Powerhead Removal
!
WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
!
WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start.
Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
IMPORTANT: The following procedure contains steps for an electric start, power tilt model. Some steps will not apply to other
models.
1.
Disconnect the battery, if applicable.
2.
Completely remove the driveshaft housing covers. Refer to Section 5A ‑ Driveshaft Housing Covers.
3.
Remove the front cowl. Refer to Section 5A ‑ Front Cowl.
4. Remove the remote control harness and cables when applicable.
5. Remove the following components from the top of the powerhead:
a.
Air box and recoil assembly. Refer to Section 3C ‑ Air Box Removal and Section 8A ‑ Recoil Starter Removal.
NOTE: Also remove the neutral interlock cable.
b.
Camshaft gear cover. Refer to Section 3C ‑ Camshaft Gear Cover/Vent Tank.
c.
Flywheel. Refer to Section 2A ‑ Flywheel.
d.
Stator. Refer to Section 2A ‑ Stator.
6. For electric start models:
a. Disconnect the battery cables from the starter motor and starter solenoid.
a - Negative battery connection at
starter motor
b - Positive battery connection at
starter solenoid
b.
Remove the starter motor. Refer to Section 2B ‑ Starter Motor Removal.
7.
Remove the stator/starter bracket:
a. Disconnect the crankshaft position sensor (CPS) from the engine harness.
b. Remove the screw and washer that holds the 14‑pin connector to the stator/starter bracket.
c. Remove the two screws and washers that connect the ground terminals to the stator/starter bracket.
Cylinder Block/Crankcase
Page 4A-8 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017
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