90-824052R3 JUNE 2002 POWERHEAD - 4A-13
General Information
NOTE: Throughout this section, STANDARD
MODELS will refer to 135/150/175/200 carbureted
and EFI outboards. HIGH PERFORMANCE
MODELS will refer to PRO MAX and SUPER
MAGNUM 150/200/225 outboards.
Powerhead “Disassembly” and “Reassembly”
instructions are printed in a sequence that should be
followed to assure best results when removing or
replacing powerhead components. If complete
disassembly is not necessary, start reassembly at
point disassembly was stopped. (Refer to “Table of
Contents,” preceding.) Usually, complete
disassembly of powerhead will be required.
If major powerhead repairs are to be performed,
remove powerhead from drive shaft housing.
Removal of powerhead is not required for 1)
inspection of cylinder walls and pistons (refer to
“Powerhead Removal and Disassembly,” following,
and remove cylinder heads and exhaust cover), 2)
minor repairs on components, such as ignition
system, carburetors, reed blocks and cylinder heads
and checking operation of thermostats.
Powerhead Removal from
Driveshaft Housing
1. Disconnect battery cables from battery terminals.
2. Disconnect fuel tank hose from outboard.
3. Remove top cowling.
4. Remove two screws which secure remote control
harness retainer and remove retainer.
1994-1995 Standard Models –
a
b
51854
a - Screws
b - Retainer
1996 Standard Models –
52188
a
b
a - Screws
b - Retainer
5. Disconnect remote oil tank hose connector.
6. Disconnect remote control harness from power-
head harness connector and wires as shown.
51851
c
e
d
a
b
f
a - Control Harness
b - Powerhead Harness
c - Trim 12 Volt Power Supply (RED)
d - Trim Up Lead (BLUE/WHITE)
e - Trim Down Lead (GREEN/WHITE)
f - Overheat Lead (TAN)
7. Remove sta-strap which secures “TELL-TALE”
hose to fitting on lower cowl and remove hose
from fitting.
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