Professional Documents
Culture Documents
1 - Important Information
Important Information
1
2
A - Specifications
B - Maintenance Electrical
C - General Information
3
D - Outboard Installation
Fuel System
2 - Electrical
A - Ignition
4
B - Charging and Starting System
C - Timing, Synchronizing, and Adjusting Powerhead
3 - Fuel System
A - Fuel Pump
B - Fuel Injection System
C - Oil Injection
Mid-Section
5
6
D - Emissions
Lower Unit
4 - Powerhead
A - Powerhead
B - Cooling
5 - Mid-Section
A - Clamp/Swivel Brackets and Driveshaft Housing
Attachments/Control Linkage
7
B - Power Trim
6 - Lower Unit
A - Gear Housing
7 - Attachments/Control Linkage
A - Throttle Cable and Shift Bracket
Page iii
75/90/115/125 115 Pro XS OptiMax
75/90/115/125
115 Pro XS
OptiMax
Direct Fuel Injection
JULY 2010, Mercury Marine. All rights reserved. Printed in U.S.A. English Version 90-8M0047659
Notice to Users of This Manual
Throughout this publication, dangers, warnings, cautions, and notices (accompanied by the International HAZARD Symbol ! )
are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when
performing the service, plus common sense operation, are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
Precautions
It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and damaging
short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or
touched by the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance
of foreign material into the cylinders which could cause extensive internal damage when the engine is started.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed.
Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in
damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations
whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches
the original.
Page i
Replacement Parts
Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as a
result.
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal
and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components
that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all
components.
Page ii
Page iv
Specifications
Important Information
1
Section 1A - Specifications A
Table of Contents
75/90/115/115 Pro XS/125 OptiMax Master Specifications MidSection Specifications..........................................1A-7
.......................................................................................1A-2 Gear Housing Specifications......................................1A-7
General Specifications................................................1A-2 Power Trim Specifications..........................................1A-8
Maintenance Specifications........................................1A-3 Cooling Specifications................................................1A-8
Ignition Specifications.................................................1A-3 Propeller Information Charts..............................................1A-8
Charging and Starting Specifications..........................1A-4 75 OptiMax.................................................................1A-8
Air Compressor Specifications....................................1A-4 90 OptiMax...............................................................1A-10
Fuel System Specifications.........................................1A-5 115 OptiMax.............................................................1A-11
Installation Specifications...........................................1A-5 115 Pro XS...............................................................1A-13
Powerhead Specifications..........................................1A-6 125 OptiMax.............................................................1A-13
Maintenance Specifications
Maintenance Specifications
Recommended fuel type Unleaded 87 octane minimum
Recommended oil TCW3 Premium Plus or OptiMax 2Cycle Outboard Oil
Oil tank capacity
Engine reservoir capacity 4.72 liter (5 US qt)
External tank (optional) 11.4 liter (12 US qt)
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
1000 marine cranking amp (minimum)
Battery rating 800 cold cranking amp (minimum)
180 amp hours (minimum)
Gearcase capacity 665.0 ml (22.5 fl oz)
Water pressure
At 625 RPM (Idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Ignition Specifications
Ignition Specifications
Type Digital inductive
Firing order 123
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
Spark plug lead resistance at 20 C (68 F) 11701330 ohms
Maximum timing Not adjustable; controlled by PCM
Idle timing Not adjustable; controlled by PCM
Throttle position sensor
At idle 0.171.05 VDC
At wideopen throttle 3.764.64 VDC
Crankshaft position sensor
Air gap (S/N 1785000 and above) Not adjustable
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Resistance at 20 C (68 F) 300350 ohms
1. All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in the "OFF" position and an amperage draw
of not more than 350.0 mA with key in the "ON" position.
Installation Specifications
a
a - Minimum transom opening
a b
b - Engine centerline for dual engine 66.0 cm
(26 in.)
18552
1. Electric fuel pump pressure, if used in conjunction with engine mechanical fuel pump, must be limited to no more than 27.4 kPa (4 psi)
Powerhead Specifications
Powerhead Specifications
Number of cylinders 3
Displacement 1523.5 cc (92.9 cu. in.)
Stroke 76.2 mm (3.0 in.)
Standard cylinder bore diameter 92.1131 mm (3.6265 in.)
Cylinder bore maximum taper (service) 0.076 mm (0.003 in.)
Cylinder bore maximum out of round (service) 0.076 mm (0.003 in.)
Oversize cylinder bore diameter 0.038 mm (0.015 in.) 92.4941 mm (3.6415 in.)
Oversize cylinder bore diameter 0.076 mm (0.030 in.) 92.8751 mm (3.6565 in.)
Cylinder liner type Cast iron
Compression 620758 kPa (90110 psi) 1.
Crankshaft
Maximum runout 0.0508 mm (0.002 in.)
Main bearing journal 41.275041.2877 mm (1.62501.6255 in.)
Bottom main bearing journal 35.008835.0215 mm (1.37831.3788 in.)
Crankshaft pin journal 35.986735.9994 mm (1.41681.4173 in.)
Connecting rod wrist pin bore diameter 28.077128.0898 mm (1.10541.1059 in.)
Connecting rod crankshaft pin diameter 44.046144.0588 mm (1.73411.7346 in.)
Piston type Aluminum
Piston skirt standard diameter 91.9226 0.0127 mm (3.619 0.0005 in.)
Piston skirt oversize diameter 0.038 mm (0.015 in.) 92.3036 0.0127 mm (3.634 0.0005 in.)
Piston skirt oversize diameter 0.076 mm (0.030 in.) 92.6846 0.0127 mm (3.649 0.0005 in.)
Piston wrist pin bore diameter 23.317423.3260 mm (0.91800.9183 in.)
Piston ring end gap 0.250.46 mm (0.0100.018 in.)
Wrist pin diameter 23.309023.3166 mm (0.91760.9179 in.)
Reed stand open (maximum) 0.51 mm (0.020 in.)
Thermostat
Stamped opening temperature 143
Start to open temperature 6062.7 C (140145 F)
Full open temperature 73.8 C (165 F)
Piston height at full open temperature (minimum) 3.302 mm (0.130 in.)
Water pressure
at 625 RPM (idle) 20.641.3 kPa (36 psi)
at 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Poppet valve opening 48.362.1 kPa (79 psi)
1. When performing cylinder compression test, place lanyard switch in the "OFF" position to prevent operation of direct injectors or remove fuse
controlling fuel and direct injectors.
MidSection Specifications
MidSection Specifications
Recommended transom height:
Long shaft 51 cm (20 in.)
Extra long shaft 64 cm (25 in.)
Steering pivot range 60
Full tilt up angle 75
Trim range 20
Tilt pin adjustment positions 5
Acceptable leakdown in 24 hours 25.4 mm (1 in.)
Allowable transom thickness (minimum) 76.2 mm (3 in.)
1. After the poppet valve opens at approximately 1800 RPM, the engine temperature will drop to 2738 C (80100 F).
Cooling Specifications
Cooling Specifications
Thermostat
Stamped opening temperature 143
Start to open temperature 6062.7 C (140145 F)
Full open temperature 73.8 C (165 F)
Piston height at full open temperature (minimum) 3.302 mm (0.130 in.)
Water pressure
At 625 RPM (idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Poppet valve opening pressure 48.362.1 kPa (79 psi)
Horn activation and speed reduction is dependent on engine RPM and
Cylinder block over temperature horn activation
load
Air compressor over temperature horn activation 90 C (194 F)
90 OptiMax
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.33:1
Righthand rotation (RH): Standard
115 OptiMax
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH): Standard
115 Pro XS
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH): Standard
125 OptiMax
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH): Standard
Important Information
1
Section 1B - Maintenance B
Table of Contents
Maintenance Specifications...............................................1B-2 Fuel Filter Replacement..............................................1B-8
Selecting Accessories for Your Outboard..........................1B-3 Draining Water from the Fuel Filter Chamber.............1B-8
EPA Regulations................................................................1B-3 Steering Link Rod Fasteners.............................................1B-8
Manufacturer's Certificate Label........................................1B-3 Fuse Replacement.............................................................1B-9
Family Number...........................................................1B-3 Inline Oil Filter Replacement ..........................................1B-10
Inspection and Maintenance Schedule..............................1B-3 Corrosion Control Anode.................................................1B-10
Before Each Use.........................................................1B-3 Battery Inspection ...........................................................1B-11
After Each Use............................................................1B-4 Battery Information...........................................................1B-11
Every 100 Hours of Use or Once Yearly, Whichever Propeller Replacement....................................................1B-12
Occurs First.............................................................1B-4 Spark Plug Inspection and Replacement.........................1B-14
Every 300 Hours of Use or Three Years.....................1B-4 Compressor Air Intake Filter............................................1B-14
Before Periods of Storage..........................................1B-4 Removal....................................................................1B-14
Flushing the Cooling System.............................................1B-4 Installation.................................................................1B-15
Flushing the Cooling System Models with Accessory Flush Alternator Belt Inspection.................................................1B-15
Hose Attachment............................................................1B-5 Lubrication Points............................................................1B-16
Flushing the Cooling System (Design 1)....................1B-5 Checking Power Trim Fluid..............................................1B-17
Flushing the Cooling System (Design 2)....................1B-5 Gearcase Lubrication.......................................................1B-17
Top Cowl Removal and Installation...................................1B-6 Draining Gearcase....................................................1B-18
Removal......................................................................1B-6 Gearcase Lubricant Capacity...................................1B-18
Installation...................................................................1B-6 Gearcase Lubricant Recommendation.....................1B-18
Cleaning Care for Top and Bottom Cowls.........................1B-6 Checking Lubricant Level and Filling Gearcase.......1B-18
Cleaning and Waxing Procedure................................1B-6 Submerged Outboard......................................................1B-18
Flywheel Cover Removal and Installation..........................1B-6 Storage Preparation.........................................................1B-18
Removal......................................................................1B-6 Protecting Internal Engine Components...................1B-20
Installation...................................................................1B-7 Protecting External Outboard Components..............1B-20
Side Panel Removal and Installation.................................1B-7 Gearcase..................................................................1B-20
Removal......................................................................1B-7 Draining Hose Flush Attachment (if Equipped).........1B-20
Installation...................................................................1B-7 Positioning Outboard for Storage.............................1B-20
Fuel System.......................................................................1B-7 Battery Storage.........................................................1B-20
Fuel Line Inspection....................................................1B-8
Maintenance Specifications
Maintenance Specifications
Recommended fuel type Unleaded 87 octane minimum
Recommended oil TCW3 Premium Plus or OptiMax 2Cycle Outboard Oil
Oil tank capacity
Engine reservoir capacity 4.72 liter (5 US qt)
External tank (optional) 11.4 liter (12 US qt)
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
1000 marine cranking amp (minimum)
Battery rating 800 cold cranking amp (minimum)
180 amp hours (minimum)
Gearcase capacity 665.0 ml (22.5 fl oz)
Water pressure
At 625 RPM (Idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Special Tools
Fuel Filter Removal/Installation Tool 91896661
Aids in the removal and installation of the fuel filter cap assembly.
24896
Attaches to the water intakes; provides a fresh water connection when flushing the
cooling system or operating the engine
9192
EPA Regulations
All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as
conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is
contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product
must be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or
repair of the emission control devices and systems may be performed by any marine spark ignition (SI) engine repair establishment
or individual.
a EMISSION CONTROL
INFORMATION a- Idle speed
b
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES f b- Engine horsepower
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
g c- Piston displacement
c IDLE SPEED (in gear): FAMILY:
d- Date of manufacture
hp cc FEL: g/kWh
h e- Valve clearance
d TIMING (IN DEGREES):
SPARK PLUG:
GAP:
f- Family number
e COLD VALVE INTAKE:
i g- Maximum emissions output for the engine family
CLEARANCE (mm) EXHAUST:
21096
h- Timing specifications
i- Recommended spark plug and gap
Family Number
The following is an illustration of a typical family number and is not a representation of any one model.
1 3 M9X M 03.4 2 G 0 7
1- Model year (3 = 2003)
2- Manufacturer (Mercury Marine)
3- Regulations (M = Marine)
2 3 4 5 6 21088
4- Engine displacement (decimal point = liters
[03.4 = 3.4L]) (no decimal point = C.I. [0113 =
113 cubic inches])
5- Technology type (1 = OB old tech, 2 = OB new
tech, 3 = SportJet, 4 = OptiJet)
6- Engine class (C = two stroke, G = four stroke)
7- Product type (0 = all except, J = SportJet, E =
EFI SportJet and 4 strokes, 3 = OptiMax, H =
high performance)
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before
installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from
starting. Place a block of wood between the propeller blade and the antiventilation plate.
1. Remove propeller. Refer to Propeller Replacement. Install the flushing attachment so the rubber cups fit tightly over the cooling
water intake.
29467
2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow so water is leaking around the rubber
cups to ensure the engine receives an adequate supply of cooling water.
27259
3. Start the engine and run it at idle speed in neutral shift position.
IMPORTANT: Do not run engine above idle when flushing.
4. Adjust water flow (if necessary) so excess water continues leaking out from around the rubber cups to ensure the engine is
receiving an adequate supply of cooling water.
27260
5. Check for a steady stream of water flowing out of the water pump indicator hole. Continue flushing the outboard for 3 to 5
minutes, carefully monitoring water supply at all times.
6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the propeller.
Flushing the Cooling System Models with Accessory Flush Hose Attachment
Flushing the Cooling System (Design 1)
Flush the water passages of the outboard with fresh water after each use. This will prevent a buildup of deposits clogging the
internal water passages.
NOTE: The engine can be running at idle speed in neutral when flushing the cooling system. Do not flush the engine using a water
source exceeding 310 kPa (45 psi).
1. Thread a water hose into the hose adapter.
2. Remove the dust cover and push the hose adapter into the flush connector until it locks in place.
a b a- Flush connector
b- Button
c- Hose adapter
d- Dust cover
c d 25163
3. Turn on the water and flush the cooling system for three minutes minimum.
IMPORTANT: Do not run the engine above idle speed when flushing.
4. Push the button in to release the hose adapter.
5. Install the dust cover.
Freezing Temperature
Drain the water out of the engine flush hose when freezing temperatures are expected. Drain the water as follows:
1. Remove the water hose from the hose adapter.
2. Insert the adapter only into the flush connector.
3. Tilt the outboard up to drain the water out of the hose.
a b
a - Hose adapter
b - Sealing washer
c - Cover
c
22703
29468
Installation
1. Engage the front hook and push cowl back over the cowl seal.
2. Push cowl down and move the rear latch lever down to lock.
Installation
Position the cover onto the three mounting pins. Insert the tabs into the slots in the side panel and push the cover down onto the
mounting pins.
a - Flywheel cover
b - Mounting pins
a c - Tabs
b
c
23754
Installation
Position the side panel onto the three mounting pins. Insert the tabs on the flywheel cover into the upper slots and push the side
panel onto the mounting pins.
b a - Side panel
c b - Upper slots
c - Mounting pins
23765
Fuel System
! 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.
Before servicing any part of the fuel system, stop the engine and disconnect the battery. Drain the fuel system completely. Use
an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be
disposed of in an approved receptacle. Any fuel system service must be performed in a wellventilated area. Inspect any completed
service work for sign of fuel leakage.
a - Filter
a b - Orings
29594
Installation
1. Lubricate the Oring seals with oil.
2. Install the fuel filter and tighten securely.
3. Squeeze the primer bulb until firm and inspect for fuel leakage at the filter.
a - Drain hose
b - Right side fitting
c - Drain screw
b
a c
29595
! WARNING
Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This
can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within
or out of the boat. Always use required components and follow instructions and torque procedures.
27843
d
Assemble steering link rod to steering cable with two flat washers and selflocking nylon insert locknut. Tighten locknut until it
seats, then back nut off 1/4 turn.
Assemble steering link rod to engine with special washer head bolt and selflocking nylon insert locknut. First torque bolt, then
torque locknut to specifications.
Fuse Replacement
Wiring circuits on the outboard are protected with fuses. If the silver band is broken, the fuse is blown. If a fuse is blown, locate
and correct the cause of the overload. If the cause is not found, the fuse may blow again. Always replace the fuse with the same
fuse rating.
26686
a b c d e f
26685
a - Cable ties
b - Arrow pointing towards the oil pump
b
28395
5. Prime the oil system prior to running the engine. Refer to Section 1D - Priming the Oil Injection Pump.
a - Gearcase anodes
b - Transom bracket anode
8261
Anodes require periodic inspection, especially in saltwater. To maintain corrosion protection, replace the anode before it is
completely eroded. Never paint or apply a protective coating on the anode, as this will reduce effectiveness of the anode.
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capability.
IMPORTANT: Read the safety and maintenance instructions which accompany your battery.
1. Turn off the engine before servicing the battery.
2. Ensure the battery is secure against movement.
3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.
4. Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.
Battery Information
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose
connections.
Do not use deepcycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
Propeller Replacement
IMPORTANT: Propellers used on this product require the Mercury Marine FloTorq III type hub or equivalent.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before
installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from
starting. Place a block of wood between the propeller blade and the antiventilation plate.
26838
IMPORTANT: Refer to Spark Plug Inspection and Replacement for removing spark plug leads.
2. Remove spark plug leads to prevent engine from starting.
26899
26900
26901
5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an
authorized dealer.
6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants AntiCorrosion Grease or 24C with Teflon.
26902
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always
apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also
each time the propeller is removed.
7. FloTorq III drive hub propellers Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut
retainer, and propeller nut onto the shaft.
a- Propeller nut
b- Propeller nut retainer
c- Rear thrust hub
d- Propeller
e- Replaceable drive sleeve
f- Forward thrust hub
a b c d e f 3223
8. Place a block of wood between gearcase and propeller and torque propeller nut to specifications.
26945
1. Remove the spark plug leads. Twist the rubber boots slightly and pull off.
26899
2. Remove the spark plugs to inspect. Replace spark plug if electrode is worn or the insulator is rough, cracked, broken, blistered,
or fouled.
26946
26947
Spark Plug
Spark plug gap 0.80 mm (0.030 in.)
4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs fingertight, and then tighten 1/4 turn or
torque to specifications.
Removal
1. Remove the flywheel cover from the engine.
2. Remove the side cover from the engine.
3. Remove the three screws securing the air filter cover to the oil tank. Remove the filter.
a - Screw (3)
b - Air filter cover
b
26913
Installation
Install the filter into the cover. Secure the cover with three screws. Tighten the screws to the specified torque.
8245
1. Inspect the alternator belt and have it replaced by an authorized dealer if any of the following conditions are found.
a. Cracks or deterioration in the rubber portion of the belt.
b. Belt surfaces rough or uneven.
29477
Lubrication Points
1. Lubricate the following with Quicksilver or Mercury Precision Lubricants AntiCorrosion Grease or 24C with Teflon.
Propeller shaft Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller
shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
26902
2. Lubricate the following with Quicksilver or Mercury Precision Lubricants 24C with Teflon or Special Lubricant 101.
a - Swivel bracket
b - Tilt support lever
a
b
27873
Tilt tube Lubricate through fitting.
29478
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
a b a - Fitting
b - Steering cable end
29479
3. Lubricate the following with lightweight oil.
Steering link rod pivot points Lubricate pivot points.
29480
27877
2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury
Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
27884
Gearcase Lubrication
When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may
have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored
appearance. If water is noticed, have the gearcase checked by your dealer. Water in the lubricant may result in premature bearing
failure or, in freezing temperatures, will turn to ice and damage the gearcase.
Draining Gearcase
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.
3. Remove vent plugs and fill/drain plug and drain lubricant.
a - Vent plugs
b - Fill/drain plug
b
26977
27001 e
4. Continue adding lubricant until it appears at the rear vent hole.
5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing lubricant tube.
6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
Submerged Outboard
A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the
water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize
internal corrosion damage to the engine.
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by freezing
of trapped water.
The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage
(two months or longer).
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage
the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible
from the fuel tank, remote fuel line, and engine fuel system.
The most effective method of storage preparation is to add the recommended amount of Mercury Precision Fuel Stabilizer and
Mercury Precision Quickleen products as described on the containers to the fuel tank before the last operation of the boat. Adding
fuel stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will
help clean and lubricate the fuel injectors.
1. Portable fuel tank Pour the required amount of gasoline stabilizer and Quickleen (follow instructions on containers) into the
fuel tank. Tip the fuel tank back and forth to mix stabilizer and Quickleen with the fuel.
2. Permanently installed fuel tank Pour the required amount of gasoline stabilizer and Quickleen (follow instructions on
containers) into a separate container and mix with approximately 1 liter (1 US qt) of gasoline. Pour this mixture into the fuel
tank.
3. Pull the drain hose off the right side fitting. Hold the open end of the hose over a container.
4. Loosen the drain screw and drain the fuel filter chamber.
a - Drain screw
b - Drain hose
c - Right side fitting
a c
b
29596
5. Tighten the drain screw and attach the hose.
6. Pull the drain hose off the left side fitting. Hold the open end of the hose over a container.
7. Loosen the drain screw and drain the float chamber.
a b
c
29597
8. Tighten the drain screw and attach the hose.
9. Premix the following in a container:
a. 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision Quickleen lubricant.
b. 8 cc (0.27 oz) or 2 teaspoons of Mercury Precision Fuel Stabilizer.
10. Remove the fuel filter. See Fuel Filter Replacement for procedure.
11. Pour this mixture into the fuel filter opening. Install the fuel filter.
12. Prime the fuel system. Refer to Section 1D - Filling the Fuel System.
13. Place the outboard in water or connect flushing attachment for circulating cooling water. Start the engine and run at idle speed
for five minutes to allow the treated fuel to fill the fuel system.
Gearcase
Drain and refill the gearcase lubricant (refer to Gearcase Lubrication).
NOTICE
Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water collected
in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.
Battery Storage
Follow the battery manufacturer's instructions for storage and recharging.
Remove the battery from the boat and check water level. Recharge if necessary.
Store the battery in a cool, dry place.
Periodically check the water level and recharge the battery during storage.
Important Information
1
Section 1C - General Information C
Table of Contents
Serial Number Location.....................................................1C-2 Fuel Filter Replacement...........................................1C-28
Powerhead Starboard View (S/N 1B417702 and Above) Draining Water from the Fuel Filter Chamber...........1C-28
.......................................................................................1C-4 Warning System..............................................................1C-29
Powerhead Induction Manifold View (S/N 1B417702 and Warning Horn Signals...............................................1C-29
Above)............................................................................1C-6 Engine Guardian System..........................................1C-29
Powerhead Port View (S/N 1B417702 and Above)...........1C-8 SmartCraft Product...................................................1C-29
Powerhead Aft View (S/N 1B417702 and Above)...........1C-10 Power Trim and Tilt..........................................................1C-30
Powerhead Top View (S/N 1B417702 and Above)..........1C-12 Power Trim Operation..............................................1C-30
Powerhead Front View (S/N 1B417701 and Below)........1C-14 Tilting Operation.......................................................1C-31
Powerhead Starboard View (S/N 1B417701 and Below) 1C-16 Manual Tilting...........................................................1C-31
Powerhead Port View (S/N 1B417701 and Below)..........1C-18 Shallow Water Operation..........................................1C-31
Powerhead Top View (S/N 1B417701 and Below)..........1C-20 Auxiliary Tilt Switch...................................................1C-31
Powerhead Aft View (S/N 1B417701 and Below)............1C-22 Compression Check........................................................1C-31
Conditions Affecting Performance...................................1C-23 Cylinder Leakage Testing................................................1C-32
Weather....................................................................1C-23 Analysis....................................................................1C-32
Weight Distribution (Passengers and Gear) Inside the Painting Procedures........................................................1C-32
Boat.......................................................................1C-23 Propellers.................................................................1C-32
Bottom of Boat .........................................................1C-23 Gear Housing...........................................................1C-33
Water Absorption......................................................1C-24 Shipping of Hazardous Material (HazMat) and Engine/
Cavitation..................................................................1C-24 Components Containing Hazardous Material..............1C-33
Ventilation.................................................................1C-24 Outboard Service Bulletin 200807...........................1C-33
Following Complete Submersion.....................................1C-24 Overview of Regulations...........................................1C-34
Saltwater Submersion (Special Instructions)............1C-24 Overview of Training Requirements.........................1C-34
Engine Submerged While Running (Special Shipping of Complete Engines and Major Assemblies
Instructions)..........................................................1C-24 ..............................................................................1C-34
Freshwater Submersion (Special Instructions).........1C-24 More Information on Hazardous Material.................1C-34
Fuel and Oil.....................................................................1C-25 Decal Application.............................................................1C-34
Fuel Recommendations............................................1C-25 Decal Removal.........................................................1C-34
Fuel Requirements...................................................1C-26 Application Instructions.............................................1C-34
Fuel Additives...........................................................1C-26 Trim Tab Adjustment.......................................................1C-35
Avoiding Fuel Flow Restriction.................................1C-26 Engine BreakIn Procedure.............................................1C-35
Oil Recommendation................................................1C-26 Gasoline/Oil BreakIn Mixture...................................1C-35
Filling Oil Injection System.......................................1C-27 BreakIn Procedure..................................................1C-35
Filling Fuel Tank.......................................................1C-28
Special Tools
Fuel Filter Removal/Installation Tool 91896661
Aids in the removal and installation of the fuel filter cap assembly.
24896
11604
b
Serial Number
e xx d
21552
Notes:
13 16
14
5 17
4
18
3 2
1
25 24 23 22 21 20 19 26704
3
5
2
6
1 7
26737
5 6 7 8 9 10 11
12
19
13
14
15
16
3
2
17
1
18
22 21 20
26707
12
11 13
14
15
10
9
16
8
17
18
7
19
6
20
3 21
2
22
26717
10
11
4 12
13
14
15
3
2 16
1 26719
15 1
14 2
13
12
3
11
10
9
5
4
32228
8
24
23
22
1
21
27
20 26
10
11
19 9
12 2
16
17
4
8
5
18
6
7
15 14 13 11239
7
4 5
2 3
1
6
15 8
26 25
14 9
24
27 16
10
13
28
11
19 18 17
23 20
4 21
12
22 11237
12 2
1
11
10
4
9
6
11238
1 12
11
13
14
22
10
15
2 9
21
3
16
8
17
20
7
18
4
12
6
19
5 11242
Bottom of Boat
For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and smooth
in fore and aft direction.
Hook: Exists when bottom is concave in fore and aft direction when viewed from the side. When boat is planing, hook causes
more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat speed.
Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage.
Water Absorption
It is imperative that all throughthehull fasteners be coated with a quality marine sealer at time of installation. Water intrusion into
the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay, and eventual
structural failure.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fastmoving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear
housing or the propeller. Common causes of cavitation are:
Weeds or other debris snagged on the propeller
Bent propeller blade
Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speedup and
a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue,
eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
Drive unit trimmed out too far
A missing propeller diffuser ring
A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing
Drive unit installed too high on transom
5572
c. Within the first 10 seconds after the key switch has been turned "ON," move the remote control handle from neutral into
forward gear three to five times. This will automatically start the priming process.
NOTE: An audible click from the oil pump indicates the pump is priming. It may take a few minutes for the pump to
complete the priming process.
N
F
8148
11. Start the engine with a fresh fuel source and let it run for at least one hour to eliminate any water in the engine.
12. If the engine fails to start, determine if the cause is fuel, electrical, or mechanical. Repair as needed.
Fuel Ratings
Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following
specifications:
USA and Canada having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline (92 [R+M]/2 Octane) is also
acceptable. Do not use leaded gasoline.
Outside USA and Canada having a posted pump Octane Rating of 90 RON minimum. Premium gasoline (98 RON) is also
acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration
requires replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcoholfree gasoline be used where
possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for
leaks and abnormalities is required.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for
long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcoholblend fuels
normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase
separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films
from internal components.
Fuel Requirements
Do not use premixed gas and oil in this engine. The engine automatically receives extra oil during engine breakin. Use a fresh
supply of the recommended gasoline during engine breakin and after engine breakin.
Fuel Additives
To minimize carbon deposit buildup in the engine, it is recommended to add Mercury or Quicksilver Quickleen Engine Treatment
additive to the engine's fuel at each tank fill throughout the boating season. Use additive as directed on container.
Oil Recommendation
Recommended Oil Mercury OptiMax/DFI or Quicksilver DFI 2-Cycle Engine Oil
Mercury OptiMax/DFI or Quicksilver DFI 2Cycle Engine Oil is recommended for your engine. If Mercury OptiMax/DFI or
Quicksilver DFI 2Cycle Engine Oil is not available, we recommend using Mercury or Quicksilver TCW3 Premium Plus 2Cycle
Oil. Severe engine damage may result from use of an inferior oil.
29462
2890 29463
3. Use the chain on the oil fill cap to check oil level. First ball marker indicates 0.94 liters (1 US qt) low. The second ball marker
indicates 1.89 liters (2 US qt) low.
b
29464
4. Slowly fill the oil tank with the specified oil. Do not overfill. Add only enough oil to bring the oil level up to the bottom of the
fill neck.
29465
5. Install oil filler cap and retighten. Reinstall the cowl cap.
29466
Fill fuel tanks outdoors away from heat, sparks, and open flames.
Remove portable fuel tanks from boat to refill them.
Always stop engine before refilling tanks.
Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its
temperature rises and can leak under pressure if the tank is completely filled.
a - Filter
a b - Orings
29594
Installation
1. Lubricate the Oring seals with oil.
2. Install the fuel filter and tighten securely.
3. Squeeze the primer bulb until firm and inspect for fuel leakage at the filter.
a - Drain hose
b - Right side fitting
c - Drain screw
b
a c
29595
Warning System
The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote
control or connected to the ignition key switch.
a
27755
Warning Horn
Function Sound Description
Start up One beep Normal system test.
Low oil Four beeps every Oil level is low in the oil tank. Refill the oil tank. Refer to Fuel and Oil.
2 minutes
Water in fuel Four beeps every Water in the fuel filter chamber reached the full level. Water can be removed from the
2 minutes chamber. Refer to Maintenance - Fuel System for water removal.
Cooling system Continuous Engine Guardian System is activated. Power limit will vary with level of overheat. Shift
problem outboard into neutral and check for a steady stream of water coming out of the water
pump indicator hole. If no water is coming out of the water pump indicator hole or flow
is intermittent, stop engine and check water intake holes for obstruction.
Oil level is critically Continuous Engine Guardian System is activated. Power limit will allow a fast idle. The oil level
low is critically low in the oil tank. Refill the oil tank. Refer to Fuel and Oil.
Oil pump failure Continuous Engine Guardian System is activated. Power limit will allow a fast idle. The warning
horn is activated if the oil pump should ever stop functioning electrically. No lubricating
oil is being supplied to the engine.
Engine overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum
allowable RPM. The system will limit the engine speed to within the allowable range.
Engine overspeed indicates a condition that should be corrected. Overspeed could
be caused by incorrect propeller pitch, engine height, trim angle, etc.
Sensor out of range Continuous Engine Guardian System is activated. Power limit may activate at full throttle speed.
Intermittent beep Engine Guardian System is activated. Power limit may restrict engine speed to idle.
Engine running cold One beep Engine is not reaching correct temperature while operating below 1000 RPM. Have
at slow speed your dealer check the engine.
SmartCraft Product
A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument
package will display are engine RPM, coolant temperature, battery voltage, fuel consumption, and engine operating hours.
The SmartCraft instrument package will also aid in Engine Guardian diagnostics. The SmartCraft instrument package will display
critical engine alarm data and potential problems.
a
a - Trim switch
b - Tilt range of travel
c - Trim range of travel
b
c 27761
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of
boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
! WARNING
Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the
operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat
in a safe manner.
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless
steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The
nonstainless steel shipping bolt should not be used in this application.
2. Trimming out or up can:
Lift the bow higher out of the water.
Generally increase top speed.
Increase clearance over submerged objects or a shallow bottom.
Increase steering torque or pull to the left at a normal installation height (with the normal righthand rotation propeller).
In excess, can cause boat porpoising (bouncing) or propeller ventilation.
Cause engine overheating if any cooling water intake holes are above the waterline.
Tilting Operation
To tilt outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will tilt up
until the switch is released or it reaches its maximum tilt position.
1. Engage the tilt support lever by rotating the knob to bring the support lever upward.
2. Lower the outboard to rest on the tilt support lever.
3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down. Lower the outboard.
b
27778
Manual Tilting
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during
reverse operation.
Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to
the desired position and tighten the manual tilt release valve.
22362
a
27779
Compression Check
1. Remove spark plugs.
2. Install compression gauge in spark plug hole.
3. Hold throttle plate at WOT.
4. Pull on the recoil rope or crank the engine over until the compression reading peaks on the gauge. Record the reading.
1. Remove all of the spark plugs from cylinders except for cylinder #1.
2. Rotate the engine clockwise until resistance is felt.
3. Continue to rotate flywheel so the timing marks on the flywheel and cylinder block are in alignment. This will be the compression
stroke for cylinder #1.
4. Remove the spark plug from cylinder #1.
5. Complete the cylinder leakdown test on the #1 spark plug hole.
6. After testing cylinder #1, install a dial indicator on the next firing order sequence cylinder.
7. Rotate the flywheel so the piston is at TDC.
8. Complete the cylinder leakdown test.
9. Complete the procedure in sequence on the remaining cylinders.
Analysis
Due to standard tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important the cylinders have somewhat
consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines have a larger percentage
of cylinder leakage than smaller engines.
If excessive leakage is present, check that the piston is at top dead center of its compression stroke. Leakage will occur if the
piston is below the exhaust port and the intake port.
To determine the cause of high percentage leaks, locate where the air is escaping from. Listen for air escaping through the intake
and exhaust.
Painting Procedures
! WARNING
Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure
that the work area is properly ventilated and wear protective eyeware, clothing, and respirators.
Propellers
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse ScotchBrite disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer.
5. Allow a minimum of one hour dry time and no more than one week before applying the finish coat.
6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black.
Gear Housing
The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint system
available in the field. The materials recommended are of high quality and approximate marine requirements. The following
procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended the listed materials
be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown
following is sufficient to refinish several gear housings.
1. Wash the gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water.
2. Wash the gear housing with soap and water. Rinse with clean water.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken
paint edges.
4. Clean gear housing thoroughly with DX330 Wax and Grease Remover.
5. Spot repair surfaces where bare metal is exposed with DX503 Alodine Treatment.
IMPORTANT: Do not use aerosol spray paints as the paint will not properly adhere to the surface, nor will the coating be
sufficiently thick to resist future paint blistering.
6. Mix Epoxy Chromate Primer DP90LF with equal part catalyst DP402LF per the manufacturer's instructions. Allow proper
induction period for permeation of the epoxy primer and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before the top coat application.
8. Use Ditzler Urethane DU9300 for Mercury Black, DU34334 for Mariner Grey, DU35466 for Force Charcoal, DU33414M for
Sea Ray White, and DFHS 37372H for Verado Silver. Catalyze all five colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce
with solvents per Ditzler label.
! WARNING
Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure
that the work area is properly ventilated and wear protective eyeware, clothing, and respirators.
NOTE: Apply one half to one mil even film thickness with a spray gun. Allow the paint to flash off for five minutes before
applying the second even coat of one half to one mil film thickness. Urethane paint will dry to the touch in a matter of hours,
but will remain sensitive to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint the sacrificial anode.
10. Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between
trim tab and gear housing.
Overview of Regulations
The Hazardous Materials Regulations (HMR) specify requirements for the safe transportation of hazardous materials in commerce
by rail car, aircraft, vessel, and motor vehicle. These comprehensive regulations govern transportationrelated activities. In general,
the HMR prescribe requirements for classification, packaging, hazard communication, incident reporting, handling, and
transportation of hazardous materials. The HMR are enforced by Pipeline Hazardous Material Safety Administration (PHMSA),
Department of Transportation (DOT), Federal Aviation Administration (FAA), Federal Highway Administration (FHWA), Federal
Railroad Administration (FRA), and the United States Coast Guard (USCG).
Decal Application
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Application Instructions
NOTE: The following decal installation instructions are provided for a wet installation. All decals should be applied wet.
Tools Required
Plastic squeegee
Stick pin
Dishwashing liquid detergent without ammonia. Do not use a soap that contains petroleum based solvents.
NOTE: Placement of decals using the wet application will allow time to position decal. Read entire installation instructions on this
technique before proceeding.
Temperature
IMPORTANT: Installation of vinyl decals should not be attempted while in direct sunlight. Air and surface temperature should be
between 15 C (60 F) and 38 C (100 F) for best application.
Surface Preparation
IMPORTANT: Do not use a soap that contains petroleum based solvents to clean application surface.
Clean entire application surface with mild dishwashing liquid and water. Rinse surface thoroughly with clean water.
1. Mix 16 ml (1/2 oz) of dishwashing liquid in 4 liter (1 US gal) of cool water to use as a wetting solution.
NOTE: Leave protective masking on the face of the decal until final steps of decal installation. This will ensure the vinyl decal
keeps its shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing from adhesive side of decal.
3. Using a spray bottle, flood the entire adhesive side of the decal with the premixed wetting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position prewetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the
outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl
surface.
7. Wipe decal surface with a soft paper towel or cloth.
8. Wait 1015 minutes.
9. Starting at one corner, carefully and slowly pull the masking off the decal surface at a 180 angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with a stick pin and press out the entrapped
air or wetting solution with your thumb, moving toward the puncture.
26816
NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is installed with the antiventilation plate
approximately 50 mm (2 inches) or more above the boat bottom.
Operate your boat at normal cruising speed, trimmed to the desired position. Turn your boat left and right and note the direction
the boat turns more easily.
If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the boat turns more easily to the left,
move the trailing edge of trim tab to the left. If the boat turns more easily to the right, move the trailing edge of trim tab to the right.
Retighten bolt and retest.
BreakIn Procedure
1. For the first hour of operation, allow the engine to warm up for 3060 seconds.
a. Run the engine at varied throttle settings, the majority of the time between 3000 and 4500 RPM or threequarter throttle.
b. Change engine speed approximately every two minutes, and avoid continuous operation at idle speed for more than
ten minutes. Short bursts of full throttle for periods up to ten seconds are acceptable.
c. Avoid trimming the outboard out (up) beyond a vertical trim position during operation.
NOTE: It is the driver's responsibility to always drive in a safe manner. Improper trim angle of the outboard when driving at
high speed can be difficult and dangerous. The purpose of specifying trim angle is to help guide the operator in determining
how to put the proper load on the engine. They are intended to be guidelines and do not suggest or require unsafe boat
operation.
2. For the next three hours of operation, change engine speed every ten minutes.
Important Information
1
Section 1D - Outboard Installation D
Table of Contents
Installation Specifications..................................................1D-2 Fuel Hose Connection..............................................1D-17
Lifting the Outboard...........................................................1D-2 Shift Cable Installation..............................................1D-18
Steering Cable Starboard Side Routed Cable.................1D-3 Throttle Cable Installation.........................................1D-19
Steering Link Rod Fasteners.............................................1D-4 Electrical, Fuel Hose, and Control Cables 0T801000
Drilling Outboard Mounting Holes......................................1D-4 1B226999.....................................................................1D-20
Determining Recommended Outboard Mounting Height Front Cover Assembly..............................................1D-20
.......................................................................................1D-6 Remote Wire Harness..............................................1D-20
Fastening the Outboard to the Transom............................1D-6 Battery Information...................................................1D-21
Mounting Bolts............................................................1D-6 Battery Cable Connections.......................................1D-22
Checking Boat Transom Construction........................1D-7 Fuel Hose Connection..............................................1D-22
Electrical, Fuel Hose, and Control Cables S/N 1B417702 Water Pressure Tube Connection............................1D-23
and Above......................................................................1D-8 Shift Cable Installation..............................................1D-23
Front Cowl Grommet..................................................1D-8 Throttle Cable Installation.........................................1D-24
Flush Hose Routing....................................................1D-9 Filling the Fuel System....................................................1D-25
Remote Boat Harness..............................................1D-10 Filling Oil Injection System...............................................1D-25
Battery Information...................................................1D-10 Priming the Oil Injection Pump........................................1D-26
Battery Cable Connections.......................................1D-11 Propeller Installation........................................................1D-27
SmartCraft Harness Connection...............................1D-11 Trim In Pin.......................................................................1D-28
Water Pressure Tube Connection............................1D-12 Paddle Wheel Speed Sensor Installation (if Equipped)...1D-28
Fuel Hose Connection..............................................1D-12 Parts Provided..........................................................1D-28
Shift Cable Installation..............................................1D-13 Selecting Location....................................................1D-29
Throttle Cable Installation.........................................1D-14 Transom Angle Requirements..................................1D-29
Electrical, Fuel Hose, and Control Cables S/N 1B227000 Installing Bracket......................................................1D-29
1B417701.....................................................................1D-15 Routing the Cable.....................................................1D-30
Front Cover Assembly..............................................1D-15 Installing and Removing the Paddle Wheel..............1D-30
Remote Wiring Harness...........................................1D-16 Wiring Connections..................................................1D-31
Battery Information...................................................1D-16 Template Paddle Wheel Speed Sensor.................1D-31
Battery Cable Connections.......................................1D-17
Installation Specifications
a
a - Minimum transom opening
a b
b - Engine centerline for dual engine 66.0 cm
(26 in.)
18552
Special Tools
Lifting Eye 91904551
Threads into the flywheel to remove the powerhead assembly from the driveshaft
housing, or to lift entire engine for removal/installation.
2756
5489
Limits the down trim angle of the power trim equipped engines, or aids in
determining the trim out angle on nonpower trim engines.
2749
15363
95
3724
3725
3727
! WARNING
Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This
can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within
or out of the boat. Always use required components and follow instructions and torque procedures.
27843
d
Assemble steering link rod to steering cable with two flat washers and selflocking nylon insert locknut. Tighten locknut until it
seats, then back nut off 1/4 turn.
Assemble steering link rod to engine with special washer head bolt and selflocking nylon insert locknut. First torque bolt, then
torque locknut to specifications.
c 2757
3973
3. Apply marine sealer to the shanks of the bolts, not the threads.
4. Fasten the outboard with the provided mounting hardware.
b
d
c 3729
60.9 cm
(24 in.)
e b
58.4 cm
(23 in.) c
56.0 cm
(22 in.)
e 53.3 cm
(21 in.) a
d
50.8 cm
(20 in.)
48.2 cm
(19 in.)
10 20 30 40 50 60 70 80
f 3728
NOTICE
1. The outboard should be mounted high enough on the transom so that exhaust relief hole will stay at least 25.4 mm (1 in.)
above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will prevent
exhaust restrictions. Exhaust restrictions will result in poor performance at idle.
2. Add 12.7 cm (5 in.) for XL models to the listed outboard mounting heights.
3. The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76 cm (30 in.) for XL models. Mounting
the outboard higher may cause damage to the gearcase components.
b 18961
a
When first determining transom strength, use a dial torque wrench. If the bolt or nut continues to turn without the torque reading
on the dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or
a transom reinforcement plate.
a
a - Large transom washer
b - Transom reinforcement plate
b
33962
d a
40952
Electrical, Fuel Hose, and Control Cables S/N 1B417702 and Above
Front Cowl Grommet
NOTE: Sufficient slack must exist in wiring, battery cables, and hoses that are routed between the grommet and engine attachment
points to relieve stress and prevent hoses from being kinked or pinched.
1. Pull up the cowl seal. Remove the access cover from the bottom cowl.
b a - Access cover
b - Screws
23714
2. Insert the lower alignment pin on the grommet into the hole in the lower cover. Ensure the lettered side of the grommet is
facing out.
3. Route the hoses, wiring, and cables through the correct opening in the grommet, as shown.
a- Flush hose
b- Grommet
a c- Remote boat harness
d- Shift cable
e- Throttle cable
f- Fuel hose
g- Upper alignment pin
h- SmartCraft harness or additional harness opening
b i- Water pressure tube
f g j- Battery cables
k- Lower alignment pin
h
e F
TH
SH B
i
d
W j
c k 23638
5. Reinstall the access cover with two bolts. Reattach the cowl seal.
6. Attach two cable ties around the grommet tube.
a - Cable tie
a
23639
a - Knockout
a b - Flush hose
23642
a
a - Remote 14 pin boat harness
23699
Battery Information
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose
connections.
Do not use deepcycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied
per battery for wing nut replacement. Metric hex nuts are not supplied.
DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
b c
(-) 15496
Dual Outboards
Connect a common ground cable (wire size same as engine battery cables) between negative () terminals on starting batteries.
b
a (-)
d
b
c (-)
d
15497
23700
23702
2. Remove the plug from the coupler and make the connection. A barb fitting (22859731) can be installed for larger diameter
hose connection.
a - Plug
b - Coupler
c - Barb fitting (22859731)
c b
23708
a - Hose clamp
b - Remote fuel hose
a b
23709
26838
c
b
23720
F N R
4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain distance measured in Step 3.
b
a - Shift cable end
a
b - Cable barrel
23721
b
a - Cable barrel
a c
b - Locknut
c - Flat washer
7736
6. Check shift cable adjustments as follows:
a. Shift the remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the
cable end.
b. Shift the remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away
from the cable end. Repeat steps a and b.
c. Shift the remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust
the barrel away from the cable end. Repeat steps a through c.
d. Shift the remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer
to the cable end. Repeat steps a through d.
26838
2. Install the throttle cable to the throttle arm with a flat washer and locknut. Tighten the locknut, then back off the locknut 1/4
turn.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
4. Place the cable barrel into the barrel retainer.
5. Lock the retainer and cables in place with the cable latch.
a- Flat washer
b- Locknut
c- Barrel retainer
c d- Cable barrel
e- Cable latch
d
a b
e
15317
a
a - Screw (2)
a b - Cover
7896
Installation
IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and routed between clamp and engine
attachment point, to relieve stress and prevent hoses from being kinked or pinched.
1. Route the fuel hose, wiring, and cables through the front cover opening.
2. If engine is equipped with a flush hose, use a needlenose pliers and carefully break out the semicircular knockout section
of plastic on the front cover halves. Route flush hose through this opening.
3. Place the neoprene wrap around the wiring, hoses, and control cables, as shown. Secure neoprene wrap with cable ties.
a - Neoprene wrap
b - Flush hose
a
5398
a
a - Screw (2)
a b - Cover
7896
a
a - 14 pin connector
b - Remote 14 pin boat harness
b
11042
Battery Information
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose
connections.
Do not use deepcycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied
per battery for wing nut replacement. Metric hex nuts are not supplied.
DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
b c
(-) 15496
Dual Outboards
Connect a common ground cable (wire size same as engine battery cables) between negative () terminals on starting batteries.
b
a (-)
d
b
c (-)
d
15497
a - Fuel hose
b - Hose clamp
b
a
7907
26838
c
b
23720
F N R
4. Push in on the shift cable end until resistance is felt. Adjust the cable barrel to attain distance measured in Step 3.
b
a - Shift cable end
a
b - Cable barrel
23721
b
a - Cable barrel
a c
b - Locknut
c - Flat washer
7736
6. Check shift cable adjustments as follows:
a. Shift the remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the
cable end.
b. Shift the remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away
from the cable end. Repeat steps a and b.
c. Shift the remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust
the barrel away from the cable end. Repeat steps a through c.
d. Shift the remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer
to the cable end. Repeat steps a through d.
26838
2. Install throttle cable to the throttle arm with flat washer and locknut. Tighten locknut, then back off locknut 1/4 turn.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
4. Place cable barrel into retainer.
5. Lock the retainer and cables in place with the cable latch.
a- Flat washer
b- Locknut
c- Barrel retainer
c d- Cable barrel
e- Cable latch
d
a b
e
15317
a
a - Screw (2)
a b - Cover
7896
Installation
IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and routed between clamp and engine
attachment point, to relieve stress and prevent hoses from being kinked or pinched.
1. Route the fuel hose, wiring, and cables through the front cover opening.
2. If engine is equipped with a flush hose, use a needlenose pliers and carefully break out the semicircular knockout section
of plastic on the front cover halves. Route flush hose through this opening.
3. Place the neoprene wrap around the wiring, hoses, and control cables, as shown. Secure neoprene wrap with cable ties.
a - Neoprene wrap
b - Flush hose
a
5398
a
a - Screw (2)
a b - Cover
7896
10392
Battery Information
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose
connections.
Do not use deepcycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied
per battery for wing nut replacement. Metric hex nuts are not supplied.
DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
b c
(-) 15496
Dual Outboards
Connect a common ground cable (wire size same as engine battery cables) between negative () terminals on starting batteries.
b
a (-)
d
b
c (-)
d
15497
a - Fuel hose
b - Hose clamp
b
a
7907
a
b c d
e
7735
26838
c
b
23720
F N R
b
a - Shift cable end
a
b - Cable barrel
23721
5. Place the cable barrel into the pocket. Fasten the cable with locknut and flat washer.
b
a - Cable barrel
a c
b - Locknut
c - Flat washer
7736
6. Check shift cable adjustments as follows:
a. Shift the remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the
cable end.
b. Shift the remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away
from the cable end. Repeat steps a and b.
c. Shift the remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust
the barrel away from the cable end. Repeat steps a through c.
d. Shift the remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer
to the cable end. Repeat steps a through d.
26838
2. Install throttle cable to the throttle arm with flat washer and locknut. Tighten locknut, then back off locknut 1/4 turn.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
4. Place cable barrel into retainer.
a- Flat washer
b- Locknut
c- Barrel retainer
c d- Cable barrel
e- Cable latch
d
a b
e
15317
a - Cowl cap
b - Oil filler cap
b 37147
3. Oil filler caps with a chain check the oil level on the chain. The first ball marker indicates 0.94 liter (1.0 US qt) low. The second
ball marker indicates 1.89 liter (2.0 US qt) low.
b
29464
b
c 37143
5. Slowly fill the oil tank with the specified oil. Do not overfill. Add only enough oil to bring the oil level up to the bottom of the
fill neck.
29465
6. Install the oil filler cap and retighten. Reinstall the cowl cap.
29466
7912
IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump. Otherwise, the fuel pump will run without
fuel during the priming process and may be damaged.
Prime the oil injection pump as follows:
27348
26846
4. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward
gear 3 to 5 times. This will automatically start the priming process.
NOTE: It may take a few minutes for the pump to complete the priming process.
Propeller Installation
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before
installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from
starting. Place a block of wood between the propeller blade and the antiventilation plate.
IMPORTANT: Propellers used on this product require the Mercury Marine FloTorq lll type hub 835257A9 or equivalent.
a- Propeller nut
b- Propeller nut retainer
c- Rear thrust hub
d- Propeller
e- Replaceable drive sleeve
f- Forward thrust hub
a b c d e f 3223
Tighten propeller nut to specified torque and bend tabs against nut.
a a - Propeller nut
b - Tabs
b
7919
Trim In Pin
! WARNING
Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the
operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat
in a safe manner.
Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to be
trimmed further in or under. This greater trim under capability is desirable to improve acceleration, reduce the angle and time spent
in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft livewells, given the variety
of available propellers and height range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bowdown planing condition
called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower.
2688
The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and
insert it in whatever adjustment hole in the transom brackets is desired. A nonstainless steel shipping bolt should not be used in
this application other than on a temporary basis.
f 29269
j
g
Selecting Location
Single engine installation Mount paddle wheel on the transom where the propeller blade is rotating downward. Usually the right
(starboard) side to minimize cavitation. If feasible, mount at least 50 mm (2 in.) beyond the swing radius of the propeller.
Dual engine installation Mount the paddle wheel between the engines as close to the centerline (keel) of the boat as possible.
On slower, heavier displacement boats, position it farther from the keel.
NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes, or outlets for live wells or any protrusion that may
cause turbulence or cavitation.
29270
a - 50 mm (2 in.)
a b a - 13 transom angle
b - 20 transom angle
29272
Stepped or undercut transom with three angles A small shim of tapered plastic, metal, or wood must be fabricated and installed,
as shown. Mount the paddle wheel on the step for best performance.
a a - Shim
29276
Installing Bracket
1. Cut out the template. At the location selected, tape the template to the transom. Make sure the black dotted line on the template
is aligned with the transom bottom edge, as shown.
2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on the template. To prevent drilling too deeply,
wrap masking tape around the drill bit 22 mm (7/8 in.) from the point end of drill bit.
NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drilling about 1.5 mm (1/16 in.) deep to prevent
surface cracks.
3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to the two #10 screws provided. Using the
washer provided, attach and tighten the bracket to the hull making sure the bracket is flush with the underside of the hull.
4. Fill any gap between the housing and the transom with a caulking material, as shown. Using a putty knife, smooth the surface
to ensure proper water flow.
e a- Template
a b- 50 mm (2 in.)
c- #10 screw
d- Flat washer (2)
b e- Caulking
c d 29282
c
e
d
29285
a
a - Tabs
b - Pins
b 29288
Wiring Connections
IMPORTANT: Before making wire connections, make sure wires are routed through the transom.
NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs inside the connector. Have the
wiring routed through the transom. Push each wire terminal into its respective location in the connector. Push wire in until they
snap into place. Secure wires into connector with the wire retainer.
DC BA
WHT
DC BA
YEL
BLU
BL K
29289
b b
a
a - Connector
b - Wire retainer
29291
Notes:
Electrical
Section 2A - Ignition
Table of Contents 2
A
Ignition Specifications........................................................2A-2 Crankshaft Position Sensor Installation....................2A-38
Electrical Components S/N 0T8010001B226999.............2A-4 Throttle Position Sensor (TPS)........................................2A-39
Electrical Components PCM Mounting S/N 1B227000 Throttle Position Sensor Removal S/N 1B417702 and
1B417701.......................................................................2A-8 Above....................................................................2A-40
Electrical Plate Components S/N 1B2270001B417701. 2A-10 Throttle Position Sensor Installation S/N 1B417702
Electrical Components S/N 1B417702 and Above..........2A-12 and Above.............................................................2A-40
Throttle Body Components S/N 1B417702 and Above....2A-14 Throttle Position Sensor Removal S/N 1B417701 and
Throttle Body Components S/N 1B417701 and Below....2A-16 Below....................................................................2A-41
Troubleshooting without a Computer Diagnostic System Throttle Position Sensor Installation S/N 1B417701
(CDS)...........................................................................2A-18 and Below.............................................................2A-41
Troubleshooting with the Computer Diagnostic System Throttle Position Sensor (TPS) Troubleshooting......2A-42
(CDS)...........................................................................2A-18 Cylinder Block Coolant Temperature Sensor...................2A-42
Troubleshooting Guide.....................................................2A-19 Cylinder Block Coolant Temperature Sensor Test. . .2A-43
Theory of Operation Internal Ignition Coil Driver Models Cylinder Block Coolant Temperature Sensor Removal
.....................................................................................2A-21 ..............................................................................2A-43
Fuse Replacement...........................................................2A-22 Cylinder Block Coolant Temperature Sensor
Propulsion Control Module (PCM)...................................2A-22 Installation.............................................................2A-44
PCM Removal ..........................................................2A-23 Air Compressor Head Temperature Sensor....................2A-45
PCM Installation........................................................2A-23 Air Compressor Head Temperature Sensor Test.....2A-45
Main Power Relay (MPR)................................................2A-25 Air Compressor Head Temperature Sensor Removal
Wire Color Code Abbreviations................................2A-25 ..............................................................................2A-46
Main Power Relay Test.............................................2A-25 Air Compressor Head Temperature Sensor Installation
Flywheel...........................................................................2A-30 ..............................................................................2A-46
Flywheel Removal....................................................2A-30 Manifold Absolute Pressure (MAP) Sensor ....................2A-47
Installation.................................................................2A-31 Manifold Absolute Pressure Sensor Test.................2A-47
Ignition Coil 3 Cylinder OptiMax....................................2A-32 Manifold Absolute Pressure Sensor Removal..........2A-48
Spark Plug Lead Ohm Test......................................2A-32 Manifold Absolute Pressure Sensor Installation.......2A-48
Ignition Coil Removal................................................2A-32 Manifold Air Temperature (MAT) Sensor ........................2A-49
Ignition Coil Installation.............................................2A-33 Manifold Air Temperature Sensor Test.....................2A-49
Ignition Coil Test..............................................................2A-34 Manifold Air Temperature Sensor Removal..............2A-50
PCM Failures Due to Failed Ignition Coil (SB Manifold Air Temperature Sensor Installation...........2A-50
200725R2)...........................................................2A-34 Shift Switch......................................................................2A-51
Ignition Coil Circuit Schematic.........................................2A-36 Guardian Protection System............................................2A-51
1.5L OptiMax Digital Signal Example.......................2A-36 Guardian System Activation.....................................2A-52
Crankshaft Position Sensor (CPS)...................................2A-37 Engine Overspeed Protection System......................2A-52
Crankshaft Position Sensor Test..............................2A-37 Warning Horn Signals...............................................2A-52
Crankshaft Position Sensor Removal.......................2A-38
Ignition Specifications
Ignition Specifications
Type Digital inductive
Firing order 123
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
Spark plug lead resistance at 20 C (68 F) 11701330 ohms
Maximum timing Not adjustable; controlled by PCM
Idle timing Not adjustable; controlled by PCM
Throttle position sensor
At idle 0.171.05 VDC
At wideopen throttle 3.764.64 VDC
Crankshaft position sensor
Air gap (S/N 1785000 and above) Not adjustable
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Resistance at 20 C (68 F) 300350 ohms
Special Tools
Computer Diagnostic System (CDS) Order through SPX
Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer Diagnostic
System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA 18003452233
4520 Canada 8003452233
Europe 49 6182 959 149
Australia (03) 95446222
Data link extension harness (3.05 m [10 ft.]) between the adapter harness and the
Digital Diagnostic Terminal or Computer Diagnostic System (CDS).
4012
Data link harness between engine and Computer Diagnostic System (CDS).
5826
TEMP
A mA COM V Hz
4516
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
56
55
42 50
41 49
56
1691
Torque
Ref. No. Qty. Description Nm lbin. lbft
41 1 Starter cable
42 1 Boot (red)
43 1 Engine harness
44 1 Fuse cover
45 1 Mini fuse (5 amp tan)
46 4 Mini fuse (20 amp yellow)
47 1 Connector (8 pin)
48 1 Clip
49 1 Battery cable
50 1 Boot
51 3 Bushing
52 3 Washer
53 3 Screw (M8 x 35) 27 20
54 3 Grommet
55 1 Cover
56 3 Grommet
57 1 Cable
58 1 Spacer
59 1 Bracket
60 1 Tfitting
61 1 Tubing
62 1 Tubing
63 1 Coupler
64 1 Plug
56
55
42 50
41 49
56
1691
10
32
9
6
3 11
8
7
2
5
18
16
17
13
5 15 16
14
7
28
3 12
20
22 23
26
2 27
21
19 3 23
24
7
30 29
25
26797
12
31 7
37 3 5
38
39
6
4
17 6
18
16
19
21
20
30
13
29
15 28
23
14 22
29 26799
10
32
9
6
3 11
8
18 7
2
5
16 25 7
26
17 33 34
3 16
5 13 15
14
7
2 29
12
20
22 23
19
27
28
21
3 23
7 24
31 30
32
21764
3
16 2
15 14
13 12 11 4
10 1
29
17
6
5
9 7
8
20 28
26
27
25
24
23
22
21 19
18
23750
3
16 2
15 14
13 12 11 4
10 1
17 29
28
6
5
9 7
8
30
20
27
26
25
24
23 19
22
21
18
1321
Troubleshooting Guide
1. Engine Cranks, but Will Not Start
Cause Action
1.0 Lanyard stop switch in wrong position Reset lanyard stop switch.
1.1 Weak battery or bad starter motor, battery voltage
Replace/charge battery. Inspect condition of starter motor.
drops below 8 volts while cranking (PCM cuts out
Check condition of battery terminals and cables.
below 8 volts) (fuel pump requires 9 volts)
Inspect air system for leaks.
1.2 Low air pressure in rail (less than 70 psi at
Inspect air filter for plugging (air pressure measured on port rail).
cranking)
Inspect air compressor reed valves, if necessary.
Check that primer bulb is firm.
Keyon engine to verify fuel pump runs for two seconds and then turns off.
1.3 No fuel Measure fuel pressure (valve on port rail).
Fuel pressure should be 96.5 6.9 kPa (14.0 1.0 psi) greater than the air
pressure.
Check fuel pressure from low pressure electric fuel pump 137.9206.8 kPa
(2030 psi).
Check for fuel leaks.
1.4 Low fuel pressure
If fuel pressure leaks down faster than air pressure, seals on the fuel pump
may be leaking.
Check air system pressure, see 1.2.
1.5 Flywheel misaligned during installation Remove flywheel and inspect.
Replace fuse.
1.6 Blown fuse
Inspect engine harness and electrical components.
1.7 Main power relay not functioning Listen for relay to click when the key switch is turned on.
Remove fuel pump fuse.
Unplug all direct injector connectors.
Remove spark plugs, one at a time, from each cylinder.
Connect spark plug leads to spark gap tester.
1.8 Spark plugs1. Crank engine, or use CDS output load test, for each ignition coil and observe
spark.
If no spark is present, replace appropriate ignition coil.
If spark is present, replace spark plugs.
Injection system:
Listen for injector ticking when cranking or connect spare injector to each
respective harness.
Ticking should start after two cranking revolutions.
Ignition system:
Check for proper operation by using an inductive timing light.
Check battery voltage while the engine is cranking, there should be no less
than 8 VDC at the power stud.
1.9 PCM not functioning
Check for blown fuse.
Check battery voltage to fuse from main power relay (purple).
Check for shorted stop wire (black/yellow).
Check the electronic spark trigger (EST) ground circuit for open or high
resistance. Normal resistance between pins B1 and C24 of the PCM should
be 0.5 ohm or less. If the PCM EST circuit has failed, all ignition coils should
be tested for proper functioning before installing a new PCM. A defective
ignition coil can cause the PCM EST ground circuit to fail.
Check crankshaft position sensor.
Defective PCM.
1.9A Crankshaft position sensor not functioning
Check battery voltage while the engine is cranking, there should be no less
than 8 VDC at the power stud.
1. Spark jumping the gap from all cylinders at the same time in the spark gap tool may cause interference in the PCM. The interference may cause
the absence of spark on some cylinders and a false diagnosis of a no spark condition. Crank engine over with only one spark plug wire connected
to spark gap tool at a time or use CDS to fire one cylinder at a time.
2. If the spark plug is partially fouled or the plug gap is too small, the CDS may indicate the incorrect cylinder as having an ignition fault. Example: If
the CDS indicates an ignition fault on cylinder #3, the problem may be on the prior cylinder in the firing order i.e. cylinder number #2.
Fuse Replacement
Wiring circuits on the outboard are protected with fuses. If the silver band is broken, the fuse is blown. If a fuse is blown, locate
and correct the cause of the overload. If the cause is not found, the fuse may blow again. Always replace the fuse with the same
fuse rating.
26686
a b c d e f
26685
PCM 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.
a
c
26827
5. Move the wire harness to gain access to the screw securing the PCM to the ignition plate.
6. Remove the three screws securing the PCM.
a - Screw (3)
26828
PCM Installation
IMPORTANT: All replacement PCM's are programed for a starboard engine installation. Replacing the PCM on a multiple engine
application requires the engine location to be programed into the PCM using the CDS.
a - Grommet (3)
b - Bushing (3)
a
b
26829
3. Secure the PCM to the ignition plate with three screws and washers. Tighten the screws to the specified torque.
a - Screw (3)
26828
4. Secure the fuse holder to the PCM with a screw. Tighten the screw to the specified torque.
a
c
26827
28309
Use the DMT 2004 digital multimeter for all of the following tests.
87
87a
86 85
30
7602
c
d e
T12
f
YEL/RED
30
86 85
h g
YEL/RED
b
BLK
BLK
87
RED
BLK
RED
RED
RED
C28
C14
BLK
RED
a
RED
BLK
RED RED
T9
RED RED
1 9 17 S105 S109
4 YEL/PUR
B
C21
S102
S104
PUR
RED/BLU
8 16 24
BLK BLK
1 12 22
1
RED/BLU
A
C22 LT BLU/WHT
LT GRN/WHT
C1
PUR
YEL/RED E P
TAN/LT BLU F D N
C
GRY G M
A B
BLK/YEL H L
K
11 21 32 BLK
J
DK BLU 29860
WHT
a- PCM
b- Power stud
c- Start solenoid
d- Starter
e- Main power relay
f- 15 amp fuse Remote harness, main power relay, and cowlmounted trim switch
g- 20 amp fuse Ignition coils circuit
h- 20 amp fuse Electric fuel pump, PCM driver power, oil pump circuit, fuel pump circuit, and direct injectors circuit
f h
g
b d
30
YEL/RED
86 85
c e 87
C28
YEL/RED
BLK
RED
BLK
RED
RED
RED
RED
C14
RED/WHT
YEL/PUR
RED/PUR
RED
RED/WHT
RED/BLK
RED/BLU
RED/YEL
RED/PUR
RED/WHT
RED
a
RED
S105 T9
RED
1 9 17
RED
4 YEL/PUR
B RED/WHT
C21
RED/WHT S109
RED/PUR
BLK BLK
8 16 24
RED/PUR
RED/PUR
1 12 22 RED/PUR S104
1
PUR
A LT BLU/WHT
C22
S102 LT GRN/WHT
C1
PUR
YEL/RED E P
TAN/LT BLU F D N
C
GRY G
A
M
B
BLK/YEL H L
J K
RED/PUR
11 21 32 DK BLU
WHT
BLK T16 29945
BRN/WHT
a- PCM
b- 5 amp fuse SmartCraft circuit
c- 20 amp fuse Electric fuel pump, PCM driver power, oil pump circuit, fuel pump circuit, and direct injectors circuit
d- 20 amp fuse Main power relay, engine harness, power trim
e- 20 amp fuse Ignition coil circuit
f- Start solenoid
g- Starter
h- Main power relay
BLK
b d
f
c e
YEL/RED
T2
C12 g
a
YEL/RED
RED
RED
RED
RED
C20
BLK
RED
RED
BLK
1 9 17
RED/WHT
RED/BLK
RED
RED/PUR
YEL/PUR
RED/PUR
RED/BLU
RED/WHT
RED/WHT
RED/YEL
RED
RED
4
B
RED/WHT
8 16 24 RED/WHT S9
1 12 22
BLK BLK
1
S1 RED/PUR
RED/PUR RED/PUR
C
C1
BLK/YEL
S3 PUR
11 21 32 TAN/LT BLU 4
BLK 3 5
2 6
YEL/RED
8
GRY 1 7
RED/PUR 29923
a- PCM
b- 5 amp fuse SmartCraft circuit
c- 20 amp fuse Electric fuel pump, PCM driver power, oil pump circuit, fuel pump circuit, and direct injectors circuit
d- 20 amp fuse Main power relay, engine harness, power trim
e- 20 amp fuse Ignition coil circuit
f- Start solenoid
g- Main power relay
Flywheel
The flywheel is weighted and balanced to improve engine running characteristics and is secured to the crankshaft with a washer
and nut. The top ring gear is used with the starter motor to start the engine. The flywheel is cast with a position pattern which
allows the PCM to monitor the position of the crankshaft while the engine is running. As the pattern passes the crankshaft position
sensor, an electrical pulse is generated and sent to the PCM. The frequency of the pattern provides crankshaft location information
to the PCM. The PCM will use this information to regulate ignition and fuel injector timing.
a a - Flywheel
9630
Flywheel Removal
! WARNING
An unexpected engine start due to rotation of the flywheel may cause serious injury. During removal, installation, or adjustment
of the flywheel, always remove the spark plug leads and isolate the leads to the engine ground.
! 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.
a - Flywheel holder
a
9753
7. Hold the flywheel with the flywheel holding tool and tighten the flywheel puller bolt until the flywheel is loose.
9757
a - Flywheel puller
NOTE: Do not strike the flywheel with a hammer or use heat to aid in the removal of the flywheel. Striking the flywheel with
a hammer or using heat to assist in the removal of the flywheel will damage the flywheel.
8. Remove the flywheel. Inspect the flywheel for cracks or damage.
9. Inspect the flywheel key for damage. Replace the flywheel key as required.
Installation
IMPORTANT: Clean the flywheel taper and the crankshaft taper with a solvent to remove contaminants. Always assemble the
flywheel to the crankshaft dry.
1. Install the flywheel key.
2. Install the flywheel onto the crankshaft. Ensure the flywheel key has not dislodged from the crankshaft keyway.
3. Secure the flywheel to the crankshaft with a washer and nut.
4. Hold the flywheel with the flywheel holding tool and tighten the flywheel nut to the specified torque.
a - Flywheel holder
9758
a - Ignition coils
9634
NOTE: The test ohm value readings listed is taken at 20 C (68 F) with a digital ohmmeter. Due to the number of different
manufacturers of meters available and temperature variance, test results may vary. Testing of the ignition spark plug lead is not
polarity sensitive.
c
a- Spark plug lead
b- Support webbing
c- Ignition coil boot
a d d- Retention ribs
9637
b
3. Remove the screws securing the ignition coils to the ignition plate.
a
c
b
9733
a
c
b
9733
a - Pin C24
b - Pin B1
a
32395
If a PCM is diagnosed as the reason for a no spark condition, test all ignition coils resistance following the ohm/pinout tests.
Replace any defective coils prior to replacing the PCM.
There are two different 5 pin ignition coils used; coil base P/N 883778 and 879984. The following information shows the ohm
values for both. Note the value between pin C and the secondary tower are different between the two coils.
NOTE: Ohm values will vary depending on the style and type of meter used. If an ohm reading is outside of the listed values by
a small amount, but the same readings are found on all or most of the ignition coils for that engine, it is likely there is nothing wrong
with the coil just a variation with the meter. When a coil is failed, the value will be outside the specified limits by a significant
amount.
Examples: A test meter that uses a 1.5 volt battery versus a meter that uses a 9 volt battery for a power source, will have different
readings. An analog meter versus digital meter will also have different readings. A high ohms value in the megaohm range may
show as infinite or an open circuit on some meters.
NOTE: Ignition coil harness service replacement connector P/N 854839T02 can be used to help test the coils by providing better
access to the coil connector pins.
b c
d a- EST pin A
a b- EST low pin B
e c- Secondary low pin C
d- Primary ground pin D
e- Battery (+) pin E
36993
NOTE: Coil base P/N 883778 ohms value between pin C and the secondary tower should be 28 megaohm. Coil base P/N 879984
ohms value between pin C and the secondary tower should be 8501200 ohms.
g 12V +
+
e
f d
c
a b
28359
a- PCM
b- EST ground ()
c- Secondary ground ()
d- Primary ground ()
e- Battery (12 v +)
f- EST digital signal (5 v +)
g- Solid state switch
a 9640
NOTE: If the engine problem occurs above 3000 RPM (runs rough, no high RPM), the ohm test of the crankshaft position
sensor may be good, but the crankshaft position sensor can still be defective.
c d a- Magnet
b- CPS
c- Pin 1
d- Pin 2
a 17025
26822
26822
26865
9641
a
26905
b
26935
2. Install the TPS onto the throttle lever bracket. Ensure the TPS is seated on the throttle lever bracket.
3. Apply Loctite 271 Threadlocker to the threads of the two screws that secure the TPS to the throttle lever bracket.
a
26905
i
g h
f
a
b
c
d
e
26896
a- Screw (3)
b- Throttle position sensor
c- Coupler
d- Screw
e- Washer
f- Bushing
g- Cam
h- Screw
i- Bracket
i
g h
f
a
b
c
d
e
26896
a- Screw (3)
b- Throttle position sensor
c- Coupler
d- Screw
e- Washer
f- Bushing
g- Cam
h- Screw
i- Bracket
26966
b a - Pin A
b - Cylinder block coolant temperature sensor
c - Pin B
a c
16973
2. Remove the cylinder block coolant temperature sensor from the cylinder block.
26966
13384
2. Install the cylinder block coolant temperature sensor into the cylinder block. Tighten the cylinder block coolant temperature
sensor to the specified torque.
3. Connect the engine harness connector to the cylinder block coolant temperature sensor.
26966
26974
b a - Pin A
b - Air compressor head temperature sensor
c - Pin B
a c
16973
26976
13384
4. Connect the engine harness connector to the air compressor head temperature sensor.
26976
26978
4. Use the DMT 2004 digital multimeter to perform an ohm check between the MAP sensor pins A, B, and C.
d a- Pin C
b- Pin A
c- Pin B
d- MAP sensor
a b
c
23432
26979
4. Secure the retaining bracket with a screw. Tighten the screw to the specified torque.
26979
26983
5. Immerse the MAT sensor into a temperature controlled media. If the readings do not match those in the table, replace the
MAT sensor and retest.
b a - Pin A
b - MAT sensor
c - Pin B
a c
16973
a b
26985
13384
2. Install the MAT sensor into the intake manifold. Tighten the MAT sensor to the specified torque.
a b
26985
Shift Switch
The shift switch is mounted on the exhaust adapter plate and is activated by a cam/notch in the upper shift shaft. The switch
position is monitored by the PCM. The PCM will change fueling, timing, and RPM limit according to whether the engine is in gear
or in neutral. There are two different shift switch activations used on the 1.5 Liter OptiMax outboards. The direction of the shift
switch activation is dependent on the manufacture year of the outboard. The OptiMax GEN II has a cam design on the upper shift
shaft that depresses the plunger while in neutral. Prior to the GEN ll change, the shift switch is normally open when in neutral.
The switch function can be monitored by the CDS.
a 9702
If the shifting operation is difficult, the shift interrupt switch function can be checked by the CDS for an open or closed operation
or with an ohmmeter.
Warning Horn
Function Sound Description
Start up One beep Normal system test.
Low oil Four beeps every Oil level is low in the oil tank. Refill the oil tank. Refer to Fuel and Oil.
2 minutes
Water in fuel Four beeps every Water in the fuel filter chamber reached the full level. Water can be removed from the
2 minutes chamber. Refer to Maintenance - Fuel System for water removal.
Cooling system Continuous Engine Guardian System is activated. Power limit will vary with level of overheat. Shift
problem outboard into neutral and check for a steady stream of water coming out of the water
pump indicator hole. If no water is coming out of the water pump indicator hole or flow
is intermittent, stop engine and check water intake holes for obstruction.
Oil level is critically Continuous Engine Guardian System is activated. Power limit will allow a fast idle. The oil level
low is critically low in the oil tank. Refill the oil tank. Refer to Fuel and Oil.
Oil pump failure Continuous Engine Guardian System is activated. Power limit will allow a fast idle. The warning
horn is activated if the oil pump should ever stop functioning electrically. No lubricating
oil is being supplied to the engine.
Warning Horn
Function Sound Description
Engine overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum
allowable RPM. The system will limit the engine speed to within the allowable range.
Engine overspeed indicates a condition that should be corrected. Overspeed could
be caused by incorrect propeller pitch, engine height, trim angle, etc.
Sensor out of range Continuous Engine Guardian System is activated. Power limit may activate at full throttle speed.
Intermittent beep Engine Guardian System is activated. Power limit may restrict engine speed to idle.
Engine running cold One beep Engine is not reaching correct temperature while operating below 1000 RPM. Have
at slow speed your dealer check the engine.
Notes:
Electrical
Section 2B - Charging and Starting System
Table of Contents 2
B
Charging and Starting Specifications.................................2B-2 Diagnosis of Alternator System on the Engine.........2B-15
Flywheel/Alternator............................................................2B-4 Alternator System Circuitry Test...............................2B-16
Starter Motor Components.................................................2B-6 Alternator Removal...................................................2B-18
Battery................................................................................2B-8 Alternator Installation................................................2B-19
Battery Cable Test......................................................2B-8 Starter System.................................................................2B-20
Original Battery Cable Length and Gauge Shipped with Starter Motor Amp Draw...........................................2B-20
Engine.....................................................................2B-8 Starting System Components...................................2B-20
Battery Cable Size for Outboard Models....................2B-8 Starter System Description.......................................2B-21
Replacement Parts...................................................2B-10 Wire Color Code Abbreviations................................2B-21
Recommended Battery.............................................2B-10 Starter Circuit Troubleshooting.................................2B-21
Battery Precautions..................................................2B-10 Starter Removal........................................................2B-33
Charging a Discharged Battery.................................2B-10 Starter Solenoid Replacement..................................2B-33
Winter Storage of Batteries.......................................2B-11 Starter Motor Pinion Gear Replacement...................2B-36
Alternator System............................................................2B-11 Starter Installation.....................................................2B-37
Wire Color Code Abbreviations................................2B-11 Key Switch Test...............................................................2B-38
System Components................................................2B-12 Three Position Key Switch........................................2B-38
Alternator Description...............................................2B-15 Four Position Key Switch..........................................2B-39
Special Tools
DMT 2004 Digital Multimeter 91892647A01
TEMP
A mA COM V Hz
4516
1. All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in the "OFF" position and an amperage draw
of not more than 350.0 mA with key in the "ON" position.
Notes:
Flywheel/Alternator
15
6
17
7
16
8 1
13
11
14 2
12
10
3
14 1683
Flywheel/Alternator
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Flywheel
2 1 Damper
3 3 Screw 33.9 25
4 1 Belt
5 1 Alternator
6 2 Screw (M10 x 45) 47.5 35
7 1 Washer
8 1 Cable
9 1 Nut (M6) 5.6 50
10 1 Alternator bracket
11 1 Pin 5.1 45
12 3 Mount
13 3 Screw (M10 x 45) 47.5 35
14 6 Washer
15 1 Plug
16 1 Washer
17 1 Nut 163 120
6
5
9
8 3
11 1
10
12
7
13 1339
Battery
Battery Cable Test
This test is used to determine if there is excessive resistance in the battery's positive or negative cables, or if the cable is sized
properly to carry the necessary current needed to crank the engine at the proper RPM.
IMPORTANT: This test must be performed while the key switch is in the "START" position. Ignore any voltage readings taken
without the circuit under load.
! WARNING
Moving parts can cause serious injury or death. Wear eye protection and keep hands, hair, and clothing away from moving parts
when performing tests or checking adjustments on an operating engine.
Disconnect the electric fuel pump and crankshaft position sensor from the engine harness where applicable. Disconnect and
isolate the spark plug leads on the engines that do not have a crankshaft position sensor. This will prevent the engine from starting
while performing the battery cable test.
1. Perform a load test on the battery following the instructions supplied with the load tester. Ensure that the battery is fully charged
after the load testing.
2. With the key switch in the "START" position, measure the voltage across the battery posts, not the cable clamps. Record the
voltage reading. If the voltage is less than 10 VDC, replace the battery.
3. Connect the red meter lead to the battery positive post. Connect the black meter lead to the starter post (the stud where the
battery positive cable is connected). With the key switch in the "START" position, measure and record the voltage.
4. If the voltage reading in step 3 was more than 1.0 VDC:
a. Check the cable connections for tightness and corrosion.
b. If the cable is tight and not corroded, replace the cable with a larger diameter cable.
5. Connect the black meter lead to the starter case. Connect the red meter lead to the battery negative post (not the cable clamp).
With the key switch in the "START" position, measure and record the voltage.
6. If the voltage reading in step 5 was more than 1.0 VDC:
a. Check the cable connections for tightness and corrosion.
b. If the cable is tight and not corroded, replace the cable with a larger diameter cable.
Resistance in the cables can cause a voltage drop and limit current to the starter. If corrosion is present, or if the starter is worn,
there may not be enough amperage to turn the starter motor.
NOTE: If the voltage at the starter is less than 11 VDC, the engine may not start.
b
2758
Replacement Parts
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal
and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components
that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all
components.
IMPORTANT: Deepcycle batteries are not suitable for use as engine starting batteries or for use as accessory batteries that are
connected to high output engine charging systems. Deepcycle battery life may be shortened by high output engine charging
systems. Refer to individual battery manufacturer instructions for specific battery charging procedures and applications.
Recommended Battery
A 12 volt marine battery with a minimum cold cranking amperage rating of 800 amperes or 1000 (minimum) marine cranking
amperes or 180 Ah (Amperes Hour) should be used.
Battery Precautions
! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe
burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
When charging batteries, an explosive gas mixture forms in each cell. Part of this gas escapes through holes in the vent plugs
and may form an explosive atmosphere around the battery if ventilation is poor. This explosive gas may remain in or around the
battery for several hours after it has been charged. Sparks or flames can ignite this gas and cause an internal explosion, which
may shatter the battery.
The following precautions should be observed to prevent an explosion:
1. Do not smoke near batteries being charged or which have been charged very recently.
2. Do not break live circuits at terminals of batteries, because a spark usually occurs at the point where a live circuit is broken.
Always be careful when connecting or disconnecting cable clamps on chargers. Poor connections are a common cause of
electrical arcs which cause explosions.
3. Do not reverse polarity of battery terminal to cable connections.
Alternator System
Wire Color Code Abbreviations
Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark
System Components
The charging system consists of the alternator, battery, 100 amp fusible link, and wiring that connects these components.
BLK b
e f
c
d
a
YEL/RED
YEL/RED
RED
BLK
RED
RED
RED
C14
RED
C6
PUR
BLK
RED
BLK
RED RED
T9 T8
RED RED
S105
PUR
RED RED
S102
i h S104
RED/BLU
BLK BLK
RED/BLU
LT BLU/WHT
j
LT GRN/WHT
C1
PUR
YEL/RED E P
TAN/LT BLU F D N
C
GRY G M
A B
BLK/YEL H L
J K
BLK
DK BLU
WHT
T16 45923
BRN/WHT
a
c
d
YEL/RED
YEL/RED
RED
BLK
RED
BLK
RED
RED
RED
RED
C6
C14
RED
PUR
RED/WHT
RED/WHT
RED/BLK
RED/BLU
RED/YEL
RED/PUR
RED
RED
S105 T9 T8
RED RED
f
RED
RED
RED
PUR
BLK BLK
S104
RED/PUR RED/PUR
RED/PUR RED/PUR
PUR
PUR
g
LT BLU/WHT h
LT GRN/WHT
C1
PUR
YEL/RED E P
TAN/LT BLU F D N
C
GRY G
A
M
B
BLK/YEL H L
J K
RED/PUR
DK BLU 29943
WHT
BLK T16
BRN/WHT
S/N 1B2270001B417701
a - 20 amp fuse Main power relay, engine harness
b - Start solenoid
c - Alternator ground
d - Alternator
e - Alternator sense and excitation leads
f - 100 amp fusible link
g - Battery
h - 14 pin harness connector
a c
BLK
e
g
f
b d
YEL/RED
T2
C12
YEL/RED
RED
RED
h
RED
RED
i
PUR
RED
RED
RED/PUR
T20 T21
PUR
BLK BLK
RED/PUR S1 RED/PUR
RED/PUR RED/PUR
j
k
C1
BLK/YEL
PUR
TAN/LT BLU 4
BLK 3 5
YEL/RED 2 6
8
GRY 29927
1 7
RED/PUR
S/N 0T8010001B226999
a - 5 amp fuse SmartCraft power
b - 20 amp fuse Power trim
c - 20 amp fuse PCM, fuel injectors, direct injectors, oil pump, fuel pumps
d - 20 amp fuse Ignition coils
e - Start solenoid
f - Alternator ground
g - Alternator
h - Alternator sense and excitation leads
i - 100 amp fusible link
j - Battery
k - 8 pin harness connector
Precautions
The following precautions must be observed when working on the alternator system. Failure to observe these precautions may
result in serious damage to the alternator system.
1. Do not attempt to polarize the alternator.
2. Do not short across or ground any of the terminals on the alternator, except when specifically instructed.
3. Never disconnect the alternator output lead, regulator harness, or battery cables when the alternator is being driven by the
engine.
4. Always remove the negative () battery cable from the battery before working on the alternator system.
5. When installing the battery, be sure to connect the negative () (grounded) battery cable to the negative () battery terminal,
and the positive (+) battery cable to the positive (+) battery terminal. Connecting the battery cables to the battery in reverse
will result in blowing the 100 amp fusible link in the output lead of the alternator.
6. When using a charger or booster battery, connect it in parallel with the existing battery (positive to positive; negative to
negative).
Alternator Description
The alternator employs a rotor that is supported in two end frames by ball bearings, and is driven at 2.8 times engine speed. The
rotor contains a field winding enclosed between two multiplefinger pole pieces. The ends of the field winding are connected to
two brushes which make continuous sliding contact with the slip rings. The current (flowing through the field winding) creates a
magnetic field that causes the adjacent fingers of the pole pieces to become alternate north and south magnetic poles.
The 3phase stator is mounted directly over the rotor pole pieces and between the two end frames. It consists of three windings
wound 120 degrees electrically out of phase on the inside of a laminated core.
The rectifier bridge contains six diodes which allows current to flow from the ground, through the stator, and to the output terminal,
but not in the opposite direction.
When current is supplied to the rotor field winding and the rotor is turned, the movement of the magnetic fields created induces
an alternating current into the stator windings. The rectifier bridge changes this alternating current to direct current which appears
at the output terminal. The diode trio is connected to the stator windings to supply current to the regulator and the rotor field during
operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that senses the voltage at the battery, and
regulates the field current to maintain alternator voltage for properly charging the battery. Current output of the alternator does
not require regulation, as maximum current output is selflimited by the design of the alternator. As long as the voltage is regulated
within the prescribed limits, the alternator cannot produce excessive current. A cutout relay in the voltage regulator also is not
required, as the rectifier diodes prevent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor field to initially start the alternator charging.
Once the alternator begins to produce output, field current is supplied solely by the diode trio.
The alternator is equipped with two fans which induce air flow through the alternator to remove heat created by the rectifier and
stator.
a - Fusible link
29692
a - Belt
29694
6. Inspect the 100 amp fusible link located on the starboard side of the engine. If the fusible link is blown, check the battery leads
for reversed polarity connection before replacing the fusible link.
29695
Output Circuit
Perform the following tests with a DMT 2004 digital multimeter to ensure the circuits between the alternator and all components
within the charging system are in good condition.
1. Connect the DMT positive (+) lead to the battery positive (+) terminal.
2. Connect the DMT negative () lead to the battery negative () terminal.
3. Supply cooling water to the engine.
4. Start the engine and increase the engine speed to approximately 1300 RPM.
5. Observe the voltage reading.
6. If the reading is between 13.5 and 14.8 volts, switch the DMT to the AC volt position. A reading of 0.25 AC volts or less
indicates the alternator diodes are functional. A reading above 0.25 AC volts indicates the diodes are faulty and the alternator
must be replaced.
NOTE: A voltage reading between 13.5 and 14.8 volts are for starting systems without a battery isolator installed. A battery
isolator will have a parasitic voltage drop and the alternator will compensate for the voltage drop. The output voltage may be
as high as 19 volts.
A very high voltage level measured at the output terminal of the alternator, may be an indication of an open circuit between
the output terminal and the battery. A blown fusible link is the most likely cause for an open circuit.
The reason for the high voltage reading is the alternator sense circuit is indicating reduced battery voltage and causes the
alternator to increase voltage output due to the blown fusible link. The voltage output could be as high as 27 volts. This higher
voltage is sometimes interpreted as a failed regulator and the complete alternator is mistakenly replaced.
7. If the reading is below 13.5 volts:
a. Connect the positive (+) DMT lead to the alternator output stud.
b. Connect the negative () DMT lead to a ground on the alternator.
c. Wiggle the engine wiring harness while observing the voltmeter. The meter should indicate the approximate battery
voltage and should not vary. If no reading is obtained or if the reading varies, inspect the wiring harness for loose
connections, corrosion, breaks, or shorts. Repair or replace the harness as required.
8. If the reading is above 15 volts at the battery without a battery isolator installed, the alternator is overcharging and must be
replaced.
a
29696
Sensing Circuit
1. Unplug the red and purple excitation/sensing wire connector from the alternator.
2. Connect the positive (+) DMT lead to the red pin and the negative () DMT lead to the alternator ground.
3. The DMT should indicate the battery voltage. If battery voltage is not present, check the red lead for a loose or dirty connection,
or damaged wiring.
a
29698
Excitation Circuit
1. Unplug the red and purple excitation/sensing wire connector from the alternator.
2. Connect the positive (+) DMT lead to the purple pin and the negative () DMT lead to the alternator ground.
3. Turn the ignition key to the "ON" position. The DMT should indicate battery voltage. If battery voltage is not present, check
the purple lead for a loose or dirty connection, damaged wiring, or a malfunctioning main power relay.
a b
29700
Alternator 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.
29704
4. Use a breaker bar to relieve the tension on the alternator belt and remove the alternator belt.
a - Breaker bar
b - Belt tensioner assembly
29705
5. Remove the screw securing the alternator ground wire. Do not lose the washer that is under the ground wire.
29708
Alternator Installation
1. Install the alternator onto the mounting bracket.
2. Apply Loctite 271 Threadlocker onto the threads of the two M10 x 50 alternator mounting screws.
3. Install a screw through the ground wire ring terminal.
4. Install a washer onto the screw and secure the alternator to the alternator mounting bracket. Do not tighten the screw.
NOTE: A washer must be under the alternator ground wire ring terminal to prevent the terminal from rotating.
5. Secure the alternator to the mounting bracket with the M10 x 50 screw and tighten both screws to the specified torque.
6. Apply Liquid Neoprene to the alternator ground screw and ring terminal to prevent corrosion.
29708
a - Breaker bar
b - Belt tensioner assembly
29705
29704
Starter System
Starter Motor Amp Draw
Starter Motor Amp Draw
No load amp draw 65 amp
Normal amp draw 200 amp
NOTICE
Engaging the starter motor while the engine is operating can damage the starter motor or flywheel. Do not engage the starter
motor continually for longer than 15 seconds. Do not engage the starter motor when the engine is operating.
Some of the tests require the battery voltage be removed from the starter solenoid to prevent unexpected engine cranking.
The following starter circuit troubleshooting chart will assist in locating any malfunction in the starting circuitry. Do not skip any of
the testing sequence procedures unless advised to do so.
Page 2B-22
7 8 4 3
b
c
10 f
5 d
T12
YEL/RED
a 6
Charging and Starting System
9 e
1 2
BLK
BLK
YEL/RED
RED
BLK
BLK
RED
RED
PUR
RED
RED
YEL/RED
BLK/YEL
PUR/WHT
C14
BLK
YEL/RED
YEL/RED
RED
BLK
S105
RED
11
Starter Circuit Troubleshooting S/N 1B417702 and Above
T9
C10
S104
g RED/BLU
RED
YEL/RED
PUR
BLK/YEL
BLK
BLK BLK
S3 S4 S2
S14
S6
RED/BLU
S1
LT BLU/WHT
BLK
LT GRN/WHT
YEL/RED
C1
PUR
RED
YEL/RED E P E P
BLK/YEL
TAN/LT BLU F D N D N
BRN
F PUR
C C
GRY G M G M
A B A
L
B
BLK/YEL H H L
J K J K
BLK
DK BLU
a- Power stud
b- Start solenoid
c- Starter solenoid
d- 15 amp harness fuse
e- Neutral start switch (tiller handle or remote control)
f- Key switch
g- Battery
Disconnect the lowpressure and highpressure electric fuel pumps from the engine harness. This will prevent the fuel pumps from
activating. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
NOTE: The disconnection of the harnesses will store failure codes in the PCM. The failure codes must be erased after completing
the troubleshooting procedure.
Battery voltage is indicated and the starter solenoid clicks.
Check the battery voltage at test point 9.
Battery voltage is greater than 9.5 volts The starter
motor is defective.
Battery voltage is less than 9.5 volts The starter
Check for battery voltage at test point 4, between the solenoid is defective.
starter solenoid yellow/red wire terminal and a
Test 2
common powerhead ground. Turn the key switch to Battery voltage is indicated and the solenoid does not click.
the "START" position. Check the starter ground at test point 10.
The ground is good The starter is defective.
The starter ground has high resistance or is open Clean
the ground cable connection or replace the ground cable.
Remove the starter motor brush lead from the starter solenoid Starter solenoid pullin coil is good.
at test point 9. Measure the resistance between the exciter Ensure battery is fully charged.
Test 2
terminal of the starter solenoid and the starter solenoid brush
lead terminal. Starter solenoid pullin coil resistance is in excess
of 0.3 10%.
Starter solenoid pullin coil is defective.
d
5
YEL/RED
RED
8
BLK
PUR
YEL/RED
BLK/YEL
PUR/WHT
BLK
BLK
1
BLK
RED
BLK
RED
RED
RED
RED
C14
YEL/RED
YEL/RED
YEL/RED
BLK
RED
S105 T9
RED
RED/WHT
RED/BLK
RED/WHT
RED/BLU
RED/YEL
RED
RED/PUR
10
Starter Circuit Troubleshooting S/N 1B2270001B417701
RED
C10
RED f
RED
RED
YEL/RED
BLK BLK
PUR
BLK/YEL
BLK
S104
RED/PUR RED/PUR
RED/PUR RED/PUR
S3 S4 S2
S14
S6
S1
LT BLU/WHT
BLK
LT GRN/WHT
C1
YEL/RED
PUR
RED
YEL/RED E P E P
BLK/YEL
TAN/LT BLU F D N F D N
BRN
C C PUR
GRY G M G M
A B A
L
B
BLK/YEL H H L
J K J K
RED/PUR
DK BLU
Disconnect the lowpressure and highpressure electric fuel pumps from the engine harness. This will prevent the fuel pumps from
activation. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
NOTE: The disconnection of the harnesses will store failure codes in the PCM. The failure codes must be erased after completing
the troubleshooting procedure.
Battery voltage is indicated and the starter solenoid clicks.
Check the battery voltage at test point 8.
Check for battery voltage at test point 3, between the Battery voltage is greater than 9.5 volts The starter
start solenoid yellow/red wire terminal and a common motor is defective.
Test 2
powerhead ground. Turn the key switch to the Battery voltage is less than 9.5 volts The starter
"START" position. solenoid is defective.
Remove the starter motor brush lead from the starter solenoid Starter solenoid pullin coil is good.
at test point 8. Measure the resistance between the exciter Ensure battery is fully charged.
Test 2
terminal of the starter solenoid and the starter solenoid brush
lead terminal. Starter solenoid pullin coil resistance is in excess
of 0.3 10%.
Starter solenoid pullin coil is defective.
Notes:
4
Charging and Starting System
7 8
A
B
PUR
E
1 T2
TAN/BLU
C
YEL/RED
D
C12
T7
RED
BLK
BLK
PUR
PUR
YEL/RED
RED
YEL/BLK
BLK/YEL
BLK/YEL
RED
YEL/RED
RED
BLK
RED
RED
BLK
RED
RED
10
BLK
BLK
RED
BLK
RED/PUR
PUR
GRY
YEL/RED
Starter Circuit Troubleshooting S/N 0T8010001B226999
S1 RED/PUR
BRN/WHT
TAN/BLU
RED/PUR RED/PUR
f
BLK/YEL
BLK
PUR
C1 YEL/RED
BLK/YEL RED
PUR BLK
TAN/LT BLU 4 TAN/BLU
BLK 3 5
2 6 GRY
YEL/RED BLK/YEL
8
GRY YEL/BLK
1 7
RED/PUR BRN/WHT
GRN/WHT
BLU/WHT
TAN
TAN
BRN/WHT
BLU/WHT 29932
GRN/WHT
Disconnect the lowpressure and highpressure electric fuel pumps from the engine harness. This will prevent the fuel pumps from
activation. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
NOTE: The disconnection of the harnesses will store failure codes in the PCM. The failure codes must be erased after completing
the troubleshooting procedure.
Battery voltage is indicated and the starter solenoid clicks.
Check the battery voltage at test point 8.
Check for battery voltage at test point 3, between the Battery voltage is greater than 9.5 volts The starter
start solenoid yellow/red wire terminal and a common motor is defective.
Test 2
powerhead ground. Turn the key switch to the Battery voltage is less than 9.5 volts The starter
"START" position. solenoid is defective.
Remove the starter motor brush lead from the starter solenoid Starter solenoid pullin coil is good.
at test point 8. Measure the resistance between the exciter Ensure battery is fully charged.
Test 2
terminal of the starter solenoid and the starter solenoid brush
lead terminal. Starter solenoid pullin coil resistance is in excess
of 0.3 10%.
Starter solenoid pullin coil is defective.
Starter 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.
27101
a
a - Starter collars (2)
b - Screw securing the starter ground wire
27102
a - Brush wire
b - Nut securing the brush wire
b
a
27103
4. Remove the three E5 Torx screws securing the starter solenoid to the starter and remove the starter solenoid.
27104
18282
2. Lubricate the end of the starter solenoid actuating plunger with 24C with Teflon.
3. Insert the starter solenoid actuating plunger end onto the fork of the solenoid arm.
23485
4. Secure the starter solenoid to the starter with three E5 Torx screws. Tighten the screws to the specified torque.
27104
a - Brush wire
b - Nut securing the brush wire
b
a
27103
a
a - Starter collars (2)
b - Screw securing the starter ground wire
27102
a - Snap ring
b - Pinion gear
a b
27105
23494
2. Install the pinion gear onto the planetary gear and clutch assembly.
3. Retain the pinion gear to the planetary gear and clutch assembly with a new snap ring.
IMPORTANT: Always install a new snap ring to retain the pinion gear to the planetary gear and clutch assembly.
a - Snap ring
a b - Pinion gear
b
27106
Starter Installation
1. Ensure the starter stop is installed.
a - Starter stop
27107
2. Install the starter onto the cylinder block. Ensure the starter stop is located in the cylinder block starter stop boss.
a - Starter stop
b - Cylinder block starter stop boss
a
27108
3. Insert a starter mounting bolt through the starter ground ring terminal.
4. Secure the starter to the cylinder block with the starter mounting brackets and four screws.
NOTE: The starter mounting brackets must be installed in the same orientation and location they were removed from.
5. Tighten the four starter mounting bracket screws by hand to allow the starter to selfalign with the starter mounting brackets.
6. Tighten the four starter mounting bracket screws to the specified torque.
7. Apply Liquid Neoprene to the upper starter ground and mounting screw.
8. Install the yellow/red exciter wire to the starter solenoid. Secure the yellow/red exciter wire to the solenoid with a lockwasher
and nut. Tighten the nut to the specified torque.
9. Apply Liquid Neoprene to the yellow/red exciter wire connection.
10. Install the starter power cable to the starter solenoid. Secure the starter power cable to the starter solenoid with a lockwasher
and nut. Tighten the nut to the specified torque.
27101
d e f 18868
c b a- Pin A
a b- Pin B
c- Pin C
d- Pin D
e- Pin E
f- Pin F
d e f
11559
Notes:
Electrical
Section 2C - Timing, Synchronizing, and Adjusting
Table of Contents 2
C
Ignition Specifications........................................................2C-2 Throttle Linkage Adjustment S/N 0T8010001B226999
Idle Speed Adjustment (All Models)...................................2C-2 ................................................................................2C-6
Throttle Linkage Adjustment..............................................2C-3
Throttle Linkage Adjustment S/N 1B227000 and Above
................................................................................2C-3
Ignition Specifications
Ignition Specifications
Type Digital inductive
Firing order 123
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
Spark plug lead resistance at 20 C (68 F) 11701330 ohms
Maximum timing Not adjustable; controlled by PCM
Idle timing Not adjustable; controlled by PCM
Throttle position sensor
At idle 0.171.05 VDC
At wideopen throttle 3.764.64 VDC
Crankshaft position sensor
Air gap (S/N 1785000 and above) Not adjustable
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Resistance at 20 C (68 F) 300350 ohms
Special Tools
Computer Diagnostic System (CDS) Order through SPX
Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer Diagnostic
System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA 18003452233
4520 Canada 8003452233
Europe 49 6182 959 149
Australia (03) 95446222
27496
2. Adjust the front mounted WOT cable nuts so there is approximately 14.73 1.1 mm (0.58 0.04 in.) of threads below the
throttle body bracket. Tighten the nuts to the specified torque.
27498
3. Ensure the throttle cable ends are correctly installed onto the throttle cam.
a b
27508
4. Loosen the WOT cable nuts and remove the WOT cable from the cable bracket.
5. Loosen the idle cable nuts.
6. Ensure the throttle lever is contacting the throttle lever stop.
7. Pull on the idle throttle cable to remove the slack.
8. Thread the top nut so it touches the cable bracket.
9. Thread the bottom nut to secure the throttle idle cable to the cable bracket. Tighten the bottom nut to the specified torque.
c
a - Throttle lever stop
b - Throttle idle cable
c - Nut
a
27511
a 27512
14. Pull the throttle lever to the wide open throttle position.
a - WOT stop
b
b - WOT stop adjustment screw
27514
15. Check the clearance of the throttle shutter arm and the throttle shutter stop.
16. Adjust the WOT stop adjustment screw so the throttle shutter arm clearance is between 0.5081.016 mm (0.020.04 in.).
27515
a
b
9863
a - Attaching plate
b - Jam nuts
c - 11.1 1.0 mm (0.44 0.04 in.)
1. Hold the throttle arm against the idle stop and adjust the lower throttle cable nuts to remove excess slack.
2. Hold the throttle arm against the idle stop and adjust the upper throttle cable nuts to remove excess slack.
IMPORTANT: Too much tension on the upper throttle cable will prevent the throttle arm from returning against the idle stop.
a- Throttle arm
b- Idle stop
c- Lower throttle cable
d- Upper throttle cable
b 9864
IMPORTANT: Throttle shutter opening at idle should not, under normal service conditions, require adjustment. However, it
may be checked to verify the clearance is 0.40 mm (0.016 in.) between the throttle shutter and the throttle bore. Adjust the
throttle shutter stop screw accordingly.
9867
3. Hold the throttle arm against the idle stop. Verify the throttle roller is in the throttle cam pocket, and that the roller rotates freely
without binding against the cam. If the roller is not positioned correctly, adjust the roller arm adjustment screw to obtain the
correct alignment.
IMPORTANT: The throttle roller to cam interface is preset at the factory. Under normal service conditions, it should not require
adjustment.
9871
a- Throttle roller
b- Throttle cam pocket
c- Adjustment screw
d- Throttle arm
e- Idle stop
4. Hold the throttle arm against the WOT stop. There should be a 0.5081.016 mm (0.020.04 in.) gap between the throttle
shutter arm and the throttle shutter stop. Adjust WOT stop screw accordingly.
e
d
f
b
c
9873
Fuel System
Section 3A - Fuel Pump
Table of Contents
3
Fuel System Specifications................................................3A-2 Fuel Pump Removal/Disassembly/Reassembly and
Fuel Pump Description/Operation......................................3A-2 Installation......................................................................3A-4
Checking for Restricted Fuel Flow Caused by AntiSiphon Removal......................................................................3A-4
Valves.............................................................................3A-2
Checking Fuel Pump Vacuum...........................................3A-3
Disassembly...............................................................3A-5
Cleaning and Inspection.............................................3A-5
A
Testing Fuel Pump.............................................................3A-3 Reassembly................................................................3A-5
Vacuum Test Troubleshooting....................................3A-4 Installation...................................................................3A-7
1. Electric fuel pump pressure, if used in conjunction with engine mechanical fuel pump, must be limited to no more than 27.4 kPa (4 psi)
5 6 7
8
a - Clear hose
4
3 9 c b - Tfitting
2 10 c - Vacuum gauge
1 11
0
b
a
8271
b
c
27111
Disassembly
1. Remove the two screws holding the fuel pump assembly together.
2. Remove the diaphragms and gaskets. Discard the diaphragms and gaskets.
3. Remove the check valves from the check valve body. Discard the check valves.
9936
Reassembly
1. Insert the retainer through the plastic check valve.
b
a - Retainer
b - Plastic check valve
8278
2. Install the check valves and retainers into the fuel pump body.
27090
3. Do not install the retainers too tight against the check valve. This will cause the check valve to distort and not seal properly
onto the check valve body.
a b
27085
a - Correct installation
b - Incorrect installation
4. Break the rod off from the retainer by bending the rod sideways.
a - Rod
a b - Retainer
8280
5. Install the rod into the retainer cap. Tap the rod down into the retainer until it is flush with the top of the retainer.
a - Rod
b - Retainer
8281
6. Install the boost spring onto the pump body and install the cap onto the boost spring.
a a - Cap
b - Boost spring
c - Pump body
b
c
8282
7. Assemble the remainder of the components. Install the retaining screws through the pump assembly to align the gaskets and
diaphragms. Tighten the screws to the specified torque.
9936
Installation
1. Secure the fuel pump to the VST with two screws. Tighten the screws to the specified torque.
2. Connect the pulse hoses onto the fuel pump assembly and secure with cable ties.
3. Connect the fuel delivery line to the engine.
b
c
27111
Fuel System
Section 3B - Fuel Injection System
Table of Contents
3
Fuel System Specifications................................................3B-2 Air Pressure Regulator.............................................3B-45
Air Compressor Specifications...........................................3B-2 Fuel Injector Test......................................................3B-45
Throttle Body Components S/N 1B417702 and Above......3B-6 Fuel Rail Removal....................................................3B-46
Throttle Body Components S/N 1B417701 and Below......3B-8
Air Hoses.........................................................................3B-10
Fuel Pressure Regulator Removal............................3B-50
Air Pressure Regulator Removal..............................3B-51
B
Air Compressor Components...........................................3B-12 Fuel Injector Removal...............................................3B-52
Vapor Separator Components S/N 1B417702 and Above Direct Injector Removal............................................3B-53
.....................................................................................3B-16 Direct Injector Tests..................................................3B-54
Vapor Separator Components S/N 1B417701 and Below Fuel Rail Cleaning....................................................3B-57
.....................................................................................3B-18 Air Regulator Installation...........................................3B-57
Reed Block Components.................................................3B-20 Fuel Pressure Regulator Installation.........................3B-59
Fuel System Hoses..........................................................3B-22 Fuel Injector Installation ...........................................3B-60
Fuel Rail Components.....................................................3B-24 Direct Injector Installation.........................................3B-61
Vapor Separator/Fuel Rail Mounting................................3B-26 Fuel Rail Installation.................................................3B-61
DFI Operation..................................................................3B-28 Air Compressor Flow Diagram.........................................3B-64
Air Induction..............................................................3B-28 Air Compressor and Fuel Pressure Tests........................3B-64
Air Compressor System............................................3B-28 Air Compressor Test.................................................3B-64
Fuel...........................................................................3B-28 Fuel Pressure Test...................................................3B-66
Oil.............................................................................3B-28 Air Compressor ...............................................................3B-66
Electrical...................................................................3B-28 Air Compressor Removal..........................................3B-66
Operation..................................................................3B-29 Air Compressor Disassembly...................................3B-69
Testing Electric Fuel Pump Output Pressure...................3B-29 Air Compressor Assembly........................................3B-70
LowPressure Electric Fuel Pump (Boost Pump).....3B-29 Air Compressor Installation.......................................3B-74
HighPressure Electric Fuel Pump............................3B-29 Fuel Pressure and Air Pressure Troubleshooting Chart. .3B-77
Vapor Separator Tank......................................................3B-30 Throttle Body ...................................................................3B-78
Vapor Separator Tank Assembly Removal...............3B-30 Throttle Body Assembly Removal.............................3B-78
Vapor Separator Tank Disassembly.........................3B-33 Throttle Body Disassembly.......................................3B-79
Fuel Flow Director ....................................................3B-36 Throttle Body Assembly............................................3B-80
Vapor Separator Tank Assembly..............................3B-36 Throttle Body Assembly Installation..........................3B-82
Vapor Separator Tank Assembly Installation............3B-40 Throttle Cable Installation ........................................3B-82
Fuel Rail...........................................................................3B-43 Air Plenum and Reed Blocks...........................................3B-86
Fuel Pressure Regulator...........................................3B-43 Air Plenum Removal.................................................3B-86
Fuel Pressure Regulator Cutaway............................3B-44 Air Plenum Installation..............................................3B-88
1. Electric fuel pump pressure, if used in conjunction with engine mechanical fuel pump, must be limited to no more than 27.4 kPa (4 psi)
Special Tools
Digital Pressure Meter 91892651A01
5786
Tests fuel and air pressure; the dual gauges allow the viewing of both pressures
simultaneously.
5822
Aids in the removal and installation of the fuel filter cap assembly.
24896
5819
8291
TEMP
A mA COM V Hz
4516
8290
Checks gear housing for leakage prior to filling with gear lubricant. Also used to
pressurize the oil injection system.
29497
11782
3
16 2
15 14
13 12 11 4
10 1
29
17
6
5
9 7
8
20 28
26
27
25
24
23
22
21 19
18
23750
3
16 2
15 14
13 12 11 4
10 1
17 29
28
6
5
9 7
8
30
20
27
26
25
24
23 19
22
21
18
1321
Air Hoses
5
6
1679
Air Hoses
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Hose
2 2 Clamp (15.3 mm)
3 1 Hose
4 1 Hose assembly
5 2 Cable tie
6 1 Air muffler
7 1 Hose
25 31
30
37
27
2 24
20
28
31
22
3 30
21
19 29
14 33 14
23 13
6
4
5
14
1
6 9
5
7
14 18 37 8
10 11
12
15
14
35
16
17
13
36
32
1681
Notes:
18
14
5 3 15
2
27
13
4
11
16
12
33
18 25
29
17 22
20 24
23
21
19
32
28
31
30
26
23704
28
18
14
5 3 15
2
27
13
4
11
16
12
33
18 25
34
17 22
20 24
23
21
19
32
28
29
31
30
26
29
28 2252
4
33
5
25
31
11
30 12
31 23 21 32
14 15
25 29 26
16
22 14 25
10 9
13 18
24
36
8
20
28
27
17
19
1673
3
1
2
13
2
2 12 6 5
8
15
7
4
11
2
10 14
9
1672
2
6
5
3 4
8
9
5
11 12
10 5
15
13
16 5
14
15
13 16
5
14
20
17
23 3
18
21 24
22 21
4
19 5
5 22
2598
10
6 3
7
9 4
110
2
6
8 7
1677
DFI Operation
Air Induction
Air enters the cowl through holes in the top aft end of the cowl. The cowl liner directs the air to the bottom of the powerhead. This
limits salt exposure to the engine components. Air volume entering the plenum is controlled with the throttle body shutter mounted
on the plenum. The throttle body shutter is actuated by the throttle shaft with two cables. When the throttle body shutter opens,
the air passes through the reed valves and into the crankcase. The throttle position sensor (TPS) is mounted on a support plate
and is in contact with the throttle shaft. The TPS transmits throttle angle information to the propulsion control module (PCM).
Fuel
IMPORTANT: Due to the inconsistent fuel quality in some areas, excessive fuel system and combustion chamber deposits are
on the rise. These deposits cause many driveability problems that range from hesitation, rough idle, spark plug fouling, to
detonation problems. This performance characteristic can be greatly reduced through regular fuel system maintenance.
To minimize fuel system and carbon deposit buildup in the engine, it is strongly recommended to add Mercury/Quicksilver
Quickleen Engine Treatment (or equivalent) to your engine's fuel at each tank fill throughout the boating season. Use additive as
directed on the container.
Fuel for the engine is stored in a fuel tank. A primer bulb is installed into the fuel line for priming the fuel system. A diaphragm fuel
pump mounted on the vapor separator tank, pulls the fuel through the fuel line. The fuel pump then pushes the fuel through a
water separating fuel filter. This filter removes contaminants and water before the fuel reaches the vapor separator tank. Fuel
vapors are vented through the bottom cowling into the atmosphere. The electric fuel pump is capable of fuel pressure in excess
of 744.6 kPa (108 psi). Fuel pressure inside the fuel rail must be at a predetermined higher pressure over the air pressure, or the
PCM calibrations will be incorrect. A fuel pressure regulator maintains the higher pressure over the air pressure in the fuel rail and
allows the excess fuel to return into the vapor separator. The fuel pressure regulator diaphragm is held closed with a spring that
requires a specific pressure to force the diaphragm off the diaphragm seat. The backside of the diaphragm is exposed to air rail
pressure. As the air rail pressure increases, the fuel pressure needed to open the regulator will equally increase.
A tracker diaphragm is used to minimize the pressure changes caused by the air compressor and fuel injectors at lower engine
RPM. The tracker diaphragm is located between the fuel and air chambers on the fuel rail. The tracker diaphragm will expand into
the lower pressure chamber side of the fuel rail when a pressure spike occurs.
Oil
Oil is not mixed with fuel before entering the combustion chamber. The oil is stored inside the reservoir. Oil flows from the oil
reservoir to the oil pump. The oil pump is mounted on the electrical plate. The oil pump is a solenoiddriven pump, actuated by
the PCM and includes seven pistons with discharge ports. The oil is discharged into the crankcase and lubricates each cylinder.
The seventh passage lubricates the air compressor. Excess oil from the compressor returns into the cylinder bores.
The PCM will change the discharge rate of the oil pump, depending upon engine demand. The PCM energizes the pump on initial
startup to fill the oil passages, eliminating the need to bleed the oil system. The PCM provides additional oil for the breakin. The
breakin time is determined by the PCM internal clock.
A remote oil tank is available as an option. Crankcase pressure will force oil from the remote oil tank into the oil reservoir on the
engine.
Electrical
The electrical system consists of the PCM, crankshaft position sensor, throttle position sensor, manifold absolute pressure sensor,
engine temperature sensor, ignition coils, fuel injectors, and direct injectors. The engine requires a battery to start and will run off
of the alternator.
Operation
Operation of the engine happens in milliseconds (ms) where exact timing is critical for performance. As the crankshaft rotates, air
is drawn into the crankcase through the throttle shutter into the plenum and through the reed valves. As the piston nears bottom
dead center, air from the crankcase is forced into the cylinder. As the crankshaft continues to rotate, the exhaust and intake ports
close. With these ports closed, fuel is injected into the cylinder. The PCM receives a signal from the throttle position sensor, engine
temperature sensor, crankshaft position sensor, and manifold absolute pressure sensor and determines when to open and close
the injectors and fire the ignition coils. The PCM opens the direct injector milliseconds before the fuel injector is opened and
discharges the air/fuel mixture at the bowl located in top of the piston milliseconds later. The piston's bowl directs the air/fuel
mixture into the center of the combustion chamber. This fuel mixture is then ignited by the spark plug.
Compressor notes: Some direct injectors are held open by the PCM to allow the compression from inside the cylinders to
pressurize the air rail faster within one or two strokes, or 60 of crankshaft rotation.
Idle notes: Idle quality is controlled by fuel volume and fuel timing. The shift switch is mounted on the exhaust adapter plate and
is activated by a cam/notch in the upper shift shaft. The PCM monitors the switch and will change fueling, timing, and RPM limits
according to whether the engine is in gear or in neutral.
60 80100 6080100
40 120 40 120
20 140 20 140
160 160
10043
a - Schrader valve
80 80
60 100 60 100
120 40 120
140 20 140
160 160
10057
! WARNING
Fuel may still remain in the fuel rails and hoses after draining the vapor separator tank (VST). To avoid a possible fire or explosion,
follow normal precautionary procedures while working with the fuel system. Use a suitable container when draining fuel from
the VST and avoid sparks, smoking, and open flame while in the presence of liquid fuel or fuel vapors.
d
10096
a a- Cable ties
b- Drain screw
c- Water sensor connector
d- Rubber hose
e- Drain fittings
b e b
c d 10055
6. Disconnect the engine harness connector from the electric fuel pump harness connector.
10058
7. Remove the fuel delivery hose from the fuel pump.
8. Remove the two fuel pump pulse hoses.
9. Remove the fuel outlet hose and the fuel return hose from the VST.
e
d
e c
10064
a - Fuel pump
b - Screw (2)
10112
a
c
10116
a - Water sensor
b - Oring
10118
10119
5. Loosen the screw securing the float pin to the VST cover. Remove the float, float pin, and needle.
a b a - Float pin
b - Screw securing the float pin
c - Float
c 27133
6. Remove the two screws and retainer securing the boost pump to the VST.
27134
7. Remove the boost pump and the highpressure pump from the VST. Disconnect the fuel pump electrical connectors from
each pump.
NOTE: Unless the VST housing or the fuel pump electrical harness needs to be replaced, do not remove the fuel pump
electrical harness from the VST housing.
a a
a- Orings
b- Boost pump
c- Highpressure pump
d- Electrical connectors
d
b
d c
a
10125
b
10129
d b
e
c 10130
d
c
b
e
a
AB
f
10141
4. Apply 2Cycle Premium Outboard Oil to the electric fuel pump Orings and the electrical harness grommet Orings.
5. Connect the electrical harness to each of the fuel pumps, red on positive (+), black on negative (). Secure the electrical
harness to the highpressure fuel pump with a cable tie.
a a
a - Fuel pump electrical harness
grommet Orings
b - Electrical harness
c - Cable tie
b
c
a
10142
a b a- Screw (2)
c b- Boost pump
c- Highpressure pump
d- Retainer
d 10122
a - Water sensor
b - Oring
10118
a- Elbow
b- Fuel pump
c- Assembly screws
a d- Attaching screws
e- Gasket (hidden)
c
b
e
d
10137
d
a- Float
b- Needle
c- Float pin
d- Screw
c a 10120
b
27141
10119
a
c
10116
c i
b
h
a
10165
f
10058
9. Secure the VST vent hose to the alternator mounting bracket with a cable tie. Do not overtighten the cable tie.
27157
Fuel Rail
Fuel Pressure Regulator
10199
The fuel pump can deliver pressure in excess of 689.5 kPa (100 psi). Excess fuel flows through the fuel pressure regulator and
is directed back into the VST through the fuel return hose. The constant fuel flow through the watercooled fuel rail prevents the
formation of fuel vapor bubbles and reduces the possibility of vapor lock.
A spring inside the fuel pressure regulator maintains a 96.5 kPa (14 psi) higher pressure difference from the air pressure in the
fuel rail. This spring holds the diaphragm against the diaphragm seat. When the engine is running, 648.1 kPa (94 psi) of air pressure
from the air compressor is routed through the air passages to the spring side of the fuel pressure regulator diaphragm. The
648.1 kPa (94 psi) air pressure in addition to the 96.5 kPa (14 psi) spring pressure, regulate system fuel pressure to 744.6 kPa
(108 psi).
6 12 6
12
7 7
11
8 8
11
10 10
9 9
10200
10219
The air pressure regulator limits the air pressure inside the rails to approximately 648.1 kPa (94 psi).
The air regulator uses a spring to control the air pressure. This 648.1 kPa (94 psi) spring holds the diaphragm against the diaphragm
seat. The air must reach a pressure that is equal to or greater than the spring pressure holding the diaphragm closed. When the
air pressure exceeds the pressure of the spring, the diaphragm is lifted off the diaphragm seat, allowing the excess air pressure
to dump into the discharge hose.
10307
! WARNING
Fuel may still remain in the fuel rails and hoses after draining the vapor separator tank (VST). To avoid a possible fire or explosion,
follow normal precautionary procedures while working with the fuel system. Use a suitable container when draining fuel from
the VST and avoid sparks, smoking, and open flame while in the presence of liquid fuel or fuel vapors.
1. Install the fuel/air pressure gauge kit and relieve the fuel pressure into an appropriate container.
d
10096
10179
b
a
c d
10181
a- Fuel hose
b- Water hose
c- Air hose
d- Fuel hose retainer screws
e- Water outlet hose
f- Air hose retainer screws
g- Air outlet hose
h- Fuel return hose
27920
a - Nuts
10182
9. Use a flat tip screwdriver to ensure the direct injectors remain in the cylinder head while removing the fuel rail.
a - Fuel rail
b - Direct injectors
a
b
b
10183
e
d
c
f
a a
b 8363
a- Screws
b- Fuel pressure regulator
c- Diaphragm
d- Spring
e- Cup
f- Regulator housing Oring
a
a - Opposing cover screws
10220
2. Install the air regulator installation tool and apply pressure to the air regulator cover. Remove the remaining two air regulator
cover screws.
10221
a
a - Air regulator installation tool
10223
a- Screws
b- Air regulator cover
c- Diaphragm
d- Spring
e- Cup
c
d
b
e
a a
10232
a - Screws
b - Pry holes
b
8355
3. Use the DMT 2004 digital multimeter to check the resistance between the fuel injector pins and the fuel injector steel body.
Replace the fuel injector if it is not within the specifications.
a - Fuel injector
ON
O FF
8309
a - Direct injector
b - Direct injector removal tool
a
b
10252
a - Cup washer
b - Retainer
10270
4. Inspect the direct injector white teflon sealing ring for signs of combustion blowby. The teflon ring will be streaked brownish
black. If blowby is present, replace the teflon sealing ring. If blowby is not present, the sealing ring may be reused.
5. Inspect the Orings and Teflon ring for cuts or abrasions. Replace the components as necessary.
6. Install the direct injector into the cylinder head.
10267
1. Connect the meter leads to the two direct injector pins. Replace the direct injector if the resistance is out of specification.
1.3
ON
OFF
10264
O U .C H
ON
OFF
27185
d b
c
29087
a
a- Dial indicator
b- Plunger
c- Nose piece
b c d- Tolerance pointers
29481
12. Note the dial indicator reading when the direct injector is actuated. The dial indicator measures the direct injector tip movement.
The dial indicator measurement should be within specification.
f d
b
c
e
29088
a- Dial indicator
b- Screw
c- Harness
d- Button
e- 9 V battery installed
f- Dial indicator set at zero
a a - Cup
b b - Spring
c - Diaphragm
c
8374
a
a - Air regulator installation tool
10223
10221
6. Apply 24C with Teflon to the air pressure regulator screw threads.
7. Install two of the air pressure regulator screws. Do not tighten the screws at this time.
8. Remove the air regulator installation tool.
a
a - Screws
a
10250
a b
e e
c
d 10208
a- Diaphragm
b- Oring
c- Spring
d- Cup
e- Screws
6. Install the cover over the spring/cup/diaphragm assembly. Install the alignment pins from the air regulator installation tool
through two of the regulator cover mounting holes and thread the alignment pins into the fuel rail.
a - Alignment pins
a a
10209
a - Screw
10211
8. Remove the alignment pins and install the two remaining screws. Tighten the screws in two steps, in the sequence shown,
to the specified torque.
2 3
a - Screws
a a
4 1
10212
a
a - Orings
b - Fuel injector nozzle
10185
4. Lubricate the fuel injector Orings with 24C with Teflon.
5. Install the fuel injector into the fuel rail. Turn the injector back and forth slightly to seat the fuel injector Orings into the fuel
rail.
b a - Injector
b - Screws
c - Retainer
a
29608
a
b c d a- Orings
b- Seal/Teflon ring installation tool
c- Teflon seal
d- Seal/Teflon ring sizing tool
27190
b
a
c d
10181
a- Fuel hose
b- Water hose
c- Air hose
d- Fuel hose retainer screws
e- Water outlet hose
f- Air hose retainer screws
g- Air outlet hose
h- Fuel return hose
8. Secure the fuel rail to the cylinder head with two nuts. Tighten the nuts to the specified torque.
a b
10273
27193
k
f m p
g
c d i
o
h
b 10294
3. Start the engine. The air pressure gauge should indicate 655.0 6.9 kPa (95 1 psi) and the fuel pressure gauge should
indicate 751.5 6.9 kPa (109 1 psi).
d
10096
10300
5. If the air pressure does not rise quickly, the following items should be checked:
Dirty air compressor air filter
Leaking air hoses
Broken air compressor reed valves
10303
2. If the fuel pressure does not rise quickly, the following items should be checked:
Proper fuel level in vapor separator tank
Check low pressure fuel pump output
Air Compressor
Air Compressor Removal
1. Use a breaker bar to release the tension on the belt and remove the belt.
b a - Belt
b - Tension pulley
a c - Air compressor
27308
2. Remove the two screws securing the air compressor outlet hose fitting retainer plate and remove the fitting from the fuel rail.
b 10277
4. Remove the air compressor outlet hose and the outlet fitting on the air compressor as an assembly.
NOTE: Removing the air compressor outlet hose from the outlet fitting on the air compressor will damage the air compressor
outlet hose.
5. Remove the air inlet hose assembly from the air compressor.
6. Disconnect the engine harness from the temperature sensor connector.
7. Remove the temperature sensor.
8. Cut the cable tie securing the water inlet hose to the air compressor and remove the water inlet hose.
9. Cut the cable tie securing the water outlet hose to the air compressor and remove the water outlet hose.
f e 27310
27312
11. Cut the cable tie securing the oil delivery line to the air compressor and remove the oil delivery line.
12. Remove the three screws securing the air compressor to the cylinder block.
27313
13. Lift the air compressor up and turn the air compressor over.
14. Cut the cable ties securing the oil return lines to the air compressor and remove the oil return lines.
c
d
27315
27331
2. Remove the screw securing the air compressor end cap to the air compressor block.
3. Remove the end cap.
27332
b
a- Pin
b- Elbow
a c- Inlet fitting
d- Air compressor cylinder head screws
c
d
27334
b
8. Push the connecting rod and piston out of the air compressor block.
9. Remove the screw securing the belt tensioner to the air compressor block. Remove the belt tensioner.
27337
10. Remove the screw securing the belt tensioner pulley to the belt tensioner.
27339
27339
a - Tensioner screw
b - Bushing (2)
c c - Belt tensioner
a b b
27356
a a - AntiSeize Compound
b - Spring end
27358
27337
a - Piston
b - Ring compressor (obtain locally)
a b 27359
a
27360
b a- Belt tensioner
a b- Screw
c- Oil delivery fitting
d- Air compressor pulley sheave
c
d
27361
a - Gasket
b b - Three reeds facing towards the head
a
27367
22. Install the air compressor head and secure with four M8 x 35 screws. Tighten the screws to the specified torque.
23. Apply Loctite 271 Threadlocker to the threads of the pin and install the pin. Tighten the pin to the specified torque.
24. Apply Loctite 567 PST Pipe Sealant to the threads of the elbows. Install the elbows onto the air compressor block and air
compressor cylinder head.
NOTE: The air compressor block elbow must be orientated to point in front of the pin. The air compressor cylinder head elbow
must be orientated towards the port aft side of the air compressor.
25. Apply Loctite 567 PST Pipe Sealant to the threads of the inlet fitting. Install the inlet fitting onto the air compressor cylinder
head. Tighten the inlet fitting so the inlet opening is orientated down.
b
a- Pin
b- Elbow
a c- Inlet fitting
d- Air compressor cylinder head screws
c
d
27334
b
27331
c
d
27315
27313
27312
13384
f e 27310
a - Retainer (2)
b - Air compressor outlet hose
29618
16. Install the fitting into the fuel rail and secure the fitting with the retainer plate.
b 10277
b a - Belt
b - Tension pulley
a c - Air compressor
27308
Throttle Body
Throttle Body Assembly Removal
1. Disconnect the engine harness connector from the throttle position sensor.
2. Loosen the four nuts securing the throttle cables to the throttle body bracket.
3. Remove the throttle cables from the throttle cam.
a
27428
4. Remove the 75.5 mm hose clamp securing the throttle body to the plenum.
5. Remove the throttle body from the plenum.
27429
a - Screw (2)
27434
a b
27435
3. Remove the screw securing the throttle cam to the throttle body assembly.
4. Remove the screw securing the throttle body bracket to the throttle body.
5. Remove the throttle body bracket and the throttle cam.
27437
6. Remove the 75.5 mm hose clamp securing the front seal to the throttle body. Remove the front seal.
27438
27438
a- Throttle cam
b- Bushing
c- Washer
d- Screw
a b c d
27455
7. Align the throttle body bracket mounting holes with the throttle body.
8. Apply Loctite 271 Threadlocker to the M6 x16 and M6 x 40 screw threads.
27437
c 27487
a b
27435
a - Screw (2)
27434
27429
27496
3. Install the WOT throttle cable onto the front mounting location on the throttle body bracket.
4. Adjust the nuts so there is 14.73 1.1 mm (0.58 0.04 in.) of threads below the throttle body bracket. Tighten the nuts to the
specified torque.
27498
c
27507
6. Ensure the throttle cable ends are correctly installed onto the throttle cam.
a b
27508
7. Route the throttle cables over the top of the cylinder block and secure with the throttle cable retainer clamp.
27510
8. Install the throttle idle cable and throttle WOT cable onto the throttle lever.
c 27492
c
a - Throttle lever stop
b - Throttle idle cable
c - Nut
a
27511
a 27512
a - WOT stop
b
b - WOT stop adjustment screw
27514
18. Check the clearance of the throttle shutter arm and the throttle shutter stop.
19. Adjust the WOT stop adjustment screw so the throttle shutter arm clearance is between 0.5081.016 mm (0.020.04 in.).
27515
a c a - Nuts
b - Cable tie
c - Screws (2)
b
27489
c
27525
4. Remove the oil line from the top of the reed plate.
5. Remove the nine screws securing the air plenum to the engine. Remove the air plenum.
a - Oil line
b - Screw (9)
a
27529
6. Remove the 15 screws securing the reed plate to the cylinder block. Remove the reed plate from the cylinder block.
10
8 9
7 6
3 4
2 1
12 11 13
27532
15 14
27536
27536
b a - Throttle cables
b - Throttle cable retainer clamp
27541
10
8 9
7 6
3 4
2 1
12 11 13
27532
15 14
9 a - Oil line
a
8 7
3
1
4
2
5 6 27543
7. Install the manifold absolute pressure sensor from the air plenum. Refer to Section 2A - Ignition - Manifold Absolute
Pressure (MAP) Sensor.
c
27525
Fuel System
Section 3C - Oil Injection
Table of Contents
3
Oiling System Components...............................................3C-2 Engine Oil Reservoir Removal...................................3C-5
Oil System Operation.........................................................3C-4 Engine Oil Reservoir Installation................................3C-6
Oil Pump Output.........................................................3C-4 Priming the Oil Injection Pump..........................................3C-8
Oil Pump Removal and Installation....................................3C-4
Oil Pump Removal......................................................3C-4
Oil Hose Connection..........................................................3C-9
Optional Remote Oil Tank Installation...............................3C-9
C
Oil Pump Installation...................................................3C-4 Low Oil Warning System Activated..................................3C-10
Engine Oil Reservoir..........................................................3C-5
13
12
11
9
14
2
4
3
3 7 11
4 6 9
5 10
3
4 5
3
1
2 6
1 7 8
1682
10319
IMPORTANT: Varify the oil hose to the air compressor is connected to the correct oil pump discharge port. The air compressor
receives less oil than the engine.
a
28411
e
a- Standard oil reservoir/air attenuator (75/90/115 OptiMax)
b- Throttle body opening
c- Air intake opening
f d- Air compressor filter
e- Vent for optional remote oil reservoir
d f- Oil hose fitting for optional remote oil reservoir
a
c
44437
e
a- 115 Pro XS/125 oil reservoir/air attenuator
b- Throttle body opening
c- Air intake opening
d- Air compressor filter
f e- Vent for optional remote oil reservoir
d f- Oil hose fitting for optional remote oil reservoir
b c
44429
2. Disconnect the engine harness connector from the low oil sensor connector.
a 10332
b
a - Air compressor air inlet hose
b - Screws and washers securing the oil reservoir
a
27401
b
a - Oil reservoir
a b - Air compressor air inlet hose
10331
3. Secure the oil reservoir to the cylinder block with two washers and screws. Tighten the screws to the specified torque.
a
a - Screws
10337
a 10332
6. Fill the oil reservoir and prime the oil pump. Refer to Priming the Oil Injection Pump.
7912
IMPORTANT: Fill the engine fuel system with fuel before priming the oil injection pump. Otherwise, the fuel pump will run without
fuel during the priming process and may be damaged.
Prime the oil injection pump as follows:
1. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb until it feels firm.
19779
26846
3. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral into forward
gear 3 to 5 times. This will automatically start the priming process.
NOTE: It may take a few minutes for the pump to complete the priming process.
a - Oil filter
10368
a
c
10369
4. Attach the molded 90 hose to the oil reservoir elbow and secure with a cable tie.
5. Install the 5/16 in. barbed end of the check valve Tfitting into the hose end and secure with a cable tie.
a - Molded 90 hose
b - Check valve Tfitting
c c - Cable tie
a
b 10370
7. Remove the pipe plug from the engine and install the check valve.
8. Remove 300 mm (12 in.) of hose from the bluestriped oil hose coming from the remote oil tank.
9. Attach the bluestriped hose to the check valve Tfitting and secure with a cable tie.
10. Attach the pulse/pressure hose to the check valve on the engine and secure with a cable tie.
a- Check valve
b- Bluestriped hose
a c- Cable tie
d- Pulse/pressure hose
b c
10371
Notes:
Fuel System
Section 3D - Emissions
Table of Contents
3
Exhaust Emission Standards.............................................3D-2 Owner Responsibility..................................................3D-3
What Are Emissions?.................................................3D-2 Exceptions..................................................................3D-3
Hydrocarbons HC....................................................3D-2 EPA Emission Regulations.........................................3D-3
Carbon Monoxide CO..............................................3D-2
Oxides of Nitrogen NOx...........................................3D-2
Manufacturer's Certification Label.....................................3D-3
Service Replacement Certification Label...........................3D-3
D
Controlling Emissions.................................................3D-2 Removal.....................................................................3D-3
Emissions Information.......................................................3D-2 Replacement..............................................................3D-3
Manufacturer's Responsibility.....................................3D-2 Installation..................................................................3D-3
Dealer Responsibility..................................................3D-2
Hydrocarbons HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with
oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as unburned
gases known as hydrocarbons.
Carbon Monoxide CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If
the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of
the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas, but, carbon often combines with insufficient oxygen (one
carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete combustion
and is a dangerous, potentially lethal gas.
Controlling Emissions
There are two principle methods of reducing emissions from a twostrokecycle marine engine. The first method is to control the
air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the
combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.
Emissions Information
Manufacturer's Responsibility
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission
levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency (EPA).
A certification decal/emissions control information label, showing emission levels and engine specifications directly related to
emissions, must be placed on each engine at the time of manufacture.
Dealer Responsibility
When performing service on all 1998 and newer outboards that carry a certification, attention must be given to any adjustments
that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within
the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their
predetermined factory specifications.
Exceptions include manufacturer's prescribed changes, such as that for altitude adjustments.
Owner Responsibility
The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification
standards.
The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed
their predetermined factory specifications.
Exceptions
Carburetor jets may be changed for high altitude use in accordance with factory recommendations.
Single engine exceptions may be allowed with permission from the EPA for racing and testing.
a EMISSION CONTROL
INFORMATION a- Idle speed
b
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES f b- Engine horsepower
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
g c- Piston displacement
c IDLE SPEED (in gear): FAMILY:
d- Date of manufacture
hp cc FEL: g/kWh
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label over the old label. Use a suitable solvent
to remove any traces of the old label adhesive from the display location.
Replacement
If the label is missing or the date code illegible, contact Mercury Marine Technical Service for assistance. A replacement
certification label will be issued through the Technical Service department.
Installation
Install the label on a clean surface in the original factory location.
Notes:
Powerhead
Section 4A - Powerhead
Table of Contents
Powerhead Specifications..................................................4A-2 Crankshaft and End Cap Bearings ..........................4A-49
Cylinder Block and Crankcase S/N 0T8010001B417701 Reed Block Assembly...............................................4A-50
.......................................................................................4A-6 End Bearing Bleed System.......................................4A-51
Cylinder Block and Crankcase S/N 1B417702 and Above Connecting Rods......................................................4A-51
.......................................................................................4A-8 Powerhead Reassembly..................................................4A-53
Poppet/Thermostat Mounting S/N 0T8010001B227699
.....................................................................................4A-10
Powerhead Preassembly Cleaning Recommendations
..............................................................................4A-53 4
Poppet/Thermostat Mounting S/N 1B227000 and Above
.....................................................................................4A-12
Crankshaft Bearings Installation...............................4A-53
Piston and Connecting Rod Assembly.....................4A-55 A
Crankshaft, Pistons, and Connecting Rods.....................4A-14 Installing Piston Rings..............................................4A-57
Throttle Lever and Linkage..............................................4A-16 Connecting Rod Assembly.......................................4A-59
Dressed Powerhead Removal.........................................4A-18 Crankshaft Assembly Installation into Cylinder Block
Removing Engine Component Assemblies......................4A-23 ..............................................................................4A-61
Fuel Rail Removal....................................................4A-23 Crankcase Cover Installation....................................4A-62
Vapor Separator Tank Assembly Removal...............4A-27 Bleed System Check Valve Installation....................4A-65
Air Plenum and Throttle Body Assembly Removal . .4A-30 Thermostat/Poppet Valve Installation.......................4A-66
Alternator Assembly Removal..................................4A-32 Flywheel Installation.................................................4A-67
Electrical Harness Assembly Removal.....................4A-33 Powerhead Installation.....................................................4A-67
Starter Motor Removal..............................................4A-36 Installing Engine Component Assemblies........................4A-68
Air Compressor Assembly Removal.........................4A-36 Flush Hose and Shift Bracket Installation.................4A-68
Oil Pump Assembly Removal...................................4A-37 Reed Plate Assembly...............................................4A-70
Flush Hose and Shift Bracket Removal....................4A-38 Oil Line Routing........................................................4A-72
Powerhead Disassembly.................................................4A-39 Recirculation and Oil Pump Line Installation............4A-73
Check Valves and Poppet Valve Removal...............4A-39 Air Compressor Assembly Installation......................4A-74
End Cap Removal.....................................................4A-40 Starter Motor Installation...........................................4A-75
Cylinder Block Disassembly.....................................4A-41 Electrical Harness Assembly Installation..................4A-76
Cleaning, Inspection, and Repair.....................................4A-46 Alternator Assembly Installation...............................4A-80
Cylinder Block and Crankcase Cover.......................4A-46 Air Plenum and Throttle Body Assembly Installation
Cylinder Bores..........................................................4A-46 ..............................................................................4A-81
Pistons and Piston Rings..........................................4A-47 Vapor Separator Tank Assembly Installation............4A-84
Crankshaft................................................................4A-48 Fuel Rail Installation ................................................4A-85
Powerhead Specifications
Powerhead Specifications
Number of cylinders 3
Displacement 1523.5 cc (92.9 cu. in.)
Stroke 76.2 mm (3.0 in.)
Standard cylinder bore diameter 92.1131 mm (3.6265 in.)
Cylinder bore maximum taper (service) 0.076 mm (0.003 in.)
Cylinder bore maximum out of round (service) 0.076 mm (0.003 in.)
Oversize cylinder bore diameter 0.038 mm (0.015 in.) 92.4941 mm (3.6415 in.)
Oversize cylinder bore diameter 0.076 mm (0.030 in.) 92.8751 mm (3.6565 in.)
Cylinder liner type Cast iron
Compression 620758 kPa (90110 psi) 1.
Crankshaft
Maximum runout 0.0508 mm (0.002 in.)
Main bearing journal 41.275041.2877 mm (1.62501.6255 in.)
Bottom main bearing journal 35.008835.0215 mm (1.37831.3788 in.)
Crankshaft pin journal 35.986735.9994 mm (1.41681.4173 in.)
Connecting rod wrist pin bore diameter 28.077128.0898 mm (1.10541.1059 in.)
Connecting rod crankshaft pin diameter 44.046144.0588 mm (1.73411.7346 in.)
Piston type Aluminum
Piston skirt standard diameter 91.9226 0.0127 mm (3.619 0.0005 in.)
Piston skirt oversize diameter 0.038 mm (0.015 in.) 92.3036 0.0127 mm (3.634 0.0005 in.)
Piston skirt oversize diameter 0.076 mm (0.030 in.) 92.6846 0.0127 mm (3.649 0.0005 in.)
Piston wrist pin bore diameter 23.317423.3260 mm (0.91800.9183 in.)
Piston ring end gap 0.250.46 mm (0.0100.018 in.)
Wrist pin diameter 23.309023.3166 mm (0.91760.9179 in.)
Reed stand open (maximum) 0.51 mm (0.020 in.)
Thermostat
Stamped opening temperature 143
Start to open temperature 6062.7 C (140145 F)
Full open temperature 73.8 C (165 F)
Piston height at full open temperature (minimum) 3.302 mm (0.130 in.)
Water pressure
at 625 RPM (idle) 20.641.3 kPa (36 psi)
at 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Poppet valve opening 48.362.1 kPa (79 psi)
1. When performing cylinder compression test, place lanyard switch in the "OFF" position to prevent operation of direct injectors or remove fuse
controlling fuel and direct injectors.
Special Tools
Lifting Eye 91904551
Threads into the flywheel to remove the powerhead assembly from the driveshaft
housing, or to lift entire engine for removal/installation.
2756
5786
Tests fuel and air pressure; the dual gauges allow the viewing of both pressures
simultaneously.
5822
6255
8505
Used to secure and rotate the powerhead during disassembly and assembly.
8493
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
33
32 29
31
34
26
25
21
28 28
1
16
15
17
22
23
15
3
7 9
21
16 3
21
10
6 12
13
5
14 8 2
35
11 12
24
18
18
19
20 4 26763
20
26
25
21
28 28
1
16
15
17
22
23
15
3
7 9
21
16 3
21
10
6 12
13
5
14 8 2
29
11 12
24
18
18
19
20 4 26765
20
14
13
25 8
12 9
10 6
15
1
11
2 3 4
5
7
11
1675
14
13
25 8
12 9
10 6
15
1
11
2 3 4
17 5
16
21
20 18
7
11
19 9435
10547
10661
1. Disconnect the positive and the negative battery cables from the battery.
2. Remove the top cowling.
3. Disconnect the fuel line.
a - Fuel line
b - Hose clamp
b
a
7907
4. Remove the two screws securing the upper clamp to the lower cowling. Remove the clamp.
a a
a - Screws
b - Upper clamp
10387
5. Remove the nut and washers securing the throttle cable and shift cable.
6. Remove the throttle cable and the shift cable from the cable barrel retainer.
d a b
e f
g 10388
a- Flat washer
b- Locknut
c- Barrel retainer
d- Throttle cable barrel
e- Barrel retainer latch
f- Shift arm nut
g- Shift cable barrel
a- Check valve
b- Hose with blue stripe
c- Cable tie
a d- Pressure hose
c
b c
d
10391
S/N 0T8010001B226999
a - Remote control harness
b - Engine harness
b
a 27582
a
S/N 1B227000 and above
a - Remote 14 pin boat harness
23699
10. Remove the oil reservoir. Refer to Section 3C - Oil Injection.
11. Disconnect the cowl tilt switch connector from the engine harness connector.
10393
b
a- Screw (M6 x 40) (4)
b- Screw (M6 x 16) (1)
c- Nut (M8) (2)
a d- Idle relief boot
10394
a
10396
16. Disconnect the blue and green trim motor harness leads.
a
10401
18. Remove the eight nuts, four washers, and two support plates securing the powerhead to the adapter plate.
c
a- Nuts and washers
b- Nuts and support plates
c- Support plate
d- Protrusion faces down
a a
10402
a - Lifting eye
10410
! WARNING
Fuel may still remain in the fuel rails and hoses after draining the vapor separator tank (VST). To avoid a possible fire or explosion,
follow normal precautionary procedures while working with the fuel system. Use a suitable container when draining fuel from
the VST and avoid sparks, smoking, and open flame while in the presence of liquid fuel or fuel vapors.
1. Install the fuel/air pressure gauge kit and relieve the fuel pressure into an appropriate container.
d
10096
10179
b
a
c d
10181
a- Fuel hose
b- Water hose
c- Air hose
d- Fuel hose retainer screws
e- Water outlet hose
f- Air hose retainer screws
g- Air outlet hose
h- Fuel return hose
27920
a - Nuts
10182
9. Use a flat tip screwdriver to ensure the direct injectors remain in the cylinder head while removing the fuel rail.
a - Fuel rail
b - Direct injectors
a
b
b
10183
27912
2. Cut the cable tie securing the VST vent hose to the alternator bracket.
27910
3. Cut the cable ties securing the fuel pump upper and lower pulse hoses to the cylinder block fittings.
4. Disconnect the engine harness connector from the water sensor connector.
5. Remove the M8 x 35 screw and washer securing the VST to the cylinder block. Remove the VST from the lower VST mounting
grommets.
c
a- Cable tie securing the lower pulse hose
d b- Water sensor connector
c- Cable tie securing the upper pulse hose
b d- Screw (M8 x 35)
a 27974
6. Remove the two M8 x 60 screws securing the washers, grommets, and large spacers to the cylinder block.
a a- Large spacer
b- Grommet
c- Washer
b d- Screw
d 27894
3. Disconnect the engine harness connector from the water sensor connector.
a f a- Cable tie
b- Drain screws
c- Water sensor connector
d- Rubber hose
e- Drain fittings
f- Alternator harnesses
e b
b
10412
c d
4. Disconnect the engine harness connector from the electric fuel pump harness connector.
10058
5. Remove the two fuel pump pulse hoses from the cylinder block.
6. Remove the three screws and washers securing the VST to the cylinder block. Remove the VST assembly.
e
d
e c
10064
10065
3. Disconnect the engine harness connector from the MAP sensor connector.
4. Disconnect the engine harness connector from the manifold air temperature sensor connector.
10069
a - Screw (9)
10070
27666
a
27668
5. Remove the three screws and washers securing the alternator mounting bracket to the cylinder block.
6. Slide the alternator assembly out from under the flywheel. Do not lose the washers that are under the alternator mounting
bracket.
27669
27670
3. Remove the alternator exciter wire harness and the battery charging fusible link cable from the clip on the engine.
27671
5. Disconnect the engine harness connector from the temperature sensor assembly.
6. Remove the water pressure hose from the Legris fitting on the cylinder block.
a
a - Temperature sensor assembly
b - Engine harness connector
c - Legris fitting on cylinder block
c
27672
7. Ensure the trim position sender wire harness is not tangled in the engine harness.
8. Disconnect the trim motor bullet connectors from the engine harness bullet connectors.
9. Disconnect the shift switch bullet connectors from the engine harness bullet connectors.
a
b 27673
10. Remove the red insulating boot covering the starter power cable.
11. Remove the nut and lockwasher securing the starter power cable to the starter.
12. Remove the nut and lockwasher securing the starter exciter wire to the starter.
13. Remove the screw securing the electrical plate ground wire to the cylinder block.
27674
15. Remove the air hose from the retainer securing the air hose to the electrical bracket.
16. Disconnect the engine harness from the air compressor temperature sensor.
17. Disconnect the engine harness from the crankshaft position sensor.
27675
18. Remove the screw securing the ground strap and the electrical bracket to the cylinder block.
a a - Screw
b - Ground strap
27676
19. Move the red insulating boot to expose the nut and lockwasher securing the battery positive cable to the power post. Remove
the nut, lockwasher, and the battery positive cable from the power post.
20. Remove the screw and washer securing the electrical bracket to the cylinder block.
c
27677
a
a - Starter ground
b - Screw (4)
27665
27679
27682
5. Remove the three screws securing the air compressor to the cylinder block.
27685
6. Cut the cable tie securing the oil return line to the cylinder block and remove the oil return line from the fitting.
27686
a - Cable ties securing the oil lines to the 90 crankcase check valve
fittings
b - Cable tie securing three oil lines
c - Cable ties securing the oil lines to the crankcase main bearing
c straight check valve fittings
b
27690
27693
5. Remove the nut and washer securing the shift link to the shift slide.
6. Bend the locking tabs securing the two screws holding the shift bracket to the cylinder block.
c c a- Shift link
b
b- Shift bracket
c- Locking tab securing screw
d- Nut and washer securing shift
link to shift slide
a
d
27705
Powerhead Disassembly
Check Valves and Poppet Valve Removal
1. Remove the three 90 check valve fittings from the crankcase cover.
2. Remove the three straight check valve fittings from the crankcase cover.
b
a
27769
3. Remove the four 90 check valve fittings on the cylinder block.
27770
a - Clip (2)
b - Screw (4)
a
b
27771
5. Remove the thermostat cover, thermostat, and poppet valve assembly from the cylinder block.
g h a- Gasket
b- Spacer
k c- Poppet
j d- Diaphragm
i e- Washer
f- Screw
g- Thermostat
h- Gasket
b
a i- Spring
c d j- Cover
e f k- Clip
27772
a - Screw (3)
10519
2. Remove the 12 perimeter screws securing the crankcase cover to the cylinder block.
a
27777
b
a - Oring
b - Oil seal
10522
a
10525
2. Identify the cylinder location of each connecting rod, piston, and rod cap with a marker or paint.
1 1
10527
3. Use a 12 point socket to remove the connecting rod cap screws. Remove the rod cap, roller bearings, and bearing cage from
the connecting rod.
4. Remove the connecting rod from the crankshaft.
10528
5. Install the rod cap onto the connecting rod assembly. Ensure the rod cap fits perfectly. Thread the rod cap screw into the
connecting rod. Tighten the rod cap screws, but do not torque.
6. Remove the remaining connecting rod assemblies the same way.
10529
a
a - Lockring
b - Lockring removal tool
10530
b a - Piston pin
b - Piston pin tool
10531
a
a - Locating washer (2)
b - Needle bearing (32)
b
10532
11. Remove the upper crankshaft bearing from the crankshaft and inspect for rust, pits, discoloration, and roughness.
10533
12. Remove the center main bearing retaining rings with an awl.
b
a - Retaining ring
b - Awl
a 10534
13. Remove the center main bearing race halves and the bearings from the crankshaft. Discard the center main bearing race
halves and the bearings.
a a
a - Center main bearing
b - Roller bearings
b 10535
10536
15. Inspect the lower crankshaft ball bearing for rust, pits, discoloration, and roughness.
IMPORTANT: Do not remove the crankshaft ball bearing unless replacement is required.
c
10538
2. Install the universal puller plate onto the lower crankshaft bearing.
3. Use the powerhead stand to press the crankshaft ball bearing from the crankshaft.
a a - Press
b - Powerhead stand
c - Universal puller plate
10540
a
a - Pipe plug
b b - Water dam
a
10554
5. Ensure all water passages and oil passages in the cylinder block and crankcase cover are not obstructed.
a - Oil ports
b - Center main bearing locating pins
a a a
b
b b
10553
Cylinder Bores
Inspect cylinder bores for scoring, scuffing, or aluminum transfer. Minor scoring or scuffing can be removed by honing. If aluminum
transfer has occurred, muriatic acid can be applied where the transfer of aluminum has occurred. Flush the cylinder bore with
water to remove any remaining acid.
Honing Procedure
1. Follow the hone manufacturer's recommendations for use of the hone and lubrication during the honing process.
2. A continuous flow of honing oil should be pumped into the work area.
NOTICE
Incorrect or excessive honing may damage cylinder bores, leading to premature engine failure. Follow the hone manufacturers
instructions measure cylinder diameter often.
3. Start stroking at the smallest diameter. Maintain firm stone pressure against cylinder wall to assure fast stock removal and
accurate results.
4. Localize the stroking in the smallest diameter until the drill speed is constant throughout the length of the bore. Expand the
stones, as necessary, to compensate for stock removal and stone wear. Stroke at a rate of 30 complete cycles per minute to
produce the best crosshatch pattern. Use honing oil generously.
5. Clean cylinder bores with hot water and detergent. Scrub with a stiff bristle brush and rinse with hot water. If the abrasive
material is not washed from the cylinder bore, rapid wear of the new piston rings and cylinder bores will occur. After cleaning,
the bores should be swabbed several times with engine oil and a clean cloth, then wiped with a clean dry cloth. The cylinders
should not be cleaned with kerosene or gasoline.
6. Measure the cylinder bore diameter with a snap gauge micrometer or bore gauge in each of the cylinders. Check for tapered,
outofround (eggshaped), and oversize bore.
10555
a - Ring grooves
8652
24 mm
(0.945 in.)
Standard diameter:
a 91.9226 mm 0.0127 mm
b (3.6190 in. 0.0005 in.)
8113
Crankshaft
1. Inspect the crankshaft and driveshaft splines for wear.
2. Check the crankshaft for straightness. Maximum runout is 0.0508 mm (0.002 in.).
3. Inspect the crankshaft oil seal surfaces. Sealing surfaces must not be grooved, pitted, or scratched.
4. Check all crankshaft bearing surfaces for rust, water marks, chatter marks, uneven wear, or overheating. Refer to Connecting
Rods.
a - Crankshaft journal
b - Crocus cloth
a
10561
6. Clean the crankshaft and ball bearing with a solvent. Replace the crankshaft if any surfaces cannot be cleaned up. Lubricate
the surfaces of the crankshaft with 2Cycle Premium Outboard Oil to prevent corrosion. Do not lubricate the crankshaft ball
bearing at this time.
! WARNING
Spindrying bearings with compressed air can cause serious injury or death. The bearings can explode, even if spun at very
slow speeds. Do not allow the bearings to spin when drying with compressed air.
NOTICE
The crankshaft bearings are matched sets. Mismatching the bearings can result in engine damage. Replace and install the
bearings in matched pairs.
a a
a - Center main bearing
b - Roller bearings
b 10535
4. Lubricate the upper roller bearing with 2Cycle Premium Outboard Oil and install onto the crankshaft.
10569
8687
NOTE: Allowable reed opening is 0.51 mm (0.020 in.) or less. Replace the reeds if any reed is standing open more than
0.51 mm (0.20 in.).
Connecting Rods
1. Check the connecting rods for alignment by placing the rods on a surface plate. If light can be seen under any portion of the
machined surfaces, if the rod has a slight wobble on the plate, or if a 0.051 mm (0.002 in.) feeler gauge can be inserted
between any machined surface and surface plate, replace the rod.
2. Check for overheating. Overheating is visible as a bluish bearing surface color, caused by inadequate lubrication or excessive
RPM.
3. Check for rust. Rust formation on bearing surfaces causes uneven pitting of surfaces.
a - Pitting
a
8688
4. Check for water marks. When bearing surfaces are subjected to water contamination, a bearing surface etching occurs. This
etching resembles the size of the bearing.
a - Water marks
a
8690
5. Check for spalling. Spalling is the loss of bearing surface, resembling flaking or chipping. Spalling is most evident on the thrust
portion of the connecting rod in line with the "I" beam. General bearing surface deterioration could be caused or accelerated
by improper lubrication.
a - Spalling
a
8691
a - Brinelling
a
8692
7. Check for uneven wear. Uneven wear could be caused by a bent connecting rod.
a - Uneven wear
a
8694
8695
c. Using a 320 grit carborundum cloth (instead of crocus cloth), clean the wrist pin end of the connecting rod using same
method as in step "b."
d. Thoroughly wash the connecting rods to remove abrasive grit. Recheck the bearing surfaces. Replace any connecting
rods that cannot be properly cleaned up. Lubricate the bearing surfaces of the connecting rods being reused with light
oil to prevent rust.
Powerhead Reassembly
Powerhead Preassembly Cleaning Recommendations
IMPORTANT: Any threaded hole or bolt with threadlocking compound that is contaminated with oil, must be thoroughly cleaned
with a solvent to remove all traces of oil contamination. Failure to remove oil contamination will result in poor threadlocking
compound adhesion.
Prior to assembling the powerhead, all threaded holes on the crankcase cover and cylinder block must be cleared of threadlocking
compound dust. Use compressed air to clear threadlocking compound dust.
Wash the cylinder block and crankcase cover with hot soapy water to remove debris and honing compound. Dry the cylinder block
with compressed air. Failure to thoroughly clean the cylinder block of honing compound and debris will result in premature engine
failure.
d a- Crankshaft
b- Crankshaft ball bearing
c c- Suitable mandrel
d- Press
a b e- Crankshaft journal
10572
a - Retaining ring
10573
10575
7. Lubricate the center main bearings and races with 2Cycle Premium Outboard Oil.
8. Install the center main bearings onto the crankshaft.
9. Install the bearing races onto the crankshaft. Ensure the locating hole on the bearing race points towards the driveshaft end
of the crankshaft.
a a
a - Center main bearings
b - Roller bearings
b 10535
10. Ensure the center main bearing retaining ring bridges both of the center main bearing fractures.
a
b 10577
b
a - Oring
b - Oil seal lip
10522
a
a - Oil seal
a b - Upper crankshaft roller
bearing
10596
8713
5. Insert the piston pin tool and push the sleeve out of the piston. Keep the piston pin tool in the piston.
6. Use a mallet and tap the wrist pin into the piston and push the piston pin tool out.
8715
a- Sleeve
b- Piston pin tool
c- Piston pin tool
d- Wrist pin
7. Install the new piston pin lockrings (one on each end of the wrist pin) with the lockring installation tool.
8717
a - Lockring
b - Lockring installation tool
c b
10625
a - Piston ring
b - Feeler gauge
c - Ring end gap
T1
1T
10626
5. Ensure the piston rings fit without binding in the ring groove.
6. Lubricate the piston, rings, and cylinder wall with 2Cycle Premium Outboard Oil.
8723
a - Locating pin
10627
27819
10632
3. Install the connecting rod bearing cages onto the crankshaft connecting rod journals.
4. Install the bearings into the connecting rod bearing cages.
5. Install the connecting rod assembly to the respective crankshaft journal.
6. Install the rod cap onto the connecting rod. Apply 2Cycle Premium Outboard Oil to the threads and face of the connecting
rod cap screws. Thread the connecting rod cap screws on fingertight.
c
a - Connecting rod cap screws
b - Bearing cage assembly
c - Raised line faces up towards
flywheel end of crankshaft
b
a
10646
b d
8726
3. After ensuring the connecting rod cap is correctly aligned, the rod cap screws must be torqued to specification in three steps.
a a
b
10654
a
a - Awl or scribe
10655
5. Lubricate the crankshaft lower oil seal area with 2Cycle Premium Outboard Oil. Install the lower end cap. Secure the lower
end cap to the cylinder block with two screws. Do not tighten the end cap screws at this time.
a
a - Lower end cap
10656
a
10657
a 10658
18 17
a
4 3
16 15
14 13
6 5
12 11
b
10 9
8 7
10373
a - Screw (3)
10519
27770
2. Install the three straight check valve fittings onto the crankcase cover. Tighten securely to ensure the check valve fittings will
not leak.
b
a
27769
2 3
1
11
10
4
5
6 7 8 12
9
10542
1- Gasket
2- Thermostat
3- Gasket
4- Spacer
5- Poppet
6- Diaphragm
7- Washer
8- Screw
9- Spring
10 - Cover
11 - Clip (2)
12 - Screw (M8 x 35) (4)
Flywheel Installation
1. Clean the crankshaft flywheel taper with a solvent. Ensure there is no debris or grease on the crankshaft flywheel taper.
2. Install the flywheel key.
a - Flywheel key
27823
b
a - Flywheel holding tool
b - Torque wrench
27826
Powerhead Installation
1. Ensure the mating surfaces between the driveshaft housing and the powerhead are scraped clean of gasket material. Failure
to ensure the mating surfaces are scraped clean of gasket material may cause a water leak or exhaust leak between the
powerhead and the driveshaft housing.
2. Install the gasket onto the driveshaft housing.
3. Apply 24C with Teflon to the driveshaft splines. Do not apply 24C with Teflon to the top of the driveshaft.
c
a- Nuts and washers
b- Nuts and support plates
c- Support plate
d- Protrusion faces down
a a
10402
7. Tighten the eight nuts to the specified torque in the sequence shown. After the initial torque, turn the nuts an additional 90.
8
7
4 6
2 1
5 3
27832
13384
3. Apply Loctite 567 PST Pipe Sealant to the threads of the temperature sensor assembly.
27693
8. Install the shift bracket to the cylinder block. Secure the shift bracket to the cylinder block with two screws and locking tab
washers. Tighten the screws to the specified torque. Bend the locking tabs to secure the screws.
a - Shift bracket
b b - Shift slide cam
a
27834
c c a- Shift link
b
b- Shift bracket
c- Locking tab securing screw
d- Locknut and washer securing
shift link to shift slide
a
d
27705
5. Secure the reed blocks to the reed plate with two screws for each reed block. Tighten the screws to the specified torque.
27536
a
10 a - Retaining bracket
8 9
7 6
5
3 4
2 1
11
12
13
15 14
27842
10501
27839
2. Install the Tfitting onto the short recirculation line that is connected to the lower end cap check valve fitting.
3. Install the short recirculation line to the lower check valve fitting on the cylinder block. Connect this short recirculation line to
the Tfitting.
4. Install the long recirculation line to the Tfitting and to the check valve fitting on top of the reed block plate.
d
27840
4. Secure three oil lines to the recirculation line with a cable tie.
a - Cable ties securing the oil lines to the 90 crankcase check valve
fittings
b - Cable tie securing three oil lines
c - Cable ties securing the oil lines to the crankcase main bearing
c straight check valve fittings
b
27690
27686
2. Install the air compressor to the cylinder block and secure with three screws. Tighten the screws to the specified torque.
27685
27682
4. Install the air compressor water hose to the water strainer fitting on the cylinder block and secure with a cable tie.
5. Retain the water hose with the clip on the thermostat cover.
6. Connect the oil pump line with the check valve to the oil line on the air compressor and secure with a cable tie.
27679
a - Starter stop
27107
a - Starter stop
b - Cylinder block starter stop boss
a
27108
a
a - Starter ground
b - Screw (4)
27665
b
a a - Screw
b - Washer
27850
2. Insert a screw with the small washer through the ground wire eyelet. Install the electrical plate to the cylinder block. Secure
the electrical plate to the cylinder block with the screw.
3. Secure the electrical plate to the cylinder block with a large washer and screw.
4. Tighten the two screws to the specified torque.
5. Apply Liquid Neoprene to the screw securing the ground wire eyelet.
c
27677
a a - Screw
b - Ground strap
27676
27675
12. Install the starter power cable to the starter and secure with a nut and lockwasher. Tighten the nut to the specified torque.
Protect the starter power cable connection with the red insulating boot.
13. Secure the starter exciter wire to the starter with a nut and lockwasher. Tighten the nut to the specified torque.
14. Apply Liquid Neoprene to the starter exciter wire terminal.
15. Secure the electrical plate ground wire to the cylinder block with a screw. Tighten the screw to the specified torque.
16. Secure the battery negative cable to the cylinder block with a screw. Tighten the screw to the specified torque.
17. Apply Liquid Neoprene to the screws securing the electrical plate ground wire and battery negative cable to the cylinder block.
27674
a
b 27673
20. Connect the engine harness connector to the temperature sensor assembly.
21. Insert the water pressure hose into the Legris fitting on the cylinder block.
a
a - Temperature sensor assembly
b - Engine harness connector
c - Legris fitting on cylinder block
c
27672
22. Retain the engine alternator exciter wire harness and the battery charging fusible link cable with the clip on the thermostat
cover.
23. Secure the 14 pin harness bracket to the cylinder block with two M6 x 25 screws. Tighten the screws to the specified torque.
27671
24. Secure the oil pump to the electrical harness bracket with three M8 x 20 screws. Tighten the screws to the specified torque.
27670
27669
b c
27854
27666
8 7
3
1
4
2
5 6
27878
10069
7. Install the throttle cable bracket to the cylinder block and secure with a M6 x 16 screw. Do not tighten the screw at this time.
8. Apply Loctite 271 Threadlocker to the M10 x 45 screw threads.
9. Install the throttle lever onto the cylinder block and secure with a washer and M10 x 45 screw.
10. Tighten the throttle lever screw to the specified torque.
11. Tighten the throttle cable bracket screw to the specified torque.
10065
a a- Large spacer
b- Grommet
c- Washer
b d- Screw
d 27894
c
a- Cable tie securing the lower pulse hose
d b- Water sensor connector
c- Cable tie securing the upper pulse hose
b d- Screw (M8 x 35)
e- Screw (M8 x 60) (2)
a 27906
27910
7. Connect the engine harness connector to the VST fuel pump connector.
27912
a
b c d a- Orings
b- Seal/Teflon ring installation tool
c- Teflon seal
d- Seal/Teflon ring sizing tool
27190
27916
b
c
27917
b a - Seal
b - Oring
a
27919
27920
a - Orings (2)
27930
b
27931
a - Oring
27932
Powerhead
Section 4B - Cooling
Table of Contents
Cooling Specifications........................................................4B-2 Troubleshooting.................................................................4B-4
1.5 Liter OptiMax Water Flow............................................4B-2 Water Pressure Check................................................4B-4
Description..................................................................4B-2 Water Strainer.............................................................4B-4
Thermostat.........................................................................4B-3 Water Pressure Sensor..............................................4B-5
Thermostat Measurement Test...................................4B-3 Water Pump Cleaning and Inspection........................4B-6
Cylinder Block Coolant Temperature Sensor.....................4B-3
Air Compressor Head Temperature Sensor......................4B-4
Cooling System Diagnosis..........................................4B-7
4
B
Cooling Specifications
Cooling Specifications
Thermostat
Stamped opening temperature 143
Start to open temperature 6062.7 C (140145 F)
Full open temperature 73.8 C (165 F)
Piston height at full open temperature (minimum) 3.302 mm (0.130 in.)
Water pressure
At 625 RPM (idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Poppet valve opening pressure 48.362.1 kPa (79 psi)
Horn activation and speed reduction is dependent on engine RPM and
Cylinder block over temperature horn activation
load
Air compressor over temperature horn activation 90 C (194 F)
Special Tools
Computer Diagnostic System (CDS) Order through SPX
Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer Diagnostic
System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA 18003452233
4520 Canada 8003452233
Europe 49 6182 959 149
Australia (03) 95446222
Thermostat
Inspect the thermostat. Replace if damaged, seized, or corroded.
3120
26966
26974
Troubleshooting
Water Pressure Check
Check the water pressure using one of these three methods:
Use the computer diagnostic system (CDS).
Water Pressure
Idle 20.641.3 kPa (36 psi)
Poppet valve opening 48.362.1 kPa (79 psi)
Wideopen throttle 75.896.5 kPa (1114 psi)
Water Strainer
The water strainer is located on the port side of the engine below the VST. The water strainer filters the water flowing to the fuel
rail and air compressor.
1. Cut the cable tie securing the water hose to the water strainer fitting and remove the water hose from the water strainer fitting.
2. Remove the water strainer fitting from the cylinder block and clean with compressed air.
3. Apply Loctite 567 PST Pipe Sealant to the strainer threads and install the water strainer into the cylinder block. Tighten the
water strainer fitting securely.
a - Water strainer
10728
d a - Fuel rail
c b - Cylinder block water temperature
b sensor assembly
c - Water pressure sensor
d - Termination resistor
28094
Warning horn
Water pressure low for more than 2 seconds Warning horn activated
Water pressure low for more than 5 seconds Warning horn activated, maximum engine RPM limited
b
8748
2. Inspect the water pump impeller for wear on the impeller blades.
3. Inspect the impeller for bonding between the hub and the impeller.
b
a - Hub
b - Impeller
10731
4. Inspect the impeller blades if they are cracked, burned, hard, or deformed.
5. Inspect the water pump cover and face plate for grooves that are more than 0.76 mm (0.030 in.) deep.
IMPORTANT: Disregard the circular groove formed by the impeller sealing bead when inspecting the cover and plate. The
depth of the water pump sealing groove does not affect the water pump output.
b 8749
a - Rubber seal
b - Rubber gasket
a b
29177
NOTE: The water pump impeller should be replaced whenever the gearcase is removed for maintenance. However, if it is
necessary to reuse the impeller, install the impeller in the same rotation as it was removed. Reversing the impeller rotation will
cause the impeller to fail.
Pressure below specification at idle 20.641.3 kPa (36 psi) Severe internal leak
Thermostat stuck open
Low water pump output
Water inlet restriction
Plugged telltale
Pressure above 44.8 kPa (6.5 psi) at idle 20.641.3 kPa (36 psi) Strainer screen for air compressor
water supply is plugged
Poppet valve flutter/water pressure drop 48.362.1 kPa (79 psi) between 12002100 Water inlet restriction
does not stop prior to 1800 RPM RPM Broken diaphragm in poppet valve
Severe internal leak
Defective poppet valve seal
Mid-Section
Section 5A - Clamp/Swivel Brackets and Driveshaft Housing
Table of Contents
MidSection Specifications.................................................5A-2 Driveshaft Housing...........................................................5A-15
Swivel Bracket and Steering Arm......................................5A-4 Driveshaft Housing Removal and Disassembly........5A-15
Transom Bracket................................................................5A-6 Driveshaft Housing Assembly and Installation..........5A-19
Exhaust Plate.....................................................................5A-8 Transom/Swivel Bracket..................................................5A-27
Driveshaft Housing...........................................................5A-10 Disassembly.............................................................5A-27
Bottom Cowl.....................................................................5A-12 Swivel Bracket/Pin Disassembly...............................5A-29
Bottom Cowl Removal.....................................................5A-14 Swivel Bracket/Pin Assembly...................................5A-30
Bottom Cowl Installation..................................................5A-14 Transom/Swivel Bracket Assembly..........................5A-31
5
A
MidSection Specifications
MidSection Specifications
Recommended transom height:
Long shaft 51 cm (20 in.)
Extra long shaft 64 cm (25 in.)
Steering pivot range 60
Full tilt up angle 75
Trim range 20
Tilt pin adjustment positions 5
Acceptable leakdown in 24 hours 25.4 mm (1 in.)
Allowable transom thickness (minimum) 76.2 mm (3 in.)
Notes:
14
13
12 12
95
17
95
2 6
95
3
1
19
18
8
7
95
6
95
20
24 21 95
23
22 3
4
14 5
15
16 1688
Transom Bracket
87
18 17 5
95
6
2 15 4
3
16
15 95
14
21
13 19
27 1 7
29 7 22
21
21
28
10 9
8
22 20
23
11
12 24
21 22
26
25
1938
Transom Bracket
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Transom bracket (starboard)
2 1 Transom bracket (port)
3 1 Grease fitting 4.5 40
4 1 Tilt tube
5 1 Nut (1.0014)
6 1 Oring
7 2 Wave washer
8 1 Nut (0.87514)
9 4 Washer
10 4 Bolt (0.50020 x 4.50)
11 4 Washer
12 4 Nut (0.50020)
13 1 Tension spring
14 1 Tilt lock lever
15 2 Nyliner
16 1 Compression spring
17 1 Knob
18 1 Groove pin
19 1 Pin
20 1 Anchor bracket
21 6 Screw (M10 x 30) 54 40
22 6 Washer
23 1 Nut (M10) 54 40
24 1 Anode assembly
25 2 Screw (M6 x 25) 7.9 70
26 2 Washer
27 2 Clip
28 1 Cwasher
29 1 Screw (1016 x 0.60)
Exhaust Plate
95
28 3 30
7
29
24
26
23
4
1 25
2 27
6
24 95
2 5 20
19
22
9
10
8
11
95
17
12
21
15
16
18
13 14
1687
Exhaust Plate
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Exhaust plate
2 4 Dowel pin
3 1 Retainer
4 2 Mount
5 4 Screw (M8 x 35) 27 20
6 2 Bolt (M12 x 175)
7 2 Nut (M12) 74.5 55
8 1 Spacer
9 1 Coupling
10 1 Gasket
11 1 Exhaust tube
12 6 Screw (M8 x 35) 27 20
13 1 Seal
14 1 Grommet
15 1 Water tube
16 1 Clamp
17 1 Upper seal
18 2 Screw (M8 x 45) 20.3 15
19 1 Clamp
20 1 Grommet
21 1 Bushing
22 1 Shift shaft
23 1 Shift link
24 2 Bushing
25 1 Washer
26 1 Nut (M6) 5.6 50
27 2 Screw (M8 x 35) 33.9 25
28 1 Screw (M8 x 70) 33.9 25
29 1 Switch
30 2 Screw (M3 x 20) 2.6 23
Driveshaft Housing
18
19
13
24 10
17
19
15
16
20
21
13
9
11
2
6 12
3 14
7
8
4
23
22
5
23
1689
Driveshaft Housing
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Driveshaft housing assembly
2 1 Stud
3 4 Stud
4 5 Washer
5 5 Nut (M10) 54.2 40
6 1 Speedometer hose
7 1 Connector (90)
8 1 Connector
9 2 Mount
10 2 Bolt (M12 x 154) 67.8 50
11 2 Washer
12 2 Nut (M12) 67.8 50
13 2 Ground wire assembly
14 1 Screw (0.25020 x 0.50) 10 88.5
15 2 Clamp
16 4 Nut
17 4 Screw (M8 x 25) 27 20
18 2 Cover
19 4 Screw (1224 x 0.620) 2.3 20
20 2 Washer
21 2 Washer (neoprene)
22 1 Spacer
23 2 Dowel pin
24 2 Plate washer
Bottom Cowl
15
14
11 12 13
16
9 19 22
4 7 21
18
17 5
9 20
34
36
8
32
39 1
2 37
33 10 23 35
24 38
25
26
27
31 6
28
30 3
29
1684
Bottom Cowl
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Bottom cowl (starboard)
2 1 Seal
3 1 Sound blanket
4 1 Bottom cowl (port)
5 1 Seal
6 1 Sound blanket
7 1 Pin
8 1 Cowl latch lever
9 2 Bushing
10 1 Vent fitting
11 1 Cam latch
12 1 Washer
13 1 Screw (M6 x 16) 10.2 90
14 1 Retainer
15 2 Screw (M6 x 16) 7.3 65
16 2 Drain check valve
17 1 Spring
18 4 Screw (M6 x 40) 7.3 65
19 1 Bracket
20 1 Latch
21 2 Screw pin
22 1 Cup
23 2 Screw (M8 x 50) 20.3 15
24 2 Nut (M8) 20.3 15
25 2 Washer
26 2 Stud
27 2 Grommet
28 2 Bushing
29 1 Lower cowl seal
30 1 Trim switch
31 1 Fitting
32 1 Retainer
33 1 Idle relief boot
34 1 Upper clamp
35 1 Lower clamp
36 2 Screw (M6 x 16) 7.3 65
37 1 Foam
38 2 Cable tie
39 1 Spacer
10393
e d
10736
e d
10736
10393
Driveshaft Housing
Driveshaft Housing Removal and Disassembly
1. Remove the powerhead. Refer to Section 4A - Powerhead.
2. Remove the lower unit. Refer to Section 6A - Gear Housing.
3. Remove the shift shaft assembly from the driveshaft housing by pulling the shift shaft straight up.
4. Remove the power trim wiring harness from the exhaust adapter plate.
10742
6. Remove the screws securing the lower mount covers to the driveshaft housing and remove the covers.
a - Screws
b - Cover
10744
a
a b c 10746
a- Screws
b- Port lower mount retainer
c- Starboard lower mount retainer
d- Ground wire port side only
8. Remove the two nuts securing the lower mounts to the bottom yoke.
10748
9. Remove the nuts securing the upper mounts to the swivel pin.
a - Nuts
b - Retainer
c - Bolts
b a
10749
10. Pull the driveshaft housing assembly away from the swivel bracket.
11. Remove the upper and lower mounts from driveshaft housing.
b
10750
a - Screws
b - Adapter plate
13. Use a mallet and a drift to break the gasket adhesion between the exhaust plate and the driveshaft housing. Remove the
exhaust plate from the driveshaft housing.
a a - Adapter plate
b - Drift
c - Protrusion
b
c
10752
14. Remove the two screws securing the water tube and remove the water tube.
a- Water tube
b- Screw (M8 x 45)
c- Exhaust tube
d- Screw (M8 x 35)
e- Water tube seal
d e
b 10753
b
10759
a- Gasket
b- Exhaust tube
c- Screw (M8 x 35) (6)
d- Water tube
e- Screw (M8 x 45) (2)
c c
e
10760
10790
10798
c b
d
a - Mounts
b - Arrows
b a
10807
16. Secure the upper mounts to the driveshaft housing with the clamp and four M8 x 35 screws. Tighten the screws to the specified
torque in the sequence shown.
a
3
1
b 2
10813
a - Clamp
b - Screw
10822
18. Slide the driveshaft housing assembly onto the swivel bracket.
a - Retainer
b - Nuts
10832
a - Nuts
b - Ground wire (port side)
10836
a - Cover
b - Screws
a
10841
c
a - Shift shaft assembly
b - Trim harness
c - Shift link nut (M6)
10846
Transom/Swivel Bracket
Disassembly
1. Trim to full up position. Engage tilt lock lever.
a - Tilt lock
21591
2. Remove the two screws securing the trim position sensor to the starboard transom bracket. Remove the trim position sensor.
c
a
21593
a - Trim sensor
b - Trim sensor mounting screw
c - Ground wire
21594
b c a - Starboard transom
a d bracket
b - Swivel bracket
c - Swivel pin assembly
d - Port transom bracket
e - 17/16 in. hex locknut
f - Tilt tube
g - 11/4 in. hex locknut
g h - Wave washer
f e
h h 21595
a- Swivel bracket
b- Retaining ring
a c- Bottom yoke
d- Swivel pin
d 21580
6. Inspect the bushings in each end of the swivel bracket. Replace if required.
a
a- Thrust washer
b b- Seal
c c- Bushing
d- Swivel bracket
e- Oring
f- Spacer
c
e
f 15501
a - Swivel bracket
a b - Seal
c - Bushing
c
b
15563
b
15612
a- Swivel bracket
b- Oring
c- Spacer
d- Swivel pin
b
a
c
d 15611
6. Align the bottom yoke mount with the upper mount on the swivel pin and assemble the bottom yoke onto the swivel pin.
7. Using a suitable mandrel, install the retaining ring into the groove on the swivel pin.
a- Swivel bracket
b- Retaining ring
a c- Bottom yoke
d- Swivel pin
d 21580
8. Lubricate the swivel pin assembly through the grease fitting in the swivel bracket.
b c a - Starboard transom
a d bracket
b - Swivel bracket
c - Swivel pin assembly
d - Port transom bracket
e - 17/16 in. hex locknut
f - Tilt tube
g - 11/4 in. hex locknut
g h - Wave washer
f e
h h 21595
9201
6. Insert a punch into the trim cylinder rod eye hole to align it with the cross hole in the upper swivel shaft.
7. Install a new trilobe pin in the upper pivot shaft and trim cylinder rod eye. Tap the new trilobe pin in until flush.
21596
8. Install the trim position sensor and ground wire. Secure with two screws. Tighten the screws to the specified torque.
c
a
21593
a - Trim sensor
b - Trim sensor mounting screw
c - Ground wire
Notes:
Mid-Section
Section 5B - Power Trim
Table of Contents
Power Trim Specifications.................................................5B-2 Down Pressure Check..............................................5B-31
Power Trim Components...................................................5B-4 Power Trim System Removal..........................................5B-33
Power Trim General Information........................................5B-6 Power Trim Disassembly.................................................5B-36
General Information....................................................5B-6 Draining Power Trim.................................................5B-36
Power Trim Operation.................................................5B-6 Trim Motor Removal.................................................5B-36
Trailering Boat/Outboard ...........................................5B-6 Power Trim Pump and Components Removal.........5B-37
Manual Tilting.............................................................5B-7 Manifold Removal.....................................................5B-38
Wire Color Code Abbreviations..........................................5B-7 Shock Rod Removal.................................................5B-38
Power Trim Flow Diagrams................................................5B-8 Shock Rod Disassembly...........................................5B-39
5
Trim Up Circuit............................................................5B-8 Memory Piston Removal...........................................5B-41
Tilt Circuit..................................................................5B-10 Power Trim Cleaning, Inspection, and Repair.................5B-42
B
Maximum Tilt............................................................5B-12 Trim Motor Electrical Tests.......................................5B-43
Trim Down................................................................5B-14 Power Trim Assembly......................................................5B-44
Shock Function Up...................................................5B-16 ORing and Seal Placement.....................................5B-44
Shock Function Return.............................................5B-18 Shock Rod Assembly................................................5B-47
Manual Tilt................................................................5B-20 Shock Rod Installation..............................................5B-49
Trim Limit..................................................................5B-22 Trim Limit Installation................................................5B-50
Reverse Operation....................................................5B-23 Manual Release Valve Installation............................5B-50
Troubleshooting...............................................................5B-23 Manifold Installation..................................................5B-51
Hydraulic System Troubleshooting...........................5B-23 Power Trim Pump and Components Installation......5B-52
Power Trim Electrical System Troubleshooting........5B-24 Trim Motor Installation..............................................5B-53
Testing the Power Trim System with Test Gauge Kit......5B-29 Bleeding Power Trim Unit.........................................5B-54
Up Pressure Check...................................................5B-29 Power Trim System Installation.......................................5B-55
Special Tools
DMT 2004 Digital Multimeter 91892647A01
TEMP
A mA COM V Hz
4516
91 822778 1
Measures the internal pressure in the up mode for a single cylinder trim system.
12203
3753
91 822778 3
Install in place of the manual release valve to measure the internal pressure of the
8861 power trim pump in the down mode.
Aids in the removal of the spool from the power trim pump.
8753
Aids in the removal of the spool from the power trim pump.
8754
8775
Allows easy removal of the trim cylinder end caps. Required if tilt limit spacers are
to be installed or if the trim in limit spacer is to be removed (to allow additional trim
in range).
9191
Heats surfaces to aid in the removal and installation of interference fit engine
components.
8776
4799
2
1
b
8
f 7 11
2
d
13
3 11
c
2
4 6
15
6
6
10
15
12
6
14
5
10 e d 10
5 9
10 10
16
5
10
17 5
10
12881
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss of
boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
! WARNING
Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the
operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat
in a safe manner.
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless
steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The
nonstainless steel shipping bolt should not be used in this application other than on a temporary basis.
2. Trimming out or up can:
Lift the bow higher out of the water
Generally increase top speed
Increase clearance over submerged objects or a shallow bottom
Increase steering torque or pull to the left at a normal installation height (with the normal righthand rotation propeller)
In excess, can cause boat porpoising (bouncing) or propeller ventilation
Cause engine overheating if any cooling water intake holes are above the waterline
Trailering Boat/Outboard
Trailer your boat with the outboard tilted down in a vertical operating position.
21997
IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering. The
outboard tilt support lever is not intended to support the outboard for trailering.
Shift the outboard to forward gear. This prevents the propeller from spinning freely.
Manual Tilting
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up during
reverse operation.
IMPORTANT: Do not operate the outboard in either the up or down position with the manual tilt valve open. Damage to the Orings
may occur.
Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard to
the desired position and tighten the manual tilt release valve.
22362
NOTE: In cold climates, the manual release valve should be opened for storage to prevent pressure buildup in the cylinder due
to thermal expansion.
b
a
j l
d i k
v
h
e
u
m n
f
g
t g
z p
y
s r q
22393
Tilt Circuit
b
a
v
h
u
j l
d i k
t e
m n
f
g
g
z p
y
s r q
22394
Maximum Tilt
a
b
v
h
u
x
c
t
j l
d i k
f m n
g
g
o
p
z
s r q
22395
Trim Down
b
a
j l
d i k
v e
h
m n
f
u
g
g
t
o
p
z
x
s r q
22396
Shock Function Up
b
a
y c
v
h
j l
d i k
t e
m n
f
g
g
o
p
x
s r q
22397
b
a
v
h
j l
y d i k
t e
m n
f
g
g
o
p
x
s r q
22398
Manual Tilt
v
h
u
j l
d i k
t e
m n
f
g
g
o
p
x
s r q
22399
Trim Limit
v
h
u
j l
d i k
t e
m n
f
g
g
o
p
z
y
s r q
22400
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or throttling back rapidly, oil in the trim system
must be locked in a static position. This is accomplished with the up and down pressure operated valves. When the pump is not
operating, the shuttle valve is in a centered position and the pressure operated valves are held closed by the springs behind the
valve poppet. Oil is now locked in both ends of the cylinder preventing the trim rod from moving in or out.
Troubleshooting
Support the outboard with a tilt lock pin when servicing the power trim system.
IMPORTANT: After debris or failed components have been found, it is recommended that unit be disassembled completely and
all Orings be replaced. Check valve components and castings must be cleaned using engine cleaner and compressed air, or
replaced prior to reassembly.
IMPORTANT: Power trim system is pressurized. Outboard must be in the full up position (trim rod fully extended) prior to fill/drain
plug or manual release valve removal.
1. Refer to instructions following if disassembly is required when servicing.
2. Follow preliminary checks before proceeding to troubleshooting flow diagrams following.
Preliminary Checks
IMPORTANT: Operate power trim system after each check to see if problem has been corrected. If the problem has not been
corrected, proceed to next check.
1. Ensure manual release valve is tightened to full clockwise position.
2. Check trim pump fluid level with outboard in full up position and fill if necessary. Refer to Bleeding Power Trim Unit in this
section.
3. Check for external leaks in power trim system. Replace defective parts if leak is found.
4. Outboard not holding tilted position (falls down to trim position) indicates debris or defective components in trim assembly.
Clean or replace components as required.
Problem/Solution
No. Problem Solution
1. Low fluid level Add Power Trim and Steering Fluid or ATF (Type Dexron III).
2. Defective hydraulic pump Pressure test pump. Refer to Testing Power Trim System, following.
3. Trim cylinder shock piston ball not seated Inspect ball seat for nicks or contamination.
Trim cylinder piston or memory piston Orings
4. Inspect Orings for cuts or abrasion.
leaking or cut
Manual release valve leaking (check condition
5. Ensure that valve is fully closed. Inspect Orings.
of Orings) (valve not fully closed)
6. Debris in system Inspect for debris. Refill system with clean fluid.
7. Battery low Check battery.
8. Electric motor defective Refer to Electrical System Troubleshooting.
9. Broken motor/pump driveshaft Inspect for damage.
10. Air pocket under pump Trim outboard from full up to full down to purge air. Add fluid as required.
11. Defective up relief valve Replace power trim pump assembly.
12. Defective down relief valve Replace power trim pump assembly.
Condition/Problem
Condition of Trim System Problem No.
The trim motor does not run when the trim button is depressed 1, 2, 4, 5, 6, 7
The trim system trims opposite of the buttons 3
The cowlmounted trim buttons do not activate the trim system 2, 4, 5, 6
Problem/Solution
No. Problem Solution
1. Battery is low or discharged Check the battery.
2. Open circuit in the trim wiring Check for an open connection.
Wiring is reversed in the remote control, cowl switch, or trim
3. Verify all the connections.
leads
4. Wire harness is corroded through Replace the wiring harness.
d
30104
The trim motor relay system, used on permanent magnet trim systems, connects each of the two wires from the trim motor to
either a ground or positive lead to allow the motor to run in both directions.
If the motor will not run in the up direction, it may be either the up relay is not making contact to 12 volts or the down relay is not
making contact to ground. The opposite is true if the system will not run down. When the system is not energized, both relays
should connect the heavy motor leads to ground.
To test which relay is faulty if the trim system does not operate in one direction:
1. Disconnect the heavy gauge pump wires from the trim control relay.
2. Check for continuity between the heavy leads from the trim relays to ground.
b 9 c
a d
a
p e
BLK
LT BLU/WHT
o
BLK
6
BLK
GRN/WHT
BLU
RED
GRN
BLK
RED
BLK
C13 C12
GRN g
n
C10
2
C17
h
RED/PUR
RED
RED/BLK
RED/ORG
RED
RED/PNK
RED
RED
RED/YEL
RED/WHT
RED/WHT
RED/BLU
RED/WHT
LT BLU/WHT
RED/WHT
RED/PUR
RED/WHT
RED
RED
C3
BRN/WHT
BLK
3 e
j
C8
S103
k
T4
BRN/WHT
8 1
C6
E P
S110 LT BLU/WHT D N
S108 F
1 9 17 RED/PUR RED/PUR G
C
M
A
GRN/WHT GRN/WHT B
m
H L
LT BLU/WHT S109 J K
C1 7
22 LT BLU/WHT
LT BLU/WHT
GRN/WHT
RED/PUR
GRN/WHT
RED/PUR
l
C7
8 16 24 44 5 22707
a- Fuse holder
b- Down relay
c- Up relay
d- Negative () 12 volt ground
e- Positive (+) 12 volt power (start solenoid)
f- Trim motor up lead
g- To trim motor
h- Trim motor down lead
i- Trim position sensor
j- 2 pin relay connector
k- 14 pin connector
l- Cowl tilt switch
m- PCM connector
n- 2 pin alternator connector
o- Main power relay
p- Power trim 15 amp fuse
Relay is good:
The pump motor wiring is defective.
Step 6: Check up Test the up relay. Refer to Power Trim The pump motor is defective.
relay. Relay Test, preceding.
Relay is faulty:
Replace the relay.
Relay is good:
The pump motor wiring is defective.
Step 6: Check down Test the down relay. Refer to Power Trim The pump motor is defective.
relay. Relay Test, preceding.
Relay is faulty:
Replace the relay.
The up and down trim switches are both 1. Faulty trim switch. 1. Replace the trim switch.
inoperative, but cowl switch does 2. A wire is open between the fuse
operate. 2. Check for a loose or corroded connection.
holder and the trim switch.
a - Test adapter
7098
e a- Brass fitting
b- Test gauge assembly
c- Tilt pin
d- Hose
a d e- Hose (not used)
c
b
7099
a
22365
10. Open valve "a" and close valve "b."
a b
7101
11. Run the trim up to the full up position. Record the pressure reading on gauge. Release the trim switch.
Power Trim
Up pressure (minimum) S/N 1B417702 and Above 19,300 kPa (2,800 psi)
Up pressure (minimum) S/N 0T8010001B417701 18,202 kPa (2,640 psi)
12. Run the trim down to release pressure and remove the spare tilt pin or bolts and nuts.
13. Tilt the outboard full up and engage the tilt lock lever.
14. Slowly remove the fill plug to bleed trapped pressure.
15. Remove the test gauge hose and adapter.
16. Install the manual release valve and secure the valve with a circlip.
17. Tighten the fill plug.
NOTE: If pressure is out of the specified pressure range, troubleshoot the system per instructions preceding in this section.
a - Test adapter
7098
e a- Brass fitting
b- Test gauge assembly
c- Tilt pin
d- Hose
a d e- Hose (not used)
c
b
7099
a b
7101
10. Run the trim to the full down position. Record the pressure reading on the gauge. Release the trim switch.
Power Trim
Down pressure 34805860 kPa (505850 psi)
11. Tilt the outboard full up and engage the tilt lock lever.
12. Slowly remove the fill plug to bleed trapped pressure.
13. Remove the test gauge hose and adapter.
14. Reinstall the manual release valve and secure the valve with a circlip.
15. Retighten the fill plug.
NOTE: If the pressure is out of specified pressure range, troubleshoot system per instructions in this section.
7084
a - Jclips
b - Wire harness
a
b
7086
3. Remove the upper trilobe pin.
7088
4. Drive out the upper pivot pin.
7089
5. Remove the sacrificial anode.
a
b 23798
23799
! WARNING
Damaged wires can cause electrical problems, resulting in system failure. In some cases, this can affect boat operation, leading
to personal injury. Use conduit, hose clamps, grommets, or other appropriate measures to protect all electrical wires. Do not
overtighten clamps and keep harnesses away from heat sources during installation.
8. Tilt the top part of the power trim assembly out first from clamp bracket and remove assembly.
7093
a - Reservoir plug
b - Manual release valve
7104
e
f
7105
a- Plug (2)
b- Spring (2)
a c- Check valve/poppet (2)
b d- Seat (2)
c e- Spool
d
e
d
c
b
a
7106
a b
7108
3. Remove three screws to remove pump. Remove filter and filter seal under pump. Remove suction seat assembly.
a a- Screw (3)
b- Filter seal
c- Filter
d- Suction seat assembly
7111
Manifold Removal
1. Remove two screws to remove manifold from cylinder.
a - Screw (2)
a 7114
a- Spring
b- Poppet
c- Spool housing
d- Trim limit spool
a
b
d 7113
51146
7115
a - End cap
c b - Oring (2)
c - Wiper ring
b
b
a
7116
1. Place the shock rod assembly on a clean work surface.
2. Remove the three screws and remove the plate from the shock rod piston.
c b a - Screw (3)
b - Plate
c - Shock rod piston
7117
3. Remove the check ball components from the shock rod piston.
4. Remove the Oring from the shock rod piston.
a- Spring (5)
b- Seat (5)
c- Ball (5)
d- Oring
c
b
a
d
7119
51146
12884
a - Spanner wrench
b b - Shock rod piston
7121
a - Shock piston
b - Oring
b
7125
11. Remove the cylinder end cap assembly from the shock rod.
12. Inspect the shock rod components. If the wiper located in the cap has failed to keep the rod clean, replace the wiper.
13. Place the end cap on a clean work surface.
14. Remove the rod wiper, inner Oring, and outer Oring.
d
a- Rod wiper
b- Cylinder end cap
c c- Inner Oring
d- Outer Oring
b
7126
a - Lockring pliers
7127
! WARNING
The memory piston cup may be expelled at a high velocity when air pressure is applied. Failure to position the cylinder opening
down and away from your body could result in personal injury.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to catch the memory piston and avoid damage or
personal injury.
2. Remove the Oring from the memory piston.
a
d
7128
a- Adapter/air hose
b- Memory piston exit
c- Shop rag
d- Memory piston
e- Oring
7132
IMPORTANT: Trim motor is not serviceable. If motor fails to run, replace motor assembly.
1
3
2
5
4
22
6
7
8
9
10
20
19
11
11
21 12 13
14
9 15
18
17
10
9
16
8 7134
O-Ring Size
NOTE: Refer to O-Ring and Seal Placement chart on previous page for description.
1 2
9
3 7
4 22
13
11
5 14
18 17 12
20 15
6
16
8
19
10 21
12561
a - Inside diameter
b - Outside diameter
c - Width
d
a- Rod wiper
b- Cylinder end cap
c c- Inner Oring
d- Outer Oring
b
7126
a - Shock piston
b - Oring
b
7125
7137
a - Spanner wrench
b b - Shock rod piston
7121
a- Spring (5)
b- Seat (5)
c- Ball (5)
d- Oring
c
b
a
d
7119
11. Secure the components with the plate. Tighten the screws to the specified torque.
c b a - Screw (3)
b - Plate
c - Shock rod piston
7117
a a - Memory piston
b - Oring
b c - Oil blow off ball passage
7140
IMPORTANT: End cap must not make contact with shock rod piston when tightening. Shock rod piston must be positioned
in cylinder deep enough to avoid contact.
5. Tighten end cap securely using spanner wrench (6.4 mm x 8 mm [1/4 in. x 5/16 in.] long pegs). If a torquing type spanner tool
is used to tighten the end cap, then tighten to the specified torque.
a- Spring
b- Poppet
c- Spool housing
d- Trim limit spool
a
b
d 7113
51146
a
a - Manifold
b - Manual release valve
c - Eclip
7141
Manifold Installation
1. Install dowel pin and two lubricated Orings into trim cylinder.
a - Oring (2)
b - Dowel pin
11022
2. Align the trim cylinder and reservoir/manifold assembly together.
b 11023
a - Screw (2)
a 7114
a a- Screw (3)
b- Filter seal
c- Filter
d- Suction seat assembly
7111
a b
7108
1. Lubricate Orings.
2. Install spool, seat with Oring, check valve/poppet, spring, and plug with Oring into pump. Repeat for other side. Tighten
plugs to specified torque.
a- Plug (2)
b- Spring (2)
a c- Check valve/poppet (2)
b d- Seat (2)
c e- Spool
d
e
d
c
b
a
7106
e
f
7105
a - Reservoir plug
b - Manual release valve
7104
a
b c 7144
4. Using a suitable punch, drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside
surface.
5. Using a suitable punch, drive lower cross pin into its respective bore until seated.
6. Install sacrificial aluminum anode to reservoir bracket placing ground strap to anode, as shown.
a
c
b 7145
7. Apply 24C with Teflon to surface of upper pivot pin, pivot pin bore, and trim ram bore.
a- Pivot pin
b- Trim ram bore
c- Cross hole
d- Transom side
b e- Engine side
a c
7146
a - Pivot pin
b - Swivel bracket
c - Trim ram
b
a c
7152
a - Trilobe pin
7088
10. Secure trim harness with clamps.
a - Jclips
b - Trim harness
a
b
7086
11. Recheck fluid level.
12. Power trim may now be operated to lower outboard to desired position. Trim system is selfpurging.
13. Reconnect power trim leads to relays under ignition cover.
14. Reinstall spark plug leads to spark plugs.
15. Reinstall cowls.
16. Connect battery leads to battery terminals.
Notes:
Lower Unit
Section 6A - Gear Housing
Table of Contents
Gear Housing Specifications..............................................6A-2 Gear Housing Assembly..................................................6A-27
Gear Housing (Driveshaft).................................................6A-8 Forward Gear Bearing Race Assembly....................6A-27
Gear Housing (Propeller Shaft)........................................6A-12 Forward Gear Assembly...........................................6A-28
General Service Recommendations................................6A-14 Bearing Carrier Assembly.........................................6A-29
Bearings....................................................................6A-14 Propeller Shaft Assembly.........................................6A-33
Shims........................................................................6A-14 Driveshaft Wear Sleeve Installation..........................6A-34
Seals.........................................................................6A-14 Lower Driveshaft Bearing Race Installation..............6A-35
Draining and Inspecting Gear Housing Lubricant............6A-14 Oil Sleeve Installation...............................................6A-36
Gear Housing Removal....................................................6A-15 Driveshaft Upper Bearing Installation.......................6A-36
Gear Housing Disassembly.............................................6A-16 Shift Shaft Assembly.................................................6A-37
Water Pump Disassembly........................................6A-16 Pinion Gear Depth and Forward Gear Backlash......6A-39
Shift Shaft Disassembly............................................6A-18 Gearcase Assembly..................................................6A-44
Bearing Carrier and Propeller Shaft Removal..........6A-19 Water Pump Assembly and Installation....................6A-46
Propeller Shaft Disassembly.....................................6A-22 Rubber Overmold Water Pump Plate.......................6A-49
Propeller Shaft Inspection.........................................6A-22
Pinion Gear, Driveshaft, and Forward Gear Removal
Gear Housing Pressure Test....................................6A-53
Gearcase Installation.......................................................6A-53 6
..............................................................................6A-23
Upper Driveshaft Bearing Removal..........................6A-26
Filling Gear Housing with Lubricant.................................6A-55
Trim Tab Adjustment and Replacement..........................6A-56
A
Oil Sleeve Removal..................................................6A-26 Replacement.............................................................6A-56
Lower Driveshaft Bearing Race Removal.................6A-26 Adjustment................................................................6A-56
Forward Gear Bearing Race Removal......................6A-27
1. After the poppet valve opens at approximately 1800 RPM, the engine temperature will drop to 2738 C (80100 F).
Special Tools
Puller Jaws Assembly 9146086A1
Removes bearing carrier and bearing races; use with Puller Bolt (9185716).
9514
Aids in the removal of various engine components. Use with puller jaws.
6761
Provides a wrench surface to turn the driveshaft. Also used to hold driveshaft for
pinion gear installation.
9448
8505
3610
8882
Installs prop shaft needle bearing into 3 jaw or 6 jaw forward gear.
8885
8877
25431 Aids in the removal and installation of various bearings and bearing races
8883
Simulates a load on the driveshaft for accurate pinion height and backlash
measurements.
8756
3608
8757
8878
Checks gear housing for leakage prior to filling with gear lubricant.
29497
34
28
30 20
35
24
7
23
26 27 33
95
25 19 7
40
11
18 41
10 38
95
12
8 39
6
14 87 37
9
3
36
12 2
13
7 17 1
15
16
4 5
45 2152
Torque
Ref. No. Qty. Description Nm lbin. lbft
40 1 Oil seal
41 2 Screw (M6 x 25) 6.8 60
42 1 Face seal
34
28
30 20
35
24
7
23
26 27 33
95
25 19 7
40
11
18 41
10 38
95
12
8 39
6
14 87 37
9
3
36
12 2
13
7 17 1
15
16
4 5
45 2152
10
8
7 4
9
5
6 2 28
3
17 27
95
15
95
14
13
20
19 12 11
18 16
30
32 95
26
24
31 25
7
95 21
22
23 1694
Bearings
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean bearings with solvent and dry with
compressed air. Air should be directed at the bearing so that it passes through the bearing. Do not spin bearing with compressed
air, as this may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with High Performance Gear
Lubricant. Do not lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches, and bearing race side wear. Work inner bearing race in and out, while holding outer
race, to check for side wear.
When inspecting tapered bearings, determine condition of rollers and inner bearing race by inspecting bearing cup for pitting,
scoring, grooves, uneven wear, imbedded particles, and/or discoloration from overheating. Always replace tapered bearing and
race as a set.
Inspect gear housing for bearing races that have spun in their respective bores. If race has spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that the roller bearing supports. Check shaft
surface for pitting, scoring, grooves, imbedded particles, uneven wear, and/or discoloration from overheating. The shaft and
bearing must be replaced, if the conditions described are found.
Shims
Keep a record of all shim amounts and location during disassembly to aid in reassembly. Be sure to follow shimming instructions
during reassembly, as gears must be installed to correct depth and have the correct amount of backlash to avoid noisy operation
and premature gear failure.
Seals
As a normal procedure, all Orings and oil seals should be replaced without regard to appearance. To prevent leakage around oil
seals, apply Loctite 271 to outer diameter of all metal case oil seals. When using Loctite on seals or threads, surfaces must be
clean and dry. To ease installation, apply 24C with Teflon on all Orings. To prevent wear, apply 24C with Teflon on inner
diameter of oil seals.
a - Vent screws
b - Fill/drain screw
b
26977
2. Inspect the gear lubricant for metal particles. Presence of a small amount of fine metal particles resembling powder indicates
normal wear. Presence of larger particles or a large quantity of fine particles, indicates need for gear housing disassembly
and inspection.
3. Note the color of the gear lubricant. White or cream color indicates the presence of water in the lubricant. Check the drain
pan for water separation from the lubricant. Presence of water in the gear lubricant indicates the need for disassembly, and
inspection of oil seals, seal surfaces, Orings, and gear housing components. Pressure check the gearcase prior to
disassembly.
NOTE: When draining the gearcase for the first time, the lubricant may appear cream colored due to the mixing of assembly
lubricant and gear lubricant. This is not an indication of water intrusion. If, during the subsequent draining of the gearcase,
the lubricant appears cream colored or milky, water may be present. Gearcase should be disassembled and all gaskets,
seals, and Orings replaced. Inspect all components for water damage.
NOTE: Gear lubricant drained from a recently run gearcase will be a light chocolate brown in color due to agitation/aeration.
Oil which is stabilized will be a clear yellow brown in color.
! 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.
3. Remove the four fasteners.
4. Remove the locknut and washer.
a
b
7156
5. Remove the gear housing.
a - Screws (4)
b
b - Water tube seal
c c - Cover
7157
a
IMPORTANT: Disregard the circular groove formed by the impeller sealing bead when inspecting the cover and plate, as the
depth of the groove will not affect the water pump output.
4. Replace the cover if the thickness of steel at the discharge slots is 1.50 mm (0.060 in.) or less, or if grooves other than the
impeller sealing bead groove in the cover roof are more than 0.75 mm (0.030 in.) deep.
5. Lift the impeller, drive key, and gasket from the driveshaft.
a - Impeller
a b - Drive key
c - Gasket
c
b
7153
6. Inspect the impeller. Replace the impeller if any of the following conditions exist:
Impeller blades are cracked, torn, or worn
Impeller is glazed or melted
Rubber portion of impeller is not bonded to impeller hub
7. Remove the plate and gasket.
a
a - Plate
c b - Gasket
c - Impeller sealing bead groove
7165
9. Remove the screws and washers.
a
7168
10. Remove the water pump base using flat screwdrivers to lightly pry up on the base.
a
a - Water pump base
7171
a - Seals
7173
12. Remove the gasket.
a a - Gasket
7174
7206
NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing.
b a - Bushing
a b - Shift shaft
7207
3. Remove the shift shaft bushing and the clip from the shift shaft.
4. Replace the shift shaft if the splines are worn or the shaft is twisted.
5. Remove and discard the Oring.
e
a- Splines
a b d a b- Shift shaft
c- Eclip
d- Oring
e- Bushing
c
7209
6. Remove and discard the seal. Do not scar the seal surface in the shift shaft bushing while removing the seal. If the seal surface
is scarred, replace the shift shaft bushing.
a - Seal
b - Oring
b 7210
a
7175
3. With the propeller shaft horizontal, use the puller jaws assembly to remove the bearing carrier from the gear housing.
4. Remove the bearing carrier/propeller shaft components as an assembly by pulling back on the propeller shaft.
5. Remove the propeller shaft from the bearing carrier.
a- Bearing carrier
b- Puller jaws
c- Puller bolt
d- Propeller shaft
b a e- Thrust hub
e
d
7177
a - Reverse gear
a b - Thrust bearing
c - Thrust washer
b
7178
a
a - Roller bearing
7180
a
b
21618
a - Oring
7187
a
a - Spring
7193
2. Apply constant pressure to the cam follower to prevent the cam follower and the internal components from ejecting out of the
propeller shaft when removing the cross pin from the clutch.
3. Use a thin blade screwdriver or awl to push the cross pin out of the clutch.
a - Cross pin
b - Cam follower
a
7194
c
a a- Cam follower
b
b- Metal balls (3)
c- Jaws
d- Sliding clutch
e- Guide block
f- Spring
7195
e f
d
a - Measuring point
b b - Bearing surface
a
29505
a a a - Clutch jaws
9711
8. Check the cam follower for wear, pitting, scoring, or rough surface. If replacement is needed, replace cam follower and shift
cam together.
b a
a- Driveshaft
b- Driveshaft holding tool
c- Lower tapered driveshaft bearing
d- Pinion gear
e- Pinion nut
f- Forward gear/bearing
d
e
7271
a
a - Retaining ring
29506
4. Use a punch and hammer to remove the forward gear needle bearing.
a 7198
b 28155
e
a- Driveshaft splines
b- Bearing surface
c- Wear sleeve
a d- Universal puller plate
e- Mallet
c
d
b
a 21538
a
a - Rubber ring
7200
b 7201
a - Oil sleeve
b - Puller assembly
b
7202
a - Bearing race
b - Shim
c - Bearing race tool
a
c
7203
a a - Race
b - Shims
c - Slide hammer
b c
7211
a- Shims
e b- Race
d c c- Bearing cup driver
d- Disassembled propeller shaft
a e- Assembled bearing carrier
b 7212
a - Mandrel
a b - Bearing
7235
c b 7239
a - Needle bearing
b b - Forward gear bearing installer
a
7236
a
a - Retaining ring
29506
7224
a a - Seal
b - Oil seal driver
b c - Bearing installation driver
7225
b
c
7228
a - Oring
b - Bearing
b c - Bearing installation tool
c
7230
a a - Thrust washer
7232
a
a - Thrust bearing
7233
a
a - Reverse gear
b - Bearing surface
7234
f g
e b Assembly Sequence
a - Spring
b - Guide block
c - Clutch
d - Metal balls (3)
e - Cam follower
f - Forward clutch teeth
d a 11120
g - Reverse clutch teeth
c
2. Align the hole in the clutch with the hole in the guide block and install the cross pin.
b
a - Apply pressure in this direction
a b - Cross pin
11121
a
a - Spring
7193
a
a - Rubber ring
7200
a - Sleeve
b - Holder
a
b
7243
a- Driveshaft
b b- Wear sleeve installation tool
c- Upper part of tool
d- Lower part of tool
a 7244
a- Shims
b- Bearing race
e c- Mandrel
d- Mandrel
e- Threaded rod
f f- Nut
d
c
7246
b
a - Oil sleeve
b - Tab
7263
a- Mandrel
b- Bearing
c- Bearing sleeve
d- Tapered end
c b
7264
a- Threaded rod
b- Nut
a c- Mandrel
d- Bearing/sleeve
e- Tapered end of sleeve
b f- Mandrel
d c
f
7268
a - Seal
b - Oring
24900
b
a b
a - Shift shaft
b - Eclip
c - Shift shaft bushing
c 7220
7. Install the shift cam. Align the hole in the shift cam with the shift shaft pilot bore in the gear housing.
b
a - Shift cam
b - Shift shaft pilot bore
7208
8. Install the shift shaft assembly. Insert the splines into the shift cam.
28139
9. Apply Loctite 271 Threadlocker to the threads of the shift shaft bushing screws.
10. Secure the shift shaft bushing to the gear housing with two screws. Tighten the screws to the specified torque.
7206
b a
a- Driveshaft
b- Driveshaft holding tool
c- Lower driveshaft tapered bearing
d- Pinion gear
e- Pinion nut
f- Forward gear/bearing assembly
d
e
7271
6. Position the gear housing with the driveshaft in a vertical position. Install the bearing preload tool with the 19 mm (3/4 in.)
sleeve over the driveshaft in the sequence shown. Ensure the holes in the sleeve are in alignment with the set screws. Tighten
the set screws securely.
d a- Coupler
b- Threaded rod
c- Sleeve 22 mm (7/8 in.)
c e d- Sleeve 19 mm (3/4 in.)
e- Split sleeve 16 mm (5/8 in.)
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i
l- Plate
j m- Nut
a k
l
13288
a
a - Bolt head
b - Nut
c - Measure distance, then increase by 25.4 mm (1 in.)
7275
10. Assemble the pinion gear locating tool, as shown. Do not tighten the collar retaining screws at this time. Install the gauging
block with the numbers pointed towards the arbor handle.
b d
e a- Arbor handle
b- Gauging block
c- Screw (2)
2 3
1
d- Split collar
4
8
c f
7277
a - Gauging block
a
7279
12. Remove the pinion gear locating tool, taking care not to move the gauging block position. Tighten the collar retaining screws.
13. Insert the pinion gear locating tool into the forward gear assembly. Position the correct gauging block flat number under the
pinion gear.
Model Gear Ratio (Pinion Gear Teeth/Reverse Gear Teeth) Use Flat Number Locating Disc Number
75/90 2.33:1 (12/28) 8 3
115/115 Pro XS/125 2.07:1 (14/29) 2 3
14. Install the locating disc against the bearing carrier shoulder in the gear housing.
15. Position the access hole, as shown.
a - Locating disc
a b - Access hole
b
7282
16. Determine the pinion gear depth by inserting a feeler gauge through the access hole in the locating disc.
17. The correct clearance between the gauging block and the pinion gear is 0.64 mm (0.025 in.).
18. If the clearance is correct, leave the bearing preload tool on the driveshaft and proceed to Forward Gear Backlash.
19. If the clearance is more than 0.64 mm (0.025 in.), add shims behind the pinion gear bearing race. If the clearance is less than
0.64 mm (0.025 in.), remove shims from behind the pinion gear bearing race.
20. Check the pinion gear depth after any change that is made to the pinion gear shimming.
d
a- Feeler gauge
c a b- Gauging block
c- Pinion gear
d- Bearing race
7283
a
a- Bearing carrier assembly
b- PVC pipe
b c- Propeller nut
c
d- Propeller shaft
e- Tab washer
d
e
7289
3. Lubricate the bearing carrier and the gear housing mating surfaces with 24C with Teflon.
4. Install the bearing carrier and propeller shaft into the gear housing with the word "TOP" (located on flange) toward the top of
the housing.
a - Oring
b - "TOP"
a
b
7308
IMPORTANT: If the bearing carrier retaining washers are not 2.29 mm (0.090 in.) thick, order new washers P/N 12855941.
6. Secure the bearing carrier with locknuts and tighten the locknuts to the specified torque.
a
7175
a- Puller bolt
b- Propeller shaft
c- Bearing carrier
d- Puller jaws
c
a b
d 7286
d f
e a- Threaded rod (obtain locally)
b- Washer (2)
c- Nut (2)
d- Dial indicator adapter kit
e- Dial indicator
f- Backlash indicator tool
c
7287
b
Dial Indicator Adapter 9183155
Backlash Indicator 91196601
Dial Indicator 9158222A1
12. Align the dial indicator with the appropriate mark on the backlash indicator tool. Ensure the dial indicator is perpendicular to
the indicator tool or an inaccurate reading will be obtained.
Gearcase Assembly
IMPORTANT: Before assembling the gear housing, ensure the pinion depth and the forward gear backlash are within
specifications.
1. Install the forward gear assembly into the gear housing.
2. Install the pinion gear tapered bearing into the gear housing.
3. Install the pinion gear and driveshaft.
4. Apply Loctite 7649 Primer N to the driveshaft threads and the threads of the new pinion nut.
b a
a- Driveshaft
b- Driveshaft holding tool
c- Lower driveshaft tapered bearing
d- Pinion gear
e- Pinion nut
f- Forward gear/bearing assembly
d
e
7271
a
a- Bearing carrier assembly
b- PVC pipe
b c- Propeller nut
c
d- Propeller shaft
e- Tab washer
d
e
7289
8. Lubricate the bearing carrier and the gear housing mating surfaces with 24C with Teflon.
a - Oring
b - "TOP"
a
b
7308
a
7175
a- Upper seal
d b- Long shoulder side of driver
c- Oil seal driver
c d- Short shoulder side of driver
e- Spring
b a
e
7313
a- Lower seal
b- Spring
c- Short shoulder side of driver
e d- Oil seal driver
e- Long shoulder side of driver
d
b c
a
7315
a a - Gasket
7174
IMPORTANT: To prevent seal lip damage, remove any burrs or sharp edges from the driveshaft splines before installing water
pump base assembly.
7. Install water pump base and secure with screws. Apply Loctite 271 Threadlocker on bottom half of threads. Tighten, in
sequence shown, to the specified torque.
a a - Screws
b - Water pump base
b
7320
a
a - Plate
c b - Gasket
c - Impeller sealing groove
7165
a - Impeller
a b - Key
c - Gasket
c
b
7153
10. Lubricate inside diameter of cover with 24C with Teflon.
11. Rotate driveshaft clockwise and push impeller housing down and over impeller until it contacts water pump base.
12. Apply Loctite 271 Threadlocker to bottom threads of cover screws. Install cover screws and tighten to the specified torque.
a - Screws
b
b - Water tube seal
c c - Cover
7157
a
NOTE: It is recommended that the gearcase be pressure tested for leaks for 5 minutes after reassembly and before gear
lubricant is added.
a- Upper seal
d b- Long shoulder side of driver
c- Oil seal driver
c d- Short shoulder side of driver
e- Spring
b a
e
7313
a- Lower seal
b- Spring
c- Short shoulder side of driver
e d- Oil seal driver
e- Long shoulder side of driver
d
b c
a
7315
a a - Gasket
7174
IMPORTANT: To prevent seal lip damage, remove any burrs or sharp edges from the driveshaft splines before installing water
pump base assembly.
7. Install water pump base and secure with screws. Apply Loctite 271 Threadlocker to the threads of the screws. Tighten to the
specified torque, in sequence shown.
a a - Screws
b - Water pump base
b
7320
a b
29177
9. Install the plate onto the water pump base with the water pump cover seal facing up.
10. Install the water pump drive key and the water pump.
a
a - Impeller
b - Drive key
c - Water pump cover seal
c
b
29183
a - Screw (4)
b
b - Water tube seal
c c - Cover
7157
a
NOTE: Before gear lubricant is added, pressure test the gearcase for five minutes to check for leaks.
7362
Gearcase Installation
1. Position outboard shift linkage into forward gear position.
F N R
7368
! 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.
b
7377
NOTICE
Installing the gear housing to the powerhead without adequately cleaning the top of the driveshaft can result in severe product
damage. Any lubricant trapped in the space between the driveshaft and the crankshaft prevent the two from properly engaging.
Always clean the top of the driveshaft before installing the gear housing.
6. Apply a light coat of 24C with Teflon onto driveshaft splines.
7. Apply a light coat of 24C with Teflon on gearcase shift shaft splines and upper shift shaft splines. Do not use lubricant on
ends of shift shafts.
a - Fasteners
b - Locknut and washer
a
b
7156
27001 e
IMPORTANT: Do not lose more than 30 cc (1 oz) of gear lubricant while reinstalling the fill/drain screw.
Replacement
Replace the trim tab if damaged. Mark the location of the old trim tab on the antiventilation plate before removal. Install the new
trim tab in the same location.
Adjustment
NOTE: The trim tab provides a means to offset balance some of the steering load that is caused by propeller torque at higher
operating speeds.
NOTE: Loosen the trim tab bolt sufficiently to allow the trim tab to disengage from the locking ridges in the gear housing before
attempting to move the tab. Do not strike the trim tab with a hard object to make adjustments.
1. Shift the engine control into neutral and turn the ignition key switch to the "OFF" position.
2. If at higher speeds the boat turns more easily to the left, loosen the screw and move the trim tab trailing edge to the left when
viewed from behind. Tighten the retaining screw to the specified torque.
3. If the boat turns more easily to the right, loosen the screw and move the trim tab trailing edge to the right when viewed from
behind. Tighten the trim tab retaining screw to the specified torque.
c
a - Trim tab
b - Antiventilation plate
c - Retaining screw and washer
b a 7383
Attachments/Control Linkage
Section 7A - Throttle Cable and Shift Bracket
Table of Contents
Throttle Body Components S/N 1B417702 and Above......7A-4 Throttle Cable Removal............................................7A-12
Throttle Body Components S/N 1B417701 and Below......7A-6 Throttle Cable Installation ........................................7A-13
Throttle Lever and Linkage................................................7A-8 Shift Bracket Removal and Installation............................7A-17
Exhaust Plate...................................................................7A-10 Shift Bracket Removal..............................................7A-17
Throttle Cable..................................................................7A-12 Shift Bracket Installation...........................................7A-17
7
A
Notes:
3
16 2
15 14
13 12 11 4
10 1
29
17
6
5
9 7
8
20 28
26
27
25
24
23
22
21 19
18
23750
3
16 2
15 14
13 12 11 4
10 1
17 29
28
6
5
9 7
8
30
20
27
26
25
24
23 19
22
21
18
1321
8
10
3
9
1
4 2
5
1327
11
12
Exhaust Plate
95
28 3 30
7
29
24
26
23
4
1 25
2 27
6
24 95
2 5 20
19
22
9
10
8
11
95
17
12
21
15
16
18
13 14
1687
Exhaust Plate
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Exhaust plate
2 4 Dowel pin
3 1 Retainer
4 2 Mount
5 4 Screw (M8 x 35) 27 20
6 2 Bolt (M12 x 175)
7 2 Nut (M12) 74.5 55
8 1 Spacer
9 1 Coupling
10 1 Gasket
11 1 Exhaust tube
12 6 Screw (M8 x 35) 27 20
13 1 Seal
14 1 Grommet
15 1 Water tube
16 1 Clamp
17 1 Upper seal
18 2 Screw (M8 x 45) 20.3 15
19 1 Clamp
20 1 Grommet
21 1 Bushing
22 1 Shift shaft
23 1 Shift link
24 2 Bushing
25 1 Washer
26 1 Nut (M6) 5.6 50
27 2 Screw (M8 x 35) 33.9 25
28 1 Screw (M8 x 70) 33.9 25
29 1 Switch
30 2 Screw (M3 x 20) 2.6 23
Throttle Cable
Throttle Cable Removal
1. Loosen the four nuts securing the throttle cables to the throttle body bracket.
a
27428
2. Cut the cable tie securing the water sensor harness connector to the fuel hose. Disconnect the engine harness from the water
sensor harness connector.
3. Remove the two screws securing the fuel pump to the vapor separator tank. Pull the fuel pump off the vapor separator tank.
4. Loosen the four nuts securing the throttle cables to the bracket. Remove the throttle cables from the bracket.
a c a - Nuts
b - Cable tie
c - Screws (2)
b
27489
c 27492
27493
27496
3. Install the WOT throttle cable onto the front mounting location on the throttle body bracket.
27498
5. Install the throttle idle cable and the throttle WOT cable to the throttle cam.
c
27507
6. Ensure the throttle cable ends are correctly installed onto the throttle cam.
a b
27508
27510
8. Install the throttle idle cable and throttle WOT cable onto the throttle lever.
NOTE: The fuel pump is removed for installation clarity. It is not necessary to remove the fuel pump to install and adjust the
throttle cables.
c 27492
c
a - Throttle lever stop
b - Throttle idle cable
c - Nut
a
27511
a 27512
a - WOT stop
b
b - WOT stop adjustment screw
27514
18. Check the clearance of the throttle shutter arm and the throttle shutter stop.
19. Adjust the WOT stop adjustment screw so the throttle shutter arm clearance is between 0.5081.016 mm (0.020.04 in.).
27515
a c a - Nuts
b - Cable tie
c - Screws (2)
b
27489
c c a- Shift link
b
b- Shift bracket
c- Locking tab securing screw
d- Nut and washer securing shift
link to shift slide
a
d
27705
2. Lubricate the shift bracket with 24C with Teflon and install the shift slide with the cam orientated towards the aft of the
powerhead.
a - Shift bracket
b b - Shift slide cam
a
27834
c c a- Shift link
b
b- Shift bracket
c- Locking tab securing screw
d- Nut and washer securing shift
link to shift slide
a
d
27705