Service Manual 5009011_200–300 HP 90°V Models AA Midsection [Stern Bracket]

Install four mount plate screws and washers and tighten to a torque of 22 to 24 ft. lbs. (30 to 33 N·m).

Tighten the small adapter to exhaust housing screws and nuts to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

Stern Bracket Disassembly

Before servicing the stern bracket:
• Remove gear case. Refer to Gear case GEAR CASE REMOVAL AND INSTALLATION on p. 290.
• Remove power head. Refer to POWER HEAD REMOVAL on p. 221.
• Remove exhaust housing. Refer to Exhaust Housing Removal on p. 268.
• The power trim/tilt unit must be removed. Refer to TRIM AND TILT SERVICE on p. 349.
Remove and discard steering shaft lock nut.

Remove the lower mount bracket and keeper.

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

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

Remove the tilt tube. Refer to TILT TUBE on p. 266.
Remove the two tilt tube washers.

Remove the anode.

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

1. Tilt tube bushing

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

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

1. Tilt limit switch
2. Retainer

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

1. Trail lock spring
2. Trail arm retainer

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

1. Trail lock bushing

Remove the two trim rod rollers from the swivel bracket.

1. Trim rod roller

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

1. Tilt support bushing

Stern Bracket Assembly

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 sup port with bushing in the swivel bracket. Tighten bushing to a torque of 28 to 30 ft. lbs. (38 to 41 N·m).

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).

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).

1. Trail lock bushing

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

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).

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.

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 Triple Guard grease.

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

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. 266.Install the steering shaft and thrust washer.

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

Install the lower mount bracket and a new locking nut with its un staked 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).

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 fit tings. Install the exhaust housing. Refer to Exhaust Housing Installation on p. 269.

The exhaust relief muffler is located at the rear of the adaptor housing and concealed by the lower motor covers. The exhaust relief grommet connects directly to the muffler assembly.

1. Exhaust relief grommet

The muffler assembly connects to the exhaust relief hoses from the adaptor housing assembly.

1. Exhaust relief grommet
2. Exhaust relief hoses