts 10-14000 provided and nylon in- sert locknuts as shown. This will help prevent a buildup of deposits from clogging the internal water passages. Your Mercury 4-Stroke Outboard Boat Motor service manual will come to you in pdf format and is compressed for a lightning fast download! Install thermostat cover hose to exhaust adaptor plate. Trim system trims opposite of buttons.
Connection for Analog Temperature Sender 6. Run the engine until the all the air has been vented out of the tank and oil starts to flow out of the tank. Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability. Purging Air From the Engine Oil Tank 1. Locate the center point of the slack or lost motion that exists in the shift cable as fol- lows: a.
If reverse gear bearing remains attached to reverse gear, install Universal Puller Plate 91-37241 and position puller plate, gear and bearing on a press with gear side down. After driveshaft is removed from gear case, remove and retain shim s that were lo- cated under upper tapered driveshaft bearing. If complete disassembly is not necessary, start reassembly at point disassembly was stopped. Clymer Mercury Outboard manuals are written specifically for the do-it-yourself enthusiast. Dial Indicator registers amount of backlash, which should be 0. Exhaust diffuser is secured to housing plate with 6 bolts. Remove reverse gear bearing adaptor.