30 - 60 hp outboard boat horsepower capacity … an outboard that exceeds the maximum horsepower...

90-10175010 100- 1 -Printed in U.S.A.

30 - 60 HP OutboardInstallation Manual

NOTICE to INSTALLERAfter completing assembly, theseinstructions should be placed with theproduct for the owner’s future use.

IMPORTANT: If the boat is to be water tested, theoperator should be familiar with the operationprocedures in the Operation and MaintenanceManual.

Table of ContentsElectric Fuel Pump 1. . . . . . . . . . . . . . . . . . . . . . . . . .

Boat Horsepower Capacity 1. . . . . . . . . . . . . . . . . . .

Outboard Remote Control 1. . . . . . . . . . . . . . . . . . . .

Selecting Accessories For The Outboard 1. . . . . . .

Installation Specifications 2. . . . . . . . . . . . . . . . . . . . .

Lifting Outboard 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cable Seal 3. . . . . . . . . . . . . . . . . . . . . . . . .

Steering Link Rod 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Outboard Non Thumb Screw Models 4. .

Installing Outboard Thumb Screws Models 5. . . . .

Wiring Harness 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cable Connections 7. . . . . . . . . . . . . . . . . . .

Shift and Throttle Cable 30-40 Hp (2-Cyl.) 8. . . . . .

Shift and Throttle Cable 40-50 Hp (3-Cyl.) 10. . . . .

Shift and Throttle Cable 60 Hp 12. . . . . . . . . . . . . . .

Oil Injection Set Up 14. . . . . . . . . . . . . . . . . . . . . . . . .

Installing Remote Oil Tank (If Equipped) 14. . . . . . .

Propeller Installation 15. . . . . . . . . . . . . . . . . . . . . . . .

Trim-In Stop Adjustment – Power Trim Models 16.

Trim Tab Adjustment 16. . . . . . . . . . . . . . . . . . . . . . . .

Electric Fuel PumpIf an electric fuel pump is used, the fuel pressure mustnot exceed 4 psig at the engine. If necessary, installa pressure regulator to regulate the pressure.

Boat Horsepower Capacity

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON CAPACITY (POUNDS) XXX

MAXIMUM WEIGHT CAPACITY XXX

U.S. COAST GUARD CAPACITY

Do not overpower or overload the boat. Most boatswill carry a required capacity plate indicating the max-imum acceptable power and load as determined bythe manufacturer following certain federal guidelines.If in doubt, contact your dealer or the boat manufac-turer.

WARNING

Using an outboard that exceeds the maximumhorsepower limit of a boat can: 1. cause loss ofboat control 2. place too much weight at the tran-som altering the designed flotation characteris-tics of the boat or 3. cause the boat to break apart,particularly around the transom area. Overpow-ering a boat can result in serious injury, death, orboat damage.

Start in Gear ProtectionThe remote control connected to the outboard mustbe equipped with a start-in-gear protection device.This prevents the engine from starting in gear.

WARNING

Avoid serious injury or death from a sudden un-expected acceleration when starting your engine.The design of this outboard requires that the re-mote control used with it must have a built instart-in-gear protection device.

Selecting Accessories ForThe OutboardGenuine Quicksilver Parts and Accessories havebeen specifically designed and tested for this out-board.

Some accessories not manufactured or sold byQuicksilver are not designed to be safely used withthis outboard or outboard operating system. Acquireand read the installation, operation, and maintenancemanuals for all selected accessories.

- 2 -

Installation Specifications

a

b

a

a – Transom Opening – Minimum Single Engine – 19 in. (483 mm)Dual Engines – 40 in. (1016 mm)

b – Engine Center Line For Dual Engine22-1/2 in. (572 mm) Minimum

Lifting OutboardElectric Start Models – Remove plastic cap from fly-wheel hub. Thread lifting ring into flywheel a minimumof 5 turns. Replace plastic cap after installation.

Manual Start Models – Use lifting eye.

- 3 -

Steering CableSTARBOARD SIDE ROUTED CABLE

1. Lubricate the entire cable end.

a

a - Quicksilver 2-4-C Marine Lubricant with Teflon

2. Insert steering cable into tilt tube.

3. Torque nut to 35 lb. ft. (47.5 N·m).

Steering Cable Seal1. Mark tilt tube 1/4 in. (6.4 mm) from end. Install

seal components.

1/4 in. (6.4mm)

a

cb d

a - 1/4 In. (6.4 mm) Markb - Plastic Spacerc - O-Ring Seald - Cap

2. Thread cap to the mark.

Steering Link Rod1. Install steering link rod per illustration.

a

c

b

f60 Hp30-40-50 Hp

d

e

a - Special Bolt (10-90041) Torque to 20 lb. ft.(27.1 N·m)b - Nylon Insert Locknut (11-34863) Torque to

20 lb. ft.(27.1 N·m)c - Spacer (12-71970)d - Flat Washer (2)e - Nylon Insert Locknut (11-34863) Tighten Locknut Until it

Seats, Then Back Nut Off 1/4 Turnf - Use Correct Hole

IMPORTANT: The steering link rod that connectsthe steering cable to the engine must be fastenedusing special bolt (“a” - Part Number 10-90041)and self locking nuts (“b” & “c” - Part Number11-34863). These locknuts must never be re-placed with common nuts (non locking) as theywill work loose and vibrate off, freeing the link rodto disengage.

WARNING

Disengagement of a steering link rod can result inthe boat taking a full, sudden, sharp turn. This po-tentially violent action can cause occupants to bethrown overboard exposing them to serious inju-ry or death.

- 4 -

Installing Outboard – NonThumb Screw Models1. Attach (tape) engine mounting template (located

in center on this manual) to boat transom.

NOTE: Drill only the top holes for Type 1Brackets

2. Type 1 Bracket – 30-40 Hp (2 Cyl.) Short ShaftVersions – Mark the two upper holes and drill17/32 in. (13.5mm) holes. Set Outboard height(Step 5) and Drill two 3/8 in. (9.5mm) lowermounting holes

3. Type 2 Bracket – 30-40-50 Hp – Mark and drillfour 17/32 in. (13.5mm) mounting holes.

4. Type 3 Bracket – 60 Hp – Mark and drill four17/32 in. (13.5mm) mounting holes.

5. Install the outboard so that the anti-ventilationplate is in-line or within 1 in. (25 mm) below thebottom of the boat.

0 - 1 in. (0 - 25mm)

a

a - Anti Ventilation Plate

6. Fasten outboard with provided mounting hard-ware shown.

Type 1 Bracket

bc

d

DRILL Only the UpperHoles Using TemplateOn This Type Bracket.Mark and drill lower holesafter outboard height isset.

a

a

d

c

e

Type 2 Bracket

a

d

c

Type 3 Bracket

a

a

e

e

a - 1/2 In. Diameter Bolts (2)b - 3/8 In. Diameter Bolts (2) c - Flat Washers (4)d - Locknuts (4)e - Marine Sealer - Apply to Shanks of Bolts, Not Threads

- 5 -

Installing Outboard – ThumbScrew Models

WARNING

Outboard must be fastened to boat transom oneof two ways: 1. permanently fastened to transomwith thumb screws, and mounting bolts (pro-vided), or 2. secured to the transom using the op-tional outboard mounting kit (shown below).Should the outboard strike an underwater objector be steered into a sharp turn, failure to fastenoutboard correctly to the boat transom withmounting bolts or optional mounting kit could re-sult in outboard ejecting suddenly off boat tran-som causing serious injury, death, boat damage,or loss of outboard.

1. Optional Outboard Mounting kits shown, must beused if outboard will not be permanently fastenedto the transom with mounting bolts.

a

30-40-50 Hp

55-60 Hp

b

a - Outboard Mounting Kit Part No. 812432A4b - Outboard Mounting Kit Part No. 812432A5

2. Center outboard on the transom.

3. Install the outboard so that the anti-ventilationplate is in-line or within 1 in. (25 mm) below thebottom of the boat.

0 - 1 in(0 - 25mm)

a

a - Anti Ventilation Plate

4. Type 1 Bracket – 30-40 Hp – Mark and drill two3/8 in. (9.5mm) lower mounting holes.

5. Type 2 Bracket – 30-50 Hp – Mark and drill two17/32 in. (13.5mm) lower mounting holes.

6. Type 3 Bracket – 55-60 Hp – Mark and drill four17/32 in. (13.5mm) mounting holes.

7. Fasten outboard with provided mounting hard-ware shown.

Type 1 Bracket Type 2 Bracket

a

bd

d

e

ff

g

e

g

f

Type 3 Bracket

c

ed

g

a - 1/2 In. Diameter Bolts (2)b - 3/8 In. Diameter Bolts (2)c - 1/2 In. Diameter Bolts (4)d - Flat Washerse - Locknutsf - Marine Sealer - Apply to Shanks of Bolts Not Threadsg - Thumb Screws - Tighten Securely

- 6 -

Wiring HarnessIMPORTANT: Warning Horn Requirement – Theremote control or key switch assembly must bewired with a warning horn. This warning horn isused with the engine warning system.

1. Route wiring harness into bottom cowl.

40-50 Hp (3 Cyl.)

60 Hp

30-40 Hp (2 Cyl.)

2. Connect wiring. Place harness into the holder.

GRN/WHTBLU/WHT

BRN/WHTTAN

BLU/WHTGRN/WHT a

GRN/WHTBLU/WHT

BRN/WHTTAN

BLU/WHTGRN/WHT a

30-40 Hp (2 Cyl.)

40-50-60 Hp (3 Cyl.)

a - Power Trim Connections

- 7 -

30-40 HP (2 CYL.) MANUAL START MODELSUSING QUICKSILVER 2000 SERIES SIDEMOUNT REMOTE CONTROL

1. Route the remote control harness (a) around theback of the engine block as shown. Position theharness so that the harness will not interfere withshift and throttle operation.

a

2. Connect the black wire (a) to engine ground andthe black/yellow wire (b) to the black/yellow en-gine wire.

BLK/YEL BLK/YEL

ENGINE GROUND

a b

a

Battery Cable ConnectionsSINGLE OUTBOARD

a

b

(+)

(–) ca - Red Sleeve (Positive)b - Black Sleeve (Negative)c - Starting Battery

DUAL OUTBOARD

1. Connect a common ground cable (wire size sameas engine battery cables) between negative (–)terminals on starting batteries.

(–)

(–)

d

d - Ground Cable (Same Wire Size As Engine Battery Cable – Connect Between Negative (–) Terminals

- 8 -

Shift and Throttle Cable 30 and 40 Hp (2 Cyl.) ModelsInstall cables into the remote control following theinstructions provided with the remote control.

NOTE: Install the shift cable to the engine first. Theshift cable is the first cable to move when the remotecontrol handle is moved out of neutral.

30-40 Hp (2 Cyl.) – Shift CableInstallation1. Position remote control and outboard into neutral.

N

2. Measure distance “a” between mounting pin andmiddle of the barrel holder.

a

b

c

a - Distance Between Pin And Middle Of Barrel Holderb - Mounting Pinc - Barrel Holder

3. Push-in on the cable end until resistance is felt.Adjust the cable barrel (b) to attain the measureddistance “a” taken in Step 2.

4. Place cable barrel into the bottom hole in the bar-rel holder. Fasten cable to pin with retainer.

a

c d

b

a - Move Cable Barrel To Attain The Measured Distance Taken In Step 2

b - Cable Barrelc - Barrel Holder – Place Barrel Into Bottom Holed - Retainer

5. Check shift cable adjustments as follows:

a. Shift remote control into forward. The propel-ler shaft should be locked in gear. If not, adjustthe barrel closer to the cable end.

b. Shift remote control into neutral. The propel-ler shaft should turn freely without drag. If not,adjust the barrel away from the cable end. Re-peat steps a and b.

c. Shift remote control into reverse while turningpropeller. The propeller shaft should belocked in gear. If not, adjust the barrel awayfrom the cable end. Repeat steps a thru c.

d. Shift remote control back to neutral. The pro-peller shaft should turn freely without drag. Ifnot, adjust the barrel closer to the cable end.Repeat steps a thru d.

- 9 -

30-40 Hp (2 Cyl.) – Throttle CableInstallation1. Position remote control into neutral.

N

2. Install cable to the throttle lever. Secure with re-tainer.

ab

a - Throttle Cableb - Retainer

3. Adjust the cable barrel so that the installed throttlecable will hold the throttle arm against the stop.

a

bc

a - Cable Barrel – Adjust To Hold Throttle Arm Against Stopb - Throttle Armc - Barrel Holder – Place barrel Into Top Hole

4. Check throttle cable adjustment as follows:

a. Shift outboard into gear a few times to activatethe throttle linkage. Make sure to rotate thepropeller shaft while shifting into reverse.

N RF

b. Return remote control to neutral. Place a thinpiece of paper between throttle arm and idlestop. Adjustment is correct when the papercan be removed without tearing, but hassome drag on it. Readjust cable barrel if nec-essary.

a

b

a - Throttle Armb - Idle Stop

5. Lock the barrel holder in place with the cablelatch.

- 10 -

Shift and Throttle Cable 40 and 50 Hp (3 Cyl.) ModelsInstall cables into the remote control following theinstructions provided with the remote control.


40-50 Hp (3 Cyl.) – Shift CableInstallation1. Position remote control and outboard into neutral.

N


a

b

c



4. Place cable barrel into the bottom hole in the bar-rel holder. Fasten cable to pin with retainer.

a

c d

b


b - Cable Barrelc - Barrel Holder – Place Barrel Into Bottom Holed - Retainer






- 11 -

40-50 Hp (3 Cyl.) – Throttle CableInstallation1. Position remote control into neutral.

N

2. Install cable to the throttle lever. Tighten locknut,then back-off the locknut 1/4 turn.

abc

a - Throttle Cableb - Nylon Washerc - Locknut – Tighten Locknut, Then Back-Off The Locknut 1/4

Turn

3. Adjust the cable barrel so that the installed throttlecable will hold the idle adjustment screw againstthe stop.

a

bc

a - Cable Barrel – Adjust To Hold Idle Adjustment Screw Against Stop

b - Idle Adjustment Screwc - Barrel Holder – Place barrel Into Top Hole



N RF

b. Return remote control to neutral. Place a thinpiece of paper between idle adjustment screwand idle stop. Adjustment is correct when thepaper can be removed without tearing, buthas some drag on it. Readjust cable barrel ifnecessary.

a

b

a - Idle Adjustment Screwb - Idle Stop


- 12 -

Shift and Throttle Cable 60 Hp ModelsInstall cables into the remote control following theinstructions provided with the remote control.


60 Hp – Shift Cable Installation1. Position remote control and outboard into neutral.

N


a

bc



4. Place cable barrel into the bottom hole in the bar-rel holder. Fasten cable to pin with locknut.

a

c

d

b

e


b - Cable Barrelc - Barrel Holder – Place Barrel Into Bottom Holed - Nylon Washere - Locknut – Tighten Locknut, Then Back-Off The Locknut 1/4

Turn






- 13 -

60 Hp – Throttle Cable Installation1. Position remote control into neutral.

N

2. Install cable to the throttle lever. Tighten locknut,then back-off the locknut 1/4 turn.

abc

a - Throttle Cableb - Nylon Washerc - Locknut – Tighten Locknut, Then Back-Off The Locknut 1/4

Turn

3. Adjust the cable barrel so that the installed throttlecable will hold the idle adjustment screw againstthe stop.

a

b

c

a - Cable Barrel – Adjust To Hold Idle Adjustment Screw Against Stop

b - Idle Adjustment Screwc - Barrel Holder – Place Barrel Into Top Hole



N RF

b. Return remote control to neutral. Place a thinpiece of paper between idle adjustment screwand idle stop. Adjustment is correct when thepaper can be removed without tearing, buthas some drag on it. Readjust cable barrel ifnecessary.

a

b

a - Idle Adjustment Screwb - Idle Stop


- 14 -

Oil Injection Set Up1. Fill engine oil tank with oil.

2. Inspect the oil pump inlet hose (a) for air bubbles.If air exists, place a shop towel below the oil pumpand loosen bleed screw (c) four turns. Allow oil toflow out of the bleed hole until air is removed fromthe hose.

3. Inspect the oil pump outlet oil hose (b) for airbubbles. If air exists, disconnect link rod from oilpump. Start engine and run at 1000 to 1500 RPM.Rotate (and hold) the pump arm full clockwise un-til the air is purged out of the hose.

a

c

b

de

a - Inlet Hoseb - Outlet Hosec - Bleed Screw – Torque to 15 lb. in. (N·m)d - Link Rode - Pump Arm

4. Reconnect the link rod. Set carburetor linkage atidle position. Alignment marks should line-up. Ifnecessary, adjust link rod.

Installing Remote Oil Tank (If Equipped)MOUNTING OIL TANK

1. Mount the remote oil tank in the boat. The tankshould be restrained from moving. Use the oiltank hold down kit provided.

2. Arrange the hoses so they will not get pinched,kinked, or stretched during operation.

NOTE: A Quicksilver Accessory oil hose extension kit(41729A3) is available.

CONNECTING REMOTE OIL TANK HOSES

3. Remove shipping caps from oil hose fittings andconnect hoses as shown. Fasten hose with sta-strap.

Oil Hoses From Engine

Oil Hoses From Remote Oil Tank

BlackBlack withBlue Stripe

Black withBlue Stripe Black

a

a - Sta-Strap – Secure Hose Connections

4. Remove the filler cap and fill remote tank with oil. Oiltank capacity is 3 gallons (11.5 liters). Reinstall fillercap and tighten securely.

IMPORTANT: Always make sure the oil tank capsare threaded on tight. An air leak will prevent oilflow to the engine.

- 15 -

Propeller Installation

3-1/4 in. (83mm) Diameter Gear Case

WARNING

If the propeller shaft is rotated while the engine isin gear, there is the possibility that the engine willcrank over and start. To prevent this type of acci-dental engine starting and possible serious inju-ry caused from being struck by a rotating propel-ler, always shift outboard to neutral position andremove spark plug leads when you are servicingthe propeller.

Flo-Torq I Drive Hub Propellers

a

c b

a - Forward Thrust Hubb - Propeller Nut Retainerc - Propeller Nut

Flo-Torq II Drive Hub Propellers

a

c

b

de

a - Forward Thrust Hubb - Replaceable Drive Sleevec - Rear Thrust Hubd - Propeller Nut Retainere - Propeller Nut

5. Tighten propeller nut to 55 lb.ft. (75 N·m). Bendtabs against nut.

a

bb

a - Propeller Nut - Torque To 55 lb. ft. (75 N·m)b - Bend Tabs Against Nut

Propeller Installation (Cont.)

4-1/4 in. (108 mm) Diameter GearCase

WARNING

If the propeller shaft is rotated while the engine isin gear, there is the possibility that the engine willcrank over and start. To prevent this type of acci-dental engine starting and possible serious inju-ry caused from being struck by a rotating propel-ler, always shift outboard to neutral position andremove spark plug leads when you are servicingthe propeller.

Flo-Torq I Drive Hub Propellers

ac

b

de

a - Forward Thrust Hubb - Continuity Washerc - Thrust Hubd - Propeller Nut Retainere - Propeller Nut

Flo-Torq II Drive Hub Propellers

ac

bde

a - Forward Thrust Hubb - Replaceable Drive Sleevec - Rear Thrust Hubd - Propeller Nut Retainere - Propeller Nut

6. Tighten propeller nut to 55 lb.ft. (75 N·m). Bendtabs into grooves.

a

b

a - Propeller Nut - Torque To 55 lb. ft. (75 N·m)b - Bend Tabs Into Grooves

- 16 -

Trim-In Stop Adjustment – Power Trim Models

40-50 HpIf an adjustment is required to the the trim-in stop, re-position the tilt stop pins as follows:

1. Lock the outboard in the full tilt position.

2. Remove bottom pivot pin.

3. Swing the power trim system outward to gain ac-cess to the tilt stop pins. Reposition the tilt stoppins in the desired holes.

4. Reinstall the bottom pivot pin. Torque pivot pinnuts to 18 lb. ft. (24.4 N·m).

28216

a

b

a

a Tilt Stop Pinsb - Bottom Pivot Pin

60 HpIf an adjustment is required, purchase a stainlesssteel tilt pin (P/N 17-49930A1) and insert it throughwhatever pin hole is desired. The non-stainless steelshipping bolt should not be used in this applicationother than on a temporary basis.

28216

a

a - Tilt Pin

Trim Tab AdjustmentThe trim tab can be adjusted within limits to help tocompensate for steering torque.

Adjust trim tab as follows:

1. If boat tends to pull to the right, move the rearedge of the trim tab to the right.

2. If boat tends to pull to the left, move the rear edgeof the trim tab to the left.

NOTE: Trim tab adjustment will have little effect re-ducing steering torque if the the anti-ventilation plateis raised 2 inches (50mm) or more above the boat bot-tom.

30 - 60 hp outboard boat horsepower capacity … an outboard that exceeds the maximum horsepower...

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