OIL COMPONENT SERVICING
To prevent accidental starting while servicing, disconnect the battery cable s at the battery.
Oil Distribution Hoses
The oil distribution hoses from each manifold MUST be the same length. DO NOT alter the length of any hoses.
| Oil Distribution Hose Length |
|---|
| Primary oil manifold to cylinder block fitting | 12 in. (305 mm) |
|---|---|
| Rear oil manifold to cylinder block fitting | 32 in. (812 mm) |
| Primary oil manifold to rear oil manifold* | 32 in. (812 mm) |
*Primary oil manifold to rear oil manifold hose has a 0.160 in. I.D. and does NOT use a hose support.
Removal
Release the hose b y depressing the outer ring of the hose retaining mechanism.
- Retainer mechanism
Once hose is re moved from the manifold, make sure hose support is in the end of the hose.
- Hose support
Installation
Cut Replacement Oil Hose, P/N 778708, to the correct length. Insert hose support in manifold end of hose. (Primary manifold to rear manifold hose does not use a hose support.)
IMPORTANT: DO NOT insert distribution hoses into manifold without a hose support.
Be sure the hose is full y inserted into manifold. Insertion depth is 5/8 in. (16 mm). Visually inspect for hose supports.
Oil Injection Pump
Removal
Disconnect the battery cables at the battery.
Remove engine cover and air silencer.
Remove the oil supply hose from the fitting (inlet) of the oil injection pump.
Disconnect the electrical connector.
IMPORTANT: Note oil distribution hose routings before proceeding with disassembly. Center hose from primary oil manifold connects to oil to inlet of rear oil manifold.
Remove oil distribution hoses from the crankcase fittings.
Remove oil injection pump clamp screw.
- Clamp screw
Remove the oil injection pump assembly.
IMPORTANT: The oil injection pump and manifold is an assembly and cannot be serviced a s individual components.
Installation
Route oil distribution hoses from the oil distribution manifold to the crankcase oil delivery fittings as they were before removal. Refer to OIL SUPPLY DIAGRAMS on p. 158.
Connect oil hoses to crankcase fittings and fasten with tie straps.
- Crankcase fitting
Connect oil hose to rear oil manifold.
- Oil to rear manifold
Install oil pump on bracket with clamp and retaining screw. Tighten to a torque of 24 to 36 in. lbs. (3 to 4 N•m).
- Clamp
Reconnect the electrical connector.
IMPORTANT: Use oil primer bulb to purge air from oil supply hose before reconnecting hose to oil pump.
Reconnect oil supply hose to the inlet fitting of oil pump. Fasten with Oetiker clamp.
- Oil supply hose
- Oetiker clamp
Make sure oiling system is primed. Check oil flow through oil distribution hoses. Check oil system operation and routing o f oil hoses. Refer to OIL SUPPLY PRIMING on p. 170.
Run the outboard and check for leaks.
Repair any oil leaks an d any kinked or misrouted hoses.
Rear Oil Pump
Removal
Disconnect the battery cables at the battery.
Remove engine cover.
Remove the oil supply hose from the fitting (inlet) of the oil pump.
Disconnect the electrical connector.
IMPORTANT: Note oil distribution hose routings before proceeding with disassembly.
Remove oil distribution hoses from the crankcase fittings.
Remove two mounting bracket screws.
- Fitting (inlet)
- Mounting bracket screws
Remove the oil injection pump assembly.
IMPORTANT: The rear oil pump and manifold is an assembly and cannot be serviced as individual components.
Remove two screws to remove oil pump assembly from mounting bracket.
- Screws
Installation
Clean threads o f screws an d apply Nut Lock to threads. Install oil pump assembly into mounting bracket with two screws. Tighten screws to a torque of 24 to 36 in. lbs. (2.7 to 4 N•m).
Install the oil injection pump and bracket with two mounting bracket screws. Tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N•m).
- Fitting (inlet)
- Mounting bracket screws
Route oil distribution hose s from the oil distribution manifold to the crankcase oil delivery fittings as they were before removal. Refer to OIL SUPPLY DIAGRAMS on p. 158.
Connect oil hoses to cylinder sleeve oil fittings on the crankcase and fasten with tie straps.
- Cylinder sleeve oil fittings – port
- Cylinder sleeve oil fittings – stbd
Connect the electrical connector.
Reconnect the oil supply hose to the inlet fitting of the oil pump. Fasten with Oetiker clamp. Orient clamp as shown.
- Oil supply hose
- Oetiker clamp
Connect the battery cables at the battery.
