Service Manual 15-30 HP E-TEC Engine Cover Service [Lower Cover Service]

Remove cable entry cover screws, cover and cable entry grommets.

1. Cable entry cover screws
2. Cable entry cover
3. Cable entry grommets

Remove lower engine cover screws.

1. Lower cover screws

Installation of lower motor covers will be easier if the following steps are performed in order:

• Install air silencer on throttle body.
• Install fuel hose on fuel connector fitting. Secure with new Oetiker clamp. Place port cover on outboard. If equipped, route battery and trim cables through grommet opening.
• Place starboard side cover into position on outboard.

1. Grommet opening
2. Battery cable

Start the screw below the exhaust relief grommet first. Tighten just enough to hold the grommet in place.

1. Start this screw first
2. Exhaust relief grommet

Start the bottom front screw next to draw cover halves together.

1. Start this screw second

Install the front latch sleeve and start the top front screw next to draw cover halves together.

1. Start this screw third

Install remaining cover screws and tighten all screws to 24 to 36 in. lbs. (3 to 4 N·m).

1. Lower cover screws

Install cable entry cover grommets, cable entry cover and cable entry cover screws. Tighten screws to 24 to 36 in. lbs. (3 to 4 N·m).

Install trim and battery cable grommet on port cover.

1. Grommet
2. Trim cable (if equipped)
3. Battery cable

Apply a light coat of Triple-Guard grease to latch handle shaft. Insert handle into lower cover.

1. Triple-Guard grease

Apply Ultra-Lock to screw threads. Place spring washer and hook into position and tighten screw to a torque of 180 in. lbs. (20 N·m).

1. Spring washer
2. Hook
3. Screw