Mariner 30 JET 40 (4 CYL) User manual

MODELS
United States 0C159200 and Above. . . . . . .
Belgium 9570305 and Above. . . . . . . . . . .
Canada 0A748269 and Above. . . . . . . . . . . .
With Serial Numbers
SERVICE
MANUAL
30 JET 40 (4 CYL)
Printed in U.S.A. 1996, Mercury Marine 90-814676R1 DECEMBER 1996

90-814676R1 DECEMBER 1996 i
Notice
Throughout this publication, “Dangers”, “Warnings”
and “Cautions” (accompanied by the International
HAZARDSymbol )areusedtoalertthemechanic
tospecialinstructionsconcerningaparticularservice
or operation that may be hazardous if performed in-
correctly or carelessly. OBSERVE THEM CARE-
FULLY!
These“SafetyAlerts”alonecannoteliminatethehaz-
ards that they signal. Strict compliance to these spe-
cial instructions when performing the service, plus
“Common Sense” operation, are major accident pre-
vention 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 per-
sonnel when servicing the products described here-
in.
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 prod-
ucts which includes the use of mechanics’ common
handtools andthe specialMercury Marineor recom-
mended tools from other suppliers.
Wecouldnotpossiblyknowofandadvisetheservice
trade of all conceivable procedures by which a ser-
vice might be performed and of the possible hazards
and/or results of each method. We have not under-
taken 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 con-
tained in this manual are based on the latest product
informationavailableatthetimeofpublication.Asre-
quired,revisionstothismanualwillbesenttoalldeal-
erscontractedbyustoselland/orservicetheseprod-
ucts.
It should be kept in mind, while working on the prod-
uct,thattheelectricalsystemandignitionsystemare
capable of violent and damaging short circuits or se-
vere 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.
Anytimetheintakeorexhaustopeningsareexposed
during service they should be covered to protect
againstaccidentalentranceofforeignmaterialwhich
could enter the cylinders and cause extensive inter-
nal damage when the engine is started.
Itisimportanttonote,duringanymaintenanceproce-
dure replacement fasteners must have the same
measurements and strength as those removed.
Numbers on the heads of the metric bolts and on the
surfacesofmetricnutsindicatetheirstrength.Ameri-
canboltsuse radial linesforthis purpose,whilemost
American nuts do not have strength markings. Mis-
matched or incorrect fasteners can result in damage
or malfunction, or possibly personal injury. There-
fore,fasteners removedshould besaved forreuse 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 1996ii
Cleanliness and Care of
Outboard Motor
A marine power product is a combination of many
machined,honed,polishedandlappedsurfaceswith
tolerancesthat aremeasured inthe tenthousands of
an inch./mm. When any product component is serv-
iced,careandcleanlinessareimportant.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
consideredstandardshoppracticeevenifnotspecif-
ically stated.
Whenever components are removed for service,
they should be retained in order. At the time of instal-
lation, they should be installed in the same locations
and with the same mating surfaces as when re-
moved.
Personnel should not work on or under an outboard
which is suspended. Outboards should be attached
toworkstands,orlowered togroundassoonas pos-
sible.
Wereserve the righttomake changes tothismanual
without prior notification.
Refertodealerservicebulletinsforotherpertinentin-
formation concerning the products described in this
manual.

Important
Information
Electrical & Ignition
Fuel System &
Carburetion
Powerhead
Mid-Section
Lower Unit
Outboard Motor
Installation/
Attachments
Oil Injection System 8
1
2
3
4
5
6
7
90-814676R1 DECEMBER 1996 iii
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

1
50332
IMPORTANT
INFORMATION
GENERAL INFORMATION and
SPECIFICATIONS

1-0 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
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. . . . . . . . . . . . . . . . . . . . . . . . .

90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-1
Propeller Information
For in-depth information on marine propellers and
boatperformance-writtenbymarineengineers-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
Themanual isdividedintoSECTIONS(shown, right)
which represents major components and systems.
Some SECTIONS are further divided into PARTS.
EachPARThas atitlepage.A“TableofContents”for
the particular PART is printed on the back of the title
page.
SECTIONS and PARTS are listed on the “Service
ManualOutline” sheetwhich immediatelyfollows the
cover of this book.
Section Section Heading
1
2
3
4
5
6
7
8
Important Information
Electrical and Ignition
Fuel System and Carburetion
Powerhead
Mid-Section
Lower Unit
Outboard Installation/Attachments
Oil Injection System

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

90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-3
Propeller Selection
1. Selectapropeller that will allowtheengine to op-
erate 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
trimangle,shouldnotbeusedindeterminingcor-
rectpropeller.)Normally,thereisa 150-350RPM
change between propeller pitches.
2. If full throttle operation is below the recom-
mended 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 wa-
terskiing,proppingupto500RPMabovetherec-
ommended range is advised. Continuous opera-
tion above the recommended maximum RPM,
however, is not permissible.
4. After initial propeller installation, the following
common conditions may require that the propel-
ler 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. Operatingwitha damagedpropelleroradirty
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
injurycausedfrombeingstruckbyarotatingpro-
peller, always shift outboard to neutral position
and remove spark plug leads when you are serv-
icing the propeller.
Coat the propeller shaft with Quicksilver Anti-Corro-
sion Grease or 2-4-C Marine Lubricant with Teflon.
IMPORTANT: To prevent the propeller hub from
corroding and seizing to the propeller shaft, es-
pecially in salt water, always apply a coat of the
recommended lubricant to the entire propeller
shaftatthe recommendedmaintenanceintervals
and also each time the propeller is removed.
Flo-Torq I Drive Hub Propellers
a
cb
a - Forward Thrust Hub
b - Propeller Nut Retainer
c - Propeller Nut
Flo-Torq II Drive Hub Propellers
a
c
b
d
e
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

1-4 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
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
mustbewatertestedforhandlingcharacteristics
after outboard installation and after any trim ad-
justments.
IMPORTANT: Some boat/outboard combina-
tions, that do not use the trim adjustment pin (a)
andaretrimmedtothefull“in”trimangle,willnot
experience any undesirable and/or unsafe steer-
ing conditions during planing speed. Thus, not
using trim adjustment pin may be desired. How-
ever, 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, un-
der 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.
Watertestthe boatnot usingthetrim adjustmentpin.
If undesirable and/or unsafe steering conditions are
experienced (boat runs with nose down), install trim
adjustment pin in proper hole to prevent unsafe han-
dling characteristics.
50157
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
looseningthemanualreleasevalve2to3turnscoun-
terclockwise.
Thetrim“out”angleofthisoutboardisnotadjustable.
Thetrimsystemhasaninternalvalvewhichwillauto-
maticallystoptheoutwardtrimtravelat200whenen-
gineRPM isapproximately 2000RPM orhigher; out-
board also has to be in water and in gear.
The outboard can be operated beyond the 200 trim
limitforoperating outboardinshallow waterif engine
RPM is kept below approximately 2000 RPM.
50158
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 IMPORTANT INFORMATION - 1-5
Checking Trim System Fluid Level
IMPORTANT: This trim system is pressurized.
Remove fill screw when outboard is trimmed to
thefull“up”position.Retightenfillscrewsecure-
ly.
1. Trimoutboardtofull“up”position.Engagetiltlock
level (a). Trim system fluid can only be checked
when outboard is in this position.
50157
2. Removefillscrewandcheck fluidlevel. Fluidlev-
el 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.
b
Trimming (Models with
Power Trim)
NOTE:Becausevaryinghulldesignsreactdifferently
invariousdegreesofroughwater,itisrecommended
toexperimentwithtrimpositionstodeterminewheth-
er trimming up or down will improve the ride in rough
water.
When trimming your outboard from a mid-trim posi-
tion(trimtabinneutral straightfore-and-aftposition),
you can expect the following results:
Trimming Outboard “Out” (“Up”)
Characteristics
WARNING
Excessive trim “out” also may reduce the stabil-
ity of some high speed hulls. To correct instabili-
ty at high speed, reduce the power GRADUALLY
and trim the outboard “In” slightly before resum-
ing 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 stan-
dard or slightly elevated transom installation
(single outboard).
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventila-
tion.
5. If trimmed out beyond the water pickup, reduced
water supply can cause serious overheating.
Trimming Outboard “In” (“Down”)
Characteristics
WARNING
Excessive speed at minimum trim “in” may
cause undesirable and/or unsafe steering condi-
tions. 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.

1-6 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
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.Iftheboatpullstotheleft(port),thetrail-
ingedgeoftrimtabmustbemoved totheleft.
2. If necessary, adjust trim tab as follows:
a. Shift outboard control into neutral and turn
ignition key to “Off” position.
b. Removeplugfrom rearof driveshafthousing
and loosen bolt and trim tab.
c. If boat pulls to the left, adjust trailing edge of
trimtab totheleft.Ifboat pullstotheright,ad-
just 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.
22750
a - Anti-Ventilation Plate
b - Adjustable Trim Tab
c - Plug
Boat Performance
Test Instructions
WARNING
A tight grip on the steering wheel/tiller handle is
alwaysadvisableandisrequiredwhenaccelerat-
ing, 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 direc-
tionuntilabalancedconditionhasbeenattained.
If the outboard is trimmed past the balanced
steering condition, the steering wheel/tiller han-
dle then will have a tendency to pull in the oppo-
site direction. Excessive trimming past the bal-
anced 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 de-
sired 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 but-
toninremote control handle) sothatthe decal on
the side of cowl is horizontal. This is a typical av-
erage setting that should give reasonable accel-
eration and top speed.
2. Go for a short familiarization ride at various
throttle and trim settings BEFORE starting test-
ing.
NOTE: Instruments should be read with eye directly
in front to eliminate any error in reading the instru-
ments.
3. When making either top speed or acceleration
runs, best accuracy will be obtained by running
withoragainst any wind.Sidewinds require driv-
ing in a constant turn to keep the boat moving
straightahead.Ifwindsare10MPH(16km/hr)or
greater, it is suggested that all acceleration runs
be made downwind.

* WOT is wide-open-throttle
90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-7
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 de-
sired. Start the test with boat motionless in the
water and outboard in neutral. A stop watch
shouldbestartedasthethrottleisquicklypushed
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 as-
sure a good average.
6. Prop “break loose” (sudden higher RPM), if not
excessive, in some cases can be beneficial dur-
ing acceleration. If undesirable “break loose” oc-
curs, it can be decreased by trimming the out-
board further under. If it remains excessive with
all similar propellers, the outboard must be low-
ered.
7. It is suggested that all applicable data be re-
cordedonachart(such asthatillustrated,follow-
ing) 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 se-
lected propeller should enable the engine to op-
erate 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 spe-
cial purpose alternate might also be desirable.
NOTE: Ahigherpitchoften gives besttopspeed,but
the next lower pitch gives adequate top speed with
much better acceleration.
Boat Test Chart (Example)

1-8 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
Lubrication Points
Item
No. Description Type of Lubricant Fresh Water Frequency Salt Water Frequency
1Throttle/Shift
Linkage Pivot
Points
Quic sil er
E ery
E ery
2Upper Shift Shaft
Quic
k
sil
v
er
2-4-C
E ery
E ery
3Tilt Lock Lever
Quic sil er
2-4-C
Mrie
E
v
ery
ys
E
v
ery
ys
4Swivel Pin
M
a
ri
n
e
Lubricant 60 Da
ys
30 Da
ys
5Ride Guide
SteeringCable
6Tilt Tube
7SteeringLink
Rod Pivot Points SAE 30W Motor Oil Every 60 Days Every 30 Days
8PropellerShaft
Quicksilver
- Special Lubricant
101
-Anti-Corrosion
Grease
-2-4-CMarine
Lubricant
Once in
Season Every 60 Days
9StarterMotor
Pinion Gear SAE 10W Motor Oil Once in Season Every 60 Days
GearHousing
BearingCarrier
and Cover Nut
Quicksilver
- Special Lubricant
101
-2-4-CMarine
Lubricant
After first 20
hours,then
once in season
e r ousi
Quic sil er
Check and fill
after first 10
days, then
every 30 days
Check and fill
after first 10
days, then
every 30 days
G
e
a
r
H
ousi
ng
Quic
k
sil
v
er
GearLube 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
Crankshaft
Splines to Drive
Shaft Splines
Quicksilver
2-4-C
Marine
Lubricant
Once in
Season Once in Season
Refertolubricationinstructionsoutlinedin“SaltWaterCorrosion-Gear
Housing Bearing Carrier and Cover Nut” of this section (see “Table of
Contents”).
Referto“GearHousingLubrication” of thissection(see“TableofCon-
tents”).
Refer to “Gear Housing Removal and Installation” (Section 5).
50195
1 - Throttle/Shift Linage Pivot Pint Lubrication
54634
2 - Upper Shift Shaft Lubrication

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

1-10 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
Gear Housing Lubrication
NOTE: Referto“Specifications,”forgear housing lu-
bricant capacity.
WARNING
If gear housing is installed on outboard, to avoid
accidental starting, disconnect (and isolate)
spark plug leads from spark plugs before work-
ing near the propeller.
CAUTION
Do not use automotive grease in the gear hous-
ing. Use only Quicksilver Gear Lube or Quicksil-
ver Super-Duty Lower Unit Lubricant.
1. Tilt outboard so that lubricant in gear housing will
draintoward frontof housing,out fillhole andinto
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 suffi-
cient time for all lubricant to drain.
b
a
a - Lubricant VENT Plug
b - Lubricant Fill Plug/Washer
4. Inspect gear lubricant for metal particles (lubri-
cant will have a “metal flake” appearance). Pres-
ence 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 inspec-
tion.
5. Notecolor ofgearlubricant.Whiteor creamcolor
indicates presence of water in lubricant. Gear lu-
bricant which has been drained from a gearcase
recently in operation will have a yellowish color
duetolubricant agitation/aeration.This isnormal
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 hous-
ing without first removing VENT plug, as trapped
airwillpreventhousingfrombeingfilled.Fillgear
housingonlywhenoutboardisinoperatingposi-
tion.
7. With outboard in operating position, insert lubri-
cant 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 mag-
netic fill plug with washer.
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 recom-
mended that the gear housing bearing carrier and
gearhousingcovernutbe lubricatedonaregularba-
sis, 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 de-
posits 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 lib-
eral amount of Quicksilver Special Lubricant 101;
or 2-4-C Marine Lubricant to the 2 ends of the bear-
ing carrier and to the gear housing and cover nut
threads, then reassemble and retorque. Refer to
gear housing disassembly and reassembly (Sec-
tion 5).

90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-11
Periodic Inspection
Conductaperiodic,systematicinspectiontouncover
and correct a failure before it can cause inconve-
nience or mechanical damage. Inspection interval is
based on average operating conditions in utility ser-
vice.Undersevereconditions,theinspectioninterval
should be shortened. Inspection includes:
1. Clean entire unit thoroughly, including all acces-
sible 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, previously.
5. LubricatestartermotorshaftwithlightfilmofSAE
1OW motor oil. Do not over-lubricate.
6. Service spark plugs. Inspect spark plug leads
and electrical leads for damage or deterioration,
as explained in Section 2 “Electrical and Ignition”
section.
7. Inspectfuellinesfordamageordeteriorationand
service fuel filters as indicated in Section 3 “Fuel
System and Carburetion.”
8. Remove propeller and inspect. Trim nicks and
burrswithafile,beingcarefulnottoremovemore
metal than absolutely necessary. Inspect for
cracks, damage or bent condition. If condition is
doubtful,refertoauthorizedQuicksilverPropeller
Repair Station facilities. Before reinstalling pro-
peller, coat propeller shaft with Quicksilver Spe-
cial Lubricant 101, Anti-Corrosion Grease or
2-4-C Marine Lubricant.
9. Inspecttheoutboardsurfacefinishfordamageor
corrosion. Thoroughly clean damaged or cor-
roded areas and apply matching paint (Quicksil-
ver Spray Paints).
10. Check trim tab and galvanic corrosion inhibitor
for damage or for deterioration from salt water
operation.
11. Checkremotecontrolsand steering.Besurethat
all connections and fittings are in good condition,
properly secured and correctly adjusted.
Flushing Outboard Cooling
System
WARNING
When flushing, be certain that area in vicinity of
propeller is clear and that no person is standing
nearby - to avoid possible injury. It is recom-
mended to remove propeller as a precautionary
measure.
1. Install Quicksilver Flushing Attachment
(44357A2) [or equivalent tool] on the gear hous-
ing from the FRONT side, positioning the rubber
cups over the water intake openings.
Typical Gear Housing
b
a
a - Water Hose (1/2 in. [13mm] I.D. or Larger)
b - Flushing Attachment (44357A2)
2. Connect hose (1/2 in. [13mm] I.D. or larger) be-
tween flushing attachment and water tap.
IMPORTANT: To prevent water pump damage, do
not start or run engine unless cooling water is
flowing.
3. With the outboard in normal operating position
(vertical), partially open water tap (IT IS NOT
NECESSARY tousefullwater pressure) andad-
just water flow so that there is a significant water
loss around the rubber cups.
4. Start engine and idle in neutral. Then increase
engine speed, not to exceed 2500 RPM.

1-12 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
5. Flushorserviceengineasrequired.Besureade-
quate cooling water is provided.
a. Water must be discharged thru “tell-tale.”
IMPORTANT: Prevent engine overheating. If wa-
ter flow is insufficient, stop engine and deter-
mine cause before continuing.
b. Flush until discharged water is clear. In salt-
water areas, run outboard 3 to 5 minutes.
c. Stop engine before turning off water.
6. Stop engine, turn water off and remove flushing
attachment from gear housing.
IMPORTANT: While and after flushing, keep out-
board in upright position until all water has
drained from drive shaft housing to prevent wa-
ter from entering the powerhead via drive shaft
housing and exhaust ports.
Following Complete
Submersion
Submergedenginetreatmentisdividedinto3distinct
problemareas.Themostcriticalissubmersioninsalt
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 nec-
essary before any attempt is made to start the en-
gine.
Submerged While Running (Special
Instructions)
When an engine is submerged while running, the
possibility of internal engine damage is greatly in-
creased. If, after engine is recovered and with spark
plugs removed, engine fails to turn over freely when
turning flywheel, the possibility of internal damage
(bent connecting rod and/or bent crankshaft) exists.
If this is the case, the powerhead must be disas-
sembled.
Submerged Engine (Fresh Water)
(Plus Special Instructions)
1. Recover engine as quickly as possible.
2. Remove cowling.
3. Flush exterior of outboard with fresh water to re-
move mud, weeds, etc. DO NOT attempt to start
engineifsand hasenteredpowerhead, aspower
head 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 posi-
tion(withsparkplugholes down)and rotatingfly-
wheel.
5. Pour alcohol into carburetor throat (alcohol will
absorb water). Again rotate flywheel.
6. Turnengineoverandpouralcoholintosparkplug
openings and again rotate flywheel.
7. Turn engine over (place spark plug opening
down) and pour engine oil into throat of carbure-
tors 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. Reinstallsparkplugs,carburetorsandfuelpump.
11. Attempttostartengine,using afreshfuelsource.
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
unableto startengine inthis period,disassemble
engine and clean all parts and apply oil as soon
as possible.

90-814676R1 DECEMBER 1996 IMPORTANT INFORMATION - 1-13
Out-of-Season Outboard
Storage
WARNING
As a safety precaution, when boat is in storage,
remove positive (+) battery cable. This will elimi-
nate 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 follow-
ing instructions outlined in “Flushing Outboard”
(see “Table of Contents”).
3. Start engine and allow to warm up. Disconnect
fuellineandallowenginetorunatlowRPMwhile
inducingapproximately2oz.(57g)ofQuicksilver
Storage Seal into each carburetor throat. Allow
engine to stall out, indicating that carburetors
have run dry.
4. Remove spark plugs from engine and spray
approximately one ounce (30ml) of Quicksilver
StorageSealintoeach sparkplughole.Manually
turn engine over several times to distribute Stor-
age 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,asexplainedin“GearHousingLubrication”
(see “Table of Contents”).
7. Clean outboard thoroughly, including all accessi-
ble 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 Special Lubricant 101,
Anti-CorrosionGreaseor2-4-CMarineLubricant
to propeller shaft and reinstall propeller. Refer to
“Propeller Installation” (see “Table of Contents”).
10. If the water pickup is clogged, the speedometer
will be inoperative. Clean the pickup with a piece
of wire or blow out with compressed air. Before
blowing out with air, disconnect the tubing from
the speedometer.
11. To prevent freeze damage, drain the speedome-
ter system of water completely before storage.
Remove tubing from speedometer fitting and
blow thru the tubing to remove water.
12. Store battery as outlined in “Out-of-Season Bat-
tery Storage,” following.
13. For out-of-season storage information on Auto-
Blend units, refer to Section 8 in this service
manual.
IMPORTANT: When storing outboard for the win-
ter,besurethatallwaterdrainholesingearhous-
ing are open and free so that all water will drain
out. If a speedometer is installed in the boat, dis-
connect the pickup tube and allow it to drain. Re-
connect the tube after draining. Trapped water
mayfreezeandexpand,thuscrackinggearhous-
ing and/or water pump housing. Check and refill
gear housing with Quicksilver Gear Lube before
storage to protect against possible water leak-
age into gear housing which is caused by loose
lubricant vent plug or loose grease fill plug. In-
spect gaskets under lubricant vent and fill plugs,
replacing any damaged gaskets, before reinstal-
ling plugs.
Out-of-Season Battery
Storage
1. Removebattery assoon aspossible andremove
all grease, sulfate and dirt from top surface.
2. Cover plates with distilled water, but not over
3/16in. (5mm) above perforated baffles.
3. Cover terminal bolts well with grease.
4. Store battery in a COOL, DRY place in a dry car-
ton or box.
5. Remove battery from storage every 60 days.
Check water level and place on charge for 5 to 6
hours at 6 amperes. DO NOT fast charge.
CAUTION
A discharged battery can be damaged by freez-
ing.

1-14 - IMPORTANT INFORMATION 90-814676R1 DECEMBER 1996
How Weather Affects Engine
Performance
It is a known fact that weather conditions exert a pro-
found 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 adop-
tion of I.S.O. (International Standards Organization)
engine test standards, as set forth in I.S.O. 3046
standardizing the computation of horsepower from
dataobtainedonthedynamometer,correctingallval-
ues to the power that the engine will produce at sea
level, at 30% relative humidity at 77F (25C) tem-
perature and a barometric pressure of 29.61 inches
of mercury.
Summer Conditions of high temperature, low baro-
metric pressure and high humidity all combine to re-
duce the engine power. This, in turn, is reflected in
decreased boat speeds--as much as 2 or 3 miles-
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 weath-
er effects, an engine--running on a hot, humid sum-
mer 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
densityis dependentuponthetemperatureoftheair,
itsbarometricpressureandwatervapor(orhumidity)
content.
Accompanyingthis weather-inspiredloss ofpower is
asecondbutmoresubtleloss.Atriggingtimeinearly
spring,the enginewas equippedwith apropeller 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 avail-
ablehorsepower,thispropellerwill,ineffect,become
too large. Consequently, the engine operates at less
than its recommended RPM.
Duetothehorsepower/RPMcharacteristicsofanen-
gine, 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 be propped 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 en-
gine also will be operating in an RPM range that dis-
courages damaging detonation. This, of course, en-
hances overall reliability and durability of the engine.