Service Manual 115-200 HP E-TEC Midsection [Stern Bracket]

Removal

Remove six screws retaining extension.

007180

1. Screws

Remove extension.

Remove grommets and seal.

Installation

Apply Adhesive 847 to the shift rod and water tube flange of the extension.

Install new grommets. Apply Adhesive 847 to the bottom flange of the extension.

Install a new seal. Apply Triple-Guard grease to outer seal surface.

007179

1. Adhesive 847

Install extension with six screws and tighten to a torque of 18 to 20 ft lb. (24 to 27 N·m).

Stern Bracket Removal

Before servicing the stern bracket:

• Remove gearcase. Refer to Gearcase GEARCASE REMOVAL AND INSTALLATION on p. 310.
• Remove powerhead. Refer to Powerhead POWERHEAD REMOVAL on p. 240.
• Remove exhaust housing. Refer to Exhaust Housing Exhaust Housing Removal on p. 286.
• Remove power trim/tilt unit. Refer to TRIM AND TILT section.

Stern Bracket Disassembly

Remove and discard steering shaft locknut.

30738

Remove the lower mount bracket and keeper.

30736

Remove the steering shaft and thrust washer. It may be necessary to tap the steering shaft out using a wood dowel and mallet.

30735

Pry out upper and lower steering shaft seals and discard. Remove the upper and lower steering shaft bushings.

30765 / 30764

Remove the tilt tube. Refer to TILT TUBE on p. 284.

Remove the two tilt tube washers.

30763

Remove the anode.

30762

1. Anode

Remove the swivel bracket. Inspect and, if necessary, replace the tilt tube bushings.

30761

1. Tilt tube bushing

Remove the trim sender unit from the port stern bracket and pull its wires through the braided tube.

30760

Remove the tilt limit switch and retainer from the swivel bracket.

30758

1. Tilt limit switch
2. Retainer

Disconnect the trail lock spring and remove it from the swivel bracket. Remove trail arm retainer.

30756

1. Trail lock spring
2. Trail arm retainer

Remove the trail lock arm and bushings from the swivel bracket.

30755

1. Trail lock bushing

Remove the two trim rod rollers from the swivel bracket.

30754

1. Trim rod roller

Remove the tilt support and bushing from the swivel bracket and inspect the detent roller and spring.

30753

IMPORTANT: Before proceeding, make sure all components have been thoroughly cleaned. Replace any seals that have been removed. Inspect all thrust washers and bushings for evidence of deterioration.

Install the detent roller and spring and the tilt support with bushing in the swivel bracket. Tighten bushing to a torque of 28 to 30 ft. lbs. (38 to 41 N·m).

30752

30753

1. Tilt support bushing

Install the two trim rod rollers on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. (25 to 27 N·m).

30754

1. Trim rod roller

Install the trail lock and bushings in the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. (25 to 27 N·m).

30755

1. Trail lock bushing

Install the trail lock spring in the swivel bracket and connect the spring to the trail lock.

30756

1. Trail lock spring
2. Trail arm retainer

Install the tilt limit switch and retainer on the swivel bracket. Tighten screws to a torque of 40 to 50 in. lbs. (4.5 to 5.5 N·m).

30758

1. Tilt limit switch
2. Retainer

Route the trim sender wires through the braided tube, and install the sender unit in the port stern bracket.

30760

Install the upper and lower steering shaft bushings and new seals in the swivel bracket. Both seal lips face out.
• Coat the outside surfaces of seals with Gasket Sealing Compound.
• Coat the bushings and seal lips with TripleGuard grease.

30765 / 30764

Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.

30761

Place the swivel bracket between the stern brackets and install the anode.

Install the tilt tube and tilt limit cam. Refer to TILT TUBE on p. 284.

Install the steering shaft and thrust washer.

30735

Install the steering shaft keeper. Apply Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount bracket.

30736

Install the lower mount bracket and a new locking nut with its unstaked side facing the mount bracket. Align the bracket with the steering arm and tighten the nut to a torque of 130 to 150 ft. lbs. (176 to 204 N·m).

30767

Fill the swivel bracket with Triple-Guard grease through the grease fitting on the bracket’s port side. Lubricate the tilt tube, swivel bracket, and stern brackets through the two forward grease fittings.

Install the exhaust housing. Refer to Exhaust Housing Installation on p. 287.