IMPORTANT 1

INFORMATION
B

MAINTENANCE
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Gear Case Lubricant Capacity . . . . . . . . . 1B-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Inspection and Maintenance Schedule . . . . 1B-2
Before Each Use . . . . . . . . . . . . . . . . . . . . 1B-2
After Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-2
Every 100 Hours of Use or Once Yearly,
Whichever Occurs First . . . . . . . . . . . . . . . 1B-2
Every 300 Hours of Use or Three Years 1B-2
Before Periods of Storage . . . . . . . . . . . . 1B-2
Flushing The Cooling System . . . . . . . . . . . . 1B-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3
Corrosion Control Anode . . . . . . . . . . . . . . . . 1B-4
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . 1B-5
Checking Power Trim Fluid . . . . . . . . . . . . . . 1B-7
60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
40/50 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Gear Case Lubrication . . . . . . . . . . . . . . . . . . 1B-8
Draining Gear Case . . . . . . . . . . . . . . . . . . 1B-8
Checking Lubricant Level and Filling
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Storage Preparations . . . . . . . . . . . . . . . . . . . 1B-9
Protecting External Outboard
Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Protecting Internal Engine Components 1B-9
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Positioning Outboard for Storage . . . . . . 1B-10
Battery Storage . . . . . . . . . . . . . . . . . . . . . 1B-10

1B-0- IMPORTANT INFORMATION 90-852572R02 NOVEMBER 2002

Specifications

Gear Case Lubricant Capacity

Gear Case Ratio Capacity
1.83:1 14.9 fl. oz. (440 mL)
1.64 :1 11.5 fl. oz. (340 mL)
2.3:1 22.5 fl. oz. (655 mL)

Special Tools
1. Flushing Attachment (44357A2)

50551

90-852572R02 NOVEMBER 2002 IMPORTANT INFORMATION - 1B-1

Inspection and Maintenance Every 100 Hours of Use or Once
Yearly, Whichever Occurs First
Schedule
1. Lubricate all lubrication points. Lubricate more
frequently when used in salt water.
Before Each Use 2. Inspect and clean spark plugs.
1. Check that lanyard stop switch stops the engine. 3. Check engine fuel filter for contaminants.
2. Visually inspect the fuel system for deterioration 4. Adjust carburetor(s) (if required).∗
or leaks.
3. Check outboard for tightness on transom. 5. Check engine timing setup.∗

4. Check steering system for binding or loose com- 6. Check corrosion control anodes. Check more fre-
ponents. quently when used in salt water.

5. Remote Control Models – Visually check steering 7. Drain and replace gear case lubricant.
link rod fasteners for proper tightness. 8. Lubricate splines on the drive shaft.
6. Check propeller blades for damage. 9. Check power trim fluid.
10. Inspect battery.
After Each Use 11. Check control cable adjustments. ∗
1. Flush out the outboard cooling system if operat- 12. Remove engine deposits with Power Tune En-
ing in salt or polluted water. gine Cleaner.
2. Wash off all salt deposits and flush out the ex- 13. Check tightness of bolts, nuts, and other fasten-
haust outlet of the propeller and gear case with ers.
fresh water if operating in salt water.
* These items should be serviced by an authorized
dealer.

Every 300 Hours of Use or Three

Years
1. Replace water pump impeller (more often if over-
heating occurs or reduced water pressure is
noted).

Before Periods of Storage

Refer to Storage Procedure.

1B-2- IMPORTANT INFORMATION 90-852572R02 NOVEMBER 2002

Flushing The Cooling 3. Start the engine and run it at idle speed in neutral
shift position.
System 4. Adjust water flow (if necessary) so excess water
Flush the internal water passages of the outboard continues leaking out from around the rubber
with fresh water after each use in salt, polluted, or cups to ensure the engine is receiving an ade-
muddy water. This will help prevent a buildup of de- quate supply of cooling water.
posits from clogging the internal water passages. 5. Check for a steady stream of water flowing out of
Use Flushing Attachment (44357A2) (or equivalent) the water pump indicator hole. Continue flushing
flushing attachment. the outboard for 3 to 5 minutes, carefully monitor-
ing water supply at all times.
WARNING
To avoid possible injury when flushing, remove
the propeller. Refer to Propeller Replacement.
1. Remove propeller (refer to Propeller Replace-
ment). Install the flushing attachment so the rub-
ber cups fit tightly over the cooling water intake
holes.

6. Stop the engine, turn off the water, and remove

the flushing attachment. Reinstall the propeller.

Fuel System
IMPORTANT: Gasoline containing alcohol (etha-
nol or methanol) can cause a formation of acid
2. Attach a water hose to the flushing attachment. during storage and can damage the fuel system.
Turn on the water and adjust the flow so water is If the gasoline being used contains alcohol, it is
leaking around the rubber cups to ensure the en- advisable to drain as much of the remaining gas-
gine receives an adequate supply of cooling wa- oline as possible from the fuel tank, remote fuel
ter. line, and engine fuel system.
Fill the fuel system (tank, hoses, fuel pump, and car-
buretors) with treated (stabilized) fuel to help prevent
formation of varnish and gum. Proceed with following
instructions.
1. Portable Fuel Tank – Pour the required amount of
Gasoline Stabilizer (follow instructions on con-
tainer) into fuel tank. Tip fuel tank back and forth
to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the re-
quired amount of Gasoline Stabilizer (follow in-
structions on container) into a separate container
and mix with approximately one quart (one liter)
of gasoline. Pour this mixture into fuel tank.

90-852572R02 NOVEMBER 2002 IMPORTANT INFORMATION - 1B-3

3. Place the outboard in water or connect flushing
attachment for circulating cooling water. Run the
engine for ten minutes to allow treated fuel to
reach the carburetors.

Corrosion Control Anode

1. Your outboard has two corrosion control anodes.
One of the anodes is the trim tab installed on the
gear case and the other is installed on the bottom
of the transom bracket assembly. An anode helps
protect the outboard against galvanic corrosion
by sacrificing its metal to be slowly eroded in-
stead of the outboard metals.

b
a - Trim Tab Anode
b - Transom Bracket Anode

NOTE: Each anode requires periodic inspection es-

pecially in salt water which will accelerate the ero-
sion. To maintain this corrosion protection, always re-
place the anode before it is completely eroded. Never
paint or apply a protective coating on the anode as
this will reduce effectiveness of the anode.

1B-4- IMPORTANT INFORMATION 90-852572R02 NOVEMBER 2002

Lubrication Points
ITEM TYPE OF FRESH WATER SALT WATER
DESCRIPTION
NO. LUBRICANT FREQUENCY FREQUENCY
Throttle/Shift linkage
1
Pivot Points
Shift Handle (Tiller
2 2-4-C with Teflon
Handle Models)
3 Swivel Pin 100 Hours of Use or
Once Per Season
Ride Guide Steering
4
Cable
5 Tilt Tube/Co-Pilot
Steering Link Rod
6 SAE 30W Motor Oil 100 Hours of Use or Once Per Season
Pivot Points
Anti-Corrosion
7 Propeller Shaft Grease or 2-4-C with
Teflon
Starter Motor Pinion
8 SAE 30W Motor Oil
Gear
9 Gear Housing Bear-
2-4-C with Teflon
* ing Carrier
10 Premium Gear Lubri-
Gear Housing
◊ cant
Engine Crankshaft
∆ Splines to Drive Shaft 2-4-C with Teflon Once Per Season
Splines
* Refer to lubrication instructions outlined in “Salt Water Cor- ◊ Refer to “Gear Housing Lubrication” of this section (see
rosion - Gear Housing Bearing Carrier and Cover Nut” “Table of Contents”).
of this section (see “Table of Contents”).
∆ Refer to “Gear Housing Removal and Installation”.

1 - Throttle/Shift Linkage Pivot Points

90-852572R02 NOVEMBER 2002 IMPORTANT INFORMATION - 1B-5

 2
2

5
5
5

5 - Tilt Tube/Co-Pilot

2 - Shift Handle (Tiller Handle Models)

6
6 - Steering Link Rod Pivot Points

3 - Swivel Pin

4 4

4 - Ride Guide Steering Cable 7

7 - Propeller Shaft

1B-6- IMPORTANT INFORMATION 90-852572R02 NOVEMBER 2002

 8 a

50157

51118 a - Tilt Lock Lever

8 - Starter Motor Pinion Gear

2. Remove fill screw and check fluid level. Fluid lev-
el should be to bottom of threads in fill hole.
3. If necessary, add Power Trim & Steering Fluid or;
Automatic Transmission Fluid (ATF) Type F, FA
or Dexron II fluid to trim system.
4. Reinstall fill screw.

40/50 HP
1. Tilt outboard to the full up position and engage
the tilt support lock.
2. Remove fill cap and check fluid level. The fluid
level should be even with the bottom of the fill
hole. Add Power Trim & Steering Fluid. If not
10 available, use automotive (ATF) automatic trans-
mission fluid.
9 50558

9 - Gear Housing Bearing Carrier

10- Gear Housing

a
Checking Power Trim Fluid
IMPORTANT: This trim system is pressurized. Remove
fill screw when outboard is trimmed to the full “up” po-
sition. Retighten fill screw securely.
b

60 HP
1. Trim outboard to full “up” position. Engage tilt lock
lever. Trim system fluid can only be checked
when outboard is in this position.

a - Tilt Support Lock

b - Fill Cap

90-852572R02 NOVEMBER 2002 IMPORTANT INFORMATION - 1B-7

Gear Case Lubrication
When adding or changing gear case lubricant, visual-
ly check for the presence of water in the lubricant. If
water is present, it may have settled to the bottom
and will drain out prior to the lubricant, or it may be
mixed with the lubricant, giving it a milky colored ap-
pearance. If water is noticed, have the gear case a
checked by your [Link] in the lubricant may re-
sult in premature bearing failure or, in freezing tem-
peratures, will turn to ice and damage the gear case.
Whenever you remove the fill/drain plug, examine
the magnetic end for metal particles. A small amount
of metal filings or fine metal particles indicates nor- b
mal gear wear. An excessive amount of metal filings
or larger particles (chips) may indicate abnormal
gear wear and should be checked by an authorized
dealer.
a - Lubricant Vent Plug/Washer
WARNING b - Lubricant Fill Plug/Washer
If gear housing is installed on outboard, to avoid 4. Inspect gear lubricant for metal particles (lubri-
accidental starting, disconnect (and isolate) cant will have a “metal flake” appearance). Pres-
spark plug leads from spark plugs before work- ence of fine metal particles (resembling powder)
ing near the propeller. on the magnetic fill plug indicates normal wear.
The presence of metal chips on the magnetic fill
CAUTION plug indicates the need for gear housing disas-
Do not use automotive grease in the gear hous- sembly and components inspection.
ing. Use only Premium Gear Lubricant. 5. Note color of gear lubricant. White or cream color
indicates presence of water in lubricant. Gear lu-
bricant which has been drained from a gear hous-
Draining Gear Case ing recently in operation, will have a yellowish col-
1. Tilt outboard so that lubricant in gear housing will or due to lubricant agitation/aeration. This is
drain toward front of housing, out fill hole and into normal and should not be confused with the pres-
clean container. ence of water.

IMPORTANT: Inspect FILL and VENT plug washers 6. Presence of water in gear lubricant indicates the
for damage. Use new washers as needed. need for disassembly and inspection of oil seals,
seal surfaces, O-rings, water pump gaskets, as
2. Remove lubricant Fill plug and washer. Note well as, gear housing components for damage.
amount of metal particles on magnetic Fill plug.
Remove all magnetic particles from Fill plug.
3. Remove Vent plug and washer and allow all lubri-
cant to drain.

1B-8- IMPORTANT INFORMATION 90-852572R02 NOVEMBER 2002

Checking Lubricant Level and Filling Storage Preparations
Gear Case The major consideration in preparing your outboard
IMPORTANT: Never add lubricant to gear housing for storage is to protect it from rust, corrosion, and
without first removing VENT plug, as trapped air damage caused by freezing of trapped water.
will prevent housing from being filled. Fill gear The following storage procedures should be followed
housing only when outboard is in operating posi- to prepare your outboard for out-of-season storage
tion. or prolonged storage (two months or longer).
NOTE: Refer to “Specifications,” for gear housing
lubricant capacity. CAUTION
1. With outboard in operating position, insert lubri- Never start or run your outboard (even momen-
cant tube into fill hole. tarily) without water circulating through all the
cooling water intake holes in the gear case to pre-
2. Fill gear housing until excess lubricant flows from
vent damage to the water pump (running dry) or
VENT hole.
overheating of the engine.

b
Protecting External Outboard
Components
1. Lubricate all outboard components listed in the
Inspection and Maintenance Schedule.
2. Touch up any paint nicks. See your dealer for
touch-up paint.
a 3. Spray Corrosion Guard on engine exterior, elec-
trical components, and other metal surfaces (ex-
cept corrosion control anodes).

a - Lubricant/Fill Hole Protecting Internal Engine

b - Vent Hole Components
NOTE: Before performing the following steps, make
3. Install VENT plug and washer. sure the fuel system has been prepared for storage.
4. Install FILL plug and washer. Refer to Fuel System.
1. Place the outboard in water or connect flushing
attachment for circulating cooling water. Start the
engine and let it run in neutral to warm up.
2. With engine running at fast idle, stop the fuel flow
a by disconnecting the remote fuel line. When en-
gine begins to stall, quickly spray Storage Seal
into carburetor until engine stops from lack of
fuel.
3. Remove the spark plugs and inject a five second
spray of Storage Seal around the inside of each
cylinder.
b 4. Rotate the flywheel manually several times to
distribute the storage seal in the cylinders. Rein-
stall spark plugs.
a - Vent Plug/Washer
b - Fill Plug/Washer

90-852572R02 NOVEMBER 2002 IMPORTANT INFORMATION - 1B-9

Gear Case
1. Drain and refill the gear case lubricant (refer to
maintenance procedure).

Positioning Outboard for Storage

1. Store outboard in an upright (vertical) position to
allow water to drain out of outboard.

CAUTION
If outboard is stored tilted up in freezing tempera-
ture, trapped cooling water or rain water that may
have entered the propeller exhaust outlet in the
gear case could freeze and cause damage to the
outboard.

Battery Storage
1. Follow the battery manufacturers instructions for
storage and recharging.
2. Remove the battery from the boat and check wa-
ter level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge
the battery during storage.

1B-10- IMPORTANT INFORMATION 90-852572R02 NOVEMBER 2002