Mercury Marathon - 30 User manual

Important
Information
Electrical
Fuel System
Powerhead
Mid-Section
Lower Unit
Attachments/
Control Linkage
Manual Starter 8
1
2
3
4
5
6
7
iii
90-826148R2 MARCH 1997
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Carburetor
C - Oil Injection
Section 4 - Powerhead
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim
C - Manual Tilt
Section 6 - Lower Unit
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle
Section 8 - Manual Starter

i90-826148R2 MARCH 1997
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 dealer’s 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 Marineorrecom-
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,thattheelectrical systemandignitionsystemare
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 radiallinesfor thispurpose,while most
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 besavedforreusein
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.

ii 90-826148R2 MARCH 1997
Cleanliness and Care of
Outboard Motor
A marine power product is a combination of many
machined,honed,polishedandlappedsurfaceswith
tolerancesthat aremeasured inthetenthousandsof
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.
Before raising or removing an outboard engine from
a boat, the following precautions should be adhered
to:
1. Check that flywheel is secured to end of crank-
shaftwith alocknutandtheliftingeye isthreaded
into flywheel a minimum of 5 turns.
2. Connect a hoist of suitable strength to the lifting
eye.
Inaddition,personnelshouldnotworkonorunderan
outboard which is suspended. Outboards should be
attached to work stands, or lowered to ground as
soon as possible.
Wereserve therightto make changesto this manual
without prior notification.
Refertodealerservicebulletinsforotherpertinentin-
formation concerning the products described in this
manual.
Page Numbering
Two number groups appear at the bottom of each
page. The example below is self-explanatory.
EXAMPLE:
90-826148 R2 MARCH 1997 LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Section Description
Section Number
Part of Section Letter
Page Number

A
1
IMPORTANTINFORMATION
SPECIFICATIONS

1A-0-IMPORTANTINFORMATION 90-826148R2 MARCH 1997
TableofContentsPage
GeneralSpecifications1A-1.......................
GeneralSpecifications1A-2.......................
GeneralSpecifications1A-3.......................

IIMPORTANTINFORMATION-1A-190-826148R2 MARCH 1997
GeneralSpecifications
Model30/40
HORSEPOWER
(KW)Model30 Model40 30 (22.4) 40 (29.8)
OUTBOARD
WEIGHT15 in.(38 cm) 20 in.(51 cm)
22-1/2in.(57 cm)
156 lbs.(70.7kg)
161 lbs.(73.0kg)
166 lbs.(75.3kg)
CYLINDER
BLOCK Type DisplacementTwoCylinder - TwoCycle 39.3cu.in.(644.4cc)
STROKELength2.796 in.(71 mm)
CYLINDER
BOREDiameter(Standard) Diameter[Oversize 0.015 (.381 mm)]
Taper/OutofRound Maximum
BoreType
CylinderFinishHone(I.D.)
2.993 in.(76 mm)
3.007 in.(76.38 mm)
0.003 in.(0.08 mm)
Cast Iron
2.993 in.(76 mm)
CRANKSHAFT Top MainBearing Journal
CenterMainBearing Journal
BottomBall Bearing Journal
Connecting Rod Journal
Runout
1.375 in.(34.93 mm)
1.216 in.(30.89 mm)
1.385 in.(35.17 mm)
1.181 in.(29.99 mm)
0.003 in.(0.076 mm)
CONNECTING
RODPiston PinEnd (I.D.) CrankpinEnd (I.D.)0.957 in.(24.31 mm) 1.499 in.(38.07 mm)
PISTONPiston Type
O.D.atSkirt (Standard)
O.D.atSkirt [Oversize 0.015 (.381 mm)]
Ring End Gap
Aluminum
2.988 in.(75.90 mm)
3.003 in.(76.28 mm)
0.010 in.-0.018 in.
(0.25 mm -0.46 mm)
REEDSReedStand Open(Maximum)
ReedStop -- Model30
-- Model40
0.020 in.(0.508 mm)
0.090 in.(2.286 mm)
NotAdjustable
GEAR
HOUSINGGearRatio Gearcase Capacity
LubricantType
ForwardGear-No.ofTeeth-Type
Pinion Gear-No.ofTeeth-Type
Pinion Height
ForwardGearBacklash
Reverse GearBacklash
WaterPressure
With Thermostat+Poppet
-- @W.O.T.
-- @Idle
All ModelsW/O Thermostat+Poppet
-- @W.O.T.
-- @Idle
PoppetValve Opening 1994-1997
PoppetValve Opening 1998 & Newer
2.0:1
14.9 oz.(440 mL)
QuicksilverGearLube PremiumBlend
26 Spiral/Bevel
13 Spiral/Bevel
0.025 in.(0.64 mm)
NoAdjustment
NoAdjustment
5-- 7PSI@5000 RPM
0.5-- 1.5PSI@750 RPM
5-- 7PSI@5000 RPM
0-- 1PSI@750 RPM
900-1000 RPM
3000-3500 RPM

1A-2-IMPORTANTINFORMATION 90-826148R2 MARCH 1997
GeneralSpecifications
Model30/40
MID
SECTIONTransomHeight - ShortShaft -Long Shaft
Steering PivotRange
TiltPinPositions
TotalTiltAngle
AllowableTransomThickness
15 in.(38 cm)
20 in.(51 cm)
90°
5+ShallowWater
70°
2-3/8in.(60.3mm)
FUEL
SYSTEMFuelPumpPressure -- @W.O.T.
-- @Idle
RecommendedGasoline
FuelTankCapacity
Break-inGasolineRatio
Manual Outboard
ElectricStartOutboard
4-7PSI(28-43 kPa)
2-1/2-- 4PSI(17-27 kPa)
AutomotiveRegularorUnleaded
withaMinimumPumpPosted
Octane Rating of87
6.6U.S.Gallons
(5Imp.Gals.; 25 Liters)
25:1
50:1(InFuelTank)
OIL
INJECTIONRecommendedOil
Oil TankCapacity/Approx.Time
Reserve Capacity/Approx.Time
Output (cc/min.)w/Pump@Full Open
QuicksilverTC-WII orTC-WIII
2-CycleOutboardOil
50.5fl.oz.(1.5liters)4.7Hours@
5250 RPM
30 Minutes@5250
8.5cc/10 Minutes@900 RPM
STARTING
SYSTEMManualStart ElectricStart
StarterDraw(UnderLoad)
(No Load)
Recoil
12 Volt
95 Amperes
20 Amperes
CHARGING
SYSTEMAlternatorOutput -- ElectricStart
RedStator
Black Stator
-- ManualStart
SinglePhase(12 Pole)
18 Amperes@3000 RPM
14 Amperes@5000 RPM
9Amperes@3000 RPM
BATTERYBatteryRating 465 Marine Cranking Amps(MCA)
or350 ColdCranking Amps(CCA)
IGNITION
SYSTEMType SparkPlug Type(NGK)
SparkPlug Gap
OptionalPlug (NGK)
Firing Order
CapacitorDischarge
BP8H-N-10
0.040 in.(1.0mm)
BPZ8H-N-10*
0.040 in.(1.0mm)
1-2

IIMPORTANTINFORMATION-1A-390-826148R2 MARCH 1997
GeneralSpecifications
Model30/40
CARBURETOR
SPECIFICATIONSIdleRPM
Full ThrottleRPMRange
-- Model30/40 Sea Pro/Marathon
-- Model40
IdleMixtureScrewAdjustment
(Preset - TurnsOut)
FloatLevel
MainJet
-- 30 Manual(WME-36/36A)/(WME-63)
-- 30 Electric(WME-37/37A)/(WME-64)
-- 40 Manual(WME-38)/(WME-66)
-- 40 Electric(WME-39/39A)/(WME-67)
-- 30 EHO(WME-42/42A)/(WME-65)
700 -800 RPM
(InForwardGear)
4500 -5500 RPM
5000 -5500 RPM
1-1/2±1/4(All ModelsExcept40 MLL)
1-3/4±1/4(WME-38 Carbon40MLL)
9/16 in.(14.29mm)
0.054 in.
0.054 in.
0.066 in.
0.066 in.
0.054 in.
TIMING
SPECIFICATIONSModelswith(S/N-0G59999 & Below) Idle
MaximumBTDC @2500-5500 RPM
3° BTDC ±3°
(NotAdjustable)
25° ±3°
(NotAdjustable)
M
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8° BTDC ±1°
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MaximumSparkAdvance
8
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B
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1TurnClockwiseAfterContacting
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ThrottlePlate

B
1
IMPORTANTINFORMATION
MAINTENANCE

90-826148R2 MARCH 19971B-0-IMPORTANTINFORMATION
TableofContentsPage
Specifications1B-1..........................
GearCase LubricantCapacity1B-1.........
SpecialTools1B-1..........................
QuicksilverLubricant/Sealant1B-1............
Inspection and MaintenanceSchedule 1B-2....
BeforeEachUse 1B-2....................
AfterEachUse 1B-2......................
Every100 HoursofUse orOnceYearly,
WhicheverOccursFirst1B-2...............
Every300 HoursofUse orThree Years1B-2
BeforePeriodsofStorage 1B-2............
Lubrication Points1B-3......................
(S/N-0G589999 & Below)1B-3.............
(S/N-0G590000 & Above)1B-3.............
Checking PowerTrimFluid 1B-5..............
GearCase Lubrication 1B-6..................
Draining GearCase 1B-6..................
Checking LubricantLeveland Filling
GearCase 1B-6..........................
PropellerReplacement1B-7..................
Removal1B-7............................
Installation 1B-7..........................
Corrosion ControlAnode 1B-8................
FuelTank1B-9.............................
Maintenance 1B-9........................
FuelTankFilter1B-9....................
FuelLine And PrimerBulb 1B-9..........
Flushing The Cooling System1B-10............
Storage 1B-10...............................
FuelSystem1B-10........................
Protecting ExternalOutboard
Components1B-11........................
Protecting InternalOutboard
Components1B-11........................
GearCase 1B-11..........................
Positioning OutboardforStorage 1B-11......
BatteryStorage 1B-11.....................

90-826148R2 MARCH 1997 IMPORTANTINFORMATION-1B-1
Specifications
GearCase LubricantCapacity
GearCase RatioCapacity
2.00:1 14.9fl.oz.(440 mL)
SpecialTools
P/N44357A2Flushing Kit.
Quicksilver
Lubricant/Sealant
Description PartNumber
GearLubricant-Premium
Blend 92-19007A24
Anti-Corrosion Grease 92-78376A6
2-4-CMarine Lubricant
w/Teflon 92-825407A12
SAE 30WMotorOil Obtain Locally

90-826148R2 MARCH 19971B-2-IMPORTANTINFORMATION
Inspection and Maintenance
Schedule
BeforeEachUse
1.Check thatlanyardstop switchstopsthe engine.
2.Visuallyinspect the fuelsystemfordeterioration
orleaks.
3.Check outboardfortightness on transom.
4.Check steering systemforbinding orloosecom-
ponents.
5.RemoteControlModels-Visuallychecksteering
linkrod fastenersforpropertightness.
6.Check propellerbladesfordamage.
AfterEachUse
1.Flush out the outboardcooling systemifoperat-
ing insaltorpolluted water.
2.Wash off all saltdepositsand flush out the ex-
haustoutletof the propellerand gearcasewith
freshwaterifoperating insaltwater.
Every 100 HoursofUse orOnce
Yearly,WhicheverOccursFirst
1.Lubricate all lubrication points.Lubricatemore
frequentlywhen used insaltwater.
2. Inspectand clean sparkplugs.
3.Check engine fuelfilterforcontaminants.
4.Adjustcarburetor(s) (ifrequired).*
5.Check engine timing setup.*
6.Checkcorrosioncontrolanodes.Checkmorefre-
quentlywhen used insaltwater.
7.Drain and replace gearcaselubricant.
8.Lubricatesplineson the driveshaft.
9.Check powertrimfluid.
10. Inspectbattery.
11.Check controlcable adjustments.*
12.Remove engine depositswithQuicksilverPower
Tune Engine Cleaner.
13.Check tightness ofbolts,nuts,and otherfasten-
ers.
*Theseitems shouldbeserviced byan authorized
dealer.
Every 300 HoursofUse orThree
Years
1.Replacewaterpumpimpeller(moreoftenifover-
heating occursor reduced waterpressureis
noted).
BeforePeriodsofStorage
RefertoStorage Procedure(Page 1B-10).

90-826148R2 MARCH 1997 IMPORTANTINFORMATION-1B-3
Lubrication Points
ITEM
NO. DESCRIPTIONTYPE OF LUBRICANTFRESHWATER FREQUENCYSALT WATER FREQUENCY
1Throttle/Shift linkage
PivotPoints
Q
u
i
c
k
s
i
l
v
e
r
2
-
4
-
C
2UpperShift Shaft Quicksilver2-4-C
M
a
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i
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e
L
u
b
r
i
c
a
n
t
3SwivelPin
M
a
r
i
n
e
L
u
b
r
i
c
a
n
t
1
0
0
H
o
u
r
s
o
f
U
s
e
o
r
4Ride Guide Steering
Cable
1
0
0
H
o
u
r
s
o
f
U
s
e
o
r
OnceinSeason
5TiltTube/Co-Pilot
6Steering LinkRod
PivotPointsSAE 30WMotorOil
1
0
0
H
o
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r
s
o
f
U
s
e
o
r
O
n
c
e
i
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S
e
a
s
o
n
7PropellorShaft QuicksilverSpecial
Lubricant101 Anti-
Corrosion Grease
1
0
0
H
o
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r
s
o
f
U
s
e
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O
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i
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S
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o
n
8StarterMotorPinion
GearSAE 10WMotorOil
9
*GearHousing Bear- ing CarrierQuicksilverSpecial Lubricant101
10
àGearHousing QuicksilverGear Lube
DEngine Crankshaft
SplinestoDriveShaft
SplinesQuicksilver2-4-C
Marine LubricantOnce inSeason
*Referto lubrication instructionsoutlined in“SaltWaterCor-
rosion -GearHousing Bearing Carrierand CoverNut”
of this section (see “Table of Contents”).
àReferto “GearHousing Lubrication”of this section (see
“TableofContents”).
DReferto “GearHousing Removaland Installation”(Sec-
tion 5).
(S/N-0G589999 & Below)
1
1
1
1
1
1
1
(S/N-0G590000 & Above)
55759
111
1
1
1
1
1
1

90-826148R2MARCH19971B-4-IMPORTANTINFORMATION
2
52662
2-UpperShiftShaftLubrication
3
3-SwivelPinGreaseFittings
WARNING
Coreofsteeringcable(transomend)mustbeful-
lyretractedintocablehousingbeforelubricating
cable.Ifcableislubricatedwhileextended,hy-
drauliclockofcablecouldoccur.
WithcoreofRideGuideSteeringcable(transom
end)fullyretracted,lubricatetransomendofsteering
cablethrugreasefittingandexposedportionofcable
endwithQuicksilver2-4-CMarineLubricant.Lubri-
cateallpivotpointswithSAE30Wengineoil.
ElectricandRemoteControlModels
4
5
6
TillerHandleModels
5
4-RideGuideSteeringGreaseFitting
5-TiltTube/Co-PilotGreaseFitting
6-SteeringLinkRodPivotPointLubrication
7
50551
7-PropellerShaftLubrication

90-826148R2 MARCH 1997 IMPORTANTINFORMATION-1B-5
52661
8
8-StarterMotorPinion GearLubrication
50558
9
9- GearHousing Lubrication
Checking PowerTrimFluid
1.Tiltoutboardtothe full up position and engage
the tiltsupportpin.
a
a- TiltSupportPin
2.Removefill cap and check fluidlevel.The fluid
levelshould be even withthe bottomof the fill
hole.Add QuicksilverPowerTrim& Steering
Fluidorautomotivetransmissionfluid(ATF)Type
F,FA,orDexron III.

90-826148R2 MARCH 19971B-6-IMPORTANTINFORMATION
GearCase Lubrication
Whenaddingorchanginggearcaselubricant,visual-
ly check forthe presence ofwaterinthe lubricant. If
waterispresent, itmayhavesettled tothe bottom
and will drain outpriortothe lubricant, oritmaybe
mixed withthe lubricant, giving itamilky colored ap-
pearance.Ifwaterisnoticed,havethe gearcase
checked by yourdealer.Waterinthe lubricantmay
resultinprematurebearingfailureor,infreezingtem-
peratures,willturntoiceand damage the gearcase.
Wheneveryou removethe fill/drain plug,examine
themagneticendformetalparticles.Asmallamount
ofmetalfilingsorfine metalparticlesindicatesnor-
malgearwear.An excessive amountofmetalfilings
orlargerparticles(chips)mayindicate abnormal
gearwearand shouldbechecked byan authorized
dealer.
WARNING
Ifgearhousing isinstalled on outboard,toavoid
accidentalstarting,disconnect (and isolate)
sparkplug leadsfromsparkplugsbeforework-
ing nearthepropeller.
CAUTION
Do notuse automotive grease inthegearhous-
ing.Use onlyQuicksilverGearLubeorQuicksil-
verSuper-DutyLowerUnitLubricant.
Draining GearCase
1.Tiltoutboardsothatlubricantingearhousingwill
draintowardfrontofhousing,outfillholeandinto
clean container.
IMPORTANT:InspectFILL and VENT plug wash-
ersfordamage.Use new washeras needed.
2.RemovelubricantFILL plug and washer.Note
amountofmetalparticlesonmagneticFILL plug.
Remove all magneticparticlesfromFILL plug.
3.RemoveVENTplug and washerand allowall lu-
bricant to drain.
a
b
a-Lubricant Vent Plug/Washer
b-Lubricant Fill Plug/Washer
4. Inspectgearlubricant formetalparticles(lubri-
cantwill have a “metalflake” appearance).Pres-
ence of fine metalparticles(resembling powder)
on the FILL plug barmagnetindicatesnormal
wear.The presence ofmetalchipson the FILL
plug barmagnetindicatesthe need forgear
housing disassemblyand componentsinspec-
tion.
5.Notecolorofgearlubricant.Whiteorcreamcolor
indicatespresence ofwaterinlubricant. Gearlu-
bricantwhichhasbeendrainedfromagearhous-
ingrecentlyin operationwillhaveayellowishcol-
ordue tolubricantagitation/aeration.Thisis
normalandshouldnotbeconfusedwiththepres-
ence ofwater.
6.Presence ofwaterin gearlubricantindicatesthe
need fordisassemblyand inspection ofoil seals,
sealsurfaces,O-rings,waterpump gasketsas
well asgearhousing componentsfordamage.
Checking LubricantLeveland Filling
GearCase
IMPORTANT:Neveradd lubricant to gearhous-
ingwithout firstremovingVENT plug,astrapped
airwillpreventhousingfrombeingfilled.Fillgear
housingonlywhenoutboardisinoperatingposi-
tion.

90-826148R2 MARCH 1997 IMPORTANTINFORMATION-1B-7
NOTE:Referto“Specifications,”forgearhousing
lubricantcapacity.
1.With outboardin operating position,insertlubri-
cant tube intofill hole.
2.Fillgearhousinguntilexcesslubricantflowsfrom
VENThole.
3.Install VENTplug and washer.
4.Install FILL plug and washer.
PropellerReplacement
Removal
1.Shift outboardto neutral(N)position.
2.Removethe sparkplug leadsto preventengine
fromstarting.
3.Straighten the bent tabson the propellernutre-
tainer.
a
a- Tabs
4.Placeablock ofwood between gearcase and
propellerto hold propellerand remove propeller
nut.
5.Pull propellerstraightoff shaft. If propelleris
seizedtotheshaft andcannotberemoved,have
the propeller removed byan authorized dealer.
Installation
WARNING
If thepropellershaft isrotatedwhilethe engine
isin gear,thereisthepossibilitythat the engine
will crankoverand start.To prevent thistypeof
accidentalengine starting and possible serious
injurycausedfrombeingstruckbyarotatingpro-
peller,always shift outboardto neutralposition
and remove sparkplug leadswhenyou are serv-
icing thepropeller.
CAUTION
Ifthepropellermovesforward-and-aftonthepro-
pellershaft (isloose),re-tightenthepropeller
nut.Operationwithaloosepropellercouldcause
damagetothethrusthub and gearhousing dur-
ing acceleration,deceleration orwhenshifting
gears.
IMPORTANT:To assurethat thepropeller re-
mains secureon theshaft during the season,pe-
riodicallycheck propellershaftnut fortightness.
1.To aidinfutureremovalof the propeller,liberally
coat the propellershaft spline with one of the fol-
lowing Quicksilverlubricants:
·SpecialLubricant101
·Anti-Corrosion Grease
·2-4-CMarine Lubricant
2.Placeforwardthrusthub on propellershaft.
50551
a
b
a- Thrust Hub
b-PropellerShaft

90-826148R2 MARCH 19971B-8-IMPORTANTINFORMATION
3.While aligning splines,placeQuicksilverpropel-
lerand tab washeron propellershaft.
4.To preventpropellerfromrotating,place a flat
block ofwood between the anti-ventilation plate
and the propeller.
5.Thread propellernuton propellershaft. Tighten
securelywithwrench[minimumof55 lb. ft. (75.0
N·m)of torque]and bend tab washertosecure
propellernut.
6.Afterfirstuse,bend the tab straight, re-tighten
propellernut [minimumof55 lb. ft. (74.6N×m)of
torque]andagainbendtabwashertosecurenut.
Check propellerperiodicallyfortightness.
51119
ab
a- Tab Washer
b-PropellerNut
Corrosion ControlAnode
The trimtab on the gearcaseisacorrosion control
anode and Modelswhich havethe longertype of
transombracketswillhaveasecondanodeinstalled.
Ananode helpsprotecttheoutboardagainstgalvan-
ic corrosion by sacrificing itsmetalto be slowly
eroded instead of the outboardmetals.
a
b
a- Trim Tab
b-Anode
NOTE:Corrosion controlanodesrequiresperiodic
inspection especiallyinsaltwaterwhichwill acceler-
atetheerosion.Tomaintainthiscorrosionprotection,
always replacethe anode beforeitis completely
eroded.Neverpaintorapplya protectivecoating on
the anode asthiswill reduce effectiveness of the
anode.

90-826148R2 MARCH 1997 IMPORTANTINFORMATION-1B-9
FuelTank
Maintenance
The inside of the fueltank shouldbecleaned once
eachseason.Dirtorwatermayhaveenteredthefuel
tankduring refilling.Clean the tankbyflushing with
clean,lead-free gasoline orkerosene.
FUEL TANK FILTER
If afuelrestriction problemisencountered, the fuel
filteron end ofoutlet tube maybe obstructed.Re-
movecoverand inspect filterforvarnish,dirtorde-
posits.Cleanfilterbyrinsinginclean,lead-freegaso-
line orkerosene.
a
b
c
d
51046
a- FuelTankFilter
b-Pick-Up Tube
c-Cover
d- Gasket
FUEL LINEAND PRIMER BULB
Periodically check fuel line and primerbulbfor
cracks,breaks,restrictionsorchafing.Check all fuel
line connectionsfortightness.All fuel line connec-
tionsmustbe clamped securely.
Primerbulb assemblyhas2check valves:Fuel inlet
(towardtank)and a fueloutlet(toward engine).
The fuel inletvalve allowsfueltofill primerbulb but
closesto prevent fuelfromreturning totankwhen
bulbis squeezed.The fueloutletvalve openswhen
primerbulbissqueezedto allowfuelflowtocarbure-
tor,butclosesasbulbisreleasedtopreventfuelfrom
returning to primerbulb.
1.Toremovefuellineclamps,gripclampwithpliers
and bend over,lapping hookbackward.
51115
2.Toinstall fuel line clamps,grip hoseclampwith
pliersand push down on hookwithscrewdriver
until hooks interlock.
51115

90-826148R2 MARCH 19971B-10 -IMPORTANTINFORMATION
Flushing TheCooling
System
WARNING
To avoid possibleinjurywhenflushing,remove
thepropeller.RefertoPropellerReplacement.
1.Remove propeller (refertoPropellerReplace-
ment). Install the flushing attachmentsothe rub-
bercupsfit tightlyoverthe cooling waterintake
holes.
2.Attachawaterhosetothe flushing attachment.
Turnonthe waterand adjust the flowsowateris
leakingaroundthe rubbercupstoensuretheen-
gine receivesan adequatesupplyofcooling wa-
ter.
3.Startthe engineand runitatidlespeedinneutral
shift position.
4.Adjustwaterflow(ifnecessary)so excess water
continuesleaking out fromaround the rubber
cupsto ensurethe engine isreceiving an ade-
quatesupplyofcooling water.
5.Checkforasteadystreamofwaterflowing outof
the waterpumpindicatorhole.Continue flushing
theoutboardfor3to5minutes,carefullymonitor-
ing watersupplyatall times.
6.Stop the engine, turn off the water,and remove
the flushing attachment. Reinstall the propeller.
Storage
The majorconsideration in preparing youroutboard
forstorage isto protectit fromrust, corrosion,and
damage caused byfreezing of trapped water.
Thefollowingstorageproceduresshouldbefollowed
to prepareyouroutboardforout-of-season storage
orprolonged storage (twomonthsorlonger).
CAUTION
Neverstartor run youroutboard(evenmomen-
tarily)withoutwatercirculating through all the
coolingwaterintakeholesinthegearcasetopre-
ventdamagetothewaterpump(running dry)or
overheating of the engine.
FuelSystem
IMPORTANT:Gasoline containing alcohol(etha-
nolor methanol)cancause a formation ofacid
during storage and can damagethefuelsystem.
If thegasolinebeing use contains alcohol, itis
advisableto drainas much of theremaining gas-
olineaspossiblefromthefueltank,remotefuel
line,and enginefuelsystem.
Fill the fuelsystem(tank,hoses, fuelpump and car-
buretors)withtreated(stabilized)fueltohelpprevent
formationofvarnishandgum.Proceedwithfollowing
instructions.