Service Manual 115-200 HP 60° V4-V6 E-TEC Midsection [Exhaust Housing]

Before removing the midsection:

• The gearcase must be removed. Refer to Gear case GEARCASE REMOVAL AND INSTALLATION on p. 301.

• The powerhead must be removed. Refer to POWERHEAD REMOVAL on p. 228.

Remove and discard four lower mount screws.

“20” Models

“25” Models

Remove the exhaust housing.

Remove lower mount covers and inspect the lower mounts.

If replacement is necessary, lubricate mount with soapy water and carefully pry at both ends to remove.

Remove three screws and exhaust valve actuator (V4 models).

1. Actuator screws

Remove the front and rear screws retaining the adapter/inner exhaust housing to the exhaust housing.

1. Adapter retaining screws

Lift the adapter/inner exhaust housing out of the exhaust housing.

Remove the water tube. Inspect water tube grommet and replace if necessary.

1. Water tube grommet

V4 MODELS

Remove circlip and washers from exhaust valve shaft on starboard side of inner exhaust housing.

1. Circlip

Remove exhaust valve shaft and washer from port side of inner exhaust housing.

Remove exhaust valves from inside the inner exhaust housing.

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).

Clean all parts with parts cleaning solvent and dry with compressed air. All nut and screw threads coated with thread locking material must be thoroughly cleaned before assembly. When using a thread locking product, be sure to prime the threads with Locquic Primer.

Examine the upper and lower thrust mounts, and replace if deteriorated or damaged.

Before checking the exhaust housing for distortion, thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion.

Check the exhaust housing for distortion. Place the housing on a surface plate. Using a dial indicator, check flatness by measuring the run-out on the top edge of housing. The maximum allowable run-out is 0.009 in. (0.228 mm). If you do not have access to a dial indicator and surface plate, seek the services of a machine shop. DO NOT attempt to straighten a distorted housing. Replace it.

IMPORTANT: A distorted exhaust housing will cause the upper driveshaft splines to wear excessively and will damage the crankshaft splines.

Inspect the water tube for obstructions or kinks, which may restrict water flow.

V4 MODELS

Assemble linkage to exhaust valve shaft as shown. Be sure the word “OUT” on the lever is facing away from the shaft.

1. “OUT” mark

Place rear of inner exhaust housing on bench. Arrange exhaust valves and linkage as shown.

Place exhaust valves in inner exhaust housing.

Push valves into housing until they drop into notch.

Insert exhaust valve shaft and washer through port side of inner exhaust housing with lever angled toward top of housing.

Secure shaft with spring washer, flat washer, and circlip.

1. Circlip

2. Spring washer

ALL MODELS

Apply Adhesive 847 to the bottom flange of the inner exhaust housing. Install a new seal. Apply Triple-Guard grease to outer seal surface.

1. Adhesive 847

2. Triple-Guard grease

Install the water tube.

1. Water tube grommet

Clean and degrease the adapter housing and outer exhaust housing mating surfaces with Cleaning Solvent. Apply Gel-Seal II sealant to the adapter flange of the exhaust housing.

Place the adapter/inner exhaust housing into the exhaust housing. Guide the water tube through the hole in the outer housing.

IMPORTANT: On V4 models, be sure that exhaust valve linkage is oriented as shown.

Apply Triple-Guard grease to threads of adapter retaining screws. Tighten two forward screws to a torque of 216 to 240 in. lbs. (24.5 to 27 N·m) and rear screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Adapter retaining screws

If removed, coat the lower mounts with soapy water and press into the exhaust housing with the “OUTSIDE” mark facing outward.

Install the mount covers. Apply Nut Lock to screws, install washers and screws, and tighten to a torque of 150 to 180 in. lbs. (17 to 20 N·m).

V4 MODELS

Check that exhaust valve linkage is oriented as shown. “OUT” marking on lever must be visible.

1. “OUT” mark

Apply a small amount of Triple-Guard grease to the actuator shaft and o-ring.

1. Shaft

2. O-ring

Carefully engage actuator shaft in linkage lever.

Rotate and push actuator into position. Apply Triple-Guard grease to screw threads and install screws and washers. Tighten screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Actuator screws

IMPORTANT: Fill actuator electrical connectors with Electrical Grease before installation.

Bring the exhaust housing into position with the stern bracket.

Install four new lower mount screws with lock patch. Tighten screws to a torque of 38 to 45 ft. lbs. (51 to 61 N·m).

Install powerhead. Refer to POWERHEAD INSTALLATION on p. 251.

Install gearcase. Refer to Gearcase GEARCASE REMOVAL AND INSTALLATION on p. 301.