MANUAL TILT ASSIST

MID-SECTION
Section 5D - Manual Tilt Assist
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Memory Piston Removal . . . . . . . . . . . . . . . 5C-24
Manual Tilt Components . . . . . . . . . . . . . . . . . . . 5C-2 Valve Block Disassembly . . . . . . . . . . . . . . . . . . 5C-26
Manual Trim Flow Diagrams . . . . . . . . . . . . . . . . 5C-4 Reassembly - O-Ring and Seal Placement . . 5C-27
Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Actual O-Ring Sizes . . . . . . . . . . . . . . . . . . . . . . 5C-28
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 O-Ring Description and Sizes . . . . . . . . . . . . . . 5C-29
Slow Tilt Down Under High Thrust . . . . . . . . 5C-8 Manual Tilt System Cleaning and Inspection . 5C-29
Under Water Strike (Valves Open) . . . . . . . 5C-10 Manual Tilt System Reassembly . . . . . . . . . . . 5C-29
Shock Function (Valves Closed) . . . . . . . . . 5C-12 Valve Block Installation . . . . . . . . . . . . . . . . . 5C-32
Shock Function Return . . . . . . . . . . . . . . . . . 5C-14 Shock Rod Reassembly . . . . . . . . . . . . . . . . 5C-33
Hydraulic System Troubleshooting . . . . . . . . . . 5C-16 Shock Rod Installation and Fluid
Manual Tilt System Removal . . . . . . . . . . . . . . . 5C-18 Filling Procedure . . . . . . . . . . . . . . . . . . . . . . 5C-35
Manual Tilt System Disassembly . . . . . . . . . . . 5C-19 Filling Procedure Option Two Instructions
Accumulator Removal . . . . . . . . . . . . . . . . . . 5C-20
Shock Rod Removal . . . . . . . . . . . . . . . . . . . 5C-21
for Making Retaining Tool . . . . . . . . . . . . . . . . .
Bleeding Manual Tilt System . . . . . . . . . . . . . . .
5C-37
5C-38
5
Shock Rod Disassembly . . . . . . . . . . . . . . . . . . 5C-21 Manual Tilt System Installation . . . . . . . . . . . . . 5C-40 D
Valve Block Removal . . . . . . . . . . . . . . . . . . 5C-24 Manual Release Valve Adjustment . . . . . . . 5C-42

Special Tools
1. Spanner Wrench P/N 91-74951

2. Heat Lamp P/N 91-63209

3. Lock-Ring Pliers P/N SRP-4 (Snap-On)

Address
Snap-On Tools Company
2801 - 80th Street
Kenosha, Wisconsin 53143
Phone 414.656.5200

90-828631R3 MARCH 1999 Page 5D-1

MANUAL TILT ASSIST

Manual Tilt Components

13
A

1 12

F 95

2
4

7
B
E
11
8
6
7

5 D
6 11 8 11
13
8 9
11 8
11

12
9
95 10
8
C
7 Loctite 271 (92-809819)
95 2-4-C With Teflon (92-850736A1)
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not avail-
able, use automotive (ATF) automatic transmission fluid.
NOTE: It is recommended that all O-rings be replaced when servicing tilt system.

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 MANUAL TILT ASSIST

Manual Tilt Components

TORQUE
REF.
NO. QTY. DESCRIPTION lb-in. lb-ft Nm
1 SHOCK ROD ASSEMBLY 45 61
1
1 SHOCK ROD ASSEMBLY (BEACHING)
2 1 MEMORY PISTON ASSEMBLY
3 1 O RING REBUILD KIT-Cylinder
4 2 O RING
5 1 CYLINDER ASSEMBLY
6 1 SCREW AND SEAL KIT
7 1 ACCUMULATOR ASSEMBLY 35 47
8 1 VALVE BODY ASSEMBLY
9 1 CAM KIT
10 1 VELOCITY VALVE KIT 75 6.2 8.5
11 1 CHECK SYSTEM REPAIR KIT 75 6.2 8.5
– 1 O RING KIT
12 2 PIN
13 2 GROOVE PIN

A – Torque cylinder cap to 45 lb-ft (61 Nm)

B – Torque Accumulator to 35 lb-ft (47 Nm)
C – Torque Velocity Valve to 75 lb-in. (8.5 Nm)
D – Torque Transfer Valve Plug to 75 lb-in. (8.5 Nm)
E – Torque Screw to 100 lb-in. (11 Nm)
F – Torque Shock Piston to 90 lb-ft (122 Nm)

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MANUAL TILT ASSIST

Manual Trim Flow Diagrams

Up Circuit

b
a

p
e
o

n
k
m

j i h g
l

Page 5D-4 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Up Circuit
With the engine in the down position, the accumulator piston (d) will be at the top of the accu-
mulator (c) with the gas at maximum pressure. To raise the engine, the camshaft lever (f)
is rotated all the way down. The internal shaft connected to the camshaft lever will move the
push rods, opening the accumulator check valve (e), both fast transfer valves (h & j) and
the down circuit slow transfer valve (i). As the operator lifts the engine, oil, under pressure
inside the accumulator, will flow around both the slow transfer valve (i) and the down circuit
fast transfer valve (h). Oil flows into the bottom of the tilt cylinder forcing the memory piston
(m) into the shock piston (n) and then forcing the shock rod up and out. Oil above the shock
piston exits the cylinder (l) through an interconnecting passage along side of the cylinder
and returns into the manifold (g). Inside the manifold the oil flows past the groove in the
surge valve (k), through the up circuit fast transfer valve (j) and mixes with the oil flowing
from the accumulator into the up cavity. With the engine in the correct position, the camshaft
lever (f) is rotated up and the push rods allow the check valves (e, h, i, & j) to close. The
closed check valves prevent the oil from traveling between cavities and locks the engine into
position.
a - Shock Rod
b - End Cap
c - Accumulator
d - Accumulator Piston
e - Accumulator Check Valve
f - Camshaft Lever
g - Manifold
h - Down Circuit Fast Transfer Valve
i - Down Circuit Slow Transfer Valve
j - Up Circuit Fast Transfer Valve
k - Surge Valve
l - Cylinder
m - Memory Piston
n - Shock Piston
o - Shock Return Valve
p - Impact Relief Valve

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MANUAL TILT ASSIST

Down Circuit

b
a

p
e

f
n

m k

j i h g
l

Page 5D-6 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Down Circuit
With the engine tilted up, the piston inside the accumulator piston (d) will be at the bottom
of the accumulator (c) and the gas pressure is low. To lower the engine, the camshaft lever
(f) is rotated down, the internal cam will cause the push rods to open the accumulator check
valve (e), both fast transfer valves (h & j) and the down circuit slow transfer valve (i). The
operator will have to press down on the engine cowl to overcome the pressure inside cylin-
der. Fluid will flow out of the bottom of the cylinder, past both the down circuit fast transfer
valve (h) and down circuit slow transfer valve (i). Fluid will flow past the up circuit fast transfer
valve (j), surge valve (k) and through the interconnecting passage into the top of the cylinder
(l). Due to the shock rod (a), the tilt cylinder cavities differ in volume, the extra fluid from the
up cavity [forced into the accumulator (c)] will cause the internal accumulator piston (d) to
compress the gas. With the engine in the correct position, the camshaft lever is rotated up
and the push rods allow the check valves (e, h, i, & j) to close.
a - Shock Rod
b - End Cap
c - Accumulator
d - Accumulator Piston
e - Accumulator Check Valve
f - Camshaft Lever
g - Manifold
h - Down Circuit Fast Transfer Valve
i - Down Circuit Slow Transfer Valve
j - Up Circuit Fast Transfer Valve
k - Surge Valve
l - Cylinder
m - Memory Piston
n - Shock Piston
o - Shock Return Valve
p - Impact Relief Valve

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MANUAL TILT ASSIST

Slow Tilt Down Under High Thrust

b
a

p f
e

n
k
m

j i h g
l

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 MANUAL TILT ASSIST

Slow Tilt Down Under High Thrust

To tilt the engine down under high thrust conditions [where the propeller thrust forces the
shock rod down, creating higher pressure below the memory piston (m)], the camshaft lever
(f) is rotated slightly downward. The internal shaft connected to the lever will open the down
circuit slow transfer valve (i) allowing oil under pressure into the cavity around the shaft. The
higher oil pressure will open the up circuit fast transfer valve (j) allowing oil from the bottom
of the cylinder to flow above the shock piston (n) while lowering the engine. Additional oil
will flow into the accumulator (c) as the internal pressure forces the accumulator check valve
(e) to open. Oil flowing into the accumulator moves the accumulator piston (d) and compres-
ses the gas.
a - Shock Rod
b - End Cap
c - Accumulator
d - Accumulator Piston
e - Accumulator Check Valve
f - Camshaft Lever
g - Manifold
h - Down Circuit Fast Transfer Valve
i - Down Circuit Slow Transfer Valve
j - Up Circuit Fast Transfer Valve
k - Surge Valve
l - Cylinder
m - Memory Piston
n - Shock Piston
o - Shock Return Valve
p - Impact Relief Valve

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MANUAL TILT ASSIST

Under Water Strike (Valves Open)

b
a

f
n
k
m

j i h g
l

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 MANUAL TILT ASSIST

Under Water Strike (Valves Open)

Should the drive unit strike a submerged object while in forward motion, the shock rod (a)
will extend from the tilt cylinder (l). Fluid will attempt to exit the cylinder through the intercon-
necting passage. The rapid fluid flow will increase the pressure below the surge valve (k),
causing the valve to move, closing the oil return passage back into the accumulator (c). Oil
inside the up cavity is locked in a static position by the closed surge valve. As the shock rod
extends outward, the pressure inside the up cavity will reach sufficient pressure to open the
shock valve (p) which opens at 880-1110 psi. Oil will flow into the cavity created as the shock
rod & shock piston (a & n) moves away from the memory piston (m).
a - Shock Rod
b - End Cap
c - Accumulator
d - Accumulator Piston
e - Accumulator Check Valve
f - Camshaft Lever
g - Manifold
h - Down Circuit Fast Transfer Valve
i - Down Circuit Slow Transfer Valve
j - Up Circuit Fast Transfer Valve
k - Surge Valve
l - Cylinder
m - Memory Piston
n - Shock Piston
o - Shock Return Valve
p - Impact Relief Valve

90-828631R3 MARCH 1999 Page 5D-11

MANUAL TILT ASSIST

Shock Function (Valves Closed)

b
a

c
Accumulator
Gas Pressure
400 psi
d

o
e

n
f

k
m

j i h g
l

Page 5D-12 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Shock Function (Valves Closed)

Should the drive unit strike a submerged object while in forward motion, the shock rod (a)
will extend from the cylinder (l). Oil inside the up cavity is locked in a static position by the
closed up circuit fast transfer valve (j), the closed down circuit slow transfer valve (i) and
closed down circuit fast transfer valve (h). Fluid will attempt to exit the cylinder through the
interconnecting passage back into the accumulator (c). The closed up circuit fast transfer
valve (j) will prevent the fluid return. As the shock rod extends outward, the pressure inside
the up cavity will reach sufficient pressure to open the shock valve (p) which opens at
880-1110 psi. Oil will flow into the cavity created as the shock rod & shock piston (n) moves
away from the memory piston (m).
a - Shock Rod
b - End Cap
c - Accumulator
d - Accumulator Piston
e - Accumulator Check Valve
f - Camshaft Lever
g - Manifold
h - Down Circuit Fast Transfer Valve
i - Down Circuit Slow Transfer Valve
j - Up Circuit Fast Transfer Valve
k - Surge Valve
l - Cylinder
m - Memory Piston
n - Shock Piston
o - Shock Return Valve
p - Impact Relief Valve

90-828631R3 MARCH 1999 Page 5D-13

MANUAL TILT ASSIST

Shock Function Return

b
a

o
e

n
f

k
m

j i h g
l

Page 5D-14 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Shock Function Return

After the drive clears the object, the shock return valve (o) will allow the oil to flow from be-
tween the shock piston (n) and memory piston (m) onto the down cavity as the drive returns
to its original running position.
a - Shock Rod
b - End Cap
c - Accumulator
d - Accumulator Piston
e - Accumulator Check Valve
f - Camshaft Lever
g - Manifold
h - Down Circuit Fast Transfer Valve
i - Down Circuit Slow Transfer Valve
j - Up Circuit Fast Transfer Valve
k - Surge Valve
l - Cylinder
m - Memory Piston
n - Shock Piston
o - Shock Return Valve
p - Impact Relief Valve

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MANUAL TILT ASSIST

Hydraulic System Troubleshooting

Refer to disassembly/reassembly instructions (following) if disassembly is required when
servicing.
IMPORTANT: After debris or failed components have been found (during trouble-
shooting procedure), it is recommended that unit be disassembled completely and
all O-rings be replaced. Check ball components and castings must be cleaned using
engine cleaner and compressed air or replaced prior to reassembly.
Support outboard with tilt lock lever when servicing manual tilt system.
1. Check manual release cam adjustment. Cam must open and close freely. Adjust cam
link rod as necessary.

51143

a - Link Rod
b - Manual Release Lever
c - Accumulator

Page 5D-16 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

2. Check for external leaks in the manual tilt system. Replace defective part(s) if leak is
found.
IMPORTANT: If cut or damaged O-rings are found, inspect machined surfaces for
scoring, burrs or debris.
3. Check for discharged accumulator. 35 to 50 lb-ft (47-68 Nm) of pulling force must be at-
tained when tilting outboard from full “down” to full “up” position. If more than 50 lb-ft (68
Nm) of force is required, replace accumulator.
a

50431

a - Weight Scale
b - Valve Lever (open position)

90-828631R3 MARCH 1999 Page 5D-17

MANUAL TILT ASSIST

Manual Tilt System Removal

CAUTION
Remove cowling and remove all spark plug leads from spark plugs to prevent acci-
dental starting while servicing outboard.

WARNING
Service or installation of the tilt system may result in loss of pressure in the shock
cylinder. If the outboard is not in the full down position, such loss of pressure will
cause the engine to fall to the full down position with a potential for damaging en-
gine or causing personal injury. To avoid such injury support outboard in the up po-
sition using tilt lock lever.

WARNING
Manual tilt system is pressurized. Accumulator must be removed when shock rod
is in the full up position, prior to servicing, otherwise oil spray-back may occur.

1. Support outboard in the up position using tilt lock lever.

2. Remove link rod.
3. Position piece of wood under transom bracket instead of tilt lock for access of removing
pin. Use suitable punch to remove (DRIVE DOWN) upper dowel pin. Retain dowel pin.

b
d

51144

51143

a - Link Rod
b - Accumulator
c - Dowel Pin
d - Wood

Page 5D-18 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

4. Position tilt lock and remove piece of wood. Use suitable punch to drive out upper pivot
pin.
5. Use punch to remove (Drive Down) lower dowel pin. Retain dowel pin.

b c
51144 51144

a - Pivot Pin
b - Tilt Lock
c - Dowel Pin

6. Use suitable punch to drive out lower pivot pin.

7. Tilt shock absorber assembly (TOP FIRST) out from clamp bracket and remove assem-
bly.

b 1

a 51144

2
51144

a - Pivot Pin
b - Manual Tilt System

Manual Tilt System Disassembly

NOTE: Accumulator contains a high pressure nitrogen charge and is NOT SERVICEABLE.
Replace if necessary.

WARNING
This tilt system is pressurized. Remove accumulator only when shock rod is in full
up position.

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MANUAL TILT ASSIST

Accumulator Removal
1. Place manual tilt system in soft jawed vise.
2. Position shock rod to full up position.
3. Open cam shaft valve (Down Position).
4. Loosen velocity valve enough to drip, wait until dripping stops.
5. When fluid stops dripping, loosen and remove accumulator.
6. If plunger can be compressed into accumulator by hand, accumulator is defective. Re-
place accumulator.

a
b

c
51143
51143

a - Accumulator
b - Cam Lever
c - Velocity Valve
d - Plunger

7. Once accumulator is removed, remove O-ring, conical spring, steel ball and plunger.
a

b
c
d

51145

a - Conical Spring
b - Steel Ball
c - Plunger
d - O-ring

Page 5D-20 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Shock Rod Removal

1. Unscrew cylinder end cap assembly using spanner wrench [1/4 in. x 5/16 in. long pegs].
2. Remove shock rod assembly from cylinder.

91-74951

51145

Shock Rod Disassembly

NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper
ring. If shock rod requires any other repair, replace shock rod assembly.

a
a - End Cap
b - O-ring (2)
c - Wiper Ring

1. Place shock rod assembly on clean work surface.

2. Remove three (3) screws and remove plate from shock rod piston.
a

b
c
51143

a - Screw (3)
b - Plate
c - Shock Rod Piston

90-828631R3 MARCH 1999 Page 5D-21

MANUAL TILT ASSIST

3. Remove check ball components from shock rod piston.

4. Remove O-ring.

c
b
a

d 51147

a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring

CAUTION
When removing shock piston, spanner wrench must have 1/4 in. x 5/16 in. long pegs
to avoid damage to shock piston.
5. Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp
(P/N 91-63209).
6. Loosen shock rod piston using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs].
7. Allow shock rod piston to cool. Remove from shock rod.
a
b

91-74951
91-63209
a - Spanner Wrench
b - Shock Rod Piston

Page 5D-22 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

8. Inspect check valve for debris; clean debris from check valve if found. If debris cannot
be cleaned from check valve, replace shock piston as an assembly.
9. Clean shock and components with compressed air.
10. Remove inner O-ring.

b
a 51199

a - Shock Piston
b - O-ring

11. Remove cylinder end cap assembly from shock rod.

12. Inspect shock. If wiper (located in cap) has failed to keep rod clean, replace wiper.
13. Place end cap on clean work surface.
14. Remove rod wiper, inner O-ring, and outer O-ring.

c
b

51147 51145
a - Rod Wiper
b - Inner O-ring
c - Outer O-ring

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MANUAL TILT ASSIST

Valve Block Removal

1. Remove two screws from the shock rod cylinder to separate the valve block.
2. Remove O-rings and dowel pins.

e
b
aa

51148
c
51146

a - Screw
b - Valve Block
c - Shock Rod Cylinder
d - O-ring (2)
e - Dowel Pin (2)

Memory Piston Removal

1. Remove memory piston from cylinder using one of two methods:
a. Using lock ring pliers P/N SRP-4 (Snap-On) or suitable tool.

SRP-4 (Snap-On)

Page 5D-24 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

b. Blowing compressed air into center O-ring hole.

WARNING
Memory piston cup may be expelled at a high velocity when air pressure is applied.
Failure to place cylinder as shown below could result in personal injury.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston. Fluid will blow out also.
2. Remove O-ring from memory piston.

a
d

51144
55466

a - Adaptor/Air Hose
b - Memory Piston Exit
c - Shop Rag
d - O-ring
e - Memory Piston

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MANUAL TILT ASSIST

Valve Block Disassembly

1. Remove check retainer plug and components.
2. Remove hydraulic oil transfer valve plugs and components.
3. Remove surge valve assembly.

c
d
e
f
a

b 51142

a - Transfer Valve Plug Assembly (2)

b - Check Retainer Plug or Screw Assembly
c - Spool
d - Spring
e - O-ring
f - Velocity Valve

4. Remove screw and remove cam assembly.

e
d

b c
a

a - Spacer Retainer Clip

b - Retainer Clip
c - Screw
d - Shaft Seal
e - Cam

Page 5D-26 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Reassembly - O-Ring and Seal Placement

1

14

7
9
6
11 12

10

13
NOTE: Lubricate all O-rings using Quicksilver Power Trim and Steering Fluid. If not avail-
able, use automotive (ATF) automatic transmission fluid.
NOTE: It is recommended that all O-rings be replaced when servicing tilt system.

90-828631R3 MARCH 1999 Page 5D-27

MANUAL TILT ASSIST

Actual O-Ring Sizes

1

2 9

14
4

5 10

13 Cutaway View of O-Ring

6 (2) 11

Width

7 12

O.D. I.D.

8 (2)

O-RINGS SHOWN ARE ACTUAL SIZE

Page 5D-28 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

O-Ring Description and Sizes

O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width
1 Wiper Ring
2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm)
3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm)
4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
5 Piston Bolt 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm)
6 (2) Manifold Split Line 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm)
7 Slow Valve 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
8 (2) Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm)
9 Accumulator 2.114 in. (53.69 mm) 2.254 in. (57.25 mm) 0.07 in. (1.78 mm)
10 Lip Seal
11 Cam Shaft 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
12 Back Up Ring
13 Surge Valve02664) 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
14 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)

Manual Tilt System Cleaning and Inspection

1. It is recommended that all O-rings exposed during disassembly be replaced.
2. Clean components, filter, and check valve seats using engine cleaner and compressed
air. Do not use cloth rags.
3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity.
4. Inspect shock rod. If scraper (located in cap) has failed to keep rod clean, replace
scraper.

Manual Tilt System Reassembly

IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in tilt
system could cause system to malfunction.
Apply Quicksilver Power Trim and Steering Fluid to all O-rings during reassembly. If not
available, use automotive (ATF) automatic transmission fluid.

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MANUAL TILT ASSIST

CAM SHAFT REASSEMBLY

IMPORTANT: Cam shaft O-ring must be lubricated using 2-4-C with Teflon.
1. Install lubricated O-ring and back up seal to cam.
2. Install shaft seal in valve block with lips facing out.
3. Install cam shaft assembly in valve block.
4. Secure cam shaft in place using insulator, retainer plate, and screw. Tighten screw
securely.

f g
e
d

c
b
a
95

95 2-4-C w/Teflon (92-850736A1)

a - Spacer Retainer Clip
b - Retainer Clip
c - Screw
d - Shaft Seal
e - O-ring
f - Back up Seal
g - Cam

VALVE BODY CHECK REASSEMBLY

1. Install lubricated O-ring, plunger, steel ball and conical spring to valve block.
a

b
c

51145

a - Conical Spring
b - Steel Ball
c - Plunger
d - O-ring

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 MANUAL TILT ASSIST

VELOCITY VALVE REASSEMBLY

1. Install spool, spring, lubricated O-ring and screw plug (surge valve assembly) into valve
block.
2. Torque velocity valve to specified torque.

a
b
c
d

a - Spool
b - Spring
c - O-ring
d - Velocity Valve
Velocity Valve Torque
75 lb-in. (8.5 Nm)

CHECK RETAINER REASSEMBLY

1. Install plunger, spring (large), ball, spring (small), and plug into valve block.

c
d
e 51142

a - Plunger
b - Spring (Large)
c - Ball
d - Spring (Small)
e - Plug

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MANUAL TILT ASSIST

VALVE PLUG REASSEMBLY

1. Install plunger, steel ball, spring, lubricated O-ring and screw plug. Torque screw plugs
to specified torque.

b
c
d
e
51142

a - Plunger (2)
b - Steel Ball (2)
c - Spring (2)
d - O-ring (2)
e - Screw Plug (2)
Screw Plug Torque
75 lb-in. (8.5 Nm)

Valve Block Installation

1. Install lubricated O-rings and dowel pins.
2. Install valve block to shock rod cylinder. Insert screws to shock rod cylinder and torque
to specified torque.

b c
1 d

a
51148
e 51146

a - O-ring (2)
b - Dowel Pin (2)
c - Valve Block
d - Screw (2)
e - Shock Rod Cylinder
Screw Torque
100 lb-in. (11.3 Nm)

Page 5D-32 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Shock Rod Reassembly

1. Install lubricated O-rings to end cap.
2. Install rod wiper.
3. Install lubricated O-rings to shock piston.

c e
b f

51145 d 51199

a - Rod Wiper
b - Inner O-ring
c - Outer O-ring
d - Shock Piston
e - O-ring
f - O-ring

4. Clamp shock rod in soft jawed vise.

5. Position cylinder end cap onto rod, as shown.

51146

90-828631R3 MARCH 1999 Page 5D-33

MANUAL TILT ASSIST

CAUTION
When installing shock rod piston, spanner wrench must have 1/4 in. x 5/16 in.
(6.4mm x 8mm) long pegs to avoid damage to shock rod piston.
6. Apply Loctite Grade “A” (271) to threads on shock rod.
7. Install shock rod piston.
8. Tighten shock rod piston securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x
8mm) long pegs]. If a torquing type spanner tool is used to tighten shock piston, then
torque to specified torque.
a b

91-74951
7

7 Loctite “271” (92-809819)

51146
a - Spanner Wrench
b - Shock Rod Piston
Shock Rod Piston Torque
90 lb-ft (122 Nm)

9. Install ball, seat, and spring (five sets) to shock rod piston.
10. Secure components with plate. Torque screws to 35 lb-in. (3.9 Nm).
11. Remove shock rod assembly from vise.

e
d
c
a

b 51147

a - Screw (3) Torque to 35 lb-in. (3.9 Nm)

b - Plate
c - Spring (5)
d - Seat (5)
e - Ball (5)

Page 5D-34 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Shock Rod Installation and Fluid Filling Procedure

NOTE: There are two ways for the filling procedure. The first is the easiest and less time
consuming.
Filling Procedure Option One
1. Place trim cylinder in soft jawed vice.
2. With manifold cam lever closed (Up Position), fill cylinder and manifold to top with Quick-
silver Power trim and steering fluid, or (ATF) automatic transmission fluid. Let bubbles
disperse.
3. Install lubricated O-ring to memory piston.
4. Using lock ring pliers (P/N 91-822778A3). Set memory piston in top of cylinder then open
cam lever (Down Position) and push memory piston down just below cylinder treads.
Close cam lever (Up Position).

51144

5. Fill top of cylinder again with fluid to top and install shock rod assembly on top memory
piston. Open cam lever (Down Position) and push shock rod assembly down to 1/8″ be-
low cylinder threads. Close cam lever (Up Position).
6. Fill top of shock rod assembly with fluid to top of cylinder. Open cam lever (Down Posi-
tion) and screw cylinder cap down.
7. Tighten end cap securely using spanner wrench [1/4 in. x 5/16 in. (6.4mm x 8mm) long
pegs]. If a torquing type spanner tool is used to tighten end cap, then torque the end cap
to specified torque. Close cam lever (Up Position).

51145

End Cap Torque

45 lb-ft (61 Nm)

90-828631R3 MARCH 1999 Page 5D-35

MANUAL TILT ASSIST

8. Open and close cam lever, watching for bubbles coming from accumulator check ball
hole. When bubbles stop, fill accumulator opening to top with fluid. Grease threads on
accumulator and opening with 2-4-C with Teflon. Start accumulator in threads and open
cam lever (Down Position). Torque accumulator to specified torque.

a b

51143

a - Accumulator
b - Cam Lever (Down Position)
Accumulator Torque
35 lb-ft (47 Nm)

NOTE: If filling procedure is done correctly, it should be hard to turn cylinder rod assembly
by hand.

Page 5D-36 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

Filling Procedure Option Two Instructions for Making

Retaining Tool

3/16 in x 3 in.
(5 x 7.5 cm)
Steel Plate

3/8 in. x 13 in.

(10 mm x 33 cm)
Threaded Rod

4in. x 1/4 in. min.

(10cm x 6.4 mm) minimum
Channel Iron

10 in.
(25 cm)
1 in. 8 in.
(25mm) (20 cm)

3 in.
(76mm)

2 holes, 7/16 in. dia. (11 mm)

5 in. 1 1/4 in. dia.

(125mm) (30m)

20 in.
(508mm)

2 in.
(50mm)

4 in.
(100 mm)

6 in. 8 in. 3/8 in. dia. 2 holes

(152mm) (203mm)

90-828631R3 MARCH 1999 Page 5D-37

MANUAL TILT ASSIST

Bleeding Manual Tilt System

IMPORTANT: While bleeding tilt system, time must be allowed between each stroke
to allow air bubbles to dissipate.
1. With shock rod in the full up position and manifold cam lever open (facing down), secure
tilt system to retaining tool and container. (A No. 10 can or 3 lb coffee can could be used.)
2. Fill container to near full level using Quicksilver Power Trim and Steering Fluid. If not
available, use automotive (ATF) automatic transmission fluid.
IMPORTANT: Fluid level must remain above accumulator opening during bleeding
process.

e b
c
a

d 50447

a - Retaining Tool
b - Tilt System
c - Container
d - Cam Lever
e - Accumulator Opening

3. Bleed unit by pushing rod down slowly (18-20 seconds per stroke) until stopped at base.
Wait until all air bubbles exit accumulator base.

50432

Page 5D-38 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

4. During up stroke, pull up on rod slowly 3 in. (76 mm) from base.
5. Wait until all air bubbles to exit accumulator base.

50433

6. Slowly cycle unit 5-8 times (round trip per cycle) using short strokes 3 in. (76 mm) from
base allowing bubbles to disappear during each stroke.
7. Allow unit to stand five minutes, then proceed to cycle unit 2-3 more times using short
strokes. No air bubbles should appear from accumulator port at this time.
8. With oil level well above accumulator port, slowly pull rod to full up position.
9. Install accumulator making sure air bubbles do not enter system.
10. Tighten accumulator snugly at this time.

50432
50432

90-828631R3 MARCH 1999 Page 5D-39

MANUAL TILT ASSIST

11. With cam lever remaining open (facing down), remove tilt assembly from oil and secure
in soft jawed vise. Torque accumulator to specified torque.

50433

Accumulator Torque
35 lb-ft (47 Nm)

Manual Tilt System Installation

1. Apply 2-4-C Marine Lubricant to lower pivot pin hole and pivot pin surface.
2. Start lower pivot pin into pivot pin hole and position lower dowel pin (retained) in its hole.
3. Reinstall manual tilt system, bottom first. Reconnect release valve link rod.

a
95
51148 1

51144
95 2-4-C w/Teflon (92-850736A1)
a - Lower Pivot Pin
b - Lower Dowel Pin
c - Manual Tilt System

Page 5D-40 90-828631R3 MARCH 1999

 MANUAL TILT ASSIST

4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assem-
bly until pivot pin is flush with outside surface.
5. Using a punch, drive lower dowel pin in until seated.

a b

51147 51148

a - Lower Pivot Pin

b - Lower Dowel Pin

6. Apply 2-4-C Marine Lubricant to surface of upper pivot pin, pivot pin hole and shock rod
hole.
7. Using a mallet, drive upper pivot pin into swivel bracket and through shock rod until pivot
pin is flush with swivel bracket.

a
c
e

f
b
d

95

51148
95 2-4-C w/Teflon (92-850736A1) 51148

a - Pivot Pin
b - Pivot Pin Bore
c - Shock Rod Bore
d - Pivot Pin
e - Swivel Bracket
f - Shock Rod

90-828631R3 MARCH 1999 Page 5D-41

MANUAL TILT ASSIST

8. Drive upper dowel pin (a) into its hole until seated.

51147

a - Dowel Pin

9. Check manual release cam adjustment. Cam must open and close freely. Adjust link rod
as necessary.

Manual Release Valve Adjustment

1. With outboard in full up position, place tilt lock lever forward.
2. Lift cam lever (with link rod) to full up position.

b
51143

a - Tilt Lock Lever

b - Cam Lever
c - Link Rod

3. Link rod end must snap onto ball of tilt lock lever without moving tilt lock lever or cam
lever.

Page 5D-42 90-828631R3 MARCH 1999