Loosen timing belt tensioner screw and remove tensioner spring. Covers models starting model year 2004, Serial Number 0T8010000 and Up Diagnostic Guide covers technical procedures and tests as well as symptoms which will help troubleshooting Mercury Optimax motors and drives. If reverse gear must be replaced, pinion gear and sliding clutch should be inspected for damage. Replace appropriate components as required. Remove the trilobe pin Power Trim System Removal 4. Replace forward gear tapered roller bearing and Lower Driveshaft Bearing race if either bearing or race are rusted or dam- 1.
With the pump gears rotating backwards, the flow of oil is reversed. Torque bolts to 18 lb. Install ball, seat, and spring five sets to shock rod piston. Possible Cause Corrective Action Faulty Engine overheat sensor. Flywheel Holder 91-52344 73790 10.
Slightest amount of debris in Power Trim the remaining seat. Center outboard on the transom. Install the thrust washer against the ball bearing. Unscrew plug from manifold and remove spring Suction Seat Removal and poppet assembly. Hold bolt Checking for Cavitation Continued from turning, and tighten locknut on bolt. The correct clearance between gauging block change in shim thickness. Secure impeller Quicksilver Anti-Corrosion Grease around the entire nut by bending tabs against the flats on the impel- mounting flange on the water intake housing and also to the threads on the six mounting bolts.
Place shim s retained from disassembly into housing. Manually shift outboard shift actuator lever to neutral. Fasten Power Trim System ground strap between anode and clamp bracket. Place trim cylinder in soft jawed vice. If you click on any of these headings it should open up a new page for that topic.
Manual release valve Inspect manual release valve. Measure the width of the leading edge on the wa- mately 7 inches higher on the transom than propeller ter intake housing. Clean shock rod and components with parts cleaner and dry with compressed air. Drive trilobe pin a into its hole until seated. Remove propeller shaft from carrier and disas- semble shaft.
Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re-as- sembly. Press tapered roller bearing onto gear. Use a petroleum based solvent for cleaning and blow out all passages with com- pressed air. Insert propeller shaft assembly into bearing carrier. Above 5000 feet, however, it is recommended that main jet size be reduced as shown per 1000 feet 304.
Position cylinder end cap onto rod as shown. Install new bearing using a suitable mandrel. Insert clean bolts note 2 sizes and finger tight- 7. Replace sliding clutch if jaws are rounded or chipped. Place shim s , retained from disassembly, into housing.
Cam pivot pin, pivot hole and shock rod hole. Install starter sheave to housing and secure in 4. Inspect shift cam for wear or galling. Remove memory piston from cylinder using one of two methods: a. Apply Perfect Seal on O. The most likely place for an open circuit is at the com- mutator bars.
Torque screws to place into cylinder. If no adjustment is necessary skip to step 11 on. Some repair procedures in this 90 horsepower outboard downloadable manual may require the use of special tools. Fuel tank empty or too low. If bearing is damaged, bearing and race must be 1. Remove race and shim s using bearing race tool 91-14308A1. Tighten cover or replace gas- cover.