Engine maintenance

Before every dive

1. The outboard engines should be greased at all 3 zerk grease fittings. The grease should be a special marine anti-corrosion grease such as Quicksilver "2-4-C"^[1] or "Special lubricant 101." An ample pressure gun is necessary. Quicksilver Pistolgrip 91-37299A1^[1] ($18.).

After every dive

1. Promptly grease engine pivot mounts to expel salt water after use in salt water at the 3 zerk grease fittings. More information is available above.

2. Remove engine cover, tilt engine head forward and lightly spray/ wash engine external parts to remove salt spray accumulation that enters this area as air is being drawn into carburetor, being careful not to get water into carburetor intake. When engine has dried, lightly spray Quicksilver "Corrosion guard"^[1] onto metal parts. Replace engine cover. If Corrosion Guard is not available, silicon spray or WD-40 may be substituted.

3. After use in salt water, promptly flush engines by running them either with 'muffs attached to a hose or in a water-filled barrel.

4. While flushing engine disconnect fuel line and allow carburetor to run until dry. This helps to prevent gums and deposits from building up in carburetor (and eventual failure). Mercury Quicksilver's "Marine fuel system treatment and stabilizer"^[1] can be added to the fuel to help clean the carburetor and will extend the life of the fuel when stored.

5. Inspect lower unit after each use to determine if any water has gotten past seals. If water is present it will run out drain hole first before lubricant. If seal has leaked it must be replaced. Otherwise salt water in lower unit can ruin it. Repairs can exceed $1000.

Yearly engine maintenance

1. Lower unit lube change - With engines that get the most use, drain old lubricant and replace it. This task is easier when done by two people.

2. Once a year remove propeller, remove old grease and accumulated salt buildup and regrease spline with Aqualube ^[2]. Otherwise propeller may corrode (weld) onto output shaft.

Routine engine care and maintenance

1. Water in gas - Gasoline in drums very commonly has water contamination. Periodically unscrew fuel filter and empty. Take care that O-ring seal is not lost.

2. Clean and lube engine mount screw threads.

3. Engines should always be stored in a vertical position. This reduces uneven pressure on engine seals and allows residual water to drain from engine.

Miscellaneous maintenance

1. Engine must be stored in upright position. These engines and seals were designed for life in a vertical position. Many (expensive) failures can happen if stored horizontally. Water will drain for days after use.

2. Long term storage - Quicksilver "Storage seal"^[1] may be sprayed into carburetor intake while turning engine over with rope pull starter or added through spark plug holes. This is a rust inhibitor and lubricant that will discourage rust formation.

3. Any screw that is loosened on the power head and does not have a special friction type locknut must have "Locktite grade #242 applied. Otherwise our experience has been that it quickly will vibrate loose. Locktite #242, a medium strength thread locker will disassemble with ordinary hand tools.

4. Spark Plugs - The newer surface gap plugs are quite long lived. As the plug threads are in aluminum, very modest pressures should be used when tightening as aluminum strips quite easily.

5. Starter Ropes - Unfortunately, they seem to break when least expected. Replace about every two years. Always take spare ropes to Catalina with instruction sheet.